Objective/ Background: TodesignabarleymaltingsystemforSugarCreekMaltingCompanyforlessthan$10,000.Thisdesignallowsforamoreuniformhighqualityroastedproductwhiledecreasingthecostfromatraditionaldrumroaster.

C A P S TO N E / D E S I G N E X P E R I E N C E 2 0 1 7

FluidizedBedRoastingofMalt.Henry Clarke (BE), Ethan Lenn (BE), Sarah Reaves (BE), Kimberly Wylin (BE)

Sponsor: Sugar Creek Malting Company

Technical Advisor: Instructors:Martin Okos

Acknowledgements:

Pre-Conversion Post-Conversion/Pre-Roasting Post-Roasting

Mass(g) 400.1 392.9 225.8MoistureContent(%) 0.4646 0.4612 0.0567

Final Design:

Constraint StakeholderRequest Deliverables

Temperature 200F- 600F 70F– 392F

Throughput 12– 15bushels Labscale(0.01bushels)

Cost <$10,000 $10,170

Equipment Drumroasterandcoolingtray

Conversionoven,fluidizedbedfor

roasting,fluidizedbedfor

coolingCurrently,theonlycompetitorforsuchadesignisacoffeecompany.Ifthisdesignweretofail,theSugarCreekMaltingCompanycouldpurchaseadrumroasterandcoolingtrayatahighercost.

Design Process:

Economic Analysis:

Global and Societal Impact:• OrganicWaste/Year:5,394kg• Emissions/Year:16,624kg• TotalWaste/Year:22,018kg• Filteredoutmaterialscanbecomposted• Scrubberonairventedtoatmosphere• TestwaterforCWAstandardsbeforereleasingitto

streams• Useheatexchangerstocutdownonenergy

consumption• Createsjobsforstudents• Neverbeenusedinthemaltindustrybefore

Recommendations:

Table1:StakeholderRequestsandFinalDeliverables

Figure2:BarleyRoastinginBed

Table2:MassBalancesandMoistureContentfromRoastingFigure1:FinalFlowDiagram

Table3:MorphologicalAnalysisofAlternatives

Figure6: FirstIterationofDesign

Figure7: SecondIterationofDesign

• Scaleupofprocesstobatchsizeof15bushels• Smallerdiameterpipesinfluidizedbedtoprevent

thebuildupofwater• Testwithdifferentkindsofbarley• Trytoachievedifferentkindsofmalt

Figure3:FluidizedBedSystem Figure4:PrevPostRoasting

• Priceofroastedmalt:$4.25/lb• Annualinsurance:$1,200• Annualrent:$12,000• Wages:$50,000• Estimatedsales:30,000units/yr• Productioncost:$1.01/lb• Breakevenpoint:2.68yearsTime(years)

$/year

Figure5:BreakevenPoint