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2015 09-13 mcs-apb-spent_grains
1. MCS-APB TIGER BREWERY
BREWERS SPENT GRAINS QUESTION
ORIGINAL RESEARCH BY:
GMIT BIODIESEL PROJECT
PREPARED BY:
LYNDON MARTIN W. BEHARRY
SEPTEMBER 11, 2015
2. EXECUTIVE SUMMARY | Page 1 of 18
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EXECUTIVE SUMMARY
Breweries worldwide face the issue of disposing Brewers Spent Grains (BSG).
This report discusses the current trends in the economic and ecologic disposal
of Brewers’ Spent Grains (BSG). The analysis concludes that the three most
viable options for a brewery in Mongolia are: 1) Methane production for recovery
(low to moderate capital investment) with composting in tandem with 2) sale
and/or donation to livestock herders; and the most capital intensive: 3)
cogeneration facility to provide steam and electrical energy to power the facility
(and potentially other facilities).
3. CONTENTS | PAGE 2
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12/29/2016 7:54
PM
EXECUTIVE SUMMARY.............................................................................................. 1
Overview .............................................................................................................. 3
A review of potential alternatives........................................................................... 4
Minimalist Schemes .................................................................................................................4
Capital Intensive Schemes.....................................................................................................5
Process Considerations ...............................................................................................................7
Attractive Alternatives........................................................................................... 8
Case Study: Methane Digester and Compost Case............................................... 10
Case Study: The Alaska Brewing Company Case ................................................. 12
Considerations Applying the Alaska Brewery Case to MCS-APB Tiger.....................14
Suggested methodology for financial analysis of BSG steam and power: ............14
Assumptions of Opportunity Cost in the MCS-APB Tiger Brewery case ..............15
Conclusion, Analysis of Data, and Looking Forward ............................................ 16
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Overview
In May 2015, MCS-APB Tiger Brewery invited GMIT-Biodiesel Project to present the
biodiesel program. GMIT student project leaders executed an excellent
demonstration, and MCS-APB Tiger agreed to provide ethanol for GMIT chemical
engineering processes of biodiesel. During the meeting, MCS-APB representatives
Messrs. VanGeel and Dobrov asked GMIT-Biodiesel Project whether GMIT could
investigate the issue of Brewers Spent Grains (BSG).
In sum, the beer brewing process produces tonnes of BSG. As example, Brazil,
which produces approximately 8.5 billion liters of beer per annum, generated 1.7
million tonnes of spent grain in 2002 (S.I. Mussatto).1
The worldwide brewing industry today actively seeks methods to: 1) dispose of BSG
in an economic manner; 2) avoid environmental damage; and 3) use the BSG to
produce economic value. This short paper aims to provide a concise review of
brewers’ responses to the problem of brewer’s spent grains under two strategies: 1)
minimal capital investment; and 2) capital intensive investment.
This document aims to succinctly review current trends in the brewery industry.
The author expects this paper will provide MCS-APB Tiger Brewery a framework
from which to begin a dialogue for further in-depth analysis. These data may give
MCS-APB Tiger Brewery a vision to choose one or more options for detailed
feasibility and engineering review; and create additional value for the Brewery and
its stakeholders.
1 These figures suggest a rough estimation of 200 grams of brewers spent grain per liter of beer
product.
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A review of potential alternatives
The following tables review the current trends in handling and disposing Brewers
Spent Grains:
MINIMAL CAPITAL INVESTMENT CAPITAL INTENSIVE INVESTMENT
Donate BSG to livestock herders
Retro-fit boiler mechanism to use BSG
as fuel
Compost BSG for later sale (or
donation) to agriculturalists (note
APB would book Public Relations
value on donation)
Install biogas production and retention
infrastructure
Discard BSG for use as landfill
Process BSG for feed (livestock, pets,
fish), and for human consumption
Contract with bakers for cash and
carry
Pelletize BSG for use and sale as fuel
Minimalist Schemes
MINIMAL CAPITAL INVESTMENT BENEFITS DETRIMENTS
Donate BSG to livestock
herders
Minimal cost (0₮ for
transport, for
instance);
Gain public relations
value;
(Potential to book a
write-down,
assuming a value
base as animal
fodder).
In summer heat,
yeasts and bacteria
growth render the
matter unfit within
24-48 hours;
Herders will not
accept the donation
in warmer months.
Compost BSG for later sale
(or donation) to
agriculturalists (note APB
would book Public Relations
value on donation)
Ecological benefit
gains some public
relations value;
Relatively low
operations cost.
