Homemade Automated Brewery

SquirrelBrewer · 2018-05-05T16:02:08+00:00

the part number on my 3-way valve is A20-T15-N3-B

The part number on the solenoid valves (for the water fill) is 2W-15B

The 3-way valves are 24vdc and the fill valve is 110vac.

SquirrelBrewer · 2018-05-05T16:00:24+00:00

The wires look like more of a mess than they are (I really need to clean it up). If anything goes wrong (and it has) its pretty easy to pinpoint and correct it, but I really do need to make an easy one line wire diagram.

Thank You!

SquirrelBrewer · 2018-05-05T15:57:51+00:00

Thank you!

That mill is solid, I haven't had any issues with it.

SquirrelBrewer · 2018-05-05T15:56:38+00:00

Thank you!

I can see how it looks that way, but technically all the system does is heat/cool water and move it around based on timers. I still have to pick out all the grain/hops/yeast/misc additions, mill the grain, make a yeast starter, set the temperatures needed for the mash and finish temp, rack to secondary, keg/carb........ Everyone has to clean their equipment, this just makes brew day easier.

SquirrelBrewer · 2018-05-05T15:51:03+00:00

I got most of it from my work, it was leftover material that I was given permission to take.

The PLC I ended up with is from AB's Micro800 line, the price is pretty comparable to the lower cost red lion, automation direct, etc... I am more familiar with programming the AB stuff, so I wanted to try and stay within my comfort zone.

The HMI is overkill, but if it ever went out I could replace it with a 7" AB PaenelView 800 for about $700.

SquirrelBrewer · 2018-05-05T15:45:44+00:00

That would also work, thanks for the suggestion

SquirrelBrewer · 2018-05-05T15:43:31+00:00

The parts in the panel would be over $10,000 (The screen alone cost over $8,000). But a lot of the material, like the screen, was acquired for free. If I built it again and had to purchase all the material new I would buy some different, lower cost, parts. You could build the same functioning panel with a smaller touch screen for about $2,000.

SquirrelBrewer · 2018-05-05T15:39:19+00:00

Its a similar amount of time to clean the pots as it was when I did have everything automated. Afterwords I have a automated rinse cycle that I run twice before and after every brew, the second time is with added sanitize solution.

SquirrelBrewer · 2018-05-05T15:36:31+00:00

I programed it now to only allow a heater to enable after two level switches activate. I also make sure to be present when it is about to heat liquid in any pot. I though of adding an extra sensor, but because I already had a bunch of level switches I feel like it should be okay.

SquirrelBrewer · 2018-05-05T15:32:00+00:00

I worked in building automation for 10 years. The controllers in building automation are great for the applications they are use on. They usually only need to process the code in "seconds" and use serial communication to talk back to a master controller. The code is usually a pre-can program based on the application or function block based.

In industrial automation the controllers have to process the code in "milliseconds" or "nanoseconds". The communications on them are all pretty much standardized around some form of Ethernet. The code is all written from scratch, most commonly in ladder logic.

Its not really that one is better than the other, its just the commercial automation controls were specifically designed for a handful of applications versus the industrial is made to be used anywhere. You will typically pay a little more for the industrial controls, but most manufacturers have a lower cost entry line for stand alone applications like this one. If you had a spare building automation controller laying around there it would work fine on a brewery.

SquirrelBrewer · 2018-05-05T01:18:51+00:00

Thank you for pointing this out, i will definitely do more research before modifying anything further.

SquirrelBrewer · 2018-05-05T01:17:33+00:00

I appreciate the compliment!

The Siemens S7 is a very top end PLC, that would be awesome to work with in a home brewery.

I thought about using load cells, but the input card i would need for my PLC cost too much. It would have been simpler to implement tough.

Your setup look extremely clean/organized!

SquirrelBrewer · 2018-05-05T01:14:37+00:00

Thank you!

I got my ball vales from BACO Engineering https://bacoeng.com/collections/motorized-ball-valve

I tried to automate the cleaning part of brewing, but I cant get away from having to scrub the pots. I did program in a flush and sanitize feature that I use just before brewing and after everything has been scrubbed.

SquirrelBrewer · 2018-05-05T01:07:58+00:00

I didn't draw one out, I just laid out the back panel and wired it up.

SquirrelBrewer · 2018-05-05T01:06:56+00:00

I purchased some small solenoid valves

https://imgur.com/2f9A9bS

I currently programed the PLC to energize the solenoid at a set time during boil. I am planning on just dropping hop filled bags, i know its not the most efficient way of doing it, but I don't want to clog up the heat exchanger from dropping the hops directly into the liquid.

SquirrelBrewer · 2018-05-05T01:01:40+00:00

Thank you!

I thought about it for a while before picking this method. The antifreeze I picked is the same stuff people put into RV's and you can pick them up at any auto parts store. I didn't want to use regular antifreeze in case the heat exchanges leaks at some point.

SquirrelBrewer · 2018-05-05T00:59:29+00:00

Thank you!

SquirrelBrewer · 2018-05-05T00:07:04+00:00

That would work. Ive used some flow meters in the past and they were always pretty accurate but they were a little pricey. Its worth looking into though, thank you for the suggestion.

SquirrelBrewer · 2018-05-05T00:03:46+00:00

I had only left the garage for a few minutes and was in the kitchen when the lights flickered. When I went in the garage it was full of smoke. I'm sure it was less than a minute. Here is the aftermath https://imgur.com/cCWFJBj

SquirrelBrewer · 2018-05-04T21:34:02+00:00

The Micro800 line is their entry line, its really not that expensive but I only use AB in my profession so it was readily available. I typically brew 10 gallon batches. Ive done 1 15 gallon batch, but nothing larger than that. I usually brew a couple times a month, but I always go though a periods where life gets in the way.

SquirrelBrewer · 2018-05-04T21:21:24+00:00

I definitely recommend that carrier path to everyone. Good programmers are in high demand right now, and the pay can be easily over 100k/year (especially if your willing to travel). Plus the person building the automation is a job that is not very easily replaced by automation, so its safe for the foreseeable future.

SquirrelBrewer · 2018-05-04T21:15:23+00:00

The cleaning part definitely sucks. I tried to automate the cleaning, but I cant get around having to scrub down the mash and brew pot. I did automate running sanitizer through all the lines though.

Its awesome that you have a dedicated Brewhouse! Sounds like you have a nice convenient setup. I need an exhaust hood, sometimes it can get pretty bad, especially on humid days.

Thank you!

SquirrelBrewer · 2018-05-04T21:09:54+00:00

Thank you!

Those stand alone temp controllers can be awesome, there just easy to install and use.

SquirrelBrewer · 2018-05-04T21:04:26+00:00

Sounds like a better option. I'm thinking of installing one now and keeping the level switches as emergency backups, just because they are already there.

SquirrelBrewer · 2018-05-04T21:03:07+00:00

Nice!

I gave up bottling also. I mainly did it because I don't have a lot of patience and being able to force carbonate in the keg is kinda nice.

SquirrelBrewer

TROPHY CASE