Brewhouse Technology

PROCESSING SYSTEMS THAT KNOW NO BOUNDARIESPROCESSING SYSTEMS THAT KNOW NO BOUNDARIES

www.briggsplc.co.uk

BRIGGS OF BURTON PLCBriggs HouseDerby Street

Burton-on-TrentStaffordshire, UK

DE14 2LH

Phone: +44 (0) 1283 566661Fax: +44 (0) 1283 545978

Email: sales@briggsplc.co.uk

BRIGGS OF BURTON INC400 Airpark Drive,

Suite 40,Rochester,NY 14624.

USA.

Phone: +1 (585) 426 2460Fax: +1 (585) 426 0250

Email: sales@briggsusa.com

three

Impeccable Credentials

possibly the oldest Process Engineers in the world

Briggs has been helping the world’s brewers, year after year, since 1740.

We believe that brewing is an holistic process - a change in mashing can have implications in wort boiling and vice-versa - let us show you how.

There is a lot of science in modern brewing and Briggs can bring enormous benefits from long experience and first class engineering skills.

Every year we help major brewers all over the world ... let us help you too.

two

five

Mash Conversionexcellence achieved through control of four key parameters

1. Low Shear Agitation Vessel Shape •Low aspect ratio(height:diameter) 0.6:1 •Tilted dish •No internal baffles

Agitator •Large - 85% of vessel diameter •Slow - max. tip speed 3.8 to 4.0 m/s •Off centre - 5% of diameter •Variable speed - optimises performance •Swept surfaces to avoid burn-on

Mash Transfer •Pipework low velocity (<1.5 m/s) •No severe directional changes •Long radius bends •Mash transfer pump has open impeller and slow speed - less than1000 rpm

Benefits of the Briggs Approach •No ‘balling’ •No mash degradation •Excellent heat transfer •Minimised oxygen pick-up •No burn-on •Homogenous mix - low colloidal buffer/shear

2. Accurate Mash Temperature Control •Independent heating zones are provided to accommodate varying mash volumes and heat-up rates •Burn-on is prevented because a steam jacket can only operate when fully covered by mash •Soft-start steam feature allows condensate purging and prevents jacket over-stress •Automatic air eliminators from jackets to ensure heat transfer efficiency •Good mixing is essential to prevent burn-on and promote temperature homogeneity •Flexible heat ramp rate - 1°C or 2°F per minute is normal •Highly accurate temperature control - accurate to 0.2°C/0.4°F of set-point

3. Oxygen Control •Oxygen control is key to flavour stability •Lipoxygenase activity at mashing has the ability to oxidise lipids/fatty acids to aldehydes, and aldehydes can be very detrimental to the flavour stability of finished beer •To reduce/eliminate Lipoxegenase effect it is necessary to attack one or more of the following: Ph (should be higher than 5.2) Lipid fatty acid availability Lipoxygenase in malt Acrospire damage in milling Hydration Temperature (should be >62°C/144°F ) Oxygen

For a modern lager brewer the most practical control parameter is oxygen elimination.

4. Grist Hydration Briggs has developed flexible hydration systems to accommodate all mash separation technologies. The mash separation method employed has a significant effect on the hydration system employed. For example, hammer milled grist used with the new generation of mash filters is much finer and denser and is used with a much lower water:grist ratio.

four

50mmClearance

Mash to Mash Separator

Condensate

Agitator

CIPGrist

Steam

MashingLiquor

MashConversion

Vessel

5% offset

Tilt

seven

Mash Separation exceeding expectations in wort quality, throughput and extract efficiency

Lauter Tuns Briggs lauter tuns are fully automated to the latest standards, using our customers preferred automation platforms including, Siemens, Rockwell, Mitsubishi and Omron.

The wort collection system uses a tried and tested, air-free design. Underflush nozzles ensure a clean underplate void, which combined with a valley bottom, provides a defined drainage path to the run-off points. The false bottom is strong and light, and easily tolerates maintenance traffic. The fully machined ‘bottom’ leaves a 20mm spacing between false and real bottom to minimise foundation liquor, and gives nominal 10% free area.

The rakes have evolved over time and have progressively optimised extraction, giving <0.8% soluble extract in spent-grains, guaranteed.

The lauter machine has a top bearing that allows easier alignment, and is above the liquid level, which is more hygienic and easier to maintain.

