Brew House Process PDF

RAYA BREWERY
BREW HOUSE PROCESS DESCRIPTION

Prepared by: Mulu Neway
15
1. Malt Reception
Holding Capacity of the silos 300 Ton*4= 1200 Tones ,2*30 tones
Major Activities Dust, Stones and other metals are removed by dust blowers, de-stoners & magnets
respectively.
The malt is conveyed to the roller mill through bucket elevators.
The silos are appropriate for space utilization & safe storage of malt.( i.e the malt will be protected
from rodents & other insects.
There is an option to fumigate the silos to avoid attack by insects.
1.1. Malt intake and storage

1. Silos for malt storage: 4 *300 t
Effective capacity :531 m3
Capacity for malt : 299 t(RO =0.56 t/m3
Cylindrical height: 12580 mm
Diameter : 6870 mm
Top angle of conical bottom: 90
Top angle of conical lid : 120
Clearance :900 mm
Outlet diameter : 400 mm
Total height : approx 18800 mm
2. Silo for malt storage day bin: 2*30 t
Effective capacity :52.2 m3
Capacity for malt : 30t(RO =0.56 t/m3
Cylindrical height: 4560 mm
Diameter : 3500 mm
Top angle of conical bottom: 90
Top angle of conical lid : 120
Clearance :900 mm
Outlet diameter : 400 mm
Total height : approx 7770 mm
3. De-stoner PVS 15 for destining of malt conveyed to grist station
Capacity : 5 t/h
Sieve inclination :(2-15 )
Ambient temperature range :20 C/40 C
Pressure air loss :1200 Pa
3
Air consumption :120 m /min
Length :2210 mm
Width :1310 mm
Height :2200 mm
Prepared by : Mulu Neway

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1.2 Process Description
1.
2.
Only well trained person must operate the processing section PS 01, PS 02.
Malt is taken to silos the volume of which is 4 x 300 t, 2 x 30t,
When the line for malt inlet to silos is turned on, you must adjust the transport line for particular silo.
When the intake to the silo position 01.10/1 takes place the drive of the gate valve 01.09 is turned
on as the first and then next drive of the chain conveyor position 01.08/1. In this case next and next
drives follow to the drive of intake basket including aspiration. This happens according to block scheme
which is operated by automat when the operator adjusts the transport line in the operating room.
Recirculation of malt from silo to silo

The operator has to adjust the transport line in the operating room before the recirculation starts.
Drives are turned on in the same mode from the last drive in the direction of the material flow .
3. Malt supply to the malt mill room
4.
When the transport line is adjusted for the malt supply from the silo no. 1 (this is only an example of the
transport line adjustment):
All the drives in the mill room must be turned on in the automatic mode. The operator will close the
gate valve 01.15. The chain conveyor 01.13 drives will start working and the screw conveyor 01.12/1 as
well. The electric gate valve under the silo 1 position 01.07/1 will open.
IT IS NECESSARY TO CHANGE THE POSITION OF THE MANUAL GATE VALVE AND REGULATE THE MALT
FLOW TO PS 02.
When the operation of malt intake and the operation of mill room take place, the intake aspiration and
mill room aspiration must take place as well.
The aspiration operation is divided into two independently operating lines.
Line 1 is the aspiration of the stone separator in PS 02. This aspiration is used only when the
line for cleaning of the malt for the beer batch is turned on.
The second system is for central aspiration of whole intake PS 01 and transport lines PS 02.
Aspiration system works in the full-blown automatic mode.
You have to change the sacks with waste. There are three sacking necks. It is necessary for the
aspiration system operation that at least 5bar of the air, for blowing of the filtrating hoses of
the filter (regeneration of the filtrating hoses), is in the central air distributor.
The grains stocked in the silos must be pre-cleaned and dry (humidity 14 %).
The outdoor large silos are equipped with 1 ventilator (only the outdoor silos), which through
the canals with perforation in the hopper will blow whole layer of the grains.
In the case of the active ventilation, it is necessary to check the parameters of the grains and
the ventilation air.
Small internal silos are protected by the building and so they do not have to be aerated.
Each silo is equipped with thermometer with several places of measuring.
The thermometer is place at the silo axis. Silos are equipped with continuous measuring of the
volume.
The upper sensor checks the volume so that the silo could not get overfilled and the lower
signalizes that the silo is empty.
The grains are drained from silos by gravitation through centre output.
Close both side outlet holes and let the grains flow away thanks to the gravity.

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The flow regulation is done by manual gate valve or by the change of screw conveyor
frequency.
The grains are transport from silo by the screw conveyor.
When automatic mode takes place, everything is adjusted for the mode and the operator does
not have to change the parameters.
When manual mode takes place (we do not recommend this), the operator has to turn on the
drives in the direction of the malt flow from the last drive. See PC scheme.
1.3. Picture description
Picture 1: malt reception

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1.4 Control panel
Set the order of silos
Silo is running for milling (ACTIVE) or silo is

waiting for milling (STOP)
Silo is enabled for milling (number of order)
or blocked (set to 0)
Picture 2: malt reception - control panel for silos 1 - 4
Restart the line, after failure

Actual order for selected silo
Picture 3: malt reception - control panel for silos 5 - 6

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1.5 Program Description
Malt reception is filling the silos with malt

If the silo max level is reached during the transport, the process switches to next selected silo. If
there are none silos left the process finishes
If the conveyor is overloaded during the transport it is together with other conveyors before it
automatically immediately stopped
In order to start them again it is necessary to release STOP button and press RESTART button
Each conveyor is blocked by the preceding conveyor run feedback to pretend the conveyor
overloading
The operator sets the order (writes numbers) of silos (or keeps the order of the last brew) and
presses the Start button. Line for filling starts automatically
All control modules start after the time set in parameters
At the end of malt reception, all control modules stop after the time is set in parameters
1.6 Process parameters
Picture 4: malt reception - process parameters

Time monitor can be set for each step. If the actual time >= monitoring time program will stop and a
new alarm message will appear in the alarm window. If monitoring time is set to 0, the step duration is
not checked.

