gusmer distilling filtration seminar notes
TRANSCRIPT
A Distiller’s Guide to
Optimal Filtration
Nathan Kreel, PhD
Gusmer Enterprises
Service with Knowledge®
Why Filter Distilled Spirits?
Clarity
Chill Proofing
Color/Flavor Adjustment
Contamination Risks (Liqueurs)
Where and What is Finishing?
Mashing → Fermentation → Distillation
→ Aging → Finishing → Bottling
• Finishing
– Dumping the barrels
– Filtering (coarse filtration)
– Cutting / Proofing - Modifying / Stabilizing
– Filtering (prior to bottling)
Finishing… What Might You Face?
Instabilities (What’s in your soup?)
Batch to Batch Variations
Formulated Products
What’s In Your Soup?
Fermented Beverages Are Complex Systems
• Substrate (Grain / Fruit / Vegetable) – Sugars / Carbohydrates / Proteins / Phenolics / Acids / Salts /
Enzyme Systems / Plus Many More Compounds
• Introduce Yeast/Bacteria → Ferment – Alcohols / Fats / Lipids / Glycerol / Sugars / Acids / Esters,
Aldehydes and other Metabolites / Plus Many More Compounds
Spirits are mostly ethanol, but compounds carry over (congeners)
or are added during additional processing
Instabilities
Equilibrium Reactions / Solubility
A + B ↔ C
Solute/Solvent ↔ Saturation
System in Equilibrium + Change = Could shift
reactions and create instabilities
– Triggers • Shift in solvent system (alcohol solubility)
• Shift in pH
• Shift in temperature
• Reactive compounds (i.e. dissolved oxygen, blending)
• Time (age)
Batch to Batch Variations
(in non-formulated products)
Small Scale or Craft Programs – may embrace
variations…up to a point
Large Scale Program – may require more
consistency
– Bottling Specifications for Color / Flavor / Aroma / Clarity (or
Turbidity)
• Turbidity specification is typically < 1 NTU (nephelometer turbidity units –
measures light scatter)
• May require color, flavor, aroma additives to meet specifications
• May require fining to remove color, flavor, aroma, or stabilize
• May consider blending similar products
Formulated and Specialty Products
• Ready to Drink Cocktails / Extractions / Liqueurs – Risk for Post Bottling Fermentations
• Low alcohol levels (<15% by volume)
• Residual sugars
• Higher pH levels (2.5 – 3.9 more stable, 4.0 to 4.9 moderately stable, above
5.0 less stable)
• May need to consider sterile filtration and/or preservative systems
– Potential for Instabilities
• Colorings, Flavorings, Aroma… Natural and Artificial Compounds
Correcting Instabilities and Variations
• General Debris and Turbidity – Filtration
• Fatty Acid / Alcohol Solubility – Chill Filtration
• Color, Flavor, Aroma Reduction – Loose Carbon or Carbon
impregnated filters
• Pectin (fruit extracts, fruit concentrates) – Enzymes
• Protein (fruit extracts, fruit concentrates) – Bentonite (pH
dependent), Silica Gels
• Phenolic / Color Stabilization (fruit, grains) – Gelatins, PVPP, Casein
Filtration Still A Necessity
Most of these processing steps will require some
type of filtration… but which filters are best for
spirits applications?
Where Filtration Occurs, Grain Receiving
Hammer Mill
Slurry / Mix tank
Liquifaction tank Fermentation tanks
Beerwell
Distillation
Ethanol Storage
Whole Stillage Tank (Feed)
Decanter
Centrifuge
DDGS (Feed)
Dryer
Wetcake (Feed)
Thin Stillage
Evaporators
Backset
Syrup
Barrel Aging
Pre-Bottling Holding Tanks
Standard/Polish
Filtration
Coarse
Filtration
Final (Bottling) Filtration
Blending Tanks
Chill Tanks
Coarse Filters in a Distillery
• Bag Filters • Housings ~ $1,000
• Polyester Felt Bags ~ $10
each
• Limited retention and “dirt
loading” capacity
• In-line Strainers • Housings ~ $600 - $1,000
• Over screens ~ $200
• Limited retention and “dirt
loading” capacity
Application: Dumping – Coarse filtration to remove any
barrel char or general debris
Types of Filter Media for Standard Filtration
DEPTH FILTER SHEETS
All Cellulose
DE Containing
Carbon Containing
SYNTHETIC CARTRIDGES
Nominal rating
Absolute rating
LOOSE POWDER
Carbon
Diatomaceous Earth
LENTICULAR STACKS
All Cellulose
DE Containing
Carbon Containing
What Type is Right for You?
