Beer Processing Solutions

Table of
contents
Introduction . . . . . . . . . . . . . . . . . . . .3
Brewing Process Diagram . . . . . . . .4
Complete Product Range . . . . . . . .5
Complete Process Solutions . . . .6-7
Automation Services . . . . . . . . . . .8-9
Maintenance Service . . . . . . . . . . .10
Wort cooling, yeast dosing,
wort aeration . . . . . . . . . . . . . .11-12
Water deaeration . . . . . . . . . . .13-14
In-line blending and mixing . . .15-16
Carbonation and nitrogenation 17-18
High gravity brewing . . . . . . . . .19-20
Pasteurizing . . . . . . . . . . . . . . . .21-22
CIP . . . . . . . . . . . . . . . . . . . . . . . . . .23
Fermentation & maturation . . . . . . .24
Filtration . . . . . . . . . . . . . . . . . . . . . .24

2
 Our first steps into the brewery equipment
business began as early as 1910 . . .

APV pioneered many of the key In 1914 APV developed a system for Today APV offers process automation
technologies involved in the brewery the culture of pure yeast and in 1923 systems, individual brewery
industry . As early as 1910, APV the company revolutionized wort process units, and a wide range
made the first welded alumin cooling by introducing the world’s first of components including pumps,
ium
brewery plate heat exchanger . valves and heat exchangers . All
beer tank on the basis of a British APV equipment and systems can be
patent, and through its commitment supported by a variety of after sales
to innovation, the company has Since then, many more developments services .
continued to make important have been introduced, placing APV
contributions to the industry ever in a better position than ever to serve
since . APV has established many the brewery industry in all specialty
milestones in brewing technology, processes .
with results that are still valid
throughout the world today .

Beer Types with Approximate Alcohol by Volume

Bottom Fermented Top Fermented
Malt Malt Wheat Malt
Münchner 4 .8% Trappist 9-10 .8% Strong Ale 6 .1-8 .4% Weizenbier 4 .8-5 .6%
Pilsner/Pilsener 4 .2-5% Kölsch 4 .8% Bitter stout 4 .4-7 .5% Berliner Weisse 3 .3%
Ur-types 4 .9% Brown Ale 2 .5-4 .5% Milk stout 3 .7-3 .8% Gueuze-Lambic
5%
Danish Lager 4 .2-4 .7% Pale Ale 4 .3-6 .6% Russian stout 9 .5%
Bock 7-7 .3% Mild Ale 2 .5-3 .6% Light Ale 2 .9-4%
Doppelbock 7-7 .3% Bitter Ale 3 .0-4 .0% Steam Beer 4 .8%

3
 The Brewing Process

4
 A Complete Product Range
APV provides a selection of Focused on adding value to your From individual units to totally
standardized process units, which product automated solutions
could be described as a series of Our process units are designed Every unit can be supplied as
building blocks . These fulfill various to exceed industry standards and a stand-alone system, ideally
brewing processes and include: enhance the value of your products . equipped for smooth and trouble free
To highlight how value is added to operation and suitable for integration
your products and processes, we
• WortMaster – Wort cooling, yeast into your central control system . But
have developed the following symbols
dosing and wort aeration
for your reference you will gain additional benefits with
• Derox – Cold and hot water a combination of units, which have
deaeration been specifically designed to operate
• BlendMaster – In-line blending and together for high performance, both
Product from a mechanical and a control
uniformity
mixing perspective .
• CarboMaster – Carbonation and homogenous products
nitrogenation
• HGBMaster – High gravity brewing Flexible APV can guarantee you a process
• PU Pasteurizer – Controlled beer production solution t ailored to your needs .
fast product changeover
pasteurization
• CIP Master
Economical
production
cost saving processes

Proven
security
tested equipment

The unit values are significant

APV Provides: Capabilities: Customer Values:
An intelligent processing unit Configuration as required Improved process:
Real time plant data: • Profitability
• Predictive maintenance • Consistency
• On-line documentation • Security
• Final product monitoring Lower operating cost
• Traceable production Longer running time
A Plug & Produce™ unit Very short commissioning time Faster return on investment
Low installation cost Easy expansion of existing plant
No interference to existing production schedules
Reduced time from order to production
Seamless integration to all plants
Easy to extend
Proven standards Improved functionality Improved repeatability
Hygenic design Product integrity safeguarded
Good reliability
State of the art processes Easy operation Quick and easy operator training
Low energy consumption Environmental improvements
Reduced waste Improved company image
Low noise emission levels
A compact unit design Container fitted Shorter delivery time
Low shipment cost Higher capacity/m²
Smallerproduction area required
Moveable equipment
Fast delivery time
Maintenance service Easy maintenance Cost effective maintenance
Optimal APV service Higher productivity
Fixed maintenance costs
A reduction in unscheduled downtime
Limited spare parts requirement
5
 Complete Process Solutions
Adding value for the brewmaster

