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Instrumentation best practices in Brewing
Ola WesstromSlide 1
04/24/2020
What we will cover
Endress+Hauser – overview
Best Practice application examples
Instrumentation for small, medium, and large brewing operations
Improving brewhouse efficiency
Maximizing extract yield
Ensuring beer quality
Yeast handling and metering
Fermentation monitoring
Transferring metering to optimize planning process and reduce packaging losses
Assuring availability of the brewery – calibration and maintenance
Tools for selection
Ola WesstromSlide 2
Instrumentation best practices in Brewing
04/24/2020
Endress+Hauser – a family company
Privately Owned by Endress Family – solid family
charter.
• 2018 Revenue 2.4B Euro
• Equity Ratio of 72.2% - financial stability
• 14,000+ Global Employees – solid back up
• +10% Yearly Revenue into R&D – leading
innovation 5,300+ Patents
Diversified Portfolio
• Food & Beverage
• Chemical
• Water & Waste water
• Oil & Gas
• Power
• Life Sciences
• Primaries and metal
Endress+Hauser - Your safe choice
Link to Corp Info
Slide 3
04/24/2020
Our Core Competence – Instrumentation and related services
Slide 4 Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
All from one manufacturer – Easy standardization
Slide 5
Level Flow Analysis Pressure Temperature Data Acquisition Systems Services
Capacitance Electromagnetic pH Pressure rel. Pt 100 Recorders Profibus PA Commissioning
Conductive Vortex Conductivity Pressure abs. Thermocouple Data managers Fieldbus FF Maintenance
Hydrostatic Coriolis Oxygen Diff. - Pressure Transmitter Displays Ethernet I/P Repair
Differential P Ultrasonic Turbidity HydroS. level Energy calc. Datalogger IO-link Calibration
Vibration Thermal-mass Chlorine Datamanager BlueTooth Training
Ultrasonic DP-flow Ammonia Paperless Rec. FieldCare Spare parts
Microwave Density/Brix Phosphate Power SupplyEngineered
systemsRisk assessment
Guided Wave Viscosity Nitrate Batch controller Inst. Base Mgm
Electromech. Steam quality Sludge level Tank inventoryReceiving Custody Transfer
Engineering
Radiometric Bio gas Water sampler
Servo gage Venturi Color
Solids flow Cell Growth
Phase separation
Raman Spectroscopy
Common platforms:
• Minimize training
• Reduce spare parts
Global market position # 1 Liquid Analysis# 1 Level# 1 Magnetic flow# 1 tie Coriolis mass flow# 2 pressure# 2 Temperature
Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
Cost and performance – balanced options
Entry level:
No or simple display
Basic performance specifications
Limited options or specials
Mid range:
Modular and repairable
Standard options and performance
Most communication protocols
High performance:
For critical or high value applications
All options and communication protocols Cerabar S PMP75
Cerabar M PMP51/55
Example: tiers for pressure/Flow
Most Endress + Hauser products are available in 2-3 levels of performance and pricing
Promag H 300/500
Promag H100
Promag 10H PicomagCerabar T PMP 23/33B
Instrumentation best practices in Brewing
Slide 6 Ola Wesstrom
04/24/2020
Simple, cost effective options for the start up brewery
Level switches
FTW23
FTW33
FTL33H
Ola WesstromSlide 7
Analysis
CM10
CLD18
Display/recorder
RSG35
Flow
Promag 10D
PicomagPressure
PMP23
PTP33B
Temperature
TMR35
TM401
Level
FMR10/20
Instrumentation best practices in Brewing
04/24/2020
IP 67/68 or 69K ingress protection
Fully welded Stainless steel enclosures
with quick disconnects
Remote options
Cable glands vs. conduit entry or fixed
cables
Memosens technology for analytical
measurement points
All surface mount electronics to survive
vibration
Convenient setup via Hart, Bluetooth or
LAN cable or Wireless LAN and
integrated web server = No special
tooling required
Hygienic design & Washdown protection – “Right Tech” for Brewing
Instrumentation best practices in Brewing
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04/24/2020
Malt and spent grain silo measurement
Slide 9
• Correct inventory information about
Malted grains (barley, wheat,adjuncts..)
as well as spent grain is best monitored
using free space radar.
