20 bbl brewing system is a common medium-sized professional brewery setup capable of producing around 620 gallons of beer per batch. This article provides a comprehensive guide to 20 bbl systems covering equipment, design, sizing, customization, suppliers, pricing, installation, operation, maintenance and more.
Overview of 20 bbl Brewing Systems
A 20 bbl brewery system is suitable for producing commercial scale craft beer volumes on the order of 5,000-15,000 barrels annually. Key details include:
Batch Size: 20 barrels or 620 gallons per brew
Annual Production Capacity: Around 5000-15,000 bbls depending on fermentation capacity and brewing frequency
Vessel & Equipment Types: Brew house with mash tun and kettle, fermenters, brite tanks, heat exchange, pumping, and cleaning modules fitted to space
Layout: Equipment can arranged in different layouts from linear to cluster to suit space
Design: Fully automated and integrated or semi-automatic systems available from different suppliers
Spaces: Approx 2000 – 5000 sq ft needed for equipment, supplies, cleaning, storage etc.
Customization: Modular equipment allows extensive customization possibilities
Budget: Around $500,000 to $1.5 million for a complete 20 bbl production brewery
Suppliers: Multiple domestic and international suppliers offering 20 bbl configurations
Brewing Process: Standard professional brewing process involving mashing, lautering, boiling, fermenting, conditioning etc.
20 bbl Brewing Equipment Guide
The key pieces of equipment needed in a 20 bbl brewery include:
| Equipment Type | Function |
|---|---|
| 20 bbl Mash Tun | Mash grains with hot liquor to extract sugars |
| 20 bbl Brew Kettle | Boil sweet wort with hops for aroma and bitterness |
| 20 bbl Fermenters | Ferment beer with yeast to convert sugars into alcohol |
| 20 bbl Brite Tanks | Clarify, condition and carbonate beer |
| Heat Exchangers | Heat/cool liquids through brewing process |
| Piping & Pumps | Move liquids between vessels |
| Cleaning Modules | Clean and sterilize all equipment |
| Control Panels | Automated system operation and data monitoring |
| Grain Handling | Mill, move and store grain |
| Ingredients/Yeast Storage | Keep hops, yeast etc fresh in controlled environment |
Brewery Design Configurations
20 bbl brewing systems can utilize different designs and equipment layouts:
| Type | Description |
|---|---|
| Linear Layout | Equipment in straight line for efficient workflows |
| Compact Layout | Clustered vessels to minimize footprint |
| Multi-level Layout | Place tanks on top of each other to maximize vertical space |
| Simple Design | Cost-effective manual operation without automation |
| Integrated Design | Fully automated PLC-based brewing operation |
| Custom Layout | Tailor equipment flow and positions to facility |
Suppliers offer modular equipment that can be configured into different shapes and arrangements as needed for individual breweries.
Brewing Process Overview
A standard professional brewing process will be used on a 20 bbl system:
- Mills barley malt into grist
- Mix grist with hot water in mash tun to convert starches into fermentable sugars
- Transfer sugary wort to brew kettle and boil with hops for sanitation and flavor
- Cool boiled wort and transfer to fermenter, add yeast to ferment over 5-7 days
- Transfer young “green” beer to conditioning tank to mature 1-2 weeks
- Filter and carbonate bright beer then package into kegs and bottles
The process uses a variety of tanks, pipes, pumps, sensors, and manual operation to convert barley malt into alcoholic beer.
Sizing and Capacity Considerations
When evaluating a 20 bbl brewing system, key sizing parameters include:
| Parameter | Typical Specifications |
|---|---|
| Total Brewery Space | 2000 – 5000 sq ft |
| Ceiling Height | 18 – 24 ft clearance |
| Grain Storage | 3-5 ton capacity |
| Beer Aging Capacity | 60-100 bbls |
| Electrical Supply | 150 kVA with 220V connection |
| Chiller Capacity | 7 – 15 HP recirculating glycol |
| Steam Boiler Horsepower | 20 – 30 boiler HP |
Adequate space is needed for all brewing equipment plus raw material storage, finished product inventory, cleaning areas, and maintenance access. Proper sizing for utilities including electric, water, drainage, steam and refrigeration is also critical.
Customization Options
20 bbl brew systems allow relatively extensive customization in areas like:
| Parameter | Typical Choices |
|---|---|
| Design & Layout | Linear, L-shaped, compact cluster, vertical stacking, custom |
| Control System | Manual operation, semi-auto, fully automated PLC + HMI |
| Grain Handling | Floor malting pit, silo, bulk bag mass, sack storage |
| Fermentation Vessels | Unitanks, open fermenters, wooden vats, hybrids |
| Additional Units | Canning line, laboratory equipment, pilot brewery, quality lab |
| Brewing Capacity | Extra vessels and space for expansion capabilities |
| Water Treatment | Various prefiltration and postfiltration stages |
Experienced suppliers can accommodate preferences for layout, automation, exotic fermenters, quality control labs, wastewater options and other special requests.
Brewery System Suppliers & Pricing
Many equipment manufacturers offer configurable 20 bbl turnkey brewery setups with typical pricing:
| Vendor | Location | Price Range |
|---|---|---|
| ABA Beer Equipment | Canada | $700,000 – $1.2 million |
| Coulee Brew Equipment | USA | $400,000 – $800,000 |
| Markson Brewing Solutions | Italy/China | $350,000 – $650,000 |
| McKenna Boilerworks | USA | $500,000 – $900,000 |
| Unitank | USA | $750,000 – $1.3 million |
Pricing varies based on degree of automation, custom features, shipping costs and other factors. Sourcing equipment domestically versus overseas can significantly impact overall 20 bbl brewery cost. Lead times also differ depending on supplier location and demand fluctuations.
