Analytical Measurement Solutions forOptimization of Your Brewing Process

Brew

ing

Indu

stry

INGOLDLeading Process Analytics

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Representative Main OfficeRepresentative Branch Office

Manufacturing

Market Organization Main OfficeMarket Organization Branch Office

MET

TLER

TOLE

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Com

pete

nce METTLER TOLEDO –

Commitment to Innovation and Quality

Worldwide presenceWe have a worldwide distributornetwork and a workforce of morethan 10000 employees. We sup-port our customers in industry byproviding comprehensive solutionsfor individual steps of their particularmanufacturing processes – fromreceipt of material, over the separateproduction stages with in-line pro-cess measurement, through to finalpackaging control, logistics andshipping. METTLER TOLEDO solu-tions can be optimally integratedinto an existing IT environment.

Our organization specializes in the area of precision instru-ment equipment and related services for industry. In thebusiness year 2008, the Group generated revenues of over US$2.0 billion. The company has been listed on theNew York Stock Exchange since 1997.

METTLER TOLEDO Group

METTLER TOLEDO instruments areemployed in research and develop-ment equally as much as for qualitycontrol purposes. The pharmaceuti-cal, chemical, food & beverage,and cosmetic industries are amongthe principal users.

Innovation and qualityOur company enjoys an excellentreputation as an innovator, and currently we invest between 90 and110 US$ million annually in re-search and development, havingincreased our overall R&D spending

by an average of more than 10%each year for the past five years.The organization takes every effortto meet the highest quality stan-dards, resolutely applying TotalQuality Management at both prod-uct and process level, but particu-larly also as part of support for cus-tomers to comply with internationalguidelines.

Process Analytics DivisionWithin the METTLER TOLEDO Group,the Process Analytics Division concentrates on analytical systemsolutions for industrial manufac-turing processes.

The Division consists of two busi-ness units, INGOLD and THORNTON,both internationally recognizedleaders in their respective marketsand technologies.

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InPro 6970 i M400

A leader in process analyticsCentered around INGOLD products,METTLER TOLEDO has establisheditself internationally as the leadingsupplier of process analytical meas-uring systems for the parameterspH, ORP, dissolved oxygen, oxygenin gases, conductivity, and turbid-ity/color – whether for applicationsin the chemical and pharmaceuticalindustries, in biotechnology, thefood and beverage sector or in waterand wastewater treatment facilities.

Ingold Ltd, founded in 1948 by Dr.Werner Ingold, and takenover by Mettler Ltd. In 1986, is today a core element of theMettler-Toledo Process Analytics Division.

INGOLD – Leading Process Analytics

Customer-oriented developmentsINGOLD products are characterizedby high quality and intelligent, de-tailed technical solutions. Our aimis to develop innovative, reliable,easy-to-use process analytics incooperation with customers. In-novations such as the first steriliz-able oxygen sensors, automaticcalibrations systems, hygienic re-tractable housings, and new intel-ligent pH electrodes and dissolvedoxygen sensors, as well as inte-

grated turbidity systems provideimproved handling, and enhancethe accuracy and reliability of themeasuring point.

INGOLD stands for technological,high-quality measurement solutionstailored to specific applications inthe area of process analytics.

process analytical instrumentationwhich includes outstanding benefitssuch as:• accuracy and reliability• high level of user-friendliness• hygienic design of wetted parts• straightforward process integra-

tion

One of the latest examples is ournew, intelligent optical dissolvedoxygen measuring system for moni-toring of filtration, blending and fill-ing processes.

Solutions for Breweries and Plant EngineeringAn experienced team of applicationspecialists and service techniciansare ready to help you in:• optimizing your process• sustaining high product quality• lowering maintenance costs• increasing yield

Apart from the well-known basicingredients used in the making ofbeer, modern automated processesare decisive for the market successof a beer or shandy.

INGOLD rendersan importantcontributiontowards theautomation ofbeverage plantsthrough itsoffering of

LED Sensor tip

Detector Emitted

O2 sensitivelayer

fluorescence light

O2

O2

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Brew

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Proc

ess From Brew House to Filling Station

the Advantages of INGOLD Measurement Technology

The beer market is currently experi-encing an intense globalizationprocess, reflected in escalatingcompetitive and cost pressures. Inaddition to this, there is growing

diversification into new, innovativebeverages that demand maximumproduction flexibility. The time tomarket is becoming ever shorter,and product quality has to be guar-

anteed at a consistently high level,accompanied by an increase inproductivity.

