注目情報

TFF technology increases yield and reduces waste streams

Breweries using Pall’s KerafluxTM Tangential Flow Filtration (TFF) technology increase yield and reduce waste streams

Overview

Up to 80% of the extract contained in the surplus yeast that collects at the bottom of tanks after fermentation and maturation can now be recovered rather than disposed of. Beer can be recovered and blended back into the brewing process at a ratio of up to 5% without negatively influencing the beer quality, increasing the yield and reducing the total beer volume needing to be produced. This represents a lower CO2 footprint, reduced water usage, and a lowering of production costs, plus the minimized waste stream reduces disposal costs and ensures a lower level of BOD’s and COD’s are returned back into the environment.

 

High quality yeast (accrued as a byproduct of beer recovery) can be recovered and sold to other industries such as the cosmetic, pharmaceutical or animal feed industries. The benefits of recovery result in increased brewery profitability, lower environmental impact, reduced use of valuable resources and a very short and attractive ROI on the equipment used to achieve it.

 

The Challenge

A brewery with an annual production capacity of 4,000,000 hl wanted to reduce production costs. A volume of approximately 500 hl of surplus yeast collected per day at the bottom of the tanks after fermentation and maturation. With 250 production days per year this equated to a total volume of 125,000 hl, equivalent to more than 3% of the brewery’s annual beer production. If recovered this yeast beer mixture offered the potential to increase the yield and reduce the overall production costs. An additional target benefit for the brewery was to reduce the burden on the environment and save valuable resources.

 

The Solution

Pall installed a Keraflux-TFF (Tangential Flow Filtration) System for yeast management using 3 x 2 Membralox® HCB series multi-channel ceramic membranes. The surplus yeast from production had an average ratio of 50% fermentation yeast to 50% maturation yeast. Approximately 500 hl of the mixture was held in a 1,200 hl tank, having a dry matter of approx. 11% and an extract of approx. 11.5° Plato, cooled to 5 °C and stored under CO2 pressure of 1.2 bar. To recover the beer the mixture was fed into the Keraflux TFF system at a constant flow at 9°C, controlled by a chiller.

 

For increased energy efficiency the pumps were frequency controlled, starting at approximately 50% of the maximum frequency. Filtration stops when the filtrate flux falls below 50% of the initial flow of 15 hl/h or if the dry matter reaches a value between 17% and 20%, which is yeast specific. Usually filtration stops by reaching the dry matter concentration. The flux is mostly constant due to the high degree of automation and control mechanisms. During the complete filtration process neither intermediate cleaning nor back flushing is necessary. Each filtration cycle lasts about 21 hours after which time a 2 hour cleaning process takes place (Includes one step: NaOH of 80°C and a concentration of 2 - 3%). An additional weekly clean with 1% HNO3 and 0.5% membrane cleaner is also conducted.

 

Beer recovery process

In a detailed example, 472 hl yeast beer mix with an initial dry matter of 10.8 % was filtered. 252 hl of beer was recovered from this mixture and blended back into the production process. The high quality of the recovered beer allows it to be blended directly back into the process without further filtration. When using other technologies such as centrifuges for beer recovery, the beer has to be blended back into the process prior to fermentation. For optimal utilization of this technology the beer should be blended back into the process as late as possible.

 

As a byproduct of the beer recovery, 220 hl of high quality yeast with a dry matter of 17.5% was recovered. This value was consciously chosen by the brewery as the yeast should be in a good condition to be pumped. The target was to reach values above 16% dry matter and a beer quality turbidity value below 0.7 EBC at 90°. One hl of recovered beer is calculated by the brewery to be worth 10€. With an average 250 hl of beer recovered per day operating 250 production days per year, the brewery can recover 62,500 hl beer; a cost benefit of 625,000€ per year. Under these brewery specific circumstances this resulted in a very attractive ROI of 1.2 years. As the system is fully automated, no additional operators were employed. The system fully satisfies the customer requirements and helps him increase the yield and reduce his environmental impact.

