Beer Processing Solutions 5600 01-08-2008 US
Transcript of Beer Processing Solutions 5600 01-08-2008 US
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Beer Processing Solutions
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Table ocontents
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 23
Fermentation & maturation 24F i l t r a t i o n 2 4
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APV pioneered many o the key
technologies involved in the brewery
industry As early as 1910, APV
made the rst welded aluminium
beer tank on the basis o a British
patent, and through its commitmentto 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 or
the culture o pure yeast and in 1923
the company revolutionized wort
cooling by introducing the world’s rst
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 oers process automation
systems, individual brewery
process units, and a wide range
o components including pumps,
valves and heat exchangers All
APV equipment and systems can besupported by a variety o ater sales
services
Our rst steps into the brewery equipment
business began as early as 1910
Beer Types with Approximate Alcohol by Volume
Bottom Fermented Top Fermented
Malt Malt Wheat Malt
Münchner 48% Trappist 9-108% Strong Ale 61-84% Weizenbier 48-56%
Pilsner/Pilsener 42-5% Kölsch 48% Bitter stout 44-75% Berliner Weisse 33%
Ur-types 49% Brown Ale 25-45% Milk stout 37-38% Gueuze-Lambic 5%
Danish Lager 42-47% Pale Ale 43-66% Russian stout 95%
Bock 7-73% Mild Ale 25-36% Light Ale 29-4%
Doppelbock 7-73% Bitter Ale 30-40% Steam Beer 48%
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The Brewing Process
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APV provides a selection o
standardized process units, which
could be described as a series o
building blocks These ulll various
brewing processes and include:
• WortMaster – Wort cooling, yeast
dosing and wort aeration
• Derox – Cold and hot water
deaeration
• BlendMaster – In-line blending and
mixing
• CarboMaster – Carbonation and
nitrogenation
• HGBMaster – High gravity brewing
• PU Pasteurizer – Controlled beerpasteurization
• CIP Master
Focused on adding value to your
product
Our process units are designed
to exceed industry standards and
enhance the value o your products
To highlight how value is added to
your products and processes, we
have developed the ollowing symbols
or your reerence
Product
uniormity
homogenous products
Flexible
production
ast 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 or smooth and trouble ree
operation and suitable or integration
into your central control system But
you will gain additional benets with
a combination o units, which have
been specically designed to operate
together or high perormance, both
rom 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 signifcant
APV Provides: Capabilities: Customer Values:
An intelligent processing unit Conguration as requiredReal time plant data:
• Predictive maintenance• On-line documentation• Final product monitoring• Traceable production
Improved process:• Protability• Consistency• Security
Lower operating costLonger running time
A Plug & Produce™ unit Very short commissioning timeLow installation costNo intererence to existing production schedulesReduced time rom order to productionSeamless integration to all plantsEasy to extend
Faster return on investmentEasy expansion o existing plant
Proven standards Improved unctionalityHygenic design
Good reliability
Improved repeatabilityProduct integrity saeguarded
State o the art processes Easy operationLow energy consumptionReduced wasteLow noise emission levels
Quick and easy operator trainingEnvironmental improvementsImproved company image
A compact unit design Container ttedLow shipment costSmallerproduction area requiredMoveable equipmentFast delivery time
Shorter delivery timeHigher capacity/m²
Maintenance service Easy maintenanceOptimal APV serviceFixed maintenance costsA reduction in unscheduled downtimeLimited spare parts requirement
Cost eective maintenanceHigher productivity
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APV draws on decades o
experience in project engineering and
management or the brewery industry
Its extensive range o reerenceinstallations includes everything rom
a single process line to complete
greeneld turnkey beer processing
solutions
To meet today’s demand or modern,
highly ecient production acilities,
APV’s in-depth knowledge o brewing
top quality beers is complemented by
expertise in process automation and
management inormation systems
APV’s technological excellence
covers processes such as
ermentation and storage, yeast
handling and treatment, beer
processing, bright beer and
pasteurization Furthermore, we have
vast experience in the areas o wort
cooling, water deaeration, and high
gravity brewing Our CIP systems
complete the process Whereverappropriate, APV integrates its strong
range o standard process units into
a project
We believe our experience is our
most important asset Previous
highly successul installations are
