Posted by: Polyco
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MALT PROCESSING SYSTEM – RAW MATERIAL PROCESSING SYSTEM

The Malt processing system is a crucial component in the raw material processing system of the beer production line, ensuring high-quality inputs for the production of beer that meets standards. Let’s explore the Malt processing system manufactured by POLYCO in the article below.

1. Key components of the Malt processing system

The main parts of the Malt kettle include the kettle body, kettle lid, and kettle bottom.

The kettle is constructed of stainless steel 304L/304-2B material according to the stainless steel manufacturer’s standards. The body is cylindrical, the lid and bottom are conical, with a stirrer assembly attached to a motor with a gearbox, with a frequency converter to control the speed. The entire structure of the kettle body, lid, and bottom is Argon welded. The inner welds are ground flat and polished to ensure a smooth surface finish Ra ≤ 1.25 mm. The cylindrical body part is insulated.

Manufacturer: POLYCO Material for insulation and bottom: stainless steel 316L Total volume up to shoulder: 49.5 m3

Kettle body:

Cylinder diameter: 4,780 mm Cylinder height: 2,500 mm Body thickness: 5mmx1,500mm + 4mm x 1,000mm Reinforced kettle bottom: 6mmx500 (reinforced part under the kettle)

Kettle lid:

Lid thickness: 4 mm Cone angle at the top: 130o

There is an interior light installed on the kettle lid. The light cover can be removed from the outside, with a light box diameter of DN270 and a CIP process indicator light. The light switch box is made of stainless steel 304, with light switch and lock switch, for safety locking, including insulation protection tubes.

The stainless steel 304 sanitary door with an observation window for the boiling process is equipped with a door open/close position sensing device connected to the central control system to ensure the operator’s safety while the system is operational. The lid part is welded to the kettle body, insulated on top of the insulation layer.

The steam outlet pipe is installed at the top of the kettle from the kettle lid to the factory roof, including: pipes, brackets, rain covers, ventilation, and insect repellent. The visible part of the pipe is ground smooth:

  • Diameter: f400mm Thickness: 2 mm Length: 6,000 mm Material: Stainless steel 304L.
  • Kettle bottom:
  • Bottom thickness: 5mm Cone angle at the bottom: 144o Material: Stainless steel 316L.

The lower part of the kettle bottom is designed as a 300mm high cylindrical body with a diameter of 380mm for convenient installation of level sensors and switches. The kettle bottom DN420 flange is made of stainless steel 304 with a motor-mounted gearbox with the kettle bottom, with a DN200 discharge pipe.

The kettle body and bottom are insulated with 100mm thick glass wool, wrapped outside with 3mm thick stainless steel 304-2B, the upper part of the cylindrical body above the floor, from the floor down to the bottom with 0.8mm thick stainless steel 304. The heat chamber is made of stainless steel 316L distributed on the kettle body and kettle bottom.

The top rim on the floor is made of 3mm thick stainless steel 304L Heating rate 65oC 75 oC, Average 1.0 oC/min; With temperature recording and adjustment equipment during the boiling process. Total heat exchange area: ~25 m2 Working pressure: 4 bar. Test pressure: 6 bar. The heating surfaces are welded with heating channels. The stirrer blades ensure gentle, uniform mixing and ensure even heat distribution throughout.

Support feet: Kettle feet are made of stainless steel S304 with a diameter of f273mm. Including: 4 upright feet with a diameter of f273mm along with all necessary connecting materials to be directly mounted on concrete floor, f500 base plate, 10mm thick.

Stainless steel washing equipment, including: 03 spray balls, convenient connecting materials for CIP and water supply. 01 spray ball capacity 36m3/h; 2.5 bar for kettle cleaning. 02 spray balls with a capacity of 5m3/h; 2.5 bar for cleaning sanitary doors and steam outlets.

Stirrer made of stainless steel 304, shaft seal blocking set with food-grade gasket.

Direct drive unit with flange connection Power: 7.5 kW; Driving speed 1,450 rpm, stirring speed about 25 rpm. IP54 protection system, Insulation class F. Stirrer motor with speed control frequency converter.

2. Malt kettle accessories

Various types of waterway valves, CIP, and common fluid routes for malt kettle;

Various types of steamway valves for malt kettle: PID control valve DN100, Compressed air control valve DN125, Compressed air control valve DN65, Hand-operated shut-off valve DN125, Hand-operated shut-off valve DN65, Hand-operated shut-off valve DN20, Steam trap for steamway DN125, Check valve DN50, Check valve DN20, Stopcock DN50, Stopcock DN20, Automatic water drain valve DN20.

Steam pressure gauge 12-liter condensate water tank Steam supply and condensate drainage pipes; unions; T; valves: made of SCH40 standard pressure steel pipes.

Pump from malt kettle to filter kettle and accessories

Pump capacity suitable for brewing capacity: Manufacturer: Alfa Laval/ KPA – EU Flow rate: 180m3/h. Head: 10mH2O. Voltage: 380V/3Ph/50Hz. Power: 7.5 kW. Material: all parts in contact with the product are made of stainless steel 316. Protection class: IP54 The pump has a shaft seal cooling part with water. Pump and motor are mounted on stainless steel feet. Automatic flow control pump with frequency converter.

CIP pump back to malt kettle and grain kettle

Pump capacity suitable for brewing capacity:

Manufacturer: Alfa Laval/ KPA – EU Flow rate: 25 m3/h. Head: 15mH2O. Voltage: 380V/3Ph/50Hz. Power: 3 kW. Material: all parts in contact with the product are made of stainless steel 316. Protection class: IP54 The pump has a shaft seal cooling part with water. Pump and motor are mounted on stainless steel feet.

Above are the details of the Malt processing system in the raw material processing system. We hope this information will be helpful for you to understand more about the design and construction of POLYCO’s malt kettle product.

POLYCO – Proud to own a team of highly skilled personnel, workers, and leading experts in the field of research, design, and manufacture of food processing equipment systems. Polyco is constantly developing, improving machinery, and automation in manufacturing plants, notably in the beer production industry.

For consultation and further information about the Malt Kettle – Raw Material Processing System, please contact:

☎ Hotline: (+84) 28. 3844.3399

📧 Email: info@polyco.com.vn