brewing technology by krones

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Technology of Beer Production turned into Technical Solution

Krones Brewing Technology

for

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Structure of Krones Training day

Brief Introduction

Why is it important to achieve uniform knowledge

throughout the company?

How are project discussion normally executed?

How does Krones work on India market?

We want to discuss your projects with you in order to

engineer your tailor made plant

How has Krones turned the technological requirements of

the single brewing steps into a technical solution

3


Functional...

Collecting of Data, information and process Parameter

Time table

General plant

engine-ering

Media supply

Sizing of the plant-

buildings

Process and line

data system/

Dataacquisition

Tender documents

(contract)

Analysis of the

submitted quotations

Technical clarifi-

cation after

contract

Monitoring of

manufacturing

andInstallation

on site

Acceptance procee-

dings

Processpa-rameter...

Engineering...

Definition...

Calculation...

Mode...

Dividing...

Evaluation …Update...

Follow up, …Piping, e. Inst.

Acceptance...

Pallet cooler

Filler

Grouped valve

Syrup room

Chemicals

Cleaningmachine

Cratewasher

Pasteur

DV-d31-0333-0 07/01 VT-Dok/MS

Legend Mineral waterCO2

Pressured airSteamCondensat

Treated waterCold waterColling tower waterSyrup/ProductCleaning forerunCleaning return

Mixer

Check valve

Shut-off valve

Ball valve

Centrifugal pumpQ=27 m3/h at H=76 mWSQ=20 m3/h at H=82 mWS

6,0 bar operating pressuren=2900 1/min, 50Hz

Locking valve

Discharge pressureInfeed pressure

Special-PVC for ozonisedwater or V4A

DN20 PVC

PVC PVC

DN

25

DN

20

O3-injectorsize 5

Shut-off valve

DN50 DN65

Static mixerDN65

PVC-sleeve Ø20DN15 Cooling water

draining

DN50DN50

Cooled ozone generatorscheduled value 0.5 g03/m3

DN50

d=4°m**wm

Status: non-alignedpre engineering - iterative process

Turn Key Project Management: General Overview Project Design & Execution

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How do we operate on the India market

Krones India Krones India Engineering

Project managerSite Manager

Account Manager

Project teamLocal architectsTax consultants

Partners Project team

Project managerVarious departments

mechanical and electrical

Krones

Senior

Project Manager

Krones Processing in Germany with all departments

Other local comp.

Customer

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On SiteTank

Fabrication

DocumentationKRONES

Warehouse / IT Technik

EngineeringProcess

Technology

EngineeringUtilities

PurchasingThird PartyMachines

UtilitiesOn Site

Supervisors

Boiler House

RefrigerationPlant

Malt HandlingSystem

WaterTreatment

Plant

Waste WaterTreatment

Plant

CO2-Recovery

Plant

EngineeringHardware

EngineeringSoftware

EngineeringWarehouse

Management

ShipmentDepartment

Manufacturing

MechanicalOn Site

Chief Supervisor

Hot ProcessEquipment

Cold ProcessEquipment

Main-Piping

Isolationand

Piping

ElectricalOn Site

Chief Supervisor

Low VoltageDistribution

„PROCESS“ „Filling“

SoftwareInstallation

ConcentrateStorage

Equipment

EngineeringCold ProcessEquipment

KRONES Systems and Engineering

Division

Blow Mouldingand Plastic

Division

InspectionDivision

Filling and ClosingDivision

LabellingDivision

Conveyer SystemDivision

Pack- andPalletizingDivision

PurchasingThird PartyMachines

PurchasingUtilities

CommissioningEngineer

SoftwareHot ProcessEquipment

TechnologyHot ProcessEquipment

SoftwareCold ProcessEquipment

TechnologyCold ProcessEquipment

Commissioningof utilities

CIP Equipment

EmergencyGenerator

Plant

CompressedAir

Supply-Plant

Controlling and on site managementControlling Production and Purchasing

Sander Hansen WashingDivision

Change overparts Division

EngineeringHot ProcessEquipment

KRONESMachinery

KRONESProcess / Plant

„Warehouse / IT“

CommercialDepartment

Project Financing

Manufacturing

CommercialDepartment

Project Financing

EngineeringAQM / Network

HardwareEquipment +

Cabling

Production Line On Site

supervisor

Filling and Closing

Technology

LabellingTechnology

InspectionTechnology

Pack- andPalletizing

Technology

WashingTechnology

Beverage ProcessingTechnology

Conveyer System

Technology

Purchasing Depart. Third

Party Machines

„PROCESS“ „Filling“„Warehouse / IT“

Customer Project Organisation

General Project Manager

Blow Mouldingand PlasticTechnology

PlantEngineering

Civil ConstructionChief Supervisor

Turnkey Projects - Organization Chart

6


Why are P&ID´s so important?

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Legend

8


Explanation of symboles used in P&ID´s

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9

Raw Material

Hops

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Other than water and malt, hops are the main substance of beer

• Bitterness and specific hops-related flavour

• Natural preservative agent

• Increase biological stability

• Promote coagulation of proteins

• Increase colloidal stability

• Increase foam stability

Hops – The „Spice“ of the beer

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Hops (lat.: Humulus lupulus)

closely related to the hemp plant

Multi-year plant (Annual)

Airborne/wind pollination

Male and female blossoms on different plants

Only female plants develop hop cones; cross-pollination must be avoided because of potential lost yield

The hop cone consists of:

• Cover leafs and pre-sheets

• Axis

• Lupulin glands (carrier of aroma, hop resins & the bitter substances)

The Hop Plant

Reference: Simon H. Steiner, Hopfen, GmbH Mainburg

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Contain larger percentage of bittering elements

7 – 18 % α-acid content

Relatively low priced

High α-acid contents may influence undesirable course bitter flavours

Typical bitter hops:

• Brewers Gold

• Hallertauer Magnum

• Northern Brewer

• Nugget

Contain large amount of aroma elements (oils)

3 – 5 % α-acid (more noble soft resins)

Relatively expensive in comparison

Fine bitterness with „hops flavour“ (fine aromatic hops smell)

Typical aroma hops:

• Hallertauer

• Hersbrucker Spält

• Saazer

• Styrian Golding

Division of Hop Types; some hops are „dual purpose“

Bittering hops Aroma hops

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Raw Material

Water

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Water, by percentage, makes up the largest raw material in beer

The quality of water has a significant influence upon the quality of the beer

Per hl sold, beer is requires a ratio of: 3,5-10 hl of water which is needed (Ø 6 hl)

The largest part of water needed, is used as water in “process water”, i.e. water not actually contained in the beer

• Cleaning and rinsing

• Cooling

• Steam production

Raw material water

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Obstruction of enzyme reactions

Lower extract yield

Increased wort viscosity

Dark wort and beer colour

Higher solution of harsh hops bitterness (hard, coarse taste)

Slower fermentation

Lack of coagulation of protein and tannins

Lowered stability of beer

Effect of higher pH

5153BI.tif

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Hardness of water

Hardness of water is expressed by the amount of dissolved ions of calcium and magnesium. Displayed in degree hardness (°)

Definition in Germany: 1°d = 10 mg CaO/l or also 7,19 mg MgO/l (= 0,357 mval/l)

Hardness of water has a big influence in the quality of beer

Hardness mmol/l

°d Description

1 0 - 0,7 0-4 Very soft

2 0,7 - 1,4

4-8 Soft

3 1,4 - 2,1

8-12 Medium hard

4 2,1 - 5,3

12-30 Hard

5 > 5,3 > 30 Very hard

Country Unit Definition

German hardness

1 ° dH 10 mg CaO/l

French hardness

1 ° fH 10 mg CaCO3/l

English hardness

1 ° eH 14,3 mg CaCO3/l

American hardness

1 ° aH 1 mg CaCO3/l

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Definition of water hardness

Total hardness

(Total of all mineral alkaline)

Carbonate hardness

(Carbonate ions of mineral alkaline)

all calcium and magnesium ions which are tied to carbon dioxide

Non carbonate hardness

(Non carbonate mineral alkaline ions)

all calcium and magnesium ions which are tied on mineral acid

CaCO3

Ca(HCO3)2

MgCO3

Mg(HCO3)2

CaSO4

CaCl2

Ca(NO3)2

MgSO4

MgCl2

Mg(NO3)2

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The water plant – supply of brew water

Warmwater

Cold water

Icewater

Glycol

Steam

Wort cooler

Cold water supply

Brewhouse / CellerCIP

Wort cooler

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Deaerated (D/A) water plant

D/A water plant consists of a deaeration station and two D/A water tanks

D/A water is used in the cold areas of the brewery to avoid any kind of oxidation of the product (filtration push outs, blending of High Gravity Beer)

Water will be heated up and then deaerated in a special column, cooled and pumped to the D/A tanks

From the D/A tanks it will be pumped to the required unit

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D/A water plant

D/A water

Tanks

Glycol

Ste

am

Condensa

te

WaterCO2

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45

Raw Material Barley

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Most important raw material for beer production is barley

Arguments: • High content of starch• Enzyme activity• Husks (serve as a natural filter in lauter tun)

Barley – belongs to the family of grasses

Division: • Summer and winter barley • 2- or more rows of kernels

Brew barley: 2-row summer barley

Barley for brewing must be malted

Raw material barley

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Two-row summer barley is very good suitable for beer production, but more expensive

Six-row barley has a higher yield per ha.

