UCMS

Brewery Design Modules
Sponsor : PP&C Engineering Policy Manager Copyright

Authors : Mr. M. Dennebos, Mr. H.E. Hopman, Mr. A.M.Th. Warmerdam
Document manager : PS - ED&DS
Issue : 02 Final
Date : April 2001
Approval Committe : BDM Steering Committee
Approval : PP&C Director
Issue : 02 UTILITY CONSUMPTION MEASURING SYSTEM HMESC : 01.30.70.010
Date : April 2001 FOR BREWERIES Page : 2 of 32
UTILITIES CONSUMPTION MEASURING SYSTEM
FOR BREWERIES
CONTENTS
Page:
1. SUMMARY 5
2. INTRODUCTION 7
2.1 AVERAGE CONSUMPTION IN DIFFERENT AREAS OF A BREWERY 7
3. DEFINITIONS 8
3.1 UTILITY CONSUMPTION MEASURING SYSTEM [UCMS] 8
3.2 UTILITY MONITORING SYSTEM [UMS] 8
3.3 UTILITY MANAGEMENT 8
4. OBJECTIVES OF A UTILITY CONSUMPTION MEASURING SYSTEM (UCMS) 9
4.1 BREWERY COMPARISON SYSTEM [BCS] 9
4.2 REDUCTION OF UTILITY CONSUMPTION AND UTILITY COST 9
5. MEASURING PHILOSOPHY 10
5.1 IDENTIFICATION OF DIFFERENT LEVELS FOR MEASURING ACCORDING TO A UCMS 10
5.1.1 Site Consumption (level 0 UCMS) 10
5.1.2 Area Consumption (level I UCMS) 10
5.1.3 Individual large consumers (level II UCMS) 10
5.1.4 Individual small consumers (UCMS level III) 11
5.2 UCMS AND COMMON COST CENTRE STRUCTURE [CCCS] 12
6. METERING 14
6.1 INSTALLATION 14
6.2 ACCURACY AND RELIABILITY OF A UCMS 14
7. TYPE OF METERING 17
7.1 REPORTING AND DATA COLLECTION 17
7.2 TYPES OF METERS 17
8. WATER 19
8.1 REQUIRED METERING POINTS 19
8.2 WATER TYPES 19
8.3 LEVEL 0 AND 1 20
8.3.1 Level II and III 21
9. ELECTRICITY 24
9.1 STARTING POINTS 24
9.2 OVERVIEW METERING POINTS PER LEVEL 24
9.3 NUMBER OF METERS AND INVESTMENTS COSTS PER LEVEL 26

9.4 AVERAGE ELECTRICITY CONSUMPTION IN THE DIFFERENT AREAS 26
10. OTHER UTILITIES : FUEL, STEAM, CO2, COMPRESSED AIR AND COOLING 27
10.1 IDENTIFICATION OF CONSUMERS 27
10.2 PRIMARY UTILITY FLOWS : FUEL AND CO2 27
10.3 SECONDARY FLOWS : STEAM, COMPRESSED AIR, COOLING 28
10.4 SUMMARY: NUMBER OF METERS AND INVESTMENT COST PER LEVEL (OTHER UTILITIES) 30
11. CONCLUSIONS AND RECOMMENDATIONS: 31
11.1 NUMBER OF METERS AND INVESTMENT COSTS: 31
11.2 POSSIBLE SAVINGS: 32

CONDITIONS OF USE
CONFIDENTIAL INFORMATION
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B.V. It reflects the Heineken knowledge and experience, which contents should not be revealed to 3rd
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THE MANAGEMENT
HEINEKEN INTERNATIONAL B.V.
Issue : 02 HMESC : 03.11.10.002

Date : Dec. 2000 Page : 1 of 1
MODIFICATION REQUEST FORM
INTRODUCTION.
This form is a means of communication to indicate your suggestions for improvement of Corporate PP&C
Documents, such as: General Process Instructions, BDM Manuals, Production Automation &
Information Technology Instructions, SHE Manual, Laboratory Instructions, Corporate Packaging
Specifications (EPS), etc.
The suggestions will be handled according to our standard procedures as quickly as possible and you will
be informed about the outcome.
SUGGESTIONS FOR IMPROVEMENT

Document type :
HMESC Code :
Issue date :
Chapter :
Page :
Suggestion(s) :
Please return this form to the PP&C Quality Systems Manager, who will forward it to the secretary of the relevant Approval
Committee.
Address:
Corporate Production Policy & Control
Room: 2.121
PO Box 510
2380 BB Zoeterwoude
The Netherlands
Tel. : (+31)715456032
Fax. : (+31)715457450
Issue : 04 HMESC : 03.11.10.001
Date : Apr 2001 Page : 1 of 1
Non Conforming Production Process request
Brewery : Originator :
Procedure: No. :
Refer. Doc.: Date :
Source : RTM Request Corp. PP&C audit Customer input Other
1. Observed shortcoming :
Process conditions Product specifications
2. Analysis of shortcoming :
3. Proposal for acceptance Non-conforming process conditions or specifications :
Duration :
4. Advice RTM/EPCM :
5. Decision Corp. PP&C :
Approval: Authorisation:
Name : Corp. PP&C Director
Date/initials : Date/initials :
Issue : 02 HMESC : 03.11.10.004

Date : Dec. 2000 Page : 1 of 1
BREWERY DESIGN MODULES
INTRODUCTION
CONTENTS
Page:
1. CORPORATE POLICY 2
1.1 BREWERY DESIGN MODULES (BDM) 2
1.2 BREWERY ENGINEERING &AUTOMATION MODULES (BEAMS). 2
1.3 EXECUTION OF ENGINEERING PROJECTS 2
1.4 SEPARATING 'POTS & PANS' TENDER FROM 'AUTOMATION' TENDER. 3
1.5 PROCEDURES FOR NON-CONFORMING PRODUCTION PROCESS 3
1.6 PROCEDURES FOR IMPROVEMENT OF THE BDMS AND BEAMS 3
1.7 AMENDMENTS TO THE BDM BEFORE THE NEXT VERSION IS RELEASED 4
2. FRAMEWORK OF BDM 4
3. HYGIENIC DESIGN MANUAL 5
4. CE MARKING 5
5. SEE ALSO CE-MARKING POLICY OF CORPORATE PP&C. 5
Issue : 05 BREWERY DESIGN MODULES HMESC : 01.30.00.011

Date : Mar. 2002 INTRODUCTION Page : 1 of 5
1. CORPORATE POLICY
The use of the Brewery Design Modules by breweries and the management and execution of engineering
projects are subject to certain rules & guidelines, which are owned by Corporate Production Policy &
Control (PP&C). These rules apply for Green field as well as Brown field breweries. In some cases the
applicability in brown field situations might be restricted. Below is an abstract of relevant Corporate
Rules & Guidelines.
1.1 BREWERY DESIGN MODULES (BDM)

Investments should be based on common standards in order to allow breweries to focus on business
improvement and innovation, rather than re-designing / re-establishing known concepts and solutions.
Standardisation of conceptual design of brewery installations is established through Brewery Design
Modules. These are manuals, based on the best available engineering expertise and know-how, while
ensuring cost effectiveness. General Process Instructions and SHE instructions are input to the making of
the BDM. Brewery Design Modules are approved by the Steering Committee BDM and authorised by the
Director of Corporate PP&C.
Rule: For all Master Plans, projects and investment applications Brewery Design Modules
(BDM) have to be used.
Guideline: The content of the Brewery Design Modules (BDM) are guideline.
1.2 BREWERY ENGINEERING &AUTOMATION MODULES (BEAMS).

Brewery Engineering & Automation Modules (BEAMs) comprise detailed engineering diagrams, process
descriptions and control procedures. The BEAMs are based on the BDMs, GPI and Brewery Set-up
according to ISA S88. The lowest level of detail is Equipment Modules and Phases (e.g. pumping,
stirring, heating up etc.).
The BEAMs (in combination with BDMs) is a standardization tool for HTS and Opcos to optimise the
project specification and execution process and to make it specialist independent. Consequently during a
project:
From the BEAM library project specific engineering diagrams (P&IDs) should be generated for
the pots & pans tender.
From the BEAM library project specific control / process descriptions should be generated for the
process control tender.
Guideline: For every project the standard solutions of the BEAM library of HTS shall be used by
generating project specific engineering diagrams and process descriptions for pots &
pans and process control part of the project. Only these documents should be used
for the tender procedure.
Note: In case a strategic alliance solution (e.g. Rockwell) is applied, a process control solution
based on BEAMs is already available and no tender for process control is required.
1.3 EXECUTION OF ENGINEERING PROJECTS

A joint decision by Operating Companies, PP&C (EPCM, RTMs) and HTS is required on the
management of engineering projects (e.g. brewhouse, packaging lines, process control). For learning
from experience reasons, it is preferred to have HTS execute projects, especially implementation of new
technologies and techniques. In any case, even if not involved directly in the management of a project,
HTS should always be involved in the conceptual phase to centralise the learning experience. To ensure
the use of our collective know-how, a process flow has been developed by HTS for the management of
projects, which includes responsibilities of the various parties involved.

