Brew House Process PDF
November 23, 2022 | Author: Anonymous | Category: N/A
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Description
RAYA BREWERY
BREW HOUSE PROCESS DESCRIPTION
Prepared by: Mulu Neway
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1. Malt Reception
Holding Capacity of the silos – 300 300 Ton*4= 1200 Tones ,2*30 tones Major Activities – Dust, Dust, Stones and other metals are removed by dust blowers, de-stoners & magnets respectively. The malt is conveyed to the roller mill through bucket elevators. The silos are appropriate for space utilization & safe storage of malt.( i.e the malt will be protected
from rodents rodents & other other insects. There is an option to fumigate the silos to avoid attack by insects.
1.1. Malt intake and storage 1. Silos for malt storage: 4 *300 t 3
Effective capacity :531 m 3
Capacity for malt : 299 t(RO =0.56 t/m Cylindrical height: 12580 mm Diameter : 6870 mm Top angle of conical bottom: 90◦ Top angle of conical lid : 120◦ 120◦
Clearance :900 mm
Outlet diameter : 400 mm Total height : approx 18800 mm
2. Silo for malt storage – day day bin: 2*30 t 3
Effective capacity :52.2 m 3
Capacity for malt : 30t(RO =0.56 t/m Cylindrical height: 4560 mm Diameter : 3500 mm Top angle of conical bottom: 90◦ Top angle of conical lid : 120◦ 120◦ Clearance :900 mm Outlet diameter : 400 mm Total height : approx 7770 mm
3. De-stoner PVS 15 for destining of malt conveyed to grist station Capacity : 5 t/h Sieve inclination :(2-15 )◦ :(2-15 )◦ Ambient temperature temperature range :20 ◦C/40 ◦C Pressure air loss :1200 Pa 3
Air consumption consumption :120 :120 m /min Length :2210 mm Width :1310 mm Height :2200 mm
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1.2 Process Description
Only well trained person must operate the processing section PS 01, PS 02. 02.
Malt is taken to silos the volume of which is 4 x 300 t, 2 x 30t, 30t,
When the line for malt inlet to silos is turned on, you must adjust the transport line for particular silo.
01.10/1 takes takes place the drive of the gate valve 01.09 is 01.09 is turned 1. When the intake to the silo position 01.10/1 on as the first and then next drive of the chain conveyor position 01.08/1 01.08/1.. In this case next and next drives follow to the drive of intake basket including aspiration. This happens according to block scheme which is operated by automat when the operator adjusts the transport line in the operating room. 2.
R ecir ci r cula culation tion of ma malt lt fr fro om ssii lo tto o silo The operator has to adjust the transport line in the operating room before the recirculation starts. Drives are turned on in the same mode from the last drive in the direction of the material flow .
3.
Malt supply to the malt mill room When the transport line is adjusted for the malt supply from the silo no. 1 (this is only an example of the transport line adjustment): All the drives drives in the mill mill room must must be turned turned on in the automatic automatic mode. mode. The operator operator will will close the gate valve 01.15. 01.15. The The chain conveyor 01.13 drives 01.13 drives will start working and the screw conveyor 01.12/1 as 01.12/1 as 01.07/1 will will open. well. The electric gate valve under the silo 1 position 01.07/1 IT IS NECESSARY TO CHANGE THE POSITION OF THE MANUAL GATE VALVE AND REGULATE THE MALT FLOW TO PS 02.
4. When the operation of malt intake and the operation of mill room take place, the intake aspiration and mill room aspiration must take place as well.
The aspiration operation is divided into two independently operating lines.
in PS 02 02.. This aspiration is used only when the Line 1 is the aspiration of the stone separator in line for cleaning of the malt for the beer batch is turned on.
The second system is for central aspiration of aspiration of whole intake PS 01 01 and and transport lines PS 02 02.. Aspiration system works works in the full-blow the full-blown n automatic automatic mode. mode. You have to change the sacks with waste. There are three sacking necks. It is necessary for the
aspiration system operation that at least 5bar of the air, for blowing of the filtrating hoses of
the filter (regeneration of the filtrating hoses), is in the central air distributor. The grains stocked in the silos must be pre-cleaned and dry ( humidity ( humidity 14 %). %). The outdoor large silos are equipped with 1 ventilator (only (only the outdoor silos), which through the canals with perforation in the hopper will blow whole layer of the grains.
In the case of the active ventilation, it is necessary to check the parameters of the grains and the ventilation air.
Small internal silos are protected by the building and so they do not have to be aerated. Each silo is equipped with thermometer with several places of measuring. The thermometer is place at the silo axis. axis. Silos are equipped with continuous measuring of the volume.
The upper sensor checks the volume so that the silo could not get overfilled and the lower signalizes that the silo is empty.
The grains are drained from silos by gravitation through centre output. Close both side outlet holes and let the grains flow away thanks to the gravity.
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The flow regulation is done by manual gate valve or by the change of screw conveyor frequency. frequenc y.
The grains are transport from silo by the screw conveyor. When automatic mode takes place, everything is adjusted for the mode and the operator does not have to change the parameters.
When manual mode takes place (we do not recommend this), the operator has to turn on the drives in the direction of the malt flow from the last drive. See PC scheme.
