FACULTY OF ENGINEERING

MECHATRONICS ENGINEERING

Automation systems for the

beer brewing
---------------------------------------------------------------------------------------------------------------------------
FINAL WORK

COURSE:
INDUSTRIAL AUTOMATION SYSTEMS
(EL224–LS9A)

TEACHER:
EDDIE ANGEL SOBRADO MALPARTIDA

AUTHORS:
●MANUEL ORTIZ ROJAS
ANDRÉ HUERTA SÁNCHEZ
EDGAR RUIZ MUNDACA
ANDRÉ GUILLÉN

UPC - SAN MIGUEL

February 2019
INDEX

1. INTRODUCTION

2. OBJECTIVES

3. SCHEMATIC DIAGRAM OF THE PRODUCTION PROCESS

4. OPERATIONS SUSCEPTIBLE TO AUTOMATION

5. AUTOMATION PLAN

6. TECHNICAL DEVELOPMENT

a. Instrumentation
b. P&ID Diagram
c. Integration diagram: networks and SCADA
d. Robotics and pneumatics

7. Conclusions

8. BIBLIOGRAPHY
1. INTRODUCTION

The purpose of this project is to describe the process of the elaboration of

craft and industrial beer, as well as the study of techniques and processes
units that guarantee its quality. Beer is a fermented beverage.
whose preparation is made from sprouted grains, mainly barley
(malta), and is flavored with hop flowers. It consists of alcohol, glycerin,
carbon dioxide, maltose, dextrin, nitrogenous substances, mineral materials
and small amounts of tannins, bitter substances, and organic acids. Its
the preparation is linked to a succession of three biochemical processes:

The formation of enzymes in the germinating cereal grain.

The degradation of starch to sugar by these enzymes.
The fermentation of sugar to alcohol and CO2.

These processes have been known for thousands of years, although it was not known how.
they were related and how they could be controlled. The brewing of beer was
carried out by the vast majority of known ancient civilizations. But it was not
until the 14th century when the first brewing industries were created in the
monasteries. After the industrial revolution and after the advancements made in the centuries
In the 18th and 19th centuries, large breweries were created. These breweries began to
brewing low fermentation beers or lagers, adding adjuncts such as the
corn or rice which are sources of starch much cheaper than barley
milkshake. Currently, it is these large factories that produce almost the entirety
of the beer consumed worldwide. In some European countries, there
they continued crafting traditional beer styles in small breweries of
local character. Most of these beers corresponded to high styles.
fermentation or ale. Currently, many micro-breweries are reappearing.
breweries around the world. Its main characteristic lies in that they use the
techniques of preparation and the raw materials that provide the greatest qualities
organoleptic qualities of their products. It is a very demanding market that is growing.
expansion.

2. OBJECTIVES

1.1. General objectives

Describe and analyze the industrial process of beer production based on a study.
meticulousness of the processes involved in its manufacturing. Likewise, the aim is to provide
recommendations to solve existing problems during the process or
recommendations to improve efficiency.

1.2. Specific objectives

Describe each unit operation used within the process.
 Create a P&ID of the processes.
Describe the control ties used.
Describe the sensors and actuators used.
Make recommendations to improve certain processes.
Put into practice the concepts and techniques developed in class through the
analysis of an industrial automation project that is presented in a
industrial or service company.

3. Description and schematic diagram of the production process

The main ingredients for beer production are barley malt, hops,
yeast and water. The malt arrives at the plant and the first thing that is done is a cleaning process,
then comes the milling process, which consists of breaking down the malt grain,
respecting as much as possible the shell or wrapping and causing the pulverization of the
flour. The malt is compressed between the rollers of the grain mill, but avoiding destruction
the shell, as it will serve as a filtering bed in the clarification operation of the must,
the time when the inside of the grain is transformed into the finest possible flour.

