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Commercial Beer Brewing Fermentation & Bright Tank Manager

In commercial brewing, consistency is brand identity. The Brewery Tank Sentinel ensures absolute batch-to-batch consistency by providing real-time tracking of specific gravity, dissolved CO2, and yeast cell density directly within fermentation and bright beer tanks. This system replaces error-prone manual sampling, prevents off-flavors from temperature spikes, and cuts tank turnover time by 25%, allowing craft and macro-breweries alike to scale production without sacrificing quality.

Precision Fermentation Control Technology:

• In-Situ Specific Gravity Monitoring: Using a vibrating fork densitometer and in-take NIR spectroscopy, the system provides continuous true Plato/Brix readings without the need to draw samples, allowing brewers to track fermentation curves in real time and precisely determine the terminal gravity point for diacetyl rests.

• Yeast Vitality & Cell Count Analytics: A laser-based optical sensor measures turbidity and uses Mie scattering algorithms to distinguish between live yeast, dead cells, and hop debris, providing accurate cell counts and viability percentages crucial for yeast harvesting and repitching schedules.

• Dissolved CO2 Precision Control for Carbonation: In bright tanks, a non-dispersive infrared (NDIR) sensor measures dissolved CO2 with 0.1 vols accuracy. This is integrated with the headspace pressure control valve to create a closed-loop carbonation system that achieves perfect carbonation levels in hours instead of days, with zero waste from over- or under-carbonation.

• CIP (Clean-in-Place) Cycle Validation and Assurance: The system monitors conductivity and temperature during CIP cycles, providing automated verification that tanks have reached the required chemical concentration and temperature for the correct contact time to ensure sterility, with all data logged for food safety audits.

End-to-End Brewery Process Management:

1. Fermentation Monitoring and Control: From knockout, the system tracks the temperature gradient and specific gravity drop, automatically controlling glycol jackets to follow the ideal fermentation profile and signaling when to initiate a diacetyl rest or cold crash.

2. Bright Tank Carbonation and Packaging: Once beer is transferred, it controls the carbonation stone and headspace pressure to hit the target CO2 level, and can interface with bottling/canning lines to ensure packaged beer specs are maintained.

3. Quality and Compliance Data Logging: Every parameter is recorded in a brewery management system (BMS)-friendly format, creating a complete digital twin of each batch for quality traceability and SQF/BRC certification audits.