Professional Brewing Systems: A Comprehensive Guide

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What is a professional brewing system?

A professional brewing system is a specialized apparatus designed for the production of beer and other fermented beverages on a larger scale. These systems vary in size and complexity, ranging from smaller setups used in craft breweries to large-scale industrial configurations.

1. Origin and Evolution: The history of brewing systems is as old as civilization itself. Ancient cultures crafted their brews using rudimentary tools and methods, but with the onset of the industrial age, there was a need for more efficient and standardized brewing systems. Today&#;s professional brewing systems are a testament to centuries of innovation and refining.
2. Components of a Brewing System: At a high level, a brewing system comprises:
   • Mash Tun: For converting starches to sugars.
   • Boiling Kettle: To boil the wort with hops.
   • Fermentation Tanks: Where the magic happens &#; yeast converts sugars to alcohol.
   • Filtration Systems: For clarity and purity.
   • Packaging: Bottling, canning, and kegging equipment.
3. Craft vs. Industrial Systems: While the foundational principles remain the same, the scale, automation, and precision distinguish a craft brewery&#;s system from that of an industrial brewery. Craft brewing systems prioritize flexibility and experimentation, whereas industrial systems aim for consistency and efficiency.
4. Technological Advancements: Modern brewing systems incorporate advanced technologies such as automated temperature control, digital monitoring, and even AI-driven analytics to predict and optimize brewing outcomes.
5. Environmental Considerations: With the rise of sustainable practices, many brewing systems now incorporate eco-friendly technologies, such as water recycling and energy-saving mechanisms.
6. The Future of Brewing Systems: As the demand for unique and varied beer styles grows, we can expect further innovations in brewing technology, focusing on versatility, efficiency, and sustainability.

Key ComponentsPurposeFound inMash TunConverts starches to sugarsBoth Craft and Industrial SystemsBoiling KettleBoils wort with hopsBoth Craft and Industrial SystemsFermentation TanksYeast fermentationBoth Craft and Industrial SystemsFiltration SystemsProvides clarity to the beerMostly in Industrial SystemsPackaging EquipmentBottling, canning, keggingBoth Craft and Industrial Systems

How much does a professional brewing system cost?

Investing in a professional brewing system can be a significant financial undertaking, influenced by multiple factors like system capacity, features, brand, and more. Understanding the pricing spectrum can help prospective brewers make informed decisions.

1. Factors Influencing Cost: Several elements can affect the price of a brewing system:
   • Capacity: The volume of beer a system can produce plays a direct role in its cost.
   • Automation Level: Manual systems are generally less expensive than fully automated ones.
   • Brand and Quality: Established brands known for durability and high performance might be pricier.
   • Additional Features: Add-ons such as advanced filtration systems, digital controls, and specialized fermenters can raise the price.
2. Craft Brewing Systems:
   • Microbrewery: These are perfect for small-scale commercial brewing or even enthusiastic homebrewers. Systems producing up to 7 barrels (a barrel is 31 gallons) might range from $15,000 to $100,000.
   • Small Craft Brewery: Systems with a capacity of 7 to 15 barrels could range between $100,000 to $500,000.
3. Industrial Brewing Systems: For large-scale commercial production, these systems have vast capacities. A system that can produce 50 barrels or more might cost upwards of $1 million, depending on its features and brand.
4. Brands to Consider:
   • Blichmann Engineering: Known for high-quality equipment for both homebrewers and commercial brewers.
   • BrauKon: A premium brand offering highly automated and efficient brewing systems.
   • JV Northwest: A popular choice for larger breweries due to their extensive capacity options and customization.
5. Maintenance and Hidden Costs: Beyond the initial investment, one must consider costs like maintenance, replacement parts, and the potential need for system upgrades.
6. Financing Options: Thankfully, several companies offer financing options for breweries, recognizing the substantial initial capital required.
7. ROI Considerations: While the initial cost might be high, the return on investment can be lucrative if the brewery gains a steady customer base and maintains quality.
8. Used Equipment: For those looking to save, purchasing used brewing equipment is an option. However, one must ensure it&#;s in good condition and meets all safety standards.

Brewing System TypePrice RangeNotable BrandsMicrobrewery$15,000 to $100,000Blichmann EngineeringSmall Craft Brewery$100,000 to $500,000BrauKonIndustrial Brewing System$1 million and upJV Northwest

What are the types of professional brewing systems?

