Tài liệu Instrumentation in the brewing industry Automation of the brewing process pot

Optimizing the yield and quality of extract production Mash tun level The Mash tun level is measured with highest reliability with the temperature compensated FMB70 hydrostatic level sen

Instrumentation in the brewing industry Automation of the brewing process

Brewing beer means to deal with natural

grown products changing from year-to-year,

harvest-to-harvest The brewer needs to

react on these changes to prepare a stable

quality of beer, and even more, it must taste

the same all year, each and every year, to

fulfill the expectation of the customer To

follow this moving target, a lot of experience

is necessary It is the art of brewing

Endress+Hauser is here to help you run

your process consistently on a high quality

level every day and night Throughout this

document you will find how state of the

art sensor technology supports the brewing

process Rising accuracy of process sensory,

along with high repeatability enables the

user to run a process in the most efficient

manner Optimized raw material use,

energy conservance and best availability

of the plant is the target of automation

The art of Brewing

Instrumentation for:

• Malting

• Malt and grain storage

• Brewhouse

• Fermentation

• Filtration

• Packaging

• CIP and water preparation

• Boiler

• CO and natural gas

Supporting the cleaning process is a basic requirement to save time and energy All shown sensors are developed to work

in hygienic processes They follow the guidelines of FDA, -A and EHEDG

Reliable measurement supplies the necessary data for the ideal process, and supports suitable solutions for tracking and tracing the beer

Silos can be easily mapped for fast commissioning and reliable measurement.

Levelflex

FMP40 Micropilot FMR250 Soliphant M FTM50 Solicap M FTI55

Energy conservation

Blocked dust filters can be a safety hazard and can also cause unnecessary energy consumption

Pressure transmitters with ceramic membrane provide reliable and cleanable option to conventional metal membranes

The PMC45 offer cost effective solution for dust hazardous area

Malt/grain inventory silos

Complete inventory management

solutions to address rising inventory

costs are easily realized with complete

packages from Endress+Hauser

freespace (FMR250) or guided wave

radar (FMP40) provide an option

to select the best-fit to address

measurement challenges due to silo

height, diameter and amount of dust

Continuous level measurement

in malt silos

View of levelflex cable

Malt and grain storage

Reliable and visible inventory status

Inventory and supply chain management

Rising commodities drives the need for real-time information

Safety precautions with level alarms

Reliable High/Low level alarms

for silos and hoppers are critical for

any application Chose between

Capacitance (FTI51) or tuning fork

(FTM50) depending on installation point

Accounting of bulk inventory kept in tanks and silos has

traditionally not had high priority This is particularly true

for bulk material such as sugar, flour and grains However,

with the rapidly rising value of these commodities it is

becoming more and more important to have a current

status of inventory levels to allow for planning and

advanced purchasing techniques

Endress+Hauser can provide scalable, turnkey solutions

for your plant with simple, local monitoring or full

integration into your ERP system Installation costs can be

kept to a minimum using wireless solutions or Ethernet

connection Solutions are available for single or multiple

site applications

Infrastructure - In Plant Monitoring or Remote Sites

Intranet/ERP Integration Data visibility for our CUSTOMER

Ethernet/Land line/GSM/GPRS for connection of remote location

Installation at our Customer location

Ethernet

Optimizing the yield and quality of extract production

Mash tun level

The Mash tun level is

measured with highest

reliability with the

temperature compensated

FMB70 hydrostatic level

sensor Remote electronics

make access easy

Promag H series: great

value for the money

Foundation water for mash

tun need to be metered

accurately

Wort kettle pressure

Energy conservation is achieved by applying pressure to wort kettle

The Cerabar M pressure transmitter is ideal for this application - simple and reliable pressure control

Boiling

In-line extract measurement with Liquiphant Density ensures stable wort quality, along with optimized energy use during wort boiling

Lauter tun wort clarity performance

A critical control point for the Lauter tun is the outflow turbidity and density Turbidity is monitored by the optical sensor AF12-ER

Mash and foundation water

pH must be monitored closely to

achieve best yield in mash tun

Non-glass IsFet pH (CPS441D/

CPS471D) sensor and retractable

holders combined with Memosens

technology brings highest

reliability and accuracy

Energy and extract loss reduction

To avoid wasting extract, lauter systems are monitored with Promass F Stopping the flush water at the exact right moment optimizes ingredients and saves energy during the boil

