Fuel Monitoring Matters

Precision cooling is an integral part of the brewing and distilling process. The quality and integrity of the finished products are reliant on accurate temperature control and reduction during key stages of brewing operations. Key aspects of production include:

During the initial stages of brewing, grain kernels are milled to form grist. The grist is transferred to the mash tun and heated water is added. During mash conversion, natural enzymes in the grist break down the malt starch into fermentable sugars. The mash is then pumped into the lauter tun where a sweet liquor (wort) is separated from the grist.

The wort is transferred to a kettle and heated to a controlled boil temperature of approximately 60°C before hops are introduced. After the boiling phase, residual malt and hop particles are removed.

For more information on the chilling process in brewing and distilling applications, as well as chiller system operation and design guidelines, view the interactive.

Whilst the wort is still hot it is rapidly cooled for the following reasons:

• The wort is susceptible to oxidative damage if left to cool slowly. Rapid cooling lessens oxidative damage minimising unwanted flavours in the product.
• Trace quantities of dimethyl sulphide (DMS) evolve from the wort during the heating stage. DMS has a low boiling point and evaporates out of the hot wort. As the wort is cooled, DMS is still produced. Slow cooling allows DMS to accumulate due to limited boil off in the brew. High DMS levels in beer and lager can add off-flavours and taint the brew. Rapid cooling of the wort to about 25 °C minimises oxidation and DMS levels improving the flavour profile of the final beverage.
• Rapid cooling achieves a cold break. Proteins are thermally shocked and precipitated from the wort. A lack of rapid chilling can result in a chill haze in the finished product. Residual proteins can precipitate as the product is cooled before consumption. This is often considered undesirable especially if the product should be clear.

The diagram below shows key aspects of the brewing process (click to enlarge).

Most breweries pass the wort through a single or double stage plate heat exchanger to achieve cooling. The application is demanding; a significant heat load must be removed quickly form the process. A glycol water mix on the water circuit is common to provide enhanced cooling capacity. A double-walled food grade heat exchanger is generally selected to prevent contamination issues between the wort and cooling fluid.

When sizing a chiller for wart cooling, consider the following:

• Overall volume of the wort to be cooled (often quoted in BBL / barrel volumes).
• Desired knock out time (cooling time required to optimise the process).
• Initial wort temperature and the desired final wort temperature.
• Will the chiller also be providing cooling capacity for other brewing processes?

The provision of cooling capacity from a precision chiller is important throughout fermentation. The chiller must regulate the fermentation temperature to prevent product spoiling. In some instances, the brew is also rapidly cooled at the end of fermentation to assist yeast flocculation.

During the fermentation stage, the wort is generally transferred into stainless steel cylindroconical vessels (CCV). Brewer’s yeast is added to the sugary wort when the vessel is filled to begin fermentation. Sugars in the wort are converted to alcohol and CO2 along with other flavour adding compounds. 

Fermentation is an exothermic process and can liberate significant heat. This heat must be controlled to protect the integrity of the brew. Temperature control is important for the following reasons:

• Different yeast varieties possess an optimum fermentation temperature range that needs to be maintained to optimise fermentation.
• Exposure to too much heat results in the formation of fusel alcohol and esters that can adversely affect the product flavour.
• Excess heat in the later fermentation stages increases yeast sensitivity to acetic and lactic acid resulting in reduced alcohol yield.
• Rapid cooling at the end of fermentation is used in some processes. The brew is cold crashed through rapid cooling to assist the flocculation of yeast resulting in a clear product prior to conditioning.

When sizing a chiller for fermentation, the following points should be considered:

• The volume of the brew/fermentation vessel (total kW heat load).
• Optimum temperature band required for fermentation.
• Will a cold crash be employed at the end of fermentation?
• Will other processes also be cooled, e.g., wort cooling?

In certain processes, beer and lager are cooled in the latter stages of conditioning and filtering. This is often done to improve product clarity and stability. In larger breweries, the temperature is often monitored and controlled during bottle and keg filling. Excess heat from bottling machines may need to be controlled to protect the integrity of the final product.

Precision water coolers are vital in the production of high-quality consumer spirits. Several steps in the production of spirits are reliant on maintaining a consistent temperature and removing excess heat. Initial production stages for whiskey and spirits mirror those in the brewing process. Additional distillation and conditioning stages follow fermentation to produce the final product.

A typical process for producing whiskey is shown in the diagram below (click to enlarge):

Precision water coolers are often employed in the following processes during the production of whiskey and other spirits:

• Wort cooling prior to fermentation.
• Control of the fermentation temperature and crash cooling.
• Chill filtration prior to bottling.

Non-filtered whisky with an ABV of 46% or lower can often form sediment in the bottle when stored in a cool place. The drink can also take on a cloudy appearance when water or ice are added before consumption. These cosmetic factors are considered undesirable in quality products. Natural fatty acids, esters and proteins in the whiskey form during distillation in addition to being imparted from the cask during maturation. These components flocculate and precipitate out of the whiskey when it is chilled.
 
