METHOD AND DEVICE FOR CONTINUOUS MALT PRODUCTION

Description

[0001] The invention relates to a malt production plant for continuous malt production and a method for continuous malt production. State of the art in malt production

[0002] The technical standard of malt production facilities has undergone virtually no significant innovations in recent decades, see Ludwig Narziss - Die Bierbrauerei, Vol. 1, 6th edition, 1976, pp. 164-242, Enke Verlag Stuttgart.

[0003] In conventional malt production systems, the cleaned grain for malting is immersed in water in one or more steeping tanks to achieve a predetermined water absorption. It is then either "wet-steeped," meaning it is pumped into the germination boxes with added water, or "dry-steeped," meaning it is transported to the germination boxes without additional water, using a screw or chain conveyor, or possibly elevators.

[0004] With this combination, the development seemed to be largely complete. With the invention of the box malthouse, often referred to as the "Saladin malthouse" after its inventor, a crucial and seemingly final step in mechanical malt production had been achieved.

[0005] The dimensions of the production facilities alone, and thus also of the product batches, have increased considerably and batches of over 300 t are no longer uncommon.

[0006] Other developments, such as moving piles or transfer boxes, were unable to establish themselves on the market because the problems that arose could not be satisfactorily resolved.

[0007] They have therefore remained rare, although the idea of ​​a continuous production method was already underlying them, but they can also be classified under the collective term "box malting", since they ultimately produce in batches.

[0008] Malt production, with all known production systems, is produced in batches. This means that a specific quantity of grain, as a whole batch, passes through all stages of the entire production process in production steps. From weighing into the soaking silos, from there into the steeping containers, then from there into the germination boxes, and after the germination process into a kiln. After kilning and the final cooling, and when the kiln-ready malt is discharged into a silo for intermediate storage, the entire batch continues to be processed (Narziss: "Die Technologie der Malzbereitung", Vol. 1, pp. 164-242, 6th edition, 1976, Enke Verlag Stuttgart). In a subsequent edition of "The Technology of Malt Preparation, Outline of Beer Brewing", 8th edition Ludwig Narziß et al. WILEY-VCH Verlag, XP093136467, trays are disclosed that are either stationary with a rotating turner or rotating with a fixed turner.

[0009] A malting plant is known from DE 1 274 548. The malting plant is equipped with an endless grain conveyor consisting of a perforated floor and curved side walls that can be periodically moved forward in a circular tunnel. Stations for soaking, germinating, drying, emptying, and feeding the grain are provided in the tunnel. According to this document, the conveyor is divided into a number of individual sections by elastic connections, with the individual sections being bridged by components of the elastic connections. The individual sections are designed as box wagons.

[0010] From DE3918438 A1 a plant for the production of malt is known, which comprises a rotating tray with a separating arrangement in the rotating tray, by means of which the tray is divided into daily batches.

[0011] The document XP093136467 (URL:https: / / web.archive.org / web / 20170301215047 / https: / / www.rauscher-maelzereien.de / keimanlagen.html) from Rauscher Engineering reveals a rotating tray and a fixed tray. The rotating tray has a fixed turner, while the fixed tray has a rotating turner.

[0012] DE 21 01 848 A1, published by C. Seeger Maschinenfabrik on July 20, 1972, discloses a device for producing malt. The tray can be designed as a rotatable disc mounted in a circular germination and / or drying box, known per se and equipped with the loading and processing devices.

[0013] The systems used so far are explained in more detail below.

[0014] Almost all of the malt production systems shown below, with and without their additional developments, follow the idea of ​​Saladin, their inventor, and are still built almost unchanged to this day. The state-of-the-art germination boxes

[0015] Saladin's invention of the "germination box" and the "germination box turner" has since represented the basic principle of all subsequent developments, hereinafter also referred to as the Saladin basic principle.

[0016] The Saladin germination box is an elongated, rectangular box in which a specific amount, i.e., a batch, of green malt is processed. "Green malt" refers to grain that has already been swollen and germinated by absorbing water during malt production.

[0017] An intermediate floor, the so-called Horde, is inserted into the box at a varying distance from the floor and rests on a supporting substructure.

[0018] The tray is made of sheet metal sieves, more rarely of slit tray sieves.

[0019] The batch of green malt rests on a specific bed on the tray and is constantly circulated by process air via a fan. The space beneath the tray serves as an air duct.

[0020] The soft grain (soaked grain) introduced into the germination box for malting is loosened and turned by the spiral-shaped turning spindles. Depending on the design of the germination box, this can lead to a so-called "sparrow formation," i.e., a clumping of the green malt due to the intertwining of the roots, which progresses due to insufficient ventilation and the resulting increased heating.

[0021] To avoid this, it is known to design the end walls of the boxes with a wave-like profile so that the gap between the turning spindles of the turner and the profiled end walls is as small as possible.

[0022] After the end of the germination phase, the green malt obtained is transported out of the germination box and to the kiln.

[0023] In order to lose as little time as possible for this intermediate production step, correspondingly large conveyor capacities must be kept available.

[0024] In the early days of the Saladin box malting process, this "cleaning out" was performed with a germination box turner. For this purpose, a lowerable flap was installed at the end of the germination box, or in the middle of the rack length for very long boxes, through which the green malt was pushed into the so-called "cleaning out chute."

[0025] A screw conveyor or a chain conveyor then transported the product from this gutter to the kiln.

[0026] In order to shorten this time-consuming work step, the following developments were made: a mobile metal wall was installed at one end of the box, which was coupled to the turner for emptying and then pulled along by it.

[0027] An extraction system was then connected to this mobile wall, which pneumatically transported the product to the kiln via telescopic tubes, a powerful rotary lobe blower, and corresponding piping. This method, pneumatic conveying, is very time-consuming and often leads to pipe blockages.

[0028] In addition, this method involves a lot of manual effort, as the telescopic tubes have to be extended again and again with intermediate pieces.

