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Partnership for optimum plant efficiency.
Servicenext level:
engineering for a better world GEA Process Engineering
Keep your plant running longer
2
Servicenext level − Our service concept.
Together with our customers, we design intelligent
solutions aimed at fully exploiting the potential of your
brewery and achieving a continuous and cost-effective
production process.
Each individual service module plays an important role for: J Plant availability J Plant efficiency J Cost control
Our customers can choose from different service modules
to define their own individual service level.
Original Spare Parts
from GEA Brewery Systems provide the
customer with the safety level required to
ensure the efficiency of his plant.
Service Level Agreements
GEA Brewery Systems offers Service Level
Agreements for improved reliability, cost
control and efficient processes.
Mechanics: Plant availability
Technology: Plant efficiency
Control system: Plant safety
Consulting/Audits
from GEA Brewery Systems are a
fundamental step towards optimum plant
efficiency.
Training
Our qualified specialists will enable your
staff to operate your plant equipment in
the most profitable way.
Repairs
performed by GEA Brewery Systems
stand for care, precision and responsibility
of the manufacturer – around the world,
wherever you need us!
Field Service
from GEA Brewey Systems provides
commissioning, inspections, maintenance,
general overhauls and the implementation
of upgrades.
Upgrade/Modernization
is required due to changing market
conditions or technical/technological
changes – we are your partner with the
necessary competence.
3
Audits − Transparency to make informed decisions.
The typical situation J Everybody identifies potential for optimization, which
is, however, difficult to assess accurately J Reluctance to intervene in the running process
In an audit, the potential of your brewery plant is evaluated
and suggestions for improvement are developed, including
an ROI calculation.
An audit can be divided into 3 phases
Phase 1 − Data collection J Process data collection using special questionnaires
prior to the actual audit
Phase 2 − On-site auditing J Process assessment during production; if possible and
appropriate, process optimization on site
Phase 3 − Data analysis, audit report and suggestions for
optimization J Analysis of the data collected on site and preparation
of suggestions for optimization, including ROI
calculations
As a result, you will receive an audit report, which
highlights the potential for optimization and includes ROI
calculations – transparency to make informed decisions for
plant performance at a high level.
Audit concept
Audit
Concrete
benefits
Plant survey
Specific
tools
Analysis
Transparency
Proposal
Process optimization/ realization of
upgrades
We provide technical/technological expertise for
the following areas J Brewhouse J Cold process area J Refrigeration plant J CO2 recovery plant J CIP J Energy J Water
Your immediate benefit from an audit J Immediate value for customers through process
optimization J Reduction of operating costs J Increase in plant efficiency J Reliable and optimized working conditions J Problem solutions J Concepts for the future
In most cases, the payback period is 3 to 12 months.
4
Energy Efficiency Check −Mobile energy data management.
Rising cost pressure, higher requirements regarding climate
protection and increasing ecological awareness of consumers
present new challenges for the brewing industry: Energy
must be used more efficiently without affecting product
quality.
Appropriate plant optimization, process modifications and
staff training result in substantial savings. However, to obtain
such benefits, breweries have to recognize, measure and
assess the weaknesses in their production process.
Therefore, GEA Brewery Systems offers the Energy Efficiency
Check, which, through the use of mobile and temporarily
installed sensors, can also be described as “mobile energy data
management“.
All energy and material flows in the brewery are determined
and solutions for efficient energy utilization – particularly
in the production process – are developed according to
DIN EN 50001 and DIN EN 16247 respectively.
Overview of the actual energy consumption and costs J Actual state on the basis of current energy demand
calculations J Weak points and savings potentials J Priorities for efficient energy use J Proposals for energy saving and process optimization J Proposals for the implementation of renewable energy J Economic evaluation of the proposals J Specific recommendations with detailed instructions
Servicenext level comprises the complete process area from malt intake to the interface with the packaging area, including
refrigeration and CO2 recovery plants
Less Costs
More Energy Efficiency –
5
Phase 1 − Quick Check (initial consulting),
approx. 2 days J Inspection of production areas J Determination of key plant data, examination of
documents J Recording or estimation of energy consumption data J Determination of measuring points for Energy
Efficiency Check J Quick Check report
Phase 2 − Efficiency Check (detailed consulting),
approx. 10 – 15 days J Identification of excessive energy consumption through
J Technological analysis of the processes J Measurement of electrical power (kWh/hl) J Measurement of thermal energy (kWh/hl; m³/hl) J Measurement of water consumption (hl/hl) J Compressed air audit (m³/hl; m³/kWh) J Examination of the refrigeration and CO2 recovery plant
J Immediate measures and staff training J Evaluation of recorded energy consumption data J Detailed report incl. list of measures to increase
efficiency, economic efficiency calculations, information
about support programs for possible/necessary
investments
Three steps towards energy optimization.
