INGOLD Leading Process Analytics Analytical Measurement Solutions for Optimization of your Brewing Process Brewing Industry 2 Representative Main Office Representative Branch Office Manufacturing Market Organization Main Office Market Organization Branch Office METTLER TOLEDO Competence METTLER TOLEDO – Commitment to Innovation and Quality Worldwide presence We have a worldwide distributor network and a workforce of more than 8500 employees. We support our customers in industry by provi- ding comprehensive solutions for individual steps of their particular manufacturing processes – from receipt of material, over the sepa- rate production stages with inline process measurement, through to final packaging control, logistics and shipping. METTLER TOLEDO solutions can be optimally integrated into an existing IT environment. Our organization specializes in the area of precision instru- ment equipment and related services for industry. In the business year 2005, the Group generated revenues of over US$1.4 billion. The company has been listed on the New York Stock Exchange since 1997. METTLER TOLEDO Group METTLER TOLEDO instruments are employed in research and develop- ment just as well as for quality con- trol purposes. The pharmaceutical, chemical, food & beverage, and cosmetic industries are among the principal users. Innovation and quality Our company enjoys an excellent reputation as an innovator, and cur- rently we invest between 60 and 70 US$ million annually in research and development, having increased our overall R&D spending by an average of more than 10% each year for the past five years. The organization takes every effort to meet the highest quality standards, resolutely applying Total Quality Management at both product and process level, but particularly also as part of support for customers to comply with international guidelines. Process Analytics Division Within the METTLER TOLEDO Group, the Process Analytics Division concentrates on analytical system solutions for industrial manufac- turing processes. The Division consists of two busi- ness units, INGOLD and THORNTON, both internationally recognized leaders in their respective markets and technologies. 3 InPro 8600 A leader in process analytics Centered around INGOLD products, METTLER TOLEDO has established itself internationally as the leading supplier of process analytical meas- urement systems for the parameters pH, ORP, dissolved oxygen, oxygen in gases, conductivity, and turbidity – whether for applications in the chemical and pharmaceutical Indus- tries, in biotechnology, the food and beverage sector or in water and wastewater treatment facilities. Ingold Ltd, founded in 1948 by Dr. Werner Ingold, and taken over by Mettler Ltd. In 1986, is today a core element of the Mettler-Toledo Process Analytics Division. INGOLD – Leading Process Analytics Customer-oriented developments INGOLD products are characterized by high quality and intelligent, detailed technical solutions. Our aim is to develop innovative, reli- able, easy-to-use process analytics in cooperation with customers. Innovations such as the first sterilize- able oxygen sensors, automatic calibrations systems, hygienic re- tractable housings, and recently, intelligent pH electrodes and dissolved oxygen sensors as well as integrated turbidity systems serve to provide improved handling, and to enhance the accuracy and reliability of the measuring point. INGOLD stands for technological, high-quality measurement solutions tailored to specific applications in the area of process analytics. Apart from the traditional, well- proven basic ingredients used in the making of beer, modern auto- mated processes also play a deci- sive role in determining the market success of a beer or shandy. INGOLD renders an important con- tribution towards the automation of beverage plants through its offering of process analytical instrumenta- tion, particularly outstanding for: • accuracy and reliability • high level of user-friendliness • hygienic design of wetted parts • straightforward process integration One of our very latest developments is the new, innovative turbidity sensor for monitoring of filtration processes. Solutions for Breweries and Plant Engineering An experienced team of application specialists and service technicians are ready to help you in: • optimizing your process • sustaining high product quality • lowering maintenance costs • increasing yield 4 ➞ 2 ➞ 4 ➞ 9 ➞ 8 ➞ 6 ➞ 3 ➞ 5 ➞ 7 ➞ 1 ➞ 15 ➞ 12 ➞ 13 ➞ 10 ➞ 11 ➞ 14 ➞ 16 ➞ 17 Water degassing Wastewater- treatment Bright beer tank Filling station Kieselguhr filter PVPP filter CIP plant Centrifuge Filtration and Filling Support processes Mash tunWater treatment Lauter tun Wort copper Whirlpool Wort cooler Yeast propagation Storage tank Fermenter Fermentation and Storage Cellar Brewhouse Water Treatment and Cleaning Brewing Process From Brewhouse to Filling Station the Advantages of INGOLD Measurement Technology The beer market is currently experi- encing an intense globalization process, reflected in escalating competitive and cost pressure. In addition to this, there is growing diversification into new, innovative beverages that call for maximum production flexibility. The time to market is becoming ever shorter, and product quality has to be guar- anteed at a consistently high level, accompanied by an increase in productivity. 