1.3. Picture description
Picture 1: malt reception
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1.4 Control panel
Set the order of silos
Silo is running for milling (ACTIVE) or silo is waiting for milling (STOP) Silo is enabled for milling (number of order) or blocked blocked set to 0 Picture 2: malt reception - control panel for silos 1 - 4
Restart the line, after failure
Actual order order for selected selected silo
Picture 3: malt reception - control panel for silos 5 - 6
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1.5 Program Description
Malt reception is filling the silos with malt If the silo max level is reached during the transport, the process switches to next selected silo. If there are none silos left the process finishes If the conveyor is overloaded during the transport it is together with other conveyors before it automatically immediately stopped
button and press RESTART button button In order to start them again it is necessary to release STOP button Each conveyor is blocked by the preceding conveyor run feedback to pretend the conveyor overloading The operator sets the order (writes numbers) of silos (or keeps the order of the last brew) and presses the the Start button. button. Line for for filling starts starts automatically automatically All control modules modules start after after the time set in parameters parameters At the end of malt reception, reception, all control modules stop after after the time time is set in paramete parameters rs
1.6 Process parameters
Picture 4: malt reception - process parameters
Time monitor can be set for each step. If the actual time >= monitoring time program will stop and a new alarm message will appear in the alarm window. If monitoring time is set to 0, the step duration is not checked.
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1.7 Process steps
0. INITIAL STATE 1. START OF ASPIRATION 2. RESERVE 3. START OF LINE 4. MALT RECEPTION 5. SWITCH TO NEXT SILO 6. STOP OF LINE 7. RESERVE 8. STOP OF ASPIRATION
2. Milling room + Classic Mill 2.1 Definiti Definition: on:
Brewing process starts with milling.
The malt is cleaned in milling line from mechanical foreign materials and fines.
2.2. Main apparatuses in milling line Item 02.04-Drum sieve - for the separation of mechanical foreign matters Item 02.04-De-stoner PVS 15 – for for the separation of stones Item 02.08-Magnetic separator – for for the separation of iron matters Item 03.01-Hammer mill – for for malt milling – Classic Classic mill Item 03.02-Crushed malt hopper Item 03.52-Pre-Masher Item 02.09- Automatic air air filter Item 02.10-Middle-pressure fan set Conveyers
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2.3. Hammer mill Description:
Manufacturer :Meura (Belgium)
Type : CLM 375
Capacity:+/- 8 t malt /h (depending on malt quality)
Consisting of : A symmetrical symmetrical milling chamber chamber : inner inner width=500 width=500 mm , diameter =650 =650 mm Electro-pneumatic inlet valve
Dynamically balanced rotor, able to rotate both directions
1 set of hammers with easy replacing & turning system Peripheral hammer tip speed at 3000 rpm : 100 m/sec 1 sieve (perforation 2.75 mm in the mill with electro-pneumatic, failsafe sieve-stretcher system,
standard non-return valves on pneumatic cylinders. Impact plates in upper part of the mill, easy to replace 1 large control door with failsafe open-door protection Temperature sensors on main bearings & mill housing without connection box, transmitters &
connection cables. A supporter supporter for proximity proximity switches switches diam.18 diam.18 mm of stop detection detection & of of rpm control. control.
a. feeding lock lock system system with geared motor control ;1.1 KW Iron cleaning magnet with easy hand cleaning & limit switch
b. Common structure for mill and motor mounted 6 silent blocks Standard motor 3000 RPM , 400/690 V, 50 HZ, high efficiency, 75 KW Elastic coupling between motor & hammer mill
c. Milling – bin bin underneath the hammer mill Housing for automatic filter unit, bolted manhole
d. Screw extractor Transmission unit 2.2 KW Support for proximity switch diam. 18 mm of rpm control Sleeve to an overload detector
e. Rotary valve Cast iron house with steel rotor Transmission 1.5 KW
f. Automatic filter with compress compressed ed air clean cleaning ing system system Built-in suction ventilator with 7.5 KW transmission Silencer at ventilator outlet Control door with locks Electronic system 240 V, 50 Hz , for jet air cleaning of the filters Oleo/hydrophobic filter medium , antistatic
g. Explosion protection for complete milling unit Reinforcements of the complete unit to resist to an internal reduced explosion pressure of 0.4
bar 2 explosion vents in milling bin sidewall burst detectors.
h. Sampling device Easy hand operation & dust tight
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2.4 Crushed malt hopper
Vertical quadrilateral vessel with conical bottom & flat lid, designed to guarantee full emptying of the
crushed malt. Vessel will be delivered in parts bolted at site.
It designed for storage of 100% of the crushed malt loading for one brew (6545 kg). Vessel is supported by legs via load. 3
Effective capacity :13.7 m 3
Total capacity : 19.5 m Length : 2800 mm Width ; 1900 mm Total height :approx. 4710 mm Material : carbon steel
a. Worm conveyor Inlet 410 * 2700 mm Outlet 219 * 219 mm 3
Transported material : crushed malt ( Ro=0.50 t/m ) Output : 25 t/h Input power drive :3 KW
b. Worm conveyor DS 300 * 5 m-for transport of crushed malt With one inlet 219 * 219 mm & one outlet 219 * 219 mm Consisting of worm, coupling, gear box & electric motor with safety switch, including flanges,
sealing & joining material. Worm conveyor is equipped by induction sensor of revolutions & induction sensor of overloading. 3
Transported material : crushed malt ( Ro=0.50 t/m )
The malt is transported from any silo or from two different silos by means of conveyors to milling room onto Drum sieve where foreign matters bigger than a kernel are separated from the malt.
It continues from drum sieve into the de-stoner where stones are separated and it follows into magnetic separator where iron foreign matters are separated.
Detached impurities are transported in stands with bags (wastes)
Cleaned malt is transported by means of conveyors in Hammer mill where it is milled on required grading. Crushed malt falls from Hammer mill into crushed malt hopper.
So milling is finished.
Milling line is provided with an aspiration – dust dust suction from the equipment. The dust is caught by means of air filter with a fun.
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2.5. Milling Description:
The malt is transported from any silo or from two different silos by means of conveyors to milling room onto Drum sieve where foreign matters bigger than a kernel are separated from the malt.
It continues from drum sieve into the de-stoner where stones are separated and it follows into magnetic separator where iron foreign matters are separated.
