BeerProcessingSolution

7/24/2019 BeerProcessingSolution

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Beer Processing Solutions


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Table ofcontents

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 of the key

technologies involved in the brewery

industry. As early as 1910, APV

made the first welded aluminium

beer tank on the basis of 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 for

the culture of pure yeast and in 1923

the company revolutionized wort

cooling by introducing the worlds first

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 offers process automation

systems, individual brewery

process units, and a wide range

of components including pumps,

valves and heat exchangers. All

APV equipment and systems can besupported by a variety of after sales

services.

Our first 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

Mnchner 4.8% Trappist 9-10.8% Strong Ale 6.1-8.4% Weizenbier 4.8-5.6%

Pilsner/Pilsener 4.2-5% Klsch 4.8% Bitter stout 4.4-7.5% Berliner Weisse 3.3%

Ur-types 4.9% Brown Ale 2.5-4.5% Milk stout 3.7-3.8% Gueuze-Lambic 5%

Danish Lager 4.2-4.7% Pale Ale 4.3-6.6% Russian stout 9.5%

Bock 7-7.3% Mild Ale 2.5-3.6% Light Ale 2.9-4%

Doppelbock 7-7.3% Bitter Ale 3.0-4.0% Steam Beer 4.8%


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The Brewing Process

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APV provides a selection of

standardized process units, which

could be described as a series of

building blocks. These fulfill 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 of your products.

To highlight how value is added to

your products and processes, we

have developed the following symbols

for your reference

Product

uniformity

homogenous products

Flexible

production

fast 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 for smooth and trouble free

operation and suitable for integration

into your central control system. But

you will gain additional benefits with

a combination of units, which have

been specifically designed to operate

together for high performance, both

from 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 significant

APV Provides: Capabilities: Customer Values:

An intelligent processing unit Configuration 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 interference to existing production schedulesReduced time from order to productionSeamless integration to all plantsEasy to extend

Faster return on investmentEasy expansion of existing plant

Proven standards Improved functionalityHygenic design

Good reliability

Improved repeatabilityProduct integrity safeguarded

State of the art processes Easy operationLow energy consumptionReduced wasteLow noise emission levels

Quick and easy operator trainingEnvironmental improvementsImproved company image

A compact unit design Container fittedLow shipment costSmallerproduction area requiredMoveable equipmentFast delivery time

Shorter delivery timeHigher capacity/m

Maintenance service Easy maintenanceOptimal APV serviceFixed maintenance costsA reduction in unscheduled downtimeLimited spare parts requirement

Cost effective maintenanceHigher productivity


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APV draws on decades of

experience in project engineering and

management for the brewery industry.

Its extensive range of referenceinstallations includes everything from

a single process line to complete

greenfield turnkey beer processing

solutions.

To meet todays demand for modern,

highly efficient production facilities,

APVs in-depth knowledge of brewing

top quality beers is complemented by

expertise in process automation and

management information systems.

APVs technological excellence

covers processes such as

fermentation and storage, yeast

handling and treatment, beer

processing, bright beer and

pasteurization. Furthermore, we have

vast experience in the areas of wort

cooling, water deaeration, and high

gravity brewing. Our CIP systems

complete the process. Whereverappropriate, APV integrates its strong

range of standard process units into

a project.

We believe our experience is our

most important asset. Previous

highly successful installations are

our customers best guarantee that a

brewery project will be implemented

on time and within budget.

Our experience ranges from

traditional methods to highly

automated systems based around the

latest proven technologies.

Highly automated systems deliver

improved effeciencies, resulting in a

faster 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

flexibility.

Further benefits for the brewmaster

and management are:

A paper free process control

system which can interface with ERP

systems

Material and quality tracking

capability

Full compatibility with brew-house

and filling 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 of brewing steps

in close co-operation with our

customers brewmaster, technologists

and process engineers. Careful

Complete Process SolutionsAdding value for the brewmaster

teamwork ensures that we

understand and recognize each of our

customers specific needs.

Detailed Engineering

This starts with the PID and

process description, followed by the

development of installation pipeline

circuit and connection plants, cable

lists, functional descriptions, program

sequences, energy calculations,

component specifications, interface

definitions, spare parts lists and

operating instructions and manuals

all dedicated exactly to ourcustomers specific brewing needs.

