WATER SOFTENING & DEMINERALIZATION IN BREWERIES


Water Softening & Demineralization for the Brewery Industry

For ion exchange there are ion exchange resins in the unit. These resins are insoluble granular polymers appropriate for the specific application. In their molecular structure they contain loosely held positive cations or negative anions. These ions exchange with the ions in the treated water as it passes through the unit.

For softening of water a cation resin containing Na+ is applied. The calcium and magnesium ions which form hardness in water, creating scale deposits, are exchanged for the sodium ions of the resin. The resin binds more strongly with Ca2+ and Mg2+ than with Na+. When most of the ions in the resin have been replaced the resin is exhausted and a regeneration cycle is initiated. Regeneration with brine strips out Ca2+ and Mg2+ from the exhausted resin.

For water demineralization basically all dissolved ions are removed from the water. Therefore, the water passes through a cation resin containing H+ to replace all cations and through an anion resin containing OH- to replace all anions. The H+ and OH- then combine and form purified water. For regeneration the cation resin is treated with an acid. The anion resin is regenerated with a strong base. Cation and anion resin can be in separate vessels or together in a single vessel (mixed bed design). Systems for ion exchange are often used as the initial steps in a more complex water purification regime.

IONTEC

iONTEC

MEMBRANE WATER DEAERATION FOR BREWERIES


Membrane water deaeration for the Brewery Industry

Based on the use of highly effective membrane modules, extraordinarily low values of residual oxygen are achieved. Each module contains thousands of hydrophobic, gas permeable hollow fiber membranes resulting in a large surface. This large internal surface of the modules maximizes the transfer area and the contact time between water and gas. While the strip gas (CO2 or N2) is applied on the inside of the hollow fibers, the water flows in counter current between them on the outside. The high partial pressure difference of O2 forces the oxygen out of the water to permeate through the gas porous membranes. Inside the membranes the oxygen flows away together with the strip gas. This fundamental scientific principle is described by Henry’s Law. The DGS system needs a minimum of energy and strip gas. Due to its modular design, the skid can easily be adapted to the required capacity (by parallel installation of membranes) and to the required residual oxygen content (by serial installation of membranes). The O2 content of the deaerated water is permanently monitored. Therefore, the system is equipped with a high precision optical OXYTRANS sensor made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for O2 control. For further processing, the virtually oxygen free water can optionally be cooled, disinfected with UV light or carbonated. Hollow fiber membranes are sensitive against particles in water. Therefore, Centec membrane deaeration systems contain specific pre-filters.

DGS

iONTEC

REVERSE OSMOSIS FOR BREWERIES


Reverse Osmosis for the Brewery Industry

Reverse osmosis (RO) is the reversal of natural osmosis. If a semipermeable membrane is placed between pure water and water with dissolved ions (salts) osmosis will come into play. The pores of the membrane only allow the passage of H2O, but not of salts, suspended solids, bacteria and larger molecules. Osmotic pressure due to a concentration difference on both sides of the membrane causes the pure water to pass through the membrane to dilute the solution on the impure side. This will continue until osmotic equilibrium (the same concentration on both sides) is reached. 

In the REVOTEC unit this process is reversed. In order to separate pure water from water containing dissolved salts and solids, pressure is applied to the contaminated water. When the applied pressure overcomes the natural osmotic pressure, pure water will pass through the membrane into the pure water side. The purified water (permeate) is practically free of all impurities. This cross-flow technology minimizes fouling of membrane elements by quickly removing the impure water (concentrate). However, depending on the contamination of the raw water, pre-treatment may be required to prevent scaling and chemical attack from oxidizing agents like chlorine. In order to exactly reach the desired water quality and to increase the capacity of the system, permeate can be blended with raw water.

REVOTEC

COLUMN WATER DEAERATION FOR BREWERIES


DeGas-Cold - Column water deaeration for the Brewery Industry

For treatment in the column deaeration system, water is dispersed at the top of the column. The column contains densely packed, thin stainless steel sheets arranged in such way that the water takes multiple paths as it flows down through the column. This maximizes the transfer surface and the contact time between the water and the strip gas (CO2 or N2). The strip gas is fed into the bottom of the column and flows upwards inside it in counter current to the water. The large partial pressure difference of O2 forces the oxygen out of the water into the gas phase. This fundamental scientific principle is described by Henry’s Law. At the top of the column the removed oxygen leaves the system as a gas, together with the undissolved CO2 or N2. To further enhance the performance and to avoid carbonation or nitrogenation of the water, the system can optionally be operated under vacuum and completely without strip gas. This reduces capital and operating costs. The O2 content of the deaerated water is permanently monitored. Therefore, the system is equipped with a high precision optical OXYTRANS sensor made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for O2 control. The virtually oxygen free water is collected at the bottom of the column. For further processing, it can optionally be cooled, disinfected with UV light or additionally carbonated. 

