GEA BEER SEMINAR I.The GEA Group : · The GEA Group is one of the world`s market and technology leaders in 90 per cent of its businesses. · GEA stands for Global Engineering Alliance · The company focuses on specialty mechanical engineering – especially process engineering and equipment. · The company reported sales of EUR 4.3 billion in 2006 and employed 17,500 people end of December, 2006. Market leadership and focus o Number one or two in each of its markets around the world o Focus on core competencies and core technologies Technology leadership through innovation o Technology leader in main markets o Traiblazer by advanced technology Strong focus “lean and cost saving” o Decentralized organizational structure with global responsibility within each division o Cost leadership through rigorous cost management Calculated risks o Stability through diversification within the core businesses across sectors and regions o Thorough risk assessment of projects Highlights Milk · Dairy Farm Systems` global market share of milking equipment roughly 30 percent · Annual milk production of around 600 million tonnes Beer · Approximately 20 per cent of global beer production in plants from GEA Tuchenhagen · GEA equipment used in moer than 50 per cent of global beer production · Global beer output approx 1.7 billion hectoliters Instant coffee · 30 per cent produced in plants using GEA technology · Global production of around 440,000 tonnes The blending system DICON-B for the original gravity optimization is explained in the following points : - high original gravity – accuray ( up to 0.05% OG) - saves raw – material(extract) - saves primary energy - economies in fermentation and storage capacities - utilization of the first and last runnings without any time consuming handling - automatic adaptation of the dosing quantity to the filter capacity - simultaneous cleaning of the beer and first/last runnings lines, thus enabling an easy and safe handling - therefore easier and safer to handle The arrangement of the system within the fitration process results from different positions : Before the filter the dosed addition of the first/last runnings into the unfiltered beer is effected before the booster pump at the filter inlet, whereby it is advantageous that the first/last runnings are filtered together with the unfiltered beer. The addition is realized volumetrically by means of a ratio control. The dosed quantity can be changed by the operator according to the existing first/last runnings quantity After the filter liquor is added for the high optimization, thus requiring a respective water deaeration system( see D 49.30 DIOX 2). The mixing point is followed by a static mixer that ensures a homogenous blending. The O.G.Liqui-Analyser arranged at the outlet of the system measures the current O.G.value, compares it with the setpoint, and controls the modulating valve in the liquor line in such a way that the setpoint is exactly reached. The varying dilution of beer by the deposit of filter aids is automatically compensated. The combination of the system with a GEA DIESSEL carbonating system(see D 46.03 DICAR) would be advantageous, as in that case the in-line CO2 meter of the carbonating system could be used for the CO2 compensation in the O.G. analyser Centrifuges are used for continous mechanical separation in breweries for: · Replacement of filtration and/or sedimentation and flotation: · Wort clarification, Weizenbier – Production · Support of Filtration processes : · Pre-clarification prior final filtration · Concentration of residuals of filtration or sedimentation processes · Beer recovery processes, hot trub concentration · Waste stream treatment · Effluent treatment/caustic cleaning Hot Wort clarification · Advantages : continuous, maximum DS, defined clarification, lowest space requirement, no DO pick up · Alternative Processes : · Whirlpool (90 % of all wort is processed like this) · SEDimentation · Filtration · Preferably SC machines to be used · Capacity up to 400 hl/h with SC 150 and 500 hl/h with GSE 200 · Sales potential for special beer types or tight production plants · Typical feed concentration 1.5 % vol Wort Recovery from Trub wort Concentration of trub may be too low : · Misfunction of whirlpool · Sedimentation tanks are used · Raw materials Alternatives : · improvement of whirlpool · trub presses(seldom used) · trub is dosed back to lauter tun(common practice) · Only SC machines to be used! · Typical feed concentration 5 – 50% vol · Ejection interval of 60`s acceptable · Sales potential in existing plants with problems, not for new plants Beer Clarification Main reasons for beer clarification with centrifuges : · Reduction of beer losses : · Green beer clarification · Lager beer clarification · Beer recovery from surplus yeast/tank bottoms · Increase of filter life time: · Green beer clarification · Lager beer clarification · Improvement of beer quality/ standardized maturation conditions: · Green beer clarification Green beer Clarification – Traditional Process § Processs § Beer from fermentation is clarified by centrifuge § Optional a green beer chiller is installed § Parameters § Yeast concentration ex centrifuge 0.1 – 2 mio cells/ml, dependant on equipment § Flow rate up to 1000 hl/h § DS of solids appr.25% § Effects § Lower solids load in in maturation=less tanks bottoms § Lower yeast count = § Yeast autolyzis is prevented during longer storage time § Reduction of lager time : only cold conditioning, yeast settling time is not limitating § Filtration is running under steady conditions § No diacetyl reduction due to low yeast concentration !! Green Beer Clarification yeast re-injection o Process o Beer from fermentation is clarified by centrifuge o Prior centrifuge surplus yeast is dosed o Parameters o Yeast conc. Ex centrifuge 0.1 – 2 mio ells/ml, dependant on flow o Flow rate up to 500hl/h+unit o DS of solids appr.25% o Effects o Technology : similar to traditional process o “ principle of the mother liquid” : yeast is dosed to beer where it comes from o Only fresh yeast needs to be processed o Reduced tank bottoms volume o Complete yeast volume is processed in one step o Process o Beer from lagercellar is clarified by centrifuge prior to filtration o Additionally a chiller can be installed o Parameters o Yeast conc.ex centrifuge 0.01 – 1 mio cells/ml, dependant on flow o Flow rate up to 1000 hl/h + unit o Removal of proteine o Effects o Standarized feed concentration to the filter o Yeast plugs are prevented o Filter can process independent from lager time and yeast concentration in maturation o No technology change o Lager time only for cold conditioning, not for yeast settling Beer recovery · surplus yeast contains between 30 – 90% beer · beer qualityis mainly depending on quality of yeast : Storage time, temperature, yeast vitality : Beer is never better than yeast it comes from · 90% of this beer can be recovered with centrifuges · Maximum solids content by use of separator : 40 by vol % · With decanter no limitation · Beer ex-centrifuges contents appr.1 mio cells/ml, beer is cloudy from proteine(polishing centrifuge may be necessary) · DS of solid yeast is appr.25 % · Membranes : · Lower DS= lower yield, only appr.18% DS can be achieved · But bright beer with no yeast · Higher stress for yeast due to long process time which may influence beer quality · Westfalia Separator is the only supplier that has all 3 systems for beer recovery in it`s scope: · Separators · Dekanters · Membranes PROFI · Profi is a cooperation of Westfalia Separator Food Tec and Pall Food beverages · This filtration system was developed to use both centrifuge and membrane filtration at it`s best performance: · The centrifuge separates the solids with optimum dry substance at high flow rate, but leaves colloidals in · The polyethersolfonmembrane separates in the fine paricles and the colloids from the beer · The poresize is 0.6 Mm Differences of PROFI to other Non – DE – Filters Ø Save and consistent process because of optimized beer – quality to membranes due to pre-clarification with special – design separator Ø Much lower losses(actual< 0.1% extract) because of separation of >99% solids at pre-clarification-stage and no retentate accruing, therefore no retentate – handling at all Ø Lower energy – consumption of complete filter – line, no cooloing integrated in the filter – line necessary, smaller circulation pumps in membrane – blocs, lower velocity of the product in the membranes, <1.2 m/sec. Ø Beer – flow only in one direction through the whole installation, no circulation/feed – and – bleed – vessel or installation Ø Only brewery – standard, non-aggressive cleaners are used for CIP of membranes Ø Membranes cleanable up to 80*C because of special design 1996 Privatbrauerei Meusel – Dreuschendorf/Germany 20 HL/H 2003 Potts Privatbrauerei – Oelde/Germany 50 HL/H 2006 Carlsberg Brewery/ Tuborg Plant – Fredericia/Danmark 400 HL/H 2007 American Brewery Group 2 X 400 HL/H Suntory Ltd./Kyoto/Japan 500 HL/H Carlsberg Brewery/ Sinebrychoff Brewery – Kerava/Finland 400 HL/H 2008 Australian Brewery Group 4 X 300 HL/H Romanian Brewery 300 HL/H GEA Ecoflex at a glance Gasketed, Welded & Brazed PHE Supplier of components – no systems 650 employees Head quarter near Hannover, Germany with brand new pressing technology New production plants : Sweden, India & USA History …from early stage 1856 Eduard Ahlborn founded Ahlborn GmbH being manufacture of dairy equipment 1928 Ahlborn GmbH started with development & production of plate heat exchangers(PHE) 1979 GEA Group acquired Ahborn Gmbh. 1995 Separation of GEA Ecoflex GmBH out off GEA Ahlborn GmbH being responsible for gasketed plate heat exchangers within GEA Group. 