Installation & Facility Requirements
Properly installing a 20 bbl brewing system requires appropriate facility infrastructure:
| Area | Requirements |
|---|---|
| Space | At least 3000-5000 sq ft to operate |
| Mezzanines | Upper levels if ceiling height limited |
| Electric | 150 kVA 3 phase power supply needed |
| Plumbing | 2 inch water lines for brewing water |
| Drainage | Floor trenches and sinks to drain 1000+ gallons |
| Ventilation | Hoods to vent steam from boil kettle |
| Floors | Slope for drainage + chemical/impact resistance |
| Doors | Large doors for equipment & material transport |
| Outdoor Space | Grain silos and ingredient delivery access |
Ensuring adequate power, water, drainage and an appropriate layout are critical to operate efficiently. Both indoor and adjacent outdoor facility areas need to be prepared.
20 bbl Brewery Operation
To produce quality beer day-to-day, the following good practices should be followed:
- Clean and sanitize all equipment thoroughly between each use
- Check piping and pumps for any residual debris before transferring
- Verify tanks have proper volume markings and sensors are calibrated
- Use precise scaling for grain, hops and other ingredients
- Take wort and beer samples throughout process to check quality
- Follow cooling profiles and pitching rates when adding yeast
- Monitor fermentation progress with density measurements
- Use microscope to ensure yeast health and pitching of new cultures
- Follow packaging best practices for sanitation and DO pickup prevention
- Track batches comprehensively through the brewery software
Attention to detail in cellaring protocol makes a real difference in achieving consistency.
Maintenance Factors
Ongoing maintenance helps maximize longevity of a 20 bbl system:
| Area | Recommended Maintenance |
|---|---|
| Pumps | Quarterly teardown to inspect impellers and seals |
| Valves | Annual valve actuation, repacking and lubrication |
| Gaskets | Biannual replacement of faded or warped gaskets |
| Sensors | Yearly calibration check on density meters |
| Weld Inspection | Annual weld inspection, address any cracks |
| Bearings | Replace brew kettle bearings every 2-3 years |
| Paint/Coatings | Spot repair flaking epoxy or stainless finishes |
| Parts Inventory | Stock common spare parts like seals, valves, fittings |
| Recordkeeping | Track completed maintenance via brewery ERP software |
Catching small issues early prevents unplanned downtime and improves safety. Keeping a log of maintenance activities provides helpful documentation and insight into asset lifecycles.
Choosing Between Brewery Suppliers
| Consideration | Evaluation Questions |
|---|---|
| Quality & Reliability | What is their reputation and track record? What warranties/guarantees offered? |
| Customization | Can they accommodate special layout requests? Unique fermenter or grain handling needs? |
| Lead Time | How long from order to delivery? Does it fit construction schedule? |
| Budget | What payment and financing terms can they offer? Any leasing? |
| Support & Service | What installation support and operator training is included? Ongoing technical support? |
| Component Integration | Does PLC/HMI tie vessels together out-of-box or require custom programming? |
| Auxiliary Options | Can additional modules like canning lines, quality labs be integrated now or later? |
| References | Can they provide references from breweries with comparable systems to call? |
| Company Stability | Have they been around for a while? Good prospects to service in future? |
| Location & Logistics | Will they oversee equipment shipping or is that handled separately? |
| Control Preferences | Is a specific level of automation desired? How customizable is system operation? |
Narrowing down top 2-3 supplier options then evaluating head-to-head on key factors facilitates making the right strategic decision when selecting a 20 bbl brew house equipment partner. Additional points like sustainability initiatives and community involvement can also weigh in for brewery owners aligning business values with vendors.
Comparing Pros and Cons of 20 bbl Systems
| Pros | Cons |
|---|---|
| Higher efficiency than smaller systems | More equipment to maintain than smaller manual systems |
| Automation improves consistency | Automation and PLC programming adds cost |
| Individual vessels support flexibility | Linear layout takes up more floorspace |
| Modular design enables phased expansions | Upfront capital investment higher than smaller builds |
| Production volume suits many taprooms | Requires an adequately sized tasting room or distribution channels |
| Supports wide variety of beer styles | Handling equipment at this scale requires forklifts for safety |
20 bbl breweries strike a balance between more personalized craft batches and larger industrial volumes. The equipment scale affords efficiency without compromising character.
FAQs
What does a complete 20 bbl brewery include?
A full 20 bbl production brewery setup consists of brewhouse vessels, fermentation tanks, brite tanks, glycol chilling system, hot liquor tank, pumping stations, automated electrical control system, grain mill and handling equipment, silos/storage, and cleaning system.
What size building is needed for a 20 bbl system?
Plan for a ~3000-5000 sq ft facility to comfortably fit a 20 bbl brewhouse layout plus fermentation area, storage, maintenance access and office functions.
Can a 20 bbl system brew smaller 10 bbl batches?
Yes, the equipment can be operated at reduced volumes more suited for a 10 bbl batch size if demand warrants, providing operational flexibility.
What is the difference between 20BBL and 20HL?
20 bbl and 20 hectoliter (HL) systems are equivalent in batch size and capacity – both represent 20 barrels or ~620 gallons per batch. HL is a metric unit while BBL is imperial.
How many beers can a 20 bbl system produce per year?
Approximately 150-300 batches can be brewed annually on a 20 bbl system depending on production schedule, yielding 5000-15000 barrels yearly. More fermentation tanks allow higher throughput.