50HL 6 Vessel Commercial Brewery Equipment
What are the design solutions for building the perfect brewery?
Every batch wort production capacity is 5000L, brewing 4~10 batches within 24 hours, and the monthly output is 160KL~400KL, the PLC control system can automatically store a variety of brewing recipes. The valve adopts a pneumatic butterfly valve, one-click operation for intelligent brewing. The volume of the fermentation tank is 10KL; the number: 12~30.
1. Brewhouse System
Stirring: Stirring should use large-diameter and low-speed stirring blades, suspended reducer and can control the stirring speed by frequency conversion, so as to avoid the formation of turbulent flow on the liquid surface of the mash during stirring and reduce the oxygen absorption of the mash. It can be lower stirring according to equipment requirements.
Heating area and method: The design of the heating jacket should allow the heating steam to enter the jacket evenly, and at the same time prevents unsmooth draining of condensed water. Therefore, the jacket should be semi-circular tube type or honeycomb type, controlled in sections, steam inlet and condensate water outlet should be multi entry and exit, ensure enough heating area, and choose good quality drain valve.
The steam jacket will produce a large amount of condensed water, which can be completely recovered. It can be used as softened water for boilers (for equipment with relatively large production capacity, it is recommended to add pipeline of steam condensate water recovery system to save boiler energy consumption)
The total operation time should be controlled within 180min. The thickness of the spent grain layer is with in 220mm-400mm, which meets the needs of various varieties of craft beer. The entire filtration time is about 2 to 3 hours, and the speed of entering the mash should be lower than 1.2m/s.
The wort reflow port is located at the bottom or upper part of the tank, and it should be avoided that the wort absorbs oxygen and splash the wort layer during the reflow; the wort collection port is conical design, more than 1.2/m2, evenly arranged.
Sieve plate: It is a machine-milled sieve plate, the hole of the sieve plate is a trapezoidal design, the aperture width is 0.7mm, and the gap between the sieve plates and between the sieve plate and the tank body after installation is ≤0.7mm.
The raking knife is designed as a straight-line or cross-type raking arm, which should have rotation and lifting functions, and can be controlled continuously or in sections. The main shaft seal adopts a high-level seal, and the sealing surface is above the liquid level, which won’t be any leakage.
For grain washing outlet, it can be nozzle type or central distribution type, the design requires large flow without impacting the grain layer.
The liquid level control adopts the design of balance column (tank) or pressure difference to avoid the occurrence of the compaction of the spent grains layer.
Temporary Storage Tank
In order to achieve multi-batch brewing, a new temporary storage slot needs to be added.
- The process parameters require that the head space is not less than 35% of the full volume. Boil time 60-100min. Evaporation strength within 8%–12%;
- The heating method adopts the internal heater with better effect;
- Set up the device for adding hops and accessories (such as dried tangerine peel, hemp pepper, honey, etc.).
The wort feeding speed is 3～5m/s and rotates counter-clockwise (clockwise).
The wort whirlpool clarifies the static time for 20min. Wort feeding time 12min.
The whirlpool tank uses centrifugal force and gravity to make the thermal coagulation and hop residue formed during boiling gradually gather in the center of the tank during the precipitation process to form a steamed bread-like sediment to achieve the purpose of solid-liquid separation.
There is a sloping bottom structure on the tank bottom structure, the entire tank bottom is inclined to the sewage outlet with a slope of 2%.
In the process of beer production, the cooling consumption of the hot wort cooling water is quite large, about 6000L of cold water, and the wort cooling adopts a thin plate heat exchanger. During this process, the hot wort and the cooling water are pumped in a turbulent form and flow countercurrently along the grooves on both sides of the grooved plate for heat exchange.
We adopt one-stage cooling method: use brewing water to cool the hot wort to the temperature of inoculating yeast at one time. The brewing water is first cooled to 2-4°C with glycol water, heated to 75-80°C after heat exchange with the hot wort, and the water can be directly recycled to the hot water tank.
2. Fermentation System
The cylindrical cone bottom fermenter can be used for pre-fermentation or post-fermentation alone, or it can be combined for pre-fermentation and post-fermentation in one tank. It has good adaptability, can also effectively reduce fermentation time and improve fermentation efficiency, and has been widely used in beer fermentation plants.
