Beer Processing Solutions

Transcription

1 Beer Processing Solutions Improving Process Profitability...Continuously sm

2 Table of contents Introduction...3 Brewing Process Diagram...4 Complete Product Range...5 Complete Process Solutions Automation Services Maintenance Service...10 Wort cooling, yeast dosing, wort aeration Water deaeration In-line blending and mixing Carbonation and nitrogenation High gravity brewing Pasteurizing CIP Fermentation & maturation Filtration

3 Our first steps into the brewery equipment business began as early as APV pioneered many of the key technologies involved in the brewery industry. As early as 1910, APV made the first welded alumin ium beer tank on the basis of a British patent, and through its commitment to 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 world s 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 specialist 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 be supported by a variety of after sales services. Beer Types with Approximate Alcohol by Volume Bottom Fermented Top Fermented Malt Malt Wheat Malt Münchner 4.8% Trappist % Strong Ale % Weizenbier % Pilsner/Pilsener 4.2-5% Kölsch 4.8% Bitter stout % Berliner Weisse 3.3% Ur-types 4.9% Brown Ale % Milk stout % Gueuze-Lambic 5% Danish Lager % Pale Ale % Russian stout 9.5% Bock 7-7.3% Mild Ale % Light Ale 2.9-4% Doppelbock 7-7.3% Bitter Ale % Steam Beer 4.8% 3

4 The Brewing Process Page 8 Page 11 Page 24 Page 15 Page 13 Page 19 Page 17 Page 23 Page 21 4 Filling

5 A Complete Product Range 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 beer pasteurization 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 From individual units to totally automated solutions Every unit can be supplied as a stand-alone system, ideally equipped for smooth and trouble free oper ation 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. The unit values are significant Proven security tested equipment APV Provides: Capabilities: Customer Values: An intelligent processing unit A Plug & Produce unit Configuration as required Real time plant data: Predictive maintenance On-line documentation Final product monitoring Traceable production Very short commissioning time Low installation cost No interference to existing production schedules Reduced time from order to production Seamless integration to all plants Easy to extend Improved process: Profitability Consistency Security Lower operating cost Longer running time Faster return on investment Easy expansion of existing plant Proven standards State of the art processes A compact unit design Maintenance service Improved functionality Hygenic design Good reliability Easy operation Low energy consumption Reduced waste Low noise emission levels Container fitted Low shipment cost Smallerproduction area required Moveable equipment Fast delivery time Easy maintenance Optimal APV service Fixed maintenance costs A reduction in unscheduled downtime Limited spare parts requirement Improved repeatability Product integrity safeguarded Quick and easy operator training Environmental improvements Improved company image Shorter delivery time Higher capacity/m² Cost effective maintenance Higher productivity 5

6 Complete Process Solutions Adding value for the brewmaster APV draws on decades of experience in project engineering and management for the brewery industry. Its extensive range of reference installations includes everything from a single process line to complete greenfield turnkey beer processing solutions. To meet today s demand for modern, highly efficient production facilities, APV s in-depth knowledge of brewing top quality beers is complemented by expertise in process automation and management information systems. APV s 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. Wherever appropriate, APV integ rates 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 customer s 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 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 our customers 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 equipment specifications relative to process flow diagrams to determine whether there are any quality, health and safety issues, which need to be addressed. 6

7 Each process step is analyzed to establish whether the equipment and control systems are adequate for safe operation under normal, abnormal and CIP 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 for communication 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 to translate 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 through sound 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 in accessing 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 has never 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. degree of automation and integration. APV provides tailored training courses for our customers personnel in both process and automation technology. 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. Training of People Breweries are operated by fewer and fewer highly trained staff, which often results in the need for an exceptional 7

8 Automation and Performance Services Solutions APV 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-of the-art automation solutions and services designed to international standards based on in-depth process knowledge together with manufacturing knowhow 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 and manufacturing 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. 8