Detached impurities are transported in stands with bags (wastes)
Cleaned malt is transported by means of conveyors in Hammer mill where it is milled on required
grading. Crushed malt falls from Hammer mill into crushed malt hopper. So milling is finished.
Milling line is provided with an aspiration – dust dust suction from the equipment. The dust is caught by means of air filter with a fun.
2.6. Preparation Preparation Brewing process is automated fully except some control steps. Before wort boiling it is necessary to put
in receipt memory parametric values of some constants: 1. Before milling start it is necessary to check put parametric values of some constants in the receipt; e.g. Malt volume form which one wort brew is produced, Speed of feeding equipment from the silo …Except
2. 3. 4. 5.
the from which milling is possible to adjust in parameters another silo from which milling will silo continue when first siloisisstarted empty it eventually An overview of parametric parametric values is show shown n is the manual “ M anual Brewery Raya_ r 03_Prop_VR” Manual The operator starts the program of fore mashing C The operator starts „Start of aspiration“. The operator checks whether aspiration fun M1222 and aspii r at asp ation ion filte fi lterr M122 M1224 4 are put in operation. The operator starts “ S tart of Classic mill ”” . Start Program steps for Classic mill follow:
5.1)
INITIAL STATE
5.2)
CHECK STARTING CONDITIONS
5.3)
SYNCHRONIZATION
5.5)
READY CONFIRMATION
5.6)
CHECK ROTOR AND STANDSTILL
5.7)
SELECT COUNTER CLOCKWISE / CLOCKWISE ROTATION SENSE
5.8)
RESET MEMO DIRECTION CHANGE – mill mill rotation is changed regularly
5.9)
REQUEST OPEN ROUTE START FAN M003.0102.050 / air aspiration from the mill
5.10)
Mill motors are started too in successive steps from last to filter feeding equipment
5.11)
START FILTER CLEANING CONTROL SYSTEM
5.12)
START ORV M003.0105.050 rotary feeder from mill charging hopper
5.13)
START HOPPER SCREW M003.0106.050 conveyor in mill charging hopper
5.14)
START MILL ROT.M003.0100.050- mill rotor
5.15)
START IRV M003.0101.050- mill feeding equipment
5.16)
START DRUM SIEVE
5.17)
START GRAIN SUPPLY LINE
5.18)
SET AMOUNT IN GRIST BIN
5.19)
MILLING
Prepared by : Mulu Neway Brewing Team Leader
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6. The operator starts „Start of line“. Conveyors and apparatuses of milling line are put in the operation stepwise on this instruction. Last equipment of milling line – Classic Classic mill is put in operation automatically first, than conveyo conveyors rs M 2206, M2203, Destoner M22012 , Drum sieve M 002.0100.050, conveyor 002.0100.050, conveyor M2201 and corresponding transporting & feeding equipment from selected silo. Classic mill” are 7. The step “Milling“ follows follows where sub steps of program sequence “ Classic are going; it is milling of required malt volume from selected silos. In the same time the aspiration is running. 8. Should some silo is empted out during milling; conveyors are switched automatically so that milling continues from other selected silo. 9. When required malt volume from selected silos is milled; automatic steps finishing milling process are made: 10. STOP OF LINE – during during this step all conveyors are switched off and apparatuses of milling line in reverse order than it was put in the operation. 11. STOP OF Classic mill 11.1)
STOP GRAIN SUPPLY
11.2)
EMPTY GRAIN SUPPLY LINE
11.3)
STOP DRUM SIEVE M002.0100.050
11.4)
STOP 23
11.5)
STOP 24
11.6)
STOP 25
11.8)
STOP IRV M003.0101.050
11.9)
STOP MILL M003.0100.050
11.10)
STOP HOPPER SCREW M003.0106.050
11.11)
STOP ORV M003.0105.050
11.12)
DEDUSTING
11.13)
MILLING COMPLETED
12. ST STOP OP OF ASPI A SPI R AT ATII ON
So milling process is finished and crushed malt is prepared in crushed malt hopper. FDS CLM Description of Classic Mill is in the manual of Meura 9716.1.3 – FDS
2.7. Program Description
Milling room is used for milling the malt If the max level in the malt hopper is reached, the process will be stopped If the right amount of malt in the silo is reached, program switches to next selected silo If the right amount in the malt hopper is reached, the process of milling is going to finish If the conveyor is overloaded during the transport, the conveyor and conveyors before them are automatically immediately stopped button and press the RESTART button button In order to start again it is necessary to release the STOP button Each conveyor is blocked by the preceding conveyor run feedback to prevent the conveyor overloading The operator sets the order (writes numbers) of silos (or keeps the order of the last brew) and presses the the Start button button -aspiration, -aspiration, classic classic mill and line starts starts automatically automatically All control modules modules start after after the time set in parameters parameters At the end of malt reception, reception, all control modules stop after after the time set in parameters parameters – Description of Classic Mill is in the manual of Meura 9716.1.3 FDS CLM
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2.8. Picture description
Picture 1: milling room + classic mill
2.9. Control Panel P anel
Set the order of silos
Silo is feeding the mill (ACTIVE) or waiting Silo is preselected to feed the mill (ENABLED) + it is in the line or set to 0 Picture 2: milling room – control control panel
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Picture 3: milling room - classic mill – control control panel
3.0.. Process parameters 3.0
Picture 4: milling room - classic mill – recipes recipes
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Picture 5: milling room + classic mill – parameters parameters
> = monitoring time program - Time monitor can be set for each step. If the actual time >= will stop and a new alarm message mes sage will appear in the alarm window. If monitoring time is set to 0, the step duration is not checked.
3.1. Process steps Steps of milling room
0.
INITIALSTATE
1. 2.
START OF ASPIRATION START OF CLASSICMILL
3.
