University of Pennsylvania ScholarlyCommons Department of Chemical & Biomolecular Senior Design Reports (CBE) Engineering 4-2013 Craft Beer Production Blake Bleier University of Pennsylvania Amanda Callahan University of Pennsylvania Samantha Farmer University of Pennsylvania Hannah Min University of Pennsylvania Follow this and additional works at: https://repository.upenn.edu/cbe_sdr Part of the Biochemical and Biomolecular Engineering Commons Bleier, Blake; Callahan, Amanda; Farmer, Samantha; and Min, Hannah, "Craft Beer Production" (2013). Senior Design Reports (CBE). 53. https://repository.upenn.edu/cbe_sdr/53 This paper is posted at ScholarlyCommons. https://repository.upenn.edu/cbe_sdr/53 For more information, please contact [email protected]. Craft Beer Production Abstract As the market demand for craft brewed beer continues to grow, small brewers are continuing to crop up to meet the demand. With the increasing number of small breweries also comes an increasing number of brewery closings—more than 80 since 2010. While the brewing process fundamentals can be mastered with little technical knowledge, the key to a prosperous brewery is optimizing the use of all resources in the process, especially considering rising energy costs. New brewing operations often have the choice between building their own facility from scratch, or contracting their brewing operations to an established facility. This project recommends a design for a craft brewery (BASH Brewing Co.) producing 13 varieties of beer with a 100,000 bbl/year total production capacity. The recommended design minimizes the use of external utilities by maximizing the heat integration of process streams. Rigorous economic analysis to determine the profitability of the process design was performed. The startup and operations costs for building an independent facility following this design were calculated, and from this a reasonable rate for contract brewing was determined. It was found that the construction of an independent facility would require a total permanent investment of $68MM and have a net present value (NPV) of $26MM with an internal rate of return (IRR) of 20.96% in the present year. To achieve the same returns, it was determined that contract brewing would only be a more economically viable option if the contracted production price is less than $8.72/gallon of beer. Disciplines Biochemical and Biomolecular Engineering | Chemical Engineering | Engineering This working paper is available at ScholarlyCommons: https://repository.upenn.edu/cbe_sdr/53 Craft Beer Production Blake Bleier | Amanda Callahan | Samantha Farmer | Hannah Min Dr. Robert Riggleman, University of Pennsylvania (Faculty Advisor) Mr. Stephen M. Tieri, DuPont Engineering Research & Technology (Industry Consultant) Department of Chemical and Biomolecular Engineering School of Engineering and Applied Science University of Pennsylvania April 9th , 2013 Table of Contents Letter of Transmittal ........................................................................................................................5 I. Abstract ...............................................................................................................................7 II. Introduction ......................................................................................................................11 Background Information ..............................................................................................15 Project Charter .............................................................................................................19 Innovation Map ............................................................................................................23 III. Concept Assessment Market Landscape ........................................................................................................27 Competitive Landscape ................................................................................................33 Customer Requirements ...............................................................................................39 IV. Process Preliminary Process Overview and Synthesis..............................................................43 Simulation Approach ...................................................................................................49 Overall Process Flowsheet ...........................................................................................55 India Pale Ale ...............................................................................................................64 Imperial India Pale Ale ................................................................................................83 Stout ...........................................................................................................................103 Pilsner ........................................................................................................................123 Lager ..........................................................................................................................143 Sour Cherry Wheat ....................................................................................................163 Summer Ale ...............................................................................................................183 Oktoberfest .................................................................................................................203 Winter Ale ..................................................................................................................223 Aged Oaked Imperial India Pale Ale .........................................................................243 Oaked Imperial Pale Ale ............................................................................................263 Extra Special Bitter ....................................................................................................283 Belgian Tripel Style ...................................................................................................303 V. Utility Requirements ......................................................................................................323 VI. Equipment Unit Descriptions .......................................................................................................329 Equipment List ..................................................................................................331 Liquids/Solids Handling ...................................................................................332 Storage Vessels .................................................................................................333 Process Vessels .................................................................................................336 Heat Exchangers & Utilities .............................................................................344 Pumps ................................................................................................................348 Equipment Specification Sheets ................................................................................349 3 VII. Other Important Considerations Environmental Concerns ............................................................................................397 Safety Considerations ................................................................................................405 VIII. Financials Equipment Cost Summary .........................................................................................397 Fixed Capital Investment Summary...........................................................................417 Operating Cost & Economic Analysis .......................................................................423 Sensitivity Analyses ...................................................................................................431 IX. Conclusions and Recommendations .............................................................................439 X. Acknowledgements ........................................................................................................443 XI. Glossary of Terms ..........................................................................................................447 XII. Appendix .........................................................................................................................451 Materials Safety Data Sheets .....................................................................................457 Detailed SWOT Analysis ...........................................................................................545 Simulation Code.........................................................................................................548 Detailed Calculations for Equipment Design and Costing ........................................551 XIII. References .......................................................................................................................561 4 University of Pennsylvania School of Engineering and Applied Science Department of Chemical & Biomolecular Engineering 220 South 33 rd Street Philadelphia, PA 19104 April 9 th , 2013 Dear Dr. Riggleman, Mr. Fabiano, and Mr. Tieri, Enclosed are our proposed process designs for the craft beer production facility, as specified in a problem statement by Mr. Stephen M. Tieri of DuPont. We have modeled a craft beer production facility capable of meeting the distribution requirements of the problem statement: