In-line Carbonation System with Porous Stone
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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, often requiring high pressures and manual intervention, leading to over- or under-carbonation issues.
Innovation Solution
A carbonation system and method involving a pressurizable vessel connected to a CO2 tank, with a pump circulating the liquid through a fitting assembly containing a carbonation stone, allowing for controlled introduction of CO2 at varying pressures to achieve rapid and consistent carbonation, using a carbonation stone with larger pores to reduce pressure restrictions and a secondary hose for slower CO2 dissolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a carbonation stone with small pores (0.5-2 microns) is used to create small bubbles for rapid CO2 dissolution, then the surface area for dissolution is increased, but the CO2 flow is restricted and high pressures (20-30 PSI) are required
Solution Approach 1:
The patent uses a porous carbonation stone with larger pores (5-50 microns) instead of traditional small pores. This allows CO2 to flow through more easily at lower pressures while still creating sufficient bubble surface area for rapid dissolution into the beer.
2Productivity
If high CO2 pressure (20-30 PSI) is applied to push CO2 through the carbonation stone, then acceptable CO2 flow rate is achieved, but the beer may become over-carbonated or under-carbonated based on operator skill
Solution Approach 1:
The patent changes the pore size parameter of the carbonation stone from traditional 0.5-2 microns to 5-50 microns. This parameter change allows achieving acceptable CO2 flow rates at lower pressures (5-15 PSI), thereby improving carbonation consistency and reducing operator skill dependency.
3Loss of time
If force-carbonation method is used with pressurized CO2 to carbonate beer quickly, then carbonation can be achieved in a week or less, but the process is manual and results in inconsistent carbonation levels
Solution Approach 1:
The patent employs a recirculation system where beer is automatically pumped through the carbonation stone and back into the keg multiple times. This self-service mechanism ensures consistent carbonation levels without requiring manual intervention or operator skill, achieving both speed and precision.
4Productivity
If CO2 is vented to allow continual flow through the system, then CO2 dissolution is maintained, but CO2 gas is wasted and expensive
Solution Approach 1:
The patent creates a closed recirculation system where CO2 continuously dissolves into the beer as it passes through the carbonation stone multiple times. This eliminates the need for venting CO2 to maintain dissolution, thereby preventing CO2 waste while maintaining efficient carbonation.
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
Enables beer carbonation to a desired level in under an hour with minimal operator input, reducing the risk of over-carbonation and improving consistency, while minimizing CO2 wastage and operational complexity.
Implementation Method 1
A pump is activated to circulate the liquid through a hose out of the vessel to a fitting assembly and out of the fitting assembly back into the vessel
Implementation Method 2
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
Implementation Method 3
the volume of CO2 (the standard unit used to measure carbonation level in the industry) is easily controlled via a carbonation chart of temperature of the beer and pressure of the CO2
Data Source
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 first pressure. A pump is activated to circulate the liquid through a hose out of the vessel to a fitting assembly and out of the fitting assembly back into the vessel. While the liquid is flowing through the fitting assembly carbon dioxide is introduced to the liquid at a second pressure level, wherein the second pressure is greater than said first pressure. After a pre-determined period of time the pump is deactivated and the carbon dioxide can cease to be introduced to the liquid flowing through the fitting assembly.