A TOUCH OF GAS Role of gases in the winery New Zealand, September 2014 l Alex Young l Market...

A TOUCH OF GASRole of gases in the winery

New Zealand, September 2014 l Alex Young l Market Development Manager – Food

World leader in gases, technologies and services for Industry and Health Doc title Date

History of gas use in the winery

A TOUCH OF GAS

2

World leader in gases, technologies and services for Industry and Health Doc title Date 3

Once upon a time 1950-1980

There was an emerging emphasis on science &

technology by institutions like Roseworthy & others

Fornachon, Hickinbotham & later Rankine et al started to extensively

research the role of oxygen

The emphasis was on the application of technology in winemaking; innovation

& creating value

The effective use of inert gases, starting with dry ice, CO2 & mixed gas was studied & implemented.

Gas performance was researched & trialled.

Winemakers started to better understand &

practice DO management.

The industry was collecting & reusing fermentation CO2

Carbonic maceration was researched & practiced

New gases & gas technology emerged; new supply options were being introduced (generation; new

gas mixers; spargers; diffusers etc).

Gas lectures at University & TAFE level were

introduced along with practical sessions (“hands

on” gas use).

Gas volumes increased markedly, to a level more than double of other

countries


Then we come to the demands of today (1)…..

4

Market Demands:

Elegance

Refinement

Delicacy

Balance

Harmony

FINESSE

Cost Demands:

Efficiency

Quality

Versatility

Labour / Costs

Asset Utilisation

PROFITABILITY

Environmental Demands:

Crush levels

Sustainability

Carbon emissions

Global warming changing wine areas/yields /style

BOD control

Innovation Demands:

Total package oxygen / oxygen management

Aroma recovery

Ferment CO2 recovery (full / partial)

Cold Stabilisation

Nitrogen generation options

New / Balanced gases / gas mixtures

Process control


And add to those…..

5

■ Emergence of New World Wines wines of equal quality competing in the same markets but with a much lower cost base.

■ Traditional wine producing countries have adapted rapidly to the changing market demands.

■ The (relative) strength of the $ has had an impact on the local industry.

■ Production became (& remains) an issue. Wineries survived by winding down assets changing structure, changing ownership.


Continued....

6

■ The “sleeper” of global warming and temperature changes 0.3 - 1.7C altering yields, changing viability, reducing

quality compressing harvest periods etc.

■ It called for a re think; one element being a re-examination of the impact of Oxygen.


A TOUCH OF GAS

Gas usage in wine making


Traditional or new world; making the choice?

8

Hyper Oxidation Large quantities of air or oxygen are added to the musts, i.e. 10 times the quantity used by the must; delayed sulfiting

Controlled Oxidation

Moderate quantity of oxygen added to the must, slightly above the stoichiometric quantity, delayed sulfiting

Traditional Vinification

Limited contact with oxygen and relatively early sulfiting

Reduction Limited contact with oxygen and early addition of SO2 combined with ascorbic acid

Hyper Reduction Extreme protection against oxygen through the application of inert gas

Typical of “new world” producers

Typical of “traditional” producers


So where is the gas link?

9

DO: <0.3mg/lDCO2: 0.5-0.7g/lSO2: ~30ppm

DO: 0.5-0.8mg/lDCO2: <0.4g/lSO2: 25-40ppm

DO: <0.5mg/lDCO2: 1.2-1.7g/lSO2: ~50ppm

Quality, value & efficiency can be achieved with balance; but you need to look at the TOTAL picture


Oxygen

10

Oxygen

CO2

SO2

“ It’s the oxygen that makes the wine. It’s what modifies the bitterness of new wines and takes away the bad taste”

Pasteur, 1866


Oxygen: In Perspective

11

T emper at ur e

Red / O x control Lees

T ur b id it y

D ur at ion ofmat ur at ion

O ak ex t r act s

INTERACTIONS

Oxygen

Racking

Stirring

Barrels

Chips

Control

Ageing

Bottling


Oxygen; by Operation

12

1 = Vidal et al 2001; 2 = Vidal et al 2003; 3 = Vidal et al 2004; 4 = Valade et al 2006; 5 = Valade et al 2007; 6 = AWRI 2011; 7 = Purdue Uni; 2010


Oxygen Management

A TOUCH OF GAS

13


Oxygen management; the role for gas.

14

Effect of Ullage oxygen %

0

0.5

1

1.5

2

2.5

3

0.5% 1% 2% 3% 4%Ullage oxygen %

Dis

solv

ed o

xyg

en m

g/l

20 C

10 C

5 C

10.00

11.00

12.00

13.00

14.00

15.00

16.00

0 30 60 90 120 150 180 210 240

Qu

alit

y s

co

re

O2 ml/l

Optimum oxygen consumption (Singleton 1989)Red (1)

Red (2)

White (1)

White (2)

(Left) To manage dissolved oxygen you need to manage ullage oxygen: BUT NOT attempt to eliminate it. Where <0.5% was targeted previously, some wines may tolerate higher levels today.