Requires land
property;
Requires regular
monitoring;
Could result in some
fire hazard (i.e.
methane seepage);
BSG is laden with
moisture (75% by
mass) and difficult to
compost before
drying;
Draws pests: insects
(flies) and rodents.
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MINIMAL CAPITAL INVESTMENT BENEFITS DETRIMENTS
Discard BSG for use as
landfill
Removes BSG
quickly from
premises.
Cash outlay for
transport.
Contract to sell BSG to
bakery companies
Provides a revenue
source to efficiently
use BSG as a food
source;
Buyer would
purchase and carry,
unburdening the
brewery of storage
and haulage costs.
Quality control of
the BSG mass;
Regulatory hurdles
of a different sort;
Sanitation
safeguards and
infrastructure;
Etc.
Capital Intensive Schemes
CAPITAL INTENSIVE
INVESTMENT
BENEFITS DETRIMENTS
Retro-fit boiler mechanism to
use BSG as fuel2
Optimum use of
BSG as an energy
supply;
Low carbon footprint
as the system is not
burning a fossil fuel;
Steam could push
electric generator
turbine;
BSG is basically a
renewable resource.
Expensive
engineering, as
MCS-APB must
tailor the system
specifically for the
plant;
Downtime delays
and production
losses during the
early phases;
BSG burns to a high
ash content –
difficult to clean the
system.
Install biogas production
infrastructure to use biogas
as ancillary fuel
Low carbon footprint
as the system is not
burning fossil fuel;
Steam generation
from biogas could
push electric
generator turbine;
Biogas is a
renewable resource.
Requires monitoring;
Potential fire and
explosion hazard
from methane
concentration;
Requires new hires
to maintain,
monitor, and process
the biogas.
2 Alaska Brewing Company has taken this initiative to actually burn BSG for steam and electric
generation. http://inhabitat.com/the-alaskan-brewing-company-runs-on-energy-generated-by-its-
own-beer/
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CAPITAL INTENSIVE
INVESTMENT
BENEFITS DETRIMENTS
Process BSG for feed
(livestock, pets, fish), and for
human consumption
Revenue source from
a wholly alternative
industry – leading to
a portfolio of assets
under management;
Potential to create
new sales streams –
even internationally.
Wholly different
business model
requiring a new
division, new
infrastructure;
Distinct set of
government
regulations;
Pelletize BSG for use and sale
as fuel
Least expensive of
the capital intensive
alternatives
Reduces overall
carbon footprint;
Yields Public
Relations value;
New revenue source.
New infrastructure
and business model;
Process engineering
costs;
Cost of binding
agent;
Requires new and
wholly distinct
distribution
channels;
Enters into
competition with
state-subsidized
coal.
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Process Considerations
All of these considerations require extraction of excess moisture from the BSG,
even if only to reduce haulage costs. Because of this, MCS-APB should consider
using a screw press to remove some of the water from the BSG. Typically, emergent
BSG contains 85% water by mass. The screw press reduces the water content down
to 65% to 70%, significantly reducing the density of the hydrated matter.
Many brewers sell BSG as a marketable commodity to bakers or livestock
managers. Such breweries dry the BSG as a matter of quality control. Dried BSG
retains a longer shelf-life. But because it is lighter, it is also less expensive to
transport. Because of this, the brewery ought to investigate the costs and benefits
of drying the spent grains to lowest possible water content.
In addition, a brewery might also consider re-processing the screw press waste
water. The stakeholders could find value distilling the fermenting effluent (with
other waste ethanol by-product) to produce industrial grade ethanol for sale to the
cosmetics industry, hospitals, universities, and schools. Keep in mind that any
engineering process ought to recycle heat through heat exchange mechanisms; but
also mitigate water loss by collecting wastewater wherever possible.
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Attractive Alternatives
Research shows many creative options to dispose and/or economically utilize
Brewers Spent Grains. Some breweries compost or grow mushrooms, and others
use the matter for baking. Many breweries combust some of the spent grains as an
ancillary heat and power source. At the extreme end of capital intensive projects,
Alaska Brewing Company created a unique boiler and power plant system which
runs completely on BSG (see case study starting page 12 in this document). And at
the low level of capital investment, many breweries either sell or donate BSG to
ranchers or livestock herders.
The analyst created this table to review the most attractive alternatives:
CAPITAL
REQUIREMENT
DISPOSAL / USE SCHEME REASONING
Low to
moderate
Negotiate with Ulaanbaatar
bakery operations to sell the
BSG
Brewers spent grains are rich in
protein and carbohydrate:
20% protein; 70% fiber;
Several U.S. microbreweries
use BSG for breads and
other baked products.
