Inline flow and concentration measurement for soft drink production

Beverage mixing systems, for example for soft drink production, need to be able to guarantee the perfect balance between output, safety and taste. Impurities also need to be ruled out completely. To monitor and control this consistent mixture, your plants need components and systems that can continuously and accurately monitor liquids under hygienic conditions. This is the only way to ensure consistently high product quality from your systems, save overall costs and utilise the potential for automating manual processes.

Demanding cleaning processes in soft drink production

Different beverages are often produced in one plant with a mixing system. After each batch process the pipelines are thoroughly flushed with cleaning fluid. This change of media between beverage production and cleaning cycle (CIP) must be reliably identified in the production process. Otherwise, large quantities of rejects can result from unintentional mixture of cleaning agents and product.

Continuous media control in the batch process

The quantities of different media used must also be continuously controlled in ongoing batch processes in order to guarantee consistent taste and the desired product quality.

It is important to accurately measure volume flow at different points when making soft drinks, as deviations in the recipe can lead to changes in taste. The desired concentration – measured in degrees Brix – must always be maintained and documented.

Grafische Darstellung eines Teils einer Getränkeproduktion mit Tanks, Mischtank und Rohren; herausgehoben dargestellt sind zwei Sensoren, ein Haufen Zuckerwürfel, dazwischen Piktogramm Achtungzeichen

Hygiene plays a decisive role in beverage production: After each media change in the batching system, the pipelines are thoroughly rinsed with CIP media. No residues can remain in the pipes, neither from the previously used liquids nor from the cleaning agents. These would mix with the beverage being subsequently produced. The result would be disposing of the product, which costs time and money.

Grafische Darstellung eines Sensors für die Inline-Konzentrationsmessung, Messfühler, Abschnitt der zugehörigen Rohrleitung; Darstellung Verschmutzung, Mikroorganismen

In conventional systems it usually takes multiple components to measure flow and concentration. The individual components need to be correctly coordinated and parameterised during start-up.

Electromagnetic flow meters often don’t do the job because demineralised water with low conductivity is used in some formulas. Installing inline sensors for concentration measurement is also not ideal. This is because they are expensive and difficult to integrate into production plants due to their size.

Grafische Darstellung eines Tanks mit Rohrleitung und dort integrierten Inline-Sensoren, zwei Technikern, Sprechblasen mit Fragezeichen, Piktogrammen Achtungzeichen

Sicher und automatisiert

The FLOWave Type 8098 measures flow, temperature and differentiation factor in soft drink production plants. To do this, it evaluates the acoustic transmission factor of different liquids. That allows it to quickly, precisely and automatically detect media changes upstream of the mixing tank. Downstream of the mixing tank, the FLOWave Type 8098 determines the exact Brix value. The result: constant product quality monitoring and successful avoidance of rejects. In addition, the FLOWave type 8098 can be integrated into any fieldbus network.

The FLOWave type 8098 provides the required measured values and transmits the collected parameters directly to the PLC. The system operator then conveniently reads out the values via the PLC. This eliminates the need for regular manual sampling – for example after each batch. The FLOWave Type 8098 ensures high measurement accuracy and high reproducibility.

Grafische Darstellung eines FLOWave Typ 8098, verkabelt mit Schaltschrank SPS; dazu Diagramm, welches Zuckergehalt, Temperatur, Dichte sowie den Ablauf von Spülvorgängen über die Zeit abbildet

Sugar content

Rinsing processes

Temperature

Density

Time

Due to its compact dimensions and light weight, the FLOWave Type 8098 flow meter can be excellently integrated into the plant design and easily installed. Different weight with the same flow rate: At just two inches in size, the flow meter weighs only 3.4 kg. By way of comparison: A Coriolis system of the same size can weigh up to 70 kg.

Gegenüberstellung: Links grafische Darstellung Coriolis-System mit der Angabe 70 kg und der dazu korrespondierenden Menge von sechs Getränkekisten; rechts grafische Darstellung Durchflussmesser FLOWave Typ 8098 mit der Angabe 3,4 kg und der dazu korrespondierenden Menge einer zur Hälfte gefüllten Getränkekiste

The FLOWave Type 8098 also masters the reliable interface determination between product and water / cleaning agents when changing between production and the rinsing phase (CIP). In doing so, it detects the change of medium very precisely by measuring the differentiation factor and not the density value, like conventional measuring instruments. This is because the density value of an alcohol-sugar mixture is very similar to that of water, at 1.00 g/cm³. By comparison, the differentiation factor differs more significantly at 1.03 g/cm³.

Grafische Darstellung eines FLOWave Typ 8098, transparent dargestellt; Wechsel der Farbe des durchfließenden Mediums von orange zu blau. Piktogramm einer orangefarbenen Flasche sowie eines Wasserhahns. Jeweils dazu Darstellung des Displays des FLOWave mit dem Betrag des Dichtefaktors in Ziffern. Symbol Kreis aus zwei gebogenen Pfeilen

Why is it important to determine the differentiation factor?

The FLOWave Type 8098 continuously determines differentiation factor, in addition to flow rates. This is a temperature-compensated measured value. If it changes, the Bürkert solution recognises that another fluid is flowing. By sending the corresponding information to the connected PLC, valves can then be controlled so that they close at the end of a batch process, for example. This fast and precise measuring avoids rejects and increases efficiency.

Learn more about how FLOWave detects media changes:

FLOWave: Detecting media changeover

The pipeline has to be rinsed with cleaning fluid after each batch process. This causes product rejects. Discover how FLOWave flowmeter reduces rejects and increases plant efficiency.

More profit by quickly identifying media changes

100 litres of liquid per minute flow through a DN50 pipeline. In conventional plants, the media changeover is time-controlled; due to the tolerance, the valve to the drain opens 15 seconds too early. Five media changes a day produce around 125 litres of waste. The FLOWave Type 8098 detects media changes faster and sends a message to the valve, which switches 10 seconds earlier – all of which protects your resources and budgets.

Videos on operation and more

Installation and operation made easy: Here you will find a large selection of videos on the FLOWave type 8098.

Measuring original wort and condensate effectively and efficiently

A familiar taste is one of the most important criteria of your beer brand. To ensure the high level of quality remains the same for every batch, you need to carefully check the original wort content during the brewing process. To work efficiently, you also need to know how much energy you actually need for your brewing process. This is, for example, indicated by the condensate that is produced when the original wort is heated with steam in the brew kettles. Find out how you can measure condensate and original wort with just one device, make your brewing process more efficient and at the same time save valuable time and energy!

FLOWave SAW flowmeter

Type 8098

No obstacles inside the measuring tube, compact, lightweight and low energy consumption
Conforms to hygienic requirements, CIP/SIP compatible
Ideal for liquids with low or no conductivity
Digital communication, parameterisation via Communicator, display
Optional: ATEX/IECEx certification, II 3G/D

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Inline flow and concentration measurement for soft drink production

Demanding cleaning processes in soft drink production