New varieties under development are very promising

Differentiation

Characteristics of grains

Characteristics of husks

Amount of starch

Amount of proteins

Two-row summer barley

Uniform grains

Thin husk

A lot of starch

Less protein

Six-row winter barley

Twisted grains

Plump husk

Less starch

More protein

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Maize

• Extract a slightly higher than malt

• Oily germ must be degreased

• Maize grits (12-14 % water)

• Maize flakes

• Maimilo

Rice• Rich in extract (90 %)• 8-9 % protein• Gelatinization at higher temperatures• Effects pale and dry beers

Adjuncts – Maize and Rice

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Wheat• Normally malted• For production of top fermented beers (hefeweizen)• High extract yield• Winter wheat has less protein

Barley• Break down with malt enzymes• Lower yield than barely which has undergone the malting process

Adjuncts – wheat and barley

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The

Malting

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Transformation of barley and wheat to malt

Germination of cereals under manmade environmental forces and control

Finally, the germination is terminated by kilning at a high temperature. The malt is then ready and is stored in silos.

Controlling parameters during malting are:

• Humidity

• Temperature

Malting facilities are generally independent factories which deliver the malt to the breweries.

To produce 1 hl of beer having an original extract of 11 %, approximately 17 kg of malt are required.

What is malting?

• Germination time

• Oxygen

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Why will barley be malted?

• Formation and activation of enzymes

• Break down of cell and structure substances, formation of colour and aroma substances

• German purity law: only water, hops, yeast and malt can be used

The brewer prefers two-rowed summer barley because of the higher extract

Barley cannot be treated directly after the harvest because of a natural protection that will avoid the germination in the field „dormancy“

The dormancy phase takes about 6 weeks The end of dormancy can be determinated with the germ energy (min. 96

out of 100 kernels must start to germinate) During this phase, the barley should have a water content of 11 - 16 %

Arguments and conditions for malting

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Malting – Process stepsRaw

barleySeparation of impurities, broken kernels and metal parts

Cleaning and grading plant

Cleaning

Barley siloSteeping vessel

Germination box

Kiln

Cleaning plant

Skinned barley – Brew barley

Dormancy

Creation of germination conditions, water absorption, cleaning

Enzyme formation, growth processes, metabolic changes (Break down of starch, protein, cell structure)

Water content < 5 % = storable

Grading

Storage

Steeping

Germination

Kilning

Cleaning

Polishing

Brewmalt

Wither (pre-drying) and subsequently kilning (formation of colour and aroma substances)

Separation of rootlets after cooling

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Process steps

1) Reference: Malt factory Weyermann, Bamberg

2) Reference: TUM Lehrstuhl für Technologie der Brauerei 1

Steeping Germination Kilning

1)

1)

1)

2)

2)

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Different malt types

Malt types:

• Pilsner malt (pale malt)

• Dark malt (Munich type)

• Vienna malt

• Caramel malt

• Acid malt

• Short grown and chit malts

• Wheat malt

• Smoked malt

• Rye malt

• Melanoidin malt

• Roasted malt

Reference: Malt factory Weyermann, Bamberg

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Malt reception and storage

• In silos

Malt transport

• Elevator

• Conveyors

• Screws

• Pneumatic (suction or compressed air)

Cleaning

Weigher (Balance)

• Weighing of malt

Malt handling

Cleaning

• Dust removal

• Grading screener

• Destoner

• Magnetic separator

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Mechanical transport systems

Mechanic transporter• Horizontal

- Conveyor- Belt- Redler

• Vertical

- Elevator

Start up of the transport system• Acoustic start up warning• Delayed against production

direction

Stop of transport system• Delayed in production

direction

Reference: www.uni-hohenheim.de

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Pneumatic transporter

Suction plant Compressed air plant

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Dust removal plant

• Danger of dust explosion

• Separates dust

• Dust will be filled into collection bags

Grading screener

• Separates impurities

Destoner

• Stones can permanently damage the crushing rollers!

Cleaning

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Weighing of malt

Tipping weighing machine Electronic balance on load cells

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Malt and adjunct handling delivered

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Rice handling

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During mashing the enzymes must be able to access all of the malt contents in order to degrade them from starches to fermentable sugars

For this the malt must be broken into smaller pieces by milling

The required amount of malt for one brew is called the grist

Milling is a mechanical breaking process of the malt/adjuncts

Before milling the malt must be cleaned

The needed amount of grist will be weight by a mechanical weighing device (dump hopper) or electronic weighing cells

Milling of malt

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Conditioning = humidify the husk with water or steam

Wet milling = the complete kernel content will be saturated while passing the crushing rollers (squeezing the malt kernels), husks are kept flexible and are intact in larger pieces – makes for a better lauter filter bed

Dry milling Wet milling

Grist mill

Hammer mill

(only for mash filter)

Two Roller mill

Four Roller mill

Five Roller mill

Six Roller mill Two Roller mill

Four Roller mill

With or without conditioning

Milling of malt

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Technology of Beer Production turned into Technical SolutionProcess Technology

Steinecker Variomill

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High yield• Get access to the valuable substances of the corn extract

High husk volume• Gentle treatment of the husk for optimal lautering conditions• Trouble-free lautering process• Clear wort• High brewing cycle

Demands contrary process • Intensive milling versus gentle crushing

Objectives of Milling Process

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Conditioned elastic husk• Optimal lautering

Dry and friable endosperm• Optimal milling results• High yield

How can Both Objectives be Achieved with Variomill?

husk

endosperm

1. addition of water

2. water absorption contact time controlled

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Considering the technological demands malt hopper

continuous steep

upper part of mill

lower part of mill

Technical Solutions

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Continuous mash quality even when quality of raw material changes

Top feed roller controls steeping time

Upper feed roller controls mill performance

Product Quality

steeping liquorcontinuous level measuring

malt

steeped malt

steeping time I

longer than

steeping time II

level I

tI

level II

tII

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Taking care about sensitiveness to

oxygen pick up

Mashing in water supplied to the homogenisation chamber via spraying system

Grist gets in contact with mashing liquor directly underneath the rollers

mashing liquor

mashing liquor

mash to mash vessel

Product Quality

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Gentle conveying of homogeneous

mash

Subject:Transfer of even high gravity mash without clumps

Solution:Low sheer force centrifugal pump with inducer

Advantages: Best condition for enzymes work, fast saccharafication leads to high yield

Product Quality

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Operational Safety

Grist capacity control, optimised product quality at nominal capacity

Subject:Raw material varies in flow properties impact on mass flow

Solution :Grist capacity control

Advantages: • Constant milling

process• Homogeneous mash

quality• Optimal utilisation of

roller life

motor

performance control

motor

motor

motorcapacity

speed control

Level indicator

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Automatic Milling gapadjustment

Easy to install in case of upgrades

Installed at operation floor

Adjunct milling possible

Flexibility

Crushing rollersbearing

Excenter milling gap adjustment

Drive for roller adjustment

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Variomill Controlled and Economical Operation

Product quality Controlled steeping

Moistened, elastic husk but dry corn

high yield, clear lauter wort and high brewing cycle

Operational safety Performance control

Optimal load to crushing rollers

homogeneous mash and long life of rollers

Flexibility One plant for entire process step

Investment for various applications, no additional constructions works, easy to install in

case of upgrades

Running costs Economical operation

Low electrical consumption, less spare parts, long life of rollers

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90

Mashing

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Dissolved malt ingredients are getting hydrated

Undissolved parts will be liquefied by: • Enzymes• Temperatures • Boiling

Enzymes are responsible for:• Degradation of starch• Degradation of proteins• Degradation of beta-glucans

All dissolved substances are called extract, expressed in % original extract (g / 100 g )e.g.: 11,3 % means, in 100 g solution contains 11,3 g extract

What happens during mashing?

