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“One of New Belgium Brewing’s core values is to honor nature at every turn. The health of our community and of our business depends upon the health of the natural environment.”
Jennifer V. OrgoliniDirector of Sustainability and Strategic Development
New Belgium Brews Up Sustainable Manufacturing
Goals• Minimizeimpactontheenvironmentby
transitioningfromfossilfuel-basedsourcestototalrenewableenergyoptions
• NewBelgiumBrewinghassetanambitiousobjectivetoreduceitswastewaterimpactbyincreasingitswastediversionrate(sansspentgrainandsludge)from73%in2007to95%by2015
• By2015,thecompanyplanstodecreasethewateruseperbarrelofbeerproducedby10%andcurtailgreenhousegasemissionsby25%
Challenges• Withthereductioninenergyusageand
materialsconsumption,NewBelgiumBrewingwasconcernedaboutmaintaininghighmanufacturingstandards
• Inordertomeetstringentenvironmentalandsustainabilitygoals,thecompanyhadtoensurethatitwouldcontinuetoproducethehighqualityproductsexpectedbyitsloyalcustomers
Solutions and Products• WonderwareSystemPlatform• WonderwareInTouchHMI• WonderwareHistorian• WonderwareActiveFactory
Results• TheInvensyssolutionhelpedintheefficientand
sustainableproductionofmorethan600,000barrels(18milliongallons)ofbeerannually
• Themethanerichbiogasbyproductfromthewastewaterplantisnowcapturedandconvertedintoelectricity,producing15%ofNewBelgium’soperatingpowerrequirements
• Thesolarphotovoltaicpanelsinstalledontheroofofthebottlingplantareabletoproduceupto200KW
• NewBelgiumBrewingisthefirstUS.brewerytoacquire100%ofitspurchasedoperatingelectricityfromwindpower
INDUSTRY:FOOD&BEVERAGE
New Belgium Brewing Companywww.newbelgium.com
Fort Collins, Colorado –NewBelgiumBrewingCompany,basedinFortCollins,Colorado,producesmillionsofgallonsofbeerannuallytoappreciativecustomersacrossthenation.ItstartedwithabucolicbicycletripthroughBelgiumandanamberalecalledFatTire,andnowisamajormicrobrewerywithdevotedlegionsofbeeraficionados.Alongwithitsemphasisonbrewingworld-classbeer,NewBelgiumBrewingalsounderstandstheimportanceofasustainablerelationshipwiththeenvironmentandhasinvestedinenvironmentalstewardshipfromitsfirstdaysofoperation.
NewBelgiumBrewingstrivestomaintainanenvironmentally,sociallyandeconomicallyconsciousbusiness.AswinneroftheEnvironmentandSafetyExcellenceAwardfromInvensysOperationsManagement,thecompanyhasproventobeastellarexampleofsustainablemanufacturing.
“OneofNewBelgiumBrewing’scorevaluesistohonornatureateveryturn,”saidJenniferV.Orgolini,DirectorofSustainabilityandStrategicDevelopmentatNewBelgiumBrewing.“Thehealthofourcommunityandourbusinessdependsuponthehealthofthenaturalenvironment.”
NewBelgiumBrewingisthethirdlargest“craftbrewery”intheU.S.,producingmorethan600,000barrels(18milliongallons)ofbeerannually.Regardlessofitssize,NewBelgiumBrewingstillmanagedtobethefirstU.S.brewerytoobtainallofitspurchasedelectricitythroughwindpower.Additionally,NewBelgiumBrewinghasincreaseditsrecycledpaperboardusagefrom44to88percent.
Itisarecognizedleaderinsustainablemanufacturingpractices,andcontinuestobalancebusinessobjectiveswitheffortstoreducewasteandminimizeitsimpactontheenvironment.NewBelgiumBrewing’snotableenvironmentalaccomplishmentshavebeenachievedwiththehelpofsolutionsfromInvensysOperationsManagement.
Thebrewery’smanufacturingintelligencesystemusesWonderwaresoftwaretoprovideextensive“trackandtrace”capabilitiesinordertoadhere
toNewBelgium’sconservationandperformancegoals.Thelevelofmonitoringisattheveryhighestlevelsofplantvigilance.Forexample,theInvensystechnologyenablesthebrewerytotrackanybottleortankofbeerbacktoallofitsingredientsandprocesseswithin30minutes.
