Case study

Pasteurizer water use reduced from 28.0 to 5.5 m³/day

WaterBreweries & BeverageFood & Beverage Processing

Pasteurizer water use fell from 28.0 to 5.5 m³/day, producing approximately $38,400 in annual savings through operational changes alone.

Carlsberg Canada

Published with Carlsberg Canada’s permission, with the source of every figure printed below.

Carlsberg Canada

How it went.

Every study on this site runs the same four beats, in the same order.

  1. 01

    Alert

    One monthly water bill, one big number, and almost no visibility into where that water was going.

  2. 02

    Cost

    $38,400 per year. Can Line Pasteurizer 2: 28.0 m³/day → 5.5 m³/day with no process changes.

  3. 03

    Fix

    Flow meters on the pasteurizer water circuit · Existing Neptune Mach 10 meters connected, not replaced · Existing Endress+Hauser and IFM meters connected · PLC data brought in via Scadametrics signalizers

  4. 04

    Restored

    5.5 m³/day, on a schedule informed entirely by the data

In full.

The problem

“They came to us with a specific challenge: one monthly water bill, one big number, almost no visibility into where that water was going.”

A brewery’s water is not one thing. It is process water, pasteurizer water, CIP, washdown and packaging, and until it is metered separately the monthly invoice cannot tell anyone which of the five moved. The quote above is the whole problem in one sentence, and the first week of meter data is what answered it.

What we installed

Flow meters on the pasteurizer water circuit, plus connection of the meters Carlsberg already owned (Neptune Mach 10, Endress+Hauser, IFM) and PLC data via Scadametrics signalizers. Nothing was ripped out.

What the data showed

“Within the first few weeks: the pasteurizer was consuming water outside of production hours. When the line was idle — between runs, overnight — water was still flowing.”

The fix

“The fix was a scheduling adjustment. No new equipment. No capital expenditure. Just a change informed entirely by data.”

The number

28.0 → 5.5 m³/day. $38,400 annualized. Source: NB Power RFP 0770-25-S510, Reference 3.

Also true

Carlsberg’s work received recognition in the AIM2Flourish global sustainability programme, and Carlsberg Group’s European ESG team cited the site as a model for potential global replication.

Closing

“You can’t fix what you can’t see.”

What the data looked like.

Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.

Pasteurizer water use reduced from 28.0 to 5.5 m³/day
IDLE FLOOR · BEFOREWater flowing, line idle15 L/min with nothing on the packerCan line 2 runningAfter: idle floor closed
PASTEURIZER WATER · ONE DAY · 30-MIN BUCKETS · SOLID = BEFORE, SECOND SERIES = AFTER
Carlsberg Canada · the second view
municipal to brewhouse, 41 L/minmunicipal to cip, 28 L/minmunicipal to pasteurizer, 19 L/minmunicipal to packaging, 17 L/minmunicipal to utilities, 12 L/minrecovered to cip, 9 L/minrecovered to packaging, 6 L/minMunicipal supply117 L/minRecovered loop15 L/minBrewhouse41 L/minCIP37 L/minPackaging washdown23 L/minPasteurizer19 L/minBoiler and tower12 L/minMunicipal supply to Brewhouse: 41 L/min, 31% of total flowMunicipal supply to CIP: 28 L/min, 21% of total flowMunicipal supply to Pasteurizer: 19 L/min, 14% of total flowMunicipal supply to Packaging washdown: 17 L/min, 13% of total flowMunicipal supply to Boiler and tower: 12 L/min, 9% of total flowRecovered loop to CIP: 9 L/min, 7% of total flowRecovered loop to Packaging washdown: 6 L/min, 5% of total flowMunicipalsupply117 L/min89% of totalRecoveredloop15 L/min11% of totalBrewhouse41 L/min31% of totalCIP37 L/min28% of totalPackagingwashdown23 L/min17% of totalPasteurizer19 L/min14% of totalBoiler andtower12 L/min9% of total
BREWERY WATER BALANCE · 24-H AVERAGE · BEFORE THE FIX

The published totals are the figures in the proof register, with their sources. The interval shape is a representative reconstruction and is flagged as such in the dataset.

What changed.

Before

28.0 m³/day, with water flowing between runs and overnight

After

5.5 m³/day, on a schedule informed entirely by the data

$38,400

per year

Can Line Pasteurizer 2: 28.0 m³/day → 5.5 m³/day with no process changes.

Source: NB Power RFP 0770-25-S510 FINAL, Reference 3

In their words.

…unprecedented visibility…

Derek Cairney, Maintenance Reliability Specialist, Carlsberg Canada

Quoted verbatim from the archive. Where only a fragment is on file it renders as a fragment with its attribution; the middle is never invented.

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