Biological and Chemical Detection in the Brewing Industry

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• Biological and Chemical Detection in the Brewing
  Industry
• Submitted by
• David Jones

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Brewing Process

• Brewing bacteriology was born when microorganisms
  responsible for the spoilage of beer were
  investigated by Louis Pasteur during the 19th
  century. He was called upon to determine why
  French beer was inferior to German Beer.
• Brewing has a long history the process has been
  know for long time, but the science of why came
  later.

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Brewing Process

• Malting Barley is adjusted and kilned
• Milling Exposes the starchy center
• Mash Conversion of starch to sugar by
  alpha-amylase and beta-amylase
• Rinse/Boil Kills bacteria and hops add bitter
  flavor
• Cooling/Fermentation Yeast addition, conversion
  of fermentable sugars to carbon dioxide and
  alcohols.

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Flavor Aspects

• Recipe
• Water Chemistry (Brewery Specific)
• Hops strength and amount isomerized (a-acids)
• Yeast Strain and Strength
• Saccharomyces Ubarum
• Saccharomyces Cerevisiae
• Fermentation lag, log, rest, pH, dissolved
  oxygen, temperature, buffer capacity, carbon
  dioxide...
• Packaging UV light, dissolved oxygen leads to
  bacterial spoilage (HACCP after fermentation)
• Flavor Agents alcohols, sulfur compounds,
  esters, Di-acetyl and Pentane-2, 3-Dione,
  Polyphenols, Dimethylsulfide (DMS)

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Fault Examples

• Off flavors fruity, harsh, sweet, or bitter
• Haze level of particles in suspension
• Lack of body level of non-fermentable sugars
  and polyphenols
• Poor head retention or formation

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Brewery Automation

• Complex chemical and biological process that
  needs to be controlled.
• Historically Process controlled by manufacturing
  process (Brewery Specific)
• Today the manufacturing is driven by flexibility
  The ability to produce a variety of beer using
  the same equipment.

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Automation PLC (Automationdirect)

• Programmable Logic Controller

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Automation PLC (Automationdirect)

• Relay Out

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Automation PLC (Automationdirect)

• Ladder Programming View

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Automation PLC (Automationdirect)
Drum Programming
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Automation PLC (Automationdirect)
PID loops
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Brewery Sensors
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Dissolved Oxygen

• On Line
• Response time lt 90 sec
• Interoperable yes Immersion or Flow Through
• Performance 1 of signal, max. 30 ppb
• Location Fermentation Tank, HACCP Point after
  Boiling Stage

Mettler Toledo
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Carbon Dioxide

• On Line
• Response time lt60 seconds for 90 step change
• Interoperable Yes Alarm relay output
• Non-dispersive infrared (NDIR) repeatable to 20
  ppm 0-2000 ppm range
• Location Fermentation ducts or HVAC ducts

Veris Industries
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Dissolved Carbon Dioxide

• At-Line
• Response time lt 7 minutes
• Technology fiber-optic, fluorescent dye
• Interoperable Probable - 4-20 mA loop or 1-5 Vdc
  (analog output)
• Performance 5 of reading or 0.2 absolute
• Location Fermentation Tanks

YSI Life Science
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pH no-Glass

• On-line
• Response time lt 90 seconds
• Interoperable yes standard VP connection
• Performance pH 0 14, 0 80C
• Gel electrolyte, Argenthal electrode, Temperature
• Location Mash tanks, Fermentation Tanks,
  Maturation, Packaging

Mettler Toledo
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Glucose/Alcohol Electrode

• On-Line
• Response time lt 2 Minutes
• Interoperable yes small voltage, BNC connector
• Reproducibility 3
• Location Mash, Fermentation, Packaging

Universal Sensors Inc.
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Yeast Monitor

• At-Line
• Response time Real-time
• Technology Electrode, temperature, capacitance
• Interoperable yes RS232 port, alarm outputs
• 10 Cell size/strain positions
• Location Fermentation, Maturation, Yeast Storage

Aber Instruments
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Yeast Monitor

• On-Line
• Response time Real-time
• Technology Radio frequency dielectrics and
  software
• Measures Capacitance in living yeast cells
  (Plasma Membranes)
• Interoperable yes RS232 port and Ethernet,
  alarm outputs
• Location Fermentation, Maturation, Yeast Storage

Aber Instruments
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Protein and Polyphenol Detection via Surface
Plasma Resonance

• Off-line
• Response time Rapid Confirmation
• Interoperable No, standalone system
• Flexibility to determine multiple compounds with
  multiple sensor chip configurations
• Location Brewing Lab (determine flavor
  constituents)

Biacore
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Gram Negative/ Gram Positive Bacteria
Contamination

• Gram Negative
• Acetic Acid Bacteria
• Pectinatus cervisiiphilus
• Enterobacteriaceae
• Zymomonas
• Pectinatus frisingensis
• Selenomonas Lacticifex
• Zymophilus raffinosivorans
• Zymophilus paucivorans
• Megaspaera

• Gram Positive 
• Lactobacillus
• Lactic Acid bacteria
• Pediococcus
• Leuconostoc
• Homofermentative cocci
• Kocuria, Micrococcus and Staphylococcus
• Endospore-forming bacteria

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Biologs G/G- Yeast detection

• Off-Line Rapid detection
• Standalone System (the rest)
• MicroPlate 96 different Chemical Substrates
• G gt310 G- gt500 Yeast gt265
• lt 5 min Hand prep
• Photo-Optical (density)
• Automated database
• Location Through-out

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Biotraces ATP Bioluminescence

• All in one Test Kit swabbing
• Off Line Cleanliness Check
• ATP enzyme-driven light emissions
• Response time lt 30 secs
• Measures light output (luminometer) or living
  cells
• Location Throughout
• Specslt150 RLU (pass)
• gt300 RLU (Fail)
• Tanks, Valves, Doors

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Chemunex Chemscan RDI

• Off-line Rapid Identification
• Technology Combination of 1)Laser Scanning
  2)cell labeling and 3)automated/database
• Fully Automated 20 hr Presence 1 hour direct
  Count
• High throughput 60 samples per hour
• Drawback lack of specific recognition of Brewery
  beer-spoilage bacteria.
• Subspecies of
• Pediococcus
• Lactobacillus

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Qualicon/DuPonts RiboPrinting

• Off-Line Rapid thorough detection 8 hrs
• Technology Random Amplified Polymorphic DNA PCR.
• Extracts DNA rRNA compares gene sequence
• DNA extracted mixed with chemiluminescent
  captured on digital image Fingerprint is
  compared with database RiboPrint
• Powerful tool for identifying subspecies of
  beer-spoiling bacteria during the middle to late
  fermentation stages.

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Conclusions

• Biosensor use is dependant upon many factors
• Brewery size Throughput, variety of brands,
  total energy used.
• Cost Potential Savings, Ability to integrate in
  to architecture, Installation cost, man power
• Potential Market Better, Cheaper, Faster
• Anheuser-Busch 47 of American Market, produced
  127.9 Million barrels (101.8 M domestically),
  Gross sales of 15.686 billion dollars, and over
  30 different brands.
• Distributed Generation The business of business
  is business. Distributed Manufacturing.

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Conclusions

• Sensing and conditioning a signal is only half of
  the process.
• Act and React Interoperable with existing
  systems
• Overarching Control Scheme
• Manufacturing Procedures

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Any Questions?