START OF LINE
4.
MILLING
5.
SWITCH SWITC H TO NEXT SILO
6.
STOP OF LINE
7.
STOP OF CLASSICMILL
8.
STOP OF ASPIRATION
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Steps of Classic mill 0.
INITIAL STATE
1.
CHECK STARTING CONDITIONS
2.
SYNCHRONIZATION
3.
READY CONFIRMATION
4.
CHECK ROTOR AND STANDSTILL
5.
SELECT COUNTERCLOCKWISE / CLOCKWISE ROTATION SENSE
6.
RESET MEMO DIRECTION CHANGE
7.
REQUEST OPEN ROUTE
8.
START FAN M003.0102.050
9.
START FILTER CLEANING CONTROL SYSTEM
10.
START ORV M003.0105.050
11.
START HOPPER SCREW M003.0106.050
12.
START MILL ROT.M003.0100.050
13.
START IRV M003.0101.050
14.
REST
15.
REST
16. 17.
START DRUM SIEVE START GAIN SUPPLY LINE
18.
SET AMOUNT IN GRIST BIN
19.
MILLING
20.
STOP GRAIN SUPPLY
21.
EMPTY GRAIN SUPPLY LINE
22.
STOP DRUMSIEVE M002.0100.050
23.
STOP 23
24.
STOP 24
25.
STOP 25
26.
STOP IRV M003.0101.050
27.
STOP MILL M003.0100.050
28.
STOP HOPPER SCREW M003.0106.050
29.
STOP ORV M003.0105.050
30.
DEDUSTING
31.
MILLING COMPLETED
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3. Pre-Mashing (Mashing -in) + Mashing 3.1 Preparati Preparation on Air :compressed :compressed air air >4 bar H Hot wa water ter tank ::P P b/n -----------
: Volume >600 hl : Temp (76 - 78) °C
Cold water tank : Volume >700 hl lit/kg The ratio of water to grist ratio is 2.3 lit/kg In case of power interruption the pre-masher will be dried & blocked by mash, must rinsed with hot water by opening the valves manually.
3.2 Pre-mash Pre-masher er
a.
b.
c.
d.
Producer : Meura, Belgium For mashing-in process Cold water circuit 1 hand operated butterfly valve 1 pneumatic modulation valve 1 non-return valve 1 pneumatically actuated double valve Hot water circuit 1 hand operated butterfly valve 1 pneumatic modulation valve 1 non-return valve 1 pneumatically actuated double valve Mixed water circuit 1 electromagnetic flow meter 1 temperature probe with convertor Instrumentation 1 electromagnetic flow meter 1 temperature probe with convertor 1 thermometer 1 pressure gauge
e. Water pumps for pre mashing Cold water pump 3 Flow rate : ± 63 m /hr Body : cast iron Impeller : stainless steel Tightness : single mechanical seal
Hot water pump 3
Flow rate : ± 63 m /hr
Body : cast iron
Impeller : stainless steel
Tightness : single mechanical seal
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3.3 Grist hydrator for Mecha-masher The grist hydrator is especially designed for fine grist & thick mashing – in in rates.
Material All parts in contact contact with the the product product are made made of ASI ASI 304 stainless stainless steel steel
Accessories Accesso ries Process valves
1 pneumatically operated sliding valve Instrumentation
One pressure gauge
3.4 Mashing in device
Type : vertical
Capacity :nominal 25 tons malt grist/h
Producer : Meura
Material : all parts in contact with the product are made of ASI 304 stainless steel
Fittings : 1 mixing vessel with side inlet from grist hydrator 1 sight glass
1 cleaning ball 1 overflow pipe
Accessories Accesso ries Instrumentation 1 high level probe indicating an inlet overflow 1 low level probe at the pre-masher outlet 1 level transmitter for level regulation Process valves 1 pneumatically operated butterfly valve CIP valves 2 pneumatically operated butterfly valve
3.5 Mash transfer pump to the mash tun (Underneath the pre-masher) a. Pump
3
Flow rate : ± 80 m /hr Type :moineau (screw type) Head :2 bar Body : special rubber Rotor: Stainless steel Tightness : robe seal
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18 b. Fittings
instrumentation 1 compensating device 1 pressure switch
For rope seal of the pump 1 hand operated ball valve 1 filter 1 selonoid valve
1 adjusting valve 1 pressure gauge 1 flow switch 1 adjusting valve
3.6 Mashing Mashing-in -in
Mixing of the malt grist with water at a pre-specified mashing-in temperature.
Tones of of grist per hour Capacity : 15 ~ 25 Tones
MEURA Mashing-in tank minimize the oxygen absorption during the mashing procedure MEURA Mashing-in kg of of grist High flexibility : 1,8 to 2,5 l / kg : From 42 °C to 63 °C
Pumping of the mash to different vessels (Mash- Tun, Mash Copper...)
3.7 Mashing
During Mashing in mash tun, take sample when the level of mash in the mash tun reaches 50% for mash H (CEREMIX)). P ; soon add add mash additives additives ( cacl cacl 2 , caso4 & Enzyme (CEREMIX)).
During the 1 rest ( 52 52 C ) add H 3 po4 based on the P of the mash measured above to adjust the PH to
st
H
( 5.35 5.35 -5.4 ) by referring referring your previous previous result. result. saccharification test confirmation confirmation “blinks on the take sample after the the 2nd rest (72 C ) when” saccharification Again take
operating screen & add iodine drops to the sample. If solution looks blue black wait the time for more conversion & recheck till you see yellow color .when you see yellow color soon click “confirm” saccharification test. test.
start on mash filter If all the conditions are ok after heating to mash off temperature ( 76 ( 76 C ), click start
operating screen to transfer the mash to mash filter.
