The steam load in beer manufacturing varies significantly. Boilers have to cope with varying
steam demands on account of seasonal variations in production as well as hourly variations
in equipment/sections in operation. The steam boiler in a brewery needs to be able to deliver
to sudden, periodic and sustained, peak loads to ensure production and productivity goals
are met. In many plants this is achieved by running multiple boilers or a larger oversized
boiler. Plants typically face challenges in running boilers at optimum efficiency especially at
varying loads.
We find that the average opportunity for energy savings in the boiler house alone is about 8-
10%. These savings come from addressing the gap between rated and actual efficiency as
well as by improving condensate and flash steam recovery in the plant. Although across
most plants the steam consumption is indirect, the condensate recovery factor (CRF) ranges
from 60-70%. Improving the CRF to 90-95% not only saves fuel but also results in water
savings.
There is also potential to utilise spent grain from the plant as a fuel in the boiler. This
addresses disposal as well as serves the purpose of generating energy from waste. Our
biomass boilers at a number of breweries are facilitating plants to utilise spent grain as fuel.
Additionally, in combination with our highly efficient boilers we also provide solutions to
monitor, analyse and control boiler house and stack parameters in real time to ensure safe,
efficient and clean boiler operations.