GEA Mechanical Equipment engineering for a better world

Systems and Processes in Breweries

Continuous. Efficient. Gentle on resources.

3

Content 4 CentrifugalSeparationTechnology–

ImprovementofQualityandEconomy

6 MachinesforBreweries

6 Self-CleaningSeparators

6 Self-CleaningSeparatorsforPolishing

9 GEAWestfaliaSeparatorhyvol®andhydry®

MachineGenerationsforAnyCapacityRange

11 DecantersinBreweries

12 HotWortSeparation

13 TrubWortSeparation

14 ColdWortSeparation

16 GreenBeerSeparation

17 GreenBeerClarificationwith

AdditionofYeast/TankBottoms

19 ClarificationofBeerbefore

KieselguhrFiltration

20 BeerFiltrationwithPROFI

23BeerRecoveryfromSurplusYeast

andTankBottoms

26 ManufactureofNon-AlcoholicBeer

28 Kvass

30 TurbidityAdjustmentwithSeparators

31 CapacitiesataGlance

4

Separatorsanddecantershavebeenthemainmachines

inthemanufactureofbeerfordecades.Inthedecisive

stepsoftheprocess,theyensureeconomicaloperation

andahighqualityofbeer.Asaspecialistinthefield

ofcentrifugalseparationtechnology,GEAWestfalia

SeparatorGroupoffersseparatorsanddecantersfor

all specific requirements. Numerous solutions for

theuseofseparatorsanddecantersinbreweriesare

presentedasexamplesonthefollowingpages.

Features

• Maximumyieldwithimprovedproductquality

• Gentleproductfeedformaximumclarification

• Hydrohermeticsealstopreventoxygen

absorption

• Smooth,low-noiseoperation

• Integrationinautomaticprocessesthrough

freelyprogrammablecontrollers

Centrifugal Separation Technology – Improvement of Quality and Economy

Green beer clarification

1 Beer recovery

2 Green beer clarification

3 Cold break

4 Clarified wort

5 Pre-clarification

Lauter tun Wort kettle Whirlpool

Malt / water Spent grains Hops

FermenterStorage tankFiltration

Cooler

Mash tun

Yeast / air

4

1

2

3

5

5

• Automaticsolidsejection

• Highdrysubstancecontents

• Highproductyield

• OptimumintegrationinexistingCIPsystems

duetohygienicdesign

• Higheconomy

• Rapidpayback

• Reductionofwastedisposalcosts

• Protectionofnaturalresources

• Reductionofstoragecosts

• Low-costoperation,serviceandmaintenance

6

Self-cleaning separators

Self-cleaningseparatorscanbeoptimallyintegrated

intheoperativeprocessesofbreweries.Thesolids

separatedintheseparatorbowlareejectedperiod-

icallyfromthebowl.Becausethisoccursatoperating

speed, a fully continuous operation is ensured.

GEAWestfaliaSeparatorGrouphasdevelopedits

machinesincloseco-operationwithitscustomers

fordecades.Anexampleofthisisthedevelopement

oftheGEAWestfaliaSeparatorhydrostop system.

With thispatenteddesign, thesolidsareejected

fromtheseparatorbowlinafractionofasecond.

Becausethesolidsareejectedinaverycompactform

bythismethod,shortpaybackperiodscanbeachieved.

Hydrohermetic seal

Thedevelopmentof thehydrohermetic sealwas

alsomadeinclosecooperationwithourcustomers.

Inthistechnique,theproductandtheatmosphere

are hermetically sealed from each other. This

Machines for Breweries

preventsoxidationofthebeer.However, thishas

evenmoreadvantagesforourcustomers.Incompar-

isonwithmechanicalseals,thehydrohermeticseal

iscompletelywear-freeandfullyCIP-compatible.

Automatic ejection control systems –

optimized automation

Variouscontrol systemsareavailable to react to

differingfeedconcentrationsanddefinetheright

timeforsolidsejection:

• Automaticejectioncontrolsystemwithturbidity

measurement

• “Self-thinker”ejectioncontrolsystemwith

sensingfluid

Gentle product feed

Theseparatorsareequippedwithahydrohermetic

productinlet.Thisnewinletsystemavoidsshear

forcesontheproduct.Theresultisamoregentle

7

Self-cleaning separators for polishing

GEAWestfaliaSeparatorGrouphasdevelopedthe

so-calledhigh-performanceclarifiersspecificallyas

apreliminarystageforalternativefiltertechnologies.