When considering a venture into the world of brewing, understanding the variety of brewing systems available is crucial. Different systems cater to various needs, scales, and brewing methodologies.

1. Home Brewing Systems: Ideal for hobbyists, these setups are compact and suited for brewing small batches. They may not have the automation of larger systems but are perfect for experimental brewing. They typically range from $100 to $2,500.
2. Microbrewery Systems: Designed for small-scale commercial production or craft breweries. They maintain a balance between capacity and the flexibility to brew diverse beer types. Systems that produce up to 7 barrels (a barrel is 31 gallons) fit into this category. They are priced between $15,000 to $100,000.
3. Small Craft Brewery Systems: These systems take things a notch higher in terms of capacity, ranging between 7 to 15 barrels. They are an ideal choice for breweries that have established a niche and are looking to expand their production. Prices range from $100,000 to $500,000.
4. Industrial Brewery Systems: Tailored for large-scale commercial breweries, these systems emphasize efficiency and consistency. Equipped with high levels of automation and sophisticated control mechanisms, they can produce 50 barrels or more. Given their massive scale and advanced features, these systems can cost upwards of $1 million.
5. Specialized Systems: Apart from the regular brewing processes, there are specialized systems designed for specific brews such as sours, lambics, or non-alcoholic beers. Their price can vary considerably based on their complexity and specialization.

System TypeCapacity (in barrels)Price RangeHome BrewingLess than 1$100 to $2,500MicrobreweryUp to 7$15,000 to $100,000Small Craft Brewery7 to 15$100,000 to $500,000Industrial Brewery50 and above$1 million and up

Functions of professional brewing systems

The craft and science of brewing involve multiple stages, each of which is crucial to the quality and flavor of the final product. A professional brewing system integrates these stages, ensuring efficiency, consistency, and scalability.

1. Mashing: This initial step involves soaking the grains in heated water to activate enzymes that convert starches into fermentable sugars. The brewing system&#;s mash tun facilitates this process.
2. Boiling: The sweet liquid obtained from mashing, known as wort, is boiled with hops in the boiling kettle. This stage not only extracts flavors from the hops but also sterilizes the wort.
3. Cooling: Post boiling, it&#;s vital to cool down the wort quickly to a temperature conducive for fermentation. Modern brewing systems come with efficient heat exchangers that expedite this cooling process.
4. Fermentation: The cooled wort is transferred to fermentation tanks, where yeast is added. Yeast consumes the fermentable sugars, producing alcohol and carbon dioxide in the process. Depending on the beer type, fermentation can last anywhere from a few days to several weeks.
5. Maturation: Once fermentation is complete, the beer is allowed to mature. This period allows the flavors to develop and any residual sugars to be consumed. Some beers might require extended maturation periods, while others can be consumed relatively fresh.
6. Packaging: After maturation, the beer is filtered and carbonated, if necessary, before being packaged in bottles, cans, or kegs. Packaging is an integral function of larger brewing systems, especially in industrial setups, as it involves filling thousands of units in a short time.

Applications of professional brewing systems

The world of beer is vast and diverse, with each style boasting a unique flavor profile, brewing technique, and history. The versatility of professional brewing systems allows brewers to cater to this diverse palate and delve into various beer styles.

1. Ale Production: Ales encompass a wide range of beers, from IPAs to stouts. Ales are typically fermented at warmer temperatures, and top-fermenting yeast strains are employed. Given their popularity and diverse styles, most brewing systems are optimized for ale production.
2. Lager Production: Lagers are fermented at cooler temperatures using bottom-fermenting yeast strains. They demand extended maturation periods, often at near-freezing temperatures. Brewing systems designed for lagers have specialized fermentation tanks and cooling systems to cater to these needs.
3. Specialty Beers: These include sours, barrel-aged beers, and seasonal brews. Sours, for instance, require a different fermentation approach, often involving wild yeast strains and bacteria. Brewing systems for such specialty beers incorporate additional features to ensure the right environment for these unique brews.
4. Non-alcoholic Beers: With the rising demand for non-alcoholic options, many breweries are exploring this category. Brewing systems for non-alcoholic beers incorporate specialized equipment to remove or limit alcohol during the brewing process.
5. Experimental Brews: The craft beer revolution has encouraged brewers to experiment, leading to creations like coffee IPAs, chili stouts, and more. Versatile brewing systems allow brewers to integrate unconventional ingredients and methods seamlessly.
6. Pilot Batches: Before scaling up production, breweries often produce pilot batches to test recipes and gauge public reaction. Many brewing systems come with pilot brewing setups, allowing for smaller-scale experimentation.
7. Educational Purposes: Brewing schools and universities use professional systems to offer hands-on training to budding brewers. These systems, while fully functional, are often smaller in scale, allowing students to grasp the intricacies of brewing.
8. Brewpubs: Many restaurants and pubs brew their beer on-site, offering a fresh and unique experience to patrons. These establishments require brewing systems that not only produce high-quality beer but also seamlessly integrate into the establishment&#;s aesthetics and operations.

