Partnership for optimum plant efficiency.

Servicenext level:

engineering for a better world GEA Process Engineering

Keep your plant running longer

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Servicenext level − Our service concept.

Together with our customers, we design intelligent

solutions aimed at fully exploiting the potential of your

brewery and achieving a continuous and cost-effective

production process.

Each individual service module plays an important role for: J Plant availability J Plant efficiency J Cost control

Our customers can choose from different service modules

to define their own individual service level.

Original Spare Parts

from GEA Brewery Systems provide the

customer with the safety level required to

ensure the efficiency of his plant.

Service Level Agreements

GEA Brewery Systems offers Service Level

Agreements for improved reliability, cost

control and efficient processes.

Mechanics: Plant availability

Technology: Plant efficiency

Control system: Plant safety

Consulting/Audits

from GEA Brewery Systems are a

fundamental step towards optimum plant

efficiency.

Training

Our qualified specialists will enable your

staff to operate your plant equipment in

the most profitable way.

Repairs

performed by GEA Brewery Systems

stand for care, precision and responsibility

of the manufacturer – around the world,

wherever you need us!

Field Service

from GEA Brewey Systems provides

commissioning, inspections, maintenance,

general overhauls and the implementation

of upgrades.

Upgrade/Modernization

is required due to changing market

conditions or technical/technological

changes – we are your partner with the

necessary competence.

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Audits − Transparency to make informed decisions.

The typical situation J Everybody identifies potential for optimization, which

is, however, difficult to assess accurately J Reluctance to intervene in the running process

In an audit, the potential of your brewery plant is evaluated

and suggestions for improvement are developed, including

an ROI calculation.

An audit can be divided into 3 phases

Phase 1 − Data collection J Process data collection using special questionnaires

prior to the actual audit

Phase 2 − On-site auditing J Process assessment during production; if possible and

appropriate, process optimization on site

Phase 3 − Data analysis, audit report and suggestions for

optimization J Analysis of the data collected on site and preparation

of suggestions for optimization, including ROI

calculations

As a result, you will receive an audit report, which

highlights the potential for optimization and includes ROI

calculations – transparency to make informed decisions for

plant performance at a high level.

Audit concept

Audit

Concrete

benefits

Plant survey

Specific

tools

Analysis

Transparency

Proposal

Process optimization/ realization of

upgrades

We provide technical/technological expertise for

the following areas J Brewhouse J Cold process area J Refrigeration plant J CO2 recovery plant J CIP J Energy J Water

Your immediate benefit from an audit J Immediate value for customers through process

optimization J Reduction of operating costs J Increase in plant efficiency J Reliable and optimized working conditions J Problem solutions J Concepts for the future

In most cases, the payback period is 3 to 12 months.

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Energy Efficiency Check −Mobile energy data management.

Rising cost pressure, higher requirements regarding climate

protection and increasing ecological awareness of consumers

present new challenges for the brewing industry: Energy

must be used more efficiently without affecting product

quality.

Appropriate plant optimization, process modifications and

staff training result in substantial savings. However, to obtain

such benefits, breweries have to recognize, measure and

assess the weaknesses in their production process.

Therefore, GEA Brewery Systems offers the Energy Efficiency

Check, which, through the use of mobile and temporarily

installed sensors, can also be described as “mobile energy data

management“.

All energy and material flows in the brewery are determined

and solutions for efficient energy utilization – particularly

in the production process – are developed according to

DIN EN 50001 and DIN EN 16247 respectively.

Overview of the actual energy consumption and costs J Actual state on the basis of current energy demand

calculations J Weak points and savings potentials J Priorities for efficient energy use J Proposals for energy saving and process optimization J Proposals for the implementation of renewable energy J Economic evaluation of the proposals J Specific recommendations with detailed instructions

Servicenext level comprises the complete process area from malt intake to the interface with the packaging area, including

refrigeration and CO2 recovery plants

Less Costs

More Energy Efficiency –

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Phase 1 − Quick Check (initial consulting),

approx. 2 days J Inspection of production areas J Determination of key plant data, examination of

documents J Recording or estimation of energy consumption data J Determination of measuring points for Energy

Efficiency Check J Quick Check report

Phase 2 − Efficiency Check (detailed consulting),

approx. 10 – 15 days J Identification of excessive energy consumption through

J Technological analysis of the processes J Measurement of electrical power (kWh/hl) J Measurement of thermal energy (kWh/hl; m³/hl) J Measurement of water consumption (hl/hl) J Compressed air audit (m³/hl; m³/kWh) J Examination of the refrigeration and CO2 recovery plant

J Immediate measures and staff training J Evaluation of recorded energy consumption data J Detailed report incl. list of measures to increase

efficiency, economic efficiency calculations, information

about support programs for possible/necessary

investments

Three steps towards energy optimization.

