Ellers Farm Distillery

The Challenge

Ellers Farm Distillery Ltd commissioned a full DSEAR Risk Assessment and Compliance Review for its distillery operations in Stamford Bridge, North Yorkshire. The assessment focused on the production, storage and handling of high-strength alcohols, combustible powders and associated process hazards across the site.

The facility manufactures and processes a range of spirits including vodka, gin and whiskey, involving:

• Fermentation processes
• Multi-stage distillation
• Rectification to 96% ABV alcohol
• Internal bulk ethanol storage
• IBC handling and transfer operations
• Carbon treatment and vodka resting tanks
• Gin still operations
• Semi-automatic bottling processes
• Storage of combustible powders including sugar and yeast

The review identified that the site handled significant quantities of flammable liquids, including approximately 40 internal IBCs containing alcohol products at varying strengths, with some stored at 96% ABV.

Key risks identified included:

• Potential vapour cloud explosion risks from alcohol releases
• Internal storage arrangements for flammable IBCs
• Ignition risks from nearby electrical equipment
• Static discharge hazards during transfer operations
• Risks associated with distillation and rectification systems
• Combustible dust risks linked to sugar and yeast handling
• Potential fire and explosion risks during bottling operations
• Storage and segregation concerns for hazardous substances

The assessment also reviewed hazardous area classifications, ignition source controls, ventilation arrangements, emergency procedures, operator training and ATEX-related considerations across the facility.

The Solution Provided

A comprehensive DSEAR risk assessment and hazardous area classification review was carried out across the entire distillery operation, covering regulations 5 through 11 of DSEAR.

The project included:

• Full review of dangerous substances used and produced onsite
• Assessment of flammable liquids, vapours and combustible dusts
• Detailed process risk analysis for all production stages
• Hazardous area classification review
• Assessment of ignition source controls
• Review of storage, transfer and handling arrangements
• Evaluation of emergency procedures and operator training
• Review of ATEX-certified equipment and electrical safety

The assessment covered a wide range of operational areas including:

• Fermentation vessels
• First distillation processes
• Rectification systems
• 96% ABV alcohol storage tanks
• Gin still operations
• Bottling plant processes
• External alcohol storage
• Boiler room chemical storage

The review identified a number of existing positive controls already in place, including:

• Hazardous area classification and certified equipment
• Gas/VOC detection systems
• Permit to work procedures
• Fire and emergency evacuation procedures
• Competency-based operator training
• Spill response arrangements
• Safe systems of work for maintenance activities

A prioritised action plan containing 22 recommendations was produced to further strengthen DSEAR compliance and operational safety. These included:

• Reviewing internal IBC storage quantities and locations
• Considering external bulk alcohol storage arrangements
• Improving segregation between ignition sources and flammable liquid hazards
• Upgrading earthing and static protection measures
• Reviewing pump and transfer arrangements
• Confirming independent high-temperature protection systems on stills
• Improving ventilation and extraction arrangements in bottling areas
• Enhancing hazardous substance storage controls

The completed assessment provided Ellers Farm Distillery with a structured roadmap to improve fire and explosion protection measures, strengthen hazardous area management and support the continued safe operation of its distillation and spirits production activities in line with DSEAR requirements.