The tuns are also designed to facilitate fast spent grains removal. Within ten minutes, spent grains are less than 400grams/metre - fully compliant with DIN 8777.

Mash Filters The latest generation of mash filters offer an excellent technology and, for some brewers, may offer advantages over lauter tuns. Briggs has installed a substantial number of mash filters for high volume brewers, with relatively fixed brew sizes/recipes. In these cases the higher capital costs have been offset by lower unit costs. We do not hesitate to recommend mash filters, where we believe the technology is better for our client.

six

nine

Wort Collection sealed and hydraulically balanced

The wort collection pipework is totally sealed and hydraulically balanced in order to achieve the recommended collection profile.

An integrated part of the system is the closed loop which reduces dissolved oxygen in the wort and provides foolproof protection from vacuum collapse of the false bottom.

The sparge system has the ability to provide high initial flow to ensure rapid replacement of the hydraulic driving head after the removal of first worts. Thereafter, it is synchronised with the worts collection flow rate.

The chart represents a real-time trend from the automation system demonstrating the following parameters:

•Differential pressure•Wort flow rate•Wort collection volume (cumulative)•Sparge flow and volumes•Lauter rake height•Lauter tun total cycle time

0

1

2

3

0

250

500

750

1000RelativeWort/SpargeFlow Rate

Sparge-on

FirstWorts

LastWorts

SecondWorts

Deep Bed Rake

Total Wort Collection Period

Top

Rake Profile

BottomDifferentialPressureM.M.WGSparge

Complete

eight

Mash Transfer low oxygen pick-up is the key to success

For lauter tun applications mash is fed across the false bottom from an appropriate number of inlet valves positioned around the circumference of the tun - rather than fromabove or from under the real bottom. This achieves a smooth low air pick-up/low-shear transfer ... and it’s proven in service time after time.

eleventen

Briggs Lauter Tun Evolution introduction dates of

new design features

1983 Briggs buy Schock Gusmer. Introduction of valley bottom.

1984 Loop seal replaces open grant to close system to oxygen.

1985 Introduction of swinging foot lauter blade.

1986 Pre-programmed run-off profiles using DP (differential pressure) and flow as control parameters.

1988 Bearing re-positioned above liquid level.

1990 Plate level mash transfer. Reduced underplate volumes. Increased diameter run-off pipes. Improved underplate flushing system.

1992 Wort recirculation below liquid level for reduced oxygen pickup. Flight angle changed from 3° to 6° and upsized.

1994 Valley bottom pulsed flushing. Improved underplate flushing system.

1996 Large diameter spent grain doors. Replaced loop seal with expanded-pipe system. Real time haze and gravity monitoring to aid inline quality measurement & control.

2000 Pneumatic powered grain-out plough to reduce grain-out time.

2002 New fabricated blade design.

2003 New real time instrumentation and automation. Increased blade density. Variable speed spent grains discharge.

2004 Variable speed run-off pump, minimising energy. Fully variable (rotation & raise lower) electro-mechanical lauter drive. Programmed lautering; lauter height, speed & run-off flow responsive to differential pressure. Maximised run-off & sparge time by overlapping; mash-in/recirc & grain out/underplate flush. Sparge control optimised to maintain benefits of small flood sparge without excessive compression.

2007 Improved fabricated lauter knife, one piece blade with lower profile. Electro-mechanical fail safe grain valve actuation. Improved underplate flush distribution using flexible connections. Plough actuator feedback system. Single mass flow meter used for run-off gravity and flow.

2009 Distillery type fabricated knife - optimised for malt distillery operation. Lower peak flow underplate flushing - manifolds split by slope and by valley.

2011 Integrated run-off flow control loop - valve and pump VSD operate to minimise shear and energy use. Electro-mechanical plough operation - eliminating rotary union.

thirteen

Automated Lauter ControlAutomation to Recipe Profile The automation system provides for:

•Haze monitoring to ensure wort clarity

•Variable speed lauter gear to suit all recipe requirements

•Continuous rake height monitoring for optimal bed raking

•Wort flow rate and differential pressure control to protect bed integrity. DP control is critical to the prevention of a ‘set-bed’

•Gravity monitoring and totalised run-off to optimise extract

•Variable speed discharge motor with power monitoring to ensure total grains discharge in minimum time

