Precision cooling is an integral part of the production and distillation process. The quality and integrity of finished products depend on careful temperature control and reduction during key stages of brewing operations. Key aspects of production include:
Must cooling and chilling requirements
During the initial stages of preparation, the wheat grains are ground to form flour. Flour is transferred to the wort and heated water is added. During wort conversion, natural enzymes in the ground meal break down malt starch into fermentable sugars. The wort is then pumped into the filtration vat where a sweet liquor (wort) is separated from the grind.
The wort is transferred to a kettle and heated to a controlled boiling temperature of about 60°C before introducing the hops. After the boiling stage, residual malt and hop particles are removed.
While the wort is still hot, it is rapidly cooled for the following reasons:
- must is susceptible to oxidative damage if allowed to cool slowly. Rapid cooling reduces oxidative damage while minimizing unwanted flavors in the product.
– Traces of dimethyl sulfide (DMS) develop from the must during the heating phase. DMS has a low boiling point and evaporates from the hot wort. When the wort is cooled, DMS is still produced. Slow cooling allows DMS to accumulate due to limited boiling in the infusion. High levels of DMS in beer and lager can add unpleasant flavors and contaminate beer. Rapid cooling of the wort to about 25°C minimizes oxidation and MSD levels while improving the flavor profile of the final beverage.
– Rapid cooling reaches a cold pause. Proteins are heat shocked and precipitated from the must. A lack of rapid cooling can result in an icy haze in the finished product. Residual protein may precipitate when the product is cooled before consumption. This is often considered undesirable especially if the product is to be clear.
The diagram below shows key aspects of the brewing process (click to enlarge).
How is wort cooling achieved?
Most breweries pass the wort through a one- or two-stage plate heat exchanger to achieve cooling. The application is demanding; a significant thermal load must be quickly removed from the process. A mixture of glycol water in the water circuit is common to provide increased cooling capacity. A double-walled food heat exchanger is generally selected to prevent contamination problems between the wort and the cooling fluid.
When sizing a chiller for wort cooling, it is important to consider the following aspects:
– Total volume of wort to be cooled (often quoted in BBL / barrel volumes).
– Desired knock out time (cooling time required to optimize the process).
– Initial must temperature and desired final must temperature.
– Will the chiller also provide cooling capacity for other brewing processes?
Temperature control during fermentation
Providing the useful cooling capacity of a precision chiller is important during fermentation. The chiller must regulate the fermentation temperature to prevent product spoilage. In some cases, the brew is also cooled rapidly at the end of fermentation to promote yeast flocculation.
During the fermentation stage, the must is generally transferred to cylindrical stainless steel vessels (CCVs). Brewer’s yeast is added to the sugary wort when the vessel is filled to begin fermentation. Sugars in the must are converted to alcohol and CO2 along with other compounds that add flavor.
Fermentation is an exothermic process and can release a considerable amount of heat. This heat must be controlled to protect the integrity of the beverage. Temperature control is important for the following reasons:
Different yeast strains possess an optimal fermentation temperature range that must be maintained to optimize fermentation.
- Exposure to excessive heat results in the formation of fusiform alcohols and esters that can adversely affect the flavor of the product.
- Excess heat in the later stages of fermentation increases the yeast’s sensitivity to acetic and lactic acid resulting in reduced alcohol yield.
- Rapid cooling at the end of fermentation is used in some processes. The beer is cold-crushed through rapid cooling to assist yeast flocculation, resulting in a clear product before conditioning.
When sizing a fermentation chiller, the following points should be considered:
- The volume of the infusion/fermentation vessel (total kW heat load).
- Optimal temperature range required for fermentation.
- Will a cold crash be employed at the end of fermentation?
- Other processes will also be cooled, such as cooling the wort
Bottling and filling
In some processes, beer and lager are cooled in the final stages of conditioning and filtering. This is often done to improve product clarity and stability. In larger breweries, temperature is often monitored and controlled during bottle and keg filling. It may be necessary to control excess heat from bottling machines to protect the integrity of the final product.
Cooling in the distillation process
Precision water coolers are vital in the production of high-quality alcohol. Several steps in alcohol production depend on maintaining a constant temperature and removing excess heat. The initial stages of whiskey and liquor production mirror those of the brewing process. Further distillation and conditioning steps follow fermentation to produce the final product.
A typical process for whiskey production is shown in the diagram below (click to enlarge):
Precision water chillers are often used in the following processes during the production of whiskey and other spirits:
– Cooling the must before fermentation.
