Beer Processing Solutions

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Table of contents

Introduction ...............................................3Brewing Process Diagram .....................4Complete Product Range ......................5Complete Process Solutions ................6Automation Services ...............................8Maintenance Service ............................ 10Wort Cooling, Yeast Dosing,Wort Aeration ........................................ 11Water Deaeration .................................. 13Inline Blending and Mixing .................. 15Carbonation and Nitrogenation ......... 17High Gravity Brewing ........................... 19Dealcoholization of Beer ..................... 21Pasteurizing ............................................ 23CIP ........................................................... 25Fermentation and Maturation, Filtration and BBT Celler ..................... 26

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APV pioneered many of the key technologies involved in the brewery industry. As early as 1910, APV made the first welded 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 worlds first brewery plate heat ex-changer.

Since then, many more developments have been introduced, placing APV in a better position than ever to serve the brewery industry in all specialty processes.Today APV offers process automation systems, individual brewery process units, and a wide range of components including pumps, valves and heat exchangers. All APV equipment and systems can be supported by

a variety of after sales services.

The block diagram below shows the position of APV units and systems in a typical brewery cold block processing line. The dark green blocks provide a survey of the APV units and systems and the lights green blocks show the fields for which complete solutions can be offered.

Our first steps into the brewery equipmentbusiness began as early as 1910...

Yeast propagation

Yeast crop

Yeast tank

Waste beer treatment

Waste yeast

Wort cooling

Wort aeration

Yeast dosing

Fermentation tank

Storage tank

Green beer cooling

Beer cooling

Filtration/Stabilisation

PU PasteurizerFlash pasteurization

Bright beer tank

CO2, N2

Treated Water

Filling

Brewhouse

Dealcoholisation

DeroxWater deaeration

BlendMasterBlending/HGB

CarboMasterCarbonation

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Page 26

FermantationMaturation

Filtration

Page 17

CarboMasterCarbonation

& nitrogenation

Page 15

BlendMasterBlending & mixing

Page 13

DeroxWater Deaeration

Page 19

Page 26

High gravitybrewing

BBT Celler

Page 23

PU PasteuriserPateurising

Page 25

CIP

Page 11

Cooling, dosingand aeration

Page 8

Automation& Control

Filling

The Brewing Process

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APV provides a selection of standardized process units, which could be described as a series of building blocks. These fulfil various brewing processes and include:

WortCooling

Yeastdosingandwortaeration

BeerChiller

Derox-Coldandhotwaterdeaera-tion

BlendMaster-Inlineblendingandmixing

CarboMaster-Carbonationandnitrogenation

PUPasteurizer-Controlledbeerpasteurization

CIPMaster

Focused on adding value to your productOur process units are designed to exceed industry standards and enhance the value of your products. To highlight how value is added toyour products and processes, wehave developed the following symbols for your reference

From individual units to totally automated solutionsEvery unit can be supplied as astand-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.

A Complete Product Range

The unit values are significant

APV Provides: Capabilities: Customer Values:

An intelligent processing unit Configuration as required Real time plant data:PredictivemaintenanceOn-linedocumentationFinalproductmonitoringTraceableproduction

Improved process:ProfitabilityConsistencySecurity

Lower operating costLonger running time

A Plug and Produce unit Very short commissioning timeLow installation costNo interference to existing production schedulesReduced time from order to productionSeamless integration to all plantsEasy to extend

Faster return on investmentEasy expansion of existing plant

Proven standards Improved functionalityHygenic designGood reliability

Improved repeatabilityProduct integrity safeguarded

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

Quick and easy operator trainingEnvironmental improvementsImproved company image

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

Shorter delivery timeHigher capacity/m

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

Cost effective maintenance Higher productivity

Product

uniformity

homogenous products

Flexible

production

fast product changeover

Economical

production

cost saving processes

Proven

security

tested equipment

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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 todays demand for modern, highly efficient production facilities, APVs in-depth knowledge of brewing top quality beers iscomplemented by expertise inprocess automation and management information systems.