Low to
moderate
Composting for agricultural use
and for methane production
(see case study page 10 below)
Assuming that MCS-APB is able
to secure a suitable area of land
nearby:
The company could set up a
functional facility to insert
the BSG into the ground;
Secure the site;
Use a venting system to
bleed off the methane;
Stir the matter for adequate
aeration;
Gain some economic benefit
from sale of fertilizer after
composting;
Gain public relations value
worldwide.
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CAPITAL
REQUIREMENT
DISPOSAL / USE SCHEME REASONING
Moderate to
high
Retrofit the brewery complex to
combust BSG to generate high-
temperature, high-pressure
steam to turn a generator
turbine
(see Alaska Brewing Company
case study page 12 below)
Assuming that MCS-APB is
willing to make a multi-million
dollar capital investment:
The company gains huge
advantages in self-
sustaining power;
The steam generator
complex is co-generating
(i.e. steam for operations,
steam for power, and steam
for heat);
Low carbon footprint;
The corporate partners each
gain valuable knowledge
base to replicate the
mechanism in other venues;
Huge public relations value
on the international level
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Case Study: Methane Digester and Compost Case
Cost-effective and ecological stratagems to manage the disposal of organic matter
require solid awareness of the organic and
biological chemistry of the baseline reactions.
The case of composting Brewers Spent Grains
(BSG) and potentially recovering methane may
be a viable alternative for a commercial
brewing enterprise. Furthermore, while
composting may certainly create a saleable
value-added product for market to the
agricultural industry, it also satisfies
regulatory demands in many jurisdictions
worldwide. And though Mongolia does not
presently assess a broad range of taxes and
fines focused to reduce carbon emissions and
ecological damage; in the future, the nation will likely pursue various charges and
financial fees for environmental issues.
The Methane Digester provides a mechanism to mix organic wastes and effluent in
a controlled environment. Secured from contact with atmospheric oxygen, micro-
organisms robustly convert the matter through a series of stages, resulting in
methane production.
(WikiMedia Commons, 2007)
One substantial pitfall restricts the application (in Mongolia) of methane generation
and composting: five to six months of severe winter cold. Without a sufficient heat
source (an expensive proposition), organic matter will freeze in a methane digester
during the winter months. Likewise, organic wastes piled and stirred for compost
will likewise freeze. The winter’s cold basically shuts down bio-chemical
decomposition. Hence, a brewery would only meet success in bio-degrading
Brewers Spent Grains during the warmer months from mid-April and through mid-
October. The cold of November through March reduces the application of such
solutions to the MCS-APB Tiger plant.
Composting BSG likewise generates four distinct challenges: 1) wintertime
temperatures restrict the compost option for half of the year; 2) access and cost of
access to a surface area of land to aerate and process the compost pile; 3) the cost
of holding that surface area of property for a time; and 4) economical means to
manage the methane generated by the digestion of the BSG matter by anaerobic
bacteria (i.e. even compost will generate methane). Since Mongolia has abundant
land, often available for extremely low costs, this case will ignore “2)” above. This
SIMPLE METHANE DIGESTER
(Mother Earth News, 2013)
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analysis suggests that any business enterprise seek public-private partnership on
the province level to secure mutual advantage.
While the combination of methane digester/composting offers ecologic and public
relations advantage, the brewery would face certain variable costs. Such a project
would necessarily require a reallocation of qualified employees to manage the
venture. In addition, since the project could only function during the warmer
months, the plant would necessarily revert to selling or donating BSG as fodder to
herders in the late autumn and winter.
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Case Study: The Alaska Brewing Company Case
Alaska Brewing Company faced a disposal problem for its Brewers Spent Grains
(BSG). Because of its remote location and distance from agricultural and animal
husbandry centers, the company incurred expenses as much as $30 per ton to ship
its BSG to cattle ranchers in the U.S. Lower 48. In response to these costs, the
company focused on a wholly novel strategy to extinguish haulage expenses. Alaska
Brewing Company investigated, purchased, and installed a $USD 1.8 million new
boiler system to use BSG as the sole fuel. Funded in part with a $500,000 grant
from the U.S. Department of Agriculture, Alaska Brewing Company forecasts that
the new system will reduce its costs for diesel fuel and electric power by as much
as 70 percent and save in excess of $1.5 million over ten years (Carbone).
Prior to installing its new BSG boiler process, Alaska Brewing Company faced the
distinct challenge of environmentally friendly disposal of its brewers spent grain.
