Two Detection Sensors That You Need To Use In Your Brewhouse System

What Brewhouse System should I use?

In addition to obligatory sensors, such as sensors that are integrated into the system to monitor temperature and reduce errors during operation, brewing is made more convenient and controllable when other types of sensors are introduced into the equipment.

With this in mind, YoLong has begun production on two new and practical sensors: (1) flow switches and (2) pressure switches. Not only is this technology cutting edge innovation, but we produce the sensors to the very highest quality and make them available to you at the best price.

The YoLong pressure switch sensor:

There are many types of pressure switches. At present, integrated into our saccharification equipment, a pressure sensor switch is used to detect compressed air. The most commonly used sensor types are electronic and mechanical.

Pressure sensor switch below / Image copyright: YoLong Brewtech

For any Brewhouse System with pneumatic valves, integrating a pressure switch can enhance equipment performance by continuously monitoring operating conditions.

Such a pneumatic system setup is ideal for winemakers. Why? Because it is often easy to forget to turn on the system’s compressed air before brewing. With the integration of a YoLong compressed air detection sensor into the system, the compressed air pressure value of the system will be lower than the set value. This means the Brewhouse System sensors are in place as both a fail-safe and a reminder.

Brewhouse system insufficient compressed air problems are so easily to avoid when you get a YoLong pressure switch sensor installed.

The YoLong Flow Switch Sensor:

When the brewing system has a flow switch, it can helps to monitor the automatic processes of the system, and stop the process automatically once the material has been transferred.

A YoLong flow switch sensor also prevents the motor from stopping or starting if the valve is opened or closed incorrectly. This helps prevent long term damage to the motor seal caused by the dry rotation of the motor.

Additionally, with the HMI, the system error information automatically sends a text message, meaning the winemaker will be immediately alerted if an error has occurred. Instant troubleshooting and problem solving at your fingertips – and improved winemaking efficiency!

Brewing is made more fun when you have easy access to successful monitoring and automation!

With the development of brewing-related science and technology happening so quickly, you can bet that more Brewhouse System sensors will be invented; when they are, YoLong will proudly integrate more sensors and switches into our brewing systems.

YoLong customers can select which is the best sensor for immediate equipment enhancement and easier monitoring of the brewing process. Please contact us if you would like to discuss and plan according to your budget.

Remember: Sensors not only improve productivity and efficiency, but they also increase the equipment’s longevity and viability.

Both the pressure sensor and flow sensors are YoLong most popular equipment update installations: they have the greatest effect on productivity at the smallest price. Keep your ear on the ground for news about other YoLong sensors in the pipeline. We plan on making winemaking easier for you today and in the future.

Additional FAQs about Sensors in a Brewhouse System

• Q: What’s the difference between a flow switch and a flow meter in a brewhouse system?
  A: A flow switch is a binary device (on/off) that detects presence or absence of flow for interlocks and protections. A flow meter measures actual volumetric or mass flow for dosing and analytics. Many brewhouse systems use a flow switch for pump/valve interlocks and a meter for precise transfers and water-in volumes.
• Q: Where should pressure switches be installed for maximum protection?
  A: Common points include the compressed air header feeding pneumatic valves, pump discharge lines (to detect blockages), and CIP supply lines. For pneumatics, set the switch below nominal line pressure (e.g., trigger at 4.5–5.5 bar in a 6–7 bar system) to alarm/lockout when air is off or insufficient.
• Q: Which sensor materials and ratings are suitable for brewing applications?
  A: Choose stainless wetted parts (316L preferred), food-grade elastomers (EPDM/FKM), IP65–IP67 enclosures, and sanitary connections (tri-clamp). Verify temperature/pressure ranges that cover mash, wort, and CIP conditions (up to ~90–100°C liquid exposure for many lines and 2–3 bar).
• Q: How do sensors integrate with PLC/HMI controls?
  A: Most flow/pressure switches provide PNP/NPN discrete outputs or 4–20 mA analog signals. They tie into PLC digital or analog inputs to drive interlocks (e.g., prevent pump run on no-flow) and HMI alarms, including SMS/email notifications when supported.
• Q: What maintenance and validation do sensors require?
  A: Monthly functional checks (simulate no-flow/low-pressure conditions), quarterly cleaning/visual inspection of probes and ports, annual calibration or replacement per OEM guidance, and documented verification during CIP to ensure reliable interlocks.

