Lion Brewery (Ceylon) PLC

Chief Engineer

Asst.Manager Electrical Engineering

Asst.Manager- Mechanical Engineering

Engineering Executive

Projects Executive

Engineering Assistant -Instrumentation

Engineering Assistants

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Lion Brewery (Ceylon) PLC

 Execution

of Operation and Maintenance of Utilities for the Production and Packaging Preventive Maintenance of Machineries Breakdown Maintenance of Machineries Calibration of Process Instrumentation Facility Management (Building & Yard Maintenance) Projects
Capacity Expansion Projects Process Improvement Projects Kaizen Projects

Operation

and maintenance of waste water treatment plant

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Utility

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 Power

system is consist of 3x1000 KVA Transformers and 3x1000 KVA generators CEB supply is 33KV and step downed to 400 V by transformers Generators supply power within 4s of CEB power failure CEB supply is switched on after 5 minutes when the supply is back Capacitor banks are used to improve the power factor
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CEB Supply

Generators

Re-Transferring of CEB CEB Supply in 4s Generator ON CEB power failure Waits for 5within minuits supply

Bus Busbar bar

Factory with power Factory without power

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 Time

of Use Tariff Unit Price Peak Rs.13.40 Off Peak Rs.7.15 Day Rs.10.25

Duration 18.30-22.30 22.30- 05.30 05.30- 18.30

Fixed

Charge Rs.3000 KVA Charge Rs.750

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2.13% 1.80%
5.20% 7.94% 8.37%

0.32%

Ref 42.26% Packaging+Logistic Air Conditioning+Office+Work Shop WWTP

10.50%

Brewing Compressed Air CO2 11.03% 10.45% water Steam Fire and storm water pumps

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 Water

is the most important utility since 95 % of beer is water Water is used in three different ways for the process as,
Hot Water Cold Water Ice Water
Capacity

80 m3/h
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Water Intake

Cl2 and Alum mixing

Removal of Alum and particles

Sand filter

Cold Water Tank

Activated Carbon Filter

Raw water tank

Iron removal Filter

Heat Exchanger

Ice Water Tank

Hot water Tank

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Hot Water Brew House Chiller Ice Water Bottling Pasteurizer Wort Cooler Cold Water DA Plant CIP & Yeast Plant Brew house & Bottling Museum, Canteen & washrooms
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 Glycol

is used for cooling purposes Ammonia is used as the refrigerant to cool Glycol in Refrigeration plant Highest Energy consumer in the plant which is 42% of the total load Latest technology is used in this plant where the plant can be operated remotely Cooling Capacity 1800 KW
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 Ice

water Cooler Centrifuge D/A water cooler Bottling Beer Cooler Canning Beer Cooler Keg Beer Cooler Green beer Cooler Filtered beer Cooler FV tank BBT
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CO2 generation in brewery Fermentation of sucrose produces ethanol and CO2 as per the following reaction. C6H12O6
Every

2 C2 H5 OH + CO2 + Others

100 Kg of sucrose fermented would produce 48.4 Kg ethanol, 46.6 Kg CO2 & 5 Kg of other compounds.
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CO2 plant description

Carbon

Dioxide is recovered and purified by two CO2 recovery plants namely,

Seeger Hypro

Capacities of two plants

Seeger - 200 Kg/hr flow rate

20000m3 Storage tank

Hypro - 300 Kg/hr flow rate

20000m3 Storage tank

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 Filtering Pressure and push the unfilted buffer tank Pressure and Mix the Kieselguhr recovery tank Empty and push back filter buffer tank Carbonator mixing BBT Pressure and empty B.B.T tanks Pressure and push keg line Pressure and Push Bottling and canning line Bottling plant Pressure bottling filler ball Push bottling beer line
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 Centrifuge Pressure PVP tank mixing line Canning

Pressure Canning ball For bubble breaker

FV tanks Pressure and empty the FV tank line Keg plant

Pressure filling head Pressure filling tank

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Compressed air is used for the operation of pneumatic valves

Compressed Capacity

air is dosed to the process

28 m3/min

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 Dry

Air

Compressed air is used in all pneumatic cylinders

CIP Process FV tank head in out

Wort areation
Wet

Air

Spent grain

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A boiler is used to generate steam for the process

Capacity With

10 T/h

the expansion another boiler will be

added to the existing system

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 Cereal

Cooker Mash Tun Wort Kettle Bottling Pasteurizer Canning Pasteurizer Bottle Washer CIP Keg Plant Generate hot water
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 All

waste water from process and factory is purified up to the given European environmental standards before sent to river Anaerobic and Aerobic methods are used It is the 3rd highest energy consumer in the plant There is a ongoing research to use the by product methane for electricity generation Capacity 52 m3/h
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 Annual

Preventive Maintenance 1st week of

July Monthly Preventive maintenance 2nd Monday in the month In critical situations online maintenance is done

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 Calibration

of pressure, temperature gauges and flow meters is mandatory requirement of ISO 22000 Calibration is done according to manufacturers standard Number of instruments in the plant are about 400

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Project Electricity Generators Main Switch Board LV Distribution Water Treatment Plant Air Compressors Refrigeration plant CO2 recovery plant FV Tanks BBT Tanks Brewing Expansion
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Previous 2000 KVA

Upgrade to 3000 KVA New switch board with 3 feeders New cable management system 80 m3/h 28m3/min 1800 KW 500 Kg/h 21 Tanks 8 Tanks 10 Brews
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50 m3/h 23 m3/min 1200 KW 200 Kg/h 16 Tanks 6 Tanks 8 Brews

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 Installation

of UPS System Power factor improvement Energy Management System Inline alcholizer Office Upgrade Energy Saving Projects Dust Extraction System

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THANK YOU
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