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1.7 Process steps

0. INITIAL STATE
1. START OF ASPIRATION
2. RESERVE
3. START OF LINE
4. MALT RECEPTION
5. SWITCH TO NEXT SILO
6. STOP OF LINE
7. RESERVE
8. STOP OF ASPIRATION
2. Milling room + Classic Mill

2.1 Definition:
Brewing process starts with milling.

The malt is cleaned in milling line from mechanical foreign materials and fines.
2.2. Main apparatuses in milling line
Item 02.04-Drum sieve - for the separation of mechanical foreign matters

Item 02.04-De-stoner PVS 15 for the separation of stones
Item 02.08-Magnetic separator for the separation of iron matters
Item 03.01-Hammer mill for malt milling Classic mill
Item 03.02-Crushed malt hopper
Item 03.52-Pre-Masher
Item 02.09-Automatic air filter
Item 02.10-Middle-pressure fan set Conveyers

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2.3. Hammer mill Description:
a.
b.
c.
d.
e.
f.
g.
h.
Manufacturer :Meura (Belgium)

Type : CLM 375
Capacity:+/- 8 t malt /h (depending on malt quality)
Consisting of :
A symmetrical milling chamber : inner width=500 mm , diameter =650 mm
Electro-pneumatic inlet valve
Dynamically balanced rotor, able to rotate both directions
1 set of hammers with easy replacing & turning system
Peripheral hammer tip speed at 3000 rpm : 100 m/sec
1 sieve (perforation 2.75 mm in the mill with electro-pneumatic, failsafe sieve-stretcher system,
standard non-return valves on pneumatic cylinders.
Impact plates in upper part of the mill, easy to replace
1 large control door with failsafe open-door protection
Temperature sensors on main bearings & mill housing without connection box, transmitters &
connection cables.
A supporter for proximity switches diam.18 mm of stop detection & of rpm control.
feeding lock system
with geared motor control ;1.1 KW
Iron cleaning magnet with easy hand cleaning & limit switch
Common structure for mill and motor mounted 6 silent blocks
Standard motor 3000 RPM , 400/690 V, 50 HZ, high efficiency, 75 KW
Elastic coupling between motor & hammer mill
Milling bin underneath the hammer mill
Housing for automatic filter unit, bolted manhole
Screw extractor
Transmission unit 2.2 KW
Support for proximity switch diam. 18 mm of rpm control
Sleeve to an overload detector
Rotary valve
Cast iron house with steel rotor
Transmission 1.5 KW
Automatic filter with compressed air cleaning system
Built-in suction ventilator with 7.5 KW transmission
Silencer at ventilator outlet
Control door with locks
Electronic system 240 V, 50 Hz , for jet air cleaning of the filters
Oleo/hydrophobic filter medium , antistatic
Explosion protection for complete milling unit
Reinforcements of the complete unit to resist to an internal reduced explosion pressure of 0.4
bar
2 explosion vents in milling bin sidewall burst detectors.
Sampling device
Easy hand operation & dust tight

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2.4 Crushed malt hopper
Vertical quadrilateral vessel with conical bottom & flat lid, designed to guarantee full emptying of the
crushed malt.
Vessel will be delivered in parts bolted at site.
It designed for storage of 100% of the crushed malt loading for one brew (6545 kg).
Vessel is supported by legs via load.
Effective capacity :13.7 m3
3
Total capacity : 19.5 m
Length : 2800 mm
Width ; 1900 mm
Total height :approx. 4710 mm
Material : carbon steel
a. Worm conveyor
Inlet 410 * 2700 mm
Outlet 219 * 219 mm
Transported material : crushed malt ( Ro=0.50 t/m3)
Output : 25 t/h
Input power drive :3 KW
b. Worm conveyor DS 300 * 5 m-for transport of crushed malt
With one inlet 219 * 219 mm & one outlet 219 * 219 mm
Consisting of worm, coupling, gear box & electric motor with safety switch, including flanges,
sealing & joining material. Worm conveyor is equipped by induction sensor of revolutions &
induction sensor of overloading.
Transported material : crushed malt ( Ro=0.50 t/m3)
The malt is transported from any silo or from two different silos by means of conveyors to milling room
onto Drum sieve where foreign matters bigger than a kernel are separated from the malt.
It continues from drum sieve into the de-stoner where stones are separated and it follows into magnetic
separator where iron foreign matters are separated.
Detached impurities are transported in stands with bags (wastes)
Cleaned malt is transported by means of conveyors in Hammer mill where it is milled on required
grading. Crushed malt falls from Hammer mill into crushed malt hopper.
So milling is finished.
Milling line is provided with an aspiration dust suction from the equipment. The dust is caught by
means of air filter with a fun.