1995 TAU Energy Products AB was acquired by GEA Group New GEA Ecobraze AB is manufacture of brazed plate heat exchanger. History …. Until today 2000 Development of NT – Series followed by LWC in 2001 2002 Acquisition of the fully welded heat exchanger part of Balcke Durr Service GmbH 2003 Move into new production & administration building 2004 Acquisition of WTT Wilchwitzer Thermo-Technik GmbH, being one of the major manufacturer of brazed plate heat exchangers 2005 Acquisition of FlatPlate Inc, being major manufacturer of brazed plate heat exchangers in the US 2006 New pressing line for gasketed heat exchangers in Sweden 2007 New production plant for gasketed heat exchangers in India 2008 New production plant for gasketted heat exchangers in USA Our Goal/Your Benefit Assist the client in choosing the right refrigeration system, by combining the initial investment with - the Cost of operation, - Maintainability, - Reliability - Sustainability. In other words, making life easier for Brewery management, Because they are busy enough with brewing Beer. What the world says Annual report InBev : ….. a reduction of greenhouse gas emissions by over 85.000 tpns each year. This is in line with the Kyoto agreement and also generates Production efficiencies.. Berkeley National Laboratory report on Breweries : ……Life cycle costs of a refrigeration installation is 7 to 10 time the initial investment…… Annual report Diageo : ……Together, these locations repreent 28% of our total electricity usage and switching to zero – or low carbon supplies has reduced our annual indirect CO2 emissions by around 50.000 tonnes… Annual report Heineken : …..the increase in oil and gas prices was the main cause for the rise in energy and water expenses by 22.9%, totalling 252 MEUR Sustainable Development report SAB Miller : ….. Target for 2007 : 1% less water and 10% less energy consumption to produce beer…. Environmental Report Carlsberg : ………The most important environmental responsibilities are the consistent efforts to reduce resource consumption, mainly energy use…… Life cycle concept Application phase Energy scan Health check Expansion advice Monitoring advice Project engineering – phase Brewery questionnaire Energy efficiency Life cycle design Standardisation Realization Service & Maintenance On call maintenance Service contracts Technical visits Spare parts Service support Average pay back time Variable speed drives Average pay back : 2.5 years Higher efficiency measurements Average pay back : 1.5 years Better matching of cooling capacity and loads Average pay back : 3.5 years Improved operations of the NH3 plant Average pay back : 5.5 years System modification and improved design Average pay back : 2.5 years Improved maintenance and operations Average pay back : < 1 years Targets to Milling Process : · Release all valuable extract from endosperm · Do not destroy husk of malt grain · Produce constant mash quality, independent from malt quality · Prepare best mash quality for high performance of lautertun · Secure lauter time (below 2 hrs.turnaround) · Secure brewhouse extract yield (98% OBY) · Avoid oxygen pick up · Guarantee permanent wort quality Milling techniques + Dry milling + Dry milling with conditioning + Huppmann Millstar with steeping conditioning Ideas of the new geometry Very even collection of wort in all areas of the grain bed avoiding localised compaction due to kinetic pressure suction effects Goals : + Faster run-offs +Better wort clarity +Better washing efficiency/extraction of the grain bed New Lauterstar design The redesign included + Run-off-geometry + Number of run-off ports + Shape of run-off cones + Distance between false bottom and lauter tun floor Wort boiling – A decisive step in the brewhouse process : · Purpose of wort boiling : Sterilization, definition of sugar composition, hop isomerisation, stripping of undesired volatiles, formation of flavour compounds · Quality : Definition of quality parameters of the final product · Economy : Wort boiling consumes approx.30% of the total energy of the brewing process * Benchmark : 80% of all breweries are using wort kettles with internal boilers for wort boiling Conventional Boiler + Vertical shell and tube heat exchanger + Conical hat, vertical tube, deflector + Steam heated + Mixing of wort by means of thermosyphon effect è Improper homogeneity è No variation of process parameters è No control of “pulsing”(= physical effect which leads to thermal stress and overfoaming) Jetstar effects : No pulsation Pulsation is an effect that occurs in internal boilers during heating of the wort Pulsation is associated with low flow rates, hence local overheating, Maillard reactions, thermal stress; fouling of boiler tubes. Jetstar eliminates pulsation No foaming during heating-up phase How?