March 10, 2011
District MichiganMBAA
Technical MeetingGrand Ledge, MI
Presentation Agenda
Pasteurization Basics Tunnel Pasteurization Technology Flash Pasteurization Technology Technology Comparison Questions and Discussion
Theory and Objective of Pasteurization
Elevated levels of heat will kill organisms Heat beer to arrest biological contamination Destroy viability of yeast Prevent post fermentation
Brewers want Pasteurize not Sterilize Minimum temperature for target organisms Limited Pasteurization units
Time and Temperature CurveMaintaining the time/temperature profile is key to preserving the process or protecting against under and over pasteurization
Pasteurization Lethal Effect
A lethal effect of 1 PU (Pasteurization Unit) is obtained when product can be held at 140F for 1 minute
Brewers typically target 10PUs to 15PUs Control of PUs is essential Elevated PUs can affect flavor degradation
Measuring Pasteurization Units
Measure at Cold Spot of container Probe position in container
Pasteurizer internal calculation Using sensing devices and programming
Calculate PUs Time above 120F Time in holding tube at Pasteurization temperature
Measuring Heat Transmission
T00384
TE M
PER
AT U
RE
F
TIME IN MINUTES
657075
80
8590
95
100
105110
115
120
125130
135
140
2 4 6 8 10 12 14 16 18 20 22 24 26 28
AVE.
TEM
P.
COLD
SPOT
TEMP
.
INITIAL BEER TEMP. 40 F (4.4 C)18.321.123.9
26.7
29.432.2
35.0
37.8
40.643.3
46.1
48.9
51.754.4
57.2
60.0
TE M
PER
AT U
RE
C
SPRAY AT 140 F (60 C)
Cold Spot is usually located at to 1 above the center of the bottom of the container
Lethal Rate Curve
MINUTES
Average 12.35 P.U.'s
Cold Spot 8.60 P.U.'s
144
143
142
141
140
139
138137136135
133
120 0.025
0.27
0.390.480.570.69
0.83
1.00
1.20
1.45
1.74
2.09
0 5 10 15
LET
HA
L R
AT
E P .
U. '
S / M
INU
TE
56.1
57.257.858.358.9
59.4
60.0
60.6
61.1
61.7
62.2
48.9
P RO
DU
CT
TE
MPE
RA
T UR
E FC PUs calculated for
product temperature above 120F.
Area under the curve equals the number of PUs achieved.
Cold spot PUs less than Average.
Pasteurization Unit GraphTEMPERATURE C
TEMPERATURE F
PU / MINUTE = 1
LOG -1 140 - F
12.5
= 1.20226(F - 140)
0.03
0.1
0.2
0.3
0.50.71.0
2.0
3.0
5.07.0
10.0
20.0
30.040.0
120 130 140 150 160
50 52 54 56 58 60 62 64 66 68 70
PU /
MI N
UT E
LOG
PU / MINUTE =
(C - 60)
-11
= 1.393
60 - C 6.94
10 PUs10 min= 140F
10 PUs30 sec= 157F
Barry-Wehmiller Advanced PU Limit SystemPU Accumulation
PU Accumulation Rate
0.01
0.10
1.00
10.00
100.00
1000.00
1
7
5
1
7
0
1
6
5
1
6
0
1
5
5
1
5
0
1
4
5
1
4
0
1
3
5
1
3
0
1
2
5
1
2
0
Product Temperature [deg F]
P
U
/
m
i
n
u
t
e
Validating Measurement
Independent validation for tunnel Several manufacturers of independent PU
measuring devices Measure time and temperature Calculate and report PU values
Machine internal validation for flash Redundancy on sensors Micro analysis
Verifying Pasteurization
Independent measurement is capable with tunnel technology only.
Redundancy can help reliability
Types of Beer Pasteurization Technology
Two basic types of beer pasteurization
1. Tunnel Pasteurization
2. Flash Pasteurization
Tunnel Pasteurizer
Tunnel Pasteurizer Overview
General Description Pasteurizer Features Pasteurizer Systems Operational Controls Reporting/Recording
Pasteurizer General Description
Length - Width # of Decks Features Systems
Pasteurizer Features
End Casings Removable
Top Covers Container
Water Blow-Off
Condensate Return System
Pasteurizer Process Systems
Regeneration Capability Heating System Belt and Drive System Spray System Pump Systems PU Control Controls, Alarms
Tunnel Pasteurizer Regeneration
Cold containers entering require heat
Hot containers exiting require cooling
ZoningSet Point BalanceMaximum RegenCompensationExit Temperature
Single Heat Exchanger System
Single Heat Exchanger with plate Heat Exchanger.Closed Loop System with hot water available on demand.