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2.5. Milling Description:
The malt is transported from any silo or from two different silos by means of conveyors to milling room
onto Drum sieve where foreign matters bigger than a kernel are separated from the malt.
It continues from drum sieve into the de-stoner where stones are separated and it follows into magnetic
separator where iron foreign matters are separated.
Detached impurities are transported in stands with bags (wastes)
Cleaned malt is transported by means of conveyors in Hammer mill where it is milled on required
grading. Crushed malt falls from Hammer mill into crushed malt hopper.
So milling is finished.
Milling line is provided with an aspiration dust suction from the equipment. The dust is caught by
means of air filter with a fun.
2.6. Preparation
Brewing process is automated fully except some control steps. Before wort boiling it is necessary to put
in receipt memory parametric values of some constants:
1. Before milling start it is necessary to check put parametric values of some constants in the receipt; e.g.
Malt volume form which one wort brew is produced, Speed of feeding equipment from the silo Except
the silo from which milling is started it is possible to adjust in parameters another silo from which milling
will continue when first silo is empty eventually
An overview of parametric values is shown is the manual Manual Brewery Raya_ r 03_Prop_VR
2. The operator starts the program of fore mashing C
3. The operator starts Start of aspiration. The operator checks whether aspiration fun M1222 and
aspiration filter M1224 are put in operation.
4. The operator starts Start of Classic mill.
5. Program steps for Classic mill follow:
5.1)
INITIAL STATE
5.2)
CHECK STARTING CONDITIONS
5.3)
SYNCHRONIZATION
5.5)
READY CONFIRMATION
5.6)
CHECK ROTOR AND STANDSTILL
5.7)
SELECT COUNTER CLOCKWISE / CLOCKWISE ROTATION SENSE
5.8)
RESET MEMO DIRECTION CHANGE mill rotation is changed regularly
5.9)
REQUEST OPEN ROUTE
5.10)
START FAN M003.0102.050 / air aspiration from the mill

Mill motors are started too in successive steps from last to filter feeding equipment
5.11)
START FILTER CLEANING CONTROL SYSTEM
5.12)
START ORV M003.0105.050 rotary feeder from mill charging hopper
5.13)
START HOPPER SCREW M003.0106.050 conveyor in mill charging hopper
5.14)
START MILL ROT.M003.0100.050- mill rotor
5.15)
START IRV M003.0101.050- mill feeding equipment
5.16)
START DRUM SIEVE
5.17)
START GRAIN SUPPLY LINE
5.18)
SET AMOUNT IN GRIST BIN
5.19)
MILLING

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6.
The operator starts Start of line. Conveyors and apparatuses of milling line are put in the operation
stepwise on this instruction. Last equipment of milling line Classic mill is put in operation automatically
first, than conveyors M 2206, M2203, Destoner M22012, Drum sieve M 002.0100.050, conveyor M2201
and corresponding transporting & feeding equipment from selected silo.
7. The step Milling follows where sub steps of program sequence Classic mill are going; it is milling of
required malt volume from selected silos. In the same time the aspiration is running.
8. Should some silo is empted out during milling; conveyors are switched automatically so that milling
continues from other selected silo.
9. When required malt volume from selected silos is milled; automatic steps finishing milling process are
made:
10. STOP OF LINE during this step all conveyors are switched off and apparatuses of milling line in reverse
order than it was put in the operation.
11. STOP OF Classic mill
11.1)
STOP GRAIN SUPPLY
11.2)
EMPTY GRAIN SUPPLY LINE
11.3)
STOP DRUM SIEVE M002.0100.050
11.4)
STOP 23
11.5)
STOP 24
11.6)
STOP 25
11.8)
STOP IRV M003.0101.050
11.9)
STOP MILL M003.0100.050
11.10)
STOP HOPPER SCREW M003.0106.050
11.11)
STOP ORV M003.0105.050
11.12)
DEDUSTING
11.13)
MILLING COMPLETED
12. STOP OF ASPIRATION
So milling process is finished and crushed malt is prepared in crushed malt hopper.
Description of Classic Mill is in the manual of Meura 9716.1.3 FDS CLM
2.7. Program Description
Milling room is used for milling the malt

If the max level in the malt hopper is reached, the process will be stopped
If the right amount of malt in the silo is reached, program switches to next selected silo
If the right amount in the malt hopper is reached, the process of milling is going to finish
If the conveyor is overloaded during the transport, the conveyor and conveyors before them are
automatically immediately stopped
In order to start again it is necessary to release the STOP button and press the RESTART button
Each conveyor is blocked by the preceding conveyor run feedback to prevent the conveyor
overloading
The operator sets the order (writes numbers) of silos (or keeps the order of the last brew) and
presses the Start button -aspiration, classic mill and line starts automatically
All control modules start after the time set in parameters
At the end of malt reception, all control modules stop after the time set in parameters
Description of Classic Mill is in the manual of Meura 9716.1.3 FDS CLM

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Picture 1: milling room + classic mill
2.9. Control Panel
Set the order of silos
Silo is feeding the mill (ACTIVE) or waiting

(STOP)
Picture 2: milling room control panel

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Silo is preselected to feed the mill

(ENABLED) + it is in the line or set to 0
(BLOCKED)
13
Picture 3: milling room - classic mill control panel
3.0. Process parameters
Picture 4: milling room - classic mill recipes

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Picture 5: milling room + classic mill parameters
Time monitor can be set for each step. If the actual time >= monitoring time program
will stop and a new alarm message will appear in the alarm window. If monitoring
time is set to 0, the step duration is not checked.
3.1. Process steps

Steps of milling room
0.
INITIALSTATE
1.
START OF ASPIRATION
2.
START OF CLASSICMILL
3.
START OF LINE
4.
MILLING
5.
SWITCH TO NEXT SILO
6.
STOP OF LINE
7.
STOP OF CLASSICMILL
8.
STOP OF ASPIRATION

