Making it Work: Starting / Expanding Your Brewery · Starting / Expanding Your Brewery . ... Beer & Conditioning ... Calculating Brew house Design Capacity. Ultimate Beer Sales Volume

Mark Benzaquen, Craft Services Email: [email protected]

Starting / Expanding Your Brewery

Making it Work:

Overview

Where Do I Begin?

Brewery Building – Space and Structural Considerations

Brewery Layout Considerations

Sizing Brewery Equipment

Packaging Line Design

Environmental Concerns

How many and what type of beers will be made at any given time

Where Do I Begin?

Marketing & Sales Plan

Establish clear brewery vision

Define Brand Portfolio

Desired Packaging Format(s)

• Brewpub or Commercial Brewery?

• Produce ales, lagers, or both?

• Consider short-term and long-term goals

Equipment

Equipment Delivery, Installation & Commissioning

Professional Fees (Engineering, Architect, Legal, etc)

Marketing & Sales Expenses

Labour (Direct & Indirect)

Start-Up Supply Costs

Real-Estate & Construction Costs

Where Do I Begin?

First-Order Estimated Budget:

Financial Plan

$500,000 - $25,000,000

Brewery Building

Real Estate Considerations

Brewpub or Commercial Brewery

Own

vs. Lease

Zoning By-Laws (Municipal)

Environmental Compliance Requirements

Greenfield vs. Brownfield

Other Considerations: • Ample Parking • High Foot Traffic

Brewery Building

Brewery Space Considerations (Commercial Brewery)

Internal Vertical Height

Internal Floor Space

• 1.00-2.75 sq ft./HL/Year;

• Min. start-up size ~5,000 sq. Ft.

• Dependent on cellar tanks size(s)

• Opportunities to build outside

Brewery Building

Brewery Structural Considerations

Drainage

Floors, Walls & Ceilings

• Floor load strength = 405-605 kg/m2

• Floor finishes: Washable (tiles, epoxy) with 2% slope toward centre of drains

• Walls & Ceiling finishes: Washable and Mould Resistant (RFP, Tiles, Paint) , Closed-pore insulation recommended

• 4”-6” diameter drain piping

• Circular drains (4”-6” diameter) and/or curved-bottom trench drains (6”–10” wide grating)

• Good size catch basin recommended

Bewery Ventilation

• Set up to maintain positive pressure in brewery environment

• Sized to ensure brewery air refreshed min. 4 times per hour

• Air conditioning for humidity control recommended

Brewery Building

Expanding Existing Brewery

Factors to consider

Identify

• Space and structural restrictions

• Opportunities for process improvements

• Capacity bottlenecks

• Plan to phase-In expansion project over time

• Product quality risks

• Opportunities to build outside

• Ongoing production demands

Brewery Layout

Warehousing

Packaging

Brewery Layout

Bright Beer &

Conditioning Filtration

Fermentation /

Aging Brewing

Milling & Grain

Handling

Establish good material and operational work flow, while allowing room for future expansion

Goal

Brewery Layout


Goal

Brewery Layout


Goal

Brewery Layout

Keep hot areas separate from cold

Considerations

Brewery Layout

• Keep dry areas separate from wet areas

• Malt storage, handling and milling areas are dust explosion hazard areas

Considerations

Brewery Layout

• Number and location of Loading Docks

• Good truck accessibility

Other Considerations

Brewery Layout

• Location of Non-Brewery Areas

• Non-Operational Functions - Visual Aesthetics and Brewery Tours

Other Considerations

Factors To Consider

Production Equipment - Sizing

• Space Availability and Structural Limitations

• Basis: 5-year sales volume forecast per brand

• Types of Beers (% Ales vs. % Lagers)

• Define mode of production operation

• Manpower resources, number of shifts per day

• Equipment Configuration


Production Capacity

Operating Capacity

Design Capacity

• Theoretical maximum output if brewery operates at same level for all 12 months/yr.

• Unrealistic as it does not account for seasonality of beer demand

• Theoretical maximum output on an adjusted basis based on fluctuating demands throughout the years (i.e. Seasonality)


Calculating Brew house Design Capacity Ultimate Beer Sales Volume (e.g. Year 5) 5,000 HL Beer/Yr Shrinkage (10%) 500 HL Beer/Yr Total Production Volume 5,500 HL Beer/Yr

Monthly Volume 1/12 of annual volume # of brews per day (3-vessel system) 4 brews/day (24hr) # brewing days per week 5.4 days/wk. # weeks per month 4.3 wks/mo.

