Kilning is one of the most crucial stages in the malting process. After germination, the “green malt” must be carefully dried and cured to halt growth at the optimum point, lock in flavour and create a product that brewers, food manufacturers and distillers can rely on for consistency. It’s the process that is the most energy intensive step in the malt production process.
For decades when energy cost or CO2 emissions weren’t a consideration, much of the hot exhaust air produced during kilning has simply been released into the atmosphere, taking valuable heat (and money) with it. In a world where energy prices are constantly rising and sustainability is no longer optional, this inefficiency is no longer acceptable. That’s why heat recovery schemes are becoming vital for modern maltsters.
Why This Matters for Maltsters Today
Energy has become one of the defining issues for malt production. Rising fuel costs, global competition and increasing sustainability demands all put pressure on maltsters to modernise their operations. Heat recovery offers a practical, proven way to address these challenges head-on. By investing in smarter kilning technology, maltsters can not only reduce costs and environmental impact but also strengthen their competitive edge in a demanding marketplace.
The tradition of malting has endured for thousands of years, but its future will depend on innovation. At Don Valley Engineering, we are committed to helping maltsters bridge that gap, preserving the craft while embracing technologies that make operations more sustainable, efficient and resilient.
The Energy Challenge of Kilning
Conventional kilning systems use indirect fired heating to provide the carefully controlled temperatures and airflow needed to dry malt evenly. While effective, they are not efficient. The sheer volume of heated air that escapes unused represents a double loss. Higher fuel bills and a larger carbon footprint.
For maltsters, this creates a threefold challenge. Firstly, energy costs continue to eat into margins at a time when competition in the brewing supply chain is fiercer than ever. Secondly, inefficiency means missed opportunities to optimise production. And thirdly, as regulations around carbon emissions tighten, the environmental impact of traditional kilning becomes an obstacle to compliance and reputation.
How Heat Recovery Changes the Equation
Heat can be recovered from a number of sources, from air to air heat exchanger to recover heat from the wet exhaust air, water glycol economisers, CHP systems, heat pumps or distillery condensate, among the most common options.
Double Deck Kilns
Further savings can be derived by sharing exhaust air between carefully phased kilns; the hot dry exhaust air from one kiln being shared to the second kiln earlier in it’s kilning cycle. This integrated approach maximises energy savings and reduces the overall heating equipment capacity, giving capital equipment cost savings as well.
Don Valley Engineering can offer double-deck kilning systems, including the full control system and philosophy to maximise fuel savings.
The DVE Approach
At Don Valley Engineering, we know that every malting facility faces its own set of challenges, shaped by scale, location and production goals. That’s why our project solutions are never one size fits all. Whether we are designing a brand-new kiln plant, retrofitting equipment into an existing facility or advising through consultancy and feasibility studies, our focus is always on delivering efficiency and value for money without compromising quality.
Our team has decades of experience in every stage of the malting process, and our ability to provide complete turnkey packages, from concept and design through to installation, commissioning and ongoing support, sets us apart as the UK’s leading provider of process plant for the maltings industry.