5 METTLER TOLEDO supplies com- plete measurement solutions – covering the water treatment stage right through to the packaging station – for the parameters: Use of INGOLD measurement systems from METTLER TOLEDO in the brewing industry Process Measurement Dissolved Oxygen pH Turbidity Conductivity position oxygen in gas Water treatment 1 ••• Mash tun 2 • Lauter tun 3 • Wort copper 4 • Whirlpool 5 • Yeast propagation 6 ••• Wort transfer line/ Wort aeration 7 •• Fermenter 8 • Storage tank 9 • Centrifuge /Separator 10 •• Kieselguhr filter 11 •• PVPP filter 12 •• Water degassing 13 • Bright beer tank 14 • Filling station 15 •• CIP plant 16 ••• Wastewater treatment 17 • ••• The measurement position numbers given in the above table correspond to the numbers in bold print on the following pages in this brochure. ➞ • dissolved oxygen • oxygen in gases • turbidity •pH • conductivity 6 InPro 3253 InTrac 798 Transmitter pH 2100 e InPro 3300 2 4 Brewhouse Inline Measurements in the Brewhouse – Crucial to the Quality of the Wort Measurement of the pH value during mashing When acidifying the mashing-in water or when mashing at lower temperatures, it is advisable to employ a glass-free ISFET pH elec- trode. This takes on particular sig- nificance if the spent grains are to be sold on the open market. Consequently, breakable glass electrodes are wholly inappropriate. Measurement of the pH value during wort acidification Maintaining the correct pH value during boiling of the wort is impor- tant in order to improve protein release. Due to the elevated temper- ature however, only high-accuracy, low-maintenance glass electrodes can be taken into consideration. The significance of a retractable housing The use of a retractable housing prolongs the serviceable life of elec- trodes, since the latter are only brought into the actual measuring position during the decisive acidifi- cation phases. Afterwards, they are retracted into the maintenance posi- tion without interruption of the ongoing process. Proper process control plays a vital role in determining the flavor, foam stability, and color of the finished beer. The relative measurement sensors are exposed to high temperatures, solid particles and turbidity constituents, and must be capable of surviving multiple CIP cycles. METTLER TOLEDO recommends • For mash acidification pH electrode InPro 3300: highest level of process safety, glass break- age completely ruled out. • For wort acidification pH electrode InPro 3253: low main- tenance requirement, but accurate due to self-cleaning reference sys- tem and special membrane glass. • Retractable housing InTrac 798 Maintenance of pH electrode without process interruption. • Transmitter pH 2100 e Ease of operation and reliability. • EasyClean systems Automated cleaning and calibration of electrodes minimizes mainte- nance effort. METTLER TOLEDO measurement loops are completed by a user- friendly transmitter that enables extremely cost-effective operation of the measuring point. 7 InPro 8600 Transmitter Trb 8300 D PDA 3/5 Turbidity measurement in the lauter tun and whirlpool Turbidity measurements are em- ployed to optimize filtration of the lauter tun and mashfilter run-offs, and/or to document charge trace- ability at the whirlpool. In line with a MEBAK (Central European Brew- ing Technology Analysis Commis- sion) recommendation, a forward light scattering measurement using dirt-resistant sensor technology is required. METTLER TOLEDO turbidity meas- urement equipment meets this recommendation by means of a compact, 25° scattered light system using dirt-resistant sapphire optics. The resulting, error-free measure- ments guarantee highest produc- tivity and optimal quality of the wort. METTLER TOLEDO recommends • Turbidity sensor InPro 8600 The compact and robust construc- tion guarantees easy and safe installation. State-of-the art manufacture using low-wear components reduces maintenance costs. • Transmitter Trb 8300 D Intuitive operator control enables time-saving during start-up and configuration. • NEW A PDA or laptop in conjunction with Bluetooth wireless communication can be used to configure and check out several different sensor units. On the other hand, transfer of meas- urement data is realized through a direct wiring connection between sensor and control system. This is a cost-effective alternative for consi- deration during plant design. 