9 Essential Brewhouse Equipment for Brewing Exceptional ...

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Introduction

In this article, we will explore the world of brewhouse equipment and its importance in the beer brewing process. Brewhouse equipment plays a crucial role in ensuring the quality, efficiency, and consistency of the brewing process. We will delve into the various types of brewhouse equipment, key considerations when choosing them, common features and accessories, as well as the benefits of investing in high-quality equipment. Additionally, we will discuss the maintenance and care required to prolong the lifespan of brewhouse equipment. So let&#;s raise our glasses and dive into the world of brewhouse equipment.

What is Brewhouse Equipment?

Before we dive into the intricacies of brewhouse equipment, let&#;s first understand what it entails. Brewhouse equipment refers to the set of machinery and vessels used in the beer brewing process. It includes equipment like mash tuns, brew kettles, fermenters, and more. These components work together to convert raw ingredients into the wort, which is then fermented to produce beer. The quality and functionality of brewhouse equipment have a significant impact on the overall brewing process and the final product.

Types of Brewhouse Equipment

Mash Tun

The mash tun is a crucial component of the brewhouse equipment. It is responsible for the mashing process, where the grains are mixed with hot water to extract sugars and other soluble components. The mash tun provides an ideal environment for enzymatic activity, converting starches into fermentable sugars. It typically features a false bottom or a perforated plate to separate the liquid wort from the spent grains.

Brew Kettle

The brew kettle, also known as the boiling kettle, is where the wort is boiled and hops are added for flavor, aroma, and bitterness. It is equipped with heating elements or steam jackets to achieve and maintain the desired temperature. The brew kettle also includes features like whirlpool ports and tangential inlets to aid in the separation of trub and hop particles.

Hot Liquor Tank

The hot liquor tank (HLT) holds hot water that is used for various purposes during the brewing process. It provides hot water for mashing, sparging, and cleaning. The HLT is typically equipped with temperature control systems and heating elements to ensure consistent and precise water temperatures.

Wort Chiller

The wort chiller is responsible for rapidly cooling the boiled wort to the desired fermentation temperature. It is crucial to cool the wort quickly to prevent unwanted microbial growth. There are various types of wort chillers, including immersion chillers, plate heat exchangers, and counterflow chillers, each offering different cooling efficiencies and methods.

Fermenters

Fermenters are vessels where the cooled wort is transferred for fermentation. They provide a controlled environment for yeast to convert sugars into alcohol and produce carbon dioxide. Fermenters come in various sizes and configurations, ranging from traditional open-top fermenters to modern conical fermenters, which offer better yeast sedimentation and ease of collection.

Bright Tank

The bright tank is the final vessel in the brewing process before packaging. It is used for conditioning, carbonating, and clarifying the beer. Bright tanks are often equipped with pressure and temperature control systems to achieve optimal carbonation levels and maintain beer freshness.

CIP System

The CIP (Clean-In-Place) system is an integral part of brewhouse equipment. It allows for efficient and automated cleaning and sanitization of brewing vessels and piping systems. The CIP system saves time and ensures proper hygiene, reducing the risk of contamination and off-flavors in the beer.

Key Considerations when Choosing Brewhouse Equipment

Choosing the right brewhouse equipment is crucial for breweries of all sizes. Several key considerations should be taken into account during the selection process.

Brewery Size and Production Capacity

The size of your brewery and desired production capacity will determine the scale of brewhouse equipment needed. Whether you are a small craft brewery or a large-scale production facility, the equipment should align with your brewing goals and output requirements.

Budget and Cost Efficiency

Budget considerations play a significant role in equipment selection. It&#;s essential to strike a balance between upfront investment and long-term cost efficiency. While it may be tempting to opt for cheaper options, investing in high-quality equipment can lead to long-term savings through improved performance and durability.

Quality and Durability

The quality and durability of brewhouse equipment are paramount. Brewing is a demanding process, and equipment should be able to withstand the rigors of repeated use and cleaning. Choosing reputable manufacturers and suppliers known for their quality craftsmanship is essential.

Brewing Process and Efficiency

Efficiency in the brewing process can save time, energy, and resources. Consider equipment features that promote efficiency, such as automated controls, heat recovery systems, and precise temperature and flow rate regulation.

Customization Options

Every brewery has unique requirements and processes. Look for equipment manufacturers that offer customization options to tailor the brewhouse equipment to your specific needs. This can include modifications to vessel sizes, control systems, and additional accessories.

Common Features and Accessories of Brewhouse Equipment

Brewhouse equipment often incorporates several common features and accessories to enhance functionality, efficiency, and safety.

