Uganda Breweries Ltd. In-plant Water CP-assesment Final presentation

1. Uganda Breweries Ltd. In-plant Water CP-assesmentFinal presentation January 25th 2007 Richard Harrow & Steffen Wissing Danbrew

2. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

3. Danbrew Ltd. Design and build Breweries Tender for plant developments Investment strategies and plans for breweries Optimising of Breweries 25 years of consultancy in the brewing industry Nearly 100 million hl design/build in more than 60 Countries including 7 African countries 60 consultants working in 7 countries presently

4. Project organisation for Uganda Breweries CP water assesment Nile Brewery Operations Director Mumbi Muiruri Engineering manager, Bardsley Msagha, Utilities manager, Matthew Mungai Head of Quality & Environment, Mrs. Agnes Acom. Danbrew Senior Consultant Richard Harrow Senior Consultant Steffen Wissing UN Programme Manager Niclas Svenningsen UCPC Technical Officer Patrick Mwesigye

5. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

6. The assignment of Danbrew UN Environmental Programme have asked Danbrew to perform In-Plant CP-assessments with a focus on water saving and waste water. This is part of the UN water saving initiative within the African brewery sector (The Abrew project). This project will Identify the potential for water savings in the African brewery sector and suggest solutions. Develop a UN project for external funding for implementing water conservation measures in the brewing sector and subsequently in the entire beverage sector in Africa. The preliminary assumption of the project is that water usage is 32 hl water per 1 hl beer. If so the water saving potential is 1.7 billion hl. l Cleaner Production methods are assumed to generate savings of 20 to 50%.

7. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

8. Cleaner Production The purpose of Cleaner Production is to reduce resource consumption and emissions from a production. Preferably by reduction of waste at source.

9. Solutions within the CP No part of the solution must be seen isolated

10. High consumption breweries and the CP �High Consumption Breweries can immediately achieve substantial reduction by addressing management issues and small changes in ancillary operations�

11. Low consumption breweries and the CP �Low Consumption Breweries need to begin focusing on all three functional groups in detail�

12. Low consumption breweries and the CP �Low Consumption Breweries need to begin focusing on al three functional groups in detail�

13. Low consumption breweries and the CP High Consumption Breweries

14. Cleaner Production Focus Areas

15. UN CP assesmentUNEP Technical report N� 33 p. 101Environmental Management in the Brewing Industry Abrew water assesment

16. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

17. Material Balance for a Typical Brewery � High Consumption

18. Material Balance for a Typical Brewery � Low Consumption

19. Water balance for Uganda Brewery � Medium Water Consumption and Low pollution

20. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

21. Water Flow for Uganda Breweries

22. Schematic Layout of a brewery

23. Schematic Layout of Uganda Breweries

24. Water flow of Uganda Breweries

25. UN CP Brewery detailed water balance model

26. Detailed Water Balance of Uganda Breweries, March 06

27. Detailed Water Balance of Uganda Breweries, December 06

29. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

30. Principle of water costing

31. Water cost calculation of UBL 1/2

32. Water cost calculation of UBL 2/2

33. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

34. Focus areas of Uganda Brewery

35. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

36. Organisation of Uganda Breweries � Partly

37. Interviews and data collection

38. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

39. Management & training Going on Utility manager is responsible for Water Consumption Follow up is done monthly by Utility Manager and I being supported by Operations Director. Targets set by Operations Director based on Benchmarking with in other Diagio sites KPI�s is monitored monthly at bill boards round the brewery The aim for water usage in 2007 is less than 7,0. Utility manager risk is job if the target is not accomplished. Planed Meters have been ordered for precise follow up towards Beer Processing and Beer house CP organisation is just been established CP � training is planned Danbrew conclusion Good management attention to water consumption Medium number of leakages and overflow that can be improves by CP Packaging has high number of leakages and overflow that can be improved by CP and management attention Water usage should be monitored monthly at bill boards round the brewery as the other KPI�s

42. KPI�s on Bill Boards, but no water consumption or waste measurements

43. Generally need and tidy, but messy in Packaging

44. Beer losses follows Water losses

45. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

48. Financial feasibility for new pasteurizer

49. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

50. High water usage in Beer house No major issues discovered during assesment. The high uses might very well be a measuring problem since Beer processing and Beerhouse together is 3,4 and the low consumption ratio is 2,9. Improvement of metering is suggested.

51. Excess Yeast Beer Recovery

52. Leak at Brewhouse Steam leak of brewhouse � recognised � it will take 2 month to repair due to spare parts have to be imported from Sparex, UK Suggestion is to use spare part company that has parts on stock the parts will be here within 3 days. Such company exists in Denmark.

53. Agenda Presentation The UN assignment Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews � who, how and what Management and Training Packaging Beer Processing Conclusion and Next Steps

54. Discovered focus areas of the brewery

55. Conclusions of UBL Water CP Assesment Theoretical potential saving of more than than 3 m hl/year or 30% but there is a large potential of waste reduction. UN assumption of African breweries using 32 hl water per hl Beer can not be confirmed UN assumption of savings 20 to 50% can be confirmed. CP assumption of gaining large effects by addressing management and procedures not having to invest heavily in equipment can be applied to UBL.

56. Next Steps Concluding the assessments Finalise the CP assesment tool Submit to UBL