Instrumentation best practices in Brewing Slide 1 Ola Wesstrom - - PowerPoint PPT Presentation

Products Solutions Services

Instrumentation best practices in Brewing

Ola Wesstrom Slide 1

04/24/2020

What we will cover

Endress+Hauser – overview Best Practice application examples Instrumentation for small, medium, and large brewing operations Improving brewhouse efficiency Maximizing extract yield Ensuring beer quality Yeast handling and metering Fermentation monitoring Transferring metering to optimize planning process and reduce packaging losses Assuring availability of the brewery – calibration and maintenance Tools for selection

Ola Wesstrom Slide 2 Instrumentation best practices in Brewing

04/24/2020

Endress+Hauser – a family company

Privately Owned by Endress Family – solid family charter.

• 2018 Revenue 2.4B Euro
• Equity Ratio of 72.2% - financial stability
• 14,000+ Global Employees – solid back up
• +10% Yearly Revenue into R&D – leading

innovation 5,300+ Patents Diversified Portfolio

• Food & Beverage
• Chemical
• Water & Waste water
• Oil & Gas
• Power
• Life Sciences
• Primaries and metal

Endress+Hauser - Your safe choice

Link to Corp Info

Slide 3

04/24/2020

Our Core Competence – Instrumentation and related services

Slide 4 Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

All from one manufacturer – Easy standardization

Slide 5 Level Flow Analysis Pressure Temperature Data Acquisition Systems Services Capacitance Electromagnetic pH Pressure rel. Pt 100 Recorders Profibus PA Commissioning Conductive Vortex Conductivity Pressure abs. Thermocouple Data managers Fieldbus FF Maintenance Hydrostatic Coriolis Oxygen

• Diff. - Pressure

Transmitter Displays Ethernet I/P Repair Differential P Ultrasonic Turbidity

• HydroS. level

Energy calc. Datalogger IO-link Calibration Vibration Thermal-mass Chlorine Datamanager BlueTooth Training Ultrasonic DP-flow Ammonia Paperless Rec. FieldCare Spare parts Microwave Density/Brix Phosphate Power Supply Engineered systems Risk assessment Guided Wave Viscosity Nitrate Batch controller

• Inst. Base Mgm

Electromech. Steam quality Sludge level Tank inventory Receiving Custody Transfer Engineering Radiometric Bio gas Water sampler Servo gage Venturi Color Solids flow Cell Growth Phase separation Raman Spectroscopy

Common platforms:

• Minimize training
• Reduce spare parts

Global market position # 1 Liquid Analysis # 1 Level # 1 Magnetic flow # 1 tie Coriolis mass flow # 2 pressure # 2 Temperature

Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Cost and performance – balanced options

• Entry level:
• No or simple display
• Basic performance specifications
• Limited options or specials
• Mid range:
• Modular and repairable
• Standard options and performance
• Most communication protocols
• High performance:
• For critical or high value applications
• All options and communication

protocols

Cerabar S PMP75 Cerabar M PMP51/55

Example: tiers for pressure/Flow Most Endress + Hauser products are available in 2-3 levels of performance and pricing

Promag H 300/500 Promag H100 Promag 10H Picomag Cerabar T PMP 23/33B Instrumentation best practices in Brewing Slide 6 Ola Wesstrom

04/24/2020

Simple, cost effective options for the start up brewery

Level switches FTW23 FTW33 FTL33H

Ola Wesstrom Slide 7

Analysis CM10 CLD18 Display/recorder RSG35 Flow Promag 10D Picomag Pressure PMP23 PTP33B Temperature TMR35 TM401 Level FMR10/20

Instrumentation best practices in Brewing

04/24/2020

• IP 67/68 or 69K ingress protection
• Fully welded Stainless steel enclosures

with quick disconnects

• Remote options
• Cable glands vs. conduit entry or fixed

cables

• Memosens technology for analytical

measurement points

• All surface mount electronics to survive

vibration

• Convenient setup via Hart, Bluetooth or

LAN cable or Wireless LAN and integrated web server = No special tooling required

Hygienic design & Washdown protection – “Right Tech” for Brewing

Instrumentation best practices in Brewing Slide 8

04/24/2020

Malt and spent grain silo measurement

Slide 9

• Correct inventory information about

Malted grains (barley, wheat,adjuncts..) as well as spent grain is best monitored using free space radar.

