ビール工場・シードルメーカーでの導入事例【生産量・キャパシティの最大化へ／英語版】

Breweries using Pall’s Keraflux® Tangential Flow Filtration (TFF) technology increase yield and reduce waste streams Overview Up to 80% of the extract contained in the surplus yeast that collects at the bottom of tanks after fermentation and maturation can now be recovered rather than disposed of. Beer can be recovered and blended back into the brewing process at a ratio of up to 5 % without negatively influencing the beer quality, increasing the yield and reducing the total beer volume needing to be produced. This represents a lower CO2 footprint, reduced water usage, and a lowering of production costs, plus the minimized waste stream reduces disposal costs and ensures a lower level of BOD’s and COD’s are returned back into the environment. High quality yeast (accrued as a byproduct of beer recovery) can be recovered and sold to other industries such as the cosmetic, pharmaceutical or animal feed industries. The benefits of recovery result in increased brewery Keraflux-TFF System 3 x 2 HCB Membranes profitability, lower environmental impact, reduced use of Usually filtration stops by reaching the dry matter valuable resources and a very short and attractive ROI concentration. The flux is mostly constant due to the high on the equipment used to achieve it. degree of automation and control mechanisms. The Challenge During the complete filtration process neither intermediate A brewery with an annual production capacity of cleaning nor back flushing is necessary. Each filtration cycle 4,000,000 hl wanted to reduce production costs. A volume lasts about 21 hours after which time a 2 hour cleaning of approximately 500 hl of surplus yeast collected per day at process takes place (Includes one step: NaOH of 80 °C and the bottom of the tanks after fermentation and maturation. a concentration of 2 - 3 %). An additional weekly clean with With 250 production days per year this equated to a total 1 % HNO3 and 0.5 % membrane cleaner is also conducted. volume of 125,000 hl, equivalent to more than 3 % of the brewery’s annual beer production. If recovered this yeast beer mixture offered the potential to increase the yield and reduce Yeast Beer the overall production costs. An additional target benefit for Working Tank the brewery was to reduce the burden on the environment Tank and save valuable resources. The Solution Pall installed a Keraflux-TFF (Tangential Flow Filtration) System for yeast management using 3 x 2 Membralox® HCB series multi-channel ceramic membranes. The surplus yeast from production had an average ratio of Pall’s Scope of Supply 50 % fermentation yeast to 50 % maturation yeast. Approximately 500 hl of the mixture was held in a 1,200 hl Beer recovery process tank, having a dry matter of approx. 11 % and an extract of In a detailed example, 472 hl yeast beer mix with an initial approx. 11.5 ° Plato, cooled to 5 °C and stored under CO2 dry matter of 10.8 % was filtered. 252 hl of beer was pressure of 1.2 bar. recovered from this mixture and blended back into the To recover the beer the mixture was fed into the Keraflux TFF production process. The high quality of the recovered beer system at a constant flow at 9 °C, controlled by a chiller. For allows it to be blended directly back into the process without increased energy efficiency the pumps were frequency further filtration. When using other technologies such as controlled, starting at approximately 50 % of the maximum centrifuges for beer recovery, the beer has to be blended frequency. Filtration stops when the filtrate flux falls below back into the process prior to fermentation. For optimal 50 % of the initial flow of 15 hl/h or if the dry matter reaches utilization of this technology the beer should be blended a value between 17 % and 20 %, which is yeast specific. back into the process as late as possible. Application Bulletin

