Beer Processing Solutions

Table of contents
Introduction................................................3
Brewing Process Diagram......................4
Complete Product Range.......................5
Complete Process Solutions.................6
Automation Services................................8
Maintenance Service............................. 10
Wort Cooling, Yeast Dosing,
Wort Aeration ........................................ 11
Water Deaeration................................... 13
Inline Blending and Mixing................... 15
Carbonation and Nitrogenation.......... 17
High Gravity Brewing............................ 19
Dealcoholization of Beer...................... 21
Pasteurizing............................................. 23
CIP............................................................ 25
Fermentation and Maturation,
Filtration and BBT Celler...................... 26

5600-03-06-2009-GB

Our first steps into the brewery equipment

business began as early as 1910...
APV pioneered many of the key
technologies involved in the
brewery industry. As early as
1910, APV made the first welded
aluminium beer tank on the basis
of a British patent, and through
its commitment to innovation,
the company has continued to
make important contributions to
the industry ever since. APV has
established many milestones in
brewing technology, with results
that are still valid throughout the
world today.
In 1914 APV developed a system
for the culture of pure yeast and in

1923 the company revolutionized

wort cooling by introducing the
worlds first brewery plate heat exchanger.
Since then, many more
developments have been
introduced, placing APV in a better
position than ever to serve the
brewery industry in all specialty
processes.
Today APV offers process
automation systems, individual
brewery process units, and
a wide range of components
including pumps, valves and heat
exchangers. All APV equipment
and systems can be supported by

a variety of after sales services.

The block diagram below shows
the position of APV units and
systems in a typical brewery cold
block processing line. The dark
green blocks provide a survey of
the APV units and systems and the
lights green blocks show the fields
for which complete solutions can
be offered.

Brewhouse
Yeast propagation

Wort cooling

Yeast tank

Wort aeration
Yeast dosing

Yeast crop

Fermentation tank

Waste beer
treatment

Green beer cooling

Waste yeast

Storage tank
Treated Water

Beer cooling
Filtration/Stabilisation

BlendMaster
Blending/HGB

Bright beer tank

Dealcoholisation

PU Pasteurizer
Flash pasteurization

CarboMaster
Carbonation

Derox
Water deaeration

CO2, N2

Filling

5600-03-06-2009-GB

The Brewing Process

Automation
& Control

Cooling, dosing
and aeration

Page 8

Page 11

Fermantation
Maturation
Filtration
Page 26

BlendMaster
Blending
& mixing

Page 15

Derox

Water Deaeration
Page 13

High gravity
brewing
Page 19

CarboMaster

Carbonation
& nitrogenation
Page 17

BBT Celler
Page 26

CIP
Page 25

PU Pasteuriser
Pateurising

Page 23

Filling
4

5600-03-06-2009-GB

A Complete Product Range

APV provides a selection of
standardized process units, which
could be described as a series of
building blocks. These fulfil various
brewing processes and include:
Wort Cooling
Yeast dosing and wort aeration
Beer Chiller

Focused on adding
value to your product
Our process units are designed
to exceed industry standards and
enhance the value of your products.
To highlight how value is added to
your products and processes, we
have developed the following
symbols for your reference

Derox - Cold and hot water deaeration

BlendMaster - Inline blending and
mixing

Product
uniformity
homogenous products

CarboMaster - Carbonation and

nitrogenation

Flexible

PU Pasteurizer - Controlled beer

pasteurization

fast product changeover

production

Economical

CIP Master

From individual units

to totally automated
solutions
Every unit can be supplied as a
stand-alone system, ideally
equipped for smooth and trouble
free operation and suitable for
integration into your central control
system. But you will gain additional
benefits with a combination of
units, which have been specifically
designed to operate together for
high performance, both from
a mechanical and a control
perspective.
APV can guarantee you a process
solution tailored to your needs.

production
cost saving processes
Proven
security
tested equipment

The unit values are significant

APV Provides:

Capabilities:

Customer Values:

An intelligent processing unit

Configuration as required
Real time plant data:
Predictive maintenance
On-line documentation
Final product monitoring
Traceable production

Improved process:
Profitability
Consistency
Security
Lower operating cost
Longer running time

A Plug and Produce unit

Very short commissioning time

Low installation cost
No interference to existing production schedules
Reduced time from order to production
Seamless integration to all plants
Easy to extend

Faster return on investment

Easy expansion of existing plant

Proven standards

Improved functionality
Hygenic design
Good reliability

Improved repeatability
Product integrity safeguarded

State of the art processes

Easy operation
Low energy consumption
Reduced waste
Low noise emission levels

Quick and easy operator training

Environmental improvements
Improved company image

A compact unit design

Container fitted
Low shipment cost
Smallerproduction area required
Moveable equipment
Fast delivery time

Shorter delivery time

Higher capacity/m

Maintenance service

Easy maintenance
Optimal APV service
Fixed maintenance costs
A reduction in unscheduled downtime
Limited spare parts requirement