Water deaeration

Wastewater treatment Bright beer tanks

Filling station

Kieselguhrfilter

CIP stations

Separator

Filtration and Filling

Supportprocesses

Mash tunWater preparation

Lauter tun Wort copper Whirlpool

Wort cooler

Yeast propagation

Separator

Fermentation tanks

Fermentation and Storage Cellar

BrewhouseWater Treatmentand Cleaning

CO2 recovery

PVPPfilter

Coloring beer tank

Storage tanks

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METTLER TOLEDO supplies com-plete measurement solutions –covering the water treatment stageright through to the packaging station – for the parameters:

• dissolved oxygen• oxygen in gases• turbidity• color• conductivity• pH

Use of INGOLD measurement systems from METTLER TOLEDO in the brewing industry

Process Measurement Dissolved Oxygen Turbidity Color Conductivity pHposition oxygen in gas

Water preparation 1 • • • •Mash tun 2 •Lauter tun 3 • •Wort copper 4 •Whirlpool 5 •Wort transfer line /Wort aeration 6 • • •Yeast propagation 7 • • •CO2 recovery plant 8 •Centrifuge / Separator 9 • •Kieselguhr filter 10 • • •PVPP filter 11 • • •Blending 12 • • •Water deaeration 13 •Filling lines 14 • • • •CIP stations 15 • • •Wastewater treatment 16 • • • •

The measurement position numbers given in the above table correspond with the numbers in bold printon the following pages in this brochure.Þ

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InPro 3253 i

InTrac 777e

InPro 3300

M400

iSense Software

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4

Brew

hous

e In-line Measurements in the Brew House –Crucial to the Quality of the Wort

Measurement of pH value during mashingWhen acidifying the mashing-inwater or when mashing at lowertemperatures, it is advisable toemploy an unbreakable ISFET pHelectrode. This takes on particularsignificance if the spent grains areto be sold on the market.

Measurement of pH value during wort acidificationMaintaining the correct pH valueduring boiling of the wort is impor-tant in order to improve proteinrelease. Due to the elevated temper-ature however, only low-mainte-nance glass electrodes can betaken into consideration.

The significance of a retractable housingThe use of a retractable housingprolongs the serviceable life of elec-trodes, since the latter are onlybrought into the actual measuringposition during the decisive acidifi-cation phases, being afterwardsretracted into the maintenanceposition without interrupting theongoing process.

Proper process control plays a vital role in determining the flavor, foam stability, and color of the finished beer. The relative measurement sensors are exposed to hightemperatures, and solid particles and turbidity constituents, and must be capable of surviving multiple CIP cycles.

METTLER TOLEDO recommends

• For mash acidificationNon-glass pH electrode InPro 3300: highest level of process safety.

• For wort acidificationpH electrode InPro 3253 i: Accurate and robust.

• Retractable housing InTrac 777eMaintenance of pH electrode withoutprocess interruption.

• Transmitter M400High versatility thanks to mixed-mode input for conventional andintelligent sensors.

• (Intelligent Sensor Management) Facilitates start-up, and signals immi-nent maintenance requirement basedon the actual sensor status.

• iSense Asset SuitePC software for pre-calibration andmanagement of ISM sensors in asafe and clean environment.

METTLER TOLEDO measurementsystems are completed by a user-friendly transmitter that enablesextremely cost-effective operation of the measuring point.

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InPro 8600

Trb 8300D or ...

... PDA

3/5Turbidity measurement in the lauter tun and whirlpoolTurbidity measurements are em-ployed to optimize filtration of thelauter tun and mash filter run-offs,and/or to document charge trace-ability at the whirlpool. In line witha MEBAK (Central European Brew-ing Technology Analysis Commis-sion) recommendation, an opticalforward light scattering measure-ment using dirt-resistant sensortechnology is required.

METTLER TOLEDO turbidity meas-urement equipment meets thisrequirement with a compact, 25° forward scattered light systemusing fouling-resistant sapphireoptics. The resulting, error-freemeasurements guarantee highestproductivity and optimal quality ofthe wort.

METTLER TOLEDO recommends

• Turbidity sensor InPro 8600The compact and robust construc-tion guarantees easy and safeinstallation.

State-of-the art manufacture usinglow-wear components reducesmaintenance costs.

