The heritage is ours. CASK
The future PACKAGING is yours.
25
years of brewing innovation, engineering, quality and service.
Microdat are one of the UK’s leading suppliers of complete brewery solutions from dry goods to brewing, fermentation, to conditioning and maturation to packaging. We led the way with computer aided design and we were the first to implement 3D modelling, We also developed the worlds first thermal fluid wort boiling: the most energy efficient solution of its kind.
Tel:
From design, software and project management through to manufacturing, installation and after sales spares, service and support, Microdat look forward to using their 25 year +44 (0)to113 0489 info@microdat.co.uk history build457 your future.
Our Heritage Your Future
Leeds, West Yorkshire, LS8 1BQ, UK
www.microdat.co.uk
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The heritage is ours. The future is yours.
25
years of brewing innovation, engineering, quality and service.
Microdat are one of the UK’s leading suppliers of complete brewery solutions from dry goods to brewing, fermentation, to conditioning and maturation to packaging. We led the way with computer aided design and we were the first to implement 3D modelling, We also developed the worlds first thermal fluid wort boiling: the most energy efficient solution of its kind. From design, software and project management through to manufacturing, installation and after sales spares, service and support, Microdat look forward to using their 25 year history to build your future.
Tel: +44 (0) 113 457 0489
info@microdat.co.uk
Leeds, West Yorkshire, LS8 1BQ, UK Microdat 2014
Telephone 0113 www.microdat.co.uk 244 5225 microdat.co.uk
Cask Packaging for the Small Craft Brewers Following many innovations, Microdat, the market leader in cask packaging, has revamped its range of cask packaging products specifically aimed at the small craft brewer.
Taylors and St Austell breweries, both of which have the latest CW340 cask washer.
This document is aimed at those requiring cask packaging at below 100 units per hour.
All Microdat products are specified using the Firkin (9 gallon cask) as the benchmark, thus a CW30 will wash 30 Firkins per hour as a minimum operation.
For a typical English ale brewery this would be in the region of up to 40 barrel brew lengths. From 40 barrels and above the Microdat mid-range cask packaging equipment is more appropriate.
The products described in this brochure are a family of products that can be linked together to form a cask packaging production line. This optimises performance and ensures that product is packaged correctly.
All Microdat cask packaging products utilise the same quality washing and filling processes which apply right across the range thus the small craft CW30 cask washer has a very similar wash process and timings to those used at the large Timothy
A well washed, clean, sanitised cask which is then metered gently and along with the correct amount of additions such as finings, primings, whole hops etc, creates a quality product. UK craft brewers produce their products with love and passion and Microdat feel exactly the same by offering the best products developed over many years of experience supporting cask conditioned ales, stouts and porters. Microdat produces quality products for quality brewers and aim to support in the long term so that Microdat too can enjoy the products produced. Cheers! to crafted real ales.
St Austell Brewery Opening Day
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Planning a Cask Packaging Line Unlike most other packaging production lines the manning of the cask line must be considered as it is not practical to remove the operator from the direct production process. (Even on a 600 cask per hour line operators are still required to man the line to keep production flowing). Bottling, canning and kegging lines can be fully automated but cask lines cannot, in practicality, be totally automated. When planning a cask packaging facility it is important to think about the operator. If the operator is looked after the packaging line for the ‘precious’ beer will also be looked after. The UK brewing industry is fortunate in that tradition has somewhat overruled regulations; but these are always there in the back ground and if a serious incident occurs it is certain the HSE and other government bodies will bring these to your immediate attention. The basis behind the manual handling regulations is common sense – therefore remove lifting, repetitive, arduous strenuous operations, noise, trap points and direct access to hazardous chemicals. This list is not exhaustive but highlights the main issues.
Cask Returns To The Brewery In large breweries the days of drays bringing back a random assortment of casks from various pubs has largely disappeared. These are mainly processed by depots where they should be sorted into owners, size etc. Depending on the brewery the cask will then be either Unitised or Palletised.
