May 2005 5 Traditionally pioneers since 1845 C o n t e n t s Dear Readers, Firstly, we trust that 2005 has been a good year for you so far... and it is with great pleasure that we present our fifth Meur@news. This newsletter, created to satisfy our customers requirement for up to date information regarding Meura s activities and new technologies is a growing success. We take great pleasure in keeping you informed about some of our latest projects and technological innovations of which we are justifiably proud. P. 1 Welcome P. 2 Shymkentpivo P. 5 Malt extract P. 8 Current News Brau Beviale 2004 - Nürnberg of Brauwelt Visit of Dr.-Ing. Karl-Ullrich Heyse o ) IBD 2005 Sun City (South Africa) Spanish-speaking seminar Video conference This year, like the other ones, Meura s priorities are research and development. We want to offer you the best products together with the most efficient project planning in order to optimise your Overall Brewhouse Yield, while maintaining top quality of the end product. With this goal in mind, Meura, as a complete brewhouse supplier, remains at your disposal to undertake all your future projects and installation requirements. Keep one length ahead with Meura s technologies! Sincerely yours, Michel Genart Managing Director Rond-Point J.-B. Meura, 1 B-7600 Péruwelz Phone : +32 69 88 69 88 Fax : +32 69 88 69 80 www.meura.com
Beer cooling skid Shymkentpivo Kazakhstan, surrounded by Russia, China, Kyrgyzstan, Uzbekistan and Turkmenistan, is an ethnically diverse republic that gained independence from the former Soviet Union at the end of the year 1991. Kazakhstan is very rich in minerals such as uranium, silver, zinc, coal and especially oil. By 2010, Kazakhstan is expected to be one of the top 5 oil producers in the world. Kazakhstan is a fast-expanding country. Since 2000, it has been enjoying a 10-percent annual growth in GDP on average. This is due to both favourable international market conditions and results of earlier innovative economic reforms. Shymkent is the third largest city in Kazakstan and is also a major industrial and cultural centre. The city has one brewery, Shymkentpivo, which is the country s top producer. Brewhouse A continuous development The story of Shymkentpivo begins in 1982 when a complete new brewery was built, originating from Czech Republic. Shymkentpivo became renowned for its high quality beer and, thanks to this success, it became the first beer producer in Kazakhstan, producing more than 25% of the beer in the country. In order to fulfil the increasing beer consumption at the end of the nineties, Shymkentpivo planned to invest by modernizing its brewery to improve its productivity and to assure a best quality beer. A Complete brewhouse revamping Stage I... The first contacts between Shymkentpivo and Meura go back to 1999 when the brewery invited Meura to tender for the modernization of its plant. After several visits, a modernization plan for the complete brewery was established. The execution of this plan, involving different phases, started in 2002. In March of that year Shymkentpivo ordered the first stage of the project consisting of the upgrading of the cooling plant (chilled water production for wort cooling + a green beer cooler), water treatment (water dealkalisation using ion exchangers), high gravity beer system (deaerated water production, beer blender, beer carbonation). All the skids were installed within 3 months in order to ensure the increasing of the production capacity by the following summer. Stage II... Only a few months later Shymkentpivo ordered the second phase of this extension plan. This project included Concerning the brewhouse, the main equipment is the following: The Milling plant modernization (fine milling technology thanks to the Meura ) Brewhouse modernization (including a, the system and the mash filter) Spent grain silo BBT department (4 BBT s of 1500hl net capacity each) Regarding the milling plant, Meura supplied Shymkentpivo, with its Classicmill combined with its Mechamasher, in order to provide an excellent hydration of the starch (lump free) with very low oxidation of the mash. system In the old Shymkentpivo brewhouse, built by Czech manufacturers, all the vessel domes were in copper. This beautiful copper presentation was maintained at the request of the brewery. The mash conversion vessels were originally equipped with carbon steel heating jackets welded on the stainless steel bottom. During the Meura survey, this system raised two problems: on one hand, due to the old age, the double