Library

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Keynote: Tracking the African future

By: Daniel Silke

01/03/2015

Daniel Silke is an Independent Political Analyst, Author and Keynote Speaker specializing in South African and International politics. He has a specialist interest in political parties and elections and is a renowned Futurist lecturing widely on issues surrounding global change, volatility and the future of the world.

IBD Membership Required

THE Craft Brewing Industry in the United States

By: Charlie Bamforth

01/03/2015

Consolidation in the brewing industry after national prohibition in the early 20th century led to a very small number of brewing companies dominating the beer industry in the United States. Following President Carter’s signing into law the ability of people to brew at home, a burgeoning number of small brewing companies have progressively emerged. There are now over 3,000 breweries in the US.

IBD Membership Required

Water, Energy and Emissions

By: Brian Ireland

01/03/2015

The late Graham Mackay had foresight. In 2009 he publically committed SABMiller’s Beer Manufacturing operations to a 25% reduction in water ratio by 2015 and a 50% reduction in fossil fuel emissions intensity by 2020. This bold step not only differentiated and enhanced SABMiller’s reputation as a corporate leader with vision :- but it also set Technical in SABMiller on a journey with many consequences. This paper lays out the how SABMiller digested Graham’s vision and converted the targets that had been developed through the convictions of a few “on the back of a fag packet” to performances that many of our divisions can be proud of. Some milestones have been achieved, and some new targets set. So as SABMiller continues it water, energy & emissions reduction journey to 2020 and beyond … how have the learnings been taken on-board and applied, and what lies ahead.

IBD Membership Required

Assuring brewing water hygiene for the future

By: Bettie Lodolo

01/03/2015

The proud tradition of beer culture has evidence of historic roots as far back as 5 000 B.C. Given the choice between water or beer as the safer beverage to consume, the preference was for beer due to the bacteriostatic properties afforded by the presence of alcohol, low pH, low nutrient availability and the presence of hops. Water remains the main ingredient in beer forming about 95% of a 5% v/v alcohol product. The demand on scarce resources, such as water, informed one of the SABMiller 10 priorities of “Making more beer using less water” with the aim of 3.5 hl/hl beer by 2015. In order to achieve this aim a number of work programs were developed in support of this objective.

IBD Membership Required

The SAB University Microbrewing Project

By: Anton Erasmus

01/03/2015

n 2004, following on from extensive Trade Brewer negotiation, an opportunity arose for SAB to sponsor the installation and commissioning of a small-scale piece of Brewing Kit at the University of Kwa-Zulu Natal’s Pietermaritzburg campus, certainly a first of its kind in South Africa. Following this successful introduction, and further requests for Installations from University of Pretoria, Witwatersrand and others, a plan was put together to harness the collective power of this combined Micro-Brewing endeavour. By 2006, extensive collaboration between The South African Breweries Limited (SAB), The Institute of Brewing and Distilling Africa Section (IBD) and the RSA State-owned Food/Bev SETA led to the sponsoring of the traineeship of selected students in various Brewing disciplines in South Africa.

IBD Membership Required

Jebel Gold

By: Alice Owambo

01/03/2015

Objective of launching Jebel Gold: To introduce a credible spirit brand in format that delivers variable serves in order to drive price point accessibility for the D/E consumer while still being a profitable opportunity for EABL.

IBD Membership Required

Foam: The state of play

By: Charlie Bamforth

01/03/2015

As much as anything in brewing, the topic of beer foam attracts emotion and is riddled with dogma. This review of the current knowledge of beer foam will address diverse areas such as why the main shortcoming in beer composition in the context of foaming may be an excess of foam negatives; why the received wisdom that some specialty malts are great for bubble stability is often false; and how to interpret the reasons for less than ideal foam performance.

IBD Membership Required

Tank beer in Cape Town

By: Denis Da Silva

01/03/2015

This paper will look at a first in Africa, the provision of bulk unpasteurised draft beer to market. This niche was seen in the market due to suitable high volume draft outlets in close proximity to the brewery. These outlets can for the first time offer fresh unpasteurised draft beer in bulk to their consumers. This has resulted in increased sales and consumer reappraisal. The paper will discuss the technical approach to beer production as well as the delivery to market, bulk beer dispensing and the marketing execution.

