New Belgium Brewing Co., Inc. New Packaging Hall Jim Spencer – Director of Engineering MBAA-Rocky Mountain District Meeting March, 2008
Presentation Overview 1.The Project Expectations & Goals 2.The Building Design 3.Process Design Elements 4.The Packaging Line 5.That’s All!
Fundamental goals and philosophy to guide the design of this project I. Additional capacity to meet the business plan: Staying with budget constraints Meeting schedule for additional capacity for summer 2007 II. Congruent with New Belgium’s culture: Innovation Sustainability High involvement culture
Major Milestones Late Spring 2006: Design work begins on both the line and the building as well as vendor evaluation and selection. May, 2006: Signed contract with KHS – Start mfg of equipment June, 2006 : Signed contract with Swinerton Builders to GC, Ground breaking and building construction begins. January, 2007 : Building shell complete, Flooring ready for equipment January, 2007: Major equipment on site - line installation begins March, 2007: TCO approval for the 600 Buckingham – Building is basically complete April 18, 2007: First Saleable beer produced cases of Fat Tire April 25, 2007: 10,000 cases filled - successfully meeting 2007 customer orders September 15, 2007: Commission the line - 98% Mechanical efficiency – 6 minutes of mechanical downtime in 8 hours!
Site Layout You are Here
Energy modeling to make energy efficient design decisions 1.eQuest software was used to design and select mechanical systems and compare with baseline ASHRAE Overall, the lighting and HVAC energy usage was reduced by 50% compared to the benchmark
HVAC Lighting Building Thermal envelope Building Materials Rapid Charger Technology for Forklifts Additional Site Features Packaging Hall Green Building Design Features
II. The Process Beer Supply Filler CIP Plant
Bright beer cellar
III.The Packaging Line Packaging Line JIT Warehouse Offices & shops
Advantages the electronically controlled filler The entire filling process is computer controlled. Quick change over Triple evacuation – very low dissolved oxygen pickup Filling independently of speed variations from the nominal speed fast/slow filling Filling adjustments during production Statistic of filling performance at single valve level including historical information on alarm Swirl for less foaming (instead of the old ‘spreader’) Hygienic design – very easy to keep clean Lower product loss and utility consumption (CO 2 )
Project Expectations I.Schedule - provide capacity for our summer 2007 selling season – completed right in time II.Budget - $3 Million under budget III.Scope – Construct a building and line that reflect the values and innovation of New Belgium Brewing. Extensive use of recycle material throughout the building Incredible energy efficient building design - so efficient that it qualified for $40,000 in incentives from the local utility. A high tech, state of the art packaging line (filler, packer, palletizer) integrated in an extremely efficient layout.