Analysis of cost saving opportunities on fermentation and efficiency review in the hot block for the Delta IPA production at BBP Port Sud

Details

Supervisors

Collin, Sonia

Faculty

Faculté des bioingénieurs

Degree label

Master de spécialisation en génie brassicole

Abstract

As the global economy faces some challenges, the brewing industry is facing the increasing raw materials and energy prices. This why this work intends to analyze schemas to reduce costs in the BBP Port Sud DELTA IPA process (hot and cold block) without altering the organoleptic profile of the final product. The first part covers a review of the cold block of the brewery with a validation of the mass density of the dry yeast used that resulted in an estimation of a mass density four times higher than the low limit reported by the provider. A full follow up of the fermentation including cell count, viability, attenuation, and pH was put in place to determine the yeast growth kinetics. With the understanding of the yeast kinetics and the mass density a Drauflassen process was implemented that optimized the yeast utilization from 10 kg to 2 kg per 250 hl batch saving 80% in yearly yeast costs. To validate the organoleptic profile volatiles concentration were analyzed by Headspace Gas Chromatography and then the samples were tasted by the production team. While the laboratory results had some variation in concentration, the sensory test showed that in this rather complex matrix the differences do not affect the overall concept of the product. An estimation of the efficiencies in the hot block, considering the Lauter tun and the full block efficiencies while digitalizing and coding in VBA for Excel an improved digital Brew sheet resulted in immediate access to the brews information in every operation to better understand the process and identify which steps are susceptible of new optimizations.