Brewhouse Setup: A Comprehensive Guide

Author: Franke

Nov. 04, 2024

Machinery

Table of Contents

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    Are you ready to embark on creating your own brewery but feel lost on the initial steps? You’re in the right place! This guide will provide you with an overview of the fundamental aspects of setting up a brewhouse—detailing various system configurations, necessary equipment, and key factors you must consider for establishing a successful brewing operation. So, grab a cold drink, relax, and let’s explore the intricacies of brewhouse setup!

    Types of Brewhouse Configurations

    One of the first and most crucial choices in establishing a brewhouse involves selecting the right brewing system configuration. The three predominant types are two-vessel, three-vessel, and four-vessel systems.

    Two-Vessel System

    This system consolidates the mash tun and lauter tun into one unit, while the boil kettle and whirlpool operate in a second vessel. It’s a suitable choice for small scale brewers or those constrained by space, as it demands less equipment and occupies a smaller footprint.

    Three-Vessel System

    Here, the mash tun, lauter tun, and boil kettle are distinct units, and the whirlpool function is integrated into the boil kettle. This setup allows for enhanced control over the brewing process, making it ideal for larger operations.

    Four-Vessel System

    A four-vessel system incorporates individual vessels for the mash tun, lauter tun, boil kettle, and whirlpool. This configuration offers the highest efficiency and control over brewing, making it perfect for larger breweries or those aiming to fully optimize their production process.

    Essential Brewhouse Equipment

    No matter which configuration you select, four key components are essential to a successful brewhouse setup.

    Mash Tun

    The mash tun initiates the brewing process by mixing crushed grains with heated water to create a mash, subsequently separated into wort and spent grains.

    Lauter Tun

    The lauter tun serves to segregate the wort from the spent grains. Through draining the wort onto a false bottom while rinsing the grains with hot water, it maximizes sugar extraction.

    Boil Kettle

    In the boil kettle, the wort is heated and boiled to sterilize it and infuse flavors from hops, a critical phase in developing the final beer's taste and aroma.

    Whirlpool

    Post-boiling, the whirlpool assists in scouring hop particles, proteins, and other solid matter from the wort by inducing a vortex, thereby centralizing the solids for easier transfer of clear wort to fermentation tanks.

    Additional Brewing Equipment

    Beyond the core brewhouse equipment, there are various additional tools that can enhance your brewing experience.

    Heat Exchanger

    A heat exchanger cools the wort promptly after boiling to avert off-flavors and encourage appropriate yeast activity during fermentation.

    Fermentation Tanks

    Fermentation tanks, often referred to as fermenters or unitanks, serve to mix the cooled wort with yeast, marking the beginning of fermentation. Available in several sizes and materials, stainless steel remains the most preferred.

    Pumps and Piping

    Effective pumps and piping systems are vital for moving liquids between vessels during brewing. Opting for high-quality pumps and thoughtfully designed piping will facilitate smooth operations while diminishing contamination risks.

    Brewhouse Automation and Control Systems

    Automation can greatly enhance the consistency and efficiency of your brewing process. Depending on your budget and expertise, these systems range from basic temperature controls to sophisticated automated solutions.

    Choosing the Right Brewhouse Size

    Your brewhouse's size will be influenced by various factors including production objectives, available space, and budget considerations. Begin by estimating your expected brewing capacity in barrels (BBL), and factor in anticipated growth when making this decision. Typically, investing in a slightly larger system would be wise to accommodate future expansion rather than swiftly outgrowing your brewhouse.

    Brewhouse Setup Costs

    The financial commitment to establish a brewhouse can be significant, affecting your plans based on size, equipment quality, and level of automation. Setup costs can fall anywhere from $100,000 to $1 million. Ongoing expenses, like maintenance, raw materials, and labor, should also be part of your consideration.

    First, the scale of your brewing endeavor greatly affects the cost. Larger systems require higher investments but can enhance your capacity as well. It is essential to strike a balance between financial limitations and production aspirations.

    Second, the quality of your equipment is critical. Although it may seem like a hefty upfront expense, investing in premium equipment often leads to reliable and sustained results, potentially saving costs on repairs and replacements over time.

    Further, your automation level will have considerable implications for your setup's costs. While basic control systems can be economical, advanced automation technology can command higher prices. Nevertheless, these systems can enhance efficiency and consistency, offsetting the initial investment over the long haul.