Guideline: The Operating Company, PP&C (EPCM or RTMs) and HTS must in an early phase of
the project (i.e. conceptual phase), but before communication with suppliers starts,
agree upon the management of projects and how & which corporate standards (e.g.
BDM, BEAMs, Strategic Alliance etc.) are to be applied. At the same time a decision
needs to be made whether specifications should be laid down in a Project Data Book
1.4 SEPARATING 'POTS & PANS' TENDER FROM 'AUTOMATION' TENDER.

Some projects are being executed turn-key, meaning that one supplier both provides the pots & pans
(e.g. tanks, piping, vessels) as well as the process control system. However for bigger projects (at least
a process cell, ref. ISA S88), it is more beneficial (in terms of cost, quality and sustainability) to separate
the tender for pots & pans and process control. Separation means that first the tender for the pots &
pans is done and the project awarded. After that the tender of process control part commences. The
following issues highlight the benefits:
Prevention that pots & pans suppliers will offer an higher price for 'pots & pans' in favour of a
complete offer including 'automation'.
To enlarge the pots & pans suppliers pool in order to get the best price for pots & pans by
including 'pots & pans' suppliers, that have less automation solution abilities (e.g. Landaluse,
Holvrika etc.)
Expertise of large process control solutions, which includes integration aspects (e.g. central
control rooms), lies with automation suppliers. Consequently the chance on a successful FAT
and commissioning is much bigger.
Sustainability of the solution of an automation supplier if better (e.g. alliance partner Rockwell).
Guideline: Projects of the size process cell (or larger) have to be separated in a pots & pans
tender and process control tender with different pools of suppliers. Tendering and
awarding of the pots & pans part should take place first, after which the tender for
process control can start. This rule applies for HTS as well as for brewery-managed
projects.
1.5 PROCEDURES FOR NON-CONFORMING PRODUCTION PROCESS

Rule: If breweries wish to deviate from the BEAMs or BDMs and implement different
solutions other than described in the BEAM or BDM, an application for derogation of
Non-conforming production process need to be forwarded to Corporate PP&C.
Technical Management of the brewery should summarise and argue their application on
a Non conforming production process request form and submit it to the Quality
Systems Manager of Corporate PP&C. Within 3 weeks the response to the request for
derogation of Non-conforming production process will be issued by the Director of
Corporate PP&C.
1.6 PROCEDURES FOR IMPROVEMENT OF THE BDMS AND BEAMS

It is of great importance to continuously improve the BDM and BEAMs solutions. If parties involved in a
project (HTS, Brewery Manager, Chief Engineer, etc) come to the conclusion that a change or addition
is recommendable, they should summarise and argue their proposal on a Modification Request Form and
submit it to the Quality Systems Manager of PP&C. The relevant Steering Committee will evaluate the
proposal according to ISO 9000 procedures of Corporate PP&C (03.11.04.402). If the proposed change or
addition to the BDM or BEAM is accepted by the Steering Committee, it will be issued for approval to the
Director of Corporate PP&C. Consequently this will ensure a critical view of the applicability of
corporate standards.
Guideline: Not later than 8 weeks after the official SAT (Site Acceptance Test) of a project, the
brewery has to give feedback whether there is a need to amend or change the BDMs or

BEAMs. Modification Request Form should be filled in and submitted to the Quality
Systems Manager of Corporate PP&C.
1.7 AMENDMENTS TO THE BDM BEFORE THE NEXT VERSION IS RELEASED

Guideline: Amendments are approved changes or comments (through e.g. MRF), which are not
incorporated in the latest version of the BDM yet. Since an update of that BDM might
take some time, a separate amendment will be attached in the KIPP and WB PP&C
Engineering (Lotus Notes). Executive en Chief Engineers in Europe will be informed
by email. However users of the BDM CD-ROM will not have access to the latest changes
to the BDM. They have to always consult their HTS account manager to ascertain the
latest status of the BDM, before applying it.
2. FRAMEWORK OF BDM
The most important part of the BDM is the Quickflow in the Chapter Summary. The Quickflow is the
decision support tool for determining the scope of any project, masterplan or investment application. The
selected options in the Quickflow result from the experiences of members of the HTS BE&UT department,
complemented with input from the breweries (through HTS Support). Where alternative executions or
design variations have been compared, the "best value for money" execution is chosen, which signifies the
best balance of relevant criteria (investment costs, technological performance, operating costs,
maintainability, etc.).
This does not necessarily result in the minimum investment at given technological demands. In most
BDMs a Low Cost Execution chapter is included, which describes low cost design at minimum
requirements, if applicable.
For the BDMs a uniform presentation has been pursued by means of a fixed set-up, which can be described
as follows:
CHAPTER 1: Introduction
Deals with Confidentiality, Corporate Rules & Guidelines, the framework of the BDM and feedback
procedures.
CHAPTER 2: Summary
Deals with a quick flow and process flow of the BDM. Quick flows indicate agreed options and variants
as well as the selected alternative and preferred variants of the BDM execution. Issues that are considered
unquestionable or without alternatives are grouped in the column Design standards.
CHAPTER 3: Process Alternatives

Deals with and compares alternative processes. It also describes all relevant process data, which in most
cases refer to "General Process Instructions".
CHAPTER 4: Equipment Alternatives

Alternative equipment or alternative concepts of the installation is described and compared on the basis of
criteria relevant for the installation.
CHAPTER 5: Design Variant

Deals in detail with the selected process equipment; design variants are mentioned and compared.
Comparison and proposed selection of alternative executions is done on the basis of "Pros and Cons".
CHAPTER 6: Engineering documents

The selected alternatives from chapters 3, 4 and 5 together create the final BDM execution which are
summarized in the Quickflow. Chapter 6 contains engineering diagrams and specification, which are not
project specific (they can be considered an example).

CHAPTER 7: Low Cost Execution (if applicable)
This chapter includes a L(ow) C(ost) E(xecution) of the same installation. Starting point remains
compliance with technological demands, but at the lowest possible investment cost. We will automatically
arrive at this design when we opt for the cheapest solution from all alternatives mentioned in chapters 4
and 5.
Lay-out and make-up of the BDM, distribution, revision, etc. have been assigned to the Document
Manager BDM of HTS Project Services section ME&S. `
3. HYGIENIC DESIGN MANUAL

It is strongly advised to consult the HTS Hygienic Design Manual during design, modification and
maintenance of any installation or equipment. One of the most important factors related to the prevention
of infections and consumer health risks is the design and condition of process equipment and associated
pipelines. Equipment of poor hygienic design needs more cleaning and des-infection.
The Hygienic Design Manual contains 'best practices' for hygienic design and maintenance, including
choice of materials. Some practices are expected to be implemented as normal practices in the brewery in
order to comply with GPI instructions, HACCP and Maintenance Policy standards. Other practices can be
classified as best available techniques (at higher cost) which are not applicable for every brewery. The
Hygienic Design Manual can be found in the standard set of Maintenance Policy Documents issued by
Corporate PP&C.
4. CE MARKING
Manufactures and suppliers (Original Equipment Manufacturer, HTS or Opcos) that assemble
installations or equipment in the European Economic Area (EEA), are obliged to supply it in accordance
with the EC Machinery Directive.
Purchasing and Engineering departments of HTS or Opcos are responsible to take up all relevant Machine
Directive aspects in the negotiation, tendering, contracting and execution phase of projects in order to
assure that CE marking of machines or installations can be achieved, as described in the Heineken
Machinery Directive manual.
During execution of a project and the operational phase of a machine or installation all parties involved
have to comply with roles & responsibilities as described in the EC Machine Directive.
Operating Companies have to make sure that delivered machines and installations are according to the EC
Machinery Directive. After handing-over of the machines or installations, the Operating Company has
been made owner and thus responsible.
Operating Companies are obliged to keep the machines and installations in good and safe condition and
shall have for each machine or installation, the relevant documentation or data available.
It should be clear that if 3rd parties design and assemble installations and equipment (including
modifications of it), Heineken (HTS and Opcos) require the least effort to comply with CE-Marking.
In order to facilitate the obligation to adhere to legal requirements, The Heineken Machinery Directive
manual has been developed, which is a guideline for Purchasing, Engineering departments and Owners of
machines and installations to specify, order, transport, assemble, install, check, modify and maintain
machines and installations in accordance with the EC Machinery Directive.
5. SEE ALSO CE-MARKING POLICY OF CORPORATE PP&C.