these are now more readily available. Many small craft breweries use combinations of pallets and locator boards (Combo Stacks) i.e. a pallet on the base (1200 x 1000 or 1200 x 800) and then plastic locator boards to separate each layer. This
Microdat defines a “Unitised Load” as a stack of 18 Firkins, in three layers, with plastic locator boards on top of each layer or similarly 8 Kilderkins in two layers of 4. Microdat defines a “Palletised load” as a stack of firkins, in layers, with a wooden pallet on the base of each layer. The numbers can vary significantly depending on the pallet size and cask size the original industry standard was the Whitbread format 8 firkins per layer on a Whitbread pallet 1310 x 1200 mm with a solid top either close fitted planks or plywood. Greene King, for example, still uses this format. The Euro-pallet and many others are also used as
enables a standard pallet truck or fork truck to transport the stack within the brewery. There are still a few breweries that use the very traditional saddle pallets. These hold the cask laid down in a cradle format; usually 6 Firkins per layer or 4 Kilderkins. They are good for filling and venting a cask as the cask can be set with its bung hole or shive on top. They are however usually heavy pallets and the casks are difficult to handle when removing them from a pallet. They were also very difficult to handle automatically hence
Whitbread Style Pallet
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why they have lost favour in the industry. However, stalwarts such as Dark Star brewing in Sussex still use saddle pallets internally but now have to make their own pallets. The main point about the above comments is to show how casks may be received at the packaging facility and thus initially beginning the reprocessing operation. So: Will they be loose casks returned in a van, stacked loosely in the yard or shed, blocked stacked and then probably rolled to the re-processing area? Or: Will they be stacked stored as Unitised, Palletised or Combination stacks and delivered for re-processing by a fork-truck, clamp-truck or simple pallet truck, in bulk? Orientation The term Microdat uses to define the casks orientation is “On End” or “Laid Down” when a cask is conveyed “Laid Down” it will be either “Cradled” in a “Vee” block laid across the conveyor, or run “Gun Barrel” in line with the conveyor. A loose cask is difficult to move in bulk at best. Two or three Firkins on a sack truck is an option but a combination stack is usually the best method for the small brewer. This allows
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a standard fork truck or pallet truck to move a stack with ease (assuming there is flat yard or warehouse). The advantage of a cask on end is it’s easy to remove the keystone (tap plug) with a keystone removal hammer (hammer with a hook end).A good operator can remove 6 keystones from a single cask layer in seconds. The harder part is removing the shive especially when the cask is on end. There are an assortment of tools, hammers, spikes and chisels around for removing shives all of which require good hand-eye coordination and strong bones and muscles. There is a danger here from back strain and repetitive strain injuries. Several hours per day knocking out shives manually will eventually cause problems with wrist and elbow joints: perhaps not immediately but possibly in years to come. These issues need to be mitigated if possible.
The Microdat DeShive Gun Microdat makes fully automated De-Shive and De-Keystone (DS-DK) machines for the larger breweries, these are £120 000 per machine removing up to 350 shives and keystones per hour. Manual
operation is usually around 11 casks per hour to DS-DK. After research and development Microdat has produced a manual shive extractor gun to aid this process. The reject line after a DS-DK machine has the casks “On End” on a reject conveyor so a single handled gun is the best option here suspended from an arm and balanced by a weight to provide free movement for a single handed gun operation whilst the cask is held by the other hand. The single handed gun works well on casks “On End” which could be in a stack as a combination stack, “Unitised” stack or “Palletised” stack. To support the gun for operation around a stack a substantial gantry unit is needed with 3 axis movements. The gun then needs to be suspended from a hose spring balancer unit mounted on a carriage. With this arrangement it is still difficult to attend to the bottom row of casks as the operator will need to bend over. There are two other options to consider depending upon the next stage of the process. For a simple rolling rail solution where the cask is laid down across two rolling rails and moved under gravity a Microdat simple De-Shive station is a solution.
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which allow the cask to swivel to locate the shive at the top. The shive gun can then be located above the casks shive and via a single trigger the operator can grip and extract the shive from the cask.
This twin is designed for higher production rates and would normally be used to feed a CW120 to CW240 cask washer.
Note: If you use a Microdat cask washer you do not need to prerinse the cask prior to washing.
Microdat provides an option to externally clean casks. The simple option is a pressure washer in the yard; however there is now a solution which works with the Microdat DS Station 3 shive gun option.
The task is simple efficient and ergonomically sound.
This simple module has infeed rolling rails normally supplied up to six metres long, complete with an adjustable stand. The rolling rails feed casks to a simple manual De-Shive station which has a plastic stop and shaped curved “Vee” blocks
The DS Station 2 £ 16,500.00 plus Vat ex works
If a brewery wants to collect separately the cask’s ullage (cask bottoms & strong effluent) so that it can be separately disposed of then this module can be used to rotate the cask to drain.
The operator then swings the mini jib to drop the shive in a bucket, again via the single trigger. The cask is then rotated 180 degrees on the blocks to dump any excess ullage into the drain via the solids collection tray.
The DS Station 1 £ 4,500.00 plus Vat ex works
further ullage which drips from the now open cask.
The liquid dumped from the cask can be either sent straight to drain or collected for processing as “Strong Effluent”. After dumping the ullage from the cask it is simply rolled from the station and down another set of rolling rails. The discharge rolling rails would normally be supplied in up to six metre lengths, however a collection tray would be fitted between the rails to collect any
External Cask Washing
A low speed simple plastic chain transport conveyor mounted in a trough is loaded with the now keystone free casks. The casks are loaded manually onto the conveyor with the keystone down to enable some ullage to drain from the cask. A manual stop will hold back the casks from entering the external washer module. The DS Station 3 shive gun will be a single handed gun mounted on a hose spring balancer on a simple overhead carriage which will enable the gun to move up and down the line of restrained casks on the slow moving conveyor.
