Keraflux™–TFF System
for Yeast ManagementFBBRKRAFLUXENc

Keraflux–TFF System for Yeast Management
The increasing cost of raw materials and energy are forcing the brewing industry to investigate new opportunities
for increasing extract yield without compromising quality. Excess yeast contains a significant amount of extract
which can be recovered by concentrating the yeast with modern cross flow technology. By combining thistechnology with controlled diafiltration, the yield can even be boosted. The recovered beer can be blended to theoriginal beer to a level of approximately 5 % volume without negatively influencing the quality.
Thus, beer recovery can make a big contribution to cost savings in the brewery.

Keraflux–TFF System 3x3 (above)

BenefitsnCost reduction can includen

Excellent beer quality• M inimal difference between original beer and• Very short return on investment (ROI) of

blended beer in terms of sensory and analytics

approximately 1-2 years• C losed system for minimum oxygen uptake• C lear cut off with low turbidity and almost yeast• Net revenue > 90 % of the invested capital peryear• High mechanical, thermal and chemical
resistance of membranes for long modulelifetime• Easy installation due to modular concept• High system availability• Dry matter up to 20 % for high yield• Low maintenance cost• Low operating expense (OPEX)• High quality yeast for salefree beernnn

 igh microbiological safety due to easy cleaning
Hand sterilization with hot water up to 90 °C (194 °F)
Easy to extend due to modular conceptHigh yield, long module lifetime, consistent beerquality and reduced energy consumption due tocontrolled process

Cost Reduction by Process Control
The process for yeast extract recovery uses a ceramic cross flow technology with specific control features to achieve
reduced costs.
nCost savings• Low consumption of cleaning agents and water• High system availability and production timen

Long production cycles and less cleaning cycles• Control of feed flow
• Control of cross flow velocity• Control of permeate flow and trans membrane pressure (TMP) at each module level against target set points
Continuous adjustment of the process parameters to variable set points minimizes energy consumption andprovides gentle treatment of the yeast during the entire process. Most important is the control of permeate flux andTMP in direct relation to the cross-flow speed and feed rate.

Process Description
The beer recovery is conducted in a batch process, which offers several advantages:nImproved performance and quality due to lower yeast concentration in system during batch cyclenReduced energy due to lower yeast concentration in system during batch cyclenYield is expected to be 80 - 90% due to diafiltration

Diafiltration Principle
In this special process developed by Pall, water is added to the yeast suspension to increase the extract and alcohol
recovery (wash out effect) without compromising the beer quality.

Beer IoT
To gain maximum advantage from the data generated by a PLC or Scada control system, Pall implemented IoT
based digital information and process management to beer systems. With this IOT-based extension of data
management in real time, different levels and hierarchies in the brewery have constant access to defined data in auser edited format.
Typical examples for digital data analytics are:nSpecific consumption data: e.g., water, cleaning agents, electricity, membranes,

nPerformance data: e.g., degree of utilization, efficiency, and downtimes

nQuality data: e.g., oxygen uptake, original extract, hazenNotifications: e.g., alarms and messages

nDocumentation and service data

In addition to actual real time data, trends, historical reviews, brand related influences, and raw material impact,
other key influencing factors can be analyzed with the IoT tool. Benchmarking with other installations within abrewery group and against the industry average is also possible and can be switched on and off.
Pall IoT provides direct online availability of all system-specific documentation and training documents, spare parts
lists, service reports, operating instructions, safety instructions and acceptance reports.
Alarm messages can be displayed directly on multiple display devices, reducing response time in the event of aproduction problem. This function can be switched activated by each individual user, selectively.
In summary, Pall IoT solutions contribute to improve plant KPI`s, process optimization and product assurance.

