What is a Centrifuge?

Transcription

Northwest District MBAA Spring 2015
“Bringing your Brewery to the Next Level”
GEA Westfalia Separator
Centrifuges for Craft Brewing
1
GEA Mechanical Equipment US, Inc. / GEA Westfalia Separator Division
Table of Contents
1. Centrifuges in Breweries
2. Basics / Theory
3. What is a Centrifuge?
4. Why use a Centrifuge?
5. Clarification efficiency
6. Potential Yield Improvement
7. Capacity Increase
8. Operation
9. Maintenance
10. Advantages / Summary
2
Centrifuges in Breweries
3
•
Hot Wort / Trub wort
•
Tank bottoms
• Process directly from the bottom of the Fermentor
•
Blended Tank Bottoms and Racked Beer
• Process Cleaner beer from the racking arm and blend in Tank Bottoms
•
Dry Hopped Beers
• Beers dry-hopped up to very high levels
•
Beer Prior to Filtration
• Increase filter run times
• Reduce Filter aid consumption
•
Polishing of Beers
• Elimination of Filter depending on desired clarity in final product
Ultimate Brewery
4
Centrifuge Basics
5
2. Basic Theory of Centrifugation
> 8,000 + g
6
Basic Theory of Centrifugation
7
•
All separation methods that use gravity or
centrifugal force occur because there is a
density difference between the continuous
media (Beer, Wort) and the media that is to be
seperated (trub, yeast, hops). The density
difference is the main factor that makes
centrifugal separation work.
•
It is the density difference that allows settling
and stratification
•
Stokes law is a fundamental law of physics
that applies to settling
Stokes law
The speed that a particle will settle is calulated by:
Vs =
D2 * (d1-d2)
18 ή
*g
Centrifuges increase the particle settling velocity
8
Stokes law
•
Increasing the particle size (D) increases the velocity
squared (minimising shear, fining agents)
D2 * (d1-d2)
Vs =
18 ή
*g
•
Increasing the density difference ((d1-d2)) increases the
D2 * (d1-d2)
settling velocity (sugar content, temperature)
Vs =
18 ή
*g
9
Stokes law
•
Decreasing the viscosity (ή) increases the settling
velocity (temperature, pH)
•
Increasing the g force increases the settling velocity
D2 * (d1-d2)
Vs =
18 ή
D2 * (d1-d2)
Vs =
18 ή
10
*g
*g
Basic Centrifuge
11
12
What is a Centrifuge?
•
Centrifuge Overview
Video
13
14
Important Design Considerations
15
•
Bowl volume
•
Sediment Space
• Important for processing tank bottoms
• Larger sediment space keep the solids away from the Disc stack
•
Clarification Area
• Beer Clarity
• Better clarity at same flow rates
•
Bowl Geometry
• Disc angle
• Bowl angle
•
G-Force
Why Use a Centrifuge?
16
•
Recover Additional Wort
• Up to 10% increased recovery
•
Recover Beer From the Tank Bottoms
• Tank bottoms can be > 50% beer
•
Increase overall Brewery Yield
• > 5% yields seen, more on dry hopped beers
•
Reduced Brewery Effluent
• Ejections removed as solid waste
• Less material sent to drains
Why Use a Centrifuge?
17
•
Increase Brewery Capacity
• Less Tank retention time required
• Less Fermentation Tanks for increased capacity
• Easier scheduling of Fermentor drops
•
Cleaner beer to Filtration or BBT
• Less Filter aid consumption ( DE, Pads, Cartridges )
• Less Product Losses at Filter ( Fewer Filter changes )
• Potentially eliminate of filter on some beer styles ( brewery decision )
Hot Wort
18
Hot Wort
19
Hot Wort
20
Typical Craft Brewing Set up
BB Tank
Fermentor
Buffer
Tank
Filter
Feed Pump
Manual Butterfly
Valves to balance
flow
21
Inline
Sight Glass
BEER RECOVERY
Beer From Rack Valve
Meter in Tank Bottoms
Blending Tank Bottoms
22
23
Solids in the Feed / Discharge
12% Inlet Sample
No solids in the outlet Sample
Solids at 0.05% down to no
visible solids seen in the
samples on beers at
production flow rates
< 50,000 Yeast cell counts or
none seen in Hemacytometer
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Process entire FV
25
Clarification
