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Our malting plants in Europe and rest of the world |
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- Antwerp (Belgium) - 240,000
tons.
- Slavonija Slad (Croatia) - 60,000 tons.
- Dunanjvaros (Hungary) - 60,000 tons.
- Issoudun (France) - 160,000 tons.
- Beijing (China) - 40,000 tons.
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Production areas of barley
and the four malting plants.
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| The
four malting plants in Europe use different
techniques and technologies which all have their
advantages. Each one is controlled to ensure
the final quality of the malt and to optimise
the cost per ton of malt produced.
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Antwerp -
Belgium
Building a malting plant near the Antwerp port silo marked
the beginning of Boortmalt’s success. Two separate
plants have been built on this site: the first tower opened
in 1989 and production quickly reached 110,000 tons a
year. It is characterised by a flat bottom steep tank
at the top of the tallest tower, 2 pre-germination boxes
below and
4 circular germination boxes. Kilning takes place in a
double-tray vessel located in the second tower. The 3
key operations of malting are therefore separated. The
second malting plant, with a capacity of 130,000 tons,
has been in operation since the summer of 2004.
Giovanni
Vercammen,
Chief Operations Officer-Maltings
"This malting plant operates on the basis of
the GKV principle, meaning that germination and kilning
take place in the same vessel. This enables us to avoid
any transfer of green malt which ensures the highest quality
of malt. The plant is also made out of 100% mild and stainless
steel, which provides us with the best possible hygiene
conditions.
The second plant has 6 GKV vessels. The perforated tray
holding the green malt is mobile. The fixed vertical turners
ensure the uniform consistency of the malt while the tray
is rotating. GKV technology is also used in Issoudun and
Nova Gradiska".
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The capacity of the Antwerp
site will soon reach 310,000 tons and other projects are
in the pipeline to enable Boortmalt to assist the development
of its customers, always with a high-quality malt and
highly efficient logistics.
Antwerp
Boortmalt site in 2009
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Issoudun - France
It all begun in 1894 for the Issoudun site with the construction
of a malting plant right in the heart of a traditional
area of quality brewing barley cultivation in central
France. More than a century later, this site is now producing
150,000 tons of malt. 50,000 tons come from the conventional
rectangular Saladin boxes which are still able to accommodate
small batches, and 100,000 tons from the new plant, the
final section of which has been up and running since 2003.
To ensure the operation of this plant for the next 20
to 30 years, various aspects have been taken into account
in terms of the environment and food safety.
Hubert Rougeot
Manager Issoudun (France)
“This plant had to be flexible
and effective enough to offer the entire quality range
demanded by our customers. This obviously involves the
use of high-quality barley, but also the flexibility of
the first important phase: steeping. For this, we have
chosen cylindrical and cone-shaped steeping tanks over
2 levels with intermediate transfer from the 1st to the
2nd level in the middle of the steeping process. This
ensures the homogeneity of the product. What we were looking
for with this tool was for the process to be as consistent
as possible, so that each of the grains meets the customer’s
desires exactly.”
The optimisation of air flows and temperature differences
between the top and bottom of the tray to improve the
quality of the malt has been taken into account; A tool
made entirely of stainless steel has been chosen for quick
and easy cleaning. The alternating germination/kilning
cycles mean that those buildings can be cleaned regularly
and food safety requirements can be met.
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Dunaújvàros
- Hungary
The malting plant in Dunaújvàros was up
and running in 1995. It joined the Boortmalt group in
2006.
Stéphane
Michel
Manager
“The establishment of the Boortmalt group in
central Europe, in Hungary in Dunaùjvàros
but also in Croatia in Nova Gradiska, is part of our strategy
for supporting customers in central Europe, in addition
to our plants in western Europe as well as China.One of
the advantages of our plants in eastern and central Europe
is their logistical positioning: they are both located
on main road networks. Dunaújvàros is located
directly on the Danube, and the plants have also been
built in or near barley cultivation areas.”
Akos Nemessalyi
Purchaser raw materials
"The Dunaùjvàros malting plant
processes around 80,000 tons of brewing barley each year:
about 20% of this is winter barley and the rest is spring
barley. We store the barley varieties separately and use
the best quality barley".
Györgyt
Basa
Chief of
production
"The total production capacity is 60,000 tons
of malt a year, which means we start one batch every day
with 180 tons of barley.Our technology varies slightly
from other Boortmalt production facilities because we
have no steep vessel tank, instead we have a washing drum
which provides the possibility for the barley to absorb
water first".
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Nova Gradiska - Croatia
In 1971, the first commercially orientated malting plant
of the former Yugoslavia was built in Nova Gradiska. Boortmalt
then replaced it by a new plant on the same site which
started in 2001.
Vlado
Bicanic
Manager
Slavonija Slad
" Slavonija Slad is
the only malting plant in Croatia, and the most up-to-date
and largest in the region.We are now producing 60,000
tons of top quality malt a year and supplying all the
breweries in Croatia, neighbouring countries like Bosnia
Herzegovina and Slovenia and top quality malt for the
brewery needs in Serbia.
GKV technology is used in Nova Gradiska. The mash, located
at the top of the tower, functions horizontally".
Emil Babess
Chief of
Production Slavonija Slad
"It is a
simple structure, consisting of a flat bottom steep on
the top and three germination and kilning vessels below.Our
process lasts eight days. First of all we load the flat
bottom steep with 385 tons of barley, which we keep there
for two days.Some barley is immersed completely under
the water, and we also have a dry period.After two days,
from the flat bottom steep, we load one of the three GKVs
which are identical. The barley is kept in the GKV for
five days of germination followed by one day of kilning.
The full process therefore lasts eight days."
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