Beer and Brewing

Beer & the Brewing Process
Instrument & Automation Solutions
22/04/2008
Msch
Slide 1
Food & Beverage Industry - Beer & Brewing Process
The meaning of life!
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 2
What do sensors mean for a brewing process?
Introduction
How was brewing controlled 200 years ago?
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 3
What do sensors mean for a brewing process?
Introduction How does it look now

The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 4
Endress+Hauser products & services for brewing
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 5
Raw material preparation
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 6
Brewery Malting plants
Introduction
Key production stages include:
The Maltings
Barley
The Brewhouse
Fermentation
Steeping
Maturation
Filling
Germination
Extract Measurement
Kilning
22/04/2008
Msch
Slide 7
Barley dressing and drying
Introduction Barley
Incoming grain is received at moisture levels of between 14% and 20%. Every load is pH inspected and tested at
The Maltings the intake point. Once tipped the grain is cleaned through dressers to remove stones, foreign objects, dust and
straw. The grain is then dried to achieve the desired moisture level of 12% - 12.5%. This process ensures that the
The Brewhouse grain is uniform and prevents natural germination and mould development.
Fermentation Once the dressing and drying processes are complete, the grain is stored in silos.
Maturation
The next step is steeping>
Filling
Extract Measurement
Level
T
pH
L
Flow F
Analytical
22/04/2008
Msch LS
Slide 8
Grain Silo Level management
Introduction
Silo measurement for inventory reasons is one of the most important topics in a malting plant.
Due to tracking and tracing reasons the demands have even increased.
The Maltings
Solid level measurement in barley and wheat silos.
The Brewhouse
A Good solution:
Fermentation
The Micropilot FMR250 is a good solution to tall grain silos. The radar offers an integral air
Maturation purge which will blow cereal dust out of the measuring horn
Filling
Extract Measurement
The Best Solution:
Level Levelflex FMP, guided radar with rod or rope, gives a clear signal, even in dusty environments,
even during filling cycles. The rope and sensor sensor can be installed even in silos that are already
in use and half full.
22/04/2008
Msch
Slide 9
Grain Silo Level management
Maintaining traditional values in a modern world
Introduction
Digital display and programming
The Maltings
Up to 100 meter measuring range
The Brewhouse
Optional 6 programmable relay outputs & 0/4-
Fermentation 20mA output
Maturation Cable or tape versions

Filling
500 Newton Motor Traction prevents cable breaks
Extract Measurement
Many cable weight options including malt bag
Level
22/04/2008
Msch
Slide 10
Steeping
Introduction Steeping
Steeping or soaking in water is the first stage of malt production. Steeping typically takes between 40
The Maltings
and 56 hours during which time 2 or 3 water changes and corresponding air rests will take place. At
The Brewhouse the end of the steeping period the grain will contain approximately 45% moisture.
Fermentation
Maturation
Filling
T
Extract Measurement
LS
Level
Flow
LS
Temperature
22/04/2008 F
Msch
Slide 11
Germination
Introduction
Following steeping the grain is transferred to a germination unit. Over the next 4-5 days the grain is encouraged
to grow under controlled conditions. It is during this time that natural enzymes are produced that will start the
The Maltings
conversion of starch into sugars.
The Brewhouse
At this stage the germinating grain is known as 'green malt'.
Fermentation
Maturation
Filling
Extract Measurement
T
Pressure
Temperature
P
22/04/2008
Msch
Slide 12
Malt Kiln
Introduction
Green malt is transferred to kilns for warm air drying to arrest the germination process and reduce
The Maltings the moisture content of the grain to 3-4%.The kilning process takes around 18 - 24 hours. At this
stage the malt takes on its distinctive flavour and colour.
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement T
P
22/04/2008
Msch
Slide 13
Brewhouse
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 14
Mash tun Wort kettle
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Level measurement mash tun and kettle with

