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When asked about the dedicated production process, Kenny Noble, who has been a master smoker for over ten years explained, “these kilns really are magic in lots of ways – the smoke adds flavour and helps preserve the salmon”. Gregorie said: "We particularly like the flower design, because the thorn in them offsets the flower. Initially, we tried thorns but it looked like Alcatraz." The final stage is to take the salty brine, add some gentle heat to create crystals of sodium chloride with natural trace elements. Gregorie said; "we have restored an industry with a modern twist, to on an old process which was energy-intensive. We are making it more sustainable." It sounds so simple, but the devil is in the detail. Marshall worked with Strathclyde University to determine the best angle for the tower to maximise use of wind, the best angle for the branches, and the best angle for dripping water.
Seeing them up close, began his obsession with tower building began and it has taken them 15 years to get to the point they are at now, with a fully functioning salt graduation tower producing a finished product. The water is then transported to their holding tanks, before being filtered and circulated. It is then pumped to the top of the tower at a rate of 1000 litres per hour, moving slowly through the tower until the salty brine reaches around 22% salinity. We have enjoyed a longstanding partnership with Asda and are delighted to bring this exclusive Extra Special product to festive feasts across the UK this Christmas. Environmental concerns are at the heart of the project, to create an entirely natural product and building the tower took a lot of effort, Gregorie explains that no one has done it ever before. At Asda, we work alongside some wonderful local suppliers to create innovative, affordable, and delicious products for shoppers to enjoy.Then they could begin to look at different locations and work out the best conditions for the process to work, in all types of humidity and weather. The brine is pumped through the tower and moved by a series of taps. The process
That used a huge amount of energy and, having looked at all the different methods I was keen to try and get something that is sustainable and environmentally friendly,” says Marshall. On the west coast of Scotland stands a wooden structure that could have been conjured from a fairytale. Two Scottish takeaways feature in Deliveroo top 100 worldwide roundup - including acclaimed Thai restaurantIt is then pumped into the pan house which uses double-skinned pans for the next stage, the heating process. When the brine reaches 26% strength, the salt crystals begin to form. It’s ultimately that 6% of different elements that has a huge effect on the flavour,” says Marshall. “It makes it a lot sweeter and allows what you’re tasting to come through more. It enhances the flavour rather than taking it over.” Research took him across the globe to look at the wide variety of production methods. “In Japan, there are more than 200 different types of salt, and they have many ways of doing it to produce a different taste or flavour,” he says. The best time for collection "depends on level of the tide, and still settled weather. Naturally, seawater is around 3% saline solution, 3.5 % is ideal" " said Gregorie.
It took us a long time to get to what we wanted by adjusting temperatures and adjusting timings,” says Marshall. “With the cycle being five days it could be frustrating, but what we’ve got is exactly what we were looking for.” The couple are really hoping that everyone in Ayrshire can get behind and support their unique artisan salt venture as it grows. Taste test We started looking at different filters and we got it looking a lot whiter but it then started to taste less good because we were taking out all the elements such as potassium, magnesium and calcium.”
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They realised their life had slowed down a bit, so they were both happy with the decision to move to Ayr, as Gregorie explains: " it was the right time, the sensible time and a good time to join the company, with change happening, within the business. Gregorie first became aware of salt evaporation or graduation towers about 15 years ago and after some research headed to Germany to visit them. Once smoked and rested, the salmon is cut into chunky slices. By cutting it this way, it allows people to appreciate the buttery texture of the salmon, which is achieved by the long, slow smoking. Gregorie and his wife Whirly are the owners of a unique structure which stands proud in the coastal landscape, looking like something out of a fairy-tale or a set from a Tim Burton film. We are very proud of our Scottish heritage and at our picturesque smokehouse in the far Northeast of Scotland, our smoked salmon experts have spent many months perfecting the production process.
It isn’t possible to put a roof over the structure to keep off the rain because it would impact airflow and prevent evaporation. Register for our free monthly Farm Shop & Deli Newsletter The salt water is dribbled through 54 wooden taps and a series of channels, which are adjusted daily according to the weather conditions, to maximise evaporation, producing a more concentrated brine.Gregorie said: "you are allowed to take so much seawater before you have to ask the Queen for permission, but we are nowhere near that level at the minute." Scotland itself has a long history of salt production, peaking in the 18th century, when producers would heat huge pans of saltwater over coal to evaporate the water. Coupert will provide special discounts for certain products during December, customers can save some money according to their actual situation. It keeps us guessing, I'm one for new things and I'm always learning, which is part of the fun. I'm still pushing to get it to work better" Although it is the same simple process as hanging your up clothes outside to dry, Gregorie explains that: "It is a dark art, which depends on how fast the wind blows, air humidity and wind direction with the ideal being 45 degrees from the prevailing wind, however, the Scottish weather is not always predictable."
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