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Documente Profesional
Documente Cultură
2. QUICK FLOW
3. YEAST MANAGEMENT
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4. YEAST PROPAGATION
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Yeast pitching
Swing bend execution dosing line
With proximity switches
Microscopic cell count
1 harvest to 1 YST
Inline cooling in harvest line
Volumetric flow measurement & Visual detection
yeast/beer
Gas block
Without carbon filter in air supply
Iso-mix (pm)
Foam catcher
With carbon filter in air supply
Yeast Storage
One yeast plant in case of muliple yeast strains
3 YST
Homogenisation using a circulation pump
Yeast rehydration
Dried yeast
Cold wort intake
Rehydration using a Carlsberg Flask
> 1 WYT
Inactivation by heat
Chemical inactivation
Automatic discharge of the WYT
Yeast propagation
Mixing by aeration
Aerated steps in propagator
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CIP
Free
Air
Inlet on max
liquid level
Coolant
FST
To lorry
FE
YEAST
COOLER
Brewhouse
CIP Return
CIP dosing
line together
with wortline
FE
To FS or FSTs
Yeast harvest:
Swing bend/flow plate execution of the cellar distribution (not indicated in picture above)
Positive displacement pump as driving force for the yeast transfer from FST to yeast storage
Flow measurement for pre- and post run activities
Sight glass to detect beer/yeast transition
Yeast deep cooler to cool the yeast from FST harvest temperature until < 2 C
1 harvest line to the yeast storage and waste yeast
Centrifugal pump to empty Yeast storage tanks to the waste yeast tank
Yeast storage and pitching:
Three yeast storage tanks
Tank cooling to maintain storage temperature
Yeast homogenisation using a positive displacement pump and a recycle line
Prevent foaming
o 50 % headspace
o Pre-pressurise YST before harvest (pressure as low as possible)
1 yeast dosing line (pitching)
Yeast dosing based on a mass flow measurement and laboratory consistency and dead cell
measurement
CIP dosing line together with the wort line
Waste Yeast plant
One Waste Yeast Tank
No yeast inactivation
Local controlled manual discharge of the WYT
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++
+
0
--
=
=
=
=
=
Add On
Consistency measurement by
density using density
measurement of mass flow
meter
+
+
+
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
A Thoma cell counter is more expensive than laboratory consistency mesurement
A yeast monitor measurement is expensive compared to relatively simple laboratory equipment
and batch sampling. A yeast monitor measures consistency and yeast viability
An additional density measurement to the mass flow meter (to measure consistency) is slightly
more expensive. It does not measure yeast viability
Technological:
Inline consistency measurement is independent of homogeneity.
Inline measurement measures each dosing, batch sampling only once and therefore storage time
dependent.
Additional density measurement of the mass flow meter still requires laboratory dead cell
measurement. In case of good yeast management, dead cell level is not very fluctuating. If
fluctuation is low, not every batch needs to be measured.
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++
+
0
--
=
=
=
=
=
Add On
Weight decrease
YST
-
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
o Mass flow measurement is more expensive
o Only one inline measurement compared to weighing cells on each YST.
Technological:
Weighing cell accuracy less than mass or volumetric flow measurement
No correction for yeast concentration in case of concentration gradients for volumetric flow
measurement
Operational:
More equipment to maintain in case of weighing cells
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++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
o No additional valves, piping and CIP program in case of cleaning together with the
wortline.
Operational:
Operational consequence of the basic solution is:
o CIP only possible in case of FST switch
Flexibility problems can occurs in case of:
o More than 1 brewhouse (2 or more dosing at the same time
o Multiple yeast strains (CIP required)
o In case of a lot of small fermenting tanks (many dosing/day)
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++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
o Additional harvest and purge line without connection with the YST in case of an additional
line.