Chill filtration is employed to prevent the above issues. The process involves dropping the whiskey temperature to 0 °C for malts (-4 °C for blends). Once chilled, the whiskey is passed through a series of tightly knit metallic meshes or paper filters under pressure. During this process, the precipitate and any other sediment or impurities from the cask (coals) are removed.
 
As with other brewing processes, food-grade heat exchanger is employed to manage the cooling.

Parker Hyperchill and Hyperchill Plus chillers deliver safe and reliable operation under varied working conditions like those typically found in the brewery and distillation industry, helping owners and operators maintain the integrity of the final product and reduce cost of ownership.

Design features on the Parker product can deliver significant benefits to the end-users in the brewing and distillation industry. 

Key features and benefits include:

• Configuration of generously sized water tank coupled with oversized condenser/evaporator allows the chiller to maintain cooling capacity even during rapid load and water temperature changes.
• High reliability, with energy management, to reduce total cost of ownership.
• Low water temperature options (down to -10°C) available for enhanced cooling.
• Stainless steel panel and high IP rating enable ease of operation in wet and humid brewing environments.
• Chillers fully compatible with the use of glycol / water mixture for demanding applications such as wort cooling.
   

For more information on the chilling process in brewing and distilling applications, as well as Hyperchill system operation and design guidelines, view the interactive.

This post was contributed by James Brown, compressed air and gas treatment/analytical gas sales manager and Filippo Turra, product manager, Parker Gas Separation and Filtration Division EMEA

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Cell culture media is a key component of upstream bioprocessing needed to encourage the growth and survival of cells. This is vital to achieving a viable cell density and, ultimately, the desired product titre. However, its filtration can be a challenge for biopharmaceutical manufacturers. 

Cell culture media is a complex mixture and typically contains up to 60 ingredients. However, the exact composition will differ based on the media chosen for the specific application.

Media is usually supplied either as a powder, concentrate or working solution. If a powdered media is used, it must be mixed and sterilized on site prior to use. 

Cell culture media can be categorized into several different formats based on its composition:

Serum is a nutritionally and protein-rich substance derived from animal blood. Serum containing media was once seen as essential for good cell growth and proliferation, however, the desire for animal component-free media due to concerns about contamination and regulation have led bioprocesses away from this media type. 

Serum is also expensive and as it is a natural product, it is by nature uncharacterized and is prone to a high degree of variation.

Serum-free media often contains proteins/protein hydrosolates and, while it is more characterized than serum-based media, it may still contain components derived from animal sources.

Animal-derived component-free media offers an alternative to serum media. It uses non-animal derived proteins and hydrololates available from soy, yeast or other non-animal-based sources.

Protein-free media allows greater chemical definition of the media's make up.

Chemically defined media aims to eliminate variation by using only fully defined components - these may be animal-derived or animal-free depending on the media.

Whichever media is used, a compromise must be found between safety, characterization and performance. Robust supplier quality assurance is needed to ensure traceability and the procurement of contamination-free media. 

The media will ultimately be chosen to suit the process. 

Depending on how characterized the media is, the concentrations of components and exact composition may vary lot-to-lot. Different medias will also have different compositions. 

The ingredients in cell culture media provide a rich nurturing environment for the cells biopharmaceutical manufacturers wish to propagate. Unfortunately, that kind of environment is a place in which bacteria or other unwanted microorganisms can flourish.

Filtration is commonly used to protect cell culture media from contamination. If the powdered media is prepared on site, it will be prepared in a mixing vessel. Components such as water will be filtered to remove contamination prior to entering the vessel and any air and gas or venting will be protected using gas filters. 

Prior to entering the bioreactor itself, the media will be filtered to ensure its sterility - and to, therefore, protect the bioreactor. This filtration may involve prefiltration as well as sterilizing-grade filtration or Mycoplasama removal filtration, depending on the process. 

0.2 micron rated validated sterilizing-grade filtration is used to achieve sterility, or if Mycoplasma contamination is of concern. 0.1 micron rated filtration validated for Mycoplasma removal should be used. Depending of the process and media, prefiltration may also be required. 

The correct design of this filtration system is crucial in optimizing the process. The design must take into account:

• The required retention of the filters.
• The sizing of the filters to ensure the required throughput can be met.
• The flow rates the filters are capable of to ensure the process can be carried out within the available time.

A number of issues can arise in the cell culture media filtration process:

• If the filters have not been sized correctly, this can result in a low flow rate - and, therefore long processing times.
• Filters may foul or block prematurely. This can be due to a variation in raw ingredients, an excess bioburden in the process, or the filtration system being too small for the batch size.
• If a process is at risk of Mycoplasma contamination, contamination may occur if a 0.1 micron Mycoplasma retentive filter isn't used.