DeGas - Cold

DeGas - Cold

COLUMN WATER DEAERATION FOR BREWERIES


DeGas-Hot - Column water deaeration for the Brewery Industry

For treatment in the column deaeration system, the water is first heated to 72 °C or more in an integrated, regenerative heat exchanger. Heating reduces the oxygen solubility and simultaneously disinfects the water. The hot water is then dispersed at the top of the column. The column contains densely packed, thin stainless steel sheets arranged in such way that the water takes multiple paths as it flows down through the column. This maximizes the transfer surface and the contact time between the water and the strip gas (CO2 or N2). The strip gas is fed into the bottom of the column and flows upwards inside it in counter current to the water. The large partial pressure difference of O2 forces the oxygen out of the water into the gas phase. This fundamental scientific principle is described by Henry’s Law. At the top of the column the removed oxygen leaves the system as a gas, together with the undissolved CO2 or N2. Hot column deaeration requires very little strip gas. The O2 content of the deaerated water is permanently monitored. Therefore, the system is equipped with a high precision optical OXYTRANS sensor made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for O2 control. The virtually oxygen free water is collected at the bottom of the column. For further processing, it can optionally be cooled or additionally carbonated.

DeGas - Hot

DeGas - hot

HOPS PRE-ISOMERIZATION FOR BREWERIES


Easyomer – Hops Pre-isomerization for the Brewery Industry

EASYOMER optimizes the yield of bitter acids from hops. A new, scientifically proven heat treatment technique with hop specific parameters (temperature, pressure, pH, concentration, time) supports the solubility of iso-alpha acids. They remain dissolved to a particular high degree up to the finished beer. Since the pre-isomerization stage is separate from the brewing process (wort boiling), this highly efficient method complies with the German Purity Law “Reinheitsgebot” and has no negative impact on the aroma profile of the beer. By using existing process equipment, CIP systems and dosing pumps for the addition of hop bitters, the investment costs can be minimized. Raw material savings and low capital costs result in a short amortization period and fast pay-back. With EASYOMER hops use can be reduced by up to 30 %.

Easyomer

easyomer

COOLING OF WART IN BREWERIES 


Wart Cooler – Cooling of wort for the Brewery Industry

For wort cooling a plate heat exchanger is used. The cooling process is done in one or two stages. In a single-stage process cold brewing water is used as the single cooling medium. The brewing water can be cooled to approx. 1 °C in a separate chiller operated with glycol, ammonia or brine. The wort enters the plate heat exchanger at about 100 °C. Due to the interaction of the hot wort and the cold brewing water in the heat exchanger, the temperature of the wort is lowered to approx. 2 - 3 °C while the temperature of the brewing water is raised to about 80 °C. The brewing water is used for the next brew, so the energy is returned to the brewing process. In a two-stage process, the hot wort is first cooled by brewing water to approx. 20 °C and then secondly by glycol, ammonia or brine to the pitching temperature. The warm brewing water can also be used for the next brew.

Wart Cooler

Wart Cooler

AERATION OF WORT IN BREWERIES


Wart Aerator – Aeration of wort for the Brewery Industry

The solubility of oxygen in wort depends on the temperature. The colder the liquid, the better is the oxygen solubility. Therefore, aeration is done after cooling of the wort. The amount of oxygen or sterile air to be added to the wort depends on various factors, e. g. original gravity, type of yeast and the desired final product characteristics. The Wort Aerator can be designed for manual or fully automated operation. Automated systems measure and control the O2 content of the wort with highest precision with an optical OXYTRANS sensor made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for O2 control. Based on oxygen and flow measurement, the amount of oxygen injected is precisely adjusted to match the measured wort flow. For O2 injection the Wort Aerator has a specifically designed Vortex-Venturi injector that feeds oxygen in a very large number of very fine bubbles directly into the product stream. Due to pressure and turbulent flow, the oxygen dissolves completely and absolutely homogeneously in a very short time. At the end of the dissolving path a control valve can be installed to keep the pressure in the system constant and above the saturation pressure. The Wort Aerator is equipped with a sterile filter system to sterilize the incoming gas.