As breweries continue to innovate and cater to evolving consumer preferences, the applications of professional brewing systems will undoubtedly expand, playing a pivotal role in shaping the future of beer.

How Professional Brewing Systems Benefit You

The surge in the craft beer industry and the fascination with homebrewing have brought attention to the pivotal role of professional brewing systems. Regardless of scale, from a small home setup to a colossal industrial brewery, these systems offer myriad benefits.

1. Consistency: One of the significant challenges brewers face is maintaining the consistency of their beer across batches. A professional brewing system provides precise control over every stage, from mashing temperatures to fermentation times, ensuring that every batch mirrors its predecessor in flavor and quality.
2. Efficiency: Time is of the essence in brewing, especially in commercial settings. These systems streamline the brewing process, reducing the time between batches and optimizing the use of ingredients. This efficiency not only speeds up production but also leads to cost savings in the long run.
3. Scalability: As a brewery grows in reputation and demand, scaling up production becomes inevitable. Professional brewing systems are designed with this growth in mind. Modular systems allow breweries to augment their capacity without overhauling the entire setup.
4. Quality Control: With advanced sensors and digital monitoring tools, modern brewing systems provide real-time feedback. This immediate data access enables brewers to make on-the-spot adjustments, ensuring the final product meets the desired quality parameters.
5. Flexibility: The dynamic nature of the beer industry demands versatility. Brewers often tweak recipes or experiment with novel ingredients. A professional system offers the flexibility to make these alterations seamlessly, allowing brewers to innovate without constraints.
6. Safety: Brewing, while rewarding, involves potential hazards, from handling boiling liquids to managing pressurized fermentation tanks. Professional systems are equipped with safety mechanisms that protect brewers from accidents, making the brewing process safer and more secure.
7. Environmental Impact: Modern brewing systems often incorporate sustainable technologies. From water recycling mechanisms to energy-efficient heating systems, these setups are designed to reduce the environmental footprint of the brewing process.

How to choose a professional brewing system

Embarking on the brewing journey, whether as a hobby or a commercial venture, involves significant decisions. One such critical decision is selecting the right brewing system. Here&#;s a guide to making an informed choice:

1. Determine Your Scale: Before diving into the technicalities, determine your brewing scale. Are you a homebrewer, a microbrewery, or an industrial-scale brewery? Your scale will dictate the system size, features, and budget.
2. Research Brands: There are numerous brewing system manufacturers, each with its specialties and reputation. Brands like Blichmann Engineering cater to both homebrewers and commercial brewers, while BrauKon is renowned for its highly automated systems. Research and reviews can guide you to a brand that aligns with your needs.
3. Decide on Automation Levels: Some brewers prefer manual control, enjoying the hands-on nature of brewing, while others lean towards automated systems for efficiency and consistency. Decide where you stand on this spectrum and choose a system accordingly.
4. Budget: As with any significant investment, budget plays a crucial role. While it&#;s essential to remain within financial bounds, remember that quality often comes at a price. Weigh the system&#;s features against its cost to ensure value for money.
5. Future Expansion: Even if you&#;re starting small, think ahead. If you plan to expand in the foreseeable future, opt for a system that allows for easy scaling up. Modular systems, which enable capacity augmentation without complete overhauls, can be a smart choice.
6. Consider Technical Support: Brewing systems, especially advanced ones, can have steep learning curves. Opt for brands that offer robust technical support, be it through detailed manuals, helplines, or on-site training.