Figure 1 Maceration

Then comes the maceration process, this is one of the most important phases of the process.
of beer production and it is where the largest amount of extract is obtained from the malt.
of the best possible quality, depending on the type of beer that is to be produced and it is where
the starch contained in the malt will be transformed into sugars through processes
natural enzymatic and biochemical processes. This phase of beer production takes place in
the mash tun - kettle, where the crushed malt is mixed with water at a temperature between
60 and 70º C, depending on the type of beer that is to be made, to promote the
processes of extraction and enzymatic hydrolysis. Maceration usually lasts between one and two
hours and the result at the end of this process is a sugary wort. The water is heated and
maintains its temperature through the steam provided by the high-pressure steam boiler
efficiency. In this phase, the alcoholic degree and the body of the future beer are decided,
function of the sugar concentration of the wort. These will depend on the amount of malt
employee and the temperature and time of maceration, which will yield more or less sugars
fermentables to be transformed into alcohol during fermentation and more or less
non-fermentable sugars, which will contribute to the body and character of the beer. To break down
el almidón contenido en la malta en azúcares, se necesitan varias enzimas que son producidas
naturally during the malting process. The next process is filtration, it is
it is necessary to separate the wort from the insoluble part of the malt called spent grain. The operation is
It is carried out in two phases in the lauter, to which the wort and spent grains are sent, after its mashing in.
the macerator-boiler. First, the must is separated and clarified from the pomace, through
re-circulation of this through the bagasse bed, which will be deposited on the slotted bottom
of the pure.

Figure 2 Filtration

Once this must is clarified, it is sent back to the mash-tun boiler. Then, it
perform the washing operation of the extract, which continues to be retained in the pomace (exhaustion),
through a hot water shower. This water, along with the extract that remained in the
bagasse and once clarified in the same way as the must, is sent to the mash tun -
boiler, where it mixes with this while waiting for the next phase to begin. The bagasse
obtained in that process is a product rich in fiber, protein, and minerals, which makes it
used as animal feed. This way, the generation of solid waste is reduced and
it turns a waste product into a highly nutritious animal feed product
nutritious. The must obtained is vigorously boiled in the cooking or boiling process.
The purpose of boiling is to stabilize the must enzymatically and microbiologically.
coagulate the proteins. The sterilization of the wort is obtained by simple boiling. By
Finally, during boiling, reducing products are formed, which contribute to the quality.
and stability of beer. The hopping of the wort is carried out during this operation. It consists of
in adding the hops to the boiling wort. Depending on the amount and the variety of
the hop used, the beer will have a greater or lesser bitterness, flavor, and aroma of it.
Not all the hops are added at the beginning of the boiling; instead, we add different ones.
varieties of hops, at different times of boiling, depending on bitterness, flavor
and the aroma that is desired to be transferred to the beer. This process usually lasts about an hour.
and two hours. The next process is sedimentation, it is necessary to separate the remains.
of hops and the solid particles generated during boiling (hot trub), of the rest
of the must. This process, also called clarification, is carried out by imparting movement
centrifugal force on the must contained within the sedimentation equipment. This movement creates a
whirlwind or vortex that drags solid particles towards the center and the bottom. After
let these particles settle at the bottom of the equipment, they are extracted by means of the
valve located at the center of the bottom of this. After boiling the must and having done
the separation of solid particles, it is hot (at about 95ºC), so before
to ferment, it needs to be cooled and prepared to have the right temperature
suitable for yeast to work well.

Figure 3 Cooling

Este enfriamiento se realiza en un intercambiador de calor de doble efecto. El mosto caliente