2025 Industry Trends for Brewhouse System Sensing

• Plug-and-play sensor modules: pre-wired manifolds and IO-Link devices simplify commissioning and diagnostics.
• Predictive maintenance: sensor health monitoring (signal stability, cycle counters) reduces unplanned downtime.
• Enhanced oxygen control: sensor-driven interlocks ensure closed transfers and purge steps occur before pumps run.
• Cybersecure controls: segmented PLC networks and authenticated HMIs protect remote alarm/notification features.
• Sustainability KPIs: sensors feed dashboards tracking water-to-beer ratio, energy per batch, and CIP efficiency.

2025 Sensor Performance and Adoption Benchmarks

Metric/Practice	Typical Target/Status	Why it Matters
Flow switch reaction time	≤50–100 ms	Prevents dry-run seal damage on pumps
Pressure switch setpoint (pneumatics)	4.5–5.5 bar trigger in 6–7 bar systems	Ensures valve actuation reliability
Enclosure/environment rating	IP65–IP67; NEMA 4X	Survives washdowns and humidity
Electrical interface	IO-Link or 4–20 mA + PNP/NPN	Easier diagnostics; flexible PLC integration
Utility savings from sensor-driven interlocks	5–12% CIP water/chemical reduction	Avoids unnecessary cycles and rework
Commissioning timeline with pre-wired skids	1–3 days for sensor checkout	Faster time-to-first-wort

Sources: Brewers Association Quality and Sustainability tools; MBAA Technical Quarterly; ISA/IEC control best practices; OEM datasheets (2024–2025). Validate for local codes and site conditions.

Latest Research Cases

Case Study 1: Flow/Pressure Interlocks Prevented Dry-Run Failures (2025)

• Background: A 20 hL brewhouse reported recurring pump seal failures after operator errors during transfer.
• Solution: Added sanitary flow switches on transfer lines and a compressed-air pressure switch tied to PLC interlocks; HMI SMS alerts configured for “no-flow” and “air-off” states.
• Results: Zero dry-run incidents over 9 months; pump seal replacements down 80%; estimated annual savings ~$6,800 in parts/labor and reduced batch risk.

Case Study 2: Sensor-Led CIP Optimization Cut Utilities (2024)

• Background: A brewpub’s CIP cycles ran longer than needed, wasting water/chemicals.
• Solution: Integrated flow confirmation on return lines and pressure verification across spray devices; PLC ended steps based on stable flow/pressure endpoints and conductivity.
• Results: Water per CIP reduced 15–20%; caustic use down 18%; CIP time shortened by 12–16 minutes per cycle without hygiene compromise.

Sources: Brewers Association Quality/Sustainability resources; MBAA TQ articles on interlocks and CIP validation; vendor application notes on IO-Link diagnostics and endpoint control.

Expert Opinions

• John Mallett, Former VP Operations, Bell’s Brewery; Author of “Malt”
• Viewpoint: “Sensor-driven interlocks are cheap insurance—protect your pumps and valves first, then layer in data for repeatability.”
• Mary Pellettieri, Brewing Quality Consultant; Author of “Quality Management for Breweries”
• Viewpoint: “Tie sensor alarms to action. An alarm without an interlock is just noise; an interlock prevents defects.”
• Dr. Tom Shellhammer, Professor of Fermentation Science, Oregon State University
• Viewpoint: “Stable flow and pressure control improve thermal and oxygen outcomes, which directly influence flavor stability.”

References: Brewers Association — https://www.brewersassociation.org/; MBAA — https://www.mbaa.com/

Practical Tools and Resources

• Brewers Association: Quality and Sustainability toolkits — https://www.brewersassociation.org/
• MBAA Technical Quarterly (controls, CIP, oxygen) — https://www.mbaa.com/
• ISA standards and guidance on instrumentation — https://www.isa.org/
• Sensor OEMs with brewing-ready devices: IFM — https://www.ifm.com/; Endress+Hauser — https://www.endress.com/; Burkert — https://www.burkert.com/
• Controls/PLC resources: Rockwell Automation — https://www.rockwellautomation.com/; Siemens — https://new.siemens.com/
• Sanitary design guidelines: 3-A Sanitary Standards — https://www.3-a.org/

Last updated: 2025-09-04
Changelog: Added 5 focused FAQs; inserted 2025 sensor benchmarks table; provided two case studies on interlocks and CIP optimization; included expert viewpoints; curated practical resources with authoritative links.
Next review date & triggers: 2026-03-01 or earlier if BA/MBAA publish updated CIP/interlock guidance, ISA standards change, or new sensor technologies (e.g., IO-Link enhancements) impact brewhouse system best practices.