(Right) the point Singleton is making is that there is a differing tolerable range of oxygen with all wines and it is related to quality (13 being average)


Oxygenation: Micro, Macro, Hyper; Traditional / technical?

15

Hyper

White wines, high polyphenol

Increases resistance to oxidative effects

Perform before any SO2 addition

In tank or in line via SS diffuser


Phases of Micro Oxygenation

16

Different phases during Micro-oxygenation

Fermentationaromas

Varietalaromas

ComlexityComlexity

Comlexity

Comlexity

Oxydativearomas

Increase of tannins

Softening

Drying

Building phase Refinement Over oxygenation

Fermentation, varietal & oxidative aromas are all elements of the complexity; BUT are grape variety specific, requiring different micro oxygenation techniques for different wines.


Gas supply; facts & fallacies

17

FACT: Gas supply is key, directly impacting on quality & efficiency

FALLACY: “N2 generation is by far the cheapest; I only pay for power”

FALLACY: “Dry Ice is the most effective for ullage management”

FALLACY: “You can’t use CO2 on red wines”

FALLACY: “The cost of gas is only minor in total terms”

FACT: The Australian average (total) gas usage is ~7m3/tonne of grapes (~ 10 litres gas/litre) BUT it is not uniform across winery sizes

FACT: Dissolved oxygen (DO) is directly linked to tank ullage oxygen %, BUT it doesn’t need to be <1% for ALL wines


Effective gas usage; Research

18

0

0.12

5

0.25

0.37

5

0.5

0.62

5

0.75

0.87

5 1

1.12

5

1.25

1.37

5

1.5

1.62

5

1.75

1.87

5 2

1.12

5

2.25

2.37

5

2.5

0.0

2.5

5.0

7.5

10.0

12.5

15.0

17.5

20.0

22.5

Tank (Gas) VolumesN2 Purge N2 surface Ar Purge Ar surface CO2 purge CO2 surface

Gas Usage (Volumes)

Ull

age

Oxy

gen

%

INRA; Montpellier, 1995. Nitrogen works by dilution, and the end usage is dictated by the initial oxygen %, which today IS NOT necessarily <1%.

Target

Nitrogen; effective ~3 volumes gasCO2; effective 1.5 volumes gasArgon; effective 1.2 volumes gas50/50 N2/CO2; effective 2.2 volumes gas


Fallacy; “The cost of gas is minor”

19

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

Dry Ice CO2 gas

N2 Gas 70/30 gas

Ann

ual c

ost

Annual real cost (gas + labour); varying ullage sizes (bottom axis). Prices can be set, but are shown as industry average, based on 48 weeks/year. AWOTE rate @ $35/hr. Packing down (topping up), gas/gas supply & ullage management techniques are critical considerations.

“Gas cost analysis” © Don Allen

Gas / System Analysis,(% of Ullage)

1

10

100

1000

10000

0 5 10 15 20 25

Gaseous Oxygen %

Gas

Use

d, V

/V %

of

Ulla

geFallacy; “It’s just a matter of using more gas”

Results from actual winery audits (right), 1970-2012. Blue marks are actual gaseous oxygen %/gas volume used. The ideal would be to fit into the red square (note: log scale)


Fallacy; “Dry Ice is the most effective”

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0 5 10 15 20 30 45 60 75 90 105 1201.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

% Gaseous O2 levels after addition of dry ice

Tank XX9

Time in mins

% G

as

eo

us

10 15 20 30 45 60 75 90 10512015018021024010.50

11.00

11.50

12.00

12.50

13.00

13.50

14.00

14.50

% Gaseous O2 levels after addition of dry ice

Tank XX1

Time in mins

% G

aseo

us

(left & below), 229kl, 75kl ullage, 5.4kg DI daily (5% of ullage).

Target <1% ullage oxygen. 0.7mg DO (actual ~1.04 {xx9} & 5.6 {xx1}).

Observation: It doesn’t work!


The real cost; a current example

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■ Dry Ice; winery example

■ Ullage 75kl■ Dry ice used = 5.4kg/tank/day■ Equivalent = 2,878 litres■ CO2 required = 18kg■ Procedure: 2 men, buckets■ Total operation time = 35min■ AWOTE rate = $35/hour■ Total operation cost (gas + labour) = $28.15■ “Real”cost = $9.78/m3

■ Mixed Gas; winery example

■ Ullage 75kl■ 30:70 CO2:N2 mix■ Equivalent = 2,878 litres■ Procedure: 1 man, pipeline■ Total operation time = 15 min■ AWOTE rate = $35/hour■ Total operation cost (gas + labour) = $10.28■ “Real” cost = $3.57/m3

Assume 30 tanks X 48 weeks/year Dry Ice Op. = $202,680

Mixed gas Op. = $74,016 (-63%)

It is noted that some infrastructure is required initially to install a pipeline, but $130,000 can buy a lot of infrastructure.

