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Brewery process modules

An introduction
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Introduction
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Brewery process modules

This booklet gives an overview of the Alfa Laval process
module concept and its application areas. The intention
is to provide basic information about the products and their
benefits as well as a brief explanation in respect to working
principles and performance.
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Index Brewery process modules

7 What is beer?

9 What is a process module?

11 What are the application areas?

15 What are the benefits for the customer?

17 What is our product portfolio?

47 What is relevant to know for an evaluation?

APPENDIX
What is High Gravity Brewing?

Lexicon of Brewery Nomenclature

65 How to contact Alfa Laval?

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What is beer?
Brewing beer is a delicate process which has
been developed step-by-step, from the
homemade beer thousands of years B.C. into
the modern large scale industrial production
plants of today. When the scale of the
production increases, so does the need
for effective operation. Optimization and
automation of the processes have become
more and more important.
Although modern technology has influenced
the brewing process, the basic principle
remains the same. The raw materials, now as
a thousand years ago, are nature’s own:
barley and other grains, water, hops and
yeast.
The industrial beer production process is
described in detail in the literature. This short
description of the basic industrial brewing
process covers the four major steps.
1. Malt production
First the barley is cleaned and soaked
(steeped) for a few days. Afterwards, the
barley germinates in vats for 6-8 days to make
so-called green malt. The next step is the
drying of malt by means of hot air (kilning).
Through this process, the malt acquires the
aroma and colour that determine the character
of the brew. The malt is then chilled, the
rootlets are removed and the malt is ready for
brewing.
2. Wort production
In the brewhouse, the malt is crushed and
mixed with water to make a mash, which is
heated in the mash tun. In this process, the
starch in the malt is converted to sugar by
enzymes, formed during malting. After this,
mash is filtered (lautering) and the liquid,
known as sweet wort, is boiled with hops
in wort boilers. Boiling extracts the bitter
substances in the hops, this contributes to the
characteristic flavour of the beer. After boiling,
the hops and other solids are separated in a
whirlpool or a separator and the wort is cooled.
3. Beer production
The next step in the process is fermentation.
Yeast is added to the wort on its way to the
fermentation vessels, where the malt sugar is
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converted to alcohol and carbon dioxide. 7
When the process is finished, after 6-8 days,
the yeast accumulates at the top/bottom of
the vessels and is removed. The fermented
green beer is then conditioned (lagered) in
tanks for 1-3 weeks depending on the beer
type. The lagering develops flavour, aroma
and other properties of the beer.
4. Beer stabilization and filling
After lagering, the last impurities and yeast
residues are removed, usually by filtration.
The beer is sometimes polished in separators
before going through the final filter resulting in
longer filter runs.
The filtered beer may vary in strength and
carbon dioxide content. These properties are
adjusted to obtain a consistent quality. The
beer is further stabilized to increase its shelf
life by removal or destruction of beer spoiling
micro-organisms. This can be done by sterile
filtration but more commonly the beer is
pasteurized, either before or after bottling or
canning.
Brewery process modules - An introduction 7
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Condensate
cooler
Water Wort cooling CIP station
Hot water or Hot wort clarification
Condensate energy storage tank Chilled
Two stage water tank
Vapour wort cooler
condenser Wort CIP R
Hot Water/CIP filtration
CIP PR
Brewwater CIP R Water Water
Brewwater Coolant Cold
Brewhouse
Hot wort CIP PR
Hop separator Coolant
Water filtration Water

Hot water
Malt Steam Condensate
Single stage
wort cooler
Whirlpool
Steam injector/
Water External vapour compressor
boiler
Wort Wort
preheater boiler
Condensate Water Steam Decanter
heater centrifuge
Water deaeration
Condensate
Decanter Condensate Steam ALDOX
centrifuge
Water

Trub

Spent grains for

bio-energy or animal food

Buffer tank
Air/oxygen Wort aeration CO2
& Yeast pitching Fermentation & Maturation CO2/air
Deaerated
Condensate

Beer recovery Yeast propagation water

Steam
from surplus yeast Oxygen/air
Coolant
Separation by
centrifuge, decanter or
membrane solution
DYNAPITCH Central sampling
AEROPITCH
AEROSET

Wort Chasing water Chasing water

Yeast Water

CIP R
CIP

Surplus yeast Yeast storage Utility heat transfer

Green beer treatment
Coolant
Yeast
Yeast thermolyzing Yeast cooling screening
Waste
yeast
Condensate Steam Refrigerant
Coolant

Coolant

Green beer
Spent yeast dewatering separation
water CIP R
Foodec decanter centrifuge Green beer
(spent yeast decanter) cooling Beer pasteurization
FLEXITHERM

Handling of waste Centrate to

yeast solids wastewater
Condensate Steam

Blending & Carbonation

Brightbeer cellar
Filtered beer tank
Beer filtration CARBOBLEND
ALEX Central sampling
CARBOSET
ALFADOSE Packaging

Coolant
Unfiltered beer
buffer tank CO2/air
Chasing water

Beer
Water
Packaging
Coolant

CIP
Non-alcoholic beer Low-alcohol beer
Beer cooling Alcoholic
AlfaBright condensate
Beer cross-flow CO2
filtration

Beer sterile filtration

Beer
pre-clarification

Permeate

Kieselguhr dewatering
Food grade steam
Foodec decanter centrifuge
(Kieselguhr dewatering)
Spinning Cone Column Membrane solution
Kieselguhr slurry

Dry KG Wastewater

Important applications covered by this booklet are indicated in blue colour on the flowchart

8 Brewery process modules - An introduction

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What is a process module?

Alfa Laval has identified certain parts within

the brewing process that constitute
independent functions i.e. process steps 9
where a certain treatment of the product takes
place with only limited influence to / from
what happens before and after. Alfa Laval has
called each of these independent functions a
“process module” (please see blue marked
areas in the flow chart on page 8) and this
designation has also been given to the
Process Module
equipment that performs the treatment.

In order to be able to deliver a process

system with a certain guaranteed
performance, it has been found beneficial to
build up and test the pre-assembled unit in
the workshop before delivery to the customer.

An Alfa Laval brewery process module

is therefore to be understood as a
frame mounted, pre-assembled and
pre-tested process system, with its
own automation, which performs a
certain function.

Brewery process modules - An introduction 9

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What are the application areas?
Alfa Laval has identified a number of process
areas suitable for use of the “modular con-
cept”. Please find below a short general
description of each of these areas and the
main process parameters involved. The
description follows the path of the beer
through the brewery.
Wort cooling
After boiling and the removal of solids, the
wort is cooled from 98-95°C to a yeast
pitching and fermentation temperature
between 7 and 14°C depending on the type
of beer. It is important that the cooling is quick
in order to avoid growth of beer spoiling micro-
organisms. Normally, it is done by plate heat
exchangers whereby the heat energy in the
wort, to a great extent, is recovered by heating
up the incoming cold process water. This
water can be utilized for other purposes within
the brewery. (See Wort cooler, page 18).
Wort aeration
Oxygen is added to the wort after the cool-
ing to provide suitable conditions for a fast
growth of the amount of yeast cells in the
tank – which in return is needed for a quick
start of the fermentation process.
Traditionally, the aeration is done by
injecting sterile air into the wort and mixing it
using turbulence - this to reach dissolved
oxygen (D.O.) levels of 8-9 ppm (mg/l).
The amount of air has by “rule of thumb”
been set at minimum 3 litres of air per
hl of wort.
Later on, an increased focus has been set
on the dosing. Insufficient aeration will have
negative influence causing reduced yeast
reproduction, slow fermentation, reduced
nitrogen absorption etc. Surplus aeration will
give an increase in fatty acids and sterols,
less enzymes available for the formation of
esters, formation of acetaldehyde etc. It is
consequently important to efficiently dissolve
the correct amount of oxygen for obtaining
optimal fermentation conditions – no surplus
and no deficiency.
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For breweries using the high gravity brewing
process, dissolved oxygen levels up to 16-20
ppm are sometimes required. If sterile air is
11
used for the aeration to D.O. levels higher
than 12-14 ppm, there is a risk of gas
breakout with related foaming problem in
the receiving fermentation tank. In that case,
the brewer sometimes uses pure oxygen
or a gas mixture containing higher oxygen
content than air. (See AEROSET™,
AEROPITCH™, page 20, 24).
Yeast pitching
(Please see Brewing yeast - A guide to
SCANDI BREW®)
Re-used or newly propagated yeast is
uniformly added to the cold wort immedi-
ately after the aeration. The yeast cell
concentration after pitching should be
10-20 million yeast cells per hl of wort.
A “rule of thumb” says that pitching to
reach 20 million cells / ml roughly
corresponds to adding 0.6-0.7 l of thick
slurry per hl wort.
Brewery process modules - An introduction 11