ConsiderationDescriptionScaleDetermine your brewing volume and frequencyBrandResearch manufacturers for quality and reputationAutomationDecide between manual, semi-automated, or fully automatedBudgetSet a price range but consider value for moneyExpansionConsider future growth and scalabilitySupportEnsure robust technical support from the manufacturer

Best 10 Professional Brewing System Manufacturers

The world of brewing has witnessed an explosion in both demand and innovation. Central to this evolution are the manufacturers who design and produce state-of-the-art brewing systems. Here&#;s a list of the top 10 manufacturers in the industry:

1. Blichmann Engineering: Catering to a wide audience, from homebrewers to commercial establishments, Blichmann is known for its quality and durability.
2. BrauKon: A powerhouse in the brewing industry, BrauKon offers highly automated and efficient systems, tailored for larger breweries.
3. JV Northwest: With extensive capacity options and a reputation for robustness, JV Northwest is a go-to for many large-scale breweries.
4. Ss Brewtech: Emerging as a favorite among craft brewers, Ss Brewtech combines innovative design with efficiency, suitable for mid-scale production.
5. Speidel: A veteran in the brewing industry, Speidel offers a range of systems, with a special focus on homebrewing setups.
6. DME Brewing Solutions: Specializing in turnkey solutions, DME offers everything from brewhouses to fermentation tanks, making them a one-stop-shop for breweries.
7. Alpha Brewing Operations: With a commitment to innovation, Alpha Brewing Operations has carved a niche for itself, especially among craft breweries.
8. PKW (Portland Kettle Works): With a blend of craftsmanship and technology, PKW offers systems that are both aesthetically pleasing and functionally superior.
9. ProBrew: Focusing on efficiency and automation, ProBrew caters predominantly to commercial establishments with high production demands.
10. MoreBeer!: A favorite among homebrewers, MoreBeer! offers compact systems packed with features, perfect for those diving into the world of brewing.

Whether you&#;re a novice brewer or a seasoned professional, these manufacturers offer a plethora of options to cater to your specific needs. As the industry continues to grow, expect even more innovation and variety from these stalwarts.

Where to Buy Professional Brewing Systems

In the ever-growing brewing industry, choosing where to purchase your brewing equipment is almost as critical as selecting the equipment itself. With countless manufacturers and suppliers worldwide, it&#;s essential to navigate this landscape informed and prepared.

1. Local Distributors: Before looking internationally, check for local distributors. They often have partnerships with major brewing system manufacturers and can offer both equipment and post-sales support. An added advantage is reduced shipping time and costs.
2. Directly from Manufacturers: Some brewers prefer to buy directly from the source. This approach ensures genuine products and often opens doors to customization. Moreover, dealing with the manufacturer offers insights into the product&#;s design, evolution, and optimal use.
3. Trade Shows and Conventions: Events like the Craft Brewers Conference or the Great American Beer Festival often feature equipment showcases. These gatherings offer hands-on experience and direct discussions with manufacturers, helping brewers make informed decisions.
4. Online Marketplaces: With the rise of e-commerce, platforms like Alibaba, BrewBids, and ProBrewer have become hotspots for brewing equipment. They provide a broad range of products, often at competitive prices, but ensure to vet sellers for authenticity.
5. Referrals and Recommendations: Sometimes, the best insights come from peers. Engage with other brewers, join brewing forums, or visit local breweries to get recommendations. Their experience can guide you to trusted suppliers.
6. International Suppliers: As the brewing industry is global, many leading manufacturers are located outside North America and Europe. Companies like YoLong Brewtech, based in Ningbo City, China, have become renowned for their quality and innovation. Founded in , YoLong Brewtech has over 15 years of experience and operates from a state-of-the-art 36,000 m2 manufacturing plant, ensuring custom-designed projects meet exact specifications.

Product Advantages of Chinese Professional Brewing Systems

China has emerged as a brewing powerhouse, with numerous manufacturers offering a wide variety of equipment. But why have Chinese brewing systems gained such traction globally? Here&#;s a deeper look:

1. Cost-Effective: One of the most significant advantages of Chinese brewing systems is their cost-effectiveness. Manufacturing costs in China tend to be lower, translating to competitive prices without compromising on quality.
2. Advanced Technology: Despite the perception of some, Chinese manufacturers employ cutting-edge technology in their production processes. Companies like YoLong Brewtech, with their vast experience and state-of-the-art facilities, produce equipment that rivals those from Western manufacturers.
3. Scalability: Chinese manufacturers cater to a wide range of clientele, from microbreweries to industrial-scale plants. This versatility ensures that they offer products catering to different scales, allowing breweries to expand without switching suppliers.
4. Customization: With their emphasis on tailor-made solutions, Chinese suppliers often provide customization options, ensuring the equipment perfectly fits the brewer&#;s needs.
5. International Standards: Leading Chinese manufacturers, aware of their global clientele, adhere to international standards. Their products often come with necessary certifications, ensuring they meet global quality and safety benchmarks.
6. Robust Support and After-sales Service: Understanding the intricacies of brewing equipment, many Chinese suppliers, including YoLong Brewtech, offer comprehensive after-sales support, ensuring their customers can navigate any challenges post-purchase.
7. Diverse Product Range: Given the vast manufacturing capacity, Chinese suppliers often have an extensive product range, from brewing kettles to fermentation tanks and packaging lines. This diversity ensures brewers can source all their needs from a single supplier.
8. Export Expertise: With their global clientele, Chinese manufacturers have honed their export processes. This expertise ensures smooth shipping, customs clearances, and delivery, minimizing post-purchase hassles for international buyers.

Best Chinese Professional Brewing System Supplier: YoLong Brewtech

China&#;s rise as a global manufacturing hub has seen the emergence of numerous brewing system suppliers. Among them, YoLong Brewtech stands out, not just for its products but also for its ethos and vision.

1. Vast Experience: Founded in , YoLong Brewtech brings over 15 years of experience to the table. This longevity is a testament to their dedication, quality, and commitment to serving the brewing industry.
2. Diverse Product Portfolio: YoLong caters to various sectors within the beverage industry, from beer and wine to cold-brewed coffee, kombucha, and infused teas. This diversity showcases their versatility and ability to innovate.
3. State-of-the-Art Facility: Located in the Ningbo City Economic Development Zone, YoLong&#;s manufacturing plant is a marvel. Spread across 36,000 m2, it&#;s equipped with advanced machinery and tools, ensuring every product is crafted to perfection.
4. Customization: YoLong&#;s emphasis on tailor-made solutions has earned them accolades. They work closely with their clients, ensuring every project aligns perfectly with the customer&#;s specifications.
5. Global Presence: While based in China, YoLong&#;s influence is global. They&#;ve catered to clients worldwide, and their products can be found in breweries across continents, a testament to their universal appeal and unmatched quality.

For those venturing into the brewing world or looking to upgrade their existing setups, YoLong Brewtech offers a blend of experience, quality, and innovation, making them a top choice among brewing system suppliers.

FAQ

Q1: What is the average lifespan of a professional brewing system?

While the lifespan can vary based on usage, maintenance, and quality, most professional brewing systems last between 10 to 20 years. Regular maintenance and proper use can extend the system&#;s life.

Q2: Can I customize my brewing system based on my brewing style?

Absolutely! Companies, especially those like YoLong Brewtech, pride themselves on offering customization options to perfectly align with your brewing needs and style.

Q3: How often should I perform maintenance on my brewing equipment?

Regular maintenance is key to longevity and optimal performance. It&#;s advisable to conduct weekly checks and thorough monthly maintenance. Always consult your equipment&#;s manual for specific guidelines.

Q4: Is it challenging to scale up my production with a professional brewing system?

Not at all! Professional brewing systems are designed with scalability in mind. Depending on the manufacturer, you can expand your production by adding components or upgrading specific parts of the system.

Q5: Are Chinese brewing systems compatible with international standards?

Leading Chinese manufacturers, like YoLong Brewtech, adhere to international standards. They produce equipment that meets global quality and safety benchmarks, ensuring compatibility with global requirements.

Q6: Do I need specialized training to operate a professional brewing system?

While professional brewing systems are designed for ease of use, training is beneficial. It ensures you utilize the system to its full potential and maintain it properly. Many manufacturers offer training sessions or manuals for guidance.

Q7: What&#;s the difference between a home brewing system and a professional one?

Home brewing systems are typically smaller and designed for personal use, handling small batches. Professional systems are more robust, designed for commercial production, and come with advanced features for efficiency and scalability.

Know More Brewing equipment

When it comes to buying the main equipment for your brewery, there are several factors to consider. In this guide, we&#;ll take a look at the essential pieces you&#;ll need, and discuss the various options where relevant.