IBD Membership Required

Kiwanda Maalum programme at Tusker

By: Felix Alala

01/03/2015

Tusker Site has just been recognized as the most improved brewery in Diageo Global Supply Excellence annual awards. This is a great achievement for the Tusker team and the site as a whole. The recognition serves to demonstrate our winning strategy anchored by the Perfect Plant Management System-Kiwanda Maalum(Perfect Plant) programme which has greatly contributed to improving our ways of working, our behaviours and capabilities on site as well as innovations, cost control and spirits growth. The Kiwanda Maalum was initiated in July 2013 and has been running for the last 1 year and 4 months on site.

IBD Membership Required

Manufacturing Way in SABMiller Africa – Tanzania story

By: Gabriel Pitso

01/03/2015

The Manufacturing Way is SABM’s key to sustainable implementation and anchoring of best work practices in manufacturing industry.Through the Manufacturing Way, world class manufacturing standards can be entrenched and sustained, as proven by the developments in Tanzania.

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Whisky effluent pre-treatment options for UASB anaerobic digestion

By: Jacques Blignaut

01/03/2015

The whisky production from maize at Wellington Distillery presents arguably the most challenging type of effluent in the whole of Distell. Although a very constant stream in terms of flow and quality is produced, the challenge lies in removing the Fats, Oils and Greases (FOG) before attempting to anaerobically digest the centrate in the existing reactor.

IBD Membership Required

High gelatinizing adjunct liquefaction in brewing – a novel approach to optimize the process

By: Jaydeep Chaterjee

01/03/2015

The inclusion of cereal-based adjuncts in beer recipes is prevalent in the African brewing industry due to its benefits in terms of extract cost and beer qualities. Brewhouse processing of high-gelatinizing adjuncts (e.g. corn, rice, sorghum and cassava) require relatively high heat input, adequate agitation and the application of thermostable alpha-amylases to effect the necessary starch gelatinization, starch solubilization and subsequent starch conversion to lower molecular weight dextrins. When applied in an adjunct cooking step in brewing, the liquefaction of high gelatinizing adjunct starch is adjudged as complete via relatively simple analytical tests such as iodine staining, photometric iodine testing and dextrose equivalent (DE).

IBD Membership Required

Bottle washer temperature reduction - Newlands Brewery experience

By: Jaco Kirstein

01/03/2015

As the demand for and cost of resources increase, the brewing sector is increasingly at risk from a sustainability perspective. Bottle washers are among the largest consumers of water and thermal energy in breweries with high volumes of returnable bottles. In this presentation the effect of lowering the bottle washing temperatures on thermal energy demand as experienced at SABMillers’ Newlands Brewery is reviewed.

IBD Membership Required

A refreshed look at HACCP in brewing

By: Edward Bourke, Joe Sheehy

01/03/2015

Hazard analysis for consumer safety in brewing depends primarily on prerequisites but also on a fully informed knowledge of the possible risks. This paper takes a new look at the possibilities that need to be considered in a competent brewing HACCP programme. While traditional large brewers have managed consumer safety for many years there is a distinct probability that the myriad of smaller players will release unsafe product. There have been numerous near misses within the industry and if attention to HACCP is lax there may be industry damaging incidents.

IBD Membership Required

Brewing up an African revolution

By: Lucy Corne

01/03/2015

The emergence of 'craft' breweries - which can be loosely defined as a brewery not owned by one of the global beer companies - in countries such as Kenya, Zimbabwe, Zambia, Namibia and especially South Africa, has been a relatively recent phenomenon that has expanded at a rapid rate. Despite the first craft brewery in Africa launching in 1983, it was only in the past five years that craft breweries started making their mark on the African beer industry.

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Pioneer wort boiling process with innovative internal cooker

By: Mario Allendoerfer

01/03/2015

Modern wort boiling systems must fit to individual process recipes which can be divided into three phases: heating, simmering and evaporating. To provide these three phases in all, an internal cooker usually relies on additional wort circulation pumps. Otherwise huge effort is necessary for cleaning, if boiling time is increased and heat supply is damped down. The here introduced innovative design provides a solution without such disadvantages. It consists of two interconnected heating segments, each can be activated separately. Two segments reflect three boiling phases. The essential function is achieved by means of Venturi effects. The required product circulation can be combined with a lowest possible heat supply. The heating segment in use always operates in optimum heating-flow condition. Simmering can be introduced as rediscovered procedure.

