Environmentally Sustainable Soy Supplemented IPA · 2019-05-01 · Design Process & SuperPro...
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Design Process & SuperPro Environmentally Sustainable Soy Supplemented IPA . Clay Bowes, Tony Hoch, Ryan Wollensak (BS Biological Engineering) References: 1 Chua, J., Lu, Y., & Liu, S. (2017). Biotransformation of soy whey into soy alcoholic beverage by four commercial strains of Saccharomyces cerevisiae. International Journal of Food Microbiology,262, 14-22. doi:10.1016/j.ijfoodmicro.2017.09.007 2 Rizkytata, B. T., Gumelar, M. T., & Abdullah, T. H. (2014). Industrial tofu wastewater as a cultivation medium of microalgae Chlorella vulgaris. Energy Procedia, 47, 56-61. 3 Plant-based Proteins Aren’t Just for Vegans Anymore. (2019). The NPD Group. Retrieved 15 April 2019, from https://urlzs.com/wZbR 4 Geankoplis, C. J. (2003). Transport processes and separation process principles:(includes unit operations). Prentice Hall Professional Technical Reference. 5 Craft Beer Industry Market Segments. (n.d.). Retrieved November 20, 2018, from https://www.brewersassociation.org/statistics/market-segments/ Instructors: Dr. Martin Okos Alyssa Christoffer Troy Tonner Acknowledgements: A huge thank you to Dr. Okos for always pushing us in the right direction. Problem Definition and Background Objectives: 1. Utilize a waste product from industrial process 2. Reduce waste by 20% via recycling spent grain and CO 2 3. Generate >25% ROI Across the globe, tofu production on average accounts for 2,610 kg of soy whey wastewater is created for every 80 kg of tofu produced 2 . Currently, this wastewater has no industrial applications, even though it is high in proteins (40-60%), carbohydrates (25-50%). The United States has seen a 24% increase in plant- based protein consumption since 2015 3 . Utilization of viable biological process wastes will increase environmental sustainability in the next 25-50 years. First to market in the soy-supplemented beverage space will solidify our breweries stance and market share in the space. With an expected profit margin of 59%, our brewery will set a precedent in the alternative-supplemented beer market and spur future economic activity in the craft beer market. Variables Of Impact Economic Analysis • Total capital investment of $2.55 million fits appropriately in expected range for microbrewery. • Total product cost of $2.2 million reduces to $0.39/12 oz bottle. • Annual Net Profit of $3.3 million and ROI of 83% indicates profitability if sales are met. • Customer life value calculated based on the quality and taste of beer sold. A customer with 50 purchases over 10 years is worth $2,300 to the brewery. Alternative Solutions and Decision Making • Continuous reaction vessels are common alternatives in mashing and fermentation. • Given the scale of our brewery output, 17,000 BBL/year, batch processing is more suited to our plant design. • Mashing and Fermentation: Stainless steel jacketed vessels • Filtration: Forgoing cold crashing, secondary microfiltration to preserve protein concentration of beer. Annual Operating Cost Manufacturing Cost $1,661,220 Direct Product Cost $1,121,129 Fixed Charges $108,502 Plant Overhead $431,589 General Expenses $523,202 Total Product Cost $2,184,425 Total Product Cost Per Beer $0.39 Selling Price $0.90 Profit Margin 59% Plant output was back calculated from the average annual output of a microbrewery: 15,000 – 20,000 BBL/year 5 . • Batch Production: 33,800 L • Batch Cycle Production: 5,633.3 L/day Modelling system based on clone recipe shown below: SuperPro beer yield differed 26% from MATLAB models. Hand calculation/excel modelling determined potential to recycle 68% of carbon dioxide. Final Solution Feasibility and Quality • With a total capital investment of $2.55 million, a total cost per unit (12 oz.) of $0.39, and a profit margin of 59% at a selling price of $0.90/unit, the brewery is financially feasible and suitable for startup. • A projected ROI of 83% was established. • Initial product is to be improved through process refinement and recipe analysis. • Global soy waste is to be tracked and marketed. • An environmentally sustainable brewing process was created through waste product utilization, internal resource renewal, and biodegradable packaging. • Optimization, process