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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.

Our green monster: the problem

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.

Hop pellets derived from the process during production: our solution

Interested in this business case? Please contact us for more information.