Reliable level in silo Overfilling the spent grain silo

is a big mess Avoid this situation with reliable level measurement using free space radar Micropilot FMR245

Adjuncts, dextrose

and enzymes

Adjuncts and dextrose must be

added with high accuracy to

optimize raw material usage

The Promass 83S provides the

best temperature stability and

accurate measurement available

today Combine this with the

possibility to ensure performance

between calibrations using the

FieldCheck verification tool

Lautertun bed density

Differential pressure across the lautertun bed is commonly using pressure transmitters with metal membranes Due to the abrasive nature of the mash and cleaning procedure the membranes are often damaged The PMC71 ceramic membrane pressure transmitter provide reliable and highly accurate alternative

Steam supply

Accurate measurement of the

steam supply for the mash tun

and wort kettle is used to identify

fouling and can have a direct impact

on energy cost Prowirl 73 with

steam computer gives you direct

BTU readings

Brewhouse

Consistent quality batch-after-batch

Wort aeration

The goal in fermentation is to produce

alcohol Based on the condition of the

yeast, oxygen supply level is controlled,

using COS21D, allowing the yeast to

populate at an optimal rate

Sterile air supply

Sterile air supply to wort aeration is best done with a thermal massflow meter The t-mass series is capable of highly accurate measurements with a large turndown range

Level measurement

Level measurement of fermentation,

aging and bright beer tanks are

done using the highly accurate and

temperature compensated FMB70

hydrostatic level transmitter

Electronic differential pressure

compensate for CO2 head pressure

Extract measurement

Extract measurement in the

fermentation vessel with

Liquiphant Density ensure a

stable fermentation process by

allowing continuous adjustment,

as needed by the actual brew

Empty pipe - high/low tank level

or detection of foam in CO 2 line

The Liquiphant M is a universal switch with no need for calibration or adjustment throughout the lifecycle

of the instrument Version is available tuned to detect foam in CO2 line

Yeast dosing

The amount of yeast is measured

with a magnetic flowmeter

Promag H combined with

an optical turbidity sensor

OUSAF12-ER to monitor the

cell concentration

Fermentation

Level measurement

CO2 storage tank level must be monitored closely to ensure uninterrupted supply Levelflex M FMP40 guided wave radar provides a set-and-forget alternative that eliminates the need for periodic calibrations The coaxial probe is ideal

Rod or cable can be used in combination with patented “end-of-probe”function

Temperature measurement

Reliable temperature measurement

is key throughout the brewing process and utilities Highest quality RTDs combined with fast response tips ensure optimal temperature control

Dissolved Oxygen measurement

Examples are for trim cooler output, degasser, packaging release and in carbonation stage The COS21D DO sensor provide reliable measurement with minimal maintenance

Liquid storage or transfer tank

Point level detection in any liquid storage or transfer tank is done reliably without the need for any calibration with the tuning fork point level switch Liquiphant FTL50H

Degassed water

pH of the degassed water must be monitored closely Non glass IsFet

pH (CPS471D) sensor and retractable holders, combined with Memosens technology, brings highest reliability and ensures purity of water

Conventional glass electrodes are also available

Filtration

Production of a consistent product with minimal beer loss

Flash pasteurizer temperature control

Fast response time is needed for stable control

High gravity blending

Minimize beer loss with

combination of high performance

metering - Promag 53H on water

and Promass 83S for combined flow

including extract (Plato°) value

Filter performance

Differential pressure is a common indicator for filter performance

Conventional DP transmitter FMD78

or electronic DP with PMC45 provide needed reliability Optical sensors can

be used for breakthrough alarm

Boundary or “taxation meter”

Require documented

traceable periodic verification

of performance FieldCheck

verification tool is easily used

to ensure performance and generate

documentation that meet 27CFR

part 25 for the Promag 53 magnetic

flowmeter between calibrations

Product identification

prior to packaging

Conductivity is monitored throughput the process A key measurement is on the packaging release tank

Conductivity sensor CLS54 is used to verify that the expected product is in the line This can be combined with optical color measurement for added safety

Bright beer tank

Highest accuracy is needed

to plan for bottling line free space radar FMR245

or hydrostatic level sensor FMB70 provide this key information

Washdown

To ensure sterility and food safety during filling the whole area is often washed down with strong detergents/sanitizer