Level
Multicap FMI 51 / Deltapilot DB 50L
22/04/2008
Msch
Slide 15
Points for quality control: Brewhouse
Introduction
Density Controls with Coriolis Flowmeter.
The Maltings
Lauter control
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Flow
Boiling control
22/04/2008
Msch
Slide 16
Lauter control for lauter tun and mash filter
Introduction
Application:
The Maltings
The differential pressure indicates the next steps
The Brewhouse at both systems. E.g. cutting deeper, use more or
less water.
Fermentation
Maturation
Solution:
Filling
Extract Measurement
DP measurement with Deltapilot
Pressure
22/04/2008
Msch
Slide 17
Wort kettle
Introduction
Wort kettle: extract control in the kettle to
The Maltings optimize the boiling time
The Brewhouse Savings in time, heat, better quality control
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 18
Hop dosing with Promass
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Flow
22/04/2008
Msch
Slide 19
Yeast handling and fermentation
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 20
Wort cooling
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Heat exchanger monitoring with Promag
Filling
Extract Measurement
Pressure
Flow
Analytical
22/04/2008
Msch
Pressure control in wort Wort pipe monitoring with
Slide 21
pipe with Cerabar Smartec conductivity
Points for quality control: Wort aeration
Introduction
Oxygen measurement in wort aeration
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Analytical
22/04/2008
Msch
Slide 22
Yeast handling
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Yeast dosing Promag Yeast Propagation with dosing station
Extract Measurement
Flow
Analytical
22/04/2008
Msch
Slide 23
Yeast dosing with Promag
Points for quality control: Fermentation
Introduction
Temperature in the different zones
The Maltings
Head pressure
The Brewhouse
Level, including overspill and empty tank protection
Fermentation Extract measurement
Maturation
Filling
Extract Measurement
Level
Flow
Analytical
22/04/2008
Msch
Slide 24
Fermentation tank equipment
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Hydrostatic level CO2-head pressure
Filling
Extract Measurement
Pressure
Temperature
22/04/2008
Msch Temperature control Refrigeration plant
Slide 25
monitoring with Cerabar
Fermentation, Extract measurement
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Pressure Extract measurement Extract measurement

Promass Deltapilot
Flow
22/04/2008
Msch
Slide 26
Maturation and filtration
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 27
Filtration
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Kieselgur silos, level switch with Soliphant

Filling
Extract Measurement
Level
Pressure
22/04/2008
Msch Kieselgur dosing
Slide 28
Pressure with Cerabar
Points for quality control: Filtration
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 29
Filtration
Introduction
The Maltings
The Brewhouse
Fermentation
Pressure monitoring Cerabar

Maturation
Filling
Extract Measurement
Pressure
22/04/2008
Msch PVPP dosing, pressure control with
Slide 30 Cerabar Filter
Filtration
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Pressure Sterile filter monitoring, Ultra filtration pressure monitoring

differential pressure
22/04/2008
Msch
Slide 31
Points for quality control: Blending
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 32
Carbonisation
Introduction
The Maltings
The Brewhouse
Carbonisation, flow
Fermentation measurement
Maturation
Filling
Extract Measurement
Pressure
22/04/2008
Hydrostatic level
Msch
in CO2 tank
Slide 33
Flash pasteurization
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Monitoring
Flow, temperature and pressure
Heat exchanger
22/04/2008 monitoring with pressure
Msch
Slide 34
Beer handling
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Monitoring of plant
Slide 35
Flow, temperature, pressure
Bright beer handling and filling
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 36
Extract Measurement
Platomass
22/04/2008
Msch
Slide 37
Introduction
Extract measurement with Platomass
The Maltings
Platomass supports automatically extract measurement to make

The Brewhouse
it easier for brewers and operators saving time and money.
Fermentation
Less instruments are necessary and automatically electronic
Maturation data transfer of Plato values from measure unit to PLC.
Filling E+H helps with knowledge for installation and pipe work
design. Together with the customer the plant layout will be
Extract Measurement
defined. All data for calculation of Plato will collected and
stored.
One solution for daily job of determination Plato important

for product quality.
22/04/2008
Msch
Slide 38
Introduction
The Maltings Basics

The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 39
Spindle: The basic instrument for extract measurement
Introduction Two times every day