Savings: ~$130,000


The “Real” gas cost in practice

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$18.00

$7.72

$9.70

$12.30

$4.20 $4.20$3.35

$4.60

$3.00$3.60

$0.00

$2.00

$4.00

$6.00

$8.00

$10.00

$12.00

$14.00

$16.00

$18.00

$20.00

Nitrogen Carbon dioxide Argon 50/50 Mix

“Real” Gas Cost/M3 (in use)

Cylinder Bulk Ex Generator Dry Ice

1 3

In order to get an accurate comparison, everything should be converted to equivalent m3 of gas. Figures are general industry, based on 2012 feedback. Unit cost is product + delivery + rental, based on average winery usages. Usage from INRA; Montpellier, France (1992) & DA field trials, 1972 – 2012 (Australia, NZ, Sth Africa).

The generator is a purchased PSA unit, taken as producing 28m3/hour @99.5%. Cost is inclusive of all financials, maintenance, back up etc.

2

In real cost terms:1. N2 ex generator2. Argon ex bulk supply3. 50/50 mix; generator &

bulk4. N2 or CO2 ex bulk


Putting it all together: examples

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42.6%

32.3%

10.5%

8.0% 6.6%

Assessment

N2 CO2 Gen. Elect. CO2e

■ 1. Recommendations; assessment: Eliminate as much dry ice usage as possible Replace it with a mixed gas regime Install some simple flow control in stage 1 Upgrade the (existing) N2 generator & utilise it more

fully. Reduce the (existing) N2 usage (packs or bulk) Lower CO2e

Net result reduction in labour costs, reduction in overall gas usage, improvement in profit per bottle, enhanced quality.

• 2. Recommendations; assessment:- Eliminate as much dry ice usage as possible- Replace it with a mixed gas regime- Implement PLC control- Install a single (or multiple) high flow gas mixers- Test / compare the recommended changes with a

“control” bank of tanks.

Net result a reduction in labour & gas costs, enhanced quality, value

& profit.

IMPROVED EARNINGS


A TOUCH OF GAS

Ideas to explore


COLD PASTEURIZATION

25

COLD PASTEURIZATION ( PCT Pressure Change Technology / preservation without sulphite addition): In PCT, a chemically inert gas (nitrogen or argon) is dissolved at high pressure in the liquid. When the liquid is exposed to a pressure of 500 bar, the solubility of the gas increases in the liquid & the dissolved gas diffuses into the microbial cells. When the pressure is abruptly decreased, the gas expands & causes the cells to burst. The gas returns to the gas phase & is recovered.

Colour is maintained over time in storage, barrels or bottles. There is no perceived change in taste. The technique can be used after vinification of white wine, after alcoholic fermentation, after malo (red wines) as well as racking & filling. Research & trials still underway.


Ideas to explore – OZONE

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OZONE TREATMENT Purovino Method,

Post harvest treatment of grapes. Grapes in bins undergo 14-20 hours fumigation with (patented) ozone treatment to send the oxidative mechanisms into “overdrive”. Usual crush protocol follows No need for SO2. Treated grapes have higher levels of polyphenols & anthocyanins & similar levels of volatile acidity. Free SO2 ~ 1ppm compared to 17ppm in control.


Ideas to explore – AROMA RECOVERY

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Perfect fit as a building block for compounded flavours in:

Beverages: Primary flavour Dairy: Ice Cream; Yoghurt Bakery: Pastries; Fillings Confectionary Wine Vanilla Enhancement

AROMA RECOVERY (SCFE super critical fluid extraction): Exposing starting material and CO2 to very precise pressure & temperature settingsTemperature minimum of 31C & pressure increased to 74 bars minimum.Supercritical CO2 flows through the material and targets and captures soluble aroma molecules. Accuracy can be adjusted by altering the pressure.


Ideas to explore – CO2 RECOVERY

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FERMENT CO2 RECOVERY / REUSE? (variety of equipment suppliers). A winery crushing 5,000 tonnes of grapes produces ~375 tonnes of fermentation CO2. The same winery will (probably) use ~60 tonnes, usually purchased. Plants can be designed to recover part or all of this fermentation CO2 (depending on economics), which may be a viable proposition in certain cases.

500t 1000t 5000t 10000t 25000t 50000t 100000t0

1000

2000

3000

4000

5000

6000

7000

8000

37 75374

748

1,870

3,740

7,480

CO2 (tonnes) from fermentation (depending on conditions)

7.560 120

15

280

560

Red figures are industry typical usages


Ideas to explore – OTHERS

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Oxidative pressing / managementIntroducing Oxygen during pressing

Total Package Oxygen TPO managementOptimizing Oxygen at BottlingPost bottling development

End of presentationThank you for your attention

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A TOUCH OF GAS Role of gases in the winery New Zealand, September 2014 l Alex Young l Market...

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