it is sent to the heat exchanger, where the wort is cooled in a first phase, from
from the initial 95ºC down to 25-30ºC, through water that circulates countercurrently, while
heats up due to the heat exchange effect between the must and the water. This hot water
it will be recovered in the hot water tank for use during the exhaustion of the bagasse,
or for cleaning the equipment, thus reducing the energy and water consumption of the plant.
In a second phase, the must will be cooled from 25-30ºC of the first phase, down to 10-
22ºC necessary for yeasts to work optimally during fermentation
of the different types of beer. The next process is fermentation, which along with the
Maceration is one of the most important processes in beer manufacturing. The wort, cooled
in the heat exchanger, it is sent to one of the fermentation tanks, at the same time as
the must is oxygenated to allow the growth of the yeast, which is added to the
fermenter to start the fermentation process, which consists of the transformation of the
sugars from the must into alcohol and carbon dioxide. For the yeast to work in
optimal conditions require a suitable temperature that ranges between 10 and 22ºC,
depending on the type of beer. This temperature will be kept constant by means of the
circulation of glycolated water through the refrigeration chamber available to the
fermenters for this purpose, since, during the fermentation process, emissions are released
heat that must be removed so as not to alter the flavors and characteristics of the beer
wants to elaborate. At the end of fermentation, the yeasts settle at the bottom of
fermenter and are withdrawn from it through the bottom valve that they have
equipment, so that its decomposition does not alter the flavor of the beer. The process of
Fermentation lasts between 5 and 20 days, depending on the type of beer.

Figure 4 Maturation

The resulting liquid from the fermentation process is stored for a time in tanks.
maturation where it rests in the cold so that the flavor and aromas achieved during the process
they stabilize and the final product maintains the desired character. To eliminate some
yeasts and remaining proteins, the filtering process is carried out, where the beer is
naturally clarified and acquires a unique brightness. After this, the beer is
ready for consumption and only the processes of packaging, inspection, coding and remain
stored.
BLOCK DIAGRAM OF THE COMPLETE PROCESS
SCHEMATIC DIAGRAM OF THE COMPLETE PROCESS
4. Operations susceptible to be automated

a) Level monitoring
Continuous level measurement is a vital operation throughout the entire development.
of beer, as this way the inventory can be optimally managed
malta and other raw materials, as well as to prevent the excessive filling of silos. This
we can implement the operation during the mashing, with important control over the
quality and quantity of malt extract. On the other hand, in the hopping process, it
you have to control the amount of hops added throughout the whole process,
since this depends on the bitterness, flavor, and aroma that the beer will have. In order to
to ensure the control of the inputs used in these processes, as well as the quality
of these, it is necessary to automate level monitoring. Finally, it is important
emphasize that the instrumentation used must withstand high levels of noise,
vibration and dust as these tend to cause errors in the perceived data.

b) Temperature monitoring

Within the development of beer, strict temperature control is required.

since in many of its phases a constant temperature must be maintained for
that the process is optimal. Accurate temperature monitoring allows
identify the existence of possible failures during the brewing of beer, to
thus being able to provide a solution at an early stage. The processes in which it is
The control of temperature is important during the mashing of the crushed malt with
water, in the fermentation of the must with the yeast, where it is necessary that the
the temperature is kept between 10 and 22°C. This is done through chambers
of cooling. In addition, it is important to monitor the temperature of the wort,
temperature in the washing tub, the yeast tank, and the temperature of
storage to ensure a consistent quality of beer. Because
It is a process that requires continuous data collection; it is an operation.
susceptible to being automated. This would mean a saving of resources both
economic, as it would reduce the likelihood of the product not being the desired one.

c) Flow monitoring
The precise dosing of additives is not only a decisive factor for quality of the
beer, but also helps reduce costs by making the operation of the
brewery be more efficient and optimize consumption.
The quality of the final product depends on the precise dosing of the ingredients.
Water is added during the mashing and filtering process in beer brewing.
Hops are added during the boiling of the wort. Yeast should be added for the
fermentation.
To ensure optimal performance and consistent quality of the beer, this
the process can be automated, ensuring precise dosing, through
mechanisms responsible for controlling the flow of ingredients for the preparation
of the beer.
 d) Pressure monitoring
The precise monitoring and control of pressure is another key factor in the
beer preparation process. Pressure measurement plays a role
important, since, with a varying pressure, the properties can change
product and therefore its quality. The level in the fermentation tanks and
Storage is often recorded by measuring pressure, for this purpose, the
differential pressure measurement technique through the preparation solids in
the washing tub is also used to control the CO2 in the fermentation tank.
The various filters are also controlled by measuring differential pressures.
Generally, these measures are taken using human resources, so
spending increases and accuracy does not remain constant.
Therefore, this is a process likely to be automated, the transmitters of
Siemens pressure sensors are suitable for different measuring applications, and
they would fulfill this purpose.

