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Brewery
BRange of Problems:
Brewing is the most material intensive sector among all food-industry branches, which outputs significant amount of solid and liquid waste. Brewing waste can be divided into solid and liquid. Solid waste includes: brewers’ grains, grain waste (barley screening), malt-sprouts and composition of barley. Liquid waste includes: grains transportation water, protein sediment, resting yeast and lager residues. Brewer’s grains constitute the main part of brewing waste. Brewing industry enterprises in Russia (over 400 enterprises) annually accumulate a great amount of brewers’ grains with moisture content of 70-80% which contain on average over 20% of dry substances with high level of protein (12-15%) exceeding almost in 3 times its content in barley. At the same time hundreds of thousand tons of brewers’ grains have been accumulated on polygons of Russian brewing enterprises. This mixture of plant and microbal proteins, complex carbohydrates, organic acids and other substances stored at open facilities and foundation pits of polygons start to emit in the air hazards of hydrolysis and decomposition on the third day (including poor odor gases – skatole, indole, ammonia). In such state waste can lie in “burial places” up to 50 years polluting biosphere by emissions. Chemical products of decomposition gradually penetrating in soil poison ground water; land becomes unsuitable for agriculture for decades (with unpredictable ecological effects). It should be underlined that not all polygons are able to accept waste for burial which can be reused in agriculture, and therefore, transportation costs turn out to be rather high. It is economically unprofitable for Russian breweries to throw brewers’ grains away. There is only one way out: such waste shall be processed on its own or sold to other organizations. However, there are few organizations which desire to buy brewers’ grains from Russian brewers. Annually an average capacity brewery generates 35,000 tons of brewers’ grains. Under conditions of such scales skillful and careful utilization of waste and by-products can not only ensure a significant profit to a processer of such waste, but also remove a threat of environment pollution. Established ecological situation in Russia requires urgent solution of the problem on large-tonnage brewers’ grains waste utilization. HSDS (Variant1) The project is based on two criteria: ecology and economy. Drying – deficiency of protein feed in Russia is over 25% and animal origin feed – over 40%. The questions on production of traditional dry animal origin feed based on bone scraps and tankage are particularly pointed in the world, including Russia, due to the fact that production volumes have been abruptly reduced because of threat of animal virus infection and “mad cow” disease. That’s why scientific and research organizations are searching for additional protein sources in the form of new feed stuff, application of which would enable to increase biological value and efficiency of combined feed and effectiveness of its consumption by animals and poultry. Brewing waste, the majority of which constitutes watery perishable products, is used irrationally that can be explained by absence of processing equipment at places of its generation. The main reason of why wet grains can’t be used is storage terms and transportation difficulties. Thus, brewers’ grains seed and turn musty at temperature of 15-30°C in the result of which its storage period is equal to 48-74 hours. Losses at wet brewers’ grains storage are linked to emerging of mycotoxins inducing hepatotoxic effect for animals (liver injury). Due to this fact the issue on methods of brewers’ grains processing which enable to preserve feed advantages of such non-traditional source of raw materials is especially relevant. From economic point of view production of dry feed stuff is of high efficiency. Dry brewers’ grains are stable at storage and transportable. Research findings of the V.M. Gorbatov All-Russian Meat Research Institute, All-Russian Scientific and Research and Technological Institute of Poultry Industry allow us to make a conclusion about an absolute perspective of dry brewers’ grains application. HSDS equipment may be installed directly on breweries or on the base of autonomous independent enterprises, including those manufacturing combined food. HSDS processing systems offer an up-to-date environmentally safe waste-free technology of brewers’ grains processing upon application of output products for needs of the livestock sector and not only this. Feed advantages of brewers’ grains (in 1 kg).
Addition to Variant 1 uppermost economic effect As it is extremely difficult to find a sales market for the end product and at first this requires extra financial and human resources the best solution is generation of power out of waste at places of its accumulation. A major brewing enterprise makes rather big investments in facilities maintaining, including heating and hot water generating for technological processes. By generating dry fine-dispersed powder with calorie content of over 6,000 kcal out of brewers’ grains a plant obtains a high-quality fuel. Cost of such fuel is ten times cheaper than all existing types of energy resources (almost for free). Economic effect from application of dry brewers’ grains as a fuel for an enterprise is the best solution both for the problem of its utilization and for the problem of further profit gain through reducing heat media costs. In order to achieve such effect it is necessary to install HSDS processing equipment and supplement it with biomass boiler equipment. In the result: - utilize waste at place of its accumulation - remove transportation costs at all - own fuel depot -independence from external energy resources - full or partial reduction of heating costs (especially in wintertime) - possible electric power generation (depending on a boiler’s type, fuel and energy complex) |