This document provides an overview of energy and resource conservation opportunities within craft brewing. It begins with an introduction to the author and their background and motivation for studying this topic. It then provides context on the growth of craft brewing and explains that craft brewing is inherently less efficient than large industrial breweries due to economies of scale. The document outlines the basic brewing process and discusses key performance indicators used to measure energy and resource usage at breweries. It then introduces a case study brewery, Diebolt Brewing Company, to analyze potential conservation measures.
1. BARLEY TO BOILER
ENERGY AND RESOURCE CONSERVATION WITHIN CRAFT BREWING
Aaron Blaise Treeson 5/7/15
CVEN 6960 Building Systems Engineering Master’s Report
2. What Lies Ahead
¨ Who am I?
¨ Why are we here today?
¨ Getting the Basics Down on Craft Brewing
¨ The Brewing Process
¨ Mapping out the Material and Energy Flows in a Brewery
¨ Energy & Resource Conservation Opportunities in the Brewing Process
¨ Meet Diebolt Brewing Company
¨ Proposed Energy & Resource Conservation Measures at Diebolt Brewing Company
¨ Conclusions
4. Engineer, Architect & Brewer
Candidate
Master of Building
System Engineering
University of Colorado
at Boulder, 2015
Masters of Architecture
University of New
Mexico, 2012
Bachelors of Fine Arts
Colorado College, 2007
Aaron Blaise Treeson
abtreeson@gmail.com 505.918.7071
6. The State of Craft Brewing
Craft brewing is one of the fastest growing sectors of the
beverage industry. A microbrew distinguishes itself
through its quality of ingredients, its non-corporate and
thoughtful production, and an implied system of values
including wholesome ingredients, community involvement,
and ecological stewardship. Unfortunately, craft brew is
in fact a more energy, resource, and byproduct intensive
product to make. “Barley to Boiler” is an investigation into
why this is and how technological and brewing innovations
can improve on the efficiency of craft brewing while
maintaining if not improving the profitability of a
microbrewery.
7. Social Sustainability --1516
Reinheitsgebot was the first beer related legislation. It
social sustainability decreed that in Bavarian, now
Germany, beer could only be brewed only from barley,
water, and hops during the summer months, avoiding
bread famines from other grains midwinter.
8. What makes a Craft Brewery?
¨ No formal definition, though this is currently being decided in a
class action lawsuit in the California courts
¨ Independently owned business in contrast to the three main
publically traded industrial producers: Anheuser-Busch,
MillerCoors, and Pabst Brewing.
¨ Currently produce at most 100,000 barrels (3,100,000
gallons) of beer per year, but this is an escalating target.
¨ Have a single brewery with limited distribution.
¨ Pride themselves in high quality beers made in a variety of
traditional and avant-garde styles that command a higher retail
price point.
12. What is a bbl?
‘Barrel’ is the standard volumetric unit in brewing
= =
Barrel (bbl) =
31 gallons
2 Standard
Kegs
330 twelve ounce pours
13. Brewpubs = Taphouse only Microbrewery < 15,000 bbl/yr
15,000 bbl/yr < Regional Breweries < 500,000 bbl/yr
Large Breweries > 500,000 bbl/yr
Classification of Craft Breweries
14. The System Boundary Quandary
28 gallons irrigation water12 oz local microbrew 0.94 gallons fresh water
Upstream Material InputsPoint of Consumption Production at Brewery
16. Schematic Brewing Process
1: Milling malted grain to create grist
2: Heating of water for mashing
