Slide 1: Dry hopping solutions
Dry hopping solutions Streamline and optimize the dry hopping process www.alfalaval.com
Slide 2: Agenda
Agenda Introduction to dry hopping (Alyce Hartvigsen) Alfa Laval solution 1: Iso-Mix External Drive (IMXD) (Alyce Hartvigsen) Alfa Laval solution 2: Alhop (Denis Martin) Q&A (All) Recording of the webinar is available. © Alfa Laval www.alfalaval.com
Slide 3: A bit about hops
A bit about hops Hop cones from female plant Cross-section drawing of a hop Grown in temperate regions Lupulin glands Yellow sticky globs of essential oils and resins Used for bittering and aroma that are the main source of aroma and bittering compounds in beer. Bract: the leaves provide ast
Slide 4: Dry hopping process
Dry hopping process The addition of hops to the fermentation or maturation vessel during or after main fermentation in order to extract the hop flavours into the beer © Alfa Laval www.alfalaval.com
Slide 5: Hop pellets
Hop pellets Hop pellets are hops that have been dried, ground into powder and then recompressed into pellets Most frequently used type: T-90 pellets (whole hops pelletized) T-90: 1 kg whole hop flowers yields 0.9 kg hop pellets Pellets are most frequently used because: − Easier to handle − L
Slide 6: Dry hopping process
Dry hopping process − Main process steps Dis- Hop addition Extraction Hop removal aggregation © Alfa Laval www.alfalaval.com
Slide 7: Scaling up of dry hopping process
Scaling up of dry hopping process Dis- Hop addition Extraction Hop removal aggregation Large-scale brewing of dry hopped brands presents some issues for brewing at scale: 5,000 hl x 200 g/hl = 1,000 kg of hop pellets A 5,000 hl fermentation tank is five stories high! Increasing hopping rates + Growt
Slide 8: Hop disaggregation – the tricky part
Hop disaggregation – the tricky part Dis- Hop addition Extraction Hop removal aggregation 10 g T90 10 g T90 pellets in dry pellets 100 ml liquid © Alfa Laval Slide 8 www.alfalaval.com
Slide 9: Hop disaggregation “live” – 20% solids
Hop disaggregation “live” – 20% solids Mixing in warm water After 2–3 minutes mixing (approximately 40° C) © Alfa Laval www.alfalaval.com
Slide 10: Hop slurry tank: agitator design is important!
Hop slurry tank: agitator design is important! Wrong: Lower of two impellers is positioned too high; Right: Third impeller blade has been added close no mixing occurs in the lower part of tank. Solids to the tank bottom. Mixing is now effective until accumulate here, causing plugging. the tank is em
Slide 11: Aroma/flavour extraction rates
Aroma/flavour extraction rates Hop aroma/flavour extraction is like making tea in cold water in a very large cup Extraction occurs at the boundary layer between the hops (tea) and beer (water) Saturation occurs at the boundary layer and inhibits further extraction in a stationary medium Extr
Slide 12: Hop settling patterns in large tanks
Hop settling patterns in large tanks Dis- Hop addition Extraction Hop removal aggregation Hop solids can settle to the tank bottom or float to the top – or both! Dosing level: 1,000 g/hl © Alfa Laval www.alfalaval.com
Slide 13: Process issues
Process issues Dis- Hop addition Extraction Hop removal aggregation Slugs of hop solids Blockages of lines, HEX, filters Carryover of solids Product losses Maturation beer during Near end of filtration ~2–3% Ending filtration → blockage filtration after Unplanned downtime/ 3–5 days Signifi
Slide 14: Solution: “Dynamic” dry hopping
Solution: “Dynamic” dry hopping More effective hops dispersion Faster and more efficient aroma/flavour extraction Shorter hop residence times Homogenization of hop particles during transfer Efficient separation of hops from beer Reduction of beer losses Reduction of process times © Alf
Slide 15: Dry hopping solutions
Dry hopping solutions Alfa Laval IMXD and Alfa Laval Alhop Alfa Laval IMXD integrated system Alfa Laval Alhop module Integrated in the fermentation/maturation vessels Skid-mounted system Hops are mixed within the main vessel Hops remain outside the main vessel For larger volumes (200–5,000
Slide 16: Solution 1: Alfa Laval Iso-Mix External Drive (IMXD)
Solution 1: Alfa Laval Iso-Mix External Drive (IMXD) Motor-driven Alfa Laval rotary jet mixer Tolerates high particulate loads Flexible hops introduction method Fast dispersion and flavour extraction Homogenization of feed to centrifuge Reduced hop residence time Reduced beer losses
Slide 17: Hop dispersion lab demo
Hop dispersion lab demo ½ minute 1 minute Addition of 5 kg hop pellets to 625 litres of water Fast disaggregation (swelling and slurrying) of the pellets Mixing in the liquid and extraction of the hop compounds 1½ minutes 2 minutes Water test conditions Recirculation at 200 hl/h and addition o
Slide 18: Alfa Laval IMXD system with hop slurry system
