01.30.55.110-Yeast Propagation and Management 2008 PDF

Rules, Standards & Procedures
Brewing Process Equipment Standard
YEAST PROPAGATION & YEAST MANAGEMENT

1. INTRODUCTION
2. QUICK FLOW
3. YEAST MANAGEMENT
3.1 BASIC DESIGN YEAST STORAGE PLANT

3.2 YEAST STORAGE CELLAR DISTRIBUTION
3.3 YEAST PITCHING
3
3
4
3.3.1 Consistency & dead cell Measurement

3.3.2 Pitching rate Measurement
3.3.3 Yeast Dosing line
4
5
5
3.4 YEAST HARVEST & PURGE

3.4.1 Yeast Harvest line distribution
3.4.2 Number of harvest lines
3.4.3 Number of harvest to 1 YST
3.4.4 Yeast cooling
3.4.5 Yeast harvest control
3.5 YEAST STORAGE
7
8
8
8
9
11
3.5.1 Number of yeast plants in case of multiple yest strains

3.5.2 YST Size
3.5.3 Number of YST
3.5.4 Yeast homogenisation method
3.5.5 Gas block or foam catcher
3.5.6 With or without carbon filter in air supply
3.5.7 Gas supply lines
3.5.8 YST cooling
3.6 WASTE YEAST PLANT
11
11
12
12
13
13
14
16
16
3.6.1 Yeast In activation

3.6.2 Control of discharge
16
16
4. YEAST PROPAGATION
17
4.1 BASIC DESIGN YEAST PROPAGATION PLANT

4.2 DRIED YEAST OR CULTURE YEAST
4.3 INTAKE OF COLD- OR HOT WORT
4.4 REHYDRATION OF YEAST
4.5 PROPAGATION
4.5.1 Propagator size
4.5.2 Mixing in the propagator
4.5.3 Aeration of the propagator
4.5.4 Non aerated steps in F(S)T or One brew fermentor
4.5.5 Propagator cooling
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Yeast Propagation & Yeast Management

Date: April 2008
Issue: 05
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1. INTRODUCTION
2. QUICK FLOW
Yeast Propagation & Yeast

Management
--- Not recommended ---
Yeast pitching
Swing bend execution dosing line
With proximity switches
Microscopic cell count
--- Add ons ---
--- Basic execution ---
Laboratory consistency & dead cell measurement
Automatic execution with mix proof

valves
Laboratory Thoma cell counter & dead
cell measurement
Aber yeast monitor
Volumetric flow measurement in dosing line
More than one dosing line
One dosing line

CIP dosing line together with wortline
Yeast harvest
Swing bend execution dosing line
With proximity switches

1 harvest line
1 harvest to 2 YST
1 harvest to 1 YST
Inline cooling in harvest line
Volumetric flow measurement & Visual detection
yeast/beer
Separate CIP of dosing line
Automatic execution with mix proof

valves
2nd harvest/purge line directly to the
WYT
1 harvest to 2 YST
Deep cooling in the YST
Turbidity measurement for detection
yeast/beer
Density measurement for detection
yeast/beer
Small purge based on volume only
Every yeast strain its own yeast plant

>3 YST
Stirrer
Gas block
Without carbon filter in air supply
Iso-mix (pm)
Foam catcher
With carbon filter in air supply
Without steaming faciilities in aeration
Waste Yeast Handling

1 WYT
No yeast inactivation
Local controlled manual discharge of the WYT
Mixing using a stirrer or pumping

system
Weighing cells YST

More than one dosing line
Yeast Storage
One yeast plant in case of muliple yeast strains
3 YST
Homogenisation using a circulation pump
Cooling to maintain storage temperature
Sterile wort intake
Mass flow measurement in dosing line
Yeast rehydration
Dried yeast
Cold wort intake
Rehydration using a Carlsberg Flask
With steaming facilities in aeration

Deep cooling in the YST
> 1 WYT
Inactivation by heat
Chemical inactivation
Automatic discharge of the WYT
Pure Culture Yeast

Hot wort intake
Rehydration using a rehydrator
Initial propagation of pure culture yeast
using a Carlsberg Flask
Yeast propagation
Mixing by aeration
Aerated steps in propagator
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3. YEAST MANAGEMENT
3.1 BASIC DESIGN YEAST STORAGE PLANT
Picture 3.1.1 Basic design yeast plant (functionality only)
Sterile air
YEAST STORAGE TANKS
CIP
Free
Air
Head space 50%