Operational:
o Change over number of tanks depending on the process time.
o 36 tanks is based on 18 days production time in FST. (Max. 3 harvest & 3 purge & 4 CIP/day)
++
+
0
--
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=
=
=
=
=
excellent
good
average
mediocre
poor
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Operationa
l
Legend:
-/-++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
Turbidity measurement and a simple flow measurement are cheaper than mass flow measurement
with density measurement
In case of applying a mass flow measurement a additional pressure control valves is required to
avoid CO2 bubbles
In case of bigger breweries flow measurement and yeast detection before the central yeast flow
plate or matrix are recommended
Operational:
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In case of big breweries with a additional purge line and a lot of activities at the same time, visual
control is not reliable
Risk of beer losses
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Basic Design
One Yeast
plant
++
+
Add On
Each yeast strain its own yeast
plant
-+
+
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
o Separate harvest lines incl. coolers
o Separate YST
o Separate dosing lines
Technological:
With an appropriate CIP philosophy it is superfluous to separate the yeast plants in case of multiple
yeast strains.
It also makes no sense, because FST are common used for all strains.
More YST required, this is a risk for longer storage times
Operational:
Higher maintenance and operational costs (additional equipment).
o A lot of additional procedures are required.
o More attention required of operators
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2
2
3
3
1:1
3:1
1:1:1
2:1:1
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution (recycling line, valves, recycle pump)
o Expensive stirrer including construction on each tank
Technological:
1 Yearly Hl produced with yeast A: yearly HL produced with yeast B: yearly HL produced with yeast C
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In combination with an inline cooler and yeast storage tank cooling to maintain the storage
temperature, basic design is homogenous and temperature stable.
A stirrer is a better mixer than a recycle pump
Stirrers are sensitive for oil leakages (SHE)
Stirrers have a better deep cooling performance
Stirrers are difficult to clean
Operational:
Flexibility: With a stirrer deep cooling in the tank is possible. This is not the case in case of
using a recycling pumps
Maintenance costs for stirrers are higher
Iso-mix system (p.m):
The isomix is system is based on a circulation using a centrifugal pump and mixing device. The main
difference compared to the basic design, is the use of a rotating mixing machine, which is positioned below
liquid level. It looks promising, because it is combining the advantages of stirring and recycling. Further
investigation on yeast viability is needed, before this application will be released.
Yeast mixing using a centrifugal pump (p,m.):
Iso mix and also some other suppliers are offering centrifugal pumps for yeast homogenization.
The results of breweries using these pumps are not evaluated yet.
++
+
0
--
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=
=
=
=
=
excellent
good
average
mediocre
poor
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PT
PI
PT
PT
PI
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PT
PI
Solution 3
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Product contact
Common/Individual
connections
Solution
Gassupply
Product integrity
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
N
N
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
N
N
I
I
I
I
C
C
C
C
I
C (I)
C (I)
I
I
I
I
I
I
I
1
1
3
2a
2b
2b
2b
2b
2a
2b (2a)
2b (2a)
2a
2a
2a
2a
2a
3
3
Wortline
Carboniser
YPT
YPT
YST
FT
FST
ST
UBT
FBT
DAWT
PSA
BT (BBT)
BT (H&T)
RBT
PBT
KGF
PVPP
Description
aerate wort
carbonise bright beer
aerate wort & yeast
pressure control wort & yeast
pressure control, yeast
pressure control, green beer
pressure control, wort/green beer/young beer/mature beer
pressure control, young beer/mature beer
pressure control, mature beer
pressure control, bright beer
pressure control, "bright beer"
pressure control, bright beer
pressure control, bright beer
pressure control, bright beer
pressure control, mature beer
pressure control, bright beer
not product related
not product related
3.5.7.1 WITH OR WITHOUT STEAMING FACILITIES IN AIR (OR OTHER GAS) SUPPLY
Modern breweries more and more are using sterile filters to prevent microbiological contamination from the
air supply.
In case a sterile (membrane) filter is installed steaming of the air supply is not necessary since the sterile
filter guarantees sterility.
