Traditionally pioneers since 1845 NEWS N 21 november 2014 Dear Readers, As ever it is a real pleasure for me to present you with our latest MeuraNews! In our 21 st issue, we take the opportunity to introduce you to three of our recent projects, each being proof of our strong partnership with our customers on all continents. You will also discover how MEURA s patented Aflosjets technology one of the secrets of the unequalled efficiency of our MEURABREWS is also amazingly efficient in the revamping of existing brewhouse vessels. Finally we would be very pleased to extend a warm welcome to you at our stand at Brau Beviale 2014, to explain our latest developments in detail. And of course, as always you will be greeted with a tasty selection of our very best Belgian beers. I wish you all pleasant reading and look forward to seeing you in Nuremberg. Sincerely yours, Christian De Brackeleire Chief Executive Officer CONTENT Hall 7, Stand 547 Come and visit us! Backus ATE Brewery p 2 Ledenika Brewery p 4 VBL Tien Giang p 7 Current News p 8
Backus ATE Brewery Backus Peru Not only famous for its Inca heritage, Peru is also the home of the Backus breweries! With 5 breweries located throughout the country (ATE, Motupe, Arequipa, Cusco and Pucallpa Breweries) the SABMiller owned Backus group is by far the most important brewer in Peru, with a market share of about 95 % of the domestic production. The Peruvian beer market totals some 14.5 million hl per year! Among its numerous breweries, ATE Brewery, located in the capital Lima, is the largest one with a current capacity of about 9 million hl sales beer. The ATE brewery was built as a greenfield plant in 1993. ATE Brewery mainly produces the Cristal brand but also brands like Pilsen Callao, Pilsen Trujillo, Cusqueña, Barena, Meura Backus Milestone The first Meura 2001 filter in Peru was installed in 1992 in the Rimac brewery. This mash filter has been relocated to the Motupe brewery in 1996 and finally to the Cusco brewery in 2010. After integration of the Meura2001 in the 2
Cusco brewery, that brewhouse became the brewhouse with the highest extract yield of all Backus breweries. Project and Equipment Due to an ever increasing demand, the ATE brewery decided to extend its production capacity. Meura was awarded with the brewhouse up-grade allowing to increase the capacity up to the required volume for the year 2020. The main reasons to choose for Meura s technologies was the high productivity (14 brews/day) and the low total cost of ownership of the Meura2001 filter. In addition, the brewery decided to install a Carbomill (hammermill under CO 2 atmosphere) to further improve the flavor stability of the final beer. Finally, to reduce the steam consumption of the brewhouse the decision was taken to install an Ecostripper (wort stripping), the first in a brewery of the SABMiller group! Before Meura s project started, the ATE brewhouse was based on two brewlines equipped with lauter tuns and producing 8-9 brews a day per line. The major target was to maintain the existing capacity of brewhouse no.1 of 9 brews a day, 1000 Hl cold wort at 16 P and to increase the capacity in brewhouse no.2 to 14 brews a day, 1000 Hl cold wort at 16 P. This to be achieved with some new key technologies: Upgrade of the malt handling. Carbomill 12 t/hr. Meura s hammermill with milling and grist storage under CO 2 atmosphere. Mechamasher 70 t/hr (mechanichal pre-masher). Cereal cooker. Mash tun. Double Meura 2001 Hybrid for 20 tons malt equivalent. Wort preheating system. Ecostripper (wort stripping). After the revamping of brewhouse no.2 (14 brews/day) and maintaining brewhouse no.1 (9 brews/day), the goal of 23 brews a day, 1000 Hl cold wort and 16 P is reality today! The up-graded brewhouse is reaching all process guarantees inquired by the brewery. The main obtained performances are: Very bright wort with a turbidity <10 mg/l Extract yield thanks to the fine milling and the Meura 2001 equal to the laboratory yield (2% more than with the lauter tun line running at only 9 brews per day) 14 brews a day thanks to the Meura2001 filter (occupation time of 100 minutes by average). Free DMS average <20 ppb thanks to the high efficiency of the Ecostripper. Meura wishes to thank the team at the Backus ATE brewery for their trust and for having awarded Meura with this challenging project! 3
