PROFI® - The future of beer filtration

A key question for the brewing industry investment today is what is the future direction for beer filtration? Pall has made its decision, and is changing from being the biggest global supplier of traditional kieselguhr filter systems to the brewing industry to membrane filter supply.

We are convinced, that only constant filtrate quality will protect the strength of the most valuable product owned by the brewery – the brand. Only holistic, continuous optimisation of benefits will boost the breweries profits. Conservation of the environment and protection of health will also safeguard the future of breweries investments and security of investment is the key for the healthy development of the brewery.

The future of beer filtration is the PROFI system.

PROFI systems combine two well-established technologies – using a centrifuge as a first stage followed by a membrane crossflow system based on hollow fibre technology. This results in clear differentiation in terms of tasks suitable for clarifiers and filters:

• High solid fraction – centrifuge
• Low solid fraction – cross flow

The PROFI system stands for "novel innovations" and for field-tested, kieselguhr-free filtration suitable for industrial-scale applications, and is from the combined technical experience from the two major market leaders – Pall and GEA Westfalia.

PROFI systems offer filter aid free filtration with the added advantages of reducing holding tank capacity and working capital tied up in the filtration process. By eliminating the use of filter aid, PROFI systems produce beer of the highest quality while contributing to conservation of the environment with the added protection to operator health.

Consideration of existing and future stringent standards and legislation governing the protection of the environment and health is an integral part of the PROFI system concept and our philosophy of Life Cycle Benefit and Brand Protection.

• Low energy consumption
• DE-free filtration
• No filter aid disposal
• Minimised media consumption
• Fulfils appropriate health regulations
• Standard cleaning agents required

Reduces operating costs

• Retentate-free process through emptying the modules with CO2 in the direction of flow
• Minimum beer losses resulting in lower operating costs
• No pre and post-run required and hence:
  o No blending of the beer and degassed water
  o No time losses
  o No additional storage tanks

The PROFI system's continuous process mode is the driving force behind its high level of productivity. Unlike traditional kieselguhr filters that require downtime for cleaning, the PROFI system concept with the combination of high-performance clarifier and patented membrane system allows round-the-clock filtration on an industrial scale.

The increasingly fluctuating process volumes, the growing brand variety and the continuous optimisation of system technologies, require the adaptation of the entire beer filtration processing if the breweries are to have long term assurances. Standardised plant components and a modular plant configuration are the basis of the PROFI system concept enabling a problem-free integration in the brewery environment.

Maximum yield is assured in separation of the yeast and coarse particles in a highly concentrated form at the centrifuge stage. Removing the coarse particles allows the membrane to operate with an internal circulation within the module system, thus eliminating the use of external retentate tanks and extra cooling.

Securing quality and improving the quality of customer brand is a significant element of the PROFI system concept. The PROFI system attains more uniform clarification efficiency than conventional systems and takes full account of the taste-sensitive characteristics of the brewery product, beer.

With a PROFI system, optimised filtration results are achieved as follows:

• Beer quality is comparable to DE filtration. Independent reports are available (Weihenstephan Berlin, Vienna)
• Turbidity 0.1 to 0.3 units (EBC) better than DE filtration
• In-line feed or tank stabilisation possible
• Yeast-free filtrate and sharp reduction in beer-spoiling bacteria
• Integrity test before each filter cycle for performance assurance
• Excellent filterability of permeate results in low costs for downstream cold sterile filters
• Negligible oxygen intake
• Fresh and crisp taste
• Ensures excellent foam and colour quality

The PROFI system allows breweries to produce the brands and volumes required by the customer when needed. This, in turn, allows for the maximisation of profit potential through professional filtration.

Utilising the advantages of centrifuge and cross-flow technologies offers the ultimate efficiency in terms of performance, cost and quality. The PROFI technology is a patented development, which has a proven track record in today's brewing industry.

The first small scale industrial plant has been in operation in a brewery since 1996. This was followed in 2003 by an Up-ScaleTM system operating in a second brewery. In 2005 a full-size system operating in a global brewery was installed. All these PROFI systems are working successfully, producing top brands with global distribution. Since the first system was installed in 1996 no membrane blockage has been observed. Besides easy installation and fast start-up, the installed systems show achievements of 100% performance within a week's operation period. Dismantling the existing kieselguhr filters shortly after start-up demonstrated the confidence of our customers have in the new PROFI technology.

The key argument for sustainability of the brewing industry is the reduction of cost and the improvement of profit. The PROFI system provides better economics combined with long-term investment security and many attributes regarding sustainability. The combination of these facts makes the PROFI system superior not only to common kielselguhr filters but also to other membrane-based technologies.

p , Pall and Upscale are trade marks of Pall Corporation

PROFI is a co-operation between Pall Food and Beverage and GEA Westfalia Separator Food Tech GmbH

® indicates a trade mark registered in the USA