Pressure Regulation
Inlet on max
liquid level
Coolant
Waste Yeast Tank
FST
To lorry
FE
YEAST
COOLER
Brewhouse
CIP Return
CIP dosing
line together
with wortline
FE
To FS or FSTs
Yeast harvest:
Swing bend/flow plate execution of the cellar distribution (not indicated in picture above)
Positive displacement pump as driving force for the yeast transfer from FST to yeast storage
Flow measurement for pre- and post run activities
Sight glass to detect beer/yeast transition
Yeast deep cooler to cool the yeast from FST harvest temperature until < 2 C
1 harvest line to the yeast storage and waste yeast
Centrifugal pump to empty Yeast storage tanks to the waste yeast tank
Yeast storage and pitching:
Three yeast storage tanks
Tank cooling to maintain storage temperature
Yeast homogenisation using a positive displacement pump and a recycle line
Prevent foaming
o 50 % headspace
o Pre-pressurise YST before harvest (pressure as low as possible)
1 yeast dosing line (pitching)
Yeast dosing based on a mass flow measurement and laboratory consistency and dead cell
measurement
CIP dosing line together with the wort line
Waste Yeast plant
One Waste Yeast Tank
No yeast inactivation
Local controlled manual discharge of the WYT
3.2 YEAST STORAGE CELLAR DISTRIBUTION

For investment costs reasons, the basic design for a yeast cellar is the flow plate (swing bend) execution.
For quality reasons or in case of high operational costs (labour), a fully automated cellar (mix proof valves)
can be considered.
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Some breweries are using proximity switches in combination with a flow plate execution.
This set up is not recommended due to the following reasons:
High investment costs (equipment, automation)
Reliability (regularly break down)
Equal procedures as for flow plate execution without proximity switches (to meet SHE
requirements)
The choice between the different distribution methods will be described in detail in the BDM Tank room.
3.3 YEAST PITCHING

Yeast dosing is part of the wort transfer from whirlpool to the fermenting tank. All the yeast necessary for a
full fermenting tank is dosed in the first brew.
3.3.1 CONSISTENCY & DEAD CELL MEASUREMENT

Pitching rate should be based on yeast consistency measurement or if available a cell count using a
Thoma/Coulter counter, all corrected for the dead cells percentage. A cell count using a microscope is not
recommended since it is not accurate enough.
This can be done using batch wise sampling and laboratory measurement, or inline measurement using a
(Aber) yeast monitor during dosing. Yeast consistency can also be measured using the density
measurement of a mass flow meter.
The basic solution is based on batch sampling and laboratory measurement. Depending on the local labour
costs or requested quality, the yeast monitor can be considered.
Table 3.3.1.1: Overview consistency & dead cell measurement choice
Item
Basic Design
Add on
Add On
Laboratory
Laboratory
Inline
consistency
measurement using a
(Aber)
Measurement
Thoma Cell counter
yeast
Monitor
Technical
++
+
-Technologica
+
+
++
l
Operational
+
Legend:
++
+
0
--
=
=
=
=
=
Add On
Consistency measurement by
density using density
measurement of mass flow
meter
+
+
+
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution
A Thoma cell counter is more expensive than laboratory consistency mesurement
A yeast monitor measurement is expensive compared to relatively simple laboratory equipment
and batch sampling. A yeast monitor measures consistency and yeast viability
An additional density measurement to the mass flow meter (to measure consistency) is slightly
more expensive. It does not measure yeast viability
Technological:
Inline consistency measurement is independent of homogeneity.
Inline measurement measures each dosing, batch sampling only once and therefore storage time
dependent.
Additional density measurement of the mass flow meter still requires laboratory dead cell
measurement. In case of good yeast management, dead cell level is not very fluctuating. If
fluctuation is low, not every batch needs to be measured.
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Operational:
In case of inline measurement only occasional calibration measurements instead of measuring
each batch in case of laboratory measurements (labour costs)
In case of good yeast management, dead cell level is not very fluctuating. If fluctuation is low, not
every batch needs to be measured.
3.3.2 PITCHING RATE MEASUREMENT

The pitching rate can be measured using inline mass flow measurement or by the decrease of weight of the
content of the yeast storage tank. (YST)
The basic solution is based on inline volumetric flow measurement.
Table 3.3.2.1: Overview pitching rate measurement
Item
Basic Design
Add on
Volumetric flow
Inline Mass flow
Measurement
Measurement
Technical
++
+
Technologica
+
l
Operational
+
+
`
Legend:
++
+
0
--
=
=
=
=
=
Add On
Weight decrease
YST
-
excellent
good
average
mediocre
poor
Technical:
o Mass flow measurement is more expensive
o Only one inline measurement compared to weighing cells on each YST.
Technological:
Weighing cell accuracy less than mass or volumetric flow measurement
No correction for yeast concentration in case of concentration gradients for volumetric flow
measurement
Operational:
More equipment to maintain in case of weighing cells
3.3.3 YEAST DOSING LINE

