Beer Processing Solution

Beer Processing Solutions
Table of
contents
Introduction . . . . . . . . . . . . . . . . . . . . 3
Brewing Process Diagram . . . . . . . . 4
Complete Product Range . . . . . . . . . 5
Complete Process Solutions . . . . 6-7
Automation Services . . . . . . . . . . . 8-9
Maintenance Service . . . . . . . . . . . . 10
Wort cooling, yeast dosing,
wort aeration . . . . . . . . . . . . . . . 11-12
Water deaeration . . . . . . . . . . . . 13-14
In-line blending and mixing . . . . 15-16
Carbonation and nitrogenation .17-18
High gravity brewing . . . . . . . . . 19-20
Pasteurizing . . . . . . . . . . . . . . . . 21-22
CIP . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fermentation & maturation . . . . . . . 24
Filtration . . . . . . . . . . . . . . . . . . . . . . 24
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.
Beer Types with Approximate Alcohol by Volume

Bottom Fermented
Top Fermented
Malt
Malt
Mnchner
Pilsner/Pilsener
Ur-types
Danish Lager
4.8%
4.2-5%
Trappist
Klsch
4.9% Brown Ale

4.2-4.7%
Pale Ale
Wheat Malt
9-10.8%
Strong Ale
4.8% Bitter stout

2.5-4.5% Milk stout
4.3-6.6% Russian stout
Bock
7-7.3% Mild Ale
2.5-3.6%
Light Ale
Doppelbock
7-7.3%
3.0-4.0%
Steam Beer
Bitter Ale
6.1-8.4%
Weizenbier
4.8-5.6%
4.4-7.5% Berliner Weisse
3.3%
3.7-3.8% Gueuze-Lambic
5%
9.5%
2.9-4%
4.8%
The Brewing Process
A Complete Product Range

APV provides a selection of
standardized process units, which
could be described as a series of
building blocks. These fulfill various
brewing processes and include:
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
WortMaster Wort cooling, yeast

dosing and wort aeration
Derox Cold and hot water
deaeration
BlendMaster In-line blending and

mixing
Product
CarboMaster Carbonation and

nitrogenation
homogenous products
HGBMaster High gravity brewing
PU Pasteurizer Controlled beer

pasteurization
CIP Master
uniformity
Flexible
production
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.
fast product changeover

Economical
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 & 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
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.
Highly automated systems deliver

improved effeciencies, resulting in a
faster return on investment, due to:

More production time
Less cleaning time
Minimum use of water, chemicals and

energy
Fewer operators
They also improve batch control,

resulting in product traceability and
flexibility.
Further benefits for the brewmaster
and management are:

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.
A paper free process control

system which can interface with ERP
systems
Material and quality tracking
capability
Full compatibility with brew-house

and filling plant as well as with other
production plants in the brewing
group
teamwork ensures that we

understand and recognize each of our
customers specific needs.
Detailed Engineering
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.
Hygienic Design
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
standards.
Process Engineering
APV uses its extensive experience
in the development, planning and
implementation of brewing steps
in close co-operation with our
customers brewmaster, technologists
and process engineers. Careful
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 analyzed to

establish whether the equipment and
control systems are adequate for safe
operation under normal, abnormal and
CIP conditions.
Latest Design Tools
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.
Project Management
a single point of contact
APV project managers are our
customers single point of contact.
They are highly experienced
and acutely aware of all critical
implementation aspects. Excellent
coordination skills enable them to
translate the efforts of APV suppliers
and other sub-suppliers into
successful projects.
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.
Installation Supervision
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 appropriate local
manpower.
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.
Optimizing
Working Procedures
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.
Training of People
Breweries are operated by fewer and
fewer highly trained staff, which often
results in the need for an exceptional
Automation and Performance Services Solutions

APV FactoryExpert
Driving manufacturing excellence
FactoryExpert is APV Automation &