• High/low alarm using point level

switch, many options available. Fork style is most reliable and common

• Always know inventory for planning

Image, Brains Brewery

Freespace radar using narrow beam 80gHz FMR67

Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Mash kettle

Ola Wesstrom Slide 10

• Level PMC51 – Ceramic

allows flush mount even with abrasive grains –Capacitance FTI51 for foam alarm pH CPS441D ISFET Pressurized KCL+ CPA875 retractable holder + CM44xR Pressure PMP51 or PMP 31 class FTR20 Soliflow – indicate grain blockages during conveying or Soliphant FTM50 high level in malt mill Temperature TM412 Strike water flow Promag H 100 or Picomag Steam flow, prowirl 200 with dry steam fraction

Instrumentation best practices in Brewing

04/24/2020

pH measurement in mash kettle

Ola Wesstrom Slide 11

pH measurement of mash is important for optimal yield, traditionally difficult with std glass glass pH sensors. The malt enzymes a- and b-amylase require a slightly acid pH to do their work. Optimum Values pH 5.3 @ 77°C

Ceramax CPS341D-7A1H1 - in mash tun

Ceramax CPS341D enamel pH sensor ROI – No need to replace for years, exceptional stability which reduce calibration intervals Reliable measurement in high solids media thanks to large sensing area and mechanical abrasion resistance

Instrumentation best practices in Brewing

04/24/2020

Wet Steam?

Ola Wesstrom Slide 12

100% steam quality 80% steam quality



In the mash tun, mash cooker as well as any other heat transfer where steam is used, cost savings can be realized by ensuring dry steam. The Prowirl 200 gives alarm on preset dry steam fraction Energy value in BTU/KJ Get to temperature faster Optimal amount of steam used, Safety by eliminate water hammer.

Prowirl 200 vortex flow meter with dry steam fraction

Instrumentation best practices in Brewing

04/24/2020

Ceramic pressure sensor in Lauter tun

Lauter bed density and level is measured with 2 x pressure transmitters or Differential pressure. Traditional metal membranes are susceptible to damage from abrasion or mechanical damage during maintenance(dinged when removing false bottoms or calibration) Typical life 2-3 years. Solution – Ceramic membrane pressure sensors Exceptional life expectancy – 15+years

Ola Wesstrom Slide 13

PMC 51 ceramic pressure FMD71 electronic DP w/ceramic sensors

Instrumentation best practices in Brewing

04/24/2020

Optimization of brewing –°Plato Monitoring

Slide 14

• The extraction of fermentable sugar (wort extract) is key to optimal

yield in brewing, this is done in the lautertun and where sparge water is used to flush out the sugar from the grain.

• Measuring the extract(°Plato) outflow enable the brewery to determine

the optimum flushing cycle time and lauter efficiency.

• Optimize sparging and “right on time” separation of weak wort
• Maximize extraction of sugars
• Reduce volume going to wort kettle (energy and capacity savings)
• Assure desired sugar concentration and low polyphenols and lipids

content

• Fast correction of channeling in lautertun

Promass Q300 °Plato/ Gravity Density 0.0002g/cc (0.01°Plato achieved in cold wort)

Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Wort Kettle – extract measurement

Slide 15

Installing the Extract meter (Promass Q) in a circulation loop in the wort kettle enables brewer to monitor the wort during the boil.

• Reach the desired evaporation rate
• Maximize wort kettle utilization
• Maximize extract yield(desired extract concentration)
• reduce worker risk (hot wort sampling)
• Maximize kettle utilization
• Reduce energy – stop when targets achieved

Promass Q300 °Plato/ Gravity Density 0.0002g/cc 0.02°Plato achieved in Hot wort)

The hot wort contain a lot of air bubbles which makes accurate measurement challenging – solved by the Promass Q MFT(Multi Frequency Technology)

Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Turbidity Monitoring of Wort - Whirlpool

Ola Wesstrom Slide 16

Optical turbidity installed on the whirlpool

• utlet allows for automatic detection of trub

cone disintegration.