9 Automation Migration for our customers with an installed base of ageing and obsolete automation equipment which can no longer adequately support their business. Furthermore, Automation Upgrade for systems that require additional functionality to meet automation and control requirements Automation Systems consisting of PLC and HMI as part of our project offering. These can be in the form of a single skid unit to plant wide automation solutions MES Applications targeting manufacturing and equipment performance, production execution, quality and tracking. We offer a saleable suite of engineered applications designed to deliver the right information, at the right time, to the right people, in the right context to drive future actions in our customers organizations to drive manufacturing excellence ERP Integration solutions that link and integrate the plant floor automation systems to our customer s enterprise or business layer ERP Integration MES Applications Automation Systems Automation Migration Automation Service 9

10 Until recently, the impact of maintenance operations on roundthe-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 your most 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 Maintenance Services Each agreement includes certain cri tical items, with each level providing progressively increasing support capability (see table below). APV is committed to providing proactive service solutions. These Maintenance Services agreements provide the best possible service to maximize your performance and deliver improved return on your investment. A Systematic Program of Strategic Maintenance 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 aren t Balance of uptime and improve mission equipment performance an option economics for effectiveness non-critical assets 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 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 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 15% Other spare 15% Other spare 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 Plant availability guarantee Designated APV maintenance manager Predictive maintenance on critical items Software upgrades Rebuilding & retrofitting consultancy Continuous process cost reduction Guaranteed performance guarantees on critical items Annual process knowledge analysis Rebuilding & retrofitting consultancy Operator audit and discount 10

11 WortMaster Wort Cooling, Yeast Dosing & Wort Aeration Ensure economical production by minimizing the use of time and additives The WortMaster product range covers 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 capacities from 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 11

12 Functional Description 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 cleaning requirement 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 water or 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 mg O2/l depending on pressure, temperature and 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 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 - Original extract measurement by 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 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. Conductivity Measurement Pro duct separation can be measured by means of conductivity to minimize product loss. 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. GLYCOL GLYCOL BREW WATER BREW WATER WORT K K STERILE AIR AERATED WORT 12

13 Derox Cold and Hot Water Deaeration Improve your beer quality with the Derox Deaerator Deaerated water is used in the brewing industry to minimize damage to beer through oxidation. It is used as a medium for purging mains and equipment 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 and developed especially for easy integration to existing lines, with a wide and flexible capacity range. Derox (cold) - adds value The standard capacity range is hl/h The Derox adds value to your products and processes in the following ways: Product uniformity: Constantly low oxygen content 50 ppb at 12 C* (below 30 ppb at >20 C.*) Continuous monitoring for required specification Economical production: Low running costs Space-saving design (high capacity/ m2) Derox+ (hot) - adds value The standard capacity range is hl/h. The Derox+ adds value to your products and processes in the following ways: Product uniformity: Constantly very low oxygen content (below 20 ppb.*) Continuous monitoring for required specification Continuous removal of undesirable THF gases Economical production: Low running costs Space-saving design (high capacity/ m2) Flexible production: 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 Flexible production: High turn down ratio (down to 25% of nominal capacity) Independent of water inlet temperature Proven security: No rings and plates inside vacuum tanks Deaerated water is pasteurized Fully CIP-cleanable * Measured as a standard deviation 13

14 Functional Description 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 88ºC. 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. 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 - Disinfection 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 25 C it is advisable to fit an optional seal water cooler. Preheater - Values below 0.03 ppm residual O2 can be achieved with a water temperature of about 20 C. 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. 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. WATER/CIP CO 2 / N 2 DEAERATED WATER Derox (Cold) 14

15 BlendMaster In-Line Blending The BlendMaster adds new dimensions to accurate standardizing and efficiency! 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: 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 Economical production: High precision blending Space-saving design (high capacity/ m 2 ) Combined blending and carbonation unit Flexible production: Easy change of recipe for fast product change Turn down ratio 25% of nominal capacity Blending ratio 1:10 to 1:2 Proven security: Continuous monitoring and regulation of the combined product Automatic switch-off, if offset exceeds the limit 15

16 Functional Description PI 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. FINAL BEER DEAERATED WATER HGB BEER FT FT DT GT 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, which measures 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 - Original extract measurement by 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 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. 16

