MBAA Rocky Mountain Out-of-towner 2008 Troy Casey MillerCoors 9.20.2008.
MillerCoors Golden Brewery Sustainability Improvement . Energy Water Waste to Landfill
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Transcript of MillerCoors Golden Brewery Sustainability Improvement . Energy Water Waste to Landfill
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MillerCoors Golden MillerCoors Golden BreweryBrewery
Sustainability ImprovementSustainability Improvement.
EnergyWater
Waste to Landfill
Julie Smith, PE, MSPlant Optimization EngineerUtilities/Technical Services
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Agenda• Corporate Goals/Leadership• Brewery Processes • Brewery Utilities• Opportunities• Waste to Landfill• Culture
Brewery Sustainability ImprovementBrewery Sustainability Improvement
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Corporate Sustainability GoalsCorporate Sustainability Goals
Energy Usage of 128 MJ/HL by 2015 Electricity Steam Vehicle Fuel
Water Usage of 3.5 HL/HL by 2012 Zero Waste to Landfill by 2015 CO2 Self-Sufficiency of 85% by 2015 50% Reduction in Green House Gas by 2020
Why Sustainability?• Customer Demand• Continue our Business• Save Money• Marketing• Responsibility for Future Generations!
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Brewery Process OverviewBrewery Process Overview
Malting
Brewing
Fermenting
Conditioning
Packaging
Warehousing
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Golden Brewery MapGolden Brewery Map
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Golden Brewery LayoutGolden Brewery Layout
Aging Cellars, Hop Storage
Malting/Kilns
Packaging/Warehouse/Gov. Cellar
Fermenting
Conditioning
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Brewing ProcessBrewing Process
• Mash In• Filter/Lauter• Boil Wort• Chill• Ferment
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FermentingFermenting
• Yeast + Wort = Beer• Maintain
Temperature• Residence Time• CO2• Yeast• To Aging
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ConditioningConditioning• Aging• Filter• Blend• To Packaging
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PackagingPackaging• Bottles, Cans and Kegs• Rinse• Fill• Label• Package• Palletize• To Warehouse
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WarehouseWarehouse
• Store Product• Move Product• Temperature• Docks
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Utilities for Brewery OperationsUtilities for Brewery Operations
Power Plant – Co-Generation Coal and Natural Gas Fired Boilers
• 800 LB Steam1) Electricity2) 400 LB Steam3) 50 LB Steam
Ammonia• Steam• Electricity
Plant Air• Steam• Electricity
Water Treatment• Electricity
Wastewater Treatment• Electricity
CO2 Recovery• Electricity
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Utilities – Map of Valley
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Utilities – Where does the Steam Go?
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Resource Savings Opportunities
Steam
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Steam Savings Opportunities Steam Savings Opportunities “Low Hanging Fruit”
Leaks Traps Control Valves Pressure Relief Valves
Process Optimization/Team Work Compression Equipment Operation Problem Solving Metering - Short-Interval Control Set Points CIP Times Quality/Efficiency
Projects HVAC Plant Air Refrigeration Brew Kettles
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Plant Air Usage - 2011
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Plant Air OpportunitiesPlant Air Opportunities Leaks Operations
Compression Equipment Set Points
Small Projects Cabinet Cooling/Pressure Venturi Vacuum Low Pressure Uses Condensate Drains Pneumatic Valves and Equipment
Large Projects Decentralization Distribution Headers
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CondensateCondensate
Return Benefits Cost Energy Waste Treatment Water Treatment
Where is it Going? Sewer Stack Steam Leaks
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Utilities – Where does the Electricity Go?
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Resource Savings Resource Savings OpportunitiesOpportunities
Electricity
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Electricity Electricity Savings Savings OpportunitiesOpportunities
Culture Lights Office Equipment Phantom Energy
Process Optimization/Team Work Metering/Short Interval Control CIP Times Pump Control Hard Shut-Downs Operating Strategy Water Usage Quality/Efficiency
Projects Lights Pump VFD’s Controls Equipment Right-Sizing
Facilities Lights HVAC Insulation
No!
Yes!