The brewery can be split into two major sections. The first is the brewhouse, also known as the &#;hot side&#;. This is where the first stage of brewing is completed, from milling to mashing, and boiling to chilling the wort.

For more information, please visit YME.

The second section is the cellar, also known as the &#;cold side&#;. This is where fermentation, conditioning, dry hopping, and everything else that happens as wort becomes beer takes place. Most brewery equipment falls into one of these two sections, with a few exceptions.

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Brewhouse (hot side) essentials

The brewhouse consists of various heated vessels, with pumps to transport the wort.

Heat source

The first decision to make is how you will heat your brewing vessels. The most common methods are:

Steam
Steam heated vessels are fairly common and require a steam generator. This simply transforms city water into boiling steam, which is then piped into steam jackets that are fitted on your vessels. Steam generators are typically powered by either natural gas, electricity, or diesel. They require a water softening system, which is normally sold with the generator. Steam tends to offer more control than other heating methods, as the input of steam can be finely adjusted.

Electricity
Vessels heated by electricity typically use elements, similar to those found in a common kitchen kettle. These come in various sizes and powers, and the best have 2 or 3 elements that can be switched off and on, providing a level of control over the heating. Electrical brewhouses have the elements in-built, and don&#;t require additional equipment.

Malt mill

Only necessary if you&#;re using uncrushed malt. Look for models that are easily adjustable. The most common models have 2 rollers, which is adequate for the needs of most small breweries, though some have 3 or more. Depending on your space, you may need a model that is easily maneuvered. Suppliers typically list the capacity in terms of weight of malt per hour.

Hot Liquor/Water Tank (HLT)

The HLT stores and heats up your brewing water (known as liquor in British brewing). The best models have at least two heating elements or steam jackets, allowing you to start heating with just a small amount of water in the vessel. Your HLT should have a level indicator for easy calculations.

In terms of size, it should be around double the size of the rest of your brewhouse. So, if you have a 500 litre boil kettle, you should order a 1,000 litre HLT. This will ensure you always have enough liquid for strike water, sparging, and cleaning.

It should also be fitted with a pump that connects to the mash tun and sparge set up via a flowmeter, as well as the CIP valves on the rest of your equipment. The pump should also allow for recirculation to ensure accurate temperature readings and even mixing of cleaning agents or sparge water additions if you&#;re using them.

Flowmeter

The flowmeter is used to accurately measure strike and sparge water. It should be heat resistant and waterproof.

Mash tun

There are many types of mash tun, from the most simple open vessels, to enclosed, heated vessels, fitted with stirring paddles. The more features, the higher the cost. For larger outputs (higher than 200 litres or so), it becomes difficult to mix the mash by hand. If you plan to use step mashing, you&#;ll need a mash tun that can be heated.

It should also be fitted with a pump that transports the mash to the lauter tun. Desirable extras include the ability to recirculate for more consistent temperatures, and an inbuilt temperature probe.

Lauter tun

The lauter tun is fitted with a filter, used to separate the sweet wort from the grain. It is also fitted with a sparge ring, connected to the HLT via the flowmeter. The ability to recirculate the hot wort back over the grain is extremely useful for clarifying the wort before transferring to the boil kettle. It&#;s not typically necessary for the lauter tun to be heated. During the sparging process, the filtered hot wort will be pumped to the boil kettle.

You will typically need a spent grain outlet &#; a side mounted door from which the spent grains can be pulled out and disposed of easily.

Boil kettle

A relatively simple, heated vessel, the best can start heating the wort with as little as 20 litres inside, reducing the time taken to reach a boil. Depending on your space, you may need a condenser. This draws the steam (and other unwanted compounds) out of an enclosed boil kettle. Alternatively, if space allows, fit a flue that leads outside. 

Whirlpool

The whirlpool vessel isn&#;t absolutely necessary, depending on the type of beer you&#;re producing. It can be used for late hop additions, and dropping solids out of suspension before transferring to the heat exchanger.

Heat exchanger

Used to drop the temperature of the boiling wort before transferring to the fermenting vessel. The most common type in breweries is a plate heat exchanger (PHE). The beer flows through one side, and cold water and glycol (or ice water) passes through the other. It should come with at least a thermometer in the beer outlet.

