The number of water conditioning stages depends on the composition of natural raw materials from the water intake, as well as the ability of the brewer to purchase equipment. The purest water is obtained by using reverse osmosis — membrane separation, which removes up to 99% of all salts, bacteria and pyrogenes.
Losses in the water conditioning site constitute up to 30% of the total water consumption of the brewery. This is the consumption for periodic washing of the filters themselves, contaminants removing membranes. The losses of raw materials in water conditioning are so significant that some manufacturers are willing to invest in equipment replacement in order to reduce consumption. Such a situation, for example, happened with one Viravix Engineering client, but Viravix experts managed to offer him less expensive procedures.
One of the solutions is the recovery of water in production. This is the reuse of liquid in technological processes. After washing filters, membranes water can be collected and used for other purposes. For example, it is used for washing floors and walls.
If the existing equipment does not allow installation of recovery tanks, then it will be upgraded. And then the water is collected for reuse.
Food companies always need a balance between energy saving and microbiological safety of the product.
When the hopped wort is cooled, an excess of hot water is created. Some manufacturers simply dump it down the drain because they don’t have refrigeration units at this stage. Reasonable water users install containers for collecting and storing hot water, which can further be used in production.
Viravix engineering experts develop a set of procedures for recovery in production, based on individual conditions at a particular brewery:
Cooling units consume a lot of electricity and not all brewers can afford them.
The Viravix Engineering Company is engaged in the design, installation and service support of CIP-stations. We initially offer the customer energy saving procedures, but we can also help at existing stations.
Clean water during CIP cleaning is available at:
This liquid can be collected in a tank and reused in the same CIP cleaning or for mopping the floors in the workshop.
Some manufacturers offer to save water by using special CIP heads that reduce consumption. This should be approached with caution. It is always necessary to strike a balance between the saving of raw materials and the quality of cleaning, because the bacteriological safety of the product directly depends on the latter.
The best option for optimizing the amount of water used in the enterprise is reasonable consumption and return to production.
The principle of operation of the bottle-washing machine is based on the constant flow of liquid through the bathtubs for:
The exact water consumption depends on the particular model of bottle-washing machine. Here we offer the same recovery to save money — to direct raw materials in the reverse order: from clean processes to dirty ones. That is, from the final rinse to presteeping.
Another solution to save water is the upgrade of syringes for rinsing bottles. Here you can control the liquid pressure: the lower it is, the lower the consumption.
We propose to install a recovery tank and a heat exchanger to cool the raw material to a certain temperature. When the line stops, to the hot zone already collected water is added, not fresh.
Equipment upgrade is another procedure for energy saving. It is used if it is impossible to install recuperation tanks on the existing pasteurizer.
Rinsers can also be equipped with recovery tanks. Initially, equipment manufacturers offer this option, but not all brewers understand its purpose and refuse such expenditures.
Meanwhile, reusing water from the rinser significantly reduces consumption. This does not mean that the brewer will be able to completely abandon the use of fresh water. But renewing water in the rinser will become less frequent.
A specific list of energy-saving procedures is determined on site. We repeat that in brewing it is important to strike a balance between the economy of raw materials and the quality of beer.