Thesemachinesdifferfromconventionalseparators

intermsoftheirhigherg-force.

Advantages

• Separationofthefinestsolidparticlespossible

bytheincreasedcentrifugalacceleration

• Substantialreductionofcostsforfilteraid

• Reduceduseofkieselguhrfiltration

• Reduceduseofconventionalseparators

• Improvedtasteofthebeerbyseparationof

polyphenolproteincomplexes

• Improvedsensorystability

treatmentandanoptimumclarifyingeffect,particu-

larlyforsensitiveproducts.GEAWestfaliaSeparator

Grouphasdevelopedtheso-calledhigh-performance

clarifiersespeciallyasanupstreamstagetoalternative

filter techniques. These machines differ from

conventionalseparatorsintheirincreasedcentrifugal

acceleration.

Features

• Continuousoperation

• Automaticoperation

• Higheconomy

• Versatileapplication

• Optimumcleaningtimeduetoautomatic

ejectioncontrolsystems

• IntegrationinCIPcirculationsystems

• Productisolatedfromtheatmosphereby

hydrohermeticseal

• Lowspacerequirement

• Easytomaintain

8

9

GEA Westfalia Separator hyvol® and hydry® Machine Generations for Any Capacity Range

Anothercommonfeatureofallthehyvol® seriesare

theextremelyquick-actingejectionvalves.Product

lossesduringseparatorejectionsarethusreducedto

aminimum.

Whendeveloping thehydry® andhyvol® series,

GEAWestfaliaSeparatorGroupfocussedonhighest

possibleDScontentsofthecentrifugallyseparated

solids.GEAWestfaliaSeparatorhydrostopejection

systemallowsdrysubstancevaluesof25–27percent

tobestandard.Optimumsolidsconcentrationare

reflectedinveryshortpaybacktimes.Productlosses

are extremely low. All the hyvol® and hydry®

separatorshavebeltdrivesandarecharacterizedby

versatilefunctionality.

GEAWestfaliaSeparatorhyvol®andhydry®represent

two new separator families. Offering optimum

machinesizesbothseriesprovidemodelsforany

capacity rangeneeded in thebeverageand food

industries.Thehyvol®andhydry®separatorsare

designedforbestpossiblecustomersbenefitandfor

quick integration into individual application

processes.

hyvol®isthenameGEAWestfaliaSeparatorGroup

gavetoitsseparatorshavinganejectionsystemvia

pistonvalves.Withahydrohermeticfeedsystem,

thenegativeeffectsofshearingforcesareminimized,

andperfectseparatingefficiencycanbeachieved.

Thisresultsinperfectseparationandproductquality.

Thehydrohermeticsealpreventstheproductfrom

beingcontaminatedbyambientair.This sealing

arrangementischaracterizedbyperfectCIPcapability

whilebeingmaintenance-free.

10

11

Decanters are solidsoriented centrifugeswitha

solid-wallbowl.Aconveyorsrew(scroll)conveys

thesolidstotheoutletports,throughwhichthey

are continuouslydischarged.Decantersareused

mainlyforclarificationofliquidswithahighsolids

content.Asomewhatfluctuatingsolidscontentin

thefeedproducthaslittleeffectonthedegreeof

clarificationorseparation.

Decanters find application in breweries for:

• Trubwortseparation

• Beerrecoveryfromsurplusyeast

Advantages of decanters:

• Highyield

• Continuousoperation.Processingtimesare

practicallyunlimited(round-the-clockoperation)

• Automaticoperationand,therebysavingsin

personnel

• Solutionsofeffluentproblems

• Flexiblewithregardtofeedconcentration

• Versatileprocessingpossibilities

Decanters in Breweries

Capacity data

Thecapacities indicated in thisbrochure for the

differentmodelsareeffectivethroughputcapacities.

Theydifferfromthecomparisoncapacitywhichis

designdependent.

Comparison capacity

The comparison capacity refers to the different

decantersproducedbyGEAWestfaliaSeparator

Group and is lower than the max. throughput

capacity.