Cost effective maintenance

Higher productivity

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Complete Process Solutions

Adding value for the brewmaster
APV draws on decades of
experience in project engineering
and management for the brewery
industry. Its extensive range of
reference installations includes
everything from a single process
line to complete greenfield turnkey
beer processing solutions.
To meet todays demand for
modern, highly efficient production
facilities, APVs in-depth knowledge
of brewing top quality beers is
complemented by expertise in
process automation and
management information systems.
APVs technological excellence
covers processes such as
fermentation and storage, yeast
handling and treatment, beer
processing, bright beer and
pasteurization. Furthermore, we
have vast experience in the areas
of wort cooling, water deaeration,
and high gravity brewing. Our
CIP systems complete the
process. Wherever appropriate,
APV integrates its strong range
of standard process units into a
project.
We believe our experience is our
most important asset. Previous
highly successful installations are
our customers best guarantee
that a brewery project will be
implemented on time and within
budget.
Our experience ranges from
traditional methods to highly
automated systems based around
the latest proven technologies.
Highly automated systems deliver
improved efficiencies, resulting in a
faster return on investment, due to:

More production time

specific needs.

Less cleaning time

Detailed Engineering

Minimum use of water, chemicals

and energy

This starts with the PID and process description, followed by the
development of installation pipeline circuit and connection plants,
cable lists, functional descriptions,
program sequences, energy
calculations, component
specifications, interface definitions,
spare parts lists and operating
instructions and manuals - all
dedicated exactly to our customers
specific brewing needs.

Fewer operators
They also improve batch control,
resulting in product traceability and
flexibility.
Further benefits for the brewmaster
and management are:
A paper free process control
system which can interface with
ERP systems
Material and quality tracking

Hygienic Design

capability

Our design is based on the latest

international standards for hygienic
design. APV uses standard design
elements, which are constantly reviewed to meet the highest

Full compatibility with brewhouse and filling plant as well as

with other production plants in
the brewing group

Process Engineering
APV uses its extensive experience
in the development, planning and
implementation of brewing steps
in close cooperation with our
customers brewmaster,
technologists and process
engineers. Careful teamwork
ensures that we understand and
recognize each of our customers

standards.

Health and Safety

HACCP/HAZOP studies can be
undertaken, reviewing equipment
specifications relative to process
flow diagrams to determine whether there are any quality, health and
safety issues, which need to be addressed.
Each process step is analysed to
establish whether the equipment
and control systems are adequate
for safe operation under normal,
abnormal and CIP conditions.

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Latest Design Tools

appropriate local manpower.

Optimizing
Working Procedures

APV uses the latest design tools.

The use of 3D models, with
possible access to full-scale
modeling from AutoCAD, provides
improved safety features by
maintaining data throughout
the project via single entry to
the database. Furthermore,
the existing AutoCAD platform
for communication with most
customers CAD Systems is
maintained.

Consistent working procedures in

sales, engineering and
management are an important part
of the value APV adds to a project.
We have therefore been certified to
ISO 9001 Standards. But that has
never been our final goal. Through
quality improvement programs,
working procedures are constantly
monitored and challenged to
increase productivity and efficiency
in all parts of our business.

Project Management
- a single point of
contact

Training of People

APV project managers are our

Environmentally
Safer Processes
In response to an increasing need
for environmentally acceptable
utility services, energy optimization
through sound design principles
is always observed. Waste
minimization and health and
safety issues are always carefully
considered.

customers single point of contact.

They are highly experienced and
acutely aware of all critical
implementation aspects. Excellent
coordination skills enable them
to trans-late the efforts of APV
suppliers and other sub-suppliers
into successful projects.

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Installation
Supervision

Breweries are operated by fewer

and fewer highly trained staff,
which often results in the need for
an exceptional degree of
automation and integration. APV
provides tailored training courses
for our customers personnel in
both process and automation
technology. Designed to extend
their skill base, increase their
specialist knowledge and update
them on the latest trends, these
courses are offered either at our
customers brewery or on APV
premises.

APV supervisors are internationally

experienced and accustomed to
all kinds of local working
environments. Armed with
excellent co-operation skills,
they are specialists in accessing

Automation and Performance

Services Solutions
APV Automation and Performance
Services combines innovative
solutions with reusable engineering
applications on open platforms
to meet our customer automation
specifications.
We offer state-of-the-art
automation solutions and
services designed to international
standards based on in-depth
process knowledge together with
manufacturing know-how and
engineering expertise that meet
regulatory requirements. This
enables customers to extend their
performance gains across their
business.

Value Streams
APV Automation and Performance
Services comprise five strategic
value streams to meet our
customers automation and
manufacturing execution needs.

Automation Service for customers existing automation equipment offering maintenance and
support programs, spare parts,
etc maintaining and improving conditions to maximize plant
uptime

APV Automation and Performance

Services is vendor independent,
it can include, for example control
systems and human machi-ne
interfaces (HMIs) from Siemens,
Rockwell, Mitsubishi, Wonderware,
etc. This enables true versatility in
our solutions.