Control Systems

Control systems are essential for maintaining precise and consistent process parameters such as temperature, pressure, and flow rate. Modern brewhouse equipment is equipped with advanced control systems that allow brewers to monitor and adjust these parameters with ease, ensuring optimal brewing conditions and quality.

Heating and Cooling Options

Brewhouse equipment may offer various heating and cooling options to meet the specific needs of the brewing process. This can include electric heating elements, steam jackets, or direct-fire burners for heating, as well as glycol jackets or recirculation systems for cooling. Having flexible heating and cooling options enables brewers to have better control over the temperature at each stage of the brewing process.

Safety Features

Safety is of utmost importance in any brewing operation. Brewhouse equipment is designed with safety features such as pressure relief valves, emergency shut-off switches, and alarm systems to ensure a safe working environment for brewers and minimize the risk of accidents or equipment damage.

Cleaning and Maintenance

Efficient cleaning and maintenance processes are vital to keep brewhouse equipment in optimal condition. Many equipment manufacturers provide features such as easy access to internal components, removable fittings, and automated cleaning systems to streamline the cleaning and maintenance tasks, saving time and effort for brewers.

Automation and Integration

Automation plays a significant role in modern brewhouse equipment. Automated processes, such as mash temperature control, wort transfer, and CIP cycles, improve efficiency, reduce human error, and allow brewers to focus on other critical tasks. Integration capabilities with brewing software and data logging systems enable brewers to gather and analyze brewing data for process optimization and quality control.

Benefits of Investing in High-Quality Brewhouse Equipment

Investing in high-quality brewhouse equipment offers numerous benefits for breweries, regardless of their size or production volume.

Consistent Brewing Results

High-quality equipment ensures consistent brewing results from batch to batch. Precise temperature control, efficient heating and cooling mechanisms, and accurate process parameters contribute to consistent flavors, aromas, and quality in the final beer product.

Are you interested in learning more about commercial brewing equipment for sale? Contact us today to secure an expert consultation!

Time and Labor Savings

Efficient brewhouse equipment saves time and labor throughout the brewing process. Automated controls, streamlined workflows, and optimized cleaning systems reduce manual intervention and repetitive tasks, allowing brewers to focus on creativity, recipe development, and quality assurance.

Improved Efficiency and Productivity

Well-designed brewhouse equipment improves overall brewing efficiency and productivity. Features like heat recovery systems, automated mash-in and lautering, and advanced wort chilling methods help optimize energy usage, shorten brewing cycles, and increase the number of batches produced within a given timeframe.

Enhanced Beer Quality

Investing in high-quality equipment directly contributes to the overall quality of the beer produced. Precise temperature control during mashing and fermentation, efficient boiling and hop utilization, and effective yeast management systems all result in beers with better clarity, flavor, and stability.

Scalability and Growth Opportunities

High-quality brewhouse equipment provides scalability and growth opportunities for breweries. As production demands increase, equipment with larger capacities or modular designs allows for expansion without significant disruptions to existing operations. The ability to upgrade or add additional vessels and accessories ensures that the brewhouse can adapt to changing market demands and business growth.

Maintenance and Care of Brewhouse Equipment

Proper maintenance and care are essential for extending the lifespan of brewhouse equipment and maximizing its performance. Here are some key considerations for maintaining brewhouse equipment:

Regular Cleaning and Sanitization

Regular and thorough cleaning and sanitization are crucial to prevent microbial contamination and off-flavors in the beer. Establish a cleaning schedule and follow industry best practices for cleaning agents, procedures, and CIP systems to ensure optimal cleanliness and hygiene.

Preventive Maintenance

Implement a preventive maintenance program for brewhouse equipment. This includes routine inspections, lubrication of moving parts, calibration of sensors, and proactive replacement of worn-out components. Regular maintenance helps identify and address potential issues before they become major problems, reducing downtime and costly repairs.

Troubleshooting and Repairs

Inevitably, brewhouse equipment may encounter issues or breakdowns. Develop troubleshooting protocols and have spare parts readily available to minimize downtime. In cases where repairs are needed, consult with equipment manufacturers or qualified technicians to ensure proper and timely resolution.

Equipment Upgrades and Modifications

As technology advances and brewing processes evolve, consider equipment upgrades and modifications to stay competitive and enhance brewing capabilities. Upgrading control systems, integrating automation features, or retrofitting vessels with additional functionalities can improve efficiency, productivity, and quality.

