INNOVATIVE COLD BLOCK SOLUTIONS 10 OKTOBER 2014 ROLAND FOLZ – DIRECTOR INNOVATION & TECHNOLOGY FOOD & BEVERAGE VLB - 3RD CHINA INTERNATIONAL BREWING CONFERENCE
FOOD & BEVERAGE PROCESS SOLUTIONS
CONTENT • PENTAIR’s offerings in the Cold Block • Experiences from and end user – Sino Belgium Beer Suzhou • Unique Technologies o Smart Valve & Piping Concepts o Quality measurement o CO2 Recovery System o Beer Membrane Filtration • Challenges of the future
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
Directions for tomorrow
MARKET DRIVERS CONSISTENCY OF THE BEER QUALITY NEED TO REDUCE OPERATIONAL EXPENDITURES IN GLOBAL COMPETITIVE ENVIRONMENT AMBITIOUS SUSTAINABILITY GOALS TO REDUCE WATER, ENERGY AND SOLID WASTE FOOTPRINTS NEED FOR MORE FLEXIBILITY IN THE BREWING PROCESS DUE TO PRODUCT DIFFERENTIATION
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COLD BLOCK PROCESS NON-STOP FROM WORT COOLER TO FILLER: FULLY INTEGRATED SOLUTIONS FROM ONE SOURCE
Including CIP Sets, Yeast Management, Storage and Dosing, CO2 Systems, Water & Waste Water Treatment, Valves, Pumps, Filters, Beer Membrane Filtration and Quality Measurement
From Chiller to Filler from one source! PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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PENTAIR’S COLD BLOCK SOLUTION • Design, Engineering & Project Management • Prefab Units and Components by Pentair
• Units and Components by third parties
• • • • •
Erection of the plant with local labor supervised by Pentair On-Site Integration of all units and components (‘System Integration’) Software and SCADA (‘Remote Operator Control’) Commissioning of the plant Hand-over & Service
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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SCOPE OF SUPPLY – TURN KEY PROJECT PROJECT STAGE
DESCRIPTION
CORE COMPETENCE PENTAIR
COOPERATION SUBCONTRACTORS
Master Plan Development
Consultancy Development
No
No
Capacity Calculations
Brewery Capacity Calculation Capacities of Utilities, Brewhouse, Cellars, Packaging, Warehouse
Yes
No
Brewery Design
Installation Lay-out Building & Civil Infrastructure
Yes No No
No Yes Yes
Process Design
Utilities Brewhouse Fermenting-Storage-Filtration-Bright Beer Packaging Wastewater Water Reuse Automation and MIS/MES
Yes No Yes No Yes Yes Yes
Yes Yes No Yes Yes No Yes
Project Execution
Quotation & Negotiations Project Management Detailed Engineering Purchasing Installation & Erection Commissioning & Start-up Monitoring MIS Service
Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
BMF-18 Compact 2
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FEATURES & BENEFITS FEATURES
BENEFITS
Decades of experience
Guarantee for a successful project
Intelligent plant design
Low CAPEX and OPEX
High quality units & components
Reliable operation
High knowledge level of brewing process
Solutions that fit and work
Focused on the lowest possible costs in own components but also in purchase (subcontractors)
Low CAPEX and OPEX
Flexible work force
Predictable planning and room for grapping last moment opportunities
Compliant to all kind of ruling in safety, health and environmental issues
Fulfilling to SHE requirements
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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PENTAIR’S UNIQUE COLD BLOCK SOLUTION • Unique technologies in Filtration of beer, CO2 recovery & Quality measurement
• High quality of key hygienic components (Valves & Pumps) & Smart Engineering
• Focus on the demands of the customer
– Flexibility in design and execution – Tailor made solution
• Specialized in the cold block processing – Know-how,
experienced staff and good reputation
Excellent solutions through Technologies and Process Knowhow! PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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中比啤酒(苏州)有限公司 Sino Belgium Beer (Suzhou) LTD.
中比啤酒 SBBZ
中比啤酒(苏州)有限公司 Sino Belgium Beer (Suzhou) Ltd. (SBBZ) 成立日期 设计产能 员工 產品
Established： 2007 Capacity： 280,000 KL # of employee: 50 Product:
中比和滨特尔 SBBZ and Pentair 中比设备主要供货商之一 1 of SBBZ’s 3 major equipment suppliers 酵母 Yeast propagation/storage 罐区 Fermenting/Bright beer/DAW tanks 清酒膜过滤 Beer Membrane Filter (BMF) 稀释机 Carbo Blender 原位清洗 CIP 啤酒回收、CO2 回收、制冷、原水处理、化验室仪 器等 Beer recovery, CO2 recovery, Refrigeration plant, Water treatment plant, Lab instruments, etc.