Effective capacity

Thisrelatestotheproductandprocess.Itdepends

on the clarifiability of the feed mixture, on the

concentrationofthesolidsinthefeed,andonthe

permissible residual moisture content of the

dischargesolidscontentoftheclarifiedliquid.The

decantercanbelargelyadaptedtotheseconditions

andrequirements.

12

Hot wort separation

Separatorsareemployedtoseparatethehottrub

createdduringboiling.Thedevelopementof this

applicationwasdonetoallowcontinuousoperation

andto improvetheeconomyincomparisonwith

conventional techniques. The separator can be

integratedintheprocessindifferentvariants.The

clarifiercanbeinstalledeitherdirectdownstream

Hot Wort Separation

ofthecopperortheintermediateturn-outvessel.

Whichofthese is thebettersolutiondependson

several factors and should be decided on an

individualbasis.Forexample,heatretentiontimes

(isomerisationofthehops,colorationetc.)mustbe

maintainedandnotexceeded.

Features

• Continuous,automaticoperation

• Improvedproductqualitybydefined,short

contacttimesanddefinedseparationrates

• HigheconomyduetohighDScontentof

thesolids

• Lowestpossiblespacerequirement

• OptimumCIPintegrationduetohygienicdesign

• Capacityrangeupto750hl/h

1 Wort kettle

2 Hot wort

3 Clarified hot wort

4 Optec

5 Cold wort

6 Self-cleaning separator

7 Trub

1

2

3

4

5

6

7

GEA Westfalia Effektive GEA Westfalia Effektive Separator capacity Separator capacityhydry® in hl / h* hyvol® in hl / h*

GSC 4 / 6 10 GSE 30 80

GSC 20 50 GSE 75 150

GSC 45 110 GSE 125 300

GSC 75 150 GSE 200 500

GSC 95 200 GSE 450 700

GSC 150 400

GSC 200 600

* Feed < 1.5 % v / v, discharge < 0.05 % v / v

13

* Feed < 15 % v / v, discharge < 0.2 % v / v

Thewhirlpoolisemployedespeciallytoclarifythe

entirehotwort.Becauseitisnotalwayspossibleto

achieveagoodseparationof the trubdue to the

fluctuatingqualityofrawmaterialsanddifferent

types of beer, the separator is an appropriate

supplement.Thetrubconeproducedoftencollapses

whenthewortisdrained.Thisphenomenoncause

theresidualturbidityoftheclarifiedworttobetoo

Trub Wort Separation

highand/or the losses tobeveryhighdue to the

inadequatethickeningofthetrub.

Whilst the wort is rotating in the whirlpool, the

separatingprocesscanbeginfromthebottom.The

recoveredwortisthencooled.

Features

• LittlelossofwortduetohighsolidDS

• Minimizeddangerofinfection

• Defined,optimumclarificationofthe

recoveredwort

• Wortaddedtotherunningbrew

• Lowheatretentiontimesofthetrubwort

• Fullycontinuous,fullyautomaticoperation

• Nooxygenabsorption(max.0.05mg/l)

• Capacityrangeupto200hl/h

• Cleaningtimesareshortenedbycontinuous

drainingofthetrubwortfromthewhirlpool

Trub wort separation

1 Wort kettle

2 Hot wort

3 Clarified wort

4 Trub wort

5 Cold wort

6 Self-cleaning separator

7 Trub

GEA Westfalia Separator Effective capacityhydry® in hl / h*

GSC 4 / 6 3

GSC 20 10

GSC 45 25

GSC 75 30

GSC 95 60

GSC 150 130

GSC 200 200

1

2 3

4

5

6

7

14

Cold wort separation

* Degree of clarification: approx. 50 %, measured in “Imhoff funnel” ** Special design

GEA Westfalia Separator Effective capacity in hydry® hl / h*

GSC 20** 30

GEA Westfalia Separator Effective capacity in hyvol® hl / h*

GSE 50 20

GSE 65 60

GSE 160 200

GSE 230 300

GSE 400 500

GSE 500 700

Insomecases,coldwortseparationisalsocarried

outinbreweries.Thehottrubisseparatedbefore

cooling.Theseparatorthereforeseparatesonlythe

remainingquantityofcoldbreak.Thecoldbreak

consistslargelyofsmall,colloidalproteinparticles.

Theviscosityof thecoldwort is relativelyhigh.

