Brochure describing brewing process and suggested use of instrumentation. Wort and extract measurements. Brew kettle, Lauter tun level.

1. Instrumentation in the brewing industry
Automation of the brewing process

2. The art of Brewing
Brewing beer means to deal with natural Supporting the cleaning process is a
grown products changing from year-to-year, basic requirement to save time and energy.
harvest-to-harvest. The brewer needs to All shown sensors are developed to work
react on these changes to prepare a stable in hygienic processes. They follow the
quality of beer, and even more, it must taste guidelines of FDA, -A and EHEDG.
the same all year, each and every year, to
fulfill the expectation of the customer. To
follow this moving target, a lot of experience
is necessary. It is the art of brewing.
Reliable measurement supplies the necessary
Endress+Hauser is here to help you run data for the ideal process, and supports suitable
your process consistently on a high quality solutions for tracking and tracing the beer.
level every day and night. Throughout this
document you will find how state of the
art sensor technology supports the brewing
process. Rising accuracy of process sensory,
along with high repeatability enables the
user to run a process in the most efficient
manner. Optimized raw material use,
energy conservance and best availability
of the plant is the target of automation.
Instrumentation for:
• Malting
• Malt and grain storage
• Brewhouse
• Fermentation
• Filtration
• Packaging
• CIP and water preparation
• Boiler
• CO and natural gas

3. Malt and grain storage
Reliable and visible inventory status
Silos can be easily mapped for
fast commissioning and reliable
measurement.
Malt/grain inventory silos Energy conservation
Complete inventory management Blocked dust filters can be a
solutions to address rising inventory safety hazard and can also cause
costs are easily realized with complete unnecessary energy consumption.
packages from Endress+Hauser. Pressure transmitters with
freespace (FMR50) or guided wave ceramic membrane provide
radar (FMP0) provide an option reliable and cleanable option to
to select the best-fit to address conventional metal membranes.
measurement challenges due to silo The PMC5 offer cost effective
height, diameter and amount of dust. solution for dust hazardous area.
Continuous level measurement
in malt silos
Levelflex Micropilot Soliphant M Solicap M
FMP0 FMR50 FTM50 FTI55 View of levelflex cable

4. Inventory and supply chain management
Rising commodities drives the need for real-time information
Accounting of bulk inventory kept in tanks and silos has Infrastructure - In Plant Monitoring or Remote Sites
traditionally not had high priority. This is particularly true
for bulk material such as sugar, flour and grains. However, Ethernet/Land line/GSM/GPRS for
connection of remote location
with the rapidly rising value of these commodities it is
becoming more and more important to have a current
Intranet/ERP Integration
status of inventory levels to allow for planning and Data visibility
advanced purchasing techniques. for our CUSTOMER
Endress+Hauser can provide scalable, turnkey solutions
for your plant with simple, local monitoring or full Ethernet
integration into your ERP system. Installation costs can be
kept to a minimum using wireless solutions or Ethernet
connection. Solutions are available for single or multiple
site applications. Installation at our
Customer location
Safety precautions with level alarms
Reliable High/Low level alarms
for silos and hoppers are critical for
any application. Chose between
Capacitance (FTI51) or tuning fork
(FTM50) depending on installation point.
5

5. Brewhouse
Optimizing the yield and quality of extract production
Mash tun level Wort kettle pressure Lauter tun wort
The Mash tun level is Energy conservation is clarity performance
measured with highest achieved by applying A critical control point for
reliability with the pressure to wort kettle. the Lauter tun is the outflow
temperature compensated The Cerabar M pressure turbidity and density.
FMB70 hydrostatic level transmitter is ideal for this Turbidity is monitored by the
sensor. Remote electronics application - simple and optical sensor AF1-ER.
make access easy. reliable pressure control.
Promag H series: great Boiling
value for the money In-line extract measurement
Foundation water for mash with Liquiphant Density
tun need to be metered ensures stable wort quality,
accurately. along with optimized energy
use during wort boiling.

