Beer Processing Solutions doc

These fulfill various brewing processes and include: • WortMaster – Wort cooling, yeast dosing and wort aeration • Derox – Cold and hot water • HGBMaster – High gravity brewing • PU Pa

Beer Processing Solutions

Table of contents

Introduction 3Brewing Process Diagram 4Complete Product Range 5Complete Process Solutions 6-7Automation Services 8-9Maintenance Service 10Wort cooling, yeast dosing,

wort aeration 11-12Water deaeration 13-14In-line blending and mixing 15-16Carbonation and nitrogenation 17-18High gravity brewing 19-20Pasteurizing 21-22CIP 23Fermentation & maturation 24Filtration 24

APV pioneered many of the key

technologies involved in the brewery

industry As early as 1910, APV

made the first welded alumin ium

beer tank on the basis of a British

patent, and through its commitment

to innovation, the company has

continued to make important

contributions to the industry ever

since APV has established many

milestones in brewing technology,

with results that are still valid

throughout the world today

In 1914 APV developed a system for the culture of pure yeast and in 1923 the company revolutionized wort cooling by introducing the world’s first brewery plate heat exchanger

Since then, many more developments have been introduced, placing APV

in a better position than ever to serve the brewery industry in all specialty processes

Today APV offers process automation systems, individual brewery

process units, and a wide range

of components including pumps, valves and heat exchangers All APV equipment and systems can be supported by a variety of after sales services

Our first steps into the brewery equipment

business began as early as 1910

Beer Types with Approximate Alcohol by Volume

Münchner 4 8% Trappist 9-10 8% Strong Ale 6 1-8 4% Weizenbier 4 8-5 6%

Pilsner/Pilsener 4 2-5% Kölsch 4 8% Bitter stout 4 4-7 5% Berliner Weisse 3 3%

Ur-types 4 9% Brown Ale 2 5-4 5% Milk stout 3 7-3 8% Gueuze-Lambic 5%

Danish Lager 4 2-4 7% Pale Ale 4 3-6 6% Russian stout 9 5%

Bock 7-7 3% Mild Ale 2 5-3 6% Light Ale 2 9-4%

Doppelbock 7-7 3% Bitter Ale 3 0-4 0% Steam Beer 4 8%

The Brewing Process

APV provides a selection of

standardized process units, which

could be described as a series of

building blocks These fulfill various

brewing processes and include:

• WortMaster – Wort cooling, yeast

dosing and wort aeration

• Derox – Cold and hot water

• HGBMaster – High gravity brewing

• PU Pasteurizer – Controlled beer

pasteurization

• CIP Master

Focused on adding value to your product

Our process units are designed

to exceed industry standards and enhance the value of your products

To highlight how value is added to your products and processes, we have developed the following symbols for your reference

Product uniformity

homogenous products

Flexible production

fast product changeover

Economical production

cost saving processes

Proven security

tested equipment

From individual units to totally automated solutions

Every unit can be supplied as

a stand-alone system, ideally equipped for smooth and trouble free oper ation and suitable for integration into your central control system But you will gain additional benefits with

a combination of units, which have been specifically designed to operate together for high performance, both from a mechanical and a control perspective

APV can guarantee you a process solution tailored to your needs

A Complete Product Range

The unit values are significant

An intelligent processing unit Configuration as required

Real time plant data:

A Plug & Produce™ unit Very short commissioning time

Low installation cost

No interference to existing production schedules Reduced time from order to production Seamless integration to all plants Easy to extend

Faster return on investment Easy expansion of existing plant

Proven standards Improved functionality

Hygenic design Good reliability

Improved repeatability Product integrity safeguarded

State of the art processes Easy operation

Low energy consumption Reduced waste Low noise emission levels

Quick and easy operator training Environmental improvements Improved company image

A compact unit design Container fitted

Low shipment cost Smallerproduction area required Moveable equipment

Fast delivery time

Shorter delivery time Higher capacity/m²

Maintenance service Easy maintenance

Optimal APV service Fixed maintenance costs

A reduction in unscheduled downtime Limited spare parts requirement

Cost effective maintenance Higher productivity

APV draws on decades of

experience in project engineering and

management for the brewery industry

Its extensive range of reference

installations includes everything from

a single process line to complete

greenfield turnkey beer processing

solutions

To meet today’s demand for modern,

highly efficient production facilities,

APV’s in-depth knowledge of brewing

top quality beers is complemented by

expertise in process automation and

management information systems

APV’s technological excellence

covers processes such as

fermentation and storage, yeast

handling and treatment, beer

processing, bright beer and

pasteurization Furthermore, we have

vast experience in the areas of wort

cooling, water deaeration, and high

gravity brewing Our CIP systems

complete the process Wherever

appropriate, APV integ rates its strong

range of standard process units into

a project

We believe our experience is our

most important asset Previous

highly successful installations are

our customer’s best guarantee that a

brewery project will be implemented

on time and within budget

Our experience ranges from

traditional methods to highly

automated systems based around the

latest proven technologies

Highly automated systems deliver improved effeciencies, resulting in a faster return on investment, due to:

• More production time

• Less cleaning time

• Minimum use of water, chemicals and energy

• Fewer operatorsThey also improve batch control, resulting in product traceability and flexibility

Further benefits for the brewmaster and management are:

• A “paper free” process control system which can interface with ERP systems

• Material and quality tracking capability

• Full compatibility with brew-house and filling plant as well as with other production plants in the brewing group

Process Engineering

APV uses its extensive experience

in the development, planning and implementation of brewing steps

in close co-operation with our customers’ brewmaster, technologists and process engineers Careful

Complete Process Solutions

Adding value for the brewmaster

teamwork ensures that we understand and recognize each of our customers’ specific needs

Detailed Engineering

This starts with the PID and process description, followed by the development of installation pipeline circuit and connection plants, cable lists, functional descriptions, program sequences, energy calculations, component specifications, interface definitions, spare parts lists and operating instructions and manuals – all dedicated exactly to our customers’ specific brewing needs

Hygienic Design

Our design is based on the latest international standards for hygienic design APV uses standard design elements, which are constantly reviewed to meet the highest standards

Health and Safety

HACCP/HAZOP studies can be undertaken, reviewing equipment specifications relative to process flow diagrams to determine whether there are any quality, health and safety issues, which need to be addressed

Each process step is analyzed to

establish whether the equipment and

control systems are adequate for safe

operation under normal, abnormal and

CIP conditions

Latest Design Tools

APV uses the latest design tools

The use of 3D models, with possible

access to full-scale modeling from

AutoCAD, provides improved

safety features by maintaining data

throughout the project via single

entry to the database Furthermore,

the existing AutoCAD platform for

communication with most customers’

CAD Systems is maintained

Project Management –

a single point of contact

APV project managers are our

customers’ single point of contact

They are highly experienced

and acutely aware of all critical

implementation aspects Excellent

coordination skills enable them to

translate the efforts of APV suppliers

and other sub-suppliers into

successful projects

Environmentally Safer Processes

In response to an increasing need for environmentally acceptable utility services, energy optimization through sound design principles is always observed Waste minimization and health and safety issues are always carefully considered

Installation Supervision

APV supervisors are internationally experienced and accustomed to all kinds of local working environments Armed with excellent co-operation skills, they are specialists in accessing appropriate local manpower

Optimizing Working Procedures

Consistent working procedures in sales, engineering and management are an important part of the value APV adds to a project We have therefore been certified to ISO

9001 Standards But that has never been our final goal Through quality improvement programs, working procedures are constantly monitored and challenged to increase productivity and efficiency in all parts

of our business

Training of People

Breweries are operated by fewer and fewer highly trained staff, which often results in the need for an exceptional

degree of automation and integration APV provides tailored training courses for our customers’ personnel

in both process and automation technology Designed to extend their skill base, increase their specialist knowledge and update them on the latest trends, these courses are offered either at our customers’ brewery or on APV premises

Automation and Performance Services Solutions

APV FactoryExpert Driving manufacturing excellence

FactoryExpert is APV Automation &

Performance Services It combines

innovative solutions with reusable

engineering applications on open

platforms to meet our customer

automation specifications

We offer state-of–the-art automation

solutions and services designed

to international standards based

on in-depth process knowledge

together with manufacturing

know-how and engineering expertise

that meet regulatory requirements

FactoryExpert enables customers

to extend their performance gains

across their business

APV FactoryExpert Value

Streams

APV FactoryExpert comprises five

strategic value streams to meet

our customers’ automation and

manufacturing execution needs

• Automation Service for customers’ existing automation equipment offering maintenance and support programs, spare parts, etc…

maintaining and improving conditions

to maximize plant uptime

APV FactoryExpert is vendor independent, it can include, for example control systems and human machine interfaces (HMIs) from Siemens, Rockwell, Mitsubishi, Wonderware, etc This enables true versatility in our solutions

ERP Integration MES Applications Automation Systems Automation Migration Automation Service

• Automation Migration for our

customers with an installed

base of ageing and obsolete

automation equipment which

can no longer adequately

sup-port their business Furthermore,

Automation Upgrade for systems

that require additional functionality

to meet automation and control

requirements

• Automation Systems consisting

of PLC and HMI as part of our

project offering These can be in

the form of a single skid unit to

plant wide automation solutions

• MES Applications targeting facturing and equipment perform-ance, production execution, quality and tracking We offer a suite of engineered applications designed

manu-to deliver the right information, at the right time, to the right people,

in the right context to drive future actions in our customers’ or-ganizations to drive manufacturing excellence

• ERP Integration solutions that link and integrate the plant floor automation systems to our customer’s enterprise or business layer

Until recently, the impact of

maintenance operations on

round-the-clock production, quality,

manufacturing flexibility, traceability,

plant safety and environmental

protection has been largely ignored

APV recognizes that cost-effective

performance of your APV equipment

is directly dependent on the ability to

design and implement a cost-effective

maintenance program

In response to these requirements,

and as part of the on-going expansion

of our customer support strategy,

APV Maintenance Services adapt to

your specific requirements

Maintenance Services consists of

multiple levels of service agreements

in order to create the ideal balance

of flexibility, improved productivity,

increased up-time and better financial

performance of all APV equipment

Different service agreements can

be created for our customers For

example:

• Basic Care

- APV service when you can plan

ahead

- Balance of uptime and

economics for non-critical

APV is committed to providing proactive service solutions These Maintenance Services agreements provide the best possible service to maximize your performance and deliver improved return on your investment Maintenance Services

Critical parts delivered same Critical parts delivered within Critical parts on site within Parts on site witin 72 hours

or next day service 24 hours 48 hours Emergency service technician Emergency service technician Emergency service technician Emergency service response

on site within same or next on site within same or next on site within same or next @ 10% discount

APV Preventive Maintenance APV Preventive Maintenance APV Preventive Maintenance One annual planned program, 24/7/365 program, 24/7/365 program, Monday to Friday maintenance visit

8am-5pm Free emergency service, Emergency service, Emergency service, Spare parts @ 10% discount 24/7/365 24/7/365 Monday-Friday, 8am-5pm

Wear parts and service parts Wear parts and service parts Wear parts included Recommended wear parts

Other spare parts @ 15% Other spare parts @ 15% Other spare parts @ 15% Technical telephone support, discount discount discount Monday-Friday, 8am-5pm Technical telephone support, Technical telephone support, Technical telephone support,

24/7/365 24/7/365 Monday-Friday, 8am-5pm Modem support included Modem support included Modem support - optional Strategy for service Strategy for service Strategy for service partnership seminar partnership seminar partnership seminar Software upgrades Predictive maintenance on

critical items Plant availability guarantee Software upgrades Designated APV maintenance Rebuilding & retrofitting manager consultancy Continuous process cost

reduction Guaranteed performance guarantees on critical items Annual process knowledge analysis

Rebuilding & retrofitting consultancy Operator audit and training

@20% discount

APV service management APV service coverage for Comprehensive APV APV service when you can and support for the your most critical equipment service support plan ahead

entire plant Plantwide strategy to Proactive approach to When service delays aren´t Balance of uptime and improve mission equipment performance an option economics for

A Systematic Program of Strategic Maintenance

The WortMaster product range

covers units designed for the

processes between the brewhouse

and fermentation, including wort

cooling, yeast dosing and wort

aeration

In addition to fast and efficient wort

cooling, WortMaster units deliver

effective and accurate in-line dosing

of yeast and air/oxygen by means of

the patented APV gas injector

Offered in a wide range of capacities from 50 – 1200 hl/hr, all WortMaster units are designed and developed for easy integration with existing lines

WortMaster

- adds value

The WortMaster adds value to your products and processes in the following ways:

Product uniformity:

• Constant monitoring and improved regulation of the process

• Repeatable fermentation performance

• Traceable production data

WortMaster – Wort Cooling, Yeast

Dosing & Wort Aeration Ensure economical production by minimizing the use of time and additives

Description

Wort Cooling - Hot wort from the

brewhouse must be cooled prior to

the addition of yeast for fermentation

This is achieved using a state of the

art plate heat exchanger with a wide

channel, which reduces the cleaning

requirement while maintaining good

heat transfer efficiency Additional

attractive features include a high

performance clamping system,

improved hanging area and EasyClip

gaskets, all of which contribute to

reduced maintenance and spare parts

requirements

The wort cooler can be designed as a

single section cooler using ice water

or as a double section cooler for

brewing water and refrigerant

Wort Aeration - Brewing yeast

requires oxygen to multiply

Traditionally this has been supplied

by blowing air through the wort with

various types of nozzles and mixers

The result was often varying oxygen

levels of typically 10-12 mg O2/l

depending on pressure, temperature

and the original gravity of the wort

Specified O2 levels with high gravity

worts are usually higher and thus pure

oxygen is often used to achieve levels

above 18 mg O2/l

The APV Gas Injector allows these

levels to be achieved by a fast

consistent mixing of wort and either

air or oxygen

Yeast Dosing - Yeast can be added

to complete the wort treatment This

has the advantage of adding yeast

immediately to the cooled wort

The actual method used can reflect local practice and the automation allows accurate MIS/MES integration

In the event of lack of product flow, the yeast supply is shut off

Aeration

• Manual Adjustable Head – Any adjustment for flow and specification must be made manually

• Modulating Head – Automatic adjustment of the head can be made from the control system This option can be retrofitted to the manual head

Dosing

• Flow Measurement – The yeast can

be dosed by means of a magnetic flowmeter

• Tank Contents Measurement – The

amount of yeast can be dosed on the basis of tank contents measured by a load cell

• Yeast Cell Measurement – The amount of yeast can be dosed on the basis of instrumentation that measures the yeast cell

• Blending Separation - The simple blending “T” can be replaced with

a 4 port double seat valve and stop valve to separate the product and component loops for cleaning

• High Accuracy Blending – A variation of this technology using mass flow measurement is capable of even higher accuracy and is used for blending of components such as hop extract or color

• Conductivity Measurement – Pro duct separation can be measured

by means of conductivity to minimize product loss