3: Mashing & lautering by steeping the grist in the hot water to make wort
4: Boiling wort to sterilize, blow off VOCs, add hops, and catalyze chemical reactions
5: Heat Extraction from boiled wort and the addition of oxygen and pitching of yeast
6: Fermentation takes several days to weeks at a prescribed temperature
7: Conditioning clarifies the beer from dead yeast and remaining sediment
8: Packaging involves kegs, bottles, or cans for onsite consumption or distribution
17. Malting & Roasting Grain
Purpose
Convert proteins to carbohydrates
Location/Vessel
Offsite in grain handling facility
Duration
Several hours
Temperature Change
Varies
Energy Transfer
Furnace to heat air and electric fans
Mass Flows
Raw grain, circulated hot air, water for
germination => wastewater and vapor,
malted grain
18. Milling Grain into Grist
Purpose
Expose endosperm and de-husk
Location/Vessel
Onsite Mill
Duration
Negligible
Temperature Change
N/A
Energy Transfer
Induction motor
Mass Flows
Malted and roasted grain => grist
19. Mashing & Lautering
Purpose
Mix hot water with grist to make wort
Location/Vessel
Mash Tun
Duration
60-90 minutes
Temperature Change
130°F - 180°F
Energy Transfer
8 – 13 kbtu/bbl
Mass Flows
Hot water & grist =>
spent grain, wort, steam
20. Boiling
Purpose
Integrate flavors, blow off
VOCs, hops additions, sterilize
Location/Vessel
Brew kettle
Duration
60-120 minutes
Temperature Change
~160°F - ~212°F
Energy Transfer
44 – 46 kbtu/bbl
Mass Flows
Wort, natural gas, oxygen,
hops => VOCs, CO2, sterile wort
21. Whirlpool
Purpose
Concentrate and filter out insoluble
compounds & ease of cleaning
Location/Vessel
Brew kettle or separate vessel
Duration
20 minutes
Temperature Change
~212°F - 210°F
Energy Transfer
Negligible
Mass Flows
Pumped wort => extracted hops, sediment
and remaining grain
22. Cooling/Heat Extraction
Purpose
Reduce the temperature of
wort for fermentation
Location/Vessel
Heat exchanger & chiller
Duration
20-120 minutes
Temperature Change
210°F - ~60°F
Energy Transfer
35 – 36 kbtu/bbl
Mass Flows
Hot wort, chilled water and/or glycol =>
cool wort, warmed water or glycol
23. Filtering, Oxigenation & Pitching
Purpose
Strip wort and start fermentation
Location/Vessel
Fermentation Tanks
Duration
20-60 minutes
Temperature Change
N/A
Energy Transfer
Minor pump energy
Mass Flows
Cooled wort, liquid yeast, oxygen
=> inoculated wort
25. Conditioning
Purpose
Clarify and mature beer
Location/Vessel
Brite tanks
Duration
Weeks to months
Temperature Change
32°F
Energy Transfer
Variable
Mass Flows
Green beer => mature beer
26. Packaging
Purpose
Allow for offsite retail
(keg, can, glass, or growler)
Location/Vessel
Onsite or vehicular
Duration
Several hours to days
Temperature Change
32°F
Energy Transfer
Drives, compressed CO2, refrigeration
Mass Flows
Mature beer => retail beer
28. KPI: Electricity
12.69
0.00 5.00 10.00 15.00 20.00 25.00
US Range Min
US Range Max
Germany Average
Yatala Brewery (AU)
Efficient Canadian Min
Efficient Canadian Max
US Industrial Scale Top 75%
US Industrial Scale Top 50%
Atomspheric Boil (7.5% evap)
Low Pressure Boil (4.5% evap)
Internal Boiler (3% evap)
GEA Brewery Systems Low
GEA Brewery Systems High
Green Brewery (854,700 bbl/yr)
German Small Breweries Average
AVERAGE
Site kWh/bbl
Onsite Electrcity Consumption Range (kWh/bbl) LBNL
Study
46%
-‐
Machine
drives
32%
-‐
Chillers
7%
-‐
HVAC
7%
-‐
Ligh;ng
8%
-‐
Miscellaneous
ESource Audit
35% - Chillers
25% - Packaging
12% - Other
10% - Compressed air
7% - Pumps
6% - Lighting
5% - Boiler management
29. KPI: Natural Gas
LBNL
Study
30-‐60%
-‐
Steam
boilers
20-‐30%
-‐
Packaging
&
