Instrumentation and Control 2015

INTRODUCTION
Malt is a natural food product that results from the transformation of a cereal grain. Barley is
the grain most used today, but wheat can also be used for making "white" beers. Malt is the main
ingredient used in brewing beer, along with water, hops, and yeast. Malts high enzyme content enables
the production of simple sugars and amino acids from the starch in the proteins. Thus malt is the source
of sugar, which is then transformed into alcohol and carbon dioxide gas in the beer. It also contributes
color and taste to the beer.
The main use of malt today is in brewing, for making beer. It is also used in distilling, to make
whisky. It can also be used as a component (as malt extract) in food manufacture (in making bread,
cereal bars, and energy drinks). Because of the products energetic and enzymatic potential, other uses
for it are emerging or could be developed. Various species of barley, both winter and spring barleys, may
be used in malt production. For a given species, different varieties are used.
The industry nowadays uses a modern technology to keep the best and high quality of the
products. In each of the process, Instrumentation and Controls manipulate the overall progression of
the manufacturing to ensure proper amount of mass or volume, temperature, speed, stress, force,
pressure, flow rate, movement, density and any other common measurement.

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Brief Discussion of Old Malt Production

Step 1: The earliest known malt house was a simple structure located at the bottom of a hill
or mountain adjacent to a stream, which could supply low temperature water by gravity. These houses
had massive stone walls with floors of stone or mortar. Small windows set in these heavy walls were the
only means of ventilation. Barley would be received into the top of such a house, and dropped into deep
cisterns for steeping. From there, it would be deposited in a pile onto the stone floor of the house for
germination.
Step 2: As growth commenced and heat was generated, the malt was shoveled from this pile
and spread in a thin bed toward the front of the room. Any necessary further cooling could only be
accomplished during the cool evenings or night hours when experienced workmen shoveled the first
thin layer of malt forward to another spot on the floor, throwing it into the air, and allowing it to fall in a
thin shower. The proper moisture was applied by the simple old-fashioned sprinkling can.
Step 3: The process of shoveling to control temperature gradually moved the bed from the rear
to the forward end of the floor, and as each successive steep was deposited onto the floor from the
steeping cistern, it followed its predecessor down the length of the floor. In this way there were on each
floor, a number of beds of malt in varying stages of germination. When the malt reached the front of the
floor, its germination was completed, and it was shoveled by hand through a trap door into wheel
barrows beneath, by means of which it was transported to the kiln for drying.
Step 4: The kiln, at that time, was simply a room with a tile floor, under which were crude
furnaces. The ceiling of the room assumed the shape of a high tapered dome, in which was located a
large duct or chimney to pass off the moist hot air. After the germinated malt was spread on the floors,
the fires were started, and drying accomplished by simple heating. The malt was agitated from time to
tie by a shovel. Later the tile floors were perforated, so that the combustion gases could pass directly
through the grain.
Step 5: All ventilation was by natural draft, and, of course, was influenced greatly by weather
conditions. The art of malting under those conditions was one of the highest. The maltster personally
controlled all processes, and through highly developed manual skill maintained proper conditions. He
alone checked the temperatures, mostly by sense. It was he who determined when more moisture was
required. In short, it was exclusively his skill and experience which brought out a finished malt of the

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proper character. Because temperature controls were dependent on atmospheric conditions, malting at
that time was confined to the cool months, which averaged about five months per year. During the rest
of the year, the house was completely closed. Naturally, with this short production season, volume was
very definitely limited.

Brief Discussion of Modern Malt Production

The basic principle of these early malt houses again prevailed for centuries, but always with the
search for new means of increasing production. It was not until the advent of steam, and later electrical
power, that any major change occurred in the malting process. Undoubtedly, someone at some time
drove ventilating bellows by water power in an effort to continue malting during the warmer weather,
but there is no definite record of such device.

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Step 1: Mixing of Barley and Rye Malt, as the raw materials for Malt Production, from their
storage down to the soaking vessel.

Malted Barley

Rye Malt

Barley and Rye Malt Composition

Rye Malt
Lovibond

Flavor

Unique Characteristics/Applications
DP 105. Another uniquely-Briess specialty malt, Rye Malt isn't
just for rye beer styles. Although brewing a traditional rye beer

3.7

Rye

is exceptionally rewarding, try adding Rye Malt to light- and

medium-colored and flavored beers for complexity. Or fire up
your new distillery and use it to make a single malt whiskey.

