A Comprehensive Guide to Commercial Brewing Systems

As the craft beer industry continues to boom, there is an increasing demand for high-quality, efficient, and optimal commercial brewing system equipment. Commercial brewing equipment is the backbone of any brewery, determining the quality, consistency, and efficiency of beer production. Micet’s commercial brewing solutions, from individual components and process modules to turnkey projects, are designed and manufactured to provide tight control over your brew while giving you the flexibility to help brew exceptional beer.

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What is a commercial brewing system?

Commercial brewing systems are specialized equipment designed for the large-scale production of beer and other fermented beverages. These systems vary in size and complexity, from small units used in craft breweries to large commercial configurations. From brewpubs and microbreweries to craft breweries and large industrial facilities, institutions rely on these systems to meet the needs of beer drinkers around the world.

1. Brewpub system: The Brewpub system is a compact brewing device used in restaurant or bar venues. They allow these establishments to offer their brews on tap, adding a unique touch to their culinary experience.
2. Microbrewery Systems: Microbrewery systems are small installations but have a wider range of features than beer bar systems. They are breweries that specialize in craft beer for sale to the local market.
3. Craft beer systems: Craft brewery systems are medium-sized equipment suitable for producing large quantities of beer and distributing it across regions or states. They keep the essence of craft beer while catering to a wider audience.
4. Industrial brewery systems: Industrial brewery systems are large-scale operations with significant production capabilities. These breweries serve beer and even , making them major players in the beer industry.

Basic components of commercial brewing system equipment

Milling equipment

Before any brewing can take place, the grains used in the brewing process need to be ground into a fine powder. Grinding equipment grinds grains to create a consistent size and texture for optimal brewing. Milling equipment varies in size and capacity, with some mills capable of processing more than 10,000 pounds of grain per hour.

Brewery equipment

Brewery equipment is at the heart of the brewing process. It consists of various components that work together to convert wort into wort. The process begins by mixing malt flour with water in a hydrator in the mash tun. After a set time, the mixture is transferred to the lauter barrel, where it is separated into liquid wort and spent grains. The wort is then boiled in a brewing kettle and hops and other ingredients are added at specific times to achieve the desired flavor profile.

Brewery basic components:

• Mash Tun: used to convert starch into sugar.
• Boil the kettle: Boil the wort with hops.
• Fermentor: Yeast converts sugar into alcohol.
• Filtration system: for clarity and purity.
• Packaging: Bottling, canning, and barreling equipment.

Commercial breweries use equipment customized to their required capacity:

PARAMETER

TYPICAL RANGE

Annual beer production capacity

1,000 – 10+ million barrels

Mash filter capacity

500 – 10,000 kg/batch

Brew kettle size

500 to 5,000 barrel batches

Fermentation tank size

100 to 3,000 barrels each

Bright beer tank size

500 to 5,000 barrels each

Mash tun

The mash tun is another important piece of equipment for commercial brewing. The mash tun has temperature control and allows you to mix the grains with water to produce the desired mash. The mash tun also heats the mixture, which helps break down the starches in the grains and convert them into the sugars needed to make the beer alcoholic.

Once the wort is ready, it is transferred to a fermenter where yeast is added. Fermenters are designed to control the temperature, pressure, and oxygen levels of the beer during fermentation. Water tanks are made of stainless steel and range in size from a few hundred to several thousand gallons. Commercial breweries need quite a few breweries, and they need to be larger to accommodate the large volumes of beer you want to produce. This is where you add yeast and turn the wort into real beer. Fermenters are controlled environments that help yeast convert sugar into alcohol.

Brit tank

Once fermentation is complete, you’ll need a place to store it. For smaller operations, you can store your beer in a fermentation tank. But, commercial breweries need to immediately release these fermenters to produce new batches of beer so the beer can be transferred to beer tanks for storage. Brite tanks are not for storage, though, as the environment in a Brite tank helps ferment beer carbonate faster so it can be packaged and consumed more .

Filtration equipment

After fermentation, the beer is transferred to conditioning tanks for aging and clarification. Beer is aged for some time, allowing the flavors to develop and mature. During this process, any remaining yeast or sediment settles to the bottom of the tank, resulting in a clear, crisp beer. While not all these substances are inedible or will spoil the product, if not removed early, they may affect the taste in ways you don’t want or cause the product to spoil faster.