our customer’s best guarantee that a
brewery project will be implemented
on time and within budget
Our experience ranges rom
traditional methods to highly
automated systems based around the
latest proven technologies
Highly automated systems deliver
improved eeciencies, resulting in a
aster return on investment, due to:
• More production time
• Less cleaning time
• Minimum use of water, chemicals and
energy
• Fewer operators
They also improve batch control,
resulting in product traceability and
fexibility
Further benets or the brewmaster
and management are:
• A “paper free” process control
system which can interace with ERP
systems
• Material and quality tracking
capability
• Full compatibility with brew-house
and lling 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 o brewing steps
in close co-operation with our
customers’ brewmaster, technologists
and process engineers Careul
Complete Process SolutionsAdding value or the brewmaster
teamwork ensures that we
understand and recognize each o our
customers’ specic needs
Detailed Engineering
This starts with the PID and
process description, ollowed by the
development o installation pipeline
circuit and connection plants, cable
lists, unctional descriptions, program
sequences, energy calculations,
component specications, interace
denitions, spare parts lists and
operating instructions and manuals
– all dedicated exactly to ourcustomers’ specic brewing needs
Hygienic Design
Our design is based on the latest
international standards or hygienic
design APV uses standard design
elements, which are constantly
reviewed to meet the highest
standards
Health and Saety
HACCP/HAZOP studies can be
undertaken, reviewing equipmentspecications relative to process fow
diagrams to determine whether there
are any quality, health and saety
issues, which need to be addressed
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Each process step is analyzed to
establish whether the equipment and
control systems are adequate or sae
operation under normal, abnormal andCIP conditions
Latest Design Tools
APV uses the latest design tools
The use o 3D models, with possible
access to ull-scale modeling rom
AutoCAD, provides improved
saety eatures by maintaining data
throughout the project via single
entry to the database Furthermore,
the existing AutoCAD platorm orcommunication with most customers’
CAD Systems is maintained
Project Management –
a single point o contact
APV project managers are our
customers’ single point o contact
They are highly experienced
and acutely aware o all critical
implementation aspects Excellent
coordination skills enable them totranslate the eorts o APV suppliers
and other sub-suppliers into
successul projects
Environmentally Saer Processes
In response to an increasing need
or environmentally acceptable utility
services, energy optimization throughsound design principles is always
observed Waste minimization and
health and saety issues are always
careully considered
Installation Supervision
APV supervisors are internationally
experienced and accustomed to all
kinds o local working environments
Armed with excellent co-operation
skills, they are specialists inaccessing appropriate local
manpower
Optimizing
Working Procedures
Consistent working procedures in
sales, engineering and management
are an important part o the value
APV adds to a project We have
thereore been certied to ISO
9001 Standards But that hasnever been our nal goal Through
quality improvement programs,
working procedures are constantly
monitored and challenged to increase
productivity and eciency in all parts
o our business
Training o People
Breweries are operated by ewer and
ewer highly trained sta, which oten
results in the need or an exceptional
degree o automation and integration
APV provides tailored training
courses or our customers’ personnel
in both process and automationtechnology Designed to extend their
skill base, increase their specialist
knowledge and update them on
the latest trends, these courses
are oered either at our customers’
brewery or on APV premises
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Automation and Perormance Services SolutionsAPV FactoryExpert
Driving manuacturing excellence
FactoryExpert is APV Automation &Perormance Services It combines
innovative solutions with reusable
engineering applications on open
platorms to meet our customer
automation specications
We offer state-of–the-art automation
solutions and services designed
to international standards based
on in-depth process knowledge
together with manuacturing know-how and engineering expertise
that meet regulatory requirements
FactoryExpert enables customers
to extend their perormance gains
across their business
APV FactoryExpert Value
Streams
APV FactoryExpert comprises ve
strategic value streams to meet
our customers’ automation andmanuacturing execution needs
• Automation Service for
customers’ existing automation
equipment oering maintenance and
support programs, spare parts, etc…
maintaining and improving conditions
to maximize plant uptime
