Critical Process Control Points Anton Paar VLB China

www.anton-paar.com

Critical Process Control Points Where, What, How and Why?

工艺控制关键点讨论

Daniel L. Gore

Application Specialist – Process Instruments

Brewer & Malter

Anton Paar GmbH

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Create a Process Plan of YOUR Brewery

啤酒生产工艺流程

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Ask a lot of questions and review your process thoroughly.

通过一些问题来回顾下生产过程

What is the difference between lab and process measurements?

Lab measurements are static snapshots of a dynamic process.

Process measurements are live streaming surveillance video.

实验室和在线测量的不同点是什么？

实验室测量是动态生产过程的静态定格拍照.

在线测量是连续的实况监视录像。

Lab and Process Instrument Basics.1

实验室及在线仪器基础1

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Ask more questions and review your process thoroughly.

通过一些问题来回顾下生产过程

Why both laboratory and process instruments?

A laboratory measurement is performed in a stable environment at a

stable temperature and is calibrated regularly with a verified standard.

A process measurement is performed under process conditions with

variable temperature, flow, pressure, and concentration and must be

verified with a representative lab sample.

为什么同时需要实验室和在线仪器呢?

实验室测量是在稳定的环境、稳定的温度和通过标准方法定期校准的仪器下完成的。

在线测量是在温度、流速、压力、浓度都在变化的生产条件下完成的，需要通过进行实验室样品测量进行校正。



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Ask more questions and keep reviewing your process.

通过更多问题来回顾下生产过程

What exactly do you need to measure?

• Temperature, extract, pH, alcohol, color, viscosity, etc.

什么是真正需要测量的?

• 温度、原浓、PH、酒精度、色度、粘度等

Where exactly do you need to measure it?

• Mash tun, lauter tun, kettle, blending, packaging, wastewater?

• Do you need a lab instrument? A portable, handheld instrument?

An inline instrument?

需要在什么点去测量?

• 糖化锅、过滤槽、煮沸锅、高浓稀释、包装、废水？

• 你需要实验室仪器吗？一个便携的手持仪器？一个在线仪器？

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Ask more questions and keep reviewing your process.

通过更多问题来回顾下生产过程

What is the total cost of ownership (TCO)?

= Instrument price + installation cost + lifetime maintenance

+ consumables + training

- increased production - time, energy and resource savings

总共的购置成本是多少(TCO)?

= 仪器价格+ 安装费用 + 维护费用 + 消耗 + 培训

- 增加的生产价值-时间、能源、财力节约

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Ask yet more questions to ensure you didn‘t miss anything.

再通过一些问题来确保没遗忘什么事情

What is the best method to use?

• Do you have an existing method already in use?

• What works best with YOUR existing systems and requirements?

• Do you have a preferred installation method?

• What are the pros and cons of available installation methods? ?

什么方法是最好的方法?

• 你现在已经有使用的方法吗?

• 什么能很好的满足你现在的系统和要求?

• 你有想要的安装方法吗?

• 什么才是有效的安装方法?

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Ask yet more questions to ensure you didn‘t miss anything.

再通过一些问题来确保没遗忘什么事情

What do you want to do with the information (short and long term)?

• Quality control? Automation? Regulatory control? All of these?

• Do you need a dedicated lab instrument? A portable instrument?

• Do you need a portable or starter system to start your QA lab?

你计划做什么事情(短期和长期)?

• 质量管理? 自动化? 法规控制? 以上所有?

• 你需要一个专用的实验室仪器吗?一个便携的仪器?

• 你需要一个便携的或者系统启动器来启动你的QA实验室吗?

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Available Measuring Principles 各种测量方式

(there are a lot....)

Alcohol

酒精度

NIR, density and sound velocity, density

and refractive index, sound velocity and

refractive index, ATR...

近红外，密度声速，密度折光，声速折光，衰减全反射

Extract

麦汁浓度

Oscillating U-tube, sound velocity,

refractive index, ATR... U型震荡管，声速，折光，衰减全反射

Color

色度 430 nm absorbance measurement... 430 nm 吸光度

pH Potentiometric 电势电位测定

Turbidity 浊度

3-angle light scattering, ratio method,

optical... 3角度光散射，比例方法，光学

CO2 Multiple volume expansion method,

optical, Henry‘s law, membrane...

多体积膨胀法，光学，亨利定律，膜渗透

O2 Optical, membrane... 光学，膜渗透

Viscosity

粘度 Rolling-ball, rotation, vibration... 转球，旋转，震动

To name just a few.....

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Method Recommendations

方法推荐

Look for approved and recognized methods:

寻找一些被公认的方法：

MEBAK: 2.9.2.3, 2.9.6.1 – 2.9.6.3

EBC: 1.6, 9.2.6, 9.28.5, 9.43.2

ASBC: Beer-2B, Beer-4, Beer-5

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Congress Mash

糊化

What to measure?

测量什么？

• °Plato (extract yield), smell, iodine test,

filtration, clarity, viscosity, pH, wort color, boiled

wort color, nitrogen content, protein solubility

and diastatic power

• °Plato浓度、气味、碘液试验、过滤、净度、粘度、PH，麦汁色度、煮沸麦汁色度、含氮量、蛋白质溶解度和糖化力

Why measure it?

为什么测量？

• Monitor malt quality, how it responds

during the mash and its ability to

convert its contents.

