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A Giant Reborn Huge New Investment at Guinness in Dublin Stream Krones Brewhouse (Brew- Dition and Modernity at the 255-Year House No

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A Giant Reborn Huge New Investment at Guinness in Dublin Stream Krones Brewhouse (Brew- Dition and Modernity at the 255-Year House No Brewery profile Interior of the new Brewhouse No.4 in St James’s Gate Brewery A giant reborn Huge new investment at Guinness in Dublin stream Krones brewhouse (Brew- dition and modernity at the 255-year house No. 4) and an extension to the old site. He explained that the total Fermentation and Beer Processing brewery output was currently seven Plant. The extension is called the million hL of beer annually and that New Cold Block (NCB), and is used the new brewhouse had expanded primarily in the production of Dia- the capacity of the site by about geo’s own ale and lager brands such 40%. Guinness stout continues to be as Harp and Kilkenny, as well as the main product with about five beers brewed under licence such as million hL produced annually along Budweiser and Carlsberg. Expansion with 1.5 million hL of lager and 0.5 of grain handling and utilities gener- million hL of ale. ation and distribution has been an in- Of the £2.3 billion of beer sales tegral part of the development. About within Diageo, the St. James’s Gate 40% of the total investment was brewery supports £1.7 billion in fin- Right to left: Paul Guinness at St. James’s spent on the new brewing facilities ished product – supplied directly Armstrong, Diageo’s Gate in Dublin has been Beer Supply Director and about 35% on the cold block from the site or by its Guinness speaking to Irish around so long that it has with 27 new fermentation and matu- Flavour Essence (GFE) concentrate Taoiseach (Prime become almost synony- ration vessels to handle the addi- business – which is exported to over Minister) Enda Kenny, mous with the city itself. tional capacity. The extra vessels 50 countries worldwide. In addition along with Diageo Chief were sourced from Holvrieka in Hol- to Guinness, the enlarged brewery Executive Ivan Since its foundation by Menezes, at the official Arthur Guinness in 1759 land and were installed and inte- also produces Carlsberg, Budweiser, grated with the existing plant by Harp, Tuborg and Satzenbrau lagers opening of the new it has rung the changes developments in St. GEA Ireland and GEA Europe. The along with Smithwick’s and James’s Gate. wrought by technological grain intake and handling element Kilkenny ales. New innovative stout developments in every was awarded to local provider beers have been recently produced era, but no change has Buttimer Ireland, who fought off for select markets and even in the been as profound as very able competition from some middle of an exceedingly busy com- what has happened in well-known international groups. missioning schedule time, space was the northern section of found to deliver these new products. Brewery overview Seventy-five per cent of the its 57-acre site in the last I met with Paul Armstrong, Supply brewery’s output is exported. The 18 months. Director, Brewing, at Diageo’s In- existing GEA Till kegging plant at ternational Supply Centre based at St. James’s Gate packages approxi- by Gerry McGovern St. James’s Gate, who put into con- mately 60% of the beer produced. text just how important the site and The remainder is transported to Dia- iageo, Guinness’ parent com- the development was for the Diageo geo’s packaging plants at Belfast in Dpany, has just completed con- parent in an overall sense. Paul told Northern Ireland and Runcorn in struction of a €169 million me that St. James’s Gate is one of England for filling into cans and bot- state-of-the-art brewhouse and brew- the oldest industrial sites in Ireland tles. Beer from St. James’s Gate is ery extension, with a brand-new 3- and Brewhouse No. 4 combines tra- shipped three times each day from 28 Brewer & Distiller International • November 2014 • www.ibd.org.uk Brewery profile now on the city’s tourist trail. The through Krones’ Steinecker off- Waterford site is currently approach- shoot, whose technology is now at ing conclusion of a sale, and an an- the heart of the new brewhouse. nouncement will appear soon. Production in Dublin is currently Project implementation run by a core team of 130 people but overview St. James’s Gate is also the head- I met with David O’Leary, Director quarters of Diageo Ireland so a total of Diageo Engineering Excellence, of 834 people are employed on the who gave me a brief outline of the site. In Ireland, over 1100 people in re-birth project, and covered all as- total are employed by Diageo. This pects of its progress from planning Dublin Porter and West Dublin city centre site also incorpo- permission to the final official open- Indies Porter, two of the rates the Guinness Storehouse – Ire- ing in