Sustainability: Eking out Capacity.

1. Sustainability: Eking out Capacity. Friday April 24, 2009 Craft-brewers conference Boston, MA, USA.

2. Green or Sustainability, relevant ? • 74 % of Americans think global warming is serious. • Consumers say green is important in making key decisions: • Products they purchase, (79%) • Where they shop, (74%) • Where they invest their money, (72%) • Would do more for the environment if they only knew how (49%) • More than 70 % of Americans are willing to pay more for organic food. (market research)

3. Creativity & Flexibility, relevant ? • craft brewing => public has a desire for interesting, unique tasteful beers. • craft brewing industry in the US => refreshing, less limited by rules more driven by an organic desire for new “interpretations” of interesting flavors & styles. • “extreme” brewing => exploring the boundaries of brewing and beverages, continuing an old “belgian” tradition of innovation. • Interesting beers • Ability to brew with new ingredients, new techniques => flexibility to be creative. • Titel 1.1.1

4. Design => intelligent combination : • available technology, • geographic smart choice, • acknowledge your brewing reality, • match your desire and innovative ambitions, • Sustainability, Flexibility & Creativity => not mutually exclusive. • Intelligent design will result in interesting beers, brewed with new technologies while socially & environmentally respectful and economically feasible.

5. New Brewery model => reality ?

6. New Brewery model => reality for US craft brewers ?= > European brewery of 850.000 sales beer. • Product mix => review the complexity of brewing. (wort streams, limited amount of beers, SKU’s) • Automation & Education => what is the skill and knowledge level of the staff, what are the tools for the staff => the automation level. (overall process automation, level of operator intervention) • Brewing technology => how is the brewery being run ? • High Gravity Brewing, • Weak wort recovery, • Centrifuge technology, • Fob tanks & Flash pasteurization draft beer,

7. Technology => what is right for my brewery ? • Subjective elements => elements of how you brew that are crucial to the taste and flavor, that are more important then their technical relevance. => yeast strains, spices, whole hops versus pallets, how you dry-hop, aging in wood, …. • Ambition to improve, to make you brewery more efficient, willingness to look at new things, to make a mistake. => boiling time, pitch rates, water sources, filtration technologies, … • Courage to manage a healthy tension between the art and science of brewing, the duet between the cook and the chemist.

8. What can we do to towards capacity ?(optimize brewing capacity) • Brewing bottle necks, where can we save time in the brewing process, • CIP procedures, loss & recovered CIP plant • Heating & cooling rates: mashing, fermentation ? • Quality control checks => release product ! • Brewing innovation, where can new technology improve brewing process, • Raw materials: malt & barley types, • Equipment: i.e. filtration & clarification technology, • Equipment: i.e. wet conditioned milling • Equipment: i.e. in line carbonation • High Gravity Brewing, increase brewing capacity with HG brewing, • Co-Brewing, use an other’s brewers facility.

9. Brewing bottlenecks • Milling technology => wet conditioned milling, • Increased lauter bed loading => 250 kg/m2 (12 brews) vs. 180 kg/m2 (12 brews for dry milling. (existing lauter tun => increase brews/day !) • Quality improvements : transfer without oxygen pick-up. • New construction: reduction in building cost : explosion proof conditions (referred to in Europe by the ATEX rules). • Mill => treated as a “ vessel “ for CIP purpose,. • Boiling => reduced boiling times, • Reduced evaporation rates => 8 % to 3-4 % • Quality improvements : TBA parameters, foam stability (soluble protein). • Sustainability => reduced energy consumption. • CIP => availability of equipment (tanks, piping, filter) => can you get all your equipment clean when it comes available ? • In-line carbonation => BBT’s occupancy time.

10. Brewing innovation: wet conditioned milling of malt

11. Brewing innovation : shorter boil time with energy recovery. (reduction of kWh/ boil => time & technology).

12. High Gravity Brewing • Brewing at a higher gravity then sales gravity, correcting ( with de-aerated water) to sales gravity post or pre-filter. • Opportunities: • Increase in brewing capacity, • Fermentation capacity, smaller tank volume, • Filtration capacity, smaller hourly filtration rate needed, • Increase in sustainable performance; water use & energy consumption ; i.e. requirement for 100 hl sales beer : • 12,5 Pl => 106 hl CW (x 8.36 kWh/hl) => 886.16 kWh • 15 Pl => 102 hl filtered beer => 83 hl beer + 19 hl water => 90 hl CW (x 8.36 kWh/hl) => 752 kWh savings of 19 % in energy per brew. • Challenges: • Taste profile => i.e. dry-hopping, even hop profile. • Production de-aerated water.

13. Co-Brewing • Brewing & packaging your beer at a facility-brewery other then your own, co-brewing your beer with an other brewer. (difference contract brewing => pay a fee/bbl for somebody else to brew & package your beer). • Opportunities: • Utilization of available capacity at an other brewer’s facility, • Opportunity to learn from other brewer, • Opportunity to produce closer to your market, • Challenges: • Creating a mutual working agreement : practically, legally, … • Use of different brewing techniques, i.e. yeast strains, malt, … • Managing the brewing of competing brands, • Staying involved – exchanging ideas.

14. Final thoughts • Sustainable => the most sustainable thing to do is to brew more beer with the facility you have => profitability is better. • Creative => more then making great beers, consider how you make your beers. • Cooperative => look at some other breweries. • Innovative => critical for the industry, critical for your brewery, important to try some of the new technologies.

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