IBD Membership Required

Ethanol – recovery from a waste stream

By: Marco van de Ven

01/03/2015

Recovering from waste is a hot topic in any industry. Both the brewing and distilling industry spend a lot of time and energy fermenting a good brew, respectively distilling it to quality alcohol. During fermentation > 95% of the alcohol is entrained in the resulting beer. The remainder of the alcohol is “lost” as vapour in the fermentation gas. This CO2 heavy gas is often considered a waste stream and purged to the atmosphere. To breweries this waste stream carries valuable CO2, which more often than not, is recovered and purified for own consumption purposes. The ethanol is scrubbed out and drained. Although growing numbers of distilleries are generating extra revenue from recovering and selling purified CO2 (in many African countries food grade CO2 is expensive to come by), it’s the recovery of ethanol from this waste stream that distillers are mainly interested in.

IBD Membership Required

Boiler water treatment management system

By: Mare-Loe Prinsloo

01/03/2015

Water treatment affects two areas within the distillation environment namely steam generation (boilers) and cooling systems (cooling towers, condensers and heat exchangers). Poor water quality could potentially lead to scale formation, corrosion and blockages due to microbial growth which have substantial financial impact in terms of repair and/or replacement cost and safety (boiler explosion).

IBD Membership Required

Evaluating the effect of pot still design on the resultant distillate

By: Pierre van Rensburg

01/03/2015

Brandy is one of the most important spirits consumed by the South African population. Many different types and styles of brandy are available on the market today. Of the different styles of brandy available, pot still brandy is considered the richest, fruitiest and most layered brandy and has a vanilla flavour due to the wood maturation. There are many factors that will influence the production and the quality of this product. Of these factors, the distillation technique, the apparatus used for the purpose of distillation together with the low wine is of utmost importance as they influence the sensory profile and the chemical composition of the distillate. The effect of different variations of pot still designs on the chemical composition and the sensory profile of the resultant distillate was investigated.

IBD Membership Required

Hop breeding for a modern and sustainable industry

By: Russell Falconer

01/03/2015

The aim of our research and breeding programme is to develop new varieties of hops which are able to compete in the market, yet are also able to be cultivated efficiently. In developing tangible breeding objectives we therefore look to our customers and their needs, but also to relevant agricultural issues. Regional and location-specific climatic conditions are also taken into consideration. Predominant among the qualities we consider are the varietal characteristics, such as resistance to or tolerance for certain diseases and also yield.

IBD Membership Required

Diploma in Brewing and examination update

By: Steve Curtis

01/03/2015

An update and overview of the IBD professional qualifications - covering progress and initiatives over the past year and providing an update on future plans including new qualifications, review of existing qualifications and the progress on the introduction of language options.

IBD Membership Required

The craft beer scene in Australia

By: Stephen Exinger

01/03/2015

The craft brewing scene in Australia certainly isn’t new. There was rapid and vibrant growth in the mid-1980’s, during which time the category gained a good level of public acceptance, but by the late-90’s the number of craft breweries had dwindled. Today there are well over 100 microbreweries in operations across Australia, with seemingly more opening each day. And as the number of craft breweries grows so does the number of craft brewers, and they have set up membership associations designed to meet their specific needs. They have organised public festivals that are growing the popularity of craft beer and are being supported by an increasingly influential online press and enthusiastic social media.

IBD Membership Required

The impact of poor brewery process control on effluent treatment plant energy cost recovery

By: Simon Pitts

01/03/2015

Anaerobic digestion, the brewery effluent treatment plant (ETP) process of choice, requires selective effluent for effective treatment and high biogas production. Placing a value on good effluent treatment plant performance has always been challenging as an ETP was always considered an expense. However with new technologies such as biogas and wastewater reclamation we can quantify cost recovery of efficient effluent treatment.