September 2014. innovations brought to land’s number-one visitor attraction David began by saying that in his market in the last six Ray Langton, Brewing and months. Operational Project Director. welcoming over 1.1 million visitors experience he had never seen a project per annum. This number is increas- of this size managed and completed in ing 10% year on year. such a speedy time window. He em- phasised just how tight the project Brewery heritage time-lines were, with only 14 months Diageo was keen to maintain all as- from achievement of planning permis- pects of the long and excellent sion to the start of brewing trials in the brewing heritage of the Guinness first of the three brew streams in June site, according to Ray Langton, 2013. The Diageo board tasked his en- Brewing and Operational Project gineering team, along with the pro- Director, and Brewhouse No. 4 is duction teams, with delivery of key the latest expression of this heritage. project requirements. The incredibly The first brewhouse was in- ambitious targets presented to them stalled by Arthur Guinness when he included, among others: took out his 9000-year lease on the • Lowest Overall Costs site in 1759 and was very much a • Zero accidents during construction David O’Leary, Director of Diageo Below: GEA Till kegging Engineering Excellence. child of its time, with wood the pre- • Highest environmental standards line at St. James Gate… dominating material for beer tank • Low cost building, showing one of the Dublin Port to Runcorn in 300hL construction and with manual labour - Yet presenting an appropriate cor- many SKUs being road tankers. Runcorn also kegs beer the main way to get work done. porate image befitting Diageo’s handled by the line… in for the British market and supplies Later, in the Industrial Revolution latest flagship production unit this case 20-litre export markets with canned and bot- years of the 1870s, Guinness in- - And befitting the links between Guinness kegs for Japan. tled product. The new Guinness stalled what was then a revolutionary the site and the capital city it re- Bottom: 300hL road Flavour Essence plant enables the brewhouse – incorporating the then sides within tanker adjacent to production of a further seven million famous Spence Kieves (Mash Tuns) David also told me that the overall Brewhouse No. 4 hL of Guinness in overseas brew- – and heralded in an era when indus- success of the project was due in no Entrance Lobby. eries. Roasting of barley for beer trialisation transformed the world. A and GFE production is carried out at third, fully-automated brewhouse the existing plant on the St. James’s was on-stream in the 1980s, the core Gate site. Three Barth roasting ma- of which were stainless-steel vessels chines run round the clock in an en- made by Balfours of Fife, Scotland, deavour to match production and later modified by Huppmann of demands, targeting 360 tonnes each Germany. Arguably this brewhouse week and plans are in place to install was associated with the era of au- a fourth roaster early in 2015. tomation, where remotely-controlled The decision by Diageo to cen- activities with PLC and networked tralise all Irish brewing activity at computers were the order of the day. St. James’s Gate resulted unfortu- In the twenty-first century, the nately in the closure of the fine Dia- main driver for this newly-trans- geo brewery sites at Kilkenny, formed brewery has been the over- Dundalk and Waterford. whelming need for sustainability. I wrote in detail last year on the Diageo’s former brewing assets Dundalk site, the Great Northern spread over the island of Ireland Brewery, just before it closed. How- were simply unsustainable, even in ever, as Paul explained, these sites the medium term. The consolidation have a new lease of life under new of all production on a site smack ownership. The Dundalk site has bang in the middle of the biggest been sold to Mr John Teeling’s Irish local market became an obvious ne- Whiskey Company distilling enter- cessity. The impact of increased vol- prise and will soon become the Great umes and modernisation of Northern Distillery. The Kilkenny equipment has led to a huge im- city site has been sold to Kilkenny provement in utility ratios, of which City Council, and Diageo invested more later. £3 million in the newly-opened A fresh instalment of Guinness’ Smithwick’s visitor centre which is brewing heritage has now begun Brewer & Distiller International • November 2014 • www.ibd.org.uk 29 Brewery profile were dispatched to land fill during Project partners and the short but intensive time of the suppliers project. When it came down to the appoint- ment of partner-suppliers to the David was proud to show me the just- project, the normal evaluation exer- arrived Platinum LEED (Leadership cises looking at cost, experience, in Energy and Environmental Design) management capabilities etc.
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