APV draws on decades of Highly automated systems deliver teamwork ensures that we
experience in project engineering and improved effeciencies, resulting in a understand and recognize each of our
management for the brewery industry . faster return on investment, due to: customers’ specific needs .
Its extensive range of reference • More production time
installations includes everything from • Less cleaning time Detailed Engineering
a single process line to complete • Minimum use of water, chemicals and
greenfield turnkey beer processing This starts with the PID and
solutions . process description, followed by the
energy
development of installation pipeline
• Fewer operators circuit and connection plants, cable
They also improve batch control, lists, functional descriptions, program
To meet today’s demand for modern, resulting in product traceability and sequences, energy calculations,
highly efficient production facilities, flexibility . component specifications, interface
APV’s in-depth knowledge of brewing definitions, spare parts lists and
top quality beers is complemented by operating instructions and manuals
expertise in process automation and Further benefits for the brewmaster – all dedicated exactly to our
management information systems . and management are: customers’ specific brewing needs .
• A “paper free” process control
APV’s technological excellence system which can interface with ERP
covers processes such as systems Hygienic Design
fermentation and storage, yeast • Material and quality tracking Our design is based on the latest
handling and treatment, beer international st andards for hygienic
processing, bright beer and capability
design . APV uses standard design
pasteurization . Furthermore, we have • Full compatibility with brew-house elements, which are constantly
vast experience in the areas of wort and filling plant as well as with other reviewed to meet the highest
cooling, water deaeration, and high production plants in the brewing standards .
gravity brewing . Our CIP systems group
complete the process . Wherever
appropriate, APV integ Process Engineering
rates its strong APV uses its extensive experience
range of standard process units into in the development, planning and
a project . implementation of brewing steps
in close co-operation with our
customers’ brewmaster, technologists
We believe our experience is our
and process engineers . Careful
most important asset . Previous
highly successful inst allations are
our customer’s best guarantee that a
brewery project will be implemented Health and Safety
on time and within budget .
Our experience ranges from HACCP/HAZOP studies can be
traditional methods to highly undertaken, reviewing equipment
automated systems based around the specifications relative to process flow
latest proven technologies . diagrams to determine whether there
are any quality, health and safety
issues, which need to be addressed .

6
Each process step is analyzed to Environmentally Safer Processes degree of automation and integration .
establish whether the equipment and In response to an increasing need APV provides tailored training
control systems are adequate for safe for environment ally acceptable utility courses for our customers’ personnel
operation under normal, abnormal and services, energy optimization through in both process and automation
CIP conditions . sound design principles is always technology . Designed to extend their
observed . Waste minimization and skill base, increase their specialist
health and safety issues are always knowledge and update them on
Latest Design Tools carefully considered . the latest trends, these courses
APV uses the latest design tools . are offered either at our customers’
The use of 3D models, with possible brewery or on APV premises .
access to full-scale modeling from Installation Supervision
AutoCAD, provides improved APV supervisors are internationally
safety features by maintaining data experienced and accustomed to all
throughout the project via single kinds of local working environments .
entry to the database . Furthermore, Armed with excellent co-operation
the existing AutoCAD platform for skills, they are specialists in
communication with most customers’ accessing appropriate local
CAD Systems is maintained . manpower
.

Project Management – Optimizing

a single point of contact Working Procedures
APV project managers are our Consistent working procedures in
customers’ single point of contact . sales, engineering and management
They are highly experienced are an important part of the value
and acutely aware of all critical APV adds to a project . We have
implementation aspects . Excellent therefore been certified to ISO
coordination skills enable them to 9001 St andards . But that has
translate the efforts of APV suppliers never been our final goal . Through
and other sub-suppliers into quality improvement programs,
successful projects . working procedures are constantly
monitored and challenged to increase
productivity and efficiency in all parts
of our business .

Training of People
Breweries are operated by fewer and
fewer highly trained staff, which often
results in the need for an exceptional

7
 Automation and Performance Services Solutions
APV FactoryExpert
Driving manufacturing excellence

FactoryExpert is APV Automation &

Performance Services . It combines
innovative solutions with reusable
engineering applications on open
platforms to meet our customer
automation specifications .

We offer state-of–the-art automation

solutions and services designed
to international standards based
on in-depth process knowledge
together with manufacturing know-
how and engineering expertise
that meet regulatory requirements .
FactoryExpert enables customers
to extend their performance gains
across their business .
• Automation Service for APV FactoryExpert is vendor
customers’ existing automation independent, it can include, for
equipment offering maintenance and example control systems and human
APV FactoryExpert Value support programs, spare parts, etc… machine interfaces (HMIs) from
Streams maintaining and improving conditions Siemens, Rockwell, Mitsubishi,
to maximize plant uptime Wonderware, etc . This enables true
APV FactoryExpert comprises five
versatility in our solutions .
strategic value streams to meet
our customers’ automation and
manufacturing execution needs .