17 CarboMaster Carbonation and Nitrogenation The CarboMaster is the answer when you are looking for a cost effective, accurate The CarboMaster is the answer when you are looking for a cost effective, accurate and flexible gas-dosing unit. The CarboMaster range covers units designed for continuous in-line injection and dissolving of gasses like CO 2, N 2. and flexible gas-dosing unit 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 as carbonation and can be integrated with other unit types, including the BlendMaster or the HGB Master. Standard capacity range: hl/h CarboMaster - adds value The CarboMaster adds value to your products and processes in the following ways: Product uniformity: High dosing accuracy (+/- 0.05g gas/kg product*) Injection independent of inlet temperature and pressure CarboMaster for high Co2 content Economical production: No gas losses Space-saving design Holding time not necessary Flexible production: Turn down to 25% of nominal capacity Inject and dissolve up to 10g gas/kg product Proven security: Constant monitoring and control of final product Fully CIP-cleanable * Measured as a standard deviation 17

18 Functional Description 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 turndown to 25% of the nominal capacity. This can be either pneumatically controlled or manually adjusted. High Carbonation Levels - The standard system is engineered to cope 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 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 advantage is that the gas usage data can be used for production control and statistics by means of a suitable control system. BEER CARBONATED BEER 18

19 HGB Master High Gravity Brewing The HGB Master is the result of a compact 3-in-one unit, which deals you all the aces in the pack 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 costeffective 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: hl/h HGB Master - adds value The HGB Master adds value to your products and processes in the following ways: Product uniformity: Constantly low oxygen content 50 ppb at 12 C* (below 30 ppb at >20 C.*) Continuous monitoring for required specification Exact conformity with the specified recipe High calibration stability High dosing accuracy (+/- 0.05g gas/ kg product*) Injection independent of inlet temperature and pressure Economical production: Low running costs High precision blending Space-saving design (high capacity/ m2) No gas losses Holding time not necessary Flexible production: Variable capacity Independent of water inlet temperature (option) Variable deaeration levels Easy change of recipe for fast product change over Turn down ratio 25% of nominal capacity Blending ratio 1:10 to 1:2 Inject and dissolve up to 10g gas/kg product Proven security: No rings and plates inside vacuum tanks Constant monitoring and control of final product Automatic switch-off, if offset exceeds the limit * Measured as a standard deviation 19

20 Functional Description Wide scale use of High Gravity Brewing has become standard modern brewing practice, as the reduction 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 blending module 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. GLYCOL GLYCOL WATER CO 2 CO 2 /N 2 FINAL BEER HGB BEER Fully CIP-cleanable 20

21 PU Pasteurizer Controlled Beer Pasteurization If you value gentle and accurate heat treatment you will also value the PU Pasteurizer 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: hl/h PU Pasteurizer - adds value The PU Pasteurizer adds value to your products and processes in the following ways: Product uniformity: Very high accuracy (computer controlled PU regulation) LowΔ T between product and heating media Economical production: Large heat regeneration (up to 94%) with low temperature filling Waste-saving design (beer/water zone) Flexible production: Turn down ratio 40% of nominal capacity Proven security: Constant overpressure downstream Constant monitoring and control of final product 21

22 Functional Description 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. The temperature 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 by means 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. 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 together with 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 the system is flushed into the buffer tank with water, which is then recirculated 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 80 C for sterilization and to balance the system. Heating of the system to balance typically takes place 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 configurations can be customized as required A double shunt for improving the coolant supply can be integrated The unit is based on a threesection plate heat exchanger with regenerative, 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, 72 C held for 30 seconds being typical. BUFFERTANK I R P WATER 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. GLYCOL GLYCOL WATER/CIP BEER CONDENSATE STEAM 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 22

23 CIP Master Go for perfect cleaning results at lower cost with the APV CIP Master 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 your products and processes in the 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 specific equipment PC solutions based on Wonderware FactorySuite Modem connection for remote controller service 23

24 Fermentation & Maturation Proper 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 during fermentation 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. Filtration Due 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 a specific 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. Your local contact: APV, An SPX Brand 105 CrossPoint Parkway Getzville, NY Phone: (716) (800) Fax: (716) answers.us@apv.com For more information about our worldwide locations, approvals, certifications, and local representatives, please visit 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 and should not be relied upon unless confirmed in writing. Certified drawings are available upon request. Issued: 07/ US 2008 SPX Corporation