technological milestones in beer membrane filtration …/media/websites/food-and... ·...
TRANSCRIPT
FOOD & BEVERAGE
TECHNOLOGICAL MILESTONES IN
BEER MEMBRANE FILTRATION
DEVELOPMENTS SINCE THE START-UP OF THE BMF IN MADRID IN 2004
18 SEPTEMBER 2014
ALBERTO ARILLO – BREWING SUPERVISOR – MADRID BREWERY – HEINEKEN
ROLAND FOLZ – DIRECTOR INNOVATION & TECHNOLOGY – FOOD & BEVERAGE – PENTAIR
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’PENTAIR Food & Beverage 2
CONTENT
• Introduction Membranes
• Beer & Membranes – The Development Phase
• The experiences of Heineken Madrid with the BMF
• The technology roadmap till today
• Challenges of the future – Directions for tomorrow
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
FRANKLIN’S QUOTE
”IN WINE THERE IS WISDOM –
IN BEER THERE IS FREEDOM –
IN WATER THERE ARE BACTERIA”
3
WATER WINE BEER
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
MEMBRAINS & MEMBRANES
4
PENTAIR R&D MEMBRANE FILTRATION
• Membranes
• Modules
• Water & Waste Water Treatment
• Beverage Filtration – Beer, Wine & Cider
…
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
SMALL & LARGE MEMBRANES – EXAMPLE WATER
5
The Pen -
0.008 l/s
Full-Scale Plant – 4,000 l/s
Sulaibiya - Kuwait
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’PENTAIR Food & Beverage 6
CONTENT
• Introduction Membranes
• Beer & Membranes – The Development Phase
• The experiences of Heineken Madrid with the BMF
• The technology roadmap till today
• Challenges of the future – Directions for tomorrow
7
MARKET DRIVERS• CONSISTENCY OF THE BEER QUALITY
• NEED TO REDUCE OPERATIONAL
EXPENDITURES IN GLOBAL
COMPETITIVE ENVIRONMENT
• AMBITIOUS SUSTAINABILITY GOALS
TO REDUCE WATER, ENERGY AND
SOLID WASTE FOOTPRINTS
• NEED FOR MORE FLEXIBILITY IN THE
BREWING PROCESS DUE TO
PRODUCT DIFFERENTIATION
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
BEER & MEMBRANES
8
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
BEER & MEMBRANES - DEVELOPMENT
CHOICES TO MAKE…• Membrane material ̴ Water FiltraFon � PolyEtherSulphon
• Pore size ̴ Beer quality
• Cross-flow speed ̴ Run volume – Energy consumption
• Flux optimization
• Cleaning /Regeneration ̴ Run volume – Chemical consumption
…PRODUCTS TO CHOOSE FOR!
9
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
THE FIRST BMF’S
10
• Heineken Madrid (Spain)
• Heineken Warka (Poland)
• Oettinger (Germany)
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’PENTAIR Food & Beverage 11
CONTENT
• Introduction Membranes
• Beer & Membranes – The Development Phase
• The experiences of Heineken Madrid with the BMF
• The technology roadmap till today
• Challenges of the future – Directions for tomorrow
HEINEKEN EspañaAutor | Fecha
Technological milestones in beer membrane filtration
Developments since the start-up of the BMF in Madrid in 2004
Alberto Arillo 18th September 2014
2013 Madrid Brewery overview
♦ Volume packaged 2.525.000 hls
♦ Main brands, Amstel (35%), Heineken (20%) and
Cruzcampo (15%)
♦ Non-alcoholic beers represented 26%
♦ Great complexity at BBT cellar, 32 different
beers
♦ Two filtration lines, Kieselguhr (400 hl/h) and
BMF (400 hl/h)
♦ BMF 2013 volume 1.090.000 hls (undiluted
beer)� 47% total
BMF Filter Line Madrid
SV
UBT FBTMEMBRANE
FILTER SKIDS
SF
CARBOBLENDER
BBT
SV: Storage Vessel
UBT: Unfiltered Beer Tank
FBT: Filtered Beer Tank
SF: Security Filter
BBT: Bright Beer Tank
PVPP FILTER
Legends
2013 BMF Performance. Skid 1 runlenght
♦ Average first running time 48
hours
♦ In volume means (4 skids)
20.000 hls before CIP
100 hl/h
280242 hls
Nº Backwash 951 294,7 hls/BW
Nº CIP 68 4121,2 hls/CIP
Permeate Flow
Volume filtered (undil.)
Skid 1 2013
2013 BMF Performance. Costs *
* Data for undiluted beer
CIP LiquidsReal 0,028 €/ hlCaustic (50%) 0,017 €/ hl
UtilitiesWater (CIP) 0,001 €/ hlDAW 0,034 €/ hlCO2 0,001 €/ hlElectricity 0,013 €/ hl
Other costMembranes 0,047 €/ hlSecurity filter 0,011 €/ hlExtract losses (0,30%) 0,040 €/ hl
TOTAL 0,191 €/ hl
BMF Madrid 10 year experience
Strenghts
♦ No quality issues since very first day !!!