8
• Automation Migration for our • MES Applications t argeting manu- • ERP Integration solutions that
customers with an installed facturing and equipment perform- link and integrate the plant floor
base of ageing and obsolete ance, production execution, quality automation systems to our
automation equipment which and tracking . We offer a suite of customer’s enterprise or business
can no longer adequately sup- engineered applications designed layer
port their business . Furthermore, to deliver the right information, at
Automation Upgrade for systems the right time, to the right people,
that require additional functionality in the right context to drive future
to meet automation and control actions in our customers’ or-
requirements ganizations to drive manufacturing
excellence

• Automation Systems consisting

of PLC and HMI as part of our
project offering . These can be in
the form of a single skid unit to
plant wide automation solutions

ERP Integration

MES Applications

Automation Systems

Automation Migration

Automation Service

9
 Maintenance Services
Until recently, the impact of • Classic Care Each agreement includes certain
maintenance operations on round- - Comprehensive APV service critical items, with each level providing
the-clock production, quality, support progressively increasing support
manufacturing flexibility, traceability, - When service delays are not an capability (see table below) .
plant safety and environmental option
protection has been largely ignored .
APV recognizes that cost-effective • Advantage Care APV is committed to providing
performance of your APV equipment - APV service coverage for your proactive service solutions . These
is directly dependent on the ability to most critical equipment Maintenance Services agreements
design and implement a cost-effective - Proactive approach to provide the best possible service to
maintenance program . equipment performance maximize your performance and deliver
improved return on your investment .
• Total Care
- APV service management and
In response to these requirements, support for the entire plant
and as part of the on-going expansion - Plant-wide strategy to improve
of our customer support strategy, mission effectiveness
APV Maintenance Services adapt to
your specific requirements .
A Systematic Program of Strategic Maintenance
Maintenance Services consists of A P V s erv i ce man age ment
an d s up por t f o r t h e
A PV s erv i ce co ve rag e fo r Co mpr ehen s iv e A P V A P V s erv i ce
y our mo s t cri t i cal e qui pm ent s e rv ic e s upp or t pl an a hea d
wh en y ou can

multiple levels of service agreements en t ir e p l ant

in order to create the ideal balance P l ant wi d e s t r at eg y t o P roa ct iv e ap pro ach t o W hen s e rv ic e del ay s are n´ t B al anc e of u pt i me and
i mpro v e mis s i on eq uip men t p erf or manc e a n op ti o n ec ono mic s f or
of flexibility, improved productivity, ef f ec t iv en es s no n-cr it i cal a s s et s

increased up-time and better financial

Total Care Advantage Care Classic Care Basic Care
performance of all APV equipment .
Cr itic a l pa rt s de liv er e d sa me Cr it ic a l pa r ts de live r e d wit h in Cr it ic al pa rt s on sit e wit h in P a rt s on s it e wit in 72hou
rs
o r n e xt da y se r vic e 24 h o u r s 48 h o ur s
Eme r ge n cy s e r vic e t e c hn ic ia n E me rge n c y s er v ic e t ec h n ic ia n Eme r ge n c y se r vic e te c h n ic ian E me r ge nc y s e rv ic e re
Different service agreements can spo n s e
o n s ite with in s am e o r n e xt on sit e wit h in s a me or n ex t on s it e wit h in s a me or n e xt @ 10% dis co u n t
be created for our customers . For day da y da y

example: AP V Pr e ve n tiv e M ai nt e n an c e A PV P re v en t ive Ma in t e na n c e AP V Pr e ve n t ive

pro gr a m, 24/ 7/ 36 5 pr o gr a m, 24/ 7/ 365 pr o gra m, M o n day t o F r ida y m ai nt e n a nc e
M a in te n a n ce
vis it
One a n n ua l pla n n ed

8a m-5pm

• Basic Care F re e em er ge n c y se r vi ce ,
24/ 7/ 365
E me rge n c y s er v ic e,
24 /7 / 365 Mo n da y-F r ida y, 8a m-5p m
Eme r ge n c y se r vic e , S pa r e pa r ts @ 10% di sc o u n t

- APV service when you can plan

We ar pa rt s a n d s e rv ic e pa r ts We a r pa r ts an d se r vi ce pa rt s We a r pa r ts in c lu de d R e c o mme n de d wea r p ar t s
ahead in cl ud ed in c lu de d r e pla c e me n t sc h e me

- Balance of uptime and Ot h er spa r e pa r ts @ 15% O th e r s pa re pa rt s @ 15% Ot h e r sp ar e p ar t s @ 15 % T e ch n ic a l te le ph o n e s u ppo r t,

economics for non-critical disc o u n t dis c o u n t dis c o un t M o n da y-F r ida y, 8a m-5pm

assets Te c hn i ca l te le ph o n e s u ppo r t,
24/ 7/ 365
T e ch n ic a l t e le ph o n e
24 /7 / 365 Mo n da y-F r ida y, 8a m-5p m
s u ppo rt , Te c h n ic al t el ep ho n e su ppo r t ,