冷区布局图 Cold Block
100 m x 30 m BMF过滤区 Beer filtration area 化学品间 Chemical room
酵母扩培 Yeast propagation
发酵罐区 Fermenting tanks
酵母罐区 Yeast storage
清酒罐区 Bright beer tanks
CIP站 CIP station
清酒膜过滤 BMF System
膜过滤对比硅藻土过滤BMF vs. kieselguhr 对质量影响 beer quality 膜过滤没有杂质污染的风险 风味稳定 BMF has no contamination risk stable taste 膜过滤過程增氧≦15 ppb BMF O2 pick-up ≦15 ppb 膜过滤基本满足中国国标对浊度的要求 BMF can meet GB requirement on turbidity
膜过滤对比硅藻土过滤BMF vs. kieselguhr 对人力影响 manpower 自动化程度高的膜过滤可节省50%人力 BMF can reduce 50% manpower due to its automation process
膜过滤对比硅藻土过滤BMF vs. kieselguhr 对酒损的影响 beer loss 膜过滤不须额外的操作即可达到较低的酒损 BMF can achieve low beer loss during normal operation, without extra operation like kieselguhr filtration
膜过滤对比硅藻土过滤BMF vs. kieselguhr 对环境的影响 EIA 员工操作环境-膜过滤没有粉尘，不影响健康 BMF has no dust risk to employee’s health 膜过滤没有处理废弃硅藻土的环境污染问题 BMF has no environmental issue like kieselguhr disposal
SMART VALVE & PIPING SYSTEMS PENTAIR SÜDMO - IntelliTank Matrix Compact, cost effective and safe alternative to conservative pipe fences/swing bend panels or valve manifolds
Valve Manifold
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
IntellitankMatrix
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SMART VALVE & PIPING SYSTEMS Valve manifold
IntelliTank-Matrix
•
No mixing of liquids and no convection to the tank.
•
Tank outlet line = Tank
•
Negative temperature influence to the fermentation process.
•
No negative temperature influence to the fermentation process.
•
Undefined fermentation process has a direct effect on the yeast cells and on the quality of the beer (autolysis).
•
Fermentation processes and temperatures can be controlled and influenced. Maintaining and increasing of product qualities.
•
High product losses and mixing areas at product outlet through long tank outlet pipes.
•
Reduction of product losses.
•
No mixing of liquids and no convection to the tank.
•
Tank outlet line = Tank
•
Negative temperature influence to the fermentation process.
•
No negative temperature influence to the fermentation process.
•
Undefined fermentation process has a direct effect on the yeast cells and on the quality of the beer (autolysis).
•
Fermentation processes and temperatures can be controlled and influenced. Maintaining and increasing of product qualities.
•
High product losses and mixing areas at product outlet through long tank outlet pipes.
•
Reduction of product losses.
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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CO2 RECOVERY SYSTEMS PENTAIR HAFFMANS - CO2 Recovery Systems Cost-effective conventional CO2 recovery plants to state-of-the-art plants incorporating the latest technologies
Fermentation
Gas balloon or Booster
Foam drain Foam separator
Gas washer CO2 Condenser
Refrigeration unit
Stripper Reboiler CO2 Evaporator
CO2 Compressor
PENTAIR
Activated Carbon Filter / Driers
‘INNOVATIVE COLD BLOCK SOLUTIONS’
CO2 to consumers
CO2 Storage tank
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LIQUIVAP – CO2 LIQUIFACTION/VAPORIZATION CUTS CO2 PLANT OPERATING COSTS - BY UP TO 60%!
BENEFITS • Short payback time (ROI) • Environmental friendly – CO2 as refrigeration
LiquiVap CO2 from recovery plant
CO2 Super heater
• Easily retrofitted into existing systems – ideal
for capacity upgrades
CO2 to consumption
• Additional CO2 Recovery without additional
energy costs
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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QUALITY MEASUREMENT O2 MEASUREMENT PRINCIPLE • Optical Oxygen sensor • Based on the quenching of luminescence caused by collision between molecular oxygen
and luminescent dye molecules in exited state • The measurement is temperature compensated
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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QUALITY MEASUREMENT O2 MEASURING Optical transmit signals to analyzer
O2 sensor Spot
O2 sensor
PRINCIPLE OF OPERATION • Oxygen (O2) sensor (sensor spot) is in contact with the medium.