heating jackets were blocked and on the other hand they presented several disadvantages. As it is known, having sufficient agitation during mashing is crucial to assure the homogeneity of the mash in the conversion vessels and to increase the heat transfer. The main disadvantages of the double heating jackets, well known to the brewer, are: The strong agitation causes particle attrition (shear forces) and mash oxidation. The fouling of the double jackets progressively reduces the heat transfer. This strongly affected the productivity of the brewhouse because of the required C.I.P of the mash conversion vessel. To solve those problems, Meura proposed an attractive alternative: the AFLOSJET. The AFLOSJET is an Anti-Fouling LOw Shearforces mash heating system developed by Meura. The AFLOSJET overcomes the main disadvantages of traditional double jackets, assuring greater mash filterability due to the no fouling of the mash vessels and limited shear forces. The 4 BBT s Let s have a look at the main assets of the : The system uses a direct clean steam injection 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 (reproducible mash vessel occupation time). Reduction of mash oxidation and shear forces. Reduction of strecker-aldehydes (less intensive heating). Excellent mash filterability. Short CIP procedure, using less chemical products and performed only once a week. Ideal solution for a brewhouse revamping. 3
mash filter Shymkentpivo, already convinced by the Meura 2001 mash filter, decided for this state-of-the-art technology to replace its two lauter tuns. Because of its excellent performance, the Meura 2001 was considered as the ideal partner to improve the wort quality. Indeed, Meura 2001 mash filter is able to produce simultaneously: High productivity (at least 14 brews/day) High extract yield (at least equal to laboratory yield) Very bright wort (Imhoff < 5ml/l) High gravity wort (> 16 P cold wort) A mash filter with 65 chambers for a throw of 12 tons malt was installed. The cold wort volume of one brew is 508hl at 16 P. Trub separation: Wort Settling Tank Always willing to provide the best technology to its customers, Meura installed a Wort Settling Tank. Compared with the whirlpool, the Wort Settling Tank presents several advantages. The most important one is the possibility to recover hot trub during the wort cooling, which allows recycling of the non-oxidized trub. While the loss of yield with a good whirlpool represents an average of 1 to 1,5%, the loss of extract with a wort settling tank when recycling the trub is almost zero. Fermentation vessels under construction Stage III To complete the Shymkentpivo modernization, the brewery has put its faith in Meura to modernize the cold block and to provide further utilities. The vessels were produced on-site together with Meura s sister company CSC-Boccard. Four supervisors stayed on-site supported by a local team. This third phase was composed by: Fermentation vessels: Meura erected 4 CCT s of 2032 hl net/2640 hl gross and 8 CCT s of 3048 hl net/4025 hl gross. Fermentation cellar (including different CIP vessels). Yeast storage and preoxygenation plant. Utilities: cooling plant, CO 2 recovery unit, oil free air compressors. Yeast pre-oxygenation plant Malt extract All over the world the demand of natural colorant and the general demand of extracts originating from malt, barley, oats, rye and wheat as well as from other cereals, is continuously increasing. These extracts can be liquid (at 80 P) or solid. The malt extract s applications are numerous in the food & beverage industry. Indeed, the malt extract is more and more often used in candies, bakery products, sauces, brewing industry... It s also used in the pharmaceutical industry, dairies,... Malt extract coming from high diastatic malt is used as natural source of alpha and beta amylase, betaglucanase, and other enzymes mostly used in the bakery industry. The advantages are multiple for the consumer. The extract and the colorant coming from malt are natural, healthy and are not coming from genetically modified raw materials. Malt extract: The malt extract can be produced from several cereals like oats, rye, barley, wheat, malt or roasted malt or from a cereal mix with rice, sorghum, millets, corn, etc... The malt extract production plant consists of a mash conversion vessel, a Meura 2001 mash filter and a heavy and weak wort vessel. The next step is the concentration stage. The following table shows the principle of the process CONCLUSION Thanks to this modernized