Overview of Commercial Micro Brewing Equipment
The equipment needed for a commercial micro brewery can vary greatly depending on the size and scale of operations. This guide covers the essential equipment for a small to medium craft brewery producing anywhere from 1 to 10,000 barrels annually. We will explore the key components and systems for mashing, lautering, boiling, fermenting, filtering, and packaging beer.
Core Equipment Needed for Commercial Micro Brewing
The core brewing equipment for a micro brewery includes:
| Equipment | Description |
|---|---|
| Mashing tun | Mixes crushed malt with hot water to extract sugars and convert starches into fermentable sugars. Often dual-purpose as the lauter tun. |
| Lauter tun | Separates liquid wort from spent grain through sparging. Can be combined with mash tun. |
| Brew kettle | Boils wort with hops to impart flavor, aroma, bitterness and preserve the beer. Often called the brewing copper. |
| Whirlpool | Settles out proteins, hops and coagulated matter after boiling. |
| Fermenter | Converts sugar into alcohol and carbon dioxide. Usually stainless steel or plastic temperature-controlled tanks. |
| Brite tank | Allows freshly fermented beer to settle, clarify and carbonate. Also called uni-tanks or serving tanks. |
| Filter | Removes yeast, haze particles and sediments for clearer beer. Plate & frame or centrifuge filters are common. |
| Bottler/Canning Line | Fills bottles/cans with beer, crowns and labels them. Requires fillers, crowners, labelers. |
| Kegging Line | Cleans, sanitizes and fills kegs. Needs a keg washer, filler and seamer. |
| Pipes and Pumps | Transfers liquids between vessels and systems. Variable speed centrifugal pumps are typical. |
| Control Panel | Automates temperatures and tank processes. Can be simple or PLC/computer-based. |
This core equipment allows for mashing, lautering, boiling, fermenting, filtering, and packaging beer in kegs, bottles or cans. Additional equipment may be needed for cleaning, milling, water treatment, quality control lab, cold liquor tank, yeast propagation, dry hopping, blending, etc. The scale and degree of automation distinguishes micro breweries from homebrewing and full-scale industrial brewing.
Key Factors in Selecting Commercial Brewing Equipment
Some key considerations when choosing commercial micro brewing equipment include:
- Production Volume – Match equipment batch and fermentation sizes and throughput to annual barrelage goals. Scale up incrementally.
- Product Variety – More styles and specialty beers require more tanks for yeast handling and fermentation flexibility.
- Growth Plans – Allow room to expand systems and capacity. Modular equipment is easier to add onto.
- Budget – Buy quality equipment that meets needs without overspending on unnecessary features. Prioritize investments.
- Quality and Reliability – Choose reputable equipment brands known for durability, safety and performance.
- Automation – Determine degree of manual versus automated control needed for labor savings and consistency.
- Installation Requirements – Factor in space, layout, utilities, power, drains, delivery access, etc.
- Service and Support – Vendor should have good documentation, training, service response times and parts availability.
Commercial Brewing Equipment Guide
This table provides an overview of the types of commercial brewing equipment available for micro breweries:
| Equipment | Types | Characteristics |
|---|---|---|
| Mash Tun | Single infusion
Multi-step infusion Decoction tun |
Sets mash thickness and temperature profile to activate enzymes and convert starches to fermentable sugars. May be combined with lauter tun or separate. |
| Lauter Tun | Grant design
Rake & frame design |
Uses rakes or sprays to separate sweet wort from spent grains. Plumbing below false bottom or external. Grant type combines mashing and lautering. |
| Brew Kettle | Direct fire
Steam jacketed Gas-fired |
The brewing copper boils wort to extract hop aromas, deactivate enzymes and sterilize. Sizes from 3-15 BBL are typical for micros. |
| Whirlpool | Internal or external | Settles out hops, proteins and break material after the boil using a gentle vortex. May be part of the brew kettle or standalone. |
| Fermenter | Cylindroconical
Open top Closed top |
Temperature-controlled stainless tanks where yeast ferments sugars into CO2 and alcohol. Sizes from 1-500 bbl. CCVs allow harvesting yeast. |
| Maturation | Cylindroconical
Uni-tanks |
Allows green beer to condition, clarify and naturally carbonate prior to packaging. Also called bright beer tanks. |
| Filter | Plate & frame
Centrifuge |
Removes yeast, hops and proteins for brighter, more stable beer. Plates press between media sheets. Centrifuges spin sediment out. |
| Bottle Filler | Counter-pressure
gravity |
Fills bottles by balancing CO2 pressure or through gravity flow. Inline operation. |
| Bottle Capper | Mechanical plunger
Magnetic rotor |
Places crown caps on bottles. Can handle twist-off caps as well. |
| Bottle Labeler | Self-adhesive
Hot glue |
Applies front and back labels to filled, capped bottles. Often integrated with fillers/cappers. |
| Can Filler | Counter-pressure
Volumetric |
Fills cans maintaining CO2 levels or by measured volume. Requires seamer integration. |
| Keg Washer | Manual
Automatic |
Cleans and sanitizes kegs before filling. Automated models have wash/rinse cycles. |
| Keg Filler | Counter-pressure
Isobaric |
Fills kegs with finished beer maintaining CO2 pressure or at equal pressure. |
| Keg Seamer | Manual
Automatic |
Attaches keg lids ensuring an airtight seal. Automated models integrate filling, purging and seaming. |
This covers the primary brewing, fermentation, filtration, and packaging equipment needed for commercial micro brewery operations from 1-10,000 bbl capacities. Equipment may be manual, semi-automated or fully automated in function.