Basic ConceptsSingle Heat Exchanger System
Benefits of the Single Heat Exchanger System Low Maintenance
Only one heat exchanger Plate Heat exchanger
Efficient use of energy Condensate return Less Pump
Horsepower required
Typical Heat Exchanger Skid Large Machine
Pasteurizer Main Belt Intralox 400 and 1900 with
Enduralox Twentebelt Combinox and
Eyelink Regina 3120 Rexnord 5997 with DTS-C
UHMW Wear Strip Attachment
Allow for UHMW expansion
Easy install and replacement
Main Drive SEW Motor/gearbox
Spray and Pump System
Pressurized water flow rate designed to optimize thermal heat transfer rates
Up to 6.8gpm/ft Thermal Dynamic Models Manual Blow Downs Even flow across the deck Predictable Heat Transfer Removable spray headers 3 1/2 header, 3/8 nozzles
Spray System Filter Screens
Redundancies for Maintaining Spray Consistency Belt side guides Belt mesh pattern Dual pump inlet screens Spray header design Spray header blow down
Filter Screen External Access Doors
Spray System Blow Down
PU Limiting
Hot Zones Add cold water
to zone reservoir Re-heat on start
up
Advanced PU Control System
Advanced PU Control System controls the pasteurization process: Guarantee very tight PU control Preserve the process curve in stop/start
conditionsMove process to container if container can not
get to process
Possible to have hot water on one header and cold water on another header from the same manifold
PresenterPresentation NotesThis model better describes the spray header design in the heating zones.Note the manifold on one side is for hot water supply and the manifold on the other side is for cooling water supply.Note that control of the demand for hot water or cooling water is exclusive to each individual spray header.In other words, one spray header can be accessing cooling water, while the one next to it is accessing hot water.
Utility Control Technology IntelliFlow
The IntelliFlow System: Used in conjunction with Advanced PU Control Water temperature separation technology Eliminates requirement for water re-heating Provides benefits of PU control without added
utility consumption
PresenterPresentation NotesIntelliFlow is a technology used during PU control mode obviously used to reduce energy consumption during that phase of the pasteurizer operation.
It achieves the utility savings by minimizing the mixing of hot and cooling water supplies.
By doing this we can realize up to 75% savings on steam and water consumption during PU control mode operation.
Pasteurizer Control Items
Sensors, proximity switches, instruments Safeties and Alarms
Pasteurizer Safety and Alarms
Hot zone pumps 2 below set point for 30 seconds will stop belt
Pressure sensors all zones below 2psi for 15 seconds stops pasteurizer
All levels satisfied before pasteurizer will start Belt speed monitored by checking starwheel pulse
duration to time set in recipe Drive overloads spring and proximity
Pasteurizer Recording Capability
Data collected from Sensors: Temperature of all zone sprays Speed of belt Levels
Data collected in the pasteurizer PLC Data sent to remote storage Data can be extracted to workable files Reports can be generated
Flash Pasteurizer
Volutherm SeriesFlash Pasteurizer
Flash Pasteurization
Pasteurization occurs prior to filling Short Time High Temperature (HTST) Heat Exchanger (plate or tube) Fixed or Variable flow rates Pasteurization calculated by Holding Time and
Temperature High Efficiency (90% regeneration) Controls are Key!
Flash Pasteurizer 180 Hl/Hr
Flash Pasteurizer 320 Hl/Hr
Flash Pasteurizer 360 Hl/Hr
Flexibility to design units to fit various applications
Juice unit with Heat Exchanger mounted on the floor for accessibility on larger pasteurizers
Often times machines can be designed to handle different products on the same unit
Flash Pasteurizer 250 Hl/Hr
Flash Pasteurizer Features
Constant PU Variable Flow rate Unit. Pressure Balance System. 90% Energy Recovery. Status and Process Alarms. Digital Paperless Chart Recorder. Fully Automatic Operation.
Flash Pasteurizer Design
Flash Pasteurizer Components
Product Flow Meter
An Electromagnetic flow measuring system is used to monitor the flow of the product at the discharge of the pasteurizer.
Product Flow Control Valve(Detail View)
4-20mA Electrical Input Signal.
Resulting in a 0-100% Valve opening.
Product Temperature MeasurementPT100 Temperature probes monitor the temperature of the fluidsWithin the pasteurizer. As the temperature changes the resistance measured by a Transmitter fitted inside the temperature probe changes.
The input signal to the pasteurizer control system is electronic4 20mA.
Product Temperature ControlA pressure reducing valve is designed for
maintaining the pressure downstream of the steam supply valve to an adjusted set point value.
Set point approximately 2.0bar The valve closes when the downstream
pressure rises.