control design, and engineering principles were implemented to create a sustainable business with grounds for further improvement after startup. • Finally, successful marketing campaigns and sales will spur the creation of a new sustainable brewing market. Investment Equipment Cost (after tax) $546,949.368 Fixed Capital Investment $2,171,288.99 Total Capital Investment $2,554,253.55 Ingredient Amount Water 5,6333 L Malt Blend 3279 kg Hop Blend 63.33 kg Supplemented Soy Protein 256.6 kg Product and Process Experimentation • New recipe was necessary after initial taste tests: Dogfish Head IPA Clone • Changes based on experimentation: single mash infusion, removal of filtration step, and addition of secondary fermentation • Main Variables: temperature and time (mashing), filtrate flow rate (filtration), temperature, time, and sugar concentration (fermentation), and temperature, time, weight of dry hopping, and clarification material (secondary fermentation) Global: Soy Waste Social: ABV, Safety Marketing Cultural: US Beer Consumption Economic: ROI, Manufacturing Cost Environmental: CO 2 Output, Waste Utilization Marketing Target Audience: Upper-middle class ages 25-50 Health Conscious Consumers Target Location: US Coasts Type of Control System Single-loop feedback Manipulated Variable Fermented wort flow rate Output Variables Internal vessel temperature Wort pH Sensor Type Orifice Meter Actuator Stepper motor linear actuator Type of Control System Single-loop feedback Manipulated Variables Glycol flow rate pH Output Variables Internal vessel temperature Wort pH Sensor Type Temperature probe pH probe Actuator Stepper motor linear actuator Type of Control System Single-loop feedback Manipulated Variables Steam flow rate Output Variables Internal mash temperature Sensor Type Type: Thermometer Actuator Stepper motor linear actuator Optimization and process control reduce cost and ensure reproducibility. Below are Process control tables for (A) mashing, (B) fermenting, and (C) filtration: (A) (B) (C) • Optimizing the pipe ID to 19 mm saved ~ $70 annually • Optimizing the # of mash tuns to 3 saved ~ $9,000 annually Process Control Optimization 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 Pipe Diameter [m] 6000 6500 7000 7500 8000 8500 Cost [$] Cost vs. Pipe Diameter 1 2 3 4 5 6 7 8 9 10 11 12 Number of mash tuns 2 2.2 2.4 2.6 2.8 3 Annual Cost [$] 10 4 Optimization of Number of Units CV-01 Control Valve 1 H-10 Glycol Chiller 5 R-01 Mash Tun 1 CV-02 Control Valve 2 H-11 Glycol Chiller 6 R-02 Mash Tun 2 CV-03 Control Valve 3 P-01 Heat Pump 1 R-03 Mash Tun 3 CV-04 Control Valve 4 P-02 Heat Pump 2 R-04 Fermenter 1 CV-05 Control Valve 5 P-03 Heat Pump 3 R-05 Brite Tank 1 CV-06 Control Valve 6 P-04 Mash Pump 1 R-06 Brite Tank 2 F-01 Lauter Tun 1 P-05 Mash Pump 2 R-07 Fermenter 2 F-02 Lauter Tun 2 P-06 Mash Pump 3 R-08 Brite Tank 3 F-03 Lauter Tun 3 P-07 Boil Pump R-09 Brite Tank 4 F-04 Interchangeable Filter P-08 Cooling Pump R-10 Fermenter 3 F-05 Interchangeable Filter P-09 Glycol Pump 1 R-11 Brite Tank 5 F-06 Interchangeable Filter P-10 Interchangeable Pump R-12 Brite Tank 6 F-07 Interchangeable Filter P-11 Glycol Pump 2 R-13 Fermenter 4 F-08 Interchangeable Filter P-12 Interchangeable Pump R-14 Brite Tank 7 F-09 Interchangeable Filter P-13 Glycol Pump 3 R-15 Brite Tank 8 H-01 Shell-Tube Exchanger 1 P-14 Interchangeable Pump R-16 Fermenter 5 H-02 Shell-Tube Exchanger 2 P-15 Glycol Pump 4 R-17 Brite Tank 9 H-03 Shell-Tube Exchanger 3 P-16 Interchangeable Pump R-18 Brite Tank 10 H-04 Boil Kettle P-17 Glycol Pump 5 R-19 Fermenter 6 H-05 Plate Frame Exchanger P-18 Interchangeable Pump R-20 Brite Tank 11 H-06 Glycol Chiller 1 P-19 Glycol Pump 6 R-21 Brite Tank 12 H-07 Glycol Chiller 2 P-20 Interchangeable Pump H-08 Glycol Chiller 3 RCT Engineering, Inc. Design of Soy IPA plant to scheduling speciation’s determined in optimization. H-09 Glycol Chiller 4 Soy IPA Plant COMPANY CONF. Drawn By Ryan Wollensak Proj # __ __ __ __ __ Appr By REV C 0 50 100 150 200 250 300 350 400 450 500 Customer Retention Time [weeks] 0 500 1000 1500 2000 CLV [$] Customer Live Value vs. Retention Time 10 sales 50 sales 100 sales
Transcript of Environmentally Sustainable Soy Supplemented IPA · 2019-05-01 · Design Process & SuperPro...
Design Process & SuperPro
Environmentally Sustainable Soy Supplemented IPA .
