Reduction of extract losses & waste water plant debottlenecking project.
Our customer, a brewery located in the Brussels area, consulted us to come up with an action plan to support their IPA capacity initiative.
3 Hop slurry streams used to be collected troughout the process and drained to the sewer:
The planned capacity increase could have been a showstopper because the brewery has stringent waste water standards.
On top of this, approx. 75% of these hop purges contain beer.
The action plan:
Collect all hop slurry streams and process.
The recovered DM to be collected as bio waste.
CAPEX requirements and payback < 2 yrs
Quality problem avoidance when adding hop pellets to hot wort (Contact time thus constant IBU results)
Debottleneck a Dry hopping operation in the cold aging cellar.
Process Dry hopping slurry derived from CCT’s.
Furthermore various hop pellet dosing units needed to be installed to improve ergonomy & automation for a sustainable result.
Lead by our Sr Consultant brewery applications, back 2 back with 1 Jr TAG Consultant for daily project operations, we started a consulting round to map existing technologies and new approaches to process hop slurry. An action plan and a business case were presented to the customer.
Phase I of this project is delivered in time and in full, with results that surpass expectations
All extract recovered to the max.
No adverse taste impact (Astringent flavour).
Dry Matter of expelled hop pellets is very high (as witnessed in video).
Removal of hop pellets & yeast decreases the processing time, thus improving CCT cycle time / occupancy.
Filtration runs are extended
Processed hop slurry from CCT with extract loss reduction averages 5%
Processed hop slurry from Cold Aging with extract loss reduction averages 3%
BTS fully debottlenecked, no more impact on waste water quality / COD
Phase II of this project is ongoing (June 2019) and will focus on the hot wort quality
Installation of a hop dosing unit & hopping facilities
Processing of the hopped wort i.o. to recuperate the hops prior to wortcooling
In the mean time, a Phase III has been initiated and will encompass a roll out to all CCT’s in the Cold Block.
Interested in this business case? Please contact us for more information.