Benefits •Predictable/repeatable wort collection periods

•Repeatable extract performance

•Controllable/repeatable wort quality

•Real-time monitoring and adjustment

•Report generation

•Recipe generation and editing

•Production scheduling and batch management

•MIS/MES integration

twelve

Lautering Data results that exceed expectations

Performing for SABMillerPerformance of a Lauter Tun for SABMiller

10 brews per day (all malt) dry milling 156 kgs/m2 plate loading

L/Kg

Mash Water Usage 3.4Sparge Water Usage 2.6Effluent (including underplate washing) 0.5

Minutes

Plate Flood/Mash Transfer/Recirculation 17Strong Worts 52Sparged Worts 52Bed Draindown 10Grain-out/Underplate Wash 19

Total Cycle Time 136

Wort Clarity (EBC) <20EBC <5EBC

% of Time 10% 90%

Extract Recovery to Kettle % w/w 99.5%Spent Grains Moisture <80% w/wResidual Soluble Extract <0.5% w/wCollection Gravity (actual) 15.5 Plato

Maximum: dry milled, high gravity & sparge efficientMaximum: conditioned dry milled, well modified maltMaximum: steep conditioned milled, well modified malt

Brews per 24 hour day

Dry

Bed

Laod

ing

Kg/m

2

3 4 5 6 7 8 9 10 11 12

100

200

300

400

500

600

fifteenfourteen

Brews Cycle Max: dry Max: Max: Steep Per time in milled conditioned conditioned Day minutes dry milled, milled, well well modified modified malt malt

3 480 500 500 520

4 360 435 435 460

5 288 375 375 400

6 240 320 320 340

7 206 275 275 290

8 180 230 235 250

9 160 190 205 220

10 144 160 175 190

11 131 130 155 170

12 120 110 140 155

seventeen

Wort BoilingAn Holistic Approach to BrewingBrewing is a business where traditions are taken seriously, where brands and brand character can take decades to establish, so we understand when sometimes we fail to persuade a client of the benefits of our external thermosyphon technology ... but we know just how good it is.

Briggs has been promoting the technology for over 20 years and has installed more than one hundred large scale commercial systems ... it’s an effective and demonstrably proven technology.

An external thermosyphon wort boiler has identical boiling characteristics to an internal wort boiler ... it shares the same thermosyphon principle. Single phase (liquid) flows into the bottom of the tubes and two-phase flows (liquid plus vapour) out of the top.

The Briggs external wort boiling system has no practical limit to the heating surface area (because it’s not limited by the size of the vessel). Therefore the following additional benefits can be achieved:

•Low ΔT - which means less damage to foam positive proteins and therefore better foam stability, low fouling rates and low colour pick-up

•Control of Evaporation - mass flow steam control and wort temperatures up to 103°C/217°F provide excellent DMSP to DMS conversion. The opportunity exists to reduce evaporation rates by increasing the amount of two-phase flow, which has been proven in large scale trials. Also proven is the massive reduction in energy costs

•Volatile Stripping - is far more effective as wort is returned above the liquid surface, no re-condensing of volatiles takes place in the body of the wort

•Wort Homogeneity - using our wort kettle configuration combined with mass flow steam control, excellent homogeneity is achieved ensuring that each particle of wort receives uniform heat treatment

•Rapid Heat-up Rate - no need to cover heating surfaces prior to steam-on which means the heat-up time is reduced

•Higher Wort Velocities - lead to lower contact times, reduced burn-on, less colour pick-up and extended times between CIP

•Lower CIP Volumes - no need to cover the entire heating surface for cleaning, as this is achieved by re-circulation

sixteen

nineteen

Symphony Wort Boiling

eighteen

The difference in density between single phase and two-phase is the driving force for the thermosyphon

What is Symphony Symphony is a very large heater surface area Briggs thermosyphon external wort boiling (EWB) system - it has been developed over a 10 year period with major brewers in large scale brewing. It has a very large heater surface area, four to five times that typical of leading competitors. This large area gives rise to even lower ΔT - which further minimises the risk to foam positive proteins and reduces fouling so that even more brews can be achieved between cleans. It massively improves brewhouse efficiency.

Large surface area and low ΔT produce huge quantities of small vapour bubbles, maximising the liquid/vapour interface area, promoting trub formation and volatile stripping.

