Water Hydraulic valves is (R)evolutionizing Carlsberg’s beer production.


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HYDRACT is control by water. The sustainable revolution that is sweeping across the industry is a challenge for an industry that already have picked all the low hanging fruits. How is it possible to find savings without new technology our new ways of thinking production? How to lower the production waste? Is it sustainable to use electricity from alternative energy sources and not reducing how much we use? A reduction of product waste and less cleaning is possible if processes are turned around and looked at in new ways. The achievement of especially late product differentiation of beverage will revolutionize the beverage industry making it possible to produce just in time and on-demand – small volume production will help the industry to better profits and unprecise forecasts will be over. The dynamic market situation that is currently happening in the beverage industry is challenging the lifetime of products. The late product differentiation will help the industry overcome this hurdle. The system brings operational scalability and flexibility to the industry where it is much needed. A lot of companies cannot envision a world that operates differently than how they work (and how they have been successful) for years. At HYDRACT we work continuously to optimize and rethink processes creating a better margin for our customers. Go beyond precision!

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Brewing a game-changer at Carlsberg Fredericia.

Over the past 10 years, Carlsberg has been closely involved in developing and testing the HYDRACT valve, and since 2016 Carlsberg has implemented the HYDRACT valve at the company’s brewery in Fredericia, Denmark. The project first started out as an energy reducing project – powered by water hydraulics – the patented valve technology reduces the electrical power consumption with more than 90%. The project evolved from being the sustainable alternative to common pneumatic valves – to enabling high precision inline mixing and working with HGB and late product differentiation.

The tests of the HYDRACT valve have exceeded our expectations. The precision and repeatability achieved with water hydraulics as an alternative to compressed air enables an entirely new approach to effective and sustainable beer production. It fundamentally changes the way we can produce beer in the future, says Anders Kokholm, Brewing Director at Carlsberg Supply Company Denmark. This has led to another project that will be finalized before Christmas 2020. When the new project is implemented Carlsberg will have more than 600 HYDRACT valves installed and operating in Fredericia – bringing huge change to the way Carlsberg is brewing.

Because water is incompressible, the hydraulic valves provides an unpreceded level of precision and control compared to pneumatic valves. HYDRACT enables customers to rethink the production methods and processes, due to the stability and precision of the HYDRACT valves.

The new way of brewing at Carlsberg, called Smart-mix, means that Carlsberg now can focus only on brewing HGB and inline mixing of these – creating a brand-new setup for the brewery – blending beer on demand for Just-In-Time filling.

Instead of storing ready for filling beer in Bright Beer Tanks, Carlsberg can now store High Gravity Beer. The various types of beer are diluted with water and/or mixed, establishing a more versatile process with a lead time of hours instead of days – in some cases weeks – thus minimizing the inventory carrying costs significantly.

The company is quickly realizing the benefits of changing its setup.  “The process is very unique,” says Anders Kokholm.  “and you cannot find a valve controlled like this one in the market today.”

The new inline mixing project not only achieves a significant energy saving for the valves but also generates less waste and consumes less water while reducing chemical use and cleaning costs up to 30%. Because Carlsberg will be able to brew bigger batches of the same HGB there will be fewer bright beer batches per year – hence less cleaning and a higher filling degree of the BBT

The way Inline mixing is done at Carlsberg, we significantly increase the capacity of the BBT bottle neck in the brewery, whilst lowering the unit cost of producing beer. The system is fully automated using advanced valve, measurement, and software technologies controlling key parameters, such as alcohol, CO2, colour in real time, producing final products within specifications and maximizing line utilization, from the smallest batch, to the highest speed and capacity available in the industry, avoiding the need for mixing tanks and systems.

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