Pilot Plant for Cereal Malting

Product Overview

The Pilot Plant for Cereal Malting, is a pilot scale plant that includes all the industrial stages for malt production.

Technical Specifications

CE00/MA — Pilot Plant for Cereal Malting

• CE00/MA Pilot Plant:
• Capacity of the plant: 250 kg.

Main elements built in AISI 304 and AISI 316

stainless steel suitable for food use.

Accessible spaces avoiding corner areas for easy

cleaning.

Composed of six units.

All units have an emergency stop.

All units are mounted on wheels for easy

transport.

Each unit is controlled independently.

GCS/CTS. Computer Controlled and Touch Screen Grain Cleaning and Steeping Unit.

Built in AISI 304 and AISI 316 stainless steel.

Truncated-conical tank with drain in the lower part that allows the tank to be completely emptied.

• Volume: 800 l.

Water jacket for internal temperature control.

External insulation.

Gate and grid system in the lower part that allows draining the water inside the tank and retaining the grain.

This allows wet and dry periods during drainage.

• Aeration system by means of compressor:
• Power: 300 W.
• CO aspiration system in dry periods by means of centrifugal fan:
• Power: 90 W.
• Maximum flow: 265 m3/h.
• Maximum pressure: 600 Pa.

Overflow that allows the cleaning of the grain and elimination of impurities.

Surface spray nozzles to maintain humidity during dry periods.

• Temperature control system:
• Heat pump (allows cooling and heating):
• Electrical power: 1.5 kW.
• COP: 5.32.

R32 refrigerant.

• Circulation pump:
• Power: 370 W.
• Control by touch PLC:

Control and programming of wet and dry periods.

Temperature control.

Monitoring of process variables.

• Instrumentation:

Six temperature sensors.

CO concentration, humidity and temperature sensor in the

suction stream.

pH sensor.

Three level switches.

Three solenoid valves.

CE00/MA Pilot Plant for Cereal Malting

GGER/CTS. Computer Controlled and Touch Screen Grain Germination Unit.

Built in AISI 304 and AISI 316 stainless steel.

• Germination tank:
• Surface area: 1.5 m2.

Perforated plate bottom that allows the homogeneous distribution of the inlet air.

Two cleaning doors.

Door for emptying system.

External insulation.

• Stirring system for removing and turning the grain:
• Power: 1.1 kW.

Includes frequency inverter.

Aeration and humidification system.

• Centrifugal fan:
• Power: 1.1 kW.

Built in stainless steel AISI 304.

Includes frequency inverter.

• Maximum flow: 650 m3/h.
• Maximum pressure: 3000 Pa.
• Air temperature control system:
• Heat pump:
• Electrical power: 1.5 kW.
• COP: 5.32.

R32 refrigerant.

• Two water circulation pumps:
• Power: 370 W.

One of them includes frequency inverter.

Heat exchangers with finned tubes.

• Accumulator tank:

Built in stainless steel AISI 316.

• Volume: 100 l.

Nozzle system for air humidification.

• Control by touch PLC:

Control and regulation of operating temperature and humidity.

Control of the stirring speed.

Monitoring of process variables.

• Instrumentation:

Six temperature sensors.

CO concentration, humidity and temperature sensor inside the germination tank.

pH sensor.

Level switch.

Three solenoid valves.

Slot sensor for measuring the speed of rotation of the blades system.

CE00/MA Pilot Plant for Cereal Malting

GDT/CTS. Computer Controlled and Touch Screen Grain Drying and Toasting Unit.

Constructed entirely of AISI 304 and AISI 316 stainless steel.

• Drying cylinder:
• Volume: 1000 l.

Perforated plate bottom for correct distribution of hot air.

External insulation.

Cleaning door.

Emptying door.

• Centrifugal fan:
• Power: 3 kW.

Includes frequency inverter.

Manufactured in AISI 304.

Allows working temperatures up to 250 °C.

• Maximum flow: 3000 m3/h.
• Maximum pressure: 3500 Pa.
• Heating resistor block for air heating:
• Power: 22.5 kW

Possibility of increasing or decreasing power.

Consult us for more information.

Air-air heat exchanger that allows to recover

• part of the heat from the exhaust gas:

Made of stainless steel AISI 316.

• Temperature range: 50-150 °C.
• Allows brewing of all types of malts: pale

roasted and black.

• Recirculation system:

Butterfly valve for external air inlet control.

Two butterfly valves with pneumatic control to regulate the circulation rate.

Two flow meters by Pitot tube.

• Paddle system for emptying the dryer:
• Power: 250 W.
• Control by touch PLC:

Control and regulation of temperature, air flow and recirculation ratio.

Monitoring of process variables.

• Instrumentation:

Temperature sensor.

Two humidity and temperature sensors before and after the bed.

Two flow meters.

Pneumatic positioners and actuators for recirculation rate control.

CE00/MA Pilot Plant for Cereal Malting

DCLM/CTS. Computer Controlled and Touch Screen Deculmer.

• Rotating drum built in AISI 304 stainless steel:
• Volume: 400 l.

Two loading and unloading doors.

• Geared motor:
• Power: 1.5 kW.

Includes frequency inverter.

Germ collection tray.

Hopper for cereal unloading.

Positioner for drum blocking. Includes limit switch system.

Slot sensor for rotation speed measurement.

• Control by touch PLC:

Rotation speed regulation.

Monitoring of process variables.

RCB. Rising Conveyor Belt.

Allows the transport of grain between the different stages of the malting plant.

Adjustable discharge height.

Mobile structure mounted on wheels.

• Geared motor:
• Power: 1.1 kW.

Start and stop system.

Emergency stop system.

Easy cleaning system.

SCH. Horizontal Screw Conveyor.

Allows the cereal to be emptied from the germinator and dryer, and feed the RCB.

Mobile structure mounted on wheels.

• Geared motor:
• Power: 750 W.

Start and stop system.

Emergency stop system.

CE00/MA Pilot Plant for Cereal Malting

• The complete pilot plant includes as well:

Advanced Real-Time SCADA and PID Control.

Open Control + Multicontrol + Real-Time Control.

Specialized Control Software based on LabVIEW.

Calibration exercises, which are included, teach the user how to calibrate a sensor and the importance of checking

the accuracy of the sensors before taking measurements.

Projector and/or electronic whiteboard compatibility allows the unit to be explained and demonstrated to an entire

class at one time.

Capable of doing applied research, real industrial simulation, training courses, etc.

Remote operation and control by the user and remote control for technical support, are always included.

Totally safe, utilizing 4 safety systems (Mechanical, Electrical, Electronic & Software).

Designed and manufactured under several quality standards.

This unit has been designed for future expansion and integration. A common expansion is the Scada-Net (ESN)

System which enables multiple students to simultaneously operate many units in a network.

• Cables and Accessories, for normal operation.

References 1 to 3 are always included in the

• Manuals: minimum supply (according to choice):
• Each unit is supplied with 8 manuals: Required Services, - CE00/MA: GCS/CTS, GGER/CTS, GDT/CTS, DCLM/CTS

Assembly and Installation, Control Software, Starting-up, SCH and RCB.

• Safety, Maintenance, Calibration & Practices Manuals. - Cables and Accessories.
• 8 Manuals for enabling normal and full operation.