Brewer’s Spent Grain Case Study
How to Achieve a Triple Bottom Line by Stabilizing a Waste Stream
The Problem
A large brewer was struggling to dispose of its vast amounts of spent grain in an economical and environmentally friendly way.
Spent Grain (or BSG) is by far the most significant byproduct of the beer brewing industry, comprising 85% of all byproducts generated. Every six-pack of beer produces about one pound of BSG, which adds up to 10 million tons in the U.S. and 42 million tons worldwide yearly.
The problem is: what to do with it all?
Currently, nine U.S. states have laws about organic waste going to landfills, and many more are considering them. When organic materials are landfilled, they're prevented from decomposing due to a lack of oxygen and instead produce carbon dioxide and methane, making landfills the least eco-friendly option.
Most brewers sell BSG as livestock feed, but as demand for beef slows or if cattle farms aren’t located nearby, this option also dries up. Other alternatives are composting or digestion, both of which have low ROl.
The Solution
GTF helped this brewer shift its mindset from seeing BSG as a waste product to an asset. After all, BSG has many desirable qualities that make it an excellent component in multiple industries. When transformed into a powder, BSG can be used as:
Bioplastics
BSG powder, thanks to its unique thermal stability properties, has been successfully converted into fillers. These biodegradable polymers can be used for everything from cutlery to car parts. This particular brewer will use it for an eco-friendly shrinkwrap for their pallets of product.
BSG - Nutritional Makeup
Food
BSG is a healthy, upcycled ingredient in cereals, bread, pasta, pet foods, and many other applications.
Nearly half of its composition is fiber. Substituting just 10% BSG in regular flour doubles the fiber content.
About 20% of BSG is protein, with 1/3 of that consisting of amino acids.
The remaining 30% is phenolic compounds, including antioxidants, anti-inflammatories, and anti-cancer agents.
BSG has almost twice the protein content of unprocessed barley or wheat and is nearly 70% higher than oats. Although BSG's protein content is lower than soy's, it can be considered an equivalent or, in some cases, a superior protein source compared to commonly consumed grains and legumes.
Packaging
BSG can also produce biodegradable paper, cardboard, corrugated, and other packaging materials. This option is a good choice because it communicates the brewer’s commitment to the environment through its packaging.
Why haven’t more brewers considered utilizing this versatile ingredient?
Challenges
BSG is highly versatile and valuable in shelf-stable form. However, due to inefficient processing methods, transforming it into a consumer good has not been feasible or economical until now.
High Moisture
BSG is laden with moisture and exits the mash tun at high temperatures, making it susceptible to bacterial growth. The moisture and sheer volume of BSG make transportation to third-party processors costly and cumbersome.
Feasibility of Drying
Current drying technologies are expensive and inefficient. Freeze drying retains the nutritional value but can take up to 20 hours daily. Heat drying is energy-intensive and occupies a large amount of floor space. Other drying technologies cannot scale up to cost-effectively process the copious amount of BSG produced.
The RENU™ Advantage
GTF's RENU™ Drying & Milling System’s revolutionary technology can rescue brewers' spent grain (BSG) and process it quickly and easily into a stable, nutritious powder. RENU™ extracts moisture and micronizes raw materials in mere seconds.
It can be installed directly on-site at the brewery to process BSG immediately before decay begins. Because of its high speed and moderate operating temperatures, RENU™ captures virtually all the fiber, protein, and antioxidants naturally found in BSG while removing over 90% of its moisture.
After just seconds in the RENU™ system, BSG is upcycled into a lightweight powder that is easy to transport and shelf-stable for up to three years.
The Results
The brewer client expects to see full ROl in under two years.
They have utilized the BSG powder as a PLA plastic alternative and now use that bioplastic in their operations to reduce packaging costs. As more systems are installed to accommodate higher production volumes, the cost reduction, environmental impact, and income generated will be exponential.
Return on Investment: 2 Years
Revenue Increase: 700%
CO2eq Avoided: 1,679 tons
From Cost Center to Profit Center
By powderizing their Brewer’s Spent Grain, this brewer will:
Mitigate waste
Reduce carbon emissions
Produce carbon off-sets
Reduce costs
Generate revenue
Build a circular supply chain
Improve profitability
Achieve their net-zero goals
Revenue Created from Brewer's Spent Grain
The brewer produced 1 million lbs. of BSG. The selling price for animal feed was $28 per ton. The selling price for powderized BSG is $0.60 per pound!
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Contact GTF Technologies today for a free consultation and discover how our eco-friendly solutions can increase your revenue and reduce your environmental impact.