Table3.5.7.1.1. With or without steaming facilities in the air supply
Item
Basic Design
Add On
Without steaming
With steaming
facilities
facilities
Technical
+
Technologica
+
+
l
Operational
+
Legend:
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Lowest investment costs for the basic solution using a sterile filter
o Steam supply including valves, pressure control and others is required in case no sterile
filter is used.
Technological:
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Steaming and sterile filtration are both securing microbiological contamination. So installing one of
the two is enough.
Operational:
Integrity check and/or planned maintenance required for sterile membrane filter
Regular steaming of the air supply is needed in case no sterile filter is installed
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CIP
Sterile air
Carlsberg flask
to sampling
point using
sterile air
50 % Head space
FE
FE
3 O2 membranes
Coolant
FE
To FS or FSTs
Wort
Water
Yeast propagation:
Swing bend/flow plate execution of the cellar distribution (not indicated in picture above)
Dried yeast
Carlsberg flask for re-hydrating dried yeast.
Centrifugal pump as driving force for the fermenting yeast transfer to FT or FST
130 Dished bottom with 3 aeration points (120 of each other)
No mechanical homogenization (only mixing by aeration)
Aeration only in propagator and not in FT or FST
Yeast transfer from propagator to F(S)T as fermenting wort. (No purge)
Last 2 propagation steps in F(S)T
Temperature control using cooling coils
Slightly overpressure to avoid microbiological contamination.
Pressure control using sterile air
50 % headspace
Yeast harvest from FST after final propagation step in FST
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Add On
Pure culture
yeast
0
++
+
0
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution. (Carlsberg Flask, Propagator)
o In general additional equipment is used for a pure yeast plant. ( wort sterilisation,
additional small propagator)
Technological:
Dried yeast has always the same quality (flocculence, flavour stability, operational). Pure yeast
plant has a risk of mutation
Operational:
Pure yeast plant requires constant attention
Dried yeast costs
=
+
0
--
Add On
1
Hot wort
Add On 2
++
0
Sterile
wort
-++
--
excellent
=
=
=
=
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
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More cooling capacity (deep cooling from 100 C to pitching temperature) on propagator or
sterilisator required
Additional YPT tank costs due to high temperature (design pressure)
Additional sterilisator in case of sterile wort
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++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
o Rehydrator is more expensive than a Carlsberg flask. (including a stirrer, temperature
control, electrical heater, empty detection, sterile filter)
Technological:
The rehydrator is recommended in case of Heineken production. All needed functionality for rehydration and process control is available on the rehydrator.
Operational:
Rehydrator is not suitable for pure culture yeast
Continuous labour activity during re-hydration uing a Carlsberg flask(I.e. manual shaking). In case
of a re-hydrator only manual filling with dried yeast.
Carlsberg flask requires almost no maintenance
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Table 4.5.1.1 Size propagator depending on FST size and only complete brews to F(S)T
FST Size
(gross
hl)
1000
2000
2500
Brew
Size
(hl)
Minimal
propagator
Liquid
level (hl)
Vol. 1st
propagation
step in F(S)T
Max. 7 x (hl)
100
200
250
35
70
90
2500
250
90
3000
300
100
4000
400
135
5000
500
170
Note: The last 2 steps are not aerated
Propagator
Gross vol.
(hl)
235
470
590
Final vol.
after last
propagation
step in F(S)T
Max. 5x
(hl)
835
1670
2090
590
700
935
1170
2090
2500
3335
4170
180
200
270
340
70
140
180
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Pressure
control YPT
Yeast propagator
PC
Pressure transmitter,
Foam detection,
Overpressure valve,
Underpressure valve,
are not shown on this scheme, but
are present!
Pressure reducer
6 2 1 bar
Controlled on/off valve
with small bore hole Pressure 0,5 bar higher
then pressure in the tank
Rota measuring
in litres/min
0
PC
50
Transparant hose provided
With quick clamp hose
connections
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Membrane
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