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Grist: total amount of the weight of malt and adjuncts needed for one brew

Mash water: required amount of water for mashing in(to get the first wort)

Sparging: amount of water needed to wash out the residual extract in the spent grains

Mash: grist and mash water

Mashing in: mixing of the grist with mash water

Second mashing: transfer of boiled part of mash to the main mash

Final mash pumping: end of mashing and transfer to the lauter tun

Some technical terms

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Property of enzymes is their action in breaking chemical bonds of a substrate

Enzyme + Substrate → Enzyme-Substrate complex → Enzyme + Product

Enzymes are effect- and substrate specified Amylases can only degrade starch and never protein• Activity depends on

- Temperature- pH- Substrate composition

• They will be inactivated by- Heat- Mechanical forces - And missing activators (inorganic material, amino acids)

Enzymes - Biocatalyst

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Enzyme Substrate Enzyme-Substrate-Complex

Products

Key-Lock-Principle

unsolved materials of grist

solved materials (extract)

enzymatic activity

Temperature, water, pH, time, concentration

Starch

High molecular weight proteins

Cellulose

Glucans

Sugar

Special proteins

Inorganic substances

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Structure of starch

Malt starch is a polysaccharide (poly = many), which means that it is formed by many monosaccharides (mono = one)

Because of the fact that yeast can ferment only mono-, di- and trisaccharides, the carbohydrates in starch has to be degraded to sugars• Monosccaharide (Glucose) Start up sugar• Disaccharide (Maltose) Main fermenting sugar• Trisaccharide (Maltotriose) Post fermenting sugar

Starch can be divided in two groups, which are different in it‘s chemical structure and characteristics

Starch Percentage

Structure Connection /Linkage

Amylose 20 – 25 % Unbranched α-1,4

Amylopectin

75 – 80 % Branched α-1,4 and α-1,6

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α-Amylase

• Endo enzyme

• Breaks 1,4-connections

• Temperature optimum: 70 – 75 °C

• pH optimum: 5,6 – 5,8

• Inactivation: > 80 °C

Dextrins

• Breaks 1,4- and 1,6-connections


• pH optimum: 5,1


Starch degrading enzymes

β-Amylase

• Exo enzyme

• Breaks 1,4-connections


• pH optimum: 5,4 – 5,6


Maltase


• pH optimum: 6,0

Saccharins

• Temperature optimum: 50 °C

• pH optimum: 5,5

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The break down (degradation) of starch takes place in 3 steps. The chronological order is unchangeable, but are connected to one another:

I. Gelantisation• Swelling and bursting of the kernels in hot water (60 °C)

• This is NOT an enzymatic action

• In this step the mash becomes more viscous

• For saccharification, the starch must be gelatinised

• Now the enzymes can start to take effect breaking down the starches

Starch degradation – I. Gelantisation

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II. Liquefaction• The long chains composed of glucose in starch are very rapidly

broken open to form smaller chains by α-amylase

• This causes a very rapid reduction of the viscosity of the gelantinised mash

• β-amylase can only slowly degrade the long chains from the non-reducing end

Starch degradation – II. Liquefaction

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III. Saccharification

• α-amylase breaks down the long starch chains to smaller dextrins

• It acts optimally at 72 to 75 °C and is rapidly destroyed at 80 °C; the optimum pH is 5,6 to 5,8

• β-amylase splits maltose off from the non-reducing end of the chains, but it also produces glucose and maltotriose

• It acts optimally at 60 to 65 °C and is very sensitive to higher temperatures. It is inactivated even at 70 °C. The optimum pH is 5,4 to 5,5

• Starch breakdown must be monitored because residues of undegraded starch and larger dextrins cause starch hazes in beer

Starch degradation – III. Saccharifiction

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pH of mash and/or wort is very important for brewing operations

Normal pH 5,6–5,9 Optimal pH:

• Mash pH : 5,4–5,6

• Wort pH : 5,1–5,2 Adjustment of pH:

• Reduction of carbonate hardness

• Burtonization of brew water (CaCl2/CaSO4)

• Acid malt

• Biological acidification (lactic acid)

• Technical lactic acid or mineral acids (does not conform to the German purity law)

Effect of pH

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Advantages of an optimal pH

Optimization and shortening of mashing times

• Better extract solution

• More fermentable sugars

• Higher final attenuation

• Low colouration

• Lowering of viscosity

• Good protein solution

Better fermentations

Smoother bitterness (beer taste)

Disadvantage

• Lower yield of bitter substance

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Effect of temperature on starch degradation

Long maltose rest

Forms a lot of fermentable extract

Production of beer with

high low

Alcohol content

Short maltose rest

Longer saccharification rest . a lot of dextrins

Control of starch degradation

• Iodine test (high molecular starch close in iodine molecules and effects a blue or black colouring)

• Determination of sugar spectrum by HPLC

• Determination of final attenuation

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Depends on:

• Malt quality

• Beer type

• Brew house equipment

• Adjuncts

Depending on the way in which the temperature is raised, mashing processes are classified into two types:• Infusion process• Decoction process (boiling of part mash)

- Single mash process- Two mash process- Three mash process

Reasons for different mashing processes

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Practice of mashing

Rest temperature

Name of rest active Enzyme

Effect in mash

35 – 45 °C β-glucan rest β-glucanase Viscosity reduction

45 – 50 °C Protein rest Peptidase Amino acid formation

62 – 65 °C Maltose rest β-amylase Maltose formation

72 – 75 °C Saccharification rest

α-amylase Dextrin formation

76 – 78 °C Final mash pumping temperature

α-amylase keeps active, post saccharification

Correlation mash water vs. total grist:

• Pale beers 4-5,0 hl/100 kg grist fast enzyme reactions

• Dark beers 3-3,5 hl/100 kg grist slower enzyme reaction, more dextrin, increased

caramelized aroma substances

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The total mash is heated with rests (steps) being used at temperatures determined by the enzyme properties

Advantage versus decoction process

• softer and pale beers

• lower energy

• easier process

• lower risk of oxidation (no additional pumping)

• only one mash vessel necessary

Infusion process

min

°C

30 60 90 120 150 18030

40

50

60

70

80

Mashing in at 50 °C

min

°C

30 60 90 120 150 18030

40

50

60

70

80

Mashing in at 35 °C

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A part mash will be boiled then pumped back to the main mash; the main mash temp. increases. Depending on the amount of part mashes (three-, two- and single mash process may occur)

Advantages versus infusion process

• more characteristic beers

• useful for poorly dissolved malt

• forced formation of melanoidins

• higher brew house yield

Decoction process

°C

30 60 90 120 150 180 min30

40

50

60

70

80

90

100boiling

part mash

main mash

Part mash . 100 °C a lot of starch less enzymes

Main mash 63 °C 73 °C less starch a lot of enzymes

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Rice starch gelantises from 85 °C and has to be boiled (decoction process)

Mostly with addition of a part of the malt mash (α-amylase of malt required to degrade the rice starch)

Mash process with rice

min

°C

30 60 90 120 150 180 210 24030

40

50

60

70

80

90

100

rice mash

boilingboiling

part mash

main mash

Cereal cooker

Rice mash (with malt)

Mash tun

Malt mash

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Process technic

ShakesBeer – the new mash system

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Tasks of mash process

Best possible mixing of grist and mash water

The desired ingredients of malt shall be dissolved optimally

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Targets of mash process

Guide target:

High yield

Fast transformations

Low energy

Optimally wort composition• Faster lautering• Faster fermentation• Good yeast sedimentation• Good beer filterability• Longer beer stability

Qualitative targets:

Low difference between AV° to EV°

Pale colour

High reduction potential of the beer

High taste stability

Low fermentation by-products

Low concentrations of DMS, fatty acids and carbonyls

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Conical form of bottom• Enhances turbulence• Faster and more homogeneous

mixing• Smallest part mashes possible

Heating zone• Reduction of fouling• Longer standing times• Increase in product quality

Agitator• Low shear forces and more

effective mixing • Lower oxygenation of mash

Geometry of vessel bottom

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Bottom and cylinder heating zone with agitator (classic system)

Requirements on heating zones

Good thermal conductivity (higher k-value)

Homogeneous and even heat distribution

Faster heating rates

Low fouling potential

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The heating zone contains an inner lying (Dimple Plates) Due to this design:

New design of heating zones

Lower steam pressures, steam temperatures and interface temperatures are needed

This results in reduced energy requirements and thus, savings

Micro turbulences improve mixing and because of this, there is quicker mash substance transformation

Reduced fouling and longer CIP intervals

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Heating zone (Dimple Plates)

MashLowinterface temperature

Micro turbulences

Profile of the ShakesBeer-tun

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k =

1

MashCNS

CNSΣ

αl

1

α

1++

s

Steam

Heat transition coefficient k:

= k*A*ΔT

Heat transfer :Q

Q

Improved Heat Transfer

A greater heat transition coefficient k means a better heat transfer and, consequently, more heat output

Turbulent mash movement results in a high heat transfer coefficient αmash and, consequently, an increased heat transition coefficient k

Heat transfer is directly associated with the mash movement

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Improved heat transfer

Significantly higher heat transition coefficient k

Higher heating rate with the same steam pressure and/or steam temperature

Constant heating process throughout the production week

Heat transition and heating rates

0

500

1000

1500

2000

2500

k-va

lue

W/m

²*K

0

1

2

3

Hea

ting

rate

°K

/ m

in

k-Wert klassisch k-Wert Dimple Plates

Heizrate klassisch Heizrate Dimple Plates

k-value classic k-valueHeating rateclassic Heat. r.

