DESIGN OF A CONTROL SYSTEM TO

ENHANCE PROCESS PERFOMANCE IN

THE PRODUCTION OF SORGHUM
BEER
CATHERINE MAWARE
1

Department of Production Engineering,
Chinhoyi University of Technology Bag 7724
Chinhoyi, Zimbabwe
cmaware@gmail.com
NORMAN GWANGWAVA
2

Department of Industrial and Manufacturing Engineering,
National University of Science and Technology, P O Box AC 939
Ascot, Bulawayo, Zimbabwe
engnormie@gmail.com,
RAPHEL M J INGURA
3

Department of Quality Assurance and Graduate Studies,
Chinhoyi University of Technology Bag 7724
Chinhoyi, Zimbabwe
rjingura@cut.ac.zw
Abstract
Breweries in Zimbabwe use limited or no control systems at all. The aim of this study was to design a control
system for monitoring and controlling mashing and cooling processes during production of a sorghum beer
brewing. The design of the control circuit was done using sensors and controllers. For temperature control a PID
controller was used. The system was able to raise the temperature of the mash to 50C for 50 minutes for
hydrolysis of protein, glucons and pentasons by proteolic enzymes. The temperature was then raised to 80C
and maintained constant for 10 minutes for optimal activity of -amylase. It was then raised to 95C for the
optimal activity of - amylase. Finally, the temperature was raised to 100C and was held constant for 60
minutes for enzyme inactivation. The control system designed in this study enhanced the process performance in
the brewing of a sorghum beer.
Keywords: Control system; mashing; sorghum beer.
1. Introduction
Control systems are useful in the brewing process. Breweries in Zimbabwe need to improve their sustainability,
in particular the use of water and energy. Brewers need to respond to the need to enhance process efficiencies by
adopting technologies to re-engineer their processes to save costs and reduce waste.
Sorghum beer is brewed from maize and sorghum. Breweries can experience variation in the viscosity of the
beer they produce. This variation can be caused by differences in the manufacturing processes and amounts of
inputs used in the brewing process. In Zimbabwe, the viscosity of beer should be between 80 100Ns/m
2
after
the first conversion and 60-80Ns/m
2
after yeast addition. The viscosities of beer produced in Zimbabwe are
generally in the range of 110Ns/ m
2
after the first conversion process and 90Ns/ m
2
after yeast addition. These
problems can be ascribed to lack of effective control systems that regulate production processes. For example, in
most breweries there is no monitoring or control of boiling in the cookers. Yet this is a critical process that must
be regulated within specific parameters [Belgium Brewing Company, (2008)].
There are nine major steps in the process of brewing sorghum beer. These are dry milling, mashing, boiling,
cooling for first conversion, heating, straining, pasteurization, second conversion and packaging [Chikezie,
(2012)]. The dry milling process involves grinding sorghum and maize grains in a motorized mill to obtain
coarse flour [Roger, 2013]. These grains are mixed with water so as to hydrolyze them. After the mashing
process, the wort is boiled so as to: sterilize it; coagulate grain protein; stop enzyme activity; drive off volatile
compounds; cause metal ions, tannin substances and lipids to be insoluble [Olajire, (2012)]. The first conversion
process involves adding barley and sorghum malt to solubilise the adjunct and malt physically and
enzymatically [Taylor, et al., (2012)]. The spent grain is removed by the process known as straining. Yeast is
then added to allow fermentation to occur. Fermentation is a process in which the singled-celled yeast convert
Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1169
sugars in the wort into carbon dioxide and alcohol[Tabernash, (2012)]. The beer is then cooled and allowed to
ferment for twelve hours.
Critical processes that require control systems are boiling, fermentation, cooling, heating and pasteurization
[Christna, (2003); Emmerson, (2008) and J acobs, (2012)]. The critical temperatures for boiling for these
processes are 50C, 80C and 95C, respectively. The mashing process can be optimized using a mashing
program with temperature-time stands of 50C 50 min, 80C 10 minutes and 95C 40minutes [Declan,
(2002)]. The process of all-grain brewing requires the brewer to attain targeted temperatures and hold them over
an extended period of time [Crandal et al.,, (2008)].
The types of controllers used in beer brewing processes are Programmable Logic Controllers (PLC),
microcontrollers and OMRON CPM2A. PLCs are used because of their simplicity, robustness, I/O interface and
reliable performance [Normanyo, (2011)]. Microcontrollers have reliable built-in hardware programmer,
simplified programming language and lively user base that offer plenty of sample codes.
The objective of this study was to design an appropriate control system for monitoring the process parameters in
the production of a sorghum beer. Process parameters such as temperature, mashing and level of water in the
cooker which affect beer quality were considered.
2. Methods
The following section illustrates how the system was designed and the software that was used to create the
control system.
2.1 Controller for the brewery
VersaMax Modular PLC CPUE05, OMRON CPM2A and Microcontroller PIC 16872 were the types of
controllers selected for the brewery. VersaMax Modular PLC CPUE05 was chosen because it had 2048
Input/Output points. The system designed had 30 Inputs and 19 Outputs and system could be expanded, hence
2048I/O points could be utilized. The system could also be interfaced with SCADA through Ethernet using
RJ 45 pin.
2.2 Modeling the control section for the mashing process
This is where the milled maize and sorghum are mixed with lactic acid and water. A solution of lactic acid at a
concentration of C
f
= 8.5 moles/dm
3
is mixed with water to obtain an outflow stream with lactic acid
concentration of C
0
. Fig 1 shows how the stirring takes place.
Stirrer
x
v

