Systems and Processes for Breweries from

GEA Westfalia Separator

Continuous. Efficient. Gentle on resources.

engineering for a better world GEA Mechanical Equipment

Contents
4 Centrifugal Separation Technology –
Improvement of Quality and Economy
6 Machines for Breweries
6 Self-Cleaning Separators
6 Self-Cleaning Separators for Polishing

9 GEA Westfalia Separator hyvol® and GEA Westfalia Separator hydry® Machine
Generations for Any Capacity Range
11 Decanters in Breweries
12 Hot Wort Separation
13 Trub Wort Separation

14 Cold Wort Separation

16 Green Beer Separation
17 Green Beer Clarification with Addition of Yeast / Tank Bottoms
19 Clarification of Beer before Kieselguhr Filtration

20 Beer Filtration with PROFI

23 Beer Recovery from Surplus Yeast and Tank Bottoms
26 Manufacture of Non-Alcoholic Beer
28 Kvass

30 Turbidity Adjustment with Separators

31 Capacities at a Glance

3
GEA Westfalia Separator
Centrifugal Separation Technology –
Improvement of Quality and Economy
Separators and decanters have been the main Features
machines in the manufacture of beer for decades. In
the decisive steps of the process, they ensure • Maximum yield with improved product quality
economical operation and a high quality of beer. As • Gentle product feed for maximum clarification
a specialist in the field of centrifugal separation • Hydrohermetic seals to prevent oxygen absorption
technology, GEA Westfalia Separator offers • Smooth, low-noise operation
separators and decanters for all specific • Integration in automatic processes through freely
requirements. Numerous solutions for the use of programmable controllers
separators and decanters in breweries are presented
as examples on the following pages.

4
GEA Westfalia Separator
• Automatic solids ejection
• High dry substance contents
• High product yield
• Optimum integration in existing CIP systems
due to hygienic design
• High economy
• Rapid payback
• Reduction of waste disposal costs
• Protection of natural resources
• Reduction of storage costs
• Low-cost operation, service and maintenance

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GEA Westfalia Separator
Machines for Breweries

Self-cleaning separators Hydrohermetic seal

Self-cleaning separators can be optimally integrated The development of the hydrohermetic seal was also
in the operative processes of breweries. The solids made in close cooperation with our customers. In
separated in the separator bowl are ejected this technique, the product and the atmosphere are
periodically from the bowl. Because this occurs at hermeti­cally sealed from each other. This prevents
operating speed, a fully continuous operation is oxidation of the beer. However, this has even more
ensured. GEA Westfalia Separator has developed its advantages for our customers. In comparison with
machines in close co-operation with its customers for mechanical seals, the hydrohermetic seal is
decades. An example of this is the de­­velop­ment of completely wear-free and fully CIP-compatible.
the GEA Westfalia Separator hydrostop system. With
this patented design, the solids are ejected from the
separator bowl in a fraction of a second. Because the Automatic ejection control systems –
solids are ejected in a very compact form by this optimized automation
method, short payback periods can be achieved.
Various control systems are available to react to
differ­ing feed concentrations and define the right
time for solids ejection:

• Automatic ejection control system with turbidity

measurement
• “Self-thinker” ejection control system with
sensing fluid.

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GEA Westfalia Separator
Gentle product feed Self-cleaning separators for polishing

The separators are equipped with a hydrohermetic GEA Westfalia Separator has developed the so-called
product inlet. This new inlet system avoids shear high-performance clarifiers specifically as a
forces on the product. The result is a more gentle preliminary stage for alternative filter technologies.
treatment and an optimum clarifying effect, These machines differ from conventional separators
particularly for sensitive products. GEA Westfalia in terms of their higher g-force.
Separator has developed the so-call­­­ed high-
performance clarifiers especially as an up­stream
stage to alternative filter techniques. These Advantages
machines differ from conventional separators in
their increased centrifugal acceleration. • Separation of the finest solid particles possible by
the increased centrifugal acceleration
• Substantial reduction of costs for filter aid
Features • Reduced use of kieselguhr filtration
• Reduced use of conventional separators
• Continuous operation • Improved taste of the beer by separation of
• Automatic operation polyphenol protein complexes
• High economy • Improved sensory stability
• Versatile application
• Optimum cleaning time due to automatic
ejection control systems
• Integration in CIP circulation systems
• Product isolated from the atmosphere by
hydrohermetic seal
• Low space requirement
• Easy to maintain