• High/low alarm using point level
switch, many options available. Fork
style is most reliable and common
• Always know inventory for planning
Image, Brains Brewery
Freespace radar using narrow beam 80gHz FMR67
Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
Mash kettle
Ola WesstromSlide 10
• Level PMC51 – Ceramic allows flush mount even with abrasive grains –Capacitance FTI51 for foam alarm
pH CPS441D ISFET Pressurized KCL+ CPA875 retractable holder + CM44xR
Pressure PMP51 or PMP 31 class
FTR20 Soliflow – indicate grain blockages during conveying or Soliphant FTM50 high level in malt mill
Temperature TM412
Strike water flow Promag H 100 or Picomag
Steam flow, prowirl200 with dry steam fraction
Instrumentation best practices in Brewing
04/24/2020
pH measurement in mash kettle
Ola WesstromSlide 11
pH measurement of mash is important for optimal yield,
traditionally difficult with std glass glass pH sensors. The
malt enzymes a- and b-amylase require a slightly acid pH to
do their work. Optimum Values pH 5.3 @ 77°C
Ceramax CPS341D-7A1H1 - in mash tun
Ceramax CPS341D enamel pH sensorROI – No need to replace for years, exceptional stability which reduce calibration intervalsReliable measurement in high solids media thanks to large sensing area and mechanical abrasion resistance
Instrumentation best practices in Brewing
04/24/2020
Wet Steam?
Ola WesstromSlide 12
100% steam quality
80% steam quality
In the mash tun, mash cooker as well as any other heat transfer where steam is used, cost savings can be realized by ensuring dry steam.The Prowirl 200 gives alarm on preset dry steam fraction
Energy value in BTU/KJ Get to temperature faster Optimal amount of steam used, Safety by eliminate water hammer.
Prowirl 200 vortex flow meter with dry steam fraction
Instrumentation best practices in Brewing
04/24/2020
Ceramic pressure sensor in Lauter tun
Lauter bed density and level is measured with 2 x
pressure transmitters or Differential pressure.
Traditional metal membranes are susceptible to
damage from abrasion or mechanical damage during
maintenance(dinged when removing false bottoms or
calibration) Typical life 2-3 years.
Solution – Ceramic membrane pressure sensors
Exceptional life expectancy – 15+years
Ola WesstromSlide 13
PMC 51 ceramic pressure
FMD71 electronic DP w/ceramic sensors
Instrumentation best practices in Brewing
04/24/2020
Optimization of brewing –°Plato Monitoring
Slide 14
• The extraction of fermentable sugar (wort extract) is key to optimal
yield in brewing, this is done in the lautertun and where sparge water is
used to flush out the sugar from the grain.
• Measuring the extract(°Plato) outflow enable the brewery to determine
the optimum flushing cycle time and lauter efficiency.
• Optimize sparging and “right on time” separation of weak wort
• Maximize extraction of sugars
• Reduce volume going to wort kettle (energy and capacity savings)
• Assure desired sugar concentration and low polyphenols and lipids
content
• Fast correction of channeling in lautertunPromass Q300 °Plato/ Gravity Density 0.0002g/cc (0.01°Plato achieved in cold wort)
Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
Wort Kettle – extract measurement
Slide 15
Installing the Extract meter (Promass Q) in a circulation loop in the
wort kettle enables brewer to monitor the wort during the boil.
• Reach the desired evaporation rate
• Maximize wort kettle utilization
• Maximize extract yield(desired extract concentration)
• reduce worker risk (hot wort sampling)
• Maximize kettle utilization
• Reduce energy – stop when targets achievedPromass Q300 °Plato/ Gravity Density 0.0002g/cc 0.02°Plato achieved in Hot wort)
The hot wort contain a lot of air bubbles which makes accurate measurement challenging – solved by the Promass Q MFT(Multi Frequency Technology)
Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
Turbidity Monitoring of Wort - Whirlpool
Ola WesstromSlide 16
Optical turbidity installed on the whirlpool outlet allows for automatic detection of trubcone disintegration. • The effectiveness of the whirlpool can be
monitored, as well as the wort quality.Reduces lost product
• Increases consistency of end product• Allows early indication of issues with
whirlpool – eg. Pumping rates too low
Instrumentation best practices in Brewing
Continuous monitoring of the
turbidity using OUSTF10 on the
whirlpool outlet
04/24/2020
Wort Aeration
Ola WesstromSlide 17
The wort is oxygenated to increase yeast activity and to start the fermentation process. Aeration of the wort is required for optimal yeast flotation and fermentation.