APVs technological excellence covers processes such as fermentation and storage, yeast handling and treatment, beer processing, bright beer and pasteurization. Furthermore, we have vast experience in the areas of wort cooling, water deaeration, and high gravity brewing. Our CIP systems complete the process. Wherever appropriate, APV integrates its strong range of standard process units into a project.

We believe our experience is our most important asset. Previous highly successful installations are our customers best guarantee that a brewery project will be implemented on time and within budget.Our experience ranges from traditional methods to highly automated systems based around the latest proven technologies.

Highly automated systems deliver improved efficiencies, resulting in a faster return on investment, due to:

Moreproductiontime

Lesscleaningtime

Minimumuseofwater,chemicalsand energy

Feweroperators

They also improve batch control, resulting in product traceability and flexibility.

Further benefits for the brewmaster and management are: Apaperfreeprocesscontrol

system which can interface with ERP systems

Materialandqualitytracking

capability

Fullcompatibilitywithbrew-house and filling plant as well as with other production plants in the brewing group

Process EngineeringAPV uses its extensive experience in the development, planning and implementation of brewing stepsin close cooperation with ourcustomers brewmaster, technologists and process engineers. Careful teamwork ensures that we understand and recognize each of our customers

Complete Process SolutionsAdding value for the brewmaster

specific needs.

Detailed EngineeringThis starts with the PID and pro-cess description, followed by thedevelopment of installation pipe-line 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 DesignOur design is based on the latest international standards for hygienic design. APV uses standard design elements, which are constantly re-viewed to meet the highest

standards.

Health and SafetyHACCP/HAZOP studies can be undertaken, reviewing equipment specifications relative to process flow diagrams to determine whet-her there are any quality, health and safety issues, which need to be ad-dressed.Each process step is analysed to establish whether the equipment and control systems are adequate for safe operation under normal, abnormal and CIP conditions.

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Latest Design ToolsAPV 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 trans-late the efforts of APV suppliers and other sub-suppliers into successful projects.

Environmentally Safer ProcessesIn 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 .

OptimizingWorking ProceduresConsistent 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.

Training of PeopleBreweries are operated by fewer and fewer highly trained staff, which often results in the need foran exceptional 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.

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Automation and PerformanceServices Solutions

APV Automation and Performance Services 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 know-how and engineering expertise that meet regulatory requirements. This enables customers to extend their performance gains across their business.

Value StreamsAPV Automation and Performance Services comprise five strategic value streams to meet our customers automation and manufacturing execution needs.

AutomationServiceforcustom-ers existing automation equip-ment offering maintenance and support programs, spare parts, etc maintaining and improv-ing conditions to maximize plant uptime

APV Automation and Performance Services is vendor independent, it can include, for example control systems and human machi-ne interfaces (HMIs) from Siemens, Rockwell, Mitsubishi, Wonderware, etc. This enables true versatility in our solutions.

9ERP Integration

MES Applications

Automation Systems

Automation Migration

Automation Service

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Automation Migration for our customers with an installed base of ageing and obsolete automation equipment which can no longer adequately sup-port their business. Further-more, Automation Upgrade for systems that require additional functionality to meet automation and control requirements

AutomationSystemsconsistingof 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

MESApplicationstargetingmanufacturing and equip-ment performance, production execution, quality and tracking. We offer a 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 ac-tions in our customers organi-zations to drive manufacturing excellence

ERPIntegrationsolutionsthatlink and integrate the plant floor automation systems to our customers enterprise or busi-ness layer

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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:

BasicCare - APV service when you can plan ahead - Balance of uptime and econo- mics for non-critical assets

ClassicCare - Comprehensive APV service

support - When service delays are not an option

AdvantageCare - APV service coverage for your

most critical equipment - Proactive approach to equip-

ment performance

TotalCare - APV service management and

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

mission effectiveness

Each agreement includes certain cri tical items, with each level providing progressively increasing sup-port 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.