Hygienic Design

Our design is based on the latest

international standards for hygienic

design. APV uses standard design

elements, which are constantly

reviewed to meet the highest

standards.

Health and Safety

HACCP/HAZOP studies can be

undertaken, reviewing equipmentspecifications relative to process flow

diagrams to determine whether there

are any quality, health and safety

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 for safe

operation under normal, abnormal andCIP conditions.

Latest Design Tools

APV uses the latest design tools.

The use of 3D models, with possible

access to full-scale modeling from

AutoCAD, provides improved

safety features by maintaining data

throughout the project via single

entry to the database. Furthermore,

the existing AutoCAD platform forcommunication with most customers

CAD Systems is maintained.

Project Management

a single point of contact

APV project managers are our

customers single point of contact.

They are highly experienced

and acutely aware of all critical

implementation aspects. Excellent

coordination skills enable them totranslate the efforts of APV suppliers

and other sub-suppliers into

successful projects.

Environmentally Safer Processes

In response to an increasing need

for environmentally acceptable utility

services, energy optimization throughsound design principles is always

observed. Waste minimization and

health and safety issues are always

carefully considered.

Installation Supervision

APV supervisors are internationally

experienced and accustomed to all

kinds of 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 of the value

APV adds to a project. We have

therefore been certified to ISO

9001 Standards. But that hasnever been our final goal. Through

quality improvement programs,

working procedures are constantly

monitored and challenged to increase

productivity and efficiency in all parts

of our business.

Training of People

Breweries are operated by fewer and

fewer highly trained staff, which often

results in the need for an exceptional

degree of automation and integration.

APV provides tailored training

courses for 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 offered either at our customers

brewery or on APV premises.


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Automation and Performance Services SolutionsAPV FactoryExpert

Driving manufacturing excellence

FactoryExpert is APV Automation &Performance Services. It combines

innovative solutions with reusable

engineering applications on open

platforms to meet our customer

automation specifications.

We offer state-ofthe-art automation

solutions and services designed

to international standards based

on in-depth process knowledge

together with manufacturing know-how and engineering expertise

that meet regulatory requirements.

FactoryExpert enables customers

to extend their performance gains

across their business.

APV FactoryExpert Value

Streams

APV FactoryExpert comprises five

strategic value streams to meet

our customers automation andmanufacturing execution needs.

Automation Service for

customers existing automation

equipment offering maintenance and

support programs, spare parts, etc

maintaining and improving conditions

to maximize plant uptime

APV FactoryExpert is vendor

independent, it can include, for

example control systems and human

machine interfaces (HMIs) from

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 of ageing and obsoleteautomation equipment whichcan no longer adequately sup-port their business. Furthermore,Automation Upgrade for systemsthat require additional functionalityto meet automation and controlrequirements

Automation Systems consisting

of PLC and HMI as part of ourproject offering. These can be inthe form of a single skid unit toplant wide automation solutions

MES Applications targeting manu-facturing and equipment perform-ance, production execution, qualityand tracking. We offer a suite ofengineered applications designedto deliver the right information, atthe right time, to the right people,in the right context to drive futureactions in our customers or-ganizations to drive manufacturingexcellence

ERP Integration solutions thatlink and integrate the plant floorautomation systems to ourcustomers enterprise or businesslayer


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Until recently, the impact of

maintenance operations on round-

the-clock production, quality,

manufacturing flexibility, traceability,

plant safety and environmental

protection has been largely ignored.

APV recognizes that cost-effective

performance of your APV equipment

is directly dependent on the ability to

design and implement a cost-effective

maintenance program.

In response to these requirements,

and as part of the on-going expansion

of our customer support strategy,

APV Maintenance Services adapt to

your specific requirements.

Maintenance Services consists of

multiple levels of service agreements

in order to create the ideal balance

of flexibility, improved productivity,

increased up-time and better financial

performance of all APV equipment.