1. SUMMARY
A set of minimally required metering points for a Utility Consumption Measuring System (UCMS) has
been developed and will be presented in this report.
The objectives of a UCMS are to generate the proper input for the Brewery Comparison System (BCS) as
well as sufficient and relevant data to aid in the reduction of utility consumption and cost and hence enable
the management of a brewery to set up an effective utility reduction programme.
The UCMS is split-up into four levels. The first two levels are identical to site and area level in
accordance with ISA S88, whereas the last two levels are far more detailed but different from process
cell and unit of ISA S88.
For all utility types these levels are detailed out worked out with regard to where meters need to be placed
to get the required data (see example for water consumption below for Packaging).
WATER CONSUMPTION
UCMS LEVEL I RECOMMENDED LAYOUT OF METERING POINTS
AREA: PACKAGING
PACKAGING
UCMS LEVEL II
PACKAGING LINE 1
PACKAGING LINE 2
PACKAGING OTHERS
PACKAGING LINE n
CRATE WASHER BOTTLE WASHER BOTTLE/CAN RINSER BOTTLE/CAN

PASTEURIZER
UCMS LEVEL III
CONVEYOR BELT
LUBRICATION FILLER
UCMS on level 0 and I is sufficient for the BCS while at least a level II UCMS is needed for a utilities
consumption reduction programme. The latter option could optionally be extended with level III.
In general it can be concluded that a Minimally Required UCMS consists of between 55-60 meters
(depending on brewery size) and that no general UCMS configuration for all breweries exists. This is
caused by differences in layout and distribution systems of different breweries.
Only level I and II of the UCMS match with the different cost centres as they are defined in the Common
Cost Centre Structure (CCCS).
A UCMS needs to be reliable (information must be trusted first hand) and a check on the
operation/function of individual meters must be warranted. When one meter is not functioning
this has to be indicated as quickly as possible. For this reason meter balancing is required, but the
increase in number of meters, especially at the most detailed levels of metering could cause and
unacceptable increase in investment costs. Meter balancing (by measuring all flows) is required
only for the levels 0 and I.
Savings of aproximately 25% in utility consumption can be reached after installation of a proper UCMS,
provided that based on the acquired data a brewery starts with full commitment an utility savings
programme. The achievable savings however strongly depend on the consumption level from which a
utility savings programme is started, e.g. a brewery where a utility savings programme is already in
operation will not be able to obtain additional savings of 25% on top of the already achieved savings.
However, utility savings should not be the only reason for the installation of a UCMS in a brewery.
UCMS should also be used as a tool to help monitor the cause of abnormally high utility consumption
quickly.
In this document approximate prices for the different meters at Level 0, I, II, and III are provided.
Payback periods of the investment costs for UCMS can range form three years for a small brewery
and one year for a big brewery (see table 1).
Table 1: Simple payback period for a UCMS
Brewery size Annual savings (NLG/year) Investment4 cost for Payback

average UCMS period
(NLG): (years):
NLG/hl1 NLG/hl2 NLG/hl3
0.11 0.48 2.9
300.000 (hl/year) 16.500 72.000 435.000 268.000 0.6-16
1.000.000 (hl/year) 55.000 240.000 1.450.000 466.000 0.3-8.5
3.000.000 (hl/year) 165.000 720.000 4.350.000 610.000 0.1-3.7
Notes :
1
): From Gap to fill analyses: lowest possible savings potential for utilities
2
): From Gap to fill analyses: average possible savings potential for utilities
3
): From Gap to fill analyses: highest possible savings potential for utilities
4
): Above pay-back periods are related to investment costs for meters only which do not include cost for a data
transmission network, reporting software and hardware.

2. INTRODUCTION
A set of minimally required metering points for a Utility Consumption Measuring System
(UCMS) has been developed and presented in this report.
Two objectives are to be reached with a UCMS:

1. Generating data for the Brewery Comparison System;
2. Generating data to aid in reduction of utility consumption and utility cost, including the
detection of excessive consumptions (e.g. leaking underground water distribution systems).
This report deals with the minimally required number of metering points for the registration of the
water and utility consumption of a brewery. Monitoring of utility installations for the purpose of
operation and control are excluded (see definitions).
2.1 AVERAGE CONSUMPTION IN DIFFERENT AREAS OF A BREWERY

An indication of the specific consumption for the various utilities is given below.
Cooling 1.5 - 3.5 kWh/hl 1.5 - 3.5 kWh/hl

Steam 10 kWh/ton.steam 0.6 kWh/hl
CO2 0.18 kWh/kg.CO2 0.5 kWh/hl
Air 0.09 - 0.15 kWh/N.m 1.0 1.5 kWh/hl
Water Treatment 0.5 2.0 kWh/m 0.4 1.4 kWh/hl
WWTP 0.25 - 1.5 kWh/kgCOD removed 0.3 4.5 kWh/hl
Brewing and cellars 1.5 kWh/hl 1.5 kWh/hl
Packaging 2.5 3.5 kWh/hl produced 2.5 3.5 kWh/hl
General 0.3 1.0 kWh/hl 0.3 1.0 kWh/hl
Water consumption utilities average 1.3 hl/hl

Water consumption packaging average 2.2 hl/hl
Water consumption brewing and cellars average 2.8 hl/hl
Water total brewery 4.0-18.0 hl/hl average 6.3 hl/hl
For details of the consumption at lower levels, see: Table 7, 9.4 and Table 11.
In chapters 8, 9 and 10, a detailed overview of UCMS level 0 III is given for water, electricity and the
other utilities.

3. DEFINITIONS
3.1 UTILITY CONSUMPTION MEASURING SYSTEM [UCMS]

Utility measuring is achieved by collecting data on the consumption of utilities using consumption meters
in the brewery. The collected data are then produced into utility consumption reports. Production reports
are generated elsewhere and are outside the scope of this policy.
3.2 UTILITY MONITORING SYSTEM [UMS]

The purpose of a UMS is to measure and analyse, by means of dedicated software, utility installations and
processes for the purpose of operation, control and optimisation. Such a system is specific for the Utilities
Area and may be used as follows:
- alarm registration;
- status registration of equipment including starting and stopping of equipment;
- visualisation, reporting of flows/consumption as in a UCMS;
- trend charting.
3.3 UTILITY MANAGEMENT

Utility management is an overall definition of the process of optimisation of the consumption of utilities
and utility installations. This includes monitoring and measuring of flows and optimisation (minimisation)
of utility consumption/utility cost.
Utility Consumption Measuring and Utility Monitoring are tools for Utility Management.

4. OBJECTIVES OF A UTILITY CONSUMPTION MEASURING SYSTEM (UCMS)

The primary objective of a UCMS is to obtain suitable data for a utility management programme. The
secondary objective is to generate the required consumption data mandatory for BCS.
4.1 BREWERY COMPARISON SYSTEM [BCS]

In order to collect the necessary data for BCS, the following consumption figures should be available in a
brewery: water, electricity, fuel, and CO2 balance.
Such utilities are considered as Primary utilities. Utilities which are produced from Primary utilities
are considered as Secondary utilities (eg steam produced from fuel-oil or natural gas, compressed air
from electricity or brew water from raw water).
Consumption data for BCS must be production related only. This means that utilities that are supplied for
other purposes (eg third parties) must be measured and reported separately. Some examples of data that
should not be reported in BCS are:
- Consumption of offices not related to beer production (Headoffice, Marketing/sales etc);
- Consumption for Softdrinks production;
- Supplies of drinking water or electricity to local inhabitants;
- Consumption in Maltings.
For more details of data used in BCS, see the handbook on BCS definitions.
4.2 REDUCTION OF UTILITY CONSUMPTION AND UTILITY COST

For this purpose, both the primary and secondary utility flows would have to be measured.
By collecting data on the consumption of utilities (steam, water, fuel, electricity, carbon dioxide,
compressed air and cooling), these figures can be compared with set targets. Targets are set
according to practical experience, best practices and benchmarks or theoretical values. If these
targets are exceeded (or a trend-wise increase is noticed) plans can be developed to reduce utilities
consumption.
Energy and water reduction policies are a starting point (pre-requisite) for a programme to reduce
utilities consumption. This programme can only be successful under the following two
conditions:
- Involvement of the brewery staff and employees.
- Adequate information on consumption by end users.
Involvement of the brewery staff means that consumers of utilities must feel responsible for their
consumption and be commended for achieving targets/reductions.
Only if the above-mentioned conditions are met, a successful conservation programme is possible.

