MillerCoors Golden Brewery Sustainability Improvement . Energy Water Waste to Landfill

MillerCoors Golden MillerCoors Golden BreweryBrewery

Sustainability ImprovementSustainability Improvement.

EnergyWater

Waste to Landfill

Julie Smith, PE, MSPlant Optimization EngineerUtilities/Technical Services

Agenda• Corporate Goals/Leadership• Brewery Processes • Brewery Utilities• Opportunities• Waste to Landfill• Culture

Brewery Sustainability ImprovementBrewery Sustainability Improvement

Corporate Sustainability GoalsCorporate 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!

Brewery Process OverviewBrewery Process Overview

Malting

Brewing

Fermenting

Conditioning

Packaging

Warehousing

Golden Brewery MapGolden Brewery Map

Golden Brewery LayoutGolden Brewery Layout

Aging Cellars, Hop Storage

Malting/Kilns

Packaging/Warehouse/Gov. Cellar

Fermenting

Conditioning

Brewing ProcessBrewing Process

• Mash In• Filter/Lauter• Boil Wort• Chill• Ferment

FermentingFermenting

• Yeast + Wort = Beer• Maintain

Temperature• Residence Time• CO2• Yeast• To Aging

ConditioningConditioning• Aging• Filter• Blend• To Packaging

PackagingPackaging• Bottles, Cans and Kegs• Rinse• Fill• Label• Package• Palletize• To Warehouse

WarehouseWarehouse

• Store Product• Move Product• Temperature• Docks

Utilities for Brewery OperationsUtilities for Brewery Operations

Power Plant – Co-Generation Coal and Natural Gas Fired Boilers

• 800 LB Steam1) Electricity2) 400 LB Steam3) 50 LB Steam

Ammonia• Steam• Electricity

Plant Air• Steam• Electricity

Water Treatment• Electricity

Wastewater Treatment• Electricity

CO2 Recovery• Electricity

Utilities – Map of Valley

Utilities – Where does the Steam Go?

Resource Savings Opportunities

Steam

Steam Savings Opportunities 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

Plant Air Usage - 2011

Plant Air OpportunitiesPlant 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

CondensateCondensate

Return Benefits Cost Energy Waste Treatment Water Treatment

Where is it Going? Sewer Stack Steam Leaks

Utilities – Where does the Electricity Go?

Resource Savings Resource Savings OpportunitiesOpportunities

Electricity

Electricity Electricity Savings Savings OpportunitiesOpportunities

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

No!

Yes!

Electricity Savings OpportunitiesElectricity Savings OpportunitiesMalting Lights ResultsMalting Lights Results

Electricity Savings OpportunitiesElectricity Savings OpportunitiesBOC HVAC Recommissioning ResultsBOC HVAC Recommissioning Results

Electricity Savings OpportunitiesElectricity Savings OpportunitiesPackaging Green Shut-DownPackaging Green Shut-Down

Utilities – Where Does the Water Go?Utilities – Where Does the Water Go?

Resource Savings Opportunities

Water and WastewaterWater and Wastewater

Savings Opportunities – Water and WastewaterSavings Opportunities – Water and WastewaterSave 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

Waste to LandfillWaste 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

Co-Products Golden BreweryCo-Products Golden BreweryBill 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

Pavilion at Investment Recovery

Employee Sales / Beer Trailer

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)

Culture and PeopleCulture and People

What is Culture?

Culture – What is Culture?Culture – What is Culture?

Definitions: 1.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.2.That which is excellent in the arts, manners, etc.3.A particular form or stage of civilization, as that of a certain nation or period: Greek culture.4.Development or improvement of the mind by education or training.5.The behaviors and beliefs characteristic of a particular social, ethnic, or age group: the youth culture; the drug culture.

CultureCultureElements for SuccessElements for Success

Leadership Green Teams Education Communication Recognition Projects Score Cards

Culture – Green TeamsCulture – Green Teams

Golden Green Team – CAREGolden Green Team – CARE““Committed to Active Responsibility for the Environment”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

Golden Brewery Golden Brewery Sustainability Results - 2011Sustainability 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