uganda breweries assessment
TRANSCRIPT
Our Brew-How makes your business more successful
Uganda Breweries Ltd. In-plant Water CP-assesment
Final presentation
January 25th 2007
Richard Harrow & Steffen Wissing
Danbrew
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Danbrew Ltd.
Design and build Breweries Tender for plant developments Investment strategies and plans for breweries Optimising of Breweries
25 years of consultancy in the brewing industry Nearly 100 million hl design/build in more than 60 Countries
including 7 African countries 60 consultants working in 7 countries presently
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
The assignment of Danbrew
UN Environmental Programme have asked Danbrew to perform In-Plant CP-assessments with a focus on water saving and waste water.
This is part of the UN water saving initiative within the African brewery sector (The Abrew project). This project will
Identify the potential for water savings in the African brewery sector and suggest solutions.
Develop a UN project for external funding for implementing water conservation measures in the brewing sector and subsequently in the entire beverage sector in Africa.
The preliminary assumption of the project is that water usage is 32 hl water per 1 hl beer. If so the water saving potential is 1.7 billion hl. l
Cleaner Production methods are assumed to generate savings of 20 to 50%.
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Cleaner Production
The purpose of Cleaner Production is to reduce resource consumption and emissions from a production.
Preferably by reduction of waste at source.
UN Technical Report N° 33 p.39- 40
Solutions within the CP
Engineering
Plant equipment
Training
No part of the solution must be seen isolated
UN Technical Report N° 33 p. 40
High consumption breweries and the CP
Engineering
Plant equipment
Training
UN Technical Report N° 33 p. 40
”High Consumption Breweries can immediately achieve substantial reduction by addressing management issues and small changes in ancillary operations”
Low consumption breweries and the CP
Engineering
Plant equipment
Training
UN Technical Report N° 33 p. 40
”Low Consumption Breweries need to begin focusing on all three functional groups in detail”
Low consumption breweries and the CP
Engineering
Plant equipment
Training
UN Technical Report N° 33 p. 40
”Low Consumption Breweries need to begin focusing on al three functional groups in detail”
Cleaner Production Focus Areas
Functional areas Focus areas to reduce resource consumption
Process Production methods Operations System design Maintenance Training
Ancillary operations Operations Individual system design System integration (process / utility) Maintenance Training
Management Target setting, monitoring control, responsibility allocation Training
Areas in which Resource Consumption May Be Reduced. UN Technical Report N° 33 p. 39
On going CP successes
Comprehensive set of CP options
Audit focus selected
Assesment organisation established
UN
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Planning and OrganisationTask 1: Obtain management commitmentTask 2: Identify barriers and solutionsTask 3: Set plant-wide CP goalsTask 4: Organize project team
Pre-AssesmentTask 5: Develop process flow chartTask 6: Evaluate inputs and outputsTask 7: Select audit focus
AssesmentTask 8: Derive materials balanceTask 9: Assess waste generation causesTask 10: Generate CP optionsTask 11: Screen CP options
Feasibility StudiesTask 12: Preliminary evaluationTask 13: Technical evaluationTask 14: Economic evaluationTask 15: Environmental evaluationTask 16: Selection of feasible options
Implementation and ContinuationTask 17: Prepare CP planTask 18: Implement feasible optionsTask 19: Monitor CP progressTask 20: Sustain CP
List of feasible options
Recognized need for CP
Comprehensive set of CP options
Audit focus selected
Assesment organisation established
Planning and OrganisationTask 1: Obtain management commitment
Task 4: Organize project team
Pre-AssesmentTask 5: Develop process flow chart Task 6: Evaluate inputs and outputs (water balance)Task 7: Select audit focus
AssesmentTask 8: Verify water balanceTask 9: Assess waste generation causesTask 10: Generate CP optionsTask 11: Screen CP options
Is there a large potential of water sawing ?
Feasibility StudiesTask 12: Preliminary evaluationTask 13: Technical evaluationTask 14: Economic evaluationTask 15: Environmental evaluationTask 16: Selection of feasible options
List of feasible options
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Material Balance for a Typical Brewery – High Consumption
Brewhouse
Fermentation / Beer Processing
Packaging
Ancillary Operations
Malt/Adjunct, 18 kg.
