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Relocation of Gaffel-Kölsch

Et bliev nix wie et wor” (“Nothing stays as it was”): that’s the wording of Article 5 in the Kölsch Constitution, a compilation of eleven idioms in the local dialect. And that also applies to the Cologne-based brewery Privatbrauerei Gaffel: capacities in its previous inner-city facility were exhausted – more space was urgently required. Needless to say, the family-managed brewery wanted to keep its independence and continue to produce efficiently. So Gaffel took a bold step towards an auspicious future – and merged its two breweries into a single plant.

It was not so very long ago that Privatbrauerei Gaffel was still operating two breweries: since 1908, it had been brewing its traditional Gaffel-Kölsch right in the heart of Cologne’s inner city, just a stone’s throw away from Cologne Cathedral. And in 1998, it then took over the Richmodis-Brauerei in the suburb of Porz-Gremberghoven. Kegs and “Pittermännchen” (10-litre Kölsch barrels), moreover, are filled in Cologne’s northern Bilderstöckchen district. Gaffel has always had its bottles contract-filled.

But it was precisely this inner-city location that entailed a few problems: Supplying the brewery with raw materials and expendables, as well as tanker-truck traffic, grew into a progressively more difficult logistical challenge; The space constraints entailed by the fact that the building complex was located in the middle of a street near Cologne’s main station did not permit any expansion. On a mere 2,000 square metres, Gaffel was brewing almost half a million hectolitres a year.

So there was only one logical consequence for Gaffel: to merge its three facilities into one in the medium term. The premises of what used to be the Richmodis Brewery were downright predestined for this plan. Not only was the autobahn only a short distance away but the existing infrastructure was likewise well-nigh ideal: the production facility is situated in a designated industrial estate – there are no problems about producing round the clock there. What’s more, the premises possess their own deep well with certified water rights. So this was a no-brainer.

Turnkey solution

No sooner said than done. Back in 2012, Gaffel had already started to make plans for the relocation, put it out to tender in the normal way among the vendors of brewery process technology – and in the end opted for Krones. “It was not really the most favourable quotation but it definitely was the best overall technical solution,” says Reiner Radke, Technology and Logistics Director, and emphasises a few major points in addition: “We’re largely using Evoguard double-seat valves throughout our production operation. These are substantially smaller than competitors’ models, and all the components

can be replaced without having to use special tools. Similar considerations apply for the Evoguard pumps, which additionally consume less energy than comparable units. What’s more, our staff were already familiar with Krones equipment: the existing Richmodis brewhouse was from Steinecker, and in our Eigelstein facility we’d already been using the Botec F1 process control system with integrated Siemens-S7 technology.”

So Gaffel placed an order with Krones for a turnkey solution, except for the new boiler house, which the brewery installed itself. Gaffel wanted to keep on using some of the existing Richmodis kit, and supplement this with new units. The only components that Gaffel took along from its original brewery in the heart of Cologne were a sheet filter and Steinecker’s TFS filtration system. “We wanted to keep the sheet filter because we’re filling in cold-sterile mode – no flash pasteurisation even, let alone pasteurisation proper,” explains Reiner Radke. “We took a deliberate decision against membrane filtration for a variety of reasons, one of them being that we’re assuming we’ll be able to run the TFS with cellulose instead of diatomite in the not too distant future.”

35 per cent less thermal energy

As far as energy savings were concerned, particularly, the new brewhouse provided Gaffel with quite a few advantages: The decision taken in favour of the EquiTherm energy recovery system made a crucial contribution towards reducing energy consumption at Gaffel’s new brewery – down by around 35 per cent for thermal energy and by about 30 per cent for electricity, in each case referenced to one hectolitre. “In terms of energy-efficiency, the EquiTherm is second to none. What’s more, the thermal impact on the mash during heat-up is small,” is Reiner Radke’s verdict. “Our energy-utilisation figures are in equilibrium: all of the thermal energy we’re producing is also consumed. At the same time, the technical outlay required to achieve this was manageable.”