3.3.3.1 NUMBER OF YEAST DOSING LINES:
The number of dosing lines is depending on the occupation of the dosing line.
The basic design is based on only 1 dosing line. In practice it is proven that single yeast breweries up to a
yearly capacity of 11.000.000 hl/year can run with only one dosing line.
Even for a brewery with multiple yeast strains it is not recommended to use more than one dosing line. With a
proper CIP philosophy (in compliance with the BDM CIP, cleaning before each dosing) only one dosing line is
sufficient.
Only in case more than 16 tanks per day need to be pitches a second dosing line can be considered.
Calculation:
Pitching time : 45 minutes
Total CIP time : 45 minutes
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Number of dosings possible per 24 h: 16 dosing actions/day
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3.3.3.2 CIP YEAST DOSING LINE
The yeast dosing line can be cleaned together with the wortline or separately.
The basic design is cleaning together with the wortline.
Table 3.3.3.2.1: Choice cleaning the dosing line together with the wortline or separately.
Item
Basic Design
Add On
CIP together with
Separate CIP of dosing
wortline
line
Technical
+
Operationa
0
++
l
Legend:
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
o No additional valves, piping and CIP program in case of cleaning together with the
wortline.
Operational:
Operational consequence of the basic solution is:
o CIP only possible in case of FST switch
Flexibility problems can occurs in case of:
o More than 1 brewhouse (2 or more dosing at the same time
o Multiple yeast strains (CIP required)
o In case of a lot of small fermenting tanks (many dosing/day)
3.4 YEAST HARVEST & PURGE

The yeast is harvested from the fermentation storage tank to the yeast storage tank or waste yeast tank.
In case the yeast quality is good in terms of generation, visual and microbiological condition, beer type and
behavior during previous fermentation, the harvest will take place to the yeast storage tank. In case the
yeast quality is insufficient in respect to the above-mentioned aspects, the harvest has to go to the waste
yeast tank.
To avoid foaming in the yeast storage tank several actions has to be taken.
First the temperature of the yeast must be lowered as soon as possible. The best way to do that is to
cool the yeast using an inline cooler.
Secondly depending on the local circumstances it is sometimes necessary to harvest under a counter
pressure. This counter pressure has to be as low as possible (max. 0.8bar) After the harvest this
counter pressure has to be relieved slowly with care, but as fast as possible.
The last foam preventing action is to apply a headspace of 50 %.
During fermentation, maturation and before emptying, the Fermenting Storage tank is purged (several
times) to the waste yeast tank. For quality reasons it is also possible to transfer yeast from the yeast
storage tank to the waste yeast tank.
3.4.1 YEAST HARVEST LINE DISTRIBUTION

Basic design is a flow plate (swing bend) execution of the yeast distribution from fermenting cellar until the
yeast storage tank.
The stipulations concerning fully automatic (mix proof valves) execution and the use of proximity switches
are the same as mentioned in Chapter 3.2
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3.4.2 NUMBER OF HARVEST LINES
The number of harvest lines depends on the number of FSTs. The basic design consists of 1 harvest line
to the YST and WYT. Depending on the number of FST, an additional line to the Waste Yeast Tank (WYT)
can be considered for harvesting or purging directly to the WYT
Table 3.4.2.1. Choice number of harvest/purge lines
Item
Basic Design
Add On
1 harvest line to YST & WYT Additional harvest/purge line to
WYT
Technical
+
Operationa
< 36 tanks
>36 tanks
l
Numb Legend:
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
o Additional harvest and purge line without connection with the YST in case of an additional
line.
Operational:
o Change over number of tanks depending on the process time.
o 36 tanks is based on 18 days production time in FST. (Max. 3 harvest & 3 purge & 4 CIP/day)
3.4.3 NUMBER OF HARVEST TO 1 YST

The basic design is based on 1 harvest to 1 FST. Mixing of yeast from several FST is not allowed.
In case the YST is too small to harvest all to one YST, it can be considered to fill 2 YSTs with 1 harvest.
To avoid (flocculence) differences between the 2 tanks, it is recommended to fill the YSTs alternating.
3.4.4 YEAST COOLING

Yeast can be cooled in the YST or inline. It should be realised that cooling from harvest temperature to < 2
C in the tank is only applicable in case the YST is intensively mixed using for example a stirrer. If a inline
cooler is installed, cooling of the yeast storage tank is still required to maintain storage temperature.
For technical and technological reasons, the basic design is an inline cooler.
Table 3.4.4.1. Choice yeast cooling
Item
Basic
Add On
Design
Inline cooler
Deep cooling in the
YST
Technical
+
-Technologica
++
l
Operational
+
Legend:
++
+
0
--
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=
=
=
=
=
excellent
good
average
mediocre
poor

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Technical:
o Deep cooling in the YST requires a stirrer in each YST
Technological:
Direct inline inactivation of yeast metabolism including CO2 production (temp: <2 C)
Cooling in tank takes at least 10 h
Operational:
Less foaming in case of direct inactivation of the yeast metabolism
3.4.5 YEAST HARVEST CONTROL