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Steps of Classic mill

0.
INITIAL STATE
1.
2.
SYNCHRONIZATION
3.
READY CONFIRMATION
4.
CHECK ROTOR AND STANDSTILL
5.
SELECT COUNTERCLOCKWISE / CLOCKWISE ROTATION SENSE
6.
RESET MEMO DIRECTION CHANGE
7.
REQUEST OPEN ROUTE
8.
START FAN M003.0102.050
9.
START FILTER CLEANING CONTROL SYSTEM
10.
START ORV M003.0105.050
11.
START HOPPER SCREW M003.0106.050
12.
START MILL ROT.M003.0100.050
13.
START IRV M003.0101.050
14.
REST
15.
REST
16.
START DRUM SIEVE
17.
START GAIN SUPPLY LINE
18.
SET AMOUNT IN GRIST BIN
19.
MILLING
20.
STOP GRAIN SUPPLY
21.
EMPTY GRAIN SUPPLY LINE
22.
STOP DRUMSIEVE M002.0100.050
23.
STOP 23
24.
STOP 24
25.
STOP 25
26.
STOP IRV M003.0101.050
27.
STOP MILL M003.0100.050
28.
STOP HOPPER SCREW M003.0106.050
29.
STOP ORV M003.0105.050
30.
DEDUSTING
31.
MILLING COMPLETED

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3. Pre-Mashing (Mashing -in) + Mashing

3.1 Preparation
Air :compressed air >4 bar

Hot water tank :PH b/n -----------: Volume >600 hl
: Temp (76 - 78) C
Cold water tank : Volume >700 hl
The ratio of water to grist ratio is 2.3 lit/kg
In case of power interruption the pre-masher will be dried & blocked by mash, must rinsed with hot
water by opening the valves manually.
3.2 Pre-masher
Producer : Meura, Belgium
For mashing-in process
a. Cold water circuit
1 hand operated butterfly valve
1 pneumatic modulation valve
1 non-return valve
1 pneumatically actuated double valve
b. Hot water circuit
1 hand operated butterfly valve
1 pneumatic modulation valve
1 non-return valve
1 pneumatically actuated double valve
c. Mixed water circuit
1 electromagnetic flow meter
1 temperature probe with convertor
d. Instrumentation
1 electromagnetic flow meter
1 temperature probe with convertor
1 thermometer
1 pressure gauge
e. Water pumps for pre mashing
Cold water pump
3
Flow rate : 63 m /hr
Body : cast iron
Impeller : stainless steel
Tightness : single mechanical seal
Hot water pump
Flow rate : 63 m3/hr
Body : cast iron
Impeller : stainless steel
Tightness : single mechanical seal

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3.3 Grist hydrator for Mecha-masher

The grist hydrator is especially designed for fine grist & thick mashing in rates.
Material
All parts in contact with the product are made of ASI 304 stainless steel
Accessories
Process valves
1 pneumatically operated sliding valve
Instrumentation
One pressure gauge
3.4 Mashing in device
Type : vertical
Capacity :nominal 25 tons malt grist/h
Producer : Meura
Material : all parts in contact with the product are made of ASI 304 stainless steel
Fittings :
1 mixing vessel with side inlet from grist hydrator
1 sight glass
1 cleaning ball
1 overflow pipe
Accessories
Instrumentation
1 high level probe indicating an inlet overflow
1 low level probe at the pre-masher outlet
1 level transmitter for level regulation
Process valves
1 pneumatically operated butterfly valve
CIP valves
2 pneumatically operated butterfly valve
3.5 Mash transfer pump to the mash tun

(Underneath the pre-masher)
a. Pump
Flow rate : 80 m /hr

Type :moineau (screw type)
Head :2 bar
Body : special rubber
Rotor: Stainless steel
Tightness : robe seal

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b. Fittings
instrumentation
1 compensating device
1 pressure switch
For rope seal of the pump
1 hand operated ball valve
1 filter
1 selonoid valve
1 adjusting valve
1 pressure gauge
1 flow switch
1 adjusting valve
3.6 Mashing-in
Mixing of the malt grist with water at a pre-specified mashing-in temperature.

MEURA Mashing-in tank minimize the oxygen absorption during the mashing procedure
Capacity : 15 ~ 25 Tones of grist per hour
High flexibility : 1,8 to 2,5 l / kg of grist
: From 42 C to 63 C
Pumping of the mash to different vessels (Mash- Tun, Mash Copper...)
3.7 Mashing
During Mashing in mash tun, take sample when the level of mash in the mash tun reaches 50% for mash
PH; soon add mash additives (cacl2, caso4 & Enzyme (CEREMIX)).
During the 1st rest (52 C) add H3po4 based on the PH of the mash measured above to adjust the PH to
(5.35 -5.4) by referring your previous result.
nd
Again take sample after the 2 rest (72 C) when saccharification test confirmation blinks on the
operating screen & add iodine drops to the sample.
If solution looks blue black wait the time for more conversion & recheck till you see yellow color .when
you see yellow color soon click confirm saccharification test.
If all the conditions are ok after heating to mash off temperature (76C), click start on mash filter
operating screen to transfer the mash to mash filter.
If problem in the wort kettle is happened you could late the mash in the mash tun by controlling the
steam flow take the time to be delay time.