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GEA Westfalia Separator
 8
GEA Westfalia Separator
GEA Westfalia Separator hyvol and
®

GEA Westfalia Separator hydry

®

Machine Generations for Any Capacity Range

GEA Westfalia Separator hyvol® and GEA Westfalia Another common feature of the hyvol series is the
Separator hydry ® represent two new separator extremely quick-acting ejection valves. Product losses
families. Offering optimum machine sizes, both series during separator ejections are thus reduced to
provide models for any capacity range needed in the a minimum.
beverage and food industries. The hyvol and hydry
separators are designed for best possible customer When developing the hydry and hyvol series,
benefit and for quick integration into individual GEA Westfalia Separator focused on highest possible
application processes. DS contents of the centrifugally separated solids.
The GEA Westfalia Separator hydrostop ejection
GEA Westfalia Separator hy vol is the name system allows dry-substance values of 25 – 27 percent
GEA Westfalia Separator gave to its separators having to bestandard. Optimum solids concentration are
an ejection system via piston valves. With a reflected in very short payback times. Product losses
hydrohermetic feed system, the negative effects of are extremely low. A ll the hy vol and hydry
shearing forces are minimized, and perfect separating separators have belt drives and are characterized
efficiency can be achieved. This results in perfect by versatile func­tionality.
separation and product quality. The hydrohermetic
seal prevents the product from being contaminated
by ambient air. This sealing arrangement is
characterized by perfect CIP capability while being
maintenance-free.

9
GEA Westfalia Separator
 10
GEA Westfalia Separator
Decanters in Breweries
Decanters are solids oriented centrifuges with a Capacity data
solid-wall bowl. A conveyor srew (scroll) conveys the
solids to the outlet ports, through which they are The capacities indicated in this brochure for the
continu­ously discharged. Decanters are used mainly differ­ent models are effective throughput capacities.
for clarifi­cation of liquids with a high solids content. They differ from the comparison capacity which is
A somewhat fluctuating solids content in the feed design dependent.
product has little effect on the degree of clarification
or separation.
Comparison capacity

Decanters find application in breweries for: The comparison capacity refers to the different
decanters produced by GEA Westfalia Separator and
• Trub wort separation is lower than the max. throughput capacity.
• Beer recovery from surplus yeast

Effective capacity
Advantages of decanters:
This relates to the product and process. It depends on
• High yield the clarifiability of the feed mixture, on the
• Continuous operation. Processing times are concentration of the solids in the feed, and on the
practically unlimited (round-the-clock operation) permissible residual moisture content of the
• Automatic operation and, thereby savings discharge solids content of the clarified liquid. The
in personnel decanter can be largely adapted to these conditions
• Solutions of effluent problems and requirements.
• Flexible with regard to feed concentration
• Versatile processing possibilities

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GEA Westfalia Separator
Hot Wort Separation
Separators are employed to separate the hot trub Features
created during boiling. The development of this
applica­tion was done to allow continuous operation • Continuous, automatic operation
and to improve the economy in comparison with • Improved product quality by defined, short
conventional techniques. The separator can be contact times and defined separation rates
integrated in the process in different variants. The • High economy due to high DS content of
clarifier can be in­stalled either directly downstream the solids
of the copper or the intermediate turn-out vessel. • Lowest possible space requirement
Which of these is the better solution depends on • Optimum CIP integration due to
several factors and should be decided on an hygienic design
individual basis. For example, heat retention times • Capacity range up to 750 hl / h
(isomerization of the hops, coloration, etc.) must be
maintained and not exceeded.

