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Carlsberg’s relocation of the Holsten brewery in Hamburg to a new greenfield site brought an opportunity to improve process efficiency and to drive down operational costs. Arup was appointed to act as the multi-disciplinary technical advisor based on our track record of successful client-side project delivery and our global expertise in the Food and Drink industry.
Challenges
Faced with Hamburg city’s requirement for the Holsten brewery to relocate or face penalties for their high truck numbers, Carlsberg needed to find a new location for their German beer production.
Rather than move abroad to where raw materials are cheap, Carlsberg chose to stay within the Hamburg district and save local jobs. This may have pleased German customers loyal to the Holsten brand, but how could Arup help our client build a winning business case in a very challenging German market?
Project Summary
56,000 m2 of production and storage area
400,000 litres of beer produced per day
1mbottles filled per day
Our solution
For the lowest capital cost project, the Arup client-side team created a building model based on DfMA (design for manufacturing and assembly) principles and the ready availability of precast manufacturers. This strategy reduced build complexity and ensured rapid building installation.
To reduce operating costs, we designed for high density storage through racking systems and high bay warehousing which helped cut logistics’ costs. Arup also planned innovative energy-savings using heat recovery from brew water and decentralised plant for the process and office spaces. To assist with the business case approval Arup used 3D visualisation tools for an enhanced stakeholder experience.
We shaped the front-end design and created a compact, single block masterplan on a very constrained site just outside of Hamburg. Our design positioned the offices and welfare within the brewery space which was key to improving workers’ accessibility and to reduce their daily travel times.
Global reach, local knowledge
Arup’s global reach allows us to draw on a multidisciplinary cross regional team and on Braveheart we were able to combine brewery design know-how from the UK with local planning and market intelligence from our Germany offices.
We managed the building permitting which was specific to breweries and we supported Carlsberg in their negotiations with the Hamburg authorities, dealing with environmental and waste issues. Our planning ensured Carlsberg had a credible programme for permit approvals, ground-breaking and eventual production.
Bright Beer Tanks within the BBT building. These tanks were recycled from the old Altona brewery and reconditioned with new legs.
Our planning work was critical for the transfer of Carlsberg people, processes and products from the old city-centre site to the new brewery and the Arup Operational Readiness (ORAT) team were available to assist Carlsberg with their strategic business move.
Find out more about our ORAT service“Arup’s professionalism and rigour on the project was significant, particularly in areas of business case development, master planning, procurement strategy and client-side project management. ” Lukasz Gladysz Carlsberg Project Director
The result
The new Holsten brewery will produce over 400,000 litres of beer per day, packaged into 1 million beer bottles and 2000 kegs. The high bay warehouse will provide increased capacity to store 18,000 pallets of ‘finished goods’ and recycle 30,000 pallets of returnable bottles with the capability of handling 100 trucks coming onto site every day. This new modern facility will not only improve production efficiency but has also ensured the longevity of the Holsten brand within Carlsberg’s beer portfolio.
Arup’s coordination with key stakeholders and suppliers, coupled with our familiarity of Carlsberg processes ensured the project remained on track and saved time and costs. Our client-side team supported Carlsberg throughout the project lifecycle and helped this key client to successfully realise their first new brewery in Western Europe for over 20 years.
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