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Bob HansenBriess Malt & Ingredients Co.
Chilton, Wisconsin USA2006 CBC
Balancing Water in the Brewhouse
Balancing Water in the Brewhouse
Brewing is a process of balancing additions of water and several soluble and insoluble components to finish with a product with exact concentrations of each component.
Introduction to Materials (Mass) Balance
Introduction to Materials (Mass) Balance
• Better Control of Process• Energy Efficiency • Water Conservation• Waste Water Reduction• Optimization of Throughput• Yield Maximization• Quality Improvement
Rewards of a Balanced ProcessRewards of a Balanced Process
Hops
Grain
Inputs
Inputs
Water
Soluble Components
Insolubles
Water
Soluble Components
Insolubles
Water
Wort
Water
Soluble Components
Spent Material
Waste Water
Water
Soluble Components
Insolubles
Water
Soluble Components
Water (Steam)
OutputsOutputs
Brewing Process
Mass Balance
Hops
Grain
Inputs
Inputs
Water
Soluble Components
Insolubles
Water
Soluble Components
Insolubles
Water
Wort
Water
Soluble Components
Spent Material
Waste Water
Water
Soluble Components
Insolubles
Water
Soluble Components
Water (Steam)
OutputsOutputs==
Water
Soluble Components
Insolubles
Water
Soluble Components
Insolubles
Brewing Process
Mass Balance
Basic Equations and TerminologyBasic Equations and Terminology
Specific Gravity
Weight of Water
Weight of Wort
=________
Degrees Plato
Weight of Wort
Weight of Wort Solids
=________
X 100
Basic Equations and TerminologyBasic Equations and Terminology
Concentration (Plato) and Relative Density (S.G.) are Related
Concentration (Plato) and Relative Density (S.G.) are Related
Degrees Plato
- 1 ) X 1000 /4
1 + (Plato X 4 / 1000)
=Specific Gravity
(
Specific Gravity = 1 + (10 X 4 / 1000)1.040
1.0400.040 ) X 1000 /410
Basic Equations and TerminologyBasic Equations and Terminology
Specific Gravity
Weight of Water
Weight of Wort
=________
X
Weight of Water = 8.34 lbs / Gal
Weight of Water = 1 kg / liter
Basic Equations and TerminologyBasic Equations and Terminology
Degrees Plato
Weight of Wort
Weight of Wort Solids
=________
X 100_______________________
Basic Equations and TerminologyBasic Equations and Terminology
Liquor / Grist Ratio Weight of
Grain
Weight of Liquor (water)
=________
Grain (500 lbs)
Inputs
Inputs
Water
(0.05 x 500 lbs = 25 lbs)
Soluble Components
(0.75 x 500 lbs = 375 lbs)
Insolubles
(0.20 x 500 lbs = 100 lbs)
Water (1500 lbs)
OutputsOutputs
Mashing
Mass Balance
Mash (2000lbs)
Water
( 25lbs + 1500 lbs = 1525 lbs)
Soluble Components
(375 lbs)
Insolubles
(100 lbs)
This is a 3.0 L/G ratio
1500 Lbs / 8.34 Lbs/Gal =
180 Gal or 5.8 Brls
Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %Grain 500 25 5% 375 75% 100 20%Water 1,500 1,500 100% - -
Total Inputs 2,000 1,525 375 100
Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Mash 2,000 1,525 375 100 Total Outputs 2,000 1,525 76.3% 375 18.8% 100 5.0%
Mash Vessel Material BalanceMash Vessel Material Balance
First Worts from Liqour : Grist
12%
14%
16%
18%
20%
22%
24%
26%
28%
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6
4.8
5.0
Liquor - Grist Ratio
Wo
rt S
olid
s (
Pla
to)
Yield 78%
Yield 76%
Yield 74%
Yield 72%
• Thicker Mashes have lower pH (0.1 or more)• Thicker Mashes Stabilize Enzymes
– Can Increase Soluble Nitrogen +10-20%– Increase Alpha Amylase Survival Time +20%
• Thicker Mashes Reduce Enzyme Mobility– Thicker Mashes Produce More Dextrinous Worts– Fermentability Can be Reduced 5%
• Water Balance Sets Maximum Extract Possible In The Brewery– Total Extract (Wort Solids)– Sets Maximum Wort Strength
Effects of Water Balance in the MashEffects of Water Balance in the Mash
Mash Volume vs Liqour : Grist
00.10.20.30.40.50.60.70.80.9
1
2 2.5 3 3.5 4 4.5 5
Liqour:Grist Ratio
Ga
llo
ns
Gal/lb Malt
Gal/lb Extract (@75%)
Inputs
Inputs
Underplate/Chase (200 lbs)
OutputsOutputs
Lautering
Mass BalanceThis is a 3.0 L/G ratio
Mash (2000lbs)
Water (1525 lbs)
Soluble Components (375 lbs)
Insolubles (100 lbs)
Sparge Water (1500 lbs)
Wort (2985 lbs)
Water (2637 lbs)
Soluble Components (348 lbs)
Insolubles (98 lbs)
Water (400 lbs)
Soluble Components (17 lbs)
Water (188 lbs)
Soluble Components (10 lbs)
Insolubles (2 lbs)
Spent Grain (515 lbs)
Drain Water (200 lbs) 23.5 gal x 1.020 x 8.34 lbs/gal
5.0 P x 200 lbs
348 / 2985 = 11.7 % (Plato)
Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %UP water 200 200 100% - 0% - 0%Sparge Water 1,500 1,500 100% - 0% - 0%Mash+Rinse 2,000 1,525 375 100 Total Inputs 3,700 3,225 375 100
Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Spent Grain 515 400 17 98 Drain water(weak wort) 200 188 10 2 Wort 2,985 2,637 348 11.7% 0 Total Outputs 3,700 3,225 375 100
Lautertun Material BalanceLautertun Material Balance
348 / 375 = 93 % Brewhouse Efficiency500 lbs x 95 % Solids = 475 lbsS.G = 1.047 x 8.34 lbs/ gal = 8.73 lbs/ gal = Weight of Wort2985 lbs / (8.73 lbs / gal) = 342 gal = 11.0 Barrels
• Balance will Determine Yield– Improper balance or timing leads to loss in grains or drain water– Yield losses lead to increased waste water costs
• Balance will Determine Preboil Wort Strength and Volume– Poor balance leads to oversparging and overdilution
• Balance can effect product quality– Oversparging leads to increased color, pH and Tannin extraction
• Balance effects runoff speed and throughput– Improper balance leads to difficult or lengthy lautercycles
Effects of Lautertun Water BalanceEffects of Lautertun Water Balance
Gallons
Pla
to
Lautertun Runoff Model
0%2%4%6%8%
10%12%14%16%18%20%
0 2000 4000 6000 8000 10000 12000 14000 16000
Gallons
Pla
to
3.0
4.0
5.0
Lautertun Runoff Model
0%2%
4%6%8%
10%
12%14%16%
18%20%
0 2000 4000 6000 8000 10000 12000 14000 16000
Gallons
Pla
to
3.0
4.0
5.0
Lautertun Runoff Model
0%2%
4%6%
8%10%12%
14%16%
18%20%
0 2000 4000 6000 8000 10000 12000 14000 16000
Gallons
Pla
to
0%10%
20%30%
40%50%60%
70%80%
90%100%
Yie
ld
3.0
4.0
5.0
Lautertun Runoff Model
0%
2%
4%
6%
8%
10%
12%
14%
16%
18%
20%
9000 10000 11000 12000 13000 14000 15000 16000
Gallons
Pla
to
60%
65%
70%
75%
80%
85%
90%
95%
100%
Yie
ld
3.0
4.0
5.0
93% Yield, 15.7 P
87% Yield, 14.3 P
Water Balance Affects RunoffWater Balance Affects Runoff
Max Flow
Viscosity
Various Factors
=_______________
X Bed Depth
Viscosity Increases Directly with Plato
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
1.09
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 120000%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2.8
2.7
3
Inputs
Inputs
OutputsOutputs
Kettle /
Whirlpool
Mass Balance
Wort (2782 lbs)
Water (2436 lbs)
Soluble Components (346 lbs)
Wort (2985lbs)
Water (2637 lbs)
Soluble Components (348 lbs)
Insolubles (3.4 lbs)
Water (0.4 lbs)
Hops (4 lbs)
Insolubles (4 lbs)
Water (16 lbs)
Spent Hops (20 lbs)
Soluble Components (1.7 lbs)
Water (6.8 lbs)
Trub (8.5 lbs)
Steam (Water) (264 lbs)
Soluble Components (0.2 lbs)
Water (83 lbs)
Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %Wort 2,985 2,637 348 0Hops 4 1 4Water 83 83
Total Inputs 3072 2,721 88.6% 348 11.3% 3.5 0.1%
Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Wort 2,782 2,436 346 12.4% 0Spent Hops and Trub 26 21 1.7 4Steam (evap) 264 264Total Outputs 3072 2,721 348 3.5
1.050 O.G. 318 Gallons 10.3 Barrels
• Water Balance Cannot be Separated from the 5 “-ations of Brewing– Sterilization– Isomerization– Concentration (Evaporation)– Carmelization (Color and Flavor Development)– Volitilization
• Excessive Concentration is Innefficient and Can Lower Quality• Concentration increases Exponentially with Water Removal
Effects of Kettle Water BalanceEffects of Kettle Water Balance
Concentration at Constant BoilingConcentration at Constant Boiling
Hours of Boiling and Concentration
10%
15%
20%
25%
0 1 2 3 4 5 6 7
Hours of Boiling
Pla
to 10 P
12 P
14 P
16 P
18 P
Barrels of 20 P Wort After Boil and Wort Color
0
5
10
15
20
10 12 14 16 18
Original Plato
Bar
rels
an
d L
ovi
bo
nd
Boiling to GravityBoiling to Gravity
Total Inputs 3,253 2,775 85.3% 595 18.3% 3.5 0.1%
Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Wort 2,960 2,488 593 20.0% 0Spent Hops and Trub 26 20 2 4Steam (evap) 267 267Total Outputs 3,253 2,775 595 3.5
1.080 O.G. 329 Gallons 10.6 Barrels
HG Beer BalanceHG Beer Balance
High Gravity BalanceHigh Gravity Balance Total Mass Water Water Extract Extract Insoluble InsolubleInputs Mass % Mass % Mass %Wort 3,249 2,750 499 0Hops 4 1 4 0Concentrated Wort 120 24 20% 96 80%Total Inputs 3,253 2,775 85.3% 595 18.3% 3.5 0.1%
Total Mass Water Water Extract Extract Insoluble InsolubleOutputs Mass % Mass % Mass %Wort 2,960 2,488 593 20.0% 0Spent Hops and Trub 26 20 2 4Steam (evap) 267 267Total Outputs 3,253 2,775 595 3.5
1.080 O.G. 329 Gallons 10.6 Barrels
SummarySummary
Questions?Questions?
ThankYou
ThankYou
Bob HansenBriess Malt & Ingredients Co.
Chilton, Wisconsin USA2006 CBC