Malting Capstone Poster
2
CAPSTONE EXPERIENCE 2014 Micro Malt House Process & Design Dr. Martin Okos (ABE) Mr. Jim Mosely People’s Brewery Acknowledgemen ts Introduction Objectives Experimental Design Final Plant Design Economic Analysis Optimization Design Alternatives Clean: Used series of sieves to remove dirt and chaff. Steep: Performed 3 immersion cycles of 8/4 hours submerged and couching respectively. Changed moisture content (MC) from 8% to 45%. Temperature set at 20 or 25° C. Aeration performed every 4 hours. Germinate: Sprayed with water and mixed every 4 hours to maintain 45% MC and keep oxygen levels and water content high. Conditions held over a 2-4 day period while temperature was set at 20 or 25° C. Kiln: A fluidized bed dryer was used to decrease MC to 4% with 40 or 60° C, 1.5 m/s air. Testing: Hulls of seeds milled and submerged in 65° C water to stimulate release of sugars. Measured sugar content in Brix over 30 minutes. Final results adjusted for weight of malt and water used. • Create a process to produce high quality malt • Perform experiments to identify key variables in production to obtain a consistent and saleable product • Perform scale-up to meet malt demand for 1% of Indiana Malt Market (110,00 lbs. per year) at a competitive price • Provide useful information to Mr. Jim Mosely to create full scale operation • Water recycled from Clean and Steeping decreases waste. Water is also recovered from wet barley as the kiln dries them. • Plant matter is recycled as a high protein animal feed. • Equipment sizing and batch size have been selected to decrease operating costs and optimize revenue. • Equipment sizing allows for five times scale up with minimal additional equipment costs. • A locally processed malt product can fill two market niches by: • Providing local product for brewers and consumers • Providing infrastructure to connect local farmers and brewers in a sustainable economic relationship • Decreasing environmental impact • Increasing demand for craft brews: • Requires local material sourcing • Requires growth of craft brewing by ~18% per annum • Increasing demand for local products and environmental sustainability by: • Decreasing CO2 emission & pollution • Decreasing landfill use • Increasing reinvestment into local community • Increasing community involvement and pride • Clean: • Steam: High cost to purchase, storing tank would be more expensive due to pressure requirements, heating requirements offset by pumping requirements to maintain pressure • Cleaning agents: Lack recyclability, more costly than water • Germination: • Floor germination: Difficult to maintain moisture content and environmental control • Kiln: • Floor kiln: Increase difficulty in recapturing water • Single vessel: Increase in equipment cost for a unified design, careful scheduling can mimic benefits • Tank Design: • Single tank for cleaning and holding water: Increase in heating and cooling costs • Raw material cost: • $0.065 per lbs. feed barley • $0.095 per lbs. malt barley • Break even price: $0.20 per lbs. • $0.80-$0.90 for bulk purchase • Price for ROI of 20%: $0.83 per lbs. • Scaling up to 5x production yield ROI of 29% Costs (Annual) Amount Total Direct $11,130 Operating $5,686 Raw Materials $5,330 Total: $22,146 Tri al Steep Temperatu re Germinati on Time Germinati on Temperatu re Kilning Temperatu re 1 0 1 0 1 2 0 0 1 1 3 0 0 0 0 4 0 0 1 0 5 0 0 0 1 6 0 1 1 0 7 1 1 0 1 8 1 1 1 1 9 1 1 0 0 10 1 0 1 0 11 1 0 0 1 Method Tanks; $48,000. 00 Kiln; $30,000.00 Deculmer ; $10,000. 00 Pumps; $12,000. 