Edwards Engineering has extended the life of three original kilns while maximising production at Simpsons Malt’s Tweed Valley Maltings site in Berwick-Upon-Tweed.
Simpsons Malt has been operating from the Tweed Valley Maltings site since 1963 and it is now the largest single maltings site in the UK. The family-run business supplies the majority of its grain product to whisky distilleries and brewers in Scotland, producing in excess of 200,000 tonnes of malt a year.
Kilns are used in the final stage of the malting process to stop the germinated grain growing, preparing it for use in the distilling and brewing processes. Traditional kilns use burners to heat air that is then blown from below through a bed of green malt. Any of the hot air that has already passed through the malt can be recaptured and thereby save burner fuel.
The three original kilns at Tweed Valley Maltings were still operating, demonstrating the resilience of the engineering in their construction. However, their energy efficiency had been eroded over time with heat escaping through the ceilings. Heat capture had also been hindered by damaged head exchangers in the recirculation ductwork.
Edwards Engineering worked closely with the team at Simpsons Malt to prioritise extending the life of existing kilns, which run continually, while ensuring production was maximised throughout the upgrade project. The project was planned to ensure that only one kiln would be out of operation at any one time.
The project team split the work into three distinct areas: the ceiling repair, the ductwork upgrade, and replacement of the glass tube head exchangers.
The ceiling replacement involved modular stainless steel panels being installed and welded together to prevent any leakage of hot air or moisture from the kilns themselves. The joints between the stainless and the brickwork were also carefully sealed and insulation installed.
The external ductwork was able to be addressed independently outside the building with careful demolition followed by rapid installation of the bespoke designed stainless ductwork sections and insulating panels. Meanwhile, the heat exchangers (many thin-walled glass tubes) were carefully craned into place to ensure no breakages.
Pat Richards, Chief Engineer for Simpsons Malt, said: “Working with Edwards to repair the three kilns ensures we have a robust infrastructure that will work efficiently for many years to come.”
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