Coldwortseparationhasdifferingsignificancein

theindividualbreweries.Acertainquantityofcold

break isdesired in thefermentationprocess,but

no hot trub must be carried over under any

circumstances.

Cold Wort Separation

Advantages

• Improvedtasteofthebeerthroughremoval

ofpolyphenolproteincomplexes

• Improvedsensorystability(attachedfattyacids

arereduced)

• Improvedheadstability(hottrubisremoved

ifthewhirlpoolmalfunctions)

• Optimisedfermentation(foulingoftheyeast

isprevented)

• Filtrationinhibitorsareremoved(lowerburden

ofproteinsonthefilter)

1 High-performance clarifier

2 Cold wort

3 Air

4 Yeast

5 Bypass for ejections

6 Fermentation tank

7 Trub

1

2

3

4

5

7

6

15

16

Green beer separation

* Feed < 20 million Hz / ml; discharge < 0.5 million yeast cells/ml

Green Beer Separation

Advantages

• Definedsecondaryfermentation

• Reductionoftheriskofyeastautolysisduring

fermentationandstorage

• Harvestofthemostactivecomponentof

theyeast,whichcanbeoptimallyemployed

asastarter

• Acceleratedreductionofthediacetyl

bydosingofKrausen

• Reducedemploymentofthefilter

• Simpleintegrationinexistinglines

• Fullyautomaticoperation

• Duetothemoderndesludgingmechanism,

theyeastisdischargedinaverycompactform

(24–26percentDS)

• Bettersaleofthesurplusyeastdue

tohighDScontent

• Reductionofbeerlosses

GEA Westfalia Effektive GEA Westfalia Effektive Separator capacity Separator capacityhydry® in hl / h* hyvol® in hl / h*

GSC 4 / 6 20 GSE 30 100

GSC 20 80 GSE 50 100

GSC 45 180 GSE 75 300

GSC 75 300 GSE 100 300

GSC 95 400 GSE 125 500

GSC 150 600 GSE 180 500

GSC 200 700 GSE 200 700

GSC 250 800 GSE 300 850

GSE 400 950

GSE 450 1.200

GSE 550 1.500

Thehighcellcountof65–75millionyeastcells/ml

in the main fermentation is not desired in

subsequent storage.Traditionally, green beer is

clarifiedbysedimentationof theyeastandother

turbidsubstances.Thebeeristhentransferedwith

aslittleyeastandsedimentaspossible.Toobtaina

controlled, rapid secondary fermentation and

maturingofthebeerinstorage,itisappropriateto

transferwithadefinednumberoflivingyeastcells.

Thiscanbeachievedbyusingaseparator.Theyeast

is fed intoacollecting tankor thebeer recovery

processandthegreenbeerisseparated.

1 Fermentation tank

2 Saleable yeast

3 Feed pump

4 Turbidity sensor

5 Self-cleaning separator

6 Maturation tank

1

2

3

4

6

5

17

The optimum process for beer recovery is the

additionofthesurplusyeastandthetankbottoms

inaseparatorduringtheclarificationofthegreen

beer. The advantages of the consistent product

qualityachievedwithgreenbeerclarificationare

added to the economy of simultaneous beer

recovery.

Advantages

• Maturingandstabilisationcanbecarriedout

withadefinedyeastcellcount(orvirtually

without)

• Longerstorageoftheyeastbeforebeerrecovery

isavoided,beerisrecovereddirectlyfromthe

freshyeast,yeastautolysisisprevented

Green Beer Clarification with Addition of Yeast / Tank Bottoms

• Theseparatoronlyhastoberated

foronecapacity

• Nofurtherinstallationsarenecessary

forbeerrecovery

• Therecoveredbeerremainsinthesamebatch

• HighDSoftherecoveredyeast.Ifnecessary,

dilutingwaterandnotbeerisdiposedofwith

theyeast

18

Clarification of beer before kieselguhr filtration

1 Feed regulation depending

on buffer-tank level

2 Buffer tank

3 Self-cleaning separator

4 Filtration

5 Feed pump

6 Maturation tank

7 Yeast

1

2

3

4

5

6

7

19

* Feed < 10 million yeast cells / ml; discharge: 0.5 million yeast cells / ml

GEA Westfalia Separator Effective capacity GEA Westfalia Separator Effective capacityhydry® in hl / h* hyvol® in hl / h*

