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Craft Bank Co., Ltd., a Kyoto Prefecture-based brewer of craft beers, and Yokogawa Electric Corporation announce the conduct of a proof of concept (PoC) test by Craft Bank and Yokogawa Group company Yokogawa Digital Corporation whereby autonomous control AI (Factorial Kernel Dynamic Policy Programming (FKDPP), a reinforcement learning-based AI algorithm) was applied to the fermentation process for Bank IPA*1, an award-winning craft beer. By manually implementing the temperature setting schedule created by this AI, brewers were able to shorten the fermentation process time from 336 hours to 240 hours, a 28% reduction. Both companies have determined that the temperature setting schedule generated by the autonomous control AI is effective in shortening the duration of the manufacturing process.
Background Information
Craft beers come in many different types with a wide variety of flavors, and high product quality that meets customer expectations and production efficiency are key concerns. Beer production involves processes such as malting, filtration, boiling, cooling, fermentation, and aging. The fermentation process takes about two weeks, during which yeasts convert sugars into alcohol and carbon dioxide, and this is followed by a several week period in which the product is aged and conditioned at low temperatures to refine the flavor. The fermentation process plays a particularly important role in determining the aroma, taste, and mouthfeel of the final product.
At Craft Bank, up until now temperature has been kept at a constant level during the fermentation period, and each day the brewmaster manually measured the sugar content and conducted sensory evaluation of aroma and taste and checked for the presence of off-flavors. With this PoC, the focus was on the impact of temperature on the speed of fermentation by the yeast, and it was confirmed that the temperature setting schedule derived by the autonomous control AI was valid and effective.
Development of the AI Solution and Implementation of the PoC Test
For the PoC, a simulator was created that replicated the beer production process. Using information provided by the brewmaster, who took into consideration all the conditions that act as stress factors on the yeast, the autonomous control AI developed a temperature setting schedule for the fermentation tank within the simulator. The brewmaster reviewed the appropriateness of this plan, and then followed it to manually set the temperature. Though sensory evaluation during the fermentation process, it was confirmed that all quality criteria were met. By setting the temperature according to the AI-based plan, the fermentation process time was reduced from 336 hours to 240 hours, a 28% reduction.
Future Plans
With the aim of producing a beer that truly is a unique Kyoto product, Craft Bank is working to introduce the use of natural yeast, hops, and other ingredients that have all been sourced from the Kyoto area. In this PoC, the emphasis was on replicating the aroma, taste, and mouthfeel of the product produced by experienced brewers. Craft Bank will in the future explore new possibilities opened up by AI, and the development of innovative new beer production techniques that are unique to Craft Bank.
Yokogawa will contribute to improving both quality and productivity and strengthening competitiveness in the manufacturing industry by applying autonomous control AI to the chemical industry*2 and also the production of fermented foods such as sake and yogurt, as well as the production of antibiotics and other pharmaceuticals that make use of enzymes as well as yeast and other microorganisms.
Craft Bank President, CEO, and Brewing Manager Daichi Haboshi commented,“As a brewer who is responsible for everything from preparation to fermentation on site every day, this initiative was very meaningful. Previously, fermentation tests were physically performed each time, so it took about a month. This time, by repeating simulations using data automatically collected by a sensor, we were able to virtually verify fermentation many times and then conduct hypothesis-based tests on actual machines. The expertise of our brewmasters in functions such as sugar content measurement, temperature control, and the sensory evaluation of the aroma and so on can be complemented by the power of AI, and with them working as partners we can see an unprecedented balance between quality and efficiency. I feel like I now have had a glimpse of one of the optimal solutions that will come through the relationship between people and AI in the AI era. We will explore new ways of producing craft beer that combines the characteristics of Kyoto with cutting-edge technology.”
Hiroaki Kanokogi, Yokogawa Electric Executive Officer, head of the Digital Strategy Division, and President of Yokogawa Digital Corporation, said,“I believe that autonomous control AI can be applied to areas where difficult trade-offs need to be solved or where humans do not have the answers. We will leverage our domain knowledge to open up new avenues for our customers to strengthen their competitiveness.”
*1. Bank IPA, a staple product of Craft Bank, won a silver medal at the Japan Great Beer Awards 2023. IPA, which stands for India Pale Ale, is traditionally made from aromatic American and New Zealand hops and features a juicy and invigorating bitterness with citrus and tropical fruit notes.
*2. In a World First, Yokogawa’s Autonomous Control AI Is Officially Adopted for Use at an ENEOS Materials Chemical Plant One year of stable operation demonstrates this next-generation control technology can decrease environmental impact, achieve stable quality, and transform operations.
About Craft Bank
Craft Bank (craftbk.net) is a craft beer brand, and the microbrewery where it is produced is located at the site of a former bank in Fukuchiyama City, Kyoto Prefecture. Founded in 2021, the company opened its microbrewery in 2022.
About Yokogawa
Yokogawa (yokogawa.com) provides advanced solutions in the areas of measurement, control, and information to customers across a broad range of industries, including energy, chemicals, materials, pharmaceuticals, and food. Yokogawa addresses customer issues regarding the optimization of production, assets, and the supply chain with the effective application of digital technologies, enabling the transition to autonomous operations.
Founded in Tokyo in 1915, Yokogawa continues to work toward a sustainable society through its 17,000+ employees in a global network of 128 companies spanning 62 countries.
The names of corporations, organizations, products, services and logos herein are either registered trademarks or trademarks of Craft Bank Co., Ltd., Yokogawa Electric Corporation, or their respective holders.
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