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.

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www.alfalaval.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)
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Brewhouse
Energy Recovery
Thermal Energy Consumption in
the Brewery

Other Mashing
16% 17%

Packaging
23%
Wort
Boiling
44%

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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

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www.alfalaval.com
www.alfalaval.com
 Vapour condenser
Vapour condenser requirements - 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

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 AlfaCond
Innovative hole configuration
Innovative pattern for condensation
Asymmetric channels
Semi-welded technology

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AlfaCond range

800
600
400

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Alfa Laval condensation techniques:

PHE type condenser

- Compact design, easier piping
- Low hold up volume, easier to regulate, quicker response time
- Light weight, low foundation load
- Small footprint, space saving
- High heat transfer, high turbulence, low fouling
- Stainless steel or exotic material
- Close temperature approach
- Easy to expand with more heat transfer area

- Low investment cost

- Low installation cost
- Low operation cost
- Low maintenance cost
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Wort pre-heating with hot water

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Calculation model

Fast estimation of potential costs savings

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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)
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Beer Recovery
from
Surplus Yeast
Beer recovery from surplus yeast
Potential
A typical Brewery produces an excess of yeast,
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.
Different equipment can be used :
Membrane microfiltration
Centrifugal technique:
High Speed Separator
Intermittent Discharging Separator
Continuous Discharging (Nozzle) Separator
Decanter

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 Beer Recovery - General Flowchart

Surplus Yeast Deaerated Blending

Water Filtration or
Recovered Beer Maturation tank
Tank

Recovered beer

Mixer

CIP Waste yeast

discharge

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UX-BOWL - Principle

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Vortex nozzles

Reduced nozzle flow Increased nozzle flow

Low feed concentration High feed concentration

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Vortex Nozzle Centrifuges for beer
recovery from harvested yeast

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Beer recovery FEUX 510

Typical results
Yeast Feed flow rate 20 -30 hl/h
Feed conc. 30 - 45 % V/V
Concentrated yeast > 20 % Dry Matter
Content
Recovered Beer < 100.000 cells/ml

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 Summary
FEUX 510 Nozzle Separator

Is a reliable, 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

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www.alfalaval.com
 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
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.alfalaval.com
Benefits of Toftejorg Products
- Mechanical Impact
Static Spray Balls are not providing any
mechanical impact, they are only distributing
liquid over the surface to be cleaned, 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.alfalaval.com
Benefits of Toftejorg Products
Less Pollution of Waste Water
The residual product is removed during the pre- cleaning
process, 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.alfalaval.com
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.alfalaval.com
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.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.com
 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.alfalaval.com
Lauter Tun
Toftejorg Product - TZ-74 BKV

Good cleaning standard

At the raking arms
Under the false bottom
No manual cleaning
needed
Less environmental impact

Slide 10 www.alfalaval.com
Wort Kettles
Toftejorg Product - 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.alfalaval.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.com
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.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.com
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