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External Cask Washer @ Deshive Gun The operator will be able to simply hold the DS extractor gun in one hand, hold and manipulate the cask in his other hand and then use the gun to extract the shive. Once the cask is De-Shived the operator will simply release the casks via a button which will index in the casks to the external washer.
The EX90 Drum Washer ÂŁ 12,995.00 plus Vat ex works Various types of conveyor are available to suit the application. The EX90 is a small efficient washer, label remover designed for small cask and keg production lines to feed a Microdat CW60, CW80 cask washer or KWF26, KWF35 or KWF60 keg washer filler. The maximum speed is
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90 units per hour to match the needs of a CW80, however it can be slowed to match the line speed and give a longer wash if required. As a new drum enters the chamber it will pass through a spray bar to wet the drum as it moves into the gate. If a drum is present within the gate it will be held back by the gate and will be washed by the simple spray bars. The drum in the gate will rotate the rear gate rollers which will, in turn, rotate the next drum held at the gate entry point. The drum within the gate will be clamped and rotated by the driven front rollers. It will be slowly rotated in front of the high pressure jets. Whilst rotating, high pressure jets will traverse the drums top and the side to effectively
clean and remove any paper labels from the area impinged by the jets. The pressure from the jets is approximately 80 bar pressure and is generated from a high pressure pump module mounted separately from the washer, on the floor, inside a sound deadening box. The pump unit is connected to the washer via a flexible hose to prevent vibration being transmitted from the pump to the external washer. A clean ½ inch bore fresh water supply should be connected to the high pressure pump inlet, also via a hose to prevent vibration transmission. After approximately 34 seconds the washed drum is released and a new drum enters the external washer gate. From the external washer the drum is delivered via a conveyor to the next processing station.
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Small Craft Brewery Cask Washing In 2013, Microdat released a new range of improved cask washers including a CW30, CW60 and CW80. The numerical value for each washer is the minimum number of Firkins the cask washer will deliver at its normal washing setting. Time is allowed for loading hence the CW80 has a downgraded performance even though it has the same relative performance as the CW30 and CW60. For a short period the CW80 could be capable of washing 90 Firkins per hour with a good operator. Please note on a Microdat cask washer you remove the shive and load the cask onto the washer thus no separate draining or rinsing is required. The Microdat cask washer has been developed over the last 25 years to provide the optimum washing performance on normal brewery-pub-brewery circulated casks.
Safety in Operation A Microdat cash washer is a safe to operate machine and complies in full with all the UK’s HSE regulations and is CE compliant.
Microdat CW80 Cask Washer There are no operator accessible trap points to trap the unwary operator’s fingers. The washer will only operate if a cask is present on a wash nozzle. A sensor at each station has to be triggered by the cask to activate the potentially dangerous, pressurised liquid flow of, hot water, strong detergents, such as hot caustic and steam
The Cask’s Condition No cask washer can guarantee to wash every cask presented to it, as it’s impossible to pre-determine its dirty state. A particularly bad, badly contaminated cask may require a second wash or a pretreatment to washing. On a Microdat cask washer all reasonable casks should be effectively cleaned on its first pass. Traditionally one of the most important men on a cask
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production line is the “Sniffer” or “Plugger” who inspects the cask after washing. A really bad cask should be picked up and withdrawn from the production line when it’s first broached as it will literally stink! A lesser infected and bad cask may pass this first test on the line, but it may still smell bad after washing which is an indication that a bad cask may need further processing to become effectively clean! Ideally
every
cask
should
be internally inspected after cleaning to ensure it smells sweet and clean and has no internal contamination. Microdat produces a “Cask Inspection Lamp” . This is used by companies such as Timothy Taylors where it is used to inspect every cask after washing before inserting a new keystone. Casks can be contaminated with many things from dead rats, birds’ nests, mice, and insects. One of the worst infestations is
that from fruit fly larva as they have a particular adhesive quality. Fruit fly infestation can be easily prevented by the landlordbarman closing the cask with a cork or stopper when used. It is in the brewers’ and cask suppliers best to make sure customers have post-dispense, cask closures. Microdat have for many years attempted to tackle the problem of fruit fly larva infestation and it’s only recently, with continued improvements and developments, that this has been successful. The latest washing system with an especially developed and manufactured rotating wash nozzle plus 5 to 6 bar washing process is the best available solution for this problem. If there is a really bad infestation it may be necessary to pretreat the cask prior to washing with a Holchem type acid based detergent is the best soaking agent to remove fruit fly larva followed by a good cask washing.
