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FOOD & BEVERAGE

TECHNOLOGICAL MILESTONES IN

BEER MEMBRANE FILTRATION

DEVELOPMENTS SINCE THE START-UP OF THE BMF IN MADRID IN 2004

18 SEPTEMBER 2014

ALBERTO ARILLO – BREWING SUPERVISOR – MADRID BREWERY – HEINEKEN

ROLAND FOLZ – DIRECTOR INNOVATION & TECHNOLOGY – FOOD & BEVERAGE – PENTAIR

PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’PENTAIR Food & Beverage 2

CONTENT

• Introduction Membranes

• Beer & Membranes – The Development Phase

• The experiences of Heineken Madrid with the BMF

• The technology roadmap till today

• Challenges of the future – Directions for tomorrow

PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’

FRANKLIN’S QUOTE

”IN WINE THERE IS WISDOM –

IN BEER THERE IS FREEDOM –

IN WATER THERE ARE BACTERIA”

3

WATER WINE BEER


MEMBRAINS & MEMBRANES

4

PENTAIR R&D MEMBRANE FILTRATION

• Membranes

• Modules

• Water & Waste Water Treatment

• Beverage Filtration – Beer, Wine & Cider

…


SMALL & LARGE MEMBRANES – EXAMPLE WATER

5

The Pen -

0.008 l/s

Full-Scale Plant – 4,000 l/s

Sulaibiya - Kuwait


CONTENT






7

MARKET DRIVERS• CONSISTENCY OF THE BEER QUALITY

• NEED TO REDUCE OPERATIONAL

EXPENDITURES IN GLOBAL

COMPETITIVE ENVIRONMENT

• AMBITIOUS SUSTAINABILITY GOALS

TO REDUCE WATER, ENERGY AND

SOLID WASTE FOOTPRINTS

• NEED FOR MORE FLEXIBILITY IN THE

BREWING PROCESS DUE TO

PRODUCT DIFFERENTIATION


BEER & MEMBRANES

8


BEER & MEMBRANES - DEVELOPMENT

CHOICES TO MAKE…• Membrane material ̴ Water FiltraFon � PolyEtherSulphon

• Pore size ̴ Beer quality

• Cross-flow speed ̴ Run volume – Energy consumption

• Flux optimization

• Cleaning /Regeneration ̴ Run volume – Chemical consumption

…PRODUCTS TO CHOOSE FOR!

9


THE FIRST BMF’S

10

• Heineken Madrid (Spain)

• Heineken Warka (Poland)

• Oettinger (Germany)


CONTENT






HEINEKEN EspañaAutor | Fecha

Technological milestones in beer membrane filtration

Developments since the start-up of the BMF in Madrid in 2004

Alberto Arillo 18th September 2014

2013 Madrid Brewery overview

♦ Volume packaged 2.525.000 hls

♦ Main brands, Amstel (35%), Heineken (20%) and

Cruzcampo (15%)

♦ Non-alcoholic beers represented 26%

♦ Great complexity at BBT cellar, 32 different

beers

♦ Two filtration lines, Kieselguhr (400 hl/h) and

BMF (400 hl/h)

♦ BMF 2013 volume 1.090.000 hls (undiluted

beer)� 47% total

BMF Filter Line Madrid

SV

UBT FBTMEMBRANE

FILTER SKIDS

SF

CARBOBLENDER

BBT

SV: Storage Vessel

UBT: Unfiltered Beer Tank

FBT: Filtered Beer Tank

SF: Security Filter

BBT: Bright Beer Tank

PVPP FILTER

Legends

2013 BMF Performance. Skid 1 runlenght

♦ Average first running time 48

hours

♦ In volume means (4 skids)

20.000 hls before CIP

100 hl/h

280242 hls

Nº Backwash 951 294,7 hls/BW

Nº CIP 68 4121,2 hls/CIP

Permeate Flow

Volume filtered (undil.)

Skid 1 2013

2013 BMF Performance. Costs *

* Data for undiluted beer

CIP LiquidsReal 0,028 €/ hlCaustic (50%) 0,017 €/ hl

UtilitiesWater (CIP) 0,001 €/ hlDAW 0,034 €/ hlCO2 0,001 €/ hlElectricity 0,013 €/ hl

Other costMembranes 0,047 €/ hlSecurity filter 0,011 €/ hlExtract losses (0,30%) 0,040 €/ hl

TOTAL 0,191 €/ hl

BMF Madrid 10 year experience

Strenghts

♦ No quality issues since very first day !!!