8 M 700 S InPro 6800 InTrac 777 6/7 8 Fermentation and Storage Cellars Measurements in the Fermentation and Storage Cellars – where Hygiene is Imperative Measurement of dissolved oxygen content The quality and vitality of the yeast strongly influence the stability of the flavor of a beer. Fluctuations during the yeast cultivation and fermenta- tion processes can be avoided if aeration is controlled by inline oxygen measurement. Correct oxy- gen concentration during the fer- mentation process ensures the de- sired concentration of aromas and of those substances which prevent premature aging of the beer. Measurement of residual oxygen content in CO 2 gas In modern brewery operations, recovery of carbon dioxide from the fermentation offgas is an important aspect relative to cost saving. Before utilization, the CO 2 must undergo purification treatment in order to arrive at the required low residual oxygen concentration. In order at standard fermentation temperatures to be able to rule out the risk of propagation of microorganisms detrimen- tal to the beer, hygienic plant design and resistance to CIP solutions are important criteria, also for inline sensors. METTLER TOLEDO recommends • O 2 sensor InPro 6800 High process safety due to hygienic design – EHEDG certified. Extremely short maintenance times due to modular design. The InPro 6800 is also suitable for gas-phase measurements. • Transmitter M 700 S Highly versatile – for oxygen meas- urements in liquids and gases. Optional dual channel measurement reduces overall costs of a measuring point. • (Intelligent Sensor Management) Facilitates start-up, and signals imminent maintenance requirement based on sensor status. • Retractable housing InTrac 777 Permanent safe access to the sensor for maintenance work without costly interruption of the ongoing process. METTLER TOLEDO oxygen meas- urement instruments are mainte- nance-friendly and provide a clear overview of the various diagnostic functions. This leads to greatly improved operational performance and availability of the measuring point. 9 M 700 S InTap 4004 e InTap 4000 e InPro 6900 9–15 Filtration and Filling Measurements during Filtration and Filling – improved Flavor Stability and Shelf Life Crucial to the quality of beer is that during storage, as well as afterwards when proceeding to final packaging, there is very little oxygen ingress and no liberation of substances that can cause haze formation. Supplementary measure- ment of pH values supports Quality Assurance procedures. Oxygen measurement during water degassing, blending, filtration and filling Oxygen concentration values below 25µ/liter (ppb) meanwhile repre- sent standard limits for packaged beer, as well as for the evaluation of plant components regarding pos- sible oxygen uptake. For use in the above mentioned process stages, METTLER TOLEDO offers high-precision and mainte- nance-friendly inline measurement systems, now newly available with improved response time and sub- ppb detection limits. Also available are portable analyzers for spot checks. METTLER TOLEDO recommends • Transmitter M 700 S Modules for Profibus PA together with a comprehensive offering of out- put modules which can be straight- forwardly linked to all types of pro- cess control systems. • O 2 Sensor InPro 6900 The low detection limit, down to the sub-ppb range, provides for reliable measurement and early warning in the case of overstepping of a limit value. • (Intelligent Sensor Management) Facilitates start-up, and signals imminent maintenance requirement based on the actual sensor status. • Portable O 2 analyzer InTap 4000 e/4004 e This cost-saving solution is suitable for comfortable routine measurement in normal everyday brewery life, and for carrying out spot checks on inline systems. 10 Trb 8300 D oder InPro 8600 PDA 10–12 Turbidity measurement during beer filtration The visual appearance of a beer – its gloss – is as much a quality criterion as is its fresh flavor. Optical dual-angle measurement instruments allow a prediction of whether turbidity of the beer is due to particles of e,g, yeast and/or filter aids, or of colloidal sub- stances such as proteins and/or glucans creating opalescence. METTLER TOLEDO offers an innova- tive solution for all types of filtration methods such as kieselguhr, kiesel- guhr-free, membrane or stabiliza- tion filters. Optimal design features allow direct comparison with stan- dard laboratory instruments, reduc- ing the risk of any misinterpretation. METTLER TOLEDO recommends • Turbidity sensor InPro 8600 Scattered light measurement 25°/90° provides reliable recogni- tion of filter breakthroughs and the detection of colloidal substances. State-of-the-art design and manufac- ture using wear-resistant compo- nents reduces maintenance costs. • NEW A PDA or laptop in conjunction with Bluetooth wireless communication can be used to configure and check out several different sensor units. On the other hand, transfer of meas- urement data is realized through a direct wiring connection between sensor and control system. This is a cost-effective alternative for consid- eration when designing the filtration plant. [...]