Brewery Optimization Water Reduction in Cleaning Operations. Linda Rastani and John Berardino

Transcription

1 Brewery Optimization Water Reduction in Cleaning Operations Linda Rastani and John Berardino

2 How do you conserve resources while effectively cleaning? The tank must be clean low consumption of fresh water low consumption of cleaning agents minimum of energy consumption amount and pollution level of waste water must be low cleaning process must be as short as possible => effective cleaning meets these requirements

3 TACT Cleaning Parameters Traditional TACT Time Action - Jet Head Approach Temperature Action Action Cleaning Impact (impingement) Reduce: Time, Chemicals & Temperature Improve: Action & Coverage Chemical Concentration Surface Coverage Slide 3

4 Comparing Static Spray Ball with Rotary Jet Head Cleaning with Static Spray Ball Cleaning with Rotary Jet Head Concentration Time Mechanics Temperature

5 Static Spray Ball Rotary Spray Head Rotary Jet Head Coverage: Means: Cascading Swirling fan Index Pattern Effect: Partial Partial to full Full Action: Low Medium High % Resources used 100% 70-75% <50% in most cases Slide 5

6 Static Spray Ball Is this Externally Self Cleaning? Is this a Well defined Jet quality? Slide 6

7 Cleaning Technology P V 1. Pressure is the driving force 1. The flow is turning the tank cleaning machine 2. Pressure is converted to water jet velocity 2. High Wall Shear Stress Zone 3. Machine gearing makes the indexed criss-cross pattern Water Jet υ t{ dυ dυ Wall Shear Stress under Turbulent Flow Conditions Min. 40 Pa at r = 11 cm Slide 7

8 Rotary Jet Head Cleaning Technology - Attack of residues Slide 8

9 Overall view Brewery Water tanks Brewhouse Fermentation and Maturation cellar Yeast storage Bright Beer Tanks Road Tanker Slide 9

10 Mash Tun Required number of Rotary Jet Heads Type number TJ20Gs 2 4 x 5.2mm, PSIG Slide 10

11 Mash Tun Slide 11

12 Mash Tun Standard cleaning water rinse 10 Min caustic recirc. 60 Min water rinse 5 Min acid recirculation 20 Min water rinse 5 Min TJ-20G water rinse 9 Min caustic recirc. 18 Min water rinse 9 Min acid recirculation 9 Min water rinse 9 Min Total 100 Min 100 USGPM = 1,600 USG per Cleaning to drain. Total 54 Min 100 USGPM = 900 USG per Cleaning to drain. Net Savings per Cleaning = 700 USG x # Boils (Or Cleaning Cycles) Example = 1 cleaning per day x 700 USG = 176,400 USG/yr (252 days) saved!

13 Mash Tun Added value by using Rotary Jet Heads The cleaning time can be reduced by 46 % Shorter down time The costs can by reduced by 60 % Higher cleaning standard Slide 13

14 Lauter Tun Required number of Rotary Jet Heads Type number TZ-74-BKV 2 4 x 7mm, PSIG Slide 14

15 Lauter Tun Slide 15

16 Lauter Tun Standard cleaning water rinse 10 Min caustic recirc. 60 Min water rinse 5 Min acid recirculation 20 Min water rinse 5 Min TZ-74 BKV water rinse 6,5 Min caustic recirc. 26 Min water rinse 6,5 Min acid recirculation 13 Min water rinse 6,5 Min Total 100 Min 200 USGPM = 3,200 USG per Cleaning to drain. total 58,5 Min 150 USGPM = 975 USG per cleaning to drain. Net Savings per Cleaning = 2,225 USG x # Brews (Or Cleaning Cycles) Example = 1 cleaning x 2,225 USG = 560,700 USG/yr (252 days) saved! Slide 16

17 Lauter Tun Added value by using Rotary Jet Heads No manual cleaning of the false bottom The cleaning time can be reduced by 41 % The costs can by reduced by 50 % Fewer environmental problems Slide 17

18 Kettle Required number of Rotary Jet Heads Cylindrical Type number TZ-74 BKV 3 4 x 7mm, 58 UGPM, 75 PSIG Slide 18

19 Kettle TZ-74 BKV The heating surfaces are hard to keep efficiently clean Many have internal heaters which do have difficult-to-clean areas Many do have Static Spray Balls which do not clean well and use large fluid volumes and strong chemicals Slide 19