It is, however, important to pitch the same
quantities of yeast in each pitching operation
in order to get a consistent quality of the
beer. Variations will cause varying fermenta-
tion times and inconsistent flavours.
After pitching, the yeast cells immediately
start to multiply by absorbing the earlier
added oxygen, which is dissolved in the
wort. (See DYNAPITCH™, AEROPITCH™
page 22, 24).
Green beer cooling
When the fermentation has reached the final
level of attenuation, the yeast settles to the
bottom or rises to the top of the fermentation
tank, depending on the yeast type. The
major part of the yeast is here removed.
Some of it is taken to yeast storage for later
re-use (please see Brewing yeast - A guide
to SCANDI BREW®) and some is being dis-
posed of. Subsequent maturation of the beer
takes place in the same tank or in a special
maturation tank.
In this context, the young beer or “green
beer” is often passed through a PHE for
efficient cooling from the fermentation tem-
perature of 10-15°C down to a maturation
temperature of –1 to +1°C. Alternatively, the
beer is cooled during a longer period of time
by use of the cooling jackets on the tank.
(See Beer cooler, page 26).
12 Brewery process modules - An introduction
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Final beer cooling
When the maturation is finalized, the beer is
filtered to remove remaining yeast and floccu-
lated proteins. Before entering the filter, the
beer is often deep-cooled in a plate heat
exchanger to temperatures –2 to –3°C in order
to increase the precipitation of proteins which
then subsequently can be removed by filtration.
(See Beer cooler, page 26).
Water deaeration
Oxygen is the worst enemy for the beer
quality. Normal process water contains a
large amount of oxygen so therefore brewers
use water where the oxygen has been partly
or completely removed from, for flushing of
lines, beer blending etc. The requirement of
today is that the D.O. level of the deaerated
water should be below 0.02 ppm.
Sometimes even stricter requirements are
applied. (See ALDOX™, ALDOX™ HGB,
page 28, 38).
Beer blending
It has become quite common that the brew-
eries produce a number of basic beer types
that are blended and where additives have
been dosed in order to make the products.
This blending has to be done in a very
delicate way with controlled proportions in
order to obtain a final beer with consistent
quality.

The High Gravity Brewing process is
explained in a separate section. Normally, the
HG beer produced has an extract value of
13-15°Plato but also higher values have been
measured.This means that the beer has to
be blended with deaerated water very accu-
rately to reach its final quality.
(See ALEX™, CARBOBLEND™,
ALDOX™ HGB page 30, 36, 38).
Beer carbonation
The amount of carbon dioxide, which is dis-
solved in the beer, will have a big influence on
the taste of the beer. Normal values for a
lager beer are in the area of 5-6 g/l of CO2
but values will vary significantly from the type
of beer. In order to secure a product with
consistent quality, it is necessary to measure
the CO2 value and if required, add more gas.
(See CARBOSET™, CARBOBLEND™,
ALDOX™ HGB, page 34, 36, 38).
Beer pasteurization
In order to obtain a reasonably long shelf life
for the final product, it is necessary to
remove or reduce the number of live bacte-
ria, yeast and mould cells that are left in the
beer at the end of the fermentation process.
This can be done by cold sterile filtration,
by plate pasteurization in a heat exchanger
or by pasteurization of the filled bottles in
a tunnel pasteurizer. (See FLEXITHERM™,
page 40).
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Cleaning-in-place (CIP)
It is necessary to clean the processing
equipment at regular intervals in order
to prevent infections affecting the
beer quality.
Nowadays, hot or cold cleaning agents are
circulated through the system whereby the
equipment is cleaned by a combination of
chemical and mechanical action created by
turbulence or spraying. Special plants, CIP
stations, are installed to store, heat and
distribute the cleaning solutions within the
brewery. In most cases, the brewhouse, fer-
mentation area and final beer handling are
cleaned from different CIP stations in order
to separate heavier soiled areas from clean
beer areas. (See CIP Station, page 44).
Brewery process modules - An introduction 13
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14 Brewery process modules - An introduction

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What are the benefits for the customer?

Brewers are often reluctant to allow welding and other installation work within the process area.
A pre-assembled and pre-tested plug-in process module provides many benefits such as:

• Small intervention into existing • An automation system with user

15
system giving shortest possible friendly well-structured operator
production stop interface

• Reduced space requirements • Short commissioning time

• Quick and easy installation giving low • Well-structured and complete

installation costs documentation

• Well-proven and reliable function based • Minimal and easy maintenance

on well-known standard components

All in all – a very favourable “total cost of ownership”!

Brewery process modules - An introduction 15

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16 Brewery process modules - An introduction

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What is our product portfolio?

Alfa Laval has developed a wide range of process modules –
designed to solve the tasks presented in the previous section
in an optimal way. Some of the modules are sold with brand
17
names while others are given a designation based on their
function. Each module is supplied with its own controls with
ability to communicate with other systems.

The product portfolio includes the following process modules.

Brewery process modules - An introduction 17

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WORT COOLER

TICS

PI TI TI PI TT

HOT WORT COLD WORT

TI PI
CHILLED
BREW WATER

TI PI
HOT
BREW WATER

One-stage wort cooler

TIC TICS

TT PI TI TI PI TT

HOT WORT COLD WORT

TIC

TT PI TI TI PI
HOT COOLING
BREW WATER MEDIUM
PI TI TI PI
COLD COOLING
BREW WATER MEDIUM

Two-stage wort cooler

18 Brewery process modules - An introduction

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Application Main technical data

Cooling of hot wort after clarification in a Capacity range: 30-1000 hl/h
separator or whirlpool.
Main benefits
Working principle • FrontLine™ or M-series plate heat
Cooling is done in counter-current flow with exchanger with clip-on gaskets.
brew water and cooling media in a sanitary • Components chosen , based on long term
plate heat exchanger. experience, provide reliable operation with a
minimum of maintenance.
Alternative configurations
• One-stage wort cooling by means of
chilled brew water.
Typical cooling program:
Wort 98°C to 8°C
Brew water 2°C to 80-85°C
• Two-stage wort cooling by means of
brew water and glycol.
Typical cooling program:
Section 1 Wort 98°C to 25-30°C
Brew water 20°C to 80-85°C
Section 2 Wort 25-30°C to 8°C
Glycol -4°C

Brewery process modules - An introduction 19

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AEROSET ™

PI FT

O2

PC

STEAM PI
WORT

FT TI PI CIP
WORT

CIP

AEROSET™ system for fully automatic and continuous aeration

20 Brewery process
Process modules
Modules - An introduction
Introduction
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Application Main technical data

Continuous and accurate aeration / oxygena- Capacity range: 50-1200 hl/h
tion of cold wort.
Main benefits
Working principle • Continuous and exact aeration achieved –
Air, oxygen gas mixture or pure oxygen is no surplus, no deficiency
injected directly into the wort via a specially • Mass flow measurement gives reliable
designed mixer/accelerator, which makes operation – no need for in-line oxygen
sure that the gas is efficiently dissolved. The analyser
required oxygen level is set at the control
panel and flow meters. A control valve makes
sure that the exact amount of oxygen is
dosed at all times. The module includes
arrangement for sterilization of the injected
air and a holding cell combined with back-
pressure valve to secure that all gas is
completely dissolved when the wort leaves
the module.