Ease of Use
HIGHEST
LOWEST
Solids Capacity (per ft2)
LOOSE POWDER
(bodyfeed)
DEPTH FILTER SHEETS =
LENTICULAR STACKS
SYNTHETIC CARTRIDGES
SYNTHETIC CARTRIDGES fast install, consistent, drip-free, storable
LENTICULAR STACKS fast install, consistent, drip-free, short storage
DEPTH FILTER SHEETS med. install, consistent, drips, short storage
LOOSE POWDER slow install, inconsistent, drip-free, no storage
Depth Filters (either sheets or stacks) are most common in distilling
Standard Polish Filters in a Distillery • Filter Press – Filter
Sheet Media – 40 cm Filter Press ~ $6,000
– 40 cm Filter Sheet Media ~
$1.65 per sheet
– Wide range of porosity and
retention rates available (0.3 to
20 microns nominal retention)
– Excellent retention and “dirt
loading” capacity
– Best economics
• Application: All general
filtration applications for
Spirits production – Coarse to polished filtration
Standard Polish Filters in a Distillery
• Lenticular Cartridge
Filters – Housings ~ $3,500 to $7,000
– Cartridges ~ $125 each
– Wide range of porosity and
retention rates available (0.3 to
20 microns nominal retention)
– Excellent retention and “dirt
loading” capacity
• Application: All general
filtration applications for
Spirits production – Coarse to polished filtration
Lenticular Cartridge vs. Sheets
Same Filter Media - Different Form
Pros & Cons - Lenticular vs. Sheets Lenticular Cartridges
– Full range of filter media
– Easy to load
– Small footprint
– No Dripping
– Sealed (more sanitary)
– More expensive per
square foot of filter media
– Low holdup volume
Filter Sheets
– Full range of filter media
– Takes more time to load
– Larger footprint
– Drips
– Exposed edges of filter
media (less sanitary)
– Less expensive per
square foot of filter media
Filtration – Types of Filter Media
https://youtu.be/ZMphfbtHyqM
Filter Sheet Demonstration
1) Some particles are too large to enter the filter & remain trapped on the surface
2) Some particles enter the filter’s interior and become trapped in the intricate network
3) If charged, some particles are attracted to the charge & become trapped
Filter Sheet Mechanisms
Sheets:
• 60x60cm sheet = ~59x59cm active sheet = 3481cm2 = 3.75 ft2
• 40x40cm sheet = 1.64 ft2
• 20x20cm sheet = 0.4 ft2
Lenticular Stacks:
Area provided by Manufacturer
Example: Gusmer’s 12” 16 cell stack = 17.7 ft2 each
Synthetic Cartridges:
Area provided by Manufacturer
Example: Millipore’s Bevigard 10” cartridge = 7.5 ft2 each
Filtration Prep – Calculating Surface Area
Sheet Area (ft2/sheet) x # of Sheets =
Filter Area (ft2)
Filter Area (ft2) x Rec. Flow Rate (gpm/ft2)*=
Total Flow (gpm) * Manufacturers provide a recommended flow rate range based on pore size
Filtration Prep – Calculating Flow Rate
Example:
1,000gal of spirit will be filtered through thirteen 40 x 40 cm sheets (polishing filter grade). How fast can I filter?
