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MBAA Western New YorkTechnical Presentation
Optimizing Brewhouse Design-A plan to expand an existing brewery-
An IntroductionReay Dicks, Snr Process Engineer
• BSc (hons), Chemical Engineering – UCT
• MSc, Bio Chemical Engineering – UCT
– Specializing in Algal Biofuels
• Initial Experience in
– City Waste Water
– Coca Cola Packaging Plant
– Platinum Flotation and Mining
– Petrochemicals - UK
UCT, 2009
An IntroductionReay Dicks, Snr Process Engineer
• BSc (hons), Chemical Engineering – UCT
• MSc, Bio Chemical Engineering – UCT
– Specializing in Algal Biofuels
• Initial Experience in
– City Waste Water
– Coca Cola Packaging Plant
– Platinum Flotation and Mining
– Petrochemicals - UK
• Briggs of Burton, PLC
– 2.5 years
– C.Eng, MIChemE
• Briggs of Burton, Inc
– 2 years, Brewing and Distilling
– P.E. Chemical
Optimizing Brewhouse Design-A plan to expand an existing brewery-
Presentation Overview Presented By
• Reay Dicks, PE, Briggs of Burton Inc.
Optimizing Brewhouse Design-A plan to expand an existing brewery-
Briggs of Burton
OverviewIs there a
Business Case?
Project Types and Studies
Benchmarking and Standards
Recipes and Brewing
Technology
Plant and Project
Flexibility
Process Capacity
Modelling
Automation
Other Topics
Briggs of Burton - Overview
Thomas Thornewill
Burton-on-Trent 1732
Thornewill & Wareham
Burton-on-Trent 1849
S Briggs & CoBurton-on-Trent
1929
S Briggs & CoBurton-on-Trent
1888
Robert MortonBurton-on-Trent
1876
Robert MortonStockton on Tees
1859
Robert Morton DG Ltd
Burton-on-Trent1968
Henry BalfourLeven1810
Henry Balfour[Pfaudler]
Leven1962
S Briggs & CoBurton-on-Trent
1982
Briggs of Burton plc
Burton-on-Trent 1986
Thornewill & Wareham
Burton-on-Trent 1919
PfaudlerRochester NY
S Briggs Inc Rochester NY
1982
Briggs of Burton plc
Burton-on-Trent 1989
Briggs of Burton Inc
Rochester NY1986
Briggs & BindleyBurton-on-Trent
1875
Shock GusmerRochester NY
S BriggsBurton-on-Trent
1865
Briggs of Burton plc
Burton-on-Trent 1993
Richard SizerHull1899
T GiustiWellinborough
T GiustiLondon
T. R. Shercliff & Co. Ltd
Burton-on-Trent 1876
Briggs of Burton plc
Burton-on-Trent 1998
APV Burnett & Rolfe
Rochester, Kent1983
Burnett & RolfeRochester, Kent
1946
Briggs of Burton plc
Burton-on-Trent 1991
Briggs PCAHolmes Chapel
1991
PCA AssociatesCongleton
The History of Briggs
Briggs Industries
Briggs Main Offices
Rochester, New York
Burton on Trent, UK
Shanghai, China
Ziemann Holvrieka Inc.Miami, USASan Diego,
Mexico
Ziemann Holvrieka GmbHOffice Hanoi, Vietnam
Ziemann HolvriekaAsia-Pacific Co. Ltd.Bangkok, Thailand
Ziemann Holvrieka GmbHOffice Moscow, Russia
Ziemann HolvriekaAsia Co. Ltd.
Nantong, China
Ziemann Holvrieka GmbHLudwigsburg, Germany
Ziemann Holvrieka A/SRanders, Denmark
Ziemann Holvrieka N.V.Menen, Belgium
Ziemann Holvrieka B.V.Emmen, Sneek
Netherlands
Briggs PLCBurton-on-Trent, UK
Rochester, USA
Ziemann Holvrieka GmbHBürgstadt, Germany
Briggs PLCShanghai, China
CIMC ENRIC Offices
• Full turn-key solution provider• Project Management• Process Engineering• Electrical Engineering• Automation and Control• Manufacturing
Briggs Specialization
• Clean In Place (CIP) and Hygienic Process Engineering
• Brewing & Distilling• Mixing, Blending, Cooking and Cooling• Yeast & Fermentation• Process Automation• Site Management
Briggs Capabilities
BREWING
ExpansionIs There A Business Case?
Business Case
Brewing Market Growth
*Bart Watson | Brewers Association Chief Economist, Julia Herz | Craft Beer Program Director.**IRI Group scan data, YTD through 7/1/18, MULO+C, Total U.S.***https://www.brewersassociation.org/statistics/by-state/
-5%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
1M+ 100K-1M 10K-100K 10K or less
Brewery Growth 2017/2018
2017 Mid-year growth 2018 Mid-year growthCEs (1 bbl = 13.78 CEs)
So How to avoid a mess?
