The document summarizes a brewery process design project with the goals of creating a regional brewery producing 40,000 barrels per year using sustainable practices. It describes the brewhouse and fermentation processes and provides stoichiometric calculations. An economic analysis shows the initial capital costs are $28 million with annual operating costs of $6.6 million but only $4.1 million in revenue, resulting in a $2.5 million annual loss. Suggested solutions include selling residual materials and accounting for sustainability measures to improve profits.

1. Brewery Process Design
BE 4380 - Bioprocess Engineering Design
Dr. Walker
Conor Bury, Jeremiah Davis, Ashleigh Hough, Katie Love, Ian Melville
April 23, 2015

2. Project Goals
creation of a regional brewery
high quality product
maximum profit
40,000 barrels per year
sustainable manufacturing practices
minimal energy consumption
minimal material waste

3. Brewhouse Phase

4. Mashing - Saccharification Enzymes
Alpha-amylase
- Cuts glucose chains indiscriminately
- Most active between 154 - 162*F
Beta-amylase
- Can only cut branches
of amylopectin
- Creates maltose (2 glucose chain)

5. Mashing Inputs and Outputs
Overall reaction
9 Starch + 1 Water → 10 Glucose
IN
Starch (Corn Grits) 727.34 g/L 4,379.3 kg/batch
Starch (Malted Barley) 699.4 g/L 8,398.4 kg/batch
Water
51,259 L/batch
OUT
Glucose 204.5 g/L 12,781 kg/batch
Starch 20.45 g/L 1,278 kg/batch
Water 49,806
L/batch

6. Lauter Tun Grant
Tank
Sparging of remaining grain
Utilizes starch still in grain
Removal of excess used grain
Provides easy transportation of
thicker material
Acts as a holding tank for wort
accumulation
Smooths variable flow rate caused
by lauter process

7. Boiling Wort
Stoichiometric Equation:
100 Hops → 3 Alpha Acids + 97 Spent Hops

8. Boiling Wort
min1 + min2 + Q1 + Q2 = mout
min1 = wort in - (129,884.49 L)
min2 = charging wort - 30 kg/min - (min-total 130,283.89 L)
Q1 = preheating (2530339141 kcal/hr)
Q2 = boiling (12093925.34 kcal/hr)
min-total - mvapor vented - mconsumed in rxn = mout
(130,283.89 L - 17276.66 L - 301.73 L = 112,705.5 L)

9. Whirlpool
Removal of protein
precipitate (trub)
Trub degrades taste
and hinders
fermentation

10. 1st Chiller
Wort: 87% H20, 11% Glucose
Q=U1A1(ΔT)=mCp(ΔT)
ṁ=108.6 m3/batch
ΔT=18-95=-77°C
U=1500 W/m2K
A=54.18 m2
Qin= 5384824 kCal/hr
Qcalc= 4996202 kCal/hr
Qwaste heat= 388622 kCal/hr
Coolant: 100% H20
Q=U1A1(ΔT)=mCp(ΔT)
ṁ=1072201 kg/h
ΔT= 5-10=-5°C
Cp= 4181 J/kg K
Qc= 5361005 kCal/hr
Qc= 6226211 W
Qwort ≈ Qcoolant
5384824 kCal/hr≈ 5361005 kCal/hr

11. Fermentation & Aging Phase

12. Wort Oxygenation Yeast
Charge
Oxygen added to wort
at concentration of
0.02 g/L
Necessary for
fermentation
Yeast added to brew
Enables fermentation
process

13. Fermentation - Stoichiometry
Overall Reaction:
1 C6H12O6 → 2 CO2 + 2 CH3CH2OH
● IN:
○ Glucose: 12396.6 kg/batch → 68870 moles
○ Yeast: 105.52 kg/batch → 44.4 moles
● Out:
○ Glucose: 1487.59 kg/batch → 8264.4 moles
○ Yeast: 622.54 kg/batch → 261.96 moles
○ Ethanol: 5066.75 kg/batch → 110147 moles
○ CO2: 4741.27 kg/batch → 107756 moles
● Reaction acting at 88%

14. Fermentation - Energy
Reaction Enthalpy:
-500 kcal/kg glucose
Total glucose consumed
10909 kg/batch
Enthalpy Produced:
5.45 * 106 kcal/batch
Total enthalpy into the system
-7.34*105 kcal/batch
Total enthalpy leaving the system
4.29*105 kcal/batch

15. Filtration
Governing Equation:
Vslurry= A∙Ncycles∙J∙tp = 63.1077 m2 ∙ 1cycle/batch∙ 500 L/m2-hr ∙ 240 min ∙1
hr/60min
Vslurry= 126215.4 L/min-batch
Mass Balance:
min = myeast/trub-out + mfiltered beer-out (126668.576 kg = 1105.235 kg + 12556.341
kg)
Energy Balance:
Hin = Hyeast/trub-out + Hfiltered beer-out (-5160.929 MJ = -44.431 MJ + -5116.499 MJ)

16. Filling & Packaging Phase

18. Batch Process Summation
Water: 212,000 kg
Barley Malt: 12,000 kg, Hops: 150 kg, Corn Grits: 6000 kg
9,000 kW-h electricity
Yields:
200,810 12oz.bottles (1 hr gameday weekend)
500 ½ kegs
126,000 kg of delicious, delicious beer

19. Sustainability
Beer is about 90% water
Need more efficient ways to heat up water during brewing process
Efficient boilers, tankless water heater, solar water heater
Solar/wind power to power brewery
Steam recapture
Rainwater capture - to reduce municipal/local stream water demand
Refrigeration is the largest use of energy in a brewery
Airlocks and proper insulation
Ambient cooling during colder weather
Underground cellar

20. Social Sustainability
Breweries play important role in moving communities towards sustainability
Sustainable business - provide jobs, put $ into economy, donate goods and expertise
Social sustainability - serve as gathering place where new ideas are generated,
friendships strengthened, and new contacts are made with community members
Social events often occur at a drinking event or involve the consumption of alcohol
All this is an acknowledgment of the type of camaraderie that can develop due in
large part to these social hubs

21. Economic Analysis: Cost
Capital (initial): $28,000,000
Working Cost per batch:
Brewhouse: $81,899
Fermentation & Aging: $64,780
Filling & Packaging: $32,568
Total: $179, 247
Annual operating cost:
$6,632,000
Cost per bottle: $0.505
Critical Costs:
Stirred Reactor: $ 750,000
Engineering: $ 3,605,000
Operator: $ 46/hr
Aqueous Waste :$42,705/yr
(rinsing and cleaning)
Marketing and transportation costs
not factored in

22. Economic Analysis: Revenue
Bottles Revenue: 3,715,000 $/yr
Keg Revenue: 371,500 $/yr
Total Revenue: 4,087,000 $/yr
Annual operating cost: 6,632,000
$/yr
Net Profit: -2,545,000 $/yr
Represents failing business
model
Solutions:
Residual materials like trub
could be resold
Sustainability measures not
taken into account
Sale price too low

23. Fin