Brewery
Performance Optimization
DBF
Leuven – February 5, 2007

Johan Galle

Our corporate mission

To optimize the performance
of our customers’ processes.
Time and time again.

www.alfalaval.com

www.alfalaval.com

com .Brewery Performance • Focus areas – Brewhouse • Minimizing Energy Consumption (Energy Recovery) • Minimizing Product Losses (Hot Wort Clarification) – Fermenting cellar • Minimizing Production Time & Product Losses (Greenbeer treatment) • Beer Recovery from surplus yeast – Filtration & Brightbeer Area • Minimizing Product Losses / avoiding KG consumption (Cross-Flow Filtration) • Routing Automation (mixproof) – Waste Water Treatment • Minimizing Sludge Volume (Sludge Thickening) www.alfalaval.

Brewhouse Energy Recovery .

alfalaval.com .Thermal Energy Consumption in the Brewery Other Mashing 16% 17% Packaging 23% Wort Boiling 44% www.

alfalaval.com .Wort Preheating / Vapour Condensing • Heating wort during transfer between lauter tun/mash filter and boiling kettle • Energy recovery by vapour condensing • Energy stored in a hot water buffer tank (Energy Saving Vessel) • Heat recovery from condensate possible for secondary hot water generation www.

com .alfalaval.www.

com .www.alfalaval.

com . Vapour condenser Vapour condenser requirements .alfalaval.parameters • Minimal pressure drop on the vapour side => relative big gap on vapour side • Minimal Temperature difference hot water / vapour => high thermal efficiency (~ turbulence) • Minimal gasket exposure on wort side • Compact www.

AlfaCond • Innovative hole configuration • Innovative pattern for condensation • Asymmetric channels • Semi-welded technology www.com .alfalaval.

AlfaCond range 800 600 400 www.alfalaval.com .

high turbulence. easier piping .Low installation cost .Low hold up volume.Stainless steel or exotic material .Light weight.Compact design. quicker response time .com .Close temperature approach .Easy to expand with more heat transfer area .Low investment cost .Low operation cost .Alfa Laval condensation techniques: PHE type condenser . easier to regulate. space saving .Low maintenance cost www. low foundation load .alfalaval.Small footprint. low fouling .High heat transfer.

Wort pre-heating with hot water www.com .alfalaval.

Calculation model • Fast estimation of potential costs savings www.com .alfalaval.

alfalaval.Brewery Performance • Focus areas – Brewhouse • Minimizing Energy Consumption (Energy Recovery) • Minimizing Product Losses (Hot Wort Clarification) – Fermenting cellar • Minimizing Production Time & Product Losses (Greenbeer treatment) • Beer Recovery from surplus yeast – Filtration & Brightbeer Area • Minimizing Product Losses / avoiding KG consumption (Cross-Flow Filtration) • Routing Automation (mixproof) – Waste Water Treatment • Minimizing Sludge Volume (Sludge Thickening) www.com .

Beer Recovery from Surplus Yeast .

alfalaval.com . amounting to typical 2% of the production volume. • About 50% of this volume (or 1% of the total production volume) can be recovered as Good Quality Beer.Beer recovery from surplus yeast Potential • A typical Brewery produces an excess of yeast. • Different equipment can be used : – Membrane microfiltration – Centrifugal technique: • High Speed Separator – Intermittent Discharging Separator – Continuous Discharging (Nozzle) Separator • Decanter www.

com .alfalaval.General Flowchart Surplus Yeast Deaerated Blending Water Filtration or Recovered Beer Maturation tank Tank Recovered beer Mixer CIP Waste yeast discharge www. Beer Recovery .

alfalaval.Principle www.UX-BOWL .com .

Vortex nozzles Reduced nozzle flow Increased nozzle flow Low feed concentration High feed concentration www.alfalaval.com .

com .alfalaval.Vortex Nozzle Centrifuges for beer recovery from harvested yeast www.

30 .000 cells/ml www.Beer recovery FEUX 510 Typical results • Yeast Feed flow rate 20 -30 hl/h • Feed conc.com .45 % V/V • Concentrated yeast > 20 % Dry Matter Content • Recovered Beer < 100.alfalaval.

flexible. simple and economic technology • Is a relatively small machine with a high solids handling capacity • Consistent results: •Low Oxygen pick-up in the recovered beer •Low remaining yeast in the recovered beer •Gentle treatment of the yeast (low damage to the yeast cells) •High Dry Matter Content of the concentrated yeast www.com . Summary FEUX 510 Nozzle Separator • Is a reliable.alfalaval.

alfalaval.com .www.

