Application Bulletin

Microbrewery Achieves Consistent Quality and

Higher Productivity with SUPRAdisc™ II Solution
Overview The microbrewery’s requirement was for a replace-
ment of the sedimentation step with a cost-effective
Since their rebirth in the 1980’s, microbreweries filtration solution that would save time, help increase
have seen rapid growth in North America, as well as production capacity within limited space, and
in the rest of the world. Fueling the demand in North produce a product of consistent visual quality for
America was the growing exposure of the American sending to the bright beer tank.
public at that time to different, more flavorful types
of European beers, which were distinct from familiar The Solution
American beers produced for the mass beer market.
This demand has grown and in 2013, microbrewery After initially considering a filter press option, the
production1 represented 3% of all beer sales in the microbrewery selected a Pall SUPRAdisc II (SD II)
United States2. filtration solution to satisfy their requirements.
Both filter press and SD II module technologies are
In order to carve out a sustainable niche in the
based on the use of filter sheets, already proven over
brewing market, microbreweries today focus on
many years in the brewing industry. Filter sheets
producing unique and innovative beers different
consist of a unique matrix of cellulose, diatomaceous
from mainstream brands. They are characterized by
earth, and perlites that provide an excellent
experimentation, different brewing techniques, rapid
combination of adsorption, surface and depth
expansion, and the need for more modern produc-
filtration to effectively remove a wide range of
tion methods. They form part of the larger craft
contaminants. They are characterized by extremely
brewing industry, which grew by 17.2% in volume
high dirt holding capacity due to their high area and
output in the USA in 20132.
porosity: a 1 m2 (10.8 ft2) filter sheet has 21,000 m2
Filtration is a key operation in a modern brewing (226,000 ft2) of inner surface area and 3,100 cm3
process, which focuses on delivering a visually (189 in3) of pore volume.
appealing, high quality and shelf-stable product. Filter sheets are available in many different grades to
Cost-effective filtration solutions, which maintain cover applications from coarse particle filtration to
product authenticity, provide high quality, and position fine filtration, colloidal removal and microbial
microbreweries for increased productivity and reduction, all typical tasks in the brewing process.
expansion are a good fit for this rapidly evolving
SD II modules capitalize on the excellent removal
industry.
performance of filter sheet media while overcoming
The Challenge the marked disadvantages of filter presses. They
are installed in enclosed housings and thus provide
A 3500 hL per year microbrewery produces tart, a hygienic solution with no drip losses, the ability to
barrel-aged sour beers, an emerging beer style in
many regions of the United States. A wide variety of
wheat, blonde, quad, red, brown and porter beers are
aged in a selection of French oak, Kentucky Bourbon
and Northwest wine barrels for a period of 6 to 18
months. They are then blended with ingredients
such as fruits and spices to create uniquely flavored
final products that have found broad acceptance.
Traditionally, after aging, the beer was racked from
the barrels into sedimentation tanks. There it was kept
for several days, to enable settling of suspended
solids, prior to further blending and processing
steps. This sedimentation step required not only
capital investment for tankage, but took up space
and could be costly in terms of discontinuous
production and down time. In addition, depending
on beer type, the visual clarity of the product was
variable.
Figure 1: SD II modules are robust, cleanable, backflushable, and
in-place steamable, satisfying rigorous production requirements
in breweries. The housings provide flexibility in production.
pressurize the beer out of the housings with carbon
dioxide for higher yields, no exposure to air or other
environmental contaminants, and no mold growth
on sheet filter edges as is the case with traditional
filter presses.
The microbrewery selected 410 mm (16 inch)
diameter SD II modules, incorporating K700 grade
Injection Moulding
sheet media, for clarification. These were installed
in a single 4-high Pall lenticular housing suitable for Filter Sheet Media
beer filtration at 37 hL/hour. For flexibility, additional
Drainage Disc
housing internals were purchased to enable use of
this housing in both 3- and 4-high configuration. Figure 3: Typical cell in a classic lenticular module
Featuring the highest filtration area among lenticulars
in the industry, namely 5 m2 (53.8 ft2) per module,
the 4-high installation provides throughputs of
approximately 1400 hL filtered beer before the
modules are exhausted. This throughput results
both from the extremely high filtration area, and
from the ability to regenerate and reuse the modules.
The extremely robust design of the SD II modules
makes it possible to regenerate them by multiple
forward and reverse flushing steps. With the use of
special hardware devices, backflushing at maximum
0.5 bar (7.3 psid) differential pressure releases the
surface load of hop particulates and residues, yeast
and other particles (Figure 2). Forward flushing with
warm water, typically at 60 °C (140 °F), solubilizes any
Figure 4: Cutaway view of classic lenticular module
contaminants but avoids denaturation of trace proteins,
which could cause premature module plugging3.
Another feature which is economical for microbreweries
is the ability to store and reuse the modules, even up
to a production break of 4-6 weeks. After cleaning,
backflushing, sanitizing and cooling, they are stored
under carbon dioxide positive pressure in their
housings, until they are needed again. Prior to next
use, they are sanitized once more.