APV FactoryExpert is vendor
independent, it can include, or
example control systems and human
machine interaces (HMIs) rom
Siemens, Rockwell, Mitsubishi,
Wonderware, etc This enables true
versatility in our solutions
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ERP Integration
MES Applications
Automation Systems
Automation Migration
Automation Service
• Automation Migration for ourcustomers with an installedbase o ageing and obsoleteautomation equipment whichcan no longer adequately sup-port their business Furthermore,Automation Upgrade or systemsthat require additional unctionalityto meet automation and controlrequirements
• Automation Systems consisting
o PLC and HMI as part o ourproject oering These can be inthe orm o a single skid unit toplant wide automation solutions
• MES Applications targeting manu-acturing and equipment perorm-ance, production execution, qualityand tracking We oer a suite oengineered applications designedto deliver the right inormation, atthe right time, to the right people,in the right context to drive utureactions in our customers’ or-ganizations to drive manuacturingexcellence
• ERP Integration solutions thatlink and integrate the plant foorautomation systems to ourcustomer’s enterprise or businesslayer
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Until recently, the impact o
maintenance operations on round-
the-clock production, quality,
manuacturing fexibility, traceability,
plant saety and environmental
protection has been largely ignored
APV recognizes that cost-eective
perormance o your APV equipment
is directly dependent on the ability to
design and implement a cost-eective
maintenance program
In response to these requirements,
and as part o the on-going expansion
o our customer support strategy,
APV Maintenance Services adapt to
your specic requirements
Maintenance Services consists o
multiple levels o service agreements
in order to create the ideal balance
o fexibility, improved productivity,
increased up-time and better nancial
perormance o all APV equipment
Dierent service agreements can
be created or our customers For
example:
• BasicCare - APV service when you can plan
ahead- Balance o uptime and
economics or non-critical assets
• ClassicCare - Comprehensive APV service
support- When service delays are not an
option
• AdvantageCare - APV service coverage or yourmost critical equipment
- Proactive approach toequipment perormance
• TotalCare - APV service management and
support or the entire plant- Plant-wide strategy to improve
mission eectiveness
Each agreement includes certain
critical items, with each level providing
progressively increasing support
capability (see table below)
APV is committed to providingproactive service solutions These
Maintenance Services agreements
provide the best possible service to
maximize your perormance and deliver
improved return on your investment
Maintenance Services
Total Care Advantage Care Classic Care Basic Care
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
day day day
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
included included replacement scheme
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 or service Strategy or service Strategy or service
partnership seminar partnership seminar partnership seminar
Sotware upgrades Predictive maintenance on
critical items
Plant availability guarantee Sotware upgrades
Designated APV maintenance Rebuilding & retroitt ing
manager consultancy
Continuous process cost
reduction
Guaranteed perormance
guarantees on critical items
Annual process knowledge
analysis
Rebuilding & retroitting
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
effectiveness non-critical assets
A Systematic Program o Strategic Maintenance
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The WortMaster product rangecovers units designed or the
processes between the brewhouse
and ermentation, including wort
cooling, yeast dosing and wort
aeration
In addition to ast and ecient wort
cooling, WortMaster units deliver
eective and accurate in-line dosing
o yeast and air/oxygen by means o
the patented APV gas injector
Oered in a wide range o capacitiesfrom 50 – 1200 hl/hr, all WortMaster
units are designed and developed or
easy integration with existing lines
WortMaster
- adds value
The WortMaster adds value to your
products and processes in the
ollowing ways:
Product uniormity:
• Constant monitoring and improved
regulation o the process
• Repeatable fermentation
perormance
Economical production:• Higher accuracy in yeast and oxygen
dosing
• Reduced fermentation time
Flexible production:
• Turn down ratio to 25% of nominal
capacity
• Constant yeast/oxygen ratio,
regardless o fow
Proven security:• Fully CIP-cleanable
• Traceable production data
WortMaster – Wort Cooling, YeastDosing & Wort Aeration
Ensure economical production by minimizing the use o time and additives
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FunctionalDescription
Wort Cooling - Hot wort rom the
brewhouse must be cooled prior to
the addition o yeast or ermentation
