MillerCoors Golden
Brewery
Sustainability Improvement
.
Energy
Water
Waste to Landfill
Julie Smith, PE, MS
Plant Optimization Engineer
Utilities/Technical Services
Brewery Sustainability Improvement
Agenda
• Corporate Goals/Leadership
• Brewery Processes
• Brewery Utilities
• Opportunities
• Waste to Landfill
• Culture
Corporate 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!
Brewery Process Overview
Malting
Brewing
Fermenting
Conditioning
Packaging
Warehousing
Golden Brewery Map
Golden Brewery Layout
Aging Cellars, Hop Storage
Power
Still
Turbine
Brewing
Packaging/Warehouse/Gov. Cellar
Malting/Kilns
YDP
Fermenting
Conditioning
Brewing Process
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Mash In
Filter/Lauter
Boil Wort
Chill
Ferment
Fermenting
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Yeast + Wort = Beer
Maintain Temperature
Residence Time
CO2
Yeast
To Aging
Conditioning
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Aging
Filter
Blend
To Packaging
Packaging
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Bottles, Cans and Kegs
Rinse
Fill
Label
Package
Palletize
To Warehouse
Warehouse
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Store Product
Move Product
Temperature
Docks
Utilities for Brewery Operations
 Power Plant – Co-Generation
 Coal and Natural Gas Fired Boilers
• 800 LB Steam
1) Electricity
2) 400 LB Steam
3) 50 LB Steam
 Ammonia
• Steam
• Electricity
 Plant Air
• Steam
• Electricity
 Water Treatment
• Electricity
 Wastewater Treatment
• Electricity
 CO2 Recovery
• Electricity
Utilities – Map of Valley
Utilities – Where does the Steam Go?
Resource Savings
Opportunities
Steam
Steam Savings Opportunities
 “Low Hanging Fruit”
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Leaks
Traps
Control Valves
Pressure Relief Valves
 Process Optimization/Team Work
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Compression Equipment Operation
Problem Solving
Metering - Short-Interval Control
Set Points
CIP Times
Quality/Efficiency
 Projects
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HVAC
Plant Air
Refrigeration
Brew Kettles
Plant Air Usage - 2011
Plant Air to Keg
West Header
East Header
MH 20 LB
Total
14,000,000
12,000,000
Plant Air, scfd
10,000,000
8,000,000
May 13 - 15 Clean
Break
July 4
6,000,000
4,000,000
2,000,000
0
Jan-11
Feb-11
Mar-11
Apr-11
May-11
Jun-11
Jul-11
July 29
Aug-11
Sep-11
Oct-11
Nov 5
Nov-11
Dec-11
Plant Air Opportunities
 Leaks
 Operations
 Compression Equipment
 Set Points
 Small Projects
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Cabinet Cooling/Pressure
Venturi Vacuum
Low Pressure Uses
Condensate Drains
Pneumatic Valves and Equipment
 Large Projects
 Decentralization
 Distribution Headers
Condensate
 Return Benefits
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Cost
Energy
Waste Treatment
Water Treatment
 Where is it Going?
 Sewer
 Stack
 Steam Leaks
Utilities – Where does the Electricity Go?
Resource Savings
Opportunities
Electricity
 Culture
Electricity
Savings
Opportunities
No!
 Lights
 Office Equipment
 Phantom Energy
 Process Optimization/Team Work
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Metering/Short Interval Control
CIP Times
Pump Control
Hard Shut-Downs
Operating Strategy
Water Usage
Quality/Efficiency
 Projects
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Lights
Pump VFD’s
Controls
Equipment Right-Sizing
 Facilities
Yes!
 Lights
 HVAC
 Insulation
Electricity Savings Opportunities
Malting Lights Results
Electricity Savings Opportunities
BOC HVAC Recommissioning Results
Electricity Savings Opportunities
Packaging Green Shut-Down
PKG1 Sub Power Usage - Spring 2011 Clean Break
PKG1 Sub
Bottle 3-1 Filler
Bottle 3-2 Filler
Can 1
Can 4
Can 5
1,600
1,400
Power Usage, kW
1,200
1,000
800
600
400
200
07-May
06-May
05-May
04-May
03-May
02-May
01-May
30-Apr
29-Apr
28-Apr
27-Apr
26-Apr
25-Apr
24-Apr
23-Apr
22-Apr
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Utilities – Where Does the Water Go?
Resource Savings
Opportunities
Water and Wastewater
Savings Opportunities – Water and Wastewater
Save Water = Save Energy!
 “Low Hanging Fruit”
 Leaks
 Controls
 Nozzles
 Team Work/Process Optimization
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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
Waste to Landfill
 Currently ReUse or Recycle >98% of Total Waste
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Spent Grain
Yeast
Ethanol Still
Glass
Cans
Single Stream
Industrial (Paper, Cardboard, Stretch Wrap, Metal)
 Still, 100 Ton/Month to Landfill (2010)
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Goal – Zero Waste in 3 years (or pretty close)
Sort, Label, Color Code
Optimize Collection
Source Reduction
Co-Products Golden Brewery
Bill 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
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
Pavilion at
Investment Recovery
Employee Sales /
Beer Trailer
Where: Pavilion at
Investment Recovery
What to bring: Pants, long
sleeved shirt, PPE (bump-cap,
steel-toes, safety-vest, and
Kevlar gloves)
Culture and People
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.
Culture
Elements for Success
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Leadership
Green Teams
Education
Communication
Recognition
Projects
Score Cards
Culture – Green Teams
Golden Green Team – CARE
“Committed to Active Responsibility for the Environment”
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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
Steam
Projects
Electrical
Projects
Water
Projects
Impact
Effort
UM Prioritization by Area
Top Priorities & Assigned Leads
Brewery Priorities & Sustainability Team
Golden Brewery Energy
Consumption, Cost, Carbon
Lighting Projects
Frick #5 Evaporative Condenser
Plant Air System Projects
Heat Exchanger Condensate Return
Process
Packaging
TS
Logistics
Packaging Line “Zero
Energy” Pilot
Keg Line Air
A Water Overflow
Packaging Dry Lube
Conditioning Cold
Sanitization
Fuel Cost and Mix
Fixed Cost Elimination
Initiatives & Projects
Electrical and Steam
Meters
Metering Plan
Cooling Tower VFD’s
Metering
Strategy
Energy
Audit
Cost
Improvements
Focused Improvements
Loss & Waste Analysis
Projects
TS Initiatives
Sustainability Team
Golden Brewery
Sustainability 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