Application of Nexisense Temperature Sensors in the Alcohol Industry: Precise Control to Enhance Brewing Quality

The alcohol industry in China has a long history and a large consumer market. Beer, as a main category, is highly sensitive to temperature control in its production process. Beer brewing mainly involves three stages: malt production, fermentation, and filtering/filling. Temperature sensors play a core role in ensuring process stability and product consistency. Nexisense temperature sensors provide reliable performance in this field, helping brewing companies achieve precise management. This article introduces the basics of sensors and explores their specific applications, principles, advantages, and practical guidance in the alcohol industry.

Definition and Function of Temperature Sensors

A temperature sensor is a device that converts temperature changes into electrical signals. In the alcohol industry, it is primarily used to monitor brewing temperatures in real time. It accurately captures temperature variations during fermentation, mashing, or storage stages and provides data to control systems, preventing temperature fluctuations from affecting yeast activity and flavor compound formation.

The Nexisense series is designed for food-grade applications, meeting hygiene standards and ensuring safety in contact with liquids. In beer production, it is not only a monitoring tool but also a key element in quality assurance.

Working Principle

Nexisense temperature sensors mainly use PT100 platinum resistance elements. PT100 resistance changes linearly with temperature (e.g., 100Ω at 0℃, increasing approximately 0.385Ω per 1℃). This resistance effect is amplified and linearized internally to produce a standard analog signal (such as 4-20mA) or digital output.

The principle emphasizes nonlinearity compensation and wide voltage supply to ensure stable output in complex brewing environments. Anti-interference design filters electromagnetic noise, suitable for workshops with frequently starting and stopping motors.

Internal Structure

The sensor has a compact and lightweight structure. The core consists of a PT100 element encapsulated in a stainless steel protective tube, typically 316L, which is corrosion-resistant and easy to clean. The probe is slender for easy insertion into tanks, and the junction box integrates a signal processing module, supporting threaded or flange installation.

The overall design emphasizes hygiene with minimal dead corners, facilitating CIP cleaning. Its small size and light weight allow flexible installation without occupying much space.

Key Advantages

Nexisense temperature sensors demonstrate clear advantages in the alcohol industry. High accuracy and stability minimize temperature deviations, directly improving beer flavor consistency. Wide voltage supply adapts to on-site power fluctuations, and strong anti-interference capability reduces false alarms.

Compact size and easy installation, combined with food-grade materials, meet brewing hygiene requirements. Nonlinearity correction further enhances measurement accuracy, suitable for long-term continuous operation. These features help companies reduce energy consumption and increase production stability.

Applications in the Alcohol Industry

Temperature sensors are mainly used in the beer fermentation stage, a critical phase that determines quality. Fermentation temperature directly affects yeast metabolism, ester production, and beverage flavor, typically controlled at 8-12℃ (lager fermentation) or 15-20℃ (ale fermentation). Sensors monitor tank temperature in real time and coordinate with cooling systems to maintain constant temperature and prevent off-flavors.

In the mashing process, they monitor wort heating to ensure optimal enzyme activity. During storage and maturation, sensors prevent temperature fluctuations from affecting clarity. In liquor or wine production, they are also used to control distillation or aging processes.

Additionally, on the filling line, sensors monitor beer temperature to prevent excessive foam or microbial contamination. In these scenarios, sensors optimize the process and support intelligent brewing.

Measurement Methods and Installation Standards

Proper installation in fermentation tanks is crucial. First, operate without power to avoid electrical hazards. Second, installation should be performed by professionals to ensure accurate positioning.

During installation, use a wrench to tighten the hex nut from the bottom to avoid twisting the upper part and damaging cables. When installed at the top, the protective tube must be inserted deeply enough (usually to the tank center) to prevent measurement errors due to liquid stratification. Multi-point placement is recommended, such as at the bottom, middle, and top of the tank, to capture the full temperature distribution.

During measurement, sensor output signals connect to a PLC or DCS for automatic adjustment. Accuracy should be checked regularly to ensure reliable data.

Maintenance Guide

Maintenance is simple but necessary regularly. After brewing, clean the sensor surface with CIP to avoid residue affecting thermal conductivity. Check cable integrity to prevent moisture ingress.

Calibrate annually and record deviation trends. In high-humidity environments, use protective covers. Store in a dry and ventilated place, avoiding extreme temperatures. These measures extend lifespan and maintain high accuracy.

Technical Specifications

Typical Nexisense specifications: PT100 sensing element, measuring range -50℃ to 150℃ (commonly used in brewing), accuracy ±0.1℃ or ±0.15% FS. Power supply 12-36V DC, output 4-20mA or digital signal. Protection IP67, material 316L stainless steel. Response time<10s, suitable for dynamic monitoring.

Other Optimization Techniques

To improve performance, a multi-sensor redundant design or integration with wireless transmission for remote monitoring can be used. Software algorithms compensate for lag, further optimizing control.

FAQ

What to do if fermentation temperature fluctuates too much?
Check sensor insertion depth and cooling system, increase stirring for uniform distribution.

Difference between PT100 and thermocouples?
PT100 provides high accuracy and stability, suitable for precise brewing control.

Signal unstable after installation?
Verify grounding and anti-interference measures; stay away from frequency converters.

Is it suitable for liquor distillation?
Yes, it can monitor distillate temperature to ensure alcohol content.

How to meet hygiene requirements?
Food-grade material, supports high-temperature steam cleaning.

Conclusion

Temperature sensors are indispensable in the alcohol industry, especially beer brewing. From fermentation monitoring to full process control, they ensure quality and efficiency. Nexisense products, with reliable design, maximize value through proper installation and maintenance, promoting precise and intelligent brewing processes. In a competitive market, choosing an appropriate temperature management solution directly translates into product advantages and business competitiveness.