Overview of Large Beer Brewery Equipment
Large beer breweries require extensive equipment and systems to produce beer on a commercial scale. This guide will provide a comprehensive overview of the key equipment needed from raw material handling to fermentation, conditioning, and packaging.
We will explore the main types of equipment, their functions, key specifications, installation requirements, suppliers, and pricing. Comparisons between equipment options are provided to help select the optimal setup. Advice on choosing suppliers and factors that affect cost is also included.
This guide is intended for entrepreneurs setting up a large brewery, engineers designing a brewing system, and brewmasters optimizing or expanding existing facilities. Use the table of contents to navigate to the sections most relevant to your needs.
Table 1: Overview of Main Beer Brewery Equipment
| Equipment | Function |
|---|---|
| Milling | Crushing malt into grist |
| Mashing | Mixing grist with hot water to convert starches to sugars |
| Lautering | Separating sweet wort from spent grains |
| Boiling | Sterilizing wort, extracting flavors, coagulating proteins |
| Whirlpool | Settling trub and hop particles |
| Wort cooling | Rapidly cooling boiled wort before fermentation |
| Fermentation | Yeast converting sugars into alcohol and CO2 |
| Maturation | Improving flavor during secondary fermentation |
| Filtration | Removing haze particles for clear beer |
| Carbonation | Dissolving CO2 into beer |
| Packaging | Kegging, bottling, canning final beer |
| CIP systems | Automated cleaning-in-place |
| Piping | Transferring liquids between vessels |
| Cooling systems | Maintaining fermentation temperature |
Milling Equipment
The first step in beer production is to crush the malt into a coarse flour called grist. This makes the starch granules more accessible for enzymes during mashing.
Table 2: Malt Milling Equipment Types
| Type | Description |
|---|---|
| Roller mill | Two or more fluted rollers rotating at different speeds to shear malt kernels |
| Hammer mill | Rotating hammers to impact and pulverize malt |
| Wet mill | Roller mill with water spray for conditioned milling |
Table 3: Malt Mill Specifications
| Parameter | Typical Range |
|---|---|
| Capacity | 1 – 20 tonnes/hr |
| Roller width | 100 – 400 mm |
| Roller diameter | 200 – 300 mm |
| Roller speed differential | 1:1.25 – 1:1.75 |
| Desired grist particle size | 0.5 – 2.5 mm |
Table 4: Malt Mill Suppliers and Pricing
| Supplier | Mill Model | Price Range |
|---|---|---|
| gcd Machinery | DUO Mill | $8,000 – $15,000 |
| Monster Brewing Hardware | MM-2 Two Roller Mill | $1,195 – $1,595 |
| American Beer Equipment | 2-roller Malt Mill | $2,100 – $2,800 |
| Pentair Food & Beverage | P1A8 Two-Roll Mill | $14,000 – $18,000 |
Roller mills offer more accurate grinding with lower risk of over-crushing compared to hammer mills. Wet milling increases yield and prevents dust. Larger mills over 5 tonnes/hour capacity are used in industrial breweries to support high throughput. Smaller 1-3 tonne/hour mills are suitable for craft breweries.
Malt mills represent 3-6% of total equipment costs in a commercial brewery. Buying a sturdy mill with adjustable rollers provides flexibility for different beer recipes. Prioritize ease of cleaning and maintenance when selecting a mill.
Mashing Equipment
Mashing converts malt starches to fermentable sugars by mixing grist and hot water. The mash vessel maintains a stable temperature for enzyme activity.
Table 5: Mashing System Types
| Type | Description |
|---|---|
| Mash tun | Stainless steel insulated tun with false bottom |
| Mash mixer | Agitator for mixing grist and water |
| Lauter tun | Combined mash/lauter tun with false bottom and sparging system |
Table 6: Mash Tun Specifications
| Parameter | Typical Range |
|---|---|
| Batch size | 5 – 600 hectoliters |
| Tun height | 1.5 – 6 meters |
| Tun diameter | 1 – 8 meters |
| Material | Stainless steel, copper |
| Insulation | Foam, cladding, jacketing |
| False bottom | Slotted/perforated stainless plate |
| Temperature | 45°C – 78°C |
| Recirculation pumps | 1 – 4 units |
Table 7: Mashing System Suppliers and Pricing
| Supplier | Equipment | Price Range |
|---|---|---|
| JVNW | 10HL Mash Tun | $15,000 – $25,000 |
| Ss Brewtech | 7bbl Mash Tun | $9,000 – $12,000 |
| Specific Mechanical | 600HL Mash Mixer | $150,000 – $220,000 |
| Paul Mueller | 10,000L Mashtun | $185,000 – $250,000 |
The optimal mash tun size balances production volume, number of batches, and beer diversity. Larger units above 100 hectoliters streamline higher volume. Smaller tuns allow more flexibility.
