Self-sufficient energy supply for breweries through biomass conversion

The question of a stable and sustainable energy supply is becoming increasingly important in strategic decisions for breweries. Rising energy prices, regulatory requirements and pressure to reduce emissions are forcing operators to take a holistic view of their processes.

This is no longer just a matter of efficient brewhouses or optimised fermentation and storage technology, but of the intelligent use of the material flows that arise during the brewing process anyway. This is precisely where a technological approach that combines energy, circular economy and economic added value comes into play.

Energy as a strategic factor in the brewing process

Breweries are among the most energy-intensive production facilities in the food industry. Heat, cooling and electricity are required for almost all process steps – from mashing and wort boiling to filtration and bottling. At the same time, waste materials are continuously produced, which until now have often been simply disposed of or insufficiently utilised for energy. At a time when security of supply and self-sufficiency are becoming increasingly important, this approach is being increasingly questioned. Technological concepts that view waste materials not as waste but as a resource are shifting the focus from pure plant engineering to integrated energy systems. The aim is to reduce external energy consumption and make the brewery more resilient to market and price fluctuations.

Biomass conversion as part of a circular economy strategy

A key starting point is biomass conversion. This involves the step-by-step processing of by-products from the brewing process and their conversion into different streams of recyclable materials. The first step focuses on the extraction of high-quality ingredients. Proteins in particular can be extracted from the residual materials and passed on to other industrial partners, for example for the production of meat substitutes. This turns an internal by-product into a marketable raw material. Building on this, a liquid mineral fertiliser is then produced. This can be used in agriculture, closing another material cycle. Only the remaining residues are ultimately used for energy production. In a biogas plant, this is used to generate enough energy to supply the entire brewing process independently. This multi-stage approach shows that energy production is not viewed in isolation, but is embedded in a comprehensive circular economy concept.

Project Phoenix and the Pronomic concept

This approach is being implemented in concrete terms in the Phoenix project, which was developed as a building block of an overarching energy concept. Phoenix is part of the so-called Pronomic concept, which aims to open the way for breweries to become independent and self-sufficient in their energy supply. The basic idea is to use residues from the brewery's own processes in such a way that they provide multiple benefits – both in terms of materials and energy. The first module for protein extraction has now reached a stage of development that allows it to be launched on the market. This provides breweries with a concrete product that not only offers ecological advantages but also opens up new revenue potential. The next stages of fertiliser production and complete energy recovery are currently being implemented and will be added step by step.

Technological expertise in brewing plant construction

This approach was developed by Steinecker, a specialist in process technology for brewing plant construction. As part of Krones AG, Steinecker can cover the entire process technology side of brewing within a larger industrial network. This integration makes it possible to view energy, material and process issues not in isolation, but as a coherent system. Many years of experience in plant engineering form the basis for new differentiating features. Today, classic brewing plants can be supplied by many providers worldwide. Competition is therefore increasingly shifting to additional value propositions beyond pure production output.

Differentiation in international competition

In the global market environment in particular, it is becoming clear that technical excellence alone is no longer enough. Breweries expect solutions that help them remain competitive in the long term. Energy self-sufficiency, resource efficiency and integration into regional material cycles are becoming decisive criteria in investment decisions. The biomass conversion approach offers several advantages at once:

• Reduction in external energy procurement and greater security of supply
• Additional revenue through the material use of residues
• Improvement of the environmental balance through closed cycles
• Greater independence from volatile energy markets

Economic added value through self-sufficiency

Self-sufficient energy supply is not an end in itself. Its benefits are particularly evident where it also makes economic sense. The combination of protein extraction, fertiliser production and biogas production creates a system that combines ecological and economic goals. Investments in such concepts not only contribute to sustainability goals, but also have a long-term monetary impact. This makes it clear that the future of brewery plant construction lies not only in higher output or faster process steps, but in the intelligent combination of technology, energy and circular economy. This is precisely where the approach presented here comes in – opening up new opportunities for breweries in an increasingly demanding market environment.