Adhesive Optical receive signal to analyzer
• The sensor spot is intensely illuminated by a light source for a short time. • Depending of the O2 content in the medium
Intensity
the sensor spot will give a light signal. • A photo detector measures this light signal and from it the oxygen content is calculated.
Time PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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FRANKLIN’S QUOTE: ”IN WINE THERE IS WISDOM – IN BEER THERE IS FREEDOM – IN WATER THERE ARE BACTERIA”
WATER PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
WINE
BEER 24
MEMBRANES & MEMBRAINS PENTAIR R&D MEMBRANE FILTRATION • Membranes • Modules • Water & Waste Water Treatment • Beverage Filtration – Beer, Wine & Cider
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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BEER MEMBRANE FILTRATION CHOICES TO MAKE… • • • • •
Membrane material ̴ Water FiltraPon PolyEtherSulphon Pore size ̴ Beer quality Cross-flow speed ̴ Run volume – Energy consumption Flux optimization Cleaning /Regeneration ̴ Run volume – Chemical consumption
…PRODUCTS TO CHOOSE FOR!
Already more than 50 units in operation! PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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MARKET DRIVERS Ѵ CONSISTENCY OF THE BEER QUALITY Ѵ NEED TO REDUCE OPERATIONAL
EXPENDITURES IN GLOBAL COMPETITIVE ENVIRONMENT
Ѵ AMBITIOUS SUSTAINABILITY GOALS TO REDUCE WATER, ENERGY AND SOLID WASTE FOOTPRINTS
Ѵ NEED FOR MORE FLEXIBILITY IN THE
BREWING PROCESS DUE TO PRODUCT DIFFERENTIATION
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REFERENCES – TURN KEY COLD BLOCK PROJECTS Year
Brewery
Location
Year
Brewery
Location
2014
Castel
Tuta, Angola
2011
Diageo
Lagos, Nigeria
2014
Heineken
Port Moresby , Papua New Guinea
2011
Brauerei Ganter
Freiburg, Germany
2014
Dashen
Debre Birhan, Ethiopia
2011
Diageo
Benin, Nigeria
2014
AB InBev
Kunming, China
2011
AB InBev
Henan, China
2013
Heineken
Lae, Papua New Guinea
2011
Heineken
Lagos, Nigeria
2013
Heineken
Bujumbura, Burundi
2011
Castel
Hawasa, Ethiopia
2013
Diageo
Kumasi, Ghana
2010
Sapporo
Ho Chi Min City, Vietnam
2012
Heineken
Bukavu, Congo
2010
AB InBev
Ziyang, China
2013
AB InBev
Foshan, China (Phase 4)
2009
Heineken
Tangerang, Indonesia
2012
Carlsberg
Kunming, China
2009
AB InBev
Foshan, China (Phase 2)
2012
Heineken
Kinshasa, Congo
2009
Heineken
Lagos, Nigeria
2012
Castel
Beni, Congo
2008
SABMiller
Ulyanovsk, Russia
2012
Heineken
Harar, Ethiopia
2008
AB InBev
Foshan, China (Phase 1)
2012
Heineken
Aba, Nigeria
2008
Castel
Bon Jesus, Angola
2012
AB InBev
Foshan, China (Phase 3)
2007
Far Eastern Industries
Suzhou, China
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
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TARGETS OF TODAY – CHALLENGES OF TOMORROW WHAT
HOW
• Low Capex and low TCO – More and more due to consolidation in the brewing industry
• Simplicity in process & design – Minimum of hardware and components and a maximum of ease of operation
• Sustainability - Water & energy consumption – (Solid) waste streams
• Maximized output • Optimal fit to all kind of breweries
• Voice of the customer - A product fitted to the specifications & conditions of the brewer – ‘Fit for purpose, fitness for use’ (Joseph Juran)
PENTAIR
‘INNOVATIVE COLD BLOCK SOLUTIONS’
• Efficiency - Standardization
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THANK YOU FOR YOUR ATTENTION!
FOOD & BEVERAGE PROCESS SOLUTIONS