Figure 5: After 21 steam cycles, deformation is evident on classic

lenticular modules (left). SD II modules (right) maintain their shape,
keeping the individual filter cells separate from each other, unob-
structed and fully available for filtration.

then assembled in a stack to form the module (Figure 4).

In this design, since support is only in the forward
flow direction, backflushing is not possible. Additionally
these modules are prone to cell deformation during
filtration, hot water sanitization or steaming (Figure 5).
This deformation causes the filter sheet cells to contact
each other, which limits the filtration availability of
Figure 2: Backflush hardware enables regeneration of the modules those surfaces.
for increased service life.
On the other hand, the unique performance and
robustness of SD II modules is due to its patented
The Design Makes the Difference
double separator design, which provides upstream
SD II modules differ significantly from typical and downstream support for the filter media (Figure 6).
lenticular modules. Commonly available lenticular The media is individually sealed and separated
modules are designed according to a traditional between polypropylene flow distribution plates, which
stacked disc concept, in which the filter sheets are results in optimal flow and higher throughput through
exposed and unprotected from reverse flow or back the available surface area, as well as a mechanically
pressure shocks. Typically two filter layers are joined robust module suitable for flow in both forward and
with a plastic drainage disc in between to form a reverse operation. The design also minimizes the
filter cell (Figure 3). The filter cell border is sealed by risk of media tearing if the modules are subjected to
injection molding around the edge and filter cells are reverse pressure shocks.
 Outside Separator
Outside Separator

Filter Sheet Media

Inside Separator

Inside Separator

Figure 6: SD II module cutaway and separator plates

The Benefits References and Footnotes

The benefits realized by SUPRAdisc II technology in

1
USA Brewers Association defines microbreweries
this application include: in terms of output as producing up to 17,550 hL
per year.
• Improved and consistent visual filtrate quality
2
USA Brewers Association 2013 data,
• Long service life resulting in economical filter www.brewersassociation.org
spend, due to regeneration and storage capability
of the modules
3
Please contact Pall regarding protocols for
cleaning, backflushing, and sanitization suitable
• High yields, with beer losses estimated at less for your application.
than 1% (depending on suspended solids load in
the beer)
• Excellent product protection from oxidation, due
to enclosed system
• Simple and flexible installation, quick filter
change-out, and ease of handling both pre- and
post-filtration
• Productivity increase with smaller footprint, due to
elimination of sedimentation tanks
For this microbrewery, the SUPRAdisc II solution
resulted in an improved, more consistent product
and it enabled higher productivity within the same,
limited space.

About Pall Corporation

Pall Corporation is a global filtration, separation and purification leader providing solutions to meet
the critical fluid management needs of customers across the broad spectrum of life sciences and
industry. We work with our customers to advance health, safety and environmentally responsible
technologies. Pall Food and Beverage provides products and services to ensure product quality
and maintain process reliability in beverage and food production. Our solutions also assist in
consumer protection, waste minimization and reduction of operating costs.

Pall Food and Beverage Visit us on the Web at www.pall.com/foodandbev

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New York – USA in your area, please go to www.pall.com/contact
+1 516 484 3600 telephone
Please contact Pall Corporation to verify that the product conforms to your national
+1 866 905 7255 toll free legislation and/or regional regulatory requirements for water and food contact use.
Because of technological developments related to the products, systems, and/or
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notice. Please consult your Pall representative or visit www.pall.com to verify that this
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FBABMBQENa February 2016