Incoming Brew Water Cooling Fermentation MaturationHouse Treatment Yeast Management Pre Stabilization Blending BBT Final Filtration Filtration Back-blending as late as possible in production process for maximum profitability As a byproduct of the beer recovery, 220 hl of high quality The Benefits yeast with a dry matter of 17.5 % was recovered. This value Using the Keraflux-TFF System for yeast management, was consciously chosen by the brewery as the yeast should breweries can significantly reduce their processing costs, use be in a good condition to be pumped. The target was to reach less resources such as water and lower their overall impact values above 16 % dry matter and a beer quality turbidity on the environment. value below 0.7 EBC at 90 °. The examples given above showed the following benefits: One hl of recovered beer is calculated by the brewery to be • Up to 80 % extract recovery worth 10 €. With an average 250 hl of beer recovered per • High quality beer for back blending prior to filtration day operating 250 production days per year, the brewery can • Turbidity of recovered beer at 90 ° below 0.7 EBC recover 62,500 hl beer; a cost benefit of 625,000 € per year. Under these brewery specific circumstances this resulted in a • Reduction of total production volumes by 1.6 % very attractive ROI of 1.2 years. As the system is fully • Reduced CO2 and water footprint automated, no additional operators were employed. The • Reduced waste stream system fully satisfies the customer requirements and helps • Reduced disposal costs him increase the yield and reduce his environmental impact. • Reduced BOD’s and COD’s returned to the environment Another brewery with the same process optimization • High quality yeast for sale with 17.5 % dry matter intentions used high gravity brewing enabling Pall to use • Attractive equipment ROI of 1.2 years diafiltration to increase the yield of the overall process. Food and Water Contact Use Diafiltration is the process of adding water to the surplus yeast to increase extract and alcohol recovery by a wash out Please contact Pall Corporation for product applicability to effect. The advantage of this method is that it achieves a specific National legislation and Regional regulatory high recovery rate. The whole process follows a fully requirements for food and water contact use. automated procedure. Separation starts without adding About Pall Corporation water until the dry matter is at 14 % when diafiltration begins. The whole process is controlled by the Pall Corporation is the largest and most diverse filtration, measurement of the ° Plato and ends at a defined brewery separation, and purification company in the world. Pall servesthe food and beverage industries with advanced membrane specific value. Using diafiltration the yield can be increased filtration technology and systems engineered up to 80%. for reliability and cost-effectiveness. Easy to The aim of this brewery was to reduce the yeast levels and install and simple to use, our systems satisfya wide range of filtration requirements. Our to recover more beer. In a detailed example, 460 hl of yeast Total Fluid Management approach offers beer mix with 15.5 ° Plato were filtered. With diafiltration and customers solutions to address the needs of the wash out effect by adding water, 564 hl with 10.1 ° Plato an entire process, encompassing filtration could be recovered, equivalent to an extract yield of 80 %. products, services, systems and training. Pall Food and Beverage Visit us on the Web at www.pall.com/foodandbev 25 Harbor Park Drive Pall Corporation has offices and plants throughout the world. For Pall representatives in your area, please go to www.pall.com/contact Port Washington, NY 11050 +1 516 484 3600 telephone Please contact Pall Corporation to verify that the product conforms to your national +1 866 905 7255 toll free US legislation and/or regional regulatory requirements for water and food contact use. Because of technological developments related to the products, systems, and/or Portsmouth - UK services described herein, the data and procedures are subject to change without notice. +44 (0)23 9230 2269 telephone Please consult your Pall representative or visit www.pall.com to verify that this +44 (0)23 9230 2509 fax information remains valid. industrialen@pall.com © Copyright 2010, Pall Corporation. Pall, , Keraflux and Membralox are trademarks of Pall Corporation. ® Indicates a trademark registered in the USA. Filtration. Separation. Solution.SM is a service mark of Pall Corporation. FBABFLXEN Printed in the UK. January 2010

Cider Producer Maximizes Yield and Increases Capacity with the Oenoflow™ HS System Overview The Challenge Filtration is a key operation in modern cider A cider mill producing 20 million liters of cider per production to deliver visually bright and shelf stable year uses an Oenoflow XL crossflow system for product. Traditionally, cider clarification has been post fermentation clarification. After fermentation performed with diatomaceous earth or sheet and maturation, the Oenoflow system clarifies the based filtration technologies. However, with more cider while concentrating the solids. Even after favorable economics, easier operation and lower consistently concentrating up to 25% solids (v/v), waste volumes, crossflow filtration systems like the cider losses are in the range of 4%. The cider Pall’s Oenoflow XL system have become more maker was looking for an economically reasonable widely adopted over the past decade. way to increase yield. While the afore-mentioned clarification systems can concentrate to high solids levels, there is still a The Solution significant amount of recoverable alcohol in the To recover additional alcohol from the cider lees, yeast at the bottom of fermentation or maturation the customer purchased Pall’s new Oenoflow HS tanks and filtration system concentrates. With or High Solids system. The system employs hollow Pall’s newest member of the Oenoflow family of fiber membranes similar to those already used in systems, the HS system, cider producers can now their cider clarification application, however, the recover high quality cider from these lees streams Oenoflow HS membranes have a wider internal to gain up to 4% capacity with no additional fiber diameter to concentrate the solids up to about capital investment. 70% by volume. For the new process, after fermentation and maturation, the hard cider at 10% alcohol is filtered by the Oenoflow XL system while the tank bottoms Application Bulletin

