WEA Conference â June 21st 2012
WEA Conference – June 21st 2012
Musical chairs: Moving product around large wineries Simon Nordestgaard & Tadro Abbott
Problem with wine product movements • Labour: – Physical work – Planning and paperwork
• Product risk: – Oxidation – Wine losses – Mistakes (e.g. incorrect blending)
• Water use: – Checking connections – Pushing – Cleaning
• Wastewater production: – Load from cleaning the source tank – Volume from water use
How many movements in the product lifetime?
• In large and complex interdependent production systems this is not a simple question to answer • Preliminary results from recent work: – Analysis of product movements recorded in one winery’s label integrity program (LIP) database
Post-fermentation movements Simple estimate
𝑉𝑠𝑦𝑠
Corrected to account for frequent small transfers 𝑣𝑖 𝑛 𝑛 𝑣 . 𝑛 𝑖=1 𝑖 𝑖=1 𝑣𝑖 𝑉𝑠𝑦𝑠
Using equipment
4.4
6.4
Pump/rack transfers
4.2
10.7
Total movements
8.6
17.1
Using equipment
5.1
9.8
Pump/rack transfers
5.5
17
Total movements
10.6
26.8
𝑛 𝑖=1 𝑣𝑖
White wine
Red wine
vi: Volume of movement i Vsys: Wine system volume n: Total number of movements in category
Pump/rack transfers by size 19% < 2 kL 70% 60%
Number of transfers
40%
Volume of transfers
30% 20% 10%
Transfer size (kL)
>300
250-300
200-250
150-200
100-150
50-100
0% 0-50
Fraction of transfers
50%
Pump/rack transfers by life stage 60%
Fraction of transfers
50%
40% Number of transfers Volume of transfers
30%
20%
10%
Finished
Blended
Varietal
0%
Wine life stage
• Varietal: Prior to blending • Blended: Blended and designated in a specific product class • Finished: Post-stabilised
Examples of wine transfersa -Making space for additives Additive (e.g. liquid tartaric acid, juice concentrate)
Remove wine to make space aSimplified
examples only
Examples of wine transfers -Topping up tank to account for thermal contraction Top-up with wine to prevent ullage
Wine contracts as it cools
Examples of wine transfers -Clarification Top-up with wine to prevent ullage
Rack wine off lees
• Clarifying multiple tanks minimises tanks requiring top-ups • Similar principles apply for other solids separation equipment (filtration/centrifugation)
Examples of wine transfers -Moving to tank near equipment
Move to tank near equipment
• Avoid by ensuring that wine is near equipment that will be needed at that point in its life, wherever possible
Examples of wine transfers -Accommodating packaging/transport specifications Adjust SO2 to bottling spec
For bottles For bulk shipping
Adjust SO2 to bulk shipping spec
Examples of wine transfers -Blending and re-blending
Wine A
Blend
Wine B
Examples of wine transfers – Distribution of recovered wine
Wine from RDV bentonite lees
Remove wine to make space
Examples of wine transfers -Accommodating small packaging runs
Packaging
Packaging
Packaging • •
Retailers placing increasingly strict limits on product age leading to shorter packaging runs. Smaller batch sizes also provide flexibility to adjust to market demand.
Examples of wine transfers -Bulk shipping leftovers
Move to bulk loading tank
Load in bulk shipping container
Move leftovers
•
Australia now exports more bulk wine than bottled wineb
bMAT
March 2012 Wine Export Approval Report
Product movement maps
Fixed processing equipment
•
Simplistic representation, but it is not unusual to see complex paths like this when you track a product through its life
Possible solutions/improvements -Winery layout • New wineries: – Design winery and tanks around required batch sizes – Design winery around process flow – Segregate bulk and boutique production processes
• Old wineries: – Partition winery as much as practicable to linearise process flow – Develop and document simple winery-wide rules on which tanks are to be used for different purposes (e.g. annotated/highlighted winery tank map) – Analyse information collected in LIP systems and discuss with production and winemaking staff to understand current practices and opportunities
Possible solutions/improvements -Optimisation software, advanced planning, coupling • Optimisation software: – A step beyond simple winery rules – Optimises movements with respect to profit, considering winery layout, schedules and other business rules – Implementation in wineries with decentralised decisionmaking could be difficult? – Initial cost may be prohibitive unless operation is particularly big/complex
• Advanced planning: – Plan in advance for product requirements (as much as possible) to allow early blending and prevent reblending/re-processing
• Couple operations, where possible: – Could another addition be made before the next racking?
Possible solutions/improvements -Process technology solutions
• Ullage management: – Many movements are associated with keeping tanks full – At the end of vintage primarily an issue of best using capacity, but at other times maintaining wine quality may be the key driver – Need a cheap solution to this problem that can be applied to existing low-technology wine tanks: • Inert gas is used by many wineries, but general perception is that nothing is as good as a full tank? What do you think? • There must be a better way! • Significant applied research work should be put into this topic
Acknowledgements • Australian grapegrowers and winemakers / Australian government for project funding through the GWRDC • The winery whose LIP we analysed and all the staff who assisted and offered advice and process insight
Musical chairs: Moving product around large wineries Simon Nordestgaard & Tadro Abbott
Problem with wine product movements • Labour: – Physical work – Planning and paperwork
• Product risk: – Oxidation – Wine losses – Mistakes (e.g. incorrect blending)
• Water use: – Checking connections – Pushing – Cleaning
• Wastewater production: – Load from cleaning the source tank – Volume from water use
How many movements in the product lifetime?