    Lastly, anticipate ongoing costs as a crucial part of your brewhouse budgeting process. Consistent maintenance, sourcing raw materials, and hiring skilled labor are ongoing expenses to take into account when estimating your brewhouse’s financial requirements.

    In conclusion, evaluate your needs comprehensively, explore various equipment solutions, and seek guidance from industry experts to make informed choices concerning your brewhouse setup costs.

    Tips for a Successful Brewhouse Setup

    1. Strategically plan your space, considering workflow, storage, and future growth.
    2. Prioritize acquiring high-quality equipment to guarantee dependable and consistent brewing outcomes.
    3. Engage with seasoned brewers and industry experts to gain insights and advice.
    4. Emphasize safety and sanitation to protect both your product and employees.
    5. Stay flexible and be ready to address unexpected challenges as you expand your brewery’s operations.

    Conclusion

    The journey of establishing a brewhouse can be complex but ultimately rewarding. With careful planning and focus on the essential elements—different brewhouse configurations, necessary equipment, automation, and sizing considerations—you are well on your way to crafting your first enticing batch of beer!

    Thank you for engaging with our guide on Brewhouse Setup. If you’re in the market for top-notch, durable, and user-friendly Brewhouse setups, we highly recommend products from Yolong Brewtech. Known for their excellent reputation, their products are time-tested for quality and reliability. For further information, explore our product page and browse our selection of brewing systems.

    The Brewing Equipment You Need to Open a Brewery

    When acquiring the essential equipment for your brewery, multiple factors require thoughtfulness. This guide outlines the fundamental components and discusses their various options.

    The brewery can essentially be divided into two main sections. The brewhouse, or 'hot side,' is the arena for completing initial brewing stages, including milling, mashing, boiling, and chilling the wort.

    The second section, known as the cellar or 'cold side,' is where fermentation, conditioning, dry-hopping, and all processes that transform wort into beer occur. Most brewery equipment will belong to one of these sections, with certain exceptions.

    Brewhouse (hot side) essentials

    The brewhouse consists of several heated vessels along with pumps for transporting the wort.

    Heat source

    The primary decision involves how you plan to heat your brewing vessels. The most common methods include:

    Steam
    Steam heated vessels are widely used and require a steam generator, which turns city water into steam, distributed through steam jackets fitted onto your vessels. Steam generators can be powered by natural gas, electricity, or diesel. A water softening system typically accompanies the generator, offering enhanced control over heating.

    Electricity
    Electric vessels usually use elements akin to those in household kettles. Available in diverse sizes and powers, the best variants contain 2 or 3 elements that toggle on and off, providing controllable heating options. Electric brewhouses have elements built-in and do not require extra equipment.

    Malt mill

    Necessary only if uncrushed malt is utilized. Look for models easily adjustable for different crush sizes. Models with two rollers suffice for most small breweries, but larger configurations are available. Depending on your space, you may also need a portable model, and suppliers usually indicate capacity in malt weight per hour.

    Hot Liquor/Water Tank (HLT)

    The HLT is where your brewing water, or liquor in British terms, is stored and heated. Optimal models include at least two heating elements, allowing you to begin heating with a partial water load. The HLT should be roughly double the capacity of your other vessels, ensuring enough liquid for strike water and cleaning.

    It must also include a pump linked to the mash tun and sparge system through a flowmeter, and CIP valves across the equipment. The pump’s design should allow for recirculation for accurate temperature readings and even blending when cleaning agents or sparge water are administered.

    Flowmeter

    The flowmeter accurately measures strike and sparge water, and must be heat-resistant and waterproof.

    Mash tun

    This component varies in type from simple open vessels to enclosed, heated designs with stirring capabilities. The more features incorporated, the higher the associated costs become. When output surpasses about 200 litres, it becomes challenging to mix the mash manually; therefore, consider heating options if incorporating step mashing.

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    Additional features may consist of a pump to shuttle the mash to the lauter tun, with desirable extras including recirculation for temperature uniformity along with an integrated temperature probe.

    Lauter tun

    The lauter tun has a filter to separate sweet wort from grains, coupled with a sparge ring linked to the HLT through the flowmeter. The ability to recirculate hot wort over the grain prior to transferring it to the boil kettle enhances clarity. There’s typically no heating requirement for the lauter tun, as it moves filtered hot wort directly into the boil kettle.

