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Monitoring Biological and Chemical Processes in Brewing Industry

Explore the intricate processes of brewing, from malting to fermentation, and learn how to control flavors and detect faults using automation and advanced sensors. Discover ideal sensor technologies for key parameters like dissolved oxygen and carbon dioxide. Embrace innovative monitoring solutions to ensure the quality of your brewery products. Stay updated with the latest practices in brewery automation and chemical detection techniques.

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Monitoring Biological and Chemical Processes in Brewing Industry

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  1. Biological and Chemical Detection in the Brewing Industry Submitted by: David Jones

  2. Brewing Process • Brewing bacteriology was born when microorganisms responsible for the spoilage of beer were investigated by Louis Pasteur during the 19th century. He was called upon to determine why French beer was inferior to German Beer. • Brewing has a long history; the process has been know for long time, but the science of why came later.

  3. Brewing Process • Malting – Barley is adjusted and kilned • Milling – Exposes the starchy center • Mash – Conversion of starch to sugar by alpha-amylase and beta-amylase • Rinse/Boil – Kills bacteria and hops add bitter flavor • Cooling/Fermentation – Yeast addition, conversion of fermentable sugars to carbon dioxide and alcohols.

  4. Flavor Aspects • Recipe • Water Chemistry (Brewery Specific) • Hops – strength and amount isomerized (a-acids) • Yeast – Strain and Strength • Saccharomyces Ubarum • Saccharomyces Cerevisiae • Fermentation: lag, log, rest, pH, dissolved oxygen, temperature, buffer capacity, carbon dioxide... • Packaging – UV light, dissolved oxygen leads to bacterial spoilage (HACCP after fermentation) • Flavor Agents: alcohols, sulfur compounds, esters, Di-acetyl and Pentane-2, 3-Dione, Polyphenols, Dimethylsulfide (DMS)

  5. Fault Examples • Off flavors: fruity, harsh, sweet, or bitter • Haze: level of particles in suspension • Lack of body – level of non-fermentable sugars and polyphenols • Poor head retention or formation

  6. Brewery Automation • Complex chemical and biological process that needs to be controlled. • Historically: Process controlled by manufacturing process (Brewery Specific) • Today the manufacturing is driven by flexibility: The ability to produce a variety of beer using the same equipment.

  7. Automation PLC (Automationdirect) Programmable Logic Controller

  8. Automation PLC (Automationdirect) Relay Out

  9. Automation PLC (Automationdirect) Ladder Programming View

  10. Automation PLC (Automationdirect) Drum Programming

  11. Automation PLC (Automationdirect) PID loops

  12. Brewery Sensors

  13. Dissolved Oxygen • On Line • Response time < 90 sec • Interoperable: yes Immersion or Flow Through • Performance: ± 1% of signal, max. ± 30 ppb • Location: Fermentation Tank, HACCP Point after Boiling Stage Mettler Toledo

  14. Carbon Dioxide • On Line • Response time <60 seconds for 90% step change • Interoperable: Yes – Alarm relay output • Non-dispersive infrared (NDIR) repeatable to ± 20 ppm 0-2000 ppm range • Location: Fermentation ducts or HVAC ducts Veris Industries

  15. Dissolved Carbon Dioxide • At-Line • Response time < 7 minutes • Technology: fiber-optic, fluorescent dye • Interoperable: Probable - 4-20 mA loop or 1-5 Vdc (analog output) • Performance: ±5% of reading or 0.2% absolute • Location: Fermentation Tanks YSI Life Science

  16. pH no-Glass • On-line • Response time < 90 seconds • Interoperable: yes – standard VP connection • Performance: pH 0 ~14, 0 ~ 80°C • Gel electrolyte, Argenthal electrode, Temperature • Location: Mash tanks, Fermentation Tanks, Maturation, Packaging Mettler Toledo

  17. Glucose/Alcohol Electrode • On-Line • Response time < 2 Minutes • Interoperable: yes small voltage, BNC connector • Reproducibility ~ 3% • Location: Mash, Fermentation, Packaging Universal Sensors Inc.

  18. Yeast Monitor • At-Line • Response time: Real-time • Technology: Electrode, temperature, capacitance • Interoperable: yes – RS232 port, alarm outputs • 10 Cell size/strain positions • Location: Fermentation, Maturation, Yeast Storage Aber Instruments

  19. Yeast Monitor • On-Line • Response time: Real-time • Technology: Radio frequency dielectrics and software • Measures Capacitance in living yeast cells (Plasma Membranes) • Interoperable: yes – RS232 port and Ethernet, alarm outputs • Location: Fermentation, Maturation, Yeast Storage Aber Instruments

  20. Protein and Polyphenol Detection via Surface Plasma Resonance • Off-line • Response time: Rapid Confirmation • Interoperable: No, standalone system • Flexibility to determine multiple compounds with multiple sensor chip configurations • Location: Brewing Lab (determine flavor constituents) Biacore

  21. Gram Negative Acetic Acid Bacteria Pectinatus cervisiiphilus Enterobacteriaceae Zymomonas Pectinatus frisingensis Selenomonas Lacticifex Zymophilus raffinosivorans Zymophilus paucivorans Megaspaera Gram Positive Lactobacillus Lactic Acid bacteria Pediococcus Leuconostoc Homofermentative cocci Kocuria, Micrococcus and Staphylococcus Endospore-forming bacteria Gram Negative/ Gram Positive Bacteria Contamination

  22. Biolog’s G+/G- Yeast detection • Off-Line – Rapid detection • Standalone System (the rest) • MicroPlate ~ 96 different Chemical Substrates • G+ >310; G- >500; Yeast >265 • < 5 min Hand prep • Photo-Optical (density) • Automated database • Location: Through-out

  23. Biotrace’s ATP Bioluminescence • All in one Test Kit: swabbing • Off Line: Cleanliness Check • ATP enzyme-driven light emissions • Response time < 30 secs • Measures light output (luminometer) or living cells • Location: Throughout • Specs:<150 RLU (pass) • >300 RLU (Fail) • Tanks, Valves, Doors…

  24. Chemunex Chemscan RDI • Off-line: Rapid Identification • Technology: Combination of 1)Laser Scanning 2)cell labeling and 3)automated/database • Fully Automated: 20 hr Presence; 1 hour direct Count • High throughput ~ 60 samples per hour • Drawback: lack of specific recognition of Brewery beer-spoilage bacteria. • Subspecies of: • Pediococcus • Lactobacillus

  25. Qualicon/DuPont’s RiboPrinting • Off-Line: Rapid thorough detection ~8 hrs • Technology: Random Amplified Polymorphic DNA PCR. • Extracts: DNA; rRNA; compares gene sequence • DNA extracted mixed with chemiluminescent; captured on digital image; Fingerprint is compared with database “RiboPrint” • Powerful tool for identifying subspecies of beer-spoiling bacteria during the middle to late fermentation stages.

  26. Conclusions • Biosensor use is dependant upon many factors • Brewery size: Throughput, variety of brands, total energy used. • Cost: Potential Savings, Ability to integrate in to architecture, Installation cost, man power… • Potential Market: Better, Cheaper, Faster • Anheuser-Busch: 47% of American Market, produced 127.9 Million barrels (101.8 M domestically), Gross sales of $15.686 billion dollars, and over 30 different brands. • Distributed Generation: The business of business is business. Distributed Manufacturing.

  27. Conclusions • Sensing and conditioning a signal is only half of the process. • Act and React: Interoperable with existing systems • Overarching Control Scheme • Manufacturing Procedures

  28. Any Questions?

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