Maintenance Services

Total Care Advantage Care Classic Care Basic Care

Agreement of delivery of critical Agreement of delivery of critical Agreement of delivery of critical Agreement of delivery of spare parts spare parts spare parts critical spare parts

Agreement of emergency Agreement of emergency Agreement of emergency Agreement of emergencyservice support service support service support service support

APV Preventive Maintenance APV Preventive Maintenance APV Preventive Maintenance One annual plannedprogram, 24/7/365 program, 24/7/365 program, Monday to Friday maintenance visit 8am-5pm

Free emergency service, Emergency service, Emergency service, Spare parts discount24/7/365 24/7/365 Monday-Friday, 8am-5pm

Wear parts and service parts Wear parts and service parts Wear parts included Recommended wear partsincluded included replacement scheme

Other spare parts discount Other spare parts discount Other spare parts discount Technical telephone support, 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 servicepartnership seminar partnership seminar partnership seminar

Software upgrades Predictive maintenance on critical items

Plant availability guarantee Software upgrades

Designated APV maintenance Rebuilding and retrofittingmanager consultancy

Continuous process costreduction

Guaranteed performanceguarantees on critical items

Annual process knowledgeanalysis

Rebuilding and retrofitting consultancy

Operator audit and training discount

APV service management APV service coverage for Comprehensive APV APV service when you canand support for the your most critical equipment service support plan aheadentire plant

Plantwide strategy to Proactive approach to When service delays arent Balance of uptime andimprove mission equipment performance an option economics foreffectiveness non-critical assets

ASystematicProgramofStrategicMaintenance

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The Wort Cooling, Yeast Dosing and Wort Aeration units are designed for the processes between the brewhouse and fermentation.

In addition to fast and efficient Wort Cooling, Yeast Dosing and Wort Aeration units deliver effective and accurate inline dosing of yeast and air/oxygen by means of the patented APV gas injector.

Offered in a wide range of capacities from 50 to 1200 hl/hr, all units are designed and developed for easy integration with

existing lines.

Product uniformity: Constantmonitoringandim-

proved regulation of the process

Repeatablefermentationper-formance

Economical production: Higheraccuracyinyeastand

oxygen dosing

Reducedfermentationtime

Flexible production:

Turndownratioto25%ofnomi-nal capacity

Constantyeast/oxygenratio,regardless of flow

Proven security: FullyCIP-cleanable

Traceableproductiondata

Wort Cooling, Yeast Dosing and Wort Aeration Ensure economical production by minimizing the use of time and additives

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wortmaster.dwg

BREW WATER

WORT

STERILE AIR

AERATED WORT

K K

GLYCOL

GLYCOL

BREW WATER

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Functional descriptionWort Cooling - Hot wort from thebrewhouse must be cooled priorto 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 re-quires oxygen to multiply. Traditionally this has been supplied by blowing air through the wort with various types of nozzles and mixers. The result was often varying oxygen levels of typically 10 to12 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 achie-ve levels above 18 mg O2/l.

The APV Gas Injector allows these levels to be achieved by a fast con-sistent mixing of wort and either air or oxygen.

Yeast Dosing - Yeast can be added to complete the wort treatment. This has the advantage of adding yeast immediately to the cooled wort. The actual method used can

reflect local practice and the auto-mation allows accurate MIS/MES integration. In the event of lack of product flow, the yeast supply is shut off.

Options

Cooling DuoSafety Plates - Additional

pro duct protection. ParaWeldPlates-Allowthe

use of NH3 as refrigerant. Bypass - Options are available

for bypassing the plate heat ex-changer to enable such opera-tions as hot and/or cold wort diversion and back washing.

Aeration Manual Adjustable Head - Any

adjustment for flow and speci-fication must be made manu-ally.

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 con-tents measured by a load cell.

Yeast Cell Measurement - The amount of yeast can be dosed on the basis of instrumentation that measures the yeast cell concentration.

Common Original Extract Measurement -

Completed through the means of a sound velocity sensor or density measurement.

Oxygen Measurement - The oxygen content of the wort can be measured using an appro-priate instrument.

Blending Separation - The simpleblendingTcanbereplaced with a 4 port double seat valve and stop valve to separate the product and com-ponent loops for cleaning.

High Accuracy Blending - A variation of this technology using mass flow measurement is capable of even higher ac-curacy and is used for blending of components such as hop extract or colour.