Project Scope
But What About? CIP Co-products Utilities HVAC Structural Manning Effluent Warehousing Permitting Upstream and
Downstream knock-on
Business Case>Scope
Business Requirement
Capacity planning model3D Modelling
Planning tools
Operations Drawings
Risk Management
Visualisation
GMP
Process Work Mapping
International Procurement
Cash Flow
Cost Control
Reporting
Scheduling
I/O Schedule
Valve Schedule
Pump Schedule
Asset Care Reporting
Instrument Schedules
Pipework access / Operator space
URS
FDS
System Development
Simulation
Process Optimization
Lean Manufacturing
World Class Operations
Flexible Manufacturing
Life Cycle Costing
Utility Loadings
Benchmarking
Continuous Improvement
Mass + Energy Balance
Safety
Financial
Process
Downtime
Automation
Project Types and Studies
Business Case>Scope>Project Type
• FEL 1-3
• FEED
• Master Plan
• Preliminary Concept designs
• Stage Gate designs
All trying to deliver:
• Capital Budget Preparation:
• Basis of Design
• Mass & Energy Balances
• Process Flow Diagram (PFDs)
• Plant Utilization
• Capacity Calculations
• Plant configuration & sizing summary
• Conceptual Plant Layout / Civil & Structural
• Equipment Loadings / Drainage Plans
• High Level Process Description
• Control System Philosophy & Architecture
• Electrical Distribution
• HAZOP?
Not Sure where to start?
BREWING
Front-End Loading Levels
FEL 1 FEL 2 FEL 3 Detailed Design± 30% Cost Certainty ± 20% Cost Certainty ± 10% Cost Certainty
Cost Certainty with Contingency (<10%)
Block Flow Diagram Process Flow Diagrams Preliminary P&IDs (IFB) P&IDs and equipment drawings (IFC)Material and Energy Balance Preliminary Equipment Design Purchase-ready major equipment specifications Major and Minor Equipment TenderPreliminary Layout Preliminary Layouts Project Execution Plan URS/FDSMultiple options design Preliminary Schedule Preliminary 3D model 3D model (IFC)
Major technologies Review Network Architecture Electrical equipment List/ Architecture Line ListIndustry standard historical costings CSA preliminary designs
COST CERTAINTY
Industry Standard for large CAPEX projects
Types of Contracts
• Consulting (E)
• Equipment Supply (OEM)
• Engineering, Procurement & Construction Management (EPCM)
• Engineering, Procurement and Construction (EPC/Turnkey)
• Sometimes a mix
• Look for a long term partner– Support
– SLAs
EPCM vs EPC
Client
Main Contractor (PC)Process Equipment:
Valves, HEX, Instruments etc.
Sub-contractors Installation
Civils EPCM Contractor
Client
Civils
Main Contractor (PC)
EPC Contractor
Process Equipment: Valves, HEX,
Instruments etc.
Sub-contractors Installation
Client Risk Client Cost
Client Cost Client Risk
EPCM - Risk Profile• Construction Risk with Client
• Process Risk shared between Client (material) and Process Contractor (design & performance)
• Risk associated with ALL equipment and installation moves to Client (delays, FOREX, insolvency)
• Engineering fees are estimated in line with programme and subject to changes at Client risk
• Potential of lowest Initial Contract Cost, BUT– Contractor has different cost profile (No material O/H
recovery)
– Lowest Cost Certainty
– Largest Human Resource Requirement
– Potential delay / extension claims
– Multiple contracts and points of contact
Client
EPCM
OEM Subcontractors
EPC (Turnkey) - Risk Profile
• Defined risks with Contractors (Briggs)
• Budget responsibility at contractors risk (lump sum bid for scope)
• Process Risk with Process Contractor
• Contractors price their risk in the contract price
• Fixed Price – Cost Certainty
• Minimum Risk
• Lowest Human Resource Requirement
• Minimizes “Extras”
• Programme risk with contractors unless affected by 3rd party.
• Client has no visibility of actual costs
• Single point of contact
• Simplified organogram / R&R matrix
• Potential of reduced programme
Client
EPC
OEMSubcontractors
Benchmarking and Standards
Business Case>Scope>Project Type>Benchmark
Benchmarking and Standards
How many Brew Masters, Brewers, Operations Managers, and Operators?
What is your current brewlength and Turn-around Time?
• What is your extract efficiency and evaporation rate?
What is your plant water:beer and power:beer usage?
• What is your Lauter Tun/ Mash Filter bed loading?
What is the viscosity of your yeast strain?
Benchmarking and Standards
Benchmarking
• Units and Overall Design and operation.
