Optimising Brewery Operations: Cost-Efficient Inert Gas Solutions through On-Site Nitrogen Generation

A South London-based brewery faced escalating operational costs and challenges in maintaining a reliable inert gas supply, crucial for ensuring the quality of its products. The brewery had been relying exclusively on CO2 for all inert gas applications, including essential product carbonation. However, the high cost of CO2, coupled with the increasing frequency of deliveries, posed significant challenges. The logistics of CO2 supply in a busy urban setting led to increased expenses, unreliable supply chains, and operational inefficiencies.

The brewery recognized the need to explore cost-effective alternatives without compromising product quality. Nitrogen gas emerged as a viable solution for most inert gas applications, except carbonation. Unlike CO2, nitrogen can be generated on-site, reducing reliance on external deliveries and lowering overall costs. This shift would not only decrease operational expenses but also mitigate the risks associated with CO2 delivery disruptions.

Given their previous experience with similar challenges in other breweries, Maziak was approached by the client with a specific request:

“We need to spec out an N2 generator based on our production requirements and then align the compressor capacity accordingly. This transition is particularly crucial as we plan to start de-aerating our liquor for high-gravity brewing by the end of the year. The primary applications for the N2 include:

1. Purging Brite Beer Tanks (24,000L vessels rated to one bar). Currently, we pressurize these tanks to 1 bar five times, releasing the pressure after each cycle.
2. Providing head pressure for packaging. The highest flow rate required would be 3000L of beer per hour while maintaining a constant pressure of 1 bar.
3. Eventually integrating N2 into our deaeration column process.”

Maziak conducted a comprehensive analysis of the brewery's operations, identifying all applications where Low-Cost Generated Nitrogen Gas could replace the use of CO2. After thorough calculations and assessments, Maziak proposed a future-proof solution centred around the deployment of Atlas Copco Nitrogen Generation equipment, powered by compressed air.

To alleviate the financial burden of capital investment, Maziak offered a flexible solution: a full-service care package under a Maziak 5-Year Rental Agreement. This arrangement included the supply, installation, and maintenance of the equipment, ensuring seamless integration and ongoing operational support.

The implementation of the Atlas Copco NGP50+ Nitrogen Gas Generator provided the brewery with over 25m³/hr of clean, Food Grade Nitrogen Gas, boasting a purity level exceeding 99.95%. This met and exceeded the site’s stringent requirements. The chosen air compressor, intentionally "over-sized," not only fulfilled the nitrogen generation needs but also catered to the site's broader compressed air demands, offering additional operational flexibility.

Maziak's extensive experience in addressing similar challenges for other breweries instilled confidence in the client. The client was assured that the proposed solution would meet their immediate needs and accommodate future expansion, such as the planned integration of nitrogen into the deaeration process.

Moreover, the 5-Year Rental Agreement ensured that all responsibilities related to maintenance, callouts, and equipment reliability were handled by Maziak, allowing the brewery to focus on its core operations with peace of mind.