Project
Minimising brewery process losses with targeted interventions
An Irish brewery engaged FDT, now part of NIRAS to investigate and mitigate significant process losses occurring during production. The objective was to identify the root causes of product loss and develop an actionable plan to enhance operational efficiency and reduce waste.
July 1, 2024
- SECTORS: Food & Beverage
- COUNTRIES: Ireland
Methodical approach to loss identification
NIRAS conducted a comprehensive mass balance to assess product flow, reviewed transfers using P&IDs and the site SCADA system, and took samples from lines and drains to quantify losses. Additionally, the team calculated the optimal pushout volumes for each transfer based on precise pipe length measurements.
Results and recommendations
- 1500 HL/year reduction in beer waste, saving €90,000 annually in raw materials.
- Environmental benefits from avoiding beer discharge into the wastewater system.
- Implementation of optimised pushout settings for more efficient transfers.
The proposed changes not only resulted in substantial cost savings but also contributed to the brewery's environmental sustainability efforts.
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