Lactic acid Q
f;
C
f
To the cooker
Q
0
, C
0

Water Q
w





Fig 1 Mashing tank
Where: Q
f
= Flow rate of lactic acid into the tank, Q
w
=Flow rate of water in to the tank, Q
0
=Flow of mash out
of the tank, C
f
=Concentration of lactic acid, C
0
= Outflow stream with lactic acid concentration, V =Volume
of tank, m
i
=Rate of lactic acid flow into the tank, m
a
=Rate of lactic acid accumulation in the tank, m
0
= Rate
of lactic acid outflow from the tank, x
v
=Volume of water into the tank, K
v
=Valve coefficient. Thus, the
following equations apply:
Q
w
= K
v*
x
v
(1)
Q
0
= Q
w
+ Q
f
(2)
m
i
= Q
f
C
f
(m
3
/s* moles/ m
3
= moles/s) (3)
m
0
= Q
0
C
0
(4)
m
a
d
dt
|F

C
0
(t)] = F
dC

dt

(5)
Where F

C
0
(t) is the lactic acid hold up for the tank at time t
Consider the law of conservation:
Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1170
Q
f
C
f
= F
d
dt
C
0
or
d
dt
C
0
+ C
0
= K x
v
(6)
Where K =C
f
K
v
/ Q
0
and =V/Q
0

The transfer function of the system:
C

(s)
X
u
(x)
=
3.247
3x+1
(7)
The equation for the system was later tested for unit step response using Matlab.
2.3 Choosing the right temperature sensor for the brewery
Platinum resistance thermometers (Pt100) were chosen because of their improved high responsiveness, high
sensitivity and long term stability in wet conditions. Resistance Temperature Detectors (RTDs) are easy to
install and have the highest accuracy for temperature. However, RTDs are expensive.
2.3.1 Modeling for temperature
Fig 2 shows a cooker control system. The output signal from a temperature sensing device which is Pt100 is
compared with the desired temperature. An error causes the controller to send a control signal to the solenoid
gas valve which produces linear movement of the valve stem, thus adjusting the flow of steam to the cooker.