plant Shymkentpivo can be proud to offer state-of-the-art beer to its customers. Weak wort tank 4 plato Fermentation cellar Through this letter, we wish to thank Shymkentpivo for their continued faith in, and loyalty to Meura. Malt Evaporator Fermentation vessels Mashing water Mash conversion vessel Wort recirculation Loop Heavy wort tank It is important to define at the beginning the kind of extract to be produced. Indeed, some modifications in the milling and brewing equipment and changes in the brewing process have to occur depending on the choice and characteristics of the final product. Nevertheless the equipment for the concentration stage can remain the same (evaporator and spray dryer). 5
First step: the milling More than 70 % of the extracts are produced from malt or barley. To guarantee 100% extraction yield (= laboratory yield) as well as to guarantee the clearest possible wort, the malt must be milled very finely. Meura, having always been concerned about providing the best technology to its customers, developed different fine milling systems taking the specification of the different used raw material into account. For raw material having a moisture content of 4% and more Meura proposes the Classicmill, which is a ventilated hammer mill with horizontal shaft. The Classicmill affords several advantages. First of all, it can finely grind malt, barley, sorghum, and some cereals having a moisture content up to 15 %. Then, thanks to the ventilated hammer mill, the risk of having the mill blocked because of the accumulation of gums due to the humidity can be overcome, as well as the risk of burning or explosion. The fineness of the grist can be regulated by changing the sieves (several sieve meshes are available). Further Meura has developed the Aflosjet system. The mash is heated up by injection of clean steam directly into the mash, this also avoids the burning of the double jackets and its subsequent fouling. The Filtration As the aim in the malt extract production is to obtain the clearest possible wort as well as a wort with the highest density, the filtration should be assured by the Meura 2001 mash filter. The Meura 2001 mash filter is a thin bed membrane-assisted mash filter which represents a lot of advantages for the malt extract production. One of these advantages is that the precompression stage allows the recovery of more than 80 % of the total extract before sparging. Related to this fact, the sparging liquor is only 2 litres per kg malt equivalent. Even weak wort can be re-used in the first step of sparging to obtain higher final extract. So, in that case the Meura 2001 mash filter assures a clear and dense wort between 25 and 30 P before evaporation. Let s have a look at some of the mash filter advantages in the malt extract production : Second step: Brewing Process For the milling of some cereals rich in cellulosic fibres like oat, or for the production of extract from crumbly products as dark malt or roasted barley, or else for the production of enzymatic malt extracts from green malt, Meura proposes the Hydromill. This device has been developed to finely grind cereals under water. It offers a perfectly controlled milling process. A buffer-column is affixed vertically over the Hydromill and makes sure the malt grains and the brewing liquor are mixed at the right temperature and in the right proportion. The inside of this equipment involves a stationary disc and a rotating disc equipped with two hammers for malt distribution over the periphery. Thanks to the flexibility of changing the gap between the two discs, adjustment in grinding can be achieved in connection with the used raw material. The Hydromill combines the process of milling and mashing in at the same time allowing a perfect hydration even at high grist/ water ratio. The Mashing-in During the mashing-in process, a particular attention should be paid to obtaining a wort with the highest possible density after filtration and before evaporation so as to reduce the investment cost of the evaporator as well as the costs of evaporation itself. A thick mash (between 25 P and 30 P) needs to be produced. Weak wort coming from the previous brew can be used for mashing-in and, if required, to achieve densities of about 30 P partly also during the sparging cycle of the mash filter. During the mix of the grist and the brewing liquor some problems of lumps formation can occur. To avoid this, Meura has developed the Mechamasher, an ideal complement to the Carbomill. The Mechamasher produces a lump free mix of up