Pall in the Brewery (more value per hectolitre)DE Free Clarification

FB1795

The Pall World

Pall Corporation is a world leader in the design, production and supply of filters,membranes and systems for the filtration and separation of liquids and gases. With an annual turnover of more than a billion dollars, we are able to handle major projects on a safe and sustainable platform.

Industry drivers for DE free filtration

Diatomaceous Earth (DE) is the mostcommonly used and approved filter materialfor beer clarification. It offers excellentfiltration characteristics whilst maintainingthe desired taste and body of the product,however the sustainability of DE filtrationhas recently been called into question forthe following reasons:

• Public and legislative debate surroundingthe health and safety classification of DE

• Handling and storage considerations fora classified substance

• Inflexibility with regard to 24/7 operation

• Potential increased disposal costs

• On going requirements to reduceoperational costs

PROFI technology offers asmart solution to thedemands of the brewingindustry offering complete DE free clarification withdirect value to the brewery:

• Constant high beer quality

- Due to minimized shear effects on theproduct, maintaining yeast integrity

- Turbidity better than DE

- Yeast free filtrate and sharp reductionin beer spoiling bacteria

- Negligible oxygen from process start up

• Maximum yield, lowering operating costs

- Retentate-free process throughemptying the modules with CO2 in thedirection of flow

- No pre and post run required, henceno time in blending and storage losses

- No ’mixed’ beers, simple changeengineering

• Continuous operation

- Smaller system sizing required

- Reduced media consumption

- High flexibility for brand change

- Reduced BBT volume required

- Permanent system availability

• No filter aid handling

- No purchasing of consumable filter aid

- No health and safety risk managementof filter aid

- Reduced waste disposal costs

PROFI technology is a co-operation between Pall food andBeverage and GEA Westfalia Separator Food Tech GmbH.

It is the engineered result of significant R&D investment built onthe extensive and unique brewing experience of the two

companies, combined in a high performance centrifuge with acrossflow ‘dead-end’ membrane system.

PROFI built on partnership

Solution for beer filtration

- combination of high efficiency centrifuge and crossflow membrane plant

Unfiltered beer

Clarified beer

Separation of solids

Chilled beer

Filtered beer

Crossflow ‘dead end’ thelowest velocity crossflowsystem

The prepared product passes from thecentrifuge to the PROFI membrane system.The basis for this system is a highlyengineered membrane module insertcovering the hollow fibre membranes. Thepatented module design includes:

• Potting in stainless steel housings for80°C sanitization and 10 bar pressureresistance

• De-coupled polymer modular insert fromthe stainless steel housing offeringunique heat stability

• Standard hollow fibre membrane withgood beer filtration characteristics

The membrane system has beenengineered to operate at a very low velocity,without a retentate loop:

• Typical crossflow velocity 1.1 – 1.5 m/s

• Offering the brewery high quality beer, aslow velocity flow does not transfer energyinto the product

• Offering the brewery minimized beerlosses because the smart PROFItechnology empties the system in theforward direction

• Offering the brewery the potential tooperate 24/7 as individual modules canbe isolated for automated CIP

The unique impact of thecentrifuge

PROFI technology employs a GEA WestfaliaPROFI centrifuge. This centrifuge has ahydrohermetic feed system that providesgentle separation of the majority of the yeastcells from the product.

The centrifugal element of the PROFIsystem benefits the brewery by providing:

• Low shearing effects

- Colloid in the feed remain undamaged

- More efficient clarification

- High dry solids separation, maximizing yield

- Better viability of yeast cells

• Simultaneous stabilization is possible bythe addition of stabilizing agents that canbe removed by the centrifuge

PROFI technology has specifically been designed to provide acontinuous operation, it is intended to be the predecessor of the

continuous brewing of the future

PROFI Continuous Operation

Cleaning and forward flowdischarge

The system is emptied with CO2 in theforward flow direction, optimizing thedischarge process by:

• Short process time for system discharge(10 mins)

• Minimizing beer losses (< 50 l)

• No pre and post runs required

• Short and simplified brand changes

• Minimal oxygen uptake < 0.02 ppm

• Low water consumption

PROFI technology also has advantagesfor CIP including:

• Standard brewery cleaners can be utilized

• Typical brewery quantities are used

• Minimized energy consumption required

• No significant increase in BOD/COD

• High temperature stability

24/7 process operation

The modular nature of the PROFI design isintended to offer breweries the reality of24/7 production.

