Pegasus - the new lautertun technology

The standards which modern lautering systems have to meet are continuously rising. Some time ago, the main focus was on quantity and quality of worts produced. The emphasis is now also increasingly on an improvement in efficiency and, above all, flexibility.

Currently, the most usual situation is to have lauter tuns running 10 brews/d. 12 brews/d are also state-of-the-art, but with somewhat more elaborate equipment. However, this is oftentimes pushing the limits in terms of peripheral equipment. High yields and a low-maintenance, upset-free operation are the basic prerequisites for meeting the exacting requirements.
The new lauter tun has been named Pegasus, taken from Greek mythology. Pegasus is a winged horse which emerges from the Medusa beheaded by Perseus.
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Wort boiling over the years

More than 100 years ago, when kettles in breweries with direct firing with fuels such as wood or coal were state-of-the-art, the fast-moving process of industrialisation was still in full swing. Seen from this angle, the transition to steam-heated kettles can be understood in principle and has been a logical progression. But discussions among brewmasters about the pros and cons of steam boiling were legion at that time.

To quote Franz Rutschmann who called out (1) "Brewers, back to open hearth boiling if you want to get back to tasty, stable, wholesome beers brimming with drinking pleasure", he felt "surrounded by enemies" who argued against open hearth boiling at the October Meeting of the VLB at the turn of the century. This resulted in inadequate excretion of protein......

New inline CO2 measurement - upstream of the filler

A new inline CO2 sensor has proven itself, not only for monitoring and controlling beer carbonisation, it also provides continuous and correct measured values upstream of the filler, when operating under stop-and-go conditions.

The CO2 content has a very strong influence on the sensory properties of beers as well as sparkling wines, alcohol-free beverages and mineral waters. Nowadays, consistent product quality and thus a constant amount of dissolved carbon dioxide is imperative. Therefore, in many modern breweries, the carbon dioxide content of beer is precisely regulated by means of post-carbonation. Fast response, highly accurate and robust inline sensors are required to measure CO2 concentration so that this regulation satisfies current quality requirements.
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New aspects of flotation

Following extensive tests on a pilot scale in 1998, the author has applied for a patent covering a continuous flotation process (1). This has considerable advantages over the state-of-the-art. Proposals about operation of existing flotation plants are derived from experience gained in carrying out the tests and from studying the relevant literature. In addition, some considerations about possible applications of the flotation process in other areas of beer production are presented.

In recent times, various publications on brewing technology have dealt with the issue of how to handle cold break.
In large operations with high brew cycles and tight brew sequences, centrifuges are oftentimes used for cold break removal, despite high costs of purchase and operation.
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"Cold break removal from cold wort - yes or no?" It is not easy for a modern medium-sized brewery to come to a decision

Even 30 years ago, the "scientific brewing luminaries" of VLB Berlin (cold break removal not required) and of the Technical University Munich-Weihenstephan (partial or complete cold break removal required) differed in their opinion. Due to this "North-South divergence", brewing technologists who regularly attended technical meetings oftentimes came away confused.
Presupposing hot break removal of more than 90%, cold break is composed of up to 50% proteins, up to about 25% polyphenols and about 25% high-molecular weight carbohydrates. It precipitates in wort at temperatures <70°C, the major part at <15°C. Cold break proper has a particle size of about <1 µ (1).
Cold trub can be minimised e.g.
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Wort boiling - current state-of-the-art

At first glance, wort preparation seems to be a simple process. Using the classical process, wort is boiled for 60 - 90 min (formerly up to 120 min) with the addition of hops, the hot break is subsequently removed. After cooling, the wort is mixed with yeast and fermented. Experience over the last 20 years has shown that each change in boiling conditions can frequently be reflected in a negative change in beer quality.

The wort boiling process has a number of objectives. Apart from evaporation of water to obtain the desired wort concentration, protein substances have to be excreted, hop bitter substances dissolved and isomerised, enzymes deactivated, undesirable volatile substances expelled and other aroma substances formed again. Boiling also renders the wort sterile. 1).
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More transparency in the brewhouse – Combined extract and flow measurement

At the beginning of 2001, in the context of modernising sections of the brewhouse at Binding Brauerei AG in Frankfurt am Main/Germany, Centec GmbH supplied and commissioned novel sensors based on ultrasound measurement. The innovation relates to the fact that both extract concentration and flow are measured simultaneously. A profibus is used for data transfer. The present contribution describes the concept and advantages of the new system.

Low-pressure external heating unit with thermal vapour compression An alternative to mechanical vapour compression? Things to watch for!

Low-pressure external heating units are usually mentally associated with mechanical vapour compression. Thermal vapour compression of vapour from boiling with high-pressure live steam is an alternative as at a low steam pressure, the live steam portion and thus condensate losses associated with this live steam portion may still be acceptable.

These and other general aspects which have to be considered in addition are dealt with in this article and should be taken into account in the decision-making process.

Mechanical vapour compression
Mechanical vapour compressors compress vapours from wort boiling to 0.35 to 0.5 barg, whereby the higher compression pressure calls for an over-proportional higher power draw compared to the lower compression pressure.35 and 0.e....

The USA energy crisis - an opportunity for a fresh start

The authors of this article have been working in the brewery engineering sector for several decades now and are owners of many patents that have delivered energy savings in breweries. As a result of many investigations and consultancy opportunities, it has also been possible to save considerable amounts of primary energy. The following article describes possible options, and the results that could be obtained by their application. It has been written with the primary aim of stimulating the American market, but is also of value to anyone interested in saving energy in breweries.

Europe many people were amazed to learn earlier this year that the USA was in the grip of an energy crisis. It forced us to take a serious look at ways to save energy, both generally and in specific areas..

Dynamic low-pressure boiling - optimised energy and process engineering

The decision of a brewery to use a particular optimum process is dependent on a number of important criteria. These include purchase costs, space requirements, process flexibility, operational and consumption costs, energy usage and environmental protection as well as achievable technological brewing conditions for optimum wort and beer quality. Wort boiling processes which are uncomplicated in use and operate with a high degree of functionality have significant advantages. This paper describes the operational characteristics and selection criteria from an energy point of view.

Classic low-pressure boiling (LPB) where wort is boiled at a constant evaporation pressure of 1.08 bar (tb = 102° C) to 1.21 bar (tb = 105° C) has been used worldwide in breweries as of 1979.g.
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Separating off original extract production using fluidised bed technology

In the brewing industry, use of fluidised bed technology opens up new possibilities for industrial beer production. This paper describes a process, patent pending, which serves to achieve the desired standardisation and quality improvement of original extract by separating off the brewhouse process.

rimary energy consumption and other production costs are also significantly reduced. Use of fluidised bed technology could revolutionise industrial beer production in the 21st century.

Use of fluidised bed technology in the brewing industry - "original extract granulate"

With the "PlatoTec" process presented here, liquid original extract is processed to dry original extract granulate by using fluidised bed technology. The plant is thus extremely flexible.