1. World Brewing Congress 2012
Process and Laboratory Instrumentation for
Critical Process Control Points in the Brewery
(Daniel Gore/Anton Paar GmbH)
July 28 – August 1, 2012
Oregon Convention Center
Portland, Oregon, U.S.A.
225
Malt
Lager Tank
Wort
Wort
Blending and FiltrationPackaging FermentationPhase Detection
Congress Mash
Mash Tun
Lauter Tun Kettle
Whirlpool
2 6
1
3
4
4 4
1
22
5
2
1
1
2 4
2
2
2
22 6
6
6
1
2
2
1
2
4
Bright Tank
Tank Truck
Filler
3 4 6 2 3 4
5
Wastewater
Wastewater Treatment
4 4
2
Brewhouse WW Packaging WWFilter Celllar WWLager Wastewater
1
2
3
4
5
6
1
2
3
4
5
Where: Malt Receiving
What: density, viscosity, color, pH
Why: One of the most important aspects of the malt is how it
performs during the mash and how well it converts its contents. The
congress mash is a common method used to determine how well specific
malt performs. Currently, denisty, extract, pH, viscosity and color are
possible in a single laboratory sample, post congress mash, while the rest
remain wet-chemical tests or require separate laboratory instrumentation.
Density determines congress mash extract while wort viscosity correlates
directly to the degree of modification and provides information on malt
solubility, expected lauter time, beer filterability, foam stability and beer
taste and directly influences product quality and process efficiency.
How: Laboratory instrument examples: DMA 35, DMA 4500 M,
Lovis 2000 M, Mash Bath
TMB, Malt Analyzer
Where: Mash Tun
What: Temperature, pH, saccharifaction or extract
Why: Mash Temperature is critical to optimize enzyme activity
and ensure optimal conversion. Accurate and reliable water and mash
temperature enable process automation and ensure consistent batch
quality.
Mash pH also impacts enzyme activity and efficiency and is helpful with
mash acidification via acid malt or other additives.
Mash extract, measured via density, is the direct result of enzyme activity
and the amount of fermentable sugars produced. Mash extract is a
primary quality parameter and enzyme efficiency indicator.
How: Laboratory instrument examples: DMA 35, DMA 4500 M
Process instrument examples: DPRn 4122, temperature
sensor, pH sensor
Where: Hot & Cold Wort (lauter tun, mash
filter, kettle, whirlpool, wort cooler)
What: Extract (specific gravity, Plato, density), viscosity, pH,
temperature
Why: Whether at the lauter tun, mash filter, kettle, external boiler,
whirlpool or wort cooler, proper wort measurement is imperative to beer
quality. Lauter tun and mash filter effluent monitoring allows the brewer to
better determine when to send first runnings to the kettle, when to send
last runnings to waste and optimize lauter tun efficiency, save water, lower
wastewater volume and influence overall brewhouse efficiency.
Kettle extract, via density or sound velocity, can reduce boil time, increase
brewhouse efficiency and output and enables further automation.
Wort Viscosity is useful as an indicator for the degree of modification, malt
solubility, expected lauter time, filterability, foam stability and beer taste and
directly influences process efficiency. Wort pH helps ensure proper hop
isomerization, product quality and improves body and overall flavor quality.
How: Laboratory instrument examples: DMA35, DMA4500M,
Lovis 2000 M
Process instrument examples: DPRn 427, SPRn 4115,
temperature, pH sensor
Where: Fermentation
What: Density, extract (apparent, real, original), alcohol, CO2
, O2
, pH,
color, turbidity, degree of fermentation, viscosity
Why: Density is a simple method to track the overall fermentation
curve and monitor fermentation speed. Real-time, continuous,
fermentation monitoring allows for quick response to hung or wild
fermentations and therefore allows prior planning of batch blending to
enable proactive production planning.
CO2 is one of the most important criteria for overall product quality.