Conductivity Measurement - Pro duct separation can be measured by means of conduc-tivity to minimize product loss.

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Deaerated water is used in the brewing industry to minimize damage to beer through oxidation. It is used as a medium for purging mains 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 re-move 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 valueThe standard capacity range is 30 to 1,500 hl/h.

The Derox adds value to your pro-ducts and processes in the follow-ing ways:

Product uniformity: Constantlylowoxygencontent

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

Continuousmonitoringforre-quired specification

Economical production: Lowrunningcosts

Space-savingdesign(highca-pacity/m2)

Flexible production: Variablecapacityandhighturn

down

Independentofwaterinlettemperature (option)

Variabledeaerationlevels

Proven security: Noringsandplatesinside

vacuum tanks

FullyCIP-cleanable

Derox - Cold and Hot Water Deaeration Improve your beer quality with the Derox Deaerator

Derox+ (hot)- adds valueThe standard capacity range is 50 to 400 hl/h.

The Derox+ adds value to your pro-ducts and processes in the following ways:

Product uniformity: Constantlyverylowoxygencon-

tent (below 20 ppb.*)

Continuousmonitoringforre-quired specification

Continuousremovalofundesir-able THF gases

Economical production: Lowrunningcosts

Space-savingdesign(highca-pacity/ m2)

Flexible production: Highturndownratio(downto

25%ofnominalcapacity)

Independentofwaterinlettem-perature

Proven security: Noringsandplatesinside

vacuum tanks

Deaeratedwaterispasteurized

FullyCIP-cleanable

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Functional description

Hot deaerationWater entering the unit is warmed by means of the regenerative sec-tion of a plate heat exchanger.

After the regenerative section, the water enters a heating section where the temperature is raised to about 88C. The water is then sprayed into the deaeration tank via special nozzles.

The deaeration tank is kept under vacuum so that the oxygen is removed with a minimum of water vapour.

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.

ColddeaerationWater 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, N2) may be applied.

From the top tank the water falls through a pipe with a vent which allows some of the water to return into the bottom tank. The level in this bottom tank is controlled by means of a level switch, which controls the water inlet valve.

The remaining water is discharged

from the unit via an adjustable manual-regulating valve.The unit is designed for CIP and does not contain packing.

Options

Hot deaeration CO2 Stripping - The use of

a small amount of stripping gas can allow the energy lost through flashing to be reduced.

Colddeaeration Chilling - Chilling of water to

match beer temperature. Differ-ent configurations are available.

UV Water Disinfection - Disin-fection of the incoming water can be obtained by the use of an ultra-violet disinfection unit.

Seal Water Cooling - In cases where the seal water will exceed 25C it is advisable to fit an optional seal water cooler.

Preheater - Values below

DEAERATED WATER

WATER/CIP

CO2 / N2

Derox (Cold)

0.03 ppm residual O2 can be achieved with a water tem-perature of about 20C. In cases where this water inlet temperature is not a normal value, a preheater 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 inline 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 sys-tems.

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The BlendMaster range covers units designed for continuous inline 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 and Derox Water Deaeration.

Standard capacity range: 50 to 1200 hl/h.

BlendMaster- adds valueThe BlendMaster adds value to your products and processes in the following ways:

Product uniformity: Ensuresexactconformitywith

the specified recipe

Highcalibrationstability

Economical production: Highprecisionblending

Space-savingdesign(highca-pacity/ m2)

Proven security: Continuousmonitoringand

regulation of the combined pro-duct

Automaticswitch-off,ifoffset

exceeds the limit

BlendMaster - Inline Blending The BlendMaster adds new dimensions to accurate standardizing and efficiency!

Flexible production: Easychangeofrecipeforfast

product change

Turndownratio25%ofnominalcapacity

Blendingratio1:10to1:2

Combined blending and carbonation unit

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Functionaldescription

Extract and alcohol are parameters usually used for duty purposes, and product declarations and accurate determination are therefore important. HGB is now a world-wide standard involving the addition of part of the brewing water after fermentation instead of within the brewhouse. Even when HGB is not a standard procedure, cutting the final beer with small amounts of water to achieve a consistent product is often required.

