Norit Beer Membrane Filtration

References

Over 75 beer brands • 22 full-scale installations • 18 breweries

Introduction

Why look for alternatives to Kieselguhr filtration?

• • • • • •

Quality Environment Health & Safety Process flexibility Process simplicity Costs

Quality • •

Standard quality parameters (taste, pH, color etc.) equal to Kieselguhr filtration! Foam better than KG filtration (average 10 sec. Nibem)!

•

Turbidity values – 90° Turbidity 0,1 – 0,2 EBC below KG – 25° Turbidity < 0,1 EBC

•

Reliable Retention of Yeast and strong reduction of beer spoilaging bacteria? Flavor stability better than with KG filtration?

•

Taste Stability / Chemical Reactions

•

ROS = Reactive Oxygen Species

Total costs of ownership ITEM

BMF

KGF Euro per HL

OPEX Membranes / Kieselguhr

0,08

0,07

Cleaning

0,04

0,02

Utilities

0,06

0,04

Beer losses

0,04

0,08

Maintenance / Service

0,03

0,03

Waste Kieselguhr

0,03

Total OPEX (Without stabilization)

0,25

0,27

Labor

0,02

0,03

CAPEX

0,10

0,10

Stabilization with silicagel

0,06

0,08

Total Costs of Ownership

0,43

0,48

Separator * Based on average run length of 15 hours and European Utility prices

0,10

Membrane properties

Filtration principles

Pore size: 0.5 micron

Filtration principles

Module

Design & Process

Filtration

Module

Filtration

Filtration diagram

600

300

Product Range

BMF-10 / BMF-60 Capacity:

10 - 60 Hl / h

Design:

Prefab / Skid

Number of Modules:

1/2/4/6

Dimensions( l x w x h):

5000x2500x3500

Product Range

BMF-150 / BMF-200 Capacity:

100 - 200 hl /h

Design:

Single-decker

Number of Modules:

18 / 24

Dimensions (l x w x h):

6000x1200x2600

Product Range

BMF - 450 / BMF - 700 Capacity:

300 - 700 hl/h

Design:

Double-decker

Number of Modules:

48 / 72

Dimensions (l x w x h): 9000x1500x4200

Line concepts

Designing a Membrane Filter BMI(A) = Average Broens-Mepschen Index:

BMI = Δ Pressure / Δ Time

Stabilization

• • •

With regenerable PVPP filter On lost base With Handtmann CSS

Line concepts / stabilization (1) Stabilization with PVPP filter

Line concepts / stabilization (1) Stabilization with PVPP filter

Line concepts / stabilization (2) Stabilization on lost base

Line concepts / stabilization (2) Stabilization on lost base

Effect Silicagel on TMP-increase Filtration of German Lager with 50g/hl 'bad xerogel' for filterability BMF 1,2 CF = 2 m/s Flux = 107L/m2/hr T = 0°C Module: RX-300

1,0

TMP (bar)

0,8 0,6 0,4 0,2 0,0 0

20

40

60 Time (min)

80

100

120

Effect Silicagel on TMP-increase Filtration of German Lager with 50g/hl 'good xerogel' for filterability BMF 1,2

CF = 2 m/s Flux = 107L/m2/hr T = 0°C Module: RX-300

1,0

TMP (bar)

0,8 0,6 0,4 0,2 0,0 0

20

40

60 Time (min)

80

100

120

Summary

•

Membrane filtration will likely improve the quality of the beer

•

Environmental and health issues are in-line with expected future requirements

• • •

Simple, flexible and straight forward process Flexible: several stabilization options available Very competitive total cost of ownership

Thank you for your attention!

Water savings in the brewery • High gravity brewing » amount of brews » amount of fermentors » amount of filter runs

amount of cleanings

• One tank operations if possible • Re-use of process water » » » »

As CIP water As flushing liquid For cleaning In theory as process water

70% of the water entering a • Less cleaning of beer filter brewery leaves it as effluent. 4 – 10 hl water is needed to produce 1 hl of beer. (image damage makes this not acceptable)

Brewery processes are intensive users of both electrical and thermal energy. 3 to 8 % of production costs of beer is energy & water.

By appropriate waste management breweries can save 4,5% on their operational costs. And the tendency of this percentage is up.