New Process Schematic Fermentation vessel up to 3 weeks Maturation vessel up to 18 months Pump Lees Oenoflow Oenoflow HS System holding tank mother tank For off-site disposal Oenoflow XL System To blending To blending are sent to a lees holding tank that also serves as 800,000 liters to approximately 285,000 liters per the feed supply for the Oenoflow HS system. The year. With the cider at 10% strength, this means XL system filtrate or clarified cider is sent alcohol losses of 28,500 liters per year. By adding downstream for final blending to bottle strength diafiltration, the alcohol losses can be further while the concentrate is sent to the lees holding reduced to approximately 3,500 liters per year tank to be further concentrated by the HS system. resulting in a system payback less than a year. The final HS system concentrate is sent for off-site Compare the losses for the process with and disposal. A schematic is shown above. without the Oenoflow HS system in the tables below. The Oenoflow HS system design incorporates In addition to the added value from the recovered diafiltration, a process where water is added to the alcohol, the customer was able to realize further lees concentrate. Diafiltration “washes out” alcohol benefits. They increased their finished cider capacity from the yeast to increase recovery and improves without the need for additional capital investments the return on investment. The resulting alcohol like fermentation tanks and the associated equipment. strength of the filtered cider batch is reduced, Without diafiltration, the HS system alone increased however, this helps to lower the water required for capacity by 2.6%. Considering diafiltration, the the downstream blending to bottle strength. cider capacity increased by 3.8%. The final By implementing the Oenoflow HS system, the concentrate or waste volumes were also reduced, customer can reduce their cider losses from therefore lowering the cost for off-site disposal. Losses without the Oenoflow HS System Losses with the Oenoflow HS System Annual volume fermented base 20,000,000 L Annual lees volume 800,000 L Initial solids loading 1% Initial solids loading in the lees tank 25% Alcohol strength 0% Alcohol strength in the lees tank 10% Alcohol volume @ 100% 2,000,000 L Alcohol volume @ 100% 80,000 L Final solids loading in the lees 25% Final solids loading in the lees 70% Volume of lees 800,000 L Volume of lees 285,714 L Diafiltrations 0 3 Alcohol content 10% Alcohol content 10% 1% Volume of alcohol losses @ 100% 80,000 L Volume of alcohol losses @ 100% 28,571 L 3,571 L Percent loss 4% Percent loss 36% 4% Strength of final batch 10% Strength of final batch 10% 6% Volume of filtrate 19,200,000 L Volume of filtrate 514,286 L 1,371,429 L

The Benefits The benefits realized upon implementation of the Oenoflow HS system in this application include: • Alcohol losses decreased from 80,000 liters per year to approximately 3,5000 liters per year • 3.8% increase in finished cider capacity without additional capital investments like fermentation vessels and the associated equipment • Attractive investment with payback less than 1 year • Lower concentrate volumes for reduced off-site disposal costs • Automated and controlled process This case study has been replicated at other cider producers of similar scale with comparable economic drivers. About Pall Corporation Pall Corporation is a global filtration, separation and purification leader providing solutions to meet the critical fluid management needs of customers across the broad spectrum of life sciences and industry. We work with our customers to advance health, safety and environmentally responsible technologies. Pall Food & Beverage provides products and services to ensure product quality and maintain process reliability in beverage and food production. Our solutions also assist in consumer protection, waste minimization and reduction of operating costs. Pall Food and Beverage Visit us on the Web at www.pall.com/foodandbev 25 Harbor Park Drive Pall Corporation has offices and plants throughout the world. For Pall representatives in your area, please go to www.pall.com/contact Port Washington, NY 11050 +1 516 484 3600 telephone Please contact Pall Corporation to verify that the product conforms to your national +1 866 905 7255 toll free US legislation and/or regional regulatory requirements for water and food contact use. Because of technological developments related to the products, systems, and/or foodandbeverage@pall.com services described herein, the data and procedures are subject to change without notice. Please consult your Pall representative or visit www.pall.com to verify that this information remains valid. © Copyright 2015, Pall Corporation. Pall, and Oenoflow are trademarks of Pall Corporation. ® Indicates a trademark registered in the USA. Filtration. Separation. Solution.SM and BETTER LIVES. BETTER PLANET. are service marks of Pall Corporation. FBABCHSEN June 2015