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GEA Westfalia Separator
Trub Wort Separation
The whirlpool is employed especially to clarify the Features
entire hot wort. Because it is always possible to
achieve a good separation of the trub due to the • Little loss of wort due to high solid DS
fluctuating quality of raw materials and different • Minimized danger of infection
types of beer, the separator is an appropriate • Defined, optimum clarification of the
supplement. The trub cone produced often collapses recovered wort
when the wort is drained. This phenomenon causes • Wort added to the running brew
the residual turbidity of the clarified wort to be • Low heat retention times of the trub wort
too high and / or the losses to be very high due to • Fully continuous, fully automatic operation
the inadequate thickening of the trub. While the • No oxygen absoption (max. 0.05 mg / l)
wort is rotating in the whirlpool, the separating • Capacity range up to 200 hl / h
process can begin from the bottom. The recovered • Cleaning times are shortened by continuous
wort is then cooled. draining of the trub wort from the whirlpool

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GEA Westfalia Separator
Cold Wort Separation
In some cases, cold wort separation is also carried out Advantages
in breweries. The hot trub is separated before cooling.
The separator therefore separates only the remaining • Improved taste of the beer through removal
quantity of cold break. The cold break consists of polyphenol protein complexes
largely of small, colloidal protein particles. The • Improved sensory stability (attached fatty acids
viscosity of the cold wort is relatively high. Cold wort are reduced)
separation has differ­ing signifiance in the individual • Improved head stability (hot trub is removed
breweries. A certain quantity of cold break is desired if the whirlpool malfunctions)
in the fermentation process, but no hot trub must be • Optimized fermentation (fouling of the yeast
carried over under any circumstances. is prevented)
• Filtration inhibitors are removed (lower burden
of proteins on the filter)

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GEA Westfalia Separator
15
GEA Westfalia Separator
Green Beer Separation
The high cell count of 65 – 75 million yeast cells / ml Advantages
in the main fermentation is not desired in
subsequent stora­g e. Traditionally, green beer is • Defined secondary fermentation
clarified by sedimentation of the yeast and other • Reduction of the risk of yeast autolysis during
turbid substances. The beer is then transfered with ­fermentation and storage
as little yeast and sediment as possible. To obtain a • Harvest of the most active component of the
controlled, rapid secondary fermentation and yeast, which can be optimally employed as
maturing of the beer in storage, it is appropriate to a ­starter
transfer with a defined number of living yeast cells. • Accelerated reduction of the diacetyl by dosing
This can be achieved by using a separator. The yeast of Krausen
is fed into a collecting tank or the beer recovery • Reduced employment of the filter
process and the green beer is separated. • Simple integration in existing lines
• Fully automatic operation
• Due to the modern desludging mechanism,
the yeast is discharged in a very compact form
(24 – 26 percent DS)
• Better sale of the surplus yeast due to high
DS content
• Reduction of beer losses

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GEA Westfalia Separator
Green Beer Clarification with Addition of
Yeast / Tank Bottoms
The optimum process for beer recovery is the addi- • The separator only has to be rated for
tion of the surplus yeast and the tank bottoms in a one capacity
separator during the clarification of the green beer. • No further installations are necessary for
The advantages of the consistent product quality beer recovery
achieved with green beer clarification are added to • The recovered beer remains in the same batch
the economy of simultaneous beer recovery. • High DS of the recovered yeast. If necessary,
dilut­ing water and not beer is disposed of with
Advantages the yeast

• Maturing and stabilization can be carried out with

a defined yeast cell count (or virtually without)
• Longer storage of the yeast before beer recovery
is avoided, beer is recovered directly from the
fresh yeast, yeast autolysis is prevented