Mo de m su ppo r t in c lu de d M o de m s u ppo r t in c lu de d Mo de m s up po rt - o pt io n
al
St r at e gy fo r s e r vic e S tr a t eg y f o r s e rv ic e S tr a te gy f o r se r vic e
par t n er s h ip s e min a r pa r tn e r sh ip s e min a r pa rt n e rs h ip se mi na r

So f twa r e u pgr a de s P re dic t ive ma in te n a n c e on

c r it ic al it e ms

Pla n t a va ila bilit y gu a ra n t ee S o ft wa re u pgr ade

s
De s ign a te d AP V ma in te n a n c e R e bu ildin g & r e tr o f itt in g
ma na ge r c o n s ul ta n c y

Co n tin u o u s pr o c e ss cost
re du c t io n

Gu a ra n t ee d pe r fo r ma n c e
gu ar a n te e s o n c r it ic a l it e ms

An n u al pr o c e ss k n o wle dge
an a ly sis

Re bu ildi ng & r et r o fit t in g

co n s u lt an c y

Ope r at o r a u dit a n d t r a in in g
@ 20% di sc o u n t

10
 WortMaster – Wort Cooling, Yeast
Dosing & Wort Aeration
Ensure economical production by minimizing the use of time and additives

The WortMaster product range Offered in a wide range of capacities Economical production:
covers units designed for the from 50 – 1200 hl/hr, all WortMaster • Higher accuracy in yeast and oxygen
processes between the brewhouse units are designed and developed for dosing
and fermentation, including wort
cooling, yeast dosing and wort
easy integration with existing linesfermentation
• Reduced . time
aeration .
Flexible production:
WortMaster • Turn down ratio to 25% of nominal
In addition to fast and efficient wort - adds value capacity
cooling, WortMaster units deliver • Constant yeast/oxygen ratio,
effective and accurate in-line dosing The WortMaster adds value to your
regardless of flow
of yeast and air/oxygen by means of products and processes in the
the patented APV gas injector . following ways:
Proven security:
• Fully CIP-cleanable
Product uniformity: • Traceable production data
• Constant monitoring and improved
regulation of the process
• Repeatable fermentation
performance

11
Functional The actual method used can reflect amount of yeast can be dosed on the
Description local practice and the automation basis of tank contents measured by a
allows accurate MIS/MES integration . load cell .
Wort Cooling - Hot wort from the In the event of lack of product flow, • Yeast Cell Measurement – The
brewhouse must be cooled prior to the yeast supply is shut off .
amount of yeast can be dosed on
the addition of yeast for fermentation . the basis of instrumentation that
This is achieved using a state of the Options measures the yeast cell
art plate heat exchanger with a wide
concentration .
channel, which reduces the cleaning
requirement while maintaining good Cooling
• DuoSafety Plates - Additional
heat transfer efficiency . Additional Common
attractive features include a high product protection .
• Original Extract Measurement -
performance clamping system, • ParaWeld Plates - Allow the use of Completed through the means of
improved hanging area and EasyClip NH3 as refrigerant . a sound velocity sensor or density
gaskets, all of which contribute to • Bypass – Options are available for measurement .
reduced maintenance and spare parts
bypassing the plate heat exchanger • Oxygen Measurement – The oxygen
requirements . to enable such operations as hot
content of the wort can be measured
and/or cold wort diversion and back
using an appropriate instrument .
washing .
• Blending Separation - The simple
The wort cooler can be designed as a blending “T” can be replaced with
single section cooler using ice water Aeration a 4 port double seat valve and stop
or as a double section cooler for • Manual Adjustable Head – Any valve to separate the product and
brewing water and refrigerant . adjustment for flow and specification component loops for cleaning .
must be made manually .
• High Accuracy Blending – A
• Modulating Head – Automatic variation of this technology using
Wort Aeration - Brewing yeast
requires oxygen to multiply . adjustment of the head can be made mass flow measurement is capable of
from the control system . This option even higher accuracy and is used for
Traditionally this has been supplied can be retrofitted to the manual head . blending of components such as hop
by blowing air through the wort with extract or color .
various types of nozzles and mixers .
The result was often varying oxygen Dosing • Conductivity Measurement –
levels of typically 10-12 mg O2/l • Flow Measurement – The yeast can Pro duct separation can be measured
depending on pressure, temperature be dosed by means of a magnetic by means of conductivity to minimize
and the original gravity of the wort . flowmeter . product loss .
• Tank Contents Measurement – The

Specified O2 levels with high gravity

worts are usually higher and thus pure
oxygen is often used to achieve levels
above 18 mg O2/l .

The APV Gas Injector allows these GLYCOL

levels to be achieved by a fast
consistent mixing of wort and either GLYCOL
air or oxygen .
BREW WATER
STERILE AIR
Yeast Dosing - Yeast can be added
BREW WATER AERATED WORT
to complete the wort treatment . This
has the advant age of adding yeast
immediately to the cooled wort . KK
WORT

w o rt mas te r. dw g

12
 Derox – Cold and Hot Water Deaeration
Improve your beer quality with the Derox Deaerator

Deaerated water is used in the

brewing industry to minimize damage
to beer through oxidation . It is used
as a medium for purging mains and
equipment and post fermentation as
part of the brewing process .