Magnetic flow meters are used to measure the volumes of high gravity beer and deaerated water. Dosing takes place by means of a simple ratio control operating a modulating valve on the water supply. This gives results that are within the accuracy of laboratory instruments and inline 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 - Completed through the means of a sound velocity sensor. This measures the velocity of sound in a fermented product, which is proportional to the original extract of the unfermented prod-uct.

Alcohol Measurement - Density measurement by means of mass flow techniques, which together with sound velocity measure-ment allow the alcohol contents to be calculated.

blendmaster.dwg

DEAERATED WATER

FINAL BEER

HGB BEER

PI

FT

FT

DT

GT

Blending Separation - The sim-pleblendingTcanbereplacedwith 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 us-ing mass flow measurement is capable of even higher accuracy and is used for blending of com-ponents such as hop extract or colour.

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The CarboMaster is the answer when you are looking for a cost effective, accurate and flexible gas-dosing unit.

The CarboMaster range covers units designed for continuous inline injection and dissolving of gasses like CO2, N2.

This equipment ensures a precise and uniform injection, by means of the patented APV gas injector (see description on page 18).

The CarboMaster is used in the brewery industry for duties such as carbonation and can be integrated with other unit types, including the BlendMaster or the HGB Master.

Standard capacity range: 50 to 1200 hl/h.

CarboMaster- adds valueThe CarboMaster adds value to your products and processes in the following ways:

Product uniformity: Highdosingaccuracy(+/-

0.05g gas/kg product*)

Injectionindependentofinlet

temperature and pressure

Economical production: Nogaslosses

Space-savingdesign

Holdingtimenotnecessary

Flexible production: Turndownto25%ofnominal

capacity

Injectanddissolveupto10ggas/kg product

Proven security: Constantmonitoringandcontrol

of final product

FullyCIP-cleanable

CarboMaster - Carbonation and Nitrogenation The CarboMaster is the answer when you are looking for a cost effective, accurate and flexible gas-dosing unit

CarboMaster for high CO2 content

* Measured as a standard deviation

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Functional description

The basis of the unit is the paten-ted 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 ofCO2 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 levelafter the addition of non-carbona-ted water.

The calculated value is compared with the measured value and theCO2 content adjusted appropriately by means of the modulating valve.

The fixed head injector can cope with variation in flow rates of about +10%.Thegassupplyisshutoffifthe product flow stops.

Options

Variable Capacity Head - The fixed head can be replaced with a variable capacity head which allowsaturndownto25%ofthenominal capacity. This can be either pneumatically controlled or manually adjusted.

High Carbonation Levels - The standard system is engineered to cope with levels of CO2 nor-mally specified in beer. Carbona-tion of up to 10g/kg CO2 may be obtained if required.

BEER

CARBONATED BEER

CO2 Measurement - An inline 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 carbona-tion. 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.

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High Gravity Brewing (HGB) com- bines the three process stages of water deaeration (Derox), inline blending (BlendMaster) and carbo-nation (CarboMaster).

SPX APV HGB Systems ensures a cost-effective process combined with very high production flexibility. The system are designed and developed especially for easy integration with existing lines, and is available in an extensive and flexible capacity range.

Standard capacity range: 50 to 1200 hl/h.

SPXAPVHGBSystems- adds valueThe SPX APV HGB Systems add value to your products and processes in the following ways:

Product uniformity: Constantlylowoxygencontent

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

Continuousmonitoringforre-quired specification

Exactconformitywiththespeci-fied recipe

Highcalibrationstability

Highdosingaccuracy(+/-0.05g gas/ kg product*)

Injectionindependentofinlettemperature and pressure

Economical production: Lowrunningcosts

Highprecisionblending

Space-savingdesign(highca-pacity/ m2)

Nogaslosses

Holdingtimenotnecessary

Flexible production: Variablecapacity

Independentofwaterinlettem-perature (option)

Variabledeaerationlevels

Easychangeofrecipeforfast

product change over

Turndownratio25%ofnominalcapacity

Blendingratio1:10to1:2

Injectanddissolveupto10ggas/kg product

Proven security: Noringsandplatesinside

vacuum tanks

Constantmonitoringandcon-trol of final product

Automaticswitch-off,ifoffsetexceeds the limit

FullyCIP-cleanable

High Gravity Brewing

* Measured as a standard deviation

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Functional descriptionWide 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 System 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 System is simpler, more compact and cheaper to im- plement 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 postrun diluted beer

Carbonation - Correction of the CO2 contents of the final beer to specification. This is normally a single point but pre-carbonation of the water can be supplied if desired.