Wort Aerator

Wort Aerator

PITCHING OF YEAST FOR BREWERIES


YeastPitch – Pitching of yeast for the Brewery Industry

The yeast pitching unit is a fully automated system that measures and controls the addition of liquid yeast into the wort line with extreme precision. In the standard design the skid is equipped with accurate flow meters. Optionally, turbidity sensors or a live yeast cell monitor can be used. Differential turbidity measurement before and after yeast dosing ensures that the right amount of yeast is dosed into the wort. Variations in the basic turbidity of the wort are automatically compensated for. As an alternative to differential turbidity measurement, the dosed yeast can be controlled by in-line live cell measurement. A specifically designed injector then blends the yeast and the wort together. The yeast cells are homogeneously distributed throughout the wort by a Vortex effect inside the injector. Due to its compact and modular design, the skid can easily be combined with a wort aerating system.

YeastPitch

YeastPitch

PURE STEAM GENERATION FOR THE BREWERY INDUSTRY 


Pure Steam Generation for Breweries

For pure steam generation the feed water enters a tubular heat exchanger with an expansion chamber above. In the tubular heat exchanger the pre-treated water is heated and steam is generated. The tubes of the heat exchanger are connected with the expansion chamber that serves as a separating column. For production of pyrogen-free steam the chamber contains a demister. After entering the expansion chamber, the steam moves further upwards in the column. By gravity and due to the specific column design, un-evaporated water droplets fall back into the lower section of the chamber, thus separating from the steam. Since the droplets may contain contaminants like endotoxins, it is vital that they are not carried forward with the steam. As an important quality characteristics, the conductivity of the pure steam condensate can optionally be monitored. If required, the pure steam generator can be enlarged by additional columns to build up a multi effect distillation system. This allows combined generation of pure water and pure steam at the same time.

PureSteam

PureSteam

INACTIVITATION OF YEAST FOR BREWERIES


Yeast Thermolizer – Inactivation of yeast for the Brewery Industry

For thermal deactivation the yeast is heated to its deactivation temperature. The yeast flows through a special heat exchanger, then into a holding tube. Hot water or steam can be used as heating medium. In the holding tube the yeast is held at the deactivation temperature for a specified time. Typically, 10 seconds at 75 °C is sufficient to deactivate yeast. In this way, all the live cell membranes are ruptured. For efficient energy use, the deactivation system can be designed as a two-stage system with a regeneration zone. The first step is energy recovery. The live yeast is heated as it flows in counter current to already deactivated hot yeast. Heat from the deactivated yeast is thereby returned to the process. In the second step the yeast is warmed up to the target deactivation temperature by the heating medium.

YeastThermolizer

YeastThermolizer

PROPAGATION OF YEAST FOR BREWERIES


Yeast Propagator – Propagation of yeast for the Brewery Industry

The Yeast Propagator consists of one or more individually controllable propagation tanks. The number and the size of the propagators relates to the brewery’s capacity, processes and the customer’s specific preferences. For yeast propagation the yeast suspension is filled into the propagator and mixed with fresh wort until the desired yeast quantity and cell concentration are reached. At the same time the mixture is aerated and gently recirculated to achieve homogeneity. Inside the propagator the yeast cells grow in sterile environment. For aeration oxygen or sterile air is used. The O2 content is permanently monitored using a high precision optical OXYTRANS sensor made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for O2 control. Ideal and stable conditions inside the propagation tank result in vital and healthy yeast cells with nearly 100 % viability. The yeast cells can be pitched into the wort stream for fermentation, or they are transferred to other propagators for further yeast growth. All yeast pumps and components in the system are designed for very gentle yeast treatment, so as to fully preserve the viability and vitality of the yeast cells. The Yeast Propagator can operate continuously or in batches. As an option, the system can be equipped with a live yeast cell monitor for highly accurate in-line cell measurement.