This is achieved using a state o the
art plate heat exchanger with a wide
channel, which reduces the cleaningrequirement while maintaining good
heat transer eciency Additional
attractive eatures include a high
perormance clamping system,
improved hanging area and EasyClip
gaskets, all o which contribute to
reduced maintenance and spare parts
requirements
The wort cooler can be designed as a
single section cooler using ice wateror as a double section cooler or
brewing water and rerigerant
Wort Aeration - Brewing yeast
requires oxygen to multiply
Traditionally this has been supplied
by blowing air through the wort with
various types o nozzles and mixers
The result was oten varying oxygen
levels o typically 10-12 mg O2/l
depending on pressure, temperatureand the original gravity o the wort
Specied O2 levels with high gravity
worts are usually higher and thus pure
oxygen is oten used to achieve levels
above 18 mg O2/l
The APV Gas Injector allows these
levels to be achieved by a ast
consistent mixing o wort and either
air or oxygen
Yeast Dosing - Yeast can be added
to complete the wort treatment This
has the advantage o adding yeast
immediately to the cooled wort
The actual method used can refect
local practice and the automation
allows accurate MIS/MES integration
In the event o lack o product fow,
the yeast supply is shut o
Options
Cooling• DuoSafety Plates - Additional
product protection
• ParaWeld Plates - Allow the use of
NH3 as rerigerant
• Bypass – Options are available for
bypassing the plate heat exchanger
to enable such operations as hot
and/or cold wort diversion and back
washing
Aeration
• Manual Adjustable Head – Any
adjustment or fow and specication
must be made manually
• Modulating Head – Automatic
adjustment o the head can be made
rom the control system This option
can be retrotted to the manual head
Dosing
• Flow Measurement – The yeast can
be dosed by means o a magnetic
fowmeter
• Tank Contents Measurement – The
amount o yeast can be dosed on the
basis o tank contents measured by a
load cell
• Yeast Cell Measurement – The
amount o yeast can be dosed on
the basis o instrumentation that
measures the yeast cell
concentration
Common
• Original Extract Measurement -
Completed through the means o
a sound velocity sensor or density
measurement
• Oxygen Measurement – The oxygen
content o the wort can be measured
using an appropriate instrument
• Blending Separation - The simple
blending “T” can be replaced with
a 4 port double seat valve and stopvalve to separate the product and
component loops or cleaning
• High Accuracy Blending – A
variation o this technology using
mass fow measurement is capable o
even higher accuracy and is used or
blending o components such as hop
extract or color
• Conductivity Measurement –
Product separation can be measured
by means o conductivity to minimize
product loss
BREW WATER
WORT
STERILE AIR
AERATED WORT
K K
GLYCOL
GLYCOL
BREW WATER
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Deaerated water is used in the
brewing industry to minimize damage
to beer through oxidation It is used
as a medium or purging mains andequipment and post ermentation as
part o the brewing process
The Derox product range covers units
designed or deaeration o processing
water Derox is used where a low O2
content is required or recommended,
or example or the lauter tun,
blending o bright beer and in High
Gravity Brewing (HGB) processing
Deaeration can be perormed by two
dierent systems - cold (Derox) or hot
(Derox+) deaeration The hot system
heats the water to high temperature,
which reduces the risk o inection
and helps remove contaminants The
cold system is capable o achieving
low levels o oxygen with low capital
and production costs
All Derox Units are designed anddeveloped especially or easy
integration to existing lines, with a
wide and fexible capacity range
Derox (cold)
- adds value
The standard capacity range is 30 –
1500 hl/h
The Derox adds value to your
products and processes in the
ollowing ways:
Product uniormity:
• Constantly low oxygen content 50
ppb at 12°C* (below 30 ppb at>20°C*)
• Continuous monitoring for required
specication
Economical production:
• Low running costs
• Space-saving design (high capacity/
m2)
Flexible production:
• Variable capacity and high turn down
• Independent of water inlet
temperature (option)
• Variable deaeration levels
Proven security:
• No rings and plates inside vacuum
tanks
• Fully CIP-cleanable
Derox+ (hot)- adds value
The standard capacity range is 50 –
400 hl/h
The Derox+ adds value to your
products and processes in the
ollowing ways:
Product uniormity:
• Constantly very low oxygen content
(below 20 ppb*)
• Continuous monitoring for requiredspecication
• Continuous removal of undesirable
THF gases
Economical production:
• Low running costs
• Space-saving design (high capacity/
m2)
Flexible production:
• High turn down ratio (down to 25%o nominal capacity)
• Independent of water inlet tempera-
ture
Proven security:
• No rings and plates inside vacuum
tanks
• Deaerated water is pasteurized