There are several configurations. The most common include a hop filter or even a hopback before the PHE, and a yeast tank and oxygenation system after the PHE. They come in many sizes, often measured in sq. metres. The larger the PHE, the quicker it cools your wort.

As a general rule of thumb, a 500 litre brewhouse doesn&#;t need much more than a 5 sq metre PHE, a 1,000 litre brewhouse works well with a 10 sq metre PHE, and so on. There should be a pipe that returns the warm city water into the HLT, providing pre-warmed water to save energy costs.

Combination vessels

Most small breweries don&#;t have separate vessels for the mash tun, lauter tun, boil kettle, and whirlpool. There are various combinations that you can use to save space. The most common include;

• Mash/lauter tun: mash, lauter, and sparge in the same vessel to save space and time. It will need to be heated if you plan to use step mashing.
• Boil kettle/whirlpool: a common space saver, it will need two outlets, one for clear wort to be transferred to the heat exchange, and a lower one for emptying the kettle at the end of the brew.
• Mash/boil kettle: with this system you mash in, then transfer the mash to a separate lauter tun, before returning the sweet wort to the original vessel to boil. An economic way to save space and allow for step mashing. Potential downside is that you have to be very thorough about removing any leftover grain before returning the wort for boiling.
• All-in-one: a simple vessel in which you mash, lauter, boil and whirlpool all in one vessel. They generally use a large basket to contain the grains, lifted up using a winch and hoist. The entire vessel can be heated, and in some cases, cooled as well. This is an affordable, space saving solution for small spaces. Speidel&#;s Braumeister series offers an all-in-one solution for up to 1,000 litre batches.

Control panel

Control panels come in many shapes and sizes. Common solutions utilize simple PID systems to monitor temperatures and control pumps, and other motorized operations, such as mash paddles, etc. Alternatively, PLC systems offer a touchscreen interface to monitor the entire process, and set automated operations.

The control panel can be restricted to the brewhouse functions, but can also encompass the chilling operations.

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Cellar (cold side) essentials

In the cellar you&#;ll mostly find fermenting vessels and conditioning tanks.

Fermenting vessels

The type of fermenting vessel you choose depends largely on the type of beer you want to brew. From simple open vessels to pressurized uni-tanks, there are several things to consider. Many small breweries prefer enclosed pressurized vessels &#; these allow for natural carbonation and faster turn-around times. However, if you plan to bottle condition your beer, pressurized vessels aren&#;t necessary.

Size is important, and it&#;s not a bad idea to have a mixture. For example if you have a 1,000 litre brew house, it can be good to have a selection of 500 litre, 1,000 litre, and 2,000 litre fermenters. This allows you to split batches for experiments, and produce larger quantities of core range beers. This depends entirely on your business model, however.

Fermenting vessels can be customized in many different ways. Some common modifications include dry hopping port, carbonation stone, racking arm, and spunding valve. As standard, they should typically come with a temperature probe, spray ball for CIP, and sample valve.

Conditioning tanks

These aren&#;t essential for all breweries, but can be a useful addition. Bright beer tanks (or BBTs) are most often used to clarify and age beers such as lager, but can also be used to add carbonation. Vertical or horizontal, there are several options.

Glycol/Ice water tank

Many breweries use a cooling agent to maintain fermentation temperatures and cold crash their beers. Glycol is the most common, which is stored in a large tank and pumped into jackets within the fermenting vessels.

If using a glycol tank, you&#;ll need a separate pump for the system, automatic (solenoid) valves on the fermenting vessels, a control panel, and industrial chillers. The glycol should also have a loop that runs through the PHE to aid in wort chilling.

Cold-side control panel

Used to maintain the temperature in your fermenting vessels, as well as control cold crashing. Like the brewhouse panel, it can be PID or PLC, or can even be incorporated into the same panel. They typically vary in size depending on how many temperature controllers they have, generally ranging from 2 to 8 or so.

It&#;s important that you can switch from manual to automatic if you use glycol in your PHE.

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Miscellaneous essentials

Besides the larger equipment for the brewhouse and cellar, there are a few other essentials you&#;ll need when opening a brewery.

Cleaning station

Also known as a CIP (clean in place) station, this is a useful addition to the brewery. Most small breweries have CIP systems in their cellar and brewhouse vessels &#; a simple spray ball that spray cleaning solutions at high pressure, coating the interior.