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A. Mash kettle Additives

phosphoric acid ---- Li (pH 5.6)
CEREMIX - ---- kg
CaCl2 - ----- kg
Caso4 - ------
kg
B. Mash kettle rests
pause 52 C :20 minutes - heating 1 C per minutes

pause 63 C :45 minutes - heating 1 C per minutes
pause 72 C : 20 minutes - saccharification heating 1 C per minutes
pause 75 C : pumping to mash filter
45-55C=protein & beta glucanase rest
62-65C=Maltose production rest
70-75C=Saccharification rest
76C=Final Mash temperature/mash out
3.4 Program description
The process starts when the operator clicks the button start on the control panel of mash kettle
Mashing-in starts automatically when the route is open and all control modules are controlled
by program sequence
Mashing-in is finished when the minimum is reached in the malt hopper and total volume of
water is reached (recipe)
Description of Mashing-in tank is in the manual of Meura 9716.1.3 FDS Mashing-in tank
Then the heating in the Mash kettle starts
When program goes through the steps of low and high sacharification temperature the process
in the Mash kettle finishes
After that Mash kettle heats to the filtration temperature

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Picture 1: mashing-in tank + mash kettle

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Preparing for cleaning
Picture 2: mash kettle control panel
Restart the line, after failure
Picture 3: mashing-in tank control panel

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Preparing for
cleaning
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3.6. Process Recipes & parameters
Picture 4: mashing-in tank + mash kettle recipes
Picture 5: mash kettle parameters

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Picture 6: mashing - in parameters
will stop and a new alarm message will appear on the alarm window. If monitoring
3.7. Process steps

A. Steps of Mashing-in tank
0.
1.
2.
3.
4.
5.
6.
Idle
7.
8.
9.
10.
11.
12.
Pre-filling - Regulation
Stabilization - Fixed speed
Stabilization - Regulation
Open route for grist
Waiting for grist supply
Mashing-in
Check starting conditions

Synchronization
Ready confirmation
Preheating hot water supply line
Open mash transfer route & seal water
Pre-filling - Fixed position

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Rinsing spray ball - Pump
13.
Rinsing spray ball - Hydrator
14.
After Run
15.
Emptying
16.
End confirmation
17.
Draining
18.
End program
19.
CIP - Check starting condo
50.
CIP - Synchronization
51.
CIP - Cleaning
52.
B. Steps of Mash kettle
0.
1.
INITIAL STATE
WAITING FOR MASHING-IN TANK
2.
3.
4.
5.
6.
7.
MASHING-IN
DELAY AFTER MASHING-IN
ADDING ENZYM
HEATING TO 52C
MASHING-IN
DELAY AFTER 52C
8.
9.
HEATING TO LST 63C

DELAY AFTER 63C
HEATING TO LST 68C
DELAY AFTER 68C
HEATING TO HST 72C
DELAY AFTER 72C
TEST SACHARIFICATION
PUMPING 1. MASH WHILE 1. FOREMASHING
CONTROL TAKING BY MASHING PAN - 1. AND 2. MASH
HEATING TO 76C
RESERVE
WAITING FOR MASH FILTER
PUMPING TO MALT FILTER WITH STIRRER
PUMPING TO MALT FILTER WITHOUT STIRRER
RINSING
DELAY AFTER RINSING
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
50.
PUMPING RINSE TO MALT FILTER

RINSING TO DRAIN
DELAY AFTER RINSING
END
CLEANING

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4. Mash Filter
4.1 Process Description
Prepare wort kettle additives based on the standard (Znso4 ,Caramel, HOP Pellet, HOP Extract)
Wort kettle should be empty to start mash filtration.
Valves should be in automatic mode.
After mash off (end of mashing) to start mash filtration click "start" on mash filter operating screen.
At the open filter step of mash filter (43), helper/operator must go to the mash filter to rinse the plates
with hot water (Temperature of 55C) after removal of the spent grain by controlling the shifting of the
plates.
First wort should be sampled after 5 minutes of start of filtration /transferring to wort collector to be
checked by laboratory (Extract, PH, color).
nd
Last running/weak wort should be sampled after 8 minutes of 2 compression to be checked by
laboratory (Extract, PH,
The process of the Mash filter can start if the conditions are fulfilled
The Mash filter is used for the filtration of the Mash.
Description of Mashing-in tank is in the manual of Meura 9716.1.3 FDS MF2001 and 9716.1.3 FDS
Spent Grains Conveyor
Conditions must be checked in the beginning of the process all conditions must be in state OK within
this step
4.3 Mash Filter Preheating
Be sure that mash filter, pre-masher & mash tun are not on working conditions.
Hot water tank( temperature (76 -78)C, volume >550 hl)
Cold water tank volume >400hl
The water comes to pre-masher & then to mash filter.
When mash filter has not been in used for long period (more than 48 hrs) it requires proceeding to a
Preheating of the plates before starting production or cleaning.
The temperature gap between the product & polypropylene plates cannot be higher than 50C.
Independent from room temperature, it is not necessary to preheat the mash filter, if it stays less than
48 hours without function.
4.4 Spent Grain removal
Frequency : Every brew

After mash filtration is finished (see open filter(43) & shifting (44) steps of mash filter)
Pushed with pressure air (5 bars) to spent grain silo.

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4.5 Process steps

Steps of production
0.
1.
2.
3.
IDLE
RESERVE
MF01.01 - CHECK START. COND.
MF01.02 - SYNCHRONISATION
4.
5.
6.
7.
8.
9.
MF01.03 - READY CONFIRMATION

MF02.01 - OPEN ROUTE
MF02.02 - CO2 FILLING
MF02.03 - STOP CO2 SUPPLY
MF03.01 - REQUSET MASH SUPPLY
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
MF03.03 - START MASH PUMP

MF03.04 - FILLING
MF04.01 - FIXED SPEED
MF04.02 - FLOW/PRESSURE CONTROL
MF04.03 - WAINTING LOW LEVEL SUPPLY LINE
MF04.04 - CLOSE MASHFILTER INLET
MF05.01 - SETUPPEAK FLOW
MF05.02 - CALCULATIONPEAK FLOW
MF05.03 - PRECOMPRESSION - CHECK COEFICIENT
24.
25.