• The effectiveness of the whirlpool can be

monitored, as well as the wort quality. Reduces lost product

• Increases consistency of end product
• Allows early indication of issues with

whirlpool – eg. Pumping rates too low

Instrumentation best practices in Brewing

Continuous monitoring of the turbidity using OUSTF10 on the whirlpool outlet

04/24/2020

Wort Aeration

Ola Wesstrom Slide 17

The wort is oxygenated to increase yeast activity and to start the fermentation process. Aeration of the wort is required for optimal yeast flotation and fermentation.

• Optical dissolved Oxygen(DO) sensor with

Memosens (pre-calibrate sensor in lab for fast exchange

• Reference LED ensures batch repeatability with

alarm if drifting.

Optical Oxygen Sensor COS81D

Image courtesy of GEA

Instrumentation best practices in Brewing

04/24/2020

Optimization of Fermentation process

Ola Wesstrom Slide 18

• Continuous monitoring of fermentation with densitometer
• Predict instead of react to signs of stuck of sluggish

fermentation

• Transfer final gravity has been reached
• Reduce lab analysis
• Improve fermentation tank utilization
• Reduce chill-water energy

Liquiphant Density, Temperature sensor +5 channel FML621 extract computer

Instrumentation best practices in Brewing

04/24/2020

Too vigorous Fermentation

Don’t want this to happen! Step 1. Monitor your fermentation Step 2. Install foam detection sensor (FTW33 or Liquiphant “foam version”) Step 3. Control your temperature

Ola Wesstrom Slide 19

Foam detection FTL50 or FTW33

Instrumentation best practices in Brewing

04/24/2020

CO2 Recovery

Ola Wesstrom Slide 20

A CO₂ recovery plant consists of a foam separator, a gas buffer container (Balloon), a scrubber, compressor, drying tower and holding tank. Maintenance free holding tank level using the guided wave radar FMP55 (coaxial style is required due to low dielectric of CO₂

Guided wave radar with coaxial probe for CO2 tank

Instrumentation best practices in Brewing

04/24/2020

Maturation / Bright beer, Packaging tank level

Accuracy is key for planning of packaging Hydrostatic pressure is at best +/- 0.1% of adjusted span. Frequent calibrations may be required to ensure performance. Sensor membrane also frequently damaged by impingement cleaning (rotary nozzles). Alternative is E+H ceramic pressure sensors PMC71/PMC51 Free Space Radar gives +/- 1mm(0.04”) independent of span Example: 15ft diameter tank 30ft high Pressure error +/- 0.36” (6.02 gallon) FMR62 error +/- 0.04” (0.22gallon)

• Increase OEE of bottling and packaging line (no more

bottles on the carousel than beer in the tank)

• Reduce extract losses (no more beer waste because bottles

are missing on the carousel)

• Energy/labor savings by matching bottles to beer for

packaging line

FMR62 free space radar gives 1mm accuracy in bright beer tanks

Ola Wesstrom Slide 21

PMC 51 ceramic pressure or FMB50 FMD71 ceramic electronic DP

Instrumentation best practices in Brewing

04/24/2020

Boundary or taxation meters

The transfer from brew house to packaging is often the taxation point and used for planning in packaging Magnetic flow meter is most commonly used for this measurement. + Reliability, small and large size, 0.2% to 0.5% volume accuracy

• Due to the CO2 in the beer, volume also include the CO2

More accurate option – Coriolis massflow – Promass Q300

High accuracy density measurement assists in the determination

• f the type of beer

0.1% volume accuracy

Ola Wesstrom Slide 22

Promag H300 Promag H100 Promass Q300

Instrumentation best practices in Brewing

04/24/2020

Simplify record keeping and reduce downtime

Ola Wesstrom Slide 23

• Verification tool – “Heartbeat verification” allows for boundary

flowmeter check without interrupting process, user friendly and clear reports (can be used for 27CFR25.42 - TTB reporting)