Performance Services. It combines
innovative solutions with reusable
engineering applications on open
platforms to meet our customer
automation specifications.
We offer state-ofthe-art automation
solutions and services designed
to international standards based
on in-depth process knowledge
together with manufacturing knowhow and engineering expertise
that meet regulatory requirements.
FactoryExpert enables customers
to extend their performance gains
across their business.
APV FactoryExpert Value
Streams
APV FactoryExpert comprises 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 FactoryExpert is vendor

independent, it can include, for
example control systems and human
machine interfaces (HMIs) from
Siemens, Rockwell, Mitsubishi,
Wonderware, etc. This enables true
versatility in our solutions.
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
Maintenance Services
Until recently, the impact of
maintenance operations on roundthe-clock production, quality,
manufacturing flexibility, traceability,
plant safety and environmental
protection has been largely ignored.
APV recognizes that cost-effective
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
economics for non-critical
assets
Classic Care
- Comprehensive APV service
support
- When service delays are not an
option
Each agreement includes certain

critical items, with each level providing
progressively increasing support
capability (see table below).
Advantage Care
- APV service coverage for your
most critical equipment
- Proactive approach to
equipment performance
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.
Total Care
- APV service management and
support for the entire plant
- Plant-wide strategy to improve
mission effectiveness
ASystematic Program of Strategic Maintenance

APVservice management
and support for the
entire plant
Plantwide strategy to
Proactive approach to
When service delays arent
improve mission
equipment performance
an option
effectiveness
APVservice when you can

plan ahead
Balance of uptime and

economics for
non-critical assets
Total Care
Advantage Care
Classic Care
Basic Care
Critical parts delivered same

or next day service
Critical parts delivered within

24 hours
Critical parts on site within

48 hours
Parts on site witin 72 hours
Emergency service technician

on site within same or next
day

day

day
Emergency service response

@ 10% discount
APV Preventive Maintenance

program, 24/7/365
program, 24/7/365


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 @ 10%discount
Wear parts and service parts

included
Wear parts and service parts

Wear parts included
included
Recommended wear parts

replacement scheme
Other spare parts @ 15%

discount

discount

discount
Technical telephone support,


24/7/365

24/7/365

Modem support included
Modem support included
Modem support - optional
Strategy for service

partnership seminar

partnership seminar

partnership seminar
Software upgrades

Predictive maintenance on
critical items
Plant availability guarantee
Software upgrades
Designated APV maintenance

manager
Rebuilding &retrofitting
consultancy
Continuous process cost

reduction
Guaranteed performance
guarantees on critical items
Annual process knowledge
analysis
Rebuilding & retrofitting
consultancy
Operator audit and training
@20% discount
10
APV service coverage for

Comprehensive APV
your most critical equipment service support
WortMaster Wort Cooling, Yeast

Dosing & Wort Aeration
Ensure economical production by minimizing the use of time and additives
The WortMaster product range

covers units designed for the
processes between the brewhouse
and fermentation, including wort
cooling, yeast dosing and wort
aeration.
In addition to fast and efficient wort
cooling, WortMaster units deliver
effective and accurate in-line dosing
of yeast and air/oxygen by means of
the patented APV gas injector.
Offered in a wide range of capacities

from 50 1200 hl/hr, all WortMaster
units are designed and developed for
easy integration with existing lines.
WortMaster
- adds value
The WortMaster adds value to your
products and processes in the
following ways:
Product uniformity:

Constant monitoring and improved

regulation of the process
Repeatable fermentation
performance
Economical production:

Higher accuracy in yeast and oxygen

dosing
Reduced fermentation time
Flexible production:

Turn down ratio to 25% of nominal

capacity
Constant yeast/oxygen ratio,

regardless of flow
Fully CIP-cleanable
Traceable production data
Proven security:
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 10-12 mg O2/l
depending on pressure, temperature
and the original gravity of the 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.
amount of yeast can be 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.
Options
Cooling

DuoSafety Plates - Additional

product 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.
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 color.
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
Specified O2 levels with high gravity

worts are usually higher and thus pure
oxygen is often used to achieve 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.
GLYCOL
GLYCOL
BREW WATER
STERILE AIR
Yeast Dosing - Yeast can be added

to complete the wort treatment. This
has the advantage of adding yeast
immediately to the cooled wort.
BREW WATER
AERATED WORT
WORT
wortmaster.dwg
12
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.
Derox (cold)
- adds value
The standard capacity range is 30
1500 hl/h
The Derox adds value to your
following ways:
All Derox Units are designed and