• OEE %
• Peak Factors
• Utility and effluent capacities
• Raw material specifications
• Used to drive Performance Guarantees on new equipment
• Variances due to recipe, staff, climate, etc
• Possible Energy rebates
Standards
• Preferred Suppliers
• Electrical and Automation
• Piping and Mechanical
• CIP/SIP
• Tagging and Labelling
• Units
• Maintenance
• Operating and safety procedures
!Never too late to start!
!Keep up to date!
Basis of Design
Defines Key Project Objectives in one document -
• Scope
• Capacity / Phasing
• Operation
• Recipe
• Materials
• Technology
• CIP
• Utilities
• Automation
• Standards
Recipes and Brewing Technology
Business Case>Scope>Project Type>Basis>Brewing Tech
Recipes
Existing Breweries Hopefully defined?
• Mutual NDAs industry Standard
• Bill of Materials
• Water Balance
• High Gravity brewing
• Equipment design extremities
• Variations and equipment capabilities
• Possible future recipes
• Recipe parameters fixed or open to change?
• Brand Split – Beer Factory vs Innovative
• Brewlengths
• Fermentation profiles
• Mutual NDAs industry Standard
• Bill of Materials
• Water Balance
• High Gravity brewing
• Equipment design extremities
• Variations and equipment capabilities
• Possible future recipes
• Recipe parameters fixed or open to change?
• Brand Split – Beer Factory vs Innovative
• Brewlengths
• Fermentation profiles
Recipes and flexibility
30
BREWING
100105110115120125130135140145150155160165170175180185190195200205210215220
0 714
21
28
35
42
49
56
63
70
77
84
91
98
105
112
119
126
133
140
147
154
161
168
175
Degre
es F
Minutes
Mash Profiles
STEAM IN
5,360 kg/h
200
25
80 4 x 50 mm Steam
1,165 kg/h Upper Side (80)
25 2 x 32 mm Cond 50
2,330 kg/h
80 4 x 50 mm Steam
1,165 kg/h Mid Side (70)
25 2 x 32 mm Cond 50
2,330 kg/h
80 4 x 50 mm Steam
1,035 kg/h Mid Side (60)
20 2 x 32 mm Cond 40
2,070 kg/h
65 4 x 40 mm Steam
780 kg/h Lower Side (50)
2 x 32 mm Cond 40
25 1,560 kg/h
4 x 50 mm Steam
100 Dish (40)
1,215 kg/h 2 x 32 mm Cond
50
2,430 kg/h
Condense Flows shown are 80max starting Flows
CONDENSE OUT
10,720 kg/h
• Decisions typically driven by: Reluctance to change
CAPEX Cost
Preference
Awareness
Customization
Timescales
Technology
31
BREWING
• Decisions should be driven by: Reluctance to change
Spares and Support
CAPEX Cost
Cost of Ownership
Preference
Fit for Purpose/Design
Awareness
Track Record
Customization
Timescales
Reliability
Performance Guarantees
Technology
32
BREWING
• What process has changed in brewing over time?
• What has changed in last 10 - 20 years?
Energy Efficiency
Water Efficiency
Cost of Automation
Hygienic Design
Qualitative Instrumentation
Equipment Utilizations
Technology
33
BREWING
A few Unit Technology Options
Milling Mashing Cooking Wort Separation Boiling Whirlpool
Dry Direct Infusion Lauter Tun Vacuum/Pressure Additions
Wet/Steep Pre-masher Decoction Mash FilterInternal/External calandria Decanter
Cracking Steeles Masher Multiple heat zones Weak Worts Simmer/Strip Combi-kettle
Roller Mill Conveying types Pre-run Vessel Vapor Condenser Trub re-useHammer Mill pH adjustment Preheating Additions
Spent Grain Pneumaveyor
Wort Cooling Yeast Fermentation Clarification Finishing Utilities
1 or 2 stage Cell Count pitching Unitanks Membrane filtration Blender carbonatorsDifferent temp ringmains
Low pressure oxygenation
Fully closed multiple strain systems
Density Fermentation
Hermetically sealed Centrifuges Recovered beer Energy Store tank
Hop Strainers Additions CO2 Recovery Inline dosing Beer Blending Recovery CIP sets
Rapid Batch yeast Propagation Homogenizers Volume purging Zero DO pickup Multiple fuel boilers
De-aeration Sparging Recovery Stabilization systemsFull condensate recovery
Autosampling Yeast collection
Dry Hopping
Yeast Cropping
Project Flexibility
Business Case>Scope>Project Type>Basis>Brewing Tech>Flexibility
Schedule
• Upgrade or Continuous improvement.