 

Another brewery with the same process optimization intentions used high gravity brewing enabling Pall to use diafiltration to increase the yield of the overall process. Diafiltration is the process of adding water to the surplus yeast to increase extract and alcohol recovery by a wash out effect. The advantage of this method is that it achieves a high recovery rate. The whole process follows a fully automated procedure.

 

Separation starts without adding water until the dry matter is at 14% when diafiltration begins. The whole process is controlled by the measurement of the ° Plato and ends at a defined brewery specific value. Using diafiltration the yield can be increased up to 80%. The aim of this brewery was to reduce the yeast levels and to recover more beer. In a detailed example, 460 hl of yeast beer mix with 15.5° Plato were filtered. With diafiltration and the wash out effect by adding water, 564 hl with 10.1 ° Plato could be recovered, equivalent to an extract yield of 80%.

 

The Benefits

Using the Keraflux-TFF System for yeast management, breweries can significantly reduce their processing costs, use less resources such as water and lower their overall impact on the environment. The examples given above showed the following benefits:

 

  • Up to 80% extract recovery
  • High quality beer for back blending prior to filtration
  • Turbidity of recovered beer at 90° below 0.7 EBC
  • Reduction of total production volumes by 1.6%
  • Reduced CO2 and water footprint
  • Reduced waste stream
  • Reduced disposal costs
  • Reduced BOD’s and COD’s returned to the environment
  • High quality yeast for sale with 17.5% dry matter
  • Attractive equipment ROI of 1.2 years

 

Food and Water Contact Use

Please contact Pall Corporation for product applicability to specific National legislation and Regional regulatory requirements for food and water contact use.

 

About Pall Corporation

Pall Corporation is the largest and most diverse filtration, separation, and purification company in the world. Pall serves the food and beverage industries with advanced membrane filtration technology and systems engineered for reliability and cost-effectiveness. Easy to install and simple to use, our systems satisfy a wide range of filtration requirements. Our Total Fluid Management approach offers customers solutions to address the needs of an entire process, encompassing filtration products, services, systems and training.

TFF Technology Increases Yield and Reduces Waste Streams

Up to 80% of the extract contained in the surplus yeast that collects at the bottom of tanks after fermentation and maturation can now be recovered rather than disposed of. Beer can be recovered and blended back into the brewing process at a ratio of up to 5% without negatively influencing the beer quality, increasing the yield and reducing the total beer volume needing to be produced. This represents a lower CO2 footprint, reduced water usage, and a lowering of production costs, plus the minimized waste stream reduces disposal costs and ensures a lower level of BOD’s and COD’s are returned back into the environment.
Up to 80% of the extract contained in the surplus yeast that collects at the bottom of tanks after fermentation and maturation can now be recovered rather than disposed of. Beer can be recovered and blended back into the brewing process at a ratio of up to 5% without negatively influencing the beer quality, increasing the yield and reducing the total beer volume needing to be produced. This represents a lower CO2 footprint, reduced water usage, and a lowering of production costs, plus the minimized waste stream reduces disposal costs and ensures a lower level of BOD’s and COD’s are returned back into the environment.
詳細を見る

Craft Brewery Preserves Image and Limits Losses

Although beer is restrictive to bacterial growth due to its low pH, ethanol concentration, and low oxygen content, the presence of certain beer spoilage bacteria including Lactobacillus, Pediococcus, Pectinatus, and Megasphaera can generate off-flavors, turbidity and acidity. Such quality deficiencies render the product unacceptable and often result in high economic losses and negative brand image. Throughout the production process, undesirable microbial contamination must be prevented to achieve the required final beer quality. Such contamination may originate from ingredients (including yeast), air and water utilities coming into contact with the product, and the environment.
Although beer is restrictive to bacterial growth due to its low pH, ethanol concentration, and low oxygen content, the presence of certain beer spoilage bacteria including Lactobacillus, Pediococcus, Pectinatus, and Megasphaera can generate off-flavors, turbidity and acidity. Such quality deficiencies render the product unacceptable and often result in high economic losses and negative brand image. Throughout the production process, undesirable microbial contamination must be prevented to achieve the required final beer quality. Such contamination may originate from ingredients (including yeast), air and water utilities coming into contact with the product, and the environment.
詳細を見る