Discontinuous
The Maltings Manual
Needs knowledge and experience
The Brewhouse
Necessary for quality
Fermentation
Maturation
Filling
Plato
Extract Measurement
22/04/2008
Msch
Slide 40
Historical measurement of extract
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Open fermentation tank
Spindle for Extract measurement

(Saccharometer)
Extract measurement is documented in curves of
22/04/2008 fermentation
Msch
Slide 41
Typical curves of fermentation
Introduction
The Maltings
Extract
The Brewhouse Temperature
Fermentation
Maturation
Filling
Pressure
Extract Measurement
22/04/2008
Msch
Point of following process
Slide 42
Measurement principles for extract determination
Introduction
Discontinuous, manual Continuous, automatic
The Maltings
Contigrad
The Brewhouse
Principle
Fermentation
Maturation
Filling
Bending oscillator
Extract Measurement
22/04/2008 Principle
Msch
Refractometer Coriolis in bypass
Slide 43
Measurement principle of Coriolis
Introduction
The Maltings
The Brewhouse

Fermentation Qm
Maturation
fR
Filling
Extract Measurement
22/04/2008
Msch
Slide 44
Contigrad extract measurement (hydrostatic pressure measurement)
Introduction
The Maltings
The Brewhouse delta P = P1-P2
Pressure P3 2
Pressure
Fermentation
distance [mm] temperature [C]
Fermentation tank 1
Maturation
Differential Density Conversion Plato
pressure calculation in Plato
Filling
Extract Measurement
Pressure 1
delta p
density= --------
delta h
22/04/2008
Msch
Slide 45
Solutions on green field sites
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling new cellar

Extract Measurement
long shutdown time
money isnt a problem
22/04/2008
Msch
Slide 46
Introduction
The Maltings Challenge and history

The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 47
Brewery Oettingen GmbH
Introduction
Founded in early middle ages - documents are known from the year 1333 -; bought by family Kollmar in
The Maltings Frnheim in 1956. The brewery was incorporated into the Oettinger Group.
The Brewhouse Production of high quality beers with low price - has led the brewery into the top 5 german beer brewers.
Fermentation Concentration on the typical business of brewers - avoiding extensive technical equipment plants as well
as any form of media advertising.
Maturation
Production of Oettinger Pils, 6 low fermentation beers, 5 high fermentation beers, 1 malt beer, 1
Filling
alcohol reduced beer and 1 alcohol-free beer. Softdrinks are also in the program.
Extract Measurement
Investment only in high quality technical equipment. Highly efficient systems which produce a high
quality product, requiring a minimum of expenditure in operation and maintenance with a maximum in
availability, are installed.
22/04/2008
Msch
Slide 48
Challenge
Introduction
Because of reorganization process control and automatization of production areas, new ideas
The Maltings regarding process optimizations were found.
The Brewhouse
Daily control of fermentation, Sometimes two times a day, the brewer has to take samples of
Fermentation
beer to define the extract.
Maturation Reducing time and money - but increasing the process quality.
Filling
Old cellar has four lines with seven tanks. Test line has to demonstrate efficiency of online
Extract Measurement extract measurement.
Construction of installation has to create stable conditions for the measurement.
22/04/2008
Msch
Slide 49
Method of Resolution
Introduction
German Institute Weihenstephan was involved to find ideal construction for installation and
The Maltings probe reservoir - in preparation: degree dissertation.
The Brewhouse
Reducing of process troubles - small diameter (DN: 8mm) and using a sample reservoir
Fermentation
(volume: 3 Liters).
Maturation Increasing the process control software for controlling extract measurement. Adjusting the
software for several additional valves.
Filling
Extract Measurement Taking beer probe into the probe reservoir, pressurizing the reservoir and do a concentration
measurement with Proline Promass 83F08.
22/04/2008
Msch
Slide 50
Introduction
The Maltings Solution and realization