Filter Media

21

Membralox Ceramic Membranes®

nHigh fluxnProven long operational lifen

Excellent resistance to corrosionnWide chemical and pH (0 - 14) compatibilitynExcellent thermal stabilitynCan be sanitized and sterilizedMembralox ModulesnnHigh performance housing design and sealing
assemblyMembralox IC Modules31) C ross section of Membralox
ceramic membrane (x1010)
2) M embralox IC ceramicmembranes3) M embralox ceramic modules

Analytical Results and Taste Panel Data
Chemical and sensory analyses carried out by independent institutes, have shown that a back blending ratioof around 5% by volume is unproblematic. The superior quality of the recovered and blended beers has been
confirmed as follows:
nNo identification of blended beers by taste panelnMinimum deviation (within analytical method sensitivity) in basic analysesn

No significant differences in esters, short chain fatty acids and stale flavor compoundsnBacked by long term experience, turbidity is typically reduced to < 0,8 EBC (90°) (standard conditions, lager beer)Commercial Aspects
The short ROI with a range between 1 –2 years makes this technology and the investment made into it very
attractive to the brewing industry.

ExampleBrewery A

Brewery B

Beer output, Sales Gravity @ 11.5 °Plato (estimate) hl/a

1,400,000

8,350,000

Beer output, HGB @ 16.0 °Plato (estimate) hl/a

1,000,000

6,000,000

Surplus yeast, 3% of HGB volume (estimate) hl/a

30,000180,000

Surplus yeast, daily batch volume to process, 300 d/a (estimate) hl/d

100

600

Extract yield %*85 (80...90)

85 (80...90)

Volume recovered beer, sales gravity hl/a

36,350218,100

Value recovered beer, sales gravity @ 10, Euro/hl (estimate) Euro/a*363,500

2,181,000

CAPEX Keraflux system and services (installation supervision andcommissioning) Euro

432,000

772,650

OPEX Euro/hl recovered beer SG

0.56

0.52

OPEX Euro/annum

20,505

113,950

ROI/a Keraflux system and services w/o periphery/integration

1.3

0.4

CAPEX periphery/integration (incl. installation supervision andcommissioning) Euro

400,000

950,000

ROI/a Keraflux system and services incl. periphery/integration

2.4

0.8

* Depending on the type of beer and yeast

Technical Data
System Type examples:(Module lines x modules high)1x1_IC

1x2_IC

3x1_IC

2x2_IC

3x2_IC

4x2_ICBrewery size, hl/a

1,400,000

3,100,000

4,900,000

6,300,000

9,700,000

12,500,000

Surplus yeast, hl/d100

225

350

450

700900Base Data:
Sales gravity

11.5 °Plato

HGB

16.0 °Plato

Surplus yeast volume

3%

Working days/a300

Process Control Solution
The units will be equipped with a state-of-the-art automation solution. Pall will cooperate with the best-establishedsuppliers of control systems in the brewing industry. In the focus of our automation strategy are features like:nMinimal investment costs and hardware requirementsnEasy handling and operationnContinuous process controlnIndependency of PLC manufacturernModern user interfacenHigh level of standardization and standard software applicability

nScalability

About Pall
Pall Corporation provides critical filtration, separation and purification solutions to meet the demanding needs of abroad spectrum of life sciences and industrial customers around the globe.

Visit us on the Web at www.pall.com/foodandbev
Contact us at www.pall.com/contact+1-866-905-7255 Food and Beverage toll freefoodandbeverage@pall.com
Corporate Headquarters
Port Washington, NY, USA+1-800-717-7255 toll free (USA)+1-516-484-5400 phone
European Headquarters
Fribourg, Switzerland+41 (0)26 350 53 00 phone
Asia-Pacific Headquarters
Singapore+65 6389 6500 phone

Pall Corporation has offices and plants throughout the world. To locate the Pall office or
distributor nearest you, visit www.pall.com/contact.
The information provided in this literature was reviewed for accuracy at the time of publication.
Product data may be subject to change without notice. For current information consult yourlocal Pall distributor or contact Pall directly.
IF APPLICABLE Please contact Pall Corporation to verify that the product conforms to yournational legislation and/or regional regulatory requirements for water and food contact use.

© Copyright 2022, Pall Corporation. Pall,, Keraflux, and Membralox are trademarks ofPall Corporation.
® Indicates a trademark registered in the USA.
FBBRKRAFLUXENc
OCTOBER 2022