If problem in the wort kettle is happened you could late the mash in the mash tun by controlling the low take the time to be “delay time”. steam f low
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A. Mash kettle Additives phospho phosphoric ric acid – ---- Li (pH 5.6) CEREMIX - ---- kg CaCl 2
- ----- kg
Caso4 - ------
kg
B. Mash kettle rests
3.4
pause 52 °C °C :20 minutes minutes - heating 1 °C per minutes
pause 63 °C °C :45 minutes minutes - heating 1 °C per per minutes
pause 72 °C °C : 20 minutes minutes - saccharifica saccharification tion heating heating 1 °C per per minutes minutes
pause 75 °C °C : pumping pumping to mash filter filter
45-55°C=protein & beta glucanase rest
62-65°C=Maltose production rest
70-75°C=Saccharification rest
76°C=Final Mash temperature/mash out
Program description
The process starts when the operator clicks the button start on the control panel of mash kettle Mashing-in starts automatically when the route is open and all control modules are controlled by program sequence Mashing-in is finished when the minimum is reached in the malt hopper and total volume of water is reached (recipe) Description of Mashing-in tank is in the manual of Meura 9716.1.3 – FDS Mashing-in FDS Mashing-in tank Then the heating in the Mash kettle starts When program goes through the steps of low and high sacharification temperature the process in the Mash kettle finishes After that that Mash kettle kettle heats heats to the filtration temperature temperature
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3.5. Picture description
Picture 1: mashing-in tank + mash kettle
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Preparing for cleaning
Picture 2: mash kettle – control control panel
Restart the line, after failure Preparing for Picture 3: mashing-in tank – control control panel
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3.6. Process Recipes & parameters
Picture 4: mashing-in tank + mash kettle – recipes recipes
Picture 5: mash kettle – parameters parameters
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Picture 6: mashing - in – parameters parameters
Time monitor can be set for each step. If the actual time >= monitoring time program will stop and a new alarm message mes sage will appear on the alarm window. If monitoring time is set to 0, the step duration is not checked.
3.7. Process steps A. Steps of Mashing-in tank tank
0. 1.
Idle Check starting conditions
2.
Synchronization
3.
Ready confirmation
4.
Preheating hot water supply line
5.
Open mash transfer route & seal water
6.
Pre-filling - Fixed position
7.
Pre-filling - Regulation
8.
Stabilization - Fixed speed
9.
Stabilization - Regulation
10.
Open route for grist
11.
Waiting for grist supply
12.
Mashing-in
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13.
Rinsing spray ball - Pump
14.
Rinsing spray ball - Hydrator
15.
After Run
16.
Emptying
17.
End confirmation
18.
Draining
19. 50.
End program CIP - Check starting condo
51.
CIP - Synchronization
CIP - Cleaning 52. B. Steps of Mash kettle
0.
INITIAL STATE
1.
WAITING FOR MASHING-IN TANK
2.
MASHING-IN
3.
DELAY AFTER MASHING-IN
4.
ADDING ENZYM ENZYM
5. 6.
HEATING TO 52°C MASHING-IN
7.
DELAY AFTER 52°C
8.
HEATING TO LST 63°C
9.
DELAY AFTER 63°C
10.
HEATING TO LST 68°C
11.
DELAY AFTER 68°C
12.
HEATING TO HST 72°C
13.
DELAY AFTER 72°C
14.
TEST SACHARIFICATION
15.
PUMPING 1. MASH WHILE 1. FOREMASHING
16.
CONTROL TAKING BY MASHING PAN - 1. AND 2. MASH
17. 18.
HEATING TO 76°C RESERVE
19.
WAITING FOR MASH FILTER
20.
PUMPING TO MALT FILTER WITH STIRRER
21.
PUMPING TO MALT FILTER WITHOUT STIRRER
22.
RINSING
23.
DELAY AFTER RINSING
24.
PUMPING RINSE TO MALT FILTER
25.
RINSING TO DRAIN
26.
DELAY AFTER RINSING
27.
END
50.
CLEANING
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4. Mash Filter 4.1 Process Descriptio Description n
Prepare wort kettle additives based on the standard ( Znso4 ,Caramel, HOP Pellet, HOP Extract ) Wort kettle should be empty to start mash filtration.
Valves should be in automatic mode. After mash mash off (end (end of mashing) mashing) to start mash mash filtration click "start" "start" on mash filter operating operating screen. screen. At the open open filter filter step of mash mash filter (43), (43), helper/operato helper/operatorr must go to the mash filter filter to rinse rinse the plates plates with hot water (Temperature of 55°C) after removal of the spent grain by controlling the shifting of the plates. First wort should be sampled after 5 minutes of start of filtration /transferring to wort collector to be Extract, color). checked by laboratory ( E xtract, PH, color). nd Last running/weak wort should be sampled after 8 minutes of 2 compression to be checked by laboratory (Extract, PH,
4.2 Program description
The process of the Mash filter can start if the conditions are fulfilled The Mash filter is used for the filtration of the Mash.
FDS MF2001 and MF2001 and 9716.1.3 – FDS FDS Description of Mashing-in tank is in the manual of Meura 9716.1.3 – FDS Spent Grains Conveyor Conditions must be checked in the beginning of the process – all all conditions must be in state OK within this step
4.3 Mash Filter Preheatin Preheating g
Be sure that mash filter, pre-masher & mash tun are not on working conditions. Hot water tank( temperature (76 -78)°C, volume >550 hl) Cold water tank volume >400hl The water comes to pre-masher & then to mash filter. When mash filter has not been in used for long period (more than 48 hrs) it requires proceeding to a Preheating of the plates before starting production or cleaning. The temperature between the product & polypropylene plates cannot be higher 50°C. Independent fromgap room temperature, it is not necessary to preheat the mash filter, ifthan it stays less than 48 hours without function.