♦ Environment and Healthy respectful, no
more kieselguhr handling !!!
♦ Membranes lifetime increased *
♦ Easy operation, no activities out of
control room
♦ No special maintenance requests
Weakness
♦ Impact of betaglucans in filterability
♦ Too long beer changes time *
♦ Dilution factor due to Backwash
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’PENTAIR Food & Beverage 19
CONTENT
• Introduction Membranes
• Beer & Membranes – The Development Phase
• The experiences of Heineken Madrid with the BMF
• The technology roadmap till today
• Challenges of the future – Directions for tomorrow
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’ 20
TECHNOLOGY ROADMAP - BMF
Sale
sV
olu
me
First
BMF
2. Gen.
BMF
Double
3. Gen.
BMF-18
First BMF
Compact
?
1990 2000 2003 2006 2009 2012 2015
New Membrane
Module type S-14
New Cleaning Agent
REAL
M2
FLEXIBEL
€$
Next to Continuous -
Also Batch operation
SUSTAINABILITY
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
PROCESS CHOICES – GOING FOR THE LOWEST TCO
• First BMF’s are continuous
• More focus on batch lines - Capex
• Now batch & continuous – 90% is
batch
• To centrifuge or not to centrifuge
21
0
10.000
20.000
30.000
40.000
50.000
60.000
very low low middle high
Ca
pa
city
[h
l/w
ee
k]
Filterability
Batch DN80 3 Skids 400
hl/h
Continuous DN80 2x2
Skids 300 hl/h - Capex
200 k€ more
Blue Not centrifuged beer
Red Centrifuged beer
(Very) Low: Fully Malt
Middle/High: Adjuncts
& Enzymes
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
IMPROVEMENTS IN THE LAST 10 YEARS
RVS housing with insert � the plastic S-14
• Hygienic Design not optimal
• Complex Skid Design
• Replacement too much labor
• Problems with potting
22
IMPROVEMENT BENEFITS €$ M2 FLEXI-
BILITY
SUSTA
INABI-
LITY
Back Flush � Soak Back Flush No water tank – Smaller pipe
diameter – Smaller pump – Lower
water consumption
Synflux � REAL One CIP tank less – Longer life time
membranes –– Simpler CIP process
Jet stream pump for chemical
dosing (‘Venturi’)
Robust dosing process – Low
maintenance costs
Simpler design membrane skid Lower amount of components –
Standardized filtration area
Module End cap 8” connection Better design – More hygienic
Compact concept for up to 250
hl/h
Plug & Play – Prefab & Tested –
Highly Standardized – Integrated
Carboblender
Ѵ Ѵ
Ѵ Ѵ
Ѵ
Ѵ
Ѵ
Ѵ
Ѵ Ѵ
Ѵ
Ѵ
Ѵ
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
CLEANING OF THE MEMBRANESTill 2009
• Hypochlorite with a specific katalysator
(Synflux) for oxidation of
polysaccharides
• Back Flush at high flow
Reasons
• Hypochlorite is aggressive towards
stainless steel and membranes
• Halogenated organic compounds
Deliverables
• Larger run volume
• Longer life time membranes (2-3 years)
• Lower water consumption
• No water tank & No specific CIP tank
� 25% lower footprint
23
From 2009
• REAL at 70oC – oxidative agent – better
removal of fouling
• Soak Back Flush – contact is more
important then flow
24
MARKET DRIVERS• CONSISTENCY OF THE BEER QUALITY
• NEED TO REDUCE OPERATIONAL
EXPENDITURES IN GLOBAL
COMPETITIVE ENVIRONMENT
• AMBITIOUS SUSTAINABILITY GOALS
TO REDUCE WATER, ENERGY AND
SOLID WASTE FOOTPRINTS
• NEED FOR MORE FLEXIBILITY IN THE
BREWING PROCESS DUE TO
PRODUCT DIFFERENTIATION
Ѵ
Ѵ
Ѵ
Ѵ
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’
TARGETS OF TODAY - CHALLENGES OF TOMORROW
25
WHAT
• Low Capex and low Total Cost of
Ownership – More and more due
to consolidation in the brewing
industry
• Sustainability - Water & energy
consumption – (Solid) waste
streams
• Voice of the customer - A product
fitted to the specifications &
conditions of the brewer – ‘Fit for
purpose, fitness for use’ (Joseph
Juran)
HOW
• Simplicity in process & design –
Minimum of hardware and
components and a maximum of
ease of operation
• Maximized output - Optimal
cleaning process and the best
membranes
• Optimal fit to all kind of breweries
– Compact, batch & continuous
filter lines – Craft brewers
• Efficiency - Standardization
PENTAIR Food & Beverage ‘Technological Milestones in Beer Membrane Filtration’PENTAIR X-Flow
QUESTIONS?
PENTAIR 27