Different service agreements can

be created for our customers. For

example:

Basic Care- APV service when you can plan

ahead- Balance of uptime and

economics for non-critical assets

Classic Care- Comprehensive APV service

support- When service delays are not an

option

Advantage Care- APV service coverage for yourmost critical equipment

- Proactive approach to equipment performance

Total Care- APV service management and

support for the entire plant- Plant-wide strategy to improve

mission effectiveness

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 performance 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 for service Strategy for service Strategy for service

partnership seminar partnership seminar partnership seminar

Software upgrades Predictive maintenance on

critical items

Plant availability guarantee Software upgrades

Designated APV maintenance Rebuilding & retrofitt ing

manager consultancy

Continuous process cost

reduction

Guaranteed performance

guarantees on critical items

Annual process knowledge

analysis

Rebuilding & retrofitting

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 arent Balance of uptime and

improve mission equipment performance an option economics for

effectiveness non-critical assets

A Systematic Program of Strategic Maintenance

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The WortMaster product rangecovers units designed for the

processes between the brewhouse

and fermentation, including wort

cooling, yeast dosing and wort

aeration.

In addition to fast and efficient wort

cooling, WortMaster units deliver

effective and accurate in-line dosing

of yeast and air/oxygen by means of

the patented APV gas injector.

Offered in a wide range of capacitiesfrom 50 1200 hl/hr, all WortMaster

units are designed and developed for

easy integration with existing lines.

WortMaster

- adds value

The WortMaster adds value to your

products and processes in the

following ways:

Product uniformity:

Constant monitoring and improved

regulation of the process

Repeatable fermentation

performance

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 of flow

Proven security: Fully CIP-cleanable

Traceable production data

WortMaster Wort Cooling, YeastDosing & Wort Aeration

Ensure economical production by minimizing the use of time and additives


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FunctionalDescription

Wort Cooling- Hot wort from the

brewhouse must be cooled prior to

the addition of yeast for fermentation.

This is achieved using a state of the

art plate heat exchanger with a wide

channel, which reduces the cleaningrequirement while maintaining good

heat transfer efficiency. Additional

attractive features include a high

performance clamping system,

improved hanging area and EasyClip

gaskets, all of 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 for

brewing water and refrigerant.

Wort Aeration- Brewing yeast

requires oxygen to multiply.

Traditionally this has been supplied

by blowing air through the wort with

various types of nozzles and mixers.

The result was often varying oxygen

levels of typically 10-12 mg O2/l

depending on pressure, temperatureand the original gravity of the wort.

Specified O2 levels with high gravity

worts are usually higher and thus pure

oxygen is often used to achieve levels

above 18 mg O2/l.

The APV Gas Injector allows these

levels to be achieved by a fast

consistent mixing of wort and either

air or oxygen.

Yeast Dosing - Yeast can be added

to complete the wort treatment. This

has the advantage of adding yeast

immediately to the cooled wort.

The actual method used can reflect

local practice and the automation

allows accurate MIS/MES integration.

In the event of lack of product flow,

the yeast supply is shut off.

Options

Cooling DuoSafety Plates - Additional

product protection.

ParaWeld Plates - Allow the use of

NH3 as refrigerant.

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 for flow and specification

must be made manually.

Modulating Head Automatic

adjustment of the head can be made

from the control system. This option

can be retrofitted to the manual head.

Dosing

Flow Measurement The yeast can

be dosed by means of a magnetic

flowmeter.

Tank Contents Measurement The

amount of yeast can be dosed on the

basis of tank contents measured by a

load cell.

Yeast Cell Measurement The

amount of yeast can be dosed on

the basis of instrumentation that

measures the yeast cell

concentration.

Common

Original Extract Measurement -

Completed through the means of

a sound velocity sensor or density

measurement.

Oxygen Measurement The oxygen

content of 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 for cleaning.

High Accuracy Blending A

variation of this technology using

mass flow measurement is capable of

even higher accuracy and is used for

blending of components such as hop

extract or color.

Conductivity Measurement

Product separation can be measured

by means of 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 for purging mains andequipment and post fermentation as

part of the brewing process.

The Derox product range covers units

designed for deaeration of processing

water. Derox is used where a low O2

content is required or recommended,

for example for the lauter tun,

blending of bright beer and in High

Gravity Brewing (HGB) processing.

Deaeration can be performed by two

different systems - cold (Derox) or hot

(Derox+) deaeration. The hot system

heats the water to high temperature,

which reduces the risk of infection

and helps remove contaminants. The

cold system is capable of achieving

low levels of oxygen with low capital

and production costs.

All Derox Units are designed anddeveloped especially for easy

integration to existing lines, with a

wide and flexible capacity range.