Yeast Propagator

Yeast Propagator

RECOVERY OF BEER FROM YEAST FOR BREWERIES


Yeast Recycler – Recovery of Beer from yeast for the Brewery Industry

For beer recovery with the Yeast Recycler well proven cross-flow technology with robust ceramic membranes is used. The modular design is applicable for all brewery sizes. The recovered filtrate is free of yeast and takes up a minimum of oxygen. Recovered beer can be blended back into the brewing process at a ratio of up to 5 % without negatively influencing the quality of the final product. By adding small amounts of water to the waste yeast, beer recovery is optimized by a wash out effect (diafiltration). The advantage of diafiltration is a higher recovery rate. The O2 content can be monitored by high precision optical OXYTRANS sensors made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for O2 control. The Yeast Recycler is highly standardized resulting in low capital costs, a short amortization period and fast pay-back. Furthermore, it can easily be expanded by adding other Centec systems, e. g. for water deaeration and for blending.

Yeast Recycler

Yeast Recycler

CLEANING-IN-PLACE FOR BREWERIES


CIP – Cleaning-in-place for the Brewery Industry

Cleaning and sanitization must be performed periodically at appropriate intervals. A typical CIP cycle consists of various steps, e. g. pre-rinse with purified water, flushes with caustics and acid solutions, intermediate and final rinse with purified water. Chemicals and detergents are sometimes used to enhance cleaning performance. Depending on the system, after each cleaning step the cleaning media is either routed to drain (lost CIP) or back to the storage tank for later re-use (batch CIP). Temperatures, flow rates and times are adapted to the system dimensions and the cleaning tasks. Hot cleaning regimes use hot caustic and/or hot water. In cold cleaning regimes all media have ambient temperature. Centec provide a large variety of CIP systems. They can be small and mobile single channel units, or large stationary multi-channel systems, including storage vessels of any size for cleaning media and rinse water recovery. CIP systems are designed by Centec in such a way that optimal cleaning results are ensured, with the lowest consumption of water, chemicals and energy. While one part of the plant is cleaned other areas can continue to produce product. Double seat valve technology prevents intermixing of product and cleaning media at any time.

CIP

CIP

HIGH GRAVITY BLENDING FOR BREWERIES


Blender – High Gravity Blending for the Brewery Industry

For High Gravity Blending wort with high extract content is produced. During fermentation this leads to a beer with higher original gravity and alcohol content. Later in the process the high gravity beer is blended with deaerated water to reach the desired final original gravity and/or alcohol content. If this is done directly in front of the BBTs or even directly in front of the filler, brewery flexibility is increased significantly. Different beers (brands) can be produced from the same mother beer. In that way, the brewery can quickly react to changing market demands. The flows and the content of original gravity and alcohol are permanently monitored and adjusted by ratio control. Therefore, the system is equipped with high precision flow meters and in-line sensors made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for alcohol control based on density and sound velocity measurement. Optionally, the Blender can be equipped with a Vortex-Venturi injector for combined supply of CO2 into the product. Systems combining High Gravity Blending and carbonation in one step are offered by Centec as compact CarboBlender skids.

BLENDER

BLENDER

HIGH GRAVITY BLENDING & CARBONATION FOR BREWERIES


CarboBlender – High Gravity Blending & Carbonation for the Brewery Industry

For High Gravity Blending wort with high extract content is produced. During fermentation this leads to a beer with higher original gravity and alcohol content. Later in the process the high gravity beer is blended with deaerated water to reach the desired final original gravity and/or alcohol content. If this is done directly in front of the BBTs or even directly in front of the filler, brewery flexibility is increased significantly. Different beers (brands) can be produced from the same mother beer. In that way, the brewery can quickly react to changing market demands. For product carbonation the CarboBlender has a specifically designed Vortex-Venturi injector that feeds carbon dioxide in a very large number of very fine bubbles directly into the product stream. Due to high pressure and turbulent flow, the CO2 dissolves completely and absolutely homogeneously in a very short time. At the end of the dissolving path a control valve is installed. This valve keeps the pressure in the system constant and above the saturation pressure. The flows and the content of original gravity and alcohol are permanently monitored and adjusted by high precision ratio control. Therefore, the system is equipped with high precision flow meters and in-line sensors made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for alcohol and CO2 control.

CarboBlender

CarboBlender

CARBONATION FOR BREWERIES


Carbonator – Carbonation for the Brewery Industry

For CO2 supply the Carbonator has a specifically designed Vortex-Venturi injector that feeds carbon dioxide in a very large number of very fine bubbles directly into the product stream. Due to high pressure and turbulent flow, the CO2 dissolves completely and absolutely homogeneously in a very short time. At the end of the dissolving path a control valve is installed. This valve keeps the pressure in the system constant and above the saturation pressure. The flows and the CO2 content are permanently monitored and automatically adjusted in the process. Therefore, the system is equipped with high precision flow meters and a CARBOTEC sensor made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for CO2 control. The desired concentration of CO2 is precisely met in the carbonated product. The Carbonator is integrated into the CIP cleaning cycle of the main product line.