Energy, 350 MJ
Electricity, 20 kWh
Water, 20 hl
1 hl Beer
Waste Water18,5 hl
1,2 kg BOD
By-productsSpent Grains, 17 kg
Yeast, 3 kg
UN Technical Report N° 33 p. 19
Material Balance for a Typical Brewery – Low Consumption
Brewhouse
Fermentation / Beer Processing
Packaging
Ancillary Operations
Malt/Adjunct, 15 kg.
Energy, 150 MJ
Electricity, 8-12 kWh
Water, 5 hl
1 hl Beer
Waste Water3,5 hl
0,8 kg BOD
By-productsSpent Grains, 14 kg
Yeast, 3 kg
UN Technical Report N° 33 p. 19
Water balance for Uganda Brewery – Medium Water Consumption and Low pollution
Brewhouse
Fermentation / Beer Processing
Packaging
Ancillary Operations
Malt/Adjunct, 15 kg.
Energy, 150 MJ
Electricity, 8-12 kWh
20 hl
Water 9,2 hl
5 hl
1 hl Beer
18,5 hlWaste Water 7,7 hl
3,5 hl
BOD HIGH. COD is 2,6 kg. This will make an BOD outlet higher than 1,2 kg.1,2 kg BOD0,8 kg BOD
NEMA target for BOD
discharge is 50 mg/l
equivalent to 0,04 kg
per hl of beer for
Uganda Breweries
El + Diesel input
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Wat
er F
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Bre
wer
ies
UGANDA BREWERIES LTD WATER BALANCE DIAGRAM, Refer item no 2.6.10
KEY
Municipal water
Treatedwater to the lake
ETP
E24
E26
E25
E27
E28
E29
Lake water
Water treatmentPlant
GPW
PumpHouse
CarbonFilters
Brew House.
Mash KettleLautertan
Copper and whirlpool
CIP
Water plant/lab
Hydrant Reservoir
TowerReservoir
Process
Heat exchangerYeast plantDPVs, Addives tank and scrabberCSRsFilter and
BBTs
Packaging
Bottle washer
Vacuum pump
Pasteuriser
makeup
Crate washerFiller
Labellerkeg plant
Caustic farm
Col
d
Liq
uor
Treatment Loses
IDU
Canteen,ClinicToilets,HR block
Toilets, Kitchenmain
Adm. Block
Canteen Reservoir
Condensate Reservoir
Casuals and packaging toilets
ReservoirTank
EngineRoomcondensers,cleaning water.
EngineRoom Reservoir
Evaporation
Yeast,Tank bottoms,used wash water and usec cleaaning water
Usedwash water, Final runnings, weak wort
Reservoir
Operation toilets and kitchen
Softening plant
SoftwaterReservoir
Blowdown
Evaporation
Condesate Reservoir
Steam
Boilers 4 and 5
Boiler feed water reservoir
Evaporation
Spent grain
E13'A
ETPAcid scrabberFine screenBiofilterChemical farmBelt pressControl room/lab
Used wash water,Beer spillagepasteuriser overflowsused spray waterused vacuum pump waterChain lube.
Hot liquor tanks
Hot liquor
Carbon filter and softener backwash water
Storm drain
Evaporation
Total Evaporation
Septic tank
Kieselguhr pit
Storm drain
Used filter aid
Septic tank
water in packaged product.