4.4 Spent Grain removal
Frequency : Every brew After mash mash filtration is finished (see open filter(43) & shifting (44) (44) steps of mash mash filter) Pushed with pressure air (5 bars) to spent grain silo.
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4.5 Process steps Steps of production
0.
IDLE
1. 2.
RESERVE MF01.01 - CHECK START. COND.
3.
MF01.02 - SYNCHRONISATION
4.
MF01.03 - READY CONFIRMATION
5.
MF02.01 - OPEN ROUTE
6.
MF02.02 - CO2 FILLING
7.
MF02.03 - STOP CO2 SUPPLY
8.
MF03.01 - REQUSET MASH SUPPLY
9.
MF03.02 - OPEN ROUTE
10.
MF03.03 - START MASH PUMP
11.
MF03.04 - FILLING
12.
MF04.01 - FIXED SPEED
13. 14.
MF04.02 - FLOW/PRESSURE CONTROL MF04.03 - WAINTING LOW LEVEL SUPPLY LINE
15.
MF04.04 - CLOSE MASHFILTER INLET
16.
MF05.01 - SETUPPEAK FLOW
17.
MF05.02 - CALCULATIONPEAK FLOW
18.
MF05.03 - PRECOMPRESSION - CHECK COEFICIENT
19.
MF06.01 - OPEN ROUTE
20.
MF06.02 - START MASH PUMP
21.
MF06.03 - OPEN FILTER INLET
22.
MF06.04 - PRE-SPARGING
23.
MF06.05 - OPEN UPPER FILTER INLET
24.
MF06.06 - FLUSH UPPER FILTER INLET
25.
MF07.01 - SPARGING VOLUME CALCULATION
26.
MF07.02 - SPARGING 1
27.
MF07.03 - SPARGING 2
28.
MF07.04 - SPARGING 3
29.
MF07.05 - CLOSE MASHFILTER INLET
30.
MF07.06 - STOP MASH PUMP
31.
MF08.01 - FIRST COMPRESSION
32.
MF08.02 - SECOND COMPRESSION
33.
MF.09 - SELECTION STEP
34.
MF09.01 - OPEN ROUTE
35.
MF09.02 - START MASH PUMP
36. 37.
MF09.03 - RINSING MF09.04 - STOP MASH PUMP
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38.
MF10.01 - EMPTYING
39.
MF10.02 - COMPLETED
40.
MF11.01 - CHECK VENT VALVE MASH SIDE OPEN
41.
MF11.02 - SLOW DECOMPRESSION
42.
MF11.03 - FINAL DECOMPRESSION
43.
MF OPEN FILTER
44. 45.
MF SHIFTING PLATES MF CLOSE FILTER
46.
RESERVE
47.
RESERVE
48.
RESERVE
49.
RESERVE
50.
CIP - CHECK STARTING CONDITIONS
51.
CIP - SYNCHRONISATION
52.
CIP - CLEANING, NEUTRALISATION
53.
CIP - OPEN MASH FILTER
54.
CIP - SHIFTING
55.
CIP - CLOSE MASH MASH FILTER
4.6 Picture description description
Picture 1: mash filter
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Prepare to cleaning, neutralization
Hot trub to Mash filter
Read – reading reading new recipes from ILOBOx is enabled Online Read – reading reading some recipes from ILOBOx is enabled Picture 2: mash filter - production – control control panel
Picture 3: mash filter – production production – start start condition
- Conditions must be checked in the beginning of the process – all all conditions must be in state OK within this step
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4.7 Process parameters
Picture 4: mash filter – recipes recipes
Picture 5: mash filter – parameters parameters
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Picture 6: mash filter – parameters parameters
-Time monitor can be set for each step. If the actual time >= monitoring m onitoring time program will stop and a new alarm message will appear in the alarm window. If monitoring time is set to 0, the step duration is not checked.
4.8 mash filter - preheating – control control panel
Picture 7: mash filter - preheating – control control panel
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4.9 Mash filter Steps of preheating 0.
IDLE
1.
RESERVE
2.
CHECK STARTING CONDITIONS
3.
SYNCHRONISATION
4. 5.
READY CONFIRMATION PREDRAINING
6.
REQUEST WATER SUPPLY
7.
OPEN ROUTE
8.
START MASH PUMP
9.
FILLING
10.
OVERFILLING
11.
CLOSE MASHFILTER INLET
12.
STOP MASH PUMP
13.
PRE-HEATING
14.
EMPTYING
15.
DRAINING
16.
SWITCH LOCAL BOX N*1 TO AUTOMATIC
17.
SYNCHRONISATION
18.
OPEN FILTER
19.
SHIFTING PLATES
20.
CLOSE FILTER
21.
DRAIN SPENT GRAINS HOPPER
22.
COMPLETED
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5. Mash filter – spent spent grains conveyor – control control panel
Picture 8: mash filter – spent spent grains conveyor – control control panel
5.1. Steps of Spent Grain Conveyor 0.
IDLE
1.
CHECK STARTING CONDITIONS
2.
CONFIRMATION DESTINATION
3.
WAIT FOR SHIFTING
4.
START HOPPER & WAIT FOR LEVEL
5.
WAITING FOR EXPELLING
6.
EXPELLING
7.
CONVEYOR DRAIN RINSING
8.
HOPPER RINSING
9.
EMPTYING
10.
DRAINING
11.
COMPLETED
12.
RESERVE
13.
RESERVE
14.
RESERVE
50.
CIP
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6. Wort- Collector
Filtered wort from mash filter is collected in wort collector. ≥89% is collected, start transfer to wort kettle When wort ≥89%
6.1 steps of wort collector
0.
Idle
1.
PUMPING TO WORT PAN
2.
WASHING 1
3.
DELAY AFTER WASHING 1
4.
PUMPING TO WORT PAN
5.