5. Automation plan

Level monitoring
For automation within level monitoring, a switch will be used.
Pointek CLS100 compact. This product is a capacitance change frequency.
inverse of 2 wires and will serve for level detection in restricted spaces,
interfaces, solids, liquids, sludges, and foam. The short insertion length of Pointek.
CLS100 of 100 mm (4") and its versatility in various applications and in containers or
pipes make it a good replacement for capacitance sensors
traditional. The information provided by this sensor would be used by a PLC that
I would monitor the level and control in the aforementioned processes in order to be able to
provide the best quality in the product.

b) Temperature monitoring
For the development of temperature monitoring automation, the
SITRANS TS300 sensor as it provides a wide range of connections
appropriate processes for the classical temperature measurement. This sensor will be
provide the data that will be constantly monitored by a PLC that
is responsible for maintaining the ideal temperature, depending on the type of process that is
I would be doing.
c) Flow monitoring

For automation in monitoring and subsequently in controlling the flow, it is

It is necessary for this process to be as precise as possible, for this the sensor is chosen.
SITRANS F M MAGFLO MAG 1100 F, which is mainly used in the industry
food, beverages, and pharmaceutical. With the information provided by the sensor, it
it can do good monitoring of the flow that reaches the containers, additionally
with the help of a PLC, the information collected by the sensor would be used to
the control of some valves, which would allow the passage of the ingredients of
in an appropriate manner and automatically.

d) Pressure monitoring

For automatic pressure monitoring, the pressure transmitter is chosen.

digital Sitrans P300, as it can be implemented in both open tanks
like in closed systems, to measure the absolute pressure in corrosive or non-corrosive liquids
corrosive, which is ideal for use in food applications.
With the implementation of this sensor, and the help of a PLC that verifies that
if the pressure is optimal, the need to use human resources is eliminated
for the measurement and subsequent decision-making regarding pressure.
 [Link] DEVELOPMENT
a. Instrumentation
Sedimentation process:

CODE LACE DESCRIPTION IMAGE

Low and high level alarm

 LAL Level sensor that indicates if the level of the material is
LAH put in the hopper at the start and the storage ones are
very high or very low.

Level relay

LY
Motor on/off contactor that drives the belts.

Current indicator

II
100 Indicate the amount of current supplied to the
motor, this is an indicator to verify the correct
operation of the pump.

High-level alarm

LL
High level visual indicator in the system hoppers.

Level control

LIC
Programmable logic controller from the brand Siemens,
this automaton controls the entire system and at the same time it
communicate with the touch screen.
 Cooling procedure:

CODE LASSO DESCRIPCIÓN IMAGE

Temperature transmitter

TT1
it consists of a platinum wire that at 0 °C has 100 ohms and
that as the temperature increases, its resistance increases
electric.

Level indicator control

101
TIC
Siemens brand programmable logic controller,
100
this automaton controls the entire level system at once
It is communicated that the belt is in position.

Temperature transmitter

TT2
SITRANS TS300 as it provides a wide range of
appropriate process connections for measurement of
classic temperature
 Filtration process:

CODE LACE DESCRIPTION IMAGE

Level indicator transmitter

LIT
Ultrasonic level transmitter that delivers a
actual reading of the water level of the system in a unit
normalized electrical current for subsequent
processing

Current to pressure converter

I/P
It is responsible for converting a 4–20 mA electrical signal.
to a pneumatic signal of 3–15 PSI

Level control valve

LCV
It is a proportional pressure control valve
responsible for regulating the flow in the pipe.

Level indicator control

 Instrument that contains a configuration HMI and
LIC monitoring in such a way that it is a link between the
103 operator and the controlled process.