Design Capacity Estimate (Total Production Volume / (12 months/yr) / (wks./mo.) / (brew days/wk) / (brews/day)

= 5,500 / (12 months)/(4.3 weeks/mo. )/(5.4 days/wk)/ (4 brews/day)

= 4.9 HL / Brew 5 HL/Brew


Calculating Brew house Operating Capacity Ultimate Beer Sales Volume (e.g. Year 5) 5,000 HL Beer/Yr Shrinkage (10%) 500 HL Beer/Yr Total Production Volume 5,500 HL Beer/Yr

Peak Month Factor 12% of annual volume # of brews per day (3-vessel system) 4 brews/day (24hr) # brewing days per week 5.4 days/wk. # weeks per month 4.3 wks/mo.

Operating Capacity Estimate (Total Production Volume x (Peak Month Factor)/(wks./mo.)/(brew days/wk)/(brews/day)

= 5,500 x (.12) / (4.3 weeks/mo. )/(5.4 days/wk)/ (4 brews/day)

= 7.5 HL / Brew 8 HL/Brew

3-Vessels Mash Tun, Brew Kettle, Whirlpool


Brew House Capacity - Vessel Configuration

Brew Volume 35 HL 50 HL # of Vessels 3 3 # of Brewing Hours per Day 24 HRs 24 HRs Brews/Day 4 Brews 4 Brews Days/Week 6 Days 6 Days Weeks/Month 4.3 Weeks 4.3 Weeks Loss 10% 10% Beer - Peak Month Volume 3,251 HL/mo 4,644 HL/mo Annual Beer Sales Volume 32,508 HL/yr 46,440 HL/yr

4-Vessels Mash Mixer, Lauter Tun, Brew Kettle, Whirlpool


3-Vessels Mash Tun, Brew Kettle, Whirlpool



4-Vessels Mash Mixer, Lauter Tun, Brew Kettle, Whirlpool


Brew House Capacity - Vessel Configuration


Calculating Fermenting/Aging Operating Capacity Ultimate Beer Sales Volume (e.g. Year 5) 5,000 HL Beer/Yr Shrinkage (6%) 300 HL Beer/Yr Total Production Volume 5,300 HL Beer/Yr

Peak Month Factor 12% of annual volume

Vessel Residence Times Lagers (includes filling, ferm + maturation + emptying + cleaning): 22 days Ales (includes filling, ferm + maturation + emptying + cleaning): 15 days Average residence time (assuming 50% lagers and 50% ales): 18.5 days Number of tank turns per month 1.65 turns/mo.

Estimated Operating Capacity (Total Production Volume) x (Peak Month Factor) / (# Tank Turns/mo.) = 5,300 x (12%) / (1.65 turns/mo.) = 386 HL 400 HL (total working volume)


Fermenting/Aging Tank Farm Capacity - Factors To Consider

• Size and Number of Tanks

More Small Tanks

• Floor Space

• Flexibility

• Process & Material Efficiency

Fewer Lager Tanks

• Floor Space

• Flexibility

• Process & Material Efficiency

Packaging Equipment - Sizing

Factors to Consider:

• Define primary packaging format



• Define secondary packaging format



• Returnable Bottles or One-Way Glass

• Pasteurized or non-pasteurized

• Est. 5-year sales volume forecast per packaging format

• Define mode of packaging operation

• Manpower resources, number of shifts per day

• Select filling speeds and calculate # of shifts/week


Year 1 Year 2 Year 3 Year 4 Year 5 Total Volume HL/yr 14,500 18,560 23,757 30,409 75,000 600 ml bottles HL/yr 5,800 8,352 11,878 16,725 45,000

50L/20L Keg Draft Volume HL/yr 8,700 10,208 11,878 13,684 30,000

HL/Yr 5,800 8,352 11,878 16,725 45,000 Weekly Production - Peak (12%) HL/Week 162 233 331 467 1,256 Bottle Content L 0.6 0.6 0.6 0.6 0.6 Weekly Production Bottles 26,977 38,847 55,248 77,790 209,302 Rated Filler Speed BPM 100 100 100 100 100 Actual Packaging speed BPM 75 75 75 75 75 Weekly Machine Time Hrs 6 9 12 17 47 # of (7hr) Shifts Per Week 0.9 1.2 1.8 2.5 6.4