u;li;es
15-‐20%
-‐
Domes;c
hot
water
>10%
-‐
Space
hea;ng
ESource
Audit
45%
-‐
Steam
boilers
25%
-‐
Packaging
20%
-‐
U;li;es
10%
-‐
Space
hea;ng
1.13
0.00
0.50
1.00
1.50
2.00
2.50
US
Range
Min
US
Range
Max
German
Average
Yatala
Brewery
(AU)
Canadian
Average
GEA
Brewery
Systems
Low
GEA
Brewery
Systems
High
GEA
Brewery
Systems
Benchmark
Green
Brewery
Required
Min
Green
Brewery
(854,700
bbl/yr)
German
Small
Breweries
Average
AVERAGE
Site
therms/bbl
Onsite
Natural
Gas
Consump=on
Range
(therms/bbl)
30. KPI: Carbon Dioxide
BIER Report
38 g CO2e – Assorted other
94 g CO2e – Malting
257 g CO2e – Brewing
319 g CO2e – Aluminum manufacturing
____________________________
708 g CO2e/12 ounce can
Climate Conservancy Report
12 g CO2e – Direct emissions
12 g CO2e – Paper production
21 g CO2e – Brewing
35 g CO2e – Assorted other
44 g CO2e – Consumer
45 g CO2e – Distribution
32 g CO2e – Malting
67 g CO2e – Barley cultivation
115 g CO2e – Glass manufacturing
149 g CO2e – Retail
____________________________
532 g CO2e/12 ounce glass
13.76
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
Asahi
(JA)
SAB
Miller
(US)
Carlsberg
(EU)
Heineken
(EU)
Fosters
(AU)
Yatala
2008
(AU)
Yatala
2001
(AU)
Canadian
Average
New
Belgium
Brewery
1998
New
Belgium
Brewery
with
Wind
1998
UK
Average
GEA
Brewery
Systems
Low
GEA
Brewery
Systems
High
Green
Brewery
(854,700
bbl/yr)
United
Na;on
Enviromental
Program
AVERAGE
Site
kg
CO2e/hl
Onsite
Carbon
Dioxide
Consump=on
(kg
of
CO2e/hl)
31. KPI: Wastewater : Beer
6.39
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
German
Average
Asahi
(JA)
SAB
Miller
(US)
Carlsberg
(EU)
Heineken
(EU)
Fosters
(AU)
Yatala
2008
(AU)
Yatala
2001
(AU)
Inbev
(EU)
US
Range
Min
US
Range
Max
Canadian
Averaage
UK
Average
Small
UK
Average
Medium
UK
Average
Large
Anheuser-‐Busch
New
Belgium
1999
Hopworks
Urban
Brewery
2013
Ins;tute
of
Brewing
Low
Ins;tute
of
Brewing
High
Green
Brewery
(854,700
bbl/yr)
AVERAGE
Wastewater
:
Produced
Beer
Wastewater
to
Beer
Produced
Ra=o
32. KPI: Energy Use Intensity (EUI)
Lawrence Berkley National Laboratory US average EUI: 335 kbtu/bbl
Brewers Association of Canada’s average EUI : 643 kbtu/bbl
German average EUI for industrial scale breweries : 278 kbtu/bbl
German average EUI for small craft breweries* : 476 kbtu/bbl
*This shows 71% increase in EUI due to the lack of economies of scale. This factors
was applied to the applied to the Lawrence Berkley National Laboratory US average
resulting a better estimate for Craft Brewery EUI in the US.
____________________________________________________________
Estimated average craft brewery EUI in the US: 573 kbtu/bbl
34. Diebolt Brewing Co.’s Case Study
• Diebolt Brewing Opened in August 2013
• Located at 3855 Mariposa Street in Denver, CO
• Father, Dan, & Son, Jack, team with several other employees
• Currently working with a 15 bbl capacity batch system
• The system was bought and installed as a single purchased
• Focuses on contemporized French ales
• No prior brewing experience beyond home brewing
• Diebolt Brewing Company has won multiple awards
• Currently transitioning to larger packaging, distribution and retail
• Annual production is growing and around 250 bbl/yr
• The space currently includes a total of roughly 8,000 sqft:
37. Diebolt’s Beer Production
y
=
0.0478x
-‐
1970.4
R²
=
0.38112
0
10
20
30
40
50
60
BBL
BBL/Month
Since
Opening
y
=
13.803x
+
23.456
R²
=
0.61882
0
20
40
60
80
100
120
Q3
2013
Q4
2013
Q1
2014
Q2
2014
Q3
2014
Q4
2014
BBL
BBL/Quarter
y
=
0.0013x
-‐
23.212
R²
=
0.00014
0
10
20
30
40
50
60
BBL
BBL/Month
in
Past
Nine
Months
on
Record
38. The Last Twenty Two Months