There are different possibilities to control pre-run, harvest/purge end and post run during harvest or purge.
The basic design is for economical reasons using a simple flow meter to calculate the harvest, pre- and
post run volumes. The beer/yeast transition is based on visual control at the sight glass.
More sophisticated methods are using inline density or turbidity (both g/l results) measurements, to detect
the transition beer/yeast.
In case of bigger breweries using a second purge (and harvest) line directly to the WYT, more than one
purge is running at the same time. In that case it is practical impossible to run without inline equipment for
the detection the transition beer /yeast.
In all possible solutions it is possible to execute small purges based on volume only.
Table 3.4.5.1. Choice harvest control
Item
Basic Design
Add on 1
Add on 2 2Add on 1
Simple volumetric Mass flow measurement with
Simple flow measurement
flow meter with
density measurement to
with turbidity measurement
visual transition
control transition
for transition control
control on sight
glass
Technical
+
0/-
Operationa
l
Legend:
-/-++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Turbidity measurement and a simple flow measurement are cheaper than mass flow measurement
with density measurement
In case of applying a mass flow measurement a additional pressure control valves is required to
avoid CO2 bubbles
In case of bigger breweries flow measurement and yeast detection before the central yeast flow
plate or matrix are recommended
Operational:
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In case of big breweries with a additional purge line and a lot of activities at the same time, visual
control is not reliable
Risk of beer losses
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3.5 YEAST STORAGE
During yeast storage the yeast must be kept at the desired temperature to keep it in good shape for pitching.
Due to heat input by the circulation pump, tank cooling to maintain the storage temperature is required. During
storage the yeast must be kept homogeneous. A slight air overpressure (max.0.05bar) is applied to prevent
microbiological contamination. If yeast quality is insufficient or if there is not enough yeast left to pitch a new
fermenting tank, the yeast must be transferred to the waste yeast tank.
3.5.1 NUMBER OF YEAST PLANTS IN CASE OF MULTIPLE YEST STRAINS

The basic design will be 1 yeast plant independent from the number of yeast strains in use.
In some breweries however there are separated yeast plants installed for each yeast strain.
Table:3.5.1.1
Item
Technical
Technologica
l
Operational
Legend:
Basic Design
One Yeast
plant
++
+
Add On
Each yeast strain its own yeast
plant
-+
+
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
o Separate harvest lines incl. coolers
o Separate YST
o Separate dosing lines
Technological:
With an appropriate CIP philosophy it is superfluous to separate the yeast plants in case of multiple
yeast strains.
It also makes no sense, because FST are common used for all strains.
More YST required, this is a risk for longer storage times
Operational:
Higher maintenance and operational costs (additional equipment).
o A lot of additional procedures are required.
o More attention required of operators
3.5.2 YST SIZE

The size of the YST mainly depends on the number of pitches per day and the FST size.
The main goal is to harvest only the amount of yeast needed. If the yield of a harvest is higher, the excess
should go directly to the WYT.
Depending on the capacity calculations the number of FST to be filled per day are determining the amount of
yeast needed per day. The YST should be big enough to dose for the required number of pitching per day.
In principle the harvest yield should be always enough to fulfil the above mentioned requirement.
As a rule of thumb the amount of harvested yeast should be 3 % of the FST content. For a FST with a nett
volume of 4000 hl, the yeast harvest will be approximately 120 hl with 40 50 % consistency.
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The amount of the purges in case no additives like tannic acid or else are used, will be another 1 %. For a
FST of 4000 hl this will be 40 hl.
3.5.3 NUMBER OF YST

The number of YST is depending on the number of yeast strains in use and the technological requirement
to minimize the yeast storage time. In case of only one yeast strain the basic design should have max. 3
YST.
The size of the YST depends on the size of the FST. (See chapter 3.5.1
Table 3.5.3.1. Number of YST
Item
Number of
YST
Basic
3
design
Ad On 1
5
Add on 2
4
Add on 3
7
Add on 4
5
Number of yeast strain

1
Production ratio in case

of multiple yeast strains1
1:0
2
2
3
3
1:1
3:1
1:1:1
2:1:1
3.5.4 YEAST HOMOGENISATION METHOD

There are several possibilities to homogenize the yeast during storage. The basic design is for economical
and microbiological reasons using a circulation line with a circulation pump.
Alternatives are a stirrer or the mixing system of iso mix.
One should realize that deep cooling in the tank, using the tank cooling coils, is not possible in the basic
design.
Cooling capacity is closely related to the film layer thickness at the tank wall. In case of using a circulation
pump, this layer is too thick to be able to deep cool the tank content within a reasonable time. The basic
solution for cooling is an inline cooler. The tank cooling is only required to keep the content on storage
temperature.
To make sure that all yeast is homogeneous or in other words to prevent a short cut in the circulation of the
yeast suspension, the position of the inlet of the recycle line should be at the maximal liquid level.
Table 3.5.4.1. Choice of homogenization method
Item
Basic Design
Add On
Recycling using a
Stirrer
pump
Technical
+
Technologica
+
l
Operational
0
0
Legend:
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution (recycling line, valves, recycle pump)
o Expensive stirrer including construction on each tank
Technological:
1 Yearly Hl produced with yeast A: yearly HL produced with yeast B: yearly HL produced with yeast C
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In combination with an inline cooler and yeast storage tank cooling to maintain the storage
temperature, basic design is homogenous and temperature stable.
A stirrer is a better mixer than a recycle pump
Stirrers are sensitive for oil leakages (SHE)
Stirrers have a better deep cooling performance
Stirrers are difficult to clean
Operational:
Flexibility: With a stirrer deep cooling in the tank is possible. This is not the case in case of
using a recycling pumps
Maintenance costs for stirrers are higher
Iso-mix system (p.m):
The isomix is system is based on a circulation using a centrifugal pump and mixing device. The main
difference compared to the basic design, is the use of a rotating mixing machine, which is positioned below
liquid level. It looks promising, because it is combining the advantages of stirring and recycling. Further
investigation on yeast viability is needed, before this application will be released.
Yeast mixing using a centrifugal pump (p,m.):
Iso mix and also some other suppliers are offering centrifugal pumps for yeast homogenization.
The results of breweries using these pumps are not evaluated yet.
3.5.5 GAS BLOCK OR FOAM CATCHER