The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 51
Usual situation
Introduction
Tank 1 Tank 2 Tank... Tank 7
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Product line
Using old,
but gold instruments.
22/04/2008
Msch
Slide 52
New installation (hardware)
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
CIP/Water
Extract Measurement
Product line
Sample
P
reservoir
Sample pipe
22/04/2008 Promass
Msch 83F08
Flowing off
Slide 53
New installation (software)
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
CIP/Water
Extract Measurement
Product line
Sample
P
reservoir
Sample pipe
22/04/2008 Promass
Msch 83F08 Process software (PLC)
Flowing off
Slide 54
Technical solution
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 55
Bill of material
Platomass measurement unit
Introduction
The Maltings
The Brewhouse
Control unit compact
Fermentation
Maturation
Aternative: control software for Simatic S7

Filling
Extract Measurement
Startup control unit
Alternative: startup Simatic S7
22/04/2008
Msch Planning and installation pipework
Slide 56
Why Endress+Hauser
Introduction
Based on worldwide experience in brewery technology, paperwork of engineering, drawings, and
The Maltings calculations, the customer was interested to continue the solution process.
The Brewhouse Close teamwork with customer because salesman was interested in a good applicable solution.
Fermentation Willingness for experience exchange with customer, Weihenstephan, and Endress+Hauser.
Maturation Development of customized solution, which was designed to a standard solution. Solution is now
reproducible.
Filling
Extract Measurement
Customer was satisfied by motivated salesman and his engagement.
No flow competitors provide this kind of product or support for this solution.
22/04/2008
Msch
Slide 57
Conclusion: Solutions with Endress+Hauser
Introduction
The Maltings
Contigrad
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Platomass
22/04/2008
Msch
Slide 58
Comparison: Solutions of Endress+Hauser
Introduction
Platomass Contigrad
The Maltings
Installation easy (black box) extensive, because two new
The Brewhouse holes have to be drilled in tank
Fermentation Accuracy 0,15 Plato ~ 0,25 Plato depends on:

(Promass) - Distance of sensors
Maturation - Head pressure in tank
- Environment temperature
Filling - Measure range of pressure sensors
Extract Measurement Requirements Beer sample will be lost above DB sensor should be covered
(3-4 liters per with beer
measurement)
Additional pipes necessary
Prices 19000.- up to 22000,- 1500 / tank

22/04/2008 (min. 10 tanks) incl. Software and two DB sensors
Msch
Slide 59
Introduction
The Maltings
Success story Waldhaus
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
09/08/2004
22/04/2008
Msch
Michael Mies
Slide 60
Application pictures
Introduction
History of the Waldhaus Brewery
The Maltings
Small company with 5 employees for all production lines (6 types of beer) beginning with
The Brewhouse
brewing, filling, bottling, and finally packing the product.
Fermentation
Brewery started with 6 fermentation tanks, increased the number up to 9 tanks.
Maturation
Target was to support small brewer team in their daily work. Accurate and repeatable
Filling
measurement doesn't waste time anymore for controlling extract during the fermentation.
Extract Measurement
Platomass reduces costs, increases the flexibility for the company.
22/04/2008
Msch
Slide 61
Introduction
The Maltings
Connection sample pipe to vessel
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 62
Introduction
The Maltings
Connections: sample pipes to valves node
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 63
Introduction Valves node

The Maltings
(front side)
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Valve node
Msch
(Platomass outlet)
Slide 64
Introduction Valves node

The Maltings
Control valve (back side)
The Brewhouse
Fermentation
Maturation
Connection indicator
Filling
for PLC
Extract Measurement
22/04/2008
Msch
Slide 65
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Screenshot PLC: Control of pipes and valves
Msch
for Platomass (Extract measurement)
Slide 66
Introduction Platomass (door opened)

