Process Design Expertise at Rosebank Distillery

Client:  Ian Macleod Distillers
Location: Falkirk, Scotland
Project: Rosebank Distillery Redevelopment
Service: Process Design & Engineering Support

Overview
Rosebank Distillery, a revered name in Lowland single malt whisky, was relaunched by Ian Macleod Distillers with a commitment to restoring its historic character while delivering a modern, efficient production facility. As part of this ambitious redevelopment, Allen Associates (HPE) Ltd was appointed to lead the process design, leveraging their specialist expertise in distillery engineering and energy-efficient operations.

Scope of Work

Allen Associates’ role encompassed the detailed process design of the distillery, from malt intake through to spirit dispatch, including:

• Design of mash house and still house systems, based on traditional Rosebank configurations – triple distillation and worm tubs
• Selection and specification of equipment including mash tun, washbacks, stills, worm tubs, and spirit handling systems
• Development of process flow diagrams (PFDs) and piping & instrumentation diagrams (P&IDs)
• Design of utility and CIP systems to ensure hygienic, safe, and robust operations
• Collaboration with the design team, client and contractors through design reviews and commissioning

Process Design Highlights

• Triple Distillation Configuration: In line with Rosebank’s heritage, the process was designed around a triple distillation regime, requiring careful balance of distillation flows, heat input, and still sizing.
• Copper Still Specification: The stills were designed to closely replicate the geometry and behaviour of the original Rosebank stills, to preserve the character of the spirit.
• Process Safety: In collaboration with IMD, the Allen Associates Process Safety team ensured the design adhered to industry best practices and relevant standards and guidance.

Outcomes

The process design developed by Allen Associates ensured the operational and quality expectations of the new Rosebank Distillery were met, while preserving the authenticity of the original site. The design delivered a balance of:

• Tradition and modernity
• Efficiency and flexibility
• Regulatory compliance and practical operability

Rosebank Distillery was successfully brought back into production, delivering spirit that is faithful to its Lowland roots but supported by 21st-century engineering standards.

Why Allen Associates

This project demonstrated Allen Associates' ability to deliver:

• Deep sector knowledge of distilling processes
• Proven experience in reviving heritage sites
• Process safety expertise – ensuring client confidence
• Robust, efficient, and scalable design solutions

Their contribution to Rosebank stands as a flagship example of intelligent process engineering aligned with tradition, craftsmanship, and modern performance expectations.