The Derox product range covers units

designed for deaeration of processing
water . Derox is used where a low O2
content is required or recommended,
for example for the lauter tun,
blending of bright beer and in High
Gravity Brewing (HGB) processing . Derox+ (hot)
Derox (cold) - adds value
- adds value
Deaeration can be performed by two The standard capacity range is 50 –
different systems - cold (Derox) or hot The standard capacity range is 30 – 400 hl/h .
(Derox+) deaeration . The hot system 1500 hl/h
heats the water to high temperature, The Derox+ adds value to your
which reduces the risk of infection products and processes in the
and helps remove contaminants . The The Derox adds value to your
products and processes in the following ways:
cold system is capable of achieving
low levels of oxygen with low capital following ways:
and production costs . Product uniformity:
Product uniformity: • Constantly very low oxygen content
• Constantly low oxygen content 50 (below 20 ppb .*)
All Derox Units are designed and ppb at 12°C* (below 30 ppb at • Continuous monitoring for required
developed especially for easy >20°C .*) specification
integration to existing lines, with a • Continuous monitoring for required • Continuous removal of undesirable
wide and flexible capacity range . specification THF gases

Economical production: Economical production:

• Low running costs • Low running costs
• Space-saving design (high capacity/ • Space-saving design (high capacity/
m2) m2)

Flexible production: Flexible production:

• Variable capacity and high turn down • High turn down ratio (down to 25%
• Independent of water inlet of nominal capacity)
temperature (option) • Independent of water inlet tempera-
• Variable deaeration levels ture

Proven security:
• No rings and plates inside vacuum
Proven security:
tanks
• No rings and plates inside vacuum
tanks • Deaerated water is pasteurized
• Fully CIP-cleanable
• Fully CIP-cleanable
* Me as u re d a s a st
a nd a r d d ev ia tio n13
Functional The remaining water is discharged • Preheater - Values below 0 .03 ppm
Description from the unit via an adjust able residual O2 can be achieved with a
manual-regulating valve . water temperature of about 20°C .
Hot deaeration In cases where this water inlet
temperature is not a normal value, a
Water entering the unit is warmed by The unit is designed for CIP and does pre-heater consisting of a shell and
means of the regenerative section of not contain packing . tube heat exchanger together with a
a plate heat exchanger . steam regulation valve and
Options
After the regenerative section, the condensate trap can be supplied .
water enters a heating section where Hot deaeration
the temperature is raised to about • CO2 Stripping - The use of a small Common
88ºC . The water is then sprayed amount of stripping gas can allow • Oxygen Measurement - The result
into the deaeration tank via special the energy lost through flashing to be of the deaeration process can be
nozzles . reduced . measured in-line with an oxygen
measuring instrument, and the values
used to initiate remedial action or
The deaeration tank is kept under Cold deaeration alarms .
vacuum so that the oxygen is removed • Chilling - Chilling of water to
with a minimum of water vapor . match beer temperature . Different • Control Panel Enhancements –
configurations are available . Advanced control systems with digital

The deaerated water is cooled in • UV Water Disinfection - Disinfec - programming allow extremely accurate
the regenerative section of the plate tion of the incoming water can be control and comprehensive data
heat exchanger and the final outlet obtained by the use of an ultra-violet collection . Many of these facilities
disinfection unit . are also available with PLC control
temperature is achieved using a
systems .
chilling section or a separate cooler, • Seal Water Cooling - In cases where
depending upon the refrigeration the seal water will exceed 25°C it is
available . advisable to fit an optional seal water
cooler .

The deaeration tank does not contain

packing and is easily cleaned .

Cold deaeration
Water is sprayed into the bottom
vacuum tank, which starts the oxygen
removal process .

The water is then pumped and

sprayed into the top vacuum tank via
an injector where stripping gas (either
CO2 or N2) may be applied .

From the top tank the water falls

through a pipe with a vent which
allows some of the water to return
W A TE R/ C IP
into the bottom tank . The level in this
bottom tank is controlled by means
of a level switch, which controls the
water inlet valve .
CO 2 / N2 DE AER AT ED W AT E R

Der o x (C old )

14
 BlendMaster – In-Line Blending
The BlendMaster adds new dimensions to accurate standardizing and efficiency!
The BlendMaster range covers units
designed for continuous in-line
blending of liquid components .

It ensures precise recipe conformity,

regardless of whether two or more
liquid components are combined .

The BlendMaster is used, for

example, in High Gravity Brewing and
in combination with other unit types
like the CarboMaster or the HGB
Master .