Packaging Equipment

After the beer has been conditioned, it is ready for packaging. Packaging equipment includes filling machines, canning machines, and barreling equipment. These machines fill, cap, label, and seal containers, preparing them for shipping and distribution.

Hygiene is an important aspect of brewing beer. Without proper cleaning, bacteria and other contaminants can ruin a batch of beer. Cleaning equipment such as CIP tanks, hoses, and pumps is necessary to ensure that all brewing equipment is cleaned and sanitized before and after each use. Cleanliness and sanitation are critical to the success of a brewery. Whether we’re talking about an automated keg cleaning system or using the right chemicals to keep your tanks clean, you can’t skip the cleaning step of brewing.

The brewing process of commercial beer brewing

1. Malting: The brewing process begins with malting, where grains such as barley are soaked in water and allowed to germinate. The malted grains are then dried in a kiln to produce malt, which is the basis of beer’s flavor.
2. Mashing: In the mashing barrel, malt is mixed with hot water to form a viscous mixture called “mash”. During this process, enzymes break down starch into fermentable sugars, producing wort.
3. Boiling: The wort is transferred to the brewing pot where it is boiled. Hops are added at this stage to impart bitterness, aroma, and flavor to the beer.
4. Fermentation: After boiling, the wort is cooled and transferred to the fermentation tank. Yeast is added to start the fermentation process, in which sugar is converted into alcohol and carbon dioxide.
5. Conditioning: After fermentation is completed, the beer will enter the conditioning stage to mature and develop its flavor.
6. Packaging: Finally, the beer is filtered, carbonated, and packaged into bottles, cans, or kegs for distribution and consumption.

Commercial Brewing System Equipment Maintenance and Care

• Regular cleaning and disinfection: Proper cleaning and disinfection are essential to prevent contamination and ensure beer quality. Daily cleaning schedules and use of food-grade disinfectants are standard practice.
• Preventive maintenance practices: Regular maintenance can extend the life of your brewing equipment. Lubrication, seal replacement, and inspection are critical to identifying and solving potential problems before they escalate.
• Troubleshooting common problems: Even with the best equipment, problems can arise. Brewers should be proficient in solving common problems to cut downtime and maintain production flow.

Commercial Brewing System Installation

• Site and facility preparation: Choosing a suitable location and preparing the facility to house the brewing system is critical.
• Equipment delivery and assembly: Ensure smooth delivery and assembly of brewing equipment to avoid delays.
• Utility connections: Proper connections to water, electricity, and steam supplies are critical to the functionality of the system.
• Testing and Commissioning: test and debug the system to ensure everything is running .

How to choose commercial brewing system equipment?

• Determine your size: Before delving into the technical details, determine the size of your brew. Are you a home brewery, a small brewery, or a commercial-scale brewery? Your scale will determine system size, capabilities, and budget.
• Decide on the level of automation: Some brewers prefer manual control and enjoy the hands-on nature of brewing, while others favor automated systems for increased efficiency and consistency. Determine where you stand on this spectrum and choose a system .
• Budget: As with any major investment, budget plays a vital role. While it’s important to stay within financial limits, remember that quality often comes at a price. Weigh the system’s features against its cost to ensure you get the best value for your money.
• Future expansion: Even if you’re starting small, think ahead. If you plan to expand in the foreseeable future, choose a system that can be expanded . Modular systems allow capacity to be added without a complete overhaul, making them a smart choice.
• Consider technical support: Brewing systems, especially advanced brewing systems, can have a steep learning curve. Choose a brand that offers strong technical support, whether through detailed manuals, a helpline, or on-site training.

When it comes to buying the main equipment for your brewery, there are several factors to consider. In this guide, we’ll take a look at the essential pieces you’ll need, and discuss the various options where relevant.

The brewery can be split into two major sections. The first is the brewhouse, also known as the ‘hot side’. This is where the first stage of brewing is completed, from milling to mashing, and boiling to chilling the wort.