Carbonator

Carbonator

DECARBONATION &CARBONATION FOR BREWERIES


DeCarbonator – DeCarbonation & Carbonation for the Brewery Industry

The system is designed to continuously adjust the CO2 content in a product to the required level. Highly efficient membrane modules allow the CO2 concentration to be increased and decreased with extraordinary accuracy. At the same time the oxygen content is reduced. Each module contains thousands of hydrophobic, gas permeable hollow fibre membranes resulting in a large surface. This large surface maximizes the transfer area and the contact time between product and gas. While CO2 is applied on the inside of the hollow fibres, the product flows in counter current between them on the outside. Depending on the CO2 partial pressure difference between the product and the gas, the CO2 permeates through the membranes either out of the membranes into the product or out of the product into the membranes. This fundamental scientific principle is described by “Henry’s Law”. The CO2 content of the carbonated product is permanently monitored. Therefore, the system is equipped with a high precision CARBOTEC sensor made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments for CO2 control. Based on this accurate in-line measurement, the carbon dioxide flow is instantly and fully automatically adjusted. The O2 content is measured with proven Centec optical OXYTRANS sensor technology.

DeCarbonator

DeCarbonator

NITROGENATION FOR BREWERIES


Nitrogenerator – Nitrogenation for the Brewery Industry

For product nitrogenation the Nitrogenator has a specifically designed Vortex-Venturi injector that feeds nitrogen in a very large number of very fine bubbles directly into the product stream. Due to high pressure and turbulent flow, the N2 dissolves completely and absolutely homogeneously in a very short time. At the end of the dissolving path a control valve is installed. This valve keeps the pressure in the system constant and above the saturation pressure. The system is equipped with high precision flow meters. Based on the measurement of the flows, the product steam and the nitrogen flow are instantly and fully automatically adjusted. Optionally, the N2 content of the nitrogenated product can be monitored by a nitrogen sensor. This sensor can be used for process control in addition to the ratio control. The desired concentration of N2 is precisely met in the nitrogenated product. The Nitrogenator is integrated into the CIP cleaning cycle of the main product line.

Nitrogenator 

Nitrogenator

ADDITIVE DOSING FOR BREWERIES


ADos – Additive Dosing for the Brewery Industry

In additive dosing smaller or larger amounts of ingredients are dosed directly into the main product stream according to a preselected recipe. The number of components can be adapted to meet individual needs. There are various possibilities to supply the additives, e. g. out of separate tanks via supply lines or out of smaller vessels located on the skid. Optionally, the vessels can be heated, purged with CO2 or N2 or equipped with agitators. Reliable flow meters, dosing pumps and pneumatic control valves permanently measure and adjust the quantities. Thus, highly accurate repeatable dosage of even smallest amounts is guaranteed. The modular system design allows for easy expansion, e. g. for mixing with deaerated water, carbonation or pasteurization of the finished product.

ADos

ADos

MULTI COMPONENT MIXING FOR BREWERIES


MultiMixer – Multi Component Mixing for the Brewery Industry

In multi component mixing different liquid or powder products are blended. The components to be mixed can be supplied from large storage tanks via supply lines or from vessels located on the skid. Mass flows and concentrations are permanently measured in the process and adjusted by ratio controllers. Therefore, the system is equipped with high precision flow meters and in-line sensors made by Centec. Centec have decades of experience in the development and manufacturing of own precision instruments. Frequently, the MultiMixer is also used for carbonation. In this case the skid contains a specifically designed Vortex-Venturi injector that feeds carbon dioxide in a very large number of very fine bubbles directly into the product stream. With the Centec mixing technology low-oxygen dosing of concentrates is possible. Based on the in-line measurements, the product steams and the carbon dioxide flow are instantly and fully automatically monitored and adjusted. Thus, repeatable results and minimum product losses are guaranteed. The modular design of the process unit allows for easy expansion, e. g. for mixing with deaerated water or for pasteurization of the finished product.