Microdat CW30Cask Washer
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The Standard Process on a Small Microdat Cask Washer is as Follows:Operation 1 De-Ullage Direct to Drain Operation 1
De-Ullage Direct to Drain On a Microdat cask washer there is no need to de-ullage or pre-rinse the cask. When the cask’s Shive (Bung) and Keystone (Tap Plug) have been removed simply place the cask on the washer and send the cask’s ullage direct to drain. This process commences when each cask is loaded. On lesser cask washers it is generally necessary to de-ullage-drain and prerinse the casks to prevent it contaminating the wash tank. This takes additional time when compared with the Microdat washing operation. A simple basket at the drain exit can collect any solids such as pegs, tuts, and corks etc. which pass through the washer before entering the drains. Operation 2 Automated Pre-rinse Direct to Drain The first washing process on a Microdat cask washer is an automated rinse with recovered final wash liquor which then flows direct to drain.
The time for the pre-rinse-to drain is sufficient only to enable the same amount of wash liquor that is recovered from the final rinse operation to be dumped to drain, (about 6 litre/cask). This is sufficient to thoroughly rinse the cask and remove the main ullage, cask bottoms and contaminates direct to drain. This balanced pre-rinse operation is what is unique about a Microdat cask washer and results in minimal water usage, effluent discharge to drain and efficient production. Operation 3 Pre-Wash to Recovered Liquor Tank This is where lesser washers start the washing process, after being manually Drained and Pre-rinsed. Recovered hot liquor is now used to pre-wash the cask. The internal drain shuttle valve will position its self automatically to divert spent wash liquor dropped from the cask to return to the recovered liquor tank. The pre-washing operation uses the recovered hot liquor to pre-wash and pre-heat the cask, prior to
the detergent wash operation. The recirculating liquor from the cask may have contaminants present and is therefore filtered twice. The first stage filter is a simple filter tray easily visible to the operator. This can be easily removed to remove the solids. A second stage filter is incorporated to protect the valves, pump and wash nozzle from blockage, this cartridge type filter is located in the tank base at the outlet to the pump, and it is again easily cleaned. Operation 4 Hot Detergent to Detergent Wash Tank The hot detergent wash uses the customers preferred or Holchem detergent and parameters can be adjusted to suit the detergent supplied. The supplier will normally recommend a detergent strength and ideal temperature. The touch screen on the new Microdat cask washers allows the operator to set the temperature and detergent dump frequency based upon the number of casks washed. A warning will show on the screen
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when nearing the pre-set limit, and then again when at the limit an alarm will show and prevent further washing. A detergent dump and refill will then be required.
cask washer - normal and extended. The normal setting can include an additional setting for different cask sizes i.e. Firkins or Kilderkins, Kilderkins are generally washed for longer.
A Holchem detergent dosingmetering pump can be added to the new cask washers on request. This adds a timed injection as a ratio when the tank initially fills or tops up. Alternatively the screen will instruct the operator to add detergent, and then wait to confirm the detergent has been added.
The extended time is an operator setting via the touch screen. It only extends the detergent wash time - not the balanced time for Final Rinse, Pre-Rinse and Pre-wash.
After a few initial cask washes the water in the pre-wash tank will have warmed up from recovering the final hot rinse liquor, excess heat from this recovered water is indirectly transferred through the tank wall to the adjacent detergent tank. This saves energy in heating the detergent tank and from cooling the detergent via cold casks. When a Microdat cask washer is actually in production the detergent heaters switch off and only effectively trims the temperature of the detergent. There are two settings for detergent washing on a Microdat
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Two stage filtering is also incorporated to protect the valves, pump and wash nozzle during recirculation of the detergent fluid through the cask.