Because of the dearth of farms and ranches in the area, the company had to dry
the BSG (a very heat-intensive and expensive process), and then ship the matter to
the Lower 48. While the firm could sell the BSG as livestock feed for $60 per ton; its
haulage costs of $30 per ton cut its potential BSG revenue in half. Feasibility
studies concluded that the new BSG boiler system could use Brewers Spent Grains
as its sole fuel, while providing steam to run the dryer and power other brewing
operations (Grass).
Alaska Brewing Company's innovative strategy stretches back twenty years to 1995
when the company installed a grain dryer. At that time, the stakeholders had
realized that the firm could mitigate its prohibitively exorbitant costs of
transporting wet BSG out of Juneau by first drying the matter. For the sixteen
years prior to installing the new boiler system in 2012, the company used about
half of its brewers spent grain as a fuel source to heat the dryer. Through those
years, brewing engineers learned how to efficiently combust the BSG. Still focused
to reduce BSG water content, by 2008 the Brewery installed a $1.7 million mash
filter press to produce a finer waste grain with less moisture. After this, the finer
BSG material induced the stakeholders to investigate systems to convert the BSG
to fuel for powering all plant operations (Grass).
While breweries around the world use spent grain as a co-fuel in energy
recovery systems, "nobody was burning spent grain as a sole fuel source for
an energy recovery system, for a steam boiler," says Brandon Smith, Alaska
Brewing Company Brewing Supervisor/Engineer. (Berlinger)
Ash build-up emerged as the major problem with Alaska Brewing Company’s BSG
boiler system. While conventional fuel boilers generate about 0.5% ash, the BSG
boiler produces over 5% ash. To focus the collection of ash, the Brewery installed a
centrifugal system to channel ash into a multi-tube cyclonic collector. The boiler
also uses a timing mechanism which periodically switches compressors to force air
to remove soot from the fire tubes. But even with these contrivances, adhesion
draws water molecules from vapor, conferring a colloidal quality to the ash-water
physical chemistry. The hydrated ash presented a gummy character; and the
brewery suffered frequent operations pauses for the engineering team to clean the
system and resume efficient combustion. Ultimately, Alaska Brewing Company
installed sonic horns using acoustic waves to “blow out” ash accumulation within
the boiler assemblies (Labs).
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The enterprise worked with external boiler and process engineers to produce this
one-of-a-kind system specifically for Alaska Brewing Company. Since the months-
long installation of the system began in 2012, the boiler experienced a continual
commercial run from October 2012 through to the publication of articles in
February 2013. Brewing Supervisor/Engineer Brandon Smith optimistically argued
that the system would save the brewery 1.5 million gallons of oil fuel over a ten
year cycle, which the prior and now defunct diesel boiler demanded. He also
posited that the new BSG boiler would pay for itself over four years (Stigall).
“If you look at the value of a spent grain as a fuel in terms of the energy
content in it versus its value just as a waste material, it goes from a net
value of $30 a ton up to $350 a ton,” Smith said. “We did a patent search
just to make sure we weren’t stepping on anybody’s toes and as far as we
can tell we’re the only ones in the world that are going to be using spent
grain as the sole fuel source for a steam boiler...We’re certainly excited to
pioneer this… Whether we envisioned we would end up where we are today,
who knows. But looking back it was certainly an integral part of it, putting
in that first grain dryer.” (Grass)
As of 2014, the Alaska Brewing Company has experienced success in its
experiment with BSG for fuel. The company argues that it may save as much as
$450,000 per annum on fuel and electricity costs (Berlinger). If these savings
projections are accurate and consistent for similar sized operations, a combined
capital investment and downtime loss on the order of $4.5 million would still
produce a payback period of only ten years, provided another brewery following this
model met similar implementation success.
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Considerations Applying the Alaska Brewery Case to MCS-APB
Tiger
A proper analysis of the financial costs and benefits demands that the analyst: 1)
determine the annual heat energy content of the brewers spent grain emerging from
the production process; 2) determine the cost in heat energy to dry the brewers
spent grain; 3) calculate the difference between the total energy and the energy
required to dry the mass; 4) calculate the cost to purchase this energy equivalent in
coal (LPG, diesel, or other); 5) project variable cost/revenue differentials including
downtime to clean boiler systems, surpluses on cogeneration of steam and electric
power, etc.; 6) work up a discounted cash flow analysis to determine the Net
Present Value of implementing the system (where the capital investment, set-up
costs, and production downtime assess the initial costs; and savings in coal or
other energy will become a future positive cash flow); and 7) work up a pay-back
period analysis.