A typical application could be dissolving air to

exactly 10 ppm into incoming wort at a tem-
perature of 8°C and a pressure of 4 bar (g).

Brewery process modules - An introduction 21

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DYNAPITCH™

FT

AERATED WORT
WORT

CIP R
CIP PI

YCT CIP R

FT

YEAST

CIP

DYNAPITCH™ system with live yeast cell analyzer Two line pitching system

22 Brewery Process
process modules
Modules - An introduction
Introduction
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Application Main technical data

Continuous and accurate pitching of yeast Capacity range: 200-1200 hl/h
into cold wort. Pitching rates: 8 to 30 x 106 Cells/ml

Working principle Main benefits

Yeast is pitched according to readings from
wort, yeast flow meters and data input
regarding pitching rate, cell concentration in
yeast slurry and the amount of wort to be
pitched. The DYNAPITCH™ can be fitted
with a viable yeast cell analyzer to secure
that the exact amount of live yeast cells is
dosed. Alternatively, the pitching can be
controlled by a cell count system based
on turbidity.
Continuous, reliable and exact yeast pitching
gives optimum conditions for the fermentation
and minimizes surplus yeast handling.
General comment
Alfa Laval is unique in offering a unit with the
viable yeast cell analyzer.

The operation can be set for “batch pitching”

whereby a batch of yeast is pitched during a
defined period of time. It can also be set for
“continuous pitching” where the yeast is
pitched continuously during the complete
wort run.

A typical application could be pitching yeast

to obtain a cell count of 20 x 106 cells per ml
wort.

Brewery
Brewery process
Process modules
Modules -- An
An introduction
Introduction 23
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AEROPITCH™

FC

PI FT

AIR/OXYGEN PI

STEAM

PC

TI PI FT PI PT

WORT WORT

CIP R
CIP
YCT
CIP R
FT

PI

YEAST

CIP

AEROPITCH™ system for fully automatic continuous aeration and yeast pitching

24 Brewery Process
process modules
Modules - An introduction
Introduction
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Application Main technical data

Continuous and accurate aeration / oxyge- Capacity range: 50-1200 hl/h
nation and pitching of yeast into cold wort. Pitching rates: 8 to 30 x 106 Cells/ml

Working principle Main benefits

This module is a combination of the Continuous, reliable and exact wort aeration
AEROSET™ and the DYNAPITCH™. The / yeast pitching gives optimized and repeat-
working principle and features have been able fermentation conditions.
presented for each of these systems.

A typical application could be dissolving air

to exactly 10 ppm into incoming wort at a
temperature of 8°C and pressure of 4 bar (g).
The yeast slurry is then pitched to obtain a
cell count of 20 x 106 cells per ml wort.

Brewery process modules - An introduction 25

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GREEN BEER / FINAL BEER COOLER

TI PI TI PI FS TT TICS

BEER CHILLED BEER

TI PI
COOLING
MEDIUM

TI PI
COOLING
MEDIUM

Beer cooling module with coolant circulation pump

26 Brewery process modules - An introduction

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Application Main technical data

Cooling of green beer during transfer from Capacity range: 30-1000 hl/h
fermentation to maturation and during chilling
of final beer before filtration. Main benefits
• FrontLine™ M-series plate heat exchanger
Working principle with clip-on gaskets.
Cooling is usually done in counter-current. • Components chosen based on long term
In case of low outlet temperature of the beer, experience provide reliable operation with
the module is equipped with a coolant circula- a minimum of maintenance.
tion pump to secure minimum temperature
difference between beer and coolant. A flow
switch is also included to further eliminate
any risk of freezing in the PHE.

• Green beer cooling

Typical cooling program:
Beer 15°C to 4°C
Coolant - 4°C

• Final beer chilling

Typical cooling program:
Beer 4°C to - 2°C
Coolant - 4°C

Brewery process modules - An introduction 27

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ALDOX™

OPEN
CIP
VENT
FC

LSL FT
WATER

COOLANT
TE TI

TC

TC

COOLANT PI

STEAM
LSH

CONDENSATE

CIP R LT

LC

TE TI

DEAERATED
WATER

PI PI
FIA FIA

CO CO
2 2

Full ALDOX™ system with balance tank, water pasteurization, cooling and additional carbonation

28 Brewery process modules - An introduction


Application
Production of deaerated and carbonated
high-quality water.
Working principle
Oxygen is removed in the stripping column.
The effective removal of oxygen is achieved by
subjecting the water to a pure carbon dioxide
environment over a packed bed operating at
atmospheric pressure. The internal packing
material ensures a large effective contact area
between liquid and gas. At the column outlet,
the virtually oxygen free water is saturated
with carbon dioxide.
The module can be fitted with additional
water treatment such as pasteurization, cooling,
additional carbonation, UV-sterilization etc.
as well as analyzers for oxygen and carbon
dioxide.
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Main technical data
Capacity range:
10-1000 hl/h
Dissolved oxygen levels:
< 0.02 ppm (can achieve < 0.01 ppm)
CO2 gas losses:
< 5%
Main benefits
• Achieves extremely low dissolved oxygen
levels – excellent for HGB
• Very low gas losses – more than 95% of the
carbon dioxide dissolved in the water
• Low energy consumption – frequency
controlled pump(s)
• No pressure vessel certification required
• Stable and reliable operation – no vacuum
pumps and no blocked membranes to
consider
• References – around 500 successful
installations throughout the world.
General note
The ALDOX™ is without question the market
leader within water deaeration systems.
Brewery process modules - An introduction 29
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ALEX™

QC

QT

CIP CIP R

FT
H.G. BLENDED
BEER BEER

FC

CIP

FT
DEAERATED
WATER

ALEX™ system fitted with Original Gravity (OG) and alcohol analyzer

30 Brewery process modules - An introduction


Application
Accurate blending of two or more liquids such
as different beer types, high gravity beer with
deaerated water, reconstitution of low alcohol
beer, etc.
Working principle
Blending is carried out by continuously con-
trolling the flows of the constituent liquids,
e.g. beer and water. Readings from flow
transmitters are used to regulate the opening
of control valves so that the required blending
ratio is obtained.
The module can be fitted with analyzers for
original gravity and alcohol to control valve
settings. It can also be provided with the
possibility for coarse ratio blending before
beer filtration and final correction blending
after filtration.
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31
Main technical data
Capacity range: 50-1000 hl/h
Blending ratio: 5-50%
Main benefits
• Efficient mixing by a specially designed
mixer/accelerator
• Excellent blending accuracy whether blend-
ing based on ratio or analyzer readings
• Virtually maintenance free
General comment
Fairly expensive as stand-alone system.
Preferably sold together with ALDOX™
as part of a high gravity brewing line.
Brewery process modules - An introduction 31
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ALFADOSE™

ALFADOSE™

32 Brewery process modules - An introduction

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Application Basic Unit

Controlled and exact dosing of large or small
volume components directly into a main prod-
uct stream. Within the brewing and beverage
industry, it is used for in-line blending, mixing
or quality adjustment to obtain the accurate
final product in one step.
The unit is self-contained and factory pre-
assembled on a frame. In compliance with
food industry regulations, all components in
contact with the process liquids are made of
stainless steel with heat resistant seals. It is
designed for CIP.