• In large and complex interdependent production systems this is not a simple question to answer • Preliminary results from recent work: – Analysis of product movements recorded in one winery’s label integrity program (LIP) database
Post-fermentation movements Simple estimate
𝑉𝑠𝑦𝑠
Corrected to account for frequent small transfers 𝑣𝑖 𝑛 𝑛 𝑣 . 𝑛 𝑖=1 𝑖 𝑖=1 𝑣𝑖 𝑉𝑠𝑦𝑠
Using equipment
4.4
6.4
Pump/rack transfers
4.2
10.7
Total movements
8.6
17.1
Using equipment
5.1
9.8
Pump/rack transfers
5.5
17
Total movements
10.6
26.8
𝑛 𝑖=1 𝑣𝑖
White wine
Red wine
vi: Volume of movement i Vsys: Wine system volume n: Total number of movements in category
Pump/rack transfers by size 19% < 2 kL 70% 60%
Number of transfers
40%
Volume of transfers
30% 20% 10%
Transfer size (kL)
>300
250-300
200-250
150-200
100-150
50-100
0% 0-50
Fraction of transfers
50%
Pump/rack transfers by life stage 60%
Fraction of transfers
50%
40% Number of transfers Volume of transfers
30%
20%
10%
Finished
Blended
Varietal
0%
Wine life stage
• Varietal: Prior to blending • Blended: Blended and designated in a specific product class • Finished: Post-stabilised
Examples of wine transfersa -Making space for additives Additive (e.g. liquid tartaric acid, juice concentrate)
Remove wine to make space aSimplified
examples only
Examples of wine transfers -Topping up tank to account for thermal contraction Top-up with wine to prevent ullage
Wine contracts as it cools
Examples of wine transfers -Clarification Top-up with wine to prevent ullage
Rack wine off lees
• Clarifying multiple tanks minimises tanks requiring top-ups • Similar principles apply for other solids separation equipment (filtration/centrifugation)
Examples of wine transfers -Moving to tank near equipment
Move to tank near equipment
• Avoid by ensuring that wine is near equipment that will be needed at that point in its life, wherever possible
Examples of wine transfers -Accommodating packaging/transport specifications Adjust SO2 to bottling spec
For bottles For bulk shipping
Adjust SO2 to bulk shipping spec
Examples of wine transfers -Blending and re-blending
Wine A
Blend
Wine B
Examples of wine transfers – Distribution of recovered wine
Wine from RDV bentonite lees
Remove wine to make space
Examples of wine transfers -Accommodating small packaging runs
Packaging
Packaging
Packaging • •
Retailers placing increasingly strict limits on product age leading to shorter packaging runs. Smaller batch sizes also provide flexibility to adjust to market demand.
Examples of wine transfers -Bulk shipping leftovers
Move to bulk loading tank
Load in bulk shipping container
Move leftovers
•
Australia now exports more bulk wine than bottled wineb
bMAT
March 2012 Wine Export Approval Report
Product movement maps
Fixed processing equipment
•
Simplistic representation, but it is not unusual to see complex paths like this when you track a product through its life
Possible solutions/improvements -Winery layout • New wineries: – Design winery and tanks around required batch sizes – Design winery around process flow – Segregate bulk and boutique production processes
• Old wineries: – Partition winery as much as practicable to linearise process flow – Develop and document simple winery-wide rules on which tanks are to be used for different purposes (e.g. annotated/highlighted winery tank map) – Analyse information collected in LIP systems and discuss with production and winemaking staff to understand current practices and opportunities
Possible solutions/improvements -Optimisation software, advanced planning, coupling • Optimisation software: – A step beyond simple winery rules – Optimises movements with respect to profit, considering winery layout, schedules and other business rules – Implementation in wineries with decentralised decisionmaking could be difficult? – Initial cost may be prohibitive unless operation is particularly big/complex
• Advanced planning: – Plan in advance for product requirements (as much as possible) to allow early blending and prevent reblending/re-processing
• Couple operations, where possible: – Could another addition be made before the next racking?
Possible solutions/improvements -Process technology solutions
• Ullage management: – Many movements are associated with keeping tanks full – At the end of vintage primarily an issue of best using capacity, but at other times maintaining wine quality may be the key driver – Need a cheap solution to this problem that can be applied to existing low-technology wine tanks: • Inert gas is used by many wineries, but general perception is that nothing is as good as a full tank? What do you think? • There must be a better way! • Significant applied research work should be put into this topic
Acknowledgements • Australian grapegrowers and winemakers / Australian government for project funding through the GWRDC • The winery whose LIP we analysed and all the staff who assisted and offered advice and process insight