Storm drain
Septic tank
Septic Tank
Interceptor to Storm
Warehouse,diversey
E16A
E14 E15
E5
E18
E12
E4
E16
E11
E13
E3
E20E4'A
E22
E23
E10
E9
E8
E7
E6
E21
Used acid scrabber ,Fine screen,Biofilter,wash water,Belt press waterQC chemicals
T and BToilets
Septic tank
Evaporation
Cleaning water to storm
Hotwell/Blowdown pit
Schematic Layout of a brewery
Ancillary Operations
Boiler PlantCooling Plant
Water Treatment PlantCO2 Recovery Plant
Compressed Air plantElectricity Supply
Waste Water TreatmentLaboratoryWorkshops
Waste Storage
Malting Plant
Brewhouse
Fermentation / Beer Processing
Packaging
Warehouse
Barley
Hops
Adjunct
Spent grains
Spent Yeast
Packaging Material
Water
Fuel
Electricity
Malt
Wort
Bright Beer
Packaged Beer
UN Technical Report N° 33 p. 19
Schematic Layout of Uganda Breweries
Ancillary Operations
Boiler PlantCooling Plant
Water Treatment PlantCO2 Recovery Plant
Compressed Air plantElectricity Supply
Waste Water TreatmentLaboratoryWorkshops
Waste Storage
Malting Plant
Brewhouse
Fermentation / Beer Processing
Packaging
Warehouse
Barley
Hops
Adjunct
Spent grains
Spent Yeast
Packaging Material
Water
Fuel
Electricity
Malt
Wort
Bright Beer
Packaged Beer
UN Technical Report N° 33 p. 19
Domestic, Office, Canteen, Gardens
Water flow of Uganda Breweries
Ancillary Operations
Boiler PlantCooling Plant
Water Treatment PlantCO2 Recovery Plant
Compressed Air plantElectricity Supply
Waste Water TreatmentLaboratoryWorkshops
Waste Storage
Malting Plant
Brewhouse
Fermentation / Beer Processing
Packaging
Warehouse
Barley
Hops
Adjunct
Spent grains
Spent Yeast
Packaging Material
Water
Fuel
Electricity
Malt
Wort
Bright Beer
Packaged Beer
UN Technical Report N° 33 p. 19
Domestic, Office, Canteen, Gardens
UN CP Brewery detailed water balance model
LA
KE
/ R
IVE
R/ B
OR
E H
OLE
hl/day 2,445hl/year 733,419
Beer sold% of sold 5.5%hl/year 82,500
Beer total losses
PACKAGING
% of sold 1.5%hl/year 22,500
Beer loss packaging
UTILITIESPROCESSINGBREWHOUSE
Ratio to sold 2.0hl/year 3,000,000
Best practice valuePackaging discharge
Wet Kg/year 39,900,000Water in hls 319,200
Spent grainWet Kg/year 5,142,857Water in hls 41,143
Yeast excess
Ratio to sold 1.4hl/year 2,100,000
Best practice valueProcessing discharge
% boiling 8%Water in hls 51.429
Evaporation
Sum of colourWater in hls 681,200
Total of necessary loss
DOMESTIC OFFICE
CANTEENGARDENS
Kg/COD/HL 1,0Brewhouse
Kg/COD/HL 0,8Beer processing
Kg/COD/HL 0.4Packaging
Kg/COD/HL 2.4Ton / year 3,600
Brewery total
WWTP
Tons/year 1,260Sludge Kg SS
WTP
% 20%water in hls 200,000
Condensate loss
Sludge & backwash
Blow down, machine cooling, evap. condensers
hl/day 16.733hl/year 5.020.000
Actual Water Intake
Wet Kg/year 1,800,000Water in hls 18,000
Kieselguhr wasteCaustic
label pulpSeptic tanks
ratio to sold 6.84hl/year 5,020,000
Water usage Actual% of sold beer 48%hl/year 5,550,000
Best practice min water use
Ratio to sold 1,3hl/year 975.000
Brewhouse dischargeBest practice value
POTENTIAL SAVING
BEST PRACTICE BEER LOSSES NECESSARY LOSSES STADARD VALUES
Ratio to sold 4,0hl/year 3.000.000COD mg/l > 250TSS mg/l >50 µs/cmpH 7~8
Best practice valueWater discharge
Ratio to sold 0.2hl/year 300,000
Utilities dischargeBest practice value
Ratio to sold 0.1hl/year 150,000
Best practice valueOthers discharge
Potential value by product
Potential value by product
Potential value by product
Potential value by product
% of sold 0.5%hl/year 7,500
Beer losses brewhouse% of sold 3.5%hl/year 52,500
