Extract measurement. 09/08/2004 Michael Mies. Slide 1

Transcription

1 Extract measurement 09/08/2004 Slide 1

2 09/08/2004 Slide 3

3 Spindle: The basic instrument for extract measurement Two times every day Discontinous Manual Needs knowledge and expierence Necessary for quality Plato Slide 4

4 Typical curves of fermentation Extract Temperature Pressure Slide 6 Point of following process

5 Measurement principles for extract determination Discontinous, manual Continous, automatic Contigrad Principle Bending oscillator Slide 7 Refractometer Principle Coriolis in bypass

6 09/08/2004 Slide 11

7 Brewery Oettingen GmbH Founded in early middle ages - documents are known from the year ; bought by family Kollmar in Fürnheim in The brewery was incorporated into the Oettinger Group. Production of high quality beers with low price - has led the brewery into the top 5 german beer brewers. Concentration on the typical business of brewers - avoiding extensive technical equipment plants as well as any form of media advertising. Production of Oettinger Pils, 6 low fermentation beers, 5 high fermentation beers, 1 malt beer, 1 alcohol reduced beer and 1 alcoholfree beer. Softdrinks are also in the program. Investment only in high quality technical equipment. Highly efficient systems which produce a high quality product, requiring a minimum of expenditure in operation and maintenance with a maximum in availability, are installed. Slide 12

8 Challenge Because of reorganisation process control and automatisation of procdution areas, new ideas regarding process optimisations were found. Daily control of fermentation, Sometimes two times a day, the brewer has to take samples of beer to define the extract. Reducing time and money - but increasing the process quality. Old cellar has four lines with seven tanks. Test line has to demostrate efficience of online extract measurement. Construction of installation has to create stable conditions for the measurement. Slide 13

9 Method of Resolution German Institute Weihenstephan was involved to find ideal construction for installation and probe reservoir - in preparation: degree dissertation. Reducing of process troubles - small diameter (DN: 8mm) and using a sample reservoir (volume: 3 Liters). Increasing the process control software for controlling extract measurement. Adjusting the software for several additional valves. Taking beer probe into the probe reservoir, pressurising the reservoir and do a concentration measurement with PROline Promass 83F08. Slide 14

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11 Usual situation Tank 1 Tank 2 Tank... Tank 7 Product line Using old, but gold instruments. Slide 16

12 New installation (hardware) Tank 1 Tank 2 Tank... Tank 7 Sample pipe Sample reservoir P CIP/Water Product line Slide 17 Promass 83F08 Flowing off

13 New installation (software) Tank 1 Tank 2 Tank... Tank 7 Sample pipe Sample reservoir P CIP/Water Product line Slide 18 Promass 83F08 Flowing off Process software (PLC)

14 Technical solution Slide 19

15 Bill of material Platomass measurement unit Control unit compact Aternative: control software for Simatic S7 Startup control unit Alternative: startup Simatic S7 Slide 20 Planning and installation pipework

16 Why Endress+Hauser Based on worldwide expierence in brewery technology, paperwork of engineering, drawings, and calculations, the customer was interested to continue the solution process. Close teamwork with customer because salesman was interested in a good applicable solution. Willingness for expierence exchange with customer, Weihenstephan, and Endress+Hauser. Development of customized solution, which was designed to a standard solution. Solution is now reproduceable. Customer was satisfied by motivated salesman and his engagement. No flow competitors provide this kind of product or support for this solution. Slide 21

17 Conclusion: Solutions with Endress+Hauser Contigrad Platomass Slide 22

18 Comparison: Solutions of Endress+Hauser Platomass Contigrad Installation easy (black box) extensive, because two new holes has to be drilled in tank Accuracy ± 0,15 Plato ~± 0,25 Plato depends on: (Promass) - Distance of sensors - Head pressure in tank - Environment temperature - Measure range of pressure sensors Requirements Beer sample will be lost above DB sensor should be covered (3-4 litres per with beer measurement) Additional pipes necessary Prices up to 22000, / tank (min. 10 tanks) incl. Software and two DB sensors Slide 23

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20 Application pictures History of Brewery Small company with 5 employees for all production lines (6 types of beer) begining with brewing, filling, bottling, and finally packing the product. Brewery started with 6 fermentation tanks, increased the number up to 9 tanks. Target was to support small brewer team in their daily work. Accurate and repeatable measurement doesn t waste time anymore for controlling extract during the fermentation. Platomass reduces costs, increases the flexibility for the company. Slide 25

21 Application pictures Connection sample pipe to vessel Slide 26

22 Application pictures Connections: sample pipes to valves node Slide 27

23 Application pictures Valves node (front side) Slide 28 Valve node (Platomass outlet)

24 Application pictures Control valve Valves node (back side) Connection indicator for PLC Slide 29

25 Application pictures Slide 30 Screenshot PLC: Control of pipes and valves for Platomass (Extract measurement)

26 Application pictures Platomass (door opened) Special installation with inspection glasses at sample bin. Slide 31

27 Application pictures Inspection glas Beer incl. foam Filling sample bin with unfiltered beer including CO 2 Slide 32

28 Application pictures Filled sample bin is pressurised for extract measurement Unfiltered beer incl. foam, but pressurised Slide 33

29 Application pictures Display of measured Plato Slide 34

30 09/08/2004 Slide 35

31 Example for profit calculation Number of tanks: 15 Days of measurement per year: 180 Cost per brewer: 30 /hour Time needed per tank (average): 20min = 1/3 hour (Taking probe, filtering, degasing sample, and measuring) Real time necessary, because doing things parallel: 5 tanks per hour = 3 hours/day per brewer Costs based on manual measurement 15 tanks * 1/3 hour * 30 /hour * 180 days = Slide per year