March 10, 2011

District Michigan
MBAA
Technical Meeting
Grand Ledge, MI

Presentation Agenda
Pasteurization Basics
Tunnel Pasteurization Technology
Flash Pasteurization Technology
Technology Comparison
Questions and Discussion

Theory and Objective of Pasteurization

Elevated levels of heat will kill organisms

Heat beer to arrest biological contamination

Destroy viability of yeast
Prevent post fermentation

Brewers want Pasteurize not Sterilize

Minimum temperature for target organisms

Limited Pasteurization units

Time and Temperature

Curve
Maintaining the
time/temperature
profile is key to
preserving the
process or
protecting against
under and over
pasteurization

Pasteurization Lethal Effect

A lethal effect of 1 PU (Pasteurization Unit) is

obtained when product can be held at 140F for 1

minute
Brewers typically target 10PUs to 15PUs

Control of PUs is essential

Elevated PUs can affect flavor degradation

Measuring Pasteurization Units

Measure at Cold Spot of container

Probe position in container

Pasteurizer internal calculation

Using sensing devices and programming

Calculate PUs

Time above 120F

Time in holding tube at Pasteurization temperature

Measuring Heat Transmission

TIME IN MINUTES
2 4 6 8 10 12 14 16 18 20 22 24 26 28
60.0
57.2

P.

54.4
51.7

125

M
TE

120

48.9

115

46.1

110

43.3

105

40.6

100

37.8

95

35.0

90

32.2

85

29.4

80

26.7

75

23.9

70

21.1
18.3

65
INITIAL BEER TEMP. 40 F (4.4 C)
SPRAY AT 140 F (60 C)

T00384

TEMPERATURE C

130

CO VE
LD . T
SP EM
OT
P

135

TEMPERATURE F

Cold Spot is
usually
located at
to 1
above the
center of the
bottom of
the container

140

PRODUCT TEMPERATURE

C F
62.2

144

61.7

143

2.09

Average 12.35 P.U.'s

1.74

Cold Spot 8.60 P.U.'s

61.1

142

1.45

60.6

141

1.20

60.0

140

1.00

59.4

139

0.83

58.9

138

0.69

58.3
57.8
57.2

137
136
135

0.57
0.48
0.39

56.1

133

0.27

48.9

120

0.025
0

10

15

MINUTES

LETHAL RATE P. U. 'S / MINUTE

Lethal Rate Curve

PUs calculated for
product temperature
above 120F.
Area under the curve
equals the number of
PUs achieved.
Cold spot PUs less
than Average.

Pasteurization Unit Graph

TEMPERATURE C

40.0
30.0

50 52 54 56

58 60 62 64

66 68 70

10 PUs

20.0

30 sec

10.0

= 157F

1
PU / MINUTE =
-1
LOG 140 - F
12.5
(F - 140)
= 1.20226

1
PU / MINUTE =
-1
LOG 60 - C
6.94
(C - 60)
= 1.393

PU / MINUTE

7.0
5.0
3.0

10 PUs

2.0

10 min
1.0

= 140F

0.7
0.5
0.3
0.2
0.1

0.03
120

130

140

150

TEMPERATURE F

160

Barry-Wehmiller Advanced PU Limit

System
PU Accumulation
PU Accumulation Rate
1000.00

10.00

175

170

165

160

155

150

145

140

135

130

125

120

1.00

0.10

0.01
Product Temperature [deg F]

PU / minute

100.00

Validating Measurement
Independent validation for tunnel

Several manufacturers of independent PU

measuring devices
Measure time and temperature
Calculate and report PU values

Machine internal validation for flash

Redundancy on sensors
Micro analysis

Verifying Pasteurization

Independent
measurement is
capable with tunnel
technology only.
Redundancy can
help reliability

Types of Beer Pasteurization Technology

Two basic types of beer pasteurization
1.

Tunnel Pasteurization

2.

Flash Pasteurization

Tunnel Pasteurizer

Tunnel Pasteurizer Overview

General Description
Pasteurizer Features
Pasteurizer Systems
Operational Controls
Reporting/Recording

Pasteurizer General Description

Length - Width
# of Decks
Features
Systems

Pasteurizer Features
End Casings
Removable

Top Covers
Container
Water BlowOff
Condensate
Return System

Pasteurizer Process Systems

Regeneration Capability
Heating System
Belt and Drive System
Spray System
Pump Systems
PU Control
Controls, Alarms

Tunnel Pasteurizer Regeneration

Cold containers
entering require heat

Hot containers exiting

require cooling
Zoning
Set Point Balance
Maximum Regen
Compensation
Exit Temperature

Single Heat Exchanger System

Single Heat Exchanger with plate Heat Exchanger.