00 Blowers; $5,000.0 0 Humidifi er; $500.00 Condenser $15,000.00 Equipment Breakdown Tri al Sugar Content 1 11.6 2 5.8 3 4.0 4 8.1 5 6.9 6 11.8 7 6.1 8 9.8 9 8.5 10 4.6 11 5.3 Pil ls 12.0 Pal e 9.7 Results Analysis Steeping temperature and germination time had the most significant effect on the final sugar content. The germination and kilning temperature had less effect than trial number. However, none are significant within a 95% confidence interval. • Problems • Several trials experienced contamination from the lack of an HTST cleaning cycle • Actual germination times deviated from planned schedule • Rootlet to seed length exceeded desired ratio Effect P Valu e T Ratio Steeping Temperatu re 0.08 81 Germinati on Time 0.11 32 Trial 0.21 83 Kilning Temperatu re 0.67 54 Germinati on Temperatu re 0.88 13 Background Direct Costs Amount Purchased Equipment delivered $125,500 Equipment Installation $56,475 Instrumentation and Controls (installed) $22,590 Piping (installed) $20,080 Electrical Systems (installed) $12,550 Building (including services) $31,375 Yard Improvements $18,825 Service Facilities (installed) $50,200 Total Direct Plant Cost $337,595 Working capital (15%) $87,850 Total Capital Investment $425,445 • Practice that dates back to ancient times • Process remains same • Current market is dominated by macro-malters • 20 companies own 70% of Market • Macro-malters hold a majority of patents • Equipment oriented • Macro-malting equipment/process is dissimilar to micro-malting • Malt is derived from the highest quality barley • Barley quality varies based on environmental conditions • Comes in varieties of 2 row and 6 row • Malt can be made from other materials such as: • Sorghum, millet, corn, wheat, and rice Total Equipment Cost: $125,500 Raw Barley Undesirable Agricultural Byproduct W ash W ater Barley Clean W ater Clean Recycled W ater Pum p 1 Holding Tank M oistAir Soiled W ater Condenser Dry Air Blow er Kiln Dryer Deculm ing M achine PlantM atter PlantM atter Final M alt Product Dry M alt Product Screen Pum p 1 M altTank Blow er Hum idifier Clean Tank CO2 Vibratory Screen W etAir Percent Material Inflow at Each Stage Barley Wate r Vibration al Clean 100 (12% MC) 0 Clean 100 (12% MC) 0 Steeping/ Germinati on 62.5 (12% MC) 37.5 Kilning 100 (45% MC) 0 Deculming 100 (4% MC) 0 Percent Material Outflow at Each Stage Barley Plant Matter Wate r Carbon Dioxide Vibrationa l Clean 95 (12% MC) 5 0 0 Clean 100 (12% MC) 0 0 0 Steeping/ Germinatio n 94.5 (45% MC) 4 0 1.5 Kilning 59 (4% MC) 0 41 0 Deculming 95 (4% MC) 5 0 0 • 1 day steeping • 4 day germination • 6.26 days per batch • 67.4 batches per year • 52 available weeks per year • 48 operating weeks per year Equipment Energy Use per Year (J) Humidifier 1.6*10 10 Condenser 4.4*10 8 Kiln 4.7*10 10 Blowers 2.0*10 11 Deculmer 2.6*10 8 Pumps 4.6*10 9 Total 2.7*10 11 Capital Investment Equipment Energy Use Scheduling
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An overview of a single, optimized malting process.
Transcript of Malting Capstone Poster
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CAPSTONE EXPERIENCE 2014Micro Malt House Process & Design Dr. Martin Okos (ABE) Mr. Jim Mosely Peoples BreweryAcknowledgementsIntroductionObjectivesExperimental Design Final Plant DesignEconomic AnalysisOptimization Design AlternativesClean: Used series of sieves to remove dirt and chaff.Steep: Performed 3 immersion cycles of 8/4 hours submerged and couching respectively. Changed moisture content (MC) from 8% to 45%. Temperature set at 20 or 25 C. Aeration performed every 4 hours.Germinate: Sprayed with water and mixed every 4 hours to maintain 45% MC and keep oxygen levels and water content high. Conditions held over a 2-4 day period while temperature was set at 20 or 25 C.Kiln: A fluidized bed dryer was used to decrease MC to 4% with 40 or 60 C, 1.5 m/s air. Testing: Hulls of seeds milled and submerged in 65 C water to stimulate release of sugars. Measured sugar content in Brix over 30 minutes. Final results adjusted for weight of malt and water used.Create a process to produce high quality malt Perform experiments to identify key variables in production to obtain a consistent and saleable productPerform scale-up to meet malt demand for 1% of Indiana Malt Market (110,00 lbs. per year) at a competitive priceProvide useful information to Mr. Jim Mosely to create full scale operationWater recycled from Clean and Steeping decreases waste. Water is also recovered from wet barley as the kiln dries them.Plant matter is recycled as a high protein animal feed.Equipment sizing and batch size