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Sustainable

Brewing Concept

Desalination
Sustainable Brewing Concept
Chemicals
Sustainable Brewing Concept
Turnkey System Integration & Automation
Introduction
Working in close cooperation with an innovative brewer, a leading brew house supplier and a filling line specialist, the Norit
Group developed a sustainable brewing concept. Integrating Norit’s innovative valve technology, membrane technology for water
utilities, CO2 systems, cold block systems, diatomaceous earth (DE)-free Beer Membrane Filtration (BMF), and quality control
equipment with all functions of a brewery, this concept creates a highly efficient and advanced operation and meets the challenges
From wort cooler to filler: one stop solution
of today and tomorrow.

The high costs of raw materials, water, energy, and logistics in virtually every geographical area force our customers to change Process water CIP Wastewater Process water CIP Wastewater
their investment philosophy and to optimize their economies of scale. Because of this, large brewing groups tend to design and treatment Unfiltrate reuse treatment treatment Filtrate reuse treatment

construct multiple three to five million hectoliter Greenfield operations instead of enlarging existing Brownfield plants to 10 or
even 15 million hectoliters.

Yeast
By introducing non-stop high gravity brewing, a continuous flow and a sophisticated use of membrane filtration, significant savings Wort cooling Crossflow Flash
management Blending
are realized on raw material usage and water and energy consumption. The highly automated brewing process requires minimal Fermentation DE-free BBT pasteurizer or
Propa- Storage filtration
carbonation sterile filtration
Wort aeration
labor, which results in additional operating cost savings. A compact footprint with an ideal brewery design lowers investments to gation Dosing

the absolute minimum. Therefore, the decision for new greenfield operations is even more favorable.

Combined with Norit’s comprehensive Global Service Management that ensures efficient plant performance, Deaerated
CO2 recovery
water
better/more precise control, better economics and the most optimal utilization, Norit’s concept offers a viable,
long-term and carefree alternative with optimal lifecycle management to conventional services.
Mix proof valve technology

Norit takes care of plant design, engineering, project management, automation, assembly, handling, scheduling, • Automation with mix proof valve technology reduces beer losses,
cleaning solution and energy
installation, commissioning, documentation, and after-sales service.
Process automation
Norit’s sustainable brewing concept was designed to help brewers • PLC, e.g. Siemens, Allen-Bradley/Control Logix/Compact Logix,
• Cut CAPEX & OPEX Modicon/Quantum

• Maximize efficiency • Scada, e.g. Winn CC, RS View, GE Fanuc/iFix, Wonderware/Intouch

• Reduce water consumption • Integrated Systems, e.g. Proleit/Brewmax, Siemens Braumat/Sistar,


Krones/Botec
• Reuse process water
• Recycle wastewater Application
• Cut energy costs • Control application software developed in accordance to ISA S88.01
• Minimize CO2 footprint Complete on-site solutions
• Reduce environmental impact • Turnkey fermentation and beer processing plants, pressure tank cellars with
panel technology, pipe fence, or double seat valve technology

Sustainable Brewing Concept


Beer Processing
BMF Flash pasteurizer or sterile filtration
Cost comparison BMF DE
Fully automated BMF provides a highly scalable DE- More stability and a longer shelf life for liquid products can be achieved with either flash pasteurization or sterile filtration. With
free brewing process with minimum footprint and Beer losses • • flash pasteurization, the pump block, heat exchanger and holding section are designed as three single skids that work together
maximum output with improved taste and colloidal and are automated as one unit. If required, a buffer tank can be added to this unit.
stability. It allows for the highest operation flexibility
Maintenance and service • •
and simplifies the filtration process. While DE can Solid waste disposal • • For particle reduction or sterile filtration a fully automated filtration unit, which allows for steam sterilization, CIP, integrity
only be used once and needs to be either recycled testing and CO2 overlay, is offered. Custom-made systems with additional features are available on request.
or disposed, membranes are a multiple use product
Labor • •
and can be utilized for up to 400 filtration cycles. Stabilization with sillicagel • • Plug and play systems
Particularly in terms of CO2 footprint, BMF proves to
be more sustainable than DE filtration.
Separator NA • • Yeast storage and propagation
• Swing-bend panels
• Tank-top equipment
• Water deaeration
• Pigging
High gravity brewing
• Cleaning-in-place (CIP)
High gravity brewing is used to increase the production capacity without investing in larger brew houses, fermentation tanks,
filtration lines, and overall footprint. The high gravity brewing process involves the production of highly concentrated wort and the
dilution of the final beer. The main steps are water deaeration, dosing, blending of the high gravity beer with deaerated water,
and finally the carbonation of the blended beer to meet the sales CO2 content. Deaeration, dosing, blending, and carbonation

Quality Control
can be combined in one single skid. Custom-made systems including all necessary units, pipework and valve manifolds can be
designed for larger capacities.

