How Sycamore saved weeks with Smart Fermentation (via PLAATO Pro)
“"PLAATO Pro is the most convenient piece of technology that a brewery can buy….. of any size!” - Samir Pandya, QA Manager, Sycamore Brewing
Benchmarking yeast performance with PLAATO to quickly track process changes
Sycamore Brewing faced a significant challenge at the start of the year: successfully integrating a new yeast strain that would be critical for 80% of their fermentations. With seasonal demand rapidly approaching, they needed to scale quickly and efficiently.
As Samir Pandya, Sycamore’s QA Manager, began trialing the new yeast, he encountered an unexpected issue – the fermentations weren't reaching full attenuation. Without real-time insights, solving this problem typically involves batch-consuming trial and error experimentation. In Samir’s estimation, Sycamore, “would have ended up with multiple batches under-attenuated, tanks and brite tanks occupied with product to be blended, and overall slowed production because of inefficient fermentations.”
"I don't think that there would ever be a situation where we don't keep these (PLAATO Pros) around. They're really valuable pieces of technology, especially at the price point that they're offered and what they can do."
- Samir Pandya, QA Manager, Sycamore Brewing
Getting immediate results so they can brew with confidence
Fortunately, Sycamore Brewing had already implemented the PLAATO Pro/Smart Fermentation system for fermentation monitoring. Samir leveraged the real-time data provided by PLAATO Pro as the system automatically compared the new fermentations against historic benchmarks and alerted him to the variance.
Samir's team quickly investigated the possible cause – the new yeast strain wasn't fully acclimated to Sycamore's higher gravity beers – and tested precise adjustments to both the yeast pitch rate and aeration. He then used Smart Fermentation (via PLAATO Pros) to track the results in real-time.
The immediate feedback from PLAATO Pro showed the fermentation trends reverting back within the correct parameters, confirming that their adjustments were successful. This quickly gave Samir and his team the confidence to proceed. “We may have figured it out on our own, but that may have taken us weeks longer,” he explains.
"They're so easy to use, they provide actionable and repeatable data and I can trust any of the guys with them. They just know exactly what to do." - Samir Pandya, QA Manager, Sycamore Brewing
Maintaining schedule and quality comes easier now too
Thanks to the data and benchmarks provided by PLAATO Pro/Smart Fermentation, Sycamore Brewing was able to avoid costly setbacks. They maintained their production schedule, ensured consistent product quality, and continued to deliver the exceptional beers their customers expect. “And that was primarily from seeing the data and charts provided by PLAATO,” says Samir.
Samir adds: "The automatic batch management really saves us because, I'll be the first to admit that I don't set the batches up on time. So being able to capture all that data is so helpful."
PLAATO’s Smart Fermentation in action; the PLAATO Pro sensors connect to your devices for instant feedback.
Ironing out fermentation flaws with PLAATO
PLAATO has helped Samir and his team address fermentation flaws with real-time data and predictions, especially for the less frequently brewed batches. While it’s easy to predict consistent brews like Mountain Candy without tech, the PLAATO system is invaluable for those irregular batches. By monitoring fermentation progress, like knowing when to spund a tank, Samir can better plan and prepare for the next stages – saving time and improving efficiency.
For example, instead of spending hours prepping on the day of a dry hop, they can get everything ready the day before, thanks to PLAATO’s predictive capabilities. This has optimised their workflow and use of resources.
Samir says: "Thanks to PLAATO, we're getting better with our predictions and we're able to use our time a lot more effectively. The PLAATO's are a big, big help in that regard."
Is your brewery facing similar fermentation challenges? Discover how PLAATO Pro can provide the real-time insights you need to optimize your brewing process.
"They are very reliable, and as a result, maybe selfishly, my quality colleague and me can take days off at the same time. In the last 3 years we've never been able to take a day off at the same time."
Want to see results like Sycamore Brewing? Get in touch with us to learn how PLAATO can help with your brewery’s goals.
