Application Example Grain and Ingredient Transfer for Brewery Applications

Introduction breweries alike are searching ity, while ensuring efficient and on further manual handling as Worldwide, breweries produce for ways to optimize production precise dispensing of the in- well as equipment costs. about two billion hectoliters efficiency, while still maintaining gredients to the process below. The wort then flows from the of beer annually, according and adhering to strict environ- wort receiver into a brew kettle. to Kirin Beer University. That mental, health and safety (EHS) Application details At this time, hops as well as same global beer market is guidelines for breweries. One additional flavors and addi- expected to reach over 700 approach is the automation of The complete brewing process typically begins with delivery of tives are added to the kettle. billion USD by 2023, according the raw ingredient delivery to The resulting flavor of the wort to First Research’s latest July both the grist mill and the brew purchased malts – germinated grains that have been dried. depends on the hops, additives, 2018 report. Growing popularity kettles using pneumatic transfer temperature and length of the of premium beers, craft beers and weighed dispensing. Both The malt can be delivered to the brewery in a variety of brewing. Flavor additives that and new products with flavor pneumatic transfer and batch can be added at this step in- innovations are all contributing weighing options as part of the methods including truck, bulk bags and even railcars. Malts clude everything from orange to this increase in production. conveying system design can peels to spices like coriander, As a result, smaller and larger significantly improve cleanabil- are then typically stored and then transferred to a grist mill, ginger and cinnamon. The final forming “grist” product, as steps include straining, cooling shown in Figure 1. This crushed and storing. grain is then transferred to a The process outlined above “mash tun”, a specialized tank which includes transfer of where a mash is created by dry ingredients can be an ex- adding water, heating and stir- tremely labor intensive when ring. This process step converts done manually. In addition, the the mixture into fermentable open environments used for the sugars. The mixture is then transfer of these ingredients can strained and rinsed to produce also lead to risk of contamina- “wort”, a liquid with high levels tion of ingredients and eventu- of these fermentable sugars. ally the end product. Inaccurate The spent grain from the tun addition of high value additives can then be conveyed using the such as spices, flavorings and same vacuum pump directly to other ingredients can add to the spent grain bin or truck as overall ingredient costs as well shown in Figure 1, thus saving as modify end product flavor.

Spent grain recovery

Ingredient delivery from bags

Conveying Conveying Conveying Spent grain to silo to grist mill to mash tun recovery