[0029] The development of mechanical removal brought a significant improvement here. With mechanical removal, the green malt is discharged upwards by a screw arranged vertically or diagonally behind the mobile wall and onto a chain conveyor or conveyor belt, where it is transported to the kiln.

[0030] Both systems are still in use.

[0031] In the early years of Saladin's germination boxes, manual labor was not yet a major economic factor. Batches were also only a few tons, with one ton corresponding to 10 3 kg.

[0032] However, under market pressure and constantly increasing demand, batches have recently increased to over 200 tons, with box lengths of up to 50 m and box widths of 6 m and more, some even 10 m, being set up. State-of-the-art germination / drying boxes

[0033] A special feature of the Saladin principle was the development of germination / drying boxes, in which the malt is kilned after the germination phase without transferring to a separate kiln. While this eliminated the need for a separate kiln, the germination box is unsuitable for the purpose conceived by Saladin because the batch remains in the box during the kiln drying process. This system eliminates the time-consuming cleaning of the kiln, but the expensive germination equipment remains unused during this time. The basic principle of Saladin, batch production in a germination box, remained unchanged in this system. State-of-the-art tower malting

[0034] The tower malting system, introduced in the 1960s, ultimately represents the most effective of the newer germination box variants. The germination box in tower malting systems is a circular structure. The tower malting systems built since then have significantly increased the efficiency of the germination boxes and significantly reduced manual labor in malt production.

[0035] Tower malthouses have been built with more than five floors and with batches of over 300 tons and plant diameters of 25 m and even more.

[0036] In some cases, one or both of the lowest floors have been converted into kilns.

[0037] The tower malthouses are also operated according to the Saladin principle. The tower malthouses also produce in batches

[0038] There are two systems to distinguish: germination boxes with a permanently installed tray or germination boxes with a rotating tray.

[0039] A first variant based on the above-mentioned state-of-the-art technology features a permanently installed tray and a rotating turner. The gap-free, fixed connection of the tray to the building walls significantly reduces product losses.

[0040] One disadvantage, however, is that the spray water supply to the turner has to be made via a trailing hose, which is often damaged.

[0041] Likewise, the discharge of the product is often problematic, as several discharge openings with closing flaps must be available in a supporting central column.

[0042] The loading and unloading screw, which is attached to the rotating turner and can be raised and lowered, conveys the product into it and it is transported further using a built-in chain conveyor or a screw conveyor.

[0043] A second, state-of-the-art variant also features a permanently installed tray. Here, the circular building lacks a supporting central column, so the product is discharged through flaps installed in the center of the tray.

[0044] The disadvantage is a self-supporting roof, and in a multi-story building, self-supporting intermediate ceilings, to which the rotating turners in the center must be suspended and thus supported.

[0045] A third variant, based on the other system, features a rotating hopper. Here, the turner is fixed to a supporting central column and mounted on the outer wall and, like the variants described above, is equipped with a raising and lowering loading and unloading auger.

[0046] The inlet of the soft material as well as the outlet of the green malt are stationary at the same place and the rotating horde carries the product further during loading and closer during unloading and it is carried out through a flap either into the central column or directly through the outer wall to the outside.

[0047] A disadvantage arises from the sealing which rubs against the rack and which lies under the malt bed and thus wears out quickly and leads to product failure, even more so if it is damaged, which happens frequently.

[0048] However, the operating principle itself has proven to be very reliable.

[0049] Separate kilns have been built several times using both systems, which are adapted to the batch sizes of the germination boxes.

[0050] A fourth variant, also based on the rotating rack system, is the "Hauner-Unimälzer." This variant also originated in the 1960s.

[0051] This special circular building design is also based on the Saladin principle.

[0052] The system is comparable to a circular germination / drying box, with the unique feature of a rotating tray. After the germination cycle, the drying cycle also runs directly on the germination tray without repositioning. Batch sizes of over 100 tons have been built several times using this variant.

[0053] The disadvantage, however, is the time the tray is occupied. This is extended by the kiln cycle time, just like with linear germination / kiln trays.

[0054] In order to achieve an economical heating system for the kilning process, which only lasts between 24 and 36 hours at the most, several univers maltsters were often connected.

[0055] When this system was introduced and in small malthouses that only produced for the needs of smaller breweries, in some cases no pre-soaking device was installed and the required product moisture was only adjusted by spray humidification. Darren according to the state of the art

[0056] The familiar separate kilns, formerly rectangular and equipped with a tilting tray, or a two-part tray in large kilns for rapid reloading, are now mostly designed as circular structures due to the huge batches. These designs are similar to the variants of the germination boxes described above in tower malthouses, but do not require turning spindles.

[0057] A loading and unloading device that can also be moved up and down is used for the even application of the germination material as well as for the discharge of the kilned malt.

[0058] Batch sizes of over 200 tons are not uncommon. The enormous air volumes required for batches of 200 tons and more are supplied by two, or in a combined air system, by three or four large fans.

[0059] The process heat is provided by appropriately dimensioned gas or oil-fired air heaters, and more rarely by hot water radiators. State-of-the-art energy saving

[0060] To save heat energy during simmering and drying, heat exchangers with inserted glass tubes have been in use for many years to extract heat energy from the moisture-saturated exhaust air and thus preheat the fresh air that is sucked in.

[0061] The saturated exhaust air passes by or through the glass tubes and condensate forms on the cold glass tubes caused by the fresh air drawn in, whereby the released heat energy is transferred to the fresh air flow.

[0062] The air connection system of two kilns, another innovation in the kiln sector, has proven to be highly efficient: The very warm, but only partially saturated exhaust air from the kiln cycle of one kiln is fed into the supply air flow of the smoldering cycle of another kiln operating at a later time.

[0063] The highly saturated exhaust air, exclusively from the alternating smoldering cycle, is then passed through the glass tube heat exchanger, where a high proportion of the heat energy contained therein is recovered through the condensation of the humidity.

[0064] The preheated fresh air stream is then passed through the air heater and reheated to the required process temperature.

[0065] The highest efficiency is achieved at low outside temperatures.