• Transmitter Trb 8300DIntuitive operator control enablestime-saving during start-up andconfiguration.

• Wireless communication optionOne PDA or laptop in conjunctionwith Bluetooth wireless communica-tion can be used to configure andcheck out several different sensorunits. Alternatively, transfer ofmeasurement data can be realizedthrough a direct wiring connectionbetween sensor and control system.This is a cost-effective alternative forconsideration during plant design.

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InPro 6850 i

InPro 8300 RAMS

InPro 6950 i

M400

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Ferm

enta

tion

and

Stor

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Cella

rs Measurements in the Fermentation and Storage Cellars –where Hygiene is Imperative

Measurement of dissolved oxygen (DO) contentThe quality and vitality of the yeaststrongly influence the stability of theflavor of a beer. Correct oxygenconcentration during the fermenta-tion process ensures the desiredconcentration of aromas and ofthose substances which preventpremature aging of the beer.

Measurement of residual oxygen content in CO2 gasRecovery of carbon dioxide from thefermentation off-gas is an importantaspect relative to cost saving. Beforeutilization, the CO2 must undergopurification treatment in order to ar-rive at the required low residual oxy-gen concentration. The purified CO2

gas is also used for post-carbona-tion of beer. Consequently the resid-ual oxygen content in purified CO2

gas must be as low as possible.

Phase separation yeast/beerReliable and reproducible detectionof phase transitions in yeast/beerseparation processes after fermenta-tion and storage leads to a higheryield of recovered yeast and beer.

At standard fermentation temperatures, propagation ofmicroorganisms is detrimental to the beer. In order to pre-vent this from occurring, hygienic plant design and use of materials resistant to CIP solutions are important crite-ria, as they are for in-line sensors.

METTLER TOLEDO recommends

• For yeast propagation and wort aerationDO sensor InPro 6850 i: high process safety due to hygienicdesign – EHEDG certified.

Also, the intelligent sensor versionconvinces with extremely shortmaintenance times due to its modu-lar design.

• For CO2 gas phase measurementsO2 sensor InPro 6950 i: intelligent sensor with low detectionlimit.

• Transmitter M400/ISMHighly versatile – for oxygen meas-urements in liquids and gases. Thetransmitter fully supports METTLERTOLEDO’s ISM technology for easysystem start-up and preventivemaintenance requirements.

• For phase separation yeast/beerThe optical product monitor InPro 8300 RAMS is easy to installand operates almost maintenance-free.

METTLER TOLEDO instruments aremaintenance-friendly and provideclearly displayed diagnostic func-tions. This leads to greatlyimproved performance and opera-tional availability.

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M400

InPro 6970 i

InPro 8300 RAMS

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Filtr

atio

nan

dFi

lling Measurements during Filtration and Filling –

improved Flavor Stability and Shelf Life

Crucial to the quality of beer is that during storage, as wellas afterwards when proceeding to final packaging, there isvery little oxygen ingress and no liberation of substancesthat can cause haze formation. Supplementary measure-ments of pH values support Quality Assurance procedures.

Dissolved oxygen (DO) measurement during water deaeration, blending, filtration and filling Oxygen concentration values below25µg/liter (ppb) represent standardlimits for beer before packaging, aswell as for the evaluation of plantcomponents regarding possibleoxygen uptake.

For use in the above mentionedprocess stages, METTLER TOLEDOoffers high-precision and mainte-nance-friendly in-line DO measure-ment systems. The newly availableoptical DO systems based on fluorescence quenching technologyset the benchmark regarding easysensor handling and longer opera-tional availability. The unique com-bination with ISM (Intelligent SensorManagement) technology providesfurther powerful tools for preventivemaintenance requirements andminimized risk of unscheduledplant downtime.

Product monitoring in filling linesReal-time identification of the cur-rent product in the filling line withoptical product monitors, and anearly alarm in the event of an un-wanted product change, increaseprocess safety.

METTLER TOLEDO recommends

For DO measurements:• Transmitter M400

Real-time monitoring tools of currentsensor status like the Dynamic Life-time Indicator (DLI) and the AdaptiveCalibration Timer (ACT) support pre-dictive maintenance requirements.

• DO Sensor InPro 6970 iThe optical measurement principleleads to easy handling and extendedmaintenance intervals.

For product identification in filling lines:

• Optical product monitor InPro 8300 RAMSEasy installation, maintenance andcalibration requirements are mainfeatures of this monitor thanks to itscompact design.