Derox (cold)

- adds value

The standard capacity range is 30

1500 hl/h

The Derox adds value to your


following ways:

Product uniformity:

Constantly low oxygen content 50

ppb at 12C* (below 30 ppb at>20C.*)

Continuous monitoring for required

specification

Economical production:

Low running costs

Space-saving design (high capacity/

m2)


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


following ways:

Product uniformity:

Constantly very low oxygen content

(below 20 ppb.*)

Continuous monitoring for requiredspecification

Continuous removal of undesirable

THF gases


Low running costs


m2)


High turn down ratio (down to 25%of nominal capacity)

Independent of water inlet tempera-

ture

Proven security:


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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Hot deaeration

Water entering the unit is warmed by

means of the regenerative section of

a plate heat exchanger.

After the regenerative section, the

water enters a heating section where

the temperature is raised to about

88C. 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 of water vapor.

The deaerated water is cooled in

the regenerative section of the plate

heat exchanger and the final outlet

temperature is achieved using a

chilling section or a separate cooler,

depending upon the refrigeration

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 falls

through a pipe with a vent which

allows some of the water to return

into the bottom tank. The level in this

bottom tank is controlled by means

of a level switch, which controls the

water inlet valve.

The remaining water is discharged

from the unit via an adjustable

manual-regulating valve.

The unit is designed for CIP and does

not contain packing.

Options

Hot deaeration

CO2 Stripping - The use of a small

amount of stripping gas can allow

the energy lost through flashing to be

reduced.

Cold deaeration

Chilling - Chilling of water to

match beer temperature. Different

configurations are available.

UV Water Disinfection - Disinfec-tion of the incoming water can be

obtained by the use of an ultra-violet

disinfection unit.

Seal Water Cooling - In cases where

the seal water will exceed 25C it is

advisable to fit an optional seal water

cooler.

DEAERATED WATER

WATER/CIP

CO2/ N2

Derox (Cold)

Preheater- Values below 0.03 ppm

residual O2 can be achieved with a

water temperature of about 20C.

In cases where this water inlet

temperature is not a normal value, a

pre-heater consisting of a shell and

tube heat exchanger together with a

steam regulation valve and

condensate trap can be supplied.

Common

Oxygen Measurement- The result

of 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 of these facilities

are also available with PLC control

systems.

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The BlendMaster range covers units

designed for continuous in-line

blending of liquid components.

It ensures precise recipe conformity,regardless of whether two or more

liquid components are combined.

The BlendMaster is used, for

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

following ways:

Product uniformity:

Ensures exact conformity with the

specified recipe

High calibration stability


High precision blending


m2)

Proven security: Continuous monitoring and

regulation of the combined product

Automatic switch-off, if offset

exceeds the limit

BlendMaster In-Line BlendingThe BlendMaster adds new dimensions to accurate standardizing and efficiency

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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Extract and alcohol are parameters

usually used for duty purposes, and

product declarations and accurate

determination are therefore important.

HGB is now a world-wide standard

involving the addition of part of the

brewing water after fermentation

instead of within the brewhouse.

Even when HGB is not a standard

procedure, cutting the final beer with

small amounts of water to achieve a

consistent product is often required.

Magnetic flow meters are used to

measure the volumes of high gravity

beer and deaerated water. Dosing

takes place by means of a simple

ratio control operating a modulating

valve on the water supply. This gives

results that are within the accuracy

of laboratory instruments and in-line

measurement. This ratio control may

be adjusted by means of an optional

sound velocity/alcohol sensor, whichmeasures the original extract of

the beer and applies appropriate

corrections.

This technique can also be used for

blending beer types or diluted beer

from filtration.

Options

Original Extract Measurement -

Completed through the means of a

sound velocity sensor. This measures

the velocity of sound in a fermented

product, which is proportional to the

original extract of the unfermented

product. Alcohol Measurement - Density

measurement by means of mass flow

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 for cleaning.

High Accuracy Blending A

variation of this technology using

mass flow measurement is capable of

even higher accuracy and is used for

blending of components such as hop

extract or color.

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The CarboMaster is the answer when

you are looking for a cost effective,

accurate and flexible gas-dosing unit.

The CarboMaster range coversunits designed for continuous in-line

injection and dissolving of gasses like

CO2, N2.

This equipment ensures a precise

and uniform injection, by means of

the patented APV gas injector (see

description on page 18).