♦ Environment and Healthy respectful, no

more kieselguhr handling !!!

♦ Membranes lifetime increased *

♦ Easy operation, no activities out of

control room

♦ No special maintenance requests

Weakness

♦ Impact of betaglucans in filterability

♦ Too long beer changes time *

♦ Dilution factor due to Backwash


CONTENT






PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’ 20

TECHNOLOGY ROADMAP - BMF

Sale

sV

olu

me

First

BMF

2. Gen.

BMF

Double

3. Gen.

BMF-18

First BMF

Compact

?

1990 2000 2003 2006 2009 2012 2015

New Membrane

Module type S-14

New Cleaning Agent

REAL

M2

FLEXIBEL

€$

Next to Continuous -

Also Batch operation

SUSTAINABILITY


PROCESS CHOICES – GOING FOR THE LOWEST TCO

• First BMF’s are continuous

• More focus on batch lines - Capex

• Now batch & continuous – 90% is

batch

• To centrifuge or not to centrifuge

21

0

10.000

20.000

30.000

40.000

50.000

60.000

very low low middle high

Ca

pa

city

[h

l/w

ee

k]

Filterability

Batch DN80 3 Skids 400

hl/h

Continuous DN80 2x2

Skids 300 hl/h - Capex

200 k€ more

Blue Not centrifuged beer

Red Centrifuged beer

(Very) Low: Fully Malt

Middle/High: Adjuncts

& Enzymes


IMPROVEMENTS IN THE LAST 10 YEARS

RVS housing with insert � the plastic S-14

• Hygienic Design not optimal

• Complex Skid Design

• Replacement too much labor

• Problems with potting

22

IMPROVEMENT BENEFITS €$ M2 FLEXI-

BILITY

SUSTA

INABI-

LITY

Back Flush � Soak Back Flush No water tank – Smaller pipe

diameter – Smaller pump – Lower

water consumption

Synflux � REAL One CIP tank less – Longer life time

membranes –– Simpler CIP process

Jet stream pump for chemical

dosing (‘Venturi’)

Robust dosing process – Low

maintenance costs

Simpler design membrane skid Lower amount of components –

Standardized filtration area

Module End cap 8” connection Better design – More hygienic

Compact concept for up to 250

hl/h

Plug & Play – Prefab & Tested –

Highly Standardized – Integrated

Carboblender

Ѵ Ѵ

Ѵ Ѵ

Ѵ

Ѵ

Ѵ

Ѵ

Ѵ Ѵ

Ѵ

Ѵ

Ѵ


CLEANING OF THE MEMBRANESTill 2009

• Hypochlorite with a specific katalysator

(Synflux) for oxidation of

polysaccharides

• Back Flush at high flow

Reasons

• Hypochlorite is aggressive towards

stainless steel and membranes

• Halogenated organic compounds

Deliverables

• Larger run volume

• Longer life time membranes (2-3 years)

• Lower water consumption

• No water tank & No specific CIP tank

� 25% lower footprint

23

From 2009

• REAL at 70oC – oxidative agent – better

removal of fouling

• Soak Back Flush – contact is more

important then flow

24

MARKET DRIVERS• CONSISTENCY OF THE BEER QUALITY

• NEED TO REDUCE OPERATIONAL

EXPENDITURES IN GLOBAL

COMPETITIVE ENVIRONMENT

• AMBITIOUS SUSTAINABILITY GOALS

TO REDUCE WATER, ENERGY AND

SOLID WASTE FOOTPRINTS

• NEED FOR MORE FLEXIBILITY IN THE

BREWING PROCESS DUE TO

PRODUCT DIFFERENTIATION

Ѵ

Ѵ

Ѵ

Ѵ


TARGETS OF TODAY - CHALLENGES OF TOMORROW

25

WHAT

• Low Capex and low Total Cost of

Ownership – More and more due

to consolidation in the brewing

industry

• Sustainability - Water & energy

consumption – (Solid) waste

streams

• Voice of the customer - A product

fitted to the specifications &

conditions of the brewer – ‘Fit for

purpose, fitness for use’ (Joseph

Juran)

HOW

• Simplicity in process & design –

Minimum of hardware and

components and a maximum of

ease of operation

• Maximized output - Optimal

cleaning process and the best

membranes

• Optimal fit to all kind of breweries

– Compact, batch & continuous

filter lines – Craft brewers

• Efficiency - Standardization

PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’PENTAIR X-Flow

QUESTIONS?

PENTAIR 27

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