1. Plant Optimization Engineer Utilities/Technical Services
MillerCoors Golden Brewery Sustainability Improvement . Energy Water Waste to Landfill
Julie Smith, PE, MS
Plant Optimization Engineer
Utilities/Technical Services

2. Brewery Sustainability Improvement
Agenda
Corporate Goals/Leadership
Brewery Processes
Brewery Utilities
Opportunities
Waste to Landfill
Culture

3. Corporate Sustainability Goals
Energy Usage of 120 MJ/HL by 2015
Electricity
Steam
Vehicle Fuel
Water Usage of 3.18 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!

5. Brewery Process Overview
Malting
Brewing
Fermenting
Conditioning
Packaging
Warehousing

6. Golden Brewery Map

7. Golden Brewery Layout Aging Cellars, Hop Storage Power YDP Still
Fermenting
Turbine
Brewing
Conditioning
Packaging/Warehouse/Gov. Cellar
Malting/Kilns

8. Brewing Process
Mash In
Filter/Lauter
Boil Wort
Chill
Ferment

9. Fermenting Yeast + Wort = Beer Maintain Temperature Residence Time CO2
To Aging

10. Conditioning
Aging
Filter
Blend
To Packaging

11. Packaging Bottles, Cans and Kegs Rinse Fill Label Package Palletize
To Warehouse

12. Warehouse
Store Product
Move Product
Temperature
Docks

13. Utilities for Brewery Operations
Ammonia
Steam
Electricity
Plant Air
Water Treatment
Wastewater Treatment
CO2 Recovery
Power Plant – Co-Generation
Coal and Natural Gas Fired Boilers
800 LB Steam
Electricity
400 LB Steam
50 LB Steam

14. Utilities – Map of Valley

15. Utilities – Where does the Steam Go?

16. Resource Savings Opportunities
Steam

20. 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

22. Plant Air Opportunities
Leaks
Operations
Compression Equipment
Set Points
Small Projects
Cabinet Cooling/Pressure
Air Shut-Off on Equipment not Operating
Low Pressure Uses
Condensate Drains
Pneumatic Valves and Equipment
Large Projects
Decentralization
Distribution Headers

23. Condensate Return Benefits Where is it Going? Cost Energy
Waste Treatment
Water Treatment
Where is it Going?
Sewer
Stack
Steam Leaks

24. Utilities – Where does the Electricity Go?

25. Resource Savings Opportunities
Electricity

26. Electricity Savings Opportunities
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
Pump VFD’s
Controls
Equipment Right-Sizing
Facilities
HVAC
Insulation
Electricity Savings Opportunities
No!
Yes!

27. Electricity Savings Opportunities Malting Lights Results

28. Electricity Savings Opportunities BOC HVAC Recommissioning Results

29. Electricity Savings Opportunities Packaging Green Shut-Down

30. Utilities – Where Does the Water Go?

31. Resource Savings Opportunities
Water and Wastewater

33. Savings Opportunities – Water and Wastewater
Save 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

34. Waste 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

37. Co-Products Golden Brewery
Bill 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

38. 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 (
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)
Pavilion at Investment Recovery
Employee Sales / Beer Trailer

41. Culture and People
What is Culture?

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

43. Culture Elements for Success Leadership Green Teams Education
Communication
Recognition
Projects
Score Cards

44. Culture – Green Teams Golden Green Team – CARE
“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

45. UM Prioritization by Area
Water Projects
Steam Projects
Electrical Projects
AUDITS
IDEAS
Effort
Impact
Top Priorities & Assigned Leads
Brewery Priorities & Sustainability Team

46. Golden Brewery Energy Sustainability Team TS Initiatives Projects
Consumption, Cost, Carbon
Sustainability Team
Loss & Waste Analysis
Process
Packaging TS
Logistics
Focused Improvements
Packaging Line “Zero Energy” Pilot
Keg Line Air
A Water Overflow
Packaging Dry Lube
Conditioning Cold Sanitization
TS Initiatives
Cost Improvements
Fuel Cost and Mix
Fixed Cost Elimination
Energy Audit
Initiatives & Projects
Metering Strategy
Electrical and Steam Meters
Metering Plan
Projects
Cooling Tower VFD’s
Heat Exchanger Condensate Return
Plant Air System Projects
Frick #5 Evaporative Condenser
Lighting Projects