Brewery of the future by Norit Leading in total costs of ownership

Purpose

Design

Design and build sustainable, state-of-the-art breweries

Sustainable

Lowest water consumption (2 hl per hl beer) Minimal energy consumption Ban Diatomaceous Earth completely

Opex

Highly automated, less labour Low energy, water and raw material consumption Minimize product losses and solid waste disposal

Capex

Full continue process, less capital goods Small footprint

TCO

Being the true leader on Total Costs of Ownership

Design Co-operatively by • Norit • Meura • Sidel

Overall design utilities & cold block Brewhouse Packaging (PET bottles)

Specifications • Brewing • Packaging

2 million Hl/a (20 Plato – 16 Plato) (prepared for extensions) 3 million Hl/a (16 Plato – sales gravity)

Continuous brewhouse Continuous flow in the cold blocK

Design HEAD OFFICE

BOTTLING HALL

48.5 mtr.

84 mtr.

96 mtr.

96 mtr.

BEER PRODUCTION

UTILITIES 126 mtr.

40.5 mtr.

200 mtr.

40 mtr.

47.5 mtr. 350 mtr.

WATER TREATMENT

Sustainable

50%

less water consumption compared to a modern brewery

High gravity brewing • Brews • Fermentors Less cleaning • Filter runs One tank operations if possible Re-use of process water • As CIP water • As flushing liquid • For cleaning Less cleaning of beer filter

Sustainable

50%

less energy consumption compared to a modern brewery

Wort boiling – Evaporation of 1,5 % high gravity Continuous flow of 200 Hl/hour • Constant production of steam, cooling and air. • Optimal heat recovery (green beer beer to filler)

High gravity • wort cooler • tank cooling • beer coolers Fermentors in closed dry room No overcapacity of steam boilers, cooling, air CO2 recovery with HRS LiquiVap

Sustainable

100%

Ban on the usage of Diatomaceous Earth in the brewery

Norit Beer Membrane Filtration • 100% Diatomaceous earth free No more alleged DE health risks Improvement of taste stability • Lower iron & oxygen levels Better chemical stability Reduction of solids discharge • 0,4 kg/ hl

Operational expenditure (OPEX)

50%

Lower beer losses

Mash filters for very high yield and high gravity Extra flushing at every transfer Beer Membrane Filter • no pre-after run Propagation and yeast management Beer recovery from surplus yeast Blending to sales gravity before filler Extract losses Brewhouse – Bright Beer Tank 0,8%

Operational expenditure (OPEX) Beerlosses 120

50% 100 80 60 40 20 0

Fair

Worldclass

Norit

Operational expenditure (OPEX) Energy savings (Thermal + Electric) 120 100 80 60 40 20 0

Fair

Worldclass

Norit

Operational expenditure (OPEX) Water consumption

100%

75%

50%

25%

0

Fair

Worldclass

Norit

Norit including reuse

Capital expenditure (CAPEX)

50%

Lower CAPEX (25 €/ Hl sales capacity)

Highly standardized units Continuing brewing • Smaller equipment • Less piping • Optimal utilities Small footprint

Norit in the brewing world Membranes

Valve technology

CO2 & O2 management

Cold block units, project management, Engineering and Beer Membrane Filtration

Waste & process water management

Relevant Norit equipment • • • • • • • • • • • • •

Norit (Diatomaceous Earth free) Membrane Filtration Propagation and yeast storage Beer recovery from surplus yeast Fermenting (storage)-green beer cooler BBT area Total CIP of brewhouse till BBT Full automation system • Siemens S7 with Intouch • Ready for MES • integration with ERP (China) Water treatment, • Waste Water Treatment plant (MBR) Blending and carbonizers C02 recovery Laboratory Valves Brewhouse and rest of brewery Water dearators

Beer processing

Hygienic valve technology

CO2 & O2 management

Waste water treatment plant

Applications & implementation Principal of Membrane Bioreactor

WASTE WATER

OPTION

BUFFER TANK

BIO REACTOR ANAEROBIC

sludge

BIO REACTOR AEROBIC

UF-PERMEATE TANK

Alternative: SF + Xiga-UF

Drinking water to Brewery Concentrate Surface-water

RO-installation

Planning

Total lead time from ordering to first production>> 10 to 12 months

Resumé • Overall concept of standard brewery Flexible to adopt requirements of brewers

• Optimal sales, logistics and T.C.O. (fully automated, internal benchmark and departments of excellence.)

• Design focused on KPI, which will be critical for the future (raw materials, energy, water, labor)

No doubts. Norit. Just Proof.