5bbl Beer Brewing Equipment: A Complete Guide

Overview of 5bbl Beer Brewing Systems

5bbl beer brewing equipments are a popular size for micro and craft breweries looking to ramp up production from smaller pilot systems or homebrew kits. With a brewing capacity around 155 gallons (588 liters) per batch, 5bbl systems allow more beer output while still enabling the flexibility and experimentation that smaller breweries require.

This guide covers key considerations in 5bbl beer brewing equipment selection, from brew house and fermentation designs to boiler requirements, accessories, installation factors and more. Whether you are planning a new microbrewery or upgrading existing infrastructure, understanding 5bbl system characteristics will ensure you choose equipment optimized for your goals.

Table: Key Features of 5bbl beer brewing equipments

Capacity per batch	Typically around 155 gallons (588 liters)
Batch frequency	1-3 batches per day depending on schedules
Beer output	Around 3,000-9,000 barrels annually
Boiler size	7-10 bbl steam boiler or gas-fired hot liquor tank
Brewhouse size	Takes up around 400-600 sq ft space
Tanks	Unitank or separate fermenter and brite tank designs
Popular with	Microbreweries, brewpubs, and taprooms
Cost range	Around $250,000-$500,000 depending on features

Types of 5bbl Brewhouses

When selecting a 5bbl brewhouse, you’ll need to choose between traditional 3-vessel or more automated 2-vessel brewhouse designs.

Table: Comparing 3-Vessel and 2-Vessel 5bbl Brewhouses

3-Vessel Brewhouse	2-Vessel Brewhouse
Contains mash tun, lauter tun, kettle	Combines mash and lauter tun into one vessel
More manual transferring of wort	Automated wort transfer
Lower equipment cost	Higher cost but more automated
More operator attention needed	Less labor for transfers
Simpler design and repairs	More integrated piping and controls

While 3-vessel systems involve more hands-on work to move wort between vessels, they provide low-cost access to commercial scale batches. 2-vessel automated brewhouses streamline the process with pumps and pipes transferring wort, but have higher equipment expenses.

The choice depends on your budget, batch frequency, and desired level of automation. Larger breweries may favor the hands-off nature of 2-vessel systems since they brew more often.

Figure: Example of a manual 3-vessel 5bbl beer brewing equipment

A typical 3-vessel brewhouse contains a mash tun, lauter tun, and kettle with manual transfers of wort between vessels.

Figure: Example of an automated 2-vessel brewhouse

A 2-vessel brewhouse condenses the mash and lauter tuns and uses pumps to automatically move wort between vessels.

5bbl Brewing System Specifications

When purchasing equipment, you’ll need to define tank sizes, material types, automation features, and spatial requirements. Use the following to guide your 5bbl system specifications.

Table: 5bbl beer brewing equipment

Vessel	Typical Size	Material Options
Mash tun	6-8 bbl	Stainless steel, copper
Lauter tun	6-8 bbl	Stainless steel, copper
Brew kettle	7-10 bbl	Stainless steel
Whirlpool	Integrated in kettle or separate 5-10 bbl tank	Stainless steel

• Mash tuns and lauter tuns are sized based on your target 5bbl batch size. Copper and stainless steel are common materials.
• The boil kettle should be slightly larger than the batch size. Stainless steel helps prevent reactions with wort.
• Whirlpools may be integrated into the boil kettle or use a separate tank for trub separation.

Table: 5bbl Brewhouse Automation & Controls

Automation & Control Options	Benefits
Digital temperature controls	Precise temperature management during mashing and boiling
Variable speed drives on pumps	Flexible control over wort transfers
Automated valves for transfers	Reduce labor with automated opening/closing of valves
Sensors for tank levels and densities	Provide monitoring and help control automated equipment
Touchscreen control panels	Allow recipe programming and control of brewing parameters

• Digital controls help dial in temperatures and maintain mash profiles. Variable frequency drives offer adjustable pump speeds.
• Automating valve opening/closing reduces the need for manual valve turning during transfers.
• Sensors add data for monitoring tank levels, wort densities, and help automate flows.
• Touchscreens give intuitive control and allow saving recipes. Look for easy to clean panels.

Table: 5bbl Brewhouse Sizing and Layout

Sizing and Layout Factors	Typical Dimensions
Height	7-12 ft ceilings to fit vessels
Floor space	Approx 400-600 sq ft
Service access	3-4 ft around tanks for cleaning and maintenance
Floor slope	Sloped floor with drains simplifies cleaning
Utilities	prophet/gas, water, drains located near vessels
Grain handling	Designate space for grain storage and milling

• A brewhouse will need high ceilings to accommodate tank heights. Expect to need 400-600 square feet.
• Leave clearance around tanks for cleaning and service access. Sloped floors simplify washdowns.
• Position utilities like steam, gas lines, water hoses, and drains near brewhouse vessels.
• Factor in space for grain storage and milling equipment. Mill should be near mash tun.