HL/Yr 5,800 8,352 11,878 16,725 45,000 Weekly Production - Peak (12%) HL/Week 162 233 331 467 1,256 Bottle Content L 0.6 0.6 0.6 0.6 0.6 Weekly Production Bottles 26,977 38,847 55,248 77,790 209,302 Rated Filler Speed BPM 40 40 40 40 40 Actual Packaging speed BPM 30 30 30 30 30 Weekly Machine Time Hrs 15 22 31 43 116 # of (7hr) Shifts Per Week 2.1 3.1 4.4 6.2 16.6

Volume Assumptions

Bottle Volumes / 40 bpm

Bottle Volumes / 100 bpm


Define speed for rest of packaging line equipment Packaging Line Speed Balancing: V-Curve Profile

Packaging Line – Design

Packaging Line - Design

Packaging Line - Configuration

Packaging Line Design - Factors To Considerations

• Space Availability For: • Equipment • Material placement and staging • Operator and maintenance access to machines • Future expansion and additional future packaging options (E.g. Multi-packs, shrink wrap, trays, etc.)

• Material, Product, & Operator Flow • Avoid operator crossovers

• Fork lift access & clearances to bring in & take away materials

• Level of Automation

Utilities

Refrigeration

Steam Boilers • High Pressure vs. Low Pressure Systems

• Recommend: Boiler systems with high turn down/start-up ability

• Boiler water treatment & condensate return systems

• Refrigerant: Glycol vs. Ammonia Systems • Outdoor vs. Indoor Systems • Single Large System vs. Modular/Expandable System

Energy Savings Strategies

• High efficiency boilers and refrigeration systems

• Motors with variable frequency drivers (VFDs), LED lighting,

• Heat/Energy Recovery Systems


Water Savings Strategies

Water Supply

• About 6 HL water consumed per HL of beer produced • Recommend min. brewery water supply = ~30 gpm at ~60 psig • Water Treatment Recommendations:

• Water Conditioning - Ion exchanger and/or water softener • Water Filtration – Sand Filter and/or activated carbon filter

• Non-Rinse Sanitizers

• CIP Water Collection/Pre-Rinse Tanks

• Grey Water Recovery Systems


Waste Water Pre-Treatment Strategies

• Retention Tank with pH adjustment system

• Biodegestors (Aerobic and Anaerobic)

• GOAL: Avoid as much solid waste as possible from going into sewer. Collect and send it to 3rd party

Waste Water • 4HL waste water per 1HL beer produced

• High solid and organic load - BOD, COD, TSS

• Large variability in Temperature and pH


COD mg/l 2000 - 6000 BOD mg/l 1200 - 3600 TSS mg/l 200-1000 Temp oC 18 - 40 pH 4.5 - 12

Parameter Unit Raw Brewery Wastewater Composition

Waste Water Pre-Treatment Strategies

• Retention Tank with pH adjustment system

• Biodegestors (Aerobic and Anaerobic)

• GOAL: Avoid as much solid waste as possible from going into sewer. Collect and send it to 3rd party

Waste Water

• 4HL waste water per 1HL beer produced

• High solid and organic load - BOD, COD, TSS

• Large variability in Temperature and pH


Brewery Solid Waste – Composition & Disposal Strategies

B

iode

grad

able

Spent Grain Cattle feed 78.7%

Malt Dust Cattle feed 0.0%

Sweet water Animal feed 1.5%

Spent Hops Cattle feed; soil amendment 6.8%

Cold Trub Cattle feed 0.7%

Spent Yeast Soup Companies/Bakeries; animal feed 9.7%

Spent DE Pig feed; soil amendment 2.3%

Oth

er

Packaging Material Local Recycling Program 0.3%

Co-Product Possible Intended Uses Estimated % Make-Up


Emission Mitigating Strategies

• Vapor condensing systems

• Foam traps

• Activated charcoal filters in air handling systems

Emissions • Include noise, vibrations and air-born contaminants

• Brewery emissions are non-toxic

• Most brewery emissions odorless except for Volatile Organic Compounds (VOC’s)

Any questions?

Thank you!

Mark Benzaquen, Craft Services Email: [email protected]

www.firstkey.com

Documents

Making it Work: Starting / Expanding Your Brewery · Starting / Expanding Your Brewery . ... Beer & Conditioning ... Calculating Brew house Design Capacity. Ultimate Beer Sales Volume