The second section is the cellar, also known as the ‘cold side’. This is where fermentation, conditioning, dry hopping, and everything else that happens as wort becomes beer takes place. Most brewery equipment falls into one of these two sections, with a few exceptions.

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Brewhouse (hot side) essentials

The brewhouse consists of various heated vessels, with pumps to transport the wort.

Heat source

The first decision to make is how you will heat your brewing vessels. The most common methods are:

Steam
Steam heated vessels are fairly common and require a steam generator. This simply transforms city water into boiling steam, which is then piped into steam jackets that are fitted on your vessels. Steam generators are typically powered by either natural gas, electricity, or diesel. They require a water softening system, which is normally sold with the generator. Steam tends to offer more control than other heating methods, as the input of steam can be finely adjusted.

Electricity
Vessels heated by electricity typically use elements, similar to those found in a common kitchen kettle. These come in various sizes and powers, and the best have 2 or 3 elements that can be switched off and on, providing a level of control over the heating. Electrical brewhouses have the elements in-built, and don’t require additional equipment.

Malt mill

Only necessary if you’re using uncrushed malt. Look for models that are easily adjustable. The most common models have 2 rollers, which is adequate for the needs of most small breweries, though some have 3 or more. Depending on your space, you may need a model that is easily maneuvered. Suppliers typically list the capacity in terms of weight of malt per hour.

Hot Liquor/Water Tank (HLT)

The HLT stores and heats up your brewing water (known as liquor in British brewing). The best models have at least two heating elements or steam jackets, allowing you to start heating with just a small amount of water in the vessel. Your HLT should have a level indicator for easy calculations.

In terms of size, it should be around double the size of the rest of your brewhouse. So, if you have a 500 litre boil kettle, you should order a 1,000 litre HLT. This will ensure you always have enough liquid for strike water, sparging, and cleaning.

It should also be fitted with a pump that connects to the mash tun and sparge set up via a flowmeter, as well as the CIP valves on the rest of your equipment. The pump should also allow for recirculation to ensure accurate temperature readings and even mixing of cleaning agents or sparge water additions if you’re using them.

Flowmeter

The flowmeter is used to accurately measure strike and sparge water. It should be heat resistant and waterproof.

Mash tun

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There are many types of mash tun, from the most simple open vessels, to enclosed, heated vessels, fitted with stirring paddles. The more features, the higher the cost. For larger outputs (higher than 200 litres or so), it becomes difficult to mix the mash by hand. If you plan to use step mashing, you’ll need a mash tun that can be heated.

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It should also be fitted with a pump that transports the mash to the lauter tun. Desirable extras include the ability to recirculate for more consistent temperatures, and an inbuilt temperature probe.

Lauter tun

The lauter tun is fitted with a filter, used to separate the sweet wort from the grain. It is also fitted with a sparge ring, connected to the HLT via the flowmeter. The ability to recirculate the hot wort back over the grain is extremely useful for clarifying the wort before transferring to the boil kettle. It’s not typically necessary for the lauter tun to be heated. During the sparging process, the filtered hot wort will be pumped to the boil kettle.

You will typically need a spent grain outlet – a side mounted door from which the spent grains can be pulled out and disposed of easily.

Boil kettle

A relatively simple, heated vessel, the best can start heating the wort with as little as 20 litres inside, reducing the time taken to reach a boil. Depending on your space, you may need a condenser. This draws the steam (and other unwanted compounds) out of an enclosed boil kettle. Alternatively, if space allows, fit a flue that leads outside. 

Whirlpool

The whirlpool vessel isn’t absolutely necessary, depending on the type of beer you’re producing. It can be used for late hop additions, and dropping solids out of suspension before transferring to the heat exchanger.

Heat exchanger

Used to drop the temperature of the boiling wort before transferring to the fermenting vessel. The most common type in breweries is a plate heat exchanger (PHE). The beer flows through one side, and cold water and glycol (or ice water) passes through the other. It should come with at least a thermometer in the beer outlet.

There are several configurations. The most common include a hop filter or even a hopback before the PHE, and a yeast tank and oxygenation system after the PHE. They come in many sizes, often measured in sq. metres. The larger the PHE, the quicker it cools your wort.

