March 10, 2011

District MichiganMBAA

Technical MeetingGrand 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 CurveMaintaining 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

T00384

TE M

PER

AT U

RE

F

TIME IN MINUTES

657075

80

8590

95

100

105110

115

120

125130

135

140

2 4 6 8 10 12 14 16 18 20 22 24 26 28

AVE.

TEM

P.

COLD

SPOT

TEMP

.

INITIAL BEER TEMP. 40 F (4.4 C)18.321.123.9

26.7

29.432.2

35.0

37.8

40.643.3

46.1

48.9

51.754.4

57.2

60.0

TE M

PER

AT U

RE

C

SPRAY AT 140 F (60 C)

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

Lethal Rate Curve

MINUTES

Average 12.35 P.U.'s

Cold Spot 8.60 P.U.'s

144

143

142

141

140

139

138137136135

133

120 0.025

0.27

0.390.480.570.69

0.83

1.00

1.20

1.45

1.74

2.09

0 5 10 15

LET

HA

L R

AT

E P .

U. '

S / M

INU

TE

56.1

57.257.858.358.9

59.4

60.0

60.6

61.1

61.7

62.2

48.9

P RO

DU

CT

TE

MPE

RA

T UR

E FC 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 GraphTEMPERATURE C

TEMPERATURE F

PU / MINUTE = 1

LOG -1 140 - F

12.5

= 1.20226(F - 140)

0.03

0.1

0.2

0.3

0.50.71.0

2.0

3.0

5.07.0

10.0

20.0

30.040.0

120 130 140 150 160

50 52 54 56 58 60 62 64 66 68 70

PU /

MI N

UT E

LOG

PU / MINUTE =

(C - 60)

-11

= 1.393

60 - C 6.94

10 PUs10 min= 140F

10 PUs30 sec= 157F

Barry-Wehmiller Advanced PU Limit SystemPU Accumulation

PU Accumulation Rate

0.01

0.10

1.00

10.00

100.00

1000.00

1

7

5

1

7

0

1

6

5

1

6

0

1

5

5

1

5

0

1

4

5

1

4

0

1

3

5

1

3

0

1

2

5

1

2

0

Product Temperature [deg F]

P

U

/

m

i

n

u

t

e

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 Blow-Off

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

ZoningSet Point BalanceMaximum RegenCompensationExit Temperature

Single Heat Exchanger System

Single Heat Exchanger with plate Heat Exchanger.Closed Loop System with hot water available on demand.

Basic ConceptsSingle 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

conditionsMove 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

PresenterPresentation NotesThis model better describes the spray header design in the heating zones.Note the manifold on one side is for hot water supply and the manifold on the other side is for cooling water supply.Note that control of the demand for hot water or cooling water is exclusive to each individual spray header.In other words, one spray header can be accessing cooling water, while the one next to it is accessing hot water.

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

PresenterPresentation NotesIntelliFlow is a technology used during PU control mode obviously used to reduce energy consumption during that phase of the pasteurizer operation.

It achieves the utility savings by minimizing the mixing of hot and cooling water supplies.

By doing this we can realize up to 75% savings on steam and water consumption during PU control mode operation.

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 SeriesFlash 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 MeasurementPT100 Temperature probes monitor the temperature of the fluidsWithin 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 electronic4 20mA.

Product Temperature ControlA 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.

The hot water that is used to raise the beer to therequired pasteurization temperature is heated using steam controlled by the pneumatic controlled valve.This valve uses a pneumatic control signal to adjustThe amount to which it opens and so the amount of

steam that can flow into the plate pack

Pneumatic Control Valve

Pressure Reducing Valve

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

TemperaturesPressuresCalculated PUsProduction / CIP Flow rateProduction / CIP / SIP ModeProduct 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 IssuesOperational IssuesQuality IssuesEconomic IssuesEquipment Issues

Application Issues

TunnelWide range of productsCarbonated or non-carbonatedContainer limitations

FlashWider range of products Product limits for plate and frameCarbonated 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 Tunnel ProcessVolutherm 200B $300,000Buffer Tank - $50,000Warmer - $375,000Clean Room $275,000Total equipment -$1,000,000

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 Tunnel ProcessVolutherm 200B Water - 140 gal/chase outSteam 8,000 btu/minBWCo WarmerWater 0gpm normalSteam - 31,500btu/minTotal Steam -39,500 btu/min

New Double Deck TunnelWater - 0gpm, running mode

- 100gpm run-out 24minsSteam 20,000 normal run

- 72,000 start-upAvg. steam - ~ 35,000btu/min

Example Comparison for Flash and Tunnel Floor space requirement

Flash Process Tunnel ProcessVolutherm 200B 200 sq. ft. Buffer tank and valves stand

- 80 sq. ft.Warmer 826 SD

- 280 sq. ft.

Total - 480 sq. ft.

New Double Deck Tunnel1120 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!

Slide Number 1Slide Number 2Presentation AgendaTheory and Objective of PasteurizationTime and Temperature CurvePasteurization Lethal EffectMeasuring Pasteurization UnitsMeasuring Heat TransmissionLethal Rate CurvePasteurization Unit GraphBarry-Wehmiller Advanced PU Limit SystemPU AccumulationValidating MeasurementVerifying Pasteurization Types of Beer Pasteurization TechnologyTunnel PasteurizerTunnel Pasteurizer OverviewPasteurizer General DescriptionPasteurizer FeaturesPasteurizer Process SystemsTunnel Pasteurizer RegenerationSingle Heat Exchanger SystemBasic Concepts Single Heat Exchanger SystemTypical Heat Exchanger Skid Large MachinePasteurizer Main BeltUHMW Wear Strip AttachmentMain Drive SEW Motor/gearboxSpray and Pump SystemSpray System Filter ScreensFilter Screen External Access DoorsSpray System Blow DownPU LimitingAdvanced PU Control System Slide Number 33Utility Control Technology IntelliFlowPasteurizer Control ItemsPasteurizer Safety and AlarmsPasteurizer Recording CapabilityFlash PasteurizerFlash PasteurizationFlash Pasteurizer 180 Hl/HrFlash Pasteurizer 320 Hl/HrFlash Pasteurizer 360 Hl/HrFlash Pasteurizer 250 Hl/HrFlash Pasteurizer FeaturesSlide Number 45Flash Pasteurizer ComponentsProduct Flow MeterProduct Flow Control Valve (Detail View)Product Temperature MeasurementProduct Temperature ControlProcess RecordingProcess RecordingCentral System OperationCentral System OperationFlash Pasteurizer Benefits and FeaturesSlide Number 56Process Comparison FactorsApplication IssuesOperational IssuesQuality IssuesEconomic IssuesExample Comparison for Flash and TunnelExample Comparison for Flash and TunnelExample Comparison for Flash and TunnelExample Comparison for Flash and TunnelSummary of Process ComparisonTime for a beer.