All instruments are IP67

or better to ensure life in washdown environment

Packaging

Keep consumers happy with clean, crisp product

Bottle and keg washing

Sanitizer concentration must

be monitored to ensure optimal cleaning efficiency

Endress+Hauser offers a full line

of analytical sensors (for example, for chlorine dioxide the CCS240 chlorine dioxide sensor works

at low flow rate, require no zero point calibration and is not affected

by conductivity fluctuations

Fillerbowl level

To ensure complete fills

and avoid beer losses the

fillerbowl level must be

measured accurately The

FMI51 capacitance level sensor

provide best accuracy under

the fast moving conditions

CIP optimization

Key process for quality, safety and yield

CIP concentration CIP concentration is critical to the food safety but also have big impact on use of detergent and energy cost for heating CIP circuit The CLD134 conductivity transmitter have the fastest temperature compensation on the market and offer dual range capability Ultrafast temperature compensation ensures best-in-class performance

Secure records

CIP records are kept secure in

video graphic recorders capable

of meeting 21CFRpart 11

Beer loss reduction

Fast and effective interface/phase

separation is key for reducing beer

and water losses The AF11 can help

you save large amounts from going

down the drain Saving you not only

in product losses but also in water

treatment costs

CIP make-up and chemical

tank inventory

Level measurement for inventory or process control of aggressive chemicals

is solved by multiple options depending

on tank size and user preference - capacitance, ultrasonic or freespace radar are most common

WAGES – Water, Air, Gas Electricity & Steam

Make a difference to the

environment and the bottom line

The starting point for any conservation

program is to know where you stand

today and then identify potential areas

for improvement For example; do you

really need a larger air compressor

or can you reduce the air usage? By

applying simple permanent or temporary

measurements you can make qualified

decisions based on facts

Endress+Hauser is in a position to

help you monitor your resources to

ensure success of your conservation

initiatives One of our clients in the

brewing industry, have reduced overall

energy consumption (WAGES) by over

300% since implementing a monitoring

program in 2006

Activity –

Setting energy targets

They now, for example, measure and recover over 90% of all CO2 and have reduced overall water consumption and natural gas usage

Typical WAGES monitoring in a brewery involve steam measurement to monitor overall efficiency and to detect problems with steam traps Vortex flowmeter combined with steam computer gives you direct energy readout

Water consumption is a big issue in the brewing industry, way too much water

is wasted in inefficient cleaning and washdown procedures, a simple magnetic flowmeter or a temporary clamp-on ultrasonic flowmeter will help you keep track while making improvements

Compressed air – a ¼” leak will cost over $8000 in energy losses Monitoring

of pressure or flow using thermal mass flow or Vortex flow meters can help identify leaks and usage during active and idle periods

CO2 and natural can both be measured with DP flow or Vortex but more and more opt for entry level Coriolis flowmeters that provide highest accuracy and direct reading in massflow without the need for additional compensation

Measurement information is collected and presented in easy to use program for trending and planning purpose Immediately see the result of your conservation programs and identify where the next opportunity is

Wastewater treatment

Reduced production losses = reduced cost of wastewater treatment

Step 1

Identify when and what is coming down the drain A simple optical sensor CUS1 mounted in the drainpipe can immediately identify a spill and the amount of solids (nutrients) Use this to implement a plan to reduce accidental spills and feed forward control for treatment plant

By implementing in-line quality

control with checks and balances the

beer losses can be kept at a minimum

However, even in the best conditions

there will be wastewater generated

By applying simple measurement and

controls the cost of water treatment

can be minimized

Step 2

pH balance, depending on the size of the plant and the local arrangement with your municipal treatment plant you may only need to monitor and balance the pH value

pH sensors in conventional glass or non-glass combined with the Endress+Hauser patented Memosens technology ensure maximum reliability and low maintenance

Step 3

The wastewater in a brewery has very high nutrient content (BOD) due to the alcohol, yeast and fermentable solids By monitoring dissolved oxygen (DO), turbidity and possibly TOC the treatment process can be optimized

Example is use of DO in aeration tanks to effectively reduce BOD levels while only running the blowers at most energy efficient levels Blower air is easily monitored with thermal or vortex shedding flowmeters

Step 4

Final effluent, depending on your level

of environmental consciousness and the city/state regulations you need to monitor and keep records of outgoing volume and residual nutrients Electromagnetic or ultrasonic flowmeters are commonly used

in combination with pH, DO, Chlorine and

at times a TOC analyzer, all captured in an electronic record such as the videographic recorder Memograph M Records can be managed in accordance with 1CFR part 11