The Nano Brewing Process Step-by-Step

Now that we’ve covered planning and equipment selection, let’s overview the nano brewing process from start to finish:

Nano Brewery Process Overview

1. Milling – The whole malted grains are crushed lightly in the grain mill to expose starches.
2. Mashing – The crushed grains are steeped in hot water in the mash tun to convert starches to fermentable sugars.
3. Lautering – The sweet liquid wort is separated from the grain fibers using the lauter tun.
4. Boiling – The wort is boiled vigorously with hops for bitterness, flavor and aroma.
5. Cooling – The hot wort is rapidly cooled after the boil to prepare for fermentation.
6. Fermenting – Yeast is pitched into cooled wort in fermenters to begin alcohol production.
7. Conditioning – Beer is left to carbonate, clarify and mature in conditioning tanks.
8. Filtration – Final polishing to remove haze particles before packaging.
9. Packaging – Beer is put into kegs, cans or bottles for distribution.

While simple in concept, as a nano brewer you have ample opportunities to tweak recipes, hops, yeasts and techniques to craft your signature beer.

Let’s explore the equipment involved in each stage of the nano brewing process.

Milling

Milling is done using an industrial grain mill – either standalone or integrated into the brewhouse. Important factors when selecting a mill include:

• Motor horsepower – needs to grind 50+ pound grain bills without jamming
• Rollers – should have adjustable gap for desired crush
• Throughput – process 1-4 BBL batches within an hour
• Cleanup – easy to dismantle and clean to prevent mold or cross-contamination

Consider future production goals, automation needs, and fallback redundancy when investing in a grain mill.

Mashing and Lautering

The mash tun and lauter tun work together to convert starches and separate sweet wort – the unfermented beer liquid. On a nano scale, these are typically combined into a single tank with a false bottom and sparging system.

Key buying considerations for mash lauter combo tanks:

• Material – Stainless steel for easy cleaning
• Insulation – Maintains temp during multi-hour mashing
• False Bottom – Perforated or slotted plates prevent grain bed compaction
• Sparging – Showers hot water for optimal extraction

Integrated heating/cooling jackets and automated temperature control systems simplify the mashing process. Budget extra for these add-ons.

Allow at least 1.5x your max brew length for mash tun sizing – oversizing allows better mixing without stuck sparges.

Brew Kettles

Your brew kettle is the heart of the brewhouse – where sugary wort gets transformed into beer via hopping and boiling. For nano kettles, prioritize:

• Dimensions – 1-4 BBLbatches plus room for foam
• Aspect Ratio – wider than tall for evaporation area
• Construction – stainless with tri-clamp fittings
• Insulation – reduce heat loss for vigorous boils
• Automation – optional PID temp control

Kettles usually come with sight glasses, volume markings and whirlpool outlets standard. Consider extras like auto-fill valves, programmable control systems or casters for mobility.

Choose your nano brewhouse centerpiece kettle based on degree of automation needed, batch sizes, and expandability for future growth.

Heat Exchangers

A plate heat exchanger (PHE) or shell and tube heat exchanger rapidly cools boiling wort after the kettle to prepare yeast pitching temps. Key traits for nano heat exchangers:

• Cooling Power – reduce 205°F wort to 68°F quickly
• Flow Rate Matching – 1-4 BBL batches per hour
• Self-Cleaning – CIP compatible with easy disassembly
• Compact – fits smaller spaces with tight tolerances

Additional recirculation pumps help maximize cooling efficiency through the exchanger continuous pass after pass.

Choose heat exchangers with power and performance matched to your batch sizes and temperatures for fast, efficient wort chilling.

Fermentation and Conditioning

Beer begins its transformation from wort to alcohol during the weeks long fermentation and conditioning phases across primary, secondary and sometimes tertiary vessels:

Fermenter Trait Priorities:

• Volume – Typically double batch capacity for headspace
• Temperature Control – Consistent ale/lager profiles
• Material – Stainless or plastic for durability
• Geometry – Conical for clarification but cylindrical work too

Consider staggered fermentation schedules to keep a steady stream of new beer available.

Allow for both ales and lagers if planning both beer types. Leave space for extra conditioning tanks, brewing sours or experimentals.

Beer Serving and Packaging

Finishing equipment like bright beer tanks, filtration, and packaging equipment help prepare your beer for customers:

Serving and Packaging Considerations:

• Carbonation – Brite tanks to naturally carbonate beer before packaging
• Bottling/Canning – Filler equipment and labeling capabilities
• Kegging – Kegs, taps, lines and CO2 distribution
• Filtration – Final clarity polishing before packaging

Start with just kegging capacity matched to serving tanks before adding bottling, canning and distribution scale packaging capabilities.

Focus first on great beer – scaling packaging and distribution comes later!

And those are the basics of the standard nano brewing process equipment by stage from grain to glass!

Common Nano Brewery Equipment Upgrades

While the full spectrum of tanks cover the core functions, nano breweries often benefit from upgrades like:

• Steam Systems – Steam-jacketed kettles and heating
• Automation – Touchscreen programmable control panels
• Grain Handling – Conveyors, lifts and silos
• CIP Systems – Clean-in-place tank spray balls & pumps
• Ice Machines – Flakers for cold glycol systems
• CO2 Purification – Reclaim yeast-produced CO2
• Water Treatment – pH balancing, chlorine removal & mineral adjustment
• Lab Equipment – Microscopes, titration kits, testing gear

Prioritize upgrades delivering automation like programmable brewing control systems first. Grain handling, ice makers and CIP can wait until ready to scale. Testing equipment helps ensure quality and consistency.

Consider clubbing together with nearby nanos on expensive equipment like steam boilers and CO2 reclaim systems.

FAQ

What is a nano brewery?

A nano brewery is a very small-scale brewery that typically produces beer in batches of less than three barrels (90 gallons or 1080 pints).

What equipment is essential for a nano brewery?

Essential equipment includes a kettle, fermenters, mash tun, heat source, fermentation vessels, cooling system, pumps, hoses, and cleaning equipment.

How much space do I need for a nano brewery?

The space needed can vary, but a typical nano brewery might require around 200-500 square feet, depending on your specific equipment and layout.

How much does nano brewery equipment cost?

Costs can vary widely, but expect to invest at least $10,000 to $50,000 or more for basic equipment. High-quality or customized equipment can significantly increase costs.

Do I need a license to operate a nano brewery?

Yes, you will need federal, state, and often local permits and licenses to legally operate a nano brewery. These requirements can vary by location.

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