4 Brews in 14 hours at Jack’s Abby
THE POTENTIAL OF AUTOMATED BREWHOUSE
The artisans of the future
The facility is 6700 sq feet and it can reach 125000 bbls of beer per year. The fully automated brewhouse has been installed two month ago, it has been able to reach 4 brews in 14 hours!
The automatic system has a scheduler that sends in different times information to the malt and mash bath. More than that it is possible to make many different beer’s types using a recipe archive on SQL server database.
Before and during the process is possible to set the distribution program in order to define the amount for one or two different fermenting tanks to set air, knock-out temperature and the last sample of gravity (default data is from recipe). The system permits the fermenting cellar management with several fermentation steps, it monitors the temperature and the theoretical gravity in relation to current samples. The user can control the entire operating sequence, from malt removal to the pressure tank, with a single platform, the high-resolution visualization system displays the complete production process at a plant.
The system is based on SIMATIC S7, on profinet IO, Wincc 7.2, safety PLC PILZ.
In order to have the correct water/malt ratio, the process value of grist weight refers at the theoretical value to calculate a correction factor for all water amounts (mash liquor, sparge liquor, copper up).
Key requirements regarding the mashing process are low-oxygen, clump-free mashing and very thorough, homogenous mixing of the mash. Treesse progetti achieved this with an automatic calculation of water flow rate and agitator speed.
The plant permits the decoction process using the lauter tun like a buffer: during the second mashing the rake machine follows the transfer level into mash kettle to empty all the grains.
In the lautering process it is important the running time and maximize the extract yield The lautering is auto-optimized, it starts with a Darcy formula applied to the process values. This automatic control provides the current theoretical values of viscosity and extract. The rake machine and the filtration flow rate are conditioned by the delta p of false bottom, and the underletting is automatic. The automatic system permits different types of sparging (fly or batch) which can be decided by recipe.
The level (or height) of the grains is calculated and the regulation works to have the correct offset over, a special graph shows the current level of liquid inside the lauter tun related by the grains.
The first wort amount is automatic calculated, but the brew master can change it to have, for instance, a single infusion wort type.
During the spent grains discharge the rake machine goes down with a long ramp conditioned by current absortion.
An External wort boiler is present with forced and/or natural boiling. The automatic system calculates the initial boiling temperature and controls the constant flow of steam.
The casting-out is managed with an automatic slow-down ramp to prevents dirty in wort line. This plant is provided with an hopback (like a recipe option)
The Cip process is very flexible:it allows different solutions for the brewhouse depending on the type of recipe. It is possible to make a complete Cip for each single unit (Mash Tun Kettle, Lauter Tun, Wort Kettle, WhirlPool, HopBack) or configuring some group of vessels (MTK+LT, LT+WK+WP, MTK+LT+WK, WK+HB ecc.). CIP process also has a specific unit to clean the external circuits of the brewhouse, like a filler machine or wort line.