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MillerCoors Golden Brewery Sustainability Improvement . Energy Water Waste to Landfill

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

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MillerCoors Golden Brewery Sustainability Improvement . Energy Water Waste to Landfill

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  1. MillerCoors Golden BrewerySustainability Improvement.EnergyWaterWaste to Landfill Julie Smith, PE, MS Plant Optimization Engineer Utilities/Technical Services

  2. Brewery Sustainability Improvement Agenda • Corporate Goals/Leadership • Brewery Processes • Brewery Utilities • Opportunities • Waste to Landfill • Culture

  3. 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!

  4. Brewery Process Overview Malting Brewing Fermenting Conditioning Packaging Warehousing

  5. Golden Brewery Map

  6. Golden Brewery Layout Aging Cellars, Hop Storage Power Still YDP Fermenting Turbine Brewing Conditioning Packaging/Warehouse/Gov. Cellar Malting/Kilns

  7. Brewing Process • Mash In • Filter/Lauter • Boil Wort • Chill • Ferment

  8. Fermenting • Yeast + Wort = Beer • Maintain Temperature • Residence Time • CO2 • Yeast • To Aging

  9. Conditioning • Aging • Filter • Blend • To Packaging

  10. Packaging • Bottles, Cans and Kegs • Rinse • Fill • Label • Package • Palletize • To Warehouse

  11. Warehouse • Store Product • Move Product • Temperature • Docks

  12. Utilities for Brewery Operations • Ammonia • Steam • Electricity • Plant Air • Steam • Electricity • Water Treatment • Electricity • Wastewater Treatment • Electricity • CO2 Recovery • Electricity • Power Plant – Co-Generation • Coal and Natural Gas Fired Boilers • 800 LB Steam • Electricity • 400 LB Steam • 50 LB Steam

  13. Utilities – Map of Valley

  14. Utilities – Where does the Steam Go?

  15. Resource Savings Opportunities Steam

  16. Steam Savings Opportunities • “Low Hanging Fruit” • Leaks • Traps • Control Valves • Pressure Relief Valves • Process Optimization/Team Work • Compression Equipment Operation • Problem Solving • Metering - Short-Interval Control • Set Points • CIP Times • Quality/Efficiency • Projects • HVAC • Plant Air • Refrigeration • Brew Kettles

  17. Plant Air Usage - 2011

  18. Plant Air Opportunities • Leaks • Operations • Compression Equipment • Set Points • Small Projects • Cabinet Cooling/Pressure • Venturi Vacuum • Low Pressure Uses • Condensate Drains • Pneumatic Valves and Equipment • Large Projects • Decentralization • Distribution Headers

  19. Condensate • Return Benefits • Cost • Energy • Waste Treatment • Water Treatment • Where is it Going? • Sewer • Stack • Steam Leaks

  20. Utilities – Where does the Electricity Go?

  21. Resource Savings Opportunities Electricity

  22. Culture • Lights • Office Equipment • Phantom Energy • Process Optimization/Team Work • Metering/Short Interval Control • CIP Times • Pump Control • Hard Shut-Downs • Operating Strategy • Water Usage • Quality/Efficiency • Projects • Lights • Pump VFD’s • Controls • Equipment Right-Sizing • Facilities • Lights • HVAC • Insulation Electricity Savings Opportunities No! Yes!

  23. Electricity Savings Opportunities Malting Lights Results

  24. Electricity Savings Opportunities BOC HVAC Recommissioning Results

  25. Electricity Savings Opportunities Packaging Green Shut-Down

  26. Utilities – Where Does the Water Go?

  27. Resource Savings Opportunities Water and Wastewater

  28. Savings Opportunities – Water and Wastewater Save Water = Save Energy! • “Low Hanging Fruit” • Leaks • Controls • Nozzles • Team Work/Process Optimization • 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

  29. Waste to Landfill • Currently ReUse or Recycle >98% of Total Waste • Spent Grain • Yeast • Ethanol Still • Glass • Cans • Single Stream • Industrial (Paper, Cardboard, Stretch Wrap, Metal) • Still, 100 Ton/Month to Landfill (2010) • Goal – Zero Waste in 3 years (or pretty close) • Sort, Label, Color Code • Optimize Collection • Source Reduction

  30. 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

  31. 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 Where:  Pavilion at Investment Recovery What to bring: Pants, long sleeved shirt, PPE (bump-cap, steel-toes, safety-vest, and Kevlar gloves) Pavilion at Investment Recovery Employee Sales / Beer Trailer

  32. Culture and People What is Culture?

  33. Culture – What is Culture? Definitions: 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. That which is excellent in the arts, manners, etc. A particular form or stage of civilization, as that of a certain nation or period: Greek culture. Development or improvement of the mind by education or training. The behaviors and beliefs characteristic of a particular social, ethnic, or age group: the youth culture; the drug culture.

  34. Culture Elements for Success • Leadership • Green Teams • Education • Communication • Recognition • Projects • Score Cards

  35. Culture – Green Teams Golden Green Team – CARE “Committed to Active Responsibility for the Environment” • 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

  36. AUDITS IDEAS Brewery Priorities & Sustainability Team Top Priorities & Assigned Leads

  37. 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

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