Fig 2 Cooker Control System
The PID system controller is connected to the current- pressure actuator. The actuator is connected to the gas
solenoid valve which continuously actuates to open or close so that the correct amount of steam will flow into
the cooker so as to raise or lower the temperature. The temperature in the cooker is measured by the Pt100
which gives feedback to the system controller for adjustment and control. The disturbance will account for the
heat losses, steam leakages and other non-ideal fluctuations.
Fig 3 shows a block diagram for the temperature control loop using the PID controller.

Fig 3 temperature control using PID controller
Where: C
t
=Thermal capacitance, R
t
=Thermal resistance, K
1
=Constant for PID, K
2
=control steam valve
constant,
Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1171

d
(t) =desired temperature,
m
(t) =Measured temperature (V),
0
(t) =Actual temperature(C), u(t) =Control
signal
V(t) =steam flow rate(m
3
/s), Q
i
(t) =heat flow rate into the cooker(J /s =W), Q
o
(t) =Heat flow through the walls
of the cooker (W), C
T
=Thermal capacitance, R
T
=Thermal resistance of the walls.
2.3.2 System equations
Controller: The control action is PID of the form of 1+
1
1
i
(s)
+I
d
(s) (8)
U(s) =K
1
[1+
1
1
i
(s)
+ I
d
(s)][
d
(s) -
m
(s) (9)
The gas solenoid valve has a first order dynamics of the form;
v
0
(s) =
K
2
1+1
i
(s)
where K
2
is the valve constant m
3
/s (10)
2.3.3 Room dynamics
Q
i
(t) Q
0
(t) =C
T
d0
dt

(11)
Heat through the walls of the cooker is as given in equation (12)
Q
0
(t) =
|
0
(t) s(t)]
R
T
(12)
Substituting equation (11) into (12)
Q
i
(t) [

0
(t) - s(t)
R
T
]=C
T
d0
dt

(13)
Multiplying by R
1

R
1
Qi(t) +s(t) =
0
(t) +R
1
CT
d0
dt

(14)
Taking Laplace Transforms
R
1
Qi(s) +s(s) =[1+R
1
C
1
]
0
(s) (15)
The thermometer equation

m
(s) =H
1

0
(s) (16)
The block diagram can be reduced to:

K
1
K
2
R
T
(1
d
s1
i (s)
)+ 1)|
d
(s)- 1+
0
(s)
1
i
(s)(1+1
1
(s)
+
0
(s) =1 +R
1
C
1

0
(s) (17)
Hence the forward gain K
f
=K
1
K
2
R
T
R
T
=0.75
C
T
=11J /K
T
1
=2.2634
The transfer function of the system:
Ha(s)
V1(s)
=
0.95
1+411.255s
(19)
The equation for the system was later tested for unit step response using Matlab.
2.4 Modeling for water level control system
The level sensor ensures correct amount of water is poured into the cooker. Greyline LIT25 sensor was chosen
because the signal relay is programmable for ON/OFF pump control, level, temperature or echo loss alarm.
Figure 4 shows a level control system for the cooker.

Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1172

Fig 4 modeling the control systemfor water level
Where K
v
=flow coefficient for water, R
f
=15s/ m
2
,
U
t
=Signal from the controller, V
1
=Volume of tank when
it has reached the required level, V
2
=Volume of tank at a particular time, A =Area of tank, H
a
=Height of
tank, R
f
=Outlet resistance of water.
V
1
(t) =K
v
U
t
(20)
Tank dynamics V
1
(t) V
2
(t) =
Ad
dt
h
a
(21)
To linearise the flow V
2
(t) =
hu(t)
R]
(22)
The measured head h
m
=H
1
. h
a
(23)
V
1
(s) -
hu(t)
R](s)
=A
s
H
a
(24)
R](s)v1(s)- Hu(s)
R](s)
=A
s
H
a
(25)
R](s)v1(s)
R](s)
=A
s
H
a
+
Hu(s)
R](s)
(26)
R](s)v1(s)
R](s)
=H
a
(A
s
+
1
R](s)
) (27)
Hu(s)
v1
=
R]
1+A(s)R](s)
(28)
PLC
CONTROLLER