GSC 4 20 GSE 30 100

GSC 20 80 GSE 50 100

GSC 45 180 GSE 65 60

GSC 75 300 GSE 75 300

GSC 95 400 GSE 100 300

GSC 150 600 GSE 125 500

GSC 200 700 GSE 160 300

GSC 250 800 GSE 180 500

GSE 200 700

GSE 230 500

GSE 300 850

GSE 400 950

GSE 450 1.200

GSE 550 1.500

Beersenteringfiltrationoftencontainlargequanti-

tiesofyeast,makingkieselguhrfiltrationdifficult.

Kieselguhr filtration itself is not problem-free.

Meansareavailableeithertoreplacethekieselguhr

filtrationoratleasttoreducetheconsumptionof

kieselguhr.Byemployingaseparatortopre-clarify

thebeer, the requireddegreeof filtering canbe

drastically reduced. The result is not only a

reductionofafilteraid,butalsoanincreasedperiod

ofoperation.Of course, the centrifuges are also

suitableforpre-clarifyingwithotherfiltersystems.

Advantages

Clarification of Beer prior to Kieselguhr Filtration

• Extensionoftheperiodofoperationofthefilter

byupto100percent,thereforeminimizedset-up

times,cleaningandwastewaterandlabourcosts

• Reductionofthetotalkieselguhrconsumption

byupto70percent

• Compensationofproductfluctuations

• HighDSoftheextractedyeastandtherefore

reducedlosses

• Incomebysaleoftheseparatedyeast

• Fullyautomatic,continuousprocess

• Nooxygenpick-up

• ClarificationofCIPmediaduringseparatorCIP

• Additionoftankbottomsforbeerrecovery

possible

• Capacityupto1.500hl/h

20

PROFIbeer filtrationplant fromGEAWestfalia

Separator Group combines a high performance

centrifuge with a membrane filtration system,

allowingperfectbeerfiltrationwithoutkieselguhr.

The unfiltered beer, containing fine and coarse

solids,isfedintotherotatingbowlandclarifiedin

thediskstack.

The coarse solids slide into the solids space of

thebowlandareejectedautomatically.Theclarified

liquid, still containing fine solids, discharges

eitherbygravityorunderpressurebymeansofa

centripetalpump.

Thepreclarifiedbeerissentintotheretentate-free

operating membrane filtration system where it

passes through hollow-fibre filtration modules.

Thentheclarifiedbeerissenttothefillingstation.

There is no installation required for retentate-

recyclingintoatank.

Beer Filtration with PROFI

Assoonasacertain trans-membranepressure is

reachedandthefiltrationefficiencydecreases,the

systemispurgedbymeansofCO2.Thisisfollowed

byaCIPcycleusingalkalinesolutionandwater.

Af ter “C leaning - In -P lace” the modules are

disinfectedat80°C.

Customer’s benefit

• Veryhighsolidsconcentrationthrough

aquick-actingejectionsystem

• Consequently,minimumproductlossonly

• Usinghighperformanceseparators,smaller

membranesystemscanbechosen

• 100percentoftheyeastisseparatedbythe

highperformanceseparator

• Partoftheproteinsareseparatedbythehigh

performanceseparator

• Thus,thePROFIprocessallowsretentate-free

filtration

PROFI Effective capacity in hl / h

PROFI 50 50

PROFI 100 100

PROFI 200 200

PROFI 300 300

PROFI 300 i 300

PROFI 400 400

PROFI 400 i 450

21

Continuous kieselguhr-free filtration

--- Particle size distribution in the discharge of standard separators__ Particle size distribution in the discharge of high-performance separators

Part

icle

cou

ntPa

rtic

le c

ount

Particle size [µm]

Particle size [µm]__ Particle size distribution in the feed stream ahead of the separators

1 MV

2 Buffer

3 Cold water

4 CIP-liquids

5 Feed pump

6 CIP 1

7 CIP 2

8 CIP 3

9 Pressure vessel

10 To filling station

11 PROFI filter system 50 – 400 hl / h

12 High-performance separator

13 CIP / water

14 CIP pump

1

2

3

4

5

6 7 8

9

10

11

12

13

14

22

23

Introduction

Dependingontheprocessused,differingquantities

ofyeastandtankbottomsareobtainedduringthe

fermentationandstorageofbeer.Inmostcases,a

substantialproportionofbeerisstillcontainedwhich

must be recovered in economically managed

processes.Moreandmorebreweriesareinvestingin

beerrecovery–forgoodreasons.Thisimprovestheir

cost-effectivenesswithoutchangingthebeerquality.

