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Biological and Chemical Detection in
the Brewing Industry
Submitted by:
David Jones
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.
Brewing Process
• Malting – Barley is adjusted and kilned
• Milling – Exposes the starchy center
• Mash – Conversion of starch to sugar by alphaamylase 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.
Flavor Aspects
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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)
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
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.
Automation PLC
(Automationdirect)
Programmable Logic Controller
Automation PLC
(Automationdirect)
Relay Out
Automation PLC
(Automationdirect)
Ladder
Programming
View
Automation PLC
(Automationdirect)
Drum Programming
Automation PLC
(Automationdirect)
PID loops
Brewery Sensors
Dissolved Oxygen
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On Line
Response time < 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
Carbon Dioxide
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On Line
Response time <60 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
Dissolved Carbon Dioxide
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At-Line
Response time < 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
pH no-Glass
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On-line
Response time < 90 seconds
Interoperable: yes – standard VP connection
Performance: pH 0 ~14, 0 ~ 80°C
Gel electrolyte, Argenthal electrode, Temperature
Location: Mash tanks, Fermentation Tanks,
Maturation, Packaging
Mettler Toledo
Glucose/Alcohol Electrode
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On-Line
Response time < 2 Minutes
Interoperable: yes small voltage, BNC connector
Reproducibility ~ 3%
Location: Mash, Fermentation, Packaging
Universal Sensors Inc.
Yeast Monitor
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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
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
Protein and Polyphenol Detection
via Surface Plasma Resonance
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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
Gram Negative/ Gram Positive
Bacteria Contamination
• Gram Negative
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Acetic Acid Bacteria
Pectinatus cervisiiphilus
Enterobacteriaceae
Zymomonas
Pectinatus frisingensis
Selenomonas Lacticifex
Zymophilus raffinosivorans
Zymophilus paucivorans
Megaspaera
• Gram Positive
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Lactobacillus
Lactic Acid bacteria
Pediococcus
Leuconostoc
Homofermentative cocci
Kocuria, Micrococcus and
Staphylococcus
– Endospore-forming bacteria
Biolog’s G+/G- Yeast detection
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Off-Line – Rapid detection
Standalone System (the rest)
MicroPlate ~ 96 different Chemical Substrates
G+ >310; G- >500; Yeast >265
< 5 min Hand prep
Photo-Optical (density)
Automated database
Location: Through-out
Biotrace’s ATP Bioluminescence
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All in one Test Kit: swabbing
Off Line: Cleanliness Check
ATP enzyme-driven light emissions
Response time < 30 secs
Measures light output (luminometer) or living
cells
Location: Throughout
Specs:<150 RLU (pass)
>300 RLU (Fail)
Tanks, Valves, Doors…
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 beerspoilage bacteria.
• Subspecies of:
– Pediococcus
– Lactobacillus
Qualicon/DuPont’s RiboPrinting
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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.
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.
Conclusions
• Sensing and conditioning a signal is only
half of the process.
– Act and React: Interoperable with existing
systems
• Overarching Control Scheme
• Manufacturing Procedures
Any Questions?