A show brewery in Germany demonstrates how this can be achieved: with mobile sensor units for flow and conductivity control, made by Anderson-Negele, even complex brewing processes can be fully automated ā with minimal personnel and investment.
The Brauner Hirsch show brewery, operated by Thomas Kuche, combines traditional brewing craftsmanship with state-of-the-art process technology. Around 1,000 visitors per week experience live how six different beers are brewed and matured according to the breweryās own recipes. Behind the scenes, a highly efficient, fully automated system ensures consistent quality and smooth operation.
Fully automated brewing with minimal personnel
Thanks to optimised plant engineering, the entire brewing process ā from the malt store to bottling ā runs fully automatically. Despite a production capacity of up to six brews of 2,000 litres per day, only one master brewer and one additional employee are required to operate the system.
To achieve this level of efficiency, Thomas Kuche relied on the expertise of Robert Bauer and his company KyffhƤuser Service and Appliance (KSA), which specialises in the design and optimisation of hygienic process systems. A key factor in the successful implementation: reliable and precise sensor technology from Anderson-Negele.
A smart solution: mobile sensor units for maximum flexibility
One of the highlights of the installation is a seemingly simple yet highly effective solution: mobile sensor units for flow and conductivity measurement. Instead of equipping each of the 12 storage and maturation tanks with fixed instrumentation, the system uses mobile units that can be flexibly connected as required.
With just one ILM-4 conductivity sensor and one FMQ flow meter, all tank processes can be controlled fully automatically. The mobile units are connected directly to the respective tank and integrated into the process via hose connections. This approach significantly reduces investment costs while maintaining full automation and process reliability.
Precise phase detection ensures maximum product yield
The ILM-4 conductivity sensor plays a central role in the process. It ensures that young beer is transferred precisely into the maturation tanks, while water and cleaning media are safely diverted. Once the process is started, everything runs automatically: several brews are processed sequentially and transferred into the same maturation tank without any manual intervention. The brewing process can run for hours without operator input. Thanks to a response time of less than one second, phase transitions are detected in real time. This minimises product losses and prevents mixing of different media ā a decisive factor for both quality and efficiency.
Reliable flow measurement for stable processes
In addition to conductivity measurement, accurate flow measurement is essential for many process steps, including recipe control, filling operations and documentation. The compact FMQ flow meter is ideally suited for integration into the mobile sensor units.
The design of the mobile stations ensures correct installation conditions, including optimised inlet and outlet sections. This prevents measurement errors caused by air bubbles or turbulence and guarantees reliable, reproducible results.
Consistent automation across all systems
The automation concept is consistently implemented throughout the entire brewery. In addition to the brewing process itself, both the flash pasteuriser and the CIP system are fully equipped with Anderson-Negele sensor technology.
The flash pasteuriser uses, among others, an FMQ flow meter and an L3 level sensor, while the CIP system integrates a comprehensive range of sensors for maximum process safety and hygiene:
- FMQ flow sensors
- L3 level sensors (hydrostatic)
- ILM-4 conductivity sensors for detergent control
- TSB temperature sensors
- P41 pressure sensors
- FTS flow switches for dry-run protection
- NCS point level sensors
The fully automated CIP system ensures reliable and reproducible cleaning of the entire brewing plant, tanks and filling systems. Precise sensor data enables exact control of cleaning media and process parameters. This not only guarantees the highest hygiene standards, but also reduces the consumption of water, chemicals and energy ā contributing to both sustainability and cost efficiency.
A model for modern craft brewing
With his show brewery, Thomas Kuche demonstrates what modern brewing technology can achieve, even on a smaller scale. The combination of intelligent plant design, mobile sensor technology and high-performance measurement systems enables a level of automation and efficiency that was previously reserved for large industrial breweries. The project shows how innovative sensor solutions from Anderson-Negele can help breweries optimise their processes, reduce costs and ensure consistently high product quality.
Mobile sensor units, in particular, offer a smart and economical way to combine flexibility with full automation ā making them an ideal solution for craft brewers and small to medium-sized operations looking to invest in the future of their production.