MultiMixer

MultiMixer

FLASH PASTEURIZATION FOR BREWERIES


FlashPasto – Flash Pasteurization for the Brewery Industry

The flash pasteurization system is designed to pasteurize the product gently without adversely affecting its colour, taste or digestibility. For optimum results, pasteurization time, temperature and pressure have to be individually adjusted. Optimum parameters depend on various factors, such as product, type of packaging and anticipated shelf life. Based on highly accurate process control, the unit guarantees constant pasteurization quality even at variable product flow directly in front of the filler. To increase the energy efficiency of the system, the product is warmed up to the pasteurization temperature in two steps. In the first step it is heated in a heat recovery section where it flows in counter current to the hot, already pasteurized product. In the second step it is gently brought to the pasteurization temperature by the heating medium, e. g. hot water, heated by steam. If the flash pasteurization system is installed directly in front of the filling machine, it can compensate for variations of product quantity picked up by the filler. CIP cleaning of the unit can take place as the same time as the main line or separately.

FlashPasto

FLASH PASTO

TANK PRESSURE CONTROL SYSTEM FOR BREWERIES


Unipressure System – Tank Pressure control system for the Brewery Industry

As compact, prefabricated assembly, the Unipressure System requires little space and is quick to install on site, with minimal field welds. It is fully automated and designed to suit each customer’s specific requirements. The system controls the supply of gases and CIP media into the tanks through the tank tops. For sterile applications a sterile gas filter is installed. Double seat valves prevent the intermixing of products and cleaning media. The Unipressure System can be combined with a Centec valve manifold or designed as an independent, compact assembly. Typically, the system is used with storage tanks, fermentation vessels, pressure tanks and deaerated water tanks.

Unipressure System

Unipressure system

DEALCOHOLIZATION OF BEER FOR BREWERIES


DeAlco Tec – Dealcoholization of beer 

For dealcoholization incoming alcohol rich product is first gently heated by a regenerative heat exchanger in counter current to the finished product. It is dispersed at the top of a specially designed evaporation column. For CO2 containing product, prior degassing prevents formation of foam. Exhaust vapours are fed into the bottom of the column. They rise upwards inside the column in counter current to the falling warm liquid. Thereby, they remove the volatile alcohol from the product. The less volatile components fall to the column base. They flow into the falling film evaporator that generates the exhaust vapour for delacoholization. Densely packed, thin stainless steel sheets in the column maximize the transfer surface and the contact time between the product and the exhaust vapours. The complete process takes place under vacuum. A key benefit of the Centec technology is the exceptionally effective alcohol removal at low temperature. The remaining alcohol-free product is pumped away and cooled for storage or further processing, e. g. for carbonation. The volatile flavours from the original product can be separated from the exhaust vapours in a special aroma recovery system and added back to enhance the taste of the finished product. If desired, the alcohol is concentrated to form liquid alcohol of up to 90 vol. % for use in other applications or for sale. For highly precise measurement and control of critical product characteristics such as alcohol, O2 and CO2 content, Centec process sensors are ideally suited. Centec have decades of experience in the development and manufacturing of own precision instruments.

DeAlco Tec

dealco

WATER PRE-TREATMENT FOR BREWERY INDUSTRIES


Water Pre-Treatment for the Brewery Industry

Raw water quality depends greatly on its source. Based on the raw water quality and the specifications for the purified water, Centec select the most appropriate technologies for each client. Usually, multi-stage regimes are necessary for water purification. For water pre-treatment, sand and multi media filters are used to remove suspended material (e. g. silt, clay, organic matter). Such material in water can reduce the effectiveness of downstream components such as ion exchange resins and reverse osmosis membranes. Soluble iron and manganese are found in water that contains no dissolved oxygen. They cause a metallic taste and form deposits in piping systems. The Centec De-Ironizer is designed for iron and manganese removal. If harmful bacteria and microbes are suspected, the water is disinfected by UV, ozone or free chlorine. Activated carbon (AC) filtration removes odours, tastes and oxidizing agents like free chlorine that can lead to chemical attack of membranes elements in subsequent purification steps.

WATER PRE-TREATMENT

WATER PRE-TREATMENT

Sand & Multi Media Filter

A sand filter only uses sand as filter medium. Whereas a multi media filter typically have 3 to 5 layers of different media types. Both are back-flushable. In a sand filter the smallest particles are trapped at the top of the media bed, while larger ones sink deeper proportional to their mass. The result is a very limited use of the media depth, because virtually all filterable particles are trapped at the very top of the filter bed. Multi media filters use several layers of different materials, each having a significantly different density. Due to the layering, larger particles are removed first at the top of the media bed, while smaller particles are trapped further below. Trapping particles in this manner, results in more effective removal of contaminants, even of very small turbidity forming particles. Furthermore, longer run times between backwash cycles are achieved.