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Electricity Savings OpportunitiesElectricity Savings OpportunitiesMalting Lights ResultsMalting Lights Results
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Electricity Savings OpportunitiesElectricity Savings OpportunitiesBOC HVAC Recommissioning ResultsBOC HVAC Recommissioning Results
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Electricity Savings OpportunitiesElectricity Savings OpportunitiesPackaging Green Shut-DownPackaging Green Shut-Down
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Utilities – Where Does the Water Go?Utilities – Where Does the Water Go?
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Resource Savings Opportunities
Water and WastewaterWater and Wastewater
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Savings Opportunities – Water and WastewaterSavings Opportunities – Water and WastewaterSave Water = Save Energy!
“Low Hanging Fruit” Leaks Controls Nozzles
Team Work/Process Optimization Problem Solving Broom Not Hose CIP Times Cleaning Machines Dry Lube Seal Water Quality/Efficiency
Projects• Re-Use
Once-Through Cooling Water Empty Can Rinse Water Reject Can Conveyance
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Waste to LandfillWaste to Landfill Currently ReUse or Recycle >98% of Total
Waste• Spent Grain• Yeast• Ethanol Still• Glass• Cans• Single Stream• Industrial (Paper, Cardboard, Stretch Wrap, Metal)
Still, 100 Ton/Month to Landfill (2010)• Goal – Zero Waste in 3 years (or pretty close)• Sort, Label, Color Code• Optimize Collection• Source Reduction
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Co-Products Golden BreweryCo-Products Golden BreweryBill Coors: “Waste is Just a Resource Out of Place”• Yeast – 12 MM LBS/year• Fuel Grade Ethanol – 2.5 MM gal/year • Spent Grain – 400 MM LBS/year
• All sold locally• Grain Dust
• Malting• Malt Storage• Grain Load-Out• Brew House
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Pavilion at Investment Recovery
Employee Sales / Beer Trailer
YOU’RE INVITED TO HELP US MAKE AN IMPACT!
As a first step to make the Golden Brewery “The Largest Zero-Waste-to-Landfill Brewery in the World”,
we need your help to:
•sort recyclables from the trash created at the brewery•paint examples of our new standardized color-coding system of lugers/dumpsters•draw up facts about trash and recycling at our brewery to create a great display
RSVP on the Volunteer Website (https://www.millercoorsvolunteers.com)
What: Operation Zero Waste CARE & Volunteer Event
When: Thursday, Sept. 15th Sorting: 7am – 8:30am
8:30 am – 10am Visit and learn: 1pm – 4pm
Where: Pavilion at Investment Recovery
What to bring: Pants, long sleeved shirt, PPE (bump-cap, steel-toes, safety-vest, and Kevlar gloves)
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Culture and PeopleCulture and People
What is Culture?
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Culture – What is Culture?Culture – What is Culture?
Definitions: 1.The quality in a person or society that arises from a concern for what is regarded as excellent in arts, letters, manners, scholarly pursuits, etc.2.That which is excellent in the arts, manners, etc.3.A particular form or stage of civilization, as that of a certain nation or period: Greek culture.4.Development or improvement of the mind by education or training.5.The behaviors and beliefs characteristic of a particular social, ethnic, or age group: the youth culture; the drug culture.
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CultureCultureElements for SuccessElements for Success
Leadership Green Teams Education Communication Recognition Projects Score Cards
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Culture – Green TeamsCulture – Green Teams
Golden Green Team – CAREGolden Green Team – CARE““Committed to Active Responsibility for the Environment”Committed to Active Responsibility for the Environment”
• Established 2006• Lunch and Learn Education• Recycling• Brown Bag Movies• Movie Library• Volunteer Opportunities
• Clear Creek Watershed• Recycling Audit• Holiday Meal – Zero Waste Bin Stewards
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Golden Brewery Golden Brewery Sustainability Results - 2011Sustainability Results - 2011
Golden Brewery 2011 Energy and Water Reduction – Most Improved of All Breweries!!
• Reduced Total Energy by 11.9%• Reduced Water by 4.5%• Reduced Waste to landfill by 17%
MillerCoors Total Reductions – All 8 Breweries• Reduced Total Energy by 3.4%• Reduced Water by 0.9%• Three Zero-Waste Breweries