Project Background

A 1000-ton production plant under a beer group in East China generates a large amount of CO₂ during the beer fermentation process. Traditional manual inspection cannot meet the requirements of modern craft brewing for precise control of CO₂ concentration. At the same time, the plant uses ammonia refrigerant to cool the fermentation tank area, and the original ammonia leak alarm system has a slow response time. In 2024, a minor ammonia leak accident occurred.

Customer Pain Points

  • The CO₂ concentration within the fermentation tank directly impacts the taste of beer and the bitterness of hops, necessitating ppm-level precise control.
  • The accumulation of CO₂ on the floor of the fermentation workshop causes asphyxiation of workers, and an early warning is required at 5000 ppm
  • Dozens of ammonia leaks occur annually in refrigeration rooms, requiring an early warning at 25 ppm and evacuation at 50 ppm
  • It is necessary to meet the data archiving requirements of the HACCP food safety management system.

U-Rion Solution

  • CO₂ Process Monitoring: 44 sets of Insight YQGT-CO2 infrared detectors, with an accuracy of 10 ppm, deployed in 22 fermentation tanks + 22 external environments
  • Ground CO₂ Safety Monitoring: 12 sets installed at low levels, specifically designed for measuring ground accumulation
  • Ammonia Leakage Special Project: 4 sets in the refrigeration room + 4 sets outside the cold room to monitor YQGT-NH3, automatically initiating emergency exhaust ventilation when exceeding 50 ppm
  • Nitrogen-filled packaging residual oxygen: 8 sets of YQGT-O2, with an accuracy of 0.01%, ensuring a shelf life of beer exceeding 6 months
  • HACCP Data Archiving: All monitoring data is archived in the cloud for 30 years, compliant with the 21 CFR Part 11 electronic signature standards
  • BMS Integration: Automatic shut-off of production line in case of exceeding limits + notification to on-duty staff

Implementation Effect

  • The fluctuation of fermentation CO₂ concentration is controlled within ±50 ppm, resulting in a +18% increase in beer batch stability.
  • No ammonia leakage incidents in refrigeration equipment rooms from 2024 to 2026
  • HACCP system audit passed, with zero fines in annual safety inspection