5600-03-06-2009-GB

 Automation Migration for our

customers with an installed
base of ageing and obsolete
automation equipment which
can no longer adequately support their business. Furthermore, Automation Upgrade for
systems that require additional
functionality to meet automation
and control requirements
Automation Systems consisting
of PLC and HMI as part of our
project offering. These can be in
the form of a single skid unit to
plant wide automation solutions

MES Applications targeting

manufacturing and equipment performance, production
execution, quality and tracking.
We offer a suite of engineered
applications designed to deliver
the right information, at the right
time, to the right people, in the
right context to drive future actions in our customers organizations to drive manufacturing
excellence

ERP Integration solutions that

link and integrate the plant
floor automation systems to our
customers enterprise or business layer

ERP Integration
MES Applications
Automation Systems
Automation Migration
Automation Service

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Maintenance Services
APV recognizes that costeffective performance of your APV
equipment is directly dependent on
the ability to design and implement
a cost-effective maintenance
program.
In response to these requirements,
and as part of the on-going
expansion of our customer support
strategy, APV Maintenance
Services adapt to your specific
requirements.
Maintenance Services consists
of multiple levels of service
agreements in order to create the
ideal balance of flexibility, improved
productivity, increased up-time and
better financial performance of all
APV equipment.
Different service agreements can
be created for our customers. For
example:
Basic Care
- APV service when you can
plan ahead
- Balance of uptime and econo-
mics for non-critical assets

Classic Care
- Comprehensive APV service
support
- When service delays are not
an option
Advantage Care
- APV service coverage for your
most critical equipment
- Proactive approach to equip ment performance
Total Care
- APV service management and
support for the entire plant
- Plant-wide strategy to improve
mission effectiveness

Each agreement includes certain

critical items, with each level
providing progressively increasing
sup-port capability (see table
below).
APV is committed to providing
proactive service solutions. These
Maintenance Services agreements
provide the best possible service
to maximize your performance and
deliver improved return on your
investment.

ASystematic Program of Strategic Maintenance

APVservice management
and support for the
entire plant

APV service coverage for

Comprehensive APV
your most critical equipment service support

APVservice when you can

plan ahead

Plantwide strategy to
Proactive approach to
When service delays arent
improve mission
equipment performance
an option
effectiveness

Total Care

Advantage Care

Classic Care

Balance of uptime and

economics for
non-critical assets

Basic Care

Agreement of delivery of critical

spare parts

Agreement of delivery of critical

spare parts

Agreement of delivery of critical

spare parts

Agreement of delivery of
critical spare parts

Agreement of emergency
service support

Agreement of emergency
service support

Agreement of emergency
service support

Agreement of emergency
service support

APV Preventive Maintenance

APV Preventive Maintenance
program, 24/7/365
program, 24/7/365

APV Preventive Maintenance

program, Monday to Friday
8am-5pm

One annual planned

maintenance visit

Free emergency service,

24/7/365

Emergency service,
24/7/365

Emergency service,
Monday-Friday, 8am-5pm

Spare parts discount

Wear parts and service parts

included

Wear parts and service parts

Wear parts included
included

Recommended wear parts

replacement scheme

Other spare parts discount

Other spare parts discount
Other spare parts discount

Technical telephone support,
24/7/365

Technical telephone support,

24/7/365

Technical telephone support,

Monday-Friday, 8am-5pm

Modem support included

Modem support included

Modem support - optional

Strategy for service

partnership seminar

Strategy for service

partnership seminar

Strategy for service

partnership seminar

Software upgrades

Predictive maintenance on
critical items

Plant availability guarantee

Software upgrades

Designated APV maintenance

manager

Rebuilding andretrofitting
consultancy

Technical telephone support,

Monday-Friday, 8am-5pm

Continuous process cost

reduction
Guaranteed performance
guarantees on critical items
Annual process knowledge
analysis
Rebuilding and retrofitting
consultancy
Operator audit and training
discount

10

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Wort Cooling,
Yeast Dosing and Wort Aeration

Ensure economical production by minimizing the use of time and

additives

The Wort Cooling, Yeast Dosing

and Wort Aeration units are
designed for the processes
between the brewhouse and
fermentation.

Offered in a wide range of

capacities from 50 to 1200 hl/
hr, all units are designed and
developed for easy integration with
existing lines.

Turn down ratio to 25% of nominal capacity

In addition to fast and efficient

Wort Cooling, Yeast Dosing and
Wort Aeration units deliver effective
and accurate inline dosing of yeast
and air/oxygen by means of the
patented APV gas injector.

Product uniformity:
Constant monitoring and improved regulation of the process

Proven security:
Fully CIP-cleanable

Repeatable fermentation performance

Flexible production:

Constant yeast/oxygen ratio,

regardless of flow

Traceable production data

Economical production:
Higher accuracy in yeast and
oxygen dosing
Reduced fermentation time

5600-03-06-2009-GB

11

Functional
description
Wort Cooling - Hot wort from the
brewhouse must be cooled prior
to the addition of yeast for
fermentation. This is achieved
using a state of the art plate heat
exchanger with a wide channel,
which reduces the cleaning
requirement while maintaining good
heat transfer efficiency. Additional
attractive features include a high
performance clamping system,
improved hanging area and
EasyClip gaskets, all of which
contribute to reduced maintenance
and spare parts requirements.
The wort cooler can be designed
as a single section cooler using ice
water or as a double section cooler
for brewing water and refrigerant.
Wort Aeration - Brewing yeast requires oxygen to multiply.
Traditionally this has been supplied
by blowing air through the wort
with various types of nozzles and
mixers. The result was often varying
oxygen levels of typically 10 to12
mg O2/l depending on pressure,
temperature and the original gravity
of the wort.
Specified O2 levels with high
gravity worts are usually higher and
thus pure oxygen is often used to
achie-ve levels above 18 mg O2/l.
The APV Gas Injector allows these
levels to be achieved by a fast consistent mixing of wort and either air
or oxygen.
Yeast Dosing - Yeast can be added
to complete the wort treatment.
This has the advantage of adding
yeast immediately to the cooled
wort. The actual method used can

reflect local practice and the automation allows accurate MIS/MES

integration. In the event of lack of
product flow, the yeast supply is
shut off.

