Craft Brewers:  Froth with Opportunities

PartnershipsOregon Manufacturing Extension Partnership –Material and Labor

OSU – Energy

PPRC –Pollution Prevention (P2)

Good Environmental Practices (Already in Place) Heat exchanger Spent grain to feed Reuse pallets Good housekeeping Restaurant grease recycle Enclosed room for boiler Earthsure Certification Energy Analysis

Good Environmental Practices (Already in Place)

Salvaged material 

OMEP:  Labor & Material FocusCanning and Keg WashingLabor:  

• Significant reduction in transfer of the product from process to cans and out the door 

‐ lifting, carrying, climbing ladders  ‐ picking up and tossing defect cans 

• Worked with staff to make keg cleaner operational  

Material:  • Number of cans dropped before filled (~8’ high 

palletized raw cans fed into canning chute)• Enhanced some of the filling machine mechanics 

to decrease can and beer loss as a result of filling/canning 

OMEP Projects:  Canning and Keg Washing

Exploring:  

‐ Can flush water used inside then be used to clean the outside of the can?   

‐ Business case for centrifuge, at a capital cost of around $200,000, which would achieve 5% gains through more efficient extraction of beer and reduction of spent yeast waste.  

NIST MEP – Impact Washington, Ecology, PPRC 

OSU Energy Efficiency Center (Available for projects in Washington State)

Three Primary Analyses/Recommendations Recommendation Estimated payback 

(with local/state incentives)

Potential Savings

Lighting Retrofit 3.9 years 21,700 kwh

Insulate steam pipes 0.4 years 276 MMBtu/year

Expansion Analysis (lighting) 0.2 years ~11,000 kwh (compared to installation of incandescents)

Additional Recommendations (Lack of Data did not allow for in-depth cost analysis)

• Wort Vapor Capture• Water Heater (On-Demand)• Heat Bridging (Warehouse metal I beams)• Canning Line Water Use • Refrigeration Controls

PPRC Walk‐Through (A Sampling of Recommendations)

• Find outlets for ‘energy waste sources’ (Hop liquor and yeast)

PPRC Walk‐ThroughWork on increased recycling (some commodities are a little challenging in Astoria…)

PPRC Walk‐Through • Keg collars  • Further minimize air flow from cold storage, with better curtains, seals, etc.• Compressed air leak test• Dry/waterless cleaning techniques to extent possible• Infrared camera assessment

Source:  sm‐printing.com

IR AssessmentHot Tank (Doors)

Cold Beer

Compression Tank & Adjacent 

Note – temperature pointer/reading not at hottest point on tank

Cold storage

Cold storage

Pub kitchenCold storage/refrigeration

Steam / Condensate Lines – Throughout Facility

Steam / Condensate Line Insulation Options:  

Mineral Wool or Calcium Silica

Mineral wool pipe insulation from IIG‐LLC.  They recommend a 

metal wrap around the outside of this product.

Mineral wool pipe insulation from Isover.   

See article comparing 

features / costs, of two different 

materials:     Megha

InsulationsCalcium silicate 

insulation Calsil

Warehouse ‐ Door 

Warehouse – Showing Areas  of Lower Spray 

Insulation Efficacy 

Summit BrewingSummit Brewing Company’s Glass Wall/ Heat Recovery Project.

Glass separation wall between the Brewhouse and the Ratskeller, with some additional ductwork and building automation controls to divert heat from the Brewhouse to the outside in the summer and to the Ratskeller during the winter.

Currently kettle heat ends up in the Ratskeller, load increases cooling needs in summer.

- Two modes, summer and winter. - Summer - bring in filtered outside air and dispel the hot air to the outside.- Winter - Brewhouse will take in room temperature air from the Ratskeller

and dispel the heat into the return air system in the Ratskeller.- Year round savings estimated by Xcel energy engineers 200,000 KWH and

6000 therms (~$20,000 per year).

Good Environmental Practices (Already in Place) Heat exchanger Spent grain to feed Reuse pallets Auto‐sensor lights and faucets in restrooms Good recycling  Good housekeeping

Opportunities/Recommendations for Improvement

Evaluate water use reduction opportunities Enclosed room for boiler Evaluate any lean/continuous improvement opportunities identified by AMEP

Perform Energy Analysis

Opportunities/Recommendations for Improvement

Implement Preventive Maintenance & Leak Detection Programs on:  

o Compressed air systemso CO2 delivery system  o Steam trapso Water connections

Other Opportunities for Improvement

Evaluate Installation of Nitrogen Generator(PPRC and Midnight Sun)

Evaluate replacement options for DE Filter(Midnight Sun)

Nitrogen Generator

Midnight Sun currently spends $50,000 to $60,000 annually on CO2

Does some onsite CO2 recovery 30% of CO2 used to carbonate beverages

Nitrogen Generator

Nitrogen Generator

Cover the headspace of stored ingredients Replace CO2 in the headspace of tanks Keg filling Reduce wastage due to fobbing when discharging beer from storage to filtration

Replace CO2 to purge equipment and pipelines

Planned for Fall of 2013 by Midnight Sun

Centrifuge Filter

Purchased in fall of 2013 Total cost to MSB was around $100,000 Alfa Laval Brew 80 Minimizes:

o Oxygen pick‐upo Loss of volatile aromaso Beer loss – discharged

solids are dry

Centrifuge Filter – Quantified Sanings

Savings of $15,000 annually over DE filter costs Able to reclaim 3‐7% more beer Reduced water use by 64,000 gals

Centrifuge Filter – Unquantified Savings

Reduced labor hours Reduced chemical usage Reduced worker exposure toDE silica dust

Denali Brewing Company / Seward Brewing Company

Excellent recycling of building materials Chiller plumbing Small scale nitrogen generator

Questions for Michelle and Ken?