AB-InBev is the largest beer manufacturer. Barley malt is one of the major ingredients in beer manufacturing.

Malt houses convert barley to malt through malting process.

Please find the attached process indicators data set of malting process for various plants.

Using the data set & Research you are expected to,
1. Benchmark the plants and establish relationship between variables to increase efficiency.
2. Suggest any process change/alternative and its impact on the overall process.
3. Identify new advancements in the malting process and its benefits. Also assess the capex investment required to implement

You can use your own creativity to challenge the status quo of problem.
Malting Plant Malt Line Number of Steep
MA-K2301-Minimum
Lines Steeping Cycle
Duration
Timeof Steep (hours) Steep Cycle Time (Hours)

PLANT1 5 7 NA 12 24
PLANT2 1 1 42 42 42
PLANT3 1 2 35 28 37
PLANT4 1 6 32 32 36
PLANT5 1 4 28 28 36
PLANT6 1 2 28 40 48
PLANT7 3 3 34 30 34
PLANT8 1 1 28 25.9 31
PLANT9 1 4 0 168 14
PLANT10 1 4 0 17 14
PLANT11 2 3 NA 32 32
PLANT12 2 2 NA 17.5 19.5
PLANT13 3 6 NA 40.5 42
PLANT14 1 2 NA 24 27
PLANT15 6 6 35 35 38
PLANT16 1 1 NA 13 18
PLANT17 1 1 0 37 21
PLANT18 1 1 0 16 16
Barley Batch Size (MT) Number of immersions (#) Number of aerations (#) Water Attemporation (Y/N) Air Attemporation S (Y/N)

50 1 1N Y
125 2 2Y Y
360 2 5min on 15min off during wet stand NA N
12.5 3 2Y N
174 2 2Y Y
350 3 3Y Y
330 1 1Y N
NA NA NA NA NA
360 2 2Y Y
85 2 1n n
317 2 2Y Y
242 3 3N N
113.4 2 2Y N
110 2 1Y Y
267 3 3Y Y
225 2 2N Y
380 2 2Y Y
0.15 2 2N N
End of Steep Moisture (%) Type of Steep Tanks (Choose) Steep Transfer-In (Choose) Steep Transfer-Out (Choose)

38 Conical pump mechanical

45 Cylindro Conical steep tanks wet Dry transfer
46 Cylindro Conical steep tanks wet Dry transfer
43.25 Conical dry wet
41-44% Conical Conveyors Conveyors + Green Malt Leg
45 FBST wet Dry transfer
36 Conical Pump Gravity
NA NA NA NA
43 - 46 Conical and flat bottom 0 0
0.41 CCT DRY WATER
42 FBST conveyor mechanical
40 Cylindro Conical steep tanks Pumps with water/barley Pumps with water/barley
41 Flat Bottom Mechanical Mechanical
44.5 Plate type After washing screw After double (GIB) screw
45 Cylindro Conical steep tanks Mechanical Gravity
39 Cylindro Conical steep tanks DRY redler WATER pump
42 FBST WATER Dry transfer
40 Cylinder / Conical tank DRY redler WATER pump
Minimum Germination Time MA-K2301 Duration of Germ (hours) Steep to Germ transfer time (Hours) Germ to Kiln transfer time (Hours)

NA 76.8 1.5 3
110 110 3 3
138 117 3.5 4.5
95 100 0.5 0.7
63 2 2.5
74.5 83.5 2.5 2.5
80 72 2 5
85 87 NA NA
78 0 0
102 1 5
NA 118 5 4.5
NA 104 1.5 4
NA 39 3 4.5
NA 98 3 3
74 74 0.9 2.4
NA 97.17 1.25 4
89 4 6
96 1.5 4
Water Attemporation G(Y/N) Air Attemporation G(Y/N) Green Malt Moisture at end Germination (%) Vessel Cleaning Time (Hours)

N Y 43 1.5
Y Y 43 2
N N 44 4
N Y 43.5 manual
Y Y 46 2
Y Y 45 4
N N 43 5
NA NA NA NA
0 0 0 0
N 0 45 8
N Y 45 4
N NA 41 3.5
Y N 41 3
N Y 39.5 0.5
Y Y 45 3
N Y 41 4
N Y 45 2
N 0 43 2
Start of Germ Temp ('C) Max of Germ Temp ('C) End of Germ Temp ('C) Minimum Kilning time MA-K2301 Duration of Kiln (hours)

18 22 15 NA 19.6
18 22 22 34
14 19 14 28
17 15.5 15.5 24 24
18.8 28.8 26.6 27
15.5 14.5 12 20.5 24.75
17 21 21 38 34
NA NA NA 28 27
0 0 0 28
20 0 16 17
18 19 19 NA 23
22 24 20 NA 18
16 20.5 20.5 NA 39
18 21 16 NA 15
19.4 23.8 23 26 31
22 16 18 NA 18
20 0 20 0.9541666667
18 0 14 20
 Kiln Heat Equipment Type
Kiln-Single, Double or triple deck (Choose) Direct or Indirect Fired (Choose)

Single-Kiln Direct
Single-Kiln Indirect Fired
Y Indirect Fired
NA Indirect Fired
Double deck Indirect Fired
Single-Kiln Indirect Fired
Single-Kiln Indirect Fired
NA NA
Single-Kiln Indirect Fired
Single-Kiln Direct
Single-Kiln Direct
Single-Kiln Direct
Single-Kiln Indirect Fired
Single-Kiln Direct
Double deck Direct
Single-Kiln Direct
Single-Kiln Direct
upstream Direct
 Heating Source for Kiln
Air to Air, Hot water Boiler, Steam Boiler, other (Choose)