Standard capacity range: 50 –1200

hl/h

BlendMaster
- adds value

The BlendMaster adds value to

your products and processes in the
following ways:

Product uniformity:
• Ensures exact conformity with the
specified recipe
• High calibration stability

Economical production:
• High precision blending
• Space-saving design (high capacity/
m2)
Co mb ined bl endi ng and car bon ati on unit

Flexible production: Proven security:

• Easy change of recipe for fast • Continuous monitoring and
regulation of the combined product
product change • Automatic switch-off, if offset
• Turn down ratio 25% of nominal exceeds the limit
capacity
• Blending ratio 1:10 to 1:2

15
Functional
Description PI

Extract and alcohol are parameters

usually used for duty purposes, and FI NA L B EE R

product declarations and accurate

determination are therefore import ant .
HGB is now a world-wide standard DE AE RATE D WATE R
involving the addition of part of the FT
DT
brewing water after fermentation
instead of within the brewhouse .
Even when HGB is not a standard
GT
procedure, cutting the final beer with FT

small amounts of water to achieve a HG B B E ER

consistent product is often required .

Magnetic flow meters are used to

measure the volumes of high gravity
beer and deaerated water . Dosing
takes place by means of a simple Options blending “T”[Link]
can be replaced with a 4
ratio control operating a modulating port double seat valve and stop valve
valve on the water supply . This gives • Original Extract Measurement -
to separate the product and
results that are within the accuracy
Completed through the means of a component loops for cleaning .
of laboratory instruments and in-line sound velocity sensor . This measures • High Accuracy Blending – A
measurement . This ratio control may the velocity of sound in a fermented variation of this technology using
be adjusted by means of an optional product, which is proportional to the
sound velocity/alcohol sensor, which original extract of the unfermented mass flow measurement is capable of
measures the original extract of product . even higher accuracy and is used for
the beer and applies appropriate blending of components such as hop
corrections . • Alcohol Measurement - Density extract or color .
measurement by means of mass flow
techniques, which together with
sound velocity measurement allow the
This technique can also be used for alcohol contents to be calculated .
blending beer types or diluted beer
• Blending Separation - The simple
from filtration .

16
 CarboMaster – Carbonation and Nitrogenation
The CarboMaster is the answer when you are looking for a cost effective, accurate
and flexible gas-dosing unit
The CarboMaster is the answer when
you are looking for a cost effective,
accurate and flexible gas-dosing unit .

The CarboMaster range covers

units designed for continuous in-line
injection and dissolving of gasses like
CO2, N2 .

This equipment ensures a precise

and uniform injection, by means of
the patented APV gas injector (see
description on page 18) .

The CarboMaster is used in the

brewery industry for duties such as
carbonation and can be integrated
with other unit types, including the
BlendMaster or the HGB Master .

Standard capacity range: 50 –1200

hl/h

CarboMaster
- adds value

The CarboMaster adds value to

your products and processes in the
following ways:

Car b oM as ter f or hi gh Co 2 cont ent

Product uniformity:
• High dosing accuracy (+/- 0.05g
gas/kg product*)
• Injection independent of inlet
temperature and pressure Economical production:
Proven security:
• No gas losses • Constant monitoring and
• Space-saving design control of final product
• Holding time not necessary
• Fully CIP-cleanable

Flexible production:
• Turn down to 25% of nominal
capacity
• Inject and dissolve up to 10g gas/kg
product

* M eas ur ed as a s t andar d
d evi ati on 17
Functional The fixed head injector can cope with CO2 contents to be automatically
variation in flow rates of about +10% . monitored and adjusted .
Description
The gas supply is shut off if the • High Precision Dosing – By means
product flow stops .
The basis of the unit is the patented of a gas flow meter, the amount
APV CO2 special injector, which of added gas can be accurately
differs from other models by injecting determined to avoid over or under
the liquid into the gas in counter Options carbonation . This is more accurate
than CO2 measurement with which
flow . This achieves quick dissolution,
it is often combined . A further ad-
and the gas is tightly bound to the • Variable Capacity Head - The fixed vantage is that the gas usage data
liquid . High levels of CO2 addition head can be replaced with a variable can be used for production control
can be obtained without long holding capacity head which allows a turn- and statistics by means of a suitable
tubes, and a precise fast regulation is down to 25% of the nominal capac- control system .
obtained . It is possible to carbonate ity . This can be either pneumatically
sales gravity beer to the desired level controlled or manually adjusted .
after the addition of non-carbonated
water . • High Carbonation Levels - The
standard system is engineered to
cope with levels of CO2 normally
specified in beer . Carbonation of up
to 10g/kg CO2 may be obtained if
The calculated value is compared
required .
with the measured value and the
CO2 content adjusted appropriately • CO2 Measurement - An in-line CO2
by means of the modulating valve .
analyzer can be installed together
with a regulating valve to allow the

BEER

CARBONATED BEER

18
 HGB Master – High Gravity Brewing
The HGB Master is the result of a compact 3-in-one unit, which deals you all the
aces in the pack
The HGB Master combines the three
process stages of water deaeration
(Derox), inline blending (BlendMaster)
and carbonation (CarboMaster)
into a single, all-inclusive process .

The HGB Master ensures a cost-

effective high gravity brewing process
combined with very high production
flexibility . The unit is designed
and developed especially for easy
integration with existing lines, and is
available in an extensive and flexible
capacity range .

