Fermentation Monitoring Using Gas Flow and Specific Gravity Change
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for monitoring fermentation in breweries are inadequate, relying on infrequent specific gravity readings that are often inaccurate and difficult to interpret, leading to inconsistent fermentation processes and challenges in maintaining product quality.
Innovation Solution
A system comprising pressure sensors, gas flow sensors, and a controller that continuously monitors pressure and gas flow to determine changes in specific gravity, allowing for real-time monitoring and control of fermentation activity, including carbon dioxide levels and yeast vitality, enabling more precise control of the brewing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If specific gravity readings are taken manually once a day with handheld hydrometers, then the measurement process is simple and inexpensive, but the data quantity is very low and fermentation progress cannot be accurately tracked
Solution Approach 1:
The patent replaces manual mechanical hydrometer measurements with an automated electronic monitoring system that uses pressure sensors and gas flow sensors to continuously track fermentation progress. The controller processes sensor signals to calculate specific gravity changes automatically, eliminating the need for manual daily readings and enabling continuous real-time monitoring of fermentation activity.
2Loss of information
If manual specific gravity readings are taken frequently, then more data is collected, but the process becomes more time-consuming and prone to human error
Solution Approach 1:
The patent implements continuous monitoring of fermentation by maintaining constant connection between pressure sensors, gas flow sensors, and the controller. The system continuously collects data without interruption, eliminating gaps in information that occur with periodic manual readings. The controller continuously processes sensor signals to track fermentation progress in real-time, ensuring complete data coverage without requiring human intervention at each measurement point.
Solution Approach 2:
The monitoring system performs self-measurement and self-recording of fermentation data. The sensors automatically detect pressure and gas flow changes, the controller calculates specific gravity changes from these measurements, and the system stores the data without requiring human operators to take readings or record results. This eliminates human error and frees operators from time-consuming manual measurement tasks.
3Reliability
If paper-based recording of specific gravity readings is used, then the system is simple, but the recorded data is easily lost or destroyed
Solution Approach 1:
The patent replaces fragile paper-based recording with an electronic data storage system. The controller receives signals from pressure and gas flow sensors, processes these signals to determine specific gravity changes, and stores the fermentation data electronically. This electronic storage eliminates the risk of data loss from physical damage to paper records while providing durable, retrievable fermentation information.
4Ease of operation
If untrained staff take specific gravity readings, then labor costs are reduced, but measurement accuracy decreases and readings may be mislabelled
Solution Approach 1:
The monitoring system performs measurements and data recording automatically without requiring human operators to interpret or record results. The sensors self-detect fermentation parameters, the controller self-calculates specific gravity changes from sensor signals, and the system self-stores the data with proper timestamps and labels. This eliminates errors from mislabeling or incorrect readings that occur when untrained staff perform manual measurements, while requiring no specialized training to operate.
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 provides accurate, real-time data on fermentation progress, allowing brewers to optimize processes, maintain consistency, and improve product quality by enabling timely adjustments and better yeast management.
Implementation Method 1
a first pressure sensor fluidly connected to the gasses region of the vessel and configured to output a signal indicative of the pressure in the gas internal region, a second pressure sensor fluidly connected to the liquid region of the vessel and configured to output a signal indicative of the pressure in the liquid internal region
Implementation Method 2
a gas flow sensor fluidly connected to the gasses outlet and configured to output a signal indicative of the gas flow though the gasses outlet
Implementation Method 3
During a fermentation process, the tank has a liquid in a first lower portion of the tank which ferments and emits gas. The gasses are collected in an upper region of the tank above the liquid. The gas produced during the beer fermentation process is carbon dioxide (CO2).
Data Source
AI summary
The invention relates to a system configured to monitor fermentation activity in a brewing vessel, the vessel comprising a gas internal region and a liquid internal region, in use, and a gasses outlet fluidly connecting the gas internal region to the environment, the system has one or more sensors configured to determine the level of the liquid region of the vessel; a gas flow sensor fluidly connected to the gasses outlet and configured to output a signal indicative of the mass or rate of gas flow though the gasses outlet; a controller configured to determine a change in specific gravity based on: the one or more sensors configured to determine the level of the liquid region of the vessel, the signal from the gas flow sensor, an initial specific gravity measurement; and wherein the controller is further configured to generate an output, display and/or store a fermentation activity signal based on the determined change in specific gravity.