Level control

LC
Siemens brand programmable logic controller,
this automaton controls the entire system and at the same time
interact with the touchscreen.

Centrifugal water pump

Bomb
It allows sucking water from the tank to make it circulate.
through the pipes to be able to fill or maintain the level of
water in the column.

Water valve

It is a joining element for pipes, it also serves to

VC
provide a constant flow to the system.

Low level alarm

LAL
It is a buoy placed at the bottom of the column.
of water, this indicates whether the tank is at a level
alarming water

Pressure Transmitter

PT
It is a differential pressure transmitter, this has the
Objective of indicating whether there is a flow of water through the pump
and that this is not working in a vacuum.

Current Indicator

II
Indicate the amount of current supplied to the
motor, this is an indicator to verify the correct
operation of the pump.
CODE LACE DESCRIPCIÓN IMAGE

High-level alarm

LAH
Level sensor that indicates if the material level in the
the hopper is very high.

Quantity relay

QY
Motor contactor on/off that drives the belt that
the materials are delivered to the CPM-60.

105 Current Indicator

II
Indicate the amount of current supplied to the
motor, this is an indicator to verify the correct
operation of the pump.

Quantity control indicator

QIC
Siemens brand programmable logic controller,
this automaton controls the quantity of the materials
delivered to the CPM-60.

Sedimentation process:
CODE LOOP DESCRIPTION IMAGE

Level transmitter

LT
Ultrasonic level transmitter that delivers a
real reading of the cement level of the system in a
normalized electric magnitude in current for its
post-processing

Low level alarm

LAL
Level sensor that indicates whether the level of the material in the
storage column is very low.

Level control valve

LCV
It is a valve responsible for allowing the passage of
cement flow in the pipe.
106

Level control
 Siemens brand programmable logic controller,
LC this automaton controls the level in the cement tower.

Current Indicator

II
Indicate the amount of current supplied to the
motor, this is an indicator to verify the correct
operation of the pump.

Pressure Transmitter

It is a pressure differential transmitter, this has the

PT objective of indicating whether there is a flow of water through the pump
and that it is not working in vain.

CODE LACE DESCRIPTION IMAGE

Low battery alert

LAL
Level sensor that indicates whether the material level in the
the tank is very low.

Pressure Transmitter

It is a differential pressure transmitter, this has the

PT Objective to indicate whether there is a flow of water through the pump.
and that it is not working in vain.
107
Current Indicator

II
Indicate the amount of current supplied to the
motor, this is an indicator to verify the correct
operation of the pump.

Level control

LC
Siemens brand programmable logic controller,
this automaton controls the level in the cement tower.
b. P&ID DIAGRAMS
c. Integration diagram: networks and SCADA

For integration at the sensor and actuator level, AS-INTERFACE will be used.
2-wire transmission without a screen, to achieve immunity to noise, with a maximum number of
stations of 61 slaves and a network range of up to 300 meters with repeaters. At the level
the field will use the FIELDBUS FOUNDATION field bus with a length of up to
2000 meters with FF protocol and a transmission of 32.25 KBits/s. And for the cell level.
(PLC, PC) and at the administrative level, FF-HSE will be used, as it is compatible with the
communication of the FIELDBUS FOUNDATION field bus with an Ethernet transmission of
up to 100 Mbps with a distance of 100m per level

AS-Interface at the sensor-actuator level

 Technical information:

Norma AS-Interface according to IEC TG 178

Transmission Index 167 Kbps
Transmission Medium Two threads without a screen
Max. No. Stations 61 slaves
Network Amplitude 300 m (with repeaters)
Topology ["bus","tree","star","ring"]
Protocol AS-Interface
Applications Actuators and sensors

Characteristics:
The cable consists of two unshielded wires. To achieve noise immunity,
the transmission is made based on a Manchester encoding.
There are slaves that have up to 4 inputs/outputs, which makes the network
can control up to 124 digital I/O.
Communication follows a master-slave scheme, in which the master
interrogate the stations by sending them messages (called telegrams) of 14 bits
and the slave responds with a 7-bit message.
A maximum cycle time of 5ms or 10ms depending on the bus version.