Standard capacity range: 50–1200

hl/h

HGB Master
- adds value

The HGB Master adds value to

your products and processes in the
following ways:

Product uniformity:
• Constantly low oxygen content 50
ppb at 12°C* (below 30 ppb at
>20°C .*)
• Continuous monitoring for required
• Injection independent of inlet • Variable deaeration levels
specification • Easy change of recipe for fast
temperature and pressure
• Exact conformity with the specified product change over
recipe • Turn down ratio 25% of nominal
• High calibration stability Economical production:
• High dosing accuracy (+/- 0.05g • Low running costs capacity
• High precision blending • Blending ratio 1:10 to 1:2
gas/ kg product*) • Space-saving design (high capacity/ • Inject and dissolve up to 10g gas/kg
m2) product
• No gas losses
• Holding time not necessary Proven security:
• No rings and plates inside vacuum
tanks
Flexible production:
• Variable capacity • Constant monitoring and control of
• Independent of water inlet final product
• Automatic switch-off, if offset
temperature (option) exceeds the limit

19
* M eas ur ed as a st and ar d dev iat ion
 implement than separate modules .
Functional The deaerated water is taken from
Description the skid to the buffer tank and an
amount returned for blending and
Wide scale use of High Gravity carbonation . Deaerated water from
Brewing has become standard the buffer tank is still available for
modern brewing practice, as the other applications .
reduction in production costs is
significant . By adjusting the extract of
the beer after filtration rather than in
the brewhouse, the final output of a Options
given plant is greatly increased .
• Hot Deaeration – For added security
with poor water quality
A High Gravity Brewing Unit • Cold Deaeration – For minimum
comprises a combination of several production costs
modules described elsewhere . The • Blending – Addition of DAW can be
normal configuration consists of normal or combined with the addition
a deaeration module, a blending of pre- and post-run diluted beer
module and a carbonation module .
• Carbonation – Correction of the
CO2 contents of the final beer to
specification . This is normally a single
The integrated unit is simpler,
point but pre-carbonation of the
more compact and cheaper to water can be supplied if desired .

G LYCO L

GLYCO L

W AT ER

CO 2

C O2 / N2 F IN AL BEER

H GB BEER

• Fully CIP-cleanable

HGB Master

20
PU Pasteurizer – Controlled Beer Pasteurization
If you value gentle and accurate heat treatment you will also value the PU Pasteurizer

The PU Pasteurizer was developed

especially for continuous heat
treatment of beer and other
carbonated drinks .

The pasteurization temperature in

the PU Pasteurizers is controlled
by Pasteurization Units (PU) and
designed for high working pressures .

The PU Pasteurizer provides effective

and gentle heat treatment of all kind
of carbonated products .

Standard capacity range: 50–500

hl/h

PU Pasteurizer
- adds value

The PU Pasteurizer adds value to

your products and processes in the
following ways:

Product uniformity:
• Very high accuracy (computer
controlled PU regulation)
• Low T between product and
heating media

Economical production:
• Large heat regeneration (up to 94%)
Flexible production: Proven security:
with low temperature filling • Constant overpressure downstream
• Turn down ratio 40% of nominal
• Waste-saving design (beer/water capacity • Constant monitoring and control of
zone)
final product

21
Functional exchanger ensures that the pressure the pasteurizer is pushed out to drain
Description on the sterile side of the regenerative or to a collection tank with fresh beer,
section is higher than the pressure and normal operation resumes .
Pasteurization is calculated on on the non-sterile side . This pump
the basis of holding time and is frequency controlled to allow
adjustment of the pressure in the The unit is started by means of a shell
temperature . The time factor is and tube heat exchanger heating
linear, and small variations have a holding cell .
water to 80°C for sterilization and
minor effect on the PU value and are to balance the system . Heating of
controlled by adjusting the flow . The the system to balance typically takes
temperature factor is exponential A modulating valve is used together place in less than 10 minutes .
and small variations lead to more with a magnetic flow meter to
substantial changes in the PU regulate the flow and thus the holding
value . The PU value is maintained time .
by the control system, adjusting Options
these parameters . In the event of
a downstream shutdown, water The beer enters a buffer tank
equipped with a load cell to • Advanced control systems with
replaces the beer in the system to digital programming allow even more
measure the contents . In the event
maint ain the balance . accurate temperature and pressure
of a downstream shutdown, the
pasteurizer continues operation until control . They can be combined with
predictive and fuzzy logic for extreme
a pre-determined maximum level is
accuracy
reached . The remaining beer in the
The temperature is controlled by system is flushed into the buffer • A conductivity meter registers the
means of hot water circulation . With tank with water, which is then re-
a beer pasteurizer, the dissolved circulated to maintain the balance . interface between beverage and
gas must be retained in solution water and reduces changeover
On resumption of downstream
throughout the process by the production, the buffer tank is emptied losses to a very low value
appropriate system pressures . The until a pre-determined minimum level • Valve types and configurations can
design system pressure can be set is reached . The water circulating in be customized as required
for each beer type to minimize energy
requirements . • A double shunt for improving the
coolant supply can be integrated