Applications and Uses of Brewing Equipment
Commercial micro brewing equipment fulfills the following roles in beer production:
| Equipment | Main Uses and Applications |
|---|---|
| Mash Tun | Mixes crushed malt with hot water for saccharification
Provides temperature control for enzyme activity Allows specific mash thickness and infusion schedules |
| Lauter Tun | Separates sweet wort from spent grains
Sparges to rinse sugars from grains Clarifies wort through settling and filtration |
| Brew Kettle | Boils wort with hops for bitterness, flavor and aroma
Evaporates water to reach target original gravity Sterilizes wort to prevent contamination |
| Whirlpool | Settles out proteins, hop debris, break material
Forms trub cone for removing precipitates |
| Fermenter | Yeast ferments sugars into alcohol and carbon dioxide
Temperature control during primary fermentation Allows harvesting yeast then cleaning |
| Brite Tank | Settles yeast and clarify green beer
Carbonates beer naturally prior to packaging Storage buffer before filling |
| Filter | Removes yeast, hop particles and haze for brightness
Increases shelf stability by removing yeast |
| Filler | Fills package (bottle, can, keg) with finished beer
Maintains CO2 levels during filling |
| Capper/Seamer | Seals package after filling to maintain carbonation
Ensures packaged product integrity |
| Labeler | Applies branded labels for packaging identification
Provides product information to consumers |
Following proper brewing processes with this equipment ensures production of high quality beer from raw ingredients fermented, clarified, and packaged correctly.
Specifications and Design of Brewing Equipment
Technical specifications and design factors vary for different types of commercial brewing equipment:
| Equipment | Key Specifications and Design Factors |
|---|---|
| Mash Tun | Thickness ratio – 2.5-3.5 qt/bbl typical
Dimensions fit batch volumes Interior finishes – stainless or alloy steel Insulation types – steam, refrigerant, insulation panel Volume markings for mash control Rake agitators for stirring mash |
| Lauter Tun | False bottom design – slots or tubes
Grant inner and outer screens – perforated plates Underlet vs. external plumbing Rake design for clearing stuck mashes Sparge rings for uniform water distribution Wort collection system below screens |
| Brew Kettle | Height to diameter ratio – 1:1 to 2.5:1 typical
Direct fire or indirect steam heating Half barrel increments for volume markings Rotation speed and direction controls Wort aeration option |
| Fermenter | Aspect ratio 3:1 typical – height to diameter
Cooling sys – glycol, refrigerant, steam, water Pressure limits – 60psi for ales, over 100 psi for lagers Construction – stainless steel or specialty alloys Sanitary fittings – tri-clover, sanitary clamp |
| Brite Tank | Pressure ratings up to 150 psi
Stackable for smaller footprints Sloped bottoms toward outlet CIP sprayballs for cleaning in place Option for dry hopping attachments |
| Filter | Media – diatomaceous earth, membranes, crossflow
Filtration ratings – 0.5-1.0 micron typical Max pressure – 100 psi Sanitary fittings – tri-clover clamps Automatic backflush capabilities |
| Bottle Filler | 2-head to 12-head for output
Gravity fill or counterpressure fill options 304 stainless steel construction Height adjustable legs Flow meter and low-foam fill sensors |
| Can Filler | Fill nozzle assemblies
Seaming chuck rollers Purging valves Enclosed design with safety interlocks Touchscreen HMI interface |
Additional factors are cleanability, automation capability, durability, power and utility requirements, and compliance with applicable regulations and standards.
