Potential for Craft Beer Breweries? - EBC Symposium€¦ · 5 TITZE, J., 2016: Beer Production with...

23
Jean Titze EBC SYMPOSIUM 2016 ▪ Wraclow ▪ 20 Sept 2016 Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?

Transcript of Potential for Craft Beer Breweries? - EBC Symposium€¦ · 5 TITZE, J., 2016: Beer Production with...

Page 1: Potential for Craft Beer Breweries? - EBC Symposium€¦ · 5 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium Modern

Jean Titze

EBC SYMPOSIUM 2016 ▪ Wraclow ▪ 20 Sept 2016

Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?

Page 2: Potential for Craft Beer Breweries? - EBC Symposium€¦ · 5 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium Modern

1 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Success factors for craft beer

“Perfect/authentic taste” is still the main reason for

consumers to buy a beer

Assuring taste stability plays another major role

good brewhouses (costs!)

On-site or locally produced food as a concept of regionality

Artisanal and/or traditional processing procedures

Beer Craft

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2 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Wort production – A relatively difficult technological process

Dedmands on …

… skills – exact observance of the wort production and its dependence on many parameters (qualifications and experience brewers).

... human resources – preparation of raw materials, brewhouse operation, monitoring and evaluation (concentration and high commitment of the operators).

... time – wort preparation in traditional way takes 6 to 15 hours.

... energy – long process with several complex temperature waveforms.

... high investment and operating costs – high cost of brewhouse (from mill to wort cooling unit), labor costs, energy consumption, difficult supplies and storage of raw materials.

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3 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Brewing with wort concentrate

TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław. 3

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4 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Brewing trials to produce a beer from standard wort and re-diluted wort concentrate

Wort concentrate ( 60 °P)

Re-diluted wort (12 °P)

Fermentation/maturation

Beer

Standard wort (12 °P)

Fermentation/maturation

Beer

Cold wort (12 °P)

Chemical-technical and sensorial

analyses

Barley malt

Milling Mashing Lautering Boiling Hot trub

separation

Hops

Cooling

Water

Wort concentration

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5 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Coag. Nitrogen mg/L ─15-20%

FAN (ninhydrin) mg/L ─5-10%

Beer

Bitterness BU ─10-15%

Total iso-α-acids mg/L ─10-15%

Colour EBC +10-15%

Foam sec ─3-5%

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Coag. Nitrogen mg/L ─15-20%

FAN (ninhydrin) mg/L ─5-10%

Beer

Bitterness BU ─10-15%

Total iso-α-acids mg/L ─10-15%

Colour EBC +10-15%

Average changes of wort and lager beer quality parameters

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Coag. Nitrogen mg/L ─15-20%

FAN (ninhydrin) mg/L ─5-10%

Beer

Bitterness BU ─10-15%

Total iso-α-acids mg/L ─10-15%

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Coag. Nitrogen mg/L ─15-20%

FAN (ninhydrin) mg/L ─5-10%

Beer

Bitterness BU ─10-15%

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Coag. Nitrogen mg/L ─15-20%

FAN (ninhydrin) mg/L ─5-10%

Beer

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Coag. Nitrogen mg/L ─15-20%

FAN (ninhydrin) mg/L ─5-10%

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Coag. Nitrogen mg/L ─15-20%

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Colour EBC +10-15%

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Total iso-α-acids mg/L ─15-25%

Parameter Unit Changes

Cold wort

Bitterness BU ─15-20%

Parameter Unit Changes

Cold wort

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6 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Conclusion 1/2

In

Hop losses occurred in wort as well as in beer (bitterness and total iso-α-acids decrease) during the concentration step.

Colours are about 10 to 15% higher Maillard products are stimulated by the

evaporation process

Slight reduction of high molecular proteins in the concentrated wort small decrease in foam stability in the final beer

Losses in FAN in the cold wort insufficient fermentation performance

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7 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Market samples

TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław. 7

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8 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Example SmartBrew®: “We split the brewing process in two“

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9 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Example: Ad of a fermentation plant (CMB)

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10 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Wort production – A relatively difficult technological process

Dedmands on …

… skills – exact observance of the wort production and its dependence on many parameters (qualifications and experience brewers).

... human resources – preparation of raw materials, brewhouse operation, monitoring and evaluation (concentration and high commitment of the operators).

... time – wort preparation in traditional way takes 6 to 15 hours.

... energy – long process with several complex temperature waveforms.