Working principle Main technical data

Dosing and mixing are carried out by continu-
ously controlling the ratio of flows of the con-
stituent components by using high precision
volume or mass flow meters. The dosing of
ingredients is pre-selected on the control
panel in the form of a recipe. The plant
automation, controlling the operation, receives
continuous data from the flow meters in the
dosing lines and regulates the speed of the
dosing pumps and/or regulating valves so the
preset dosing ratios are accurately main-
tained.
Capacity ranges, final product, hl/h: 50-220
Dosing ratios: 1-30%
Main benefits
In combination with ALEX™ or
CARBOBLEND™, blending and carbonation,
it provides a system for creating new beers
by a combination of two or more basic beer
types and additives in the form of colour,
flavours, extracts etc.

Brewery
Brewery Process
process modules
Modules--An
Anintroduction
Introduction 33
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CARBOSET™

QC

QT

CIP CIP R
PC

PI TI PI
CARBONATED
BEER
BEER

FI

CIP
PI

CO 2

CARBOSET™ system with integrated CO2 analyzer for fully automatic and continuous carbonation

34 Brewery process modules - An introduction


Application
Continuous and accurate carbonation of the
final beer before filling.
Working principle
Carbon dioxide is injected directly into the
beer via a specially designed mixer/accel-
erator, which makes sure that the gas is
efficiently dissolved. The required carbona-
tion level is set at the control panel and flow
meters and a control valve makes sure that
the exact amount of gas is dosed at all
times. The module includes a holding cell
combined with a back-pressure valve to
secure that all gas is completely dissolved
when the beer leaves the module.
A typical application could be carbonation
to exactly 6.0 g/l CO2ppm of incoming beer
at a temperature of 2°C and a pressure of
4 bar (g).
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35
Main technical data
Capacity range: 50-1000 hl/h
Carbonation level: up to 7 g/l
Main benefits
• A specially designed mixer/accelerator gives
quick and efficient dissolving of carbon
dioxide
• A vertical holding cell eliminates the risk of
gas bubble formations
• Very accurate carbonation achieved
• Very reliable operation
• Low and easy maintenance
General note
The system is not the cheapest on the market
but customer satisfaction often results in
repeat orders.
Brewery process modules - An introduction 35
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CARBOBLEND™

QC

QT

CIP CIP R
PC

FT PI TI PI
H.G. CARBONATED
BEER BEER

CIP FI

FC

FT
DEAERATED
WATER

CIP
PI

CO 2

CARBOBLEND™ system for fully automatic and continuous blending and carbonation of the beer

36 Brewery process modules - An introduction


Application
Continuous and accurate blending and
carbonation of beer.
Working principle
This module is a combination of the ALEX™
and the CARBOSET™. The working principle
and features have been presented for each of
these systems.
A typical application could be blending and
carbonation of high gravity beer coming in at
12°P, 2°C, 3.5 g/l CO2 and a pressure of 4
bar (g) with deaereted water and carbon
dioxide to achieve a final OG value of 10.5°P
and a carbonation level of 5.5 g/l CO2.
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37
Main technical data
Capacity range: 50-800 hl/h
Blending ratio: 5-50%
Carbonation level: up to 7 g/l CO2
Main benefits
• Excellent blending and carbonation accu-
racy whether blending based on ratio or
analyzer readings
• A specially designed mixer/accelerator
gives efficient mixing combined with quick
and efficient dissolving of carbon dioxide
• A vertical holding cell eliminates the risk of
gas bubble formations
• Very reliable operation
• Low and easy maintenance
• References – more than 100 successful
installations around the world
General comment
Is often sold together with ALDOX™ to form
a complete Alfa Laval HGB line.
Brewery process modules - An introduction 37
 Return to Menu

ALDOX™HGB

CIP PR OPEN
VENT
WATER FC
FT TT TI

CIP R
SURPLUS
DAW

PI
BLENDED
BEER LSH

HANDHELD
CO2 ANALYSER LT

UV SC
PI TI FT FT PI
H.G.
BEER

CIP
PI FC
FT FIA PI
FIA
CO 2 CO 2

ALDOX™ HGB system without balance tank but with UV-sterilizer

38 Brewery process modules - An introduction


Application
Production of deaerated high-quality water.
All or part of the water is used for controlled
blending into high gravity beer, with subse-
quent carbonation.
Working principle
The ALDOX™ water deaeration as well as
the ALEX™ blending and CARBOSET™
carbonation systems are described above.
The ALDOX™ HGB is a combination of
these – providing all three functions within
one compact module.
The system has the benefit that the buffer
tank for deaerated water can be eliminated in
case deaerated water is used only for the
blending operation. Blending water is drawn
directly from the ALDOX™ set into recircula-
tion mode whereby the pressure to the
blending point is secured by a constant
pressure modulating valve.
The module can be fitted with additional
water treatment such as pasteurization, cool-
ing, additional carbonation, UV-sterilization,
etc. as well as in-line analyzers for oxygen,
carbon dioxide, original gravity and alcohol.
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39
Main technical data
Capacity range: 30/100 to 120/220 hl/h
(deaeration/blending capacities)
Dissolved oxygen levels: < 0.02 ppm
(can achieve < 0.01 ppm) in deaerated water
CO2 gas losses: < 5%
Main benefits
• Three functions in one compact module
• Achieves extremely low dissolved oxygen
levels – excellent for HGB
• Very low gas losses – more than 95% of
the carbon dioxide dissolves in the water
• Low energy consumption – frequency con-
trolled pump(s) • References – more than 350 successful
• Possibility to eliminate deaerated water ALDOX™ and more than 100
buffer tank CARBOBLEND™ form base for the
• Stable and reliable operation – no vacuum HGB module design
pumps and no blocked membranes to
consider. Excellent blending and carbona- General comment
tion accuracy whether blending based on This combined module is mainly intended as
ratio or analyzer readings an economic alternative for small or medium
• A specially designed mixer/accelerator sized breweries where the main use of
gives efficient mixing combined with quick deaerated water is for HGB blending.
and efficient dissolving of carbon dioxide
Brewery process modules - An introduction 39
 Return to Menu

FLEXITHERM™

PIC PS

PI TI PI
PT

PAST. BEER

FT FC

CIP R TI

TIC TE

TI

TI

COOLANT

COOLANT

FLUSH WATER TIC

PI TI TE

BEER

CIP STEAM

Full FLEXITHERM™ system, in this case with product booster pump, coolant circulation loop and automatic valves for heating, cooling and product flow

40 Brewery process modules - An introduction

 Return to Menu

Application Main technical data

Plate pasteurization of beer with accurate Capacity range: 10-600 hl/h
control of pasteurization parameters to ensure Pasteurization effect: 10-150 PU
uniform and consistent product treatment. Heat recovery: 90-95%

Working principle Main benefits

In the plate heat exchanger, the incoming • Continuous and exact pasteurization of
unpasteurized beer is heated to pasteuriza- the beer achieved independent of varying
tion temperature in two steps. First regenera- production conditions.
tive heating by outgoing pasteurized beer for • Adapts to filler demand while securing
heat recovery. Then circulating hot water, a guaranteed pasteurization effect –
which in its turn is heated by steam in a no under- and no over- pasteurization.
brazed PHE, does the final heating. The • FrontLine™ plate heat exchanger with
required gentle heat treatment is achieved by clip-on gaskets.
a combination of temperature and holding • More than 150 successful installations
time. worldwide.
The flow of the FLEXITHERM™ can be
adjusted in order to cater for variation in
filling machine demand. Recirculation of the
product can be avoided by utilising a pas-
teurized beer tank. If the filling capacity
decreases, the level in the tank will increase
and the FLEXITHERM™ flow rate will be
reduced accordingly (F-version only).
Pasteurization temperature will then be
decreased to compensate for the increased
holding time.