The new boiler house likewise makes its contribution towards saving energy: it was possible to almost halve the previous figure for steam consumption of around ten tons of steam per hour.

Gaffel can now use solely natural gas, which is usually more affordable. What’s more, the central CIP system has a positive effect on energy consumption. Its centralisation, separated for unfiltrate and filtrate, has made for a reduction in the range of cleaning agents and disinfectants required. Gaffel is now using only caustic soda solution and nitric/phosphoric acid as cleaning agents, and peracetic acid as a disinfectant. The brewery does entirely without chlorine-based products or similar agents. “This simplifies our handling routines, reduces consumption and has less of an impact on the wastewater,” says Reiner Radke. Inductive flow meters have been installed in every department for measuring consumption levels, thus making sure that these latter can be accurately assigned and checked. Outside the central chemicals store Krones built a discharge station, so as to secure the wastewater against possible disasters.

Fermentation and storage cellar expanded

Gaffel likewise had its capacities for bright-beer, fermentation and storage tanks expanded by Krones in one go. In its old facility, the brewery had still worked with open fermentation and bitter foam on the green beer wort. It is now changing over to the two-tank fermentation process in cylindro-conical tanks. Needless to say, the brewery wanted to keep the high quality standards at their excellent levels. And the sampling tests proved that this had actually been achieved: “The customers didn’t even notice that we’d relocated – they were able to continue to relish the excellent taste of Gaffel-Kölsch that they’d been used to,” explains Reiner Radke. “We supplied the 2016 Cologne carnival season still from the old brewery. After that, we discontinued production there, relocated the filtration system to the new brewery, and started production here more or less seamlessly – without having to blend old beer stocks with freshly brewed beer.” And taking delivery of the new tanks likewise went off without a hitch. “The new cylindro-conical tanks are about 22 metres high and six metres in diameter. That was the maximum size we were able to transport from the banks of the Rhine through Cologne – but it worked,” explains Reiner Radke. “One of the major advantages here was that the tanks arrived in fully insulated condition on site, where they were placed on steel support frames. All that needed to be done after that was to link them up to each other.”

Central filtering-aid management

Filtering aids and stabilising agents are managed centrally at Gaffel. Krones installed a big-bag system with weighing-cell technology, dosing unit and initial blending tank. Dosing and initial blending have been fully automated. The staff use a crane to suspend the new big bags as needed, and other than that have no contact with the diatomite. “This increases occupational safety and reduces possible health risks. In a modern-day brewing operation, there is less and less physical work to do, what we need here nowadays is the staff’s intellectual input,” says Reiner Radke.

Krones likewise supplied a new diatomite disposal tank, a carbonation system and a water deaeration system for the filter cellar. The Hydronomic water treatment system consists of a manganese-removal module, an activated-carbon filter and a reverse-osmosis system. These components treat the water extracted from the brewery’s own deep well. Gaffel likewise had a ventilation system installed centrally for the entire brewery, tasked with preventing mould formation. All sections of the brewery are run from two control centres, featuring a redundant Krones Botec F1 system for managing the process. The vector-based, zoomable, graphical interfaces have been designed for intuitive operator control: each employee can configure the individual modules for program control on a screen window at his/her own discretion, using multiple displays (dashboard function).

Good cooperation

At peak times, up to 90 fitters were working on site. The safety precautions taken certainly paid off: during all of that time, there was not a single workplace accident.

It is now possible to operate the brewery in three shifts with only ten employees, six of whom are working in production and four in quality assurance. “Theoretically, we’d be able to run the brewery with one operator per shift, if it weren’t for the tanker-truck and container traffic,” explains Reiner Radke. “Our cooperation with Krones was good and professional, and since a project of this kind does of course also change over time it was important that both sides adopted a flexible stance when it came to any modifications required. Any difficulties cropping up were dealt with satisfactorily for both parties, any differences of opinion equitably resolved. Line erection proceeded on schedule as planned.”