– Fermentation temperature control and rapid cooling.
– Cold filtration before bottling.
Cold filtration
Unfiltered whiskey with an ABV of 46 percent or less can often form sediment in the bottle if stored in a cool place. The drink can also take on a cloudy appearance by adding water or ice before consumption. These cosmetic factors are considered undesirable in quality products. Natural fatty acids, esters and proteins may be present in whiskey during distillation in addition to being imparted by the cask during maturation. These components flocculate and precipitate out of the whiskey when it is chilled.
Cold filtration is used to prevent the above problems. The process involves lowering the temperature of the whiskey to 0°C for malts (-4°C for blends). Once cooled, the whiskey is passed through a series of tightly woven wire mesh or paper filters under pressure. During this process, the precipitate and any other sediment or impurities from the barrel (charcoal) are removed.
As with other fermentation processes, a food heat exchanger is used to manage cooling.
Why choose Parker?
Process Chillers in the series – Hyperchill and Hyperchill Plus Process Chillers – from Parker Hannifin provide safe and reliable operation under different working conditions such as those typical of the brewing and distilling industries, helping owners and operators maintain the integrity of the final product and reduce cost of ownership.
Parker’s product design features can offer significant benefits to end users in the brewing and distilling industry.
Key features and benefits include:
– The configuration of the generously sized internal water tank coupled with an oversized condenser/evaporator enables the chiller to maintain cooling capacity even during rapid loading and water temperature changes.
– High reliability with energy management to reduce total cost of ownership.
– Low water temperature options (down to -10°C) available for enhanced cooling.
– The stainless steel panel and high IP rating allow easy use in wet brewing environments. – Fully compatible chillers using glycol/water mixtures for demanding applications such as wort cooling.
This article was written with contributions from:
Fabio Bruno
Compressed Air Purification, Gas Generation & Process Cooling Application Engineer
Region South EMEA
If you liked this article perhaps you might also be interested:
How compressed air redefines bottling processes
How to reduce costs and ensure maximum safety in the dairy industry
The Advantages of Self-Production of Nitrogen in Dairy and Dairy.
Precision cooling is an integral part of the production and distillation process. The quality and integrity of finished products depend on careful temperature control and reduction during key stages of brewing operations. Key aspects of production include:
Must cooling and chilling requirements
During the initial stages of preparation, the wheat grains are ground to form flour. Flour is transferred to the wort and heated water is added. During wort conversion, natural enzymes in the ground meal break down malt starch into fermentable sugars. The wort is then pumped into the filtration vat where a sweet liquor (wort) is separated from the grind.
The wort is transferred to a kettle and heated to a controlled boiling temperature of about 60°C before introducing the hops. After the boiling stage, residual malt and hop particles are removed.
For more information on the cooling process in brewing and distilling applications, as well as refrigeration system operation and design guidelines, please click to access the interactive presentation tool.
While the wort is still hot, it is rapidly cooled for the following reasons:
must is susceptible to oxidative damage if allowed to cool slowly. Rapid cooling reduces oxidative damage while minimizing unwanted flavors in the product.
– Traces of dimethyl sulfide (DMS) develop from the must during the heating phase. DMS has a low boiling point and evaporates from the hot wort. When the wort is cooled, DMS is still produced. Slow cooling allows DMS to accumulate due to limited boiling in the infusion. High levels of DMS in beer and lager can add unpleasant flavors and contaminate beer. Rapid cooling of the wort to about 25°C minimizes oxidation and MSD levels while improving the flavor profile of the final beverage.
– Rapid cooling reaches a cold pause. Proteins are heat shocked and precipitated from the must. A lack of rapid cooling can result in an icy haze in the finished product. Residual protein may precipitate when the product is cooled before consumption. This is often considered undesirable especially if the product is to be clear.
The diagram below shows key aspects of the brewing process (click to enlarge).
How is wort cooling achieved?
Most breweries pass the wort through a one- or two-stage plate heat exchanger to achieve cooling. The application is demanding; a significant heat load must be quickly removed from the process. A mixture of glycol water in the water circuit is common to provide increased cooling capacity. A double-walled food heat exchanger is generally selected to prevent contamination problems between the wort and the cooling fluid.
When sizing a chiller for wort cooling, it is important to consider the following aspects:
– Total volume of wort to be cooled (often quoted in BBL / barrel volumes).
– Desired knock out time (cooling time required to optimize the process).
– Initial must temperature and desired final must temperature.