The CarboMaster is used in the

brewery industry for 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


following ways:

Product uniformity:

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


Turn down to 25% of nominal

capacity

Inject and dissolve up to 10g gas/kg

product

Proven security:

Constant monitoring andcontrol of final product

Fully CIP-cleanable

CarboMaster Carbonation and NitrogenationThe CarboMaster is the answer when you are looking for a cost effective, accurate

and flexible gas-dosing unit

CarboMaster for high Co2 content

* Measured as a standard deviation


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The basis of the unit is the patented

APV CO2 special injector, which

differs from other models by injecting

the liquid into the gas in counter

flow. This achieves quick dissolution,

and the gas is tightly bound to the

liquid. High levels of CO2 addition

can be obtained without long holding

tubes, and a precise fast regulation is

obtained. It is possible to carbonate

sales gravity beer to the desired level

after the addition of non-carbonated

water.

The calculated value is compared

with the measured value and the

CO2 content adjusted appropriately

by means of the modulating valve.

The fixed head injector can cope with

variation in flow rates of about +10%.

The gas supply is shut off if the

product flow stops.

Options

Variable Capacity Head- The fixed

head can be replaced with a variable

capacity head which allows a turn-

down to 25% of the nominal capac-

ity. This can be either pneumatically

controlled or manually adjusted.

High Carbonation Levels - The

standard system is engineered tocope with levels of CO2 normally

specified in beer. Carbonation of up

to 10g/kg CO2 may be obtained if

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

of a gas flow meter, the amount

of added gas can be accurately

determined to avoid over or under

carbonation. This is more accurate

than CO2 measurement with which

it is often combined. A further ad-

vantage is that the gas usage data

can be used for production control

and statistics by means of a suitable

control system.

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The HGB Master combines the three

process stages of water deaeration

(Derox), inline blending (BlendMaster)

and carbonation (CarboMaster)

into a single, all-inclusive process.

The HGB Master ensures a cost-

effective high gravity brewing process

combined with very high production

flexibility. The unit is designed

and developed especially for easy

integration with existing lines, and is

available in an extensive and flexible

capacity range.

Standard capacity range: 501200

hl/h

HGB Master- adds value

The HGB Master adds value to


following ways:

Product uniformity: Constantly low oxygen content 50

ppb at 12C* (below 30 ppb at

>20C.*)

Continuous monitoring for required

specification

Exact conformity with the specied

recipe

High calibration stability

High dosing accuracy (+/- 0.05g

gas/ kg product*)

Injection independent of inlet

temperature and pressure


Low running costs

High precision blending


m2)

No gas losses

Holding time not necessary


Variable capacity

Independent of water inlet

temperature (option)

Variable deaeration levels

Easy change of recipe for fast

product change over


capacity

Blending ratio 1:10 to 1:2

Inject and dissolve up to 10g gas/kgproduct

Proven security:


tanks

Constant monitoring and control of

final product

Automatic switch-off, if offset

exceeds the limit

HGB Master High Gravity BrewingThe HGB Master is the result of a compact 3-in-one unit, which deals you all the

aces in the pack

* Measured as a standard deviation


20/24

Fully CIP-cleanable


Wide scale use of High Gravity

Brewing has become standard

modern brewing practice, as thereduction in production costs is

significant. By adjusting the extract of

the beer after filtration rather than in

the brewhouse, the final output of a

given plant is greatly increased.

A High Gravity Brewing Unit

comprises a combination of several

modules described elsewhere. The

normal configuration consists of

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 from

the skid to the buffer tank and an

amount returned for blending and

carbonation. Deaerated water from

the buffer tank is still available for

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

of pre- and post-run diluted beer Carbonation Correction of the

CO2 contents of the final beer to

specification. This is normally a single

point but pre-carbonation of the

water can be supplied if desired.

HGB BEER

CO2/N2

WATER

GLYCOL

GLYCOL

CO2

FINAL BEER

20


21/24

The PU Pasteurizer was developed

especially for continuous heat

treatment of beer and other

carbonated drinks.

The pasteurization temperature in

the PU Pasteurizers is controlled

by Pasteurization Units (PU) and

designed for high working pressures.

The PU Pasteurizer provides effective

and gentle heat treatment of all kind

of carbonated products.

