BREWERS ASSOCIATION Carbonation Demystified: Carbonation Basics, Natural Carbonation and the CO2 Supply A member outreach initiative of the Brewers Association Technical CommitteeBREWERS ASSOCIATION Power Hours are normally one hour. Last year’s Freshness Power Hour went about an hour and 15 minutes. You are free to log off as needed. Please know the complete presentation with audio and Q&A will be posted in the members only section of BrewersAssociation.org so you can go back to reference any portions you wish at a later time.BREWERS ASSOCIATION I. The Basics of Carbonation - Dave Meheen, President, Meheen Manufacturing Il. Principles of Natural Carbonation Marty Velas, Director of Brewing Operations, Smoky Mountain Breweries Ill. COz Supply Chain and Purity Jim Tomczyk, Purification, Dehydration and Filtration Market Development Manager, Parker - domnick hunterCarbonation: The Basics Dave Meheen 3 yUnderstanding Beer Carbonation + How Carbonation Effects Beer * Presentation + Mouthfeel * Taste/Smell * What are CO2 Volumes > Determining CO2 Volumes | ¢ Effect of Temperature on CO2 § * Carbonating stones é + Types = + Wetting Pressure = ° Operating Carbonating Stones : * Calculating Pressure and Flow Rates AbsorptionBA What Are CO>2 Volumes BREWERS ASSOCIATION * CO is very soluble in beer: o solubility increases with increasing pressure; o solubility decreases with increasing temperature + Inthe US, the amount of CO; in beer is most often referred to in terms of “volumes” (defined as the volume the CO2 gas would occupy at atmospheric pressure and 0’ C if it were removed from the beer) + Most packaged beers are considered normally carbonated with 2.45 to 2.85 volumes of dissolved CO Henry's Law Video: http://www.youtube.com/watch?v=8yU5y-cFX00Zahm Gehaltemeter * CO, volumes in beer are determined by physical laws * The solubility of CO, in beer depends on the temperature and pressure conditions of the beer and gas at equilibrium conditions, meaning the same amount of CO, is diffusing out of the beer as is being dissolved back into solution > It is critical that the readings used for determining CO, volumes are taken under equilibrium conditions, and the instruments used are accurateBA BREWERS ASSOCIATION Carbonation Level Reference Chart -EN MANUFACTURING 1. (S338N. Oregon Ave, Pasco, WA 99301 (G09) 547-7029. Fax (869) 547-0959 Web @ hitp:/www:mcheen-mfg.com Beer carbonation at various temperatures and pressures Pounds per Square Inch mete fs Tis be Dee 19) 197 ‘To use this chart: First find the beer temperature along the left hand vertical edge, Then read the pressure across the top and where the two eross, read the volumes of COp,BREWERS ASSOCIATION By Carbonation Level Reference Chart The values in this table assume sea-level altitude, beer specific gravity of 1.015, and beer alcohol content at 3.8% abw or 4.8% abv. Values shown are in psig, or gauge pressure It’s important to remember that carbonation is proportional to absolute pressure, not gauge pressure. Atmospheric pressure drops as elevation goes up. Therefore, the gauge pressure needed to achieve proper carbonation at elevations above sea level must be increased. Add 1 psi for every 2,000 feet above sea level For example, a retailer at sea level would use 11.3 psi gauge pressure to maintain 2.5 volumes of CO2 in beer served at 38° F. That same retailer would need 13.3 psi gauge pressure at 4,000 feet elevation to maintain 2.5 volumes of CO COz2 Pressure Temperature Volumes Chart, information about carbonation and partial pressures can be found in the Draught Beer Quality Manual: www.DraughtQuality.org, Appendices B&CEffect of Temperature On Carbonation BREWERS ASSOCIATION + For best results when using force carbonation in a tank, the beer should be as cold as possible, ideally 30°-32° F. > CO gas solubility increases as beer liquid temperature decreases > COQz gas solubility decreases as beer liquid temperature increases “* Therefore, the colder the beer, the more readily CO2 is absorbed into solution. This results in quicker carbonation and more efficient use of CO2. + For example, 10 psi CO2: > 330F MM gives ~2.6 volumes CO > 400F — only ~2.3 volumes COzCarbonating Stone Types + Carbonating stones increase the surface area contact with the beer by producing tiny bubbles of CO2 which dissolve more readily in beer than bigger bubbles. + Carbonating stones are generally made of porous stainless steel or ceramic. Both work well for producing curtains of tiny bubbles which are readily absorbed into cold beer.BAY Carbonating Stone Operating Tiny Bubbles Video on YouTube:Carbonating Stone Operating 5 psi Tiny Bubbles Video on YouTube: http://www. youtube.com/watch?v=1zUzOwPLMasBA BREWERS ASSOCIATION Carbonating Stone Wetting Pressure All carbonating stones, regardless of type, have what is known as a “wetting pressure” The wetting pressure is the amount of pressure required for the CO; to pass through the pores of the carbonating stone and begin to make bubbles Wetting pressures are, generally speaking, between 2-8 psi Ceramic stones typically have higher wetting pressures than stainless steel Knowing the pressure required for each stone to begin making bubbles is important as well as the pressure when the bubbles will stop. Not all stones are created equal - “your mileage may vary” Important: excessive pressure often will cause a stone to be ineffective at making small bubbles. More later...Operating Carbonating Stones Critical points for carbonation: Clean carbonating stone making tiny bubbles * Tank not overfilled, with 15-20% head space * Cooling system is up to the task = Cold beer * But, glycol not too cold (28 oF minimum to prevent freezing of beer in tank and uneven carbonation)BA BREWERS ASSOCIATION Operating Carbonating Stones Calibrating your stone: Connect the carbonation stone with its holder to a CO; bottle with good quality regulator and gauge Place the stone in a bucket of water with the stone submerged and in its orientation the same as it will be installed in the tank Slowly increase the pressure until a curtain of fine bubbles forms and record the gauge pressure (psi) Next slowly decrease the pressure until the bubbles stop and record that gauge pressure (psi). These pressures can be used to help with diagnosing carbonation issues. ** If you see any leakage of gas from around the holder, correct the leak and repeat this test. Next with the stone still in the bucket of water, turn the CO) pressure to 30 psi and observe the bubbles. If the bubbles are excessively large or the curtain of tiny bubbles is lost, too much COz is passing through the stone. To correct this, a small adjustable needle valve can be installed in the CO, line prior to the stone. Adjust the needle valve down until you observe a correct curtain of tiny bubbles from the stone.Bi Operating Carbonating Stones BREWERS Assia resect spec stom Effect of Beer Static Pressure: +Every 28” of beer liquid height adds 1 psi of pressure on the stone +In the example to the left the liquid height is 84” above our stone “Therefore, 84+ 28”= 3 psi a4 Regulator So for example, for a stone with 5 psi wetting pressure to carbonate this tank, you would need to add the 3 psi liquid pressure + 5 psi rez wetting pressure. 8 psi is required from the CO; regulator for the stone to start producing bubbles heer es4F Carbonating stqne Assume a target of 2.58 volumes in the beer at 34°F. From the chart the equilibrium pressure in the head space of the tank when carbonation is complete will be 10 psi * Therefore, if all is ideal the CO2 pressure needed at the stone is the wetting pressure (5 psi) + liquid head pressure (3 psi) + the final equilibrium pressure (10 psi) = 18 psiBA BREWERS ASSOCIATION Operating Carbonating Stones It is desirable at the beginning of the carbonating process to use a relatively low differential pressure between the stone and the head space in the tank while bleeding gas from the top of the tank. > This can scrub unwanted dissolved air out of the beer picked up during transfer, filtration or the brewing process o Be especially careful not to over do this: too much CO scrubbed through the beer can cause foaming in the tank and strip away the desirable nose from the beer.BA BREWERS ASSOCIATION Operating Carbonating Stones In an ideal world all of the CO2 from the stone would be absorbed into the beer; but things are rarely ideal, so just because you have 10 psi in the head space, doesn’t necessarily mean you have 2.58 volumes in the beer + Each tank should be tested during carbonation to ensure proper carbonation levels with high quality calibrated gauges on your tester + Beer carbonation using a stone can take a few hours to several days + Best results achieved using a relatively slow step carbonation process which tends to yield smaller bubbles and better head retention than rapid carbonation by agitation. Step carbonation refers to adding gas slowly and ensuring the carbonation stone always makes a curtain of tiny bubbles. So you might start your carbonation process at ¥-1 psi above the total wetting pressure of the stone and leave it at that pressure for a period of time, then increase the pressure in small increments every ¥ hour or so. + Agitation is caused by turning the pressure to the stone on full blast and forcing large amounts of