The basic design of the yeast storage plant is to blow off the CO2 to the free air without a foam catcher.
The foam catcher (FC) can be used in case the CO2 needs to be recovered. The FC prevents fouling of
the CO2 recuperation line and plant as a result of foam in the system (over foaming YST, foam in the CO2
flow).
Fore more detailed information about the choice between a gas blocks and a foam catcher see BDM Tank
room in the Foam Catcher chapter.
3.5.6 WITH OR WITHOUT CARBON FILTER IN AIR SUPPLY

Some breweries are using carbon filters in the compressed air lines to wort aeration, yeast storage,
propagation plant and other tanks using air for pressure control.
A carbon filter is not part of the basic, since most of the breweries are not using the filters neither reporting
problems related with off flavors coming from the air supply.
In case there is a problem, carbon filters are considered to be best practice to remove off flavors and other
contaminants from air.
Table 3.5.6.1. With or without carbon filter in the air supply
Item
Basic Design
Add On
Without carbon
With carbon
filter
filter
Technical
+
Technologica
+
l
Operational
+
0
Legend:
++
+
0
--
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=
=
=
=
=
excellent
good
average
mediocre
poor

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Technical:
Lowest investment costs for the basic solution
o Carbon filter is an additional investment
o Positioned before membrane filter
Technological:
A carbon filter removes potential contaminants like off flavours from the compressed air
Operational:
Integrity check and/or planned maintenance required
3.5.7 GAS SUPPLY LINES

There are several ways to execute gas supply lines. In the drawings below you find the execution variants
for dosing of gasses in product lines during transfers and pressure control.
Solution 1 is to be used of dosing gasses in a product.
Solution 2A is to be used in case of tanks with a individual gas supply for pressure control
Solution 2B is to be used in case of a common gas supply line with several users for pressure control
Solution 3 is to be used if a mix proof valve is superfluous. ( no product contact)
PT
PI
PT
PI
Solution 2a: Product safe (Individual)
Solution 1: Cleanable & Product safe
PT
PT
PI
Solution 2b: Product safe (Common)
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PT
PI
Solution 3

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Product contact
Common/Individual
connections
Solution
Gassupply
Product integrity
Table: 3.5.7.1 Overview when to apply which solution
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
N
N
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
N
N
I
I
I
I
C
C
C
C
I
C (I)
C (I)
I
I
I
I
I
I
I
1
1
3
2a
2b
2b
2b
2b
2a
2b (2a)
2b (2a)
2a
2a
2a
2a
2a
3
3
Wortline
Carboniser
YPT
YPT
YST
FT
FST
ST
UBT
FBT
DAWT
PSA
BT (BBT)
BT (H&T)
RBT
PBT
KGF
PVPP
Description
aerate wort
carbonise bright beer
aerate wort & yeast
pressure control wort & yeast
pressure control, yeast
pressure control, green beer
pressure control, wort/green beer/young beer/mature beer
pressure control, young beer/mature beer
pressure control, mature beer
pressure control, bright beer
pressure control, "bright beer"
pressure control, mature beer
not product related
not product related
3.5.7.1 WITH OR WITHOUT STEAMING FACILITIES IN AIR (OR OTHER GAS) SUPPLY
Modern breweries more and more are using sterile filters to prevent microbiological contamination from the
air supply.
In case a sterile (membrane) filter is installed steaming of the air supply is not necessary since the sterile
filter guarantees sterility.
Table3.5.7.1.1. With or without steaming facilities in the air supply
Item
Basic Design
Add On
Without steaming
With steaming
facilities
facilities
Technical
+
Technologica
+
+
l
Operational
+
Legend:
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Lowest investment costs for the basic solution using a sterile filter
o Steam supply including valves, pressure control and others is required in case no sterile
filter is used.
Technological:
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Steaming and sterile filtration are both securing microbiological contamination. So installing one of
the two is enough.
Operational:
Integrity check and/or planned maintenance required for sterile membrane filter
Regular steaming of the air supply is needed in case no sterile filter is installed
3.5.7.2 CIP OF THE GAS SUPPLY LINES

Modern breweries more and more are using sterile filters to prevent microbiological contamination from the
air or other gas supply.
Basic installation design should be done in such a way, that CIP of the gas supply lines upstream the
sterile filter is not necessary.
Down stream the sterile filter precautions to prevent contamination of the filter and supply line with liquid
should be taken. (Non-return (check) valves)
In case of direct dosing of gas into liquids, the lines from non-return valves until the dosing point should be
executed cleanable. (Manually as done i.e at the propagator or automatic i.e. the air dosing point in the
cold wort)
3.5.8 YST COOLING