Beer losses processing
Nile BreweryJan 07
(data year Mar 05/Apr 06)
% of intake 33%hl/year 3,768,800
Potential water saving
ACTUALS
Detailed Water Balance of Uganda Breweries, March 06LA
KE
/ R
IVE
R/ B
OR
E H
OLE
hl/day 2,628hl/year 788,472
Beer sold% of sold 5.5%hl/year 43,366
Beer total losses
PACKAGING
% of sold 1.5%hl/year 11,827
Beer loss packaging
UTILITIESPROCESSINGBREWHOUSE
Ratio to sold 2.0hl/year 1,576,944
Best practice valuePackaging discharge
Wet Kg/year 20,973,355Water in hls 167,787
Spent grainWet Kg/year 2,703,333Water in hls 21,627
Yeast excess
Ratio to sold 1.5hl/year 1,182,708
Best practice valueProcessing discharge
% boiling 9%Water in hls 60,825
Evaporation
Sum of colourWater in hls 417,395
Total of necessary loss
DOMESTIC OFFICE
CANTEENGARDENS
Kg/COD/HL 1.2Brewhouse
Kg/COD/HL 0.8Beer processing
Kg/COD/HL 0.4Packaging
Kg/COD/HL 2.4Ton / year 1,892
Brewery total
WWTP
Tons/year 873Sludge Kg SS
WTP
% 30%water in hls 157,694
Condensate loss
Sludge & backwash
Blow down, machine cooling, evap. condensers
hl/day 25,144hl/year 7,543,236
Actual Water Intake
Wet Kg/year 946,166Water in hls 9,462
Kieselguhr wasteCaustic
label pulpSeptic tanks
ratio to sold 9.57hl/year 7,543,236
Water usage ActualRatio to sold 3.9hl/year 3,075,041
Best practice min water use
Ratio to sold 1.3hl/year 1,025,014
Brewhouse dischargeBest practice value
POTENTIAL SAVING
BEST PRACTICE BEER LOSSESNECESSARY LOSSES
Ratio to sold 4.2hl/year 3,311,582COD mg/l <250TSS mg/l <50 µs/cmpH 7~8
Water dischargeBest practice value
Ratio to sold 0.3hl/year 236,542
Utilities dischargeBest practice value
Ratio to sold 0.1hl/year 78,847
Best practice valueOthers discharge
Potential value by product
Potential value by product
Potential value by product
Potential value by product
% of sold 0.5%hl/year 3,942
Beer losses brewhouse% of sold 3.5%hl/year 27,597
Beer losses processing
Uganda Breweries LtdTrough month as whole basis
Ratio to sold 4.7hl/year 3,679,723
Potential water saving
ACTUALS
ratio to sold 2.58hl/year 2,034,960
Brewhouse actual usageratio to sold 0.66hl/year 517,320
Process actual usageratio to sold 0.44hl/year 343,320
Utilities usage
ratio to sold 0.09hl/year 683,796
Domestic actual usage
ratio to sold 5.03hl/year 3,963,840
Packaging actual usage
Detailed Water Balance of Uganda Breweries, December 06LA
KE
/ R
IVE
R/ B
OR
E H
OLE
hl/day 3,464hl/year 1,039,224
Beer sold% of sold 5.5%hl/year 57,157
Beer total losses
PACKAGING
% of sold 1.5%hl/year 15,588
Beer loss packaging
UTILITIESPROCESSINGBREWHOUSE
Ratio to sold 2.0hl/year 2,078,448
Best practice valuePackaging discharge
Wet Kg/year 27,643,358Water in hls 221,147
Spent grainWet Kg/year 5,142,857Water in hls 41,143
Yeast excess
Ratio to sold 1.5hl/year 1,558,836
Best practice valueProcessing discharge
% boiling 9%Water in hls 80,169
Evaporation
Sum of colourWater in hls 550,135
Total of necessary loss
DOMESTIC OFFICE
CANTEENGARDENS
Kg/COD/HL 1.2Brewhouse
Kg/COD/HL 0.8Beer processing
Kg/COD/HL 0.4Packaging
Kg/COD/HL 2.4Ton / year 2,494
Brewery total
WWTP
Tons/year 873Sludge Kg SS
WTP
% 30%water in hls 207,845
Condensate loss
Sludge & backwash
Blow down, machine cooling, evap. condensers
hl/day 25,194hl/year 7,558,092
Actual Water Intake
Wet Kg/year 1,247,069Water in hls 12,471
Kieselguhr wasteCaustic
label pulpSeptic tanks
ratio to sold 7.27hl/year 7,558,092
Water usage ActualRatio to sold 3.9hl/year 4,052,974
Best practice min water use
