Effect of Malthouse Size and Transportation on the Environmental Profile of Malt Production

Malting is one of the most energy-intensive stages in beer brewing, yet its environmental impacts remain under-characterized despite recent efficiency gains. Barley and malt transport drive significant greenhouse gas emissions in import-dependent countries, while local, small-scale production can offset those savings through lower process efficiencies or higher resource use. This study conducted a cradle-to-gate Life Cycle Assessment (LCA) of three Italian malthouses—small, medium, and large—using SimaPro 10.2.0.0 and a functional unit of 1 kg of malted barley delivered by bulk truck to local breweries. Primary data on barley, water, methane, and electricity consumption, as well as waste generation, were collected via questionnaires; secondary data were sourced from Ecoinvent and Agri-Footprint. Impact categories were evaluated using the Cumulative Energy Demand (CED) and Product Environmental Footprint (PEF) methodologies. Barley cultivation dominates the footprint (84–92% of total impacts when using local grain). Drying and transport contribute 3.7–4.4% and 0–8.4% of impacts, respectively, depending on facility scale and import share. Smaller malthouses exhibit higher per-kilogram impacts due to lower energy efficiency and transportation modes. Mitigation strategies —including sustainable agriculture, renewable energy adoption, logistics optimization, and process improvements—can substantially reduce impacts. Notably, sourcing barley from low-impact suppliers alone lowers the carbon footprint from 0.80 to 0.66 kg CO 2e /kg, freshwater eutrophication from 227 to 32 CTU e /kg, land use from 196 to 136 Pt/kg, and overall PEF from 192 to 81 µPt/kg. These results underscore the critical role of feedstock sourcing and process efficiency in decarbonizing malt production and provide a quantitative baseline for targeted sustainability interventions.