END OF PUMPING
6.
RESERVE
7.
WASHING 2
8.
DELAY AFTER WASHING 2
9.
CIRCULATION OF CHANGER
10.
DRAINING
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7. Wort Boiling 7.1 Preparati Preparation on After complete complete transferring transferring of of Clear filtered filtered sweet sweet wort wort from wort collector. collector.
Constant stream flow, cold-water & compressed water has to be available
H
At start of of boiling take take sample sample from wort wort – pan ,to be checked checked by laboratory laboratory for (Extract (Extract ,P ,color,) HOP Extract & Caramel should be prepared in the first vessel & automatic dosing time will be during st
pressure increase &1 hoping step @96°C. HOP pellet & Znso4 should be prepared in the second vessel & automatic dosing time will be during nd pressure boiling &2 hoping step @98°C. At the end of boiling, boiling, take sample sample from from wort pan, pan, to be checked by by laboratory laboratory for (Extract, (Extract, PH, color,) color,) of the wort. H P at the end of boiling should be within (5.2-5.25). Wort is boiled in wort pan with the addition of HOP components in order to; Coagulate proteins ,protein-polyphenol reaction products which can be removed as hot-trub Concentrate Extract, which lowered as a result of sparging -water during filtering. Sterilize wort Extract bitter-resins of HOP components which give the final beer with the necessary bitterness; as a result of isomerization.
Enzyme inactivation also takes place; this prevents the continual breakdown of proteins & starch during fermentation. H Lowers wort P as a result of loss of water &release of hop-acids (alpha-acids) & increase wort color.
7.2 Program Description
Wort pan is used for boiling the mash with hop Operator can select preheating of mash during the step pumping from Wort collector Operator can select heating of water during the step pressure boiling – vapor vapor way Atmospheric Atmosph eric boiling boiling will start and and valve valve in chimney chimney will close after after pumping pumping from wort wort collector The Next step is pressure boiling, the pressure in wort pan is regulated by the step pressure boiling Step pressure boiling is finished in set time Step atmospheric boiling happens after that. this step is finished in set time as well Pumping to whirlpool happens after atmospheric boiling
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7.3 Picture description description
Picture 1: wort pan + sugar
Vapour way during boiling - on/off
Preheating during pumping to wort pan - on/off on/off
Picture 2: wort pan – control control panel
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Picture 3: sugar 03.24A – control control panel
Picture 3: sugar 03.24B – control control panel
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7.4 Process parameters
Picture 4: wort pan – recipes recipes
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Picture 5: wort pan – parameters parameters
Time monitor can be set for each step. If the actual time >= monitoring time program will stop and a new alarm message mes sage will appear in the alarm window. If monitoring time is set to 0, the step duration is not checked
.
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7.5 Process steps A. Steps of Wort pan 0.
INITIALSTATE
1.
PUMPING TO WORT PAN
2.
PUMPING AND BOILING
3.
WAITING TO TOTAL VOLUME
4.
HEATING TO BOIL
5.
ATMOSPHERIC ATMOSPHE RIC BOILING BOILING 01
6.
PRESSURE INCREASE
7.
PRESSURE BOILING
8.
PRESSURE REDUCTION
9.
ATMOSPHERIC ATMOSPHE RIC BOILING BOILING 02
10.
RESERVE
11.
RESERVE
12. 13.
RESERVE BOILING
14.
TESTING DEGREE OF BEER 01
WATER 15. ADDING WATER 16.
BREW ENDING
17.
TESTING DEGREE OF BEER 02
18.
WAITING FOR PUMPING TO WHIRLPOOL
19.
PUMPING TO WHIRLPOOL
20.
PUMPING TO WHIRLPOOL AND RINSING WORT PAN
21.
RINSING 1 WORT PAN AND EXTRACTORS
22.
RINSING 1 - DELAY
23.
RINSING 1 - PUMPING
24. 25.
RINSING 1 - ENDING OF PUMPING RINSING 2 WORT PAN AND EXTRACTORS
26.
RINSING 2 - DELAY
27.
END
50.
Cleaning
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8. Whirlpool 8.1 Preparati Preparation on
After end of boiling boiling from the the wort kettle take sample of end of boiling & "confirm sampling” for wort transfer to the wort settling tank from the wort pan operating window. Boiled and hopped-wort is separated from trub materials & clarified by pumping the wort in a Whirlpool & allowing hot-trub to settle for 20'. Put the CCT number on the whirl pool window on the ”Number of Target CCT”
8.2 Program Program Description Whirlpool
Capacity of wort cooling :300 hl/h 3 Total capacity :32.3 m 3 Effective capacity : 26.1 m Inside diameter : 4250 mm
Trub tank 3
Total capacity : 2 m
Inside diameter :1350 mm Height :2900 mm
Top angle of bottom :70◦ :70◦
Material :stainless steel
Whirlpool is used for filtrating wort. Operator can select pumping part of wort to propagation. Operator can select the air to the wort . After the pumping pumping from from wort pan pan is put put to Rest step (it stays stays in idle idle state). Next step is fermenting (pumping to CCT); the wort is cooled down to the set point temperature while it is being pumped to CCT. If the temperature is higher than set in parameters or the flow is less than the parameter, program will stop.