WonderwareSystemPlatformservesasthefoundationformanagingthecomplexnetworkofproductproductionandenergymanagementsystems.WonderwareInTouchprovidesanintuitivegraphicalinterfacetohelpmanagersrunoverallplantoperations,InBatchmanagesbatchingoperationsandWonderwareHistorianisthebrewery’sarchiveofreal-timeandhistoricalproductiondata.TheProductionEventsModuleenablestherecordingofproductioneventsthathelpNewBelgiumBrewingunderstandproductandproductionhistory.Itcapturesanddistributesinformationrelatedtothegenealogyofmaterials,equipmentusage,eventsandwhichpersonnelwereutilizedduringproductionactivities.
Sustainable Technology Goes Down Smooth
“Everyprojectthatwedesign,wethinkoftheenvironmentfirst,”saidIgorValuyev,ChiefElectricalandAutomationsEngineer.“Breweryoperationscanbeverymaterialandenergyconsuming,sowetrytodesignourequipmentaroundnotjustourprocessesandourbeerproduction,but,also,ourenergyconsumption.That’swhereWonderwarewasabletooffertheadditionalbenefitofmanagingoperationsandhelpingusachievehighlevelsofsustainability.”
NewBelgiumBrewingstrivestoactasarolemodelateveryopportunity.Itstrivestoserveasanindustryinfluencer,encouragingashifttowardsustainabletechnologieswithotherbusinessesthroughoutthecommunity.Withinthecompany,managersrefertotheenergypolicyas“alternativelyempowered.”Alternativelyempoweredmeansmakingbusinessdecisionsbasedonminimizingenvironmentalimpact,encouragingthegrowthofitsemployeeownersandbeingasociallyresponsiblecontributortothecommunity.
“Alternativelyempoweredencompasseseverythingwedohereatthebrewery,”saidOrgolini.“Thatmakesusdifferentandgivesustheenergyforoursuccess.Invensyshashadalong-timecommitmenttosustainabilitysoithasbeenagreatassetinourbusinessmissiontominimizeourfootprintontheenvironment.”
WiththehelpofWonderwareWest,anInvensyspartnerandsystemintegrator,NewBelgiumBrewinghasusedInvensyssolutionstomakeitsenvironmentalandsustainabilityprojectssucceed.NewBelgiumBrewinghasdirectlyimplementedthreetechnologiestoreducewasteandmaintainasustainablebusiness.
Atitson-siteprocesswatertreatmentplant,thebreweryusesmicrobestocleanallofitsproductionwastewater.Thewatertreatmentresultsinamethane-richbiogas.Theexcessmethaneisthencapturedandconvertedintoelectricity.Thisengineproducesupto15percentofNewBelgiumBrewing’selectricityneeds,turningawastestreamintoapowersource.WonderwareInTouchHMIplaysakeyroleinvisualizing,optimizingandcontrollingtheentirewastewatertreatmentprocesssothatNewBelgiumBrewingcanmanageitsbiogasproductionandleveragetheenergypowerreturnonitswatertreatmentprocess.
WonderwareActiveFactorysoftwareisdeployedthroughoutNewBelgiumBrewing’soperationssothatmanagerscananalyzeandoptimizeallenergyusage.ActiveFactorymonitorseverydetail,fromroomtemperaturestofacilityusagetocleaningrequirements.EventheaccountantsuseActiveFactorytomonitorbatchdataandproductalcoholcontenttomeetgovernmentreportingandtaxationrequirements.
NewBelgiumBrewinghasalsoemployedphotovoltaictechnologytoproduceelectricityfromthesun.PanelshavebeenplacedontheroofofNewBelgium’spackaginghall.Thesesolarphotovoltaicpanelsareabletoproduceupto200KW.
WiththeInvensystechnology,thecompanyisabletomonitortotalproductionofkilowatthoursgeneratedonareal-timebasisaswellastrackhistoricalpowerproductionrecordstooptimizeoperationsbasedonseasonalsolarenergypatterns.Thehistoricalrecordsalsoarekeytohelpingthecompanydetermineexactsolarpanelupgraderequirementsforbusinessgrowthresultinginhigherelectricaldemand.
Finally,NewBelgiumBrewingwasamongthefirsttoharnessthepowerofthewind.In1999,thecompanystartedpurchasingpowerfromaneighboringwindfarminWyoming,significantlyincreasingitssourcingofrenewableenergy.Allthreeoftheseeffortstomaintainasustainablebusinesshaveeffectivelyworkedtoreducewasteandprotectnaturalresources.