COz through the beer. Agitation allows much of the CO: to bypass being absorbed into the beer and can cause: © foaming inside the tank; o loss of nose; o diminished quality of the finished beer; © difficulty obtaining consistent results regarding desired volumes even with regular testing. + There are commercial solution such as the Meheen Tank Manager which duplicate manual step carbonation, freeing up your time and yielding better consistencyPrinciples of Natural Carbonation Marty VélasNatural Carbonation Two Main Techniques: 1. Spunding 2. KrauseningBREWERS ASSOCIATION Spunding Spunding (German word meaning to stopper) is the process of closing the primary fermentation tank to trap naturally occurring carbon dioxide gas emitted by the yeast at the tail end of fermentation.Spunding ValveSpunding Theory * Close fermenter when 1.0 - 1.5 degree Plato of residual fermentation is anticipated ¢ Allow the internal pressure of the tank to rise to an appropriate pressure based on the temperature of the green beer + Use the CO2 temperature/pressure chart to achieve the desired level of carbonationBREWERS ASSOCIATION Spunding In Practice Most fermenters currently in use are fitted with a pressure relief device to vent any pressure above 1 bar (14.7 psi). So 14.7 psi is the high end limit of the pressure side of the equation Effectively, maintaining the high end of this scale (just below 1 bar) requires that the temperature is the factor to be monitored / manipulatedSpunding Practical Example To achieve a carbonation level of 2.9 volumes, the 14 psi limit pressure would need to be held at a temperature of around 36 degrees F But since the temperature at the time of spunding will be primary fermentation temperature (65-70 F for ales or 45-50 F for lagers, the desired carbonation level of 2.9 will not be achieved immediately Understanding the dynamics of tank shape & gas concentration stratification is helpful BREWERS ASSOCIATIONSpunding Practical Example BREWERS ASSOCIATION * Dissolving gas in liquid is not even or instantaneous, so use stepwise pressure maintenance and temperature drops. As temperature drops are introduced and the maturation points are held, gas is continuously concentrated throughout the body of the tank Subsequently the head pressure will drop due to condensing of the liquid and may need to be bumpedSpunding Practical Example + The end result needs to be derived empirically for different starting temperature/pressure levels and different pneumatic buffer (headspace) BREWERS ASSOCIATION Regardless of starting temperature, the desired carbonation level will be derived during the final cooling phase Once 30-32 degrees F is achieved pre- filtration the pressure should be allowed to settle or adjusted to the corresponding pressure on the chart in slide #7BREWERS ASSOCIATION Spunding Practical Example ¢ Use slightly higher CO2 volumes to compensate for an expected loss of carbonation during filtration and filling of the receiving tank (usually on the order of 0.2 - 0.3 volumes). Achieve by maintaining slightly higher tank pressure. Although more massaging of the process is called for, benefits include: > A finer, more intrinsic conditioning > A smoother texture >A more stable gas/liquid solution > A smaller CO; billKrausening + Another time honored technique which takes advantage of the spunding process + Beer is allowed to attenuate completely (instead of using residual fermentables in primary) * Beer is then injected with a small percentage of actively fermenting wort from a subsequent batch (around 10% the volume of the green beer)Krausening Advantages include: + Enhanced diacetyl reduction due to the introduction of active, healthy yeast * Reduced risk of oxidation upon racking * Results in a more complete attenuation Disadvantages include: * Higher acetaldehyde levels ¢ Must have similar beer at the right stage ready to goCOz2 Supply Chain and Purity Jim TomezykBREWERS ASSOCIATION Beverage CO> Supplies The quality of Carbon Dioxide used in the beverage industry is strictly controlled by both the beverage companies and gas supply companies e e © CO, is a by-product of various processes and is generally of poor quality when un-treated Therefore, a number of purification steps and quality checks are employed on these suppliesBREWERS ASSOCIATION Plant CO2 Supplies Carbon dioxide used in beverage production plants (Beer, sparkling wine, CSD, etc.) is generally supplied as a bulk liquid from a gas supply company The quality of CO2 is controlled and monitored by in-plant analysis or by the requirement of a Certificate of Analysis from the gas supplier | > Always specify “Beverage Grade