• Filter area = 1.64 ft2 active area/sheet X 13 sheets =
21.3 ft2 total filter area
• Flow Rate = 16 gal/hr/ft2* X 21.3 ft2 = 341 gal/hr =
5.7 gal/min flow rate
*note: manufacturer rec. 8-24 gal/hr/ft2 for polishing grades
• Time needed for Filtration = 1,000gal ÷ 341 gal/hr =
2.9 hrs total filtration time
Filtration Prep – Calculating Flow Rate
Filtration Start-up – Filter Press 1. Inspect press gaskets & plates for cracks
2. Carefully load sheets into press:
• Cockled surface should face inlet plate
• Media edges should be visible around plate
• Ensure media is not pinched in gaskets
3. Tighten press ~50% and begin recirculating spirit or H2O to
equilibrate (close outlet vent once press is filled)
4. Once edges of sheet are wet, tighten press snugly
5. Begin Filtration
Filtration Start-up – Lenticular Stack 1. Inspect gaskets/ O-ring (media base & housing base)
2. Place stack(s) on center post & hand-tighten locking assembly
3. Close dome and seal
4. Open top vent & fill housing (with spirit or H2O)
5. Close vent & flush/recirculate to equilibrate
6. Begin Filtration
Application / Flow Rates / ∆P
Application Filter Grades Recommended
Flow Rates
g/hr/sqft
Max. Flow Rates
g/hr/sqft
Max. Diff.
Pressure
Coarse Filtration 1925-1940 24 to 32 30 to 40 45
Polish/Clarifying
Filtration
1945-1960 8 to 24 20 to 30 45
Sterile Prep./Pre-
Membrane Filtration
1965-1975 3 to 12 10 to 15 21
Application Guide
Efficiency dependent on processing conditions (flow
rate, differential pressures, particle type, etc.) – Lower flow rates allow for better retention
– Lower differential pressures allow for better retention
Important Filtration Parameters
Flow Rate
Follow the Manufacturer’s recommended limits
• Filter grade (↓ pore size = ↓ flow rate)
• Surface area (gpm/ft2, ↑ ft2 = ↑ gpm)
Differential Pressure
Follow the Manufacturer’s recommended limit
• Differential Pressure (psid) = inlet psi – outlet psi
• Filter Run psid = psid @ finish – psid @ start
Filtration Run – CONSISTENCY
Consistent products improve filtration consistency
• If variability is expected in the product, may be best to
add a “safety factor” by increasing filter area
Consistent preparation improves filtration consistency
• If chilling, chill to the same temp every time
• If dosing carbon:
• dose at the same rate (lb/gal) every time (or adjust
filter area accordingly)
• provide the same contact time
• provide the same level of agitation every time
Potential Outcomes – Optimal (Ideal Scenario)
Filtration Results:
Pressure increased throughout batch filtration but didn’t hit terminal psid
Resulting Product:
Achieved product target (clarity or color)
Fully utilized filter sheets
based on achieving
pressure differential and
maintaining color spec
Sheets not underutilized,
not throwing away
unused material, sized
appropriately
Potential Outcomes – Under Utilized Filtration Results:
Minimal pressure rise throughout batch filtration
Potential Outcomes – Under Utilized Filtration Results:
Minimal pressure rise throughout batch filtration
Optimization Options (to fully utilize filter):
• If flow rate is NOT a bottleneck: – Use fewer filter sheets & reduced flow rate accordingly
• If flow rate IS a bottleneck: – Filter a larger volume of product through the sheets
Under utilized sheets, throwing away capacity. Instead, use fewer sheets, slow down
flow rate. For larger producers, continue using sheets with similar batch material
This situation is all about saving $$$
Potential Outcomes – Over Worked Filtration Results:
Terminal pressure hit midway through batch filtration, requiring shut down to change out filter media.
Potential Outcomes – Over Worked Filtration Results:
Terminal pressure hit midway through batch filtration, requiring shut down to change out filter media.
Optimization Option:
• Use more sheets & increase flow rate accordingly if desired
Undersized system – all about time
saving
Then again, time is $$$
Filtration Shut-down
Reasons to shut-down filtration:
• Batch filtration completed
• Terminal differential pressure reached – DO NOT EXCEED!
Maximizing yield:
Gently push out fluid remaining in the press/housing using gas
(air, nitrogen, CO2, etc.)
• Use low pressure (normally a few psi) to keep pressure and
flow rate below normal operating conditions
• Where to apply the gas:
• For stacks/cartridges – apply gas at top vent/gauge port
• For presses – apply gas at regular inlet
Cheat Sheet for Optimal Filtration • Calculate the appropriate flow rate based on Manufacturer’s
recommendations
• Product and preparation consistency will improve filtration
consistency
• Check your gaskets/O-rings!
