A Smart, Speed-Controlled Pumping Solution is Boosting the Brewery’s Efficiency, and Sustainability

Despite continually investing in cutting-edge technologies, the brewery’s ammonia and evaporative cooling systems - essential for regulating temperatures during brewing—relied on outdated, inefficient, and difficult-to-maintain pumps. With the original pumps discontinued and production demands at an all-time high, the brewery needed a reliable solution to modernise its systems and minimise disruptions.

The recommended solution was Grundfos NBSE end-suction pumps powered by a Grundfos MLE motor with an integrated VFD. This intelligent solution adapts pump speed according to demand, achieving significant energy savings. However, the brewery was initially unaware of the capabilities of VFD solutions and was simply seeking a reliable upgrade to enhance system efficiency and uptime. They were sceptical about the MLE's ability to manage controls without a dedicated Programmable Logic Controller, typically required for monitoring plant operations.

To address these concerns, the Grundfos team demonstrated the cascade function and multi-master control for redundant backup with the Grundfos MLE, which features an integrated VFD and a permanent magnet IE5 motor that is more energy-efficient than regular motors. The demonstration convinced the brewery’s team, and the maintenance manager was impressed by the simplicity of the MLE motor's intelligence, insights, and controllability, as well as the ease of maintenance offered by the NBSE pumps, which allow quick seal replacements on-site.

With the brewery team on board, four pumps were ordered, and a single-day switchover was scheduled. The installation crew completed the piping in the morning, followed by programming and commissioning in the afternoon with support from the team and Grundfos. Unlike traditional installations that require communication running long cables back to the PLC from each pump, the cascade functionality of the Grundfos MLE eliminates long cables. The setup requires only one wire with three conductors and a daisy-chained communication wire between the four pumps. Programming the cascade operation for all four pumps took just 30 minutes.

Once operational, the system demonstrated seamless performance during flow rate tests. The brewery achieved 100% capacity with three NBSE pumps, leaving the fourth as a redundant backup. Additionally, redundant master controls and pressure sensors ensured fail-safe operation, effectively reducing downtime risks.

Since its installation in August 2024, the brewery's new system has run smoothly and resulted in:

Increased Efficiency: The brewery now achieves full capacity with fewer pumps, saving energy and reducing maintenance, contributing to their sustainability goals.

Simplified Maintenance and Operations: The NBSE pump design allows for faster seal replacements, minimising downtime for repairs and maintenance. The elimination of the PLC system also reduces the complexity of managing the cooling system, as the built-in PID controller handles all the logic without needing third-party components.

Redundancy and Reliability: Redundant controls and master pumps ensure uninterrupted operations.

Cost Savings: The new system has eliminated the need for rental chillers, saving the brewery approximately AUD $45,000 per month during peak temperatures. Additionally, simplified system controls have reduced operational costs.

Thrilled with the results, this upgrade also aligns with the brewery’s overarching goals of reducing its carbon footprint, conserving water, and improving operational efficiency. Beyond the cooling systems, the brewery is exploring other areas for potential upgrades, including boiler feed pumps, acid dosing systems, and CO2 recovery.