... PDA

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Transmitter Trb 8300D or ...

InPro 8600

10/11Turbidity measurement during beer filtrationThe visual appearance of a beer –its brightness and its color – is asmuch a quality criterion as is itsfresh flavor. Optical dual-anglemeasurement instruments allow aprediction of whether the turbidity in the beer is caused by particlessuch as yeast and/or filter aids orthrough dissolved colloids such as proteins and/or glucans causingopalescence.

METTLER TOLEDO offers an innova-tive solution for all types of filtra-tion methods such as Kieselguhr,Kieselguhr-free, membrane or stabi-lization filters. Optimal design fea-tures allow direct comparison withstandard laboratory instruments,reducing the risk of any misinterpre-tation.

Optional color measure-ment in blending processesBlending of beer with deaeratedwater, coloring beer or other addi-tives influences the appearance ofthe final beverage. Beverage bright-ness and color – or to be exact, theyellowness – can be monitored withthe combined turbidity/color unit.

METTLER TOLEDO recommends

• Turbidity sensor InPro 8600Scattered light measurement25°/90° provides reliable recognitionof filter breakthroughs and the detec-tion of dissolved colloids.

State-of-the-art design and manufac-ture using wear-resistant compo-nents reduces maintenance costs.

• Turbidity/Color sensor InPro 8600/W/3Simultaneous measurement of bev-erage brightness and color providedby one compact sensor reducesinvestment and installation costs.

• Bluetooth communication for full integrationOne PDA or laptop in conjunction withBluetooth wireless communicationcan be used to configure and checkout several different sensor units.Alternatively, transfer of measurementdata can be realized through a directwiring connection between sensorand control system. This is a cost-effective alternative for considerationduring plant design.

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EC 400 plus ...

... retractable housing InTrac 798

... transmitter M 700S plus ...

6/14Measurement of pH values in wort transfer and filling lines To increase operational safety, pH measurement in these lines pro-vides a valuable service. The im-mediate detection of residual caus-tic soda solution or breakthroughsinto the product prevents filling ofcontaminated end product.

METTLER TOLEDO also offers Easy-Clean systems for automated sen-sor cleaning and calibration inorder to achieve maximum equip-ment availability at minimum main-tenance effort.

METTLER TOLEDO recommends

EasyClean cleaning andcalibration system• Optimal adaptation to the process

conditions thanks to wide range ofprogram sequences.

• Low maintenance costs due to minimal consumption of buffer andcleaning solutions as well as longerelectrode life guaranteed.

• Linking to process control systemspossible either conventionally or viaPROFIBUS® PA.

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InPro 7108-VAR

M300

InPro 3250 i

15/1

CIP

Syst

ems

and

Wat

erTr

eatm

entP

roce

ss Measurements in CIP Systemsand in the Water Treatment Processes

Measurement of conductivity and pH value in CIPplants and water treatmentWhen increasing the concentrationof the caustic solution in the CIPbatch tank and for separation of the cleaning solutions in returnpipes, conductivity systems providea proven service. The compact-design sensors can be installedwithout problem in pipes with anarrow cross-section. The user soft-ware of the pH and conductivitytransmitter is easily understand-able.

METTLER TOLEDO systems facilitatethe initial instruction and training ofpersonnel. The associated pH elec-trode is particularly cost-efficientdue to its long operational life.

The economic use of fresh water, as well as the multipleuse of cleaning solutions, present a further basis forachieving overall cost reduction in line with the strive forgreater efficiency of the brewing process. Here also, in-linesystems are of help in monitoring and optimizing the rela-tive sub-processes.

METTLER TOLEDO recommends

• Conductivity sensor InPro 7108Compact and hygienic design pro-vide optimal results.

• pH electrode InPro 3250Long-life electrode with precisionmeasurement performance due tounique combination of self-cleaningreference system and special mem-brane glass.

• Transmitter M300Reliable and user-friendly.

Optional dual-channel measurementreduces investment and installationcosts.

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Was

tew

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Trea

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Measurement of pH value, oxygen concentration,conductivity and suspended solidsin wastewater treatment facilitiesEffective, automated cleaning ofsensors increases their operationallife.

METTLER TOLEDO offers an efficientsensor cleaning system coveringthe parameters pH, oxygen andsuspended solids, which takes theburden off maintenance personneland lowers operating costs. Con-ductivity can be measured using aninductive sensor insensitive to con-tamination.