As a general rule of thumb, a 500 litre brewhouse doesn’t need much more than a 5 sq metre PHE, a 1,000 litre brewhouse works well with a 10 sq metre PHE, and so on. There should be a pipe that returns the warm city water into the HLT, providing pre-warmed water to save energy costs.

Combination vessels

Most small breweries don’t have separate vessels for the mash tun, lauter tun, boil kettle, and whirlpool. There are various combinations that you can use to save space. The most common include;

• Mash/lauter tun: mash, lauter, and sparge in the same vessel to save space and time. It will need to be heated if you plan to use step mashing.
• Boil kettle/whirlpool: a common space saver, it will need two outlets, one for clear wort to be transferred to the heat exchange, and a lower one for emptying the kettle at the end of the brew.
• Mash/boil kettle: with this system you mash in, then transfer the mash to a separate lauter tun, before returning the sweet wort to the original vessel to boil. An economic way to save space and allow for step mashing. Potential downside is that you have to be very thorough about removing any leftover grain before returning the wort for boiling.
• All-in-one: a simple vessel in which you mash, lauter, boil and whirlpool all in one vessel. They generally use a large basket to contain the grains, lifted up using a winch and hoist. The entire vessel can be heated, and in some cases, cooled as well. This is an affordable, space saving solution for small spaces. Speidel’s Braumeister series offers an all-in-one solution for up to 1,000 litre batches.

Control panel

Control panels come in many shapes and sizes. Common solutions utilize simple PID systems to monitor temperatures and control pumps, and other motorized operations, such as mash paddles, etc. Alternatively, PLC systems offer a touchscreen interface to monitor the entire process, and set automated operations.

The control panel can be restricted to the brewhouse functions, but can also encompass the chilling operations.

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Cellar (cold side) essentials

In the cellar you’ll mostly find fermenting vessels and conditioning tanks.

Fermenting vessels

The type of fermenting vessel you choose depends largely on the type of beer you want to brew. From simple open vessels to pressurized uni-tanks, there are several things to consider. Many small breweries prefer enclosed pressurized vessels – these allow for natural carbonation and faster turn-around times. However, if you plan to bottle condition your beer, pressurized vessels aren’t necessary.

Size is important, and it’s not a bad idea to have a mixture. For example if you have a 1,000 litre brew house, it can be good to have a selection of 500 litre, 1,000 litre, and 2,000 litre fermenters. This allows you to split batches for experiments, and produce larger quantities of core range beers. This depends entirely on your business model, however.

Fermenting vessels can be customized in many different ways. Some common modifications include dry hopping port, carbonation stone, racking arm, and spunding valve. As standard, they should typically come with a temperature probe, spray ball for CIP, and sample valve.

Conditioning tanks

These aren’t essential for all breweries, but can be a useful addition. Bright beer tanks (or BBTs) are most often used to clarify and age beers such as lager, but can also be used to add carbonation. Vertical or horizontal, there are several options.

Glycol/Ice water tank

Many breweries use a cooling agent to maintain fermentation temperatures and cold crash their beers. Glycol is the most common, which is stored in a large tank and pumped into jackets within the fermenting vessels.

If using a glycol tank, you’ll need a separate pump for the system, automatic (solenoid) valves on the fermenting vessels, a control panel, and industrial chillers. The glycol should also have a loop that runs through the PHE to aid in wort chilling.

Cold-side control panel

Used to maintain the temperature in your fermenting vessels, as well as control cold crashing. Like the brewhouse panel, it can be PID or PLC, or can even be incorporated into the same panel. They typically vary in size depending on how many temperature controllers they have, generally ranging from 2 to 8 or so.

It’s important that you can switch from manual to automatic if you use glycol in your PHE.

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Miscellaneous essentials

Besides the larger equipment for the brewhouse and cellar, there are a few other essentials you’ll need when opening a brewery.

Cleaning station

Also known as a CIP (clean in place) station, this is a useful addition to the brewery. Most small breweries have CIP systems in their cellar and brewhouse vessels – a simple spray ball that spray cleaning solutions at high pressure, coating the interior.