The hot water that is used to raise the beer to therequired pasteurization temperature is heated using steam controlled by the pneumatic controlled valve.This valve uses a pneumatic control signal to adjustThe amount to which it opens and so the amount of
steam that can flow into the plate pack
Pneumatic Control Valve
Pressure Reducing Valve
Process Recording
Touch Screen HMI Select recipes Operational functions Adjust parameters Alarm displays
Digital Paperless Process Logger Records temperatures Records flow rates Records pressures CIP and Run modes
Process Recording
TemperaturesPressuresCalculated PUsProduction / CIP Flow rateProduction / CIP / SIP ModeProduct In Machine
Central System Operation
Central System Operation
Flash Pasteurizer Benefits and Features
Performance tolerance to with in 1PU Variable flow, variable temperature Maximum regeneration Quality monitoring, alarms, reports, archiving Machine self-diagnostics Operation safe-guards for PU protection Gentle product handling (HTST) Compact footprint, Low energy use
PROCESS COMPARISONS
Process Comparison Factors
Application IssuesOperational IssuesQuality IssuesEconomic IssuesEquipment Issues
Application Issues
TunnelWide range of productsCarbonated or non-carbonatedContainer limitations
FlashWider range of products Product limits for plate and frameCarbonated or non-carbonated
Operational Issues Tunnel
Controls and Complexity can be less More forgiving Reduced requirement for micro control Manual machine cleaning PU Control required for line conditions
Flash Cleaning and Sanitation Increased Line availability reduced Enhanced microbiological testing CIP systems are critical Buffer systems for handling line conditions
Quality Issues Tunnel Taste affects possible with prolonged stops Validation using independent device Reduced requirement for micro control Exit temperatures
Flash Minimal taste affects Potential for recontamination Validation trust sensors, redundancy Ability to re-circulate Disinfecting caps and containers filler contact points
Economic Issues Tunnel High capital costs for new equipment and installation Operating costs can be high Reduced costs for monitoring quality Increased line utilization
Flash Capital cost can include warmer, filling room upgrades High efficiency reduces utility cost (warmer?) Less floor space required
Example Comparison for Flash and Tunnel
Example Selection: Brewery
Bottle production line operating at 800bpm Target PUs at 10 +/- 2 Target BOT at 75F
Example Comparison for Flash and Tunnel Equipment Cost
Flash Process Tunnel ProcessVolutherm 200B $300,000Buffer Tank - $50,000Warmer - $375,000Clean Room $275,000Total equipment -$1,000,000
New Double Deck sized correctly to optimize utility consumption and provide low product exit temperatures- $1,500,000
Example Comparison for Flash and Tunnel Utility Consumption
Flash Process Tunnel ProcessVolutherm 200B Water - 140 gal/chase outSteam 8,000 btu/minBWCo WarmerWater 0gpm normalSteam - 31,500btu/minTotal Steam -39,500 btu/min
New Double Deck TunnelWater - 0gpm, running mode
- 100gpm run-out 24minsSteam 20,000 normal run
- 72,000 start-upAvg. steam - ~ 35,000btu/min
Example Comparison for Flash and Tunnel Floor space requirement
Flash Process Tunnel ProcessVolutherm 200B 200 sq. ft. Buffer tank and valves stand
- 80 sq. ft.Warmer 826 SD
- 280 sq. ft.
Total - 480 sq. ft.
New Double Deck Tunnel1120 sq. ft.
Summary of Process Comparison
Capital Cost Similar when considering clean room Utility Consumption Similar when using warmer Process Considerations Culture change for flash Cleaning Materials/Sanitizing Agents and Micro
Control requirements Higher costs for flash Available Packaging Line Time Higher for tunnel Floor Space Flash has reduced space requirement
Time for a beer.
Thanks for listening!
Slide Number 1Slide Number 2Presentation AgendaTheory and Objective of PasteurizationTime and Temperature CurvePasteurization Lethal EffectMeasuring Pasteurization UnitsMeasuring Heat TransmissionLethal Rate CurvePasteurization Unit GraphBarry-Wehmiller Advanced PU Limit SystemPU AccumulationValidating MeasurementVerifying Pasteurization Types of Beer Pasteurization TechnologyTunnel PasteurizerTunnel Pasteurizer OverviewPasteurizer General DescriptionPasteurizer FeaturesPasteurizer Process SystemsTunnel Pasteurizer RegenerationSingle Heat Exchanger SystemBasic Concepts Single Heat Exchanger SystemTypical Heat Exchanger Skid Large MachinePasteurizer Main BeltUHMW Wear Strip AttachmentMain Drive SEW Motor/gearboxSpray and Pump SystemSpray System Filter ScreensFilter Screen External Access DoorsSpray System Blow DownPU LimitingAdvanced PU Control System Slide Number 33Utility Control Technology IntelliFlowPasteurizer Control ItemsPasteurizer Safety and AlarmsPasteurizer Recording CapabilityFlash PasteurizerFlash PasteurizationFlash Pasteurizer 180 Hl/HrFlash Pasteurizer 320 Hl/HrFlash Pasteurizer 360 Hl/HrFlash Pasteurizer 250 Hl/HrFlash Pasteurizer FeaturesSlide Number 45Flash Pasteurizer ComponentsProduct Flow MeterProduct Flow Control Valve (Detail View)Product Temperature MeasurementProduct Temperature ControlProcess RecordingProcess RecordingCentral System OperationCentral System OperationFlash Pasteurizer Benefits and FeaturesSlide Number 56Process Comparison FactorsApplication IssuesOperational IssuesQuality IssuesEconomic IssuesExample Comparison for Flash and TunnelExample Comparison for Flash and TunnelExample Comparison for Flash and TunnelExample Comparison for Flash and TunnelSummary of Process ComparisonTime for a beer.
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