Clay Bowes, Tony Hoch, Ryan Wollensak (BS Biological Engineering)
References:1Chua, J., Lu, Y., & Liu, S. (2017). Biotransformation of soy whey into soy alcoholic beverage by four commercial strains of Saccharomyces cerevisiae. International Journal of Food Microbiology,262, 14-22. doi:10.1016/j.ijfoodmicro.2017.09.0072Rizkytata, B. T., Gumelar, M. T., & Abdullah, T. H. (2014). Industrial tofu wastewater as a cultivation medium of microalgae Chlorella vulgaris. Energy Procedia, 47, 56-61.3Plant-based Proteins Aren’t Just for Vegans Anymore. (2019). The NPD Group. Retrieved 15 April 2019, from https://urlzs.com/wZbR4Geankoplis, C. J. (2003). Transport processes and separation process principles:(includes unit operations). Prentice Hall Professional Technical Reference.5Craft Beer Industry Market Segments. (n.d.). Retrieved November 20, 2018, from https://www.brewersassociation.org/statistics/market-segments/
Instructors: Dr. Martin OkosAlyssa ChristofferTroy Tonner
Acknowledgements:A huge thank you to Dr. Okos for always pushing us in the right direction.
Problem Definition and BackgroundObjectives:1. Utilize a waste product from industrial process2. Reduce waste by 20% via recycling spent grain and CO23. Generate >25% ROIAcross the globe, tofu production on average accounts for 2,610 kg of soy whey wastewater is created for every 80 kg of tofu produced2. Currently, this wastewater has no industrial applications, even though it is high in proteins (40-60%), carbohydrates (25-50%). The United States has seen a 24% increase in plant-based protein consumption since 20153. Utilization of viable biological process wastes will increase environmental sustainability in the next 25-50 years. First to market in the soy-supplemented beverage space will solidify our breweries stance and market share in the space. With an expected profit margin of 59%, our brewery will set a precedent in the alternative-supplemented beer market and spur future economic activity in the craft beer market.
Variables Of Impact Economic Analysis• Total capital investment of $2.55
million fits appropriately in expected range for microbrewery.
• Total product cost of $2.2 million reduces to $0.39/12 oz bottle.
• Annual Net Profit of $3.3 million and ROI of 83% indicates profitability if sales are met.
• Customer life value calculated based on the quality and taste of beer sold. A customer with 50 purchases over 10 years is worth $2,300 to the brewery.
Alternative Solutions and Decision Making• Continuous reaction vessels are
common alternatives in mashing and fermentation.
• Given the scale of our brewery output, 17,000 BBL/year, batch processing is more suited to our plant design.
• Mashing and Fermentation: Stainless steel jacketed vessels
• Filtration: Forgoing cold crashing, secondary microfiltration to preserve protein concentration of beer.
Annual Operating CostManufacturing Cost $1,661,220
Direct Product Cost $1,121,129Fixed Charges $108,502Plant Overhead $431,589
General Expenses $523,202Total Product Cost $2,184,425Total Product Cost Per Beer $0.39Selling Price $0.90Profit Margin 59%
Plant output was back calculated from the average annual output of a microbrewery: 15,000 – 20,000 BBL/year5. • Batch Production: 33,800 L• Batch Cycle Production: 5,633.3 L/dayModelling system based on clone recipe shown below:
SuperPro beer yield differed 26% from MATLAB models. Hand calculation/excel modelling determined potential to recycle 68% of carbon dioxide.
Final Solution Feasibility and Quality• With a total capital investment of $2.55 million, a total cost per unit (12 oz.) of $0.39,
and a profit margin of 59% at a selling price of $0.90/unit, the brewery is financially feasible and suitable for startup.
• A projected ROI of 83% was established.• Initial product is to be improved through process refinement and recipe analysis. • Global soy waste is to be tracked and marketed.• An environmentally sustainable brewing process was created through waste product
utilization, internal resource renewal, and biodegradable packaging. • Optimization, process control design, and engineering principles were implemented to
create a sustainable business with grounds for further improvement after startup.• Finally, successful marketing campaigns and sales will spur the creation of a new
sustainable brewing market.