20 Kettle Standard cleaning water rinse 10 Min caustic recirc. 90 Min water rinse 10 Min acid recirculation 20 Min water rinse 10 Min Total 130 Min 170 USGPM = 3,230 USG to drain TZ-74 BKV water rinse 13,5 Min caustic recirc. 36 Min water rinse 9 Min acid recirculation 13,5 Min water rinse 9 Min Total 81 Min 175 USGPM = 2,365 USG to drain Net Savings per Cleaning = 865 USG x # Boils (Or Cleaning Cycles) Example = 1 cleaning per day x 865 USG = 217,980 USG/yr (252 days) saved! Slide 20

21 Kettle Added value by using Rotary Jet Heads The cleaning time can be reduced by 37 % Shorter down time The costs can be reduced by 35 % Validation possibility Slide 21

22 Whirlpool Required number of Rotary Jet Heads Type number TZ74-SC 1 Slide 22

23 Whirlpool Slide 23

24 Whirlpool Standard cleaning water rinse 10 Min caustic recirc. 60 Min water rinse 10 Min acid recirculation 20 Min water rinse 10 Min Total 110 Min 80 USGPM = 1,280 USG to Drain per cleaning TJ 74-SC water rinse 11 Min caustic recirc. 22 Min water rinse 5.5 Min acid recirculation 11 Min water rinse 5.5 Min Total 55 Min 46 USGPM = Net 600 USG to Drain per cleaning Net Savings per Cleaning = 680 USG x # Boils (Or Cleaning Cylces) Example = 1 cleaning per x 680 USG = 171,360 USG/yr (252 days) saved! Slide 24

25 Whirlpool Added value by using Rotary Jet Heads The cleaning time can be reduced by 50 % Shorter down time The costs can by reduced by 60 % Faster breakup of trub & hops Slide 25

26 350 Barrel CCT Fermenter Required number of Rotary Jet Heads Type number TJ20G 1 Slide 26

27 350 Barrel CCT Fermenter Slide 27

28 350 Barrel CCT Fermenter Standard cleaning water rinse 10 Min caustic recirc. 60 Min water rinse 10 Min acid recirculation 20 Min water rinse 10 Min Total 110 Min 80 USGPM = 1,280 USG to Drain per cleaning TJ-20G water rinse 11 Min caustic recirc. 22 Min water rinse 11 Min acid recirculation 11 Min water rinse 11 Min Total 66 Min 46 USGPM = Net 600 USG to Drain per cleaning Net Savings per Cleaning = 680 USG x # fermenters x #fermentations Example = 15 fermenters x 26 fermentations x 680 USG = 265,200 USG/yr Slide 28

29 350 Barrel CCT Fermenter Added value by using Rotary Jet Heads The cleaning time can be reduced by 40 % Shorter down time The costs can by reduced by 62 % Verifiable results Slide 29

30 1100 Barrel Maturation Tank Required number of Rotary Jet Heads Type number TZ x 7mm, PSIG Slide 30

31 1100 Barrel Maturation Tank Slide 31

32 1100 Barrel Maturation Tank Standard cleaning water rinse 10 Min caustic recirc. 40 Min water rinse 10 Min acid recirculation 20 Min water rinse 10 Min TZ-74 water rinse 11 Min caustic recirc. 22 Min water rinse 11 Min acid recirculation 11 Min water rinse 11 Min Total 90 Min Net Once-Through Volume per cleaning = 1, USGPM Total 66 Min Net Once-Through Volume per cleaning = USGPM Net Savings per Cleaning = 1,080 USG x # tanks x # cycles/tank Example = 5 tanks x 10 x 1,080 USG = 54,000 USG/yr Slide 32

33 1100 Barrel Maturation Tank Added value by using Rotary Jet Heads The cleaning time can be reduced by 28 % Shorter down time The costs can by reduced by 50 % Slide 33

34 Brewery Wide Savings Mash Tun = 176,400 USG/yr Lauter Tun = 560,700 USG/yr Brew Kettle = 217,980 USG/yr Whirlpool = 171,360 USG/yr Fermenters = 265,200 USG/yr Maturation = 54,000 USG/yr OLD VOLUME = 2,943,320 USG/yr NEW VOLUME = 1,497,680 USG/yr Net Percentage Reduction = ~ 50% Slide 34

35 Advantages New Tank Farm Fewer Rotary Jet machines and lower flow rates result in significant lower costs of CIP-cleaning equipment smaller tanks in the CIP plant smaller pipe diameter smaller valve size smaller pumps

36 Benefits using RSH & Jet Heads Cleaning standard Repeatable high cleaning standard Less than 1 year pay-back Volume of water, waste and detergents Flow reduction up to 50% Water Consumption can be reduced by up to 75% Detergent Consumption can be reduced by up to 75% Time Cleaning time can be reduced by 50% allowing more time for production Cleaning Production Cleaning Production Slide 36

37 Thank You