Meura 2001 Hybrid equipped with a light curtain and a protection screen. LEDENIKA BREWERY The Ledenika Brewery is located in Mezdra, a small Bulgarian city with approx. 12.000 inhabitants, 100km North of Sofia. It is named after the nearby Ledenika cave, and passed on its name to its most famous lager beer, Ledenika. The brewery was established in 1964. The long relationship between the brewery and Meura started in the 1980s with the installation of a complete fermentation cellar including 12 cylindroconical tanks. Ledenika and Meura have maintained a strong relation since, based on technological trust and reliability. In 2011, after a period of financial difficulties, the brewery was shut down for almost 3 years. Having been acquired by Litex Commerce in 2013, important investments were needed in order to restart the beer production. The original brewhouse was installed in the 1991 by a Czech supplier and in poor conditions. The new owner contacted Meura and signed in September 2013 the order for the brewhouse revamping. Ledenika brewery is the third brewery in Bulgaria installing Meura s state-of-the-art technologies. Earlier, the Zagorka brewery (Heineken), and the Astika brewery (Molson Coors) decided to work with Meura for their brewhouse revamping (including a Meura2001 filter). 4
Before the order award, the brewery requested Meura to audit the equipment and to propose the most suitable revamping while keeping certain budgetary constraints in mind. Three major issues were emphasised after the audit: 1. Poor performance of the mash tuns. The mash tuns had a stainless steel bottom part, carbon steel steam jackets and a copper dome. In addition to the low heating speed, the double jackets had some mechanical issues. 2. The lauter tun had a low extract yield and was the bottleneck of the brewhouse. 3. The wort kettle required a high evaporation rate. Consequently the high heat load was reducing the flavor stability of the final beer. Meura s mission was to revamp the brewhouse by improving the mash heating, mash filtration and the boiling process. The final target was to improve the productivity, efficiency and flavour stability of the final beer. To achieve this, Meura supplied the following technologies: A hammermill (Classicmill CLM3) Upgrade of the mash tun thanks to the Aflosjet technology, new hydrator and new low shear agitator Meura 2001 Hybrid mash filter for throws of 8,5 tons malt (or malt equivalent) Upgrade of the wort kettle with an external boiler including 3 hop dosing units. The automation works and the electrical installation supervision were achieved with Meura s partner, the company Montelektro. One of the most outstanding aspects in this project is the installation of the Meura Aflosjets. This Meura state-of-the-art patented technology enables to heat mash optimally and quickly, irrespective of the size of the kettle compared to a double jacket technology and this without any fouling issue. We take the opportunity to thank the new Ledenika team for its trust in our equipement and team. Installation of Aflosjets on the existing mash tun Drilling of holes into the mash tun Installation of Aflosjets New mixing device for the mash tun The AFLOSJET system uses direct steam diffusion that gently heats the mash, providing numerous advantages compared to a conventional system using double jackets: Rapid and constant rise in temperature independent from CIP cycles (equal mash vessel occupation time all week long). No fouling issue Reduction of mash oxidation and shear forces, thanks to a gentle mixing Reduction of Strecker aldehydes. Excellent mash filterability. Only a weekly CIP required thus lower amount of chemicals for cleaning. Ideal solution for a brewhouse revamping. Technical description The patented AFLOSJET technology works at a low steam pressure. The function of the agitator with the AFLOSJET system is no longer to assure a heat transfer as it is the case with a double jacket, but to make sure the brew is homogeneous. For this reason, the AFLOSJET system requires a type of agitator different from the double jacket system. The system is the ideal solution for a brewhouse re-vamping. It is installed without a long halt in production and is an attractive economical solution compared to the installation of new conversion vessels. 5
Today, the Ledenika brewery is celebrating its 50 th anniversary and we wish them all the best for at least the next 50 years! Interview with Miroslav Dinev, project consultant during the execution and currently Plant Manager of Ledenika Brewery Why did you decide to work with Meura on this project? I was familiar with the Meura2001 mash filter technology. It was the initial reason to contact Meura. An important advantage of the Meura2001 was the opportunity to double the capacity of the brewhouse at a later stage. By choosing the Meura2001 we were able to produce at least 12 brews a day. In future, we will extend the capacity just by installing the Aflosjets on the second mash vessel and connecting the existing old wort kettle using a wort holding vessel. With little additional investment