Warburtons, the UK's largest baker, has secured planning permission from Burnley Council to construct a new bio-fermentation plant at its Billington Road factory. This will allow the company to produce its own cream yeast on site, a key ingredient in the crumpets that the facility churns out at a rate of 1.4 million per day.
The new production capability is part of a £100m nationwide investment in manufacturing capacity, reaffirmed by the firm in May. This came just weeks after a fire on its potato cake line caused significant damage to part of the building, though the crumpet production area was left untouched.
On-site yeast production to boost efficiency
Previously, the cream yeast used to create the crumpets' spongey texture had to be bought in from external suppliers. This living material feeds on sugars in the mix, producing carbon dioxide that gives the product its bubbled structure. However, transporting yeast is problematic because it is a living single-cell microorganism, which degrades in effectiveness during transit and limits its specialisation.
With the new fermentation tanks, Warburtons will be able to pipe its own specialised yeast directly into its manufacturing lines or to other factories. Two 6.8-metre-high steel fermentation tanks will form the centre of the new production compound, located adjacent to the flour silo at the Billington Road site. The construction will take over part of the car park, resulting in the loss of two parking spaces.
Boosting crumpet output at Burnley site
The new structure will help to boost the output of two new high-speed crumpet production lines announced in April. The Burnley factory, which operates 364 days a year, produces almost 510 million crumpets annually, accounting for two-thirds of the UK's crumpet supply. The on-site yeast production is expected to enhance the efficiency and quality of this output, with Burnley-born yeast soon giving the baked product its distinctive bubbles.
The investment underscores Warburtons' commitment to its Burnley facilities, which are the main producer of sandwich thins, wraps, and crumpets for the company. The planning approval marks a significant step in the firm's strategy to streamline production and reduce reliance on external suppliers.