Article 10 of the Kölsch Constitution reads: “Drinks de ejne met?” (“Like to have a drink with us?”) – Reiner Radke’s answer to this question can meanwhile be a confident “Yes”, now that this project has been successfully concluded.

Matthias Pohl

Krones AG

Tel. +49 8161 953-266

British Brewing Company launches their very own brew on tap this June

Craft beer enthusiasts in the city are either hard at work on, or looking for some new and freshly brewed beer options to sip on. Not until a while ago, the ordinary Indian tippler only had a handful of options for a refreshing cold pint; but now, the young beer drinkers of the city are experimenting with newer and more exotic brews.

This June, your favourite neighbourhood Gastropub, British Brewing Company known for its local and international beers, lip-smacking cocktails, spirits and an extensive list of wines along with simple and unpretentious food is all set to launch their very own first exclusive craft beer called ‘THE ONE’ – brewed by one of the most young and hip breweries in the country today. Under its all new property called ‘The Beer Diaries’, they will introduce one new signature brew every three months under contract.

THE ONE is a 6.5% Belgian style Golden Ale, with a typical spice on the nose and a crisp finish that is subtle but has hints of alcohol that a Belgian style Golden Ale promises to have. The flavour of the beer is effervescent and sweet on the palate. This one promises to be a Belgian Golden Ale in its true sense!

“In Great Britain, a “local” pub, bar, restaurant is the centre of town life and is a place to relax, meet friends and family, refuel the body and the spirit, share news, be entertained and reconnect in an unhurried and welcoming atmosphere. We’ve always been striving to meet the needs and demands of the discerning diner. To further excite and upgrade the beer drinking experience British style we are finally launching our very own beer called ‘THE ONE’ which is a Belgian Golden Ale. So just drop by, sit back and relax with a glass of this beery goodness at your nearest British Brewing Company outlet” says Ajit Dhumal, director at British Brewing Company, Mumbai.

With the launch of this all new brew, British Brewing Company will let one choose yet another interesting pour with a classic style and a locally inspired twist.

The taste of Scotch


Global Malts Ambassador for Diageo, Donald Colville, explains the nuances of Scotch and especially those of Diageo Malts.

Donald Colville, Diageo Global Scotch Ambassador – Malts, on his first visit to India is a man on a mission. Given the task of supporting the development of all of Diageo’s Single Malt Scotch Whiskies – The Singleton, Talisker, Cardhu, Lagavulin, Caol Ila and Oban, while managing the Global PR and Influencer strategy for Diageo Scotch Whiskies, he also overlooks the Diageo Scotch Whisky Education courses worldwide. He is an expert on all of Diageo’s 28 single malt distilleries and

related sites.

Donald joined Diageo in 2008 and was appointed as Diageo’s Global Scotch Whisky Ambassador – Malts in December 2010.

Growing up in Scotland’s historical whisky capital, Campbeltown, Donald has deep roots in whisky distilling as his great-grandfather previously operated the Dalintober Distillery, a supplier to the

Johnnie Walker blends.

There are six Scotch regions Speyside, Highlands, Lowlands, Islands, Campbeltown and Islay. The Highlands is the largest of the whisky producing regions in Scotland and generally produces more

full-bodies whiskies with deeper notes of peat and smoke. Lowlands is located at the southernmost part of Scotland, and is a flat region with no mountains. Scotch from this region are generally considered

as the most light bodied of the Single Malts. Speyside, is the center for whisky in Scotland. More than half the distilleries in Scotland are located in Speyside. Although geographically part of the Highlands, its unique characteristics the waters of the river Spey, which distilleries use straight from the river Spey in their production process, make the Speyside scotch the country’s most complex, and known for their

sweetness and elegant flavors and aromas. Campbeltown was once the whisky capital of Scotland. The Scotch here is peaty, and has a salty hint and a briny character. Islay, pronunced “eye-luh”, scotch is considered to be the smokiest and strongest-flavored Scotch of the single malts. Their strong flavor is believed to be due to the region’s exposure to the high winds and seas of the west coast. Island – considered by all as a region of its own, produces Scotch that can be described as a milder version of

Islay whisky (sort of like a hybrid between Highland and Islay whiskies).