The yeast storage tank has one cooling zone with cooling agent temperature control. To prevent freezing
of the product, the cool medium temperature at the outlet is controlled using a control valve. The
temperature must be kept at 1 +/- 1.
In the basic design, with deep cooling in the harvest line and mixing by pumping using the by-pass, cooling
capacity of the YST should be enough to keep the tank on storage temperature. In case of deep cooling in
the tank, the cooling capacity and mixing method should be designed to be able the content within the
desired cooling time.
3.6 WASTE YEAST PLANT

A basic yeast plant consists of 1 WYT. The WYT is insulated and has no cooling. The CIP of the WYT is
done lost based. (no CIP return)
The size of the waste yeast tank is equal to the size of the YST.
A centrifugal pump is used for yeast discharge to the lorry or truck.
3.6.1 YEAST IN ACTIVATION

Surplus yeast is a valuable protein-rich product, it can be used as human food ingredient or as an animal
feed. Surplus yeast can be applied without treatment as a wet pig feed (or less common as a cattle feed)
provided that hygienic measures are taken. Surplus yeast can be conserved with chemicals or by drying in
order to extend the shelf life and to meet eventual customer requirements.
The basic design is without inactivation facilities. In case the surplus yeast is killed, one can use steam
injection or dosing an additive for chemical inactivation. Heat inactivation using steam is cheaper than
chemical dosing, using a dosing unit.
3.6.2 CONTROL OF DISCHARGE

Discharge can be controlled locally or using the plant control system. For cost reasons and the fact that
most of the time there is no possibility to control the level of the truck or lorry using the plant control
system, the basic design is based on local manual control.
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4. YEAST PROPAGATION
The aim of the yeast propagation process is to produce sufficient and high vitality yeast for the first production
fermentation. After the re-hydration time the wort and re-hydrated yeast are transferred to the propagator. Then the
yeast is, after adding an amount of wort, propagated during a certain time and at a certain temperature. During
propagation the re-hydrated yeast is aerated and after reaching the desired apparently extract wort is added for
the next propagation step.
4.1 BASIC DESIGN YEAST PROPAGATION PLANT

Picture 4.1.1 Basic design propagation plant (Functionality only)
PROPAGATOR
Pressure regulation To free air
CIP
Sterile air
Carlsberg flask
to sampling
point using
sterile air
50 % Head space
FE
FE
3 O2 membranes
Coolant
FE
To FS or FSTs
Wort
Water
Yeast propagation:
Swing bend/flow plate execution of the cellar distribution (not indicated in picture above)
Dried yeast
Carlsberg flask for re-hydrating dried yeast.
Centrifugal pump as driving force for the fermenting yeast transfer to FT or FST
130 Dished bottom with 3 aeration points (120 of each other)
No mechanical homogenization (only mixing by aeration)
Aeration only in propagator and not in FT or FST
Yeast transfer from propagator to F(S)T as fermenting wort. (No purge)
Last 2 propagation steps in F(S)T
Temperature control using cooling coils
Slightly overpressure to avoid microbiological contamination.
Pressure control using sterile air
50 % headspace
Yeast harvest from FST after final propagation step in FST
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4.2 DRIED YEAST OR CULTURE YEAST
For cost reasons, the basic design is based on the use of dried yeast.
A lot of breweries are however still using pure culture yeast.
Table 4.2.1. Choice of yeast
Item
Basic
Design
Dried yeast
Technical
Technologica
l
Operational
Legend:
Add On
Pure culture
yeast
0
++
+
0
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
Low investment costs for the basic solution. (Carlsberg Flask, Propagator)
o In general additional equipment is used for a pure yeast plant. ( wort sterilisation,
additional small propagator)
Technological:
Dried yeast has always the same quality (flocculence, flavour stability, operational). Pure yeast
plant has a risk of mutation
Operational:
Pure yeast plant requires constant attention
Dried yeast costs
4.3 INTAKE OF COLD- OR HOT WORT

The basic design is based on the intake of cold wort.
In some breweries also intake of hot wort and/or wort sterilisation are applied.
We do not recommend using sterile wort, since it is increasing the investment- and operational costs and it
brings hardly any technological advantage.
Table 4.3.1. Wort intake
Item
Basic
Design
Cold wort
Technical
Technological
aspects
Operational
Legend: ++
=
+
0
--
Add On
1
Hot wort
Add On 2
++
0
Sterile
wort
-++
--
excellent
=
=
=
=
good
average
mediocre
poor
Technical:
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o
o
o
More cooling capacity (deep cooling from 100 C to pitching temperature) on propagator or
sterilisator required
Additional YPT tank costs due to high temperature (design pressure)
Additional sterilisator in case of sterile wort
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Technological:
In practice initial propagation intake with cold wort, hot wort or sterile wort are all proven to be
reliable in case of a proper CIP philosophy. Intake of cold wort is giving the same security for
microbiological contamination as normal production fermentation. More security is not really
required since final steps in propagation are also with wort on pitching temperature.
Security level increases in case of intake of hot wort in the propagator only for the first propagation
step, since this step is the most critical (lowest yeast concentration, highest pH and lowest alcohol
concentration). The following propagation steps in the propagator and FST are done with normal
wort on pitching temperature
Intake of sterile wort is only giving slightly more security, since following propagation steps are also
using sterile wort. Since this steps are less critical and the following propagation steps in the FST
are done with normal pitching wort.
Operational:
Additional processes and required for hot wort and for sterile wort also additional equipment
Higher occupation of propagator in case of hot wort
Additional operator attention needed.
Additional operational costs in case of heating using a sterilisator
4.4 REHYDRATION OF YEAST

