When Soufflet Malt required an upgrade to the pelletiser process at its Burton‑upon‑Trent facility to support more efficient, safer production, it turned to Woodward Group for support.

Our central aim was to modernise Soufflet Malt’s existing system by increasing automation, improving operator safety, enhancing process control, and enabling the use of multiple product‑specific recipes.

About Soufflet Malt

With 29 sites in Europe, Asia, Latin America and Africa, Soufflet Malt has an annual production capacity of 2,400,000 tonnes of malt to meet the demands of its customers around the world. Its agronomic expertise combined with its industrial excellence ensures the availability of a wide range of exceptional malts, standard or special, kilned or roasted, with the aim of continuously improving the sustainability of Soufflet Malt products.

Woodward Group has previously supported Soufflet Malt with the installation of two new 225‑tonne germination vessels at the same site, providing a strong understanding of the operation and a trusted foundation for the next phase of work.

What we did

Woodward Group delivered a comprehensive project that included the supply and integration of a new MCC control panel, together with an HMI for process operation. This required the removal and replacement of existing systems and cabling, the installation of new sensors to support optimal system performance, and the integration of new controls while retaining most of the existing mechanical components.

Throughout the project, Woodward Group worked closely with the client and relevant suppliers. We conducted detailed site surveys to address explosive atmosphere requirements, produced a detailed Functional Design Specification, developed new software and an enhanced user interface for the HMI station, and carried out thorough commissioning and testing of all installed elements.

The results

We’re delighted that the project was delivered in full compliance with the client’s specifications, ensuring safe execution, minimal process downtime, and a cost‑effective installation. Already, the upgraded pelletiser process has significantly improved operational efficiency for Soufflet Malt by reducing the need for operator intervention, resulting in a safer and more streamlined workflow.

Ultimately, having enhanced control of both the process and overall production has contributed to a higher‑quality end product. Additionally, the components supplied are fully compliant with ATEX requirements, ensuring a safer working environment within the designated explosive‑atmosphere areas.

If you’d like more information about our services or would like to discuss your next project, please get in touch.