Phase 3 − Upgrade (measure) J Installation, commissioning and assessment of the
measure J Staff training J Further optimization measures
6
Upgrade − Our innovations – Your benefit.
Experience shows that over the course of time the
equipment or process technology used requires adjustments
and modifications due to new demands on equipment
or production technology. This can eventually result in
reduced system efficiency.
This can be caused by a number of reasons: J Different raw materials J Modified workflow J Change of equipment properties J Undocumented settings of system parameters
In addition, external factors have changed our customers’
view on reference values, such as the specific water
consumption in certain production areas, the total CO2
demand for production or the required amount of CIP
media.
With tailored audits and a dedicated team of experienced
brewing technologists and experts in process technology,
GEA Brewery Systems focuses on improving the efficiency
and the consumption data of your brewery.
In every brewery plant from GEA Brewery Systems the
engineers apply the latest know-how and innovative
technology in order to produce high quality beers with
optimum energy utilization. This is what our customers
expect and they are right to do so.
We offer comprehensive modernization and expansion
services to ensure your high level of product quality, plant
efficiency and plant availability for many years.
Our service begins with a detailed analysis. Your brewery
equipment is thoroughly checked and evaluated in an audit.
This audit can be conducted for individual plant sections
or for the complete brewery including refrigeration and
process automation. All important process parameters as
well as safety aspects, energy consumption etc. are taken
into account. Special attention is paid to value creation:
quantities of raw materials used, energy expenditure, yield
and output.
7
Servicenext level − the results speak for themselves J High plant availability J Excellent system efficiency J Spare parts availability as required
Optimized operating costs (TCO)
Your lautering system at LAUTERSTAR™
performance level
We bring also your lauter tun to the performance level of
the LAUTERSTAR™. The upgrade can easily be executed
step by step.
Yield J Yield increases of up to 2 percentage points have been
achieved
Capacity J Optimizing the lauter tun shortens the lautering
process as well as the ancillary process steps and leads
to a higher brewhouse capacity
Optimization in the brewhouse.
JETSTAR™ – for minimum total evaporation
The JETSTAR™ divides the wort boiling process into
two distinct steps: the thermal conversion step and the
evaporation step. This improves the efficiency of wort boiling,
saves primary energy and the wort quality improves.
Energy J Boiling with JETSTAR™, total evaporation can be
reduced to figures below 4 % J Immediate impact on fuel consumption, particularly in
atmospheric kettles without energy storage system
Quality J Due to gentle heating and homogeneous wort treatment,
the thermal load on the wort is reduced J Improved flavor stability of the beers and conservation
of the foam-positive protein fractions
Efficient use of heat with an energy storage system
The thermal energy required for evaporation during wort
boiling can be easily recovered with an efficiency of more
than 90 % and directly reused in the brewhouse. Low-
pressure boiling in combination with our design of the
energy storage tank allows a wide range of evaporation
rates. The system is balanced at 4.5 % total evaporation and
no hot water surplus is produced.
Energy J Savings of up to 60 % with a retrofit of energy storage
systems
Quality J The hot water produced is used to heat the wort by
means of a plate heat exchanger J Gentle conditions reduce the thermal stress due to a low
interfacial temperature
FACTS & FIGURES:
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GEA Process Engineering
GEA Brewery Systems GmbH Huppmann Tuchenhagen
Locations:
Heinrich-Huppmann-Str. 1, 97318 Kitzingen, Germany Phone +49 9321 303-0, Fax +49 9321 303-603
Am Industriepark 2–10, 21514 Büchen, Germany Phone +49 4155 49-0, Fax +49 4155 49-2770
gea-brewerysystems @ gea.com, www.gea.com
We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 index.
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