... Treatment Process Measurements in CIP Systems and in Water Treatment Processes The economic use of fresh water as well as the multiple use of cleaning solutions together present a further basis for achieving overall cost reduction in the strive to achieve greater efficiency of the brewing process Here also, inline systems are of particular help in monitoring and optimizing the relative sub-processes Measurement. .. Integration with PROFIBUS® Easy – Fast – Cost-Saving The fieldbus protocol PROFIBUS PA enables you to fully benefit from the advantages of digital communication METTLER TOLEDO supports the integration of analytical measurement into PROFIBUS process control systems via a range of appropriate, high-performance transmitters for pH, dissolved oxygen and conductivity In modern breweries, PROFIBUS is widely... Line PROFIBUS PA transmitters is supplied via the bus Full PROFIBUS PA integration of METTLER TOLEDO instrumentation ® • PROFIBUS transmitters from METTLER TOLEDO are fully integrated in the device library of SIMATIC® PDM Straightforward integration and management during the entire lifespan save both time and money Profibus® DP Segment coupler Profibus® PA PROFIBUS® is a registered trademark of Profibus... instruments are PROFIBUS certified and therefore easy to integrate In addition, users are provided with state -of- the-art diagnostics technology in order to achieve enhanced process safety Advantages of the PROFIBUS® PA transmitter from METTLER TOLEDO • The GSD files accompanying the transmitters enable complete integration of pH, O2, and conductivity solutions into the process control system • Power for the... assurance of high operational reliability with minimal costs for maintenance and spare parts • pH, O2, conductivity, suspended solids Inexpensive sensor alternatives in METTLER TOLEDO quality ensure reliable measurement performance EasyClean 100 InDip 550 For pH: InPro 4010 For O2: InPro 6050 For turbidity: InPro 8050 For conductivity: InPro 7250 13 ServiceXXL Service Offerings Covering our Products – for. .. Request more information • Get a quote Country-specific information • Select Country/Area to get access to your local support Search functionality • Enter keyword to find requested information Visit our website for fast and competent information Find and download product and application documents • Product News • Industry Newsletters • Application News www.mt.com/pro Visit for more information Sales... work at service depot • Sensor refurbishment • Installation/commissioning • Training/seminars • Maintenance contracts • On-site qualification/verification Online support for the brewing industry METTLER TOLEDO offers the brewing industry a special interactive section on the Internet at www.mt.com/pro/beer, in which applications and useful information as well as some tips relative to process analytics... information as well as some tips relative to process analytics can be found Services offering METTLER TOLEDO offers very attractive service options, ranging from product guidance, over installation through to maintenance contracts For the brewing industry specifically, we offer the following services: Click to open interactive brewing process 14 Distribution network Based at several global production sites, with.. .Measurement of 7/15 pH values in wort transfer and filling lines To increase operational safety, pH measurement in these lines provides a valuable service The immediate detection of residual caustic soda solution or breakthroughs into the product prevents filling of contaminated end product METTLER TOLEDO also offers EasyClean systems for automated sensor cleaning and... Measurement of 16/1 conductivity and pH value in CIP plants and in water treatment When increasing the concentration of the caustic solution in the CIP staple tank, and for separation of the cleaning solutions in return pipes, conductivity systems provide a proven service The compactly designed sensors can be installed without problem in pipes with a narrow cross-section The user software of the pH and . INGOLD Leading Process Analytics Analytical Measurement Solutions for Optimization of your Brewing Process Brewing Industry 2 Representative Main Office Representative. the integration of analytical measurement into PROFIBUS process control systems via a range of appropriate, high-performance transmitters for pH, dissolved