• Fully CIP-cleanable
Derox – Cold and Hot Water DeaerationImprove your beer quality with the Derox Deaerator
* Measured as a standard deviatio
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FunctionalDescription
Hot deaeration
Water entering the unit is warmed by
means o the regenerative section o
a plate heat exchanger
Ater the regenerative section, the
water enters a heating section where
the temperature is raised to about
88ºC The water is then sprayed
into the deaeration tank via special
nozzles
The deaeration tank is kept under
vacuum so that the oxygen is removed
with a minimum o water vapor
The deaerated water is cooled in
the regenerative section o the plate
heat exchanger and the nal outlet
temperature is achieved using a
chilling section or a separate cooler,
depending upon the rerigeration
available
The deaeration tank does not contain
packing and is easily cleaned
Cold deaeration
Water is sprayed into the bottom
vacuum tank, which starts the oxygen
removal process
The water is then pumped and
sprayed into the top vacuum tank via
an injector where stripping gas (either
CO2 or N2) may be applied
From the top tank the water alls
through a pipe with a vent which
allows some o the water to return
into the bottom tank The level in this
bottom tank is controlled by means
o a level switch, which controls the
water inlet valve
The remaining water is discharged
rom the unit via an adjustable
manual-regulating valve
The unit is designed or CIP and does
not contain packing
Options
Hot deaeration
• CO2 Stripping - The use o a small
amount o stripping gas can allow
the energy lost through fashing to be
reduced
Cold deaeration
• Chilling - Chilling of water to
match beer temperature Dierent
congurations are available
• UV Water Disinfection - Disinfec-tion o the incoming water can be
obtained by the use o an ultra-violet
disinection unit
• Seal Water Cooling - In cases where
the seal water will exceed 25°C it is
advisable to t an optional seal water
cooler
DEAERATED WATER
WATER/CIP
CO2 / N2
Derox (Cold)
• Preheater - Values below 003 ppm
residual O2 can be achieved with a
water temperature o about 20°C
In cases where this water inlet
temperature is not a normal value, a
pre-heater consisting o a shell and
tube heat exchanger together with a
steam regulation valve and
condensate trap can be supplied
Common
• Oxygen Measurement - The result
o the deaeration process can be
measured in-line with an oxygen
measuring instrument, and the values
used to initiate remedial action or
alarms
• Control Panel Enhancements –
Advanced control systems with digital
programming allow extremely accurate
control and comprehensive data
collection Many o these acilities
are also available with PLC control
systems
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The BlendMaster range covers units
designed or continuous in-line
blending o liquid components
It ensures precise recipe conormity,regardless o whether two or more
liquid components are combined
The BlendMaster is used, or
example, in High Gravity Brewing and
in combination with other unit types
like the CarboMaster or the HGB
Master
Standard capacity range: 50 –1200
hl/h
BlendMaster- adds value
The BlendMaster adds value to
your products and processes in the
ollowing ways:
Product uniormity:
• Ensures exact conformity with the
specied recipe
• High calibration stability
Economical production:
• High precision blending
• Space-saving design (high capacity/
m2)
Proven security:• Continuous monitoring and
regulation o the combined product
• Automatic switch-off, if offset
exceeds the limit
BlendMaster – In-Line BlendingThe BlendMaster adds new dimensions to accurate standardizing and eciency
Flexible production:• Easy change of recipe for fast
product change
• Turn down ratio 25% of nominal
capacity
• Blending ratio 1:10 to 1:2
Combined blending and carbonation unit
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FunctionalDescription
Extract and alcohol are parameters
usually used or duty purposes, and
product declarations and accurate
determination are thereore important
HGB is now a world-wide standard
involving the addition o part o the
brewing water ater ermentation
instead o within the brewhouse
Even when HGB is not a standard
procedure, cutting the nal beer with
small amounts o water to achieve a
consistent product is oten required
Magnetic fow meters are used to
measure the volumes o high gravity
beer and deaerated water Dosing
takes place by means o a simple
ratio control operating a modulating
valve on the water supply This gives
results that are within the accuracy
o laboratory instruments and in-line
measurement This ratio control may
be adjusted by means o an optional
sound velocity/alcohol sensor, whichmeasures the original extract o
the beer and applies appropriate
corrections
This technique can also be used or
blending beer types or diluted beer
rom ltration
Options
• Original Extract Measurement -
Completed through the means o a
sound velocity sensor This measures
the velocity o sound in a ermented
