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MillerCoors Golden MillerCoors Golden BreweryBrewery
Sustainability ImprovementSustainability Improvement.
EnergyWater
Waste to Landfill
Julie Smith, PE, MSPlant Optimization EngineerUtilities/Technical Services
Agenda• Corporate Goals/Leadership• Brewery Processes • Brewery Utilities• Opportunities• Waste to Landfill• Culture
Brewery Sustainability ImprovementBrewery Sustainability Improvement
Corporate Sustainability GoalsCorporate Sustainability Goals
Energy Usage of 120 MJ/HL by 2015 Electricity Steam Vehicle Fuel
Water Usage of 3.18 HL/HL by 2012 Zero Waste to Landfill by 2015 CO2 Self-Sufficiency of 85% by 2015 50% Reduction in Green House Gas by 2020
Why Sustainability?• Customer Demand• Continue our Business• Save Money• Marketing• Responsibility for Future Generations!
Monthly Indicator*
Mthly ActualMthly Stretch
TargetMthly Budget
TargetActual YTD
2012YTD Stretch Goal YTD Budget STPY % Change
People/Process
Tech
MillerCoors 155 165 173 145 143 154 154 -5.7%
Milwaukee 138 154 156 133 138 140 147 -9.5%
Fort Worth 126 103 105 113 104 105 111 1.9%
Eden 162 175 165 141 156 163 170 -17.1%
Albany 134 142 156 130 132 145 140 -7.5%
Irwindale 118 115 124 123 122 131 130 -5.2%
Trenton 137 160 184 145 143 164 156 -7.1%
Golden 252 288 307 226 215 229 234 -3.5%
Shenandoah 128 109 116 106 99 106 106 -0.3%
Monthly Indicator*
Mthly ActualMthly Stretch
TargetMthly Budget
TargetActual YTD
2012YTD Stretch Goal YTD Budget STPY % Change
People/Process
Tech
MillerCoors 3.86 3.92 4.01 3.82 3.83 3.92 4.07 -6.0%
Milwaukee 3.63 3.68 3.75 4.07 3.85 3.92 4.77 -14.8%
Fort Worth 3.59 3.31 3.38 3.47 3.41 3.48 3.53 -1.8%
Eden 3.46 3.97 4.05 3.34 3.77 3.85 3.91 -14.6%
Albany 3.53 3.54 3.62 3.67 3.60 3.68 3.81 -3.6%
Irwindale 3.36 3.53 3.60 3.69 3.66 3.73 3.73 -1.1%
Trenton 3.56 3.98 4.16 3.56 3.55 3.71 3.76 -5.2%
Golden 5.35 4.85 5.01 4.63 4.56 4.71 4.82 -3.9% NP
Shenandoah 3.82 4.09 4.15 3.86 3.91 3.97 4.09 -5.8%
High Usage
Typical Usage
Reduced Usage
60- 80%
Stretch Reduction >80%
Water (hl/hl) FEWER
Monthly Indicator Monthly/YTD/Budget KPI FEWER - People/ Process & Technology
*Monthly Indicator relative to 2009-2011 usage rates. Linear regression model factors include brewed, packed, weather, rainfall, electrical generation.
Above Upper Target
Nothing Planned - NP
< 60%
Between Stretch &Upper Target
December 2012
Total Energy (MJ/hl) FEWER
SIT Goals
2011 2012 2013 2014 2015
Water 4.07 3.83 3.57 3.38 3.18
Energy 154 143 136 128 120
Brewery Process OverviewBrewery Process Overview
Malting
Brewing
Fermenting
Conditioning
Packaging
Warehousing
Golden Brewery MapGolden Brewery Map
Golden Brewery LayoutGolden Brewery Layout
Aging Cellars, Hop Storage
Malting/Kilns
Packaging/Warehouse/Gov. Cellar
Fermenting
Conditioning
Brewing ProcessBrewing Process
• Mash In• Filter/Lauter• Boil Wort• Chill• Ferment
FermentingFermenting
• Yeast + Wort = Beer• Maintain
Temperature• Residence Time• CO2• Yeast• To Aging
ConditioningConditioning• Aging• Filter• Blend• To Packaging
PackagingPackaging• Bottles, Cans and Kegs• Rinse• Fill• Label• Package• Palletize• To Warehouse
WarehouseWarehouse
• Store Product• Move Product• Temperature• Docks
Utilities for Brewery OperationsUtilities for Brewery Operations
Power Plant – Co-Generation Coal and Natural Gas Fired Boilers
• 800 LB Steam1) Electricity2) 400 LB Steam3) 50 LB Steam
Ammonia• Steam• Electricity
Plant Air• Steam• Electricity
Water Treatment• Electricity
Wastewater Treatment• Electricity
CO2 Recovery• Electricity
Utilities – Map of Valley
Utilities – Where does the Steam Go?