and Timothy Taylors. It is possible to have a final cold, cask rinse, using a sterile agent such as Holchem’s PAA. Microdat does not necessarily recommend this form of sterilisation but there is an option on the new Microdat cask washers touch screen to select cold sterilisation. Please note that all critical settings are protected by a passwords to prevent unauthorised access to the setting pages. Operation 6 Steam Injection
Operation 5 Final Rinse Water Tank
to
Recovered
The final process on a Microdat cask washer is a Hot Final Rinse to sanitise the cask. This pulsed washing operation ensures the casks internal surfaces have reached 80 degs centigrade plus, at which point most organisms which will spoil cask ale, have been destroyed. This principle applies to all Microdat cask washers from the CW30 to the large CW340 used by brewers such as St Austell
It is also possible to add an additional steaming valve; however experience suggests that this does not deliver any benefits to cask washing and adds significant cost to the washing and sanitisation process. As a cask is not a pressure vessel and technically should not be pressurised above 0.5 bar it’s not practical to fully steam sterilise a cask. (This is not true of a brewery keg which is a recognised pressure vessel rated at 3 bar gauge pressure). Micdodat will add a steam
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option upon request to any cask washer. If an added steaming option is used the condensate from the cask will be recovered back to the recovered liquor tank. If steam is used from an existing steam boiler, please note that it must be clean culinary grade steam as it is being injected into a clean cask. The pressure should be 0.5 bar gauge maximum which will normally require a steam reducing set and culinary grade, steam filter. These additional components are available from Microdat on request. If steam is not available and it si required to steam casks in the traditional way, Microdat can supply a small electrically heated, steam generator for just this task. This removes the need for steam pipework, reducing sets and culinary filters. Microdat also these units on the keg washer fillers. Operation 7 Remove The Washed Cask When the washer completes its processes and satisfies the pre-set wash parameters (time, temperature and pressure) the
result is a clean, washed and sanitised cask which will not spoil crafted beer or cider. At the end of the washing process the cask will be drained and ready to be removed from the washer. If during the various processes a cask parameter is not met then the washing process will hold and an appropriate alarm will be displayed. A log of any alarms is retained in the washing machine’s digital processor and can be reviewed via the screen or remotely via an internet network connection to the machine. All the new 2013 Microdat cask washers have inbuilt remote diagnostics and data logging capability so that we can remotely assist you with operational issues and minor faults from Microdat’s HQ in Leeds; or data is recorded from the washer; e.g. the time each cask was cleaned. The machine could even log the cask’s data from a bar code, or RFID tag if required. The Clean Washed Cask In an ideal world the cleaned and sanitised cask would be
either filled or closed to prevent contamination of the clean cask. A hot clean sanitised cask will be filled with hot vapoursteam which will condense, this draws in air and possible air born contaminants from the surrounding environment which could spoil your beer. The best and traditional solution is to wash and fill immediately; a keystone should always be fitted securely, and of the correct type to match a hot cask. If the cask is not to be filled then the cask should be closed with a shive. This does not have to be fully hammered home; but note the partial vacuum formed within the hot closed cask may draw in the shive. The Microdat shive extractor gun can be very useful in removing a shive from a closed washed cask for filling; and yet still allow this shive to be reused after filling. The better solution is to wash and fill. For a small brewery one man can easily wash and fill effectively. Why double handle the casks when there is really no need to and a very good hygienic reason they should not be?
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Small Craft Brewery Cask Filling While it is possible to manually fill a cask from a tank via a simple hose, valve and tube it is not very efficient for a number of reasons. The operator will have to remain with the manual filling valve and will need to measure and control the fill level. On all Microdat cask fillers the filling is fully automatic. The simple CF50 brim fills to about 95 to 97% of the full volume leaving the operator to finalise (top up) the fill. The operator can prepare the next cask whilst the cask fills on the filler. The CF55 and CF80 are totally automatic fills. The total time to fill a batch of casks is much faster using a Microdat cask filler than manual filling. On a typical manual filling operation the initial beer flow is rapid and encourages oxygen pickup, fobbing and removes some of the natural carbon dioxide conditioning from the beer. The beer flow via a Microdat cask filler is controlled and gentle using a peristaltic hose pump. The initial flow of beer is
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slow and gentle thus reducing the oxygen pick up in the beer, to improving quality. Beer is often wasted by overfilling the cask; it takes considerable time, care, patience and concentration to reliably, hand fill casks. The Microdat CF50 brim fill or CF55 or CF80 metered fill controls the final fill such that beer is not wasted by over-filling the cask. Beer losses of less than 0.5% are typical with good beer and process systems. Isinglass finings dosing can be missed or incorrectly dosed by the operator leading to cloudy beer, returned beer, dissatisfied customers and potentially lost sales. All the Microdat cask fillers inject the correct amount of Isinglass finings into the main flow beer stream to ensure its does not contact a hot cask and is thoroughly mixed in. High Flow-Low Flow and the lack of flow control means that brewery vessels often used for racking have high static heads when full and then a low static head when nearing empty. This is very relevant when using cylindrical conical vessels. A
typical manual butterfly valve is a poor beer flow regulator. Microdat’s cask fillers fill every cask at the same consistent speed, using precisely controlled and variable beer flow. The special HHP pump holds back high flows from a tall full vessel and speeds up the flow when the vessel is nearly empty. Microdat’s cask fillers control consistent flow from the racking vessel, whether you fill directly from FV, CT or transfer and fill from a dedicated racking tank, RT. On a Microdat cask racker-filler the operator does not need to stoop to fill the cask, the cask is either placed on a kicker cradle or a rolling rail system. The filling head is designed to enable the operator to remain standing straight whilst operating the filling head but the actual valve which closes off the final beer flow is as low as is practically possible to prevent beer loss when the filling stops. The typical manual hose, tube and valve assembly of a small brewery cask filling system accounts for much more losses if the beer tube is kept long or the manual filling operator has to stoop down on a short tube and low cask.