Options
Cooling
DuoSafety Plates - Additional
pro duct protection.
ParaWeld Plates - Allow the
use of NH3 as refrigerant.
Bypass - Options are available
for bypassing the plate heat exchanger to enable such operations as hot and/or cold wort
diversion and back washing.

dosed on the basis of tank contents measured by a load cell.

Yeast Cell Measurement - The
amount of yeast can be dosed
on the basis of instrumentation
that measures the yeast cell
concentration.

Common
Original Extract Measurement Completed through the means
of a sound velocity sensor or
density measurement.
Oxygen Measurement - The
oxygen content of the wort can
be measured using an appropriate instrument.
Blending Separation - The
simple blending T can be
replaced with a 4 port double
seat valve and stop valve to
separate the product and component loops for cleaning.
High Accuracy Blending - A
variation of this technology
using mass flow measurement
is capable of even higher accuracy and is used for blending
of components such as hop
extract or colour.
Conductivity Measurement
- Product separation can be
measured by means of conductivity to minimize product loss.

Aeration
Manual Adjustable Head - Any
adjustment for flow and specification must be made manually.
Modulating Head - Automatic
adjustment of the head can be
made from the control system.
This option can be retrofitted
to the manual head.
Dosing
Flow Measurement - The yeast
can be dosed by means of a
magnetic flowmeter.
Tank Contents Measurement
- The amount of yeast can be

GLYCOL

GLYCOL

BREW WATER
STERILE AIR
BREW WATER

AERATED WORT

WORT

wortmaster.dwg

12

5600-03-06-2009-GB

Derox - Cold and Hot Water Deaeration

Improve your beer quality with the Derox Deaerator
Deaerated water is used in the
brewing industry to minimize
damage to beer through oxidation.
It is used as a medium for purging
mains and equipment and post
fermentation as part of the brewing
process.
The Derox product range covers
units designed for deaeration of
processing water. Derox is used
where a low O2 content is required
or recommended, for example for
the lauter tun, blending of bright
beer and in High Gravity Brewing
(HGB) processing.
Deaeration can be performed by
two different systems - cold
(Derox) or hot (Derox+) deaeration.
The hot system heats the water to
high temperature, which reduces
the risk of infection and helps remove contaminants. The cold
system is capable of achieving low
levels of oxygen with low capital
and production costs.
All Derox Units are designed and
developed especially for easy
integration to existing lines, with a
wide and flexible capacity range.

Derox (cold)
- adds value
The standard capacity range is 30
to 1,500 hl/h.

Derox+ (hot)
- adds value
The standard capacity range is 50
to 400 hl/h.

The Derox adds value to your products and processes in the following ways:

The Derox+ adds value to your products and processes in the

following ways:

Product uniformity:
Constantly low oxygen content
50 ppb at 12C* (below 30 ppb
at >20C.*)

Product uniformity:
Constantly very low oxygen content (below 20 ppb.*)

Continuous monitoring for required specification

Economical production:
Low running costs
Space-saving design (high capacity/m2)
Flexible production:
Variable capacity and high turn
down
Independent of water inlet
temperature (option)

Continuous monitoring for required specification

Continuous removal of undesirable THF gases
Economical production:
Low running costs
Space-saving design (high capacity/ m2)
Flexible production:
High turn down ratio (down to
25% of nominal capacity)

Variable deaeration levels

Independent of water inlet temperature

Proven security:
No rings and plates inside
vacuum tanks

Proven security:
No rings and plates inside
vacuum tanks

Fully CIP-cleanable

Deaerated water is pasteurized

Fully CIP-cleanable

5600-03-06-2009-GB

13

Functional
description
Hot deaeration
Water entering the unit is warmed
by means of the regenerative section of a plate heat exchanger.
After the regenerative section, the
water enters a heating section
where the temperature is raised
to about 88C. The water is then
sprayed into the deaeration tank via
special nozzles.
WATER/CIP

The deaeration tank is kept under

vacuum so that the oxygen is
removed with a minimum of water
vapour.
The deaerated water is cooled in
the regenerative section of the
plate heat exchanger and the final
outlet temperature is achieved
using a chilling section or a
separate cooler, depending upon
the refrigeration available.

CO2 / N2

Derox (Cold)

from the unit via an adjustable

manual-regulating valve.
The unit is designed for CIP and
does not contain packing.

The deaeration tank does not

contain packing and is easily
cleaned.

Options

Cold deaeration
Water is sprayed into the bottom
vacuum tank, which starts the
oxygen removal process.

Hot deaeration
CO2 Stripping - The use of
a small amount of stripping
gas can allow the energy lost
through flashing to be reduced.