product, which is proportional to the
original extract o the unermented
product• Alcohol Measurement - Density
measurement by means o mass fow
techniques, which together with
sound velocity measurement allow the
alcohol contents to be calculated
• Blending Separation - The simple
DEAERATED WATER
FINAL BEER
HGB BEER
PI
FT
FT
DT
GT
blending “T” can be replaced with a 4
port double seat valve and stop valve
to separate the product and
component loops or cleaning
• High Accuracy Blending – A
variation o this technology using
mass fow measurement is capable o
even higher accuracy and is used or
blending o components such as hop
extract or color
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The CarboMaster is the answer when
you are looking or a cost eective,
accurate and fexible gas-dosing unit
The CarboMaster range coversunits designed or continuous in-line
injection and dissolving o gasses like
CO2, N2
This equipment ensures a precise
and uniorm injection, by means o
the patented APV gas injector (see
description on page 18)
The CarboMaster is used in the
brewery industry or duties such ascarbonation and can be integrated
with other unit types, including the
BlendMaster or the HGB Master
Standard capacity range: 50 –1200
hl/h
CarboMaster- adds value
The CarboMaster adds value to
your products and processes in the
ollowing ways:
Product uniormity:
• High dosing accuracy (+/- 0.05g
gas/kg product*)
• Injection independent of inlet
temperature and pressure Economical production:
• No gas losses
• Space-saving design
• Holding time not necessary
Flexible production:
• Turn down to 25% of nominal
capacity
• Inject and dissolve up to 10g gas/kg
product
Proven security:
• Constant monitoring andcontrol o nal product
• Fully CIP-cleanable
CarboMaster – Carbonation and NitrogenationThe CarboMaster is the answer when you are looking or a cost eective, accurate
and fexible gas-dosing unit
CarboMaster or high Co2 content
* Measured as a standard deviation
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FunctionalDescription
The basis o the unit is the patented
APV CO2 special injector, which
diers rom other models by injecting
the liquid into the gas in counter
fow This achieves quick dissolution,
and the gas is tightly bound to the
liquid High levels o CO2 addition
can be obtained without long holding
tubes, and a precise ast regulation is
obtained It is possible to carbonate
sales gravity beer to the desired level
ater the addition o non-carbonated
water
The calculated value is compared
with the measured value and the
CO2 content adjusted appropriately
by means o the modulating valve
The xed head injector can cope with
variation in fow rates o about +10%
The gas supply is shut o i the
product fow stops
Options
• Variable Capacity Head - The xed
head can be replaced with a variable
capacity head which allows a turn-
down to 25% o the nominal capac-
ity This can be either pneumatically
controlled or manually adjusted
• High Carbonation Levels - The
standard system is engineered tocope with levels o CO2 normally
specied in beer Carbonation o up
to 10g/kg CO2 may be obtained i
required
• CO2 Measurement - An in-line CO2
analyzer can be installed together
with a regulating valve to allow the
BEER
CARBONATED BEER
CO2 contents to be automatically
monitored and adjusted
• High Precision Dosing – By means
o a gas fow meter, the amount
o added gas can be accurately
determined to avoid over or under
carbonation This is more accurate
than CO2 measurement with which
it is oten combined A urther ad-
vantage is that the gas usage data
can be used or production control
and statistics by means o a suitable
control system
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The HGB Master combines the three
process stages o water deaeration
(Derox), inline blending (BlendMaster)
and carbonation (CarboMaster)
into a single, all-inclusive process
The HGB Master ensures a cost-
eective high gravity brewing process
combined with very high production
fexibility The unit is designed
and developed especially or easy
integration with existing lines, and is
available in an extensive and fexible
capacity range
Standard capacity range: 50–1200
hl/h
HGB Master- adds value
The HGB Master adds value to
your products and processes in the
ollowing ways:
Product uniormity:• Constantly low oxygen content 50
ppb at 12°C* (below 30 ppb at
>20°C*)
• Continuous monitoring for required
specication
• Exact conformity with the specied
recipe
• High calibration stability
• High dosing accuracy (+/- 0.05g
gas/ kg product*)
• Injection independent of inlet
temperature and pressure
Economical production:
• Low running costs
• High precision blending
• Space-saving design (high capacity/
m2)
• No gas losses
• Holding time not necessary
Flexible production:
• Variable capacity
• Independent of water inlet
temperature (option)
• Variable deaeration levels
• Easy change of recipe for fast
product change over
• Turn down ratio 25% of nominal
capacity
• Blending ratio 1:10 to 1:2