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Advantages of ShakesBeer

Product quality

Reduced energy consumption

Reduced mashing time

Flexibility

• Better mixing• Less fouling• Gentle heating of the mash• Higher enzyme potential• Better substrate transformation

• Heating up of very concentrated mash is possible = low mash volume

• Better heat capacity• Lower heating medium temperature• Lower condensate temperatures

• Faster heat up• Faster and better homogenization• Faster substrate transformation

• Independent of the type and concentration of mash

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125

Lautering

126


126

Mash is a mixing of

• Solved materials (wort) → consists extract

• Unsolved materials (spent grains) → consists husk and germs

Lautering is the separation of wort from the spent grains

Only wort is used for beer production, spent grains will be disposed(animal feed)

There are two different lauter systems:• Lauter tun• Mash filter

What happens during lautering?

127


Target of lautering:

• Production of high quality wort with minimised rest wort extract in the spent grains

The husks of malt form a natural filter layer through which the wort flows

The process of lautering is divided into two sections:

Expiry of the first wort:

Dissolved substances running out

• Elution of the spent grains (sparging)

• Elution of the spent grains by second worts to an extract of 0,8 - 2 % (last runnings concentration)

Lautering

128


Storing the mash into the lauter tun is called final mash pumping. In order to reduce the oxygen content the mash is filled carefully from the bottom.

The insoluble parts of the mash are settling down first. They create a natural filter layer.

In order to improve the properties of the filter layer the drains are opened and the wort is pumped into a circle until it is clear enough.

When the aimed turbidity content is reached the clear wort is transferred into the cooking unit or into a pre run vessel.

This process usually takes between 45 to 75 minutes.

Lautering with lauter tun

M

from mash tun

to wort kettle

lauterin

g

129


The lautering process is faster when the wort is diluted and hot (max. 78 °C) Lower viscosity

Since there is still extract left in the spend grain it is washed out with hot water. This process is called sparging. The spend waters called second worts. The process usually takes between 45 till 75 minutes.

The process has to be suited to the product. If too much water is used the husks are bleached out and the colour and flavour of the wort is effected negatively. In case of too less water usage too much extract is left in the spent grains (costs…)

Normally 4 to 5 hl are used per 1000kg grains

The last second wort is called „last runnigs“ (The extract content is between 0,8 up to 2,0 %)

Lautering with lauter tun

M

from mash tun

to wort kettle

lauterin

g

130


The lauter tun is shaped roundly. Above the tank bottom a second filter bottom consisting of diverse segments is installed. The space between the bottoms is approximately 1 cm. In addition a cutting and racking device is installed.

The wort is discharged by a variety of drains.

Construction of the lauter tun

131


The cutting device is adjustable in height

The shape of the knives are responsible for the extract content in the spent grains

In addition a spend grain trap is installed into the filter bottom

Cutting and racking device

132


Goal:• Used for a homogenous dispersions of

the wort

• Racking the spend grain mass to assure a constant wort flow (computer controlled)

• For a homogenous elution of spent grains

• Responsible for spend grain removal

Cutting and racking device

133


The collected clear wort between the bottoms is discharged through the drains

In a classical mash tun there is only one drain per square meter

The Pegasus system has nearly twice as much drains (1,6 per m2)

The drains have to be installed in a way so that there won't be a suction effect. Otherwise the spent grain mass is compressed and the flow rate decreases

The arrangement of the drains is also important for a homogenous elution of the spent grains

Run-off openings

0.6

1.0

0.8 0.8

0.7 0.6

0.5 0.6

136

Technology of Beer Production turned into Technical SolutionProcess Technology

Lauter Technology System Pegasus

136

137


Tasks: Separation of liquid phase (= wort) from solid contents (= spent grains)

of the mash.This process can be split up to two steps:

• Draw-off first wort• Elution of spent grains (= second wort)

Influence to:• Yield• Fermentation• Filtration• Taste• Stability of beer

Tasks and influences of lautering

138


Objectives of lautering

Fast and complete lautering

Economic obtaining of extract

Maximum extract yield

Clear wort

High quality wort

Time-saving

Obtaining a high quality wort with maximum extract yield

140


Shaft guide

Central arrangement of instruments

Shaft guide above wort level – no contact with product service-reduced construction

Level probe installed in the conus

Easy access for maintenance works

Central conus

142


Lauter system

Ring-shaped lauter surface

Even formation of filter bed

Flow-optimized lautering process with ring-shaped lauter surface for homogeneous wort discharge

High load of false bottom possible =>savings re. vessel-size

Ideal for production of high-gravity-brews

143


Flow-optimised run-off sources

Up to two run-off-ports per m² lauter surface

Identic tap pipes with a flow-optimized inlet conus

• even flow-speeds

• even „elution“ of filter-cake in the whole filter area

• no punctual eddy-effect to filter-cake at the area of inlet cones

Lauter wort collecting pipe

• Increased lautering speed

• Increased extract yield

Lauter system

144


New design of raking device

Adjustment to higher demands

Combination of straight- and „zigzag“-knifes

Optimal raking effect

Especially designed spent grains knifes at raking arms

effective and fast spent grains discharge out from the vessel

145


Pegasus: Our Solution – Your Advantage!

Product quality

Maintenance- and operational costs

Flexibility

Production safety

146


Advantages of Pegasus realised at

Hyderabad Lautertun

147


Product Quality

Optimized obtaining of extract

High extract yield

Elutable extract in the spent grains very low (less or equal 0,5 %)

Low weak wort concentration possible

Higher extract yield with less sparging water because of fast extract decrease kettle full amount hl/100 kg

malt

0

5

10

15

20

0 1 2 3 4 5 6 7

extr

act

°P

PEGASUS

conventional lauter tun

148


Leipzig as an example for optimized obtaining of extract –

Pegasus vs. old lautering system

Technical data „Pegasus“

Volume: 423 hl

Diameter: 7,000mm

Area: 35.3 m2

False bottom load with grist of 7000 kg: 199.5kg/m2

Product Quality

149


Leipzig as an example for optimized obtaining of extract – Pegasus vs. old lautering system

Flutable extract [%]

Digestible extract [%]

Spent grains water content [%]

Total occupation time in min.

Turbidity in EBC

Brews per day

Old lautering system

1,6

0,5

79,0

170

—

8,45

Pegasus®

0,5

0,5

78,8

117

< 20 for 65 % of lautering time

12,3

Product Quality

151


Production Safety

Independent from grist system

High brewing cycles possible (up to 14 brews per days)

Fully automatic process for production and CIP

Reliability because of intelligent construction

service-reduced

154


The Advantages at a Glance

Highest product quality because of:optimized obtaining of extract obtaining of high quality worts with maximum extract yield

Maximum production safety because of:fully-automatized process and reliable, service-reduced construction

High flexibility because of:flexible grist amounts and selection of raw material

Lowest maintenance- and operational costs because of:service-reduced construction, low spare parts inventory and –costs, low cleaning costs

155


Further plants required for

discharge, extract recovery and

capacity reasons

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156

Wort Boiling

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157

The lautered wort will be boiled between 50 and 90 min (with Stromboli 60 min); during this time the hops are added.

