Automated Brewing: The Deutsche Beverage + Process Advantage

Why is Automation in Brewing So Important?

In the craft beverage industry, automation is becoming increasingly crucial. Deutsche Beverage+Process stands out by offering customized automation solutions tailored to the unique needs of craft breweries, distilleries, commercial coffee, and more. The aim is to transform the customer’s production processes to meet their production and efficiency goals. The result of integrating automation is greater efficiency, reduction in labor, and a better product. There are now automation options to fit every budget, meaning any sanitary processing operation will benefit.

Crafting Better Beer with Automation

Automation is the key to consistent and high-quality beer production. It allows for a reduction in human error, ensures repeatability, and provides the ability to troubleshoot remotely. With the addition of simple automation features like lauter transfer, auto-fill, with hydrostatic pressure sensors, remote access, auto-knockout, auto-blending, boil-over protection and more brewers can save significant time, increasing overall labor efficiency. The capacity to manage multiple aspects of brewery operations remotely or through automated systems not only enhances the quality of the beer but also the quality of the work environment.

By integrating grain and material handling into the control panel, Deutsche ensures that the right amounts of ingredients are used every time. This precision handling is part of what makes automation such a valuable asset. It’s not just about reducing physical labor; it’s about ensuring that every variable in the brewing process is meticulously controlled. This leads to a more consistent product, which is essential for breweries that pride themselves on the quality and reliability of their craft beers.

Customization for Specific Needs

Customization is at the heart of Deutsche Beverage + Process automation solutions. Recognizing that no two breweries or specialty coffee producers are the same, they offer a complete library of standard processes that are common across the industry, such as step mash and lauter transfer and kettle souring. However, they go further by customizing these processes to fit the unique production requirements of their clients. Whether it’s integrating a new pump for knockout and CIP processes or accommodating a unique brewing method, the company ensures that automation is not a one-size-fits-all solution but a bespoke system tailored to specific needs.

Furthermore, Deutsche Beverage + Process is open to innovation and individual ideas for automation. They have a history of accommodating unique requests, such as a remote mash-in process facilitated by a pneumatic knifegate valve. This level of customization empowers customers to start their processes before even arriving at the facility, exemplifying how automation can be adapted to fit the precise needs and creative ideas of craft beverage makers.

A collaboration with Siemens for control systems, coupled with a dedicated in-house panel shop, ensures that our automation systems are not only consistent and at the forefront of technology but also rigorously tested for efficient start-up operations. Our in-house panel shop handles all programing, design, and panel build-out. This level of commitment underscores our commitment to providing Deutsche customers with the most advanced and current features available, guaranteeing a seamless and state-of-the-art brewing experience.

Data Analytics and Reporting

To optimize production efficiency, Deutsche equips its systems with robust data analytics and reporting capabilities. The primary function of their system is to track and hold data, which is crucial for effective troubleshooting. This feature allows production staff to swiftly identify and address issues such as unexpected temperature changes, with data readily available for analysis. Additionally, the capability to export data into user-friendly formats like Excel means that insights can be easily shared and acted upon.

In larger operations where long-term data trends are essential for strategic planning, Deutsche Beverage + Process can provide additional data output capabilities. This integration with database management software ensures that the valuable data collected by their automation systems can contribute to comprehensive trend analysis. Such data is instrumental in making informed decisions that drive efficiency and productivity in the craft beverage production process.

Remote Monitoring and Control

Remote monitoring and control are standout features of Deutsche in automation systems, providing flexibility and enhanced oversight for brewers and distillers. The Siemens interface app is a prime example of this, offering intuitive control over the system from anywhere within the production facility or even remotely from home. The impact of this capability is significant—it means that processes such as lagering a beer or monitoring cellar temperatures can be managed without being physically present at the controls location.

The ability to set timers for operations from a smartphone or tablet is not just a convenience; it represents a shift in how production environments operate. It allows for better time management and process optimization, as critical functions like beer knockout can be scheduled to fit around other tasks or outside of standard working hours. This level of control, accessible through a user-friendly interface, empowers producers to manage their operations more effectively, ensuring that product quality is maintained without sacrificing personal time.

Maintenance and Upgrades

Maintenance of Deutsche automated systems is proactive and preventive. With high-quality Siemens PLCs and control panel parts, the systems are built for reliability. However, the company recommends semi-annual checks to prevent issues like loose wires, which can occur due to temperature changes and regular use. There are also fail-safes designed within the panel to protect more expensive components and the brewing equipment itself. With a robust two-year warranty, clients have peace of mind regarding the longevity and performance of their systems.

