1.4 million crumpets made every day at Warburton’s site
Baking giant Warburtons has been given the go-ahead to start producing an industrial amount of an essential ingredient at its Billington Road factory, where two-thirds of the UK’s crumpets are produced every day.
The new production capability is just one part of Warburtons’ large investment in its Burnley facilities, the main producer of sandwich thins, wraps, and crumpets for the UK’s largest baker.
This £100m nationwide investment in its manufacturing capacity was reaffirmed by the firm in May, just weeks after a fault on its potato cake line caused a massive fire that ripped through the facility.
It took two days and dozens of firefighters to put out this accidental blaze, which caused serious damage to a portion of the building, but left the important crumpet production area untouched.
1.4 million of these classic British breakfast staples fly out the door of the firm’s Burnley factory every day. That is almost 510 million over the 364 days the factory operates every year.
But a key ingredient in producing the crumpets’ quintessential spongey structure, known as ‘cream yeast’, was previously having to be bought in. This living material feeds on the sugars in the mix and turns it into carbon dioxide, which creates the product’s bubbled texture.
However, after gaining planning permission from Burnley Council for the construction of a new bio-fermentation plant, Warburtons will now be able to produce vast quantities of this liquid yeast on site.
This is important as yeast is a living single cell microorganism, so transporting the ingredient to a factory inevitably causes it to become less effective and requires it to be less specialised for general sale.
But with these new fermentation tanks, Warburtons will be able to pipe its own specialised yeast straight into its manufacturing lines, or to its other factories.
Two 6.8 metre high steel fermentation tanks will form the centre of this new production compound, which is adjacent to the flour silo at the Billington Road site. This area will take over a portion of the car park, resulting in the loss of two spaces.
The new structure will help to boost the output of two new high-speed crumpet production lines at the facility that were announced in April, with Burnley-born yeast soon giving the baked product its distinctive bubbles.









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