Commercial Brewing Equipment Standards and Regulations
Commercial brewing equipment in the United States must comply with the following standards and regulations:
| Standard/Regulation | Key Requirements and Guidance |
|---|---|
| ASME Pressure Vessel Code Section VIII | Design, fabrication, inspection and certification requirements for pressurized tanks and vessels. |
| NSF/ANSI Standards | Materials, design and construction requirements for food/beverage contact surfaces under NSF/ANSI 18 and 61. |
| OSHA General Duty Clause | Equipment cannot present recognized workplace hazards that can cause harm. |
| Tax and Trade Bureau (TTB) | Equipment surfaces, valves, fittings must not contaminate beer or leach hazardous substances per TTB regulations. |
| FDA Food Code | Construction requirements for food equipment as adopted by local jurisdictions. |
| Building and Electrical Codes | Equipment installation must comply with state and local building, mechanical, plumbing, fire and electrical codes. |
| Beer Purity Laws | Adherence to Germany’s Beer Purity Law or US FDA Standards of Identity for certain beer styles. |
Compliance ensures equipment safety, sanitation, reliability and proper functionality. Work with experienced brewery engineering firms who understand applicable regulations and design requirements.
Brewing Equipment Manufacturers and Suppliers
Reputable brewing equipment suppliers and manufacturers include:
| Company | Location | Specialties |
|---|---|---|
| JV Northwest | Canby, Oregon | Brewhouses, fermentation, brite tanks, filtration |
| Psycho Brew | Portland, Oregon | Manual and automatic keg lines, canning lines |
| Specific Mechanical | Victoria, British Columbia | Brewhouses, mash filters, wort boiling systems |
| Premier Stainless | Escondido, California | Fermentation, brite tanks, filtration, packaging |
| Craftwerk Brewing Systems | Lake Oswego, Oregon | Nano and micro brewhouses, fermentation, brite tanks |
| American Beer Equipment | Lincoln, California | Fermenters, brite tanks, kegging, canning lines |
| Delta Beverage Systems | Belmont, California | Labelers, bottle and can fillers, conveyors, packagers |
| Pro Refrigeration | Everett, Washington | Glycol chilling, fermentation, brite tanks, servers |
Shop around to compare prices and find the ideal systems for your specific brewery. Look for established vendors with proven equipment reliability and responsive technical support.
Commercial Micro Brewing Equipment Pricing
Equipment costs for a micro brewery producing 1,000 to 5,000 barrels annually may range around:
| Equipment | Price Range |
|---|---|
| 3-7 bbl brewhouse | $75,000 to $150,000 |
| 10-15 bbl fermenters | $8,000 to $12,000 each |
| 10-30 bbl brite tanks | $7,500 to $15,000 each |
| Centrifuge or plate filter | $20,000 to $50,000 |
| Manual bottle filler | $4,000 to $10,000 |
| Manual labeling machine | $2,500 to $7,000 |
| Semi-auto keg line | $7,500 to $15,000 |
| Glycol chiller 7-10HP | $8,000 to $12,000 |
| Piping, pumps, hardware | $5,000 to $10,000 |
| Control panels, automation | $10,000 to $25,000 |
Total equipment investment for a 1,000 to 5,000 bbl micro brewery may thus range from $150,000 to $500,000 or more depending on the degree of automation and purchased capabilities. Evaluate return on investment and payback period when budgeting.
Installation and Facility Requirements
Proper installation and facility provisions are needed for brewing equipment:
| Consideration | Installation Factors and Requirements |
|---|---|
| Space and Layout | Floorspace for equipment footprints plus clearance
Layout for material flow and operations Ceiling height for tall vessels Equipment grouping into brewhouse, cellar, packaging |
| Utilities | Electric power – 3 phase 480VAC typical
Water – brewing liquor supply lines Steam generation if needed Glycol supply and return lines CO2 lines |
| Drainage | Floor trenches and drains for cleaning
Sewer connections rated for volume Solids separation for waste slurry |
| Structural | Concrete pads rated for load
Flooring that withstands traffic and chemicals Walls and roofing for weather resistance |
| Ventilation | Hoods over kettles and vent streams
Climate control system capacity |
| Receiving/Delivery | Loading docks for equipment delivery access
Route into facility for large vessels |
| Fire Protection | Sprinkler systems for property protection
Chemical storage considerations |
Work closely with equipment vendors and specialists during design and construction to integrate systems appropriately. This ensures successful equipment installation and operation.