The company’s approach to upgrades and support is equally thorough. A dedicated controls engineering team is available to remotely address software or hardware issues that may arise, minimizing potential downtime. This remote service is made possible by the inclusion of mGuard, an Ethernet device that allows the engineering team to access the system from anywhere, providing timely assistance. This level of support ensures that any necessary maintenance or upgrades can be performed efficiently and with minimal interruption to the production process.

The DUR System: A Comprehensive Automation Solution by Deutsche

The DUR system is Deutsche’s flagship automation package, offering a complete suite of advanced features. The name comes from the German word, dur, meaning major. This top-of-the-line system provides comprehensive control over the brewing process from the brewhouse to the cellar equipment with options for future expansion, making it a scalable solution for growing operations. Equipped with the necessary sensors, HMI screen, and flowmeters, the DUR system sets the foundation for precise and controlled production, from water blending to lauter transfer and other automated features.

The strength of the DUR system lies in its versatility and its inclusion of the full spectrum of Deutsche’s automation library. It allows for the integration of sophisticated processes and features like pneumatic valves, ensuring a streamlined and less labor-intensive operation. The system is also designed with future growth in mind, providing plenty of IO for additional cellar tanks or automated programs. This foresight ensures that the DUR system is not just a solution for current needs but an investment in the future efficiency and capabilities of the production facility.

Enhanced Production Capabilities with Automation

Blending automation, auto-fill functionality, and lauter transfer are specific examples of how Deutsche’s automation can revolutionize brewing operations. The blending valve, a key component in achieving precise mash temperatures, operates with a plunger mechanism controlled by a temperature probe, automating the mix of hot and cold water. This precision allows brewers to focus on other tasks, confident in the consistency of their mash.

Lauter transfer is similarly optimized with flowmeters and VFDs, allowing for a specific flow rate and timing that can be walked away from, knowing that the vessel will be filled accurately and consistently. These automated features reduce the manual workload, ensuring each batch of beer is consistent with the last, and freeing up brewers to manage other crucial aspects of the brewery.

Boil over protection is a critical safety feature in both craft and production brewing, where the risks are significantly higher than in home brewing due to the intense heat generated by direct fire and steam systems. These systems can produce vigorous, rolling boils that, depending on various factors like beer recipe, hop additions, or even the brewery’s elevation, may occasionally lead to boil overs. To combat this, a capacitance sensor can be integrated into the brewing system. This sensor is designed to detect the early signs of foaming, automatically shutting off the heat source before a boil over can occur. Such technology not only prevents messy and hazardous incidents but also enhances the brewing process’s safety and efficiency, allowing brewers to focus on crafting quality beer without the constant worry of boil over risks.

The Auto-knockout system represents a significant advancement in brewing technology, serving as a quintessential upgrade in the DUR program suite. It features an IFM flowmeter coupled with a state-of-the-art digital temperature probe situated at the wort outlet of the heat exchanger, functioning in unison with the kettle/whirlpool pump and either a knockout or cold pump. The integration of a Variable Frequency Drive (VFD) within the control panel is pivotal, as it finely tunes the wort pump’s velocity to achieve the desired knockout temperature with precision. This level of control and automation not only guarantees uniformity across different batches, enhancing product consistency, but it also strategically allocates manpower by liberating the operator from this task, thus allowing them to engage in other essential brewery operations.

Wort grant level monitoring is another automation feature crucial to brewers. Designed to optimize the brewing process by incorporating a straightforward yet effective IFM pressure sensor on the wort grant. This sensor is cleverly interlocked with the pump’s Variable Frequency Drive (VFD), creating a synergy that carefully monitors and regulates the filtration pace through the grain bed. The result is meticulous control that avoids over-aggressive filtration, which is essential in preventing common brewing pitfalls such as stuck mashes and potential damage to the brewing equipment. Additionally, this precision in the brewing process plays a pivotal role in enhancing the beer’s clarity, ensuring that each batch meets the high-quality standards expected in the craft brewing industry.