Ratio to sold 1.3hl/year 1,350,991
Brewhouse dischargeBest practice value
POTENTIAL SAVING
BEST PRACTICE BEER LOSSESNECESSARY LOSSES
Ratio to sold 4.2hl/year 4,364,741COD mg/l <250TSS mg/l <50 μs/cmpH 7~8
Best practice valueWater discharge
Ratio to sold 0.3hl/year 311,767
Utilities dischargeBest practice value
Ratio to sold 0.1hl/year 103,922
Others dischargeBest practice value
Potential value by product
Potential value by product
Potential value by product
Potential value by product
% of sold 0.5%hl/year 5,196
Beer losses brewhouse% of sold 3.5%hl/year 36,373
Beer losses processing
Uganda Breweries Ltd
Ratio to sold 2.4hl/year 2,465,894
Potential water saving
ACTUALS
ratio to sold 2.32hl/year 2,407,320
Brewhouse actual usageratio to sold 0.62hl/year 640,680
Process actual usageratio to sold 0.33hl/year 347,880
Utilities usage
ratio to sold 0.04hl/year 322,920
Domestic actual usage
ratio to sold 3.70hl/year 3,840,600
Packaging actual usage
K ey Figures - Water Specific consumption ratio: 5 hl/hl
Brewhouse : 25%
Beer Processing : 29%
Packaging : 40%
Warehouse : 0%
Utilities : 5%
Other functions : 1%
Brewhouse
Beer Processing
Packaging
Utilities
Other Functions
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Principle of water costing
Lake Victoria
Municipal water
Water treatment
Pumps
Pumps
441 UGX / hl
• Electricity for pumps
• Chemicals
• People for operations and maintenance
Brewery
1700 UGX / hl
Flat fee
1,4 m UGX / yearLake
Victoria
1700 UGX / hl
Flat fee
3 m UGX / year
Water cost calculation of UBL 1/21 COST OF ELECTRICITY
(A) ELECTRIC MOTORS IN USE1 Lake pump 30Kw2 clarifier pump 15Kw3 clarifier mixer 3.7Kw4 Alum mixer 0.37Kw5 Alum dosing pump 0.18Kw6 Lime mixer 0.37Kw7 Lime dosing pump 0.75Kw8 Chlorine booster 1.10Kw9 BW pump 7.5Kw
10 Packaging pump 22Kw11 GPW pump 7.5Kw
SUBTOTAL 88.47Kw12 1% lighting 0.88Kw
GRANDTOTAL 89.35Kw
(B) YEARLY POWER USAGE365 daysX24hrx89.35Kw=782,706Kw-Hrs
C Unit cost of electricity=123USH/Kw-Hr
(D ) Total cost of electricity per year=123x782,706=96,272,838USH
(E) Total Volume of water processed=721,992M3
(F) Unit cost of electricity=96,272,838/721,992=133.34USH/M3
Water cost calculation of UBL 2/22 MAN POWER COST
(A) Total salary for 4 operators/month=USH 1,866,000
(B) Yearly salarly=22,392,000USH
© Manpower cost per unit=22,392,000/721,992=31USH/M3
3 MAINTENANCE COST(A) Yearly maintenance cost=USH 199,518,463
(B) Maintenance cost per unit=199,518,463/721,992=276USH/M3
4 COST OF PERMIT=USH 3,000,000 per yearPermit cost per unit=3,000,000/721,992=4.2USH/M3
5 COST OF CHEMICALS PER UNIT=0.8USH/M3
TOTAL COST PER UNIT(when extracting from the lake)=133.34+31+276+4.2+0.8=445.34USH/M3
6 COST PER UNIT OF PURCHASED WATER=1716USH/M3
7 POWER COST IF TREATING PURCHASED WATER= 89.35Kw-30Kw(lake pump)=59.35Kw(A) Electricity unit cost of purchased water=(59.35x365x24x123)/721992=88.5USH/M3
TOTAL COST PER UNIT (when purchasing water)=88.5+31=276+0.8+1716=2112.3USH/M3
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Focus areas of Uganda BreweryActual ratio
Peak / non peak
Low Consumption
Ratio
Potential savings
Average usage in 2006 9,2 5,0 3.570.000 hl/year
1.574,4 m UGX
715.623 EUR
Major loss at Packaging Peak / non peak 3,7 / 5,1
2,0 2.040.000 hl/year
899,6 m UGX
408.927 EUR
Medium loss at Brewhouse 2,3 / 2,6 1,3 977.500 hl/year
431,1 m UGX
195.944 EUR
Large difference between water efficiency of peak and trough period
7,3 / 9,6 (Diff < 1,5) 680.000 hl/year
