Fermentation Cellar design

www.alfalaval.com

− Brewery Systems

29/04/2021 | © Alfa Laval 1 |

Fermentation cellar design Alexander Stogniy,

Global Sales Manager, Brewery systems

Denis Martin,

Crafts Modules Manager, Brewery systems

www.alfalaval.com

The brewery cold block− From wort cooling to packaging

| © Alfa Laval29/04/2021 2 |

Stable quality

Food safety

and hygiene

Sustainability

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Custom turnkey solutions for the cold block− From wort cooling to packaging

Optimizing process design for

new or existing facilities

• Biological contamination

• Oxygen pick up

• Product losses

• Yeast management

• Fermentation efficiency

• Product stabilization

• Cleaning-in-Place (CIP) efficiency

• Water and energy consumption

• Waste stream management

• Other areas

| © Alfa Laval29/04/2021 3 |

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What we’ll talk about today− Agenda

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• Fermentation tanks layout and

installation options

• Pipe bridges and piping layout

• State of the art valve cluster design– Product routing

– CIP and gas routing

– CIP

• Features of sustainable design

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Tank layout

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Tank layout− Plan now for the future

• Future brewery development

and expansion

• Maintenance and site logistics

• Installation plan optimization

• Length of piping = operation

efficiency and waste

management

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Extension

Tip 1 – optimize space usage− What to consider when choosing an optimal tank layout

• Position equipment for easier

installation and service

• Plan for possible pipe routes, filling and

emptying distances

• Consider future extension capabilities

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Tip 2 – tank grouping− Tank layout

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Valve cluster

Valve cluster

Valve cluster

Valve cluster

Valve cluster

Valve cluster

Pump

Valve cluster

Valve cluster

Valve cluster

Valve cluster

Pump

Pump Brewhouse

Brewhouse

Existing

New

Existing

New

Option 2Option 1

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Tip 3 – process and CIP flexibility− Tank layout

| © Alfa Laval29/04/2021 9 |

Pump


Pipe bridges and

piping layout

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Pipe bridges and piping layout− Example

Leave adequate space

for future:

• Pipes

• Walkways

• Maintenance

• Electrical hardware

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Filtration

CIP

Brewhouse

Glycol

supply

Main pipe bridge

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Pipe bridges and piping layout− Important for all breweries

| © Alfa Laval29/04/2021 12 |

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Piping layout− Expansion loops

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Wort line

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Pipe bridges and piping layout− Craft brewery example

Well-designed pipe bridges and piping

layout means cellar design that is:

• Safe

• Efficient

• Expandable

| © Alfa Laval29/04/2021 14 |

What to avoid


Tank installation options

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Tank installation options− Investments and complexity

Slab-mounted tanks

• Smaller building to maintain,

less OPEX

• More space for equipment and

piping underneath the tanks

• Higher CAPEX

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Leg-mounted tanks

• Larger building to maintain

• Higher OPEX

• Less space for equipment and

piping underneath the tanks

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Tank installation options− Installation and safety

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Slab-mounted tanks

• Physical separation between

installation crews

• Improved installation time

• Better control of site safety

Leg-mounted tanks

• Complex safety management

if tanks are built on site

• Increased installation time


Valve clusters for process routing

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Product valve cluster design− Loop design

Advantages when the tank outlet

pipe is separated from the tank

• Reduced extract losses due to

more efficient product push outs

and recovery

• Best cleanability and CIP efficiency

• Increased product quality – no

product is left in the pipe during

fermentation

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Surplus yeast

Additive

Tank CIP

return Wort

Deaerated

water

Green

beer

Yeast

harvest

CIP supply

tank loop

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Product valve cluster design− Loop design for full process flexibility and hygiene

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Tank loop hot

CIP supply

(from CIP 4)

Tank cold

CIP return

(to CIP 5)

8 m

Green beer

transfer line

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Product valve cluster design− Push out and prime lines for reduced product loss

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Additive

Deaerated

water

Wort

Tanks CIP

return

Green

beer

Yeast

harvest

Surplus

yeast

CIP supply

tank loop

Green

beer

transfer

line

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Product valve cluster design and tank outlet− Tank outlet operation

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Green beer block

as close as

possible to the

tank prevents

losses

Deaerated water

purge line as close as

possible to the tank

minimizes water

consumption

Tank outlet

mixproof valve

opens to allow

green beer flow to

main valve cluster

Green beer to main

valve cluster

Yeast to main

valve cluster

Deaerated water

purge line as close as

possible to the tank

minimizes water

consumption

Tank outlet mixproof

valve opens to allow

yeast flow to main

valve cluster

Yeast block as

close as possible

to the tank

prevents

losses

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Product valve cluster design and tank outlet− Sampling and drains

| © Alfa Laval29/04/2021 23 |

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Valve cluster design and new tank outlet

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From

tank

CIP

return

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Valve cluster design and combined loop− Easy cleanability, reduced water consumption and minimized product loss

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Four tanks connectedTwo tanks connected