... high investment and operating costs – high cost of brewhouse (from mill to wort cooling unit), labor costs, energy consumption, difficult supplies and storage of raw materials

... high investment and operating costs – high cost of brewhouse (from mill to wort cooling unit), labor costs, energy consumption, difficult supplies and storage of raw materials

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11 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Cost calculation

TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław. 10

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12 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Variable costs for a craft brewery (model calculation) 1/4

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Malt (─ spent grain revenue)

18.5 kg/hL ∙ 500 €/t (─ 0.15 €/hL)

9.10 -

Hops 10 g α-acid/hL ∙ 300 €/kg 3.00 - Hopped wort concentrate (60 °P)

20 kg/hL ∙ 2.50 €/kg - 50.00

CO2 (carbon dioxide) 1.5 kg/hL ∙ 2.00 €/kg 3.00 3.00 Yeast (dry yeast) 10.00 10.00 Raw materials (total) 25.10 63.00

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Malt (─ spent grain revenue)

18.5 kg/hL ∙ 500 €/t (─ 0.15 €/hL)

9.10 -

Hops 10 g α-acid/hL ∙ 300 €/kg 3.00 - Hopped wort concentrate (60 °P)

20 kg/hL ∙ 2.50 €/kg - 50.00

CO2 (carbon dioxide) 1.5 kg/hL ∙ 2.00 €/kg 3.00 3.00 Yeast (dry yeast) 10.00 10.00

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Malt (─ spent grain revenue)

18.5 kg/hL ∙ 500 €/t (─ 0.15 €/hL)

9.10 -

Hops 10 g α-acid/hL ∙ 300 €/kg 3.00 - Hopped wort concentrate (60 °P)

20 kg/hL ∙ 2.50 €/kg - 50.00

CO2 (carbon dioxide) 1.5 kg/hL ∙ 2.00 €/kg 3.00 3.00

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Malt (─ spent grain revenue)

18.5 kg/hL ∙ 500 €/t (─ 0.15 €/hL)

9.10 -

Hops 10 g α-acid/hL ∙ 300 €/kg 3.00 - Hopped wort concentrate (60 °P)

20 kg/hL ∙ 2.50 €/kg - 50.00

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Malt (─ spent grain revenue)

18.5 kg/hL ∙ 500 €/t (─ 0.15 €/hL)

9.10 -

Hops 10 g α-acid/hL ∙ 300 €/kg 3.00 -

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Malt (─ spent grain revenue)

18.5 kg/hL ∙ 500 €/t (─ 0.15 €/hL)

9.10 -

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL

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13 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Variable costs for a craft brewery (model calculation) 1/4

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Malt (─ spent grain revenue)

18.5 kg/hL ∙ 500 €/t (─ 0.15 €/hL)

9.10 -

Hops 10 g α-acid/hL ∙ 300 €/kg 3.00 - Hopped wort concentrate (60 °P)

20 kg/hL ∙ 2.50 €/kg - 50.00

CO2 (carbon dioxide) 1.5 kg/hL ∙ 2.00 €/kg 3.00 3.00 Yeast (dry yeast) 10.00 10.00 Raw materials (total) 25.10 63.00

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00

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14 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Variable costs for a craft brewery (model calculation) 2/4

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Water 0.9 m³/hL ∙ 3.00 €/m³ 2.70 1.98 Wastewater 0.8 m³/hL ∙ 2.00 €/m³ 1.60 1.05 Electric power 14 kWh/hL∙ 0.18 €/kWh 2.52 2.52 Gas 6 m³/hL ∙ 0.75 €/t 4.50 0.45 Energy (total) 11.32 6.00

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Water 0.9 m³/hL ∙ 3.00 €/m³ 2.70 1.98 Wastewater 0.8 m³/hL ∙ 2.00 €/m³ 1.60 1.05 Electric power 14 kWh/hL∙ 0.18 €/kWh 2.52 2.52 Gas 6 m³/hL ∙ 0.75 €/t 4.50 0.45

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Water 0.9 m³/hL ∙ 3.00 €/m³ 2.70 1.98 Wastewater 0.8 m³/hL ∙ 2.00 €/m³ 1.60 1.05 Electric power 14 kWh/hL∙ 0.18 €/kWh 2.52 2.52

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Water 0.9 m³/hL ∙ 3.00 €/m³ 2.70 1.98 Wastewater 0.8 m³/hL ∙ 2.00 €/m³ 1.60 1.05

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Water 0.9 m³/hL ∙ 3.00 €/m³ 2.70 1.98

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00

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15 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Variable costs for a craft brewery (model calculation) 2/4

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Water 0.9 m³/hL ∙ 3.00 €/m³ 2.70 1.98 Wastewater 0.8 m³/hL ∙ 2.00 €/m³ 1.60 1.05 Electric power 14 kWh/hL∙ 0.18 €/kWh 2.52 2.52 Gas 6 m³/hL ∙ 0.75 €/t 4.50 0.45 Energy (total) 11.32 6.00

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00

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16 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Variable costs for a craft brewery (model calculation) 3/4

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

Filter aids 0.75 0.75 Processing aids 0.75 0.75 Laboratory materials 0.25 0.20 Maintenance 0.60 0.45 Disposal 0.50 0.30 Other operating costs (total)

4.35 3.35

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

Filter aids 0.75 0.75 Processing aids 0.75 0.75 Laboratory materials 0.25 0.20 Maintenance 0.60 0.45 Disposal 0.50 0.30

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

Filter aids 0.75 0.75 Processing aids 0.75 0.75 Laboratory materials 0.25 0.20 Maintenance 0.60 0.45

