We have found after many years of projects and trying to make almost ready technology work for our specific requirements that often it is best to build your own. So we did.

We built our own brewing control panel to control all of the brewhouse functions. We took a lot of tried and true high tech components that we have used many times in the past on other projects and combined them with some new systems to make a control panel that gives us a high degree of data, precision and control over the time, temperature and process of brewing.

The objectives of the control panel:

1. Present the temperature of each brew kettle process digitally in Celsius
2. Provide PID controlled temperature processing
1. The ability to set a temperature and have whatever process is required happen to maintain that temperature within 1 degree C
2. this includes auto-ignite, auto flame off, auto flame sense, pump controls and HERMS processing
3. Provide both automated and manual controls including manual overrides
4. Provide a central place to monitor and control all processes
5. Turn all processes into precise, repeatable, science based steps based on real time data feedback
6. Provide real time satellite coordinates for all undersea assets

We accomplished all but number 6 (at this current time.)  We have used it for one full batch and it worked flawlessly on the pilot system. It simplified and made every step more efficient. We hit almost every temperature and time milestone. However it worked a little too well as it was mesmerizing to watch it automate the core processes. So much so that we forgot to adjust the water kettle temperature soon enough and had to extend the mashing a bit to wait for the right sparge temp to be reached and auto-sparge to start.

Right now we have our temporary labels on till the sweet custom made ones arrive and the control panel frame is being built right now to house it.

This was also the first time that Nanelle was the brewer. She took her favorite beer, our Belgian Tropical Wit and brewed it using the new control panel system. It is still on our 80 liter pilot system as our new 2HL system is being custom built just for us to our design and should be ready in a few months. So she made every part of the beer from grinding the malt on our new stainless steel roller mill Barley Crusher to final runnings into the fermenter. Even not fully functioning on the pilot system, the new control system worked like a PHD nerd discovering a new phenomenon. It passed all systems go.

Here is what we did to accomplish our objectives and bring more control to our beer brewing. More science to our craft.

1. We built our own control panel
2. We used 3 PID controllers and one time controller
3. We used 3 multi stage actuator buttons
4. And 3 dual stage switch buttons
5. A lot of resistors, power blocks, transformers, 70 meters of electrical wire and a lot of experience

Here is how the system works:

1. PID controller 1 monitors the Hot Liquor Tank temperature
1. we program it to our desired set point depending on what stage of the mash or sparge process we are in
2. We program the halo range of the temperature variation (in our case less than 1 degree C)
3. it auto ignites ad auto extinguishes the direct fire kettle to maintain that temperature within the range
2. PID 2 monitors the temperature of the Mash
1. we program it to our desired set point
2. We program the halo range of the temperature variation (in our case less than 1 degree C)
3. the controller automatically engages the HERMS system to maintain the desired temperature
4. this process also provides a smooth Vorlauf to aid in clarity and flavor
3. Micro-switch #2 controls the pump for the boil kettle
1. Allows manual control of whirlpooling after boil to drop out trub
2. allows manual control of pump to move wort through hop rocket and plate chiller
4. PID 3 measures the temperature of the wort as it leaves the plate chiller
1. It allows us to adjust the flow rate of the hot wort to maintain temperature
5. For each process we also have a auto/manual micro switch that allows us to switch off and on each controller and switch to manual control at any time and even switch back at any time with no disruption
6. There is also a multi timer that not only times each process but can also control burners or pumps based on time as well as temperature.

Yes it is all somewhat complex but Nanelle and I have had many years of experience from our days of running a crazy coffee company in Silicon Valley with building systems like this when we either could not afford the fancy pre-built systems or did not like the way they worked. So we ended up building our own machines.

We are working on a few other process controls and data feedback to add to the control panel as we go forward with our nano brewery. But for now it works awesome, simplifies the whole brewing process, brings tight control and repeatable science based brewing to our lovely craft.

Some might ask why we would want a control panel on a hand crafted product like our Craft Beer. Isn’t making beer supposed to be an art form?

No.

There is an old saying: Brewers make wort. Yeast makes beer.

Or as I always say: “Yeast is magic!”

Brewing beer is easy. Brewing really great craft beer is very hard. Making it taste fantastic is nearly impossible. Brewing beer is a very scientific, detail oriented process. It is a craft not art. It is hard, difficult work and exacting science.

The art comes in with the recipe. Combining just the right mix of truly spectacular raw ingredients in unique and inspiring ways to create amazing flavors and feelings. That is the art. The mark of the artist. The fun part. The tasty part.

But without really tight science it is nearly impossible to produce great craft beer. It can be done. But without the constraint of tight science the art of beer doesn’t feel right.

So our goal is not to treat the brewing of beer like it was unconstrained art. But to treat it like a centuries old Craft that requires not only great passion and skill but great science as well. Although the great thing about brewing craft beer is that all the science, high tech toys, imported brew systems and gadgets in the world cant help make great beer without great people and great passion.

So what kinds of system or process control have you done in your brewing?