The Maltings
The Brewhouse
Fermentation Special installation with inspection

glasses at sample bin.
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 67
Introduction
The Maltings
The Brewhouse
Fermentation
Maturation
Filling
Inspection glas Beer incl. foam
Extract Measurement
Filling sample bin with unfiltered beer including CO2
22/04/2008
Msch
Slide 68
Introduction
Filled sample bin is pressurized
The Maltings for extract measurement
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
Unfiltered beer incl. foam, but

pressurised
22/04/2008
Msch
Slide 69
Introduction
The Maltings
Display of measured Plato
The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
22/04/2008
Msch
Slide 70
Introduction
The Maltings Cost effectiveness

The Brewhouse
Fermentation
Maturation
Filling
Extract Measurement
03/08/2007
22/04/2008
Msch
Michael Mies
Slide 71
Cost effectiveness
Introduction
Example for profit calculation
The Maltings
Number of tanks: 15
Days of measurement per year: 180

The Brewhouse
Cost per brewer: 30/hour

Fermentation
Time needed per tank (average): 20min = 1/3 hour

Maturation
(Taking probe, filtering, degasing sample, and measuring)
Filling
Real time necessary, because doing things parallel:
5 tanks per hour = 3 hours/day per brewer and per shift
Extract Measurement
Costs based on manual measurement
15 tanks * 1/3 hour * 30/hour * 180 days =

22/04/2008
Msch
27.000 per year / sample
Slide 72
How many samples do you take in your brewery?
Your own calculation (example)
Introduction
The Maltings
The Brewhouse Numbers of tanks 15 tanks

Fermentation
Sample taking per day 1 sample(s)/ day
Maturation
Rate for brewer 30 / h
Days per year in use 180 days
Filling
Time per tank 20 min
Extract Measurement
Saving per year 27.000
22/04/2008
Msch
Slide 73

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Beer & the Brewing Process

Instrument & Automation Solutions

The meaning of life!

What do sensors mean for a brewing process?

What do sensors mean for a brewing process?

Introduction How does it look now

Endress+Hauser products & services for brewing

Raw material preparation

Brewery Malting plants

Barley dressing and drying

Grain Silo Level management

The Best Solution:

Maturation Cable or tape versions

Mash tun Wort kettle

Level measurement mash tun and kettle with

Points for quality control: Brewhouse

Lauter control for lauter tun and mash filter

The Brewhouse Savings in time, heat, better quality control

Hop dosing with Promass

Yeast handling and fermentation

Points for quality control: Wort aeration

Points for quality control: Fermentation

Fermentation Extract measurement

Fermentation tank equipment

Fermentation, Extract measurement

Pressure Extract measurement Extract measurement

Maturation and filtration

Kieselgur silos, level switch with Soliphant

Points for quality control: Filtration

Pressure monitoring Cerabar

Pressure Sterile filter monitoring, Ultra filtration pressure monitoring

Points for quality control: Blending

Bright beer handling and filling

Platomass supports automatically extract measurement to make

One solution for daily job of determination Plato important

The Maltings Basics

Spindle: The basic instrument for extract measurement

Introduction Two times every day

Historical measurement of extract

Open fermentation tank

Spindle for Extract measurement

Typical curves of fermentation

Measurement principles for extract determination

Measurement principle of Coriolis

Contigrad extract measurement (hydrostatic pressure measurement)

The Brewhouse delta P = P1-P2

Solutions on green field sites

Filling new cellar

money isnt a problem

The Maltings Challenge and history

Brewery Oettingen GmbH

Construction of installation has to create stable conditions for the measurement.

The Maltings Solution and realization

New installation (hardware)

New installation (software)

Aternative: control software for Simatic S7

Startup control unit

Alternative: startup Simatic S7

Conclusion: Solutions with Endress+Hauser

Comparison: Solutions of Endress+Hauser

Fermentation Accuracy 0,15 Plato ~ 0,25 Plato depends on:

Prices 19000.- up to 22000,- 1500 / tank