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African Petrochemicals Edition July/August Edition 14.4 {2017}

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NEW APPROACHES TO AN OLD OBJECTIVE Measuring and regulation technology in the brewing process 18 Sensors and measuring technology have become an indispensable part of nearly all sectors of industry and modern life. There is not a single industrial sector in which measuring, testing, monitoring or automation is not used. This applies to everything from the recording of process variables in process technology to the analysis of product characteristics in the entire producing industry, such as the food and beverage industry. Sensors are used with increasing success in order to give products competitive features that set them apart without significantly increasing production costs. In this high-tech field, Europe and Germany in particular play a leading role in terms of technological standard and global market share. Based on turnover, European providers cover about 35 per cent of world demand for sensor products. The AMA Association for Sensors and Measurement Systems estimates the number of manufacturers of industrial sensors and measuring systems in Europe to be around 1000 companies. In total, there are about 3000 European companies that work in the field of sensors, including manufacturers, retailers, engineering offices and specialised service providers. Against this backdrop, it is clear that measuring technology is a futureoriented sector with a high demand for innovation and is of existential importance for a country like Germany. This also means that companies must combine their strengths in terms of quality, production and innovation in order to succeed in the highly competitive world market. GHM Messtechnik GmbH is one of these companies. In 2007 it developed the vision of combining different areas of expertise and profiling itself as a hidden champion for the development of customer-oriented solutions that are appropriate for the market. The GHM Group, consisting of Greisinger, Honsberg, Martens, Imtron and the Italian environmental measuring technology manufacturer Delta OHM, currently concentrates on the bundling of synergies of these five tradition-based companies. The Martens location has been focused on producing hygienic sensors for conductivity and temperature for several years. This has been expanded over time into a complete product portfolio of modern and extremely compact sensors for breweries and beverage producers. Two application examples from these areas are described below. “We see many opportunities for our range of hygienic instrumentation in the South African food and beverage market” commented Jan Grobler, Managing Director of GHM Messtechnik in South Africa. “From our hygienic flowmeters, level and temperature measurement devices through to our precise and accurate benchtop measurement, we know that the accuracy, reliability and quality of our technology is what gives GHM Messtechnik the edge in this sector” Grobler said. Grobler added “We recently introduced the GHM Messtechnik Turbidimeter, MAT 433/437 which is used for phase detection in the food and beverage industry. The absorption measurement principle, according to EN ISO 27027, is designed to measure very high turbiditys. The turbidity is output as a percentage of the maximum measurement value. This value can be converted with an integrated conversion table into material-specific concentrations or into the formazine based unit FAU. This is a very high-tech measurement device which ensures less wastage particularly in the dairy and brewing sectors”. Yeast monitoring Multi-function tanks are often used in modern breweries with the objective of avoiding frequent product change. They are also used for the fermentation process. The yeast used in this process settles in layers in the lower portion of the tank. In order to be able to work efficiently and with high quality, the dead yeast cells are separated from the active yeast cells. While the dead cells are no longer used in the brewing process, the active yeast cells can still be used as pitching yeast. In order to ensure this, only the lowest layer of dead yeast is removed from the tank in an initial step. Then the next layers are separated from still fermentable yeast and beer in another step. For this purpose, a turbidity sensor is installed directly at the tank outlet or in the yeast return line. This sensor measures the turbidity of the yeast/beer mixture flowing through it, independently of the colour. After the end of the storage or maturation time, a majority of the yeast remaining in the tank has now settled as lees. Since this portion of the yeast is decisive for the quality of beer, it should be separated from the beer as precisely as possible when emptying the tank. This task of phase separation is also monitored by the already available turbidity sensor, wherein it is important that the turbidity value is measured as precisely and reproducibly as possible. Only in this way can the possibility of product contamination and beer product losses be eliminated. As a result, a consistent quality of the beer can be assured. The turbidity value, which is directly output as a 4-20 mA current signal or alternatively via a pre-adjusted limit value contact, can also be used with an external control unit for control of downstream valves, including delivery to a membrane filter unit or in the storage tank. The MAT433/437 turbidity meter is particularly suited for the above measurement applications. Small batch production and individual beer types. For production of small batches and individual types in 50 litre vats, for ex-ample, the GHM Messtechnik Group offers new measuring and

egulation components for the equipment of small breweries. This makes it possible for dedicated regional beer brewers and private home brewers to achieve a verifiable process with strict adherence to the recipes that they have created. The desired beer is the result of the individual recipe based on experience and creativity. For this purpose, modern measuring and regulation technology is used in combination with state-of-the-art communication technology for surprisingly simple and transparent use. A compact GHM-ONE multi-function regulator mounted directly in the system processes all measurements of the sensors certified for food production. These sensors include the durable and precise GHM-GTL series temperature sensors and GHM-MFI flow meters, as well as the GHM-MLP fill level sensor and GHM-MLC limit level switch, which can recognise two different media by their capacitive properties, such as beer and foam. The GHM-ONE can then communicate the appropriate control commands to the heating and cooling units, pumps, three-way valves and stirrers in the system. The colour display of the regulating device shows the operator the current status of the recipe process and the quality of all regulating circuits and provides graphic and textbased instructions for the progression of the process. The operator confirms this locally on the touch display of the GHM-ONE. A special feature is the individual recipe specification developed for the practitioner with a clearly arranged table with the individual steps and their selected parameters. This shows the brewer their individual recipe “step by step”, as specified for the process. This can take place via a screen of any size in the form of a Windows-based laptop, industrial panel PC or tablet. The independently operating GHM-ONE multifunction regulator communicates with these PCs via its integrated Ethernet interface or wirelessly with the tablet via a standard WLAN gateway. With these devices positioned conveniently alongside the production system, the specially developed GHM-CAT tool runs with the new ‘Beer production program editor’ function, which simplifies operation of a brewing system. The brewer creates the necessary steps according to their mash method of choice (e.g. comprising more than 60 different variable steps). He enters specifications for the exact parameters of the temperature profiles, holding times and step enabling conditions, the duration and number of pumping processes between the mash tank and lauter tun, the corresponding heating and cooling processes and the freely variable repetition processes for mash processing. With this clear representation of the recipe in the logical sequence of the process and the corresponding set-points and actual values, the brewer recognises the successful progression of the brewing process at first glance. In addition to the monitoring of close tolerance ranges for quality control and documented verification, the brewer is also provided with graphic trend representations and selectable process data reports to record batch production data. This brewing solution offers all creative beer brewers and their system manufacturers a professional and transparent, individual process that is also suitable for small batches. The clearly arranged technology aids in continuously creating new taste experiences from foods and beverages that have been appreciated for hundreds of years and reproducing them in the form of unique recipes. GHM Messtechnik South Africa is part of GHM Messtechnik GmbH, an amalgamation of globally renowned companies comprising: Greisinger Electronic, Honsberg Instruments, Martens Elektronik, Imtron, T & A (Telemetry & Automation) and Delta Ohm (Italy). Footnote: This article was originally written by: Markus Unglert, Sector Manager of Food & Pharmaceuticals, GHM Group, who since 2010 has been working exclusively in food technology, dairy, breweries and beverages sectors for the GHM Group, Germany. Further information is available from Jan Grobler, Managing Director GHM Messtechnik South Africa Tel: 011 902 0158 Email: 19


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