8.3 wort-coolin wort-cooling g
There should be Enough amount of ice water (4 ͦ C ) Cold wort Aeration line should be sterilized with steam & cooled down for first brew.(by fermentation operator) CIP of Wort cooling line (by brew house operator) the receiver CCT, wort line to the receiver CCT (by fermentation fermenta tion operator) operator) should be done done & line & manual hand hand valves should be be connected connected and opened. Put the CCT number on the whirl pool window on the ”Number of Target CCT” Receiver CCT should be in the "Filling step" to be ready by fermentation operator Start transferring the hopped, clarified wort through plate heat exchanger by clicking "confirmation” for transferring transferring to CCT CCT from whirlpool whirlpool operating operating screen. The water that goes out from the heat exchanger is hot & got to the hot water tank. Around 7hl 7hl water is pushed & drained drained under the CCT's CCT's CIP outlet outlet valve first, first, and then cooled cooled wort wort is filled to the the CCT by switching switching on the CCT's CCT's wort inlet inlet auto valve. valve. Cooled wort temperature should be 8°C, Aeration of the Cooled Cooled wort wort shall be be started by selecting/clic selecting/clicking king "Air" "Air" from brew house computer computer after transferring of 30HL to CCT& stopped after transferring of 200HL.(should be done by brew house operator) No aeration is for last brews
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Aerated & agitated agitated Yeast Yeast (for about about 3 hrs)is pitched pitched with first brew in automatic automatic mode (Yeast (Yeast will be pitched based based on the the consistency consistency & viability viability result from microbiolog microbiology) y) refer under yeast yeast pitching pitching by topic.( b y fermentation operator ) If the wort is for yeast propagation purpose follow the procedure under yeast propagation. After 15 minutes, minutes, take take sample sample for cold wort to be be checked by laboratory laboratory (Original (Original wort gravity gravity /cold wort Extract, PH, Color & for organoleptic taste (by brew house operator).
At the end the wort is pushed pushed to CCT CCT with water water (7hl) & is drained, drained, when the the water is is reached at the CCT, by switching on the CIP outlet automatic valve of the CCT or wort is completely filled to the CCT by switching off wort inlet automatic valve of the CCT.
8.4 Preparation
Fermenting 1 wort flow 350 hl/hr Fermenting 2 wort flow 180 hl/hr Temperature of wort 8°C Ice water level full (95%) Ice water temperature = monitoring time Time monitor can be set for each step. If the actual time >= program will stop and and a new alarm message will appear in the alarm alarm window. If monitoring time is set to 0, the step duration is not checked.
8.8 Process steps A. Steps of Whirlpool Whirlpool 0.
INITIAL STATE
1.
PUMPING 1 TO WHIRLPOOL
2.
PUMPING 2 TO WHIRLPOOL
3.
END OF PUMPING
4.
REST
5.
WAITING FOR PROPAGATION
6.
PROPAGATION - FLUSH OUT
7.
PROPAGATION - WAITING FOR PUMPING
8.
PROPAGATION - FILLING WATER
9. 10.
PROPAGATION - FILLING WORT WAITING FOR PUSH IN
11.
PROPAGATION - PUSH IN
12.
WAITING 1 - FERMENTING
13.
STARTING COOLER
14.
CCT - PUSH IN TO DRAIN
15.
WAITING FOR CCT
16.
FERMENTING 1
17.
FERMENTING 2
18.
FERMENTING 3 PUMPING TO CCT
19.
END OF FERMENTING
20.
PUSH IN TO CCT
21.
PUSH IN TO DRAIN
22.
WAITNIG FOR DRAINING
23.
DRAINING OF SLUDGE
24.
WAITING FOR RINSE
25.
RINSING 1
26.
RINSING 1 - DELAY
27.
RINSING 2
28.
RINSING 2 - DELAY
29.
RINSING 3
30.
RINSING 3 - DELAY
31.
RINSING 4
32.
RINSING 4 - DELAY
33.
RINSING 5
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34.
PUMPING TO CCT DRAIN
35.
END
50.
CLENING
B. Steps of Hot trub 0.
INITIALSTATE
1.
DELAY
2.
CIRCULATION
3.
PUMPING TO MASHFILTER
4.
RINSING
5.
DELAY AFTER RINSING
6.
PUMPING RINSING TO MF
7.
PUSHING WITH WATER
8.
RINSING 2
9.
DRAINING
9. Water system + vapor system 9.1. Program description
Water system is used for mashing-in, sparging, and rinsing the tanks in the Brew house Vapor way is used for heating the technological water. Technological water pre-heats the mash to wort pan Pump M5201 is M5201 is started, if the water for rinsing the tanks in the Brew house is needed Pipes for mashing-in and sparging are directly connected to hot and cold water tanks
Cold water tank 3
Effective capacity :30 m
Total capacity :31 m Inside diameter :2400 mm
Total height :7600 mm
Material :stainless steel
3
Hot water tank
Water temperature 80◦C
Effective capacity :75m
Total capacity : 77.9m
Inside diameter :3600 mm
Total height :8600 mm Material :stainless steel
3
3
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Ice water tank 3
Effective capacity :33.2m
Total capacity :34.75m
Inside diameter :2600 mm
Total height :approx. 8500 mm
Material :stainless steel
3
9.2 Picture Description Description
Picture 1: water system
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9.3 Process parameters
Picture 2: water system – parameters parameters
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10. Spent Malt system
When the Silo is full the spent grain should be transported by truck for cattle feed. Controlled/operated by Brew house of operator in automatic/manual mode. Thermolized yeast may add to the spent grain if there is thermolized yeast.
10.1 Program description description
Spent malt from the mash filter is stored in spent malt tank If the dispensing of malt starts, malt valve under the conveyor opens. After that the conveyor starts In the step issue of malt the air is flipping and water valve is opened Dispensing of malt finishes, when the operator presses the button End Button Pause pauses the process – Stops Stops the conveyor, air valve and water valve will be closed, only malt valve will be opened
10.2 Picture Description
Picture 1: spent malt system
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Picture 2: spent malt system - control panel
10.3 Process parameters
Picture 3: spent malt system - control panel
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10.4 Process steps 0.
Idle
1.
ENABLE OF ISSUE
2.
OPEN OF M3220
3.
ISSUE OF SPENT
4.
END OF ISSUE
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