FLAVOR & COLOR CONTRIBUTIONS

Malt Style: Rye Malt
Flavor: Spicy Rye
Color: Golden leaning toward orange hues
CHARACTERISTICS / APPLICATIONS
An often overlooked malt, Rye Malt has a unique spicy rye flavor for the production of great rye beer.
In addition, Rye Malt can help build flavor and develop complexity in many beer styles, all the way from
medium flavored lagers to dark ales.
We recommend you start light. Use in 5% increments until your desired flavor is achieved.
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Rye Malt is fully modified. It performs well in a single temperature infusion mash if used at less than
20% of total grist.
Hulless and with a high beta glucan content, Rye Malt can result in a sticky mash and slow lautering.
We recommend adding rice hulls when usage levels approach 20% and supplementing with a
betaglucanase enzyme above 35% for manageable lautering.
1-3% Adds dryness and a touch of spicy rye flavor and interest to many beer styles, from medium
flavored lagers to dark ales
5% Rye Pale Ales, Wheat and Smoked Beers
10-35% Roggenbier (German Rye Beer), American Rye Beer
NOTE: Grains are pre-crushed in 1 lb. Bags

Malted Barley
Malted barley is the source of the sugars (principally maltose) which are fermented into beer.
The grain partially germinates, releasing enzymes in the aleurone layer (outermost layer of the
endosperm). New enzymes are created that break down the endosperm's protein/carbohydrate matrix
into smaller carbohydrates, amino acids and lipids, and open up the seed's starch reserves. The
endosperm is composed of large and small starch granules that are packed in a protein matrix. The cell
walls within the matrix holding the starch granules are primarily composed of beta-glucans (a type of
cellulose), some pentosans (gummy polysaccharide) and some protein. The degree to which the
enzymes unpack the starch granules (i.e. breakdown the endosperm) for use by the growing plant (or
brewers) is referred to as the "modification." It refers to all of the polymer-degrading processes that
occur during malting.
Barley is the worlds most nutritional crop and is recommended for beer brewing. This is
because barley contains many elements that are rich sources of health and energy for brewing yeast.
The composition of barley, including the percentage of minerals, gives a general idea about its uses in
brewing industry. Barley contains about
Starch 62 66 %

Sugars 1 2 %

-glucan 3 5 %

Other hemicelluloses (pentosans) 4 7 %

Cellulose 4-5 %

Lipids 2 3 %

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Protein 8 13 %

Amino acids and peptides 0.5 %

Nucleic acids 0.2 0.3 Minerals 2 %

Other substances 5-6 %
Step 2: Soaking process of Malted Barley and Rye Malt into the soaking vessel with the addition
of water as the cleaning agent.
The process of malt production starts with dipping the grain in stainless steel tubs. The grain is
washed and soaked at the same time the soaking may last up to two days. The soaking process gives
the grain required amount of moisture and increases their vitality.
Step 3: Germination process of the soaked ingredient with a defined level of temperature.
After soaking, the grain is transferred to the germination chamber by hydrotransport.
In the germination chamber, air of necessary humidity and temperature is blown through the
grain mass. During the process of germination, the goal is to accumulate as much ferments as possible in
the grains.
Step 4: Roasting/Drying Process of the germinated ingredients from the previous process.
After germination, the grain is moved to the dryer/roaster.
The drying/roasting process is carried out, using warm air and applying specific modes of
temperature. Drying/roasting alters not only the moisture content, but also flavour, odour and aroma.
Step 5: Grounding and Cleaning Process of the roasted grains.
Dried grain (green malt) is transferred to the sprout breaking mechanism, where the sprouts are
removed, as they impart an unpleasant taste to beer.
The dried grain is cooled, weighed and transferred to elevator bins. After a period of ripening,
they become an ingredient for making good beer light malt.
Step 6: Pumping process of the malt into the large storage silos for storage and preparation for
delivery.
Step 7: Extraction of Beer from the storage tanks for the delivery and distribution to clients.
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The Instrumentation and Control used for:

Mixing of the raw materials:

MicroTREK - (Guided Microwave) : LEVEL TRANSMITTERS

THERMOPOINT TM - (Multipoint temperature transmitter) : TEMPERATURE METERS

NIVOROTA-(Rotary Paddle): Level Switches

Soaking process for the mixed barley and rye.

EchoTREK for liquids - (Ultrasonic Compact) : LEVEL TRANSMITTERS

NIVOSWITCH for liquids - (Vibrating Fork) : LEVEL SWITCHES

NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL TRANSMITTERS

Germination process.

THERMOCONT TT - (Temperature transmitter) : TEMPERATURE METERS

NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL TRANSMITTERS

Roasting process.

NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL TRANSMITTERS

THERMOCONT TT - (Temperature transmitter) : TEMPERATURE METERS

Storing the malt product into vessels before to distribute to its customer and buyers.

NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL TRANSMITTERS

MicroTREK - (Guided Microwave) : LEVEL TRANSMITTERS

NIVOROTA - (Rotary Paddle) : LEVEL SWITCHES

NIVOCONT R - (Vibrating Rod) : LEVEL SWITCHES

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Tables References

MicroTREK - (Guided
Microwave) : LEVEL
TRANSMITTERS

FEATURES

APPLICATIONS

SPECIFICATIONS

Two-wire TDR
Technology

Level, volume
measurement

Power supply: 18-35 V

DC

Digital communication

Liquids, powders and

granular mediums with
Er>1.4

Accuracy: 5 mm

High accuracy: 5 mm
High pressure range
High temperature
range
Extremely low dead
band
Large Dot-Matrix
graphic display
Local programming
feature

Medium with
turbulent surface,
dense dust, vapour or
pressurized gas layers
above the product
surface
For all tank shapes, for
narrow vessels

Medium temperature:
-30...+ 200 C
Pressure: max. 40 bar
Measuring range: up
to 24 m
Output: 4-20mA, loop
powered
Communication: HART

Heavy industrial
applications

Process connection: 1''

1 1/2'' or flanges

Text-based menu
system

Ingress Protection:IP
65

Plastic coated stainless

steel probes (PFA, FEP,
PP),

ATEX approval:
II 1 G Ex ia IIC T6...T3
II 1 G Ex ia IIB T6...T3
II 1D iaD A20/A21 IP65
T100C

Aluminium and plastic

housing
Wide range of probes
Explosion-proof
models

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THERMOPOINT TM (Multipoint
temperature
transmitter) :
TEMPERATURE
METERS

FEATURES

2-wire multipont
temperature
Transmitter
Max. 30m probe
length

APPLICATIONS

SPECIFICATIONS

For normal and

hazardous materials

Power supply: 12-36 V

DC

Temperature
measurement of liquids
,or powdered, granular
or free flowing solids

Measuring range: For

liquids: -40C.+125C

Max. 15 sensors

For solids: 10C.+85C

Grain industry
Max 35kN tensile force
Feed industry
Digitally addressed
sensors
HART communication
Ex ia or Dust Ex
protection
APPLICATIONS

Food industry

Accuracy:
-10C...+85C: 0,5C
-40C...-10C and
+85C...125C: 2C
Max. tensile force:
35kN
Probe length: 5-30m
Output: HART
Protection: IP67
Approval:
ATEX Ex II 1 G Ex ia IIB
T6..T4
ATEX Ex II 1 D Ex iaD
A20/A21 T85C IP67
ATEX Ex II 1 D Ex ta/tb
IIIC T85C Da IP67

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NIVOROTA - (Rotary
Paddle) : LEVEL
SWITCHES

FEATURES
Two-wire TDR Technology

APPLICATIONS
Level, volume
measurement

Digital communication
High accuracy: 5 mm
High pressure range

Liquids, powders
and granular
mediums with
Er>1.4

SPECIFICATIONS
Power supply:
230/120/24 V AC, 24 V
DC
Temperature: - 30C to
200C
Pressure: max. 3 bar

High temperature range

Extremely low dead band
Large Dot-Matrix graphic
display
Local programming feature

Medium with
turbulent surface,
dense dust, vapour
or pressurized gas
layers above the
product surface

Text-based menu system

For all tank

shapes, for narrow
vessels

Plastic coated stainless

steel probes (PFA, FEP, PP),

Heavy industrial
applications

Aluminium and plastic

housing

Output: SPDT Relay

250V AC, 15A
Process connection:
mouniting plate, or
BSPT 1'' / 11/2''
Ingress protection:
IP67
Ex marking: ATEX II 1/2
D Ex tb IIIC T__C IP67
Da/Db

Wide range of probes

Explosion-proof models

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EchoTREK for liquids (Ultrasonic Compact) :

LEVEL TRANSMITTERS

FEATURES

2- or 4-wire compact
transmitters

APPLICATIONS

Almost any liquids

Level, volume and

open channel flow
measurement

Reliable
measurement in
challenging
applications such
as vapour/fume,
stirrer, foam with
liquids

Non-contact level
metering
Narrow 5 beam angle
Fully temperature
compensated
Excellent signal
processing via QUEST+
software
PP, PVDF, PTFE,
stainless steel or foam
faced
Transducers
Optional field indicator
and plug-in
programmer
/display

SPECIFICATIONS

Power supply:
- 2-wire: 12.5-36V DC
- 4-wire: 24 V AC/DC; 230
V AC 11.4-40V DC / 11.428V AC
Ambient temperature: 30 C to +70 C
Medium temperature: 30 C to +100 C
Pressure: 0.3 - 3 bar
Measuring range:
-0.2 to 25 m for liquids
Outputs: 4-20 mA, relay,
HART, PROFIBUS PA
Protection: IP 67
Approvals: ATEX II 1 G
EEx ia IIB T6

Optional switching
relay
Built-in DataLogger
Plastic or aluminium
housing
* HART +
* PROFIBUS PA +
Secondary lightning
protection
Explosion-proof
models
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NIVOSWITCH for
liquids - (Vibrating
Fork) : LEVEL
SWITCHES

FEATURES

No moving parts
Self-cleaning for most
media
High immunity against
vibrations
Stainless steel and
coated (PFA) probes
Solid rod extension up
to 3 m
Various output
configurations
Selectable density
High or low fail-safe
mode
Plastic, aluminium or
stainless steel housing
Explosion-proof
models

APPLICATIONS

SPECIFICATIONS

Most liquids with min.