O2 is good in some places and bad in others, too O2 little oxygen at the
start of fermentation slows or prevents yeast growth and causes slow
fermentation, while too much oxygen after yeast propagation causes
numerous product stability and quality issues.
pH levels during fermentation are also helpful to ensure consistent product
quality and taste and allow for prior planning of batch blending.
Turbidity is useful for monitoring cold settling, overall beer filterability and
final product quality.
Temperature control is imperative for optimum yeast activity and ensures
proper and consistent flavor profile and product.
How: Laboratory instrument examples: DMA35, Alcolyzer Beer
Analyzer System, Lovis
2000 M, CarboQC, OxyQC
Process instrument examples: Temperature, pH sensor,
turbidity
Where: Blending & Filtration
What: Density, extract (apparent, real, original), alcohol, CO2, O2, pH,
color, turbidity, degree of fermentation, viscosity
Why: Whether high gravity blending, fine tuning or blending, accurate
inline measurement of alcohol, extract, CO2
, O2
, color, and turbidity
can provide an immediate, significant improvement to product quality,
consistency and production efficiency. Often found pre-installed on larger
blending or filter systems, inline instrumentation is also easily added to
most any existing system. The viscosity of beer provides information as to
beer filterability.
How: Laboratory instrument examples: DMA35, Alcolyzer Beer
Analyzer System,
CarboQC, OxyQC, Lovis
Process instrument examples: Beer Monitor, Carbo 510
Where: Packaging
What: Density, extract (apparent, real, original), alcohol, CO2, O2, pH,
color, turbidity, degree of fermentation, viscosity
Why: This is the last, inline measurement possible. Accurate, inline
measurement of alcohol, extract, CO2, O2, color, and turbidity can provide
an immediate, significant improvement to product quality, consistency and
production efficiency. Often found pre-installed on larger blending or filter
systems, inline instrumentation is also easily added to most any existing
system.
How: Laboratory instrument examples: DMA35, Alcolyzer Beer
Analyzer System,
CarboQC, OxyQC
Process instrument examples: Beer Monitor, Carbo 510,
pH sensor, turbidity
Where: Packaged Beer
What: “7 parameters in 5 minutes from 1 package”
Density, extract (apparent, real, original), alcohol, CO2, O2, pH, color,
turbidity, degree of fermentation, viscosity, calories, TPO (total package
oxygen)
Why: Final product quality is what your customer sees and
experiences every time a package is opened. This is the last and final spot
check of packaged product before it leaves the plant and should not be
ignored. A very quick measurement time prevents long production stops
and increases production efficiency.
How: Laboratory instrument examples: DMA35, Alcolyzer Beer
Analyzer System,
CarboQC, OxyQC
Where: Product Transfer
What: Phase detection, beer/water interface
Why: The larger the brewery, the longer the piping and all the more
water it holds. With simple, inline, phase detection, only water is flushed
from the line, product is saved and overall product quality is guaranteed.
How: Process instrument examples: SPRn 4115
Where: Wastewater
What: COD, alcohol, % caustic, density, conductivity, pH, turbidity
Why: Upstream COD alarm, downstream COD monitoring in real
time. Wastewater concentrations are very low and a COD of 10,000
mg/l is actually less than 1° Plato. In addition, an extract change of only
0.01° Plato is the equivalent of 112 mg/l COD and an alcohol change of
only 0.01% m/m is the equivalent of 209 mg/l COD. Depending on the
size of the wastewater treatment center, even a minor, unmonitored spill
can potentially ruin the complete system and have tremendous financial
repercussions in the form of high fines and even legal fees.
How: Laboratory instrument examples: Alcolyzer Beer Analyzer
System, wet chemical
analysis
Process instrument examples: COD Monitor,
TOC Analyzer
Process applicationsLaboratory applications
Wort cooler
2
3
4
22
2
6
5
2
6
4
4
1
2
2
4
4
5
1
4
3
3