Closed Loop System with hot water available on
demand.

Basic Concepts
Single Heat Exchanger System
Benefits of the Single Heat

Exchanger System
Low Maintenance

Only one heat exchanger

Plate Heat exchanger

Efficient use of energy

Condensate return
Less Pump
Horsepower required

Typical Heat Exchanger Skid Large

Machine

Pasteurizer Main Belt

Intralox 400 and 1900 with

Enduralox
Twentebelt Combinox and
Eyelink
Regina 3120
Rexnord 5997 with DTS-C

UHMW Wear Strip Attachment

Allow for UHMW expansion

Easy install and replacement

Main Drive SEW Motor/gearbox

Spray and Pump System

Pressurized water flow rate

designed to optimize thermal

heat transfer rates
Up to 6.8gpm/ft
Thermal Dynamic Models
Manual Blow Downs
Even flow across the deck
Predictable Heat Transfer
Removable spray headers
3 1/2 header, 3/8 nozzles

Spray System Filter

Screens
Redundancies for Maintaining Spray Consistency

Belt side guides

Belt mesh pattern
Dual pump inlet screens
Spray header design
Spray header blow down

Filter Screen External Access Doors

Spray System Blow Down

PU Limiting
Hot Zones
Add cold water

to zone reservoir
Re-heat on start
up

Advanced PU Control System

Advanced PU Control System controls the

pasteurization process:
Guarantee very tight PU control
Preserve the process curve in stop/start
conditions
Move process to container if container can not
get to process

Possible to have hot water on

one header and cold water on
another header from the same
manifold

Utility Control Technology IntelliFlow

The IntelliFlow System:

Used in conjunction with Advanced PU Control

Water temperature separation technology
Eliminates requirement for water re-heating
Provides benefits of PU control without added
utility consumption

Pasteurizer Control Items

Sensors, proximity switches, instruments
Safeties and Alarms

Pasteurizer Safety and Alarms

Hot zone pumps 2 below set point for 30 seconds

will stop belt

Pressure sensors all zones below 2psi for 15
seconds stops pasteurizer
All levels satisfied before pasteurizer will start
Belt speed monitored by checking starwheel pulse
duration to time set in recipe
Drive overloads spring and proximity

Pasteurizer Recording Capability

Data collected from Sensors:
Temperature of all zone sprays
Speed of belt
Levels
Data collected in the pasteurizer PLC
Data sent to remote storage
Data can be extracted to workable files
Reports can be generated

Flash Pasteurizer
Volutherm Series
Flash Pasteurizer

Flash Pasteurization

Pasteurization occurs prior to filling

Short Time High Temperature (HTST)
Heat Exchanger (plate or tube)
Fixed or Variable flow rates
Pasteurization calculated by Holding Time and
Temperature
High Efficiency (90% regeneration)
Controls are Key!

Flash Pasteurizer 180 Hl/Hr

Flash Pasteurizer 320 Hl/Hr

Flash Pasteurizer 360 Hl/Hr

Flexibility to design
units to fit various
applications
Juice unit with Heat
Exchanger mounted
on the floor for
accessibility on
larger pasteurizers
Often times machines
can be designed to
handle different
products on the same
unit

Flash Pasteurizer 250 Hl/Hr

Flash Pasteurizer Features

Constant PU Variable Flow rate Unit.
Pressure Balance System.
90% Energy Recovery.
Status and Process Alarms.
Digital Paperless Chart Recorder.
Fully Automatic Operation.

Flash Pasteurizer Design

Flash Pasteurizer
Components

Product Flow Meter

An Electromagnetic flow measuring system is used to monitor the flow of the

product at the discharge of the pasteurizer.

Product Flow Control Valve

(Detail View)

4-20mA Electrical Input Signal.

Resulting in a 0-100% Valve opening.

Product Temperature Measurement

PT100 Temperature probes monitor the temperature of the fluids
Within the pasteurizer.
As the temperature changes the resistance measured by a
Transmitter fitted inside the temperature probe changes.
The input signal to the pasteurizer control system is electronic
4 20mA.

