Closed-Loop Beer Carbonation System with Feedback Control

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Solution Overview

Problem

Current methods for carbonating beer, such as krausening and force-carbonation, are time-consuming and result in inconsistent carbonation levels, leading to over- or under-carbonation, and can waste CO2, affecting beer quality and aroma.

Innovation Solution

A closed-loop carbonation system using a pump and carbonation stone with a controlled pressure system, where CO2 is recirculated through a vessel to achieve desired carbonation levels quickly, minimizing operator intervention and preserving beer aromas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If force-carbonation method is used with carbonation stone, then carbonation speed is improved, but CO2 pressure requirement increases and operator skill dependency increases

Engineering Contradiction:

Improvecarbonation speedVSAvoidCO2 pressure

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The system uses a controller that receives input from a carbonation level sensor to automatically adjust the CO2 injection rate, creating a closed-loop feedback system that maintains consistent carbonation levels without requiring high pressures or operator skill

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention replaces the mechanical force-carbonation method (which relies on high CO2 pressure forced through stones) with a controlled injection system that uses precise metering and feedback control to achieve carbonation at lower, more manageable pressures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If force-carbonation method is used with carbonation stone, then carbonation speed is improved, but carbonation consistency deteriorates

Engineering Contradiction:

Improvecarbonation speedVSAvoidcarbonation consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The controller continuously monitors carbonation level via sensor input and automatically adjusts CO2 injection to maintain the target level, ensuring consistent results regardless of operator skill or variations in the process

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system is self-regulating through the feedback loop, automatically correcting deviations from the target carbonation level without requiring manual intervention or operator judgment

Inventive Principle:

Principle #25Self-service

3Productivity

If tank is vented to allow continuous CO2 flow, then carbonation speed is improved, but CO2 waste increases and aroma loss increases

Engineering Contradiction:

Improvecarbonation speedVSAvoidCO2 waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The feedback control system monitors carbonation levels and stops CO2 injection when the target is reached, preventing the continuous venting and waste associated with traditional methods while maintaining fast carbonation speeds

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system recovers by precisely controlling CO2 injection to match actual carbonation needs, discarding the wasteful practice of continuous venting by using feedback to stop injection at the optimal point

Inventive Principle:

Principle #34Discarding and recovering

4Productivity

If tank is vented to allow continuous CO2 flow, then carbonation speed is improved, but beer aroma quality deteriorates

Engineering Contradiction:

Improvecarbonation speedVSAvoidaroma loss

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The feedback control system prevents excessive CO2 injection that would strip volatile aromas by stopping injection when the target carbonation level is reached, preserving beer quality while maintaining fast carbonation

Inventive Principle:

Principle #23Feedback

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

The system rapidly carbonates beer to a consistent level in under an hour, reducing the risk of over-carbonation and preserving volatile aromas, while minimizing CO2 waste.

Implementation Method 1

These stones create small bubbles of CO2 to be exposed to the beer. The small bubbles present a very large surface area to the beer, speeding along the dissolution into the beer.

Methodology Applied

Scientific EffectBubble formation and surface area effect: Bubble

Implementation Method 2

A pump is activated to circulate carbon dioxide accumulating in the head space through a hose out of the vessel back into the vessel at a carbonation stone. Carbon dioxide is introduced to the liquid at a desired pressure level

Methodology Applied

Scientific EffectGas circulation and dissolution: Diffusion

Data Source

PatentUS11219873B1Carbonation method

Publication Date: 2022.01.11 JR BLICHMANN HOLDINGS LLC

AI summary

A method and apparatus for carbonating a liquid in a pressurizable vessel, including first connecting a vessel with a carbon dioxide tank, wherein said vessel contains a liquid. A vessel can then be pressurized with carbon dioxide to a desired pressure. A pump or compressor can be activated to circulate gas through a hose out of the head space of the vessel to a carbonating stone back into the vessel. After a pre-determined period of time the pump is deactivated, and the carbon dioxide can cease to be introduced to the liquid within the vessel.