we can easily reach a production of more than 5000hl cold wort per day. The Aflosjet technology was explained at the first meetings. We immediately understood that this innovative system would lead to savings and a higher profitability of the project. Thus the performances of the technologies (especially the Meura2001 and Aflosjet) convinced us to decide working with Meura. How do you evaluate the co-operation with Meura s team on this project? The project went very well. Each of Meura s specialists was available at the right time and the co-ordination went very well. Thanks to the teamwork and the professionalism, the project was launched on time. After the commissioning we experienced good follow-up by Meura s specialists as well. What is your overall opinion of the project? The most important thing for us is the positive reception of the Ledenika beer by our customers. They like the beer produced with the new Meura technology and the new recipe too. That is the reward for our professionalism and the hard work of all those involved in the reopening of the brewery and the relaunch of the Ledenika brand. 6
Vietnam Brewery VBL Tien Giang Vietnam is the third largest beer producer in Asia, with an annual production of about 30 million hectolitres per year! One of the largest and fastest growing brewing groups in the country is VBL (Vietnam Breweries Limited), the first in the premium sector! VBL, created as a joint venture between Heineken (majority shareholder) and Saigon Trading Group (Satra), owns a total of 4 breweries including 2 equipped with a complete Meura brewhouse: VBL Da Nang (2011) and recently VLB Tien Giang (2014). VBL Tien Giang was previously equipped with an old brewhouse that no longer could meet the increasing demand, nor provide high quality of the end product. The brewery therefore decided to renovate its equipment and called Meura. The VBL group had already entrusted Meura with the order of VBL Da Nang s new brewhouse and was highly satisfied with its brand new equipment. Meura supplied a turnkey brewhouse of 440 hl cold wort at 17.5 P, of course equipped with a Meura 2001 filter. Meura was supported by Boccard Shanghai in this project (Meura s Chinese subsidiary) that took charge of the equipment for the raw material handling and an important part of the brewhouse vessels. The automation supervision based on Brewmaxx was installed by Montelektro. VBL Tien Giang has now a capacity of 1.8 million hl and is one of the largest and most modern of Vietnamese breweries! We would like to thank VBL for its continued trust in Meura s team and technologies with this article and we all wish them great success for the future! 7
Current news Craft Brewers conference Jeroen Vandenbussche, Chief Commercial officer, and Mark Plutshack, sales representative attended the Craft Brewers Conference organised in Denver, USA in April. It was a great opportunity to meet a lot of American Craft Brewers and to present our Meura 2001 Micro and Meura 2001 Craft Junior especially developed for them. MBAA Bahamas In March, Christian De Brackeleire, CEO and Raul Martinez, Area Sales Manager, took to Nassau to participate in the Master Brewers Association of the Americas convention. Many interesting contacts were made there! WDSC Glasglow Drinktec India Jeroen Vandenbuscche, Chief Commercial Officer, accompanied by Wouter Vermeersh, Area Sales Manager, have exhibited at Drinktec India held in Mumbai. They shared the booth of Praj Industries, Meura s Indian partner and both companies had a successful fair! China Brew China Beverage 2014 The China Brew and Beverage fair is held every two years in Beijing and took place on 13-16 October 2014. Noah Zhai, Sales & Marketing Manager of Boccard Shanghai and Guy Depraetere, Business Unit Manager of Boccard Shanghai, exhibited there and had a lot of very interesting meetings! Future Events Brau Beviale, Germany (Nuremberg) 11-13 November 2014 IBD, Mozambique (Maputo) 1-6 March 2015 Craft Brewers Conference, USA (Portland) 14-17 April EBC, Portugal (Porto) 24-28 May 2015 David Clifford, UK Operations Manager and Jeroen Vandenbussche, Chief Commercial Officer, exhibited at the Worldwide Distilled Spirit Conference organised in Glasgow in September. This 3-yearly event is the ideal place to show how Meura also can be a reliable partner to the distilling industry. Editorial Department : Editor-in-Chief : Jeroen VANDENBUSSCHE, Chief Commercial Officer Managing Editor : Bénédicte Everaert, Marketing Communication Manager Design, layout & printing : Ex nihilo - Belgium Traditionally pioneers since 1845 Meura S.A. Rond-Point J.-B. Meura, 1 - B-7600 Péruwelz (Belgium) - P: +32 69 88 69 88 - F: +32 69 88 69 80 - sales@meura.com - www.meura.com