The unit is based on a three-

section plate heat exchanger with
regenerative, heating and cooling
sections . The heating section is part
of a heating cycle in which water is
warmed by means of a shell and tube
heat exchanger . The beer temperature
is variable, 72°C held for 30 seconds BUF F ERTANK WA TER
being typical .
I RP

The cooling duty is selected G LYCO L

CO NDE NS AT E

according to packaging requirements . S TE A M

G LYC OL
A regenerative outlet temperature as
close as possible to the packaging
temperature allows reduced energy WAT ER /C IP

consumption . B EER

A high-pressure pump supplies p u p a st .d w g

the regenerative section outlet with

the required pressure . A booster
pump between the regenerative and
heating sections of the plate heat

22
 Fermentation & Maturation
Proper ferment ation requires wort
Filtration
Due to seasonal fluctuations in the
CIP Master
Go for perfect cleaning results at lower cost with the APV CIP Master
cooled to the right temperature, quality of the raw material and the
aerated to the right oxygen content complexity of the process itself,
and dosed with the right amount filtration is one of the more complex
The production
of active yeast cells of highdesigns
. APV quality beer parts of the brewing process . APV
using
highly highly efficient
automated process operating
systems works in close co-operation with
that continuously controleffective,
techniques requires careful reputable suppliers of filtration
all essential
cleaningbefore
parameters of equipment
and during. APV offers systems to meet the needs of a
CIP modules as standardized
fermentation and maturation, ensuring specific project .
compact
an end product units
of aorconsistently
units tailored exactly
high
to our
quality . customers specific projects
and needs .
It is important to control the different
phases of the filtration process and
The The
control systems of fermenter integrate them into the rest of the
APV CIP Master is a fully beer processing line, ensuring that
cooling and thesystem,
automatic processprogrammed
system are
designed to provide cohesive support the required production capacity is
to achieve optimal cleaning of the reached .
to brew masters,
process process
equipment . engineers
and automation specialists to help
them to meet the requirements for
specific beer types . The result is
The APV
a complete andCIP Master
well-documented
– adds
process linevalue
designed to maintain
the characteristics of the beer and to
meetThe
consumer
APV CIP expect ations
Master addsforvalue
highto Proven security new APV units .
quality
your. products and processes in the The design of the CIP Master by
• If appropriate, the CIP Master is fully
following ways: tested before delivery APV incorporates the requirements
• Proven functionality and reduced
of production schedules to minimize
Product uniformity downtime . This forms the basis
commissioning time
• Fully automatic CIP programs ensure for selecting the appropriate tank
numbers and volumes together with
perfect cleaning
the number of lines .
Functional
Economical production description
• Full automation reduces manpower
• Optimization of functionality leads to The standard APV control consists
of a controller with an operator panel .
reduced cleaning The APV CIP Master is a fully The signal exchange between the
automatic, self-contained unit . instruments/controller/control room is
It comprises a complete set of performed using a bus system .
Flexible Production equipment for CIP, including, for
Your l ocal cont act :
• Easy implementation of options due example, tanks for water, acid and
to modular design caustic soda, pumps, tubular and/
• The APV CIP Master is skid mounted or plate heat exchangers, valves and Options
when possible, which allows easy instrumentation such as conductivity
relocation in the event of production and flow transmitters .
restructuring The CIP program covers the • 3, 4 or 5 tank systems
complete cycle . Detergent or water • Different tank sizes
selection, detergent concentrations • Number of lines
• Tubular or plate heat exchangers
and cycle temperatures and times are
APV, An SPX Brand • Low cost manual CIP systems
fully controlled . • Customer specific equipment
105 CrossPoint Parkway
Getzville, NY 14068 • PC solutions based on Wonderware
Phone: (716) 692-3000 (800)207-2708 Fax: (716)692-1715
E-mail: answers .us@apv .com
For mo re in for m at ion abo ut our wo rl dwi de The
locat io ns ,appr o APV
vals , ceCIP Master
rt ifi cat is fully
io ns , and local r ep r es ent ati ves , p leas e vi si t ww
w .ap v .c om . FactorySuite™
integrated with the process line and
SP X r es er ve s t he r ight to i ncor po rat e our lat es t d es ign and m ate ri al changes wit ho ut not ic e o r ob lig ati on .
candatbe
Des ig n f eat ur es , mat er i als o f cons t r uct ion and d ime ns ional a, used
as deswith
cr ib edexisting bull eti n, ar e p r ov ided f or yo urconnection
in t his equipment • Modem in for m at ion for
onl remote
y and
s hould no t be r el ied upo n u nles s c onfi r med i n w r it ing . Cer t ifi ed d raw ing s ar e avai lable up on r eques t .
(including filling machines) as well as controller service
Issued: Date 5600-01-08-2008-US Copyright © 2008 SPX Corporation
23