Engineering & Consulting
Engineering and Consulting – world-wide
ES PROJECTS is an engineering and consulting company.
Independent partner in performing projects – as a specialist in subareas or as turnkey-manager.
Specialized in the beverage industry, especially in brewery-technologies.
Projects in different countries and the cooperation with famous companies brought the necessary international experiences.
Consulting and Engineering– an overview
Engineering
In engineering we understand the complete technology and the several steps of process. Because of the conditions we will plan the details and accompany the execution.
| Engineering - Process-engineering and flow-planning - CAD-designs - Programming and automotives - Plant designing/ planning |
Consulting
ES PROJECTS belongs to the few companies that commands real knowledge in brewing – technical demands can be put into action.
Consulting |
Planning of brewery plants
Often consulted fundamental matters: How much are the costs in production for one hectolitre of beer and which resources will be needed, what is the required space of a brewery and how much space is needed for bottling.
The following, you will find a short and incomplete overview of the parameters of a brewery. These informations only give interested readers from offline of the business a first overview.
General
The range of brewery plants is manifold.
Summarized you can divide them into three big categories:
| Brewery categories | |||
| Pub brewery or microbrewery | 2.000 hl pa | ||
| Regional breweries | 200.000 hl pa | ||
| Supra-regional breweries | > 1.000.000 hl pa | ||
Along modernisations and extensions in capacity there are also new buildings – the Greenfield projects. Especially in the emerging markets complete new buildings are still performed.
Strategic decisions
When building a new plant the following decisions have to be reached:
Strategic and basic decisions |
Operating capacitiy
Especially the Greenfiled-project has no optimum in capacity. Often a brand has to be build up before the output grows organically.
If a brewery with an output of about 200,000hl a year is to be plant, for instance, capacities of the plant and the energy resources have to be designed accordingly. In the first month or years. Perhaps, the plant will be utilized in a low percentage.
Not to neglect the so-called peak, the monthly top value.Normally these monthly values are about 10 to 12 % of the yearly amount. However there are breweries, like for instance, they are strong depending on tourism or other regional facts, they decree over higher top values.
Basically intends: The specific costs – the costs of each produced unit – goes down with an increase of capacity. However the risk and the volume of the initial investment rise. The fixed costs – absolutely seen – are very high, even at a lower capacity.
Smaller companies don’t have access to some technological possibilities or they are not profitable for operating efficiency.
By building a bigger plant you accept a higher risk but you also have advantages: For example you can operate a 500,000 hl-brewery with about the same staff as you need for a 2-million-hl-brewery (this applies to the production only). Also the specific investment amount for each hectoliter-capacity will be reduced with a growth of the plant.
To reduce the risk and the initial investment, the upgradeability of the plant remains to be discussed.
Site eslection
Factors of the site selection |
Area space required
Specified conditions for area- and space requirements are hard to convert. The literature refers to several formulas for the specific area space required; however the actual data given are very individual and are for example dependent on the technological general conditions, output peaks, expandability and many other factors.
| Floor space required* | ||||
| Breweries – production only | ||||
| Pub brewery or microbrewery | 200 m² | |||
| 200,000-hl-brewery | 2.000 m² | |||
| 2,000,000-hl-brewery | 5.000 m² | |||
| Bottling lines | ||||
| 50,000 disposable-glass-bottles/hour-line | 500… 1.500 m² | |||
| 40,000 multi-trip-glass-bottle/hour-line | 1.500… 2.500 m² | |||
| 100,000 multi-trip-glass-bottle/hour-line | 2.500… 3.500 m² | |||
| Full pack and returned empties | ||||
| About once more the same area as the bottling line | ||||
| Office and administration | ||||
| Office and administration | 100… 2.000 m² | |||
| Outside facilities, access road etc. | ||||
| * All figures are just averages from diverse projects; the total range, depending on the project, can be much wider. | ||||
The required space for full pack and returned empties in particular, depends on the surroundings –the kind of store (storage technology for area or high shelves warehouses), the packaging, as well as the seasonal peak values and desired buffer capacities.
A general reference number for the total area space required is 1 hectare per 100,000 hl pa, that is to say 10,000 m2 per 100,000 hl pa.