5. MEASURING PHILOSOPHY
The utility consumption of a brewery consists of the sum of various smaller consumers, which are
distributed over the various departments of a brewery. At one end is the total brewery
consumption (relevant for BCS) and at the other end is a large number of small individual
consumers. In between are the consumption of the different areas.
For these reasons, different levels of detailed metering are required and shown below.
5.1 IDENTIFICATION OF DIFFERENT LEVELS FOR MEASURING ACCORDING TO A UCMS

Four levels of UCMS detailing are considered (in line with the physical distribution system of
most breweries and the most important cost allocation centres).
At UCMS levels 0 and I (see below) of metering, the consumption of different production areas
and third parties as well as non-production related consumption can be compared. In due time
sufficiently detailed information will become available through BCS to compare the production-
related consumption of breweries world-wide.
5.1.1 SITE CONSUMPTION (LEVEL 0 UCMS)

This is the minimum level of metering currently existing at all breweries for billing and generation
of data. Only the overall (brewery/site) consumption is measured. In some cases, if the
consumption of non-beer production related parts of the brewery (eg for softdrinks production,
offices and deliveries to third parties) are included in the overall figure, then the data acquired at
this level would not be sufficient for BCS use [see 4.1].
5.1.2 AREA CONSUMPTION (LEVEL I UCMS)

Area Consumption (level I UCMS) includes the following brewery areas:
- Beer production:
- Packaging;
- Utilities;
- Distribution and logistics;
- Brewery general (separate headquarters/offices only)
5.1.3 INDIVIDUAL LARGE CONSUMERS (LEVEL II UCMS)

At this level of detailed metering, sufficient information is available to start utility conservation
programmes. The identification of large consumers, which require more meters, is very important.
The choice can be found chapters 8 and 10 of this policy.
After installing a system with Level II metering, information will become available with which it
is possible to decide which parts of Level III are required.

5.1.4 INDIVIDUAL SMALL CONSUMERS (UCMS LEVEL III)

This level of detailed measurement of utility consumption for minimising utility consumption is normally
applied in certain situations. Some examples are as follows:
- If electricity consumption at the Utilities area is higher than the set target, the various equipment have
to be measured separately to find which is the high consumer;
- For conversion processes like steam boilers and cooling plants, measurement of consumption at this
level will monitor the operating efficiency and assist in the optimisation of the system. Examples are:
- monitoring COP of the cooling installation;
- efficiency of steam boilers : fuel consumption per ton steam;
- efficiency of air compressors : electricity consumption per Nm3 air.

5.2 UCMS AND COMMON COST CENTRE STRUCTURE [CCCS]
In this chapter the relationship between cost allocation and the Utility Consumption Measuring System is
explained.
The objective of the CCCS, which is common for all breweries and is based on ISA S88 structure, is to
introduce a cost allocation system in which all costs can be assigned to various operations e.g.
Maintenance, Personnel, Energy & Water etc.
9-Central Technical Service

Cost centres (LEVEL 1)
8-Distribution&Logistics
4-General Production
Who is responsible?
5-Beer Production
6-Packaging
7-Utilities
Common Chart of Account
For what responsible?
1 Personnel costs
2 Maintenance costs X
3 Energy&water costs
4 Depreciation costs
5 Other fixed costs
The first objective of a UCMS is to generate data for analysing and reducing utility consumption of
various consumers in the brewery. These measurements can also be used to capture the cost of utility
consumption under the respective cost centres provided in a brewery. Therefore the information from a
UCMS has to be as much as is practically identical to the cost coding structure of the brewery. This to
enable linking cost centre responsibility (of a person) to utility consumption.
The structure of the CCCS is common for levels 0 and I of the UCMS; i.e. area level of the CCCS is level I
of UCMS. The site (Brewery is level 0) has nine areas:
- general finance & support;
- marketing;
- sales;
- production general,
- production (beer) production;
- production packaging;
- production utilities;
- distribution & logistics;
- production - technical services.

This means that if utility consumption is measured for e.g. Production-Packaging, cost related to this
consumption can be allocated directly to the corresponding cost centre for that same area. However levels
II and III of the UCMS are not similar to the Process Cell and Train level (ISA S88 standard) of the CCCS.
Due to the fact that large consumption (cost) of utilities takes place in different parts of the brewery than
other cost (e.g. an office has primary cost for personnel but negligible consumption of utilities), the
structure and level of detailing between level II and III of UCMS and CCCS differ.
So level 0 and 1 of UCMS basically coincide with CCCS, but levels II and III of UCMS strongly differ.
Problems will arise during allocating cost based on UCMS level II and III measurements. This means that
every brewery needs to identify how they can properly allocate the cost of measured utility consumption at
level II and III to the right cost centres of the different budget responsibles (e.g. cost of water consumption
to cost centre of One Way Packaging line no. 1 of teamleader X).
Table 2: Relation of the subdivisions between CCCS and a UCMS

Division in: To be measured in: Differences between CCCS and
Common Cost Centre Structure: Utility Consumption BCS/UCMS:
Measuring System:
CCCS Area or level : Area or UCMS level 0 and I: Remarks (CCCS): Remarks
(UCMS/BCS):
Third parties Yes Not mentioned

0 Brewery General Finance Yes/No Yes for electricity Miscellaneous or
and Support, Marketing, Sales only offices
and Production General
5 Production - Beer Production Yes
6 Production Packaging Yes
7 Production Utilities Yes
8 Production Distribution & Yes Miscellaneous or
Logistics offices
9 Production - Technical No Yes for electricity Miscellaneous or
Services only offices
Notes:
1. Brewery General (in CCCS consisting of: finance, support, marketing, etc.) is not covered by a
UCMS for reasons already explained (negligible consumption and finely distributed end-users).
Although e.g. air-conditioning in the tropics can consume substantial power and is part of the
fixed cost in the brewery, these types of consumers consists of a large number of small consumers
distributed over the site and therefore it is impractical to monitor individually. The reduction of
this type of consumption is considered part of good housekeeping (operation based on time clocks
or on presence of staff).
2. Third parties (maltings, softdrinks production, etc) are covered in CCCS, but as part of Production
Beer Production (other). This consumption however is required for BCS purposes and therefor
has to be measured in UCMS.

6. METERING
6.1 INSTALLATION
The number of meters required and the investment cost of a UCMS are very much dependent on the
following:
- The number of meters is influenced by:
- The distribution system of the various utilities on the brewery
- The number of meters already available
- The installation costs are influenced by:

- The local labour costs
- Bypasses of meters where required
- Location of meters (pipe bridge, etc)
- The cost of individual meters depends on:

- The required accuracy
- The type of meter selected (see section 7.2)
The use of meters could be minimised in some situations as shown in the schematic.
C
A
D
Item E is not measured physically with a meter but may be calculated as:
E = A [B + C+ D]
This saves the cost of installing one meter. However if one meter fails, the calculated
consumption would be in error. If E is also provided with a meter and if one of the meters fails or
gives a wrong reading, it will be relatively easy to detect the malfunction (this can even be
automated).
6.2 ACCURACY AND RELIABILITY OF A UCMS
A UCMS needs to be reliable (information must be trusted first hand) and a check on the
operation/function of individual meters must be straightforward. When one meter is not
functioning this has to be indicated as quickly as possible. This is easily revealed if all data
collected is put in a spreadsheet and a monthly trend of consumption may be compared. A faulty
meter reading will throw up figures which are way off.
Although individual meters with an accuracy of < 1 % are normally used it will be impossible to
achieve the same accuracy for a complete UCMS. Experience has shown that a field accuracy of
1-2 % is achievable. When the differences between flow balances deviates > 3 % the source of this
difference has to be traced (usually a meter has failed).