Standard Operating Procedures
Follow manufacturer instructions for proper commercial brewing equipment operation:
| Equipment | Standard Operating Procedure |
|---|---|
| Mash Tun | Check valves are closed before filling
Recirculate to eliminate dough balls Monitor temperature and pH Rake mash thoroughly if needed |
| Lauter Tun | Gradually start sparge water flow
Adjust rake speed to prevent sticking Monitor runnings clarity and adjust flowrate Stop before tannin extraction |
| Brew Kettle | Start heating once runnings are diverted
Add first hop addition at boil start Monitor boil rate and boil-over foam Add whirlfloc and mineral salts |
| Fermenter | Sanitize thoroughly before use
Aerate wort before pitching yeast Control temp profile during fermentation Check gravity daily at end |
| Brite Tank | Clean and sanitize prior to transfer
Chill beer to 30-40°F to settle yeast |
| Filter | Backflush between beer batches
Check pad/membrane condition Adjust flow rate and pressure differential |
| Bottle/Keg Filler | Clean filler parts and lines
Check CO2 pressure settings Monitor fill levels and foaming Ensure caps/lids applied properly |
Maintain logs for each batch with operational data. Follow all safety procedures per OSHA and company guidelines.
Maintenance and Cleaning
Routine maintenance and cleaning ensures longevity:
| Equipment | Maintenance and Cleaning |
|---|---|
| Pumps | Lubricate as specified by manufacturer
Rebuild/replace seals periodically |
| Valves | Inspect valve stems, seats and seals
Tighten packing nuts Replace worn out valve assemblies |
| Gaskets | Check for leaks indicating gasket wear
Replace compromised gaskets |
| Tanks | Inspect interior and exterior surfaces
Repair any dents or damage Replace insulation as needed |
| Sensors | Calibrate temperature and pressure sensors
Check cable connections Replace defective sensors |
| Cleaning | Clean tanks and lines with caustic then acid cleaners |
Choosing a Brewing Equipment Supplier
When selecting a brewing equipment supplier, consider:
| Factor | Guidance |
|---|---|
| Reputation and Experience | Choose an established supplier in business for 10+ years with proven systems. Ask for client references. |
| Product Quality | Look for high quality stainless steel and meticulous welds. Ask about materials and manufacturing. |
| Range of Equipment | Supplier should offer all major equipment types needed for brewhouse, cellar, and packaging. |
| Customization | Ability to modify standard equipment or custom fabricate tanks and systems for your needs. |
| Design Services | Engineering team that can help design and spec equipment tailored to your production goals. |
| Customer Support | Responsive technical support team for commissioning, training, and troubleshooting. |
| Installation Services | Capability to deliver and install equipment properly onsite with all needed utilities. |
| Local Representation | Sales and service location near your brewery is ideal for support and parts. |
| Parts Availability | Supplier should stock common replacement parts for quick repairs and service. |
| Documentation | Clear operating and maintenance manuals for equipment operation. |
| Compliance | Equipment certified to meet ASME, OSHA, NSF, TTB, FDA, and other regulations. |
Start dialogues with top suppliers early in your brewery planning process to find the right partner.
Comparing Brewing Equipment Manufacturers
When comparing equipment suppliers, assess:
| Company | Quality | Cost | Lead Time | Service |
|---|---|---|---|---|
| Supplier 1 | High grade stainless steel, meticulous welds | $$$ | 10-12 weeks | Knowledgeable support staff, located nationwide |
| Supplier 2 | More basic fabrication, some inconsistencies | $$ | 6-8 weeks | Limited experience with craft breweries |
| Supplier 3 | Top notch equipment, food/bev grade materials | $$$$ | 12-16 weeks | Excellent local service team and parts inventory |
Carefully weigh factors like quality, delivery, support capabilities, and total cost of ownership when selecting systems.