Alfa Laval IMXD system with hop slurry system Prepared hop slurry dosed into the tanks through the Alfa Laval IMXD loops during circulation © Alfa Laval Slide 18 www.alfalaval.com
Slide 19: Efficient hop removal and reduced losses
Efficient hop removal and reduced losses Homogeneous solids loading to the centrifuge inlet Complete removal of hops solids and regular discharge intervals Reduced losses means Sample of solids Pre-centrifuge less waste streams discharge → post centrifuge © Alfa Laval www.alfalaval.com
Slide 20: Homogeneous solids loading to the centrifuge
Homogeneous solids loading to the centrifuge Samples taken at the centrifuge inlet throughout the transfer. All samples have consistent solid concentrations. © Alfa Laval www.alfalaval.com
Slide 21: Discharge of hop solids from the centrifuge
Discharge of hop solids from the centrifuge Operation on haze control (turbidity at separator outlet) is optimal for automatic control If this control is not available, timed discharges should work Trial and error may be necessary to find the optimal discharge interval to provide appropriate s
Slide 22: Requirements for Alfa Laval IMXD implementation
Requirements for Alfa Laval IMXD implementation Removable/swing cone on tank Minimum 1-meter clearance below tank Tank volume typically > 150 hl Any method of hop addition suitable Control of hop dosing rate necessary Hop removal by centrifugation optimal Hop removal by sludge-out okay
Slide 23: Site installation of Alfa Laval IMXD on the fermenter
Site installation of Alfa Laval IMXD on the fermenter © Alfa Laval Slide 23 www.alfalaval.com
Slide 24: Customer results with Alfa Laval IMXD
Customer results with Alfa Laval IMXD Brand 1 Brand 2 Criterion Old method IMXD Old method IMXD Tank residence time 5–7 days 24-36 hours 7–10 days 24-36 hours (from end of ferment to filtration) Number of tanks used 4 2 4–5 2 Solids removed Solids removed through through Up to 10% Up to 15% centrifu
Slide 25: Summary: Dry hopping with Alfa Laval IMXD
Summary: Dry hopping with Alfa Laval IMXD Significant reduction in process No significant differences in beer time and energy consumption flavour Significant reduction in beer Potential for larger product batches losses and waste streams Potential for higher dry hop dosing Complete hop r
Slide 26: Solution 2: Dry Hopping System
Solution 2: Alfa Laval Alhop Dry Hopping System Skid-mounted system Dis- Hop addition Extraction Hop removal aggregation © Alfa Laval www.alfalaval.com
Slide 27: Alfa Laval Alhop Dry Hopping System: How it works
Alfa Laval Alhop Dry Hopping System How it works Hops in Beer out Beer in © Alfa Laval www.alfalaval.com
Slide 28: Alfa Laval Alhop Dry Hopping System: Overview
Alfa Laval Alhop Dry Hopping System Overview Upper drain / vent Hop inlet Beer outlet Air/CO2 inlet Drains Beer inlet © Alfa Laval www.alfalaval.com
Slide 29: Alfa Laval Alhop Dry Hopping System
Alfa Laval Alhop Dry Hopping System Dis- Hop addition Extraction Hop removal aggregation Status: clean and empty system CO2 © Alfa Laval www.alfalaval.com
Slide 30: Alfa Laval Alhop Dry Hopping System
Alfa Laval Alhop Dry Hopping System Dis- Hop addition Extraction Hop removal aggregation CO2 out Beer in © Alfa Laval www.alfalaval.com
Slide 31: Alfa Laval Alhop Dry Hopping System
Alfa Laval Alhop Dry Hopping System Dis- Hop addition Extraction Hop removal aggregation Dry hopped beer out Beer in © Alfa Laval www.alfalaval.com
Slide 32: Alfa Laval Alhop Dry Hopping System
Alfa Laval Alhop Dry Hopping System Dis- Hop addition Extraction Hop removal aggregation Dry hopped beer out Beer in © Alfa Laval www.alfalaval.com
Slide 33: Alfa Laval Alhop Dry Hopping System: Beer recovery
Alfa Laval Alhop Dry Hopping System Beer • Concentration recovery • Diafiltration © Alfa Laval www.alfalaval.com
Slide 34: Beer recovery – concentration
Alfa Laval Alhop Dry Hopping System Beer recovery – concentration CO2 addition Dry hopped beer out Closed beer in © Alfa Laval www.alfalaval.com
Slide 35: Beer recovery – diafiltration
Alfa Laval Alhop Dry Hopping System Beer recovery – diafiltration Vent surplus of CO2 addition Dry hopped beer and DAW out DAW addition © Alfa Laval www.alfalaval.com
Slide 36: Is hop recovery possible?
Alfa Laval Alhop Dry Hopping System Is hop recovery possible? © Alfa Laval www.alfalaval.com
Slide 37: Hop recovery
Alfa Laval Alhop Dry Hopping System Hop recovery DAW out DAW in © Alfa Laval www.alfalaval.com
Slide 38: Contact us
Contact us Click below and fill in the contact form. https://www.alfalaval.com/products/process-solutions/brewery-solutions/dry- hopping/contact-us/ © Alfa Laval Slide 38 www.alfalaval.com
Slide 39: More information
More information Dry hopping Beer production Alfa Laval IMXD Commercial brewing Alfa Laval Alhop Craft brewing © Alfa Laval www.alfalaval.com
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