299,9 m UGX
136.309 EUR
Water measurement difficult but sufficient
Beer Processing and Brew house can not be separated 100%
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Organisation of Uganda Breweries – Partly
Managing DirectorSupplies
James Musyoki
Logistics
Procurement & purchasing
PackagingG. Kabuthi
BrewingEdward Katorobo
Cellars Filtration
EngineeringService Mgt.
Bardsley Msagha
Finance HRQA &
EnvironmentAgnes Acom
OperationsMumbi Muiruri
Brewhouse
UtilitiesMatthew Mungai
Mechanical EngineeringJB. Matoru
Electrical EngineeringE. Kasumba
Packaging Engineering
A. Atwine
Head BrewerGeorge Mbogo
CP specialist
Interviews and data collection
Functional areas
Focus areas to reduce resource consumption
Questions to be addressed
Process Production methods Operations System design Maintenance Training
Courses for high and low consumption
Programme or future plans around water usages.
Training
Management follows up
Ancillary operations
Operations Individual system design System integration (process /
utility) Maintenance Training
Manage-ment
Target setting, monitoring control, responsibility allocation
Training
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Management & training
Going on Utility manager is responsible for Water Consumption Follow up is done monthly by Utility Manager and I being supported by Operations
Director. Targets set by Operations Director based on Benchmarking with in other Diagio sites KPI’s is monitored monthly at bill boards round the brewery The aim for water usage in 2007 is less than 7,0. Utility manager risk is job if the target is
not accomplished.
Planed Meters have been ordered for precise follow up towards Beer Processing and Beer house CP organisation is just been established CP – training is planned
Danbrew conclusion Good management attention to water consumption Medium number of leakages and overflow that can be improves by CP Packaging has high number of leakages and overflow that can be improved by CP and
management attention Water usage should be monitored monthly at bill boards round the brewery as the other
KPI’s
Hose pipe size / guns and&or automatic timer on tap
Storm drains connected to effluent drain / can give probl;ms for effluent plant in rain storm
Water meters
KPI’s on Bill Boards, but no water consumption or waste measurements
Generally need and tidy, but messy in Packaging
Beer losses follows Water losses
Water & beer loss ratios
-
2,00
4,00
6,00
8,00
10,00
12,00
Jan06
Feb06
Mar06
Apr06
May06
Jun 06 Jul 06 Aug06
Sep06
Oct 06 Nov06
Dec06
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Vacuum pump - can use water free types – combine waters over cooling tower etc
Water losses from the pasteuriser
Fin
anci
al f
easi
bil
ity
for
new
pas
teu
rize
rAssumptions
Assummed profit on bottle also lost
Annual production 850.000 HlsPrice to retailer for one euro bottle 1.160 UGSDuty on gate value 60% 1,60net gate value per bottle 725 UGSNo. of bottles per year 170.000.000 noBottle size 0,5 litresLoss of bottles & beer pasteuriser 1% %No of botttles lost 1.700.000 no.Value of beer lost 1.232.500.000 UGSEuro to UGS 2.200 €Value of bottles & beer lost 560.227 €
Saved running costs with new machineWater lost 6.640 €Energy lost 4.300 €New bottle cost 392 UGSValue of lost bottle trips (normal 20 trips) say 10 trips 196 UGS eachNo. of bottles lost 1.700.000 no.Cost of lost trips 333.200.000 UGSCost of lost trips 151.455 €Running costs saved with new machine annually 162.395 €
