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MillerCoors Golden Brewery Sustainability Improvement MillerCoors Golden Brewery Sustainability Improvement. Energy Water Waste to Landfill Julie Smith,

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Presentation on theme: "MillerCoors Golden Brewery Sustainability Improvement MillerCoors Golden Brewery Sustainability Improvement. Energy Water Waste to Landfill Julie Smith,"— Presentation transcript:

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

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

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  CO 2 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 PowerYDPStill Malting/Kilns Packaging/Warehouse/Gov. Cellar Fermenting Conditioning Turbine Brewing

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

9 Fermenting Yeast + Wort = Beer Maintain Temperature Residence Time CO2 Yeast 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  Power Plant – Co-Generation  Coal and Natural Gas Fired Boilers 800 LB Steam 1)Electricity 2)400 LB Steam 3)50 LB Steam  Ammonia Steam Electricity  Plant Air Steam Electricity  Water Treatment Electricity  Wastewater Treatment Electricity  CO 2 Recovery Electricity

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 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 Lights Pump VFD’s Controls Equipment Right-Sizing  Facilities Lights HVAC Insulation 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 Pavilion at Investment Recovery Employee Sales / Beer Trailer 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)



41 Culture and People What is Culture?

42 Culture – What is Culture? Definitions: 1.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. 2.That which is excellent in the arts, manners, etc. 3.A particular form or stage of civilization, as that of a certain nation or period: Greek culture. 4.Development or improvement of the mind by education or training. 5.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 Top Priorities & Assigned Leads Brewery Priorities & Sustainability Team Effort Impact


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