The water is then pumped and

sprayed into the top vacuum tank
via an injector where stripping gas
(either CO2, N2) may be applied.

Cold deaeration
Chilling - Chilling of water to
match beer temperature. Different configurations are available.

From the top tank the water falls

through a pipe with a vent which
allows some of the water to return
into the bottom tank. The level in
this bottom tank is controlled by
means of a level switch, which
controls the water inlet valve.
The remaining water is discharged

14

DEAERATED WATER

UV Water Disinfection - Disinfection of the incoming water

can be obtained by the use of an
ultra-violet disinfection unit.
Seal Water Cooling - In cases
where the seal water will exceed
25C it is advisable to fit an
optional seal water cooler.
Preheater - Values below

0.03 ppm residual O2 can be

achieved with a water temperature of about 20C. In
cases where this water inlet
temperature is not a normal
value, a preheater consisting of
a shell and tube heat exchanger
together with a steam regulation
valve and condensate trap can
be supplied.
Common
Oxygen Measurement - The
result of the deaeration process
can be measured inline with an
oxygen measuring instrument,
and the values used to initiate
remedial action or alarms.
Control Panel Enhancements
- Advanced control systems
with digital programming allow
extremely accurate control and
comprehensive data collection.
Many of these facilities are also
available with PLC control systems.

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BlendMaster - Inline Blending

The BlendMaster adds new dimensions to accurate standardizing

and efficiency!
The BlendMaster range covers
units designed for continuous inline
blending of liquid components.
It ensures precise recipe
conformity, regardless of whether
two or more liquid components are
combined.
The BlendMaster is used, for
example, in High Gravity Brewing
and in combination with other unit
types like the CarboMaster and
Derox Water Deaeration.
Standard capacity range: 50 to
1200 hl/h.

BlendMaster
- adds value
The BlendMaster adds value to
your products and processes in the
following ways:

Product uniformity:
Ensures exact conformity with
the specified recipe
High calibration stability
Economical production:
High precision blending
Space-saving design (high capacity/ m2)

Combined blending and carbonation unit

Flexible production:
Easy change of recipe for fast

Proven security:
Continuous monitoring and

product change

regulation of the combined product

Turn down ratio 25% of nominal

capacity
Blending ratio 1:10 to 1:2

5600-03-06-2009-GB

Automatic switch-off, if offset

exceeds the limit

15

Functional
description
Extract and alcohol are parameters
usually used for duty purposes,
and product declarations and
accurate determination are
therefore important. HGB is now
a world-wide standard involving
the addition of part of the brewing
water after fermentation instead of
within the brewhouse. Even when
HGB is not a standard procedure,
cutting the final beer with small
amounts of water to achieve
a consistent product is often
required.
Magnetic flow meters are used to
measure the volumes of high gravity
beer and deaerated water. Dosing
takes place by means of a simple
ratio control operating a modulating
valve on the water supply. This
gives results that are within the
accuracy of laboratory instruments
and inline measurement. This ratio
control may be adjusted by means
of an optional sound velocity/
alcohol sensor, which measures
the original extract of the beer and
applies appropriate corrections.
This technique can also be used for
blending beer types or diluted beer
from filtration.

16

PI

FINAL BEER

DEAERATED WATER
FT

FT

DT

GT

HGB BEER

Options
blendmaster.dwg

Original Extract Measurement Completed through the means

of a sound velocity sensor. This
measures the velocity of sound
in a fermented product, which
is proportional to the original
extract of the unfermented product.
Alcohol Measurement - Density
measurement by means of mass
flow techniques, which together
with sound velocity measurement allow the alcohol contents
to be calculated.

Blending Separation - The simple blending T can be replaced

with a 4 port double seat valve
and stop valve to separate the
product and component loops
for cleaning.
High Accuracy Blending - A
variation of this technology using mass flow measurement is
capable of even higher accuracy
and is used for blending of components such as hop extract or
colour.

5600-03-06-2009-GB

CarboMaster
- Carbonation and Nitrogenation
The CarboMaster is the answer when you are looking for a cost
effective, accurate and flexible gas-dosing unit
The CarboMaster is the answer
when you are looking for a cost
effective, accurate and flexible gasdosing unit.
The CarboMaster range covers
units designed for continuous inline
injection and dissolving of gasses
like CO2, N2.
This equipment ensures a precise
and uniform injection, by means of
the patented APV gas injector (see
description on page 18).
The CarboMaster is used in the
brewery industry for duties such as
carbonation and can be integrated
with other unit types, including the
BlendMaster or the HGB Master.
Standard capacity range: 50 to
1200 hl/h.

CarboMaster
- adds value
The CarboMaster adds value to
your products and processes in the
following ways:

CarboMaster for high CO2 content

Product uniformity:
High dosing accuracy (+/0.05g gas/kg product*)

Flexible production:
Turn down to 25% of nominal
capacity

Injection independent of inlet

Inject and dissolve up to 10g

gas/kg product

temperature and pressure

Economical production:
No gas losses
Space-saving design
Holding time not necessary

Proven security:
Constant monitoring and control
of final product
Fully CIP-cleanable

* Measured as a standard deviation

5600-03-06-2009-GB

17

Functional
description
The basis of the unit is the patented APV CO2 special injector,
which differs from other models by
injecting the liquid into the gas in
counter flow. This achieves quick
dissolution, and the gas is tightly
bound to the liquid. High levels of
CO2 addition can be obtained
without long holding tubes, and a
precise fast regulation is obtained.
It is possible to carbonate sales
gravity beer to the desired level
after the addition of non-carbonated water.
The calculated value is compared
with the measured value and the
CO2 content adjusted
appropriately by means of the
modulating valve.