Pall Aria™ System Rescues Bottled Spring Water Producer from Plant Closure

Spring water is a valuable natural resource, which requires good purification treatment before appearing on grocery store shelves as high purity, visually pleasing bottled product. Filtration is a key process step required to achieve consistently high product quality. The costs associated with filtration may be substantial, depending on source water quality. Disposable filters are a technically sound solution but their use may become economically unsustainable in the face of difficult or variable quality source water.
Spring water is a valuable natural resource, which requires good purification treatment before appearing on grocery store shelves as high purity, visually pleasing bottled product. Filtration is a key process step required to achieve consistently high product quality. The costs associated with filtration may be substantial, depending on source water quality. Disposable filters are a technically sound solution but their use may become economically unsustainable in the face of difficult or variable quality source water.
詳細を見る

Microflow System Offers 10 Months Payback in Cheese Brine Purification

Salting by immersion in brine is used for many varieties of cheese worldwide. During repeated immersions fat, curd particles and microorganisms from the cheese plus the accumulation of proteins and other components builds up a nutrient-rich environment for the salt resistant microorganisms. Reused brine may then become a reservoir of unwanted microorganisms, such as gas- or pigmentproducing bacteria, yeast and mold, or salt resistant pathogens, cross-contaminating the cheese and impacting their quality. Good control of the brine and the brining operation is essential to ensure consistent daily production. Additionally, brine disposal is coming under increasing focus. High disposal costs or volume limitations in specific areas are driving the demand for greater brine reuse, to generate operating cost savings and minimize the plant environmental footprint.
Salting by immersion in brine is used for many varieties of cheese worldwide. During repeated immersions fat, curd particles and microorganisms from the cheese plus the accumulation of proteins and other components builds up a nutrient-rich environment for the salt resistant microorganisms. Reused brine may then become a reservoir of unwanted microorganisms, such as gas- or pigmentproducing bacteria, yeast and mold, or salt resistant pathogens, cross-contaminating the cheese and impacting their quality. Good control of the brine and the brining operation is essential to ensure consistent daily production. Additionally, brine disposal is coming under increasing focus. High disposal costs or volume limitations in specific areas are driving the demand for greater brine reuse, to generate operating cost savings and minimize the plant environmental footprint.
詳細を見る

Distillers Improve Quality While Reducing Operating Costs with SUPRApak™ Technology

Filtration of spirits can be a challenging task. It is essential to remove contaminants that may cause turbidity while retaining the quality enhancing components in the product. Filter sheets are the traditional method for achieving this delicate balance. Sheets are comprised of a unique matrix of materials that provide an excellent combination of adsorption and depth filtration, making them an ideal solution for turbidity reduction and haze removal in spirits. Filter sheets are available in multiple grades to cover a wide range of applications from filtration of cordials to chill haze reduction in brown spirits to particle removal in white spirits. Additionally many plate and frame filter units have the flexibility to add or remove sheets to suit the batch size, flow rate or the specific product to be filtered.
Filtration of spirits can be a challenging task. It is essential to remove contaminants that may cause turbidity while retaining the quality enhancing components in the product. Filter sheets are the traditional method for achieving this delicate balance. Sheets are comprised of a unique matrix of materials that provide an excellent combination of adsorption and depth filtration, making them an ideal solution for turbidity reduction and haze removal in spirits. Filter sheets are available in multiple grades to cover a wide range of applications from filtration of cordials to chill haze reduction in brown spirits to particle removal in white spirits. Additionally many plate and frame filter units have the flexibility to add or remove sheets to suit the batch size, flow rate or the specific product to be filtered.
詳細を見る

Fermentation Broth Clarification Systems for Food and Feed Ingredients Manufacturing