For the brewery the automated systemgives benefits in terms of initial capitalexpenditure and on going operationalcosts including:

• A reduced system requirement to takeinto account 24/7 continuous operation

• High Flexibility at start up and brandchange

• Full automation with zero manpoweroperation

• Reducing power consumption perhectolitre

• Minimized water consumption per hectolitre

Available sizes from 20 - 500 Hl / Hour

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 160

1

2

3

4

CIP 0.53

CIPFiltration Filtration

Filtration FiltrationFiltration

Filtration Filtration

Filtration Filtration

0.53

CIP 0.53

CIP 0.53

CIP 0.53

CIP 0.53

CIP

Sustainability

• DE consumption is eradicated

• Water consumption < 0.15Hl / Hl beer

• Energy – low thermalconsumption

• Energy – Electrical 0.3 –0.6 kWh

• Reducing waste

• Reducing chemicalconsumption

The PROFI design is the technology of the future providing high beer quality and microbiologicalsafety on a sustainable platform.

Microbiological safetyThe PROFI system can easily be integritytested in-situ due to its cluster design andmodular set-up. Individual integrity testscan be carried out cluster by cluster withinone block during the continuous process.Beer quality is comparable to traditional DEand sheet filtration. Proven by independentlaboratories and experts:

• Maximized availability due to the clustertechnique

• Taste no difference reported (dataavailable from Pall)

• Extract, alcohol, color, bitter units andfoam show no difference

• Microbiological safety

• Colloidal stability comparable

• No increase of iron, manganese ionsthrough filter aids

A PROFI system is an investment in cost effectiveclarification, sustainable technology and brewery

flexibility. The figures below indicate the economicalbenefits that a brewery can be rewarded with

in comparison to the operation of conventional DE clarification.

The ultimate assurance

Economical Benefits

Filter media cost lower than DE 10 – 30 %

Stabilisation cost comparable to DE

Thermal Energy cost lower than DE 60 –75 %

Electric Energy cost comparable to DE

Water consumption lower than DE 25 – 40 %

Manpower lower than DE 80%

Disposal cost lower than DE > 95%

Service cost lower than DE 30 – 50%

Westfalia SeparatorFood Tec GmbH

Mechanical SeparationDivision

Pall Food and BeverageNew York - USA 800.360.7255 toll free +1 516 484 5400 telephone +1 516 625 3610 fax

Bad Kreuznach - Germany+49 (0)671 88 22 0 telephone +49 (0)671 88 22 200 fax infobk@europe.pall.com

Portsmouth - UK+44 (0)23 9230 2269 telephone +44 (0)23 9230 2509 fax processuk@pall.com

Pall Corporation has offices and plants throughout the world in locations including:Argentina, Australia, Austria, Belgium, Brazil, Canada, China, France, Germany, Hong Kong,India, Indonesia, Ireland, Italy, Japan, Korea, Malaysia, Mexico, the Netherlands, NewZealand, Norway, Poland, Puerto Rico, Russia, Singapore, Spain, South Africa, Sweden,Switzerland, Taiwan, Thailand, United Kingdom, and the United States. Distributors arelocated in all major industrial areas of the world.

Contact us on the web at www.pall.com/foodandbev

CS912/IM/92005

and Pall are trade marks of Pall Corporation.

PROFI is a co-operation between Pall Food and Beverage and GEA Westfalia Separator Food Tech GmbH

® indicates a trade mark registered in the USA

Filtration.Separation.Solution is a service mark of Pall Corporation

© Pall Europe Limited 2005