Most Popular Automation Features

• Lauter transfer
• Blending automation
• Auto-fill functionality
• Boil over protection
• Auto-knockout system
• Wort grant level monitoring
• CIP process options
• Material handling
• Over twenty more automated feature add-ons

Integration with Existing Systems

Deutsche’s approach to integrating automation with existing systems is a careful and planned process. By setting up their systems to send or receive data, tags, or communication from current equipment, they ensure a smooth transition to automated processes. Spare IO ports and Ethernet connectivity are considered during the design phase, providing a framework for seamless integration. This attention to detail in the initial stages of system design ensures that automation enhances production capabilities without disrupting the workflow of existing operations.

Once the systems are in place, the compatibility with established setups allows for a harmonious operation. The ability to interface with existing motors, instruments, valves, and control panels means that the new automation can be integrated without the need for extensive modifications to current processes. This not only saves time and resources but also reduces the learning curve for staff, allowing them to adapt to the new technology in a familiar environment.

Safety and Sustainability: Core Elements of Automation

Deutsche Beverage + Process’s commitment to safety is evidenced in the construction of their control panels and systems. They incorporate interlocks and emergency stops in their programming, which act as a safety net against equipment failure. Safety level switches in direct fire and electric systems further ensure that there is adequate water or wort before activation to prevent equipment damage.

Waste reduction is another significant advantage of adopting Deutsche’s automation. Automated processes are precise and efficient, minimizing waste and ensuring sustainability in production. By ensuring that each ingredient is used efficiently and that production processes are as lean as possible, breweries not only save on costs but also contribute to environmental conservation.

Your Partner in Automation for Craft Beer and Beverage Production

The automation solutions offered by Deutsche provide an ecosystem of efficiency, safety, and quality. From seamless integration with existing systems to the advanced automation capabilities these solutions are designed to meet the evolving needs of the craft beverage industry. By reducing waste, ensuring consistency, and minimizing labor through intelligent automation, breweries and distilleries can focus on innovation and growth. Deutsche’s commitment to customization, data analytics, and remote capabilities reflects an understanding that the future of beverage production is not just automated but intelligently so.

More Industries Benefiting from Deutsche’s Automated Systems

Deutsche Beverage+Process is revolutionizing the way industries think about automation, extending its reach far beyond the realm of craft brewing. This innovative company now offers comprehensive automation solutions for a wide array of sectors including distilling, coffee/tea production, cannabis/hemp processing, mixing and blending, various beverage-related fields, co-packing, and sanitary processing fields. The impact of automation in these industries is profound, transforming traditional processes into streamlined, efficient operations.

In the world of craft spirits, automation is changing the game by improving precision in the distillation process. This not only ensures a consistent quality and flavor profile, which are crucial for spirits, but it also enhances efficiency and safety by allowing for remote monitoring and control of the distillation process. Coffee and tea producers, particularly those specializing in premium varieties, benefit from automation through the ability to precisely control steeping times and temperatures. This is essential for extracting the perfect flavor and maintaining consistency across batches, ensuring that each cup meets the high standards expected by consumers.

The fast-growing cannabis industry is another area where automation is making a significant impact. With strict regulatory requirements for product consistency and labeling, automation assists in achieving precise dosing and packaging, thereby ensuring compliance and quality. Similarly, the infused beverage market, which includes products like CBD-infused drinks, relies on automation for complex mixing and emulsification processes. This ensures that the final product is stable and homogenous, meeting the high expectations of consumers in this innovative market segment.

Kombucha and other fermented drinks also benefit from automation, particularly in maintaining the strict environmental controls necessary for producing high-quality beverages. The precision afforded by automation is invaluable in achieving the desired balance of flavors and ensuring product consistency. In the chemical, pharmaceutical, and nutraceutical industries, where regulations are stringent and quality control is paramount, automation plays a critical role. It not only ensures compliance with manufacturing practices but also helps maintain clean and controlled environments. Furthermore, detailed records provided by automated systems are essential for quality control and traceability.

The adoption of automation by these industries leads to higher quality, consistency, and yields, along with increased operational efficiencies. Over time, the investment in automation

typically results in cost savings, due to reduced labor needs and increased production capacities. The precision and control offered by automated systems can even contribute to the production of award-winning products, thanks to the enhanced ability to replicate successful batches.

Deutsche Beverage+Process’s foray into providing custom-designed equipment and systems for these diverse industries underscores its commitment to efficiency, value, consistency, and reliability. By embracing automation, companies within these sectors are not only optimizing their operations but are also setting new standards for quality and innovation.

 

Frequently Asked Questions About Automated Brewing Equipment