Malts, responsible f Talisker, Cardhu, Lagavulin, Caol Ila and Oban, to name a few. Some of the classic

single malts in the Diageo repertoire include:

Lagavulin 16 YO Aged in oak casks for at least sixteen years, this much sought-after that’s typical of southern Islay, but also has a beautiful complexity that offers hints of sweet and malty notes.

Oban 14 YO A combination of rich sweet orange notes with a gentle smoky dryness and appetising spice distinguishes this lovingly-matured Highland malt.

Caol Ila Malt 12 YO A smoky, sea-fresh aperitif, this one comes with beautiful notes of citrus and malt from remote Island of Islay.

Talisker 10 YO Made by the sea, this is the classic stalwart of the Talisker family. A rich dried-fruit sweetness, clouds of smoke, strong barley-malt flavours, warming and intense, this one.

Singleton of Glen Ord 12 YO A fruity, well-composed liquid that manages to be both light and smooth without compromising any depth of flavour or fullness of palate. Savour the good taste.

Many of the whiskies from Diageo’s repertoire are appropriately paired with Indian food. “There is Talisker which is from Scotland with a smoky flavour which combines well with the chillies in the Indian food. There is also Glenmore which is a complex whisky and goes well with richer, spicier food that is the norm in India. In India there is a wide variety of breads and Glenmore is apt for them too,”

says Colville.

He is also the judge at the Diageo Reserve World Class Comp part of the competition are the seminars

and the training sessions that are held to improve the skills in the industry.” He also adds that there has been an unbelievable improvement in the skills of the bartenders as compared to past years. “I can see that there is a staggering difference in the learning and understanding of flavours, in the use of new modern techniques and the use of spices among the bartenders in India now,” says Colville.

IMFL. In the first six months of 2016, India emerged as the third-biggest export market for Scotch, The average age of the whisky drinker too is coming down, says Colville. From being a drink of the middle age and elderly men, there is an expanding of the net. It has now become age neutral.” It has

also helped that whiskies now come in a number of flavours and a wide variety of cocktails can be concocted which appeal to a diverse audience.

Whisky, which Colville describes as age- and gender-neutral, accounts for almost 60% of the IMFL. While India remains the whisky capital of the world, Scotch remains the world’s favourite whisky,” says Colville.

“Using single malt in a long drink or a cocktail is another way to popularise the drink,” says Colville. The idea of using a Lagavulin, a Talisker or a Cardhu in a cocktail might sound incongruous to the

whisky connoisseur but Colville says it can be a platform for creating a wonderful drink. “If you taste a Talisker Old Fashioned and a generic Old Fashioned, there is a marked difference, and that could be a start of a journey.”

Colville shows a preference for blended Scotch whiskies because they are blend of many good single malts. Our biggest-selling brands in India are Black Dog and Johnnie Walker Black Label. In single malt, it would be Talisker.” People can try different things. One has to be open to experimentation. So, the best way to consume single malt — any way you want.”

Diageo operates 28 malt distilleries, accounting for nearly one-third of the industry’s total capacity, along with Scotland’s largest grain distillery at Cameronbridge. Of these 14 are for single malts and 14 are for blended Scotches. The company’s leading brand is Johnnie Walker; the best-selling blended Scotch in the world, but it boasts other high-ranking blended brands such as J&B and Bells, along with an array of respected single malts, including Cardhu, Talisker, Mortlach and The Singleton.

There are 118 licensed distilleries in Scotland. Ninety three percent are for blending and seven percent are for single malts.