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CF55 Single Head Cask Racker-Filler ÂŁ 14,995.00 plus Vat ex works This machine appears at first glance to be very similar to the CF50 however it has much more in common with its sister the CF80. The CF55 can be converted to a CF80 in the future by simply adding the extra head, valve and beer manifold etc. Microdat can supply a self-install kit of parts with instructions and downloadable software changes to Plc processor via the Internet or a service engineer can upgrade. The CF55 and CF80 share the same common modern and powerful Plc, touch screen, computer based, digital controller. This unit is able to hold powerful control software and has memory capability to store many programs, recipes and data and communications options. This miniature Plc controller has more computing power than many breweries which supply the beer for filling. Meter Filling Standard)
(Included
as
Both the CF55 and CF80 use accurate meter filling as standard thus saving on wasted beer and overfilling the cask.
Microdat CF55 Most casks are oversize too much beer may be supplied with brim fill systems. Filling and selling a cask with accurate contents is what is demanded from both local trading standards and HMRC. The space left in the top of a cask is also beneficial as it allows the shive to be safely hammered home and made secure. This is never a problem with real cask conditioned beer as the carbon dioxide has already filled the space during filling and any oxygen will be quickly consumed by the live yeast conditioning the casks beer within.
The CF55 and CF80 Filling Operation On the CF50 a simple manual butterfly valve is used to open the flow port for the beer whilst on the CF80 a fully automated valve arrangement is incorporated into the filling heads. The operator commences filling by a button which triggers the controller to open the valve and start the pumping and metering operation. The operator can now leave the system to fill automatically. On a CF55 the operator may be tasked with washing and filling and could thus be off loading a CW30 or CW60 cask washer,
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inserting a keystone and loading the next casks to wash. When the CF55 has fully completed its filling operation the filling tube will automatically withdraw leaving the cask clear for closing and re-shiving. The operator then simply ejects the full cask and loads the next cask. The Microdat CW30 or CW60 and CF55 are thus perfectly matched for a single operator washing and filling operation.
CF80 Twin Head Cask Racker-Filler £ 18,495.00 plus Vat ex On a CF80, with its second head, much higher production can be achieved such that two men will be required to get full performance from a CW80 and CF80 washer filler system. The CF80 with its second head and filling station can be prepared and readied whilst the other head is filling. Thus the next cask can be racked, oriented and the second head inserted. The operator will then press the start button on the second head which will be logged within the CF80’s controller’s memory.
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Microdat CF80 Cask Filler As soon as the first cask is filled the divert beer values will transfer over the beer flow to the second head and the next cask will be filled immediately and automatically. The first cask will be left ready for closing, reshiving and ejection etc. Blending Options on the CF55 and CF80 Ex-works price from £3,895.00 Plus Vat A simple but very useful feature of the intelligent CF55 and CF80 is the ability to blend beers from two stock beers. By adding a blending pack an extra pair of auto-valves is added to the beer inlet. Via a simple recipe selection a blended beer can be created
in the cask. For example Beer C could be created from 2/3rd Beer A added to 1/3rd beer B. Other recipes can be held within the controller’s memory to provide a simple but effective and reliable metered beer blending option. Detachable HHP40 Pump Unit (Included as Standard) The CF50, CF55 and CF80 cask fillers also have a new major advantage: the cask fillers come with a separate, detachable, HHP40 (Hygienic Hose Pump). As a separate pump unit the HHP40 is a very versatile and useful brewery pump. Its flow rate is variable, from 0 to 87 litre/min with its own integral, variable speed, digital drive controller.
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CIP & Cleaning The HHP40 provides the perfect solution for tank cleaning and CIP scavenging. In the same way it can self-clean the cask fillers it can be used for a variety of other brewery cleaning activities. When removed from the cask fillers it loses its pulsation damper which means its pumping action will have a more pronounced pulsation action as the twin rollers squash the tube in side during every revolution. This feature is very effective at cleaning and improving the cleaning action during CIP. As a vessel cleaning pump it can rely on both its suction to scavenge the vessel or pipework and its ability to produce pressure and pressure pulses for cleaning. The HHP40 makes a perfect CIP supply and scavenge pump combined into one package. The Microdat “Mobile CIP From ÂŁ6,995.00 plus Vat ex works A Microdat Mobile-CIP-Tank (MCT) provides the ideal and simple solution to small brewery cleaning. It enables small breweries to utilise a large brewery 3 tank cleaning system with recovered liquor via the detachable HHP40 cask filler pump. The system can be manually operated or via the
intelligent CF55 or CF80 control system it can be fully automated. The MCT is based upon a special vacuum rated mobile vessel and a set of 3-port divert control valves. The unit connects to the supply tanks, a cold water supply, the vessel to be cleaned and the HHP40 pump. The system can supply a tank rinse to drain, a full pre-wash with recovered liquor from the last tank clean, a full caustic wash (hot or cold) and full post rinse, recovering the first caustic enriched wash, to the recovery tank and then enabling a final recirculated post rinse with PAA which is eventually sent to drain. During the whole of the CIP the pump will operate to supply the correct cleaning pressure for the tanks spray ball and scavenge the tank to provide an effective clean. General Beer Transfer Within The Brewery (Included as standard) The HHP40 makes an ideal beer transfer pump to transfer beer from vessel to vessel. The
gentle pumping action which is low shear protects the beer, maintains condition and does not encourage oxygenation. The pump totally controls the flow such that when it stops rotating its stops the flow. The pump rotational speed is directly proportional to the flow rate. The HHP40 is rated at 1.25 litre/rev. The pump can be used for metering beer flow but accuracy is compromised by significant changes in pressure. Simply counting the number of pump revolutions during a beer transfer can provide a reasonable indication of the volume delivered, but Microdat can supply a range of good value and robust Magflow Hygienic Meters for accurate beer metering. This unique pump unit also has the ability to reverse flow and push beer in both directions through the pump, thus it is possible to part empty a vessel via a hose to the pump and then reverse the pump to return the beer from the pump to the tank thereby saving the beer from the hose.