• Increased calibration interval = reduced cost for removing and

sending meter for calibration

• Increased trust in measurement = focus on real issues
• Reduced impact on operations = less downtime

Instrumentation best practices in Brewing

04/24/2020

Field Xpert SMT70 – the one tool for configuration and asset management

Ola Wesstrom Slide 24

Any device (instruments, valves etc) Always up to date 20 languages Generate reports Upload to Asset management

Instrumentation best practices in Brewing

04/24/2020

Digital Tools - Endress Operations App (IOS, Android) Instant access to all info – save time

Ola Wesstrom Slide 25

Look for “Endress operations” app

Scan the QR code on instrument and instant have access to all device information

Instrumentation best practices in Brewing

04/24/2020

Connected Support

Ola Wesstrom Slide 26

• Remote mentor video calling
• We see what you see
• Document Navigation
• Guided workflow
• Mobile forms

1) 24/7 Helpdesk support 2) Need step by step help right now – download the mobile app and use your own mobile device to connect with help desk. We can see what you see and guide you. 3) More advanced or want handsfree, contact us for Headset device. 4) Onsite commissioning, service and calibrations

Instrumentation best practices in Brewing

04/24/2020

High precision and ISO17025 accredited flow, Pressure, temperature ++ calibration Training facilities

Factory Calibration Services

Slide 27 Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

On-site Flow Calibration Rigs

• Flow Calibration Rig

Ola Wesstrom Slide 28

Trailers are equipped with Flow, Pressure, Temperature, liquid analysis calibration equipment.

• Temperature Oil Baths
• Pressure Calibrators

Instrumentation best practices in Brewing

04/24/2020

Energy loss reductions – What is accuracy worth?

Accuracy and repeatability is your friend, ensure that instruments are calibrated and right for the application. How much is +/- 0.7% uncertainty worth over a year

• f production?

Example: simple temperature measurement on a pasteurizer. Actual temp is 164 but temp sensor shows 162F. This 2deg difference = 24lb/h steam loss. 24lb/h x 2000h x $0.046/lb= $2200 per year energy loss

Ola Wesstrom Slide 29

Temperature sensor with

• QuickNeck. Remove sensor for

calibration without disconnecting or opening line. 15min Time saving/calibration Food safety Operator safety Temperature sensor withQuickneck and TrustSens Self calibrating @ 118°C(244°F) >30min time saving/calibration Food safety Operator safety

TM412, 411 TM371, 372

Instrumentation best practices in Brewing

04/24/2020

Tools to assist you

www.endress.com https://www.us.endress.com/en/search?filter.text=applicator a. Look under your industry choice b. Product selection via application parameters c. Application solutions (diary, beverage, utilities d. Make your selection

Slide 30 Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Measure, Analyze, Compute, Monitor, Service, Audit Data Collection, Bus Engineering, Control

F

VMI, ERP, Visualization , e-Business

“MIP” means going beyond the measuring point…

Ola Wesstrom Slide 31 Instrumentation best practices in Brewing

04/24/2020

Control of the CIP-unit

Slide 32 Level measurement with FMB50 Conductivity measurement with CLS54D Conductivity measurement in return line with CLS54D Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Steam System Optimization – Control based on actual Energy usage

Slide 33

Nat Gas BTU/ SCF Steam [BTU/ LBS Condensate return BTU/GPM Make-up water Feed water Flue gas Blow down

Air

Fuel Condensate Steam

heat heat heat Efficiency    ,

De-aerator/ Economizer

Vortex flow with wet steam alarm and compensation Applicator

Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Waste water instrumentation

Slide 34

Level, flow, biogas, pH, DO, TOC, COD, SAC, nitrate, phosphate, Samplers and more

Ola Wesstrom Instrumentation best practices in Brewing

04/24/2020

Goals and challenges in Brewing

Ola Wesstrom Slide 35

Resource conservation

• Extract loss reduction initiatives
• In-line quality monitoring - Repeatability
• Energy reduction
• Water conservation
• Optimization/expansion of water treatment capabilities

Compliance to safety and quality standards

• Calibration services and best practices
• Education and training of operators/technical staff

Instrumentation best practices in Brewing