The fixed head injector can cope

with variation in flow rates of about
+10%. The gas supply is shut off if
the product flow stops.

Options
Variable Capacity Head - The
fixed head can be replaced with
a variable capacity head which
allows a turndown to 25% of the
nominal capacity. This can be
either pneumatically controlled
or manually adjusted.
High Carbonation Levels - The
standard system is engineered
to cope with levels of CO2 normally specified in beer. Carbonation of up to 10g/kg CO2 may
be obtained if required.

CO2 Measurement - An inline

CO2 analyzer can be installed
together with a regulating valve
to allow the CO2 contents to
be automatically monitored and
adjusted.
High Precision Dosing - By
means of a gas flow meter,
the amount of added gas can
be accurately determined to
avoid over or under carbonation. This is more accurate than
CO2 measurement with which
it is often combined. A further
advantage is that the gas usage
data can be used for production
control and statistics by means
of a suitable control system.

BEER

CARBONATED BEER

18

5600-03-06-2009-GB

High Gravity Brewing

High Gravity Brewing (HGB) combines the three process stages of
water deaeration (Derox), inline
blending (BlendMaster) and carbonation (CarboMaster).
SPX APV HGB Systems ensures
a cost-effective process combined
with very high production flexibility.
The system are designed and
developed especially for easy
integration with existing lines, and
is available in an extensive and
flexible capacity range.
Standard capacity range: 50 to
1200 hl/h.

SPX APV HGB

Systems
- adds value
The SPX APV HGB Systems add
value to your products and
processes in the following ways:
Product uniformity:
Constantly low oxygen content
50 ppb at 12C* (below 30 ppb
at >20C.*)

High dosing accuracy (+/0.05g gas/ kg product*)

Variable deaeration levels

Continuous monitoring for required specification

Injection independent of inlet

temperature and pressure

Economical production:
Low running costs

Blending ratio 1:10 to 1:2

Exact conformity with the specified recipe

High calibration stability

High precision blending

Easy change of recipe for fast

Turn down ratio 25% of nominal
capacity
Inject and dissolve up to 10g
gas/kg product

Space-saving design (high capacity/ m2)

No gas losses

product change over

Holding time not necessary

Proven security:
No rings and plates inside
vacuum tanks

Flexible production:
Variable capacity

Constant monitoring and control of final product

Independent of water inlet temperature (option)

Automatic switch-off, if offset

exceeds the limit

Fully CIP-cleanable

* Measured as a standard deviation

5600-03-06-2009-GB

19

Functional
description
Wide scale use of High Gravity
Brewing has become standard
modern brewing practice, as the
reduction in production costs is
significant. By adjusting the extract
of the beer after filtration rather
than in the brewhouse, the final
output of a given plant is greatly
increased.
A High Gravity Brewing System
comprises a combination of several
modules described elsewhere. The
normal configuration consists of a
deaeration module, a blending
module and a carbonation module.
The integrated System is simpler,
more compact and cheaper to implement than separate modules.

The deaerated water is taken from

the skid to the buffer tank and an
amount returned for blending and
carbonation. Deaerated water from
the buffer tank is still available for
other applications.

Options
Hot Deaeration - For added
security with poor water quality
Cold Deaeration - For minimum
production costs
Blending - Addition of DAW can
be normal or combined with the
addition of pre- and postrun
diluted beer
Carbonation - Correction of the
CO2 contents of the final beer to
specification. This is normally a
single point but pre-carbonation
of the water can be supplied if
desired.

GLYCOL
GLYCOL

WATER

CO2
CO2/N2

FINAL BEER

HGB BEER

HGB Master

20

5600-03-06-2009-GB

Dealcoholization of Beer

Gentle treatment - Beer must taste like beer

SPX APV has a number of systems

for partial or total removal of
ethanol from beer and wine. These
include dialysis, distillation and
evaporation.
Dialysis has the advantage
of being a low temperature
process, whereas the thermal
processes operate at slightly
higher temperatures. However,
the thermal processes are usually
less expensive due to much lower
maintenance costs.