Wort is re-circulated through a significantly increased number of long heater tubes, and wort is returned to the kettle above the liquid surface with a tangential action that helps maintain market leading levels of wort homogeneity.

Better volatile stripping is achieved with more two-phase flow, more bubbles and bigger bubbles at the top of the tube bundle, allowing the Brewmaster to consider lower evaporation rates.

Lower evaporation rates lead to far lower energy costs.

Symphony ‘Plus’Brings together the wort boiling and whirlpool operations in one ‘combination’ vessel. This provides the additional benefit of eliminating vessel-to-vessel transfer time (and associated shear damage). Trub particle size reduction is avoided - ‘Plus’ allows even more particulate solids to be removed as ‘hot-break’, creating the potential for further extended filtration runs. Another benefit of the transfer elimination is that there is reduced stand time between the end of the boil phase and the start of wort cooling - this means there is less time for low level residual DMSP to convert. There is also far better space utilisation.

twenty-one

Symphony Repeatable Control - Brewafter Brew

Heating Phase Throughout this phase there is the greatest potential for fouling, burn-on and colour pick-up.

The EWB wort outlet temperature is controlled by the temperature controller. When recipe pre-heat start volume is attained, the wort is pre-heated up to the pre-heat target temperature (99°C), by ramping the temperature setpoint from its initial (actual) temperature up to target temperature, at a recipe ramp rate (over the fill period). The aim is to achieve the target temperature at or before completion of filling. This prevents excessive steam flows, reduces fouling and prevents premature evaporation. Throughout this phase the pumped route is open until the thermosyphon is established.

Boil Phase At the start of this phase the steam totaliser is set to zero, and the mass flow of steam necessary to achieve the desired evaporation rate is metered into the EWB, to ensure consistent heat treatment to the wort on every brew.

Cleaning Phase The above method of control combined with the system design, minimises fouling and extends the number of brews between CIP.

Units in operation are achieving up to 40 brews between CIP.

Cleaning takes place when the unit is no longer capable of condensing the steam flow demand set by the recipe.

twenty

CIP INLET

STEAM FLOWCONTROL VALVE

EXTERNALWORTBOILER

TANGENTIAL RETURN TO VESSELPROVIDING ‘WHIRLPOOL’ ACTION

AND EXCELLENT MIXING OF VESSEL CONTENTS

CONSTANTSTEAM PRESSURESET AT3 BAR MAX.

PUMP BY-PASS(PRE-HEAT ONLY)

CONDENSATE

STEAMMETER

TEMPTRANS

FLOWCONTROL

twenty-three

Symphony quality and cost benefits

Improve Quality •Large heater surface area - low ΔT - which benefits foam and flavour stability (15% improvement in large scale trials) - the Briggs heater area is up to five times larger than some leading competitors

•Promotes excellent protein de-naturation and coagulation, leading to good hot-break. If the ‘Plus’ option is selected then the shear associated with vessel to vessel transfer is removed and more particulate soilds are removed as ‘hot-break’

•Downstream benefits in filtration and haze reduction

•Excellent volatile stripping

•Excellent temperature homogeneity

•Low DMS in final beer - 40% reduction in large scale trials

Reduce Costs •Much reduced energy costs - lower steam pressures, lower evaporation losses - conventional kettle evaporation typically represents 20% of TOTAL brewery energy costs. With the Briggs Symphony system evaporation rates are potentially as low as 4%, potentially halving evaporation energy losses

•Briggs EWB systems allow up to 40 brews between CIP - saves on energy, chemical and effluent costs ... and significantly increases plant utilisation/productivity

•Brewing capacity is higher from the same footprint, capital utilisation is better (enhancement can be even more significant with ‘Plus’ combined kettle/whirlpool)

•Can be retro-fitted to existing installations

•Reduced filter loads, reduced consumables costs, reduced times - brighter wort

twenty-four

Symphony ‘Plus’Brings together the wort boiling and whirlpool operations in one ‘combination’ vessel. This provides the additional benefit of eliminating vessel-to-vessel transfer time (and associated shear damage). Trub particle size reduction is avoided - ‘Plus’ allows even more particulate solids to be removed as ‘hot-break’, creating the potential for further extended filtration runs. Another benefit of the transfer elimination is that there is reduced stand time between the end of the boil phase and the start of wort cooling - this means there is less time for low level residual DMSP to convert. There is also far better space utilisation.

twenty-five

Symphony results from SABMiller’s Prospecton brewery South Africa

Briggs has installed over one hundred large scale thermosyphon EWB systems and hundreds more internal boilers or pumped external boilers. We are hugely indebted to SABMiller for allowing us to share some of their empirical data for a large thermosyphon EWB.