Before propagation, the dried yeast has to be rehydrated with a light coloured pilsener type wort. The basic
design is based on a Carlsberg flask. A more expensive alternative is the re-hydrator, which is used for rehydrating dried Heineken yeast.
Table 4.3.1. Choice of rehydration method
Item
Basic Design Add On
Carlsberg
Reflask
hydrator
Technical
++
Technological
0
++
aspects
Operational
+
Legend:
++
+
0
--
=
=
=
=
=
excellent
good
average
mediocre
poor
Technical:
o Rehydrator is more expensive than a Carlsberg flask. (including a stirrer, temperature
control, electrical heater, empty detection, sterile filter)
Technological:
The rehydrator is recommended in case of Heineken production. All needed functionality for rehydration and process control is available on the rehydrator.
Operational:
Rehydrator is not suitable for pure culture yeast
Continuous labour activity during re-hydration uing a Carlsberg flask(I.e. manual shaking). In case
of a re-hydrator only manual filling with dried yeast.
Carlsberg flask requires almost no maintenance
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4.5 PROPAGATION
To avoid foam formation it is allowed to fill the propagator with max. 0.3bar head pressure. After finishing
the wort intake, the pressure has to be relieved to max. 0.05bar.This slight overpressure prevents outside
air coming in and thus prevents microbiological contamination.
During the cleaning of the propagator an overpressure can be applied to prevent vacuum.
The propagator itself is dedicated for the propagation only. In smaller breweries often a combined yeast
storage tank and propagator is used. To avoid cross contamination this is not recommended.
Mechanical mixing of the propagator is not recommended. Mixing during aeration is sufficient.
In case a Carlsberg flask is used for re-hydration or pure culture yeast, the yeast is transferred from the
flask to the YPT using sterile air. Before dosing the yeast to the YPT, using the sample point of the YPT,
the sampling point can be easily sterilized using alcohol and a flame.
Some breweries are using steam to sterilize the sampling point. This is not recommended since it requires
additional equipment and it is more time consuming.
4.5.1 PROPAGATOR SIZE

The size of the propagator is depending on the fermentation volume in the F(S)T. The propagator should have
a headspace of 50 %.
Topping up in the F(S)T with partial brews during the last 2 propagation steps is causing operational
problems, especially in case of basic cellar design with manual actions. Therefore basic sizing of the YPT is
based on adding complete brews to the F(S)T.
Starting points for the table below are:
Minimal cooling volume in the F(S)T is at least 2 brews
Addition of partial brews to the propagator and only complete brews to the F(S)T
8 brews/F(S)T
Table 4.5.1.1 Size propagator depending on FST size and only complete brews to F(S)T
FST Size
(gross
hl)
1000
2000
2500
Brew
Size
(hl)
Minimal
propagator
Liquid
level (hl)
Vol. 1st
propagation
step in F(S)T
Max. 7 x (hl)
100
200
250
35
70
90
2500
250
90
3000
300
100
4000
400
135
5000
500
170
Note: The last 2 steps are not aerated
Propagator
Gross vol.
(hl)
235
470
590
Final vol.
after last
propagation
step in F(S)T
Max. 5x
(hl)
835
1670
2090
590
700
935
1170
2090
2500
3335
4170
180
200
270
340
70
140
180
4.5.2 MIXING IN THE PROPAGATOR

Stirrers or pumping systems using a by -pass are not recommended, since mechanical agitation of the
propagator content is not allowed..
Mixing will be done by the aeration flow and CO2 production during fermentation.
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4.5.3 AERATION OF THE PROPAGATOR
To stimulate yeast growth and yeast vitality, additional aeration of the propagation wort should be applied
for the first propagation step(s). Additional aeration is not allowed for the last 2 propagation steps. This
means :
Total 3 propagation steps additional aeration during the first propagation step
Total 4 propagation steps additional aeration during the first 2 propagation steps
For mixing reasons there are 3 injection points at the bottom of the tank. To get good mixing, aeration is done
using 3 membranes in the bottom of the propagator. The membranes are placed 120 from each other. It is
not necessary to install a blocking detection. If one of the dosing points is locked, this is easily visible
through the sight glass on top of the propagator. A simple Rota measuring device is sufficient for the air
flow measurement, aeration flow needs to be tuned only once based on the level of the last propagation
step.
To make sure that the air pressure in front of the membrane is always at least a 0,5 bar higher than at the
product side, a pressure transmitter in the aeration line is necessary. To avoid contamination caused by
sweating of the membrane, it is advisable to maintain always a small airflow through the membrane.
The maximal air pressure on membrane is 1,5 bar.
It is recommended to use transparent hose for connection to membrane to make blockings visible.
Picture 4.5.2.1. Overview aeration propagator