6. Brewhouse
Steam supply Reliable level in silo
Accurate measurement of the Overfilling the spent grain silo
steam supply for the mash tun is a big mess. Avoid this
and wort kettle is used to identify situation with reliable level
fouling and can have a direct impact measurement using free space
on energy cost. Prowirl 7 with radar Micropilot FMR5.
steam computer gives you direct
BTU readings.
Mash and foundation water Energy and extract loss reduction
pH must be monitored closely to To avoid wasting extract, lauter
achieve best yield in mash tun. systems are monitored with
Non-glass IsFet pH (CPS1D/ Promass F. Stopping the flush
CPS71D) sensor and retractable water at the exact right
holders combined with Memosens moment optimizes ingredients
technology brings highest and saves energy during the boil.
reliability and accuracy.
Adjuncts, dextrose Lautertun bed density
and enzymes Differential pressure across the
Adjuncts and dextrose must be lautertun bed is commonly using
added with high accuracy to pressure transmitters with metal
optimize raw material usage. membranes. Due to the abrasive
The Promass 8S provides the nature of the mash and cleaning
best temperature stability and procedure the membranes are
accurate measurement available often damaged. The PMC71
today. Combine this with the ceramic membrane pressure
possibility to ensure performance transmitter provide reliable and
between calibrations using the highly accurate alternative.
FieldCheck verification tool.
7

7. Fermentation
Consistent quality batch-after-batch
Wort aeration Sterile air supply
The goal in fermentation is to produce Sterile air supply to wort aeration is
alcohol. Based on the condition of the best done with a thermal massflow
yeast, oxygen supply level is controlled, meter. The t-mass series is capable of
using COS1D, allowing the yeast to highly accurate measurements with a
populate at an optimal rate. large turndown range.
8

8. Fermentation
Level measurement Temperature measurement
Level measurement of fermentation, Reliable temperature measurement
aging and bright beer tanks are is key throughout the brewing
done using the highly accurate and process and utilities. Highest
temperature compensated FMB70 quality RTDs combined with
hydrostatic level transmitter. fast response tips ensure optimal
Electronic differential pressure temperature control.
compensate for CO head pressure.
Yeast dosing Empty pipe - high/low tank level
The amount of yeast is measured or detection of foam in CO2 line
with a magnetic flowmeter The Liquiphant M is a universal
Promag H combined with switch with no need for calibration or
an optical turbidity sensor adjustment throughout the lifecycle
OUSAF1-ER to monitor the of the instrument. Version is available
cell concentration. tuned to detect foam in CO line.
Extract measurement Level measurement
Extract measurement in the CO storage tank level must be
fermentation vessel with monitored closely to ensure uninterrupted
Liquiphant Density ensure a supply. Levelflex M FMP0 guided wave
stable fermentation process by radar provides a set-and-forget alternative
allowing continuous adjustment, that eliminates the need for periodic
as needed by the actual brew. calibrations. The coaxial probe is ideal.
Rod or cable can be used in combination
with patented “end-of-probe”function.

9. Filtration
Production of a consistent product with minimal beer loss
Degassed water
pH of the degassed water must be
monitored closely. Non glass IsFet
pH (CPS71D) sensor and retractable
holders, combined with Memosens
technology, brings highest reliability
and ensures purity of water.
Conventional glass electrodes are
also available.
Flash pasteurizer
temperature control Dissolved Oxygen measurement
Fast response time is Examples are for trim cooler output,
needed for stable control degasser, packaging release and in
carbonation stage. The COS1D DO
sensor provide reliable measurement
with minimal maintenance.
High gravity blending Filter performance Liquid storage or transfer tank
Minimize beer loss with Differential pressure is a common Point level detection in any liquid
combination of high performance indicator for filter performance. storage or transfer tank is done reliably
metering - Promag 5H on water Conventional DP transmitter FMD78 without the need for any calibration
and Promass 8S for combined flow or electronic DP with PMC5 provide with the tuning fork point level switch
including extract (Plato°) value. needed reliability. Optical sensors can Liquiphant FTL50H.
be used for breakthrough alarm.
10