Brewery process modules - An introduction 41

 Return to Menu

Buffer Tank and Routing System

LS

VENT
BUFFER TANK
LS

PI

CO 2
LS

PRODUCT OUT
PRODUCT IN

CIP R
CIP R

Valve arrangement for buffer tank with CIP return pump

42 Brewery process modules - An introduction

 Return to Menu

Application Main technical data

Tank and valve arrangement to cater for Capacity range: 10-1000 hl/h
efficient buffering and distribution of products
such as deaerated water or pasteurized beer. Main benefits
It is only sold in combination with other • When sold together with other process
process modules. modules, the tank functions are integrated
into the control system for the main
Working principle module.
The system includes a valve arrangement for • Components chosen based on long term
products to and from the buffer tank, a gas experience provide reliable operation with
pressure regulation system to control the tank a minimum of maintenance.
top pressure and a product distribution pump
to deliver products to filler or other users. In
case the tank is designed for high pressure,
the distribution pump is replaced by a CIP
return pump to secure proper cleaning /
sterilization of the tank.

Further included are normally level switches

for the tank and a multiple unit or tank top-
plate with safety valve, anti-vacuum valve
and CIP-lance to be placed on top of the
tank. The tank itself is sometimes provided
by the customer.

Brewery process modules - An introduction 43

 Return to Menu

CIP Station

FLUSH WATER LYE

Two/three-tank CIP station for hot cleaning with concentrate dosing

44 Brewery process modules - An introduction


Application
System for providing cleaning solutions for
reliable and optimized sanitation of process
piping, tanks and other equipment.
Working principle
All parameters that affect the cleaning, such
as temperature, concentration of detergents
and time, are automatically controlled –
individually set for each cleaned object. A
CIP stand-by programme monitors the filling
of the CIP tanks, heating up of the tank
content and dosing detergent concentrate
to obtain the right concentration before
starting a cleaning cycle.
The system includes valve arrangement for
CIP supply from tanks, a plate heat
exchanger for heating of the CIP solutions,
valve arrangement for returning solutions to
detergent tanks for re-use. Further included
is a system for automatic dosing of concen-
trated detergents so that the plant is ready
for operation at all times.
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Main technical data
Capacity range: 10-600 hl/h
Main benefits
• Fully automated – consistent cleaning,
low running cost, low energy and chemical
consumption.
• Flow or pressure control – correct individual
capacity for each object and minimized
energy consumption for CIP pump.
• Volume control – no mixing of liquids, accu-
rate sorting and low environmental load.
• Locally supplied tanks – low investment or
second-hand tanks.
Brewery process modules - An introduction 45
 Return to Menu

Based on the above presentation of different

application areas and product descriptions, it
should be possible to identify brewery process
parts suitable for utilization of a pre-assembled
and pre-tested process module. In order for
Alfa Laval to review the possibilities in further
detail and to issue a quotation, certain process
data – such as the ones mentioned here – will
be required.

46 Brewery process modules - An introduction

 Return to Menu

What is relevant to know for an evaluation?

Application: Process information

Main product, incoming: Capacity (hl/h); Content (OG, Alcohol etc.); Pressure (kPa);
Temperature (ºC), Dissolved gases (g/l)

Added product(s): Content (Bx, cell count etc.); Capacity (hl/h); Pressure (kPa);
Temperature (ºC)
47
Product treatment: Pasteurization, Cooling, UV-sterilization etc.

Product, out: Capacity (hl/h); Content (OG, alcohol, cell count etc.); Pressure (kPa);
Temperature (ºC), Dissolved gases (g/l, ppm)

Service media: Power (VAC, Hz), Steam pressure (kPa), Coolant (type,
Temperature (°C), Pressure (kPa)), Gases (purity %)

Automation: Automation level, PLC type, Analyser(s), Signal exchange

Comments: CIP conditions, Space limitations, Specific component demands, etc.

Brewery process modules - An introduction 47

 Return to Menu

Appendix
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What is High Gravity Brewing?

High Gravity Brewing - HGB - was developed in the UK and USA to

increase brewery output without the need for large capital investment.
The procedure has now spread out to most of the major brewing groups
worldwide. It simply means to brew strong beer and subsequently blend
it with deaerated water to the desired final beer quality.

If we speak about “High Gravity Beer”- we define it by the OG (Original

Gravity) of the wort, defined in ºP (Plato), resp. ºB (Balling) in some coun-
tries. Both are equivalent to % extract.

High gravity brewing has been found to be a cost effective way of

increasing output without having to add additional brewhouse, fermenta-
tion or maturation capacity.

Current practice is to produce HGB beer with a maximum Original Gravity

(OG) of 16 ºP, which is subsequently blended to 12 ºP for packaging.
(Finished beer, about 5% by volume ethyl alcohol).
Currently advanced trials in Canada and South Africa are producing
various types of wort with 18 ºP and even 22 ºP Original Gravity, which
seems to be the theoretical upper limit for good beer.
APPENDIX 49

What is High Gravity Brewing?
Brewhouse
Raw material
High gravity brewing was developed also through the use of sugar and
wort syrups, as adjuncts which add extract directly to the wort kettle.
High gravity wort can be produced from all standard brewing materials,
including 100% malt brews but there may be some loss of extract
recovery with the higher collection gravities and when process times in
brewhouse are longer. Some breweries practice weak wort recycling or
use a modern thin-bed mash filter.
Mashing
There is a tendency to favour thicker mashes with water: grist ratios of
1:2,8 to 1:3,0 to achieve a higher first wort extract. Otherwise standard
mashing regimes tend to be used with a standard temperature pro-
grammed mash similar to conventional process.
Sometimes, the programme uses a shorter proteolytic rest at slightly
higher temperature to reduce the free amino nitrogen content but this
often has to be compensated by a longer saccharification time.
Wort separation
The most efficient wort separation system for high gravity wort is the
modem thin-bed mash filter, which produces high gravity wort with low
extract losses (12-14 batches per day possible).
50 APPENDIX
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Conventional lautertun or mash filter can be a bottleneck for HGB but
under most circumstances, they are able to produce a ºP wort with few
production problems (8-12 batches per day possible).
No matter which wort separation system is used, the first wort should
be as strong as possible, to allow the use of more sparging water to
ensure a good extract yield.
To improve extract recovery, the last run-off (mostly below 2% extract)
can be collected and used as mashing liquor for the next brew. The
quality of the last runs can be improved by treating with active carbon.
It should not be stored over longer periods.
As with all mashing systems, oxidation of mash and wort should be
avoided. This can be achieved by designing the brewhouse so that the
mash-inlet to mash vessels and lautertun are at the bottom of the ves-
sels and by using deaerated brewing water for mashing and sparging.
pH of wort should be low - around pH 5,0 - not higher. This can be
achieved by addition of natural lactic acid or by adding of phosphoric acid.
Wort boiling
No principle difference to conventional brewing. If steam is cheap, addi-
tional evaporation (say extra 20 minutes boil) may be beneficial in gravity
without detriment to quality.
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Typical brew and oxygen. Generally, pure oxygen is to be avoided as it

