BROOKLYN BREWERY, NEW YORK – Are Safe, Economical and Repeat- While Being Mindful of the Retail Able
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by Eric Ottaway (Brooklyn Brewery) & Joachim Gunkel (BeerBev LLC) In order to produce beers at the out- We found in BeerBev a partner standing level of Brooklyn Brewery who could bring the utmost in all these raw materials and proces- efficient brewery design, minimizing ses have to be handled in ways that both capex and operating costs, BROOKLYN BREWERY, NEW YORK – are safe, economical and repeat- while being mindful of the retail able. consumer experience and design aesthetic. – Eric Ottaway PLANNING AND DESIGNING A UNIQUE PLANNING FOR THE FUTURE CRAFT BREWERY BeerBev, known for not following To keep up with growing demand conventional paths of standardi- Brooklyn Brewery has teamed up zed brewery solutions was naturally The chances are high that you have heard or even tried the with the brewing, consulting & the partner of choice for Brooklyn beers of Brooklyn Brewery. From its humble beginning in 1988 engineering specialist BeerBev LLC Brewery for independently exploring it took the brewery 22 years to get to 100,000 sold barrels per to jointly develop, plan and design and defining tailor-made innovative a unique craft brewery in a histo- and cost effective solutions for this year, but after this only three years were needed to break the ric industrial building in Brooklyn, challenging project. annual production mark of 200,000 barrels. Currently Brooklyn New York. Brewery is producing 260,000 barrels and their famous beers BeerBev’s scope went beyond In cooperation with Brooklyn are to be found in restaurants, bars, and retailers across 26 U.S. The project scope included the technical and technological solu- Brewery BeerBev defined planning and execution of the vari- tions and included amongst other states and in 20 countries. The stellar growth of this craft the following main project ous design stages while taking into things also the provision of informa- brewing pioneer is based on the dedication of its founders objectives for the new brewery: consideration different locations tion and data required by the local to brew the best beer possible, on consumers giving and brewery specific requirements, authorities for project approval. It • Flavor match with the existing preference to craft beers over existing main stream brands, providing capacity and flexibility for also included the development of brand portfolio on its commitment to the Brooklyn neighborhood, the future expansion as well as consu- an architectural design concept that • Highest flexibility to expand rejuvenation of Brooklyn, and also on the rise of social media Majority owners Eric (left) and Robin Ottaway flank co-founder mer experience topics including an ensured an appealing integration the future brand portfolio inclu- and using this media to its fullest potential. Steve Hindy. Photo: Buck Ennis attractive architectural design. of the new brewery in the historic ding the ability for small batch architecture of the chosen building. production between 50% and 100% of total brew size In order to achieve such an acco- wer honey, Belgian candi sugar, and INDIVIDUAL SOLUTIONS FOR A PIONEERING BRAND VARIETY lade the processes at the Brooklyn sweet orange peel are introduced UNIQUE PROJECT • Ensuring that the overall Brewery are highly innovative and into the process. Furthermore these brewery design fits in well with Since its beginning, Brooklyn complex and this is reflected in their beers are 100% bottle re-fermented. It was clear to Brooklyn Brewery that the historic building and that Brewery has brewed full flavor beers: common industry standard solutions the state-of-the-art brewery beers that enrich the quality of life, Already the flagship beer, Brooklyn would not achieve the desired project would be built for maximum tradition and culture of the commu- Lager, uses the increasingly com- goals and objectives, because brewery production efficiency and nities it serves. Its award-winning mon technique of dry hopping – specific, complex parameters had to capacity roster of year-round, seasonal and adding hop cones or pellets to the be considered right from the start. • Ensuring that future project specialty beers have gained the fermenter or storage tank in order to expansions could be carried Brewery notoriety as one of the top extract the hop oils without adding out in different phases without craft beer producers in the world. bitterness. The Brooklyn Dry Irish interrupting production Stout requires the use (and milling!) • Highest production, operation In our portfolio you’ll find more of unmalted barley. The traditional and energy efficiency traditional styles – Lagers, IPAs, Pumpkin Beer Post Road is made Stouts, Weisse beers, Saisons – but using hundreds of pounds of pump- • An environmentally friendly and kin and nutmeg. green brewery design also beers that explore both new • Visitor friendly design and forgotten techniques, such as And when we turn to the real 100% bottle re-fermentation, barrel specialties like Local 1 and Local 2, • Equipment to be manufactured aging, and the use of wild yeasts