In other words, to apply the Alaska Brewing Company model to any other brewery,
the cost of the instant brewery’s boiler fuel source becomes the functional
savings=opportunity cost of lost positive cash-flow to the firm. In this light, if MCS-
APB Tiger uses coal to fire its boilers, the analyst need account for the dried BSG’s
energy-equivalent purchase price for coal. If the brewery uses natural gas, one
ought to price the BSG in its energy-equivalent purchase price for gas, etc. Further,
any feasibility analysis ought to review the brewery’s current usage and expenses
for electric power and determine the probable production of electric power via the
BSG boiler-generator complex of various output between 1 Mega-watt and 2 Mega-
watt (contingent upon the brewery’s current consumption and growth strategy). In
the case of MCS-APB, one might also consider whether larger scale could be
beneficial for the brewery to act as a power generator profit center to supply power
to other MCS divisions.
Suggested methodology for financial analysis of BSG steam and
power:
CURRENT VARIABLE COST =
POTENTIAL SAVINGS
(OPPORTUNITY COST OF LOST
REVENUE AS A POWER GENERATOR
PROFIT CENTER)
FINANCIAL VALUE
Cost of Coal fuel (measured in
cost of heat content per tonne)
(Adjusted for heat content per mass unit; and
adjusted for the costs of drying the BSG)
Equals the value of the produced and dried
mass of BSG to generate the heat content in
the coal, LPG or natural gas analog for boiler
steam. ADD TO THIS:
Value of electricity produced from the
generator/transformer complex.
Cost of LPG / natural gas fuel
(measured in cost of heat content
per tonne)
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Assumptions of Opportunity Cost in the MCS-APB Tiger
Brewery case
The brewery produces at a capacity of 120,000 hectoliters (My News Desk,
2007);
One liter of brewed beer produces 200 grams of spent grain (dry mass);
MCS-APB Tiger Brewery produces, roughly, 2,400 tonne BSG per annum;
The heat content of BSG is 18.64 MJ/kg (Mussatto, 2014);
The heat content of (Australian) thermal coal is 25.46 MJ/kg;
BSG produces only 73.21% of the heat of thermal coal;
Market price for (Australian) thermal coal is $USD 62.18 at August 2015
(Index Mundi);
The annual cost of coal to achieve the thermal content of 2,400 tonne BSG equals
73.21% X 2,400 MT/annum X $62.18/MT = $109,257/annum. In other words, the
opportunity cost of not using each tonne of BSG to generate heat is 73.21% X
$62.18/MT = $45.52 per MT.
Contingent upon whether MCS-APB Tiger Brewery produces steam with thermal
coal, natural gas, diesel, or amps from the grid, the firm does suffer a substantial
loss of (benchmark) value of $45 per tonne as the opportunity cost of not using
BSG as fuel (at current coal prices). And the reader ought to recall the volatility of
coal price, and the impact this volatility imputes to production variable costs.
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Conclusion, Analysis of Data, and Looking Forward
This research endeavor aimed to provide a review of current trends in the Brewing
Industry addressing Brewers Spent Grains. Through their business cycle, many
brewers engage this discussion at one stage or another. The literature shows that
brewers may adopt one strategy and then evolve into another; and some breweries
adopt several strategies at once.
While some brewers adopt vertical integration, other enterprises enfold public
relations niches seeking stringent environmental standards. Some brewers merge
the production of spent grains with power generation, methane production for
energy recycle back to operations, or for a baking subsidiary. And others just give
away their spent grains. Regardless of approach, the data clearly show that well-
devised stratagems to dispose or utilize Brewers Spent Grains provide value to
stakeholders, and reduce headaches related to environmental best practices.
To complete this preliminary analysis, GMIT did not seek proprietary data. Nor did
GMIT seek proprietary process engineering design information. Rather, this instant
analysis is general, aiming to give a succinct overview. Looking forward, GMIT
hopes that MCS-APB Tiger will call upon the University to design and engineer a
program and technology backbone specifically tailored for brewery operations. The
University aims to provide true value for all stakeholders: the owners, the
employees, the community and government, and the environment. We provide this
valuable initial report as an introduction to our University’s range of capabilities.
We look forward for research and development consulting with MCS-APB Tiger.
18. REFERENCES | PAGE 17
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http://www.indexmundi.com/commodities/?commodity=coal-
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Mother Earth News. (2013). Powered By Pie: Siemens We Can Change The World 7th Grade
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