De-Ironizer

Dissolved iron and manganese are removed from water by oxidation and subsequent filtration. Fe2+ is oxidized to Fe3+, which with oxygen, forms the insoluble iron complex Fe(OH)3. Mn2+ is oxidized to Mn4+, which with oxygen, forms insoluble MnO2. An ideal and low-cost method of providing oxidation is to use the oxygen in air as the oxidizing agent. For removal of the insoluble iron and manganese gravel can serve as filtration media. By cyclical back-flushing the iron and manganese particles are washed out and removed.

Activated Carbon Filter

Activated carbon filtration is a method of filtering that uses a bed of activated carbon to remove contaminants by chemical absorption. Due to the highly porous structure of activated carbon, each carbon particle provides an extremely large surface area. Contaminant molecules are trapped inside this structure. Activated carbon adsorbs organic substances which cause odours and tastes. Furthermore, it acts as a catalyst in contact with free chlorine supporting the reaction of free chlorine to harmless chloride ions.

Disinfection

Chlorine is an inexpensive treatment method for deactivating microorganisms like bacteria and viruses. Stored in pressurized containers, it can be injected as a gas directly into the water. Alternatively, a sodium hypochlorite solution can be used. This solution is easier to handle than chlorine gas. Disinfection can also be achieved with calcium hypochlorite, a solid disinfectant. This form can be stored as powders, granules or tablets. Ozone (O3) is another powerful oxidizing agent. It is pumped into water systems to kill biological contaminants like bacteria and viruses. Since ozone gas is very unstable, O3 needs to be created on site. Ozone is pure active oxygen and produces no residual odours or tastes in water. Also ultraviolet (UV) light can be used to kill harmful microorganisms. The UV process is an attractive option in many cases because it is chemical-free and investment costs are low.

ENQUIRE

PROCESS SYSTEMS FOR CRAFT BREWERIES


Craft Line – Process Systems for craft Breweries

Centec offer a selection of cost-effective process systems specifically designed for craft breweries. These skids are typically used for capacities up to 50 hl/h. They are characterized by a lower level of automation and optional high precision sensor technology. The Centec Craft Line is easy to implement and to configure.  

Craft Line

Craft Line

Craft DeGaS-Cold

For treatment in the column deaeration system, water is dispersed at the top of the column. The column contains densely packed, thin stainless steel sheets arranged in such way that the water takes multiple paths as it flows down through the column. This maximizes the transfer surface and the contact time between the water and the strip gas (CO2 or N2). The strip gas is fed into the bottom of the column and flows upwards inside it in counter current to the water. The large partial pressure difference of O2 forces the oxygen out of the water into the gas phase. This fundamental scientific principle is described by Henry’s Law. At the top of the column the removed oxygen leaves the system as a gas, together with the undissolved CO2 or N2. To further enhance the performance and to avoid carbonation or nitrogenation of the water, the system can optionally be operated under vacuum and completely without strip gas. This reduces capital and operating costs. Also as an option, the O2 content of the deaerated water can be permanently monitored. Therefore, the system is equipped with a high precision optical OXYTRANS sensor made by Centec.

Craft Wort Aerator

The Craft Wort Aerator is designed for manual operation. Based on optional high precision oxygen and flow measurement, the amount of O2 injected can be accurately adjusted to match the measured wort flow. For O2 injection the Wort Aerator has a specifically designed Vortex-Venturi injector that feeds oxygen in a very large number of very fine bubbles directly into the product stream. Due to pressure and turbulent flow, the oxygen dissolves completely and absolutely homogeneously in a very short time. At the end of the optional dissolving path a control valve can be installed to keep the pressure in the system constant and above the saturation pressure. The Wort Aerator can be equipped with a sterile filter system to sterilize the incoming gas.

Craft Blender

The Craft Blender is used for blending high gravity beer with deaerated water or for blending beer with syrup. If this is done directly in front of the filler, brewery flexibility is increased significantly. Different beers or beer-based mixed drinks can be produced from the same mother beer. In that way, the brewery can quickly react to changing market demands. Optionally, the flows and the content of original gravity and alcohol can be permanently monitored and adjusted by ratio control. Therefore, the system is equipped with high precision flow meters and in-line sensors made by Centec. Also as an option, the Craft Blender can be equipped with a Vortex-Venturi injector for combined supply of CO2 into the product.

