Presentacion Capstone Cervecera

Use of Malt Trub and Spent Grain (Process by-

Products) to Produce Food for Cattle

Natasha R. Casiano VélezIván J. Vargas RiveraJeffrey Traverso Ruiz

Prof. Patricia Ortiz BermúdezMentors: Ing. José L. Lebrón

Ing. Marlon Cabrera Agro. Alvaro Arias

Agenda:

www.cerveceradepr.com

• History of the Company• Project Background• Project Statement• Objectives• Procedure• Cattle Nutrition

Requirements

• Results• Project Design• Cost Analysis• Conclusions

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History of Company:


Founded in 1937 by Alfonso Valdés.In 2003 the 3rd generation of Valdés family took the Company’s leadership.


History of Products:


1938- Cerveza India 1939- Malta India




•1979- Medalla Light •The name was inspired by the medals received in the Panamerican Games celebrated in P.R. on that year.




2010- Silver Key Light 2011- Magna Premium Lager


Project Background: Ingredients

Malted Barley Hop Water Yeast



Project Background: Process

Malt Receiving GrindingMaceration Filtration Boiling

Bright Beer Tanks

Packing

Filtration Fermentation & Maturation

Cooling

Maelstrom or Whirpool

CO2

SterileAir

Malt Trub

http://www.empresas-polar.com/proceso_cervecero/pro_lupulo_es.html

Project Statement:•Malt trub processing in the treatment plant costs $32 per 1,000 gallons.

•Malt trub has an elevated organic load which, when treated,produces strong odors.

•The company produces about 5,000 gallons average per week.

•Which costs approximately $8,300 per year.



Objective of the Project:


• Develop a viable solution to lower the costs of processing the malt trub.

• A meeting with cattle ranchers was held in order to come up with the idea of preparing a mixture of industrial and poultry waste to prepare cattle food.


Procedure



• Spent Grain (SG)• Malt Trub (MT)• Chicken Poultry (CP)• Spent Grain + Chicken Poultry 1:1, 1:4• Malt Trub + Chicken Poultry 1:1• Spent Grain + Malt Trub + Chicken Poultry 1:1:1• Spent Grain + Malt Trub 1:1, 3:1, 1:2

Samples

Parameters:


• Crude Protein • Soluble Protein• Acid Detergent Fiber• Neutral Detergent Fiber• Non-Fiber Carbohydrates• Total Digestible Nutrients

• Net Energy - Maintenance, Lactation, Gain

• Mineral Content - P, Mg, S, Ca, K, Na

• Metal Content - Mn, Zn, Mo, Fe, Cu

• pH


Reference Data:



Results:

• Forage Quality Report

Results: Crude and Soluble Protein Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Fiber Content Analysis in Samples Containing Malt Trub, Spent Grain and Chicken Poultry

Results: Nutrient Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Nutrient Energy Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Mineral Content (I) Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Mineral Content (II) Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Manganese Content in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Zinc Content Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Molybdenum Content Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Iron Content Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry

Results: Copper Content Analysis in Samples Containing Spent Grain, Malt Trub, and Chicken Poultry


Sample Average pHSpent Grain 4.533Malt Trub 4.150Chicken Poultry 7.133Spent Grain, Chicken Poultry 1:1 6.700Spent Grain, Chicken Poultry 1:4 7.133Malt Trub, Chicken Poultry 1:1 7.333Spent Grain, Malt Trub, Chicken Poultry 1:1:1 6.333Spent Grain, Malt Trub 1:1 3.700Spent Grain, Malt Trub 3:1 3.700Spent Grain, Malt Trub 1:2 3.900

Results: pH Values (As Feed)

Decision Factor Matrix

Parameters Weight Spent Grain Malt Trub Chicken Poultry

Protein 1 3 1 5

Fiber 1 3 0 3

Dig. Nutrients 2 5 5 5

Energy 2 4 5 4

Minerals 3 4 2 1

Metals 2 5 4 1

pH 1 3 3 5

Est. Carbs 1 0 5 0

Total 13 49/65 43/65 37/65


Parameters Weight SG + CP 1:1 SG + CP 1:4 MT + CP 1:1

Protein 1 4 5 5

Fiber 1 5 5 5

Dig. Nutrients 2 5 5 5

Energy 2 4 4 4

Minerals 3 1 1 1

Metals 2 1 1 1

pH 1 5 5 5

Est. Carbs 1 0 0 3

Total 13 37/65 38/65 41/65


Parameters Weight SG+MT+CP 1:1:1

SG + MT 1:1 SG + MT 3:1 SG+MT 1:2

Protein 1 4 3 3 3

Fiber 1 3 2 3 2

Dig. Nutrients 2 5 5 5 5

Energy 2 4 4 4 4

Minerals 3 2 4 4 4

Metals 2 2 5 5 5

pH 1 4 3 3 3

Est. Carbs 1 2 3 2 4

Total 12 41/60 50/60 51/60 52/60

Final Mixture Selection:

• Suggested by Agro. Arias:– Spent Grain, Malt Trub, and Chicken Poultry 1:1:1 for beef cattle.– Spent Grain alone for dairy cows.

• We determined by data analysis that the best sample is Spent Grain, Malt Trub 3:1


General (Ideal) Process

Spent Grain Drying 24h

Final Product

Malt Trub From

Maturation Process


Alternative Process

Spent Grain Storage

Malt Trub From

Maturation Process

Malt Trub Storage

Cost Analysis: Investments vs. Income


InvestmentsFirst Year ($) Consequent Years ($)338,162.22 270,547.50

•*If sold at $0.01/lb•**Assuming a scope of 1% among dairies around the island.

Yearly Income

*Food Sales ($)**Malt Trub Expense

Reduction ($)23,933.48 8,342,857.14

Conclusions and Recommendations


• Cheaper option for cattle feeding purposes.• High incomes.• Analyze other spent grain: malt trub: chicken manure

proportions.• Establish sample analyses based on swine nutritional

requirements.

Acknowledgements:


• University of Puerto Rico, Mayagüez– Mentors

• «Compañía Cervecera de Puerto Rico»– José Lebrón– Marlon Cabrera– Carlos Colberg

• Agro. Álvaro Arias

References:


Presentacion Capstone Cervecera

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