Advantages of Buying Turnkey Brewing Systems
The advantages of purchasing pre-engineered turnkey brewing systems include:
- Simplified purchasing with all equipment from one supplier
- Pre-tested, integrated systems with combined functionality
- Reduced engineering time and costs
- No dealing with separate vendors
- Streamlined installation with single point of contact
- Supplier manages construction and utility coordination
- Standardized training on full system operation
- Coordinated warranty and service for all components
- May qualify for lower pricing than piecing together
Turnkeys are ideal for less complex micro setups. For larger breweries or extensive customization, an assembled best-of-breed approach may be better.
Potential Drawbacks of Turnkey Brewery Systems
Some potential drawbacks of buying pre-packaged turnkey brewing systems:
- Less flexibility or customization options
- May still require separate purchases for peripherals
- Supplier may push their in-house equipment brands
- Could receive generic equipment rather than top models
- Less ability to optimize each equipment selection
- Additional costs if existing facility requires modifications
- Single vendor accountability if issues arise
- Upgrade limitations as you outgrow starter system
Weigh the pros and cons of turnkeys versus mix-and-match equipment purchasing strategies.
Key Differences Between Pilot and Production Brewing Systems
Pilot brewing systems differ from full production breweries in:
| Parameter | Pilot System | Production System |
|---|---|---|
| Batch Size | 1-3 BBL typical | 7+ BBL capacity |
| Brewhouse | Manual operation | More automated |
| Fermentation | Single vessels | Multiple dedicated tanks |
| Filtration | Benchtop scale | Full production filter |
| Packaging | Growlers, crowlers | Canning/bottling line |
| Utilities | residential scale | Industrial grade |
| Controls | Basic panels | Advanced automation |
| Cleaning | Manual CIP | Automated CIP |
| Materials | Stainless steel | Heavy duty stainless |
| Cost | $50K to $250K | $500K+ |
Pilot systems allow small test batch brewing for R&D. Production breweries are engineered for larger volume commercial manufacturing. Invest in pilot facilities first to refine recipes and processes.
Tips for Expanding Brewing Capacity
When upgrading equipment to expand brewing capacity:
- Gradually scale up fermenter and brewhouse sizes
- Add more fermentation and brite tanks
- Improve automation for labor savings
- Plan for utility, drainage, and space expansions
- Invest in higher output packaging equipment
- Upgrade glycol chilling capacity
- Improve QA/QC capabilities and lab equipment
- Expand grain handling and raw material storage
- Focus on improving quality and consistency first
- Carefully project sales volumes and growth rate
- Consider modular add-ons versus complete replacements
Conduct throughput analysis to identify capacity bottlenecks. Target strategic upgrades for the most constrained systems first.
FAQs
What are the typical price ranges for micro brewing equipment?
Equipment prices for a micro brewery producing 1,000 to 5,000 barrels annually may range from $150,000 to $500,000 or more depending on the level of automation.
What are the essential brewing equipment pieces needed?
The core equipment needed includes a mash tun, lauter tun, brew kettle, fermenters, brite tanks, filtration, and packaging equipment for kegging, bottling or canning. Additional equipment like a whirlpool, mill, chiller and lab equipment may supplement the basics.
What are the size requirements for a micro brewery?
A minimum of ~1,000 sq ft is needed, but 3,000+ sq ft is ideal. This provides sufficient space for brewhouse vessels, multiple fermenters and brite tanks, packaging lines, storage, and an office/lab area.
How much power is required to operate brewing equipment?
Total power needs vary greatly. A basic rule of thumb is around 1kW per barrel of annual capacity, so a 7 bbl brewery producing 1,000 barrels a year needs ~7kW. Provide flexible 3 phase electrical infrastructure.
What are the most important factors in selecting equipment?
Key factors include production goals, growth plans, budget, product variety, quality, reliability, automation needs, installation requirements, and vendor reputation and support capabilities.
Should I buy new or used equipment?
Buying new equipment from reputable suppliers generally provides the best quality assurance and warranty support. However, excellent deals on used equipment in good condition are possible from plant closures or upgrades. Carefully inspect used equipment first.
What standards apply to commercial brewing equipment in the US?
Key regulations include ASME Pressure Vessel Code for pressurized tanks, NSF/ANSI standards for food contact surfaces, OSHA general duty clause, TTB beverage equipment guidelines, FDA Food Code, and local building codes.