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Beer Transfer, Rousing & Auxiliary Finings Mixing Preparing Racking
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beer
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Cask quality is all about consistency, the auxiliary finings (AF) should be well mixed in. In large breweries this is usually metered and injected into the beer stream during transfer from FV to RT and the RT will usually have a rouser (stirrer) to ensure that the beer is well mixed with the AF and has a consistent yeast count throughout the whole product batch prior to racking. The now separate HHP40 pump from the fillers provides the ideal solution to perfect beer preparation. Simply add the auxiliary to the FV and rouse using the HHP40, this will both mix-in the AF and ensure the whole beer batch has a consistent yeast count. After gentle circulation the beer will be ready to rack. On the more intelligent CF55 and CF80 cask fillers it is possible to have automated auxiliary injection of silica based finings as this can be metered and injected into the beer stream by a separate HHP pump unit mounted into the beer feed to the CF55 or CF80. This type of auxiliary finings injection
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is not recommended for alginate finings which should ideally have a holding period of about 4hr prior to racking. Hand dosing AF into FV and then using the separate HHP40 beer filler pump as a rouser is the better solution for alginate finings. The HHP 40 can both suck and blow. It is also ideal for handling difficult and semi-solid products like yeast and can be used for transferring yeast, pitching yeast and skimming yeast on a cask plant. For further details see the documents on Yeast handling and Hygienic Hose Pumps. On larger breweries with fixed piping systems the special Microdat Hygienic Hose Pumps up to 65mm bore are being purchased specially to replace three traditional pumps for beer transfers, CIP scavenging and yeast handling. If you purchase the new Microdat cask fillers you get this multipurpose pumping solution for free! Casks Post Racking The final problem for a small cask brewer after racking is product labelling, data collection, full cask handling and warehousing.
At larger breweries Microdat provides a range of automated and semi-automated solutions to cover the above areas. We also have solutions for the smaller discerning brewer who wants to record product data, label the product well and provide a production team with the correct manual handling solutions. Data Collection Starting at the CF55 and CF80 Racker The intelligent Plc, touch screen, computer controller within the CF55 and CF80 are modern day powerful programmable devices which are easily networked and connected to other brewery systems. By simply interfacing the touch screen controller to the brewery IT network and internet enables Microdat to support you remotely should you require, help, software updates, additional recipes and functionality. It also allows Microdat to transfer data to other systems. Thus information on each cask is held within the controller such as the time and date filled, the actual volume and other production data such as “who� the racking operative was and the product data. Reading and recording cask data from cask bar codes is also possible. Special requests can be discussed, where
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possible Microdat are happy to incorporate new ideas and enhance the product.
Cask Handling
Cask Labelling
At larger breweries Microdat supplies fully automated handling solutions for casks at up to 600 Firkins/hr and kegs up to 1200 x 50 litre kegs/hr.
Microdat is actively involved with cask labelling at larger breweries fully automated cask and keg labelling systems are manufactured and installed. Due to recent developments with partners Microdat can also supply print and apply labelling solutions which directly link to systems such as the CF55 and CF80 racking-cask-filling machines.
In small breweries there are requirements for manual handling of full casks of significant weight, substantially above the maximum weights allowable for lifting, on a regular and continued basis. Anyone designing a working system for handling full casks should consult the HSE manual handling regulations and guidance information.