A good definition for a quality beer is a beer that consistently meets specification. To ensure consistency
and that the required specifications are met, each step of the production process in a brewery should
be controlled, starting with the arrival of raw materials to the analysis of beer samples taken randomly
among the bottles in the holding room. Norit has solutions for the following quality control aspects:

• Total CO2 and O2 management (in-line, at-line and lab)


• Foam measurement (lab)
• Turbidity measurement (in-line/at-line/lab)
• Alcohol/Plato measurement (in-line)
• Monitoring of downstream processes such as pasteurization or keg/bottle washing (in-line)

In addition to individual pieces of equipment Norit offers a Total Lab Solution (TLS). Each TLS project
is customized, whether it is upgrading an existing lab or part of a new brewery. As needed a TLS
can include layout, design and equipping of the laboratory, in-house training, and commissioning of
the project. In a comprehensive sweep, Norit provides or sources the supply of lab furniture, quality
control equipment, glassware, consumables, chemicals and anything else a customer may need. The
advantage of a TLS project lies with the expertise that Norit provides by overseeing the entire project
from concept to commissioning to after-sales service with advanced operator training courses in the
area of preventive maintenance.

Sustainable Brewing Concept


Water & CO2 Global Service
Water management
When assessing and reducing the environmental footprint of a brewery, one focus area is the reduction of the water footprint.
Management
Because water is essential to the brewing process, both as an ingredient and in the production process, it must be given special Today, service is much more than just repair and maintenance. Service contracts are an integral part of your preventive maintenance
attention. Norit’s expertise in water use and its wide range of technologies provide the ideal solutions for brewery water management. program. During project management, Norit’s service team is introduced to the customer and assists with commissioning. On-site
the service team gathers valuable information about the local conditions of an operation. With performance data monitoring, they
• A Water Audit determines the current water usage and water streams in a production plant and highlights opportunities to are able to acquire long-term data, which ensures that troubleshooting and service activities can be very efficient and to the point
reduce overall water consumption. in case of an emergency. Depending on the type of service level agreement, a customer can solely focus on the core business and
• Process water polishing prepares product water to comply with the specific needs of a brewery utilizing membrane technology be assured that the potential for continuous improvement of a brewery is explored on a regular basis.
and activated carbon (decolorization and THM removal).
• Wastewater treatment with Membrane BioReactor (MBR) technology provides better water quality, smaller footprint, less Norit’s lifecycle/service management can be divided into two phases: design and operation. Proposal/planning, contract
sludge, adherence to legislation, and reduced handling costs when compared to conventional wastewater treatment. management, and engineering up to commissioning are typical design services. Start-up, monitoring, consulting (24/7 helpdesk),
• Effluent polishing prepares effluent for specific process requirements with activated carbon or membrane treatment. maintenance/ replacement of components, evaluation and optimization are components of the operation services. The overall
goal is to secure that an operation is running in the best possible and most cost-efficient way.
Typical water consumption Norit’s optimal
in a modern brewery water balance
One of Norit’s service beliefs is that acting is always better than reacting. Our pro-active service approach aims at:
Water type Usage % hl hl
Brewing water Brewing 30 1.2 1.2
• Improving production periods
Brewing water Process cleaning 17.5 0.7
• Reducing downtime
Soft water Bottle/keg cleaning 20 0.8
• Lowering the energy consumption
Plant water General service 10 0.4 0.4
• Limiting maintenance costs to a bare minimum
Denim water Boiler feed 2.5 0.1 0.1
• Increasing the ROI of an operation
Flush water Rinse/concentrate from RO/IEX 20 0.8 0.8
Total 100 4.0 2.5

24/7
helpdesk
CO2 Systems Contract management
CO2 is an important ingredient, which has a large influence on the beer quality and customers’ acceptance of the product. In
modern breweries CO2 recovery plants are common practice to provide for the CO2 supply of the brewery. By means of HLP plant
design breweries are able to recover food-grade CO2 from fermentation to meet the demand for beer production but at the same
time giving a surplus of food-grade CO2, which can be used in the production of soft drinks. The advantage is that fermentation CO2
produced from the beer itself offers a guarantee to the brewery that the recovered CO2 has fundamentally no food-alien substances. Certified local
Plant audits and service teams
maintenance More control
Heat recovery system LiquiVap Better economics
A CO2 recovery plant consists of several units, of which CO2 liquefaction and evaporation units account for a large portion of Optimal utilization
the plant’s energy consumption. With LiquiVap, the required energy can be reduced by up to 60%. Effectively, it simultaneously
facilitates the liquefaction of incoming CO2 gas (from the fermenters) and vaporization of incoming liquid CO2 (from the storage
tanks).
Data trending/
Pro-active monitoring, reporting
CO2 as refrigerant data analysis
For the production of liquid fermentation CO2, the CO2 has to be cooled to -24 to -34 ºC. Therefore, a CO2 recovery plant is
usually equipped with a cooling plant that typically uses NH3 or Freon as a coolant. Because of the environmental disadvantages of
Training
these cooling agents, the non-corrosive nature of CO2 as refrigerant makes it safe for workers to use and for the environment. In
addition, it offers excellent thermodynamic properties.

Sustainable Brewing Concept


Norit NV
Hertmerweg 42c • 7625 RH Zenderen • The Netherlands
T +31 74 255 07 77 • F +31 74 255 07 79
BoF E 9-2009

E info@noritpt.com • I www.norit.com
Please visit our website to obtain information about your local support! Norit reserves the right to make changes in the specifications at any time.

Sustainable Brewing Concept