Table: Utilities and Installation Requirements

Utility/Installation Needs	Typical Specifications
Electrical	3 phase, 200-400A, 480VAC distribution panel
Plumbing	2-3″ water lines, drains, glycol cooling lines
Steam	7-10 bbl steam generator if needed
Compressed air	Air compressor and lines for pneumatics
Ventilation	Hoods over kettles, roof vents
Installation	Concrete foundation, floor coating
Commissioning	Supplier oversight of equipment calibration

• A 480V 3-phase electrical supply with 200-400A capacity is typical.
• Water, drains, and cooling lines should be 2-3″ diameter to suit pumps.
• Some systems use steam boilers or direct fire gas systems instead of steam generators.
• Air compressors and lines are needed if using pneumatic valves or actuators.
• Provide hoods and roof vents for brewhouse ventilation.
• Concrete foundations and chemical resistant floor coatings are common.
• Have the supplier commission and calibrate the system.

Fermentation Tanks for 5bbl beer brewing equipments

You’ll also need fermentation and bright tanks appropriately sized for your batch volumes and schedule.

Table: Fermentation Tank Options for 5bbl beer brewing equipments

Type	Specs	Benefits
Unitanks	Dual purpose fermenter and bright tank in one vessel	Compact footprint, flexible use
Separate tanks	Dedicated fermenters and brite tanks	Optimized for each purpose

• Unitanks combine fermentation and beer clarifying into one tank for efficiency.
• Some brewers use dedicated fermenters and bright tanks for optimal conditions in each.

Table: Fermentation Tank Sizing

Tank Volume	Use Case
3-5 bbl	Smaller than brewhouse batch size allows staggered fermentation cycles
7-10 bbl	Same as brewhouse size for synchronous fermentation
12-20 bbl	Larger tanks enable higher capacity and seasonal fluctuations

• Fermenters may be smaller than the brewhouse batch size to provide staging.
• Matching the brewhouse size synchronizes fermentation cycles.
• Larger tanks build in headroom for lagering or peak production periods.

Table: Fermentation Tank Specifications

Specification	Details
Material	Stainless steel for durability and sanitation
Jacketed	Glycol or steam jackets to control temperature
Agitators	Impellers or rousing arms for yeast suspension
Sensors	Density, pH, temperature sensors for monitoring
Controls	Automated temperature and agitation programming
Connections	Sample valves, manways, CIP sprayballs, glycol or steam inlets

• Stainless steel provides an impervious, sanitary surface for fermentation.
• Jacketing allows precise temperature control during fermentation.
• Agitators keep yeast in suspension and support healthy fermentation.
• Sensors help monitor ongoing fermentation progress.
• Automated controls dial in temperature profiles and agitation.
• Include sample ports, sprayballs, Temperature sensor connections.

Table: Fermentation Cellar Design Factors

Design Factor	Guidelines
Tank height	7-10 ft typical from cellar floor to top of tank
Spacing	2-3 ft between tanks and walls for access
Flooring	Sealed concrete or epoxy coating
Drainage	Sloped floor to drains
Cooling	Glycol chiller unit sized for tank volume
Ventilation	Air exchange rates appropriate for cellar design

• Allow for sufficient cellar height and spacing around tanks for access.
• Sealed concrete or epoxy floors simplify cleaning and drainage.
• Install glycol chiller systems for fermentation temperature control.
• Provide adequate air exchanges to control humidity and temperature.

Boiler Systems for 5bbl beer brewing equipment

The brewhouse boiler provides hot water and steam to heat wort to boiling and maintain mash temperatures.

Table: Boiler System Options for 5bbl Brewing

Type	Details	Benefits
Steam boiler	7-10 bbl firetube or coil boiler	Efficient, powerful steam supply
Gas-fired hot liquor tank	300-500 gallon indirect hot water tank	Compact, lower cost

• Steam boilers offer high energy steam but require more space and maintenance. Popular for repeated batches.
• Hot liquor tanks use direct gas firing for hot water with a smaller footprint but slower heating.

Table: Key Boiler Specifications

Parameter	Typical values
Steam boiler output	150-200 boiler HP
Hot water output	500,000-1 million BTU/hr
Steam pressure	Up to 15 psi maximum
Hot water temperature	Up to 195°F
Fuel source	Natural gas, propane

• Look for 150-200 boiler horsepower steam boilers or 500,000-1 million BTU gas hot liquor tanks.
• Steam pressure should reach around 15 psi maximum.
• Target 195°F hot water temperature for mashing.
• Fuel with natural gas or propane depending on availability.