FIELD BUS at field level

Contains PLCs that manage the areas of the process intertechnologically related.
example, assembly lines, transport lines, complex machines

There are two important parts of thearchitectureofsystemFieldbus: interconnection and application.

The interconnection refers to the transmission ofdata froma device to another, it can be a
field device, console operator or a configurator. This is the part of the protocol
ofcommunication offield bus.
Fieldbus at the cell level

At this level of automation, all operations of the process can be visualized.

intervene manually in it.

Features:
It is based on the use of the computer with SCADA-type software.
The behavior of the plant is represented graphically and dynamically.
The operator station connects to the controller
SCADA is an open architecture software.
Cost savings on peripheral equipment installation
 Allows communication at a higher level, example management networks type
Ethernet, etc.

Application:

Comparative:
H1 HSE
Transmission 31.25 kbit/s 10 Mbit/s or 100 Mbit/s
Distance by segment 1.900m 100 m
2 threads Yes No
Bus energy Yes No
Intrinsic safety If No
Redundancia No Yes
Determinism Yes Yes (with switches)

• El nivel H1 es utilizado para instrumentos de campo.

The HSE level is used at the Control level.
The H1 and HSE levels complement each other.
Administrative level
At this level, computers are responsible for administrative and business functions.
for the whole process.

Communication through HMI

The SIMATIC HMI panels offer modern operating and visualization functions combined with
characteristics such as robustness, stability, and simplicity. SIMATIC HMI is optimized for
satisfy their specific human-machine interface needs using open interfaces and
standardized in hardware and software, which allow efficient integration into their systems of
automation.
d. Robotics and pneumatics
In the industry, pneumatic systems are generally used for veneering, labeling, and
packaging of various products, as these systems reduce energy consumption
electric since they only need an electric compressor and an air tank in order to
perform various tasks, in the same way it is very safe as it does not pose risks of
pollution nor exposure to injuries. Based on this idea, the system will be designed
3 in 1 tire for filling, coating, or labeling for processed water, in this way
3 double-acting pneumatic cylinders will be needed for the operation of each task and
A 100% pneumatic arrangement can be made using 3-2 and 5-2 valves, in addition to
career ends for each piston or alternatively the system can be controlled through a
electronic card or with a PLC. The design of the 100% pneumatic operation would be
the following way:

The operation of bottling is simple as it starts from a conveyor belt.

we arrange the 3 actuators along this, first the piston is activated
bottling as soon as an empty bottle is detected, immediately after filling,
With the end of the races, we realize that the action has already finished, and we proceed to it.
coiling and once finished, labeling is done, all that logic is done through
pneumatic valves and the necessary limit switches. It is worth noting that this operation
It is calculated with a belt at a certain frequency and it will be necessary to use the sensors of
presence of objects. In addition, the actuators can be arranged to perform the same task.
for more than 2 bottles at the same time, it would only depend on a mechanical arrangement
appropriate.
7. Conclusions
[Link]
- Selector for Instrumentation and Process Analytics from Siemens. (2019).
Compiled: 5 from October 2019, from[Link]
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Wi1BVFQ=)/Z3_PIA_PORTAL/~flNUQVRFPTMxMDQ1LjAwMi4wMS4wMQ==?~okc
ode=EV_GUI-IND

- Natural craft beer production, Brewing beer | Enigma. (2019). Reviewed

October 5, 2019, collected from:[Link]
enigma/production process

- Webquest Creator 2. (2019). Revised on October 5, 2019, collected from

[Link]
vA40iTNWL6qUt-TeglVyhcSAnKxC44Mavwrojhhlka3SYc

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[Link]
A-107-2_MANUAL_DE_AUDITORIA_MEDIOAMBIENTAL-
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2/2_DESCRIPTION_OF_THE_BEER_BREWING_PROCESS.PDF