Reducing Brewery Production Costs Through On-Site Nitrogen Generation
The Challenge
The client, a brewery undergoing expansion, faced rising production costs, with the increasing and uncontrollable cost of Carbon Dioxide (CO2) being a primary concern. Like many breweries, they used CO2 for a variety of non-carbonation applications due to its inert properties and availability on-site. However, the cost of CO2 was spiralling, making it a major contributor to production expenses.
The challenge for Maziak was to help the brewery reduce its dependence on CO2 without compromising the quality of its processes or operations, while also stabilising the brewery's gas-related costs for the future.
The Solution
Maziak recommended switching from CO2 to Nitrogen Gas (N2) for the brewery’s non-carbonation applications, as nitrogen is also an inert gas but far more cost-effective. The lowest-cost solution for nitrogen generation involved using the site’s existing compressed air system paired with a nitrogen generator to produce Food Grade Nitrogen Gas on-site.
Key steps in the solution implementation:
•Utilising Existing Resources: The brewery’s existing Atlas Copco air compressor was used to power the nitrogen generator, producing enough compressed air for both nitrogen generation and other pneumatic needs around the brewery.
•Fast Installation and Commissioning: Maziak installed and commissioned the nitrogen generator system within three days. The system was calibrated to ensure the nitrogen met food-grade standards and was produced at the correct pressure and volume for the brewery’s operations.
•Comprehensive Application: The on-site nitrogen generator now supplies nitrogen for all non-carbonation processes, such as Tank Top Pressure, Pipe Purging, Bottling, Canning, and Kegging lines. Atlas Copco’s nitrogen generator also comes with a 5-year All Cover warranty, with annual servicing and recalibration by Maziak to ensure optimal performance.
The Result
•Reduced Production Costs: By generating nitrogen on-site, the brewery significantly lowered its gas expenses, eliminating the need to purchase expensive CO2 for non-carbonation applications.
•Future-Proofed Gas Supply: The brewery now has a stable, reliable, and controllable supply of nitrogen, shielding them from CO2 price fluctuations and supply issues.
•Environmental Benefits: The brewery has reduced its carbon footprint by lowering reliance on CO2, contributing to its sustainability goals.
•Long-Term Technical Support: Maziak provides ongoing maintenance and support through a fixed-price service agreement, ensuring the system continues to deliver maximum efficiency with minimal disruptions.
Through Maziak’s tailored nitrogen generation solution, the brewery gained full control over its gas supply, reduced costs, and improved the sustainability and scalability of its operations.