– Will the chiller also provide cooling capacity for other brewing processes?
Temperature control during fermentation
Providing the useful cooling capacity of a precision chiller is important during fermentation. The chiller must regulate the fermentation temperature to prevent product spoilage. In some cases, the brew is also cooled rapidly at the end of fermentation to promote yeast flocculation.
During the fermentation stage, the must is generally transferred to cylindrical stainless steel vessels (CCVs). Brewer’s yeast is added to the sugary wort when the vessel is filled to begin fermentation. Sugars in the must are converted to alcohol and CO2 along with other compounds that add flavor.
Fermentation is an exothermic process and can release a considerable amount of heat. This heat must be controlled to protect the integrity of the beverage. Temperature control is important for the following reasons:
Different yeast strains possess an optimal fermentation temperature range that must be maintained to optimize fermentation.
Exposure to excessive heat results in the formation of fusiform alcohols and esters that can adversely affect the flavor of the product.
Excess heat in the later stages of fermentation increases the yeast’s sensitivity to acetic and lactic acid resulting in reduced alcohol yield.
Rapid cooling at the end of fermentation is used in some processes. The beer is cold-crushed through rapid cooling to assist yeast flocculation, resulting in a clear product before conditioning.
When sizing a fermentation chiller, the following points should be considered:
The volume of the infusion/fermentation vessel (total kW heat load).
Optimal temperature range required for fermentation.
Will a cold crash be employed at the end of fermentation?
Other processes will also be cooled, such as cooling the wort
Bottling and filling
In some processes, beer and lager are cooled in the final stages of conditioning and filtering. This is often done to improve product clarity and stability. In larger breweries, temperature is often monitored and controlled during bottle and keg filling. It may be necessary to control excess heat from bottling machines to protect the integrity of the final product.
Cooling in the distillation process
Precision water coolers are vital in the production of high-quality alcohol. Several steps in alcohol production depend on maintaining a constant temperature and removing excess heat. The initial stages of whiskey and liquor production mirror those of the brewing process. Further distillation and conditioning steps follow fermentation to produce the final product.
A typical process for whiskey production is shown in the diagram below (click to enlarge):
Precision water chillers are often used in the following processes during the production of whiskey and other spirits:
– Cooling the must before fermentation.
– Fermentation temperature control and rapid cooling.
– Cold filtration before bottling.
Cold filtration
Unfiltered whiskey with an ABV of 46 percent or less can often form sediment in the bottle if stored in a cool place. The drink can also take on a cloudy appearance by adding water or ice before consumption. These cosmetic factors are considered undesirable in quality products. Natural fatty acids, esters and proteins may be present in whiskey during distillation in addition to being imparted by the cask during maturation. These components flocculate and precipitate out of the whiskey when it is chilled.
Cold filtration is used to prevent the above problems. The process involves lowering the temperature of the whiskey to 0°C for malts (-4°C for blends). Once cooled, the whiskey is passed through a series of tightly woven wire meshes or paper filters under pressure. During this process, the precipitate and any other sediment or impurities from the barrel (charcoal) are removed.
As with other fermentation processes, a food heat exchanger is used to manage cooling.
Why choose Parker?
The series-Parker Hannifin’s Hyperchill and Hyperchill Plus Process Chillers-provide safe and reliable operation under different working conditions such as those typical of the brewing and distilling industries, helping owners and operators maintain the integrity of the final product and reduce cost of ownership.
Parker’s product design features can offer significant benefits to end users in the brewing and distilling industry.
Key features and benefits include:
– The configuration of the generously sized internal water tank coupled with an oversized condenser/evaporator enables the chiller to maintain cooling capacity even during rapid loading and water temperature changes.
– High reliability with energy management to reduce total cost of ownership.
– Low water temperature options (down to -10°C) available for enhanced cooling.
– The stainless steel panel and high IP rating allow easy use in wet brewing environments. – Fully compatible chillers using glycol/water mixtures for demanding applications such as wort cooling.
For more information about the cooling process in brewing and distilling applications, as well as Hyperchill system operation and design guidelines, just click to view the interactive tool.
This article was written with contributions from:
Fabio Bruno
Compressed Air Purification, Gas Generation & Process Cooling Application Engineer
Region South EMEA
If you liked this article perhaps you might also be interested:
How compressed air redefines bottling processes
How to reduce costs and ensure maximum safety in the dairy industry
The Advantages of Self-Production of Nitrogen in Dairy and Dairy.
Parker Hannifin | Parker Hannifin