• The total amount of lautered/filtered wort before boiling is called „full-kettle-wort“, the wort after boiling is called „cast out wort“

During wort boiling several processes take place:• Sterilization of wort• Evaporation of water (3-4 % total evaporation)• Deactivation of enzyme reactions• Solution and isomerisation of hop substances• Colouring of wort• Coagulation of proteins• Evaporation of negative aroma substances (DMS)

Wort boiling

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158

Solution and isomerisation of hop substances

Hops are added to the boiling wort to give a bitter taste (to offset the sweetness of the sugars from malts) and give a desired hop flavour

Hops will aid in the precipitation of protein and aid as a preservative The bitter substance losses until finished beer are approximately 65 -

70 % The addition/s will be calculated in amount of α-acid. The times and

amounts depend on the beer type being brewed The longer boiling takes place, the more the hops will be isomerisized Hop oils are very volatile at higher temperatures Typical hop additition for a Pils:

Hops addition

Partition of α-acid

dosing

Moment Hops products

I 50 % 10 min after start boiling Bitter hops Extract

II 35 % 30 min after start boiling Bitter hops Aroma hops

Extract Pellets

III 15 % 5 min before cast out Aroma hops

Pellets

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159

Sterilization of wort

• Bacteria from malt dust can get into the mash (→ acid beer)

• Bacteria are killed after 15 min of boiling

• Wort is a good nutrition medium for bacteria because it contains sugar, amino acids, vitamins and inorganic substances

• The antiseptic effect of hops and the low pH aid in avoiding contamination

Deactivation of enzymes

• Helps to define the composition of the wort; if enzyme action continues then the wort profile will be changed

• Enzymes are destroyed by high temperatures (boiling)

Sterilization of wort / Deactivation of enzymes

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160

Evaporation of volatile substances from malt and hops (products of melanoidin reaction, hops oil, sulphur compounds, aldehyde, and fats)

• Guide parameter is dimethylsulfide (DMS)

- An easily volatile sulphur compound of malt

- After splitting of DMS-Precursors, DMS is set free

- Effects an unwanted taste in beer (vegetable like aromas)

- Taste threshold: 50-60 g DMS/l (to 100 g, according to the beer type)

- The longer and more intensive the boiling is the more DMS-P will be split in DMS and evaporated

- Use of DMS-P poor malt

Evaporation of unwanted flavours

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161

To adjust the wort concentration water must evaporate

• The amount of concentration is adjusted according to the beer type

(high concentration → too much alcohol)

Much energy → high evaporation• Dimension of evaporation:

- Evaporation rate shows how much % full-kettle amount per hl has evaporated

Precise heating energy =Decreased energy costs• Better product quality• Energy recovering should be done

Evaporation of water

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162

Compounds of

• Proteins and tannins

• Insoluble bonds = clumps

The clumps which are formed during boiling are called hot break

These protein clumps should be taken out completely

Good break formation can be achieved by:• Longer boiling time• Intensive movement of boiling wort• Lower pH (optimum 5,0 - 5,2)

Target: approx. 2-3 mg coaguable, nitrogen containing substances /100 ml wort

Coagulation of protein

Context:• Low koag-N in cast-out

wort:- Low risk of cold

haze- Bad beer foam

171


171

Prozesstechnik

Boiling SystemStromboli

171

172


172

Reduced evaporation

Improved evaporation of DMS

Less negative influence on foam positive proteins

Lower thermal loads (low TBZ-increase)

Requirements to modern wort boiling systems

173


173

Forced fusion of DMS and coag. N.

Destruction of foam positive substances by pulsating during heat up

Strong thermal load on wort

High costs and environmental load by high evaporation and frequent cleanings

Problems of classical internal boiler

Condensate

Steam

Wort

174


174

Points of temperature measurement in internal boiler kettle

175


175

Separation and adjustment of coag. N and DMS-content means „out stinking“ of flavours and spared treatment of foam positive proteins at the same time is possible

Homogenisation of wort without heating is possible due to enhanced circulation effect

What Stromboli can…

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176

Flows and mixing in Stromboli

Aroma control

Jet pumpDirection shield

Protein control

Defined circulation

Frequency controlled pump

177


177

Wort baffle plate

The jet pump – „heart“ of Stromboli

Jet pump

178


178

Classical internal boiler Stromboli Stromboli 3D

Reconstruction of a classical internal boiler

179


179

Boiling phase 1: Intensive driving off of unwanted compounds and aromas, break down of coag. N

Boiling pause: Splitting of DMS-P, only low energy, intensive „moving“ and „hot holding“ of wort

Boiling phase 2: Again intensive removal free DMS

Principle of boiling

180


180

Circulation with Stromboli

181


181

Fouling in heating tubes

Normal boiler after 8 brews without

forced circulation

Stromboli

after 40 brews

182


182

Environment protection

Significant reduced primary energy requirement

Less exhaust gases (CO2 , CO, NOx, SOx etc.)

Reduction of fresh water consumption and waste water

Reduction of cleaning medium (CIP) demand

Stromboli reduces the total evaporation at the internal boiler to 3 - 3,5 %

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183

Comparison in evaporation ratesStromboli - conventional boiling

2

3

4

5

6

7

8

%

Stromboli

Conventional internal boiler

184


184

Reduction of DMS and DMS-P Stromboli - conventional boiling

DMSPDMS

Stromboli

Internal boiler

Full kettle60 min boiling timeStromboli 266 62Internal boiler 288 78

Full kettle60 min boiling timeStromboli 231 12Internal boiler 223 13

92

92,5

93

93,5

94

94,5

95

95,5

Red

ucti

on

in

%

71

72

73

74

75

76

77

Red

ucti

on

in

%

186


186

0

10

20

30

40

50

60

Full kettle 60 min boiling time TBZ

Comparation TBZ Stromboli - conventional boiling

Full kettle60 min boiling timeStromboli 34,0 48,0Internal boiler 23,8 43,5

TBZ14,019,7

Stromboli

Internal boiler

187


187

Comparation foam points by LG Foamtester Stromboli - conventional boiling

Stromboli

Internal boiler

100

105

110

115

120

125

130

135

140

Type: Pils

100

105

110

115

120

125

130

135

140

Type: Pale

190


190

Low cleaning costs (no interruption of production process because of intermediate cleanings)

Fully automatic process for CIP and production

Consistent energy requirements and consumption

Consistent evaporation rates

Production security

195


196


Increase of TBN during boiling < 15

Increased flavour stability of beer

Coagulable nitrogen adjustable

Improvement of beer foam stability

Efficient evaporation of undesirable flavours

DMS end of boiling < 20

Homogeneous wort treatment

Enormous savings in water, cleaning agents and - time, up to 80 %

Increased productivity of Wort kettle, up to 5 %

Easy retrofit table

No pressure kettle needed

Conclusion

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197

The word handling after boiling is also called the „wort way“

The wort way is divided in different steps:• Cast out of wort• Separation of hot trub• Wort cooling• Wort aeration• Cold trub separation (if desired)• Yeast dosing

Wort treatment after boiling

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198

Wort transfer to next vessel, e.g. hot wort tank, is called „cast out“

What is hot trub?• Removal of coarse break• Consists of:

- 50-60 % Proteins- 15-20 % Bitter substances- 20 % Tannins - 5 % Ash

• Influence of hot trub- Coats the yeast- Reduces stability of the beer

Cast out of wort

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199

For removal following vessels can be used:• Cool ship (old)• Settling tank / Hot wort tank• Whirlpool / Whirlpool kettle• Centrifuge• Filtration

Whirlpool• Classical sedimentation process• Tangential inlet of wort (with max. 4 m/s)• Centrifugal forces form a trub cone• Lateral wort outlets at different heights

Removal of hot trub

Tangential inlet

Outlets

200


200

Hot wort tank – Sedimentation tank

Stromboli

Wort cooler

Trub tank

Turbidity measurement

201


201

Wort will be cooled down to „pitching temperature“ by a plate cooler• The plate exchanger

consists of a large number of thin metal plates

• Arranged behind one another, between which wort and cold water flow alternately

• Heat exchange: cold to hot water, hot to cold wort

Below 60 °C the previously clear wort starts to become turbid. This turbidity is called „cold trub“.

Wort cooling

202


202

Single-stageIce water at 1 to 2 °C is heated in the plate heat exchanger to 80 to 88 °C whilst hort wort at 95 to 98 °C is cooled to pitching temperature

Plate heat exchanger

6-8 °C

1-2 °C

95-98 °C

85-88 °C

6-8 °C

10-15 °C95-98 °C

85-88 °C

+1-2 °C

Precooling Deep cooling

Ice water tank

Two-stageIn the larger precooling section the wort transfers heat to cold process water. Whilst the wort is cooled to about 16 to 18 °C, the cold water is heated to about 80 to 88 °C. In the smaller low temperature section the wort is cooled by ice water at 1 to 2 °C to the desired pitching temperature.