A CIP station typically consists of 2 or 3 vessels (around 50 &#; 200 litres normally), attached to a cleaning pump. Ideally, the station should be mobile to avoid using long pipes during cleaning cycles. One tank is typically used for a caustic cleaning agent and is often heated via an element, while a second is used for sanitizing acid washes. 

A third tank can be used for other acids (for passivation, beer stone removal, etc.) or simply for rinse water. Cleaning solutions are pumped into the vessels that need to be cleaned, and recirculated for the adequate period of time.

Hoses & pipelines

You need food-grade, heat resistant hoses in the brewery, that can take a decent amount of pressure. You&#;ll find decent hoses in Romania rated up to around 10 bars. It&#;s good to buy various lengths, long and short. Shorter hoses are best for cleaning, as they allow for higher pressure during cleaning cycles. Ideally, use hoses with tri-clamp connections, as these can be connected to make longer runs when required.

Pipelines will typically be supplied when ordering brewery equipment, linking pumps to vessels, and ensuring a steady flow of wort and beer. Stainless steel is the best material.

CO2 tanks and regulators

Even if you carbonate your beer naturally, you&#;ll need a CO2 tank or two throughout the brewing process. If you plan to move your beer to another vessel, you&#;ll need to purge the oxygen from the pipes and tanks using CO2. It&#;s also used during packaging, to maintain the pressure in the tank.

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Packaging essentials

Let&#;s start with the most important part:

Bottling/canning machine

Whether you use cans or bottles, you&#;ll need a filling machine. There are many different types to choose from. Particularly with bottling machines, you&#;ll need to know if you&#;ll package carbonated beer, or rely on bottle conditioning for carbonation. If you plan to package carbonated beer, you&#;ll need an isobaric (counter pressure) bottling or canning line.

In this instance, the entire process is carried out under pressure, with very little opportunity for oxygen to seep into the beer. With such machines, it&#;s important that the machine is able to purge the bottles/cans of oxygen prior to filling. Filling lines vary depending on how many filling heads you need, but can also carry out a multitude of other tasks, from washing to labeling and capping.

Labelling machine

Many small breweries continue to apply labels by hand, but the job goes faster with a labelling machine. You can find manual, semi-automatic, and automatic options depending on your needs. Choosing a labelling machine will require you to think ahead in terms of branding. Will you use a single label, back and front, neck label, etc?

Bottle washer

Properly washing your bottles prior to use will increase the shelf life of your beer and keep infections out. The most simple solution is to use a home-brew style set up, with an immersible pump and jet sprays. However, if budget allows or output demands, you can opt for larger bottle washing machines as well. Some filling lines also wash the bottles/cans before filling.

Kegging equipment

Whether you use metal or plastic kegs, you&#;ll need a few pieces of equipment with which to fill them. Be sure to order a few keg couplers first and foremost. The simplest way to keg is to hook up a simple beer line quick connect (john guest fitting) to the fermenting vessel via a tri-clamp fitting.

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Essential spares!

Brewery parts wear down over time, and it&#;s important to have a good supply of spares to prevent delays and quality issues.

Gaskets, clamps, valves

When buying an entire brewery, you&#;ll normally receive a set of clamps and gaskets to connect everything together. Tri-clamps and silicon gaskets are a good choice, rather than threaded connections that can become damaged more easily. Be sure to request a set of spare gaskets and clamps.

Many breweries use butterfly valves throughout the brewery. Over time, these can wear down and start to leak, so it&#;s good to have a few spares. Plus, you&#;ll often find several uses for extra valves.

Sight glasses

Sight glasses are a great way to check on your beer throughout its life span, from checking for wort clarity during the sparge or bottling, to monitoring oxygen intake during transfer to the fermenter. However, they can leak from time to time, so it&#;s a good idea to order spares.

Probes and gauges

Temperature probes and pressure gauges can cause big problems if they fail, so it&#;s a good idea to have a few spares in the brewery.

This wraps up our piece on the brewing equipment you&#;ll need to open a brewery. There are some other tools that will help you along the way. Some you already know if you&#;re into homebrewing (such as a hydrometer or scales for hops and malt), others are optional (such as microscopes or dissolved oxygen meters). If you&#;re looking to open a commercial brewery and need some assistance along the way, drop us a line and we&#;ll take it from there.

Cover photo via r/The Brewery (used with permission)

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