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GEA Westfalia Separator
 18
GEA Westfalia Separator
Clarification of Beer prior to Kieselguhr Filtration
Beers entering filtration often contain large Advantages
quantities of yeast, making kieselguhr filtration
difficult. Kieselguhr filtration itself is not problem- • Extension of the period of operation of the filter
free. Means are available either to replace the by up to 100 percent, therefore minimized set-up
kieselguhr filtration or at least to reduce the times, cleaning and waste water and labor costs
consumption of kieselguhr. By em­p loying a • Reduction of the total kieselguhr consumption by
separator to pre-clarify the beer, the re­quired degree up to 70 percent
of filtering can be drastically reduced. The result is • Compensation of product fluctuations
not only a reduction of a filter aid, but also an • High DS of the extracted yeast and therefore
in­c reased period of operation. Of course, the reduced losses
centrifuges are also suitable for pre-clarifying with • Income by sale of the separated yeast
other filter systems. • Fully automatic, continuous process
• No oxygen pick-up
• Clarification of CIP media during separator CIP
• Addition of tank bottoms for beer recovery
possible
• Capacity up to 1500 hl / h

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GEA Westfalia Separator
Beer Filtration with PROFI
PROFI beer filtration plant from GEA Westfalia Customer’s benefit
Separator combines a high performance centrifuge
with a membrane filtration system, allowing perfect • Very high solids concentration through
beer filtration without kieselguhr. a quick-acting ejection system
• Consequently, minimum product loss
The unfiltered beer, containing fine and coarse solids, • Using high performance separators, smaller
is fed into the rotating bowl and clarified in the membrane systems can be chosen
disk set. • 100 percent of the yeast is separated by the
high performance separator
The coarse solids slide into the solids space of the • Part of the proteins are separated by the high
bowl and are ejected automatically. The clarified performance separator
liquid, still containing fine solids, discharges either • Thus, the PROFI process allows retentate-free
by gravity or under pressure by means of a filtration
centripetal pump.

The preclarified beer is sent into the retentate-free

operating membrane filtration system where it passes
through hollow-fiber filtration modules. Then, the
clarified beer is sent to the filling station. There is no
installation required for retentate-recycling into
a tank.

As soon as a certain trans-membrane pressure is

reached and the filtration efficiency decreases, the
system is purged by means of CO2. This is followed
by a CIP cycle using alkaline solution and water. After
“Cleaning-In-Place” the modules are disinfected at
80 °C.

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GEA Westfalia Separator
21
GEA Westfalia Separator
 22
GEA Westfalia Separator
Beer Recovery from Surplus Yeast
and Tank Bottoms
Introduction series are used exclusively for the recovery of beer.
The short processing time of just 120 seconds
Depending on the process used, differing quantities ensures gentle treatment of the yeast. On the other
of yeast and tank bottoms are obtained during hand, production times are long: the separator is
the fermentation and storage of beer. In most subject to standard CIP only every 72 hours. The
cases, a substantial proportion of beer is still GSC 150 separator, which is specifically suited to
contained which must be recovered in economically this task, ensures that the yeast is treated to a dry
managed processes. substance content of around 25 percent thanks to
the GEA Westfalia Separator hydrostop discharge
More and more breweries are investing in beer system. The hydrohermetic inlet ensures gentle
recovery – for good reasons. This improves their treatment of the product. Depending on throughput,
cost-effectiveness without changing the beer quality. the recovered beer still contains around 0.1 to 2
Indeed, the yeast and tank bottom volume accounts million cells per milliliter. The hydrohermetic seal
for approximately 4 percent of total annual output, also prevents the product from coming into contact
and of this figure approximately 60 percent can be with external air, and guarantees absolutely wear-
recovered in the form of beer. In a brewery with an free operation.
output of one million hectoliters, this corresponds
to a volume of 24,000 hectoliters. Which of the With the GSC 150 separator, it is possible for beer to
three possible systems (separator, decanter and be recovered from yeast and also for the green beer
ceramic membrane filter) is used in a specific from the fermentation tank to be clarified following
application depending on the particular the addition of yeast upstream of the separator
circumstances of the brewery. GEA Westfalia (see page 17).
Separator is the only provider worldwide to offer
mechanical and process engineering solutions In the feed, the yeast concentration may be max. 40
customized to every situation. percent (by volume). However, using a fully
automatic facility for adding water in the feed of the
Extremely simple process management separator, the concentration can be reduced to the
with separators permissible level at any time.