TANKAREA,A
GREYLINELIT25
H
1
V
1
H
a
CONTROL VALVE
(K
v
)
U H
d

H
m

V
Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1173

Fig 5 Open loop system
H
c
(s)
v
1
(s)
=
K

R
]
1+411.255s

K
v
= 0.1 R
f
=9.5m
3
/s
The transfer function of the system:

H
c
(s)
v
1
(s)
=
0.95
1+411.255s
(29)
The system was later tested for unit step response using Matlab.
3.0 Results and Discussion
The research focused on the design of the control system for sorghum beer brewing process. The research
illustrated on the designing of the system from first principles and the simulation of the temperature control
system was done using Matlab.
3.1 Results for the mashing tank
The transfer function for the mashing process was obtained from first principles. The transfer function for the
process obtained was:
C

(s)
X
u
(x)
=
3.247
3x+1
(7)
The system was then tested for open loop unit step response and it produced an amplified input response signal
by a factor of 3.25. The PID control algorithm was then implemented and the system was tested using a
Proportional controller. The system managed to achieve a unit step function with no overshoots, however the
rise time was 105seconds. The system was again tested with the aid of the proportional derivative controller so
as to reduce the rise time and system response time. The system rise time was 0.5 seconds and the system
achieved the desired set point with no overshoot. The Proportional Derivative controller was selected for the
mashing section. This can be seen in figure 6 shown below.

Fig 6 Combined graphs for the PID control system
K
v
R
1 +A(s)R(s)

V
1
(s)
H
d
(s
H
m
(s
Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1174
3.2 Water level control the system
The transfer function that was obtained from first principles was
H
c
(s)
v
1
(s)
=
0.95
1+411.255s
(19)
The system was tested for unit step open loop response. The gain of the transfer function was 0.95. The rise time
was 1500 seconds and the settling time was 500 seconds. The proportional controller was introduced so as to
lower the rise time. The gain of the system was 0.865 and the settling time was 250 seconds. This showed that
the proportional controller reduced the gain from 0.95 to 0.865. The proportional derivative was then
introduced. It reduced the controller gain to 0.815 and the rise time was 250 seconds. The proportional integral
was also introduced so as to increase the gain of the system. The amplitude obtained showed that the system was
now unstable. An overshoot of 0.8 was achieved and the settling time increased to 500 seconds. The
Proportional Integral Derivative control system was introduced and the system was tested for unit step response.
The response time for the system was reduced from 500 seconds to 10 seconds. Figure 7 shows the combined
graphs for the control system.

Fig 7 Combined graphs for the PID control system
3.3 Results for the temperature control system
The model that was designed using Simulink was run to check if the temperature would rise in the desired
manner. The graph shown in Figure 8 was obtained after running the model. The system was able to perform as
per desired response. The mash was raised to 50C for 50 minutes for the hydrolysis of protein, -glucons and
pentasons by proteolic enzymes. The temperature was then raised to 80C and was maintained constant for 10
minutes for the optimal activity of -amylase. It was then raised to 95C and maintained for 40 minutes for the
optimal activity of - amylase. Finally, the temperature was raised to 100C and was held constant for 60
minutes to inactivate the enzymes.

Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1175

Fig 8 Temperature control graph
4.0 Conclusions and Recommendations
The main aim of the research was to design a control system that that would monitor and control the mashing
process, boiling of the mash in the cooker and the amount of water added in the cooker during the beer brewing
process. The temperature control system was designed that gave the desired response to the raised temperature,
initially to 50C and maintained it for 50 minutes, to 80C and maintained it for 10 minutes. The system
managed to raise the temperature to 95C and maintained it for 40 minutes and finally the temperature was also
raised to 100C and maintained at that stage for 60 minutes.
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Catherine Maware et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 5 No.06 June 2013 1176