When a flowmeter fails, this would only be noticed when large enough differences appear in a
report (eg if a meter fails on the last day of the month, the monthly report will show a relatively
small difference of 1/31 x monthly consumption). Only when the next completed reporting period
has ended, the difference would be noticed (in this case a month in which no consumption would
be reported). In a UCMS spreadsheet, a cross-check sheet is useful. This provides a quick check
on the monthly trend. For better control of utilities consumption, readings for UCMS should be
taken weekly or even daily.
In the following recommendations for a reliable UCMS are presented:

1. Meter balancing:
What goes in must come out. This is only possible by measuring all individual flows.
Advantage: Quick and reliable.
Disadvantage: Cost of increased number of meters.
2. Checking individual meters with a portable meter:
Monthly checking will have to be performed on all meters. For critical Level 0 meters such as
those used for billing of water usage, it is not recommended that the brewery invest in
additional meters to cross check the readings. The sum of the downstream distribution meters
can be used for this (meter balancing required).
3. Comparing actual with budget consumption:
When comparing consumption to budget and targets (eg running hours) and large differences
are noticed, this can be an indication of malfunctioning meters.
Conclusion:
Meter balancing is preferred, but this increases the number of meters especially at the most
detailed levels of metering and results in an unacceptable higher investment cost.
Recommendations:
- Meter balancing (by measuring all flows) is required, but only for levels 0 and I;
- Although all three methods described above have their disadvantages, they should be used as
deemed suitable for the application it is intended for.

Recommended setup
Supply
Meter 1
a: 100
a: 20
Meter 2
a: 25
Meter 3
a: 15
Meter 4
a: 40
From this diagram it can be seen that when e.g. meter No 4 becomes defective, the sum of meters
1, 2, 3 and 4 = 60 units (20 + 25 + 15 + 0) when compared to the supply of 100 units, will indicate
a difference of 40 units. From this comparison it can then be concluded that meter no 4 is
defective.
If however meter 4 does not exist, the consumption is calculated as follows:

Supply (sum of meters 1,2 and 3) = 40 units.
If meter 3 becomes defective, the result is that meter 3 will indicate no consumption and meter 4
will indicate a consumption of 55 units.

7. TYPE OF METERING
7.1 REPORTING AND DATA COLLECTION

Data on consumption could be collected either manually or automatically. It is preferred, at least
for the most important consumers (see: meters required), to collect the data automatically
(including the generation of reports). For this report however automatic data collection,
transmission and reporting are not considered.
The following is an example of the reports, which can be generated:
- Consumption per: Day, Week, Month, Year, and monthly going average (13 months).
Divided per area, process cell and consumer (cost centre) and compared with a set target.
7.2 TYPES OF METERS

Below is a table showing the recommended types and accuracy of meters typically applied for measuring
flows for different utilities. The difference in accuracy between meters when installed is due to the fact
that the conditions in the field differ from those under which the meters have been tested (turbulence,
mounting, etc).
Table 3a: Type of meters.

Application: Measuring principle: Meter Application
Accuracy accuracy
(%) (%)
Water supply meters [volume] Magnetic flow meter 0.5 1
Water distribution meters [volume] Magnetic flow meter 0.5 1
Wastewater meters, pipeline [volume] Magnetic flow meter 0.5 1
Wastewater meters, open canal [volume] Ultrasonic level 0.5 1
Steam volume Vortex 1 1.5
Steam mass (central or decentral p/T Vortex/Orifice 1 2
correction)
Air [volume] Vortex/Orifice 1 2
Carbon dioxide mass (central or decentral p/T Vortex 1 2
correction)
Secondary cooling medium Magnetic flow meter 0.5 1
Electricity supply Electronic Class 0.2 0.5
Electricity distribution Electronic Class 0.5 1
Note:
- Mechanical (water) meters are an acceptable alternative if already present.
- Mechanical meters to be equiped with electrical outputs for future automatic data collection.
In order to give an indication of the cost for the different meters involved the table below has been
produced.

Table 4b: Meter cost.

DN40 DN50 DN80 DN100 DN150 DN200
Water supply magnetic flow meter 3000 3000 3400 3600 4000
Water distribution magnetic flow meter 3000 3000 3400 3600 4000
Waste water, meter in pipe 3600 4000 5000
Magnetic flow meter
Waste water, meter in open channel excluding 3000
civil works. Ultrasonor Flow meter
Steam volume Vortex meter 3900 3600 4200 4700
Steam mass p/T compensation Vortex meter 8300 8000 8700 9200
Steam mass p/T compensation Orifice meter 8000 8100 8200 10200
CO2 volume Vortex meter 3900 3600 4200 4700
CO2 p/T compensation Vortex meter 8300 8000 8700 9200
CO2 p/T compensation Orifice meter 8000 8100 8200 10200
Secondary cooling agent 6000 6000 6400 6600 7000
Magnetic flow meter + 2 xPt100
Air volume Vortex meter 3900 3600 4200 4700
Fuel PD meter DN 25
5750 7100
Natural Gas p/T compensation
Turbine meter 10000 10500 11000
Natural Gas p/T compensation
PD meter 11500 12000 15000
Electrical supply acc. 0.2 % 15000
Electrical supply acc. 0.5 % 2500
Note:
The prices are in NLG and based on net prices (Heineken-supplier agreements) including local
mechanical installation, electrical supply, excluding piping.

8. WATER
8.1 REQUIRED METERING POINTS

The calculations of the different consumption are based on the report Feasibility Study - Cost-effective
Reduction of Water Usage for Hatay Brewery Ltd.. These consumption figures are then used to decide if
a meter is required on an installation. When large consumers of water in the brewery are measured [>3%
of total brewery consumption], this would cover approximately 70% of the total site consumption.
8.2 WATER TYPES

The utilities department normally supplies different types of water to the various parts of the
brewery. The types of water supplied in a typical brewery are: general purpose for sanitary use,
product water for brewing and softened water. Condensate recovery is only used within the utility
department for boiler feed water. Not all breweries use all these types of water. Some only use
one type for all applications, others use two or more types of water.
Different areas use different water types:

- the Packaging area uses mainly softened- and some general purpose water
- the Brewhouse and Cellars are using brewing- and general purpose water
- the Beerfiltration is using brewing-, standardisation- and general purpose water
On Site and Area level (Level 0 and I) all these water types have to be metered at all relevant
locations. See the table Table 5: Area water types.
Table 5: Area water types

Water type produced/used:
Area General purpose Softened Product/brewing
Brewery general (offices) Yes No No
Utilities Yes Yes Yes
Packaging Yes Yes No
Brewing and cellars Yes No Yes
Distribution & logistics Yes No No
Technical services Yes No No
Others (third parties, maltings, softdrinks, etc) Yes Yes Yes

8.3 LEVEL 0 AND 1

The following table shows the calculation of individual (departmental and third parties) water
consumption of a typical brewery. The different water types are summed up for each consumer.
Table 6: Area consumptions
Area: Water consumption: Water discharge (to sewer): Metering
required
Hl/hl % of brewery Hl/hl % of department % of brewery
total total total
Utilities1 1.3 18 1.3 100 18 Yes
Brewing and 2.8 48 1.4 88 19 Yes
cellars1
Packaging1 2.2 31 2.2 100 31 Yes
Site brewery 6.3 97 4.9 68 Yes
1
): Including others: Brewery general, distribution & logistics, technical services and offices (need separate
measurement for BCS purposes, 0.5 hl/hl).
The difference between total brewery Water consumption and Discharge to sewer are losses
through evaporation (wort boiling, evaporative condensers) and product treatment.
The number of meters for level 0 depends on the number of incoming raw water supplies (number
of city water lines, wells or other supplies). This can vary between two and eight units (on average
5 meters are installed).
A typical brewery using three water types and divided into six areas (exclude third parties)
requires thirteen meters for level I (see Table 5: Area water types and Table 6: Area consumptions)
MEASURING WATER CONSUMPTION

Recommended layout of metering points
SURFACE WATER SUPPLY CITY WATER SUPPLY WELLWATER SUPPLY
LINE 1 LINE 1 WELL 1
LINE 2 LINE 2 WELL 2
LINE 3,4, ... LINE 3,4,.... WELL 3,4,...
UMS LEVEL 0 = SITE
SITE CONSUMPTION THIRD PARTIES
UMS LEVEL I = AREA
AREA: BREWERY AREA: BEER AREA: DISTR. &

AREA: PACKAGING AREA: UTILITIES LOGISTICS AREA: TECH. SERVICES
GENERAL PRODUCTION
All boxes are measuring points.