y = 2.6541x - 105623
R² = 0.26879
-
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Electricity: kWh/month
y = 0.0006x + 1.8072
R² = 0.00365
0
5
10
15
20
25
30
35
Power Demand: kW/month
39. The Last Twenty Two Months
y = 0.2284x - 9277.2
R² = 0.10815
0
100
200
300
400
500
600
700
Sewage: bbl/month
y = 0.3038x - 12421
R² = 0.17784
0
100
200
300
400
500
600
700
Fresh Water: bbl/month
40. The Last Twenty Two Months
y = 0.5057x - 20846
R² = 0.13904
-
100
200
300
400
500
600
700
800
Natural Gas: therms/month
y = 0.1204x - 4959.3
R² = 0.96098
0
20
40
60
80
100
120
140
Carbon Dioxide: kg/month
41. Monthly Cost since Opening
$-
$100
$200
$300
$400
$500
$600
$700
$800
$900
$1,000
$1,100
$1,200
$1,300
$1,400
$1,500
$1,600
$1,700
Diebolt Brewing Company’s Related Monthly Costs
ELECTRICITY FEES LEASED GAS TANKS CARBON DIOXIDE KWH CONSUMED SEWAGE FRESH WATER KW DEMAND NATURAL GAS
42. Water and CO2 Intensities
0.00
5.00
10.00
15.00
20.00
25.00
30.00
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Fresh
Water
/
Beer
kg
CO2/BBL
CO2
&
Fresh
Water
Intensity
Kilograms
of
Carbon
Dioxide/BBL
Beer
Fresh
Water
:
Produced
Beer
Diebolt uses on average 11.5 units of water to each unit of produced beer, well
within the range of 10 – 14.7. Municipal water data is very non-accurate data.
Diebolt purchases 2.5 kg of CO2/bbl, while fermentation usually creates 2.56 –
4.5 kg CO2/bbl.
43. Diebolt’s Energy Use Intensity
Diebolts estimated
current EUI
_______________
642 kbtu/bbl
Estimated average
craft brewery EUI in
the US
_______________
573 kbtu/bbl
Percent Overage
______________
12%
48. Reduce Peak Load Simulations
y = 0.0006x + 1.8072
R² = 0.00365
0
5
10
15
20
25
30
35
Power Demand: kW/month
Schedule C Max Draw : 25 kW
Diebolt Average Draw: 27.8 kW
Diebolt Peak Draw: 31 kW
Solutions:
Demand Side Management
Onsite Generation
49. Demand Side Management
Interview with Bill Brayden of Brayden Automation & Energy Sentry
Paraphrase of Dr. Brayden’s Comments:
DSM system to reduced peak demand from 31 kW to 25 kW from a limited
number of significant draws (i.e. chillers) is very easy. The addition of onsite
photovoltaic generation is beneficial. 40 kW is about the max demand before
loads are not adequately met.
50. Photovoltaic Array Simulation
10 kWd Flatplate Photovoltaic Array Simulation with NREL’s SAM
All federal, state, city, and utility incentives taken into account
Cost: $25,580
Generation: 15,138 kWh/yr
Percent energy reduction: 22%
Range in demand reduction: 0 kW – 5 kW
60. New Heat Exchanger Finances
Savings NPV
10 Years
$162 -$360
5 Years
-$889 -$982
15 Years
$1,323 $154
20 Years
$2,606 $579
25 Years
$4,021 $929
61. Currently Brewery Lighting
• Observably over-illuminated given low occupancy
• 7,200 square foot brewhouse is illuminated throughout the day & evening
• 16 total luminaires
• Each luminaire has six T8 florescent
• Each T8 is rated at 2,800 lumens with a downward reflector
• This effectively equates to over 37 fc (1 fc = 1 lumen/sqft)
• This is well in excess of required by the Illuminating Engineer Society
66. Lighting Iterations: NPV vs Time
NPV
5
Years
NPV
10
Years
NPV
15
Years
NPV
20
Years
NPV
25
Years
-‐$6,000.00
-‐$4,000.00
-‐$2,000.00
$0.00
$2,000.00
$4,000.00
$6,000.00
$8,000.00
(2)
Reduc=on
(3)
Reduc=on
&
Reschedule
(4)
Reduc=on,
Reschedule,
&
LED
Replacement
NPV
Mesh
of
(1),
(2),
&
(3)
at
5
Year
Incriments
68. Thank You! Questions?
Touch
the
earth
lightly,
use
the
earth
gently,
nourish
the
life
of
the
world
in
our
care:
gi6
of
great
wonder,
ours
to
surrender,
trust
for
the
children
tomorrow
will
bear.
-‐Shirley
E.
Murray