[0066] In summary, a uniform state of the art in production technology cannot be determined due to the large number of systems.

[0067] The diverse variants of production systems are still in use, even in new plants.

[0068] New production plants have been built for all of the systems mentioned, and more are already being planned worldwide.

[0069] When looking at all known production systems together, it is obvious that they all produce in batches or only semi-continuously and that, even with the various additional facilities, they still correspond to Saladin's idea.

[0070] However, the current state-of-the-art batch-based production method has several disadvantages: Production loses valuable time due to interruptions caused by batch relocation, leading to product loss. This requires multiple use of conveyor equipment and personnel. Furthermore, the expensive production chain remains unused at times. This is especially true with germination / drying boxes and the "Hauner-Unimälzer" system.

[0071] In older germination box systems, the tray sieves often have to be lifted out by hand for cleaning, which is hard physical work and results in additional loss of time.

[0072] With the newly designed, increasingly larger production plants, the germination box turners have to become wider and wider and therefore have more and more turning spindles and therefore require additional turning spindle drives.

[0073] In addition, each turner must have its own loading and unloading device, so that the investment costs as well as the maintenance costs increase disproportionately.

[0074] In order to limit the time losses during the relocation phases, very powerful conveyors must be used, which require a high energy consumption.

[0075] For example, if a batch of 200 tons is to be transported further with an elevator in two hours, the required drive power is 30 - 50 kW, depending on the conveying height.

[0076] For the transport of the product from the soaking to the germination boxes, wet soaking or dry, from the germination boxes then after the germination phase to the kiln and after the kiln drying process from here on to the silos, additional conveyors with high transport capacity are required, which are also only used for short periods of time at intervals.

[0077] If several production units do not work together, they stand unused in the time between them; if they fail due to an accident, for example, further time is lost in production until they are ready for operation again.

[0078] To compensate for conveyor failures and avoid potential time losses, appropriately voluminous buffer silos must be kept as close as possible to the discharge point. In older tilting kilns, this is the "rumen" below, from which the material is removed with a lower conveying capacity, while the kiln can be reloaded.

[0079] Due to the many manual tasks that must be performed at intervals during production, the personnel requirements in all systems are high.

[0080] What makes matters worse is that recruiting staff for this work is already extremely difficult.

[0081] To resolve the frequent faults, specialised personnel such as machine fitters or electricians with knowledge of control technology must also be deployed, who often have to be available on call even at night.

[0082] In this form, the box malting according to the "Saladin" principle is no longer viable.

[0083] It is clear that the economic efficiency of malt production can hardly be increased any further with the current production systems. Only the move to ever larger production units will yield further gains, which naturally also increases investment and maintenance costs, as well as the risk of failure. In terms of energy consumption and personnel problems, batch-based malt production can no longer meet the demands of the times.

[0084] However, it is no longer possible to eliminate or improve these disadvantageous conditions in batch-based production.

[0085] The invention therefore has the object of at least partially eliminating or minimizing the above disadvantages. Description of the invention

[0086] The object of the invention is achieved by the device for continuous malt production according to claim 1 and the method according to claim 9. Useful embodiments emerge from the dependent claims.

[0087] The device according to the invention for continuous malt production comprises a circular ring building comprising a floor, walls, and a ceiling arranged opposite the floor, wherein a movable germination box is arranged in the circular ring building. The germination box is circular and designed to move continuously forward without interruption. The circular ring germination box has a tray floor and side walls. The circular ring germination box has no section divisions by fixtures such as walls and the like. A germination box turner is arranged on an upper side of the side walls facing away from the tray floor. The germination box turner is carried by the germination box and is movable relative to the circular ring germination box.

[0088] The method according to the invention using the above device comprises: Continuous introduction of grain, undergoing a germination process, and continuous discharge of the processed grain, in particular the ready-to-dry malt.

[0089] The advantage of the method and device according to the invention is as follows: Starting from batch production, a batch that runs into the second process day must be immediately followed by a new batch that runs into the first process day.

[0090] If this runs into the second day of the process, a new batch must follow it, and this process continues in this way: A new batch must be introduced into the production process every day until the process runs to the kiln, one after the other, essentially on a single production line. Batches cannot follow one after the other; instead, either soft grain or soaking grain must be continuously introduced into the production line, which then continuously runs through the production process. Example calculation for a fictitious linear system (not according to this invention)

[0091] An annual output of 50,000 tonnes (50,000 t) of malt requires approximately 62,500 tonnes (62,500 t) of raw grain.

[0092] Assuming that a germination / drying box, in a linear design as previously used, without an upstream switch (softening device), could produce continuously for 8760 hours per year, this would result in an hourly output of: 62,500 t / 8,760 h = 7.135 t / h of raw grain to be brought in, assuming a loading of 600 kg / m 2< , then: 7,135 kg / h / 600 kg / m 2< = 11.9 m 2< / h, ie approximately 12 m 2< tray area / h is required;

[0093] Assuming: Assuming the box width is 6.0 m, the forward speed is: 12 m 2 < / h: 6 m = 2 m / h. With a process interval of 6 days for the germination phase without soaking, this results in 144 hours, and an additional 36 hours for smoldering / drying / cooling, this would result in a tray length of: 180 h × 2 m / h = 360 Meter .

[0094] This results in a total tray area of: (box width x box length) = 6 mx 360 m =2160 m 2< tray area.

[0095] Even if four germination / drying boxes were set up, the length of each box would be 90 meters and even if the box width were 10 m instead of 6 m, the boxes would still be 54 m long.

[0096] For this to happen, the tray on which the green malt bed lies would have to move forward continuously, i.e. practically a conveyor chain consisting of tray elements that run forward with the malt bed on the top and back empty on the bottom, a paternoster system.

[0097] However, this circumstance also requires that the circulating chain of the racks be more than twice the length of the actual usable area, which would result in significant elongation due to wear.

[0098] Therefore, if an economic annual production is to be achieved, either large lengths of boxes or several boxes would have to be built next to each other.