26
Product Clarity
Good clarities can be attained even with
high solids in the feed as seen in the
photo and the next slides.
Solids loading up to < 10 % ideal but up to
40% possible at reduced flow rates
If the eliminate filtration is desired, lower
flow rate will be required to attain the
desired outlet clarity.
When processing the tank bottoms higher
solids in the outlet will be seen
27
Basic Separation
28
Centrifuge only, no filtration
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Yield / Beer Recovery
30
•
The Centrifuge can process all of your fermentor
•
Minimal Cropping (except for quality reasons)
•
Tank bottoms can be >50% beer
•
Yield increases of 5 – 10% have been validated in testing and production
depending on beer style
•
Additional product to package without any additional brews or raw
ingredients
Product Yield
Spray water off
Dry Yeast Solids ejected
equals more bottles of
beer per brew
Spray water on
31
32
33
34
Heavy Dry Hopped Ejections
Yeast and Hops Discharge from
an Imperial IPA product and no
Spray water
Discharge from dry hopped
product with Spray Water
35
Yield
•
No additional Raw Ingredient Costs
•
No Additional Brews required
•
More Beer
•
Additional Packaging costs ( for extra beer recovered )
•
Beer Revenue minus packaging costs =
$$$$ Additional revenue to the brewery $$$$
36
37
Case Example ( 40,000 bbl facility )
38
•
Bottling example
•
Average sales price per case $20.00
•
Packaging costs ~$6.00 per case (bottles , six-packs, crowns, labels,
etc…)
•
Labor $2.38 per case,
only a 2.5 % increase, so $0.06 per case. All set up, break down and
cleaning are already accounted for in the main packaging labor
•
$20.00 - $6.00 - $0.06 = $13.94 gross profit per case x 13.77 cases/bbl x
600 bbls = $114,980.00
Revenue Increase
VOLUME
YIELD
PER YEAR / INCREASE
BBL's
%
BBL/YR
Bottles/YR
Cases/YR
5%
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Value per
Case
Packaging
Potenital
Packaging
Labor per Revenue per
cost per case
case
year
$20
$6.00
$0.12
5,000
5%
250
82,667
3,444
$20
$6.00
$0.12
$47,812
10,000
5%
500
165,333
6,889
$20
$6.00
$0.12
$95,625
25,000
5%
1250
413,333
17,222
$20
$6.00
$0.12
$239,062
50,000
5%
2500
826,667
34,444
$20
$6.00
$0.12
$478,123
100,000
5%
5000
1,653,333
68,889
$20
$6.00
$0.12
$956,247
Solids Ejection
High Concentrated
Solids gives minimal
Beer Losses
=
and more beer to sell to
your customers to
enjoy!
40
41
Capacity Increase
( Case Example 40,000 bbl facility )
•
Centrifuges can process high solids levels of yeast and hops
• 40% by volume if processing directly from the tank bottoms
42
•
No more waiting for additional tank retention time to get the yeast loading
down to process in the filter or rack.
•
Eliminate additional tank retention time ( settling days )
•
On a typical 12 day process with two days shorter tank retention time
equals a 16+% increase in capacity
•
More turns of the fermentors per year give increase capacity without
additional fermentor purchases
Capacity Increase
43
•
Even bigger difference with big dry-hopped beers
•
Old method: ferment, cool, and flocculate, then drain as much as yeast
as possible before dry-hopping
•
This was generally an 18 day process for “big” beers
•
Dry-hopping: 10 days
•
Total tank retention time: 28 days.
•
•
New SOP: Dry-hop at the end of fermentation, regardless of cell count
Approx. day 8, followed by 10 days on dry-hops for a total of 18 days
•
This is a 10 day decrease in tank retention time = 35+% increase in
capacity
Capacity Increase
•
When the brewery looked at the facilities overall production
• 470 bbl of increased capacity available with centrifuge in process
• Increased capacity due to shortened tank retention time equated to
the value of two 240 bbl fermentors
• Estimate: $65,000 per tank, our total value is $130,000 of increased