Air
Controlled on/off valve
Sterile filter
Pressure
control YPT
Yeast propagator
PC
Pressure transmitter,
Foam detection,
Overpressure valve,
Underpressure valve,
are not shown on this scheme, but
are present!
Pressure reducer
6 2 1 bar
Controlled on/off valve
with small bore hole Pressure 0,5 bar higher
then pressure in the tank
Rota measuring
in litres/min
0
PC
50
Transparant hose provided
With quick clamp hose
connections
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It is recommended to change the membranes after cleaning and disinfection. The autoclaved membranes
with housing are replaced before the next propagation using alcohol to disinfect. It is not necessary to
apply steaming of the system. The system after the sterile filter can be considered as sterile.
The original CPM housings will be applied to fit the membranes to the tank.
Picture 4.5.2.2.Picture membrane housing
This part including membranes
to be autoclaved in the laboratory
before propagation.
Membrane
Substitute peace to be placed

before propagator cleaning
Difficult to clean when membranes

remain in position, so apply
Pipe solution indicated, however the same

principle is for the tank cone execution.
4.5.4 NON AERATED STEPS IN F(S)T OR ONE BREW FERMENTOR

The basic design is based on propagation of the last 2 steps in a FT or FST. In case the minimal cooling
level of the FST is more than 2 brews a so-called One Brew Fermentor can be considered.
The size of this fermentor should be based on a nett volume of 20 % of the F(S)T.
4.5.4.1 AERATION LINES WITH OR WITHOUT CARBON FILTER

See chapter 3.5.6
4.5.4.2 AERATION LINES WITH OR WITHOUT CIP OR STEAMING FACILITIES

See chapter 3.5.7and 3.5.7.2
4.5.5 PROPAGATOR COOLING

The propagator has besides the cone cooling two cooling zones on the shell, with cooling agent supply
flow control to control the fermentation temperature.
The cooling medium is alcohol/water. The cooling zones must be corresponding with the intake volumes
for the propagation steps.
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Date: April 2008
Issue: 05
Page: 23 of 23

01.30.55.110-Yeast Propagation and Management 2008 PDF

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Rules, Standards & Procedures

Brewing Process Equipment Standard

YEAST PROPAGATION & YEAST MANAGEMENT

3.1 BASIC DESIGN YEAST STORAGE PLANT

3.3.1 Consistency & dead cell Measurement

3.4 YEAST HARVEST & PURGE

3.5 YEAST STORAGE

3.5.1 Number of yeast plants in case of multiple yest strains

3.6 WASTE YEAST PLANT

3.6.1 Yeast In activation

4.1 BASIC DESIGN YEAST PROPAGATION PLANT

Yeast Propagation & Yeast Management

Rules, Standards & Procedures

Brewing Process Equipment Standard

Yeast Propagation & Yeast

--- Add ons ---

--- Basic execution ---

Laboratory consistency & dead cell measurement

Automatic execution with mix proof

Volumetric flow measurement in dosing line

More than one dosing line

One dosing line

With proximity switches

Separate CIP of dosing line

Automatic execution with mix proof

Every yeast strain its own yeast plant

Without steaming faciilities in aeration

Waste Yeast Handling

Mixing using a stirrer or pumping

Weighing cells YST

Cooling to maintain storage temperature

Sterile wort intake

Mass flow measurement in dosing line

With steaming facilities in aeration

Pure Culture Yeast

Yeast Propagation & Yeast Management

Rules, Standards & Procedures

Brewing Process Equipment Standard

YEAST STORAGE TANKS

Head space 50%

Waste Yeast Tank

3.2 YEAST STORAGE CELLAR DISTRIBUTION

Yeast Propagation & Yeast Management

Rules, Standards & Procedures

Brewing Process Equipment Standard

3.3 YEAST PITCHING

3.3.1 CONSISTENCY & DEAD CELL MEASUREMENT

Yeast Propagation & Yeast Management

Rules, Standards & Procedures

Brewing Process Equipment Standard

3.3.2 PITCHING RATE MEASUREMENT

3.3.3 YEAST DOSING LINE

Yeast Propagation & Yeast Management

Rules, Standards & Procedures

Brewing Process Equipment Standard

Yeast Propagation & Yeast Management

Rules, Standards & Procedures

Brewing Process Equipment Standard

3.4 YEAST HARVEST & PURGE

3.4.1 YEAST HARVEST LINE DISTRIBUTION

Yeast Propagation & Yeast Management

Rules, Standards & Procedures

Brewing Process Equipment Standard