[0099] On the other hand, the practical implementation of this idea would require problematic, unmanageable, and complex technology.

[0100] The wear and tear on the drive and drive technology would be very severe and would far exceed anything known so far.

[0101] These two factors alone, along with other problem areas such as cleaning and maintenance, make a linear production system seem impractical.

[0102] In particular: 1. the 360 ​​meter length of a tray determined in the example calculation is not feasible with a linear germination box, 2. the division into several boxes in order to achieve a technically feasible length is not feasible for cost reasons, 3. the technology is expected to be difficult to handle and 4. with the determined tray area, none of the proven variants of the tower malting can be considered, even not when divided into several germination boxes, since the turning spans as well as the multiple drive technology would be disproportionate 5. a separate loading and unloading system is necessary for each unit.

[0103] For these reasons, both technical feasibility and economic viability are ruled out. To design a cost-effective and low-maintenance system that eliminates these factors, a different system concept must be developed, one that can be derived in particular from the two factors mentioned in points 1 and 4.

[0104] As shown in the above example calculation for a fictitious, linear production plant, a very large rack area of ​​2160 m 2 is required for a permanent, organic production process.

[0105] To solve the problem according to the invention, the following criteria must therefore be met.

[0106] To create this tray area according to 1., a very large diameter is required. To avoid the problem of excessive turret span from 4., the tray width must be very narrow.

[0107] Therefore, the diameter of the central column must follow the increasing outer diameter of the system until both requirements are met.

[0108] As the diameter of the central column increases, it becomes a separate structure, which together with the outer wall of the complex creates a circular ring building.

[0109] The criteria outlined above are achieved with the device for continuous malt production according to the invention.

[0110] The device according to the invention comprises a circular building in which a germination box is arranged. According to the invention, the germination box is circular, i.e., it forms a closed circular ring. A germination box turner is arranged on the germination box. The special feature of this invention is the narrow, circular, and mobile germination box, which continuously moves forward without interruption, also carrying the germination box turner along with it.

[0111] For the annual output of 50,000 tonnes assumed above, the following values ​​result for the device according to the invention: The 360 ​​metres length of the tray determined above, with otherwise identical parameters, results in an inner diameter of the circular ring of 115 metres as a circular ring design and an outer diameter of 127 metres with a box width of 6 m.

[0112] For example, with an outer diameter of only 100 meters, and the same tray area of ​​2160 m², the calculated inner diameter would be 85.15 meters, assuming 85 meters. This results in a tray width of 7.5 m and the same tray and turner width.

[0113] The tray area is then calculated at 2179 m² compared to the 2160 m² theoretically required for an annual production of 50,000 t of malt with a continuously operating plant. This results in technically manageable conditions for the device according to the invention.

[0114] The narrow width of the circular ring germination box reduces the spans of the germination box turners, the tray supports. Furthermore, special partition elements, the room dividers, can be used in the space below the tray, the lower tray area, to create narrowly spaced sections. At the same time, this design creates the necessary length for the tray. These partition elements are designed to prevent the transfer of process air between adjacent sections in the lower tray area.

[0115] Secondly, the circular ring building encloses an area where buildings can advantageously be arranged to accommodate peripheral facilities, such as offices, social rooms, and storage silos and their annexes, which house the necessary facilities for receiving the grain. However, the circular ring facility could also be built around existing operational buildings.

[0116] The continuous production process according to the invention produces malt in a permanent and uninterrupted production process.

[0117] The entire production process according to this method includes the entire, predetermined germination cycle, with or without a separate steeping, the entire simmering cycle, as well as the drying cycle and the cooling phase and, at the end of this, the permanent discharge of the dried malt without the product having to be relocated.

[0118] In particular, the device features a 24-hour (1-day) idle period, i.e., an area between unloading and loading that is unoccupied, during which the tray remains unoccupied. This period can be used for cleaning or repair work.

[0119] This means that grain prepared for malting is always brought into the production plant at the same point in a constant, continuous transport flow. It is carried in the continuously rotating, circular germination box without relocation and passes through all stages of the day-long production cycle at a very slow speed and without interruption until the storable kiln malt is discharged.

[0120] This production method according to the invention cannot be applied in any of the known production systems; therefore, a suitable production system was newly developed which enables this production process.

[0121] A circular, mobile germination box, also installed in a tunnel-like circular building with very large diameters, moves continuously forward at a slow speed, without interruption.

[0122] The germination box turners required for turning and loosening are carried by the mobile germination box.

[0123] The germination box turners have their own feed drive and therefore move independently of the running movement of the germination box, on their own guide rails that are attached to the top of the side walls of the germination box.

[0124] The turners are conveniently positioned over the course of the germination cycle so that they each have a day's stretch to work.

[0125] At the specified inlet point, in particular by means of a loading device, the soft material is transferred to the distribution machine via an upstream continuously operating softening device, e.g., a soaking screw, in a continuous transport stream by means of peripheral conveyors. The loading device can comprise the distribution machine.

[0126] With this special distribution device, the soft material is evenly applied to the preset bed height across the entire width of the tray, while the circular ring germination box continues to move continuously.

[0127] Every twelve hours of continuous loading, the germination box turners begin the turn, one after the other, just as the sections of the lower tray area and thus the germination days are passed through. During this time, the product is constantly aerated with process air.

[0128] This process of turning and aerating corresponds to that in the linear germination boxes, according to Saladin.

[0129] Meanwhile, the germination box continues to run, soft material is continuously fed in and distributed onto the tray and now passes through the second, third and further all sections of the lower tray area, while soft material is continuously applied to the tray at the inlet point.

[0130] After another twelve hours, the turners begin their turnarounds again in the so-called pilgrim step rhythm, from the position to which they had been carried resting on the rails.

[0131] After the turn, they switch off and are carried resting in the germination box for another twelve hours, from where they then begin another turn. The times given are examples and can be adjusted by a specialist.

