Wort collection and boiling
The wort flowing out of the filter tank and filling the boiling tank is often the longest part of the linear brewing cycle.Time is often wasted in the process of heating the boiling tank to a boiling state.Some precautions for heating wort in wort collection and boiling pots: The heating capacity of the boiling tank: Regardless of whether the boiling tank is jacketed or has a built-in or external heater, the heat transfer surface must be correctly adjusted in size and position to ensure that the liquid in the tank is in the boiling stage as required.
Insulation: In order to reduce the possibility of “radiation loss” and provide protection for operators, it is very important to insulate the surface of the boiling tank.It is recommended to apply at least 7cm of insulation material to the bottom head and side wall areas.
Steam emptying: The correct design of the size of the steam pipe is very important, so that the steam and condensate can be effectively removed.Evaporation rate, chimney length and environmental conditions are important factors in chimney selection.In the case of using a “stacking fan”, size is again the key.When using a fan that opens the door to boil, the entrained air will cool the upper layer of the wort, resulting in reduced boiling power, loss of evaporation rate, reduced surface temperature, and ineffective removal of volatiles.If the fan is too small, it will limit the steam flow, thereby increasing the possibility of overboiling.
Steam pressure: If you check the steam meter, you will realize the importance of steam pressure and its relationship with temperature.The high-pressure boiling tank is ideal because when adjusted for the boiling tank, it will remain consistent under pressure and independent of the needs of other breweries.The pressure of the low-pressure boiling tank will fluctuate with changes in the system load.Most control systems of the low-pressure z boiling tank will shut it down if a steam pressure of 15 psi is detected.There is also a pressure reducing valve on the steam pipeline. In a low-pressure system, the pressure valve releases the pressure at 15 psi.Therefore, the pressure setting point of the boiling tank should be set as high as possible to a point where it will not close.
Quantitative method: Using temperature as the measurement basis for boiling time rather than the eye's perception of boiling helps to add structure to the brewing process and ensure that the product is more consistent.
Separation of swirling sedimentation and residue
Whether your saccharification uses a dedicated swirl tank or a combination tank for boiling swirl, residue separation is essential to the product quality and yield of beer.It is also important to minimize solids passing through the wort cooler.There are several design factors for the swirling/boiling swirling tank that will help minimize time without affecting the separation capacity：
Geometry of the storage tank: The main function of the vortex process is to rotate the contents of the tank to form a residue pile in the center of the container.The correct vortex size is implied in the high diameter ratio, wort volume and density, including hops and hops addition rate.
Residue removal: Water is an expensive commodity.The design of the residue removal outlet should be aimed at efficient and timely removal of residues while minimizing water consumption.
The last step of the brewing cycle is mainly about the cooling of wort, and some process regulations should be considered.：
Time: Although the equipment can be designed to meet almost any shortest possible cooling time, wort cooling usually takes 30-40 minutes.
Coolant: Breweries usually use water, cold liquid, ethylene glycol or a combination to cool the wort through a plate heat exchanger.It is very important to correctly adjust the size of the wort cooler according to the cooling time, wort temperature range and pipeline pressure.Coolers are generally divided into single-stage or double-stage.No matter which cooler option is used, it is important to check the energy balance of heat removal (wort cooling), water circulation, and cooling requirements.
Urban water-The water temperature in the city varies by region and season. Depending on the temperature of the cold wort, it may need to be supplemented with frozen liquid or ethylene glycol.
Coolant –frozen water)-The coolant ensures a constant cooling medium that is always below the target temperature.Frozen water is converted into hot water during work and reused during the brewing process.
Water and ethylene glycol-supplementary refrigerants are usually done through the second stage in the plate heat exchanger.The wort is first cooled by urban water supply or filtered water, and then cooled with ethylene glycol.This can better control the temperature and reduce water consumption when the wort temperature is close to the target temperature.
Flushing/disinfection: Heavy hops and ingredient loads, coupled with poor separation of residues in the whirlpool, lead to excessive cold flocculants and potential blockages in the wort cooler.It is good practice to install reverse flushing and CIP of coolers and piping systems.The method of disinfecting the cold wort pipeline and fermentation tank should also be considered during the design phase