HGB Master

HGB BEER

CO2/N2

WATER

GLYCOL

GLYCOL

CO2

FINAL BEER

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Dealcoholization of BeerGentletreatment-Beermusttastelikebeer

SPX APV has a number of systems for partial or total removal of ethanol from beer and wine. These include dialysis, distillation and evaporation.

Dialysis has the advantage of being a low temperature process, whereas the thermal processes operate at slightly higher temperatures. However, the thermal processes are usually less expensive due to much lower maintenance costs.

Functional descriptionDialysis - A typical dialysis pro-cess is shown in the picture. The process is a combination of a thermal distillation and a membrane system. The beer flows inside the capillary membrane. The carrier liquid (dialysate) flows outside the capillary in counter current direction to the beer, where it

causes the alcohol flow through the membrane. This concentration differential provokes the permeation of alcohol and minimises the reduction of even the smallest taste components. This means gentle de-alcoholisation with optimum conservation of the flavour compounds typical of the product. The alcohol absorbed by dialysate is removed continuously in a vacuum distillation column, thus making an economically efficient dialysate circuit. After the stripping process the carrier liquid is cooled down to the dialysis temperature and led back into the membrane system.

The plant is built up in five main sections:

Feeding unitMembrane systemVacuum distillation systemCooling and filtration unit for carrier liquidCIP unit

Dialysis system - adds value

Simple, reliable process sequenceNo thermal or mechanical stress to beerReduction of the alcohol con- tent at cellar temperature (operation temperature of 10C)No dilution or concentration of the beerNo loss of natural carbonationNo change of colourExcellent beer quality (as near as possible to the original beer)The dialyses system allows an alcoholreductionbelow0.5%based on nearly all traditional beersProven technologyConstant monitoring and control of final product

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Fully cleanable by CIP Distillation - A typical APV distillation process is shown in the flow schematic below. Beer or wine is pumped through a plate heat exchanger where it is heated regeneratively by returning de-alcoholized product. Further heating with hot water occurs in the same heat exchanger. The beer is then flashed at a relatively high vacuum. The flash releases the high volatile components. The degree of flash will control the amount of esters and other aromasin the final product. Some ethanol will also flash, but the main content will be recovered in the final product.

The flashed liquid is pumped to the top of a stripping column. This column operates under vacuum in

order to minimize the thermal effect on the beer. The alcohol removed at the top of the column is condensed. The column is an APV dual flow design specifically designed for hygienic applications. If necessary, the stripped ethanol canbeconcentratedtoover90%v/v by rectification.

The de-alcoholized beer from the bottom of the column is partially cooled by the beer feed and further cooled by chilled water. The cold beer is then sprayed into a recombiner vessel to absorb the aromas that had been flashed. The beer is cooled further for storage.

One particular advantage of distillation is that, when necessary, the ethanol content can be reduced

STEAM

STEAM

FEED BALANCE

TANK

RECOMBINERDE-

ESTERIZERALCOHOL

STRIPPINGCOLUMN

CONDENSER

REBOILER

REBOILERHOT WATER

REHEATHOT WATER

HEATREGENCOOL

PLATE HEAT EXCHANGER

PRODUCT

FEED

COOLING WATER

TO HOT WELL

to extremely low levels.

The operating temperature is usually below 55 deg C but can be lower if refrigeration is used for the condenser.

Evaporation - A similar process with a 4 stage APV Falling Film plate evaporator used instead of the stripper column. The beer is partially evaporated in four separate stages at about 40 deg C. The hold up in the evaporator is shorter than in the stripper column, but the ethanol cannot be reduced to very lowlevels.Typicallya5%v/vbeercanbereducedto0.35%v/v.