[0132] The turning path is conveniently limited by sensors permanently positioned on a building wall or on the ceiling. The sensors are adjusted so that the turning paths overlap briefly, ensuring even aeration of the germinating material and thus preventing sparrowing. In particular, the present device eliminates the need for complicated adjustment of the turning paths to the profile of the end faces of germination boxes, since according to the present invention, the circular ring germination box has no walls dividing the sections.

[0133] After another twelve hours, and then at twelve-hour intervals, the turning cycles begin again. The first batch of soaked malt now reaches the first section of the kilning cycle as finished green malt.

[0134] Further turning is eliminated during the kilning cycle. The green malt now passes through all the silting / kiln sections, which are arranged according to the specified silting / kiln program in the lower rack chamber, at the same speed.

[0135] These represent the temperature scheme of the simmering / drying program.

[0136] This is followed by the cooling section, at the end of which the malt is discharged. For this purpose, a discharge device, preferably a stationary one, is expediently provided.

[0137] At the discharge point, which is only one day's journey (the idle route) away from the inlet point, after the entire production cycle has been completed, malt ready for kilning is continuously conveyed out of the circular germination box and transferred to the subsequent conveyor lines for further processing.

[0138] The circulation cycle is only fully completed after the complete circulation of the germination box, including the empty area of ​​one day's distance to be traversed.

[0139] This process repeats itself endlessly, meaning that the plant continuously produces malt until it is shut down intentionally or due to force majeure.

[0140] The product then continues to pass through the disinfection and cleaning line in the peripheral area of ​​the production plant, from where it is transported directly to the loading silos or storage silos.

[0141] With the device according to the invention for continuous malt production, it is possible, similar to the "Hauner-Unimälzer", to start up malt production even without a separate steeping and without a separate kiln.

[0142] It is sufficient to feed the grain prepared for malting into the plant in a permanent flow using a washing screw and to achieve the final moisture content required for the process by spraying it with water.

[0143] In this case, however, an extension of the throughput time in the germination box must be accepted, which otherwise runs ahead in separate switches.

[0144] The present study is already based on such a production scheme with a 6-day germination cycle.

[0145] In one embodiment, however, this disadvantage can be eliminated by later adding a switch device that also operates continuously, and the cycle time is shortened by as many days as are now spent in the separate switch.

[0146] The same applies if an additional, separate, continuous kiln is added. This further shortens the cycle time by the time saved in the germination-kiln cycle, increasing the plant's production output.

[0147] Due to the continuous production method, all required peripheral components are limited to very advantageous small dimensions, both on the side of the supply of raw materials and the removal of the kiln malt.

[0148] The same applies to further processing, such as disinfection, cleaning, polishing and dust extraction and filtering systems.

[0149] For example, with an annual plant output of 50,000 tons of malt, conveyor lines and cleaning machines with a capacity of 10 t / h are sufficient for further processing the hourly output of 6 t / h of kiln malt. Brief description of the drawings

[0150] Fig. 1 shows a circular ring building of the device for continuous malt production according to the invention; Fig. 2 shows a cross-section through a circular ring germination box of the device for continuous malt production; and Fig. 3 shows an enlarged detail in the area of ​​the germination box turner bearing.

[0151] The drawings are schematic representations without scale. Like parts are represented by like reference numerals throughout the drawings. The drawings are merely an exemplary, non-limiting embodiment of the invention. Description of the drawings circular building

[0152] Fig. 1shows the device 1 for continuous malt production. This comprises a circular ring building 2. The circular ring building 2 is a continuous circular ring of large diameter. It has a circular floor 3 and a circular ceiling 5, as well as cylindrical walls 4. The floor 3, walls 4, and ceiling 5 enclose a tunnel-like, circular interior.

[0153] In its tunnel-like interior, a germination box 6 is installed, which also consists of a complete, uninterrupted circular ring.

[0154] The circular building 2 can be constructed as a steel structure or in solid construction and is made of heat-insulating materials or protected with insulating materials against heat loss and climatic influences.

[0155] The floor 3, walls 4, and ceiling 5 of the interior are conveniently clad with waterproof, stainless steel sheeting. If the building is constructed of masonry or concrete, the surface can also be coated with a waterproof paint.

[0156] The plant is dimensioned to meet the planned annual output so that the purpose of producing this amount of malt can be achieved.

[0157] The circular building 2 can be constructed as a single-story or multi-story building, with each story forming an independent production unit.

[0158] The circular ring building 2 can be built on supporting pillars so that it is high enough above the paved terrain to provide clearance height for heavy transport vehicles, possibly railway wagons, in order to be able to use an interior area 29 which is delimited in the circumferential direction by the inner wall 4 of the circular ring building.

[0159] However, this has no significance for the functionality of the facility. The space beneath this circular ring also has no specific purpose and can be used for the construction of any operational buildings, provided the circular ring, i.e., the floor 3 and the walls 4, are not located directly on the foundations near the ground.

[0160] If the nature of the site allows it, the passage into the interior area 29 enclosed by the circular ring building 2 can also be created by tunneling and the circular ring building 2 can be set on foundations close to the ground. Germination box

[0161] In the circular building 2, a mobile, circular germination box 6 is arranged, which is Fig. 2is shown in cross-section. The mobile circular ring germination box 6 has a tray base 14 and side walls 15, which extend, in particular, perpendicularly from the tray base 14. The mobile circular ring germination box 6 has no section division in the direction of rotation in order to enable a continuous process.

[0162] The mobile circular ring germination box 6, which resembles a U-shaped, open-topped "U" in cross-section, is a torsion-resistant construction made of metal profiles. The side walls 15 are lined with stainless steel sheeting.

[0163] The bottom of the germination box is formed by the tray base 14 made of sieve elements, which are firmly screwed to the circular ring surface with the tray supports 13.

[0164] On the two side walls 15, in particular an upper surface of the side walls 15, the guide rails 16 for the germination box turners 18 rest on welded contact plates and are firmly screwed to them.