10. Packaging
Keep consumers happy with clean, crisp product
Boundary or “taxation meter” Product identification Bottle and keg washing
Require documented prior to packaging Sanitizer concentration must
traceable periodic verification Conductivity is monitored be monitored to ensure
of performance. FieldCheck throughput the process. A optimal cleaning efficiency.
verification tool is easily used key measurement is on the Endress+Hauser offers a full line
to ensure performance and generate packaging release tank. of analytical sensors (for example,
documentation that meet 7CFR Conductivity sensor CLS5 is for chlorine dioxide the CCS0
part 5 for the Promag 5 magnetic used to verify that the expected chlorine dioxide sensor works
flowmeter between calibrations. product is in the line. This at low flow rate, require no zero
can be combined with optical color point calibration and is not affected
measurement for added safety. by conductivity fluctuations.
Fillerbowl level Washdown Bright beer tank
To ensure complete fills To ensure sterility and food Highest accuracy is needed
and avoid beer losses the safety during filling the to plan for bottling line
fillerbowl level must be whole area is often washed free space radar FMR5
measured accurately. The down with strong or hydrostatic level sensor
FMI51 capacitance level sensor detergents/sanitizer. FMB70 provide this key
provide best accuracy under All instruments are IP7 information.
the fast moving conditions. or better to ensure life in
washdown environment.
11

11. CIP optimization
Key process for quality, safety and yield
Secure records CIP make-up and chemical
CIP records are kept secure in tank inventory
video graphic recorders capable Level measurement for inventory or
of meeting 1CFRpart 11. process control of aggressive chemicals
is solved by multiple options depending
on tank size and user preference -
capacitance, ultrasonic or freespace
radar are most common.
Beer loss reduction CIP concentration
Fast and effective interface/phase CIP concentration is critical to the food
separation is key for reducing beer safety but also have big impact on use of
and water losses. The AF11 can help detergent and energy cost for heating
you save large amounts from going CIP circuit. The CLD1 conductivity
down the drain. Saving you not only transmitter have the fastest temperature
in product losses but also in water compensation on the market and offer
treatment costs. dual range capability. Ultrafast temperature
compensation ensures best-in-class performance.
1

12. WAGES – Water, Air, Gas Electricity Steam
Make a difference to the
environment and the bottom line
The starting point for any conservation They now, for example, measure and Compressed air – a ¼” leak will cost
program is to know where you stand recover over 0% of all CO and have over $8000 in energy losses. Monitoring
today and then identify potential areas reduced overall water consumption and of pressure or flow using thermal mass
for improvement. For example; do you natural gas usage. flow or Vortex flow meters can help
really need a larger air compressor identify leaks and usage during active
or can you reduce the air usage? By Typical WAGES monitoring in a brewery and idle periods.
applying simple permanent or temporary involve steam measurement to monitor
measurements you can make qualified overall efficiency and to detect problems CO and natural can both be measured
decisions based on facts. with steam traps. Vortex flowmeter with DP flow or Vortex but more and more
combined with steam computer gives you opt for entry level Coriolis flowmeters
Endress+Hauser is in a position to direct energy readout. that provide highest accuracy and direct
help you monitor your resources to reading in massflow without the need for
ensure success of your conservation Water consumption is a big issue in the additional compensation
initiatives. One of our clients in the brewing industry, way too much water
brewing industry, have reduced overall is wasted in inefficient cleaning and Measurement information is collected
energy consumption (WAGES) by over washdown procedures, a simple magnetic and presented in easy to use program
00% since implementing a monitoring flowmeter or a temporary clamp-on for trending and planning purpose.
program in 00. ultrasonic flowmeter will help you keep Immediately see the result of your
track while making improvements. conservation programs and identify
where the next opportunity is.
Setting energy targets
Activity –
1