WortIce water

Brew water

Wort

203


203

Water house – Brew water supply

Warmwater

Coldwater

Icewater

Glycol

Steam

Wort cooler

Cold water supply

Brew house / CellarCIP

Wort cooler

204


The aeration of cold wort is the only time during the entire beer production process that oxygen is deliberately added

Yeast needs oxygen to multiply The oxygen is taken up by the yeast within a few hours and does not

damage the wort quality To dissolve the air in cold wort the air must be injected as very small

bubbles and turbulently mixed with the cold wort. An oxygen content of 8 to 9 mg/l is aimed for

204

Wort aeration

205


205

Below 60 °C clear wort becomes turbid;this turbidity consists of:• 60-70 % Proteins • 20 % Tannins

Removal by:• Sedimentation• Centrifuge• Filtration• Flotation (mostly used with air bubbles)

Removal of cold trub

206


206

Raw Material

Yeast

207


207

Unicellular eukaryotic microorganisms

The yeast cell is oval to round with a length of 3,5-8,0 x 5,0-7,5 µm

Reproduction by budding

The brewing industry differs in

• Culture yeast (only these are used for beer processing)

• Foreign yeast (bakers yeast, wine yeast)

Division of culture yeast in:

• Bottom fermenting yeast

• Top fermenting yeast

Yeast

Saccharomyces carlsbergensis

Saccharomyces cerevisiae

212


212

Yeasts normally reproduces by budding.

During budding a small bubble like protuberance from the mother cell is formed into part of the cytoplasm as well as a daughter nucleus, formed by division, passes.

In some yeast strains, the mother and the daughter cells separate from one another completely as a result of which bud scars remain on the mother cell.

In other strains, the cells remain connected to one another and form chains.

The growth is divided into phases:

• Latent or lag phase: takes some hours, activation of metabolism

• Log or exponential phase: growth rate is constant and maximal

• Declining phase: rate of cell death exceeds the rate of new cell formation

Yeast works to 30 °C, above 40 °C will de deactivated, low temperatures clam the yeast but will not kill it.

Yeast multiplication

213


213

Propagation and Storage of

Yeast

214


214

Yeast has a large influence on the character of beer

• That is the reason why each brewery has its own yeast strain

• For beer production only pure culture yeast is used

• The best qualified and strongest yeast will be isolated and multiplicated as long as the amount for pitching is enough

Pure culture yeast

• Will be stored in the laboratory

• Bought from other breweries or yeast supply laboratories

• Stored and sold in yeast library

Breweries buy yeast in form of:

• Agar slant culture

• Dry yeast

• Liquid yeast

Yeast strain / Pure culture yeast

215


215

The pure yeast cultivation is also called yeast propagation

• Multiplication of yeast from one cell to pitching amount

Steps of propagation:

• Harvest of qualified yeast cell

• Cultivation in laboratory

• Propagation in yeast cellar to pitching amount

Yeast has two metabolisms

• With oxygen aerobic metabolism → multiplication of yeast cells

• Without oxygen anaerobic metabolism → fermentation

Under continuous addition of nutrients (wort) and oxygen (aeration) the yeast multiplies and grows in numbers

Sterile conditions are essential

Controlling parameters: cell concentration and amount

Yeast propagation

216


216

Agar slant culture

vaccination ring10 ml

liquid yeast1 l

liquid yeast

100 ml sterile wortstart fermenting at room temperature

1 l sterile wortfermenting at 18 °C

5 l sterile wortfermenting at 14 – 15 °C

Carlsberg-flask

25 l sterile wortfermenting at 12 – 14 °C

Yeast cultivation

lag phase

log phase PROPAGATION PHASE

lag phaseadaption phase

log phaseexponential phase

stag phasestationary phase

declining phase

217


217

Pure yeast cultivation

The multiplication of pure cultivated yeast takes place in the propagator

• Flexible temperature control by tank cooling

• Continuous circulation of the yeast-wort-mixture with air injection

• Defined wort additions in desired multiplication phase

A wort sterilizer increases the flexibility of propagation

• Independent of brew house

• Has heating and cooling zones

218


218

Propagation plant

Sterile air

Sterile air

Steam

Glycol

Wort To wort line

CIP

Condensate

PropagatorSterilizer

219


219

Propagation plant

220


220

At the end of fermentation the yeast goes to:

• The bottom of the tank (bottom fermenting yeast)

• The beer surface (top fermenting yeast)

Collection of yeast called „Yeast harvest“

Treatment after the harvest:

• Harvested yeast can be aerated (separation of CO2) and immediately dosed into the next brew

• Before next pitching, yeast is often washed through a sieve (separation of tannins and bitter substances) to rinse substances that coat the yeast and may interfere with yeast metabolism

• Stored in cooled vessels

Amount of cycles yeast can be used:

• Biology, activity, degeneration

- Bottom yeast up to 8 cycles

- Top fermenting yeast more

Yeast storage

221


221

Intermediate storage of harvested yeast until the next use under optimal conditions

• Cooled storage tanks

• Vitalisation of yeast by controlled aeration and circulation

• Possible to add wort for activation of yeast

Yeast storage

222


222

Yeast storage

223


223

Yeast washing means always:

• Biological risk

• Attenuation of the yeast

Yeast storage

• Always inconvenient; should be as short as possible

• As cold as possible (to reduce the yeast activity)

• Longer storage only under wort (preferred) or beer

• Storage under water is not recommended

• Yeast can be vitalized before pitching

(addition of wort and aeration)

Risks of yeast washing and storage

224


224

Planned out concept to ensure steady beer production

• Preparation of the needed amount of biologically faultless and vital cultured yeast

• Vitalisation of harvested yeast

• Economical exploitation of waste yeast with possibility of beer recovering or yeast drying

• Biological faultless cleaning; no protruding instrumentation in tank

• Additional hygienic security by special cleaning philosophies and regimens

Yeast management

225


225

Air Injector

Circulation with Air Injector

• Smooth yeast aeration

• Problem-free upgrade

• Can be automated

• CIP able/sterilisation with steam

Sterile air

Wort-Yeast-Mix

226


226

Maximal flexibility by variable circulation cycles and aeration intervals

Guarantee of thorough mixing of contents

Smooth product treatment

Biologically faultless cleaning

Can be automated

Advantages of circulation

227


227

Yeast managementCIP

Yeast cultivation

Yeast storage„Yeast tank“

Yeast handling„Waste yeast tank“

Yeast cooler

Yeast propagator

Wort sterilisation

Aeration for„multiplication“

Aeration for„Vitalisation“

Of stored yeast

Yeast drying Beer recovering

Yeast disposal

Residual beer

Circulation with„Air Injector“

„Yeast harvest“

„Pitching“

Fermentation

Storage cellar

-Separator

-Crossflow-Microfiltration

-High performance decanter

228


228

Fermentation and Maturation

229


229

The pitching of yeast to cold wort (cleared, cooled and aerated wort) the fermentation process begins.

Pitching ratio of yeast is about 0,5 – 1,0 l of yeast per hl of wort which generally corresponds to 15 – 30 millions yeast cells per ml wort

During fermentation, the yeast growth is up to three or four times.

Filling of a fermenting tank can be done by:• One filling cycle, tank is full after one batch• More filling cycles, i.e. several brews are pumped into the tank. Filling of a tank with more than one brew should not last

more than 16 hours.

Fermenting can be speed up with:• Higher yeast dosing ratio • Temperature • Aeration

Yeast pitching in wort

230


230

Fermentation

Start of fermentation by pitching vital yeast

Exact control of fermentation by temperature of fermenting vessel

• According to quality aspects

• According to fermentation procedure

• According to the intensity of fermentation

Control parameter of main fermentation

• Yeast cell count

• Degree of attenuation after fermentation

• Fermentation by-products

231


231

Degree of attenuation is to evaluate the fermentation

This value shows the amount of fermented extractin relation to the amount of extract of unfermentedcold wort.

For calculation of attenuation you need two values• Extract of wort before fermentation• Extract of green beer at sampling time

Degree of attenuation % = (extract before fermentation – extract of sample) x 100

extract before fermentation

This value is called apparent attenuation.

