Fermentation tanks play a key role in many industries, producing various products by promoting the fermentation process of liquids. They are widely used in the food, beverage, pharmaceutical, and other industries. Their main function is to provide a fermentation environment to promote the growth and metabolism of microorganisms. Through fermentation conditions, fermentation tanks can improve fermentation efficiency and product consistency, which has a direct impact on the flavor, quality, and production cost of the final product.
Table of Contents
What is a fermenter?
A fermenter is a special container used in the fermentation process and is widely used in the food, beverage, pharmaceutical, and chemical industries. The main function of a fermenter is to provide a suitable environment for microorganisms to promote fermentation reactions and produce various products. Fermenters are often used to produce yeast, beer, wine, vinegar, medicines, and other fermented products.
Features of a fermenter:
- Temperature control system: It can adjust and maintain the optimal temperature required in the fermentation process to optimize the activity and metabolism of microorganisms.
- Stirring function: It can evenly mix the fermentation liquid to ensure the uniform distribution of nutrients and the full contact of microorganisms.
- Sealing design: The sealing structure of the fermenter prevents external contaminants from entering, ensuring the purity of the fermentation process and the quality of the product.
- Monitoring and automation: It can record and adjust fermentation parameters in real-time to improve the convenience and accuracy of operation.
Types of fermentation tanks
- Open fermentation tanks: The tanks are open at the top and are usually used for traditional brewing methods, such as some types of ale, which allows yeast to come into contact with air, but this may also increase the risk of contamination.
- Closed fermentation tanks: The tanks are completely closed to prevent air and external contaminants from entering. Suitable for most modern brews, especially lager.
- Cylindrical conical fermentation tanks: The bottom of the fermentation tank is conical, which facilitates the sediment to be concentrated at the bottom and easily discharged. This design helps to improve the clarity of the beer.
- Horizontal fermentation tanks: The tanks are designed to be placed horizontally, which helps to better stir and control the temperature during the fermentation process, and are suitable for brewing processes that require special treatment.
- Pressure fermentation tanks: The tanks can withstand a certain amount of pressure and are suitable for high-pressure fermentation processes or secondary fermentation. Pressure fermentation can help reduce the formation of esters and other by-products and improve the flavor of the beer.
- Fermentation tanks: Usually used in large-scale breweries, with the function of controlling temperature and pressure to ensure the consistency and stability of the fermentation process.
- Fermentation room: This is a room or space with a temperature control system that can accommodate multiple fermentation tanks, suitable for breweries that need to precisely control fermentation conditions.
Fermentation in a fermenter
Charging
- Wort preparation: Before fermentation begins, the wort usually needs to go through steps such as boiling and cooling. The wort contains the main sugars of beer, which the yeast will use for fermentation.
- Adding wort: Transfer the cooled wort to the fermenter. Make sure the wort temperature is suitable for yeast fermentation. For ale, the suitable temperature range is usually 15-20°C, while lager requires lower temperatures.
Inoculating yeast
- Choosing yeast strains: Choose the appropriate yeast strain based on the type of beer and flavor requirements. Ale yeast and lager yeast are the two most common types.
- Adding yeast: Add yeast to the wort in the fermenter. Dry yeast or liquid yeast can be used, and usually follow the brewer’s guidelines on the recommended amount of yeast and the method of adding yeast.
Fermentation process
- Start the temperature control system: Set up and start the temperature control system to keep the fermentation liquid within the appropriate temperature range. This is a key factor to ensure that the yeast works properly.
- Gas discharge: During the fermentation process, yeast will produce carbon dioxide and other gases. Release these gases through airlocks or other exhaust devices to prevent excessive pressure in the tank.
- Fermentation stage: Yeast actively converts sugar into alcohol and carbon dioxide. During this stage, the fermentation liquid will produce foam and bubbles, the alcohol concentration of the fermentation liquid is stable, and the production of carbon dioxide gradually decreases.
Fermentation completion treatment
- Fermentation completion: At the end of the fermentation process, the sugar in the fermentation liquid is converted into alcohol. At this time, measurement is required to confirm whether the fermentation is complete.
- Sediment removal: After the fermentation is over, sediment will accumulate at the bottom. Use a sediment discharge device to remove these sediments.
Sampling and quality control
- Sampling test: Take samples regularly to check the quality of the fermentation liquid, including alcohol concentration, sugar content, pH value, and flavor.
- Quality control: Ensure that the flavor, taste, and other quality standards of the beer during the maturation stage meet expectations.
How to choose the right fermentation tank?
Tank Material
Fermentation tank size
The size of the fermentation tank is another important factor to consider. The size of the fermentation tank should be appropriate for the size of your brewery and the amount of beer you intend to produce. Small breweries may require a fermentation tank with a capacity of 5 to 10 barrels, while large breweries may require a fermentation tank with a capacity of 30 to 50 barrels or more.
Shape and Design
The shape and design of the fermentation tank can also affect the fermentation process. Conical tanks are the most popular because they facilitate the collection of yeast and other sediment during the fermentation process. However, other shapes such as cylindrical, cylindrical, or square may also be suitable depending on the specific needs of the brewery.
Pressure Rating
The pressure rating of a fermenter is another important consideration. The fermenter should be able to withstand the pressure created during the fermentation process without compromising the integrity of the fermenter. Pressure ratings are usually measured in pounds per square inch (PSI), and the fermenter should be rated for the type of beer you want to produce.
Other Features
Some fermenters come with extra features, such as built-in thermometers, airlocks, or spigots. These features are convenient, but they can also increase the price of the fermenter. Consider which features are important to you and weigh them against your budget.
Demand trends for fermenters
- Automation and intelligence: The market demand for fermenters with advanced automation control and data monitoring is rising. These systems can provide precise temperature control, pH monitoring, and data recording, and improve operational efficiency and consistency of the fermentation process.
- Miniaturization: Small fermenter designs are becoming more and more popular, especially in R&D and small and medium-scale production. Such equipment provides flexibility and scalability, suitable for changing production needs.
- Green and sustainability: Environmental protection and sustainable production requirements have driven the demand for low-energy and high-efficiency fermenters. Energy-saving technology and waste management systems are becoming increasingly important.
- Customization: With the increase in demand for specific applications, the customization trend of fermenters is rising. Enterprises need to customize the design and function of fermenters according to specific production processes or product requirements.
- Integrated systems: Such as the integration of fermenters with analytical instruments and control systems, improves the consistency of production processes and the management of data flows.
- Market globalization: With the globalization of the beer market, suppliers and manufacturers of fermenters are paying more and more attention to the needs of the international market, which has promoted the development of fermenters of different specifications and standards.