Product Temperature Control

Pressure Reducing Valve

A pressure reducing valve is designed for

maintaining the pressure downstream of the steam
supply valve to an adjusted set point value.
Set point approximately 2.0bar
The valve closes when the downstream
pressure rises.
Pneumatic Control Valve

The hot water that is used to raise the beer to the

required pasteurization temperature is heated using
steam controlled by the pneumatic controlled valve.
This valve uses a pneumatic control signal to adjust
The amount to which it opens and so the amount of
steam that can flow into the plate pack

Process Recording
Touch Screen HMI
Select recipes
Operational functions
Adjust parameters
Alarm displays
Digital Paperless Process Logger
Records temperatures
Records flow rates
Records pressures
CIP and Run modes

Process Recording
Temperatures
Pressures
Calculated PUs
Production / CIP Flow rate
Production / CIP / SIP Mode
Product In Machine

Central System Operation

Central System Operation

Flash Pasteurizer Benefits and Features

Performance tolerance to with in 1PU
Variable flow, variable temperature
Maximum regeneration
Quality monitoring, alarms, reports, archiving
Machine self-diagnostics
Operation safe-guards for PU protection
Gentle product handling (HTST)
Compact footprint, Low energy use

PROCESS COMPARISONS

Process Comparison Factors

Application Issues
Operational Issues
Quality Issues
Economic Issues
Equipment Issues

Application Issues
Tunnel
Wide range of products
Carbonated or non-carbonated
Container limitations
Flash
Wider range of products
Product limits for plate and frame
Carbonated or non-carbonated

Operational Issues
Tunnel

Controls and Complexity can be less

More forgiving
Reduced requirement for micro control
Manual machine cleaning
PU Control required for line conditions

Flash

Cleaning and Sanitation Increased

Line availability reduced
Enhanced microbiological testing
CIP systems are critical
Buffer systems for handling line conditions

Quality Issues
Tunnel

Taste affects possible with prolonged stops

Validation using independent device
Reduced requirement for micro control
Exit temperatures
Flash
Minimal taste affects
Potential for recontamination
Validation trust sensors, redundancy
Ability to re-circulate
Disinfecting caps and containers filler contact points

Economic Issues
Tunnel

High capital costs for new equipment and installation

Operating costs can be high
Reduced costs for monitoring quality
Increased line utilization
Flash
Capital cost can include warmer, filling room upgrades
High efficiency reduces utility cost (warmer?)
Less floor space required

Example Comparison for Flash and Tunnel

Example Selection:

Brewery

Bottle production line operating at 800bpm

Target PUs at 10 +/- 2
Target BOT at 75F

Example Comparison for Flash and

Tunnel
Equipment Cost

Flash Process
Volutherm 200B
$300,000
Buffer Tank - $50,000
Warmer - $375,000
Clean Room $275,000
Total equipment $1,000,000

Tunnel Process
New Double Deck sized
correctly to optimize utility
consumption and provide low
product exit temperatures
- $1,500,000

Example Comparison for Flash and

Tunnel
Utility Consumption

Flash Process
Volutherm 200B
Water - 140 gal/chase out
Steam 8,000 btu/min
BWCo Warmer
Water 0gpm normal
Steam - 31,500btu/min
Total Steam -39,500
btu/min

Tunnel Process
New Double Deck Tunnel
Water - 0gpm, running mode
- 100gpm run-out
24mins
Steam 20,000 normal run
- 72,000 start-up
Avg. steam - ~
35,000btu/min

Example Comparison for Flash and

Tunnel
Floor space requirement

Flash Process

Tunnel Process

Volutherm 200B 200 sq. ft.

Buffer tank and valves stand
- 80 sq. ft.
Warmer 826 SD
- 280 sq. ft.

New Double Deck Tunnel

1120 sq. ft.

Total - 480 sq. ft.

Summary of Process Comparison

Capital Cost Similar when considering clean room
Utility Consumption Similar when using warmer
Process Considerations Culture change for flash
Cleaning Materials/Sanitizing Agents and Micro

Control requirements Higher costs for flash

Available Packaging Line Time Higher for tunnel
Floor Space Flash has reduced space requirement

Time for a beer.

Thanks for listening!