CO2” from your supplier > Ask for a lot analysis rather than a typical analysis > Make sure your in-house piping or tubing is resistant to COz . You should never see liquid in COz process tubing.CO> Certificate of Analysis A Certificate of Analysis states the results and the acceptance limits of the specific analyses performed on a sample from the liquid carbon dioxide batch before delivery.CO, Impurities & ContaminantsBREWERS ASSOCIATION CO, Impurities & Contaminants Commercial CO2 is produced from a wide variety of sources — petroleum industry, ammonia production, lee Quality can vary by region based on the source industry Impurities may remain in the CO2 due to residual traces carried over from the feedstock, or an inefficient or poorly maintained gas treatment system ** Contaminants may be introduced via the storage and distribution of the liquid CO2 e.g. from tankers, hoses, holding tanks, cylinders etc. > Insist your supplier deliver to you with dedicated beverage industry delivery trucksPotential Impurity Sources 8 ASSOCIATION on Ce Cee eee) a panaais ‘Aldehydes v v v ¥ Benzene v v v v v Carbon Monoxide ¥ v v v v Carbonyl Sulphide v v v v ‘Cyclic Aliphatic Hydrocarbons v v v v ¥ Dimethyl Suiphide v v v Ethanol v v v v v v Ethyl Benzene v v v v Hyrdrogen Sulphide v v v v v v Ketones v v v v v v Mercaptans v v v v v v Nitrogen Oxides v v v v v Sulphur Dioxide v v v v v Toluene v v v v v Volatile Hydrocarbons ¥ v v v v v Xylene v v v v v Source CGA G-6.2 (2000) - Commodity Specification For Carbon DioxideCO2 Quality GuidelinesBeverage Grade CO2 There are a number of Beverage Grade CO2 Quality guidelines that exist: + ISBT CO2 Quality & Analytical Procedure Bibliography 2001 + CGA G-6.2 Commodity Specification for Carbon Dioxide + EIGA Carbon Dioxide Sources, Certification, Quality Standards and Verification ISBT CO2 Purity Guidelines can be found in Appendix A of the BA Draught Beer Quality Manual, and at www.DraughtQuality.orgBA BREWERS ASSOCIATION ISBT Quality Guidelines Potential Contaminant Total Volatile Hydrocarbons (as Methane) Total Aromatic Hydrocarbon fergie Emig ppm (v/v) 50 ppm (v/v) max, of which a maximum of 20 ppm (viv) as total non-methane hydrocarbons 0.02 ppm (v/v) max. ECE Sensory Regulatory /Acetaldehyde Total Sulphur (excluding SO2, as S) 0.2 ppm (viv) max. 0.1 ppm (v/v) max. Sensory Sensory Source: ISBT CO2 Quality Guidelines & Analytical Procedure Bibliography, 2001CO>2 Purification SystemsCOz2 Purification Systems Usually are static adsorption systems for use with beverage grade CO), designed to act as “Quality Incident Protection Devices” Purpose: to ensure that beverage quality is not adversely effected by potential trace impurities that could be present in the gas feed stock Reason: CO, supplies are not uniform. For example, after Hurricane KatrinaWhy does a brewery need a CO2 aia purification system? To the extent CO: is another ingredient in finished beer, a CO; purification system ensures that the CO2 gas used in beer production is free from impurities or contaminants that have a negative impact on the flavor, taste or appearance of the final beverage.BAY Contamination Examples The following pictures show examples of contamination that has been successfully removed by a domnick hunter PCO2 system.COz2 Storage & Evaporation CO, Liquid Storage Tank PCO, Gas Phase Purifier ATynical PCO, InstallationStage 4 Removal of sulphur Compounds ie. COS, H2S Stage 3 Primary removal of hydrocarbons i.e, Benzene Stage 2 Removal of moisture & partial removal of hydrocarbons Bi The Inside Story BREWERS ASSOCIATION Stage 5 0.01 Micron Particle filtration Stage 1 0.01 Micron NVOR filtrationPreferential Adsorption 8 ASSOCIATION Prenrieneninn Me ae i) Pee a end Particles down to 0.01 micron Particulate 8 a a a Moisture Vapour a a a a 8 ens ‘Momat Hycocabon v a v Ethyl Benzene Aromatic Hydrocarbon # @ v Xylene Aromatic Hydrocarbon. v a v {yelohexane Nolte Organic Hydocarbon | v a v ‘caalehyde ‘Volatile Organic Hydocarbon 5 @ ai Propy Aloha \olatle Organic Hydocarbon v a a Dimethyl tee ‘eal gai Hydearbon v a ¥ BK Nolte Organic Hydocarbon v a ¥ Eianol Nolte Organic Hydocarbon tf @ a Wie Oxide Toxie Gas v y y (Nitrogen Dioxide Torie Gas v v v Suiphur Dioxide Torie Gas v v v Garbonyl Sulphide ‘Sulphur Compound a a a Hydrogen Sulphide Sulphur Compound a a a Dimethyl Suphide Sulphur Compound a a 8 Propy Mercaptan ‘Sulphur Compound a a a aQ&A Thank You to Our Presenters: Dave Meheen Marty Velas Jim Tomczyk This presentation, including an audio transcript and complete Q&A, will be available soon in the Power Hour archive of the Members-Only section of BrewersAssociation.Org. Register today!