    A side-mounted door serves as a spent grain outlet for easy removal and disposal.

    Boil kettle

    A straightforward, heated vessel, optimal designs can begin heating wort with as little as 20 litres onboard, expediting the boiling process. Depending on available space, a condenser may be necessary to extract steam and other unwanted compounds from an enclosed boil kettle. Alternatively, if space permits, a flue leading outdoors is advisable.

    Whirlpool

    Although not mandatory depending on the beer you produce, whirlpool vessels can accommodate late hop additions and assist in dropping solids from suspension before transference to the heat exchanger.

    Heat exchanger

    The heat exchanger cools the boiling wort prior to its transition into the fermenting unit. The most prevalent in breweries is the plate heat exchanger (PHE), where beer flows through one side while cold water or glycol (or ice water) passes through the opposite side. It should include at least one thermometer at the beer outlet for temperature measurement.

    Different configurations are viable, the most common including hop filters before the PHE and yeast tanks and aeration systems after it. Sizes of heat exchangers vary, commonly calculated in square meters. As a general guideline, a 500 litre brewhouse necessitates no more than a 5 square meter PHE, whereas a 1,000 litre brewhouse pairs well with a 10 square meter unit. Warm city water is returned into the HLT after the heat exchanger to provide pre-warmed water, promoting energy savings.

    Combination vessels

    Typically, small breweries lack separate mash tun, lauter tun, boil kettle, and whirlpool vessels. Various combinations can maximize space efficiency; common pairings include:

    • Mash/lauter tun: utilizes the same vessel for mashing, lautering, and sparging, saving time and space. It requires heating if you practice step mashing.
    • Boil kettle/whirlpool: space-efficient and must feature two outlets, one for clear wort leading to the heat exchange and the other for emptying at brew’s close.
    • Mash/boil kettle: involves mashing, transferring mash to a separate lauter tun, and returning sweet wort to the original vessel for boiling to save space and facilitate step mashing. Ensure thorough grain removal before boiling.
    • All-in-one: an economical and space-efficient solution for small environments where all processes occur in a single vessel, typically utilizing a large basket to contain grains, lifted by winch and hoist. Models like Speidel’s Braumeister series cater to batches of up to 1,000 litres.

    Control panel

    Control panels exhibit diverse shapes and sizes, often employing simple PID systems for temperature monitoring and machinery operation. Alternatively, PLC systems boast touchscreen interfaces that manage comprehensive processes and permit automated procedures.

    The control panel may strictly handle brewhouse chores or also extend to chilling operations.

    Cellar (cold side) essentials

    In the cellar, you'll predominantly find fermentation and conditioning vessels.

    Fermenting vessels

    Selecting the fermenting vessel type mostly hinges on your target beer. Options range from simple open vessels to pressurized uni-tanks; many small breweries favor enclosed pressurized vessels due to their ability to facilitate natural carbonation and quicker turnaround times. However, if you aim for bottled conditioning, you may forgo the necessity of pressurized units.

    Size matters significantly, and diversity can be beneficial. For instance, possessing a combination of 500, 1,000, and 2,000 litre fermenters alongside a 1,000 litre brewhouse allows for batch splitting for experiments and producing larger quantities of core beers, though your approach may depend on your business strategy.

    Customization options abound for fermenting vessels, which may include dry hopping ports, carbonation stones, racking arms, and spunding valves. Standard vessels usually include temperature probes, CIP spray balls, and sample valves.

    Conditioning tanks

    While not mandatory for every brewery, conditioning tanks can indeed offer valuable additions. Bright beer tanks (BBTs) primarily serve to clarify or age beers like lagers; they can also facilitate carbonation. Available in vertical or horizontal designs, various formats exist.

    Glycol/Ice water tank

    Breweries commonly employ cooling agents to sustain fermentation temperatures and cold-crash their beers, with glycol being the most popular, stored in sizable tanks and circulated through jackets within fermentation vessels.

    If utilizing a glycol tank, you will need to incorporate a distinct pump for the system, automatic solenoid valves on fermentation vessels, a control panel, and industrial chillers to manage the glycol. The glycol should also circulate through the PHE to aid in wort chilling.

    Cold-side control panel

    This panel manages temperatures within fermenting vessels and oversees cold crashing, similar in design to brewhouse control panels. They can vary significantly based on the number of temperature controllers and may range from 2 to 8 or more.