A typical brew to produce 565 hl cold wort of 13.3º OG would require: can be injurious to yeast.
10,000 kg malt
300 hl mashing liquor Yeast pitching: The pitching rate is higher than for standard gravity
400 hl sparging liquor brews. The reason for this is that the yeast has difficul-
Evaporation during boiling 10% total ties in growing when the sugar concentration is high.
By adding 1,000 kg sugar extract directly to the wort boiler, the original Hence, a normal lager of 12 ºP OG which may be
extract will be increased to 15 ºP (for 16 ºP wort malt increases to pitched at a rate of 15 million cells per millilitre will have
10,250 kg and sugar to 1,400 kg). to be pitched at between 20 to 25 million cells per
millilitre for a fermentation at 15ºP OG extract.
By using equipment which can measure viable yeast
Wort treatment cells, yeast pitching can be significantly improved.
If beer is produced with a higher alcohol content than
7,5% the yeast may ferment more slowly and be in a
Requirements: Rapid wort cooling, good wort aeration, correct and
poorer physiological state and show a reduced viability
controlled yeast dosing.
after cropping.
This effect is especially bad in modern, tall, cylindro-
Wort Cooling: Not longer than 11⁄2 hour per brew, ideal is 1 hour
conical tanks.
Due to higher OG, increase of colour is possible, if
cooling time is too long (i.e. long storage of hot
By using fermenting tanks with higher volume than one brew, normally
exposed wort).
each brew is aerated and pitched with yeast, however practices
vary widely.
Aeration: Minimum 8 mg 02/l, often requires oxygen levels
between 10 to 16 mg 02/l. The usual calculation is that
1ºP OG requires 1 mg 02/l, hence for 15ºP OG = 15 mg
02/l. For aeration up to approx. 12 mg/l and standard
fermenter top pressure, normal air can be used. Aeration
to higher levels has to be achieved with a mixture of air

APPENDIX 51
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What is High Gravity Brewing?

Fermentation and Storage BBTs - bright beer tanks

Similar to conventional process.
Fermentation
Similar to conventional fermentation. Typically slightly higher starting and Blending with water
fermenting temperatures are used. If aeration and yeast pitching is not Highest demand on quality of water for blending with HG-beer and
optimized, it will result in longer fermentation times. blending to required OG.

• Water should be treated through normal water treatment plants.

Storage • Definitely low hardness, specially no Carbonate and low Ca2-ions
Similar to conventional process. • Should be very low in Oxygen - below 0.05 ppm (mg/l)
• Should be cold, around 1 to 3 ºC
Typical fermenting and storage process • It should be of good microbiological quality, e.g. pasteurized.
Aeration; 10-16 mg 02/l • It should be carbonated - up to similar level as the high gravity beer.
Yeast: 25 million cells / ml
Fermentation: 10 days at 12 ºC followed by the first removal of yeast. Blending of HG-beer with water can be done:
7 days at 5 ºC, with second removal of yeast. Cooling • before filtration
to -1,5 ºC in tank or through a plate heat exchanger • after filtration
• approximate adjustment before filtration and final correction after
filtration.

Filtration, BBTs and Blending
Filtration
Similar to conventional process: Kieselguhr filter, sheet filter, PVPP
stabilization, adding of stabilizers, etc. or any combination.
Each system has advantages and disadvantages - has to be discussed
from case to case and depends on the type of beer, content of yeast in
beer, type of filter, capacity of filter, etc.

52 APPENDIX

Blending can be done:
• on proportion, with manual or automatic control
• automatic control of OG of blended beer
• automatic control of alcohol content of blended beer
Typical process:
• Blending before filtration on automatic proportion control from 15 to
12,5 – 13 ºP OG
• Filtration - Kieselguhr filter - PVPP-filter - trap filter
• Final dosing of water with automatic control of OG to 12 ºP OG
• Automatic dosing of C02 to get required C02 in beer - i.e. 5,5 g/l
HGB-Economy
Building a new brewery
Appox. 5 - 7,5% of investment can be saved.
Extension of an existing brewery
Savings are much higher and depend very much on existing equipment
and if building work is involved.
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Operating cost
+ saving of energy in brewhouse and for wort cooling
+ savings of water/CIP
+ reduced effluent
+ reduced cost for personnel - more beer can be produced with same
personnel
+ less maintenance
- cost for production of deaerated water
- possible poorer extract yield (higher losses) from brewing materials,
principally hops
- if uncontrolled, beer losses are more expensive
- change / no change to beer flavour.
Advantages
+ higher beer production with only limited investment. On average,
production can be increased by up to 25% by brewing HG brewing.
+ pay-back time for equipment required for HGB depending of size of
brewery
Large brewery (1,0 million hl/y): 1/2 year
Smaller breweries: 1 - 2 years
Based on: “High Gravity Brewing” by Muller & Pohl, BRAUWELT 36-1994
“Brauereitechnologie Weltweit” by Narziß, BRAUWELT: 17/18 -1996
APPENDIX 53

LEXICON of Brewery Nomenclature
ACETIC ACID
The acid of vinegar (should not be present in sound beer…).
ACROSPIRE
Shoot that grows from grain of barley during malting.
ADJUNCT
Any material, other than barley malt, that provides fermentable
sugars in the wort. Starch adjuncts include maize, rice, barley
and wheat and must be added to the mash. Sugar adjuncts
include sucrose (household sugar), invert sugar, glucose, corn,
and barley syrups and are added directly to the wort.
ALE
A top fermented beer, as opposed to lager. Formerly used to
signify an unhopped beverage.
ALPHA-ACIDS
A group of substances present in the resin glands of hops.
Under the conditions of wort boiling alpha-acids are converted
to iso-alpha-acids. These are mainly responsible for the bitter
flavour of beer.
ATTEMPERATION
Control of temperature during fermentation.
ATTENUATION
Transformation of the fermentable sugars in the wort by yeast
(fermentation) - into carbon dioxide and alcohol.
ATTENUATION LIMIT
The limit to which a fermentation will go, i.e. when all the
fermentables have been used up by the yeast.
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ANTI-FOAM
Substance used to depress foam in fermenting vessel thereby
increasing its operational capacity.
AUXILIARY FINING
Substances added to beer to assist fining action.
BARLEY
Grain most commonly used for brewing.
BARLEY SYRUP
A fermentable extract of barley, prepared by hydrolysis of
the grain starch by artificial enzymes (see below), followed
by concentration of the liquid to a high level of solids.
BARREL BEER
Imperial or UK bbl = 1.636 hl
US bbl = 1,173 hl.
BEER CONDITION
The gas released on pouring beer.
BEER DUTY
The charge levied on beer by the customs and excise.
The charge is proportional to 0.G. or alcohol content.
BETA-ACIDS
A group of substances present in the resin glands of
hops. They are chemically related to alpha-acids and the
products obtained from them on boiling with the wort
make a minor contribution to the bitterness of beer.