The cylindrical cone-bottom fermentation tanks are all made of 304 stainless steel plates. The upper head of the tank is provided with manholes, safety valves, pressure gauges, CO2 discharge ports, etc. The tank body is equipped with a complex cooling system. There is a stainless steel rotating spraying ball in the center of the upper part of the cone. The thermal insulation material is usually polyurethane foam, and the thickness is selected according to the local climate. For the washing of large fermentation tanks and wine storage equipment, use an automatic cleaning system. The system is equipped with lye tank, hot water tank, disinfection tank, acid tank and pipes and pumps for circulation.
The above is a brief discussion of the functions, characteristics and process parameters of brewhouse equipment, water treatment and fermentation. Generally speaking, a set of qualified equipment should be designed, manufactured and installed according to the characteristics of craft brewing, and only by fully considering the adaptability, cleanliness, high efficiency, oxygen avoidance, energy saving, safety and other factors of the equipment can it meet the needs of beer production.
6 Questions About Building a Commercial Brewery
When preparing to build a microbrewery, many problems may arise from the design stage to the customer’s first sip of beer. Brewing a batch of craft beer requires many steps, including precise weight, precise time, and almost obsessive scientific methods. When you adjust any process of brewing beer, it will affect the final product (beer).
Start with Excellent Equipment and Reliable Design
If you want to be able to brew high-quality beer, please buy high-quality brewery equipment as your top priority. Brewing equipment is a place where beer is produced and a place where brewers can use their talents. Similarly, high-quality brewing equipment can also help brew delicious beer batch by batch, and it’s always the case.
Brewery equipment plays a vital role in the brewing process. Brewery equipment can help brewers to better complete the brewing process (grinding, saccharification, filtration, boiling, spin-down, cooling, fermentation, clarification, filtration, packaging). Excellent brewing equipment can ensure that no other problems will be encountered during the brewing process.
We will mark numbers on the pipes of the brewery equipment, and you can connect the equipment through numbers. But, some customers often encounter unforeseen problems beyond professional knowledge. We can provide you with online installation technical guidance. If this is still very challenging for you, we can ask a local agent to help you with the installation.
2. Temperature Consistency
When brewing beer, the temperature is another important part of the brewing process. Because beer is very sensitive to temperature during the brewing process, the beer must be heated to a precise temperature. Also, it is necessary to maintain the temperature within the set time range. This has higher requirements for the control system, and the automated control system can help you simplify the temperature control process.
When you brew a new style of craft beer, the first question you need to consider is whether the process can be repeated? If not, you will not achieve great long-term success. When purchasing brewery equipment, try to choose equipment that can meet all your requirements to ease the development of craft beer with new flavors. Of course, automation can help you take repeatability to a new level.
4. Brewing Capacity
Before opening the brewery, you need to carefully plan every component of the brewing operation. Combine time, cost, brewing requirements, and sales volume to develop a complete brewery plan. Otherwise, you may be bottlenecked.
5. Scalability / Expansion
Does your device support expansion? This is a very important issue because many craft breweries have underestimated their sales and can only buy larger brewing equipment to meet them. You also need to consider the size of the equipment, it is recommended to choose equipment that is 50% larger than you expect. If you plan to buy brewery equipment from China, you also need to consider the production cycle and shipping schedule. The price of Chinese brewery equipment is more competitive, and equipment with the largest capacity possible can be purchased at a lower cost.
6. Learn Brewing Knowledge
Building a new microbrewery is a daunting task, especially if you have no previous experience in commercial brewing. If you have never worked in a brewery or have relevant direct experience, you recommend consulting with experienced brewers. Of course, you can also take courses with professional brewers, who can help you complete all the things you need to start the brewery. Brewing beer is a great industry worth participating in, but you must learn.
Building a commercial brewery has a lot of matters to consider, no matter before or after, clik here to see points that needs to pay attention after opening the brewery.
Micet Group provides global customers with the construction, design, and installation of customized microbrewery equipment and complete turnkey breweries in China. We have agents in many countries, they can provide you with equipment installation support, you can also visit our brewery equipment. If possible, I suggest you come to China and we will show you our production process. If you are ready to open your own brewery, please contact us for turnkey solutions and quotations for the design, construction, and installation of microbreweries, nano breweries, medium and large breweries.
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Here are 3 ways the best craft breweries have become successful:
- Embracing the entrepreneurial spirit.
- A customer-centric approach to taste.
- Breweries supporting each other.
One of the most important decisions a potential new brewery can make is to come to visit our engineers and salespeople to discuss their needs. Our staff can answer all of your design and engineering questions, as well as go into detail.