Task
In the brewing process, all JUMO solutions that are relevant for the brewing industry were to be combined in a compact plant that could be used for demonstration purposes in addition to the manufacturing of the anniversary beer. Also, all processes were to be automated, monitored, and visualized as well as have a high level of process and food safety. After brewing, the possibility of CIP cleaning was to be available.
Approach
In our search for the necessary engineering expertise and a regional brewery that could build such a plant and also brew the anniversary beer, we quickly came across the company Burkard und Gärtner (B+G), a specialist in plant design and construction, and the company HUNFELT BRAEU, a young brewery just outside of Fulda. The brewing plant uses 13 innovative JUMO components that ensure highly efficient processes and a golden yellow Pils with a pleasant bitterness.
In addition to the mash tun and lauter tun, the plant was also equipped with a hot water tank. Except for the lauter tun, all vessels are heated electrically via their inner wall; JUMO TYA 202 power controllers are used to control the heating elements.
The sensors used were installed in the plant with process connections G 1/2 (hygienic), JUMO PEKA (EHEDG certified) and clamp, and connected via IO-Link, or via a 4 to 20 mA signal.
The newly developed JUMO DELOS S02 pressure transmitter is used to measure the fill levels of the hot water tank, mash tun, and wort pan. The differential pressure sensor JUMO TAROS S46 H performs the differential pressure measurement under the false bottom of the lauter tun.
The JUMO flowTRANS US W02 is used to measure the volume of the main and subsequent castings. At the outlet of the wort cooler, the new JUMO flowTRANS MAG H20 measures both the flow rate and the temperature. The temperature in the respective containers is determined using the JUMO dTRANS T1000 to determine the temperature in the respective containers.
The limit indicator JUMO ZELOS C01 LS is used as dry-run protection for the pumps for water/CIP function and for mash/wort.
Automation, evaluation and CIP cleaning
The plant is controlled via the JUMO variTRON 500 touch (an automation system with touch panel) and the JUMO smartWARE SCADA (a software for process monitoring and control).
Recipes for individual beer types can be configured intuitively without programming skills using the JUMO variTRON Program App. JUMO smartWARE Evaluation, another software solution, also enables the recording of all process parameters so that the brewing process can be evaluated and verified with an automated batch report.
During CIP cleaning, the JUMO digiLine CI HT10, a head transmitter with an inductive conductivity sensor, determines the concentration of the different cleaning media via the temperature-compensated conductance in the hot water tank. The respective CIP functions can be configured and verified via the above-mentioned JUMO variTRON Program App and JUMO smartWARE Evaluation.
Project outcome
The planning of the plant on the basis of an intelligent 3D CAD model and manufacturing methods such as orbital welding technology meant that the project − which was mainly handled by trainees from B+G − was completed in just a few months.
This has resulted in a fully automated brewing plant in compact skid design which is completely made of stainless steel, has an output of 100 liters of cold wort, and which features an automated CIP function (Cleaning in Place). The brewing plant is a classic 3-unit brewhouse with lauter tun. Potential brew size is approximately 100 liters. Depending on the type of beer, this corresponds to a malt pour of approximately 20 kg.