1. www.anton-paar.com
Critical Process Control Points
Where, What, How and Why?
工艺控制关键点讨论
Daniel L. Gore
Application Specialist – Process Instruments
Brewer & Malter
Anton Paar GmbH

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Create a Process Plan of YOUR Brewery
啤酒生产工艺流程

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Ask a lot of questions and review your process thoroughly.
通过一些问题来回顾下生产过程
What is the difference between lab and process measurements?
 Lab measurements are static snapshots of a dynamic process.
 Process measurements are live streaming surveillance video.
实验室和在线测量的不同点是什么？
 实验室测量是动态生产过程的静态定格拍照.
 在线测量是连续的实况监视录像。
Lab and Process Instrument Basics.1
实验室及在线仪器基础1

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Ask more questions and review your process thoroughly.
通过一些问题来回顾下生产过程
Why both laboratory and process instruments?
 A laboratory measurement is performed in a stable environment at a
stable temperature and is calibrated regularly with a verified standard.
 A process measurement is performed under process conditions with
variable temperature, flow, pressure, and concentration and must be
verified with a representative lab sample.
为什么同时需要实验室和在线仪器呢?
 实验室测量是在稳定的环境、稳定的温度和通过标准方法定期校准的仪器
下完成的。
 在线测量是在温度、流速、压力、浓度都在变化的生产条件下完成的，需
要通过进行实验室样品测量进行校正。
Lab and Process Instrument Basics.2
实验室及在线仪器基础2

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Lab and Process Instrument Basics.3
实验室及在线仪器基础3
Ask more questions and keep reviewing your process.
通过更多问题来回顾下生产过程
What exactly do you need to measure?
• Temperature, extract, pH, alcohol, color, viscosity, etc.
什么是真正需要测量的?
• 温度、原浓、PH、酒精度、色度、粘度等
Where exactly do you need to measure it?
• Mash tun, lauter tun, kettle, blending, packaging, wastewater?
• Do you need a lab instrument? A portable, handheld instrument?
An inline instrument?
需要在什么点去测量?
• 糖化锅、过滤槽、煮沸锅、高浓稀释、包装、废水？
• 你需要实验室仪器吗？一个便携的手持仪器？一个在线仪器？

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Lab and Process Instrument Basics.4
实验室及在线仪器基础4
Ask more questions and keep reviewing your process.
通过更多问题来回顾下生产过程
What is the total cost of ownership (TCO)?
= Instrument price + installation cost + lifetime maintenance
+ consumables + training
- increased production - time, energy and resource savings
总共的购置成本是多少(TCO)?
= 仪器价格+ 安装费用 + 维护费用 + 消耗 + 培训
- 增加的生产价值-时间、能源、财力节约

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Lab and Process Instrument Basics.5
实验室及在线仪器基础5
Ask yet more questions to ensure you didn‘t miss anything.
再通过一些问题来确保没遗忘什么事情
What is the best method to use?
• Do you have an existing method already in use?
• What works best with YOUR existing systems and requirements?
• Do you have a preferred installation method?
• What are the pros and cons of available installation methods? ?
什么方法是最好的方法?
• 你现在已经有使用的方法吗?
• 什么能很好的满足你现在的系统和要求?
• 你有想要的安装方法吗?
• 什么才是有效的安装方法?

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Lab and Process Instrument Basics.6
实验室及在线仪器基础6
Ask yet more questions to ensure you didn‘t miss anything.
再通过一些问题来确保没遗忘什么事情
What do you want to do with the information (short and long term)?
• Quality control? Automation? Regulatory control? All of these?
• Do you need a dedicated lab instrument? A portable instrument?
• Do you need a portable or starter system to start your QA lab?
你计划做什么事情(短期和长期)?
• 质量管理? 自动化? 法规控制? 以上所有?
• 你需要一个专用的实验室仪器吗?一个便携的仪器?
• 你需要一个便携的或者系统启动器来启动你的QA实验室吗?

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Available Measuring Principles 各种测量方式
(there are a lot....)
Alcohol
酒精度
NIR, density and sound velocity, density
and refractive index, sound velocity and
refractive index, ATR...
近红外，密度声速，密度折光，声速折
光，衰减全反射
Extract
麦汁浓度
Oscillating U-tube, sound velocity,
refractive index, ATR...
U型震荡管，声速，折光，衰减全反射
Color
色度
430 nm absorbance measurement... 430 nm 吸光度
pH Potentiometric 电势电位测定
Turbidity
浊度
3-angle light scattering, ratio method,
optical...
3角度光散射，比例方法，光学
CO2
Multiple volume expansion method,
optical, Henry‘s law, membrane...
多体积膨胀法，光学，亨利定律，膜渗
透
O2 Optical, membrane... 光学，膜渗透
Viscosity
粘度
Rolling-ball, rotation, vibration... 转球，旋转，震动
To name just a few.....