For example, Microdat can supply, print and apply industrial thermal transfer labellers which, once the filling is complete can be applied by the racking operative. This label can be uniquely time and date stamped, with the product code and bar code data or the new 3D bar codes if required. Readable links to your website, for product data and special promotions, can also be incorporated. Full
At very low production levels simple solutions can be applied but when production levels exceed 30 heavy units per hour it is really time to consider mechanical handling aids. On the basic cask filler, rolling the cask away on the floor is the simple solution, however, leaving the cask laid down on the floor is very expensive and poorly utilises warehousing space. To maximise warehousing space it is necessary to stack cask This was originally done using a saddle pallet and a fork truck. Saddle pallets have almost disappeared from the UK’s brewing industry as they are heavy and difficult to use. They did, however, have the
advantage that they maintained the cask laid down and thus could allow the cask to vent via the bung and a breathable peg. It was also useful to have the cask in this orientation for injecting isinglass finings just prior to dispatch. Modern finings however are now generally added during filling and so this type of storage and palletising system has almost died out. At most UK larger breweries the “Unitised Load” and plastic locator board has become the norm. This however requires a specialist brewery clamp truck to hand the Unitised stacks of 18 Firkins and 8 Kilderkins. Microdat has both semiautomated and fully automated solutions for Unitised loads but these generally become viable and necessary on cask racker-fillers producing over 120 Firkins/hr. There are a few major UK brewers who still use the special “Whitbread” wooden pallets with solid boarded or plywood tops with dimensions of 1320mm x 1200mm palletising casks like this is very expensive to automate. The common solution for smaller breweries is a combination system using standard base wooden pallets 1200 x 1000 or 1200 x 800 mm for Firkins with a second or third layer separated
Cask Labeller Panel
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Microdat CKL-150 Cask and Keg Lifter
by a plastic locator board. For Kilderkins a 1200 x 1000 or 1000 x 1000 mm pallet can be used. The standard plastic locator board is reasonably light and can generally be handled by one man.
CKL-150 Cask & Keg Lifter for 150kgs £ 12,995.00 plus Vat ex Thus the Microdat solution for small breweries with cask racker-fillers like our CF50 to CF120 range is our “Cask Lifter”. This simple jib type heavy duty crane is easy to operate with its swinging arm and free running carriage. The lifter has a unique hook which locks to the cask either from the “laid down” or cask “on end” position.
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Simple up and down buttons raise a lower the cask under precise digital drive control and lock in position when the rise or lower button is released.
The stacker operator then simply positions the jib, collects the cask and moves it to the pallet-unitised combination stack (combo stack).
Unlike vacuum lifters the load stops and freezes at position via a strong electro-mechanical break unit which fails safe if the power fails. There is no fan, no noise, and no unwanted movements.
The cask will swivel to the vertical as it’s lifted so it’s then easy to position the cask on the base pallet or on a second layer.
With the new 2013 racker-filler designs it is easy to have simple rolling rails below the filling positions with ejectors to eject the full cask down the rails to the cask lifter.
A standard fork or powered pallet truck can move the combo stack to the warehouse. If the brewery purchases a clamp truck the cask lifter can be used to assemble unitised loads of 18 firkins or 8 Kilderkins.
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Upgrades and Trade-Ins As a brewery grows there are many options to upgrade from Microdat’s portfolio of cask products to either enhance existing machines and systems, or alternatively explore Microdat’s generous trade-in deals. In almost all cases Microdat are happy to upgrade and tradein existing machines for new machines. Alternatively Microdat are happy to assist in selling on old Microdat machines when buying new. On sale facilities will include free advertising both on the Microdat website and via Microdat’s regular mail shots. Microdat will also fully refurbish,
service or resite any existing Microdat machines on request. In some cases Microdat will also consider trade-ins and upgrades to other manufacturers machines such as Chadburn, Gimson, Tusker, Neubecker and Esau & Hebuer. Microdat have over the years either acquired these businesses, and thus holds the legal rights to the drawings, designs software etc., or have worked with and gained extensive experience of the equipment.
Financing Growth Microdat work with Bluestone Leasing to finance new capital equipment from the simple CW30 cask washer to whole breweries.
Microdat Cask Products for Small Breweries Microdat are not always the cheapest in the market but Microdat machines are robust, reliable and long lived. Any machine installation is a small project in its own right and any initial teething difficulties will always be remedied with the customer. Many of the best and oldest brewers of real ale in the UK use Microdat products; a testament to the quality of the product. Microdat’s process experts and brewing consultants Paul Ambler and Graham Walker are available to Microdat customers for consultation on request.
Microdat 2014
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The heritage is ours. The future is yours.
25
years of brewing innovation, engineering, quality and service.
Microdat are one of the UK’s leading suppliers of complete brewery solutions from dry goods to brewing, fermentation, to conditioning and maturation to packaging. We led the way with computer aided design and we were the first to implement 3D modelling, We also developed the worlds first thermal fluid wort boiling: the most energy efficient solution of its kind. From design, software and project management through to manufacturing, installation and after sales spares, service and support, Microdat look forward to using their 25 year history to build your future.
Tel: +44 (0) 113 457 0489 info@microdat.co.uk Telephone 0113 244 5225
Leeds, West Yorkshire, LS8 1BQ, UK microdat.co.uk
www.microdat.co.uk
Microdat 2014