13. Wastewater treatment
Reduced production losses = reduced cost of wastewater treatment
By implementing in-line quality Step 1 Step 2
control with checks and balances the Identify when and what is coming down pH balance, depending on the size of the
beer losses can be kept at a minimum. the drain. A simple optical sensor CUS1 plant and the local arrangement with your
However, even in the best conditions mounted in the drainpipe can immediately municipal treatment plant you may only
there will be wastewater generated. identify a spill and the amount of solids need to monitor and balance the pH value.
By applying simple measurement and (nutrients). Use this to implement a plan to pH sensors in conventional glass or non-glass
controls the cost of water treatment reduce accidental spills and feed forward combined with the Endress+Hauser patented
can be minimized. control for treatment plant. Memosens technology ensure maximum
reliability and low maintenance.
Step 3 Step 4
The wastewater in a brewery has very high Final effluent, depending on your level
nutrient content (BOD) due to the alcohol, of environmental consciousness and the
yeast and fermentable solids. By monitoring city/state regulations you need to monitor
dissolved oxygen (DO), turbidity and possibly and keep records of outgoing volume and
TOC the treatment process can be optimized. residual nutrients. Electromagnetic or
Example is use of DO in aeration tanks to ultrasonic flowmeters are commonly used
effectively reduce BOD levels while only in combination with pH, DO, Chlorine and
running the blowers at most energy efficient at times a TOC analyzer, all captured in an
levels. Blower air is easily monitored with electronic record such as the videographic
thermal or vortex shedding flowmeters. recorder Memograph M. Records can be
managed in accordance with 1CFR part 11
and is easily shared with authorities.
1

14. Calibration and instrumentation maintenance
Focus on your core competence - outsource the rest to the experts
Predictive maintenance and properly executed calibrations
are becoming more important as tools to maintain beer
quality, reduce downtime and to be in compliance with
consumer driven as well as regulatory demands.
Verification of Taxation meters
Depending on the country and size of annual production
there are requirement to document how much beer is Discussion around the SOPs, calibration certificates,
produced. To ensure accuracy of reported production metrology plan labels and electronic recordings
volume, calibration or verification documentation of the
flowmeter is required. For example, in USA, the Alcohol
Taxation is governed by the US Department of Treasury
Alcohol and Tobacco Tax and Trade Bureau (TTB). The TTB
requirements are defined in 1CFRpart 5.
On-site calibration of Laboratory calibration of
pressure devices level instruments
Endress+Hauser provides the option to do a wet calibration
or a flowmeter verification that meets the TTB document
requirements. Using the FieldCheck verification tool which
is traceable to NIST standards a fast on-site verification is On-site calibration of On-site calibration of
done without removing the meter from service, reducing temperature instruments analysis devices
downtime and labor costs.
Instrumentation today offers a wide range of onboard diagnostics
that can tell you if a device is in need of a check-up. Unfortunately,
many times these functions are not used to their full capability. Let
Endress+Hauser help you reach the full potential.
Calibration or Verification and diagnostics, terms often misunderstood
• Calibration = Comparison of performance parameter against a
traceable reference
• Verification = Test of electronics or sensor with signal simulator.
Simulator should be traceable to recognized standard
• Diagnostics = Onboard or external self check of key performance
parameters and signal values that show health of sensor and
transmitter
On-site calibration of flowmeters
using mobile flow rig
15

15. Endress+Hauser’s product portfolio
Level Pressure Flow
• Capacitance (RF) • Gauge/absolute • Electromagnetic
• Conductive • Differential pressure • Vortex shedding
• Mechanical • Hydrostatic • Coriolis mass flow
• Vibration • Ultrasonic
• Ultrasonic • Open channel
• Radar • D/P flow
• Guided radar (TDR) • Thermal mass flow
• Hydrostatic
Temperature Liquid Analysis Recorders
• Temperature transmitters • Conductivity • Paperless recorders
• RTDs/thermocouples • pH/ORP • Visual data managers
• Sensors • Chlorine • Safety data managers
• Dissolved oxygen • Displays
• Turbidity • Barriers
• Chemical analyzers • Power supplies
• Nitrate/organic sensors
• Sludge level
• Sampling stations
Solutions Service
• Wireless networks • Start-up www.us.endress.com/e-direct
• Inventory control • Training
• Shop on-line for low-cost
• Energy monitoring • Calibration
instruments, devices and
• Tank farm monitoring • Maintenance contracts
components
• Life cycle management • Installed base audit
• Plant asset management
• Flow management solutions
• Wastewater treatment optimization
ISO 001:000 Certified
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