The Prospecton wort boiling system was built and commissioned by Briggs in 1996 and has a brew size of 1000 hl. In the year 2000 we revisited the site and conducted large scale trials with SABMiller, to determine the benefits of wort boiling with very large heater surface areas.

We believe the summary data presented here makes a compelling case for the benefits of our new Symphony wort boiling system.

This table shows how the trial compared with SABMiller’s previous brewing norm. It should be noted that the trial used an evaporation rate of only 4%/hr compared with the previous standard 7%/hr - total evaporation fell to only 5% with a lower steam pressure/temperature.

The trial showed no areas of quality degradation and one key quality improvement in the area of flavour stability. A 15% improvement was evident as measured by electron spin resonance, helping flavour, foam and shelf life.

With lower steam pressures and lower evaporation comes major cost savings. There is no empirical evidence that evaporating water helps volatile stripping. There is plenty of evidence that evaporating water costs money.

Kettle full volume Hls

Evaporation Rate % / Hr

Boil Duration Hrs

Total Evaporation %

Heater Surface Area m2

m2 / Hl

Steam Inside Heater °C

Bar Gauge

CONTROL TRIAL

532 532

7 4

1.25 1.25

8.75 5

228 228

0.43 0.43

118 114

0.9 0.65

Fermentation and Beer Filtration Normal

Required Colloidal Stability (Shelf Life) 15% improvement

Taste Panel Rating Normal

Triangular Taste Test No significant difference

DMS 40% reduction

Aldehyde (volatiles) No increase

Foam and all other analytical parameters Within specification

Savings/Million Hectolitres of Beer/Annum Oil Coal

Steam Generation Fossil Fuel Reduction Tonnes 280 460

CO2 Emission Reduction Tonnes 830 1200

twenty-four

twenty-seven

Brewhouse Automation step improvements in productivity

From raw materials through to wort cooling and fermentation, Briggs is able to automate and manage batch processes to maximise productivity at lowest cost with highest quality and consistency.

Briggs uses up to the minute process control techniques and standards, allowing clients real operational and strategic benefit from what are major capital investments.

S88.01 The S88 standard enables clear and concise transfer of information between different disciplines, specifically the Process Engineer and the Automation Engineer. The standard breaks down ‘process areas’ into ‘process cells’, ‘process units’, ‘equipment modules’ and finally ‘phases’. Using these smaller ‘blocks’ the URS (User Requirement Specification), FDS (Functional Design Specification) and ultimately the final control software, are constructed in a logical ‘easy to follow’ way.

IEC 1131-3 This standard describes control languages, including graphical and traditional ladder logic. MES products based on S88.01 generally use this standard for high level control system languages and now PLCs such as Siemens and Rockwell are compliant.

Thin Slice Implementation Rather than fully implementing each life cycle (from design through to simulation and documentation) on each and every process unit, a single process unit is identified and all of its life cycles are then completed and verified to the customer’s satisfaction. This is carried out in short time-scales with the minimum resource effort, risk and expenditure. The benefits are to both client and Briggs.

Coopers, Adelaide, Australia - The World’s first PCS 7 controlled Brewhouse For Coopers new mash filter based Brewhouse in Adelaide, Australia, Briggs Automation engineered what is believed to bethe World’s first brewhouse control system based on Siemens Process Control System PCS7.

The control system combines the strengths of PCS7: High visibility of process, direct access to sequence SFCs (Sequential Function Charts), DCS (Distributed Control System) functionality with PLC flexibility, allied with the cost and technology advantages of Profibus PA and ASi networks replacing traditional analog and digital I/O structures. The PCS7 operator interface is particularly user friendly, all screens have a common “look and feel” with clear plant mimics, sequence diagnostics and “hot button” links to other related screens.

twenty-six

Standards Development

User Requirement Specification

Functional Design Specification

Software Coding/Development

Software Testing

Software Sequence Simulation

Commissioning/Testing

Final Documentation