    Capability to switch between manual and automatic settings is vital if glycol circulates through the PHE.

    Miscellaneous essentials

    Beyond the larger brewhouse and cellar equipment, several other essentials are necessary when starting a brewery.

    Cleaning station

    Often referred to as a CIP (clean in place) station, this addition proves advantageous in the brewery setting. Most small breweries install CIP systems within both cellars and brewhouses; straightforward spray balls distribute cleaning solutions under pressure to coat the interiors of vessels.

    Typically, a CIP station consists of 2 or 3 tanks (roughly 50 to 200 litres), connected to a cleaning pump. Ideally, the station should be mobile to eliminate the need for long pipes during cleaning cycles. A tank is often designated for a caustic cleaning agent and heated, while a second tank may be used for acid washes or rinse water.

    Hoses & pipelines

    Employing compatible, heat-resistant hoses is essential for a functional brewery capable of withstanding considerable pressure. Good options can be found in Romania, rated up to around 10 bars. It’s advisable to buy several lengths, utilizing shorter hoses for cleaning for increased pressure during those cycles. Hoses featuring tri-clamp fittings allow for flexible connections when longer runs are necessary.

    Pipelines generally accompany brewery equipment orders, linking pumps to vessels to secure a steady flow of wort and beer. Stainless steel is the optimal material for these applications.

    CO2 tanks and regulators

    Even if your beer ferments naturally, obtaining one or more CO2 tanks is essential throughout the brewing process. If transferring beer to another vessel, purging oxygen from pipes and tanks using CO2 minimizes oxygen exposure; CO2 is also crucial during packaging to sustain pressure in tanks.

    Packaging essentials

    Commencing with a critical component:

    Bottling/canning machine

    Regardless of your choice to package beer in cans or bottles, a reliable filling machine is necessary. Numerous varieties exist, with bottling machines requiring knowledge of whether carbonated beer will be packaged or if bottle conditioning will suffice. If carbonated beer packaging is chosen, an isobaric (counter-pressure) bottling or canning line is required.

    This process predominantly occurs under pressure, minimizing oxygen entry into the beer. Therefore, purging oxygen from bottles or cans before filling is paramount. The number of filling heads desired influences the filling lines, which can also facilitate washing, labeling, and capping.

    Labelling machine

    While manual labeling is common among smaller breweries, a labeling machine accelerates the process. Various manual, semi-automatic, and automatic options exist, contingent on your operational needs. Planning regarding branding will inform choices; contemplate using a single label, front and back, or neck labels as appropriate.

    Bottle washer

    Thoroughly washing your bottles before use extends the shelf life of your beer and mitigates infection risks. A basic home-brew setup may suffice, utilizing an immersible pump and jet sprays; larger washing machines may also be warranted if budget and output allow. Some filling lines also provide washing functionalities pre-filling.

    Kegging equipment

    Whether working with metal or plastic kegs, certain equipment is necessary to facilitate filling. At minimum, acquire several keg couplers. The simplest kegging method involves connecting a beer line quick connect (John Guest fitting) to the fermenting vessel via a tri-clamp connection.

    Essential spares!

    As brewery equipment experiences wear over time, maintaining a healthy inventory of spare parts is vital for avoiding interruptions and preserving quality.

    Gaskets, clamps, valves

    When purchasing a complete brewery system, a set of clamps and gaskets typically accompanies it for connecting various components. Tri-clamps and silicone gaskets are preferable over threaded connections, which can be more prone to damage. A set of spare gaskets and clamps should also be obtained.

    Many breweries utilize butterfly valves throughout, which may wear down and leak. Keeping several spares on hand proves advantageous, as they can fulfill multiple purposes.

    Sight glasses

    Sight glasses offer a convenient way to gauge the condition of your beer from sparge clarity to oxygen level monitoring during transfer to fermentation. However, periodic leaks may necessitate ordering replacements.

    Probes and gauges

    Temperature probes and pressure gauges are critical for maintaining process integrity; hence, maintaining a supply of spares is prudent.

    This concludes our overview of the equipment necessary for launching a brewery. Numerous additional tools may assist your efforts. While some may seem familiar if you’re an avid homebrewer (like hydrometers or scales for malt and hops), others are optional (such as microscopes or dissolved oxygen meters). Should you need assistance establishing a commercial brewery, feel free to reach out, and we’ll support your journey.

    Cover photo via r/The Brewery (used with permission)

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