0.7 kg/dm3 density
and max. 10,000 mm2/s
viscosity

Power supply: 20-255V

AC, 20-60V DC

Corrosive, thick,
turbulent, flowing
liquids

Ambient temperature:
-40 C to +70 C
Medium temperature:
-40 C to +130 C
Medium pressure:
max. 40 bar
Process connection:
1'', 11/2'' or flanges or
hygienic fittings
Output: 1 or 2 SPDT
relays, 2-wire AC or DC,
transistor (PNP, NPN)
Ingress protection: IP
65/68, IP 67
Ex marking:
-ATEX II 1 G Ex ia IIC
T4...T6 Ga
-ATEX II 1 G Ex ia IIB
T4...T6 Ga
Approvals: Germanischer Lloyd
(GL) only for Compact
type (RF-400)
instruments

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NIVOPRESS D (Hydrostatic level /

pressure) : LEVEL
TRANSMITTERS

FEATURES

Two-wire compact
transmitter
Stainless steel
diaphragm
Measuring range: 0.1400 bar, -1 bar

APPLICATIONS

Most liquids and

masses in tanks and
vessels
Chemicals with dense
vapour or gas layers
above the surface

SPECIFICATIONS

Power supply:
-10-36V DC
Ambient temperature:
-25 C to +70 C
Medium temperature:
-25 C to +125 C

Foaming liquids
Scalable analogue
output

Viscous or corrosive
materials

Pressure: 0.1-400 bar,

-1 bar

Programmable
damping

Outputs: 4-20 mA,

HART

Level and pressure

management

Process connection:
1/2'', 1'', 11/2'' process
connection or hygienic
fitting

Secondary lightning
protection

Protection: IP 65
High overload
capability

Approvals: ATEX II 1 G
EEx ia IIC T6...T4

High accuracy <0.25%

Wide temperature
ranges
HART communication
Explosion-proof
models

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THERMOCONT TT (Temperature
transmitter) :
TEMPERATURE
METERS

FEATURES

2-wire compact
temperature indicator,
Transmitter
Integral Pt 100 probe
Plug-in type indicator
and programming unit
Measurement range: 50 C .. +600 C
Resolution: 0.1 C up
to 200 C

APPLICATIONS

SPECIFICATIONS

Normal and explosive

mediums

Power supply: 10...36

V DC

Temperature
indication and
transmission

Ambient temperature:
-20 C .. +88 C

Signal transmission to
large distances

Medium temperature:
-50 C .. +600 C
Pressure: max. 25 bar
Output: 4...20 mA,
HART
Process connection:
M20x1.5, 1/2'', flange

HART communication
Protection: IP 65
Probe length upto 3 m
ATEX
Aluminium or plastic
housing
Fully programmable
Heavy duty field
mountable housing
Explosion-proof
models

II 2 G EEx d IIB T6-T1

II 2(1) G EEx d ia IIB T6T1
II 1/2 G EEx d ia IIB T6T1
II 2(1) G EEx ia IIC T6T1
II 1/2 G EEx ia IIC T6-T1

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NIVOCONT R (Vibrating Rod) :

LEVEL SWITCHES

FEATURES
No moving parts
Self-cleaning for most
media
Stainless steel
vibrating section
Solid rod or flexible
cable extension up to
20 m
Plastic or aluminium
housing
Selectable density
High or low fail-safe
mode
Selectable switching
delay
Dust-Ex models

MALT PRODUCTION

APPLICATIONS
Almost any granular
material and powder
with min. 0.05 kg/dm3
bulk density
Grain, flour, plastic
granules, cement, fly
ash

SPECIFICATIONS
Power supply: 20255
V AC/DC
Ambient temperature:
-30 C to +50 C
Medium temperature:
-30 C to +160 C
Pressure: max. 25 bar
Process connection:
11/2''
Output: relay (SPDT)
or electronic switch
(SPST)
Protection:IP65, IP 67
(housing)
Ex marking: ATEX 1/2
D tD A20/21 IP67 T*

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References:

http://oregonstate.edu/instruct/css/330/five/BarleyOverview.htm
http://www.brewps.com/rye-malt-1-pound.html
http://www.probrewer.com/library/malt/the-maltingprocess/
http://www.maltosa.lt/en/production_of_malt,step.2
http://nivelco.com/egyeb/swf/malata_eng.html

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