bob hansen briess malt & ingredients co. chilton, wisconsin usa 2006 cbc balancing water in the...

Bob HansenBriess Malt & Ingredients Co.

Chilton, Wisconsin USA2006 CBC

Balancing Water in the Brewhouse

Balancing Water in the Brewhouse

Brewing is a process of balancing additions of water and several soluble and insoluble components to finish with a product with exact concentrations of each component.

Introduction to Materials (Mass) Balance

Introduction to Materials (Mass) Balance

• Better Control of Process• Energy Efficiency • Water Conservation• Waste Water Reduction• Optimization of Throughput• Yield Maximization• Quality Improvement

Rewards of a Balanced ProcessRewards of a Balanced Process

Hops

Grain

Inputs

Inputs

Water

Soluble Components

Insolubles

Water

Soluble Components

Insolubles

Water

Wort

Water

Soluble Components

Spent Material

Waste Water

Water

Soluble Components

Insolubles

Water

Soluble Components

Water (Steam)

OutputsOutputs

Brewing Process

Mass Balance

Hops

Grain

Inputs

Inputs

Water

Soluble Components

Insolubles

Water

Soluble Components

Insolubles

Water

Wort

Water

Soluble Components

Spent Material

Waste Water

Water

Soluble Components

Insolubles

Water

Soluble Components

Water (Steam)

OutputsOutputs==

Water

Soluble Components

Insolubles

Water

Soluble Components

Insolubles

Brewing Process

Mass Balance

Basic Equations and TerminologyBasic Equations and Terminology

Specific Gravity

Weight of Water

Weight of Wort

=________

Degrees Plato

Weight of Wort

Weight of Wort Solids

=________

X 100


Concentration (Plato) and Relative Density (S.G.) are Related

Concentration (Plato) and Relative Density (S.G.) are Related

Degrees Plato

- 1 ) X 1000 /4

1 + (Plato X 4 / 1000)

=Specific Gravity

(

Specific Gravity = 1 + (10 X 4 / 1000)1.040

1.0400.040 ) X 1000 /410


Specific Gravity

Weight of Water

Weight of Wort

=________

X

Weight of Water = 8.34 lbs / Gal

Weight of Water = 1 kg / liter


Degrees Plato

Weight of Wort

Weight of Wort Solids

=________

X 100_______________________


Liquor / Grist Ratio Weight of

Grain

Weight of Liquor (water)

=________

Grain (500 lbs)

Inputs

Inputs

Water

(0.05 x 500 lbs = 25 lbs)

Soluble Components

(0.75 x 500 lbs = 375 lbs)

Insolubles

(0.20 x 500 lbs = 100 lbs)

Water (1500 lbs)

OutputsOutputs

Mashing

Mass Balance

Mash (2000lbs)

Water

( 25lbs + 1500 lbs = 1525 lbs)

Soluble Components

(375 lbs)

Insolubles

(100 lbs)

This is a 3.0 L/G ratio

1500 Lbs / 8.34 Lbs/Gal =

180 Gal or 5.8 Brls

Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %Grain 500 25 5% 375 75% 100 20%Water 1,500 1,500 100% - -

Total Inputs 2,000 1,525 375 100

Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Mash 2,000 1,525 375 100 Total Outputs 2,000 1,525 76.3% 375 18.8% 100 5.0%

Mash Vessel Material BalanceMash Vessel Material Balance

First Worts from Liqour : Grist

12%

14%

16%

18%

20%

22%

24%

26%

28%

2.0

2.2

2.4

2.6

2.8

3.0

3.2

3.4

3.6

3.8

4.0

4.2

4.4

4.6

4.8

5.0

Liquor - Grist Ratio

Wo

rt S

olid

s (

Pla

to)

Yield 78%

Yield 76%

Yield 74%

Yield 72%

• Thicker Mashes have lower pH (0.1 or more)• Thicker Mashes Stabilize Enzymes

– Can Increase Soluble Nitrogen +10-20%– Increase Alpha Amylase Survival Time +20%

• Thicker Mashes Reduce Enzyme Mobility– Thicker Mashes Produce More Dextrinous Worts– Fermentability Can be Reduced 5%

• Water Balance Sets Maximum Extract Possible In The Brewery– Total Extract (Wort Solids)– Sets Maximum Wort Strength

Effects of Water Balance in the MashEffects of Water Balance in the Mash

Mash Volume vs Liqour : Grist

00.10.20.30.40.50.60.70.80.9

1

2 2.5 3 3.5 4 4.5 5

Liqour:Grist Ratio

Ga

llo

ns

Gal/lb Malt

Gal/lb Extract (@75%)

Inputs

Inputs

Underplate/Chase (200 lbs)

OutputsOutputs

Lautering

Mass BalanceThis is a 3.0 L/G ratio

Mash (2000lbs)

Water (1525 lbs)

Soluble Components (375 lbs)

Insolubles (100 lbs)

Sparge Water (1500 lbs)

Wort (2985 lbs)

Water (2637 lbs)


Insolubles (98 lbs)

Water (400 lbs)


Water (188 lbs)


Insolubles (2 lbs)

Spent Grain (515 lbs)

Drain Water (200 lbs) 23.5 gal x 1.020 x 8.34 lbs/gal

5.0 P x 200 lbs

348 / 2985 = 11.7 % (Plato)

Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %UP water 200 200 100% - 0% - 0%Sparge Water 1,500 1,500 100% - 0% - 0%Mash+Rinse 2,000 1,525 375 100 Total Inputs 3,700 3,225 375 100

Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Spent Grain 515 400 17 98 Drain water(weak wort) 200 188 10 2 Wort 2,985 2,637 348 11.7% 0 Total Outputs 3,700 3,225 375 100

Lautertun Material BalanceLautertun Material Balance

348 / 375 = 93 % Brewhouse Efficiency500 lbs x 95 % Solids = 475 lbsS.G = 1.047 x 8.34 lbs/ gal = 8.73 lbs/ gal = Weight of Wort2985 lbs / (8.73 lbs / gal) = 342 gal = 11.0 Barrels

• Balance will Determine Yield– Improper balance or timing leads to loss in grains or drain water– Yield losses lead to increased waste water costs

• Balance will Determine Preboil Wort Strength and Volume– Poor balance leads to oversparging and overdilution

• Balance can effect product quality– Oversparging leads to increased color, pH and Tannin extraction

• Balance effects runoff speed and throughput– Improper balance leads to difficult or lengthy lautercycles

Effects of Lautertun Water BalanceEffects of Lautertun Water Balance

Gallons

Pla

to

Lautertun Runoff Model

0%2%4%6%8%

10%12%14%16%18%20%

0 2000 4000 6000 8000 10000 12000 14000 16000

Gallons

Pla

to

3.0

4.0

5.0


0%2%

4%6%8%

10%

12%14%16%

18%20%

0 2000 4000 6000 8000 10000 12000 14000 16000

Gallons

Pla

to

3.0

4.0

5.0


0%2%

4%6%

8%10%12%

14%16%

18%20%

0 2000 4000 6000 8000 10000 12000 14000 16000

Gallons

Pla

to

0%10%

20%30%

40%50%60%

70%80%

90%100%

Yie

ld

3.0

4.0

5.0


0%

2%

4%

6%

8%

10%

12%

14%

16%

18%

20%

9000 10000 11000 12000 13000 14000 15000 16000

Gallons

Pla

to

60%

65%

70%

75%

80%

85%

90%

95%

100%

Yie

ld

3.0

4.0

5.0

93% Yield, 15.7 P

87% Yield, 14.3 P

Water Balance Affects RunoffWater Balance Affects Runoff

Max Flow

Viscosity

Various Factors

=_______________

X Bed Depth

Viscosity Increases Directly with Plato

1.01

1.02

1.03

1.04

1.05

1.06

1.07

1.08

1.09

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 120000%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2.8

2.7

3

Inputs

Inputs

OutputsOutputs

Kettle /

Whirlpool

Mass Balance

Wort (2782 lbs)

Water (2436 lbs)


Wort (2985lbs)

Water (2637 lbs)


Insolubles (3.4 lbs)

Water (0.4 lbs)

Hops (4 lbs)

Insolubles (4 lbs)

Water (16 lbs)

Spent Hops (20 lbs)

Soluble Components (1.7 lbs)

Water (6.8 lbs)

Trub (8.5 lbs)

Steam (Water) (264 lbs)

Soluble Components (0.2 lbs)

Water (83 lbs)

Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %Wort 2,985 2,637 348 0Hops 4 1 4Water 83 83

Total Inputs 3072 2,721 88.6% 348 11.3% 3.5 0.1%

Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Wort 2,782 2,436 346 12.4% 0Spent Hops and Trub 26 21 1.7 4Steam (evap) 264 264Total Outputs 3072 2,721 348 3.5

1.050 O.G. 318 Gallons 10.3 Barrels

• Water Balance Cannot be Separated from the 5 “-ations of Brewing– Sterilization– Isomerization– Concentration (Evaporation)– Carmelization (Color and Flavor Development)– Volitilization

• Excessive Concentration is Innefficient and Can Lower Quality• Concentration increases Exponentially with Water Removal

Effects of Kettle Water BalanceEffects of Kettle Water Balance

Concentration at Constant BoilingConcentration at Constant Boiling

Hours of Boiling and Concentration

10%

15%

20%

25%

0 1 2 3 4 5 6 7

Hours of Boiling

Pla

to 10 P

12 P

14 P

16 P

18 P

Barrels of 20 P Wort After Boil and Wort Color

0

5

10

15

20

10 12 14 16 18

Original Plato

Bar

rels

an

d L

ovi

bo

nd

Boiling to GravityBoiling to Gravity

Total Inputs 3,253 2,775 85.3% 595 18.3% 3.5 0.1%

Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Wort 2,960 2,488 593 20.0% 0Spent Hops and Trub 26 20 2 4Steam (evap) 267 267Total Outputs 3,253 2,775 595 3.5


HG Beer BalanceHG Beer Balance

High Gravity BalanceHigh Gravity Balance Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %Wort 3,249 2,750 499 0Hops 4 1 4 0Concentrated Wort 120 24 20% 96 80%Total Inputs 3,253 2,775 85.3% 595 18.3% 3.5 0.1%

Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Wort 2,960 2,488 593 20.0% 0Spent Hops and Trub 26 20 2 4Steam (evap) 267 267Total Outputs 3,253 2,775 595 3.5


SummarySummary

Questions?Questions?

ThankYou

ThankYou

Bob HansenBriess Malt & Ingredients Co.

Chilton, Wisconsin USA2006 CBC

bob hansen briess malt & ingredients co. chilton, wisconsin usa 2006 cbc balancing water in the...

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