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

Filter aids 0.75 0.75 Processing aids 0.75 0.75 Laboratory materials 0.25 0.20

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

Filter aids 0.75 0.75 Processing aids 0.75 0.75

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

Filter aids 0.75 0.75

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

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17 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Variable costs for a craft brewery (model calculation) 3/4

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Detergents & desinfections

1.50 0.90

Filter aids 0.75 0.75 Processing aids 0.75 0.75 Laboratory materials 0.25 0.20 Maintenance 0.60 0.45 Disposal 0.50 0.30 Other operating costs (total)

4.35 3.35

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Other operating costs (total)

4.35 3.35

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18 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Variable costs for a craft brewery (model calculation) 4/4

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Other operating costs (total)

4.35 3.35

Beer tax 10.00 10.00 Variable costs (total) 50.77 82.35

Brewed with … … standard

wort … wort

concentrate Variable costs (model calculation) €/hL €/hL Raw materials (total) 25.10 63.00 Energy (total) 11.32 6.00 Other operating costs (total)

4.35 3.35

Beer tax 10.00 10.00

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19 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Brewed with … … standard

wort … wort

concentrate

€ €

Investment costs (total)

30 hL brewhouse 980,000 400,000

Financial requirements

approximately 1,050,000 430,000

Owner's equity 250,000 250,000

Deficit 800,000 180,000

Annuity* for 800 T€ (180 T€)

3% and 15 years, approx. 67,000 15,000

*(paying back incl. interest)

Cost calculation for a craft brewery 1/2

Brewed with … … standard

wort … wort

concentrate

€ €

Investment costs (total)

30 hL brewhouse 980,000 400,000

Financial requirements

approximately 1,050,000 430,000

Owner's equity 250,000 250,000

Deficit 800,000 180,000

Brewed with … … standard

wort … wort

concentrate

€ €

Investment costs (total)

30 hL brewhouse 980,000 400,000

Financial requirements

approximately 1,050,000 430,000

Owner's equity 250,000 250,000

Brewed with … … standard

wort … wort

concentrate

€ €

Investment costs (total)

30 hL brewhouse 980,000 400,000

Financial requirements

approximately 1,050,000 430,000

Brewed with … … standard

wort … wort

concentrate

€ €

Investment costs (total)

30 hL brewhouse 980,000 400,000

Brewed with … … standard

wort … wort

concentrate

€ €

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20 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Brewed with … … standard

wort … wort

concentrate

€/a €/a

Income/revenue 2,000 hL/a ∙ 250 €/hL 500,000 500,000

Variable costs 2,000 hL/a ∙ 51 €/hL (82 €/hL)

─101,540 ─164,700

Fix costs ─180,500 ─180,500

Cash flow/overplus 217,960 154,800

Paying back incl. interest

─67,000 ─15,000

Return 150,960 139,800

Cost calculation for a craft brewery 2/2

Brewed with … … standard

wort … wort

concentrate

€/a €/a

Income/revenue 2,000 hL/a ∙ 250 €/hL 500,000 500,000

Variable costs 2,000 hL/a ∙ 51 €/hL (82 €/hL)

─101,540 ─164,700

Fix costs ─180,500 ─180,500

Cash flow/overplus 217,960 154,800

Paying back incl. interest

─67,000 ─15,000

Brewed with … … standard

wort … wort

concentrate

€/a €/a

Income/revenue 2,000 hL/a ∙ 250 €/hL 500,000 500,000

Variable costs 2,000 hL/a ∙ 51 €/hL (82 €/hL)

─101,540 ─164,700

Fix costs ─180,500 ─180,500

Cash flow/overplus 217,960 154,800

Brewed with … … standard

wort … wort

concentrate

€/a €/a

Income/revenue 2,000 hL/a ∙ 250 €/hL 500,000 500,000

Variable costs 2,000 hL/a ∙ 51 €/hL (82 €/hL)

─101,540 ─164,700

Fix costs ─180,500 ─180,500

Brewed with … … standard

wort … wort

concentrate

€/a €/a

Income/revenue 2,000 hL/a ∙ 250 €/hL 500,000 500,000

Variable costs 2,000 hL/a ∙ 51 €/hL (82 €/hL)

─101,540 ─164,700

Brewed with … … standard

wort … wort

concentrate

€/a €/a

Income/revenue 2,000 hL/a ∙ 250 €/hL 500,000 500,000

Brewed with … … standard

wort … wort

concentrate

€/a €/a

Regardless of the small difference in the final company's return, the use of hopped wort concentrate makes sense for people with a low capital cover to save investment costs even for a brewery size of 30 hL.

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21 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Conclusion 2/2

To produce a premium beer from concentrate, a high quality hopped wort concentrate has to be chosen.

The presented cost savings shall help the brewer to decide if the use of wort concentrate will lead to a significant cost optimization as well as to a lean production to enable craft produced beer.

Nevertheless, the compensation of short investment budgets while using hopped wort concentrates should always be accompanied by securing an objective beer quality.

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22 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.

Thank you very much for your attention!

22 TITZE, J., 2016: Beer Production with Wort Concentrate — Potential for Craft Beer Breweries?. EBC Symposium “Modern brewhouse technologies and wort production”, Wrocław.