However, these issues can be mitigated by optimizing the filtration system correctly.

Parker supports biopharmaceutical manufacturers in filtration system optimization through testing, process trials and validation as well as technical support for existing systems. We have an extensive range of filters designed for cell culture media filtration including PROPOR SG, our standard 0.2 micron sterilizing grade product, PROPOR HC, our high capacity sterilizing grade product for difficult to filter or variable medias and PROPOR MR 0.1 micron filter designed for use in processes where Mycoplasma contamination is a concern. 

For more information on cell culture media filtration, view our recent webinar: Optimization of Cell Culture Media Filtration in Bioprocessing

This post was contributed by David Heaney, market development manager, Parker Bioscience Filtration, UK

Parker Bioscience Filtration specializes in automating and controlling bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.

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The microbial stabilization of beer is of critical importance for the shelf-life of beers – and as beers are exported all over the world, it’s vital that their original characteristics still remain intact when they arrive in the glasses of thirsty consumers in faraway markets. 

An increasing number of brewers are turning to sterile filtration as a reliable method to ensure a longer shelf-life of their packaged beer. Indeed, many brewery operations have been moving away from flash pasteurization – the traditional method of removing spoilage organisms – due to its negative impact on the flavour profile of the end product and the many advantages offered by sterile filtration.  

It has been shown that beer which has been filtered to achieve stabilization retains its unique and desirable characteristics more efficiently than beer stabilized through flash pasteurization: the sterile filtration process is gentler, compared to the harsh process of flash pasteurization. Sterile filtration can also have a beneficial effect on taste characteristics throughout the duration of the beer’s shelf-life. 

And there are more advantages too. 

• The performance of sterile filtration can more easily be monitored, because of the relative simplicity of cold stabilization systems.  
• The filters used in sterile filtration minimize adsorption of desirable components and help to protect beer head retention. 
• Beer losses when using sterile filtration can be significantly lower than flash pasteurization.  
• Sterile filtration uses less energy than the flash pasteurization process – as it does not require plate heat exchangers. 
• Water consumption is reduced, as sterile filtration does not necessitate a buffer tank. 
• Sterile filtration requires fewer parts, making the systems easier to operate than flash pasteurization systems.  
• Pasteurization hardware is large and expensive in comparison to the lower initial outlay for a sterile filtration setup. 

Parker Bioscience has built a partnership with Agidens Process Automation that combines more than 50 years of brewing filtration experience and industry-leading products to deliver a better beverage. Starting with Parker Bioscience Filtration's detailed knowledge and experience of brewing processes and automation, Parker offers cutting-edge technology for use in sterile filtration. Using this technology, Agidens is now offering a platform of sterile filtration/cold stabilization modules to suit a range of beer flow capacities and specifications, as a more efficient alternative to pasteurization.    

The combined experience of Agidens Process Automation and Parker Bioscience Filtration was recently brought to bear for Zagrebačka pivovara in Croatia, which is part of Molson Coors. Zagrebačka pivovara wanted to expand its range with a premium, non-pasteurized lager and needed to work with a provider with proven expertise in cold stabilization technology. 

It commissioned Agidens to implement a Cold Stabilization Module (CSM) at its brewery site in Zagreb, Croatia. In just five months, Agidens’ engineering team was able to provide a tailor-made CSM solution that was integrated into the brewery’s existing production line.

The CSM installation consists of three modules for a total length of 6.75 metres:

• Filtration skid 
• Distribution cluster 
• CIP skid

The site was only accessible via a small elevator which meant that the CSM had to be custom-designed, disassembled and transported before it could be re-built and installed on site.  

The CSM installed at the Zagrebačka pivovara site filters an average of 250 hectolitres of beer per hour. 

The CSM uses Parker Bioscience Filtration’s PREPOR NG and BEVPOR BR filters in a combination to achieve microbial stability whilst protecting the taste characteristics of the premium lager.  

The BEVPOR BR range of filters is constructed with a unique Polyethersulphone (PES) membrane, offering a long service life and therefore a highly efficient solution with a low cost of operation in sterile filtration of beer applications. 

Parker Bioscience Filtration’s PREPOR NG filters have been specifically developed to remove yeast and particulate such as filter aids and haze components. The superior level of retention ensures that a consistent quality of the brew is delivered and provides a greater level of membrane filter protection during cold stabilization. 

For more information on Parker Bioscience Filtration’s sterile filtration solutions for the brewing market visit our website.  

This post was contributed by Lee Pattison, Food and Beverage Product Manager, Parker Bioscience Filtration, United Kingdom.  

Parker Bioscience Filtration offers filtration solutions to protect the quality and taste of beverage products. By working with our application experts, manufacturers can develop a tailored solution to ensure their beverage is free from contamination, full of flavour and visibly clear. 

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