Episode 293: RO Sustainability at Firestone Walker
Nov 6, 2023
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Evan Meffert, an expert in sustainability at Firestone Walker, discusses the decision-making process for breweries regarding the use of reverse osmosis technology to treat their water. The podcast explores factors influencing the decision, advanced use of RO membranes by Firestone Walker, the role of sulfate, determining connectivity, and the overall impact and ROI of water savings. Also mentioned are BSI brewing partner ad, Lupulin Exchange, upcoming events, and treatment of wastewater concentrate.
Blending RO-treated water with untreated water can improve efficiency and save costs in breweries.
The implementation of a partial RO bypass system can result in significant water and cost savings for breweries.
Deep dives
Using Reverse Osmosis to Treat Brewing Water
Reverse osmosis (RO) is sometimes necessary in breweries for two reasons. Firstly, if the source water contains undesirable contaminants like lead, RO acts as a positive barrier to remove them. Secondly, brewers may use RO to have ultimate control over water profiles, adjusting them for different beer styles. However, RO can be a wasteful process, as it produces concentrate that must be discharged. Traditional RO technology wastes one gallon of concentrate for every three gallons of permeate produced. A case study at Firestone Walker Brewery in California explored a solution involving a partial bypass of the RO system. By blending RO-treated water with a portion of untreated water, the brewery achieved greater efficiency and saved costs. The blending process required careful monitoring and control of key water quality parameters such as sulfate, alkalinity, chloride, and hardness. Through bench testing and assessment of brewing water and finished beer baselines, the brewery ensured that the final blend met quality and flavor standards. Additionally, considerations for microbial stability and the treatment of concentrate in the wastewater system were addressed.
Evaluating the Impact and Benefits
The implementation of the partial RO bypass system at Firestone Walker Brewery resulted in a significant return on investment. The cost of the project was around $4,000, but the brewery achieved annual savings of approximately 1.5 million gallons of concentrate, which translated to about $38,000 in savings. This also led to reduced electrical consumption due to decreased runtime of the RO grid. Furthermore, there were minor savings in salt adjustments. The project paid for itself in a short period of time and offered a valuable strategy for water conservation and cost-effective brewery operations.
Considerations and Implications
While the partial RO bypass system proved successful for Firestone Walker Brewery, there are certain factors that limit its applicability. Water quality parameters, particularly sulfate, must be carefully evaluated to determine the appropriate bypass blend. Some constituents, such as lead, high iron or manganese levels, or significant oxidants, may make the bypass system impractical or ineffective. Additionally, microbial stability must be taken into account when using dechlorinated water in the brewing process. Overall, the partial RO bypass system offers significant water and cost savings, but its suitability depends on individual brewery circumstances and objectives.
Wastewater Treatment and Environmental Considerations
The concentrate produced by the RO system is highly concentrated and must be discharged appropriately. In the case of Firestone Walker Brewery, the concentrate was directed to their wastewater treatment system, where it underwent pre-treatment before being discharged back to the local municipality. Decreasing the amount of concentrate going down the drain was beneficial for effluent management, as excess salts and total dissolved solids were major concerns in the effluent. Reusing or finding alternative applications for the concentrate remains an ongoing challenge for breweries.