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Process Solutions Guide

Brewing Brew Kettle


Milling Mashing Lautering

Brew Kettle

Fermentation

Finishing & Packaging

Utilities

Brew Kettle is the fourth unit in this six-step overview of brewing.

Overview of Brew Kettle Process


The sweet wort run-off from the lauter tun is delivered to the brew kettle. The function of the brew kettle is to boil the wort, along with hops, adjuncts and other flavouring, to ready the wort for the fermentation cellar. The brew kettle is filled to a set volume and steam is injected into the heating coils. The wort is brought to a vigorous boil for sixty to ninety minutes. The boiling process sterilizes the wort, coagulates proteins and vaporizes undesired volatiles and excess water in the wort. Boiling also is critical to bring out the desired flavours based on the hops and other adjuncts that are added in the brew kettle. Temperature and level in the brew kettle must be monitored to maintain a turbulent boil, yet prevent boil-over out the kettle door. After the boil, the bittersweet wort is pumped into another vessel called a whirlpool. The wort is swirled around this tank where the coagulated solids from the boiling process, called trub or break, settle at the center of the tank. The wort is then drawn off from the edge of the tank, leaving these solids behind. The wort is pumped out of the whirlpool and through a heat exchanger. During this process, the wort is cooled from approximately 200F to roughly 65F. Temperature is monitored at the inlet and outlet of the heat exchanger and density (Plato) is measured to monitor the extract concentration of wort. At this point, the wort is ready for delivery to the fermentation cellar.

Select Critical Control Points of Brew Kettle

Brew KettlePlato

Accurate control of evaporation profile ensures consistent beer quality, predictable fermentation time and fermenter fill levels.

Wort pH
The wort pH is monitored to determine hop solubility and can be controlled to affect body, palate and clarity.

Saturated Steam Pressure and Flow


Monitor and measure energy use at the brew kettles to optimize steam usage and reduce costs.

Adjunct Syrup Flow


Critical to measure the sugar content of adjunct syrups which are often added to increase fermentable sugars in the wort. It is important to add the precise sugar content to the brew in order to maintain consistent taste of the final product.

Hop Extract Flow


Liquid hop extract is added to the wort to impart the desired flavors and other traits to the beer. Accurate measurement of hop addition is critical to achieve desired final taste.

Temperature
Maintaining a vigorous boil is required during this process, yet excessive temperature will result in boil-over and loss of product and efficiency.

Brewing Brew Kettle Improving Brewery Efficiency


Brew Kettle Plato
Control Point Challenge: Accurate control of evaporation profile ensures consistent beer quality and predictable fermentation time. Solution: Measuring on-line concentration (Plato) in the brew kettle can be accomplished with the use of a Micro Motion meter. This not only eliminates the need for manual sampling of wort extract concentration and the inaccuracy introduced by human error, but also provides real-time information on the evaporation process.

Process Solutions Guide

Recommended Product Solution


Micro Motion CMF200
Mass flow accuracy of 0.10% In-line density accuracy of 0.2 Plato\Balling Clean-In-Place

Wort pH
Control Point Challenge: Monitoring of the wort pH determines hop solubility and controls body, palate and clarity. Solution: Accurate on-line pH measurement using non-glass ISFET sensor (TFS396), eliminating the need to extract samples and bring to a laboratory for pH determination. For hot wort applications, use Hx338 sensor, which is designed for higher temperature applications.

Rosemount Analytical TFS396

Rosemount Analytical HX338

Non-glass ISFET sensor Sanitary Tri-Clamp process connections Reduced drift with TupH reference in a single unit

High temp applications up to 130C Optional emp compensation Can be used with an automatic retractable assembly

Saturated Steam Pressure and Flow


Control Point Challenge: Optimize energy use at the brew kettles. Solution: Steam mass flow measurement with dynamic compensation of pressure and temperature is achieved by using a multivariable transmitter which provides instantaneous and totalized mass steam flow. Steam mass flow can be used for unit operations energy balance and overall plant efficiency calculations.

Rosemount Mass Probar 3095


Mass flow accuracy of 1.0% of rate Multivariable flow, pressure, temperature and dP Real-time fully compensated mass flow HART output Five years stability

Adjunct Syrup Flow


Control Point Challenge: Accurate measurement of sugar content of adjunct syrups. Solution: Micro Motion meters can be used to directly measure the sugar concentration of the syrups and ensure that the final net sugar content delivered to the kettle is accurate.

Micro Motion CMF100


Mass flow rate accuracy of 0.10% Low flow capability, 0-3 lb/min In-line Brix (% sugar) measurement Clean-In-Place

Hop Extract Flow


Control Point Challenge: Accurate measurement of liquid hop extract flow to achieve desired final taste. Solution: Due to the high cost of liquid hop extract and the need to add precise quantities to obtain consistent and desired taste, Coriolis meters are used to accurately measure additions to the brew kettle.

Micro Motion CMF025


Mass flow accuracy of 0.10% No moving parts Clean-In-Place

Temperature
Control Point Challenge: Temperature measurement for boiling control. Solution: Reliable temperature measurement for boiling control is achieved by using direct mount sensor and transmitter reducing the error induced by electromagnetic noise and extension cables. Using the sensor matching option for RTDs increases accuracy, reducing waste of energy.

Rosemount 644 Temperature


Universal RTD/Thermocouple 4-20mA + HART 0.03C accuracy Direct mount sensor Small & light 2 year stability

MC-00779

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