BITTERING PRINCIPALS OF HOPS
Those substances present in the flowers of the hop, which are
extracted during copper boiling and converted to the materials
which give beer its characteristic bitter taste. Alpha-acids are the
most important of these bittering principals.
BOTTOMS
Deposit of yeasts and solids formed during fermentation.
(see spent grains).
BOTTOM FERMENTATION
Fermentation of wort by a strain of yeast which settles to the bottom
of the vessel as the fermentation becomes less vigorous. The fermen-
tation is carried out by yeast suspended in the wort, just as in top
fermentation.
BRIGHT BEER
Beer which has been fined or filtered or centrifuged after fermentation.
BREAK
Hot/Coarse, Cold/Fine - see Trub.
BREWERS
There are three categories of persons who brew beer:
1. Publican brewers, or brewing victuallers, who retail their beer on
the same premises where it is made.
2. Common brewers, or brewers for sale, who sell beer in bulk to
retailers, or who retail their own beer on premises other than
those of the brewery.
3. Home brewers.
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BUSH
Ancient sign for an inn (hence: “Good wine needs no bush”). Probably
of Roman origin; a “bush” of ivy and vine leaves was the symbol of
the wine-god, Bacchus.
CASK
A barrel-shaped container made of wood, aluminum or stainless
steel with two holes in it. The tap-hole is in the flat end (or head)
of the cask and the bung-hole is in its curved side. The bung-hole
is sealed with a wooden bung or shive; when the cask arrives
at the pub cellar, it is placed on its side. The shive is pierced and
plugged with a porous peg or spile. When conditioning has
been completed, the porous peg, is replaced by a hard spile,
which is not removed until the contents of the cask are
broached.
CASK-CONDITIONED
Beer of which the carbon dioxide gas content has been obtained by
slow fermentation in the cask.
COLD BREAK
Similar to hot break but forms when the wort is cooled down.
CONDITION
The amount of carbon dioxide dissolved in the beer. Some lagers can
carry as much as 7 grams per litre.
CONDITIONING
The process of “maturation” and dissolving carbon dioxide in the beer,
so that it has a liveliness and sparkles in the glass when served. The
term is usually reserved for processes, which accomplish this by
means of fermentation, rather than by carbonation.
LEXICON OF BREWERY NOMENCLATURE 55

LEXICON of Brewery Nomenclature
CONICAL
A type of fermenting vessel.
COPPER
The vessel or kettle in which the wort is boiled with the hops.
The name derives from the fact that in former times the vessel
was usually made of copper; stainless steel is the favoured
metal for construction of modern coppers.
COPPER FINING
Substances added to wort, near the end of the boil, to assist
the formation of the hot break.
CRYSTAL MALT
A substance obtained by heating kilned malt with water; this
results in the conversion of starch to sugars and is accompa-
nied by some caramelization. It is often added to light beers to
give fullness to the finished beer.
CYTASE
An enzyme which removes the cellulose coating of starch
granules.
DECOCTION
Mashing system using physical mass transfer of mash to raise
its temperature (common for lager brewing).
DEXTRINS
Wort-soluble sugars of which the molecules are made of from
5 to 20 simple sugar units (polysaccharides).
They arise from incomplete enzymic breakdown of malt starch
and are not directly fermentable by yeast. However, they are
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slowly converted to fermentable sugars by enzymes present in
yeast cells. Dextrins are not as sweet as simple sugars, and
give the beer fullness of palate or “body”.
DIASTASE
Enzyme in barley which converts starch to fermentable sugar.
(see Mashing)
DRAUGHT
Beer served from bulk vessels, casks or kegs (as opposed to
bottles or cans).
DRY-HOPPING
The practice of adding a small amount of fresh hops to the
beer as it is casked, in order to increase its hop aroma.
EXTRACT
Malt sugars in solution (Wort). Real/apparent, see also gravity.
ENZYMES
These are complex proteins, which are extremely efficient
catalysts for certain specific chemical reactions; in brewing,
they are responsible for converting starch to fermentable
sugars. Enzymes are naturally-occurring substances but
some of them can be artificially manufactured by bacterial
fermentation.
FERMENTATION
Another word for anaerobic metabolism. The chemical
definition is that fermentation is the process whereby a living
organism extracts energy from sugar (carbohydrates) in the
absence of oxygen.
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The popular understanding of the word is that it is the process GLUCOSE

whereby yeast transforms the wort into beer (or the grape juice
into wine).
FINING
Material added to beer to clarify it by flocculating and settling yeast
and other suspended solids. The fining most commonly used is isin-
glass, a collagen obtained from fish swim bladders; it is added to
beer as a solution in dilute acid.
FLOWER
“Head” of German beer as served. Can take 15 minutes to pour
correctly.
A monosaccharide that is regarded as the basic of all sugars,
because it is the most easily digestible carbohydrate by most living
organisms. It has a sweet taste to man. Yeast consumes glucose.
GOODS
See grist. (Note, empty and full goods store refers to empty and full
bottles warehouse).
GRAVITY
The specific gravity of beer multiplied by 1000 (or density in kg/m3
expressed as a number). Related terms, original gravity (O.G.),
finished gravity and present gravity (P.G.).

FOB GREEN BEER

Froth, foam. Beer at the completion of fermentation, before racking and further
conditioning at the brewery or pub.
FREE BOARD
Head space or volume above fermenting wort to allow for fob or foam GRIST
produced by fermentation. The mixture of all the substances which produce fermentable material
in the wort, including malt, grains, brewing sugars, corn and barley
FRUCTOSE syrups. The term is sometimes used in a more limited sense to
It is a monosaccharide that tastes sweet to man. Yeast consumes include only the starch sources used, namely malt and cereal
fructose. The difference between fructose and glucose is the way the adjuncts.
molecule is put together – the elements are the same.
GYLE
GALLON A brew.
Imperial or English Gallon = 4,54611 litres.
US Gallon = 3.785 litres. GYPSUM
Calcium sulphate or plaster of Paris. Commonly an important con-
GILL stituent of water (“or liquor”) if beer has to be clear.
1/2 pint (English Gin/Sprit Measure 1/8 or 1/6 GILL).

LEXICON OF BREWERY NOMENCLATURE 57


LEXICON of Brewery Nomenclature
58 Brewery process modules - An introduction
HEAD
The creamy foam on beer.
HIGH KRAUSSEND
High kraussend is an old German term (Hoch kraüssend) for
the yeast when it is most active during fermentation. It is called
so because the foam on top of the fermenter looks like high
curls. They appear at the stage of the fermentation when the
yeast consumes carbohydrates at the highest rate. In former
days, it was also used to decide when propagation was fin-
ished but is not used as such anymore as there is no relation
between the best time to stop propagation and the maximum
carbohydrate consumption.
HOP
The flower of the hop plant (humulus lupulus) used in beer for
its preservative and bittering qualities.
HOT BREAK
Sediment which develops during the boil, often compounded
of protein, starch, tannins etc. (or trub)
HOP EXTRACTS
A concentrated extract from whole hops; if it is untreated, it
must be added to the wort during boiling, as with whole hops.
More often, the extract has been heated with alkali to convert
alpha-acids to iso-alpha-acids and this “isomerised” extract
can be added to the wort after boiling, which gives better
utilisation of the extract.
HOPPED WORT
Wort which has been boiled with hop flowers in the copper.
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HOPPING DOWN
Addition of dry hops to cask before dispatch.
INFUSION
(see also Decoction) Mashing system where mash remains in
the same vessel at constant temperature (isothermal mash -
common for Ale brewing). Temperature programmed infusion
mash - system where mash remains in same vessel whilst it is
heated to set temperatures (used for both Lager and
Ale Brewing).
INVERT SUGAR
Sucrose (a disaccharide), the normal household sugar obtained
from sugar-cane, is not directly fermentable by yeast. Hydrolysis
of sucrose with dilute acid gives invert sugar, which is a mixture
of the readily-fermentable sugars, glucose and fructose.
ISO-ALPHA-ACIDS
A complex mixture of substances formed from alpha-acids
during wort boiling and which is the main source of the bitter
flavor of beer.
ISOMERISATION
A term describing any process in which one chemical com-
pound is converted to another compound having the same
molecular formula as the first but with different chemical and
physical properties. In brewing, the term generally refers to the
conversion of alpha-acids to iso-alpha-acids, either in the wort
boiling stage or when hop extract is heated with alkali.
KEG
An aluminium or stainless steel container for beer, which may
be barrel-shaped, or straight-sided. It is distinguished from a