The separator represents the most simple process Depending on the specific conditions, GEA
solution with minimum investment costs. Westfalia Separator also offers nozzle separators as
Separators of the GEA Westfalia Separator hydry® an alternative.

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GEA Westfalia Separator
Decanter plus polisher

It is possible to further improve beer recovery by

means of a decanter by combining a decanter and
separator or connecting a decanter and separator in
series. The yeast is initially concentrated by the
decanter to a maximum dry matter of 25 to 28
percent, thus achieving an optimum yield. The beer
which is recovered from the decanter is then
processed further in a small polisher from around
one million cells per milliliter to fewer than 1000
cells per milliliter. The beer which is treated in this
way is solids-free.

So much beer is still in the yeast

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GEA Westfalia Separator
 Yeast Tank

Buffer Tank

Water

to yeast processing

Nozzle separator

Processing with nozzle separators

Beer recovery with nozzle separators Customized solution instead of a patent recipe
produces clear beer
In order to decide which of these beer recovery
The design of these separators makes them so systems should ideally be used, the technology
powerful that they can process the relevant yeast experts of GEA Westfalia Separator analyze in
and tank bottom volumes with relatively low advance the precise individual requirements of the
machine costs. This results in amortization periods particular brewery. In general however: centrifugal
which were previously unattainable. technology used for beer recovery offers the best
returns compared with all other systems. The
The nozzle separator processes the yeast which is extremely short process times provided with this
additionally internally diluted with water. This technology also produce a beer of excellent quality.
makes it suitable for small or medium-sized In order to be on the safe side, however, the beer
breweries depending on the yeast economy. In should always pass through a flash pasteurizer
addition to the nozzle separator, a yeast collecting facility in order to deactivate any separated proteases
tank is required where the yeast or tank bottoms are which would otherwise have a negative impact on
stored homogenously. In the tank, the yeast, the head of the beer. GEA Westfalia Separator can
possibly with already degassed water, is set to the also offer the corresponding solutions from a single
original wort value or mixed “inline” on the way to source in this respect.
the separator. The separator then continuously
separates this supply into a flow with yeast of
around 80 percent by volume. Using this
technological trick of “washing out yeast,” a nozzle
separator can achieve extract yields of 90 percent. Separator type Effective capacity
in hl/h*
GSC 4 1
The recovered extract is likewise diluted in this
GSC 20 4
case. This makes the nozzle separator process
GSC 45 8
particularly suitable for “high gravity“ brewing GSC 95 16
since the recovered extract is ideal for cutting the GSC 150 30
original beer to the desired strength for sale. GSC 200 40
GCB 506 20 - 40
If the market demands a system which pays off in HFC 15 10
no time, GEA Westfalia Separator now offers tailor- HFE 45 30
made solutions to meet these requirements. *Feed < 30%, discharge < 1% (by vol.)

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GEA Westfalia Separator
Production of Non-Alcoholic Beer
Interrupted fermentation to manufacture non-alcoholic beer

The manufacture of low-alcohol or non-alcoholic

beer can be realized with separators by interrupting
the fermentation process.

