May. 20, 2024
Machinery
Beer production equipment encompasses a wide range of machinery used in the process of brewing and fermenting malts into alcoholic beverages. This specialized equipment plays crucial roles, from milling and mashing to packaging. Whether you’re running a small craft brewery or a large commercial brewery, understanding the essential equipment needed is vital for efficient production and quality control.
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The typical beer production process involves multiple steps, including:
The main equipment involved includes:
Additional equipment like pumping systems, piping, control panels, cleaning systems and conveyors connect the process.
The table below summarizes the key equipment:
| Equipment | Description |
|---|---|
| Milling Machines | Hammer or roller mills break malt grains into grist for mashing. Determine extract efficiency. |
| Mash Tun | Mixes grist with hot liquor for starch conversion. Sets wort composition. |
| Lauter Tun | Separates wort from spent grains through sieves/strainers. Impacts wort clarity. |
| Brew Kettle | Boils wort with hops for sterilization, extraction and bitterness. Defines style. |
| Whirlpool | Settles hop trub and coagulants via centrifugal force. Necessary for clear wort. |
| Heat Exchanger | Rapidly cools boiling wort to fermentation temperature. Prevents contamination. |
| Fermentation Tanks | Yeast converts sugars into alcohol anaerobically. Stainless steel preferred. Control temperature. |
| Beer Storage Tanks | Ages beer post-fermentation. BBTs clean up beer pre-packaging via filters/stabilizers. |
| Beer Filter | Clarifies final beer, increases shelf life by removing yeast etc. Various depth filtration options. |
| Filler/Packager | Kegging, bottling, canning systems to retail packaging. Care for oxygen pickup, sterility. |
The typical industrial brewing process involves:
Malt grains are milled into grist by hammer or roller mills, then mixed with heated water. The degree of milling impacts extract potential via husk shearing and kernel crushing. Well-modified malt needs less disruption. Standard cast rollers can handle 1000kg/hr.
Grist and water, known as mash, are mixed thoroughly in the mash tun to activate enzymes, convert starches and extract soluble sugars. Insulated stainless steel tuns have separate temperature controls and agitators. Up to 20:1 liquor-to-grist ratio. 1 to 2 hour process.
Sweet wort is separated from spent grain residue in a lauter tun or within the mash tun in brew-in-a-basket systems. Shallow rakes facilitate extraction through grain bed filters. 90 to 120 mins.
The wort is boiled vigorously with hops in the brewkettle. Copper heating jackets or direct steam injection. 1 to 2 hour process extracts hop resins, precipitates proteins, sterilizes and condenses wort. Sets style.
Hop debris and coagulants settle out in a whirlpool tank following boiling. 30 minutes settling before wort cooling.
Heat exchangers rapidly cool boiled wort to fermentation temperatures, while maintaining sterility. 80°C to 12°C within plate heat exchangers.
Yeast is pitched into cooled wort in fermenters to metabolize sugars into alcohol. Temperature-controlled stainless steel vessels from 300L to 3000+L based on batch size. Lagering follows for flavor development.
Clarifies beer of residual yeast etc. prior to packaging. Depth, sheet and sterile membrane filtration options with variables pore sizes. Sterile buffer tanks store filtered beer pre-filler.
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Carbon dioxide gas dissolves into beer to carbonate, before kegging, canning or bottling lines package beer. Fully automated filling at high cleanliness standards. Various labeling, sealing and casing systems.
Commercial beer production requires equipment with capacities matched to business scale:
| Yearly barrel production | Batch size (bbl) | Vessels (HL) |
|---|---|---|
| 1,000 – 10,000 | 15 – 30 | Fermenters: 300 – 1,500 |
| 10,000 – 25,000 | 30 – 60 | Fermenters: 1,500 – 3,000 |
| 25,000 – 50,000 | 60 – 120 | Fermenters: Up to 20,000 |
| 50,000+ | 120+ | Mega tanks up to 30,000+ |
Sufficient lautering, mashing, boiling and whirlpool capacity must support batch sizes, along with enough horizontal/vertical storage tanks for fermenting, aging and filtering processes. Filler capacity and packaging line throughput must also align.
Space planning is critical – height for tanks, floorspace for mills and fillers, plant layout that allows smooth workflow and cleaning access. Gravity instead of pumping between steps saves costs.
Key factors in production equipment selection, plant design and factory planning:
Working closely with equipment vendors and specialists lets craft brewers customize the brewhouse design and factory layout to meet niche requirements within budget constraints. Pilot systems help provide manufacturing data.
Modular configurations give flexibility to modify pieces independently – for example starting with a manual mill + mash filter then upgrading to an automated inline mill, mash mixer and lauter tun.
There is a diverse beer equipment supplier ecosystem catering to commercial breweries. Below is a sampling of established vendors and typical price ranges:
| Category | Supplier Examples | Turnkey System Price Range |
|---|---|---|
| Integrated, Medium | Specific Mechanical Systems, Craftwerk, Brewmation | $250,000 to $2 million |
| Integrated, Large | AB Mauri, Garhy, Ziemann Group | $2 million to $10+ million |
| Tanks | DME, Newlands, Glycol King | $5,000 to $500,000 each |
| Mills | Bühler Group | $25,000 to $250,000 |
| Brewhouses | JVNW, Marks Design, Nxicorp | $100,000 to $1 million |
| Filler/Packagers | KHS, Krones, Alfa Laval | $100,000 to $2 million |
| Lab Equipment | Anton Paar, Orbis | $2,000 to $100,000+ |
Pricing varies based on quality, customization, ancillary equipment/controls needed for a complete system and after-sales support offered. Local equipment reps provide quotes for configured solutions. Proposals detail pricing structure – equipment costs, install charges, shipping/duties, etc.
Equipment commissioning checks assembly, utilities, controls and trial batches ensure smooth handoff. Operator training is key before launch. Proper SOP documentation and maintenance keeps optimal performance for years.
For more information, please visit commercial brewing equipment manufacturer.
Flooring/foundations per specs, assembly support, safety checks
Short trial runs check valves, switches, measurements etc.
Equipment vendor provides operator onboarding on procedures
Standard operating procedures manual covers usage guidelines
Daily/weekly inspection and cleaning
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