Investment
Equipment Cost (after tax) $546,949.368
Fixed Capital Investment $2,171,288.99
Total Capital Investment $2,554,253.55
Ingredient AmountWater 5,6333 LMalt Blend 3279 kgHop Blend 63.33 kgSupplemented Soy Protein 256.6 kg
Product and Process Experimentation• New recipe was necessary after initial taste tests: Dogfish Head IPA
Clone• Changes based on experimentation: single mash infusion, removal
of filtration step, and addition of secondary fermentation• Main Variables: temperature and time (mashing), filtrate flow rate
(filtration), temperature, time, and sugar concentration (fermentation), and temperature, time, weight of dry hopping, and clarification material (secondary fermentation)
Global: Soy WasteSocial: ABV, Safety MarketingCultural: US Beer ConsumptionEconomic: ROI, Manufacturing CostEnvironmental: CO2 Output, Waste UtilizationMarketingTarget Audience: Upper-middle class ages 25-50Health Conscious Consumers
Target Location:US Coasts
Blaa Blaa Blaa
Type of Control System Single-loop feedbackManipulated Variables Glycol flow rate
pHOutput Variables Internal vessel temperature
Wort pHSensor Type Type: Temperature Probe
Type: pH probeActuator Stepper motor linear actuator
Type of Control System Single-loop feedbackManipulated Variables Steam flow rateOutput Variables Internal mash temperatureSensor Type ThermometerActuator Stepper motor linear actuator
Type of Control System Single-loop feedbackManipulated Variable Fermented wort flow rateOutput Variables Internal vessel temperature
Wort pHSensor Type Orifice MeterActuator Stepper motor linear actuator
Type of Control System Single-loop feedbackManipulated Variable Fermented wort flow rateOutput Variables Internal vessel temperature
Wort pHSensor Type Orifice MeterActuator Stepper motor linear actuator
Type of Control System Single-loop feedbackManipulated Variables Glycol flow rate
pHOutput Variables Internal vessel temperature
Wort pHSensor Type Temperature probe
pH probeActuator Stepper motor linear actuator
Type of Control System Single-loop feedbackManipulated Variables Steam flow rateOutput Variables Internal mash temperatureSensor Type Type: ThermometerActuator Stepper motor linear actuator
Optimization and process control reduce cost and ensure reproducibility. Below are Process control tables for (A) mashing, (B) fermenting, and (C) filtration:
(A)
(B)
(C)
• Optimizing the pipe ID to 19 mm saved~ $70 annually
• Optimizing the # of mash tuns to 3 saved ~ $9,000 annually
Process Control Optimization
0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1Pipe Diameter [m]
6000
6500
7000
7500
8000
8500
Cost
[$]
Cost vs. Pipe Diameter
1 2 3 4 5 6 7 8 9 10 11 12Number of mash tuns
2
2.2
2.4
2.6
2.8
3
Annu
al Co
st [$]
104 Optimization of Number of Units
CV-01 Control Valve 1 H-10 Glycol Chiller 5 R-01 Mash Tun 1CV-02 Control Valve 2 H-11 Glycol Chiller 6 R-02 Mash Tun 2CV-03 Control Valve 3 P-01 Heat Pump 1 R-03 Mash Tun 3CV-04 Control Valve 4 P-02 Heat Pump 2 R-04 Fermenter 1CV-05 Control Valve 5 P-03 Heat Pump 3 R-05 Brite Tank 1CV-06 Control Valve 6 P-04 Mash Pump 1 R-06 Brite Tank 2F-01 Lauter Tun 1 P-05 Mash Pump 2 R-07 Fermenter 2F-02 Lauter Tun 2 P-06 Mash Pump 3 R-08 Brite Tank 3F-03 Lauter Tun 3 P-07 Boil Pump R-09 Brite Tank 4F-04 Interchangeable Filter P-08 Cooling Pump R-10 Fermenter 3F-05 Interchangeable Filter P-09 Glycol Pump 1 R-11 Brite Tank 5F-06 Interchangeable Filter P-10 Interchangeable Pump R-12 Brite Tank 6F-07 Interchangeable Filter P-11 Glycol Pump 2 R-13 Fermenter 4F-08 Interchangeable Filter P-12 Interchangeable Pump R-14 Brite Tank 7F-09 Interchangeable Filter P-13 Glycol Pump 3 R-15 Brite Tank 8H-01 Shell-Tube Exchanger 1 P-14 Interchangeable Pump R-16 Fermenter 5H-02 Shell-Tube Exchanger 2 P-15 Glycol Pump 4 R-17 Brite Tank 9H-03 Shell-Tube Exchanger 3 P-16 Interchangeable Pump R-18 Brite Tank 10H-04 Boil Kettle P-17 Glycol Pump 5 R-19 Fermenter 6H-05 Plate Frame Exchanger P-18 Interchangeable Pump R-20 Brite Tank 11H-06 Glycol Chiller 1 P-19 Glycol Pump 6 R-21 Brite Tank 12H-07 Glycol Chiller 2 P-20 Interchangeable PumpH-08 Glycol Chiller 3 RCT Engineering, Inc. Design of Soy IPA plant to scheduling
speciation’s determined in optimization.H-09 Glycol Chiller 4 Soy IPA PlantCOMPANYCONF.
Drawn By Ryan Wollensak Proj # __ __ __ __ __Appr By REV C
0 50 100 150 200 250 300 350 400 450 500Customer Retention Time [weeks]
0
500
1000
1500
2000
CLV
[$]
Customer Live Value vs. Retention Time
10 sales50 sales100 sales