Cost of new pasteuriser 35,000 bph 520.000 €Shipping 25.000 €Installation cost 45.000 €Duty, Clearing & forwarding 88.500Total 678.500 €
Current estimate of loss due to bottle breakage in pasteuriser
Current losses are same for whole year
Current losses are 1% for calculation
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
High water usage in Beer house
Ratio to sold 1.5hl/year 1,558,836
Best practice valueProcessing discharge
Ratio to sold 1.3hl/year 1,350,991
Brewhouse dischargeBest practice value
Potential value by product
ratio to sold 2.32hl/year 2,407,320
Brewhouse actual usageratio to sold 0.62hl/year 640,680
Process actual usage
Ratio to sold 1.5hl/year 1,182,708
Best practice valueProcessing discharge
Ratio to sold 1.3hl/year 1,025,014
Brewhouse dischargeBest practice value
Potential value by product
ratio to sold 2.58hl/year 2,034,960
Brewhouse actual usageratio to sold 0.66hl/year 517,320
Process actual usage
No major issues discovered during assesment.
The high uses might very well be a measuring problem since Beer processing and Beerhouse together is 3,4 and the low consumption ratio is 2,9.
Improvement of metering is suggested.
Excess Yeast Beer Recovery
TT
SGL
WT
WT
FT
Fermentation tank
Yeast storage
tank
RECOVER BEER IN YEAST
DRYING OF YEAST
SOLD FOR ANIMAL
FEED
BEER SAVED
WATER SAVED(YEAST 82% WATER)
BOD LEVELS REDUCED
BY-PRODUCTS VALUE
CAPITAL COST FOR EQUIPMENT OR ADAPT PROCESS (LOW COST)
DRYING OF THE YEAST HAS BENIFIT OF
BETTER SALES POTENITIAL BUT
VERY COSTLY ON ENERGY
Fermentation tank
ALL YEAST WASHED
ONLY BEER / YEAST PHASE
WASHED
Agenda
1. Presentation2. The UN assignment3. Cleaner Production Assesment Methodology
Pre Assesment3. Overall Material Balance4. Audit tool based on process flow chart for water5. Water costing6. Focus areas
Assesment6. Interviews – who, how and what7. Management and Training8. Packaging9. Beer Processing
10. Conclusion and Next Steps
Discovered focus areas of the brewery
Main issues Danbrew conclusions
Average usage 9,2 in 2006
Good management attention to water consumption Medium number of leakages and overflow the can be improves by CP Packaging has high number of leakages and overflow the can be improved
by CP and management attention Water usage should be monitored monthly at bill boards round the brewery
as the other KPI’s
Major loss at Packaging
+ Peak/Trough
Period diff.
The pasteurised should be replaced by at new. ROI will be 1 year and 400.000 hl of water can be saved.
Very capacity utilisation prevents maintenance. Lack of maintenance causes very high water and beer losses. Capacity should be expanded.
Medium loss at Brewhouse
The meters at UBL does not apply fully to the Danbrew/UN assesment model
Excess yeast beer recovery
Water measurement
Meters have been ordered. Issue closed
Conclusions of UBL Water CP Assesment
Theoretical potential saving of more than than 3 m hl/year or 30% but there is a large potential of waste reduction.
UN assumption of African breweries using 32 hl water per hl Beer can not be confirmed
UN assumption of savings 20 to 50% can be confirmed.
CP assumption of gaining large effects by addressing management and procedures not having to invest heavily in equipment can be applied to UBL.
Next Steps
Concluding the assessments Finalise the CP assesment tool Submit to UBL
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