Functional
description
Dialysis - A typical dialysis process is shown in the picture. The
process is a combination of a
thermal distillation and a membrane
system. The beer flows inside the
capillary membrane. The carrier
liquid (dialysate) flows outside the
capillary in counter current
direction to the beer, where it

5600-03-06-2009-GB

causes the alcohol flow through

the membrane. This concentration
differential provokes the permeation
of alcohol and minimises the
reduction of even the smallest
taste components. This means
gentle de-alcoholisation with
optimum conservation of the flavour
compounds typical of the product.
The alcohol absorbed by dialysate
is removed continuously in a
vacuum distillation column, thus
making an economically efficient
dialysate circuit. After the stripping
process the carrier liquid is cooled
down to the dialysis temperature
and led back into the membrane
system.
The plant is built up in five main
sections:
Feeding unit
Membrane system
Vacuum distillation system
Cooling and filtration unit for
carrier liquid
CIP unit

Dialysis system
- adds value
Simple, reliable process
sequence
No thermal or mechanical stress
to beer
Reduction of the alcohol content at cellar temperature
(operation temperature of
10C)
No dilution or concentration of
the beer
No loss of natural carbonation
No change of colour
Excellent beer quality (as near
as possible to the original beer)
The dialyses system allows an
alcohol reduction below 0.5%
based on nearly all traditional
beers
Proven technology
Constant monitoring and
control of final product

21

 Fully cleanable by CIP

Distillation - A typical APV
distillation process is shown in
the flow schematic below. Beer
or wine is pumped through a
plate heat exchanger where it is
heated regeneratively by returning
de-alcoholized product. Further
heating with hot water occurs in
the same heat exchanger. The beer
is then flashed at a relatively high
vacuum. The flash releases the high
volatile components. The degree
of flash will control the amount of
esters and other aromasin the final
product. Some ethanol will also
flash, but the main content will be
recovered in the final product.

order to minimize the thermal

effect on the beer. The alcohol
removed at the top of the column
is condensed. The column is an
APV dual flow design specifically
designed for hygienic applications.
If necessary, the stripped ethanol
can be concentrated to over 90%
v/v by rectification.

The flashed liquid is pumped to

the top of a stripping column. This
column operates under vacuum in

One particular advantage of

distillation is that, when necessary,
the ethanol content can be reduced

The de-alcoholized beer from the

bottom of the column is partially
cooled by the beer feed and
further cooled by chilled water. The
cold beer is then sprayed into a
recombiner vessel to absorb the
aromas that had been flashed. The
beer is cooled further for storage.

to extremely low levels.

The operating temperature is
usually below 55 deg C but can be
lower if refrigeration is used for the
condenser.
Evaporation - A similar process
with a 4 stage APV Falling Film
plate evaporator used instead of
the stripper column. The beer is
partially evaporated in four separate
stages at about 40 deg C. The
hold up in the evaporator is shorter
than in the stripper column, but the
ethanol cannot be reduced to very
low levels. Typically a 5% v/v beer
can be reduced to 0.35% v/v.

COOLING WATER

DEESTERIZER

RECOMBINER

ALCOHOL
STRIPPING
COLUMN

CONDENSER

TO HOT WELL

PRODUCT

COOL

REGEN

HEAT

FEED
BALANCE
TANK
FEED

REBOILER
PLATE HEAT
EXCHANGER

REHEAT
HOT WATER

REBOILER
HOT WATER
STEAM

22

STEAM

5600-03-06-2009-GB

PU Pasteurizer
- Controlled Beer Pasteurization

If you value gentle and accurate heat treatment you will also value the
PU Pasteurizer
The PU Pasteurizer was developed
especially for continuous heat
treatment of beer and other
carbonated drinks.
The pasteurization temperature in
the PU Pasteurizers is controlled
by Pasteurization Units (PU) and
designed for high working
pressures.
The PU Pasteurizer provides effective and gentle heat treatment of all
kind of carbonated products.
Standard capacity range: 50 to
500 hl/h.

PU Pasteurizer
- adds value
The PU Pasteurizer adds value to
your products and processes in the
following ways:
Product uniformity:
Very high accuracy (computer
controlled PU regulation)
Low T between product and
heating media

Economical production:
Large heat regeneration (up to
94%) with low temperature filling
Waste-saving design (beer/water zone)

Proven security:
Constant overpressure downstream
Constant monitoring and control of final product

Flexible production:
Turn down ratio 40% of nominal
capacity

5600-03-06-2009-GB

23

Functional
description
Pasteurization is calculated on
the basis of holding time and
temperature. The time factor is
linear, and small variations have a
minor effect on the PU value and
are controlled by adjusting the flow.
The temperature factor is
exponential and small variations
lead to more substantial changes
in the PU value. The PU value is
maintained by the control system,
adjusting these parameters. In the
event of a downstream shutdown,
water replaces the beer in the
system to maintain the balance.
The temperature is controlled by
means of hot water circulation.
With a beer pasteurizer, the
dissolved gas must be retained in
solution throughout the process by
the appropriate system pressures.
The design system pressure can be
set for each beer type to minimize
energy requirements.
The unit is based on a threesection plate heat exchanger with
regenerative, heating and cooling
sections. The heating section is
part of a heating cycle in which
water is warmed by means of a
shell and tube heat exchanger. The
beer temperature is variable, 72C
held for 30 seconds being typical.
The cooling duty is selected
according to packaging
requirements. A regenerative outlet
temperature as close as possible to
the packaging temperature allows
reduced energy consumption.

heat exchanger ensures that the

pressure on the sterile side of the
regenerative section is higher than
the pressure on the non-sterile
side. This pump is frequency
control-led to allow adjustment of
the pressure in the holding cell.
A modulating valve is used together
with a magnetic flow meter to
regulate the flow and thus the
holding time.
The beer enters a buffer tank equipped with a load cell to measure the contents. In the event of
a downstream shutdown, the
pasteurizer continues operation
until a pre-determined maximum
level is reached. The remaining
beer in the system is flushed into
the buffer tank with water, which
is then re-circulated to maintain
the balance. On resumption of
downstream production, the
buffer tank is emptied until a
pre-determined minimum level is
reached. The water circulating in
the pasteurizer is pushed out to
drain or to a collection tank with
fresh beer, and normal operation