[0165] The germination box 6 continuously moves forward in the same direction during the production process. For this purpose, it is mounted beneath its side walls 15 on an inner and an outer circular ring-shaped raceway 7, which rest on a track consisting of many rollers 8. This means that the raceway 7 is connected to the circular ring germination box 6. A roller track with many rollers 8 is fixedly arranged in the circular ring building, and the germination box 6 with the raceway 7 are moved forward on the roller track.

[0166] The side walls 15, in particular a torsion-resistant construction made of galvanized or stainless steel profiles and / or lined with stainless steel sheet on the inside, are the load-bearing elements of the annular germination box. They are firmly bolted to bracket rings welded to the raceways 7.

[0167] Directly above the raceways 7, the tray base 14 is inserted between the side walls 15 of the germination box 6.

[0168] Depending on the calculated filling height of the germinating material, the side walls 15 of the germination box 6, above the tray floor 14, have a height of 1.5 meters to 2.5 meters.

[0169] At the top, on the side walls 15, the guide rails 16 for the germination box turners 18, which are also curved according to their radius, are placed on welded contact plates and firmly screwed to them. Roller drive

[0170] A roller drive is located beneath the germination box 6. The roller drive is mounted on the floor 3 of the circular building 2 and includes the rollers 8.

[0171] The rollers 8 made of wear-resistant material are inserted with their axles into roller blocks 9.

[0172] The axes of the rollers 8 are expediently milled at both head ends to a square key surface and thus inserted into the side parts of the roller blocks 9.

[0173] The side panels of the roller blocks 9 also feature square cutouts with the same key size. The side panels are firmly screwed to brackets and, together with them, form the roller blocks 9.

[0174] The consoles are placed on supports 10 and distributed on the walls 4 of the circular ring building 2 at equal intervals around the entire circumference of the inner and outer raceway 7.

[0175] The supports 10 are firmly connected to the walls 4 of the circular building.

[0176] The two races 7 of the germination ring box are made of bent steel profiles, with the bending radius being derived from the diameter of the designed production system, device 1.

[0177] They are assembled from segments to form complete circular rings and carry the attached germination box 6.

[0178] The tray supports 13, which span a lower tray space 30 and to which the tray floor 14 is firmly screwed, also rest on the raceways 7.

[0179] For the propulsion of the germination box 6, a bracket ring is attached to one of the two races 7, to which racks 11 are screwed, into which the gears of feed drives 12 engage. Subhorde Room

[0180] The tray supports 13 bridge the lower tray space 30 and are placed on the inside and outside of the two raceways 7 and are firmly connected to them, e.g., by screwing. They support the tray floor 14, which is connected, in particular, by screwing, to the tray supports 13 to form a solid platform.

[0181] In particular, room divider elements (not shown) are arranged in the lower scrotum space 30, which extend upwards, in particular, from the floor 3 of the circular building 2. The room divider elements can, in particular, be movable and divide the lower scrotum space into several sections.

[0182] Elastic sealing elements are attached, in particular screwed, to the underside of the tray supports 13, which are designed to prevent the transfer of process air into a respective adjacent section by passing over room divider elements. Horde floor

[0183] The bottom of the circular germination box 6 is formed by the tray base 14. It is inserted in the lower area, at the height directly above the raceways 7, between the side walls 15 of the germination box 6 and is firmly connected, in particular screwed, to these. The tray base 14 consists of individual tray screens that can be interconnected, e.g., screwed, to form tray segments. The tray screens are screwed together with the tray supports 13 to form a circular surface.

[0184] The tray screens are made of perforated screen plates or preferably slotted screens that are welded onto contoured profile frames.

[0185] They can be made of galvanized steel, but better of stainless steel. Germination box turner

[0186] Germination box turners 18 are arranged on the circular ring germination box 6.

[0187] The germination box turners 18 correspond in their design to the classic "Saladin germination box turner" and in the same way turn and loosen the sprouting material using the spiral-shaped turning spindles 20.

[0188] It is the special feature of the device 1 according to the invention that the germination box turners 18 are carried by the germination box 6 which is constantly moving forward.

[0189] When turning, these turners move via their own drives 21, once in the direction of travel of the circular ring germination box and then in the opposite direction during the next turn. The working distance of the turners is limited by sensors, each of which is permanently installed on a wall 4 or the ceiling 5 of the circular ring building 2.

[0190] The germination box turners 18 move completely independently of the permanent running movement of the germination box during the turning movement.

[0191] To drive the germination box turners 18, feed gears engage with racks which are also screwed to the guide rails 16 in this circular ring design.

[0192] The guide rails 16 are the track for the germination box turners 18. Their radius corresponds to that of the inner or outer side wall 15 of the germination box.

[0193] The guide rails 16, made of bent steel profiles, conveniently rest on welded contact plates on the upper edge of the side walls 15 and are firmly connected to them, e.g., by screwing. A flat profile made of wear-resistant material is attached to the upper side of the curved profiles as wear protection 17, which serves as the running surface for the germination box turners 18.

[0194] In contrast to the elongated "Saladin germination box," with straight rails, the turners here must run on slightly curved rails 16, which results in a differential speed from the outer to the inner rail 16. The differential speed is adjusted by varying the number of teeth on the racks or by a differential gear.

[0195] The mobile circular ring germination box 6 is driven by several feed drives 12, which comprise gear motors, and by toothed racks 11, which are screwed to a bracket ring; this is welded laterally to one of the two races 7.

[0196] The speed of movement of the circular germination box 6, which can have a circumference of two hundred meters or more, is extremely slow, so that it only rotates one revolution during the entire production cycle, together with a predetermined idle distance.

[0197] It is a special feature of the device according to the invention for continuous malt production that the lower tray space 30 has an important function as a service space for repair work, e.g. for replacing rollers 8 during operation.

[0198] These necessary tasks can be carried out safely during uninterrupted production operations, as can the routine, routine cleaning and service work.

[0199] The lower tray room 30 is conveniently accessible and, in this configuration, has a height of at least two meters from the floor 3 of the circular building 2 to below the tray supports 13. Section division

[0200] As in the classic Saladin box, where this height is only about 0.5 m to 1.0 m, the lower tray space also serves as an air duct for supplying the process air and is therefore divided into sections, in particular daily sections, of the continuous production process.