• Inject and dissolve up to 10g gas/kgproduct
Proven security:
• No rings and plates inside vacuum
tanks
• Constant monitoring and control of
nal product
• Automatic switch-off, if offset
exceeds the limit
HGB Master – High Gravity BrewingThe HGB Master is the result o a compact 3-in-one unit, which deals you all the
aces in the pack
* Measured as a standard deviation
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• Fully CIP-cleanable
FunctionalDescription
Wide scale use o High Gravity
Brewing has become standard
modern brewing practice, as thereduction in production costs is
signicant By adjusting the extract o
the beer ater ltration rather than in
the brewhouse, the nal output o a
given plant is greatly increased
A High Gravity Brewing Unit
comprises a combination o several
modules described elsewhere The
normal conguration consists o
a deaeration module, a blendingmodule and a carbonation module
The integrated unit is simpler,
more compact and cheaper to
implement than separate modules
The deaerated water is taken rom
the skid to the buer tank and an
amount returned or blending and
carbonation Deaerated water rom
the buer tank is still available or
other applications
Options
• Hot Deaeration – For added security
with poor water quality
• Cold Deaeration – For minimum
production costs
• Blending – Addition of DAW can be
normal or combined with the addition
o pre- and post-run diluted beer• Carbonation – Correction of the
CO2 contents o the nal beer to
specication This is normally a single
point but pre-carbonation o the
water can be supplied i desired
HGB BEER
CO2 /N2
WATER
GLYCOL
GLYCOL
CO2
FINAL BEER
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The PU Pasteurizer was developed
especially or continuous heat
treatment o beer and other
carbonated drinks
The pasteurization temperature in
the PU Pasteurizers is controlled
by Pasteurization Units (PU) and
designed or high working pressures
The PU Pasteurizer provides eective
and gentle heat treatment o all kind
o carbonated products
Standard capacity range: 50–500
hl/h
PU Pasteurizer- adds value
The PU Pasteurizer adds value to
your products and processes in the
ollowing ways:
Product uniormity:
• Very high accuracy (computer
controlled PU regulation)
• LowΔ T between product and
heating media
Economical production:
• Large heat regeneration (up to 94%)
with low temperature lling
• Waste-saving design (beer/water
zone)
Flexible production:
• Turn down ratio 40% of nominal
capacity
Proven security:
• Constant overpressure downstream
• Constant monitoring and control of
nal product
PU Pasteurizer – Controlled Beer PasteurizationI you value gentle and accurate heat treatment you will also value the PU Pasteurizer
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FunctionalDescription
Pasteurization is calculated on
the basis o holding time and
temperature The time actor is
linear, and small variations have a
minor eect on the PU value and are
controlled by adjusting the fow Thetemperature actor is exponential
and small variations lead to more
substantial changes in the PU
value The PU value is maintained
by the control system, adjusting
these parameters In the event o
a downstream shutdown, water
replaces the beer in the system to
maintain the balance
The temperature is controlled bymeans o hot water circulation With
a beer pasteurizer, the dissolved
gas must be retained in solution
throughout the process by the
appropriate system pressures The
design system pressure can be set
or each beer type to minimize energy
requirements
The unit is based on a three-
section plate heat exchanger withregenerative, heating and cooling
sections The heating section is part
o a heating cycle in which water is
warmed by means o a shell and tube
heat exchanger The beer temperature
is variable, 72°C held or 30 seconds
being typical
The cooling duty is selected
according to packaging requirements
A regenerative outlet temperature as
close as possible to the packaging
temperature allows reduced energy
consumption
A high-pressure pump supplies
the regenerative section outlet with
the required pressure A booster
pump between the regenerative and
heating sections o the plate heat
exchanger ensures that the pressure
on the sterile side o the regenerative
section is higher than the pressure
on the non-sterile side This pump
is requency controlled to allow
adjustment o the pressure in the
holding cell
A modulating valve is used togetherwith a magnetic fow meter to
regulate the fow and thus the holding
time
The beer enters a buer tank
equipped with a load cell to
measure the contents In the event
o a downstream shutdown, the
pasteurizer continues operation until
a pre-determined maximum level is
reached The remaining beer in thesystem is fushed into the buer
tank with water, which is then re-
circulated to maintain the balance
On resumption o downstream
production, the buer tank is emptied
until a pre-determined minimum level
is reached The water circulating in
the pasteurizer is pushed out to drain
or to a collection tank with resh beer,