Hot Water
Steam boiler
Steam
Steam heaters
Steam Boiler
Gas burner
Hot water boiler
NA
Steam Boiler
0
Natural Gas
Hot air
Hot Water Boiler
Steam Boiler
NA
Hot Water
0
0
 Gross Dirty Barley to Clean Barley to
Average Cool Down Time Requirement (time from end of kilning to transfer) (Hours) Moisture (%) Malt Clean Malt Clean Malt
Produced Yield (#) Yield (#)

1 4.5 85,005 1.130536868 1.177772317

1.5 4.8 9,724 1.299270404 1.200915484
N 4.6 93,584 1.328635237 1.122157634
0 4.5 27,226 1.193624208 0.138847007
0.25 5 131,600 1.236279379 1.208663731
1 4.5 81,854 1.187439969 1.18565472
1 5 187,245 0 1.26152207
NA NA 78,827 1.190795041 1.17306994
1 4.5 186,687 1.234091812 1.178374539
0.5 5 116,851 1.172561048 1.159888542
0.8333333333 5.5 206,884 1.177906169 1.169021519
0.1666666667 5.5 191,296 1.163663542 1.151342248
1 5.5 123,141 1.095841353 1.15271112
0.5 4.5 28,337 1.234820377 1.190975505
1 5 305,530 1.150436946 1.148388702
0.33 5.2 94,556 1.179973088 1.154977946
0.8333333333 5 126,139 1.173044025 1.166307522
0.5 4.9 103,003 1.17 1.16440616
 Water
Usage
Total Technical Total Plant Total Energy Electrical Heat Usage Electrical Heat Usage Water Usage
Total Barley to Productivity Productivity Ratio Usage ratio Ratio (MJ/MT Ratio Usage ratio Ratio (MJ/MT Ratio (m3/MT
Malt Loss (MT per man (MT per man (MJ/Metric (KWh/MT of of cleaned (m3/MT (KWh/MT of of cleaned of cleaned
of
hr) hour) Tonne) cleaned malt) malt) cleaned malt) malt) malt)
cleaned
malt)

0.177772317 0.946303879 0.380534184 4706.2658 135.102 4219.8986 2.8989 0.35402171 0.463725121 0.019455705
0.299270404 0.209704991 0.072189234 5165.0478 216.5955 4385.304 3.75 0.567567537 0.481901538 0.025167785
0.328635237 1.940972726 0.955555206 3327.504 146.92 2798.592 4.43 0.384989635 0.307537582 0.029731544
0.193624208 0.451287855 0.169894384 3896.9388 179.3835 3251.1582 5.2157 0.470057094 0.357270132 0.035004698
0.236279379 2.270022252 1.56029546 3593.02676 149.8646 3053.5142 6.3524 0.392705674 0.335551011 0.042633557
0.187439969 2.386695241 1.117553656 3026.67452 129.6537 2559.9212 6.0782 0.339744968 0.281310022 0.040793289
0.26152207 0.857527454 0.857527454 4107.897417 130.5270604 3638 3.79 0.342033524 0.39978022 0.025436242
0.190795041 1.871216632 1.823515843 2052.056 129.11 1587.26 2.86 0.338320254 0.174424176 0.019194631
0.234091812 0.672136012 0.429383926 4304 185 3638 3.51 0.484774588 0.39978022 0.023557047
0.172561048 0.768631274 0.453665347 3027.14156 153.7371 2473.688 5.7518 0.402853185 0.271833846 0.038602685
0.177906169 1.252208662 0.823939595 3072.79316 121.4786 2635.4702 4.2761 0.31832291 0.28961211 0.028698658
0.163663542 1.390886091 0.699313612 1925.276501 119.8860803 1493.686612 4.9981 0.314149866 0.164141386 0.033544295
0.15271112 3.951975892 1.206070932 2475.106 156.06 1913.29 5.06 0.40894012 0.210251648 0.033959732
0.234820377 0.923043322 0.682336383 3619.15552 146.5912 3091.4272 4.3848 0.384128046 0.339717275 0.029428188
0.150436946 4.800609641 3.181609914 3249.74472 151.3017 2705.0586 7.3272 0.396471456 0.297259187 0.049175839
0.179973088 0.995748785 0.499994579 3098.36778 156.1183 2536.3419 5.2814 0.40909289 0.27871889 0.035445638
0.173044025 1.722117617 0.925376138 3282.03178 139.6568 2779.2673 5.0681 0.365957123 0.305413989 0.034014094
0.191649313 0.775100237 0.446460425 3041.76124 144.6479 2521.0288 4.5672 0.379035817 0.277036132 0.030652349
 Total Technical
Total Barley to Productivity
Consumption Malt Loss (MT per man
hr)

0.837202536 0.115195954 0.107361378

1.07463686 0.025527916 0.020366989
0.722258761 0.236279497 0.269593975
0.862331923 0.054936407 0.047932869
0.770890242 0.276335524 0.440211359
0.661848278 0.290538421 0.315299138
0.767249985 0.104388976 0.241937079
0.531939061 0.227787912 0.514474603
0.908111855 0.081820809 0.121143518
0.713289716 0.09356742 0.127994117
0.636633677 0.152434513 0.232460824
0.511835547 0.169316066 0.19729968
0.6531515 0.481083975 0.340272812
0.753273509 0.112364388 0.192509838
0.742906481 0.584390298 0.89763821
0.723257417 0.121215007 0.141065137
0.705385206 0.209637713 0.261079454
0.686724298 0.094354903 0.125961368