A CIP station typically consists of 2 or 3 vessels (around 50 – 200 litres normally), attached to a cleaning pump. Ideally, the station should be mobile to avoid using long pipes during cleaning cycles. One tank is typically used for a caustic cleaning agent and is often heated via an element, while a second is used for sanitizing acid washes. 

A third tank can be used for other acids (for passivation, beer stone removal, etc.) or simply for rinse water. Cleaning solutions are pumped into the vessels that need to be cleaned, and recirculated for the adequate period of time.

Hoses & pipelines

You need food-grade, heat resistant hoses in the brewery, that can take a decent amount of pressure. You’ll find decent hoses in Romania rated up to around 10 bars. It’s good to buy various lengths, long and short. Shorter hoses are best for cleaning, as they allow for higher pressure during cleaning cycles. Ideally, use hoses with tri-clamp connections, as these can be connected to make longer runs when required.

Pipelines will typically be supplied when ordering brewery equipment, linking pumps to vessels, and ensuring a steady flow of wort and beer. Stainless steel is the best material.

CO2 tanks and regulators

Even if you carbonate your beer naturally, you’ll need a CO2 tank or two throughout the brewing process. If you plan to move your beer to another vessel, you’ll need to purge the oxygen from the pipes and tanks using CO2. It’s also used during packaging, to maintain the pressure in the tank.

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Packaging essentials

Let’s start with the most important part:

Bottling/canning machine

Whether you use cans or bottles, you’ll need a filling machine. There are many different types to choose from. Particularly with bottling machines, you’ll need to know if you’ll package carbonated beer, or rely on bottle conditioning for carbonation. If you plan to package carbonated beer, you’ll need an isobaric (counter pressure) bottling or canning line.

In this instance, the entire process is carried out under pressure, with very little opportunity for oxygen to seep into the beer. With such machines, it’s important that the machine is able to purge the bottles/cans of oxygen prior to filling. Filling lines vary depending on how many filling heads you need, but can also carry out a multitude of other tasks, from washing to labeling and capping.

Labelling machine

Many small breweries continue to apply labels by hand, but the job goes faster with a labelling machine. You can find manual, semi-automatic, and automatic options depending on your needs. Choosing a labelling machine will require you to think ahead in terms of branding. Will you use a single label, back and front, neck label, etc?

Bottle washer

Properly washing your bottles prior to use will increase the shelf life of your beer and keep infections out. The most simple solution is to use a home-brew style set up, with an immersible pump and jet sprays. However, if budget allows or output demands, you can opt for larger bottle washing machines as well. Some filling lines also wash the bottles/cans before filling.

Kegging equipment

Whether you use metal or plastic kegs, you’ll need a few pieces of equipment with which to fill them. Be sure to order a few keg couplers first and foremost. The simplest way to keg is to hook up a simple beer line quick connect (john guest fitting) to the fermenting vessel via a tri-clamp fitting.

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Essential spares!

Brewery parts wear down over time, and it’s important to have a good supply of spares to prevent delays and quality issues.

Gaskets, clamps, valves

When buying an entire brewery, you’ll normally receive a set of clamps and gaskets to connect everything together. Tri-clamps and silicon gaskets are a good choice, rather than threaded connections that can become damaged more easily. Be sure to request a set of spare gaskets and clamps.

Many breweries use butterfly valves throughout the brewery. Over time, these can wear down and start to leak, so it’s good to have a few spares. Plus, you’ll often find several uses for extra valves.

Sight glasses

Sight glasses are a great way to check on your beer throughout its life span, from checking for wort clarity during the sparge or bottling, to monitoring oxygen intake during transfer to the fermenter. However, they can leak from time to time, so it’s a good idea to order spares.

Probes and gauges

Temperature probes and pressure gauges can cause big problems if they fail, so it’s a good idea to have a few spares in the brewery.

This wraps up our piece on the brewing equipment you’ll need to open a brewery. There are some other tools that will help you along the way. Some you already know if you’re into homebrewing (such as a hydrometer or scales for hops and malt), others are optional (such as microscopes or dissolved oxygen meters). If you’re looking to open a commercial brewery and need some assistance along the way, drop us a line and we’ll take it from there.

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

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