Program Book - Master Brewers Association of the Americas

P-104
Understanding the value generated from achieving tighter
temperature control of process water through the use of new
technology
NIGEL BARTLETT (1)
(1) Emech Control Limited, Auckland, New Zealand
Reducing process variability was highlighted in a 2001 ARC
study as a focus for maximizing in the future. Process variability
surrounding the use of water, the most precious resource, has
gained attention in the triple bottom line economy as the true
cost of water is understood. The paradox that businesses face is
that many manufacturers frequently install the latest technology
for control systems, yet insist on antiquated valve technology in
processes because “if it isn’t broken, why fix it”? Little has changed
in the process of blending water, with an acceptance of 30 year
old valve design, pneumatically actuated, externally controlled
using independent monitoring and control logic. Incremental
improvements in components have delivered little change in process
performance. Recent developments in shear action swirl mix
valves, combined with high resolution electronic actuation and fast
response temperature probes, enable true high speed closed loop
control. This fundamental step change in performance can deliver
sustainable value to organizations in water, energy and maintenance
savings. These new valves have shortened the mixing zone from what
was accepted as 8 to 15 pipe diameters from the outlet of the valve to
the point of monitoring to complete mix at the valve. This reduction
provides value in both reduced volumetric quantity variance, as well
as improved time function. Traditional pneumatic actuation relies
on assumed constant air pressure and quality, maintained through
energy intensive compressors, driers and maintenance intervention.
Electro pneumatic positioning has improved, but is still reliant on
assumed air pressures and quality. Technology is now available in
the form of high speed and resolution electronic stepping motors
combined with high torque planetary gear trains that provide
speed equal to pneumatics, but resolution and accuracy that is
unmatched. High speed, negative temperature co-efficient NTC
probes that deliver greater accuracy than resistance temperature
detector (RTD) probes are now integrated as part of these actuator
and valve packages, including configurable closed loop temperature
control software, and deliver a new a standard of accuracy. The cost
of process variance to companies is apparent in a number of forms,
both tangible and tacit. The direct cost of water and the gas bill
are tangible measures. The cost of wasted energy can be calculated
using the specific heat equation and can be observed in many control
rooms as the area under the actual line on temperature monitoring
graphs that is above the temperature set point. Innovative use of
technology to reduce the use of resources will drive robust economic
growth and meet sustainability demands into the future.
Nigel Bartlett graduated with an engineering degree from the
Auckland University School of Engineering in 1996, studying
operations research and process engineering. He began employment
as a process engineer with Fletcher Challenge Limited in 1996 and
spent a number of years in process improvement projects combined
with operations management. Redundancy in 2000 meant a change
in industry with a move to capital project sale and execution for
Westfalia Separator NZ, part of the multinational GEA Westfalia
Separator group. Here Nigel was fundamental in designing and
implementing process upgrades for a number of the brewing and
winery sector companies in New Zealand that delivered quality
improvements combined with waste and energy reductions. A
MBA from the University of Waikato in 2005 provided additional
skills to articulate from a business sense the true value in process
improvement with particular regard to water and utility savings.
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Nigel is the vice president sales and marketing for Emech Control and
is responsible for project design, sales management, and execution
for Emech technology. Emech is a New Zealand-based leading
technology provider that assists manufacturers to meet consumer and
regulatory demands to ensure that processes have as little impact on
the environment as possible.
P-105
Sustainability practices in brewing and packaging—Impact of
sanitation programs on overall water consumption
JOSEPH DIRKSEN (1)
(1) Ecolab Inc., St. Paul, MN
Many brewers monitor the ratio of water consumption to beer
production as a measure of process efficiency. CIP cleaning and
sanitizing accounts for a significant portion of the water used in
brewing operations. This paper will review water consumption at
several large breweries. It will compare sanitation-related water
consumption in brewing and packaging. Recommendations are
made to optimize water consumption in cleaning and sanitizing,
through innovative cleaning chemistry, CIP programming and
engineering.
Joe Dirksen is senior technical coordinator for Ecolab Inc., Food
and Beverage Division. He is responsible for technical support to
the beverage, bottled water, and brewery markets. Joe has been
associated with Ecolab for 28 years in a variety of technical,
marketing, and sales positions, including product development
chemist, international R&D manager, beverage marketing manager,
and beverage corporate accounts. Joe has a B.A. degree in chemistry
from St. John’s University, Collegeville, MN, and a MBA from the
University of St. Thomas, St. Paul, MN. Joe is a member of the
International Society of Beverage Technologists (ISBT) and chair
of the ISBT Sanitation and Microbiological Control Committee.
Joe is also a member of the MBAA and ASBC. Joe is a certified food
safety professional through the National Environmental Health
Association.