capacity per year
This gave the brewery the additional capacity with the
use of the Centrifuge without adding additional
Fermentors to the brewery.
44
Small Breweries ( < 5,000 to 10,000 BBL/Year )
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Yield Increase small brewery
46
•
What does it mean if you are a 5000 bbl brewery and pub?
•
Estimate a 3% increase in yield on 5000 bbls, which yields 150 bbls.
•
For this example assume all of the extra beer was sold at the Pub or Tap
room
•
$4.00 pints - $1.00 /pint for Microstar charges- $0.50/pint for labor =
$2.50/pint profit
•
150 bbls x 248 pints/bbl x $2.50/pint = $93,000.00
Operation
47
•
From a dead stop:
Start Centrifuge
10 minutes to ramp up to speed
Ready for CIP or sanitize or goes into Idle Mode
•
Sanitize Centrifuge:
Same time as lines are sanitized ( no additional
time required )
Centrifuge program has a sanitize mode
•
Transition to Process
Select Recipe for product to be processes
Go from Sanitize directly to product
•
End of Product Run:
Transition directly to next product
Push lines with CO2 of water
Rinse lines and CIP
Operation
48
•
CIP
Systems have a CIP program included
Start CIP and clean along with process lines.
Full CIP cycle with Rinse, Caustic, Final rinse
approx. 45
•
Shut down:
Stop Centrifuge
Let unit spin to a stop
Turn off utilities
Maintenance
49
•
Annual maintenance
Based on operating hours
or
12 months time
•
Minor Overhaul
Inspect bowl
Replace gaskets, o-rings, etc. on bowl, oil change
•
Major Overhaul
Minor work as well as the bearings, belt, etc. on
the drive
•
Maintenance Plans:
Use Factory Service Technicians
3 year fixed price programs with Parts and Labor
Schedule service as required ( based on hours )
Purchase parts only and have in-house
maintenance do the work
Advantages
50
•
DO pick up
• DO pick up across the centrifuge
< 20 PPB
•
Process complete fermentor volume,
either blended ( preferred method ) or
100% tank bottom from cone
•
Ease of Operation
• Control scheme very user friendly
• Operator not required 100% on machine, can operate and do other
functions in the brewery simultaneously
•
High Yield due to Bowl Ejection system and Controls
• Thick solids ejected, > 22% DS in sludge, no free liquid
• Can be pumped directly into spent yeast tank
Advantages
51
•
Shorten Fermentation retention times
• Process Beer without waiting additional days for settling
• Increase brewery capacity
•
Filtration Improvement
• Less Filter Aid consumption due to cleaner beer to filter
• Longer filtration runs between re-coating which gives increase yield
as well
•
Stabilizer additions to products and removal by Centrifuge possible
•
Standardization of cloudy beer products
•
Potential Elimination of Filtration
• Would need to be validated by each Brewery location and style
Advantages
52
•
Reduced Effluent
• Yeast / Hops / Trub removed as solid waste
• Less material sent to drain
•
Better Hop Character
• Hops put under high G-force
• Better extraction of oils from hops
• Much anecdotal information from centrifuge customers
•
Less Hops usage possible
• Some breweries have reduced the dry hopping rates
• Brewery decision
SUMMARY
53
•
Centrifuge can recover the beer currently being sent to drain
•
Increase yield can have a large impact on revenue
•
Filtration improved with lower solids loading to filter or elimination of filter
•
Less Filter aid consumption or disposal
•
Reduced effluent to drains
•
Brewery capacity increase possible with shortened retention times prior to
processing
•
Can schedule fermentation drops better
•
Sizes to fit every breweries requirements
THANK YOU FOR YOUR ATTENTION!
GEA Westfalia Separator
Chris Boos
[email protected]
54

What is a Centrifuge?

Transcription

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