cask in that it has only one hole in it and is always placed on its end
whilst in service at the pub. Beer can only be dispensed from a keg
by means of carbon dioxide under pressure.
KEYSTONE
A wooden or plastic bung which fits into the end of the cask, into
which the tap eventually will be driven through.
KILN
Used in the maltings for drying malt after its germination.
KILNING
Hot air drying of malt; the process is carefully regulated for removing
the water without destroying the malt enzymes.
LAGER
A bottom fermented beer.
LAMBIC
A rare Belgian beer, unique as it is fermented by a wild yeasts.
LAUTER TUN
Decoction Brewhouse vessel used to separate the wort from the
grains after completion of a mashing programme. (Lauter is the
German word for “clarifying”).
LIQUOR
In the brewing industry commonly used as synonym for treated
water.
LUPULIN
Yellow powder in the hop flower containing the oils and resins which
give the hop its bitterness.
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MALT
Malt is the basic ingredient of the food (wort), which is prepared for
the yeast when it shall produce beer. Malt is germinated barley.
Barley, like all grains, contains a lot of starch. The yeast
cannot digest starch so the starch must be transformed to sugar.
The polysaccharide must be chemically broken down to monosac-
charide and disaccharide. When the barley germinates, the starch
is broken by means of enzymes and a lot of maltose is formed,
which the yeast can digest.
MALT EXTRACT
This is a syrup or solid extract which has been prepared by mashing
malt and then concentrating the wort to a high solids level by heating
at moderate temperatures under vacuum.
MASH
The mixing of brewing liquor and grist.
MASHING
The process in which malt is mixed with hot water enabling the
enzymes present in the malt to convert its starch to easily-
fermentable sugars.
MASH TUN (or TUB)
The vessel used for the mashing process. It is usually made of stain-
less steel or copper and is fitted with a false bottom of perforated
plates, which permits ready run-off of the wort when mashing is
complete.
MILK STOUT
Former name for a stout in which lactose (milk sugar) has been
utilised.
Brewery
LEXICONProcess
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ModulesNOMENCLATURE
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LEXICON of Brewery Nomenclature MODIFICATION

Net action of enzymes, which develops in the endosperm dur-
ing malting.
POLISHING
Final filtration of beer to give its brilliance.

PRESENT GRAVITY (P.G.)

NATURALLY-CONDITIONED The actual, specific gravity of beer after fermentation.
Beer, the carbon dioxide content of which has been pro-
duced only by fermentation in cask or bottle and not by PRIMINGS
carbonation. A sugar solution added at casking of the beer, partly to
provide fermentable material for the conditioning stage,
NOGGIN and partly to sweeten the beer.
Quarter-pint.
QUART
NOSE A quarter-gallon.
Smell of beer (cf. bouquet of wine).
RACKING
NUTRIENT Running the green beer off from its yeast deposit, either
Nitrogenous matter added to wort to boost the action of the directly into cask or into bulk containers for further condi-
yeast; yeast food. tioning at the brewery.

ORIGINAL GRAVITY (O.G.) RACKING BACK

The specific gravity of a beer as measured immediately prior to
fermentation.
PASTEURIZATION
Heat-treatment of filtered beer, which acts to destroy residual
yeast cells and any bacteria which may be present in the beer.
PINT
Imperial pint - 20 liw.oz.; reputed pint - a 12 oz. bottle.
PITCH
Pitching means dosing of yeast – in the right quantity - when a
new fermentation is going to start.
A receiving vessel for primarily fermented beer.
ROCKY HEAD
The yeast covering which forms on the surface of the beer
during the initial stages of fermentation. This head rises to a
considerable distance above the surface of the beer and in
doing so, forms weird, convoluted shapes, from which comes
its descriptive name.
ROUSE
To stir vigorously from the bottom of vessel.
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SACCHAROMETER SPILE
An instrument weighted to float vertically in sugar solution and carrying Small wooden peg which is a close fit in the hole in the shive and is
a calibrated scale from which the specific gravity can be read directly. loosened to admit air and allow beer to be drawn from the barrel.
Afterwards it must be pressed home again or the beer will lose
SHIVE condition. (Different spiles in summer and winter).
Circular wood plug, bored centrally, used to seal a filled cask.
SQUARE
SKIMMING A type of fermenting vessel.
Removal of yeast from beer after fermentation.
STARTING TANK
SPARGE Vat sometimes used for wort in the earliest stages of fermentation.
Liquor sprayed over the mash. (later transferred to main fermenting vessel).

SPARGING STERIILIZATION
The technique of sprinkling hot water onto the grain bed after mashing Destruction of bacteria, yeasts etc. by heat or chemicals.
to obtain the maximum yield of fermentable extract from the malt.
Derived from the same root as asparagus, bunches of which were STILLION
used by ancient Greek priests to sprinkle holy water. Wooden cradle or stand for cask.

SPECIFIC GRAVITY STOUT

The weight of a given volume of liquid, relative to the weight of the A black beer of high gravity, usually bitter.
same volume of water.
SUCROSE
SPENT GRAINS Normal table sugar. A disaccharide that consists of one molecule of
The solid residue left after mashing, which is often sold as animal feed glucose and one molecule of fructose linked together.
- and today can be used for high fibre bread.
SWEET WORT
SPEAR/EXTRACTOR The wort resulting from the mashing in process (before hops
The tube and connector used to extract beer from a sealed container are added).
e.g. keg or top pressure cask.

Brewery
LEXICONProcess
OF BREWERY
ModulesNOMENCLATURE
- An Introduction 61
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LEXICON of Brewery Nomenclature SYPHON

See Rack.
TUN ROUND
A type of fermenting vessel .

TANK BEER ULLAGE

Usually bright beer cellared in tanks. Waste beer.

TOP FERMENTATION VALINCHE

Fermentation of wort by strains of yeast which rise to the
surface of the beer. The fermentation is carried out by yeast
suspended in the wort, just as in bottom fermentation.
TOP-PRESSURE
The system in which beer is dispensed by means of carbon
dioxide pressure applied over the beer in a cask.
TRADITIONAL BEER
Usually draught beer (in casks) which contains yeast and
continues to ferment in the cask or bottle e.g. a ’live’ beer
(in bottle of White Shield, Worthington and Guinness).
TRUB
Hot Trub (hot break) is the precipitate of some of the protein-
aceous material caused by boiling the wort. (Commonly taken
to include any carry over spent hops, hop powder, hop pellets
and any other insoluble material). Cold Trub (cold break) is that
coagulum of further protein and tannin, which material precipi-
tates during/after wort cooling (sometimes separated in a
“flotation tank” prior to the main fermenting vessel) .
A tube used to extract samples of beer from cask.
WORT
The solution of fermentable sugars and other materials which
is obtained from the malt after mashing. Sweet wort is wort
resulting from the mashing-in process and hops is wort which
has been boiled with hop flowers in the copper. Wort is
analogous to ”must” in wine-making.
YEAST
Micro-organisms, of which the metabolism produces ethyl
alcohol as waste product. Bottom fermenting yeast (lager) -
Saccharomyces Carlsbergensis, Top fermenting yeast (Ale) -
Saccharomyces Cerevisiae or Saccharomyces Uvarum
(Baker’s yeast also strains of Cerevisiae).

TUN
Name given to many vessels in a brewery (c.f. Mash Tun).
Once a measure (wine): 252 gallons.
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64 Brewery process modules - An introduction

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How to contact Alfa Laval?

Brewery
Brewery Process
process modules
Modules--An
Anintroduction
Introduction 65
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