Indeed,theyeastandtankbottomvolumeaccounts

forapproximately4percentoftotalannualoutput,

andofthisfigureapproximately60percentcanbe

recoveredintheformofbeer.Inabrewerywithan

outputofonemillionhectolitres,thiscorrespondsto

avolumeof24,000hectolitres.Whichofthethree

possiblesystems(separator,decanterandceramic

membrane filter) isused inaspecificapplication

depends on the particular circumstances of the

brewery.GEAWestfaliaSeparatorGroupistheonly

providerworldwidetooffermechanicalandprocess

engineeringsolutionscustomisedtoeverysituation.

Extremely simple process management with

separators

Theseparatorrepresentsthemostsimpleprocess

solutionwithminimuminvestmentcosts.Separators

of theGEAWestfaliaSeparatorhydry®seriesare

usedexclusivelyfortherecoveryofbeer.Theshort

processingtimeofjust120secondsensuresgentle

Beer Recovery from Surplus Yeast and Tank Bottoms

treatmentoftheyeast.Ontheotherhand,production

timesarelong:theseparatorissubjecttostandard

CIPonlyevery72hours.TheGSC150separator,

whichisspecificallysuitedtothistask,ensuresthat

theyeast is treated toadrysubstancecontentof

around 25 percent thanks to the GEAWestfalia

Separator hydrostop discharge system. The

hydrohermeticinletensuresgentletreatmentofthe

product.Dependingonthroughput,therecovered

beerstillcontainsaround0.1to2millioncellsper

millilitre.Thehydrohermeticsealalsopreventsthe

productfromcomingintocontactwithexternalair,

andguaranteesabsolutelywear-freeoperation.

WiththeGSC150separator,itispossibleforbeertobe

recoveredfromyeastandalsoforthegreenbeerfrom

the fermentation tank tobeclarified following the

additionofyeastupstreamoftheseparator(seepage17).

Inthefeed,theyeastconcentrationmaybemax.40

percent (by volume). However, using a fully

automaticfacilityforaddingwaterinthefeedof

theseparator,theconcentrationcanbereducedto

thepermissiblelevelatanytime.

Dependingonthespecificconditions,GEAWestfalia

SeparatorGroupalsooffersnozzleseparatorsasan

alternative.

Processing with separator

1 Yeast tank

2 Beer storage tank

3 Water

4 To yeast processing

5 Self-cleaning clarifier

1 23

45

24

Decanter plus polisher

Itispossibletofurtherimprovebeerrecoveryby

meansofadecanterbycombiningadecanterand

separatororconnectingadecanterandseparatorin

series.Theyeast is initially concentratedby the

decanter to a maximum dry matter of 25 to

28percent,thusachievinganoptimumyield.The

beerwhichisrecoveredfromthedecanteristhen

processedfurtherinasmallpolisherfromaround

1millioncellspermillilitretofewerthan1000cells

permillilitre.Thebeerwhichistreatedinthisway

issolids-free.

So much beer is still in the yeast

Processing with decanter and separator

1 Yeast tank

2 Buffer tank

3 Feed pump

4 Decanter

5 To yeast processing

6 Green beer

7 Separator

8 Flash pasteurizer

1

2

6

3

4

5

7

8

25

Separator type Effective capacity in hl / h*

GSC 4 1

GSC 20 4

GSC 45 8

GSC 95 16

GSC 150 30

GSC 200 40

GCB 506 20 – 40

HFC 15 10

HFE 45 30

* Feed < 30 %, discharge < 1 % (by vol.)

Beer recovery with nozzle separators produces

clear beer

The design of these separators makes them so

powerfulthattheycanprocesstherelevantyeast

and tank bottom volumes with relatively low

machinecosts.Thisresultsinamortisationperiods

which were previously unthought-of with new

machinesinthisspecialapplicationarea.

Thenozzleseparatorprocessestheyeastwhichis

additionally internally diluted with water. This

makes it suitablealso forsmallormedium-sized

breweries depending on the yeast economy. In

additiontothenozzleseparator,ayeastcollecting

tankisrequiredwheretheyeastortankbottoms

arestoredhomo-genously. In the tank, theyeast,

possiblywithalreadydegassedwater,issettothe

originalwortvalueormixed“inline”onthewayto

the separator. The separator then continuously

separates this supply into a flow with yeast of

a round 80 percent by vo lume . Us ing th i s

technologicaltrickof“washingoutyeast“,anozzle

separatorcanachieveextractyieldsof90percent.

The recoveredextract is likewisediluted in this

case. This makes the nozzle separator process

particularly suitable for “high gravity“ brewing

sincetherecoveredextractisidealforcuttingthe

originalbeertothedesiredstrengthforsale.

Ifthemarketdemandsasystemwhichpaysoffinno

time,GEAWestfaliaSeparatorGroupnowoffers

tailor-madesolutionstomeettheserequirements.

Customized solution instead of a patent recipe

In order to decide which of these beer recovery

systems should ideally be used, the technology

expertsofGEAWestfaliaSeparatorGroupanalysein

advancethepreciseindividualrequirementsofthe

particularbrewery.Ingeneralhowever:centrifugal

technologyused forbeer recoveryoffers thebest

returns compared with all other systems. The

extremely shortprocess timesprovidedwith this

technologyalsoproduceabeerofexcellentquality.In

ordertobeonthesafeside,however,thebeershould

alwayspass throughaflashpasteurizer facility in

order todeactivateanyseparatedproteaseswhich

wouldotherwisehaveanegativeimpactonthehead

ofthebeer.GEAWestfaliaSeparatorGroupcanalso

offer the corresponding solutions from a single

sourceinthisrespect.

Processing with nozzle separators

1 Yeast tank

2 Buffer tank

3 Water

4 To yeast processing

5 Self-cleaning clarifier

1

2

3

4

5

26

Themanufactureof low-alcoholornon-alcoholic

beercanberealisedwithseparatorsbyinterrupting

thefermentationprocess.

Advantages

• Shortproductiontimesbecausethebeermust

notbede-alcoholisedintheentirebatch

• Highestproductquality

• Rapidpayback

• Excellentprice/performanceratio

• Goodmicrobiologicalcontroloftheprocess

• Lowcostsforoperationbynotusingfiltering

media

• Separatorcanbeusedinotherprocessestoo

Production of Non-Alcoholic BeerInterrupted fermentation to manufacture non-alcoholic beer

Manufacture of non-alcoholic beer

1 Fermentation tank

2 Yeast

3 Feed pump

4 Optec

5 Recirculation

6 Self-cleaning separator

7 Maturation tank

1

2

3

4

5

6

7

28

Kvass is a slightly sour, carbonated soft drink

obtainedbyfermentingthebasicingredientswater,

rye and malt. It is a prized drink in many Eastern

European countries, especially at warmer times of

year,traditionallymostcommoninRussia.Itisalso

from this country that we derive the name kvass,

which means something like “sour drink”. With

separators from GEA Westfalia Separator Group, a

continuous production line can be supplied which

combines the simplest imaginable process

managementwithoptimumproductquality.

Water,malt,ryeflourandkvassyeastarerequired

toproducekvass.Dependingonthetype,flavour-

ingslikemintcanalsobeadded.Theprocessdiffers

from theproductionofbeer in thatnohopsare

addedandalcoholicfermentationissuppressed.As

aresult,kvassisusuallyonlyslightlyalcoholic.Self-

cleaningclarifiers fromGEAWestfaliaSeparator

Groupareinstalledbetweenthestoragetankand

thebuffertankandclarifythekvassfromunwanted

solidparticlessuchasresidualyeast.Theeffective

centrifugesworkcontinuously,withoutpre-orpost-

run,andrequirenofilteraids.Themaximumdry

substancereducesproductlossestoaminimum.At

thesametime,theproductqualityalsosaysmuch

abouttheclarifiers,asflavourisnotimpairedby

absorptioninanyway.