Craft Carbonator

For CO2 supply the Craft Carbonator has a specifically designed Vortex-Venturi injector that feeds carbon dioxide in a very large number of very fine bubbles directly into the product stream. Due to high pressure and turbulent flow, the CO2 dissolves completely and absolutely homogeneously in a very short time. At the end of the optional dissolving path a control valve is installed. This valve keeps the pressure in the system constant and above the saturation pressure. The flows and the CO2 content are permanently monitored and automatically adjusted in the process (option). Therefore, the system can be equipped with high precision flow meters and a CARBOTEC sensor made by Centec.

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ULTRAVIOLET (UV) LIGHT TREATMENT IN BREWERIES


Ultraviolet (UV) light for the Brewery Industry

Process water in contact with beer carries specific microbiological hazards, so it is critical to have the right water treatment strategy in place. Each production process includes specific microbiological hazards. In other words, each process should be protected against specific micro-organisms.

Traditionally, UV systems for the brewing industry are based on ‘general UV dose’ of 25 or 40 mJ/cm2. The experts at bestUV have a different approach. bestUV designs UV systems for the brewing industry that are based on the hazards specific to a stage of beer production.

In breweries, some micro-organisms can be killed with low UV doses. Others require high UV doses. So, the UV disinfection strategy is determined by the type of micro-organism (bacteria, moulds, yeasts), position of the UV treatment to the end-product (beer), and the function of the process water to treat.

The advantage of UV treatment is that is a chemical-free method, which does not change the taste, color, pH, minerals of the process water. No residuals are left in the treated water to get in contact with the end product.

BetaLine UV South Africa

BetaLine UV

BetaLine-E South Africa

BetaLine-E UV

AlfaLine UV South Africa

AlfaLine UV

KappaLine UV South Africa

KappaLine UV

KappaLine UV

The KappaLine UV series is the most forward-looking UV system available in the market today. It features ‘in-one-line’ positioning for the in and out connections and perpendicularly positioned, very compact low-pressure UV amalgam lamps, called EcoLight.

The high-efficient ‘state-of-the-art’ EcoLight lamps emit germicidal wavelengths at 254nm and were specially developed by bestUV for use in the compact KappaLine UV systems. 

This unique combination of compactness and high efficiency makes it stand out as the only system available in the market that combines all the advantages of both medium- and low- pressure systems.

The lamplife is extremely long, meaning the operational costs are relatively low compared to others.

The KappaLine UV system is biodosimetric tested and was approved by the Austrian Institute Ö-norm (M+27 12 998 6326:2001) and Norwegian Institute for Public Health (NIPH Liste B).

These official approvals allow the KappaLine UV to be used in larger waterworks and smaller drinking water facilities to protect consumers against waterborne pathogens, including most bacteria, viruses, parasites, protozoa (Cryptosporidium, Giardia) and bacterial spores.

The KappaLine UV is officially tested and approved with a cleaning device (manual or motor-driven). This device prevents fouling of the protecting quartz sleeves, greatly reducing UV light loss.

The CFD (Computational Fluid Dynamics) designed and biodosimetric approved KappaLine UV provides optimal protection against pathogens, delivering the highest performance for the lowest operational costs.
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AlfaLine UV

AlfaLine UV, the most compact UV system, is designed for all types of water treatment.

The so-called “I-shape”, where the water’s inlet and outlet are in one line, results in low headloss, and very easy installation in new or existing pipelines.

The long-life medium-pressure UV lamps are compact and emit a broad spectrum of wavelengths with a high intensity.

AlfaLine UV systems prevent fouling of the quartz sleeves and UV sensor with an effective manual or electrical ‘anti-fouling mechanism’.

The Power Control System (PCS) enables the UV lamps to run at the most optimal setting to save energy and increase lamplife. This reduces operational costs and increases your return on investment.

The Lambda PLC controller ensures optimal operation of the AlfaLine UV. It provides the operator with valuable information about inputs and outputs, actual UV dose, UV intensity, lamp and system running hours, 4-20mA UV output, maintenance, warnings and alarms. The controller can be equipped with a BUS-connection to communicate with an external master PLC.
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