Sustainability: Eking out Capacity. Friday April 24, 2009 Craft-brewers conference Boston, MA, USA.

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Sustainability: Eking out Capacity. Friday April 24, 2009 Craft-brewers conference Boston, MA, USA.

Transcript of Sustainability: Eking out Capacity. Friday April 24, 2009 Craft-brewers conference Boston, MA, USA.

Sustainability: Eking out Capacity.

Friday April 24, 2009Craft-brewers conference

Boston, MA, USA.

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Green or Sustainability, relevant ?

74 % of Americans think global warming is serious.Consumers say green is important in making key decisions:

Products they purchase, (79%)Where they shop, (74%)Where they invest their money, (72%)Would do more for the environment if they only knew how (49%)

More than 70 % of Americans are willing to pay more for organic food.

(market research)

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Creativity & Flexibility, relevant ?

craft brewing => public has a desire for interesting, unique tasteful beers.craft brewing industry in the US => refreshing, less limited by rules more driven by an organic desire for new “interpretations” of interesting flavors & styles. “extreme” brewing => exploring the boundaries of brewing and beverages, continuing an old “belgian” tradition of innovation.

Interesting beersAbility to brew with new ingredients, new techniques => flexibility to be

creative.

Titel 1.1.1

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Design => intelligent combination :

available technology, geographic smart choice, acknowledge your brewing reality,match your desire and innovative ambitions,

Sustainability, Flexibility & Creativity => not mutually exclusive. Intelligent design will result in interesting

beers, brewed with new technologies while socially & environmentally respectful and economically feasible.

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New Brewery model => reality ?

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New Brewery model => reality for US craft brewers ?

= > European brewery of 850.000 sales beer.

Product mix => review the complexity of brewing.(wort streams, limited amount of beers, SKU’s)

Automation & Education => what is the skill and knowledge level of the staff, what are the tools for the staff => the automation level.

(overall process automation, level of operator intervention)

Brewing technology => how is the brewery being run ? High Gravity Brewing,Weak wort recovery,Centrifuge technology,Fob tanks & Flash pasteurization draft beer,

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Technology => what is right for my brewery ?

Subjective elements => elements of how you brew that are crucial to the taste and flavor, that are more important then their technical relevance.=> yeast strains, spices, whole hops versus pallets, how you dry-hop, aging in wood, ….

Ambition to improve, to make you brewery more efficient, willingness to look at new things, to make a mistake.

=> boiling time, pitch rates, water sources, filtration technologies, …

Courage to manage a healthy tension between the art and science of brewing, the duet between the cook and the chemist.

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What can we do to towards capacity ?(optimize brewing capacity)

Brewing bottle necks, where can we save time in the brewing process,

CIP procedures, loss & recovered CIP plant Heating & cooling rates: mashing, fermentation ?

Quality control checks => release product ! Brewing innovation, where can new technology improve brewing process,

Raw materials: malt & barley types,Equipment: i.e. filtration & clarification technology,Equipment: i.e. wet conditioned millingEquipment: i.e. in line carbonation

High Gravity Brewing, increase brewing capacity with HG brewing, Co-Brewing, use an other’s brewers facility.

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Brewing bottlenecks

Milling technology => wet conditioned milling,Increased lauter bed loading => 250 kg/m2 (12 brews) vs. 180 kg/m2 (12 brews for dry milling. (existing lauter tun => increase brews/day !) Quality improvements : transfer without oxygen pick-up.New construction: reduction in building cost : explosion proof conditions (referred to in Europe by the ATEX rules).Mill => treated as a “ vessel “ for CIP purpose,.

Boiling => reduced boiling times, Reduced evaporation rates => 8 % to 3-4 % Quality improvements : TBA parameters, foam stability (soluble protein).Sustainability => reduced energy consumption.

CIP => availability of equipment (tanks, piping, filter) => can you get all your equipment clean when it comes available ?In-line carbonation => BBT’s occupancy time.

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Brewing innovation: wet conditioned milling of malt

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Brewing innovation : shorter boil time with energy recovery. (reduction of kWh/ boil => time & technology).

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High Gravity Brewing Brewing at a higher gravity then sales gravity, correcting ( with de-aerated water) to sales gravity post or pre-filter.Opportunities:

Increase in brewing capacity,Fermentation capacity, smaller tank volume, Filtration capacity, smaller hourly filtration rate needed,

Increase in sustainable performance; water use & energy consumption ; i.e. requirement for 100 hl sales beer :

12,5 Pl => 106 hl CW (x 8.36 kWh/hl) => 886.16 kWh15 Pl => 102 hl filtered beer => 83 hl beer + 19 hl water => 90 hl CW (x 8.36 kWh/hl) => 752 kWh savings of 19 % in energy per brew.

Challenges:Taste profile => i.e. dry-hopping, even hop profile. Production de-aerated water.

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Co-Brewing

Brewing & packaging your beer at a facility-brewery other then your own, co-brewing your beer with an other brewer. (difference contract brewing => pay a fee/bbl for somebody else to brew & package your beer).

• Opportunities: – Utilization of available capacity at an other brewer’s facility,– Opportunity to learn from other brewer,– Opportunity to produce closer to your market,

• Challenges:– Creating a mutual working agreement : practically, legally, …– Use of different brewing techniques, i.e. yeast strains, malt, …– Managing the brewing of competing brands,– Staying involved – exchanging ideas.

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Final thoughts

• Sustainable => the most sustainable thing to do is to brew more beer with the facility you have => profitability is better.

• Creative => more then making great beers, consider how you make your beers.

• Cooperative => look at some otherbreweries.

• Innovative => critical for the industry, critical for your brewery, important to try some of the new technologies.

contactinformatie

Contact information USA

Floris Delée

[ a ] 325 Cherry Street, unit 208, 80521 Fort Collins, Colorado, USA

[ p ] +1 (970) 224 2374

[ m ]

+1 (970) 215 0061

[ f ] +1 (970) 224 2358

[ e ] [email protected]

[ w ]

www.kathinka.be 

Contact information Belgium

Robert Delée

[ a ] Van Luppenstraat 10, 2018 Antwerpen, België

[ t ] +32(0)473 581 950

[ m ]

+32(0)477 96 37 71

[ f ] +32(0)3 230 31 08

[ e ] [email protected]

[ w ]

www.kathinka.be