Beverage & Brewery Gas Detection

Application Note Overview

First we'll a quick overview of the following application note by Draeger (Gas Detection in Breweries and the Beverage Industry); which discusses the importance of gas detection in breweries and beverage production facilities. Since multiple gases are used and/or generated during processes such as cleaning, sterilization, refrigeration, and fermentation having a gas detection system in place is critical to workplace safety. It outlines the potential hazards from toxic, corrosive, and flammable gases and provides Draeger Safety solutions for effective monitoring.

Key gases of concern include:

• Chlorine, Chlorine Dioxide, Hydrogen Peroxide, and Ozone, used for water sterilization and disinfection, which pose toxicity risks if leaked.

• Ammonia, commonly used in refrigeration systems, which is toxic, corrosive, and potentially explosive under certain conditions.

• Carbon Dioxide, naturally produced during fermentation and used for carbonation, which can accumulate in confined or low-lying areas and displace oxygen, creating an asphyxiation hazard.

Draeger’s recommended detection solutions include Polytron transmitters and DrägerSensors tailored for each gas type (e.g., Cl₂, ClO₂, H₂O₂, O₃, NH₃, and CO₂). These detectors offer high sensitivity, long service life, and reliable performance even in challenging brewery environments. The application note also includes real-world examples of installations at major global beverage producers such as Guinness, Heineken, Pepsi, and Molson Breweries. Lastly, the paper emphasizes that integrated gas detection systems are vital for ensuring worker safety, product quality, and compliance within the beverage manufacturing industry.

Diving Deeper into — The Importance of Gas Detection in Breweries and the Beverage Industry

Behind every pint of beer or bottle of soda lies a complex production process that relies heavily on the use and control of gases. From fermentation to sterilization and cooling, gases such as carbon dioxide, ammonia, chlorine, ozone, and hydrogen peroxide play a vital role. However, these same gases can pose serious safety hazards if not properly monitored, making gas detection an essential component of brewery and beverage plant safety.

During beverage production, gases serve multiple purposes. Carbon dioxide (CO₂) is a natural byproduct of fermentation and is also added later for carbonation. While it’s harmless in small amounts, CO₂ is heavier than air and can collect in confined or low-lying areas, displacing oxygen and creating a risk of asphyxiation. In refrigeration systems, ammonia (NH₃) is a popular and efficient cooling agent, but it is also toxic and flammable. A small leak near a compressor or valve can quickly turn into a serious incident if not detected early.

The cleaning and sterilization processes also introduce additional gas hazards. Chlorine, chlorine dioxide, hydrogen peroxide, and ozone are widely used for sanitizing water, pipes, and equipment. Though effective disinfectants, they are highly reactive and toxic at even low concentrations. Continuous monitoring is therefore critical to protect workers and maintain safe production environments.

To address these challenges, Draeger's gas detection solutions provide beverage manufacturers the tools to detect gas leaks quickly and accurately. The Draeger Polytron series and corresponding DrägerSensors can identify a wide range of hazardous gases (from chlorine and ozone to carbon dioxide and ammonia) ensuring compliance with safety standards and minimizing downtime. These systems offer robust performance, long sensor life, and high resistance to environmental interference, making them ideal for demanding industrial applications.

Gas Detector Placement in Breweries & Beverage Facilities

Looking for info about where to place gas detectors at you facility? We can help!

The number and placement of gas detectors should come from a professional (like us). Why? Professionals perform a risk-based assessment considering gas type, leak sources, airflow and human occupancy. Then we use our expertise to help you select the right gas detection equipment for your application. Click to read more about gas detection points and placements.

General industry guidelines are as follows:

Fermentation & Carbonation Areas

• Gas: CO₂
• Placement: Low to the ground — because CO₂ is heavier than air and can accumulate in pits or confined spaces.

Compressor & Refrigeration Rooms

• Gas: NH₃ (Ammonia)
• Placement: Near the ceiling — ammonia is lighter than air and rises first during a leak.

Cleaning & Sterilization Areas

• Gases: Cl₂, ClO₂, O₃, H₂O₂
• Placement: At breathing height near process equipment or storage areas — close to possible leak sources but away from washdown zones.

General Tips

• Avoid placing detectors directly in airflow or near vents.
• Protect sensors from washdowns and mechanical damage.
• Use Polytron IR CO₂, Polytron NH₃, and DrägerSensor Cl₂/O₃ models for optimal coverage.
• Proper sensor placement is just as important as the technology itself.