[0201] The division of the annular sub-tray space 30 into sections is carried out in particular by means of special, lightweight room dividers, the positioning of which can be changed.

[0202] The room dividers also prevent process air from passing into the adjacent process sections, because different temperatures can be set there.

[0203] In one design, each section represents a daily portion of the germination process, which occurs continuously in the rotating circular germination box.

[0204] However, the division can be changed into any sections, e.g. for the production of special malts.

[0205] A separate access door, located in one of the walls 4 of the circular building, conveniently leads to each section, allowing access at any time. In a simmering / drying area, a pressure equalization lock is additionally installed at the doors due to the higher air pressure there. fans

[0206] A separate fan supplies automatically conditioned process air to each section of the lower tray room 30 as needed in the germination area. To maintain temperature control during warmer times of the day, an external refrigeration system is conveniently installed in an adjacent building, connected to the cooling registers in the air duct. Frequency converters allow the fan speeds to be changed and automatically adjusted to meet demand. Sections in the smoldering / drying area

[0207] For practical purposes, the division of the sections in the simmering / drying process is designed to reflect the time course of the applicable temperature regime. Each section of the simmering / drying cycle is equipped with its own fan that blows in the appropriately conditioned process air. Heating of smoldering and drying kilns

[0208] Air heaters heat the process air to the required temperature. They can be fired with gas or heating oil. The process air can also be heated using hot water or electric heaters.

[0209] The temperature is controlled automatically according to a drying program.

[0210] The temperature in the lower trough as well as above the malt bed is constantly monitored and regulated by temperature sensors, which are conveniently installed in the respective sections. Soft transport

[0211] Grain prepared for malting is continuously brought in via peripheral transport means, such as screw conveyors or chain conveyors, and an upstream, continuously operating soaking device, e.g. a soaking screw, ensures the permanent inflow of soaking material. Loading device

[0212] The loading device 25 is an application and distribution device; it is installed in a fixed location in the circular building 2.

[0213] The permanent introduction of the soft material into the device - production plant - always takes place at the same place where a loading device 25 is permanently installed in the circular building 2, as in Fig. 1 shown.

[0214] It distributes the permanent inflow of soft material to a closed bed in the circular germination box 6. A screw conveyor transports the soft material to a chute, from which it is distributed across the entire width onto the tray floor 14.

[0215] To set different bed heights, the height is adjusted using an adjustment mechanism. Optional sensors detect the flow of soft material and adjust the height accordingly. A control platform 26 is conveniently attached to the device for maintenance work. Energy savings through heat recovery during kilning

[0216] A well-known method for saving energy is used to extract a large part of the heat energy from the steam-saturated exhaust air from the smoldering process using a glass tube heat exchanger and transfer it to the fresh air supply before this, together with the returned smoldering air, is heated to the required process air temperature via the heating elements. Air connection system

[0217] Another option for saving heating energy is the air connection system between two or more kilns. This is also a well-known method with very high efficiency.

[0218] The very warm but unsaturated exhaust air from the drying phase of one kiln is fed into the smoldering air supply of another kiln via an air duct system for further use, and in this way the unused thermal energy of the drying air is reintroduced into the smoldering process as process heat.

[0219] A particular advantage is achieved with the novel system of the circular ring germination box 6 in that the two sections of the smoldering and drying cycles are located close together on the same tray and thus this air connection can be easily established by means of short ducts. Further use of exhaust air

[0220] In a further embodiment, an amount of heat from the moist, saturated exhaust air stream after the glass tube heat exchanger that would otherwise not be further recuperated is used to preheat the soaking grain during the winter months.

[0221] The moisture of the saturated, warm smoldering exhaust air condenses on the cold grain and thus leads to a certain amount of water absorption and warming.

[0222] The smoldering section, which is located very close to the grain feed lines and has a glass tube heat exchanger above it, offers this possibility. Condensate collection tank

[0223] The condensate water that forms in the glass tube heat exchanger is conveniently fed into a collection tank and reused for cleaning purposes. Discharge of the kiln malt

[0224] In a further embodiment, the device 1 comprises an unloading device 27, which is installed in the circular building 2 after the malt cooling section. It discharges the kilned malt and transfers it to peripheral transport means 28 for further processing.

[0225] Since the kiln malt bed often does not collapse when only being removed from below, thus creating a build-up that collapses irregularly, in one design three small diameter screw conveyors are installed in front of a support plate, arranged one above the other.

[0226] These feed the kiln malt to an inclined screw conveyor, which conveys it over the side wall 15 of the circular ring germination box 6 and transfers it to peripheral transport means 28 at the same location.

[0227] A conveniently installed dust extraction system extracts the resulting malt dust and feeds it to by-product processing.

[0228] In the direction of travel after the unloading device, an idle area 31 of the horde 14 begins, in which service work can be carried out.

[0229] Since the tray 14 behind the support plate of the unloading device 27 is always empty and thus accessible, an operating platform is not required here. Idle range

[0230] In the idle area, which is located immediately behind the unloading device 27, also known as the discharge device, and is a 24-hour daily distance, the usual cleaning work is carried out on and under the conveyor 14. "A daily distance" refers to a circular segment that is moved forward in one day.

[0231] In addition, any necessary repair or replacement work on the tray floor 14 or on the seals 23 can be carried out without interrupting continuous production operations.

[0232] This means that the device does not have to be shut down regularly and production losses are significantly reduced.

[0233] Due to the special feature of this invention, in that the entire germination box 6 rotates, no gaps occur between the side walls 15, which are firmly screwed to the tray base 14, and between the tray sieves, which are screwed together. This prevents product losses due to leaks in the tray area.

[0234] This also prevents product from being ejected, as is often seen at the top of traditional germination boxes. Sealing

[0235] In order to prevent losses of process air, sealing elements 23 made of elastomers are also expediently screwed to the side walls 15 of the germination box 6, which run around the germination box 6. The sealing elements 23 are particularly Fig. 3 They grind on replaceable grinding surfaces 24 that are screwed to the building walls 4.