Conclusion

Brewhouse equipment plays a crucial role in the brewing process, impacting the quality, consistency, and efficiency of beer production. Choosing the right equipment, considering key factors such as brewery size, budget, and customization options, is essential for success. High-quality equipment offers benefits like consistent brewing results, time and labor savings, improved efficiency and productivity, enhanced beer quality, and scalability for future growth. Proper maintenance, regular cleaning, and proactive care are vital to prolonging equipment lifespan and ensuring optimal performance. By investing in reliable brewhouse equipment and maintaining it properly, breweries can continue to craft exceptional beers and thrive in the competitive brewing industry.

FAQs

Q: Can brewhouse equipment be customized to fit specific brewery needs?

A: Yes, many equipment manufacturers offer customization options to tailor brewhouse equipment according to specific brewery requirements. This includes modifications to vessel sizes, control systems, and additional accessories.

Q: How often should brewhouse equipment be cleaned and sanitized?

A: Brewhouse equipment should be regularly cleaned and sanitized according to a predetermined schedule. The frequency depends on usage and the specific requirements of the brewing process.

Q: What are some common safety features in brewhouse equipment?

A: Common safety features in brewhouse equipment include pressure relief valves, emergency shut-off switches, alarm systems, and safety interlocks to ensure a safe working environment for brewers.

Q: How can brewhouse equipment improve brewing efficiency?

A: Brewhouse equipment can improve brewing efficiency through features like automated controls, heat recovery systems, optimized workflows, and precise temperature regulation, reducing energy consumption and shortening brewing cycles.

Q: What are the advantages of investing in high-quality brewhouse equipment?

A: Investing in high-quality brewhouse equipment leads to consistent brewing results, time and labor savings, improved efficiency and productivity, enhanced beer quality, and scalability for future growth opportunities.

We researched brewing equipment for about two years before placing an order. There are so many factors to consider such as size, number of vessels, type of heat source, cooling the wort, as well as country of manufacturing and engineering origin.

Here&#;s a summary of the main issues that were considered and our approach to a solution.

Vessels needed for brewing

Commercial brewing requires several different types of big vessels made of stainless steel. First, the water gets heated in a dedicated vessel called the Hot Liquor Tank (&#;liquor&#; is referring to the technical term for any liquid used in a process of some kind, not the liquid that gets you drunk). The hot water is then transferred to a vessel known as the Mash/Lauter Tun where it saturates milled grain to extract the delicious sugars and flavors.

Example of a hot liquor tank.

After a little while, the carbohydrate-rich water is transferred to the Boil Kettle right next to the mash tun where it is brought to boiling temperature by a direct gas-fired burner, indirect gas-fired burner, steam, or electric elements. Hops (and other special ingredients depending on the recipe) are added during the boil. Once that is completed, the boil kettle becomes a Whirlpool, forcing the water into a vortex that separates it from the larger particles in the solution (like large clusters of hops).

The Boil Kettle/Whirlpool and the Mash/Lauter Tun are usually right next to each other with a platform and stairs between them so the brewer can visually monitor the process and add ingredients. Collectively, they&#;re referred to as the Brewhouse. As breweries expand (reach the limit of beer that can be produced from the brewhouse in a 24 hour period), they will often add a third vessel for a dedicated whirlpool (and then a fourth vessel for dedicated lauter). This increases the churn rate and increases labor efficiency so more beer can be produced each day.

Example of a brewhouse comprised of a Mash/Lauter tun, platform, and brew kettle.

The hot liquid is then cooled and transferred to a Fermenting Vessel where yeast is added and the magic of transforming sugars to alcohol begins for several days to a few weeks. Then the fermentation process is stopped and beer is transferred to a Brite Tank where it is cooled even further to allow remaining particles in the beer to fall to the bottom of the tank. Once finished, the beer can be kegged or bottled/canned for serving.

Sizing Considerations

Most start-up microbreweries size their brewhouse at 10-30 barrels (1 barrel = 31.5 gallons = 2 big kegs = 240 pints of beer) and have equivalent-sized fermenter/brite tanks.

Sizing the brewhouse is a balancing act for a new brewery that can&#;t be sure of sales and growth. Starting too big will place a strain on initial expenditures as well as make a bad batch of beer a costly mistake. Starting too small will make it difficult to catch up with demand and increases the cost of ingredients per batch since smaller systems utilize hops at lower efficiency. Many brewers will tell you that doubling the size of your system is much less than double the cost. This is usually true, however, that alone is not a good reason for buying a bigger system.

Consider the amount of physical space available in the brewery. If there isn&#;t much room to add additional fermenting and brite tanks in the future, starting with a large brewing system isn&#;t wise. It&#;s also important to consider the clear height of the ceiling compared to the diagonal height of the fermenting/brite vessels. These are the tallest vessels. Unless your space has a tall dock door, these tanks need adequate ceiling height to be tilted up to standing within the space. Large breweries will often create an opening in the ceiling to drop in these tanks.

