Aseptic Disposable Brewing Bags for Sterile Fermentation
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Solution Overview
Problem
The craft beer industry faces challenges such as high production costs due to expensive equipment, labor, and environmental compliance issues, as well as limitations in the three-tiered liquor distribution system, which hinder the growth of small-scale breweries.
Innovation Solution
A brewing system that uses aseptic, disposable bags for fermentation and conditioning, incorporating UV-treated water and pre-packaged dry ingredients to maintain a sterile environment, reducing the need for chemical sanitizing and minimizing equipment costs, while automating the brewing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional brewing equipment and processes are used, then beer can be produced, but production costs are high due to expensive equipment, labor, and chemical sanitizing requirements
Solution Approach 1:
The patent employs disposable sterile bags for fermentation and conditioning that replace expensive, complex brewing equipment. These single-use bags eliminate the need for costly sanitizing chemicals and extensive cleaning procedures, directly reducing production costs while maintaining brewing functionality.
Solution Approach 2:
The patent extracts the essential brewing function from complex equipment and implements it through simple disposable bags. By removing unnecessary equipment complexity and focusing only on the core fermentation and conditioning functions, the system reduces both cost and complexity while maintaining effectiveness.
2Reliability
If chemical sanitizing is used to maintain sterile environment, then microbial contamination is prevented, but environmental pollution increases and costs rise
Solution Approach 1:
The patent uses disposable sterile bags that are pre-sanitized during manufacturing. This eliminates the need for chemical sanitizing agents during operation, preventing chemical pollution of the environment while maintaining a sterile brewing environment throughout the process.
Solution Approach 2:
The bags are sanitized and prepared in advance during manufacturing before being used in the brewing process. This preliminary sanitization action eliminates the need for subsequent chemical sanitizing steps, reducing environmental harm while ensuring sterile conditions are maintained throughout brewing.
3Reliability
If high labor costs are incurred for maintaining brewing conditions, then quality control is improved, but production efficiency decreases
Solution Approach 1:
The disposable bags are designed to be self-contained with integrated temperature control and sterile barriers. The system serves itself by eliminating the need for complex manual monitoring and maintenance of brewing conditions, thereby reducing labor requirements while maintaining quality control through the built-in features of the disposable system.
4Adaptability or versatility
If small-scale breweries operate in expensive retail locations, then market access is achieved, but fixed costs increase significantly
Solution Approach 1:
By adopting disposable brewing bags, small-scale breweries dramatically reduce their equipment and operational fixed costs. This cost reduction enables them to operate more profitably even in expensive retail locations, improving their financial adaptability and market competitiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system significantly reduces production costs, simplifies waste management, and allows for efficient beer production with unskilled labor, enabling small-scale breweries to increase output and reduce the cost per serving.
Implementation Method 1
a water supply subsystem that is effective to measure, filter, and expose incoming water to UV light
Implementation Method 2
transferring the powdered malt into a disposable second aseptic dry, sealed fermenter bag for fermentation in the fermentation tank to form fermented beer
Data Source
AI summary
A brewing system for fermenting beer when isolated from any possible micro-biological contamination comprises a first holding frame in a fermentation tank, a second holding frame in a bright beer tank, a water supply subsystem that is effective to measure, filter, and expose incoming water to UV light, a mixing subsystem that is effective to connect fittings or glands clamped onto manifolds of the fermentation and bright beer tanks, and aseptic dry, sealed bags containing dry ingredients of powdered malt extract, beer mixes, hops, and yeast. The brewing system includes a valve for connecting the water supply subsystem to the fermentation tank, and a mechanism for transferring the powdered malt into a disposable second aseptic dry, sealed fermenter bag for fermentation in the fermentation tank to form fermented beer. The disposable fermenter bag has ports on a bottom manifold and is designed to fit into the first holding frame that is insulated and custom controls its temperature. A transfer mechanism directs the fermented beer into a third aseptic bag disposed on a second holding frame inside a bright beer tank in which the fermented beer is conditioned and carbonated. Finally, a dispensing mechanism is connected to the bright beer tank for discharging a consistent contaminant free beer product to serve drinking customers.