Resource Savings Opportunities
Steam
Steam Savings Opportunities Steam Savings Opportunities “Low Hanging Fruit”
Leaks Traps Control Valves Pressure Relief Valves
Process Optimization/Team Work Compression Equipment Operation Problem Solving Metering - Short-Interval Control Set Points CIP Times Quality/Efficiency
Projects HVAC Plant Air Refrigeration Brew Kettles
Plant Air OpportunitiesPlant Air Opportunities Leaks Operations
Compression Equipment Set Points
Small Projects Cabinet Cooling/Pressure Air Shut-Off on Equipment not Operating Low Pressure Uses Condensate Drains Pneumatic Valves and Equipment
Large Projects Decentralization Distribution Headers
CondensateCondensate
Return Benefits Cost Energy Waste Treatment Water Treatment
Where is it Going? Sewer Stack Steam Leaks
Utilities – Where does the Electricity Go?
Resource Savings Resource Savings OpportunitiesOpportunities
Electricity
Electricity Electricity Savings Savings OpportunitiesOpportunities
Culture Lights Office Equipment Phantom Energy
Process Optimization/Team Work Metering/Short Interval Control CIP Times Pump Control Hard Shut-Downs Operating Strategy Water Usage Quality/Efficiency
Projects Lights Pump VFD’s Controls Equipment Right-Sizing
Facilities Lights HVAC Insulation
No!
Yes!
Electricity Savings OpportunitiesElectricity Savings OpportunitiesMalting Lights ResultsMalting Lights Results
Electricity Savings OpportunitiesElectricity Savings OpportunitiesBOC HVAC Recommissioning ResultsBOC HVAC Recommissioning Results
Electricity Savings OpportunitiesElectricity Savings OpportunitiesPackaging Green Shut-DownPackaging Green Shut-Down
Utilities – Where Does the Water Go?Utilities – Where Does the Water Go?
Resource Savings Opportunities
Water and WastewaterWater and Wastewater
Savings Opportunities – Water and WastewaterSavings Opportunities – Water and WastewaterSave Water = Save Energy!
“Low Hanging Fruit” Leaks Controls Nozzles
Team Work/Process Optimization Problem Solving Broom Not Hose CIP Times Cleaning Machines Dry Lube Seal Water Quality/Efficiency
Projects• Re-Use
Once-Through Cooling Water Empty Can Rinse Water Reject Can Conveyance
Waste to LandfillWaste to Landfill Currently ReUse or Recycle >98% of Total
Waste• Spent Grain• Yeast• Ethanol Still• Glass• Cans• Single Stream• Industrial (Paper, Cardboard, Stretch Wrap, Metal)
Still, 100 Ton/Month to Landfill (2010)• Goal – Zero Waste in 3 years (or pretty close)• Sort, Label, Color Code• Optimize Collection• Source Reduction
Co-Products Golden BreweryCo-Products Golden BreweryBill Coors: “Waste is Just a Resource Out of Place”• Yeast – 12 MM LBS/year• Fuel Grade Ethanol – 2.5 MM gal/year • Spent Grain – 400 MM LBS/year
• All sold locally• Grain Dust
• Malting• Malt Storage• Grain Load-Out• Brew House
Pavilion at Investment Recovery
Employee Sales / Beer Trailer
YOU’RE INVITED TO HELP US MAKE AN IMPACT!
As a first step to make the Golden Brewery “The Largest Zero-Waste-to-Landfill Brewery in the World”,
we need your help to:
•sort recyclables from the trash created at the brewery•paint examples of our new standardized color-coding system of lugers/dumpsters•draw up facts about trash and recycling at our brewery to create a great display
RSVP on the Volunteer Website (https://www.millercoorsvolunteers.com)
What: Operation Zero Waste CARE & Volunteer Event
When: Thursday, Sept. 15th Sorting: 7am – 8:30am
8:30 am – 10am Visit and learn: 1pm – 4pm
Where: Pavilion at Investment Recovery
What to bring: Pants, long sleeved shirt, PPE (bump-cap, steel-toes, safety-vest, and Kevlar gloves)
Culture and PeopleCulture and People
What is Culture?
Culture – What is Culture?Culture – What is Culture?
Definitions: 1.The quality in a person or society that arises from a concern for what is regarded as excellent in arts, letters, manners, scholarly pursuits, etc.2.That which is excellent in the arts, manners, etc.3.A particular form or stage of civilization, as that of a certain nation or period: Greek culture.4.Development or improvement of the mind by education or training.5.The behaviors and beliefs characteristic of a particular social, ethnic, or age group: the youth culture; the drug culture.
CultureCultureElements for SuccessElements for Success
Leadership Green Teams Education Communication Recognition Projects Score Cards
Culture – Green TeamsCulture – Green Teams
Golden Green Team – CAREGolden Green Team – CARE““Committed to Active Responsibility for the Environment”Committed to Active Responsibility for the Environment”
• Established 2006• Lunch and Learn Education• Recycling• Brown Bag Movies• Movie Library• Volunteer Opportunities
• Clear Creek Watershed• Recycling Audit• Holiday Meal – Zero Waste Bin Stewards