and normal operation resumes
The unit is started by means o a shell
and tube heat exchanger heating
water to 80°C or sterilization and
to balance the system Heating o
the system to balance typically takesplace in less than 10 minutes
Options
• Advanced control systems with
digital programming allow even more
accurate temperature and pressure
control They can be combined with
predictive and uzzy logic or extreme
accuracy
• A conductivity meter registers the
interace between beverage and
water and reduces changeover
losses to a very low value
• Valve types and congurations can
be customized as required
• A double shunt for improving the
coolant supply can be integrated
GLYCOL
GLYCOL
BEER
BUFFERTANK
WATER/CIP
WATER
CONDENSATE
STEAM
I R P
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The production o high quality beer
using highly ecient operating
techniques requires eective, careul
cleaning o equipment APV oers
CIP modules as standardized
compact units or units tailored exactly
to our customers specic projects
and needs
The APV CIP Master is a ully
automatic system, programmed
to achieve optimal cleaning o the
process equipment
The APV CIP Master
– adds value
The APV CIP Master adds value to
your products and processes in the
ollowing ways:
Product uniormity
• Fully automatic CIP programs ensure
perect cleaning
Economical production• Full automation reduces manpower
• Optimization of functionality leads to
reduced cleaning
Flexible Production
• Easy implementation of options due
to modular design
• The APV CIP Master is skid mounted
when possible, which allows easy
relocation in the event o production
restructuring
Proven security
• If appropriate, the CIP Master is fully
tested beore delivery
• Proven functionality and reduced
commissioning time
Functional
description
The APV CIP Master is a ully
automatic, sel-contained unit
It comprises a complete set o
equipment or CIP, including, or
example, tanks or water, acid and
caustic soda, pumps, tubular and/
or plate heat exchangers, valves and
instrumentation such as conductivity
and fow transmittersThe CIP program covers the
complete cycle Detergent or water
selection, detergent concentrations
and cycle temperatures and times are
ully controlled
The APV CIP Master is ully
integrated with the process line and
can be used with existing equipment
(including lling machines) as well as
new APV units
The design o the CIP Master by
APV incorporates the requirements
o production schedules to minimize
downtime This orms the basis
or selecting the appropriate tank
numbers and volumes together with
the number o lines
The standard APV control consists
o a controller with an operator panel
The signal exchange between the
instruments/controller/control room is
perormed using a bus system
Options
• 3, 4 or 5 tank systems
• Different tank sizes
• Number of lines
• Tubular or plate heat exchangers
• Low cost manual CIP systems
• Customer specic equipment
• PC solutions based on Wonderware
FactorySuite™
• Modem connection for remote
controller service
CIP MasterGo or perect cleaning results at lower cost with the APV CIP Master
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Fermentation & Maturation
Proper ermentation requires wort
cooled to the right temperature,
aerated to the right oxygen content
and dosed with the right amount
o active yeast cells APV designs
highly automated process systems
that continuously control all essential
parameters beore and duringermentation and maturation, ensuring
an end product o a consistently high
quality
The control systems o ermenter
cooling and the process system are
designed to provide cohesive support
to brew masters, process engineers
and automation specialists to help
them to meet the requirements or
specic beer types The result is
a complete and well-documented
process line designed to maintain
the characteristics o the beer and to
meet consumer expectations or high
quality
FiltrationDue to seasonal fuctuations in the
quality o the raw material and the
complexity o the process itsel,
ltration is one o the more complex
parts o the brewing process APV
works in close co-operation with
reputable suppliers o ltration
systems to meet the needs o aspecic project
It is important to control the dierent
phases o the ltration process and
integrate them into the rest o the
beer processing line, ensuring that
the required production capacity is
reached
APV, An SPX Brand105 CrossPoint ParkwayGetzville, NY 14068Phone: (716) 692-3000 (800)207-2708 Fax: (716)692-1715E-mail: answersus@apvcom
For more inormation about our worldwide locations, approvals, certications, and local representatives, please visit wwwapvcom
SPX reserves the right to incorporate our latest design and material changes without notice or obligationDesign eatures, materials o construction and dimensional data, as described in this bulletin, are provided or your inormation only andshould not be relied upon unless conrmed in writing Certied drawings are available upon request
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