developed especially for easy
integration to existing lines, with a
wide and flexible capacity range.
Derox+ (hot)
- adds value
The standard capacity range is 50
400 hl/h.
The Derox+ adds value to your
following ways:
Product uniformity:
Product uniformity:
Constantly low oxygen content 50

ppb at 12C* (below 30 ppb at
>20C.*)
Constantly very low oxygen content

(below 20 ppb.*)
Continuous monitoring for required

specification
Continuous removal of undesirable

THF gases

specification
Low running costs
Low running costs
Space-saving design (high capacity/

m2)

m2)
Variable capacity and high turn down
Independent of water inlet

temperature (option)
High turn down ratio (down to 25%

of nominal capacity)
Independent of water inlet temperature
No rings and plates inside vacuum

tanks
Variable deaeration levels
Proven security:
Proven security:


tanks
Deaerated water is pasteurized
Fully CIP-cleanable
Fully CIP-cleanable
* Measured as a standard deviation
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.
The remaining water is discharged

from the unit via an adjustable
manual-regulating valve.
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
pre-heater consisting of a shell and
tube heat exchanger together with a
steam regulation valve and
condensate trap can be supplied.
The unit is designed for CIP and does

not contain packing.
Options
Hot deaeration

CO2 Stripping - The use of a small

amount of stripping gas can allow
the energy lost through flashing to be
reduced.
The deaeration tank is kept under

vacuum so that the oxygen is removed
with a minimum of water vapor.
Cold deaeration
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.
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.
Chilling - Chilling of water to

match beer temperature. Different
configurations are available.
Common

Oxygen Measurement - The result

of the deaeration process can be
measured in-line 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.
The deaeration tank does not contain

packing and is easily cleaned.
Cold deaeration
Water is sprayed into the bottom
vacuum tank, which starts the oxygen
removal process.
The water is then pumped and
sprayed into the top vacuum tank via
an injector where stripping gas (either
CO2 or N2) may be applied.
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.
WATER/CIP
CO2 / N2
Derox (Cold)
14
DEAERATED WATER
BlendMaster In-Line Blending
The BlendMaster adds new dimensions to accurate standardizing and efficiency!

The BlendMaster range covers units
designed for continuous in-line
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 or the HGB
Master.
Standard capacity range: 50 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

High precision blending

m2)
Combined blending and carbonation unit
Proven security:
Easy change of recipe for fast
product change
regulation of the combined product
Turn down ratio 25% of nominal

capacity
Automatic switch-off, if offset
exceeds the limit
Continuous monitoring and
Blending ratio 1:10 to 1:2
15
Functional
Description
PI
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 in-line
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
FINAL BEER
DEAERATED WATER
FT
FT
DT
GT
HGB BEER
Options

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 blendmaster.dwg
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 color.
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 gas-dosing unit.
The CarboMaster range covers
units designed for continuous in-line
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 1200
hl/h
CarboMaster
- adds value
The CarboMaster adds value to
following ways:
CarboMaster for high Co2 content
Product uniformity:

High dosing accuracy (+/- 0.05g

gas/kg product*)
Injection independent of inlet
temperature and pressure

No gas losses
Space-saving design
Holding time not necessary
Proven security:

Constant monitoring and

control of final product
Fully CIP-cleanable

Turn down to 25% of nominal

capacity
Inject and dissolve up to 10g gas/kg

product
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 in-line 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
HGB Master High Gravity Brewing
The HGB Master is the result of a compact 3-in-one unit, which deals you all the
aces in the pack
The HGB Master combines the three
process stages of water deaeration
(Derox), inline blending (BlendMaster)
and carbonation (CarboMaster)
into a single, all-inclusive process.
The HGB Master ensures a costeffective high gravity brewing process
combined with very high production
flexibility. The unit is designed
and developed especially for easy
integration with existing lines, and is
available in an extensive and flexible
capacity range.
Standard capacity range: 501200
hl/h
HGB Master
- adds value
The HGB Master adds value to
following ways:
Product uniformity:

Constantly low oxygen content 50

ppb at 12C* (below 30 ppb at
>20C.*)

specification
Exact conformity with the specified

recipe
High calibration stability
High dosing accuracy (+/- 0.05g

gas/ kg product*)
Injection independent of inlet
Variable deaeration levels
temperature and pressure
Easy change of recipe for fast
product change over

capacity

Low running costs
High precision blending
Blending ratio 1:10 to 1:2

m2)
Inject and dissolve up to 10g gas/kg

product
No gas losses
Holding time not necessary
Variable capacity
Independent of water inlet
temperature (option)
Proven security:


tanks
Constant monitoring and control of

final product
Automatic switch-off, if offset
exceeds the limit
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 Unit
comprises a combination of several
modules described elsewhere. The
normal configuration consists of
a deaeration module, a blending
module and a carbonation module.
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 post-run 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.
The integrated unit is simpler,

more compact and cheaper to
GLYCOL
GLYCOL
WATER
CO2
CO2/N2
HGB BEER
Fully CIP-cleanable
HGB Master
20
FINAL BEER
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: 50500
hl/h
PU Pasteurizer
- adds value
The PU Pasteurizer adds value to
following ways:
Product uniformity:

Very high accuracy (computer
controlled PU regulation)
Low T between product and
heating media

Large heat regeneration (up to 94%)

with low temperature filling
Waste-saving design (beer/water
zone)
Proven security:


capacity
Constant overpressure downstream
Constant monitoring and control of

final product
21
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.
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 heat
22
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 controlled 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 recirculated 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
BUFFERTANK
GLYCOL
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.
Options

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
A conductivity meter registers the
interface between beverage and
water and reduces changeover

losses to a very low value
Valve types and configurations can

be customized as required
A double shunt for improving the

coolant supply can be integrated
WATER
GLYCOL
the pasteurizer is pushed out to drain

or to a collection tank with fresh beer,
and normal operation resumes.
CONDENSATE
STEAM
WATER/CIP
BEER
pupast.dwg
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
following ways:
Product uniformity

Fully automatic CIP programs ensure

perfect cleaning
Economical production

Full automation reduces manpower
Optimization of functionality leads to

reduced cleaning
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
Flexible Production
Proven security

If appropriate, the CIP Master is fully

tested before delivery
Proven functionality and reduced

commissioning time
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 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
PC solutions based on Wonderware

FactorySuite
Modem connection for remote

controller service
23
Fermentation & Maturation
Filtration
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.
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.
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.
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.
Your local contact:
APV, An SPX Brand

105 CrossPoint Parkway
Getzville, NY 14068
Phone: (716) 692-3000 (800)207-2708 Fax: (716)692-1715
E-mail: answers.us@apv.com
For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.apv.com.
SPX 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. Certified drawings are available upon request.
Issued: Date 5600-01-08-2008-US
Copyright 2008 SPX Corporation

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Beer Processing Solutions

Our first steps into the brewery equipment

APV pioneered many of the key

In 1914 APV developed a system for

Today APV offers process automation

Beer Types with Approximate Alcohol by Volume

4.9% Brown Ale

4.8% Bitter stout

7-7.3% Mild Ale

4.4-7.5% Berliner Weisse

The Brewing Process

A Complete Product Range

Focused on adding value to your

WortMaster Wort cooling, yeast

Derox Cold and hot water

BlendMaster In-line blending and

CarboMaster Carbonation and

HGBMaster High gravity brewing

PU Pasteurizer Controlled beer

From individual units to totally

fast product changeover

The unit values are significant

An intelligent processing unit

Final product monitoring

A Plug & Produce unit

Very short commissioning time

Faster return on investment

State of the art processes

Quick and easy operator training

A compact unit design

Shorter delivery time

Cost effective maintenance

Complete Process Solutions

APV draws on decades of

Highly automated systems deliver

More production time

Less cleaning time

Minimum use of water, chemicals and

They also improve batch control,

APVs technological excellence

A paper free process control

Material and quality tracking

Full compatibility with brew-house

teamwork ensures that we

Health and Safety

Each process step is analyzed to

Environmentally Safer Processes

degree of automation and integration.

Automation and Performance Services Solutions

FactoryExpert is APV Automation &

Automation Service for

APV FactoryExpert is vendor

Automation Migration for our

Automation Systems consisting

ERP Integration solutions that

Each agreement includes certain

APV is committed to providing

ASystematic Program of Strategic Maintenance

APVservice when you can

Balance of uptime and

Critical parts delivered same

Critical parts delivered within

Critical parts on site within