Kvass

Features

• Simplestprocessmanagement

• Effectiveclarificationwithoutconsumables

(filteraid)

• Optimumproductquality,noimpairment

oftastebyabsorption

• Lowlossesduetomaximumdrysubstance

• Continuousoperatingmode

• Nopre-orpost-run

• Easyinstallationandintegration

• Levelofautomationcustomizableto

individualcustomerrequirements

GEA Westfalia Separator Effective capacityhydry® in hl / h

GSC 45 100

GSC 75 150

GSC 150 300

GEA Westfalia Separator Effective capacityhyvol® in hl / h

GSE 30 50

GSE 300 500

29

Clarifying kvass

Kvass – Russian national beverageTurbid – before separation

Kvass – Russian national beverageClear – after separation

1 Storage tank

2 Feed pump

3 Self-cleaning clarifier

4 Buffer tank

5 Short time heating / bottling

1

23

4

5

30

ParticularlyinthemanufactureofGerman“Hefe-

weizenbier“(beerbrewedfromwheat),itisimportant

topresentthecustomeraproductwithaconsistent

qualityoftheturbidity.Problemsoccurparticularly

inhighstoragetanksbecausetheyeastconcentration

variesduetosedimentation.Theuseofseparators

issuitableinthiscasetocompensatetheconcentration.

Thestoredbeerisseparated.Simultaneously,unsep-

aratedbeer isadded throughabypass toensure

constant turbidity values throughout the entire

productioncycle.Forthispurpose,theturbidityis

measuredat theoutletof theseparatorandafter

mixing.Thecontrolvalveinthebypasspipeisthen

controlledby these twovalues and thenominal

value.

Turbidity Adjustment with Separators

Advantages

• Consistentbeerquality

• Continuousoperation

• Simpleprocesscontrol

Feed Discharge

Hot wort < 1.5 % v / v < 0.05 % v / v

Trub wort < 15 % v / v < 0.2 % v / v

Cold wort clarifying efficiency approx. 50 %

measured in “Imhoff Funnel“

Green beer < 20 million < 1 million

Pre-clarification yeast cells / ml yeast cells / ml

Before filtration < 10 million < 0.5 million

yeast cells / ml yeast cells / ml

Beer recovery < 30 % v / v < 1 % v / v

31

Effective capacities of the separators, in hl / h

* In special design** Yeast concentration in feed: max. 5 million yeast cells / ml

Depending on extract characteristics and solids concentration in feed and discharge, the values may vary

Capacities at a Glance

Type Hot Trub Cold Green Pre-clarifica- Beer Beer filtration / wort wort wort beer tion before recovery PROFI filtration

GSE 30 80 – – 100 100 – –

GSE 50** – – 20 100 100 – –

GSE 65** – – 60 – 60 – –

GSE 75 150 – – 300 300 – –

GSE 100** – – – 300 300 – –

GSE 125 300 – – 500 500 – –

GSE 160 – – 200 – 300 – –

GSE 180** – – – 500 500 – –

GSE 200 500 – – 700 700 – –

GSE 230** – – 300 – 500 – –

GSE 300 – – – 850 850 – –

GSE 400 – – 500 950 950 – –

GSE 450** 700 – – 1.200 1.200 – –

GSE 550 – – – 1.500 1.500 – –

GSA 500 – – 700 – – – –

GSC 4 / 6 10 3 – 20 20 1 –f

GSC 20 50 10 30* 80 80 4 –

GSC 45 110 25 – 180 180 8 –

GSC 75 150 30 – 300 300 9 –

GSC 95 200 60 – 400 400 16 –

GSC 150 400 130 – 600 600 30 –

GSC 200** 600 200 – 700 700 40 –

GSC 250** – – – 800 800 – –

HFC 15 – – – – 10 –

HFE 45 – – – – 30 –

PROFI PROFI 50 – – – – – 50

PROFI 100 – – – – – 100

PROFI 200 – – – – – 200

PROFI 300 – – – – – 300

PROFI 300i – – – – – 300

PROFI 400 – – – – – 400

PROFI 400i – – – – – 450

GEA WestfaliaSeparatorhyvol®

GEA WestfaliaSeparatorhydry®

GEA Group is a global engineering company with multi-billion euro sales and operations in more than

50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and

process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

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Werner-Habig-Straße 1, 59302 Oelde, GermanyPhone: +49 2522 77-0, Fax: +49 2522 77-2089www.gea.com