• T&M or Fixed Priced
• Overall timescales/Phasing identified
• Long lead procurement needs
• Critical path analysis
• Resource / staffing plan identified
• Threat to timescale study
• Tax Exemptions
• Program Control - EWNs
Process Capacity Modelling
Business Case>Scope>Project Type>Basis>Brewing Tech>Flexibility>Capacities
• Allows visualization of equipment requirements to suit plant capacity
• Graphical representation of the plant operation, alongside capacity calculations
• Identifies equipment and manning requirements, route design including process and CIP, utility loadings
• Identifies pinch points and bottlenecks
• Can be used to quickly evaluate multiple scenarios and generate OPEX and CAPEX optimal solution.
What is Capacity Plan Modelling?
BREWING
Where should I spend my Money??
Capacity Modelling
8 BPD PINCH POINT
1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 500 hL 500 hL 500 hL 500 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL
Days CCT 1 CCT 2 CCT 3 CCT 4 CCT 5 CCT 6 CCT 7 CCT 8 CCT 9 CCT 10 CCT 11 CCT 12 CCT 13 CCT 14 CCT 15 CCT 16 CCT17 CCT18 CCT19 CCT20 CCT21 CCT22 CCT23 CCT24 CCT25 CCT26 CCT27
1 Fermenting Fermenting Fermenting Fermenting
2 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
3 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
4 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
5 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
6 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
7 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
8 CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
9 MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
10 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
11 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
12 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting
13 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
14 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
15 Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting
16 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH
17 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
18 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
19 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
20 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
21 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
22 CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING
23 MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
24 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
25 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
26 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting
27 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
28 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
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Manual EXCEL
Capacity Modelling
8 BPD PINCH POINT
1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 500 hL 500 hL 500 hL 500 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL
Days CCT 1 CCT 2 CCT 3 CCT 4 CCT 5 CCT 6 CCT 7 CCT 8 CCT 9 CCT 10 CCT 11 CCT 12 CCT 13 CCT 14 CCT 15 CCT 16 CCT17 CCT18 CCT19 CCT20 CCT21 CCT22 CCT23 CCT24 CCT25 CCT26 CCT27
1 Fermenting Fermenting Fermenting Fermenting
2 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
3 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
4 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
5 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
6 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
7 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
8 CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
9 MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
10 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
11 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
12 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting
13 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
14 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
15 Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting
16 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH
17 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
18 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
19 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
20 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
21 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
22 CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING
23 MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
24 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
25 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
26 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting
27 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
28 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
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MATURING
Manual Graphical
Capacity Modelling
8 BPD PINCH POINT
1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 500 hL 500 hL 500 hL 500 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL 1000 hL
Days CCT 1 CCT 2 CCT 3 CCT 4 CCT 5 CCT 6 CCT 7 CCT 8 CCT 9 CCT 10 CCT 11 CCT 12 CCT 13 CCT 14 CCT 15 CCT 16 CCT17 CCT18 CCT19 CCT20 CCT21 CCT22 CCT23 CCT24 CCT25 CCT26 CCT27
1 Fermenting Fermenting Fermenting Fermenting
2 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
3 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
4 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
5 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
6 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
7 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
8 CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
9 MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
10 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
11 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
12 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting
13 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
14 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
15 Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting
16 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH
17 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
18 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
19 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
20 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
21 Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING MATURING MATURING MATURING MATURING
22 CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting MATURING
23 MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
24 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
25 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting Fermenting
26 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting Fermenting Fermenting Fermenting Fermenting
27 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
28 MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING Fermenting Fermenting Fermenting Fermenting Fermenting
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH CRASH CRASH CRASH Fermenting
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING CRASH
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING MATURING
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MATURINGCapacity models
Brewlength vs BPD
• More brews/day x Smaller Brewlength
• Lower peak / smoother utility loads
• Smaller physical size – shorter runs
• Reduced energy loss
Brews/Day TAT(mins)
Brewlength(Bbl)
Daily Production(bbl/day)
14 100 200 2800
12 120 233 2800
10 140 280 2800
8 180 350 2800
6 240 466 2800
Capacity Modelling
Automation and Control
Business Case>Scope>Project Type>Basis>Brewing Tech>Flexibility>Capacities>Automation
Automation and Control
My Industry Observations
• Allen Bradley vs Siemens.
• Rockwell Factory Talk Brew, Brewmaxx and Ignition
• Conventional and 24v vs Profibus and Asi
• Conduit vs Cable Tray
• Hardwired vs Ethernet
• Reporting
• Variable control vs sequence control
010111001
Other Topics
Business Case>Scope>Project Type>Basis>Brewing Tech>Flexibility>Capacities>Automation>Other
Layout Considerations
Good process flow & effective space use means minimal pump & conveyor power use.
Energy Saving Systems
Special ThanksBriggs of Burton
Sponsors of the EventFX Matt Brewing Co
Andy and the MBAA team
Thankyou for your attention
Questions?