MF06.03 - OPEN FILTER INLET
MF06.04 - PRE-SPARGING
MF06.05 - OPEN UPPER FILTER INLET
MF06.06 - FLUSH UPPER FILTER INLET
MF07.01 - SPARGING VOLUME CALCULATION
26.
27.
28.
29.
30.
31.
MF07.02 - SPARGING 1
MF07.05 - CLOSE MASHFILTER INLET
MF07.06 - STOP MASH PUMP
MF08.01 - FIRST COMPRESSION
32.
33.
34.
35.
MF08.02 - SECOND COMPRESSION

MF.09 - SELECTION STEP
36.
37.
MF09.03 - RINSING
MF09.04 - STOP MASH PUMP
22.
23.

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38.
39.
40.
MF10.01 - EMPTYING
MF10.02 - COMPLETED
MF11.01 - CHECK VENT VALVE MASH SIDE OPEN
41.
42.
43.
44.
45.
46.
MF11.02 - SLOW DECOMPRESSION

MF11.03 - FINAL DECOMPRESSION
MF OPEN FILTER
MF SHIFTING PLATES
MF CLOSE FILTER
RESERVE
47.
48.
49.
50.
51.
52.
RESERVE
RESERVE
RESERVE
CIP - CHECK STARTING CONDITIONS
CIP - SYNCHRONISATION
CIP - CLEANING, NEUTRALISATION
53.
54.
55.
CIP - OPEN MASH FILTER

CIP - SHIFTING
CIP - CLOSE MASH FILTER
4.6 Picture description
Picture 1: mash filter

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Prepare to cleaning, neutralization
Hot trub to Mash filter
Read reading new recipes from ILOBOx is enabled

Online Read reading some recipes from ILOBOx is
enabled
Picture 2: mash filter - production control panel Write writing to ILOBox is enabled
Picture 3: mash filter production start condition
Conditions must be checked in the beginning of the process all conditions must be in
state OK within this step

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Picture 4: mash filter recipes
Picture 5: mash filter parameters

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Picture 6: mash filter parameters
-Time monitor can be set for each step. If the actual time >= monitoring time program will
stop and a new alarm message will appear in the alarm window. If monitoring time is set to
0, the step duration is not checked.
4.8 mash filter - preheating control panel
Picture 7: mash filter - preheating control panel

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4.9 Mash filter Steps of preheating

0.
IDLE
1.
2.
3.
4.
5.
6.
RESERVE
SYNCHRONISATION
READY CONFIRMATION
PREDRAINING
REQUEST WATER SUPPLY
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
OPEN ROUTE
START MASH PUMP
FILLING
OVERFILLING
CLOSE MASHFILTER INLET
STOP MASH PUMP
PRE-HEATING
EMPTYING
DRAINING
SWITCH LOCAL BOX N*1 TO AUTOMATIC
SYNCHRONISATION
OPEN FILTER
SHIFTING PLATES
CLOSE FILTER
DRAIN SPENT GRAINS HOPPER
COMPLETED

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5. Mash filter spent grains conveyor control panel
Picture 8: mash filter spent grains conveyor control panel
5.1. Steps of Spent Grain Conveyor

0.
1.
2.
3.
4.
5.
IDLE
CONFIRMATION DESTINATION
WAIT FOR SHIFTING
START HOPPER & WAIT FOR LEVEL
WAITING FOR EXPELLING
6.
7.
EXPELLING
CONVEYOR DRAIN RINSING
8.
9.
10.
11.
12.
13.
HOPPER RINSING
EMPTYING
DRAINING
COMPLETED
RESERVE
RESERVE
14.
50.
RESERVE
CIP

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6. Wort- Collector
Filtered wort from mash filter is collected in wort collector.

When wort 89% is collected, start transfer to wort kettle
6.1 steps of wort collector

0.
Idle
1.
2.
3.
4.
5.
6.
PUMPING TO WORT PAN

WASHING 1
DELAY AFTER WASHING 1
PUMPING TO WORT PAN
END OF PUMPING
RESERVE
7.
8.
9.
10.
WASHING 2
DELAY AFTER WASHING 2
CIRCULATION OF CHANGER
DRAINING

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7. Wort Boiling
7.1 Preparation
After complete transferring of Clear filtered sweet wort from wort collector.
Constant stream flow, cold-water & compressed water has to be available
At start of boiling take sample from wort pan ,to be checked by laboratory for (Extract ,PH ,color,)
HOP Extract & Caramel should be prepared in the first vessel & automatic dosing time will be during
pressure increase &1st hoping step @96C.
HOP pellet & Znso4 should be prepared in the second vessel & automatic dosing time will be during
nd
pressure boiling &2 hoping step @98C.
At the end of boiling, take sample from wort pan, to be checked by laboratory for (Extract, PH, color,) of
the wort.
H
P at the end of boiling should be within (5.2-5.25).
Wort is boiled in wort pan with the addition of HOP components in order to;
Coagulate proteins ,protein-polyphenol reaction products which can be removed as hot-trub

Concentrate Extract, which lowered as a result of sparging -water during filtering.
Sterilize wort
Extract bitter-resins of HOP components which give the final beer with the necessary bitterness; as
a result of isomerization.
Enzyme inactivation also takes place; this prevents the continual breakdown of proteins & starch
during fermentation.
Lowers wort PH as a result of loss of water &release of hop-acids (alpha-acids) & increase wort
color.
Wort pan is used for boiling the mash with hop

Operator can select preheating of mash during the step pumping from Wort collector
Operator can select heating of water during the step pressure boiling vapor way
Atmospheric boiling will start and valve in chimney will close after pumping from wort collector
The Next step is pressure boiling, the pressure in wort pan is regulated by the step pressure boiling
Step pressure boiling is finished in set time
Step atmospheric boiling happens after that. this step is finished in set time as well
Pumping to whirlpool happens after atmospheric boiling

