Case study | Automated Brix calculations and fermentation monitoring
How to improve wine quality with automated fermentation monitoring
The process of fermentation in winemaking turns the juice from the grapes into the wine we enjoy. During this process yeasts convert the sugars in the juice into ethanol, which reduces the amount of dissolved sugars and as well as density of the media. Degrees Brix is the measurement most commonly used in winemaking, and it is a measurement of the dissolved sugar content in an aqueous solution.
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| Visualize Brix values | Reliable, real-time data | Increase efficiency |
Results
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Higher wine quality due to precise Brix value calculations and temperature monitoring
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Reduced risk of inaccurate measurements performed with a densitometer, refractometer, or hydrometer
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Redirected hours of labor from manual tank checks to value-added work
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Visualization in industrial software of fermentation progress inside all tanks
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Easy installation of components on the pumpover line of red wine fermentation tanks
The challenge
Many wineries start as small operations, where manual processes seem cost-effective and easiest to implement. As a winery grows, it may run into challenges where those operational inefficiencies are difficult to scale up wine production. It may appear that components on a tank are more expensive, when in reality they save labor costs and provide more reliable product quality from batch to batch. Wine fermentation is an incredibly important part of the winemaking process, where yeast converts the sugars in the grape juice to alcohol. As the yeast converts the sucrose, the specific density of the juice decreases in a predictable pattern that correlates to the alcohol content of the final product. Degrees Brix is the most commonly used measurement in winemaking, capturing the dissolved sugar content left in an aqueous solution.
Brix values are often calculated by a winery employee manually checking the progression of fermentation by pulling a sample from the tank to measure with a handheld instrument, such as a portable refractometer. These instruments measure the current sugar content remaining in the wine, which changes the density of the liquid. The brix readings are then entered into a computer and a fermentation curve is plotted on a graph to track the conversion from sugar to alcohol in the liquid at specific points in time.
The disadvantages of manual Brix level measurements are:
- Risk of entering inaccurate Brix values
- Lack of visibility to fermentation progress between measurement points
- Inaccurate Brix values due to variation in the sugar content of the juice in different areas of the tank
The solution - why ifm?
ifm provides automation solutions that scale with the growth of wine production. To automate Brix monitoring, wineries can add two ifm PI17 series pressure sensors at a fixed height apart from each other on the primary fermentation process tank. By using two fixed pressure sensor measurements, you can continuously monitor density to calculate Specific Gravity (γ ) or degrees Brix (Bx) (see Density Measurement application) using the equations below:
Instead of performing these calculations manually, ifm IO-Link masters enable you to send the pressure data to any higher level software system. To provide a comprehensive solution, ifm now offers a pre-programmed display controller that can receive the temperature and differential pressure data from the sensors and automatically calculate the Brix measurement in real-time. This reduces the need to source specialized programming knowledge. Simply input the height of the tank and the controller will populate the Brix curve on the screen.
Continuously monitoring the changes in Brix during fermentation provides valuable process data to ensure fermentation is progressing normally. It provides an early detection system for identifying problems during fermentation. This allows a winemaker to make adjustments to the batch when possible. Automating access to real-time Brix data provides:
- Improved process and product quality
- Increased accuracy from aggregate tank data
- Simplified data collection and visualization
Another significant benefit of using two pressure sensors to calculate Brix is that it ensures a more accurate portrayal of how fermentation is progressing throughout the entire tank. This is because density over a larger fluid column provides a more aggregate measurement. It reduces the possibility of a sampling error that might occur if measurements are performed manually from the top of the tank. The ifm solution offers another advantage, as the pressure sensors can be installed on the pump over line of a red wine fermentation tank. This allows a winery to avoid new tank penetrations while still receiving accurate, real-time Brix data.
Technologies
Explore the underlying technologies that power this solution.
IO-Link technology: this technology is the foundation of scalable automation solutions, and it is embedded in ifm sensors. This technology allows the sensors to communicate the wine fermentation data via ethernet. The fully digital signal provides higher resolution due to eliminating analog conversions.
Pressure Sensors: ifm PI17 series pressure sensors have the resolution necessary to monitor small changes in sugar content to accurately measure Brix. Install two at a fixed height apart from each other on the primary fermentation process tank.
Preprogrammed display controller: Aftering installing the ifm PI pressure sensors, this preprogrammed display controller easily visualizes the Brix curve in real time. The CR series can be used for machine control or simple visualization and monitoring.
Gain a competitive edge
Automated wine fermentation contributes to the production of a more stable and higher-quality product. Wineries of any size benefit from the increased accuracy when monitoring the fermentation process and logging historical data for future use. Whether small wineries monitor each batch closely for slight variations in flavor or commercial wineries monitor hundreds of fermentation tanks simultaneously, automated brix monitoring can benefit operations of all sizes. It all starts with one IO-Link master, which allows for flexible solutions that are both cost-effective and easy to implement. Data generated from automation processes offer valuable insights for further improvements. Winemakers can leverage this data to fine-tune their operations, increase efficiency, reduce costs, and continually improve wine quality.