to 30 to 35 P. The Mechamasher achieves a ratio water/ malt as low as 1,5 L/Kg. By entering the mashtun from the bottom, Meura takes care to avoid on one hand the oxygen pick up and, on the other hand, shear forces during the brewing process thanks to special agitators. This technique then enhances a better mash filtration due to the NON Formation of large molecules responsible for a high viscosity. Meura has experience with brews up to 35 P. Productivity Short filtration cycles with the highest efficiency due to the high filtration surface. Perfect for high gravity brewing with first wort up to 35 Plato (with the use of a weak wort tank). Flexible load: 80 to 110 % of the nominal capacity. Fully-automated process. Efficiency Extract yield equal to the laboratory yield resulting in savings of raw materials. Very dry spent grains up to 30% of dry material. CONCLUSION As you can see, the malt extract, used in a lot of different Food and Beverage sectors, has the advantage of being one of the best natural products. The extract originating from dark malt or roasted barley can be used as a natural product to obtain different types of beer. It can be added in the copper or, when it is specially produced, it can also be added to the final beer. Showing interest in the development of this market, Meura decided to design and manufacture tailor-made equipment in order to provide solutions to all the malt extract producers. Meura s equipment, specially developed for all kind of raw materials, assures our customers of the best malt extract, whatever their requirements! Clear worts can be produced regardless of the presence or absence of husk material (from 0 to 100%) in the mash. Easy filtration with many different kinds of raw materials (malted or not). Acceptance of a high proportion of adjuncts (up to 100% with the use of exogenous enzymes). No final rinsing between filtration cycles, which is limiting the amount of wasted water. Quality Bright wort (Imhoff cone < 2 ml/l) without first wort recirculation. References: Major malt extract producers have adopted our technology in many countries such as: Finland, USA, UK, South Africa, Australia, Mexico, Chile, Italy, Denmark, Switzerland, Singapore, India,... 7
Brau Beviale 2004 - Nürnberg From November 10 th to 12 th 2004 Meura exhibited at the renowned Brau Beviale fair in Nürnberg (Germany). As expected, this was a real success for Meura as well as for the visitors who, once again, showed their deepest interest in Meura s technologies. The Area Sales Managers and some of our customers at the Meura stand. Visit of Dr.-Ing. Karl-Ullrich Heyse of Brauwelt On 24 th February 2005, Meura was very honoured to welcome Dr.-Ing. Karl-Ullrich Heyse, Editor-in-Chief of Brauwelt, who came to Meura in Péruwelz to visit our new premises. Spanish-speaking seminar From the 7 th until the 11 th of March 2005, Meura organised a technical seminar for twenty-two Spanish-speaking brewers coming from all over the world. The guests visited the Meura brewhouse of Rodenbach and our R&D department in Louvain-la-Neuve where they took part in some practical workshop procedures. They finally visited our new premises, as well as our new workshop in Péruwelz. Dr.-Ing. Karl-Ullrich Heyse with, on the left, Michel Genart, Managing Director, and on the right, Jeroen Vandenbussche, Are Sales Manager. IBD 2005 Sun City (South Africa) From the 6 th to the 11 th of March 2005 Meura took part in the 10 th IBD Convention at Sun City. Claude Bauduin, Meura Area Sales Manager for Africa & Western Europe, took this opportunity to present a poster entitled Global Benefits of Pre-mashing under CO 2 and High Gravity Brewing on Beer Quality and Environment. Claude Bauduin, Area Sales Manager, presenting a poster at the IBD 2005. The whole group during the visit to Meura in Péruwelz Video conference Always looking to improve the efficiency of the contact with our customers, we have installed a Video conference room in our new premises in Péruwelz. This enables us to organise meetings from Péruwelz with people working all over the world. If you want to arrange an appointment, please first contact us at the +32 69 88 69 88. Rond-Point J.-B. Meura, 1 B-7600 Péruwelz Phone : +32 69 88 69 88 Fax : +32 69 88 69 80 www.meura.com E-mail : Sales@meura.com Publisher : MEURA Editorial Department : Editors-in-Chief : - Michel GENART, Managing Director - Patrick BOCCARD, Chairman Managing Editor : - Françoise Lombaerde, Marketing Communication Assistant Design, layout & printing : - Losfeld Belgium