What is the importance of temperature control in the fermentation process?

Fermentation tanks are a key element in the process of brewing beer, wine, producing bioethanol and other fermented products, and maintaining a constant temperature in them is essential. The fermentation process involves the conversion of sugars present in raw materials by yeast (or other microorganisms) into alcohol and carbon dioxide. During this process, heat is generated, which can raise the temperature of the wort (water-sugar mixture) above the optimal level for the yeast. The temperature controller used helps keep this variable in check. To ensure stable and optimal fermentation, tanks must be properly cooled.

Temperature control in fermentation is a key part of the process that affects the quality of the final product. Optimal temperature is essential to ensure proper yeast performance, as even small deviations can lead to undesirable flavors and aromas. In addition, precise control of this parameter helps maintain production consistency and ensures microbiological safety.

What fermentation temperature control challenges has the brewery encountered?

Our client is a small but rapidly growing craft brewery. This breweryapproached us with a need to maintain optimal temperature conditions in two new fermentation tanks. The plant needed a system that was easy to use, even for operators without much technical experience. An intuitive user interface and the ability to easily make settings were crucial to ensure effective management of the fermentation process. The system needed to be able to adjust parameters quickly and easily, monitor temperatures precisely, and respond quickly to any deviations from the norm.

In addition, due to the aforementioned rapid growth rate, the brewery needed a system with easy expansion capabilities. The anticipated increase in production and the addition of new tanks required a flexible, scalable automation system that would not require the replacement of existing equipment in the future.

Our solution - a system with a PLC and Pt100 resistance temperature sensors

Taking these needs into account, we offered the Södra Maltfabriken AB brewery a complete solution, including a mTRON PLCand Pt100 resistance temperature sensors. This system provides the required precise temperature control, flexibility, and future expandability.

Temperature sensors for the brewing industry

The Pt100 resistance temperature sensors were chosen for their high accuracy and stability. They monitor the temperature in three zones of each fermentation tank: top, middle and bottom. This makes it possible to maintain optimal conditions for the fermentation process throughout the tank.

JUMO PLC as temperature controller for the fermentation tank zones

At the heart of the system is the freely programmable JUMO mTRON T PLC, responsible for collecting data from Pt100 sensors, analyzing them and making decisions on temperature control. It is equipped with an OPC server, Ethernet and a system bus, which allows integration with other systems and remote monitoring and control.

HMI interface - viewing fermentation parameters

The JUMO mTRON T system is equipped with an HMI (Human-Machine Interface), which allows operators to view all relevant parameters in real time. The screen displays current temperatures in each zone, the status of magnetic valves and any alarms. The intuitive interface allows for easy monitoring and management of the system.

Individual settings for each zone and tank possible

The JUMO mTRON T system allows brewery operators to set individual temperature setpoints (setpoints) for each of the three temperature zones (top, middle, bottom) in each of the two fermentation tanks. This allows operators to adjust the temperature in different parts of the tank depending on the specific needs of the fermentation process.

Magnetic valve control

The system uses magnetic valves to control the flow of coolant through the cooling jacket around each zone of the tank. Based on data from temperature sensors, the PLC opens or closes the magnetic valves to precisely regulate the temperature inside the fermenters. When the temperature in a zone exceeds a preset setpoint, the valves open, allowing coolant to flow through and lower the temperature. When the temperature returns to normal, the valves close, stopping cooling.

Manual and automatic control

The system allows both manual and automatic control of the fermentation process. Operators can manually set setpoints for each temperature zone of the tank using the HMI, adjusting parameters to meet current needs. Alternatively, they can select one of the pre-programmed operating modes that automatically control the temperature according to predefined temperature cycles. The automatic modes ensure consistency and repeatability of the fermentation process, which is key to maintaining high quality beer.

What were the benefits of implementing an automation system at the brewery?

The implementation of the JUMO mTRON T automation system at the Södra Maltfabriken AB brewery has brought many benefits, significantly improving the efficiency and quality of beer production. Precise temperature control has made it possible to maintain optimal fermentation conditions, necessary for proper yeast performance and high quality of the final product. The system ensured temperature stability in three zones of each tank, minimizing the risk of overheating or overcooling the wort.

Independent control of the fermentation tanks gave the brewery greater flexibility in production planning, allowing different stages of fermentation to run simultaneously. With precise control of the magnetic valves, the system optimized energy consumption, resulting in operational cost savings.

The HMI interface and remote monitoring have increased operating convenience and allowed rapid response to any deviations from the norm. The modular design of the system allows easy expansion with new tanks and modules, providing flexibility and scalability in line with the brewery's growing production needs. All in all, the implementation of the system with temperature sensors and the JUMO mTRON T controller has helped optimize processes, increase efficiency and support the further development of the brewery.

About the author

My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.

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