Process efficiency in winery operations: a broad review of potentially beneficial techniques and technologies RESEARCH REPORT Key Submission Contact: Nick Palousis, CEO 0408 896 552 [email protected] www.2xe.com.au 1 Contents Executive Summary ......................................................................................................... 7 Introduction .................................................................................................................... 10 Background ................................................................................................................ 10 Project methodology .................................................................................................. 11 Report overview ......................................................................................................... 12 1. Process Efficiency Mapping ....................................................................................... 13 Process efficiency ‘hot spot’ mapping in wine production .......................................... 13 Comparison of the FMCG sectors with potential relevance to wine production ......... 14 Uniqueness of Wine Industry ..................................................................................... 15 2. Identification of general process efficiency issues in the wine industry ...................... 16 Overview .................................................................................................................... 16 Measurement of metrics – The beginning of process efficiency ................................. 16 Size of business ......................................................................................................... 17 Production Speed ....................................................................................................... 18 Labour Efficiencies ..................................................................................................... 19 Materials Efficiency .................................................................................................... 19 Energy Efficiency ....................................................................................................... 20 Water Efficiency ......................................................................................................... 21 Automation / Production Control ................................................................................ 21 3. Key process efficiency opportunities across the wine production process ................. 23 Receival ..................................................................................................................... 23 Key Metrics ............................................................................................................. 23 Temperature ........................................................................................................... 23 Strategies deployed by FMCG industries ............................................................... 24 Quality .................................................................................................................... 24 2 Destemming / Crushing .............................................................................................. 25 Key metrics ............................................................................................................. 25 Overview ................................................................................................................ 25 Production Speed ................................................................................................... 26 Strategies deployed by FMCG industries ............................................................... 27 Automation and real time analysis .......................................................................... 28 Labour Efficiency .................................................................................................... 29 Materials Efficiency ................................................................................................. 29 Energy Efficiency .................................................................................................... 30 Water Efficiency ...................................................................................................... 30 Fermentation .............................................................................................................. 32 Key metrics ............................................................................................................. 32 Overview ................................................................................................................ 32 Production Speed ................................................................................................... 33 Automation and Energy Efficiency .......................................................................... 34 Preventatives .......................................................................................................... 34 Strategies deployed by FMCG industries ............................................................... 35 Pressing ..................................................................................................................... 36 Key metrics ............................................................................................................. 36 Overview ................................................................................................................ 36 Production speed .................................................................................................... 36 Strategies deployed by FMCG industries ............................................................... 38 Clarification ................................................................................................................ 39 Key Metrics ............................................................................................................. 39 Overview ................................................................................................................ 39 Production speed, energy efficiency ....................................................................... 39 Strategies deployed by FMCG industries ............................................................... 40 3 Stabilisation ................................................................................................................ 41 Key Metrics ............................................................................................................. 41 Overview ................................................................................................................ 41 Energy Efficiency .................................................................................................... 42 Key Metrics ............................................................................................................. 43 Strategies deployed by FMCG industries ............................................................... 43 Maturation .................................................................................................................. 44 Key Metrics ............................................................................................................. 44 Overview ................................................................................................................ 44 Energy Efficiency .................................................................................................... 45 Measuring key metrics ............................................................................................ 46 Strategies deployed by FMCG industries ............................................................... 47 Bottling ....................................................................................................................... 48 Key metrics ............................................................................................................. 48 Production speed .................................................................................................... 49 Water efficiency ...................................................................................................... 49 Energy efficiency .................................................................................................... 50 Materials efficiency ................................................................................................. 50 Strategies deployed by FMCG industries ............................................................... 50 Automation ............................................................................................................. 51 Warehouse / dispatch ................................................................................................ 52 Key metrics ............................................................................................................. 52 Overview ................................................................................................................ 52 Pick orders.............................................................................................................. 52 Warehouse layout ................................................................................................... 53 Decreasing double handling ................................................................................... 53 Transport