Ingredient delivery from trucks or railcars

to Brewing process

Figure 1: Brewery process flow, from raw ingredient delivery to mash tun

1 Grain and Ingredient Transfer for Brewery Applications

In order to optimize handling puts. Applications which involve ergonomics, cost of ingredients, pressure conveying often in- as well as ingredient safety and clude loading and unloading product quality, automated of large volume vessels such material handling processes in- as silos, railcars, trucks, and cluding pneumatic transfer and bulk bags automated weighing/dispens- ing, such as those supplied by PD transfer Coperion and Coperion K-Tron are quickly becoming the pro- In cases where PD truck unload- cess improvements of choice. ing is possible, a flexible hose is connected from a pressure blower to the PD truck, upon Malted barley transfer arrival at the brewery, and Photo 2: ZRD rotary valve from truck to silo another from the PD truck to The arrival and transfer of ma- the conveying line. The system jor ingredients such as malted operator selects the desired barley, corn or rice to a brewery destination (for example, silo 1 can include a number of differ- for malted barley on the truck ent types of conveying systems. unload control panel). The mode of transfer of ingredi- When the system is started, ents is dependent upon a wide the blower pressurizes the PD variety of process parameters, truck and conveys material Photo 1: Filter receiver including material characteris- via positive pressure from the tics, distance to be transferred, truck through the conveying dust. This is one of the reasons required rate of transfer, and the line and directly into the silo. why vacuum systems are of- type of container in which the Many times, an inline magnet ten used in higher sanitary or ingredient is originally received. installed in the conveying line dust containment applications. Pneumatic conveying systems to remove any metal particles Another advantage of vacuum are used to transfer dry materi- which may be present in the systems is the simple design for als from one process to another conveyed material. When the multiple pickup points. It should via either positive (pressure) high level sensor in the silo is be noted, however, that the or negative (vacuum) modes. activated, the operator closes distances and throughputs pos- Photo 3: Scale hopper Typical systems include an air the material flow gate on the sible with a vacuum system are source, a material feed de- truck and allows the system to limited due to the finite level of ery safety, the Coperion rotary vice, a convey line and some purge the conveying line before vacuum that can be generated. valves can also be equipped type of air/material separator, finally stopping the operation. Often a combination of pressure with the innovative Rotorcheck such as the Coperion K-Tron and vacuum conveying designs design option (Photo 5), which filter receiver shown in Photo Pneumatic transfer – are used for a system, as shown detects any metal to metal con- 1. Pneumatic systems typically vacuum vs. pressure in Figure 1 with delivery to the tact in the valve, as a function operate in a fully enclosed line, mash tun, taking full advantage of electrical resistance between Depending upon the volumes which greatly improves hygienic of the process and efficiencies the rotating vanes and housing. required, other possible sources operation and also minimizes of each technology. This system is ideal for detec- of ingredient delivery include product loss. tion of contaminant metal in the boxes, sacks, bulk bags or super Majors such as grains are often Robust and safe product as a result of wear and sacks. In all of the ingredient received by truck or railcar and can be instrumental to ensure transfer steps, pneumatic con- rotary valves then stored in silos prior to us- safe operation. age. Truck unloading can be veying systems can be used In either of these types of con- to transfer these ingredients. veying applications, Coperion done via positive or negative Batching ingredients pressure. Pressure Differential These systems can also utilize K-Tron high efficiency rotary (PD) trucks and railcars use either positive or negative pres- valves can be utilized (Photo to brew kettles positive pressure to unload sure dilute phase conveying. 2). These rotary valves can be In many brewery applications, material, whereas other types Vacuum (negative pressure) provided for blow through sys- additional ingredients such of delivery to the batching step systems, such as shown in Fig- tems or for discharge valves at as flavors, additives and hops of process can involve either ure 1, are often used for lower the bottom of silos or feed bins. are added directly to the brew positive pressure or negative volumes and shorter distances. These specialty valves include kettle, as shown in Figure 2. In pressure pneumatic conveying. One of the advantages of options for EHEDG and ATEX order to accurately weigh and Positive pressure conveying vacuum systems is the inward certification, and to ensure a meter these ingredients they systems are typically used to also suction created by the robust and operationally safe may be transferred to a batch- transport product over long vacuum blower and reduction brewery operation. ing station prior to the kettle. distances and at high through- of any outward leakage of As an added benefit for brew- This station often includes a

2 metering device such as a ro- be expected. Once the desired Aeropass principle of Pneumatic or tary valve which delivers the weight has been achieved, the operation mechanical conveying product to a scale hopper on kettle then calls for material, the load cells. This method is called discharge valve is activated and The Aeropass valve operates As an alternative to the pneu- Gain-in-Weight (GIW) batching. the material in the scale hopper on a diverter type principle matic conveying options out- is discharged. and is ideal for diverting mate- lined above, mechanical con- rial directly into a hopper from veying is sometimes also used. Batch weighing with a conveying line. Due to the A mechanical conveying system scale hoppers Multi-destination valve’s low-clearance height, uses a mechanical device (such Scale hoppers are receiving majors batching it is ideal when requiring inline as conveyor belt, flexible screw, hoppers suspended on load When major ingredient batch- diverters in tight spaces. As bucket elevator) that is in direct cells for ingredient batch weigh- ing requires a single ingredient shown in the diagram, the valve contact with the conveyed ing (see Photo 3 and Figure to be delivered to multiple sta- includes an internal wafer type material. Conversely the pre- 2). The material enters the tions or multiple ingredients device which allows for the viously described pneumatic scale hopper until the precise delivered to a single destination, discharge of material into the conveyors utilize gas (typically weight and/or combination scale hoppers with specialty hopper below when activated in air) to transfer the suspended of materials is achieved. With Aeropass™ valves mounted the correct discharge position. material through the convey the scale weighing system, after the scale hopper can be After the weighed material is line. A distinctive difference weigh accuracies of +/- 0.5% used (see Figure 3). After the discharged into the first brew between the two modes is that of the full scale capacity can fluidized material is discharged kettle, the Aeropass valve can pneumatic conveyors have al- from a source such as a silo or be immediately switched to most no moving parts, resulting bulk bag, it will typically drop allow for the transfer of the in less downtime for cleaning into a scale hopper, is weighed, material in the conveying line and maintenance than their and then conveyed. Once in either to the next process, or mechanical counterparts. the convey line, it is then trans- back into the original source. Additional advantages of pneu- ported to the Aeropass valve, This closed loop design results matic conveying for brewery located above the receiving in a more efficient method of applications include the fol- vessel(s) or brew tanks. product transfer with higher lowing: product yields. >>Less maintenance required When designing a batching sys- >>Increased operator safety due tem, it is important to discuss all to fewer moving parts aspects of the design require- ments, including the expected >>Increased product safety changeover and cleaning times, due to enclosed convey line as these options can greatly minimizing product contami- affect the overall system cost, nation. ingredient accuracy and total >>Less product loss and dust Photo 4: Bag dump station batching times. leakage; this is especially true in vacuum systems where the material stays within the line due to the negative pressure It should be noted however, Ingredient delivery Conveying from bags to brew kettles that there are cases where both (flavors and additives) modes can be used in a system together. This may be the case, Aeropass valves for example, when headroom