• Optical dissolved Oxygen(DO) sensor with Memosens (pre-calibrate sensor in lab for fast exchange
• Reference LED ensures batch repeatability with alarm if drifting.
Optical Oxygen Sensor COS81D
Image courtesy of GEA
Instrumentation best practices in Brewing
04/24/2020
Optimization of Fermentation process
Ola WesstromSlide 18
• Continuous monitoring of fermentation with densitometer
• Predict instead of react to signs of stuck of sluggish
fermentation
• Transfer final gravity has been reached
• Reduce lab analysis
• Improve fermentation tank utilization
• Reduce chill-water energy
Liquiphant Density, Temperature sensor +5 channel FML621 extract computer
Instrumentation best practices in Brewing
04/24/2020
Too vigorous Fermentation
Don’t want this to happen!
Step 1. Monitor your fermentation
Step 2. Install foam detection sensor (FTW33 or
Liquiphant “foam version”)
Step 3. Control your temperature
Ola WesstromSlide 19
Foam detection FTL50 or FTW33
Instrumentation best practices in Brewing
04/24/2020
CO2 Recovery
Ola WesstromSlide 20
A CO₂ recovery plant consists of a foam separator, a gas buffer container (Balloon), a scrubber, compressor, drying tower and holding tank.
Maintenance free holding tank level using the guided wave radar FMP55 (coaxial style is required due to low dielectric of CO₂
Guided wave radar with coaxial probe for CO2 tank
Instrumentation best practices in Brewing
04/24/2020
Maturation / Bright beer, Packaging tank level
Accuracy is key for planning of packagingHydrostatic pressure is at best +/- 0.1% of adjusted span. Frequent calibrations may be required to ensure performance. Sensor membrane also frequently damaged by impingement cleaning (rotary nozzles). Alternative is E+H ceramic pressure sensors PMC71/PMC51
Free Space Radar gives +/- 1mm(0.04”) independent of spanExample: 15ft diameter tank 30ft highPressure error +/- 0.36” (6.02 gallon)FMR62 error +/- 0.04” (0.22gallon)
• Increase OEE of bottling and packaging line (no more bottles on the carousel than beer in the tank)
• Reduce extract losses (no more beer waste because bottles are missing on the carousel)
• Energy/labor savings by matching bottles to beer for packaging line
FMR62 free space radar gives 1mm accuracy in bright beer tanks
Ola WesstromSlide 21
PMC 51 ceramic pressure or FMB50
FMD71 ceramic electronic DP
Instrumentation best practices in Brewing
04/24/2020
Boundary or taxation meters
The transfer from brew house to packaging is often the
taxation point and used for planning in packaging
Magnetic flow meter is most commonly used for this
measurement.
