Sustainability has become a priority for many craft breweries with CO2 recovery becoming more  widespread in the US. Yet, misconceptions persist, leaving some brewers skeptical and hesitant  to adopt CO2 recovery technology. We’ll debunk common myths about CO2 recovery and show  how modern solutions can be valuable for any scale of operation. 

 

Myth #1: CO2 Recovery Isn’t Necessary Because CO2 is Abundant and Cheap 

While CO2 is in fact somewhat abundant in the atmosphere (0.04%), commercial CO2 that’s  suitable for beverage use is not as readily available. Many breweries are dependent on purchased  CO2 for their operation, but prices fluctuate in a volatile market due to supply chain issues,  impacting costs and availability.  

In recent years, CO2 shortages have posed a significant challenge for breweries across Europe,  Australia, and islands. In North America, these fluctuating CO2 prices have added to the  uncertainty, with Canada and several U.S. states being hit particularly hard. The shutdown of  major CO2 recovery plants – the most current ones being in Virginia and Georgia (info HERE) whether due to maintenance or permanently, has left many breweries struggling to maintain  operations, and some were forced into force majeure agreements. These shutdowns have caused  CO2 prices to skyrocket to as much as six times their previous levels in some areas, not including  additional surcharges. 

In the UK, the brewing industry faced at least a 300% price increase in CO2 during 2020 and  2021, with widespread shortages causing a serious disruption to production. Some regions  experienced such severe supply chain failures that they were unable to meet the demand for  CO2, forcing breweries to temporarily suspend operations while others were forced to fully close. 

Stewart Brewing in Scotland, a DALUM customer, experienced the dramatic increase in CO2  prices. In 2016, they paid approximately £250 per ton, but by 2021, that cost had surged to  around £1,000 per ton (more info HERE). Sebago Brewing in Maine also struggled with supply  issues and was happy to install a recovery unit to future-proof their brewery (info HERE).  

By investing in a CO2 recovery system, beverage producers can eliminate reliance on external  CO2 suppliers, lowering costs and their environmental impact.

 

Myth #2: If I Recover My Own CO2, My Industrial CO2 Supplier Will Cut Me Off 

One common concern among brewers considering CO2 recovery systems is the fear that  recovering their own CO2 will jeopardize their relationship with industrial CO2 suppliers. Some  suppliers may suggest that using a recovery system could disqualify them from receiving future  deliveries. However, many suppliers are still open to making spot deliveries to breweries with CO2  recovery systems in place. 

Furthermore, CO2 deliveries can be made that will prevent any gas from the brewery’s liquid tank  entering the delivery truck tank by not connecting the return line to the delivery tank. This is  possible when the delivery truck has an on-board pressure builder circuit. Our experience is that  breweries that take an up-front, proactive discussion with their CO2 supplier regarding their intent  to self-collect are able to come up with a workable solution for both parties. 

 

Myth #3: All Craft-Scale CO2 Recovery Systems Are Created Equal 

With craft-scale CO2 recovery still being a relatively new concept, it’s important to recognize that  not all are alike. Each system varies in quality, efficiency, and suitability for specific brewery  needs. Since there are only a few viable suppliers on the market, brewers should compare their  options carefully. One of the most reliable ways to assess a system’s effectiveness is by speaking  with other brewers who use it, ideally, through on-site visits to see the equipment in action and  understand its long-term benefits and challenges. 

For breweries determined to become self-sufficient, reliability is key. Systems designed for  continuous, around-the-clock fermentation must be robust, with minimal downtime, and  equipped with features like automatic start-stop functions and remote monitoring. Reliable  factory support is equally important, as quick and effective service can make a substantial  difference in managing maintenance, reducing operating costs, and extending the time between  overhauls. 

Purity and safety are also high priorities. By recovering CO2 directly from their own fermentation,  breweries gain full control over the CO2 quality and source. To reliably meet food-grade or  beverage-grade standards, it’s essential to select a system that can liquefy CO2 to at least 99.9%  purity, ensuring it remains completely odor-free and suitable for beverage use. 

Brewers should also ask about recovery rate of total fermentation gas, maximum processing  capacity and look at their current CO2 usage vs. the anticipated recovery amount from any given  supplier. Additional questions to ask include the average time it takes a brewery to start collecting  from unit start-up date and maintenance.

Ultimately, not every system can deliver on these critical features, and the right choice depends  on a brewery’s specific goals for efficiency, quality, and control. 

 

Myth #4: CO2 Recovery is Only Viable for Large-Scale Industries 

Contrary to the perception that CO2 recovery requires large-scale operations, even small and  medium-sized breweries can benefit from this technology. Compact systems, like DALUM’s  smaller model for breweries with a production capacity starting at 800 BBL, starts at around  $40,000, making CO2 recovery an accessible option for craft breweries. In regions where CO2  costs are high (over $0.30 a pound), the payback period can be as short as one year, while in  areas with lower CO2 costs, the investment may take a bit longer to recoup. This flexibility makes  CO2 recovery viable for businesses of all sizes and allows them to reduce operating costs while  enhancing sustainability. 