both Belgian inspired strong Ales, locally as much as possible, in such as Brettanomyces. natural ingredients like demerara the U.S.A – Eric Ottaway cane sugar from Mauritius, wildflo- During the engineering phase • Minimizing losses in each area CHALLENGE APPROACH BeerBev input its vast experience • Energy consumption calculation FRUITS OF LABOR and know-how for the benefit of the of 73 MJ /bbl Being aware of the complexity and project – a contribution which often By applying its unique holistic pro- • Minimization of headcounts uniqueness of the project, Beerbev went far beyond standard solutions. ject approach, BeerBev was able to due to optimized operation and first took the time to listen and optimize each area of the brewery automation discuss the project in detail with BeerBev’s attention to even producing the most efficient and Brooklyn Brewery to get a thorough the smallest details combined effective brewery performance and understanding of the Brewery’s with its innovative and holistic We found BeerBev’s suggested so- operation, minimizing energy and project goals and objectives. project approach had a big impact, lutions to be very innovative, often water consumption, as well as redu- as shown by the following examples: challenging standard assumptions, cing losses. Beerbev reviewed and examined • Heating device in the mashtun and proposing unique ideas. brewery specific technologies and The comprehensive documentation designed for 30° Plato and – Eric Ottaway techniques, and also examined many and decision support provided by 13° Plato mash types other parameters such as brand BeerBev enabled Brooklyn Brewery variety, extract targets, production • Consideration of special mash Following the value engineering ex- to get a clear overview of the in- • Integration of existing • Utilization of solar power to relevant ingredients, fermentation pumps ercise, BeerBev provided Brooklyn vestment required for each phase equipment generate electricity and storage time, applied hopping • Increase in whirlpool capacity Brewery with a comprehensive including opportunities to shift in- • Tank farm: fermenting, storage • Green brewery concept design procedures such as dry hopping or due to higher trub volume from documentation containing technical vestments between phases, and or combi tank, open or closed cone hopping, clarification time up to • Green building design hop usage specifications, layouts, construction showed CAPEX savings of up to filling, and also packaging parame- process drawings for local manufacturing, 20% • Automation level • Brew size that can handle ters which included brand specific • CCT dimensioning for 0.5 P&ID diagrams, process descrip- volumes between 60 to 120 bbl / secondary packaging requirements brews, 1-2 brews, 4 brews etc. tion, budget prices, and tender brew to ensure that the filling, packaging documents. Working with BeerBev we came up and warehouse requirements were • Hop dosing systems • Energy savings of up to 60% with an extremely advanced design fully understood and considered • Energy recovery system in the brewhouse that would allow us to be both very to enable an optimum and holistic • Hot water or steam heating for project solution. CRAFTED SOLUTIONS • Water consumption of only efficient and innovative at the same vessels 2.7 bbl per bbl sales of beer time. We could not have completed • Kieselguhr-free filtration In order to provide Brooklyn Brewery the project without them. We spent a significant amount technology versus kieselguhr with the appropriate decision- – Eric Ottaway of time reviewing all of our filtration making tool, BeerBev developed requirements in excruciating detail a specific “decision support note” • Beer recovery from yeast and to make sure that everything was for each of the above mentioned www.beerbev.net | [email protected] sediments taken into account – Eric Ottaway topics, Besides presenting a techni- • Applicable filling and cal and technological evaluation packaging technologies and production impact Beerbev also • Recycling of caustic, acid and included a costing overview and In close cooperation with disinfection comparison regarding investment Brooklyn Brewery, Beerbev costs (CAPEX), operational costs defined the following topics • Refrigeration plant operation (OPEX) as well as Total-cost-of- as value engineering areas: with NH3 or glycol multi-stage Ownership (TCO) for selected cascade system • Developing different capacity equipment, technologies and pos- models to cover the Brooklyn • Wastewater handling: sible alternatives Brewery’s sales volume is it necessary to build a wastewater treatment plant For investment overview purposes projections ***** or can waste-water be BeerBev developed a detailed bud- THE BEST INGREDIENTS • Milling system: conditioning, discharged into the municipal get overview considering: TO REALIZE YOUR wet, or dry milling BREWERY CONCEPT sewer system • Purchasing price of equipment • Brewhouse sizing: • Co–generation plant in • OPEX saving (incl. head count) one or two brewhouses combination with absorption • Energy cost saving DON‘T WORRY – KEEP BREWING! refrigeration plant • ROI calculation BEERBEV PROJECT SOLUTIONS • TCO calculation.