+ Reliability, small and large size, 0.2% to 0.5% volume
accuracy
- Due to the CO2 in the beer, volume also include the CO2
More accurate option – Coriolis massflow – Promass Q300
High accuracy density measurement assists in the determination
of the type of beer
0.1% volume accuracy
Ola WesstromSlide 22
Promag H300 Promag H100
Promass Q300
Instrumentation best practices in Brewing
04/24/2020
Simplify record keeping and reduce downtime
Ola WesstromSlide 23
• Verification tool – “Heartbeat verification” allows for boundary
flowmeter check without interrupting process, user friendly
and clear reports (can be used for 27CFR25.42 - TTB reporting)
• Increased calibration interval = reduced cost for removing and
sending meter for calibration
• Increased trust in measurement = focus on real issues
• Reduced impact on operations = less downtime
Instrumentation best practices in Brewing
04/24/2020
Field Xpert SMT70 – the one tool for configuration and asset management
Ola WesstromSlide 24
Any device (instruments, valves etc)Always up to date20 languagesGenerate reportsUpload to Asset management
Instrumentation best practices in Brewing
04/24/2020
Digital Tools - Endress Operations App (IOS, Android)Instant access to all info – save time
Ola WesstromSlide 25
Look for “Endress operations” app
Scan the QR code on instrument and instant have access to all device information
Instrumentation best practices in Brewing
04/24/2020
Connected Support
Ola WesstromSlide 26
•Remote mentor video calling•We see what you see•Document Navigation•Guided workflow•Mobile forms
1) 24/7 Helpdesk support
2) Need step by step help right now – download the mobile app and
use your own mobile device to connect with help desk. We can see
what you see and guide you.
3) More advanced or want handsfree, contact us for Headset device.
4) Onsite commissioning, service and calibrations
Instrumentation best practices in Brewing
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High precision and ISO17025 accredited flow, Pressure, temperature ++ calibration
Training facilities
Factory Calibration Services
Slide 27 Ola Wesstrom
Instrumentation best practices in Brewing
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On-site Flow Calibration Rigs
• Flow Calibration Rig
Ola WesstromSlide 28
Trailers are equipped with Flow, Pressure,
Temperature, liquid analysis calibration equipment.
• Temperature Oil Baths • Pressure Calibrators
Instrumentation best practices in Brewing
04/24/2020
Energy loss reductions – What is accuracy worth?
Accuracy and repeatability is your friend, ensure that instruments are calibrated
and right for the application. How much is +/- 0.7% uncertainty worth over a year
of production?
Example: simple temperature measurement on a pasteurizer. Actual temp is 164 but
temp sensor shows 162F. This 2deg difference = 24lb/h steam loss.
24lb/h x 2000h x $0.046/lb= $2200 per year energy loss
Ola WesstromSlide 29
Temperature sensor with QuickNeck. Remove sensor for calibration without disconnecting or opening line.15min Time saving/calibrationFood safetyOperator safety
Temperature sensor withQuickneck and TrustSensSelf calibrating @ 118°C(244°F)>30min time saving/calibrationFood safetyOperator safety
TM412, 411 TM371, 372
Instrumentation best practices in Brewing
04/24/2020
Tools to assist you
www.endress.com
https://www.us.endress.com/en/search?filter.text=applicator
a. Look under your industry choice
b. Product selection via application parameters
c. Application solutions (diary, beverage, utilities
d. Make your selection
Slide 30 Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
TM
TM
Measure, Analyze, Compute, Monitor, Service, Audit
Data Collection, Bus Engineering, Control
F
VMI, ERP, Visualization, e-Business
“MIP” means going beyond the measuring point…
Ola WesstromSlide 31
Instrumentation best practices in Brewing
04/24/2020
Control of the CIP-unit
Slide 32
Level measurement with FMB50
Conductivity measurement with CLS54D
Conductivity measurement in return line with CLS54D
Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
Steam System Optimization – Control based on actual Energy usage
Slide 33
Nat GasBTU/ SCF
Steam[BTU/ LBS
Condensate return
BTU/GPM
Make-up water
Feed water
Flue gas
Blow downAir
Fuel
CondensateSteam
heat
heatheatEfficiency
,
De-aerator/ Economizer
Vortex flow with wet steam alarm and compensation
Applicator
Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
Waste water instrumentation
Slide 34
Level, flow, biogas, pH, DO, TOC, COD, SAC, nitrate, phosphate, Samplers
and more
Ola Wesstrom
Instrumentation best practices in Brewing
04/24/2020
Goals and challenges in Brewing
Ola WesstromSlide 35
Resource conservation
• Extract loss reduction initiatives
• In-line quality monitoring - Repeatability
• Energy reduction
• Water conservation
• Optimization/expansion of water treatment capabilities
Compliance to safety and quality standards
• Calibration services and best practices
• Education and training of operators/technical staff
Instrumentation best practices in Brewing