Scale hoppers

Blower Brew kettles

Rotary valves

Figure 2: Batch weighing of ingredients and flavors to the brew kettles Figure 3: Aeropass valve

3 Grain and Ingredient Transfer for Brewery Applications

above the brew kettle or tank Coperion advantage to transfer of ingredients is an >>Complete systems design in- issue. In this case, materials tegration of the brewing pro- may be transferred for the bulk cess for one source supply. of the distance via pneumatic transfer, and then sent to a re- >>Global systems engineering ceiver or batch weigher above group with extensive ap- a mechanical screw. The screw plication experience for the then transfers the final ingredi- entire dry material handling ents direct to the kettle. brewery processing line en- sures optimal design with an It is important when evaluat- emphasis on product safety, ing different modes of transfer quick product changeover, that manufacturers work with and increased efficiency. Photo 5: ZRD rotary valve with RotorCheck system engineers such as those at Coperion K-Tron who are >>Engineered solutions from experienced in a variety of op- both Coperion and Coperion >>Extensive material handling tions, so that the most efficient K-Tron reflect extensive ex- knowledge in a wide vari- operation be chosen for the perience in hygienic and ety of ingredients by the brewery application. sanitary design standards, engineers at Coperion and including CIP/COP, EHEDG, Coperion K-Tron ensures the FSMA, GFSI, USDA, and 3A most efficient means of prod- Conclusion where applicable. uct transfer. Properly weighing and accu- >>All system receivers and >>Superior global service net- rately delivering all the ingre- components are designed work to ensure 24-7 support dients for the brewery process with ease of maintenance and and coverage of your com- without manual intervention accessibility in mind. plete brewery processing line. can result in a number of process advantages, includ- >>Coperion and Coperion K- ing fewer mistakes, better Tron rotary and Aeropass accuracy, lower bulk costs, valves are available in a va- improved product quality and riety of sizes and design op- savings in manufacturing costs. tions and meet CE and ATEX In addition, using devices and 3D classifications. systems which involve highly >>Coperion K-Tron Weigh Scale accurate weighing and meter- Hoppers and Batch Weigh ing of precious and expensive Receivers are designed to ingredients such as flavors and provide batch weigh accura- additives can result in lower cies of ± 0.5% of the full scale overall ingredient costs. The capacity. highly experienced personnel >>Integrated control systems of Coperion K‑Tron can provide featuring Coperion K-Tron a wide variety of design and SmartConnex and custom- layout options in both ingredi- ized PLC control allow for ent transfer and delivery to help a variety of programming brewery manufacturers to not options including ingredient only lower process costs but control and recipe manage- also to improve efficiency and ment. product quality.

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