have been selected to decrease operating costs and optimize revenue.Equipment sizing allows for five times scale up with minimal additional equipment costs.A locally processed malt product can fill two market niches by:Providing local product for brewers and consumersProviding infrastructure to connect local farmers and brewers in a sustainable economic relationshipDecreasing environmental impactIncreasing demand for craft brews:Requires local material sourcing Requires growth of craft brewing by ~18% per annumIncreasing demand for local products and environmental sustainability by:Decreasing CO2 emission & pollution Decreasing landfill useIncreasing reinvestment into local communityIncreasing community involvement and pride
Clean: Steam: High cost to purchase, storing tank would be more expensive due to pressure requirements, heating requirements offset by pumping requirements to maintain pressureCleaning agents: Lack recyclability, more costly than waterGermination: Floor germination: Difficult to maintain moisture content and environmental controlKiln: Floor kiln: Increase difficulty in recapturing waterSingle vessel: Increase in equipment cost for a unified design, careful scheduling can mimic benefitsTank Design:Single tank for cleaning and holding water: Increase in heating and cooling costs
Raw material cost:$0.065 per lbs. feed barley$0.095 per lbs. malt barleyBreak even price: $0.20 per lbs.$0.80-$0.90 for bulk purchasePrice for ROI of 20%: $0.83 per lbs.Scaling up to 5x production yield ROI of 29%
Costs (Annual)AmountTotal Direct $11,130Operating$5,686Raw Materials$5,330Total: $22,146TrialSteep TemperatureGermination TimeGermination TemperatureKilning Temperature101012001130000400105000160110711018111191100101010111001MethodEquipment BreakdownTrialSugar Content111.625.834.048.156.9611.876.189.898.5104.6115.3Pills12.0Pale9.7ResultsAnalysisSteeping temperature and germination time had the most significant effect on the final sugar content. The germination and kilning temperature had less effect than trial number. However, none are significant within a 95% confidence interval. ProblemsSeveral trials experienced contamination from the lack of an HTST cleaning cycleActual germination times deviated from planned schedule Rootlet to seed length exceeded desired ratioEffectP ValueT RatioSteeping Temperature0.0881Germination Time0.1132Trial0.2183Kilning Temperature0.6754Germination Temperature0.8813Background
Direct CostsAmountPurchased Equipment delivered$125,500Equipment Installation$56,475Instrumentation and Controls (installed)$22,590Piping (installed)$20,080Electrical Systems (installed)$12,550Building (including services)$31,375Yard Improvements$18,825Service Facilities (installed)$50,200Total Direct Plant Cost$337,595Working capital (15%)$87,850Total Capital Investment$425,445Practice that dates back to ancient timesProcess remains sameCurrent market is dominated by macro-malters 20 companies own 70% of MarketMacro-malters hold a majority of patentsEquipment orientedMacro-malting equipment/process is dissimilar to micro-maltingMalt is derived from the highest quality barleyBarley quality varies based on environmental conditionsComes in varieties of 2 row and 6 rowMalt can be made from other materials such as:Sorghum, millet, corn, wheat, and rice
Total Equipment Cost: $125,500
Percent Material Inflow at Each StageBarleyWaterVibrational Clean100 (12% MC)0Clean 100 (12% MC)0Steeping/ Germination62.5 (12% MC)37.5Kilning100 (45% MC)0Deculming100 (4% MC)0Percent Material Outflow at Each StageBarleyPlant MatterWaterCarbon DioxideVibrational Clean95 (12% MC)500Clean 100 (12% MC)000Steeping/ Germination94.5 (45% MC)401.5Kilning59 (4% MC)0410Deculming95 (4% MC)5001 day steeping4 day germination6.26 days per batch67.4 batches per year52 available weeks per year48 operating weeks per yearEquipmentEnergy Use per Year (J)Humidifier1.6*1010Condenser4.4*108Kiln4.7*1010Blowers2.0*1011Deculmer2.6*108Pumps4.6*109Total2.7*1011Capital InvestmentEquipment Energy UseScheduling
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