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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 effec-tive and gentle heat treatment of all kind of carbonated products. Standard capacity range: 50 to 500 hl/h.

PU Pasteurizer- adds valueThe PU Pasteurizer adds value to your products and processes in the following ways:

Product uniformity: Veryhighaccuracy(computer

controlled PU regulation)

Low T between product and

heating media Economical production: Largeheatregeneration(upto

94%)withlowtemperaturefill-ing

Waste-savingdesign(beer/wa-ter zone)

Flexible production: Turndownratio40%ofnominal

capacity

Proven security: Constantoverpressuredown-

stream

Constantmonitoringandcon-trol of final product

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

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Functional descriptionPasteurization 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.

The unit is based on a three-section 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, 72C held for 30 seconds being typical.

The cooling duty is selected according to packaging requirements. A regenerative outlet temperature as close as possible to the packaging temperature allows reduced energy consumption.

A high-pressure pump supplies the regenerative section outlet with the required pressure. A booster pump between the regenerative and heating sections of the plate

heat exchanger ensures that the pressure on the sterile side of the regenerative section is higher than the pressure on the non-sterile side. This pump is frequency control-led 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 e-quipped with a load cell to mea-sure 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 re-circulated to maintain the balance. On resumption of downstream production, the buffer tank is emptied until a pre-determined minimum level is reached. The water circulating in the pasteurizer is pushed out to drain or to a collection tank with fresh beer, and normal operation

resumes.The unit is started by means of a shell and tube heat exchanger heating water to 80C for sterilization and to balance the system. Heating of the system to balance typically takes place in less than 10 minutes.

Options Advancedcontrolsystemswith

digital programming allow even more accurate temperature and pressure control. They can be combined with predictive and fuzzy logic for extreme accuracy

Aconductivitymeterregistersthe interface between beverage and water and reduces change-over losses to a very low value

Valvetypesandconfigurationscan be customized as required

Adoubleshuntforimprovingthecoolant supply can be integrated

pupast.dwg

GLYCOL

GLYCOL

BEER

BUFFERTANK

WATER/CIP

WATER

CONDENSATE

STEAM

I R P

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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 auto- matic system, programmed to achieve optimal cleaning of the process equipment.

TheAPVCIPMaster- adds valueThe APV CIP Master adds value to your products and processes in the following ways:

Product uniformity FullyautomaticCIPprogramsen-

sure perfect cleaning

Economical production Fullautomationreducesmanpower

Optimizationoffunctionalityleadstoreduced cleaning

Flexible Production Easyimplementationofoptionsdue

to modular design

TheAPVCIPMasterisskidmounted when possible, which al-lows easy relocation in the event of production restructuring

Proven security Ifappropriate,theCIPMasterisfully

tested before delivery

Provenfunctionalityandreducedcommissioning time

Functional descriptionThe 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 3,4or5tanksystems

Differenttanksizes

Numberoflines

Tubularorplateheatexchangers

LowcostmanualCIPsystems

Customerspecificequipment

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

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Fermentation and 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.

FiltrationDue to seasonal fluctuations in the quality of the raw material and the complexity of the process itself, filtration is one of the more complex parts of the brewing process. APV works in close co-operation with reputable suppliers of filtration systems to meet the needs of 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.

BBTCellarWith modern filtration and HGB equipment available as continuous processes, the requirements and flexibility of the BBT Cellar are highly demanding.

Strictly hygienic conditions and low oxygen levels must be maintained. As todays industry demands a wide variety of product mixes andbeer types, the control and flexibility of the BBT Cellar is increasingly important.

We offer detailed designs of the BBT Cellar, including pressure CIP,

C0 utilisation and fully automated flow control systems.

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APV, An SPX BrandPasteursvej 1DK-8600 SilkeborgPhone: +45 70 278 278 Fax: +45 70 278 330

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

SPX Corporation 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.

Issued: 06/2009 5600-03-06-2009-GB Copyright 2009 SPX Corporation

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