Beverage Forum InBev Seminar 2007 Alfa Laval Tank Equipment A/S Slide 1 .

Presentation Contents • Theoretical basics • Benefits of using Toftejorg equipment • Toftejorg products in brewing application Slide 2 www.alfalaval.com .

alfalaval.com .Demands of the Cleaning The tank must be clean • low consumption of fresh water • low consumption of cleaning agents • minimum of energy consumption • amount and pollution level of waste water must be low • cleaning process must be as short as possible => effective cleaning is meeting these requirements Slide 3 www.

they are only distributing liquid over the surface to be cleaned.Benefits of Toftejorg Products . relying on the cascading flow. • Rotary Jet Heads are designed to provide – distribution of liquid in a pre-determined pattern – mechanical impact to the surface to be cleaned. => most of the residual product is already removed during the pre-cleaning Slide 4 www.Mechanical Impact • Static Spray Balls are not providing any mechanical impact.com .alfalaval.

so the caustic is less contaminated in the caustic cleaning cycle which means: • longer life of the caustic • less caustic in the waste water • less COD in the waste water Slide 5 www.Benefits of Toftejorg Products Less Pollution of Waste Water The residual product is removed during the pre.com .cleaning process.alfalaval.

com .alfalaval.Benefits of Toftejorg Products Less Consumption of Caustic Caustic cleaning can be left out because of the strong mechanical removal of the organic residues => no costs for caustics => no caustics => less COD in waste water => no jet blasting of CO2 => less CO2 in environment => immediate switch over to CO2 recuperation during filling of the tanks => collection of a higher amount of CO2 Slide 6 www.

Benefits of Toftejorg Products Also with caustic cleaning. there are still considerable improvements and cost savings • consumption of fresh water decreases • concentration of caustics decreases • contamination of waste water decreases • cleaning time shortens significantly • in some cases reduction of manual cleaning Slide 7 www.com .alfalaval.

alfalaval.com .Benefits of Toftejorg Products Fewer Tank Cleaning Machines The small number of Rotary Jet Heads and the lower flow rate result in significant lower costs of CIP-cleaning equipment • smaller tanks in the CIP plant • smaller pipe diameter • smaller valve size • reduced number of valves (alternating valves are not needed in horizontal tanks) Slide 8 www.

alfalaval. Benefits of Toftejorg Products • Rotacheck verification system consists of a build-in pressure sensor connected to a relay box • Electronic monitoring that Rotary Jet Heads is functioning correctly by given a signal each time one of the jets impinges on the sensor Slide 9 www.com .

Lauter Tun Toftejorg Product .alfalaval.com .TZ-74 BKV • Good cleaning standard • At the raking arms • Under the false bottom • No manual cleaning needed • Less environmental impact Slide 10 www.

com .alfalaval.TZ-74 BKV • The heating surfaces are hard TZ 74 in action to keep efficiently clean • Many have internal heaters which do have “difficult-to-clean areas” • Many do have Static Spray Balls which do not clean well and use large fluid volumes and strong chemicals Slide 11 www.Wort Kettles Toftejorg Product .

com .Whirlpool Toftejorg Product .TZ-74 SC • More easy to discharge the Trub • Short cleaning to make the Trub mobile • Low water addition to the Trub • Same machine used for Trub discharging and cleaning Slide 12 www.alfalaval.

Fermentation Toftejorg Product .TZ-74 SC • Use pre-rinse to remove all residues • Jet impact cleaning at thefill/yeast band level • Direct impact on the vessel cone area • Guaranteed 360 degree coverage • Use of acid as an alternative to caustic Slide 13 www.com .alfalaval.

com .Benefits of using Toftejorg rotary spray and jet heads • Time – Cleaning time can be reduced by 50% – allowing more time for production Cleaning Cleaning Production Production Slide 14 www.alfalaval.

Benefits of using Toftejorg rotary spray and jet heads • Cleaning standard – Constantly high cleaning standard • Volume of water. waste and detergents – Flow can be reduced by 50% – Consumption of water can be reduced with up to 75% – Consumption of detergent can be reduced with up to 75% Slide 15 www.alfalaval.com .

Beverage Forum InBev Seminar 2007 Thank you for your attention!! Slide 16 .