Degree of attenuation

232


232

Final attenuation (Vfinal)

• Is the highest apparent degree of attenuation which can be reached by fermentation of all fermentable materials in the extract

• It is predetermined by the action of starch degrading enzymes in the brewery and measured in the laboratory

Fermenting degree (Vferment)

• Shows the degree of attenuation of the green beer at the moment of transfer (pumping from fermenting to storage cellar)

• Normally 10 – 15 % below final attenuation

Limit attenuation (Vlimit)

• Is determined before the beer is filled into containers for sale

• The difference between Vfinal and Vlimit should be very small (max. 3 %)

• To guaranty a good stability and biological security

Definitions of attenuation degrees

233


233

Apparent attenuation degree• Extract of green beer at the moment of sampling

by spindling (without alcohol separation)

• The actual value is not exact because the alcohol changes the density and influences the result

- Easy handling- Neglect able, because of a systematic

error

Real attenuation degree• Removal of alcohol by heating• Elaborate method; only done in the laboratory

Difference apparent and real attenuation degree

~ 2,7~ 2,7~ 12,5 ~ 3,9

hosing outputfinal

attenuated

fermented extracts

fermentable extracts

unferment-able extracts

pitching

234


234

Classical cold fermentation (cold fermentation – cold maturation)

• Low by-products

Cold fermentation – warm maturation

• Low by-products

• Fast break down during maturation

Warm fermentation – warm maturation

• High by-products

• Fast break down

Pressure fermentation

• High temperatures, pressure inhibits yeast multiplication

low by-products

Methods of fermentation

236


236

From the moment that yeast is added to the wort, it is called green beer

Green beer is passes through following steps during fermentation:

• I. Creaming- Beer surface is covered with a white sheet of fine

bubble foam; Fermentation has started

• II. Young heads- This fine foam is getting higher and brown on the top

(Main-) Fermentation

237


237

• III. High heads- The heads are getting higher with bigger bubbles; most

intensive step – high extract break down ( 1,5-2,3 °P per day )

• IV. Brown heads- Intensity of fermentation is going back, heads are breaking

down and become more brown

• V. Ready for transfer- Heads keep on breaking down, surface brown

Fermentation

238


238

239


239

Start of post fermentation by lowering the temperature and yeast harvest

Exact control of post fermentation and maturation by process temperature and residual extract

• Bunging pressure

• Maturation time

• Fermentation intensity

Control parameter for post fermentation and maturation

• Attenuation limit

• By-products

• Clarification

• CO2-content

Maturation

240


240

Post fermentation and maturation take place in following steps:

Fermentation of remaining extract and break down of by-products

Enrichment of CO2

Natural clarification by sedimentation of yeast and other haze causing particles

Maturation of taste

Post fermentation and maturation

243


243

During maturation haze particles are settling out of the beer; the sludge formed from settling is called sediment

Maturation is performed cold (approx. –1,5 to + 2,0 °C) and lasts about 1 to 5 weeks

At this temperatures bitter substances settle out

The maturation process has a big influence on: • Taste• Foam stability• Chemical-physical stability

Clarification and maturation

244


244

Break down of sugar Protein compounds

• Break down of total nitrogen substances to about 20-25 %, • Amino acids are taken from yeast• High molecular N falls out aided by the fall in pH

pH-fall • Acid formation by yeast, from pH 5,2 to pH 4,4

Colour lightening • Direct correlation with pH fall • Fall out of tannins and melanoidins• Extraction of colour into the foam surface• Yeast cells absorb some of the colour

Reduction of bitter substances and tannins• Bitter substances are extracted by the pH movement, tannins

react with proteins to for protein-tannin complexes

Changes from wort to beer

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245

Building and enrichment of CO2 in beer

• CO2 washes weak volatiles out

• Inhibits certain germs

• Responsible for the sparkle and foam stability

• Is controlled through pressure and temperature

• Clarification• Sedimentation of yeast, undissolved protein and

tannins Building of by-products (will be partly broken down)

• By-products are intermediate or end products of yeast metabolism

• May have a positive or negative influence on the smell and taste of beer

• Negative taste components must be broken down during maturation

Changes from wort to beer

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Higher alcohols (fusel oils)

• Increased by

- Higher fermentation temperatures

- Stronger aeration of pitching wort

- Low yeast dosing Esters

• Important aroma substances in beer • Products of reactions with acid and alcohol • Yeast strain has a big influence• High yeast multiplication produces less esters

Sulphuric compounds; • Yeast metabolism produces volatile sulphuric compounds like

H2S

• These can be washed out by CO2

Vicinal diketone (VDK)

By-products

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256


256

High degree of automation

High investment costs

Maintenance demand

Risk of infections due to poor maintenance

Full automatic cellar

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258

All process steps are controlled automatically

Cellar has fixed piping system

Connects by double seat valves

• Automatic way preparation

• With feedback signals

• Leakage security

Absolute biological security;

no manual handling


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259

A compromise between hose and full automatic cellar

Lower Investments

Operator must be trained (hygiene / microbiology)

CIP-able

Variable degree of automation (initiators, pneumatic valves)

Semi automatic cellar with panel

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260


261


261

Control of tank cooling in automatic

Fixed piping system and panels

Connections by swing bends and pneumatic valves

• manual way preparation

• optional with feedback signals

Automatic program started by operator

But: No 100 % biological security,

because of manual handling


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267

How the ideal cellar looks?

Automation degree

• From manual to full automatic

Tank methods

• Classical or forced methods

Execution

• Periphery (cooling medium, tank- and cellar equipment

Construction method

• Construction kind and place

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Beer Filtration

276


Filter cellarMaturation

Filling hall

Bright beer tank

CIP

Rest beer

Rest beer

Rest beer

CO2

Additive dosing

PP-Tank

Separator

Mixing device

Beer cooler

Buffertank unfiltrate

KG-filter

PVPP-filter

Buffertank filtrate

Particle filter(Option)

Membrane filter(Option)

Blending Unit

Filter systems

KG-Handling

Post run

TFS K (Candle filter)FS 100-130 K(Horizontal filter)Sheet filter

Bag ripperBig Bag StationMixing stationDisposalDrying

TFS S (Candle filter)FS 100-130 S (Horizontal filter)

Trap filterGAF filter

Sirona

CarbonisingSterilisation

Degassing (DA Water)

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Filtration is a man-made clarification of beer which has to fulfil the following objects:• Removing of turbid substances

- Yeast- Hop resins- Proteins and polyphenolic substances

• Removing or reducing of substances which could cause turbidity (best-before date)

- Proteins - Polyphenols

• Removing of microorganisms - Yeast- Bacteria

• Brightness (→ customers request)• Sensory improvement (taste)

Beer filtration

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Precoat-filtration

• Candle filter

• Horizontal filter

• Kieselguhr frame filter

Crossflow-Filtration

Separator

Sheet filter

Module filter

Candle filter

Different types of beer filtration Filter aids for procoating:

• Kieselguhr

• Perlite

• Cellulose

• PVPP

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Surface filtration

• Particles are not able to penetrate the pores in the filter medium (micro sieve, membrane). They are restrained and this coating is becoming more and more thick.

• Filtration is becoming more and more capillary but the flow is decreasing more and more.

E.g.: Crossflow-membrane-filtration

Mechanisms of filtration

flow

rat

epressure (Δ p )

280


Deep bed filtration

• High porous filter aids with big surface and mazelike arrangement (e.g.: kieselguhr) force the liquid to go a long way through the filter cake.

There are two effects, mostly they appear in combination:

• Mechanical sieve effect

• Due to mazelike arrangement the sieve effect is caused, substances are restrained

• Adsorption

• Due to different charging substances are adsorbed

Mechanisms of filtration

flow

rate

pressure (Δ p)-

flow

rate

pressure (Δ p)

281


Beer filtration: Pore size 0,2 - 0,8 m

Siz

e c

on

trast

Meth

od

sP

art

icle

siz

e

[µm] 0,0001 0,001 0,01 0,1 1,0 10 1001000

= 1 nm = 1 µm= 1 mm

Micro filtration

Ultra filtration

Nano filtration

Reverse osmosis

Normal filtration

Centrifuges

Hydrozyclones

Oils / Fats

Metal-ions

Sand partiles

Salts

Colours

Proteins

HairColloidesSaccharidsViren

Bacteria

Yeast cells

Separation methods

282


Yeast cells

Bacteria

Filter fabrics

Kieselguhr (filter aid)

4-8 µm

fine mid coarse

2-10 µm10-20 µm 20-40 µm

1-4 µm

55 µm

Deep bed filtration

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Principle of precoat filtration

Kieselguhr is coated onto a support layer

• As layer is used:

- Candle

- Metal braid cloth

- Cellulose layer

- Gaps are at 50-80 µm

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Composition of Kieselguhr coatings (filter cake)

The first kieselguhr coating is directly put on the support layer, that there is a basic filtration coating and no kieselguhr can pass the support layer any more.

