Instrumentation best practices in Brewing

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Instrumentation best practices in Brewing

Ola WesstromSlide 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 WesstromSlide 2


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

https://www.endress.com/en/Endress-Hauser-group/endresshauser-at-a-glance

04/24/2020

Our Core Competence – Instrumentation and related services

Slide 4 Ola Wesstrom


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 SupplyEngineered

systemsRisk assessment

Guided Wave Viscosity Nitrate Batch controller Inst. Base Mgm

Electromech. Steam quality Sludge level Tank inventoryReceiving 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


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 PicomagCerabar T PMP 23/33B



04/24/2020

Simple, cost effective options for the start up brewery

Level switches

FTW23

FTW33

FTL33H

Ola WesstromSlide 7

Analysis

CM10

CLD18

Display/recorder

RSG35

Flow

Promag 10D

PicomagPressure

PMP23

PTP33B

Temperature

TMR35

TM401

Level

FMR10/20


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


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


04/24/2020

Mash kettle

Ola WesstromSlide 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, prowirl200 with dry steam fraction


04/24/2020

pH measurement in mash kettle


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 sensorROI – No need to replace for years, exceptional stability which reduce calibration intervalsReliable measurement in high solids media thanks to large sensing area and mechanical abrasion resistance


04/24/2020

Wet Steam?


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


https://www.us.endress.com/en/field-instruments-overview/flow-measurement-product-overview/Vortex-flowmeter-Proline-Prowirl-F200

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


PMC 51 ceramic pressure

FMD71 electronic DP w/ceramic sensors


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

Ola Wesstrom


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 achievedPromass 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


https://www.us.endress.com/en/field-instruments-overview/flow-measurement-product-overview/Coriolis-flowmeter-Promass-Q300

04/24/2020

Turbidity Monitoring of Wort - Whirlpool


Optical turbidity installed on the whirlpool outlet allows for automatic detection of trubcone 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


Continuous monitoring of the

turbidity using OUSTF10 on the

whirlpool outlet

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Wort Aeration


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


04/24/2020

Optimization of Fermentation process


• 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


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


Foam detection FTL50 or FTW33


04/24/2020

CO2 Recovery


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


04/24/2020

Maturation / Bright beer, Packaging tank level

Accuracy is key for planning of packagingHydrostatic 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 spanExample: 15ft diameter tank 30ft highPressure 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


PMC 51 ceramic pressure or FMB50

FMD71 ceramic electronic DP


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

of the type of beer

0.1% volume accuracy


Promag H300 Promag H100

Promass Q300


04/24/2020

Simplify record keeping and reduce downtime


• 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


https://www.endress.com/en/Field-instruments-overview/measurement-technologies/Heartbeat-Technology

04/24/2020

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


Any device (instruments, valves etc)Always up to date20 languagesGenerate reportsUpload to Asset management


04/24/2020

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


Look for “Endress operations” app

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


04/24/2020

Connected Support


•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


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

Training facilities

Factory Calibration Services



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On-site Flow Calibration Rigs

• Flow Calibration Rig


Trailers are equipped with Flow, Pressure,

Temperature, liquid analysis calibration equipment.

• Temperature Oil Baths • Pressure Calibrators


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

of 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


Temperature sensor with QuickNeck. Remove sensor for calibration without disconnecting or opening line.15min Time saving/calibrationFood safetyOperator safety

Temperature sensor withQuickneck and TrustSensSelf calibrating @ 118°C(244°F)>30min time saving/calibrationFood safetyOperator safety

TM412, 411 TM371, 372


https://www.us.endress.com/en/field-instruments-overview/temperature-measurement-thermometers-transmitters/iTHERM-TrustSens-TM372

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



http://www.endress.com/

https://www.us.endress.com/en/search?filter.text=applicator

04/24/2020

TM

TM

Measure, Analyze, Compute, Monitor, Service, Audit

Data Collection, Bus Engineering, Control

F

VMI, ERP, Visualization, e-Business

“MIP” means going beyond the measuring point…



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


04/24/2020

Steam System Optimization – Control based on actual Energy usage

Slide 33

Nat GasBTU/ SCF

Steam[BTU/ LBS

Condensate return

BTU/GPM

Make-up water

Feed water

Flue gas

Blow downAir

Fuel

CondensateSteam

heat

heatheatEfficiency

,

De-aerator/ Economizer

Vortex flow with wet steam alarm and compensation

Applicator

Ola Wesstrom


https://www.us.endress.com/en/Field-instruments-overview/Flow-measurement-product-overview/Vortex-flowmeter-Proline-Prowirl-F200?highlight=prowirl%20200

https://www.endress.com/en/product-tools/life-cycle-management/planning-engineering-traceability/applicator-select-size-instrument

04/24/2020

Waste water instrumentation

Slide 34

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

and more

Ola Wesstrom


04/24/2020

Goals and challenges in Brewing


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

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