Consider starting with a smaller brewhouse with room to add a dedicated whirlpool in the future. Then size the fermenters/brite tanks at double the size of the brewhouse. The tanks can be half filled when business is slow and filled completely with double batches from the brewhouse when demand increases. This allows the brewery to double their capacity with only about 30% higher initial cost compared to having to purchase additional tanks (which would be 100% additional cost).

Number of Vessels

A general rule of thumb is to purchase the number of fermenters and brite tanks needed to take you through the first 2-3 years of production. You can calculate the approximate maximum annual capacity of a fermenter using these metrics:

Daily fermenting volume available = # vessels * volume of vessel

Turns per year = # of brew days per year / days to ferment average beer

Annual capacity = fermenting volume * turns per year

A way to simplify this is to assume 80% ale production (shorter fermentation time), 20% lager production (longer fermentation time) and 50 weeks of brewing (assumes some vacation and/or maintenance time):

Annual capacity = fermenting volume * 42

This also assumes that you have sufficient number of brite tanks to rotate beers this quickly.

If you plan to have a lot of different beers on tap at any given time, consider starting with the same ratio of brite to fermenting vessels.

Brewhouse Heat Source

There are three heat sources for the hot liquor tank and brew kettle:

• Direct FireA flame heats the exterior of the tank which transfers heat to the liquid in the tank.
  • Pros: least expensive; best option for small systems
  • Cons: a concentrated area of heat that can scorch the wort;  inefficient energy utilization (heat lost to surrounding air); not for use on systems larger than 10 barrels
• Indirect FireA relatively new method where flame heats air in a separate burner box that is then circulated throughout a jacket around the tank.
  • Pros: priced similar to direct fire; no scorching
  • Cons: not as efficient as electric or steam; not for use on systems larger than 10 barrels
• ElectricLarge heating elements are placed inside the kettle just like a residential electric water heater.
  • Pros: less expensive than steam; very efficient energy utilization
  • Cons: electricity sometimes more expensive than gas; needs 3-phase heavy power; not for use on systems larger than 10 barrels
• SteamThis is the industry standard for brewing systems sized 15 barrels and up. A separate boiler heats water with gas flame to create steam that is circulated through an insulated steel jacket around the kettle.
  • Pros: fairly efficient; heats quickly
  • Cons: most expensive; requires separate costly boiler; boiler maintenance

Choosing a Supplier

There are many suppliers of brewing vessels, especially given the boom of new breweries within the last decade. But most suppliers do not actually manufacture the vessels themselves. Rather, they are typically imported from manufacturers in China or other countries. While this can keep costs down for customers, the quality of the design, materials, and build varies wildly.

If you do end up choosing a supplier that imports equipment, pick one that uses US-based engineers to design the equipment. Remember that importing from overseas adds significant shipping charges, often about 10% of the cost of the equipment itself. The wait time for delivery is also longer.

Verify that any foreign-built equipment has electrical components that are rated for your country along with design specifications in English.

The brewing industry typically places the most value on domestically designed and manufactured vessels. The US tends to have higher standards for the quality of steel used in food-grade equipment and the build tends to be better. This of course comes at a higher cost, but may be made up with saving more from shipping.

For any supplier, it&#;s very important to check their references. Ask for a list of their customers and contact them personally to inquire:

• What was ordered
• Quality of equipment received
• Any delays
• Issues encountered and how supplier responded
• Whether they would order from the supplier again
• If they recommend this supplier

Our Approach

We decided on a 10 barrel indirect fire brewhouse for the following reasons:

• Indirect fire provided the benefits of even heating like steam does but without the cost and maintenance of a boiler.
• We didn&#;t want a boiler so that limits us to brewhouse sizes of less than 15 barrels
• Significant reduction in overall equipment costs compared to larger systems but still big enough to produce beer for distribution (compared to systems smaller than 10 barrels)

Since our business plan calls for a heavy taproom focus initially, we need enough brite tanks to allow for more different styles of beer we are planning to produce. So we ordered tanks in a 1:1 ratio &#; 3 brite tanks and 3 fermenters. These are all sized at 20 barrels to allow for eventually double batching to increase production capacity without having to add more tanks. If you do this, make sure the supplier adjusts the glycol jacket around the vessel. Since glycol jackets are normally only around the upper half of the vessel, they won&#;t adequately cool a tank that is only half full.

We selected Rocky Mountain Vessels, a US-based supplier that designs and manufactures vessels at their Colorado location. In addition, the steel is sourced domestically. Can&#;t get much better than that. We&#;re looking forward to delivery sometime this June, !