IBD Membership Required

PET barrier for beer – showcase the impact of barrier from empirical studies from within SABMiller

By: Stedrick Saayman

01/03/2015

PET bottles are widely used as food and beverage packaging. PET Bottles are strong, shatterproof, lightweight, transparent, safe, recyclable and offers design flexibility. The principal weakness of PET containers is that PET is not impervious to oxygen, carbon dioxide and water vapour. PET is therefore incapable of matching the shelf life offered by cans and glass bottles. Despite these limitations, PET provides practical shelf life durations for specific products: Around 70% of all PET packaging is used for carbonates and water. The balance is made up of other food and beverages, while beer accounts for only 2%. The slow adoption rate of PET for beer packaging can be partially attributed to beer’s sensitivity to Oxygen and the loss of Carbon Dioxide. PET is however increasingly used as beer packaging and many technologies are available to reduce gas permeation rates to achieve better product stability.

IBD Membership Required

Steinecker low temperature brewery – an efficient tool for energy saving

By: Tobias Brauer

01/03/2015

Steam at temperatures of around 130 °C – 150 °C is currently used at most state-of-the art breweries. Discontinuous heat generation and high condensate and flash steam losses make steam boilers at many breweries relatively inefficient. With the Steinecker EquiTherm system the energy consumption is extremely low and the brewing process can be supplied with thermal energy at very low temperatures. The maximum hot water temperature at the "low-temperature brewery" is only at less than 115 °C and proven to be sufficient. Heat is transferred using a low-loss heat transfer station and an energy storage unit which was designed specifically for the peak loads and Steinecker EquiTherm heat recovery system. The storage unit supplies regenerative and recuperative heat to the entire brewery.

IBD Membership Required

Seconds and litres – Zambia’s story

By: Thorsten Fink

01/03/2015

Zambian Breweries (ZB) Plc's new state-of-the-art Brewery in Ndola has commenced operations in October 2012 and the old brewery was finally shut down in March 2013. The Brewery is designed for 1.000.000hl per year and is currently running at 600.000hl. After the Performance Acceptance Test, the aim was to become the fastest Brew House with the lowest water usage in the SABMiller group. Therefore every single step from the automated system was analysed on how to reduce the Occupations times in each vessel as well as the water usage in the Brew House. To realize our Vision of the fastest Brew House, each “second” which was able to be cut out was important for brewery.

IBD Membership Required

New malting barley varieties in western Europe – sustainable production, malting and brewing characteristics

By: Thomas Zahn

01/03/2015

Efforts in breeding of new malting barley varieties led to shorter life cycles, particularly for 2-row spring malting barley varieties: Whereas 20 years ago a new 2-row spring barley variety was grown for 10 years nowadays life cycle has come down to 5 years. This enabled impressing improvements not only in agronomic yields and disease resistance leading to reduced use of agrochemicals, but also in malting and brewing characteristics: Brew house yields are higher than ever, and a wide range of enzymatic activities and in protein modification can be obtained combining comfortable yeast nutrition with smooth wort and beer filtration.

IBD Membership Required

Concentrating for use brewery wastewater using solar energy

By: Valentine Wambui

01/03/2015

The brewing industry is one of the largest industrial users of water with an average of 7 parts water used to produce 1 part beer .The current usage rate versus the growing population may create an unsustainable pattern. The long-term sustainability and growth of a brewery may depend on its ability to efficiently use its water resources especially in Kenya which is a water stressed country. Because of the high concentration of organic load, brewery wastewater is rich in nutrients and may be used for irrigation purposes. Kenya being astride the equator and extending four degrees on either side, receives a considerable amount of solar radiation. Daily insolation ranges from 4-6kWh/m2.

IBD Membership Required

Decanter in a brewhouse – challenge and opportunity?

By: Rudolf Michel

01/03/2015

In the brewing industry mash filtration with lauter tuns and mash filters is considered as state-of-the-art. In 1980 the industry saw first applications of a mash separation technique using decanters. Another 20 years later the design of the decanter has improved to avoid shear and oxygen pick up during mash separation. The paper will explain the major difference between mash filtration and mash separation in a centrifugal field and the impact on the design of the brewhouse operation. Using decanter technology in a brewhouse opens a wide range of opportunities.

IBD Membership Required

Hygienic welded fabrication - a challenge

By: Tony Paterson

01/03/2015

Process plants are typically made up of tanks, heat exchangers, distillation columns and interconnecting thin wall pipes. Food and beverage process plants need to comply with increasingly onerous health legislation. This limits acceptable bacteria and spore counts in the final product. Bacteria are directly associated with the build-up of bio films on product contact surfaces,