FEATURE BOILERS, BURNERS & CONTROLS
STEAM BOILERS FUEL major brewery expansion
Magic Rock Brewing has installed a 100hsp 4VT steam boiler from CFB Boilers to generate steam for several vital steam-powered processes at its new site, helping to increase output
M
agic Rock has come a long way in a short space of time. Brothers
Richard and Jonny Burhouse aided by head brewer Stuart Ross started the brewery in 2011 and exceptional demand in the first few years necessitated an expansion in 2015 to a new 25,000 sq ft facility close to Huddersfield town centre. The move led to considerable investment in new brew kit, much of which is steam-powered: in the brewing process for heating and boiling wort in the kettle; for heating the detergent bath and steaming the casks at the end of the cleaning cycle; and heating a series of CIP (clean-in-place) tanks which provide heated detergent and water for cleaning the brewing vessels.
STEAM THE BEST OPTION “The output capacity at our previous site was only 5,000 hectolitres a year and quite simply we needed to move in order to meet demand,” says Ross. “Steam was our best option at the new site as it’s better and faster at performing the heating function. We are now on course to output 15,000 hectolitres this year and 20,000 in 2017 which will represent a four-fold increase in around 24 months. The new location has allowed us to introduce a canning line which adds to our cask and keg portfolio and open our own 4,000 sq ft bar where beer fans can sample the Magic Rock portfolio as close to the source as possible.” Magic Rock and CFB Boilers were
introduced via social media; at the time of its relocation the brewery issued a tweet saying it was expanding to new premises. This was immediately seen by CFB Boilers who replied asking if the company required steam? A subsequent site visit determined that Magic Rock required a 75hsp boiler, however CFB Boilers had a completely refurbished, pre-owned 100hsp 4VT steam boiler ready at its manufacturing facility and was able to offer it at a similar rate to a newly manufactured smaller model. “When we heard CFB Boilers’ proposal
we realised we could get extra steam capacity from the 100hsp 4VT which would make us future-proof in the event
18 MAY 2016 | FACTORY EQUIPMENT
of further expansion at the same price as a new 80hsp 4VT steam boiler,” explains Ross. “It was a perfect solution for us.” Steam boilers offer numerous advantages over electric counterparts. Not only are they much cheaper to run (electric is almost five times more expensive than natural gas) but steam offers far better temperature control which is very useful for brewing processes such as heating and boiling wort. This process uses a lot of energy which can escape into the atmosphere. Unfortunately, this is common with conventional vessels featuring integral coils which lose heat energy via the flue. In contrast, the 4VT steam boiler has a
special line that returns condensate to the boiler’s steam chamber at a temperature of 70-90C. This heat recovery function means that the water requires less energy and time to heat which is a valuable feature for breweries that manufacture multiple beers where the time it takes for a vessel to complete a cycle needs to be as short as possible. At Magic Rock this technical advantage
is exploited to produce a host of ales and stouts. All of these beers now benefit from the use of the 100hsp 4VT Steam Boiler from CFB Boilers which was installed in June 2015. “Steam boilers are cheaper to run than electric boilers and this efficiency will
In addition to cost- savings associated with the 4VT’s energy efficient operation CFB Boilers helped Magic Rock save over £13,000 during installation
help us achieve a quick return on our investment,” says Ross. “It is more cost effective than having separate gas heaters on each jacketed vessel.” For breweries with steam-fired jacketed vessels the 4VT offers a distinct energy efficiency advantage over similar vertical boilers due to its four-pass technology. Unlike two- or three-pass designs, four- pass technology means that combustion gasses pass generated heat over water heating surfaces four times which maximises the opportunity for heat transfer. The result is exceptional efficiency and low exit flue temperature. “We like the fact that the boiler
switches itself off when it’s not being used, thus saving further energy,” says Ross. “The 4VT is well insulated and can distribute heat more effectively.” A further impressive feature is its steam chamber which is approximately 30% larger than most other vertical steam boilers. This not only ensures that the boiler can more efficiently fulfil variable steam load requirements, dealing effectively with peaks and troughs but virtually eliminates boiler priming by preventing excessive moisture being carried over in the steam. Reducing moisture levels in the steam that is produced extends the boiler life and reduces the need for frequent descaling. Prior to installation the 100hsp
pre-owned boiler had been completely refurbished by CFB Boilers with all the original burners and controls replaced and new cladding installed.
COST-SAVING INSTALLATION SOLUTION In addition to cost-savings associated with the 4VT’s energy efficient operation CFB Boilers helped Magic Rock save over £13,000 during installation by assisting with the positioning of its gas meter and developing a solution to negate the need for a gas booster. With its 4VT steam boiler in place Magic Rock is now ramping up output across its cask, keg and can portfolio.
CFB Boilers T: 01255 224500
www.steamboilers.co.uk
/ FACTORYEQUIPMENT
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