Charlie Foxall Brisbane - Department of Industry, … · · 2013-06-21Industrial Biothechnology...

Industrial BiothechnologyWorkshop 3rd Nov 08Charlie Foxall

Industrial Bio-Technology

Towards Sustainability In Beverage Manufacturing using Natural Biological Processes


• Foster’s and the Yatala Site• Brewing Beer• Water• Energy, Fossil Fuel, GHG• Benefits for Foster’s and the

Community


Foster’s Group

An Australian owned producer of Premium Beverages including Beer, Cider and Wine.Foster’s; Crown Lager; Carlton Draught; Victoria Bitter; Cascade; Pure Blonde; Mercury; Strongbow; Torquay; Black Douglas; Cougar; Beringer;Wolf Blass; Penfolds; Rosemount; Saltram, etc.


Our GoalZero HarmOr Injury

Our CommitmentFoster’s HSE Policy

Our StandardsFoster’s HSE Manual

Our ActionsSite Practices and Procedures


Power Brewing 1988

• Power Brewing Formed in April 1987.

• Bare Field November 1987.• First Brew July 1988.• Launched September 1988.• 25,000,000 litre beer p/a.• A little over 1.5% of the

Australian Beer Market.


Power Brewing 1992

• Steady Expansion• More Products• Nominal capacity

140,000,000 litre beer p.a.• Produced 73,000,000• CUB need to find more

suitable production site.• CUB buys into business.• Major Expansion in 1993.


CUB - 2002

• Steady Expansion• More Products• Capacity 250,000,000 litre

beer p.a.• Produced 230,000,000• Cheapest / most effective

producer in group.• Benchmark for other sites.


Foster’s – Present Day

• Major Expansion ($175m)• Capacity 450,000,000 litre

beer p.a.• About 25% of the

Australian Beer Market.• Many opportunities for

process improvements. • Cheapest / most effective

producer in group.• Benchmark for other sites.


20 Years of Beers

• In 1988 we produced 1 product, Power’s Bitter, and put it in a bottle, a can or a Keg. In other words 3 skus. We had about 50 employees.

• We now produce about 18 Brewstreams and over 25 blended products and put them in big and little bottles with all sorts of shapes and colours as well as cans and kegs. We now have 330 employees.

• In addition we have recently installed a new packaging line to bottle spirits and RTD’s.

• We are producing 20 times the volume and 30 or 40 times the complexity.


Brewing Beer• Beer is the world’s oldest and most widely

consumed alcoholic beverage and the third most popular drink after water and tea.

• Beer production dates back to the 6th millennium BC and is recorded in the written histories of Egypt and Mesopotamia.

• Beer is produced by the action of micro-organisms on sugars and starches.

• Along with bread making it is one of the earliest examples of bio-technology.


Water• The Earths Surface is about 71% Water• About 1,460 Terratonnes• 97% in the ocean – 2.4% in ice caps – 1.6% underground

and about 0.025% in lakes and rivers.• According to the Australian Bureau of Statistics (2005),

Agriculture uses 67% of Queensland’s water, Domestic use is 11%, Water Industry (including distribution losses) is 16% and Industry uses 3%.

• Industry, therefore, uses about 10% of the Urban Water Supply, only 1/3 of domestic usage.

• Individual Industries, however, can use very large quantities. We use about a gigalitre a year.

• South East Queensland in drought condition and on severe Water Restrictions.


Where a Brewery uses Water

• Beer is mostly water – to make a litre of beer you need a minimum of 1 litre of water

• Process Heating by Steam• Cooling Towers for Refrigeration Systems• Pasteurisation• Cleaning of vessels, pipes etc• General Site Cleanup• Grounds• Drinking, washing etc. by staff


How much Water Yatala

• “Rule of thumb” in 1988 was 7:1 Water to Beer.• Power Brewing ratio about 5.5 – 6.5 : 1.• At present a “good” water use ratio is

internationally accepted around 4.5 to 5.5 : 1• Site upgrade in 1993 following CUB involvement

required the installation of a Primary Effluent Treatment Plant – UASB - Anaerobic system. Water to Beer ratio about 5:1 – Effluent flow rate about 75% of capacity.

• Continuous capacity upgrade to 2003 forced a reduction to a ratio of 3.5:1, in order to remain within the capacity of our waste treatment plant.


Major Expansion 2003 -2005

• The decision to close our NSW brewery and upgrade Yatala gave us an opportunity to do much better, by introducing water reduction initiatives, including internal water recycling.

• Biggest issue was convincing doubters. Perception of problem with recycled water. To really benefit from recycling the water must be used beneficially.

• To prove concept we built a 1/20th scale pilot plant and ran it for eight months.

• We also modelled the salt and thermal balance for several proposed scenarios on a computer.


Pilot Plant


Water Purification• On the basis of the pilot results we went to tender

for a full scale plant.• Cost approx $6,500,000.• Overall, water related component of the upgrade

was about $14,000,000. • Issues with council, particularly with salt

concentration.• Agreed to limit salts in effluent.• RO Plant for Brew Water.• Other small projects.• Now using > 50% less Caustic Soda than 2003.


The Water Recovery Process

• Process Steps for water treatment• Pre-screening followed by clarification• Pre-acidification• Anaerobic Treatment with biogas production• Dissolved air flotation• Moving Bed Bioreactor• Dissolved Air Flotation Filter• Micro Filtration• Reverse Osmosis


Recovered Water• Average 1.5 million litres per day water recovered

since 19/1/05.• About 65% of effluent stream.• Final product is considerably purer than Brisbane

water supply, typically 80 ppm tds and zero organics.

• Genuine recycling as the water is used for the processes that put it down the drain in the first place.

• Not used for product and does not come into final contact with product.

• Many benefits from the use of RO treated water in plant processes.


Cui Bono? – Foster’s

• If we still consumed now what we did in1992.• Water – 6 kL/kL > 2.2 kL/kL• Effluent – 4.5kL/kL > 0.9kL/kL

– COD – 5000 > 500– TSS – 1000 > 400

• We would use ~ 1,500 megalitres a day more water at a cost of $2,100,000 and massive head works charges.

• Effluent discharge would be 1440 megalitres a day more with 6480 tonnes of COD and a cost of $8,500,000.


Cui Bono? – Community

• The untreated waste stream from the brewery is approximately equivalent to the biological load of 200,000 EP.

• It takes 60 kWh/year to treat one EP = 1,200 gWh/year = > $800,000 = 12,480 tonnes GHG.

• Full treatment to potable product at Yatala uses 1/7 as much power.

• Biogas production ~ $500,000.• Actual GHG to produce ~ 400,000,000 litres of

beer per year is down about 44% in ten years.


Research in Biotechnology

• Pilot Plant for “Beer Battery”• Team from UQ headed By Dr

Korneel Rabaey.• Producing electricity directly

from the biological treatment of wastewater.

• Some issues with original concept.

• Exciting new prospects from process.


The Role of Industry in the Environment

• Foster’s Yatala was proud to be the inaugural recipient of the EPA’s Sustainable Industries Award for Industrial Eco-efficiency in 2006.

• We are equally proud to be the ongoing sponsors of that segment since then.

• We have good relationships with all levels of Government, with Universities and other businesses.

• Industries are an integral part of our society, not a separate bit sitting on the side.

• Use of simple, robust bio-technologies delivers positive benefits to all stakeholders.

• We are ALL feeling the effects of climate change and ALL need to do what is necessary to survive.

Charlie Foxall Brisbane - Department of Industry, … · · 2013-06-21Industrial Biothechnology...

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