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!

Measuring flow rate and original wort concentration for consistently high beer quality

From the brewery to the fermentation cellar – the flow, temperature and concentration of your beer needs to be measured continuously throughout the brewing process to guarantee consistent taste and alcohol content in every batch. Wort is boiled in the wort copper at temperatures of more than 80° Celsius, which denatures and settles the malt enzymes originally contained in the brew. The evaporation of water during boiling concentrates the wort to the original wort specific to each variety. The original wort is determined at the end of the boiling process. A heat exchanger cools the wort to the temperature required for adding yeast and it is then fed into the fermentation tank for fermentation.

Reliable system measurement and control

Your machines should reliably and economically keep brewing processes within the defined optimum efficiency ranges. Bürkert can provide you comprehensive support with development expertise and extensive product portfolio for liquid control, for example the FLOWave Type 8098 flow and concentration meter. The great advantage of this innovative flow meter: It combines two to three conventional sensors into one and measures the flow rate, original wort content, temperature and liquid properties throughout the brewing process. This allows you to reduce overall costs and intelligently automate processes.

The FLOWave Type 8098 measures the flow volume inline during the transport from one container to the next. FLOWave also detects differentiation factors and temperatures of the original wort, thus determining the concentration of the product in degree Plato. This automated and continuous measuring process ensures a constantly high level of reliability and product quality as well as lower media losses, all while making manual sampling superfluous.

Vereinfachte grafische Darstellung einer Brauereianlage; damit verknüpft Durchfluss- und Konzentrationsmesser FLOWave Typ 8098, dazu Durchfluss-Zeit-Diagramm; Symbole Sicherheit, Piktogramm Achtungzeichen an den Kurvenspitzen der Kennlinie, Symbol Stoppuhr

The FLOWave Type 8098 measures several parameters at the same time and transfers the parameters collected directly to the controller. With conventional solutions, measuring different parameters only works with two different devices interacting. As a result, the Bürkert solution saves you component costs, time for their parameterisation and even reduces the complexity of the system.

Grafische Darstellung Durchfluss- und Konzentrationsmesser FLOWave Typ 8098 mit Anbindung Schaltschrank SPS; dazu magnetisch-induktiver Durchflussmesser, Temperatursensor, Sensor für die Inline-Konzentrationsmessung, diese durchgestrichen; Symbol Produktivitätssteigerung

The FLOWave Type 8098 does not need any sensors in the measuring tube that come into contact with the medium. This ensures completely hygienic conditions when measuring flow rates. A range of certificates (3A and EHEDG) confirm this feature.

Frontale Fotografie Durchfluss- und Konzentrationsmesser FLOWave Typ 8098, dazu isometrische Darstellung mit Blick ins Innere; Pfeile, die die Fließrichtung anzeigen

Optimize energy consumption through efficient solutions for condensate measurement

The challenge every master brewer faces

The technical equipment in your brewery requires steam or hot water for brewing, pasteurisation, sterilisation, washing and cleaning. The challenge: Excessive energy consumption reduces profits and unnecessarily consumes resources. You can only work efficiently if you know the exact amount of energy for each step in the brewing process. By processing measurement data in a heat quantity calculator, you can receive real-time process data.

Why conventional condensate measurement methods have disadvantages

Conventional solutions consist of two temperature sensors in the supply and return lines, a flowmeter for steam and a heat quantity calculator. However, these components are complicated to install and the high temperatures cause them to wear more quickly.

Flow measurement with SAW technology is the solution

The FLOWave Type 8098 can measure the amount and temperature of condensate. If you optimise energy flow with these measurement results you can increase the efficiency of your plant – and improve your energy balance. The Bürkert FLOWave Type 8098 flow sensor measures not only flow rates but also the temperatures and wort gravity – thereby ensuring the beer keeps flowing with the known quality. Your production benefits: your brewing plants work all the more efficiently after optimisation. Since FLOWave measures liquids conductivity independently, you can also easily determine the amount of heat in condensate. This gives you a decisive advantage: with the Bürkert system solution you can identify and optimise the energy consumption of individual consumers in the production process.

8 reasons why your brewing plant works more efficiently with FLOWave

Regardless of the conductivity of the medium, FLOWave measures the volume flow with an accuracy of 0.4% of the measured value. The temperature tolerance here is less than 1 ° C.

FLOWave consists of a stainless steel tube. It does not require any sensors that come into contact with the medium and thus measures the flow in completely hygienic conditions. This is confirmed by various certificates. ASME BPE, 3A and EHEDG.

FLOWave devices utilise the Bürkert device platform EDIP. It facilitates handling of the devices and their integration into an existing fieldbus system. EDIP is our contribution to Industry 4.0.

Compact and lightweight, the flow meter fits into any system and is easy to install. A FLOWave device measures just two inches in size and weighs 3.4 kg. By way of comparison: A two-inch Coriolis system weighs 70 kg.

FLOWave measures the differentiation factor and therefore detects changes to the fluid very quickly. This simplifies the separation of production steps and makes your system more productive.

The high-resolution 2.4" display offers flexible operation with intuitive, graphic user guidance. Freely definable measured value names and the ability to optionally display one to four measured values, a trend curve and the configuration interface allow for a customized display. The WLAN module also allows you to access measurement parameters remotely using a web browser. This is useful when FLOWave is mounted at inaccessible points in the process.

In addition to the flow rate, FLOWave also measures the differentiation factor and temperature – to ensure you always have your wort gravity under control. Since FLOWave measures liquids conductivity independently, you can also measure condensate. Thanks to the “acoustic transmission factor” function, FLOWave even detects changes in condensate that could indicate possible cracks in your heat exchanger.

FLOWave is installed in the condensate line. At this point in the process the flowmeter is exposed to much lower temperatures than in the steam line. In other words: no wear at high temperatures. The solution also requires little maintenance and offers a long service life.

Measure original wort continuously to save time and money

Conventional flow rate sensors are unable to measure original wort concentration. As such, master brewers have to collect samples manually, cool the samples and use a hydrometer to measure the wort – twice per batch on average. With FLOWave, you can automatically measure the flow rate and original wort concentration as the beer flows, thereby easily enhancing the efficiency of your brewing plant.

System with manual measuring method System with continuous automated measurement

Condensate: Discover your savings potential!

Conventional solutions are often complicated to install and entail very high purchasing costs. Instead of having a flow sensor, a heat quantity calculator and two temperature sensors, you can simply install FLOWave.

Schematische Darstellung Würzepfanne mit Peripherie Durchflusssensor, Wärmemengenrechner und zwei Temperatursensoren; Piktogramm FLOWave Typ 8098, Symbol Kreis aus vier gebogenen Pfeilen, Symbol Sparschwein, Betrag in Ziffern 1200 Euro

Installed on the condensate line, this compact solution alongside a temperature sensor in the steam line reliably detects your energy quantities – as well as potential impurities caused by possible cracks in the heat exchanger. In addition to energy efficiency, we do everything to ensure that your plant enjoys a long service life.

Videos on operation and more

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

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