Standard capacity range: 50500

hl/h

PU Pasteurizer- adds value

The PU Pasteurizer adds value to


following ways:

Product uniformity:

Very high accuracy (computer

controlled PU regulation)

LowT between product and

heating media


Large heat regeneration (up to 94%)

with low temperature filling

Waste-saving design (beer/water

zone)



capacity

Proven security:

Constant overpressure downstream

Constant monitoring and control of

final product

PU Pasteurizer Controlled Beer PasteurizationIf you value gentle and accurate heat treatment you will also value the PU Pasteurizer


22/24


Pasteurization is calculated on

the basis of holding time and

temperature. The time factor is

linear, and small variations have a

minor effect on the PU value and are

controlled by adjusting the flow. Thetemperature factor 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 of

a downstream shutdown, water

replaces the beer in the system to

maintain the balance.

The temperature is controlled bymeans of 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

for 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

of a heating cycle in which water is

warmed by means of a shell and tube

heat exchanger. The beer temperature

is variable, 72C held for 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 of the plate heat

exchanger ensures that the pressure

on the sterile side of the regenerative

section is higher than the pressure

on the non-sterile side. This pump

is frequency controlled to allow

adjustment of the pressure in the

holding cell.

A modulating valve is used togetherwith a magnetic flow meter to

regulate the flow and thus the holding

time.

The beer enters a buffer tank

equipped with a load cell to

measure the contents. In the event

of a downstream shutdown, the

pasteurizer continues operation until

a pre-determined maximum level is

reached. The remaining beer in thesystem is flushed into the buffer

tank with water, which is then re-

circulated to maintain the balance.

On resumption of downstream

production, the buffer 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 fresh beer,

and normal operation resumes.

The unit is started by means of a shell

and tube heat exchanger heating

water to 80C for sterilization and

to balance the system. Heating of

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 fuzzy logic for extreme

accuracy

A conductivity meter registers the

interface 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

22


23/24

The production of high quality beer

using highly efficient operating

techniques requires effective, careful

cleaning of equipment. APV offers

CIP modules as standardized

compact units or units tailored exactly

to our customers specific projects

and needs.

The APV CIP Master is a fully

automatic system, programmed

to achieve optimal cleaning of the

process equipment.

The APV CIP Master

adds value

The APV CIP Master adds value to


following ways:

Product uniformity

Fully automatic CIP programs ensure

perfect 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 of production

restructuring

Proven security

If appropriate, the CIP Master is fully

tested before delivery

Proven functionality and reduced

commissioning time

Functional

description

The APV CIP Master is a fully

automatic, self-contained unit.

It comprises a complete set of

equipment for CIP, including, for

example, tanks for water, acid and

caustic soda, pumps, tubular and/

or plate heat exchangers, valves and

instrumentation such as conductivity

and flow transmitters.The CIP program covers the

complete cycle. Detergent or water

selection, detergent concentrations

and cycle temperatures and times are

fully controlled.

The APV CIP Master is fully

integrated with the process line and

can be used with existing equipment

(including filling machines) as well as

new APV units.

The design of the CIP Master by

APV incorporates the requirements

of production schedules to minimize

downtime. This forms the basis

for selecting the appropriate tank

numbers and volumes together with

the number of lines.

The standard APV control consists

of a controller with an operator panel.

The signal exchange between the

instruments/controller/control room is

performed 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 for perfect cleaning results at lower cost with the APV CIP Master


24/24

Fermentation & MaturationProper fermentation requires wort

cooled to the right temperature,

aerated to the right oxygen content

and dosed with the right amount

of active yeast cells. APV designs

highly automated process systems

that continuously control all essential

parameters before and duringfermentation and maturation, ensuring

an end product of a consistently high

quality.

The control systems of fermenter

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 for

specific beer types. The result is

a complete and well-documented

process line designed to maintain

the characteristics of the beer and to

meet consumer expectations for high

quality.

FiltrationDue to seasonal fluctuations in the

quality of the raw material and the

complexity of the process itself,

filtration is one of the more complex

parts of the brewing process. APV

works in close co-operation with

reputable suppliers of filtration

systems to meet the needs of aspecific project.

It is important to control the different

phases of the filtration process and

integrate them into the rest of 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: [email protected]

For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.apv.com.

SPX reserves the right to incorporate our latest design and material changes without notice or obligation.Design features, materials of construction and dimensional data, as described in this bulletin, are provided for your information only andshould not be relied upon unless confirmed in writing Certified drawings are available upon request

Your local contact:

BeerProcessingSolution

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