MICRO-BREWERY

AUTOMATION

Alexis Caicedo Valencia

 CONTENT

•PROJECT DESCRIPTION
•STAGE 1
•STAGE 2
•STAGE 4
•CONCLUSIONS
 PROJECT DESCRIPTION
A group of entrepreneurs aims to open an alluring pub in
Bogotá. The pub has to offer high-quality craft beer with
exotic flavors. It is expected a demand of 50 liters of beer
per week. In this aim, the entrepreneurs have contacted
a master brewer to elaborate an attractive beer recipe.
Since the recipe is already done, a group of students
have the task to automate a section of this recipe.
The beer ingredients are: powder malt and water with
PH of 4.0 (at room temperature = 21°C).
The process that students must
automate is as follows:

1. Add 50 liters of water to Tank A

(see the figure).
2. Add 30 pounds of malt to Tank A .
3. Then Heat up Tank A to 52 Celsius.
4. While temperature arises, the
content in Tank A must be constantly
stirred.
5. When Tank A reach 52 degrees, the
temperature must remain still for 8
minutes without being stirred.
6. After 8 minutes, heat up Tank A,
again up to 62 degrees Celsius.
7. While temperature arises, the
content in Tank A must be constantly
stirred.
8. When Tank A reach 62 degrees,
the temperature must remain still
for 62 minutes without being stirred.
9. After 15 minutes, open valves B
and C to filter the thickness of the
mixture.
10. Then, when the filtering is done,
close valve C, As a result, Tank B
retains malt thick and the liquid
remains in Tank C
 STAGE 1
Activities to develop for this stage are:
1. Define that it is a sensor and an actuator.
2. Perform the flow chart describing the micro-brewery
process.
3. Distinguish possible sensors and actuators that could be
used to control temperature, liquid level, pressure,
displacement and angular movement.
4. Create a list of innovative ideas for the micro-brewery
process.
Definitions:
Actuator: Is a device with the ability to generate a force
that exerts a change of position, state or speed of some
kind on a mechanical element, from the transformation
of energy (Ramírez, LGC, Jiménez, GSA, & Carreño, JM
(2014 )).

Sensor: Element of a measure system directly affected

by the action of some phenomena, mass, body or some
kind of substance that carries the magnitude to
measure. (VIM, metrology, 3rd edition of 2012)
Flow chart of the micro-brewery process:
Table about actuators:
Advantages and
Variable Type of actuator Principle of functioning
disadvantages
Converts the electric energy It works so fine but it will not be
Angular movement Motor
into mechanical energy any cheap.
converts the energy of the
compressed air in mechanical It needs frequent maintenance
Linear movement Pneumatic work by means of a linear but it permits the general
movement of work, or of system operation
motors.
Raises the normal voltage, It has a quite good
representing the main source performance but it is necessary
Temperature Serpentine coil of accumulation of electrical to control the overheating
energy for the supply of the because its own temperature
spark plugs provokes error in the system.
Acts on a device to promote its It requires manual handling
Liquid level Valve
operation however it is cheap.
Table about sensors :
Measurand Type of sensor Principle of functioning Advantages and disadvantages
The junction of two different metals (e.g. Low cost,

Thermocouple cromel-alumel) induces a voltage as a function high precision, high operation range, low
of temperature sensitivity, etc.
It is a variable resistor that contracts or It is cheap but it need a good circuit to adapt
Temperature PTC expands the material within in a variable the incoming signal, it has a good sensibility
temperature but it range is short
It has an incredible precision and a wide
It measures the radiated energy from all the range, it works without touching or having a
PYROMETER
bodies around direct contact with the system that has to be
measured however it is quite expensive
CAPACITIVE Like the exercise where the dielectric in a
It is cheap, handy, however, it need a good
capacitor changes, the value of capacitance
circuit to adapt the incoming signal.
Liquid level changes if the liquid level changes.
It the simplest one, imagine a potentiometer
It has the same pros and no pros as the
BUOY that changes it value of resistance because
capacitive, but this one is cheaper.
there is a stick stuck in the pommel.
Pressure NOZZLE Determine the liquid flow Works accord with the required system.
PITOT TUBE Measure the total pressure with the static one. High range and good efficiency
It measures the current required from a
It is a simple system to control, it helps to
Displacement Differential transformer sensor, so if the current increases then the
move an object without crashing the motor.
torque has increased
List of innovative ideas

• It would really save money if the company

cultivate its own yeast.