TheWonderwaresoftwareplaysanintegralroleinNewBelgiumBrewing’senergyconservationefforts,frommonitoringpowerproductiontotuningoperationstomaximizeitsrenewableenergysources.Steam,waterandelectricityconsumptionistrackedcontinuouslythroughthebreweryandeveryeffortismadetominimizeenergydemands.Forexample,theInvensyssolutionscontroltheentirelightingsystemforthebreweryoperation,withsensorsthatcandimorturnofflightsinareaswherenoworkersarepresent.
A Smart Approach to Energy Management
Withhighenergycosts,theenergycomponentofproductioncostiscriticaltoanybusiness.NewBelgiumBrewinghasrecentlyincorporatedthe“SmartGrid”tomanageitstechnologiesandequipment.Thisallowsforloadshedding,orintentionallyengineeredelectricalpoweroutages,whenthestrainonthemunicipalpowergridistoohigh,whilealsomaintainingatwo-waycommunicationwiththelocalpowercompany.
Inthefuture,mostfacilitieswillbenodesonanintelligentenergysupplychainnetworkandmanagingthecostofenergywillproduceacompetitiveadvantageoverplantsunabletoleveragetheopportunitiesofferedbydemandresponse,selfgeneration,dispatchabledistributedgenerationandreal-timemarketpricingforenergy.TheSmartGriddeliverstangiblebenefitstoboththebreweryandthecommunity.Wonderwaresoftware,whichisoptimizedforenergymanagement,wasfinelytunedbyWonderwareWesttohelpNewBelgiumBrewingmaximizeitsSmartGridinitiatives.
“TheSmartGridprovidestheinternalmeteringthatletsusknowhowmuchenergyweareusingthroughouttheprocess,”saidOrgolini.“TheWonderwaresoftwarehelpsuscommunicatewithourlocalutilitytoinformthemimmediatelywhatweareusingandcommunicatewithuswhenweneedtoshedload.”
UsingtheSmartGridgivesNewBelgiumthestrengthtogrowitsbusinessandimprovethewelfareofitsemployeeswhilehelpingtoprotecttheenvironmentinacostefficientmanner.WiththehelpofInvensys,NewBelgiumBrewingprotectstheenvironmentwhilemaintainingasafe
andsustainablebusiness.Thejourneytowardsustainableoperationsisneverending.NewBelgiumBrewingiscontinuingtoimproveitscarbonfootprintandhopestoreducegreenhouseemissionsby25percentbytheyear2015.
“EveryWonderwaresystemiswhatouroperatorsprettymuchuse.That’swhereourdataisbeingextractedfrom,soitkindofunitesallofthesystemstogether.WeunifyourplantinformationthroughWonderware,”saidValuyev.“We’vebeenutilizingInTouchfor10yearsplusforextendedperiodoftime.We’reprettyhappywiththissystem.”
Whatstartedwithapastoralbiketripthroughthefertilevalleys,sandyplainsandthicklyforestedhillsandplateausoftheArdenneshasbecomeamajoremployee-ownedmicrobrewerywithadedicationtoprotectingtheworld’snaturalresources.FocusingonsustainabilityandtheenvironmentgivesNewBelgiumBrewingthestrengthtogrowitsbusiness,improvethewelfareofitsworkersandhelpprotectMotherEarth,withalittlehelpfromInvensys.
Invensys,theInvensyslogo,ArchestrA,Avantis,Eurotherm,Foxboro,IMServ,InFusion,SimSci-Esscor,Skelta,Triconex,andWonderwarearetrademarksofInvensysplc,itssubsidiariesoraffiliates.Allotherbrandsandproductnamesmaybethetrademarksorservicemarksoftheirrepresentativeowners.
©2011InvensysSystems,Inc.Allrightsreserved.Nopartofthematerialprotectedbythiscopyrightmaybereproducedorutilizedinanyformorbyanymeans,electronicormechanical,includingphotocopying,recording,broadcasting,orbyanyinformationstorageandretrievalsystem,withoutpermissioninwritingfromInvensysSystems,Inc.
Invensys Operations Management • 5601 Granite Parkway III, #1000, Plano, TX 75024 • Tel: (469) 365-6400 • Fax: (469) 365-6401 • iom.invensys.com
Rev.06/11PNWW-4050