 

Myth #5: Recovered CO2 Isn’t Pure Enough for Food and Beverage Use 

One of the most prevalent myths is that CO2 recovered during fermentation lacks the purity  required for beverage use. In reality, some modern craft-scale CO2 recovery systems, like the one  from DALUM, are engineered to meet or exceed beverage-grade purity standards. Through  rigorous purification and processing, these systems deliver CO2 that is both high-purity and safe  for use in beverages, while being collected from a known source. Eddie Gadd, President of  Ramsgate Brewery and owner of a DALUM CO2 Recovery Plant, conducted an experiment to test  the quality of the recovered CO2 using a burette from Orbisphere. The results showed that the  purity exceeds 99.99%, showcasing control of quality in the final product. 

Craft breweries can enjoy a stable supply of beverage-grade CO2 without concern over purity or  quality fluctuations that can occur with external suppliers. 

Link to experiment HERE 

 

Myth #6: CO2 Recovery Technology is Too Complex and Expensive to Maintain 

Historically, efforts to adapt industrial-scale CO2 recovery technology for craft breweries faced  significant challenges, with systems being too complex and costly to operate successfully on a  smaller scale. However, modern craft-scale CO2 recovery technology has evolved into a financially viable solution for small and mid-sized breweries. Today’s systems are simpler, more  automated, and far more affordable, with user-friendly interfaces, and minimal maintenance  requirements. 

Furthermore, the savings from reducing reliance on purchased CO2 offset the initial investment  within just a few years. At DALUM, we see that our customers reach break-even after 1-3 years,  depending on their production size and cost of CO2 in their specific area. By securing their own  CO2 supply, breweries not only achieve greater control but also see a compelling return on  investment. These savings allow many breweries to reinvest in projects that enhance production  efficiency and/or advance sustainability efforts. 

In addition, commissioning a DALUM system takes only a day or two before it is up and running  and collecting CO2. This quick installation ensures that breweries can start benefiting from CO2  recovery immediately. 

 

Myth #7: You Can’t Collect CO2 from Multiple Fermenters 

CO2 recovery systems are not limited to capturing gas from a single fermenter. The DALUM CO2  collection plants are designed and sized to handle gas collection from multiple fermenters  simultaneously. This feature makes them ideal for breweries of all sizes and allows for more  efficient CO2 collection across different fermentation vessels, large or small. The flexibility  ensures that breweries can recover CO2 from all their fermentation stages, reducing waste and  improving the overall sustainability of their operations. 

 

Myth #8: Craft-Scale Plants Don’t Capture Enough CO2 to Make Breweries  Independent 

Some believe that craft-scale CO2 recovery systems can’t recover enough CO2 to support a  brewery’s entire production process. DALUM’s systems are designed to efficiently collect CO2  from fermentation with average recovery rates of 7-8 lbs. of CO2 per barrel. This amount is often  sufficient to cover the brewery’s CO2 needs for carbonation, tank purging, and other applications,  depending on the production scale. 

Maximizing efficiency and reducing waste are critical to achieving CO2 independence. If a  brewery’s brewing schedule isn’t optimized, there’s a risk of wasting potentially recoverable CO2.  For example, if multiple fermenters aren’t tapped for CO2 recovery at the right time, valuable CO2  may go uncollected. However, we have seen that breweries get better at utilizing their CO2  recovery systems. By understanding how the system works and adjusting their brewing schedules  accordingly, brewers can capture more CO2 and reduce unnecessary waste. Some breweries initially use more CO2 than they truly need, but with time, they refine their processes and become  more efficient in their CO2 usage. 

In fact, some breweries end up collecting more CO2 than they require and are able to sell the  excess to other local businesses and create a new revenue stream. 

Several DALUM customers are benefiting from this, including Stewart Brewing in Scotland. They  are annually producing 45 tons of CO2 but only consuming 35 tons, leaving them with 10 tons of  excess CO2. Svaneke Bryghus, located on the island of Bornholm, has been selling their excess  CO2 for several years to other businesses on the island, where CO2 is particularly expensive to  source. 

 

Breweries whose packaging mix is over 50% cans may find it difficult to be CO2 independent  since canning requires a lot of CO2. They should look at their current CO2 consumption vs. the  anticipated collection amount. DALUM runs an analysis for each brewery to help with this. In  cases where CO2 recovery alone cannot meet all the brewery’s needs, brewers can also use a  nitrogen generator to fill in the gap. Nitrogen is used in various stages of brewing and packaging,  and a nitrogen generator can help supplement CO2 to ensure full independence. By combining  CO2 recovery with nitrogen generation, breweries can achieve a reliable and cost-effective  solution for self-sufficiency in gas supply.