• 控制麦芽质量，糊化过程中如何反应及转化力

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Lauter Tun/Mash Filter Outlet

过滤槽/麦汁过滤出口

What to measure?

测量什么？

• °Plato (extract), temperature, viscosity, pH

°Plato (麦汁), 温度，粘度， pH

Why measure it?

为什么测量？

• Monitor first runnings, main wort and

last runnings

监控生产开始，进程及结束

• Automate when to send wort to the kettle or last

runnings to wastewater

实现自动输送麦汁到煮沸锅或自动输送至废水回收。

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Why measure it?

为什么测量？

• Save time and water, increase lauter tun

efficiency, reduce wastewater

节约时间和水，提高过滤槽效率，降低水耗

• Shorten boil time and increase kettle

efficiency

减少煮沸时间，增加煮沸效率

• Ensure further enzyme activity

确保更长的酶活性

• Ensure proper viscosity for optimal extract

and lauter time

确保适当的粘度来得到最佳的麦汁和过滤时间

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To kettle →

There are many options... 有很多选择…

Volume

Meter

DPRn

SPRn

mPDS 1100 or mPDS 5

ESC

ENTER

TEMP +16.14 °C

DENS: 1.33317 g/cm3

:

PER-D: 2574.976 us

Ai-curr: 0.160 mA

mPDS 1100

L

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How and where to measure it?

怎样？在哪里测量？

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Kettle

煮沸锅

What to measure?

测量什么?

• Extract, temperature, viscosity, pH

麦汁浓度，温度，粘度，pH

Why measure it?

为什么测量？

• Reduce boil time and increase kettle

efficiency

减少煮沸时间，增加煮沸效率

• Save time and energy

节省时间和能源

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Kettle

煮沸锅

Why measure it?

为什么测量？

• Enable further automation for boil end

提高煮沸的自动化程度

• Ensure proper viscosity for filterability

确保合适的粘度以提高滤过率

• Monitor foam stability

监控泡沫稳定性

• Ensure proper hop isomerization

保证适当的异构化作用

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Hot water mPDS 1100 or mPDS 5

ESC

ENTER

TEMP +16.14 °C

DENS: 1.33317 g/cm3

:

PER-D: 2574.976 us

Ai-curr: 0.160 mA

mPDS 1100

L

06

Hot water

Kettle

煮沸锅

External

boiler

DPRn

SPRn

SP

Rn

There are many options... 有很多选择…


怎样？在哪里测量？

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Production Increase Brewhouse ROI

生产增加酿酒厂的ROI

Example:

8 brews/day (3 hours/brew)

x 10 min saved/brew

= 80 min/day saved

80 min/day saved

x 7 days

= 3.1 extra brews/week

3.1 extra brews/week x 52 weeks/year

= 161 extra brews/year possible

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Cellar and Product Blending

发酵及高浓稀释

What to measure?

测量什么?

• Extract, alcohol, CO2, O2, pH, color, turbidity, viscosity, etc.

浓度、酒精度, CO2, O2, pH, 色度, 浊度, 粘度等

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Why measure it?

为什么测量？

• Monitor fermentation progress and avoid fermentation issues

控制发酵进程，避免发酵问题

• Proactively blend product to avoid production bottlenecks

混合产品，避免生产瓶颈

• Adjust CO2 content before packaging

包装之前校正CO2浓度

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Why measure it?

为什么测量？

• Avoid tax issues (gravity or alcohol and country specific)

避免税金事宜（比重或酒精度或政府明确的）

• Ensure product consistancy and quality

确保产品质量和一致性

• Increase production

增加产量

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Pressure and flow control

CO

2

H2O

Process pump

Blending

To BBT

and

carbonation

Measure Alcohol, Real and Original Extract and CO2

测量酒精度、真浓、原浓和CO2


PLC

DSRn

Ca

rbo

51

0

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Production Increase: Blending ROI

产量增加：混合ROI

Real Example:

Target alcohol is 4.8%

200hl beer @ 4.9% alc blended with 4.17 hl H2O

= 204.17hl beer @ 4.8% alc

Every liter of water = additional beer

每多加一升水=多产的啤酒

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Packaged Product

成品包装

What to measure? 测量什么?

• Extract, alcohol, CO2, O2, TPO, pH, color, turbidity, viscosity, etc.

浓度、酒精度, CO2, O2, TPO, pH, 色度，浊度，粘度等

Why measure it? 为什么测量?

• This is the last QA check possible

这是最后的QA检查

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Packaged Product

成品包装

Why measure it? 为什么测量？

• Ensure product consistancy and quality

确保产品质量和一致性

• Verify process instrumentation

核实在线仪器的可靠性

• Avoid tax issues

避免税金事宜

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Possible Lab Measurements

可能的实验室测量

Wort / Fermentation

麦汁/发酵

% Alcohol (v/v, w/w)

°Plato

Color色度

Viscosity粘度

Degree of fermentation…

发酵度

Beer 啤酒

%v/v 酒精度

°Plato original extract原浓

Apparent, real and orginal

extract, calories…

表观浓度，真浓，原浓，卡路里

Options 选项

Color

色度

Turbidity

浊度

CO2

pH

O2

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Thank you!

Thank you

Prost! 乾杯！ Cheers!

Critical Process Control Points Anton Paar VLB China

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