New Belgium Brewing (NBB), Birleşik Devletlerdeki yeni nesil biracılık tesislerinin en başarılı olanlarından biridir. 1991 Yılında Fort Collins, Colorado'da yılda 1 milyon hektolitre ürün çıktısı ile kurulmuş olup, dünyanın üçüncü en büyük butik bira üreticisidir. Şu anda New Belgium Brewing, Asheville, Kuzey Carolina'da ekstra bir büyüme yapmayı planlamaktadır. ABD'nin doğu kıyısındaki yeni bira üretim tesisinin yılda yaklaşık 625.000 hectolitre bira üretmesi beklenmektedir.

Başarılı butik biracılar için "Almanya'da yapılan" biracılık ekipmanı

NBB kontrat imzası

2013'te Münih'te gerçekleşen drinktec'te New Belgium Brewing, proje mühendisliği, proje planlaması, ekipman teslimat ve montajı için anahtar teslim tedarikçi sorumluluğuyla GEA Biracılık Sistemlerine güvenmiştir. Bira imalathanesi ve soğuk proses alanı için yenilikçi ürünler ve teknolojiler, uluslararası düzeyde tanınmış biracılık ekipmanı üreticisinin iki ayrı yerdeki tesisinden ve GEA Grubunun diğer şirketlerinden gelmektedir.

NBB hikayesi 1989 yılında biracılık tesisinin ortak kurucusu Jeff Lebesch, Avrupa'daki bira şehirlerini gezmek üzere motorla yola çıktığında başladı. Bu geziden ilk birasının adı için bir fikirle geri döndü: „Fat Tire“ (Kalın Lastik). Bir çok bira "stili" eklendi: örneğin, New Begium'un ABD genelinde 37 dağıtım eyaletinde satışa sunduğu IPA'lar ve Blonde'lar. Geleneksel butik biracılık, New Belgium Brewing'de daima önemli bir rol oynamıştır.
The modern brewhouse is designed for a capacity of 200 hl cold wort per brew and will produce up to 12 brews per day.
Wort preparation begins with the MILLSTAR™, the efficient wet mill from GEA. With its integrated automatic quality system it enables uniform conditioning of the malt and homogeneous milling. To ensure maximum extract yield, high wort quality and efficient use of resources in the lautering process, a lauter tun with LAUTERSTAR™ technology will be used. With a diameter of 6,100 mm, it provides a lot of flexibility for present and future recipes. Continuous control of the lautering process is realized by the multifunctional lautering management (MLM). This ensures high reproducibility for all brews.

Nazik şıra kaynatma

Asheville konsept tasarım

Şıra, JETSTAR™ dahili kazan ile atmosferik kaynatmaboiling with a JETSTAR™ internal boiler. This internal boiler
provides not only high flexibility for the requested wort
qualities of each beer type. The innovative two-phase boiling
system from GEA also allows to separate the processes of
wort boiling and evaporation. With this gentle method,
important protein fractions are preserved. Furthermore, the
necessary homogeneous mixing and circulation in the wort
kettle is ensured. All wort particles are evenly boiled and
the hop bitter substances in the wort are optimally extracted
and isomerized. The two-phase boiling leads to excellent
technological values for DMS reduction, TBI and coagulable protein: an ideal method to obtain consistently high wort and flavor stability for perfect beer and foam quality.

Less primary energy
The energy storage system for a maximum evaporation of only 4 % allows the operation of a so-called energy-balanced
brewhouse: Primary energy is only required for wort boiling and the final step of the heating process. Thus, the
consumption of primary energy is reduced significantly. The control module Intelligent Wort Management (IWM) from
GEA Brewery Systems regulates the wort boiling process and precisely calculates the evaporation rate. It does not matter
whether other ingredients are added to the wort kettle after the start of boiling.

Summary of the brewing line equipment 

  • MILLSTAR™ for conditioned wet milling with a capacity  of 20 t/h
  • Mash kettle 
  • LAUTERSTAR™ with wort pre-run tank and wort heater 
  • Atmospheric wort kettle for 200 hl with JETSTAR™  internal boiler system and automatic hop dosing vessels
  • Energy recovery system with energy storage tank 
  • Whirlpool with wort pre-cooling
  • Wort cooling, hot and cold water tanks for the brewing  process
  • CIP system
Extension of cold process area and beer filtration
Yeast management and the integration of the Fermentation  and storage tanks in the cold process area are handled semi-automatically.  The yeast dosing equipment and the yeast  storage tanks will be integrated in close cooperation with the
subcontractors of NBB.

All processes, from filtration to bottling and also the two  CIP systems, are fully automated. The CIP systems with  GEA valves and valve blocks comprise three  and five tanks each for tank and pipe cleaning. Thus, the  systems are designed for the entire cold process area  including bottling. The CIP tanks will be manufactured  by GEA. Cleaning of all large and small  tanks is also intended to be done with cleaning equipment from GEA. The fermentation tanks, which require  intensive cleaning, will be equipped with orbital cleaners;  other process tanks will have rotating or static spray balls.

Typical hop flavor
Green beer will be treated with a GEA separator  GSC 150 with a capacity of 240 hl/h. The connection with  a fully automatic dosing and mixing system for Special  dry hopping gives the typical strong hoppy flavors to  the different beer types. The subsequent beer Filtration  is traditionally done with a Filtrox kieselguhr filter type Synox PF with a filtration capacity of 180 hl/h. This System is very flexible, especially in the processing of small Batch sizes. Instead of two combined tanks (PT2/VNL), a FBB tank is used, supporting the flexibility of the filter.

A water deaeration unit (hot deaeration) with upstream  activated carbon filter reduces the chlorine content. The unit  with a capacity of 100 hl/h guarantees lowest oxygen values in the deaerated water. The filtered beer will then be stored in six bright beer tanks provided with GEA valve blocks and double seat valves. An automatically controlled  CO2 pressure compensation line ensures little CO2 losses  during filling and emptying of the tanks.

Automation and process control
The GEA process automation solution controls the entire  production process: from malt intake up to the bright beer tank cellar. The Wonderware system platform ArchestrA is used including the MES products for the SCADA level.  The underlying PLC platform is based on the Rockwell ControlLogix® control system with standard and library functions and the Rockwell Equipment Phase Manager.  NBB developed the automation solution together with GEA.GEA proses otomasyonu çözümü, bütün üretim prosesini kontrol eder: malt alımından parlak bira tank deposuna kadar. MES ürünleri içeren Wonderware sistem platformu ArchestrA, SCADA seviyesi için kullanılmaktadır. Altta yatan PLC platformu, standart ve kütüphane fonksiyonlu Rockwell ControlLogix® kontrol sistemini ve Rockwell Ekipman Faz Yöneticisini temel almaktadır. NBB, GEA ile birlikte otomasyon çözümünü geliştirdi.
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