8.3.1 LEVEL II AND III
In the following table, the consumption of the various large individual consumers is calculated.
Depending on the percentage of the total brewery consumption (> 5 %), a decision may be made to
install a meter for level II. When all large (individual consumers > 5 % of the brewery total) are
measured then 67 % of the total water consumption will be known (measured) and 33 % remains
unknown (smallest and diffuse consumers).
Table 7: Water consumption of individual consumers.

Consumer: Consumption Losses (to sewer):
Hl/hl Hl/hl % of % of brewery Metering
department total required
Bottle washer 0.83 0.83 37 13 Yes
Crate washer 0.35 0.35 16 5 Yes
Filler 0.21 0.21 9 3 No
Showers 0.07 0.07 3 1 No
Pasteurizer 0.49 0.49 22 7 Yes
Conveyor belt lubrication 0.28 0.28 13 4 No
Production Packaging total 2.2 2.2 100 33 Yes
Water Losses 0.6 0.6 46 9 Yes
Boiler feedwater make-up2 0.02 0.02 N.A. 0.3 Yes
Cooling 0.3 0.3 23 5 Yes
CO2 treatment 0.12 0.12 9 2 No
1)
Air compression 0 0 see 0 See 1)
Miscellaneous 0.27 0.27 20 4 No
Production Utilities total 1.3 1.3 100 20 Yes
Standardisation water 0.2 - - - No
Beer filtration & PVPP 0.02 0.02 0.1 0.3 No
Cleaning and Disinfection 0.2 0.2 20 3 No
Chase water 0.05 0.05 5 0.7 No
Miscellaneous 0.53 0.53 53 8 Yes
Cellars total 1.0 0.8 78.1 12 Yes
Wort/beer3 0.92 - - - Yes
Spent grains/trub 0.15 - - - No
Wort vapour 0.1 - - - No
Chase water 0.06 0.03 1 0.9 No
CIP installations 0.32 0.32 18 4 No
Miscellaneous 0.25 0.25 14 4 No
Brewhouse total 1.8 0.6 33 9 Yes
Production Beer total 2.8 1.4 50 21 Yes
Total Brewery Consumption 6.3 4.9 -- 74
1
) Depending on type of compressor cooling.
2
) Quantity of boiler feedwater make-up gives important information concerning condensate return (and
subsequently of losses) of production areas.
3
) Quantity of product water used for wort cooling and subsequently for wort preparation (another 0.08 hl/hl
will later be added during standardisation.
As can be seen from this table, an estimated 12 meters (12 flows are > 3 % of the brewery total)
are required for level II. This is independent from the water types distributed but depends more on
the distribution system and the number of users like CIP installations and miscellaneous.
For level III, approximately another 14 meters are required.

Conclusion:
RECOMMENDED LAYOUT OF METERING POINTS
AREA: UTILITIES
(WATER LOSSES)
UMS LEVEL I
AREA: UTILITIES
UMS LEVEL II
PROCESS CELL CONDENSATE RETURN
(FROM SITE)
BOILER FEEDWATER MAKUP
UMS LEVEL III

PROCES CELL
COOLIING CARBON DIOXIDE INSTALLATION COMPRESSED AIR INSTALLATION OTHERS

RECOMMENDED LAYOUT OF METERING POINTS
AREA: BEER PRODUCTION

UMS LEVEL I
AREA: BEER PRODUCTION
UMS LEVEL I CELLARS

YEAST CELLAR
(PROCESS CELL) (PROCESS CELL)
BREWHOUSE SERVICE BLOCK
(PROCESS CELL) (PROCESS
YEAST CELLAR CELL)
(PROCESS CELL)CELLAR
(PROCESS CELL)
UMS LEVEL II FILTRATION
(PROCESS CELL)
WORT COOLING OTHERS STANDARDISATION WATER OTHERS
UMS LEVEL III
SPENT GRAINS/TRUB CIP INSTALLATIONS CHASE WATER KIESELGUHR FILTRATION
CHASE WATER CIP INSTALLATIONS PVPP STABILISATION

WATER CONSUMPTION
UCMS LEVEL I RECOMMENDED LAYOUT OF METERING POINTS
AREA: PACKAGING
PACKAGING
UCMS LEVEL II
PACKAGING LINE 1
PACKAGING LINE 2
PACKAGING OTHERS
PACKAGING LINE n
CRATE WASHER BOTTLE WASHER BOTTLE/CAN RINSER BOTTLE/CAN

PASTEURIZER
UCMS LEVEL III
CONVEYOR BELT
LUBRICATION FILLER
An estimate of water meters and costs (excluded are data cabling, transmission, installation, etc)
required for a UCMS for the various Levels is presented in the following table:
Table 8: Number of water meters

Number of meters: Investment cost (NLG x 1.000):
Range: Typical: Range: Typical:
Level 0 2-8 meters 5 7-28 18
Level I 8-16 meters. 12 28-56 40
Level II 20-30 meters 24 70-105 84
Level III 40-47 meters 45 140-165 160
The quantity in the lower range is valid for small breweries (approximately 300.000 hl/year). The
figure under typical is valid for a brewery size of 1.000.000 hl/year and those in the higher range
is for a brewery size of 3.000.000 hl/year.

9. ELECTRICITY
9.1 STARTING POINTS

For electricity, there is primary supply and secondary supply.
The Electricity Company supplies the primary electricity, while the secondary electricity supply is
generated by the brewerys generator sets.
9.2 OVERVIEW METERING POINTS PER LEVEL
Electricity Flow 1
TRANSFORMERS GENERATORS
TRANSFORMER 1 GENERATOR 1
Level 0
// See electricity Flow 2
COOLING UNIT STEAM CO2 AIR WATER UTILITIES
CONTROLPANEL STEAMBOILER 1 CONTROLPANEL CONTROLPANEL WATERTREATM.
COMPRESSOR 1 STEAMBOILER 2 COMPR. UNIT 1 COMPRESSOR 1 WWT
COMPRESSOR 2 STEAMBOILER 3 COMPR. UNIT 2 COMPRESSOR 2 WELL WATER Level 2
COMPRESSOR COMPR. UNIT .. COMPRESSOR . ...
PUMPS . CO2 COMPR. 1 . ..
CONDENSORS CO2 COMPR. 2
Level 3
EVAPORATORS FREON COMPR. 3
.. FREON COMPR. 2

Electricity Flow 2
See Electricity Flow 1 // // See Electricity Flow 3

PRODUCTION (BEER) Level 1
RAW MATERIALS BREWHOUSE SERVICE BLOCK MALT PRODUCTION SOFTDRINK GLASS PRODUCTION
PRODUCTION
Level 2
MALT INTAKE BREWHOUSE 1 FILTER
MALT TREATMENT BREWHOUSE 2 CIP
MILLING BREWHOUSE 3 CELLARS
Level 3
Electricity Flow 3
See
Electricity
Flow 2 //
TECHNICAL PRODUCTION Level 1

DISTR. & LOGIST. PACKING GENERAL
SERVICES GENERAL
LINE 1 ..
LINE 2
LINE Level 2
GARAGE PER MACHINE WORKSHOP OFFICES HEAD QUATERS
FORKLIFTS . MEDICAL CENTRE MEDICAL CENTRE
STORES
Level 3

9.3 NUMBER OF METERS AND INVESTMENTS COSTS PER LEVEL
An estimate of the number of meters and investments costs required for a minimal required UCMS
depends strongly on the local situation.
The investment costs for level 0 depends on the requirements of the Electricity company and is based on a
kWh meter, kVAr meter and a max demand metering system per measuring point.
The investment costs of the other levels is based on one kWh meter per measuring point.
The meters have to be read locally and have a pulse output for collecting data in the future.
Table 9: Number of electricity meters.