Phase 3 − Upgrade (measure) J Installation, commissioning and assessment of the

measure J Staff training J Further optimization measures

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Upgrade − Our innovations – Your benefit.

Experience shows that over the course of time the

equipment or process technology used requires adjustments

and modifications due to new demands on equipment

or production technology. This can eventually result in

reduced system efficiency.

This can be caused by a number of reasons: J Different raw materials J Modified workflow J Change of equipment properties J Undocumented settings of system parameters

In addition, external factors have changed our customers’

view on reference values, such as the specific water

consumption in certain production areas, the total CO2

demand for production or the required amount of CIP

media.

With tailored audits and a dedicated team of experienced

brewing technologists and experts in process technology,

GEA Brewery Systems focuses on improving the efficiency

and the consumption data of your brewery.

In every brewery plant from GEA Brewery Systems the

engineers apply the latest know-how and innovative

technology in order to produce high quality beers with

optimum energy utilization. This is what our customers

expect and they are right to do so.

We offer comprehensive modernization and expansion

services to ensure your high level of product quality, plant

efficiency and plant availability for many years.

Our service begins with a detailed analysis. Your brewery

equipment is thoroughly checked and evaluated in an audit.

This audit can be conducted for individual plant sections

or for the complete brewery including refrigeration and

process automation. All important process parameters as

well as safety aspects, energy consumption etc. are taken

into account. Special attention is paid to value creation:

quantities of raw materials used, energy expenditure, yield

and output.

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Servicenext level − the results speak for themselves J High plant availability J Excellent system efficiency J Spare parts availability as required

Optimized operating costs (TCO)

Your lautering system at LAUTERSTAR™

performance level

We bring also your lauter tun to the performance level of

the LAUTERSTAR™. The upgrade can easily be executed

step by step.

Yield J Yield increases of up to 2 percentage points have been

achieved

Capacity J Optimizing the lauter tun shortens the lautering

process as well as the ancillary process steps and leads

to a higher brewhouse capacity

Optimization in the brewhouse.

JETSTAR™ – for minimum total evaporation

The JETSTAR™ divides the wort boiling process into

two distinct steps: the thermal conversion step and the

evaporation step. This improves the efficiency of wort boiling,

saves primary energy and the wort quality improves.

Energy J Boiling with JETSTAR™, total evaporation can be

reduced to figures below 4 % J Immediate impact on fuel consumption, particularly in

atmospheric kettles without energy storage system

Quality J Due to gentle heating and homogeneous wort treatment,

the thermal load on the wort is reduced J Improved flavor stability of the beers and conservation

of the foam-positive protein fractions

Efficient use of heat with an energy storage system

The thermal energy required for evaporation during wort

boiling can be easily recovered with an efficiency of more

than 90 % and directly reused in the brewhouse. Low-

pressure boiling in combination with our design of the

energy storage tank allows a wide range of evaporation

rates. The system is balanced at 4.5 % total evaporation and

no hot water surplus is produced.

Energy J Savings of up to 60 % with a retrofit of energy storage

systems

Quality J The hot water produced is used to heat the wort by

means of a plate heat exchanger J Gentle conditions reduce the thermal stress due to a low

interfacial temperature

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GEA Process Engineering

GEA Brewery Systems GmbH Huppmann Tuchenhagen

Locations:

Heinrich-Huppmann-Str. 1, 97318 Kitzingen, Germany Phone +49 9321 303-0, Fax +49 9321 303-603

Am Industriepark 2–10, 21514 Büchen, Germany Phone +49 4155 49-0, Fax +49 4155 49-2770

gea-brewerysystems @ gea.com, www.gea.com

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 index.