For pH:InPro 4010

For O2:InPro 6050

For turbidity:InPro 8050

For conductivity:InPro 7250

EasyClean 100 InDip 550

METTLER TOLEDO recommends

• EasyClean 100/InDip 550For installation in open basins andchannels. Effective sensor cleaningat application-specific intervals pro-vides assurance of high operationalreliability with minimal costs formaintenance and spare parts.

• pH, O2, conductivity, suspended solidsInexpensive sensor alternatives inMETTLER TOLEDO quality ensurereliable measurement performance.

Measurements in Wastewater Treatment Facilities

Fouling of sensors in wastewater leads to uncertainty aboutthe measurement results and can even result in measure-ment system failure. Here also METTLER TOLEDO providesefficient and practical solutions.

14www.mt.com/beer

Serv

iceX

XL Service Offerings Covering our Products – for End-Users and System Fabricators

ServiceXXL – a METTLER TOLEDOservice conceptOur comprehensive sales advisoryand technical services have estab-lished us as a competent partner forour customers everywhere in theworld. Many globally manufacturingcompanies trust in our competenceand long-standing experience.

Services offeringMETTLER TOLEDO offers very attrac-tive service options, ranging fromproduct guidance, over installationthrough to maintenance contracts.For the brewing industry specifi-cally, we offer the following serv-ices:

METTLER TOLEDO offers attractive services to customers,ranging from product guidance, through installation, toservice contracts.

Distribution networkBased at several global productionsites, with more than 30 marketorganizations and numerous salesrepresentatives, METTLER TOLEDOmaintains a worldwide distributionnetwork and is always close to itscustomers.

Online support for the brewingindustryMETTLER TOLEDO offers the brew-ing industry a special interactivesection on the Internet atwww.mt.com/Beer, in which appli-cations and useful information aswell as some tips relative toprocess analytics can be found.

Plant engineeringTime is money. Our detailed prod-uct documentation (SpecBook)together with local support duringspecification, installation and com-missioning contribute to on-sched-ule project realization.

Service

• Repair work at service depot

• Sensor refurbishment

• Installation/commissioning

• Training/seminars

• Maintenance contracts

• On-site qualification/verification

Click to open interactive brewing process.

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Dig

italC

omm

unic

atio

n System Integration with PROFIBUS®

Easy – Fast – Cost-Saving

The fieldbus protocol PROFIBUS® enables you to fullybenefit from the advantages of digital communication.METTLER TOLEDO supports integration of analytical meas-urement into PROFIBUS® process control systems via arange of appropriate, high-performance transmitters for pH, dissolved oxygen and conductivity.

In modern breweries, PROFIBUS® iswidely used as a cost-saving tech-nology to improve productivity.METTLER TOLEDO instruments arePROFIBUS® certified and thereforeeasy to integrate.

In addition, users are provided withstate-of-the-art diagnostics technol-ogy in order to achieve enhancedprocess safety.

Segmentcoupler

Profibus® PA

Profibus® DP

PROFIBUS® is a registered trademark of Profibus InternationalSIMATIC® is a registered trademark of SIEMENS AG

Full PROFIBUS PA integration of METTLER TOLEDOinstrumentation

Advantagesof the PROFIBUS® PA trans-mitter from METTLER TOLEDO

• The GSD files accompanying thetransmitters enable complete inte-gration of pH, O2 and conductivitysolutions into the process controlsystem.

• Power for the METTLER TOLEDOAdvanced Line PROFIBUS® PA trans-mitters is supplied via the bus.

• PROFIBUS® transmitters from METTLER TOLEDO are fully inte-grated in the device library ofSIMATIC® PDM. Straightforward integration and management duringthe entire lifespan save both timeand money

• (Intelligent Sensor Management) Diagnostic information and mainte-nance requests from ISM sensors canalso be integrated into your PLC viaPROFIBUS PA thus leading to a uniqueintegrated concept for optimated main-tenance management.

Visit for more informationwww.mt.com/pro

Sales and service:

Management Systemcertified according toISO 9001 / ISO 14001

9001certified

ISO14001certified

ISO

Mettler-Toledo AGProcess AnalyticsCH -8902 Urdorf, SwitzerlandPhone +41 44 729 62 11Fax +41 44 729 66 36

Subject to technical changes. © 08/2009 Mettler-Toledo AG.Printed in Switzerland. 52 900 308

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