Follow-up Questions for Opening A Brewery

What vessels does the brewery need?

In response to the initial question, we discussed how many brewing vessels were needed. A four-vessel brewing system would include a wort tun, a lauter tun, a brew kettle, and a whirlpool. A three-vessel brewing system offers a choice: a combined wort/lauter tun or a combined brew kettle/whirlpool? Each has its advantages and disadvantages.

Brewhouse/Percolator Combination

Brewers often find this setup shortens brewing time. Having separate kettles and whirlpools means you can begin the second percolation as soon as the first cup of coffee enters the whirlpool.

In addition, a micro-heat exchanger can be installed between the kettle and whirlpool to lower the wort temperature for the addition of aroma hops. Brewers can achieve better results by adding aroma hops to the cooler wort in the whirlpool.

Combining a Kettle and Whirlpool

If you're planning a stratified mash, using a separate mash tun means a more even mash temperature. Using a mash tun/lauter tun combination can easily lead to temperature stratification in the wort. Furthermore, this combined brewhouse makes the mashing process much easier.

Next, after transferring the mash to the lauter tun, the lauter tun dimensions can be adjusted to a thinner bed, resulting in better outflow and higher efficiency.

In subsequent discussions, we focused on brewery vessel options. Even with a dual-container system, we had options. We could use a "German brewing system," which, while only having two vessels, is actually three tanks.

1. Three tanks for mashing/boiling, lautering, and whirlpool

2. Three tanks each for mashing/boiling, HLT, and kettle/whirlpool

For example, with option 1, the lauter tun is located above the whirlpool, so the footprint is suitable for two vessels, but you actually have three.

Do you want a grain conveyor system?

This often depends on the size of your brewery and your budget. If your system capacity is 800 liters or less, I generally recommend against a grain conveyor system. If your beer production exceeds 1,500 liters, a grain conveyor system is definitely a more suitable option. It can save labor, prevent injuries, and provide better mash mixing based on the brewery's design.

Also, for larger systems, the type of grinder you purchase is a factor to consider. Brewery efficiency is crucial when planning brewery production. Consistent grist milling is essential for improving brewery productivity, which means you may need to upgrade your malt grinder. While upgrading your malt grinder can be costly, it will pay for itself over time.

Fermentation Vessels (FVs) and Unitank Design

It's not a big deal, but most breweries these days opt for unit tanks instead of dedicated fermenters. This also means you need to include carbide in these unit tanks. The carbide is typically placed above the cone inside the tank.

If you're running a brewery and space is very tight, you might want a "leaner" fermenter. Of course, if building height allows, you can also stack your fermenters. This allows you to fit as many fermenters as needed in a smaller space to meet projected sales demand.

If your brewing process requires a large volume of hops, you'll need a dedicated, sufficiently large hop inlet. Next, we need to discuss the location of your desired manway: do you want a side or top manway? If you use a top manway, you probably don't need a jump inlet.

Also, we need to discuss the operating pressure and rotation of the beer tanks. In modern breweries, most beer tanks are equipped with rotary valves, and Chinese-made beer tanks have an operating pressure of 30 PSI. Don't forget those PRVs (pressure relief valves)!

Do you want a beer brite tank (BBT)?

Some breweries now opt not to use a BBT. They only use free-flowing (FV) and packaging. If you run a brewpub and sell all your beer in kegs, this might be right for you.

If you do prefer a BBT, the rule of thumb is 1 BBT for every 5 FV. This is just a guideline; realistically, depending on your brewing style, you might only need 1 BBT for 8 to 10 FV.

What are the regulations in your country?

Some countries have stricter steam requirements than others. If you're opening a brewery in a densely built-up area, you may not be able to install a steam machine due to health and safety regulations. If you're in Australia, you'll need AS1210 certification and a design registration number for your steam tank. If you're planning to open a brewery in Europe, CE certification is required.

Do you want to pilot a brewing system?

Having a pilot brewing system allows you to try out new brewing recipes or ingredients, helping you determine if it's worth scaling up to a larger brewing system.

A pilot brewing system allows you to have fun and brew some super-niche beers to please your craft beer customers without having to go into full-scale production.

Can it be stored off-site?

Many of our clients are considering small-scale beer bottling in their bars. When it comes to bottling, the actual empty cans take up a lot of space. For a bar, you want to maximize the floor space available to your customers.

I often ask clients if off-site storage is possible. Often, a warehouse is nearby, but the rent is cheaper.

If you plan to bottle your beer, you'll likely employ delivery drivers. This means you can also deliver goods to the brewery for production when needed.

Is filtration necessary?

A small homebrewer might not choose to filter their beer. However, in a production brewery, you may need some form of separation technology, depending on the size of your brewery and your project budget.

Production and Operation Status

Many customers frequently ask if we can help them install and start up their breweries and train their teams. DEGONG engineers have previously helped install and commission brewery projects in many other countries. We also commission the equipment before it leaves the factory and mark the connected pipes with numbers. Simply follow the instructions to complete the brewery equipment installation.