Advantages

• Short production times because the beer must

not be de-alcoholized in the entire batch
• Highest product quality
• Rapid payback
• Excellent price / performance ratio
• Good microbiological control of the process
• Low costs for operation by not using
filtering media
• Separator can be used in other processes too

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GEA Westfalia Separator
Kvass
Kvass is a slightly sour, carbonated soft drink obtained The effective centrifuges work continuously, without
by fermenting the basic ingredients water, rye and pre- or post-run, and require no filter aids. The
malt. It is a prized drink in many Eastern European maximum dry substance reduces product losses to a
countries, especially at warmer times of year, minimum. At the same time, the product quality
traditionally most common in Russia. It is also from also says much about the clarifiers, as flavor is not
this country that we derive the name kvass, which impaired by absorption in any way.
means something like “sour drink”. With separators
from GEA Westfalia Separator, a continuous Features
production line can be supplied which combines the
simplest imaginable process management with • Simplest process management
optimum product quality. • Effective clarification without consumables
(filter aid)
Water, malt, rye flour and kvass yeast are required • Optimum product quality, no impairment
to produce kvass. Depending on the type, flavorings of taste by absorption
like mint can also be added. The process differs • Low losses due to maximum dry subsatnce
from the production of beer in that no hops are • Continuous operating mode
added and alcoholic fermentation is suppressed. As • No pre- or post-run
a result, kvass is usually only slightly alcoholic. • Easy installation and integration
Self-cleaning clarifiers from GEA Westfalia • Level of automation customizable to individual
Separator are installed between the storage tank customer requirements
and the buffer tank and clarify the kvass from
unwanted solid particles such as residual yeast.

Effective capacity
in hl/h
GSC 45 100
GSC 75 150
GSC 150 300
Effective capacity
in hl/h
GSE 30 50
GSE 50 100
GSE 160 200
GSE 300 500

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GEA Westfalia Separator
Kvass – Russian national beverage Kvass – Russian national beverage
Turbid – before separation Clear – after separation

29
GEA Westfalia Separator
Turbidity Adjustment with Separators

Particularly in the manufacture of German For this purpose, the turbidity is measured at the
“Hefeweizen­­bier“ (beer brewed from wheat), it is outlet of the separator and after mixing. The control
important to present the customer a product with valve in the bypass pipe is then controlled by these
a consistent quality of the turbidity. Problems two values and the nominal value.
occur particularly in high stor­age tanks because the
yeast concentration varies due to sedimentation. Advantages
The use of separators is suitable in this case to
compensate the concentration. The stored beer is • Consistent beer quality
separated. Simultaneously, unsep­a rated beer is • Continuous operation
added through a bypass to ensure constant turbidity • Simple process control
values throughout the entire production cycle.

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GEA Westfalia Separator
Capacities at a Glance
Effective capacities of the separators, in hl / h

tion before recovery PROFI

31
GEA Westfalia Separator
Excellence Passion Integrity Responsibility GEA-versity

GEA Group is a global mechanical engineering company with ­multi-billion euro sales and ­operations
in more than 50 countries. Founded in 1881, the company is one of the largest providers of
­innovative equipment and ­process technology. GEA Group is listed in the STOXX Europe 600 Index.

Westfalia, Westfalia Separator, hydry and hyvol are registered trademarks of GEA Westfalia Separator GmbH.
GEA Mechanical Equipment US, Inc.
GEA Westfalia Separator Division
Headquarters: West Coast:
100 Fairway Court Western Region Customer Support Center
Northvale, NJ 07647 555 Baldwin Road
201-767-3900 Patterson, CA 95363
209-895-6300
Midwest:
725 Tollgate Road, Suite B
Elgin, IL 60123 GEA Mechanical Equipment Canada, Inc.
630-503-4700
GEA Westfalia Separator Canada Division
South:
4725 Lakeland Commerce Parkway, Suite 4 835 Harrington Court
Lakeland, FL 33805 Burlington, ON L7N 3P3
863-603-8900 289-288-5500

Southwest:
2408 Timberloch Place, Suite C-4 Toll-Free: 800-722-6622
The Woodlands, TX 77380 24-Hour Technical Help: 800-509-9299
2380

281-465-7900 [Link]