• All the final beers should be contained just in

glass bottles, that can be returned, that way the
ambient wins and the company should not worry
too much in making the bottles.
 STAGE 2

Activities to develop for this stage are:

1. Define PID controller
2. Describe the technical specifications of the services
and actuators necessary for microbrewery
3. Design two PID controllers: one for the temperature
and one for the liquid level.
Description of the technical specifications of the services and actuators

• First step: valve A is placed in the open state, allowing water with PH 4.0 to pass
to tank A. When the level of tank A reaches 50 liters of water, valve A closes.
• Process two: the hopper valve containing ground malt is opened, falling into
tank A until 30 pounds of malt is completed, then the hopper valve is closed.
• Process three: With 50 Liters of water and 30 Pounds of ground malt, start to
rotate the spatula to stir the mixture and turn on the coil to heat the mixture to
52 ° C.
• Step four: When this temperature is reached, the spatula is turned off and the
temperature is maintained at 52 ° C for 8 minutes. After eight minutes the
spatula is turned on again while the temperature of the mixture is raised to 62 °
C.
• Fifth step: Once this temperature is reached, the spatula is turned off again and
kept at this temperature for 15 minutes. After 15 minutes, valve B is opened to
strain the mixture and valve C where the final mixture is stored.
When the process starts, SV 01 is activated by means of the PLC to allow the passage of PH 4.0 water
to tank A, until it reaches 50 liters of water.
The water tank with PH 4.0 has a level sensor LT 01, which sends a 4-20 mA signal to the PLC with a
range of 0 to 100 liters, to establish the amount of water poured into Tank A, upon reaching 50 Liters is
deactivated SV 01.
When this process is finished the PLC drives SV 04 to pour the ground malt, the ground malt hopper
has a WT 01 weight sensor that, like LT 01, sends a standard 4-20mA signal in a range of 0 to 80
pounds to the PLC to determine the amount discharged and upon reaching 30 pounds stop providing
malt to tank A by deactivating SV 04.
Then the PLC proceeds to operate the agitator and the coil. By means of TT 01, the PLC obtains
temperature information in tank A (signal 4-20mA, range 0-100 ° C).
At 52 ° C the PLC turns off the stirrer for 8 minutes and during this time it makes a PID control of the
coil to keep the temperature at 52 °.
After 8 minutes the agitator starts again and allowing the coil to work at maximum until it reaches 62 °
C.
After reaching 62 °, the agitator is switched off again and the PID control is now carried out again with
SET POINT at 62 ° C for 15 minutes. After this time the PLC proceeds to activate SV 02 and SV 03, so
that the mixture from tank A passes to Tank B where it is filtered leaving the remains of malt in the
filter and passing the must to tank C by means of SV 03 where Leave for fermentation.
PID controller design
 STAGE 4

Activities to develop for this stage are:

1. Define PLC, ladder language and LabView.
2. Develop a ladder language program that executes the
micro-brewery process.
3. Develop a program in LabView that runs the micro-
brewery process.
Definitions:

PLC: The "PLC" (Programmable Logic Controller) is a electronic device

that is programmed to perform control actions automatically.

Ladder language: they are commonly used schemes to represent the

control logic of industrial systems It is called a "ladder" diagram because
it they resemble a ladder, with two vertical rails (of feeding) and "steps"
(horizontal lines), in which there are control circuits that define logic
through functions.

Labview: It is a graphic programming environment, the language used to

program in it is called "Language G, where the" G "symbolizes that it is a
graphic type language.
Ladder language program
In this interface (developed in CODESYS), it is in purple
tone %IX0.0 or %QX0.0, the first expression refers to that a
pin is physically assigned to one of the variables described,
for Q, we talk of the outputs in our PLC.
In the previous image, the variables T1 and T2 are
appreciated, which will be our timers and will be
responsible for stopping the process for the 8 and 15
minutes requested in different stages.
With respect to the development of the stairs, we must
initial for the interlocking of the ignition and bear in mind
that the last staircase should take us to the interlocking to
ensure that the process will be repeated indefinitely.
LabView program
In the instrument panel, there are 4 main indicators, the
temperature of the boiler, the condition of the coil and the
spatula, together with a green indicator to know if the
microbrewery process has come to an end.
Each of the 4 valves have their respective green indicator,
only when they are on will we have water flow with pH
4.0, or malt, or mixtures before and after filtering.
The last important components for the development of
the production line, are the level indicators of each tank,
of the boiler and hopper that are in the capacity to show
the values at every moment.
 CONCLUSIONS
• The use of a simple flow chart is essential to systematize the form of the solution
and the saber of several elements that are due to (in this case) systematize the
microbrewery and not make bad economic investments.

• With the development of this activity we acquire new skills for the design of
automated processes in the industry such as learning to program in Ladder
language.

• LabView software allows us to provide infinite solutions both in the industry and
in small businesses that seek to improve the way of working. With this tool we
can handle complex systems with a variety of systems and actuators.
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¡MUCHAS GRACIAS!