Producers of bulk food and feed ingredients such as amino acids, organic acids, and vitamins use fermentation as the basis of their production. Today’s modern industrial biotechnology processes use carefully selected and purified microbial cell cultures to produce an ever-increasing variety of ingredients and increase productivity. During fermentation, the microorganisms multiply in industrial bioreactors, utilizing a carbohydrate source for energy. The course of microbial growth progresses under well-controlled conditions of aeration, agitation rate, temperature, pH and other parameters. Fermentation can last from a few hours to several days. The metabolic end products produced by the microorganisms are the basis for many ingredients used today.
Producers of bulk food and feed ingredients such as amino acids, organic acids, and vitamins use fermentation as the basis of their production. Today’s modern industrial biotechnology processes use carefully selected and purified microbial cell cultures to produce an ever-increasing variety of ingredients and increase productivity. During fermentation, the microorganisms multiply in industrial bioreactors, utilizing a carbohydrate source for energy. The course of microbial growth progresses under well-controlled conditions of aeration, agitation rate, temperature, pH and other parameters. Fermentation can last from a few hours to several days. The metabolic end products produced by the microorganisms are the basis for many ingredients used today.
詳細を見る

Cider Producer Maximizes Yield and Increases Capacity with the Oenoflow™ HS System

Filtration is a key operation in modern cider production to deliver visually bright and shelf stable product. Traditionally, cider clarification has been performed with diatomaceous earth or sheet based filtration technologies. However, with more favorable economics, easier operation and lower waste volumes, crossflow filtration systems like Pall’s Oenoflow XL system have become more widely adopted over the past decade.
Filtration is a key operation in modern cider production to deliver visually bright and shelf stable product. Traditionally, cider clarification has been performed with diatomaceous earth or sheet based filtration technologies. However, with more favorable economics, easier operation and lower waste volumes, crossflow filtration systems like Pall’s Oenoflow XL system have become more widely adopted over the past decade.
詳細を見る

TAB Filtration Significantly Improves Ready to Drink Tea Quality and Yield

Ready to drink tea, fruit juices and drinks, carbonated soft drinks, and other beverages are subject to spoilage due to the presence of heatresistant, acidophilic bacterial spores (TAB). The thermoacidophilic spores may originate either from exposure to agricultural raw materials such as in fruit juice production, or from contamination in the beverage ingredients, such as sweeteners, juice and tea concentrates, or flavors, essences, and colors from natural extracts.
Ready to drink tea, fruit juices and drinks, carbonated soft drinks, and other beverages are subject to spoilage due to the presence of heatresistant, acidophilic bacterial spores (TAB). The thermoacidophilic spores may originate either from exposure to agricultural raw materials such as in fruit juice production, or from contamination in the beverage ingredients, such as sweeteners, juice and tea concentrates, or flavors, essences, and colors from natural extracts.
詳細を見る

Cross-flow Lees Filter Experience Delivers Efficiency and Economy at Yalumba

Recovery of wine from lees represents one of the most challenging forms of filtration faced by wineries. The high concentration and variability of the suspended solids limit the suitable filtration technologies, while strict environmental regulations and sustainability programs are increasing pressure to reduce waste volumes. Traditionally, lees filtration is performed with filter aid based systems like rotary vacuum drum (RVD) or chamber press filters. While these systems typically have good volumetric recovery of the wine from the solids, there are some inherent drawbacks that can affect wine quality. The open design allows for oxygen pick-up and the recovered wine often needs further processing. The wine is typically downgraded in value and used in blends instead of added back to the original batch.
Recovery of wine from lees represents one of the most challenging forms of filtration faced by wineries. The high concentration and variability of the suspended solids limit the suitable filtration technologies, while strict environmental regulations and sustainability programs are increasing pressure to reduce waste volumes. Traditionally, lees filtration is performed with filter aid based systems like rotary vacuum drum (RVD) or chamber press filters. While these systems typically have good volumetric recovery of the wine from the solids, there are some inherent drawbacks that can affect wine quality. The open design allows for oxygen pick-up and the recovered wine often needs further processing. The wine is typically downgraded in value and used in blends instead of added back to the original batch.
詳細を見る