• 1. Precoating → with coarse kieselguhr

The second kieselguhr coating is put on the first one. This is for safety and to be able to filtrate the first incoming beer already

• 2. Precoating → with a mixture from more fine kieselguhr products

With kieselguhr dosing during filtration we keep the filter cake permeable

• The brilliance of filtration is determined by the proportion from coarse to mid to fine kieselguhr

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TFS filtration system

(Twin Flow System)

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Candle filter (TFS)

Filter candles are screwed on the register

Unfiltrate is running through the filter cake as filtrate into the candle to the collecting pipes

Low investment and maintenance costs in comparison to a horizontal filter

Controlled disposition of kieselguhr due to bypass flow of unfiltrate

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Targets for an efficient precoat filter

A perfect distribution of filter aids controlled via bypass flow

Independency from filter aid (kieselguhr, alternative filter aids, PVPP)

Significant reduction of water consumption

Increase of filtrate quality (biology, low O2-uptake)

Increase of filter cycles

Decrease of operation costs

Development of Twin Flow System (TFS)

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Conventional Candle filter

Head plate divides filtrate from unfiltrate area

Distribution of precoat kieselguhr is only going via unknown flow inside the filter vessel, no control possible

Irregular setup of kieselguhr coating along the candles

Irregular particle distribution from on top and bottom

Distributor at the entrance of unfiltrate is only a inadequate compensation #

filtrate

unfiltrate

top plate

kieselguhr distribution across filter surface by „vagabond flow“

filtrate area

blending paths begin at end of the candles and/or at the inlet

unfiltrate area

inlet distributor

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TFS filter

Register pipe work instead of head plate

Flow against filter areas is controlled via bypass flow of unfiltrate

Constant distribution of filter aid on bottom as well as on top: optimized filtration

Increase of cleaning efficiency of vessel and filter candles (sprayball!)

The whole vessel is unfiltrate area

filtrate

unfiltrate

bypassregister-piping

controlled distribution of kieselguhr by directed bypass-flow

adjustable partial flows = controlled filtration

unfiltrate area = whole vessel

292


Conventional candle filter TFS-filterbypass

V = VSink

filtrate

unfiltrate

V = 0 %

unfiltrate

filtrate

V = 100 %

V = 100 % + Vsink

293


Register

Bypass

Filtrate outlet

Inlet distributor

Inlet unfiltrate

Sprayball

TFS filter elements

Innovations at TFS filter

294


Register with 2 outlets

295


Register with 2 outlets - detailed

296


The filter element

Inner pipe for volume reduction and increase of stability of the filter element

Metallic seal and O-ring between element and register

Ringpipe for optimized flow and increase of backwash effect

filtration rinsing

297


Tests of precoat with filtrated beer and pushout with CO2

Berliner Kindl brewery: 400 hl/h 2400 mm long filter elementsafter precoat with filtrate beer

Sag after push out of the vessel with CO2 with maximum of trub volume

298


outlet

Bypass 0 %

Filtrate 0 %

inlet

0 %

Plant layout

299


Separation of first runnings via bypass

Minimum mixed phase, even with brand changes

300


bypass 12 %

filtrate 100 %

unfiltrate

112 %

filtrate

Filtration

About 12 % bypass flow

Depends on filter aid and filterability of unfiltrate beer

301


TFS: Our solution – Your advantage

Product quality

better turbidity results, less particles in filtrate, high biological safety and minimized oxygen uptake

Production safety

Easy backwash of TFS filter candles, no manual cleaning required, high operating reliability

FlexibilityUsage of various filter aids possible (kieselguhr, perlits, PVPP, alternative filter aids on basis of cellulose, starch or polymers) Specific adjustment of bypass flow = alternative filter aid!

302


Efficiency

• Up to 1/3 less rinsing water

• Up to 1/3 less precoating

• Up to 25 % less kieselguhr

consumption

• Reduction of waste kieselguhr

• Reduction of first and last runnings

• In average p 10 % better

• Longer filtration time possible

saving of 10 – 30 filtration cycles per

year!

TFS: Our solution – Your advantage

303


Unfiltrate

• Viscosity (β-glucan)

• Complex proteins

• Yeast cells per ml

• Gravity (residual extract)

Filtration technology

• Flow rate

• Build up of filter cake

• Process technology

Filter aid

• Porosity

• Mixture

Influencing factors for filtration

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312

Cleaning &

Disinfection

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313

Cleaning

• Removal of residues and deposits by way of mechanical or chemical means

• Generation of clean and sanitary surfaces

Disinfection

• Selective killing of pathogenic and other harmful microorganisms (MO’s) in piping and vessels so that the MO’s will not cause contaminations

• Avoiding of infection and destruction of unwanted microorganisms

Sterilisation

• Physical or chemical process which kills ALL microorganisms and spores

• Complete sterility

Definitions

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314

Acidic cleaning agents

• H2SO4, HNO3, H3PO4

• Used for removing of inorganic substances like scaling (minerals) and other deposits coming from water hardness

Neutral cleaning agents

• Ionic and non-ionic tensids and mixtures

• These are molecules with hydrophobic and hydrophilic in part

• They are used for removing of oils and fats

Alkaline cleaning agents

• NaOH, KOH

• They are used for removing organic substances like sugars, proteins and fats

Cleaning agents

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315

Considerations for object (surface) you want to clean

• Dirt

• Age of deposits

• Texture

• Sticking properties

Cleaning agent (e.g. acids for scaling)

Concentration of the cleaning agent

Contact time

Temperature

Cleaning procedure

• Mechanical

• Chemical

• Combined

Factors of influence on cleaning

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To get a better cleaning effect, cleaning agents often have additives:

• Complexing agents

- Softeners take away Ca and Mg

• Antifoam agents

• Avoiding of scaling

• Protection from corrosion

• Wetting agents

- Reduces surface tension

• Stabilizers

Additives of cleaning agents

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317

Contact phase

• Ingredients of the cleaning agents solubilise (surface active substances)

Wetting phase

• Total wetting of the deposits by surface active substances

Penetration phase

• Dirt is partly taken away from the surface

Dispersion phase

• Disintegration of dirt particles

Emulsification and suspension phase

• Trapping of substances and evacuation

Post cleaning phase

• Defined by soil carrying ability of the cleaning agent (avoiding reprecipitation)

Procedures of cleaning

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Types of cleaning procedures

• Manual (with brushes) or automatic cleaning• Chemical or mechanical cleaning• Low pressure cleaning (1 – 8 bar) or high pressure (10 – 150 bar) • Lost or recovered cleaning (CIP)

Precautions and protection• Protective clothing• „First water then concentrate...“• Never put cleaning or disinfectant agents into food packaging• If there is contact, rinse with lots of water and contact physician

Material compatibility• You have to watch the reaction between cleaning and disinfectant

agents and materials (e.g. never use chlorine containing agents in contact with stainless steel pitting corrosion, causes seals to degenerate

Types of cleaning procedures and precautions

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CIP (Cleaning in Place) - Cleaning plant

SteamRecovered water

Causticbrewhouse

Causticwort line

Acid Cold water

Warm water

CIP return wort line

CIP return brewhouse

upconcentrateW

ort

lin

e

CIP prerun brewhouse

Caustic concentrate

Acid concentrate

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320

Typical cleaning recipe

• Rinsing with water

• Cleaning with caustic


• Cleaning with acid


• Disinfection

There are different CIP-plants for the different departments (brewhouse, unfiltrate area, filtrate area, bottling). If we do so cleaning agents used can be more selective

Concentration is measured by conductivity measurement devices

Caustic can be regenerated by sedimentation, sieving or filtration

Never mix caustic and acidic cleaning agents, it is very dangerous !!!

Carefully monitor temperatures while cleaning tanks (hot → cold → vacuum) !!!

Water tank – cold

Water tank – hot

Recovered water tank

Caustic tank – cold

Caustic tank – hot

Acid tank

CIP cleaning procedures

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Requirements:• High water solubility• General performance• No resistance to microorganisms• Cleaning effect with low temperatures• Low surface tension• No condensation• Good rinsing properties• Low costs, nontoxic, sprayable without foaming

Types of disinfectants:• Mechanical (sterile filtration)• Physical (ultraviolet rays)• Thermal (steam or hot water)• Chemical

Disinfectant

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Alcohol• Only kills live cells, not spores

Aldehyde (Formaldehyde – formalin compounds)• Broadly based cleaning effect• Low effect on yeast and mildews• Slow cleaning effect• Pharmacy taste • Cancer causing

Phenols• Foreign odour• Poorly water soluble

Halogens (NaOCl, Jod) • Do not use for stainless steel• Chlorination of water• Activated chlorine for cleaning

Chemical disinfectants

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Oxidisers • H2 O2, paracetic acid• No residue (disaggregation to

O2 and H2O)• Long residence time

Quaternary ammonium compounds• Wetting agent with low surface

tension• High surface activity • High anti microbiological effect • 0,1-0,2 % • Problems with rinsing • Reduction of foam stability• Sulphurous agents (Na2S2O5,

sulphurous acid)• Amphotensids, antibiotics,

chemo-therapeutics

Chemical disinfectants

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Thank you!

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