Table: Boiler Installation Requirements

Item	Considerations
Ventilation	Stainless steel flue sized for boiler capacity
Gas supply	1-2″ gas line with sufficient BTU capacity
Water	Feedwater treatment system to condition water
Controls	Automated blowdown valves, level sensors
Location	Within 50 ft of brewhouse

• Stainless steel flue should remove exhaust and sized for boiler CFM capacity.
• Ensure gas line sizing suits the boiler BTU rating.
• Treat feedwater to remove minerals and prolong boiler life.
• Automate blowdown and monitor water level.
• Position near the brewhouse for efficient steam distribution.

Additional Equipment for 5bbl beer brewing equipments

Supplement your core brewhouse, fermentation, and boiler equipment with these additional accessories and infrastructure.

Table: Cleaning and Sanitation Equipment

Item	Details
CIP skid	Tank and pump skid to deliver hot cleaning solutions from a central station
Sprayballs	Rotate to clean interior of tanks
Heat exchanger	Uses hot water or steam to sanitize solution before spraying tanks
Foamers	Applies foaming caustic and acid solutions to exterior of tanks

• A CIP skid pumps heated cleaning solutions from a central station to each tank.
• Sprayballs rotate to clean interiors. Exterior foamers cover outside surfaces.
• Heat exchangers ensure proper sanitizing solution temperatures.

Table: Additional Brewhouse Equipment

Item	Purpose
Grist case	Holds milled grain above mash tun
Grist hydrator	Wets grist before adding to mash tun to prevent dough balls
Mash paddle	Stirs mash to evenly hydrate grain particles
Grant	Collects wort from lauter tun before pumping to kettle
Whirlpool stand	Supports a whirlpool tank above the boil kettle

• Grist cases hold milled grain. Grist hydrators wet grist before mashing in.
• Mash paddles evenly mix grain and water. Grants collect wort between vessels.
• Whirlpool stands allow installing a whirlpool tank overhead.

Table: Fermentation Accessories

Item	Purpose
Glycol chiller	Cools glycol used in jackets to control fermentation temperature
Aeration stone	Oxygenates wort prior to pitching yeast
CO2 system	Carbons fermented beer and pushes it from tanks
Lees filter	Removes yeast and hop particles when transferring beer

• Glycol chillers provide fermentation temperature control.
• An aeration stone oxygenates wort to improve yeast health.
• Use CO2 to carbonate and transfer finished beer, and a lees filter to clarify.

Table: Infrastructure and Utilities

Item	Purpose
Grain handling	Receiving, milling, storing grain
Ingredient station	Scales and containers for weighing out hop additions
Chillers	Glycol or refrigerant-based system to provide process cooling
Water treatment	Filters and softeners to condition brewing liquor
Wastewater	Clarifier or filtration to remove solids before draining
Building insulation	Maintain stable brewing temperatures year-round

• Proper grain handling involves receiving, milling, and storing.
• Use scales to accurately weigh out hop additions.
• Install industrial chillers for wort cooling and glycol systems.
• Treat water to remove chlorine and minerals that affect brewing.
• Wastewater may need filtering to catch spent grains and trub.
• Insulate warehouse spaces to prevent temperature swings.

5bbl Brewing Equipment Suppliers

There is a wide range of equipment manufacturers and suppliers to choose from when purchasing 5bbl beer brewing equipments.

Table: Leading 5bbl beer brewing equipment Suppliers

Company	Locations	Product Lines
Specific Mechanical	Canada, USA	brewhouses, fermentation, steam boilers
JV Northwest	USA	brewhouses, fermentation, controls
Premier Stainless	USA	manual and automated brewhouses, tanks
Russell Hendrix	USA	brewhouses, tanks, steam systems
ABS Commercial	Italy, USA	brewhouses, fermentation, water treatment

• Specific Mechanical offers an end-to-end brewhouse, fermentation, and boiler product line made in North America.
• JV Northwest focuses on brewhouses and integrated control systems.
• Premier Stainless provides brewhouses from manual 3-vessel to automated options with fermentation.
• Russell Hendrix carries a range of brewhouses, tanks, and steam equipment made in the USA.
• ABS Commercial builds brewhouses and fermentation in Italy and the US with water treatment systems.

When requesting quotes, provide key parameters like batch size, degree of automation, number of fermentation tanks, utility requirements and budget. Get multiple bids to compare options.

Table: Estimated Cost Ranges for 5bbl beer brewing equipment

Equipment	Cost Range
3-vessel brewhouse	$50000 – $75000
2-vessel brewhouse	$40000 – $60000
Fermentation tanks	$3000 – $4000 bbl
Steam boiler	$4000 – $4500 installed
Grain handling and mill	$1500 – $3500
Glycol chiller	$3000 – $5000
TOTAL	Around $55000-$100000