Valve clusters for CIP and gas routing

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CIP and gas valve cluster design− Vertical

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• More lightweight piping

• More compact installation

• Easier installation due to pipes from above

• Easier access for valve maintenance

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CIP and gas valve cluster design− Vertical

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CIP and gas valve cluster design− Horizontal

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CIPCIP

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Valve cluster design and maintenance− Horizontal

• No splashing around

the cluster

• Convenient maintenance

platforms

| © Alfa Laval29/04/2021 30 |

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CO2 recovery line and exhaust line cleaning

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Fermentation

tankFoam

trap

CO2 recovery

CO2 recovery

CIP supply CIP return

• No pressure

build-up in CO2

recovery lines

• Full cleanability

by hot CIP

• Applied to all gas

lines

CO2 recovery

CIP return

CIP supply


Sampling options

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Sampling options for automatic cellars

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Complete automatic centralized

sampling, including CIP and

sterilization requires no operator

intervention

Sampling with manual

connection for cleaning

requires operator to connect

sampling valve to the CIP pipe

Sampling at each tank with

automatic CIP does not require

operator to connect sampling

valve for CIP

Alfa Laval offers three alternatives for sampling from the fermentation tanks along with cleaning-in-place

1 2 3

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Sampling options

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• Sampling at floor level

• No manual operation required for cleaning

• Effective CIP cleaning during the tank CIP

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Sampling from fermenters− Detailed view

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Sampling from the cone

or shell on the big tanks

CIP, during the tank CIP

DN25/10

DN80/25

CIP supply


Density control in fermentation tanks

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Density control

• Based on high-quality

vibration sensor

• Affordable technology

• Easy to integrate

• High precision

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DP

Density probe


Fermentation cellar construction sets

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Fermentation cellar construction sets− Pre-engineered piping and instrumentation diagrams

Optimal solutions for specific projects

• Many design options

• Range of automation

• Verified hygienic designs

Why pre-engineered construction sets?

• Highest hygienic standards

• Production flexibility

• Product quality

• Operational safety

| © Alfa Laval29/04/2021 39 |

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Fermentation cellar design− Summary

Efficient, sustainable, easily expandable and

maintenance-friendly

• Take a holistic approach to tank layout – today

and tomorrow

• Choose the right installation option: slab-mounted

or leg-mounted installation?

• Plan the pipe bridges and piping layout to

make installation easy and create more space

in the cellar

• Design valve clusters for optimal operation and

minimize use of water and energy

• Automatic density control for better cellar

performance

| © Alfa Laval29/04/2021 40 |

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Cold blocks around the world− Alfa Laval installations

Aldox

>900since 1990

Engineered solutions

IMXD

Dry hopping

>50since 2017

Flexitherm

>500since 1990

Iso-Mix

Fermentation

>500since 2010

Carboblend,

Carboset and Alex

>300since 1990

Decanter

Intelligent Whirlpool

Systems

>25since 2012

Tank top systems

>3,200since 2011

BSF

>120since 1990

HSS

>390since 2012

Yards

Carib

Breweries

Heineken

Rwanda

Carlsberg

Poland

Carlsberg

Belarus

Efes

Turkey

Baltika

Brewery

Heineken

AibaHeineken

Ota

Unicer

Porto

Heineken

Panama

Tunis

Ambev

Ponta Grossa

Heineken

Surinam

Modelo

Yucateca

Westmalle

Asahi

Australia

Faxe

Denmark

Heineken

Indonesia

AB InBev

Australia

Complete process block

ABInBev

Karnataka

CG Brewery

Nepal

AB InBev

Wuhan

Master India

Brewing

AB InBev

Leuven

Ambev

Sete Lagoas Ambev

Nova Rio

Modelo

Zacatecas

Modelo

Centro

Diageo

Ireland

Duvel

AB InBev

Mozambique

Province Brands

Canada

| © Alfa Laval29/04/2021 41 |

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Any further questions

Please feel free to contact:

| © Alfa Laval29/04/2021 42 |

Alexander Stogniy

Global Sales Manager

Alfa Laval Brewery Systems

[email protected]

+45 277 786 94

Denis Martin

Crafts Modules Manager

Alfa Laval Brewery Systems

[email protected]

+45 395 365 83

Visit our web page for more information

https://www.alfalaval.com/industries/food-dairy-beverage/beverage-processing/beer-production/commercial-brewing/

https://www.alfalaval.com/industries/food-dairy-beverage/beverage-processing/beer-production/commercial-brewing/


Q&A

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Webinars for brewers− Upcoming events

| © Alfa Laval29/04/2021 44 |

Beer concentration with Revos™ – the

future of beer production and distributionWebinar 17 June, 2021

Click here to visit the webinar web page

https://www.alfalaval.com/industries/food-dairy-beverage/webinars/beer-concentration-with-revostm-the-future-of-beer-production-and-distribution/

https://www.alfalaval.com/industries/food-dairy-beverage/webinars/beer-concentration-with-revostm-the-future-of-beer-production-and-distribution/

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Fermentation Cellar design

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