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7.3 Picture description
Picture 1: wort pan + sugar
Vapour way during boiling - on/off
Preheating during pumping to wort

pan - on/off
Picture 2: wort pan control panel

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Picture 3: sugar 03.24A control panel
Picture 3: sugar 03.24B control panel

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Picture 4: wort pan recipes

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Picture 5: wort pan parameters

will stop and a new alarm message will appear in the alarm window. If monitoring

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7.5 Process steps

A. Steps of Wort pan
0.
1.
2.
3.
INITIALSTATE
PUMPING TO WORT PAN
PUMPING AND BOILING
WAITING TO TOTAL VOLUME
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
HEATING TO BOIL
ATMOSPHERIC BOILING 01
PRESSURE INCREASE
PRESSURE BOILING
PRESSURE REDUCTION
ATMOSPHERIC BOILING 02
RESERVE
RESERVE
RESERVE
BOILING
18.
19.
TESTING DEGREE OF BEER 01

ADDING WATER
BREW ENDING
TESTING DEGREE OF BEER 02
WAITING FOR PUMPING TO WHIRLPOOL
PUMPING TO WHIRLPOOL
20.
21.
22.
23.
24.
25.
PUMPING TO WHIRLPOOL AND RINSING WORT PAN

RINSING 1 WORT PAN AND EXTRACTORS
RINSING 1 - DELAY
RINSING 1 - PUMPING
RINSING 1 - ENDING OF PUMPING
RINSING 2 WORT PAN AND EXTRACTORS
26.
27.
50.
RINSING 2 - DELAY
END
Cleaning
16.
17.

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8. Whirlpool
8.1 Preparation
After end of boiling from the wort kettle take sample of end of boiling & "confirm sampling for wort
transfer to the wort settling tank from the wort pan operating window.
Boiled and hopped-wort is separated from trub materials & clarified by pumping the wort in a
Whirlpool & allowing hot-trub to settle for 20'.
Put the CCT number on the whirl pool window on the Number of Target CCT

Whirlpool
Capacity of wort cooling :300 hl/h

3
Total capacity :32.3 m
Effective capacity : 26.1 m3
Inside diameter : 4250 mm
Trub tank
Total capacity : 2 m3
Inside diameter :1350 mm
Height :2900 mm
Top angle of bottom :70
Material :stainless steel
Whirlpool is used for filtrating wort.

Operator can select pumping part of wort to propagation.
Operator can select the air to the wort .
After the pumping from wort pan is put to Rest step (it stays in idle state).
Next step is fermenting (pumping to CCT); the wort is cooled down to the set point temperature while
it is being pumped to CCT.
If the temperature is higher than set in parameters or the flow is less than the parameter, program will
stop.
8.3 wort-cooling
There should be Enough amount of ice water (4 C)

Cold wort Aeration line should be sterilized with steam & cooled down for first brew.(by fermentation
operator)
CIP of Wort cooling line (by brew house operator) the receiver CCT, wort line to the receiver CCT (by
fermentation operator) should be done & line & manual hand valves should be connected and opened.
Put the CCT number on the whirl pool window on the Number of Target CCT
Receiver CCT should be in the "Filling step" to be ready by fermentation operator
Start transferring the hopped, clarified wort through plate heat exchanger by clicking "confirmation
for transferring to CCT from whirlpool operating screen.
The water that goes out from the heat exchanger is hot & got to the hot water tank.
Around 7hl water is pushed & drained under the CCT's CIP outlet valve first, and then cooled wort is
filled to the CCT by switching on the CCT's wort inlet auto valve.
Cooled wort temperature should be 8C,
Aeration of the Cooled wort shall be started by selecting/clicking "Air" from brew house computer after
transferring of 30HL to CCT& stopped after transferring of 200HL.(should be done by brew house
operator)
No aeration is for last brews

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Aerated & agitated Yeast (for about 3 hrs)is pitched with first brew in automatic mode (Yeast will be
pitched based on the consistency & viability result from microbiology) refer under yeast pitching
topic.(by fermentation operator)
If the wort is for yeast propagation purpose follow the procedure under yeast propagation.
After 15 minutes, take sample for cold wort to be checked by laboratory (Original wort gravity /cold
wort Extract, PH, Color & for organoleptic taste (by brew house operator).
At the end the wort is pushed to CCT with water (7hl) & is drained, when the water is reached at the
CCT, by switching on the CIP outlet automatic valve of the CCT or wort is completely filled to the CCT by
switching off wort inlet automatic valve of the CCT.
8.4 Preparation
Fermenting 1 wort flow 350 hl/hr

Fermenting 2 wort flow 180 hl/hr
Temperature of wort 8C
Ice water level full (95%)
Ice water temperature <= 4C
Sterile air flow 30 kg/hr
8.5 Hot trub
When the wort is completely transferred to CCT, trub will be drained to the trub tank (see step 22 of
whirlpool)
The separated hot trub shall be dosed for next brews when transferring of mash from mash tun to mash
filter in automatic mode (when 25hl mash is left on mash kettle), if it is not stayed more than 24 hrs
otherwise released to the drainage.
8.6 Picture Description

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Picture 1: whirlpool
Wort to propagation
Air to wort
Picture 2: whirlpool control panel

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Picture 3: whirlpool recipes
Picture 4: whirlpool parameters

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Time monitor can be set for each step. If the actual time >= monitoring time
program will stop and a new alarm message will appear in the alarm window.
If monitoring time is set to 0, the step duration is not checked.
8.8 Process steps

A. Steps of Whirlpool
0.
1.
2.
3.
4.
5.
INITIAL STATE
PUMPING 1 TO WHIRLPOOL
PUMPING 2 TO WHIRLPOOL
END OF PUMPING
REST
WAITING FOR PROPAGATION
6.
7.
8.
9.
10.
11.
PROPAGATION - FLUSH OUT

