New Belgium Brewing Co., Inc.
New Packaging HallJim Spencer – Director of Engineering
MBAA-Rocky Mountain District MeetingMarch, 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 2007II. Congruent with New Belgium’s
culture:
• Innovation
• Sustainability
• High involvement culture
Major Milestones• Late 2005 - 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 - 789 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 90.1 2004.2.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 HallGreen Building Design
Features
II. The Process
Beer Supply
Filler
CIP Plant
Bright beer cellar
III.The Packaging Line
Packaging Line
JIT Warehouse
Offices &
shop
s
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 (CO2)
Project Expectations
I. Schedule - provide capacity for our summer 2007 selling season – completed right in time
II. Budget - $3 Million under budgetIII. 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.