• Follow Manufacturer instructions for start-up
• Monitor flow rate, pressure & product targets during filtration
• Do NOT exceed recommended pressure before termination
• In any of these scenarios, if NTU spec is higher than desire,
need to consider a tighter sheet
Filter Press Troubleshooting Symptom Underlying Issue Root Cause Solution
Leakage
Poor seal at the
gasket
Worn or cracked
gaskets
Replace gaskets; use operator manual or contact the
supplier to determine thickness
Incorrect gasket size Replace gaskets with gaskets that are the correct
thickness (see above)
Poor seal around the
media
Insufficient filter press
tightening
If unable to properly tighten the press by hand, a
“cheater” bar or hydraulic closure can be used
Misaligned sheets Take your time and carefully align each sheet while
dressing the press to ensure proper sealing
Missing guide rods Short-term: carefully hold sheets while tightening press
Long-term: purchase replacement rods
Incorrect operating
parameters
High pressure or
excessive flow rate
Follow filter sheet product literature for proper
operating conditions of grade in use
Unexpected
short life
Filter sheets placed
backwards
Gradient density in
opposite direction
Always face the cockled side of the sheet towards the
plate with an un-gasketed inlet port
Incorrect operating
parameters
High pressure or
excessive flow rate
Follow filter sheet product literature for proper
operating conditions of grade in use
Unexpected
breakthrough
Incorrect operating
parameters
High pressure or
excessive flow rate
Follow filter sheet product literature for proper
operating conditions of grade in use
Stack (Lenticular) Filter Troubleshooting Symptom Underlying Issue Root Cause Solution
Unexpected
breakthrough
Stack filter has ruptured
Unintended back-pressure
(most common cause)
Always install a quick acting check
valve at the exit of the housing
Improper storage
(rare)
Never remove wet stacks from housing
for storage, if needed, store in closed
housing
Fluid is bypassing the
media
Missing stack gasket
(most common cause)
Always check each stack to ensure it
has its end gaskets while installing
Center post not properly sealed
(rare)
Follow literature instructions to hand
tighten the follower assembly, this is
sufficient for a proper seal
Incorrect operating
parameters
High pressure or excessive flow
rate
Follow filter sheet product literature for
proper operating conditions of grade in
use
Leakage at base of
the housing
Housing is not properly
sealed
Torn or misaligned o-ring at
housing base
(most common cause)
Always inspect the o-ring before use
and replace if damaged. Make sure o-
ring is properly seated in its grove and
housing bolts are snug
Housing base bolts are not
properly tightened
(rare)
Follow housing literature instructions to
hand tighten the base bolts, a wrench
or “cheater” bar can also be used if
necessary depending on the housing
model
Filtration with Synthetic (PVDF or PES)
• Depth Filter Media – Thick matrix of gradient density
media (Fiber, DE, resin) in which
the filtration occurs on the surface
and interior of the matrix
– High “dirt loading” capacity
– Nominal micron rating (0.5 to 20
microns)
– Appropriate for most Spirits
applications
• Surface Filter Media – A thin matrix of media (PVDF or
PES) in which the filtration occurs
mostly on the surface
– Low “dirt loading” capacity
– Absolute micron rating (0.45
microns)
– Membrane filter – appropriate for
aseptic “sterile” filtration of
beverages
Bottling Line Filters in a Distillery • Cartridge Filters
– Housing ~ $1,500 to $3,000
– Cartridges ~ $125
– Better retention and “dirt loading”
capacity
– Wide range of micron options,
filter media choices and cartridge
sizes
Filtration Start-up – Synthetic Cartridge
1. Inspect O-rings (cartridges & housing base)
2. Install cartridges in housing
3. Close dome & seal
4. Open top vent & fill housing (with spirit or H2O)
5. Close vent & flush/recirculate to equilibrate
6. Begin Filtration
Finally, Please remember…
– Coarse Standard/Polish Final(Bottling)…not the opposite
direction…this DOES NOT WORK!
– FILTRATION in your process potentially will require the most attention!
You can vary the setup…
– Cartridge filters and housing can be used for coarse filtration
– Lenticular and Sheet filters can be used for coarse filtration or bottling
Work with your supplier to determine what works best for you
Questions?
Thank You! Nathan Kreel, PhD
Distilling Industry Specialist
Technical Sales Representative, Southeast US
240-810-2650
www.gusmerdistilling.com
Service with Knowledge®