PROPAGATION - WAITING FOR PUMPING
PROPAGATION - FILLING WATER
PROPAGATION - FILLING WORT
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
WAITING FOR PUSH IN

PROPAGATION - PUSH IN
WAITING 1 - FERMENTING
STARTING COOLER
CCT - PUSH IN TO DRAIN
WAITING FOR CCT
FERMENTING 1
FERMENTING 2
FERMENTING 3 PUMPING TO CCT
END OF FERMENTING
PUSH IN TO CCT
PUSH IN TO DRAIN
WAITNIG FOR DRAINING
DRAINING OF SLUDGE
WAITING FOR RINSE
RINSING 1
RINSING 1 - DELAY
RINSING 2
28.
29.
30.
31.
RINSING 2 - DELAY
RINSING 3
RINSING 3 - DELAY
RINSING 4
32.
33.
RINSING 4 - DELAY
RINSING 5
12.
13.
14.
15.

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34.
35.
50.
PUMPING TO CCT DRAIN

END
CLENING
B. Steps of Hot trub

0.
1.
2.
3.
4.
5.
6.
7.
8.
9.
INITIALSTATE
DELAY
CIRCULATION
PUMPING TO MASHFILTER
RINSING
DELAY AFTER RINSING
PUMPING RINSING TO MF
PUSHING WITH WATER
RINSING 2
DRAINING
9. Water system + vapor system

9.1. Program description
Water system is used for mashing-in, sparging, and rinsing the tanks in the Brew house
Vapor way is used for heating the technological water.
Technological water pre-heats the mash to wort pan
Pump M5201 is started, if the water for rinsing the tanks in the Brew house is needed
Pipes for mashing-in and sparging are directly connected to hot and cold water tanks
Cold water tank
Effective capacity :30 m3

3
Total capacity :31 m
Total height :7600 mm
Hot water tank
Water temperature 80C

Effective capacity :75m3
Total capacity : 77.9m3
Total height :8600 mm

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Ice water tank
Effective capacity :33.2m3

3
Total capacity :34.75m
Total height :approx. 8500 mm
Picture 1: water system

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Picture 2: water system parameters

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10. Spent Malt system
When the Silo is full the spent grain should be transported by truck for cattle feed.
Controlled/operated by Brew house of operator in automatic/manual mode.
Thermolized yeast may add to the spent grain if there is thermolized yeast.
Spent malt from the mash filter is stored in spent malt tank
If the dispensing of malt starts, malt valve under the conveyor opens. After that the conveyor starts
In the step issue of malt the air is flipping and water valve is opened
Dispensing of malt finishes, when the operator presses the button End
Button Pause pauses the process Stops the conveyor, air valve and water valve will be closed, only
malt valve will be opened
Picture 1: spent malt system

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Picture 2: spent malt system - control panel
Picture 3: spent malt system - control panel

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10.4 Process steps

0.
Idle
1.
2.
ENABLE OF ISSUE
OPEN OF M3220
ISSUE OF SPENT
END OF ISSUE
3.
4.

Brewing Team Leader

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RAYA BREWERY

BREW HOUSE PROCESS DESCRIPTION

1.1. Malt intake and storage

3. De-stoner PVS 15 for destining of malt conveyed to grist station

Prepared by : Mulu Neway

1.2 Process Description

Recirculation of malt from silo to silo

3. Malt supply to the malt mill room

The aspiration operation is divided into two independently operating lines.

Prepared by : Mulu Neway

1.3. Picture description

Picture 1: malt reception

Prepared by : Mulu Neway

1.4 Control panel

Set the order of silos

Silo is running for milling (ACTIVE) or silo is

Restart the line, after failure

Picture 3: malt reception - control panel for silos 5 - 6

Prepared by : Mulu Neway

1.5 Program Description

Malt reception is filling the silos with malt

1.6 Process parameters

Picture 4: malt reception - process parameters

Prepared by : Mulu Neway

1.7 Process steps

2. Milling room + Classic Mill

Brewing process starts with milling.

2.2. Main apparatuses in milling line

Item 02.04-Drum sieve - for the separation of mechanical foreign matters

Prepared by : Mulu Neway

2.3. Hammer mill Description:

Manufacturer :Meura (Belgium)

Prepared by : Mulu Neway

2.4 Crushed malt hopper

Prepared by : Mulu Neway

2.5. Milling Description:

CHECK STARTING CONDITIONS

CHECK ROTOR AND STANDSTILL

SELECT COUNTER CLOCKWISE / CLOCKWISE ROTATION SENSE

RESET MEMO DIRECTION CHANGE mill rotation is changed regularly

REQUEST OPEN ROUTE

START FAN M003.0102.050 / air aspiration from the mill

START FILTER CLEANING CONTROL SYSTEM

START ORV M003.0105.050 rotary feeder from mill charging hopper

START HOPPER SCREW M003.0106.050 conveyor in mill charging hopper

START MILL ROT.M003.0100.050- mill rotor

START IRV M003.0101.050- mill feeding equipment

START DRUM SIEVE

START GRAIN SUPPLY LINE

SET AMOUNT IN GRIST BIN

Prepared by : Mulu Neway

STOP GRAIN SUPPLY

EMPTY GRAIN SUPPLY LINE

STOP DRUM SIEVE M002.0100.050

STOP IRV M003.0101.050

STOP MILL M003.0100.050

STOP HOPPER SCREW M003.0106.050

STOP ORV M003.0105.050

12. STOP OF ASPIRATION

2.7. Program Description

Milling room is used for milling the malt

Prepared by : Mulu Neway

2.8. Picture description