Investitment amounts
In comparison with the area requirement, the amount of investment is higher depending on technological factors. Again in this case: the bigger the capacity the less the capital of each hl.
The bottling or filling is a major factor and the question of given possibilities. About 40 % of the total investment of technology are the average of the costs for the bottling.
| Amount to be invested (Engineering) * | |||
| Capacity | Investment | Investment per hl | |
| Microbreweries** | 1…5 Thl | 0,1…1,0 M€ | 100…200 € |
| Regional breweries | 200 Thl | 12…36 M€ | 60…180 € |
| Supra-regional breweries | 2.000 Thl |
25…120 M€ | 12…60 € |
*Averages |
|||
Operational decisions in case of a new building
Decisions should be reached on objective criteria. This is not alway easy to do. Especially at a “First Market Entry” some things can not be decided objectively. Furthermore the philosophy of the brewmaster or the investor is crucial.
Operational decisions |
Brewery Technology
The technolgical possibilities are manifold. Everybody has to reach his own philosophy from the combination of regional conditions and his ambitions. Following, please find a short and fragmentary overview of imprtant technological and procedural parameters:
| Brewery Technology | |
Basics |
|
| Brands and marketing: | - Product line and recipes |
General |
|
| General | - Degree of automation |
| Raw materials | |
| Water purification | - Quality and quantity |
| Malt and additives | - Raw materials |
Brewhouse |
|
| General | - Energy consumption |
| Mashing | - Single decoction mahsing |
| Filtration | - Lauter tun or mash filter |
| Boiling | - Boiling procedure |
| Hot break | - Type of separation |
| Cleaning | - CIP-system |
Fermentation and storage |
|
| General | - Cooling agent |
| Cooling and pitching | - Wort cooling |
| Cold break | - type of separation |
| Fermentation and storage | - Fermentation parameters |
| Cooling | - Fermentation to storage |
| Yeast management | - Supply and storage |
| CO2-Recovery | - Quality and quantity |
| Cleaning | - CIP-system |
Filtration and bottling tank cellar |
|
| Cooling | - Quick freezer yes or no |
| Separation | - Separation yes or no |
| Filtration | - quantity and quality |
| Stabilisation | - quantity and quality |
| Carbonisation and blending | - °Plato sales beer - CO2-contents |
| Bottling tanks | - tank parameters and assembly |
| Cleaning | - CIP-system |
| Supply facilities | |
Compressed air |
|
| Coldness | |
| Steam | |
| Auxilliary means and supplies | |
| General | - quality and quantity |
Quality Assurance |
|
| Production | - In/OnLine-measuring- and control-systems |
| Laboratory | - central or local quality assurance |
Waste water treatment |
|
| General | - quality and quantity |
| Note: without apsects of bottling ; without guaranty of completeness | |
Raw materials, auxiliary means and supplies
Following, a short list of the raw materials, auxiliary means and supplies which are needed. All the materials are not even listed complete, it is only for orientation.
Raw materials, auxiliary means and supplies* |
|
| per hl sales beer | |
Raw materials** |
|
| Water | 0,5…0,7 m³ |
| Malt | 14…16 kg |
| Hops | 4…8 g alpha |
Energies** |
|
| Electrical energy | 9…13 kWh |
| Heat energy/cooling energy | 120…160 MJ |
| Total energy-equivalent | 150…210 MJ |
Auxiliary means |
|
| Kieselguhr | 200…300 g |
| Silica gel | 50…100 g |
| PVPP | 20…50 g |
| Cleaning agents (caustic, acid, desi) | 150…250 g |
| By-products** | |
| Spent grains | 16…18 kg |
| Waste yeast | 2…4 kg |
| CO2 | 4,5 kg |
| There utilisable CO2 | 2,5…3,5 kg |
| Waste water | 0,4…0,6 m³ |
| Waste kieselguhr | 0,6…0,9 kg |
| Sludge | 3…5 kg |
*The figures are highly depending on the size of the plant and the technological procedures. Here we have listed averages. Especially the values for a microbrewery have not been covered; these are partly much higher. |
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Using other key figures in your plant? Your information will be treated confidential!
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