Advanced control systems with

digital programming allow even
more accurate temperature and
pressure control. They can be
combined with predictive and
fuzzy logic for extreme accuracy

Valve types and configurations

can be customized as required
A double shunt for improving the
coolant supply can be integrated

WATER

GLYCOL

Options

A conductivity meter registers

the interface between beverage
and water and reduces changeover losses to a very low value

BUFFERTANK

GLYCOL

resumes.
The unit is started by means of a
shell and tube heat exchanger
heating water to 80C for
sterilization and to balance the
system. Heating of the system to
balance typically takes place in less
than 10 minutes.

CONDENSATE
STEAM

WATER/CIP
BEER

A high-pressure pump supplies

the regenerative section outlet with
the required pressure. A booster
pump between the regenerative
and heating sections of the plate

24

pupast.dwg

5600-03-06-2009-GB

CIP Master

Go for perfect cleaning results at lower cost with the APV CIP Master
The production of high quality beer
using highly efficient operating
techniques requires effective,
careful cleaning of equipment.
APV offers CIP modules as
standardized compact units or units
tailored exactly to our customers
specific projects and needs.
The APV CIP Master is a fully automatic system, programmed to
achieve optimal cleaning of the
process equipment.

The APV CIP Master

- adds value
The APV CIP Master adds value to
your products and processes in the
following ways:
Product uniformity
Fully automatic CIP programs ensure perfect cleaning

Economical production

Proven security
If appropriate, the CIP Master is fully
tested before delivery
Proven functionality and reduced
commissioning time

Full automation reduces manpower

Optimization of functionality leads to
reduced cleaning

Flexible Production
Easy implementation of options due
to modular design
The APV CIP Master is skid
mounted when possible, which allows easy relocation in the event of
production restructuring

Functional
description
The APV CIP Master is a fully
automatic, self-contained unit.
It comprises a complete set of
equipment for CIP, including, for
example, tanks for water, acid and
caustic soda, pumps, tubular and/
or plate heat exchangers, valves
and instrumentation such as
conductivity and flow transmitters.
The CIP program covers the
complete cycle. Detergent or water
selection, detergent concentrations
and cycle temperatures and times
are fully controlled.
The APV CIP Master is fully
integrated with the process line
and can be used with existing
equipment (including filling

5600-03-06-2009-GB

machines) as well as new APV

units.
The design of the CIP Master by
APV incorporates the requirements
of production schedules to
minimize downtime. This forms the
basis for selecting the appropriate
tank numbers and volumes
together with the number of lines.
The standard APV control consists
of a controller with an operator
panel. The signal exchange
between the instruments/controller/
control room is performed using a
bus system.

Options
3, 4 or 5 tank systems
Different tank sizes
Number of lines
Tubular or plate heat exchangers
Low cost manual CIP systems
Customer specific equipment

25

Fermentation and
Maturation
Proper fermentation requires wort
cooled to the right temperature,
aerated to the right oxygen content
and dosed with the right amount
of active yeast cells. APV designs
highly automated process systems
that continuously control all
essential parameters before and
during fermentation and maturation,
ensuring an end product of a
consistently high quality.
The control systems of fermenter
cooling and the process system
are designed to provide cohesive
support to brew masters, process
engineers and automation
specialists to help them to meet
the requirements for specific beer
types. The result is a complete
and well-documented process
line designed to maintain the
characteristics of the beer and to
meet consumer expectations for
high quality.

26

Filtration
Due to seasonal fluctuations in the
quality of the raw material and the
complexity of the process itself,
filtration is one of the more complex
parts of the brewing process. APV
works in close co-operation with
reputable suppliers of filtration
systems to meet the needs of a
specific project.
It is important to control the
different phases of the filtration
process and integrate them into
the rest of the beer processing
line, ensuring that the required
production capacity is reached.

BBT Cellar
With modern filtration and HGB
equipment available as continuous
processes, the requirements and
flexibility of the BBT Cellar are
highly demanding.
Strictly hygienic conditions and low
oxygen levels must be maintained.
As todays industry demands a
wide variety of product mixes and
beer types, the control and
flexibility of the BBT Cellar is
increasingly important.
We offer detailed designs of the
BBT Cellar, including pressure CIP,
C0 utilisation and fully automated
flow control systems.

5600-03-06-2009-GB

5600-03-06-2009-GB

Your local contact:

APV, An SPX Brand

Pasteursvej 1
DK-8600 Silkeborg
Phone: +45 70 278 278 Fax: +45 70 278 330
For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.apv.com.
SPX Corporation reserves the right to incorporate our latest design and material changes without notice or obligation.
Design features, materials of construction and dimensional data, as described in this bulletin, are provided for your information only and
should not be relied upon unless confirmed in writing.

Issued: 06/2009 5600-03-06-2009-GB

Copyright 2009 SPX Corporation