Number of meters: Investment cost x 1000
NLG
300.000 1.000.000 3.000.000 Per meter: 300.000 1.000.000 3.000.000
hl/yr. hl/yr. hl/yr. NLG hl/yr. hl/yr. hl/yr.
Level 0 1-2 5-6 10-15 15.0001 17.5 25 50
Level I 5-8 6-12 10-20 2.500 12-20 15-30 25-40
Level II 15-20 20-35 35-50 2.500 35-50 50-90 90-125
Level III > 50 > 80 > 100 2.500 > 125 > 200 > 250
1
): Electricity meters for billing are more expensive than meters for Utility Monitoring (the required accuracy is
higher). Per brewery size one meter for billing has been included.
9.4 AVERAGE ELECTRICITY CONSUMPTION IN THE DIFFERENT AREAS
Table 10: Average electricity consumption in the different areas

Specific brewery
consumption
Performance Performance Unit kWh/hl kWh/hl
indicator (low indicator (high (low range) (high range)
range) range)
Cooling -- -- -- 1.5 3.5
Steam 10 -- KWh/Ton 0.6 --
Carbon dioxide 0.18 -- KWh/kg 0.5 --
Air 0.09 0.15 KWh/Nm3 1.0 1.5
Water treatment 0.5 2.0 KWh/m3 0.4 1.4
Wastewater treatment 0.25 1.5 kWh/kg CODremoved 0.3 4.5
plant
Brewing/Cellars -- -- -- 1.5 --
Packaging -- -- -- 2.5 3.5
General -- -- -- 0.3 1.0
Notes:
1
): Average Electricity consumption:
The average electricity consumption will be somewhere between 8,6 and 18 kWh/hl.
2
): The electricity consumption of a cooling installation depends also on the place of the brewery (eg Tropics) and
on the temperature of the incoming water.
3
): The electricity consumption of the WWTP depends on the degree of pollution of the wastewater and if an aerobic
or anaerobic system is installed.

10. OTHER UTILITIES : FUEL, STEAM, CO2, COMPRESSED AIR AND COOLING
10.1 IDENTIFICATION OF CONSUMERS

Various utilities are used throughout the brewery. A general overview of the consumers is shown in the
following table:
Table 11:. Specific values of consumption: Indicative and average values.
Unit Fuel CO2 Steam Compressed air Cooling

Brewing and cellars: % - - - - -
- brewhouse % - - 35-45 10-20 25
- tankroom/service block % - 40 10-20 5-10 50
Packaging % - 40 30-40 50-60 0-10
Utilities % 90-100 10 5-10 5-10 10
Brewery general % 0-10 - 0-10 - -
10.2 PRIMARY UTILITY FLOWS : FUEL AND CO2

Measuring points are schematically shown below.
Fuel measurement
BREWERY FUEL INTAKE

Level 0
Utilities Level 1
STEAM PLANT GENERATOR PLANT BREWERY GENERAL OTHER (eg softdrink)
BOILER 1 GENERATOR.SET 1 OFFICES

Level 2
BOILER 2 GENERATOR SET 2 ..
BOILER . GENERATOR SET
Comments:
- number of meters on level II depends on the number of boilers, generator-sets etc.
Table 12: Number and investment cost of fuel meters.

FUEL Number of meters Investment cost
(NLG x 1.000)
Level 0 1-2 5-10
Level I 3-4 15-20
Level II 4-81 20-40
Level III depending on local situation -
1
): Depending on local situation

recuperation <-- --> consumption CO2 measurement

L
BREWERY INCOMING CO2 PURCHASE BREWERY OUTGOING CO 2 SOLD
RECUPERATION FSTS BEER PRODUCTION PACKAGING OTHER (eg. softdrink)
DEAERATED WATER PLANT INDIVIDUAL PACKAGING LINES
L
BRIGHT BEER TANKS ETCETERA
KIESELGUHR FILTER
INDIVIDUAL CONSUMERS
Table 13: Number and investment cost of CO2 meters.

CO2 Number of meters Investment cost (NLG x 1.000)
Level 0 1-2 8.5-17
Level I 2-4 17-34
Level II 4-6 34-51
10.3 SECONDARY FLOWS : STEAM, COMPRESSED AIR, COOLING

Measuring points are schematically shown below.
Steam measurement
BREWERY INCOMING ( IF NOT PRODUCED BY BREWERY BOILERS )

Level 0
UTILITIES BEER PRODUCTION PACKAGING BREWERY GENERAL OTHER (eg. softdrink)
Level 1
BREWHOUSE TANK ROOM/SERVICE BLOCK INDIVIDUAL PACKAGING LINES HEATING OF BUILDINGS Level 2
WORT PRODUCTION CIP INDIVIDUAL CONSUMER E.G. BOTTLE WASHER Level 3
HOT WATER/ CIP DAW-PLANT ( WHEN THERMAL )
Table 14: Number and investment cost of steam meters.

Steam Number of meters Investment cost (NLG x 1.000)
Level 0 1 10
Level I 4-5 40-50
Level II 4-6 40-60

Compressed air measurement
Level 0
NONE
BREWERY TOTAL DRY AIR BREWHOUSE SPENT GRAINS OTHER (eg. softdrink)
Level 1
PACKAGING BREWHOUSE UTILITIES

Level 2
PACKAGING LINES BREWHOUSE E.G. WASTE

WATERTREATMENT
INDIVIDUAL CONSUMERS TANK ROOM/ SERVICE BLOCK
E.G. ENGINE ROOM
ETCETERA
Level 3
Table 15: Number and investment cost of air meters.

Compressed air Number of meters Investment cost
(NLG x 1.000)
Level 0 0 -
Level I 2-3 8-12
Level II 3 12
Cooling measurement
NONE
level 0
PACKAGING BEER PRODUCTION OTHER (eg.softdrink) BREWERY GENERAL
Level 1
INDIVIDUAL PACK. . LINES BREWHOUSE TANK ROOM/SERVICE INDIVIDUAL CONSUMERS

BLOCK Level 2
INDIVIDUAL CONSUMERS E.G. WORT COOLING E.G. FSTS

E.G. PASTEURISER Level 3
E.G. DAW PLANT
Table 16: Number and investment cost of cooling meters.

Cooling Number of meters Investment cost (NLG x 1.000)
Level 0 0 -
Level I 1 if applicable 6
Level II 3 18
Level III Depending on local situation -

10.4 SUMMARY: NUMBER OF METERS AND INVESTMENT COST PER LEVEL (OTHER UTILITIES)
An estimate of the number of meters and investment cost required for FUEL, STEAM, CO2,
COMPRESSED AIR AND COOLING are as follows:
Table 17: Number and investment cost of Other utilities meters.

Number of meters: Investment cost per level
(NLG x 1.000)
Level O 3-5 24-37
Level I: 12-17 86-122
Level II 18-26 124-181
Level III: 25-50, or more depending on N.A.
local situation

11. CONCLUSIONS AND RECOMMENDATIONS:

Conclusions and recommendations:
1. It is recommended to design a UCMS for the brewery into four levels of increasing detail
(level 0, I, II and III).
2. For BCS purposes, a UCMS with levels 0 and I detailing is sufficient.
3. For a proper programme for the reduction of Energy and Water consumption, a UCMS with
level II should be considered (optionally level III only when cost / benefits is clear).
4. Balancing of meters (system reliability) is only practicable for levels 0 and I of a UCMS.
5. With a Minimally Required UCMS, adequate brewery management support savings of
approximately 10-25 % on the consumption of Energy and Water can be achieved.
6. No general UCMS configuration for different1 breweries exists because of the different
brewery layouts.
Remark:
1
): These differences are caused by: differences in distribution systems, differences in cost of
utilities and presence or absence of existing flowmeters.
11.1 NUMBER OF METERS AND INVESTMENT COSTS:

An estimate of the number of meters and investment cost (included are: mounting, local cabling
based on Dutch price levels) required for a Utility Consumption Measuring System for the
various Levels and for each brewery size is presented in the following tables:
Note:
Not included are costs for data transmission to a centralized data collection and reporting
computer.
Table 18: Total number of meters and investment cost of a Utility Consumption Measurement System.
Brewery size 300.000 hl per year: Total investment cost
(per level)
Water: Electricity: Other Utilities: Total (NLG x 1.000):
Number of meters Number of meters Number of meters Number Cost
Level 0 2 2 3 7 50
Level I: 8 6 12 26 129
Level II 20 18 18 56 239
Level III: 40 < 50 >25 > 100 > 500
Table 19 Total number of meters and investment cost of a Utility Consumption Measurement System.
Brewery size 1.000.000 hl per year: Total investment cost
(per level)
Level O 5 5 5 15 80
Level I: 12 9 13 34 160
Level II 24 28 22 74 306
Level III: 45 > 80 35 > 150 > 600

Table 20: Total number of meters and investment cost of a Utility Consumption Measurement System.
Brewery size 3.000.000 hl per year: Total investment cost
(per level)
Level 0 8 12 5 25 110
Level I: 16 15 17 48 216
Level II 30 43 26 99 394
Level III: 47 > 100 50 > 200 > 750
The total number (and subsequently the investment cost) of meters can vary 30 % according to the local
situation (number of meters already present, different types and number of utilities, brewery layout and
distribution system).
11.2 POSSIBLE SAVINGS:

Experience has shown (Zoeterwoude) that a UCMS with level II detailing and management support can
result in savings on consumption of Energy and Water of approximately 25 %. It will be clear that the
potential savings strongly depend on the results of utility reduction programmes already present.
To establish the payback period (if any) of a UCMS an estimated payback period has to be
calculated.
For this calculation the investment cost of a UCMS and the savings in Utilities cost have to be
estimated.
The cost of Utilities and the savings potential:

From the Gap to fill analyses (year 2000) the data in Table 21 have been summarised. It can be
seen that the total savings potential amounts to NLG 25,286,000 or NLG/hl 0.48. However there
are large regional differences, from NLG/hl 0.115 (France, The Netherlands and Italy) to NLG/hl
2.924 (Caribean).
Table 21: Possible regional utility savings
Possible savings:
Number of Hl produced (1998): Gap to fill:
Region:
breweries: hl/year NLG/year NLG/hl
Africa & Middle East 17 7,552,000 13,200,000 1.748
Asia Pacific 15 6,560,000 5,522,000 0.842
Caribean 5 602,000 1,760,000 2.924
Europe 1 15 23,600,000 2,721,400 0.115
Europe 2 5 7,577,000 968,000 0.128
Others 5 3,070,000 1,115,400 0.363
Total 62 52,735,000 25,286,800 0.480
Saving potential/payback period:

As can be seen from the following table, the payback period of a UCMS strongly depends on the
size of the brewery and the cost of utilities. These factors have to be considered when a decision
has to be made if a UCMS would be implemented for a specific brewery.
The investment cost of a UCMS strongly depends on the number of required meters and much less
on the brewery size.
A UCMS with level 0 is already present on all breweries, to reach the required level (level II)
additional investments are required. To get from level 0 to level II the sum of the investments for
level I and II are required.
The following table shows a simple estimate of the returns for the installation of a UCMS for
different brewery sizes. Some assumptions have been made:
- Assuming that 50% of the achievable savings are attributable to the implementation of a
UCMS
- A utilities saving programme is in place;
- The remaining 50% to be achieved with additional investments in process optimisation and
equipment.
Table 22: Simple payback period for a UCMS
Brewery size Annual savings (NLG/year)* Investment cost for Payback

average UCMS period
(NLG): (years):
NLG/hl NLG/hl NLG/hl
0.11 0.48 2.9
300.000 (hl/year) 16.500 72.000 435.000 268.000 0.6-16
1.000.000 (hl/year) 55.000 240.000 1.450.000 466.000 0.3-8.5
3.000.000 (hl/year) 165.000 720.000 4.350.000 610.000 0.1-3.7
Note : Above pay-back periods are related to investment costs (including installation) for meters
only. Cost for a data transmission network, reporting software and hardware are not included.
It is clear that the annual savings would not be reached in one year (following the investment in a UCMS).
The actual savings and the speed with which they are achieved depend strongly on the input of the brewery
staff.
From this table it can be seen that the payback period covers a very wide range (0.1-16 years). It is
therefore necessary to determine the possible savings for each individual brewery before a decision
is made if a UCMS is feasible.

MODIFICATION REQUEST FORM
INTRODUCTION.
This form is a means of communication to indicate your suggestions for improvement of Corporate PP&C
Engineering Policy Instructions & Procedures, such as Production Automation & Information
Technology Instructions, BDM Manuals, SHE Policies & Instructions, etc.
SUGGESTIONS FOR IMPROVEMENT

Document type :
HMESC Code :
Issue date :
Chapter :
Page :
Suggestion(s) :
Please return this form to the Document Manager (Wim Vergunst HTS), who will forward it to the secretary
of the relevant Steering Committee .
Address:
Heineken Technical Services
PO Box 510
2380 BB Zoeterwoude
The Netherlands
Attn.: W.P. Vergunst, room 4.159
Phone: (+31)715456186
Fax: (+31)715457888
email: [email protected]
Issue : 02 HMESC : 03.11.10.003

Date : Mar 2001 Page : 1 of 1

UCMS

Uploaded by

UCMS

Uploaded by

Brewery Design Modules

Sponsor : PP&C Engineering Policy Manager Copyright

UTILITIES CONSUMPTION MEASURING SYSTEM

Issue : 02 UTILITY CONSUMPTION MEASURING SYSTEM HMESC : 01.30.70.010

Issue : 02 UTILITY CONSUMPTION MEASURING SYSTEM HMESC : 01.30.70.010

Heineken Technical Services

Issue : 02 HMESC : 03.11.10.002

SUGGESTIONS FOR IMPROVEMENT

Refer. Doc.: Date :

Source : RTM Request Corp. PP&C audit Customer input Other

3. Proposal for acceptance Non-conforming process conditions or specifications :

5. Decision Corp. PP&C :

Name : Corp. PP&C Director

Issue : 02 HMESC : 03.11.10.004

BREWERY DESIGN MODULES

3. HYGIENIC DESIGN MANUAL 5

5. SEE ALSO CE-MARKING POLICY OF CORPORATE PP&C. 5

Issue : 05 BREWERY DESIGN MODULES HMESC : 01.30.00.011

1.1 BREWERY DESIGN MODULES (BDM)

1.2 BREWERY ENGINEERING &AUTOMATION MODULES (BEAMS).

1.3 EXECUTION OF ENGINEERING PROJECTS

Issue : 05 BREWERY DESIGN MODULES HMESC : 01.30.00.011

1.4 SEPARATING 'POTS & PANS' TENDER FROM 'AUTOMATION' TENDER.

1.5 PROCEDURES FOR NON-CONFORMING PRODUCTION PROCESS

1.6 PROCEDURES FOR IMPROVEMENT OF THE BDMS AND BEAMS

Issue : 05 BREWERY DESIGN MODULES HMESC : 01.30.00.011

1.7 AMENDMENTS TO THE BDM BEFORE THE NEXT VERSION IS RELEASED

CHAPTER 3: Process Alternatives

CHAPTER 4: Equipment Alternatives

CHAPTER 5: Design Variant

CHAPTER 6: Engineering documents

Issue : 05 BREWERY DESIGN MODULES HMESC : 01.30.00.011

3. HYGIENIC DESIGN MANUAL

5. SEE ALSO CE-MARKING POLICY OF CORPORATE PP&C.

Issue : 05 BREWERY DESIGN MODULES HMESC : 01.30.00.011

CRATE WASHER BOTTLE WASHER BOTTLE/CAN RINSER BOTTLE/CAN

UCMS LEVEL III

Table 1: Simple payback period for a UCMS

Brewery size Annual savings (NLG/year) Investment4 cost for Payback

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Two objectives are to be reached with a UCMS:

2.1 AVERAGE CONSUMPTION IN DIFFERENT AREAS OF A BREWERY

Cooling 1.5 - 3.5 kWh/hl 1.5 - 3.5 kWh/hl

Water consumption utilities average 1.3 hl/hl

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3.1 UTILITY CONSUMPTION MEASURING SYSTEM [UCMS]

3.2 UTILITY MONITORING SYSTEM [UMS]

3.3 UTILITY MANAGEMENT

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4. OBJECTIVES OF A UTILITY CONSUMPTION MEASURING SYSTEM (UCMS)

4.1 BREWERY COMPARISON SYSTEM [BCS]

4.2 REDUCTION OF UTILITY CONSUMPTION AND UTILITY COST

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5.1 IDENTIFICATION OF DIFFERENT LEVELS FOR MEASURING ACCORDING TO A UCMS

5.1.1 SITE CONSUMPTION (LEVEL 0 UCMS)

5.1.2 AREA CONSUMPTION (LEVEL I UCMS)

5.1.3 INDIVIDUAL LARGE CONSUMERS (LEVEL II UCMS)

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5.1.4 INDIVIDUAL SMALL CONSUMERS (UCMS LEVEL III)

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9-Central Technical Service

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Table 2: Relation of the subdivisions between CCCS and a UCMS

Third parties Yes Not mentioned

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- The installation costs are influenced by:

- The cost of individual meters depends on:

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In the following recommendations for a reliable UCMS are presented:

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If however meter 4 does not exist, the consumption is calculated as follows:

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7.1 REPORTING AND DATA COLLECTION

7.2 TYPES OF METERS

Table 3a: Type of meters.

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