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Method Recommendations
方法推荐
Look for approved and recognized methods:
寻找一些被公认的方法：
 MEBAK: 2.9.2.3, 2.9.6.1 – 2.9.6.3
 EBC: 1.6, 9.2.6, 9.28.5, 9.43.2
 ASBC: Beer-2B, Beer-4, Beer-5

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Congress Mash
糊化
What to measure?
测量什么？
• °Plato (extract yield), smell, iodine test,
filtration, clarity, viscosity, pH, wort color, boiled
wort color, nitrogen content, protein solubility
and diastatic power
• °Plato浓度、气味、碘液试验、过滤、净度、粘
度、PH，麦汁色度、煮沸麦汁色度、含氮量、
蛋白质溶解度和糖化力
Why measure it?
为什么测量？
• Monitor malt quality, how it responds
during the mash and its ability to
convert its contents.
• 控制麦芽质量，糊化过程中如何反应及转化力

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Lauter Tun/Mash Filter Outlet
过滤槽/麦汁过滤出口
What to measure?
测量什么？
• °Plato (extract), temperature, viscosity, pH
°Plato (麦汁), 温度，粘度， pH
Why measure it?
为什么测量？
• Monitor first runnings, main wort and
last runnings
监控生产开始，进程及结束
• Automate when to send wort to the kettle or last
runnings to wastewater
实现自动输送麦汁到煮沸锅或自动输送至废水回收。

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Lauter Tun/Mash Filter Outlet
过滤槽/麦汁过滤出口
Why measure it?
为什么测量？
• Save time and water, increase lauter tun
efficiency, reduce wastewater
节约时间和水，提高过滤槽效率，降低水耗
• Shorten boil time and increase kettle
efficiency
减少煮沸时间，增加煮沸效率
• Ensure further enzyme activity
确保更长的酶活性
• Ensure proper viscosity for optimal extract
and lauter time
确保适当的粘度来得到最佳的麦汁和过滤时间

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Lauter Tun/Mash Filter Outlet
过滤槽/麦汁过滤出口
To kettle →
There are many options... 有很多选择…
Volume
Meter
DPRn
SPRn
mPDS 1100 or mPDS 5
ESC
ENTER
TEMP +16.14 °C
DENS: 1.33317 g/cm3
:
PER-D: 2574.976 us
Ai-curr: 0.160 mA
mPDS 1100
L
06
How and where to measure it?
怎样？在哪里测量？

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Kettle
煮沸锅
What to measure?
测量什么?
• Extract, temperature, viscosity, pH
麦汁浓度，温度，粘度，pH
Why measure it?
为什么测量？
• Reduce boil time and increase kettle
efficiency
减少煮沸时间，增加煮沸效率
• Save time and energy
节省时间和能源

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Kettle
煮沸锅
Why measure it?
为什么测量？
• Enable further automation for boil end
提高煮沸的自动化程度
• Ensure proper viscosity for filterability
确保合适的粘度以提高滤过率
• Monitor foam stability
监控泡沫稳定性
• Ensure proper hop isomerization
保证适当的异构化作用

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Hot water
mPDS 1100 or mPDS 5
ESC
ENTER
TEMP +16.14 °C
DENS: 1.33317 g/cm3
:
PER-D: 2574.976 us
Ai-curr: 0.160 mA
mPDS 1100
L
06
Hot water
Kettle
煮沸锅
External
boiler
DPRn
SPRn
SPRn
There are many options... 有很多选择…
How and where to measure it?
怎样？在哪里测量？

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Production Increase Brewhouse ROI
生产增加酿酒厂的ROI
Example:
8 brews/day (3 hours/brew)
x 10 min saved/brew
= 80 min/day saved
80 min/day saved
x 7 days
= 3.1 extra brews/week
3.1 extra brews/week x 52 weeks/year
= 161 extra brews/year possible

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Cellar and Product Blending
发酵及高浓稀释
What to measure?
测量什么?
• Extract, alcohol, CO2, O2, pH, color, turbidity, viscosity, etc.
浓度、酒精度, CO2, O2, pH, 色度, 浊度, 粘度等

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Cellar and Product Blending
发酵及高浓稀释
Why measure it?
为什么测量？
• Monitor fermentation progress and avoid fermentation issues
控制发酵进程，避免发酵问题
• Proactively blend product to avoid production bottlenecks
混合产品，避免生产瓶颈
• Adjust CO2 content before packaging
包装之前校正CO2浓度

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Cellar and Product Blending
发酵及高浓稀释
Why measure it?
为什么测量？
• Avoid tax issues (gravity or alcohol and country specific)
避免税金事宜（比重或酒精度或政府明确的）
• Ensure product consistancy and quality
确保产品质量和一致性
• Increase production
增加产量

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Cellar and Product Blending
发酵及高浓稀释
Pressure and flow control
CO2
H2O
Process pump
Blending
To BBT
and
carbonation
Measure Alcohol, Real and Original Extract and CO2
测量酒精度、真浓、原浓和CO2
How and where to measure it?
PLC
DSRn
Carbo510

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Production Increase: Blending ROI
产量增加：混合ROI
Real Example:
Target alcohol is 4.8%
200hl beer @ 4.9% alc blended with 4.17 hl H2O
= 204.17hl beer @ 4.8% alc
Every liter of water = additional beer
每多加一升水=多产的啤酒

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Packaged Product
成品包装
What to measure? 测量什么?
• Extract, alcohol, CO2, O2, TPO, pH, color, turbidity, viscosity, etc.
浓度、酒精度, CO2, O2, TPO, pH, 色度，浊度，粘度等
Why measure it? 为什么测量?
• This is the last QA check possible
这是最后的QA检查

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Packaged Product
成品包装
Why measure it? 为什么测量？
• Ensure product consistancy and quality
确保产品质量和一致性
• Verify process instrumentation
核实在线仪器的可靠性
• Avoid tax issues
避免税金事宜

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Possible Lab Measurements
可能的实验室测量
Wort / Fermentation
麦汁/发酵
 % Alcohol (v/v, w/w)
 °Plato
 Color色度
 Viscosity粘度
 Degree of fermentation…
发酵度
Beer 啤酒
 %v/v 酒精度
 °Plato original extract原浓
 Apparent, real and orginal
extract, calories…
表观浓度，真浓，原浓，卡路里
Options 选项
 Color
色度
 Turbidity
浊度
 CO2
 pH
 O2

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Thank you!
Thank you
Prost! 乾杯！ Cheers!