[0236] In this way, they close the gaps between the side walls 15 of the advancing circular ring germination box 6 and the building walls 4 and prevent the loss of process air.

[0237] The elastic-seal seals 23 according to the invention in this embodiment are located outside the product-contact area. Product losses due to defective seals cannot occur at this location. The wear load on the seals 23 is also significantly lower. In addition, these seals can be replaced during continuous production. Service and repair work during production

[0238] A further advantage of the device 1 according to the invention is that all necessary repair and part replacement work can be carried out safely without interrupting operation.

[0239] This means that once the plant has been put into operation, it will no longer be brought to a standstill due to procedural or technical incidents, unless it is shut down by force majeure or intentionally. Production expansion through later addition of a switch

[0240] In one embodiment, a later addition and the integration of a separate, continuous steeping device is not associated with any restrictions on the production process, apart from a brief interruption to adjust the circulation speed. Such an addition then increases the plant's production output by the time saved during the steeping phase.

[0241] Since the rotation time is now reduced by the time saved during the steeping and the likewise shortened drying phase, it is necessary to increase the rotation speed so that the germination box 6 completes a full revolution in the now shorter cycle time. Accordingly, the gear ratio of the germination box drive 12 must be changed, e.g., from "I1" to "I2," i.e., from a first gear ratio to a second gear ratio.

[0242] To increase the rotational speed, the pulleys of the electric motor and the reduction gear are replaced.

[0243] For the soaking phase on the tray - tray base 14 of the annular germination box 6 - two days = 48 hours are scheduled in an exemplary production schedule. The corresponding circulation time of 204 hours is thus reduced to 156 hours due to the elimination of the soaking time. Due to the faster circulation speed, the circulation time of the annular germination box 6 through the sections of the simmering / drying phase defined by the space divider elements in the lower tray space 30 is also reduced from 36 hours to 27.5 hours. To achieve the required drying performance in this shorter time, the fan power is increased accordingly. With careful preparation of this conversion measure, the time required is less than one working hour, during which continuous operation must be interrupted.

[0244] The feeding of the soft material continues in the same way as before, including the distribution in the ring-shaped germination box 6, but with a faster feeding. Addition of a separate continuously operating kiln

[0245] In one embodiment, the device can be further expanded with the later addition of an additional kiln, thus further increasing productivity.

[0246] In contrast to the upstream installation of a continuous steeping system, however, the integration of a separate kiln, although this also operates in continuous mode, requires a longer production interruption.

[0247] Since the entire circular area of ​​the horde, with the exception of the idle time / idle area, is now used exclusively for the germination cycle, but this is not extended in time, the rotation speed of the germination box 6 must be increased again.

[0248] The process is exactly the same as for a separate kiln conversion. Essential components for the simmering / drying cycle, such as the fans and heating system, can be reused in the separate kiln if they are converted for this purpose.

[0249] This requires a corresponding changeover time. List of reference symbols

[0250] 1 Device 2 Circular building 3 Floor 4 Walls 5 Ceiling 6 Germination box 7 Running rings 8 Rollers 9 Roller supports 10 Roller supports 11 Rack 12 Feed drive 13 Tray support 14 Tray floor 15 Side walls 16 Guide rails for germination box turner 17 Wear pad 18 Germination box turner 19 Rollers of the germination box turner 20 Turning spindles 21 Turner feed drive 22 Racks for turner feed 23 Elastic seal 24 Contact strip 25 Loading device 26 Service bridge 27 Unloading device 28 Means of transport 29 Enclosed interior area 30 Lower tray space 31 Idle area

Claims

1. An Apparatus (1) for continuous malt production, comprising a circular ring building (2), comprising a floor (3), walls (4) and a ceiling (5), which is arranged opposite the floor, wherein a movable circular ring-shaped germination box (6) is arranged in the circular ring building (2), which is designed to move forward permanently without interruption, wherein the germination box (6) has a tray floor (14) and side walls (15), wherein a germination box turner (18) is arranged on an upper side of the side walls (15) facing away from the tray floor (14), wherein the germination box turner (18) is carried along by the germination box (6) and is movable relative to the germination box (6) .

2. The apparatus (1) according to claim 1, wherein a sub- tray floor - chamber (30), which is arranged between the floor (3) and the tray floor (14) in the circular ring building (2), is subdivided into a plurality of sections, wherein room dividers are provided for subdivision, which prevent the passage of process air between adjacent sections.

3. The apparatus (1) according to one of the preceding claims, wherein the device further comprises a loading device (25) which is arranged in a stationary manner in the circular ring building (2).

4. The apparatus (1) according to one of the preceding claims, wherein the device (1) further comprises a discharge device or unloading device (27) which is arranged in a stationary manner in the circular ring building (2) and is designed for discharging the kilned malt.

5. The apparatus (1) according to claim 4, wherein the germination box (6) further comprises an idle area (31) which is located behind the unloading device (27) in the direction of germination box travel, which is arranged in a stationary manner in the circular ring building (2).

6. The apparatus (1) according to one of the preceding claims, wherein the apparatus (1) comprises a kilning device which is arranged in the circular ring building (2), in particular in the germination box (6), after a germination region, in particular in the direction of germination in front of an unloading device.

7. The apparatus (1) according to one of the preceding claims, wherein the apparatus (1) comprises a steeping device which is arranged upstream of the loading device outside the circular ring building (2).

8. The apparatus (1) according to one of the preceding claims, wherein the upper side walls (15) are provided with running rails (16) on which the germination box turner (18) is movable by means of its own feed drive.

9. A method for producing malt with an apparatus (1) according to any one of the preceding claims, comprising continuously introducing grain, passing through a germination process, continuously discharging the processed grain.

10. The method according to claim 9 further comprising: passing through a withering and kilning process after the germination process, and continuously discharging the processed grain as kilned malt.