Integrated mash filters or lauter tuns simplify the lautering process. Agitators and pumps should be rated for viscosity of mash. Expect mashing systems to comprise 10-15% of the total brewery capital cost.
Lautering Equipment
Lautering separates the sweet wort from spent grains after mashing. This involves recirculating then draining the wort while retaining the solids.
Table 8: Lautering Equipment
| Equipment | Description |
|---|---|
| Mash filter | Screen and plates for filtration |
| Grant | Intermediate collection vessel |
| Rakes | Removal of grain bed clogs |
| Sparge arms | Water spray for extraction |
Table 9: Lautering Specifications
| Parameter | Typical Range |
|---|---|
| Flow rate | 10 – 60 hl/hr |
| Filter screen | 0.5 – 2.5 mm openings |
| Sparge water temperature | 75°C – 78°C |
| Total sparge time | 60 – 180 minutes |
| Typical extract efficiency | 75% – 85% |
Table 10: Lautering Suppliers and Pricing
| Supplier | Equipment | Price |
|---|---|---|
| Ziemann Holvrieka | Mash filter | $150,000 – $350,000 |
| Specific Mechanical | Grant tanks | $8,000 – $15,000 |
| GEA Group | Wort collection troughs | $4,000 – $10,000 |
| Pentair | Internal rakes | $3,000 – $6,000 |
Mash filters provide faster runoff rates and greater extract efficiency versus traditional lauter tuns. Complete lautering systems will add 8-15% to the total capital cost.
Maximize yield, runoff rate, and wort clarity by optimizing sparge pH, rake design, flow patterns, and grain bed depth. Gentle grain handling preserves filter screens.
Wort Boiling Equipment
Vigorous wort boiling accomplishes multiple objectives before fermentation:
- Sterilization
- Protein coagulation
- Concentration through evaporation
- Isomerization of hop alpha acids
- Maillard reactions for color and flavor
Table 11: Wort Boiling Equipment
| Equipment | Description |
|---|---|
| Brew kettle | Boils wort with heat and ventilation |
| Whirlpool tank | Settles trub and hops |
| Calandria | External heating chamber |
| Heat exchanger | Rapid wort cooling |
Table 12: Brew Kettle Specifications
| Parameter | Typical Range |
|---|---|
| Volume | 10 – 600 hectoliters |
| Height to diameter ratio | 1:1 – 1:2 |
| Heating power | 300 – 1500 kW |
| Boiling temperature | 96°C – 102°C |
| Boil duration | 60 – 120 minutes |
| Evaporation rate | 5-10% per hour |
Table 13: Wort Boiling Suppliers and Pricing
| Supplier | Equipment | Price Range |
|---|---|---|
| JVNW | 50 hl Brew Kettle | $120,000 – $180,000 |
| Ss Brewtech | 7 bbl Brew Kettle | $18,000 – $24,000 |
| Newlands System | 600 hl Kettle | $350,000 – $600,000 |
| Hitech Equipment | Calandria | $60,000 – $120,000 |
Kettles with calandria heating maintain constant mash temperatures. Larger diameter kettles improve evaporation rates and hop utilization. Boiling equipment represents 15-25% of total capital investment.
Optimize heat flux, material thickness, and boiling vigor based on production targets. Automated wort boiling significantly improves batch consistency.
Whirlpool Equipment
Whirlpool vessels use a centrifugal spin to separate trub particles, coagulated proteins, and hop debris from wort after boiling.
Table 14: Whirlpool Equipment
| Type | Description |
|---|---|
| Whirlpool tank | Cylindrical tank with tangential inlet |
| Rotor and drive | Rotates wort in whirlpool |
| Baffles | Stabilize vortex and flow pattern |
Table 15: Whirlpool Specifications
| Parameter | Typical Range |
|---|---|
| Tank diameter | 1 – 5 meters |
| Tank height | 1 – 3 meters |
| Retention time | 10 – 30 minutes |
| Spin speed | 1 – 5 RPM |
| Trub removal | 50 – 80% |
Table 16: Whirlpool Suppliers and Pricing
| Supplier | Equipment | Price Range |
|---|---|---|
| JVNW | 7bbl Whirlpool | $12,000 – $18,000 |
| Ss Brewtech | 3.5bbl Whirlpool | $4,500 – $6,000 |
| Specific Mechanical | 200hl Whirlpool | $45,000 – $80,000 |
| Paul Mueller | Rotor drive | $4,000 – $7,000 |
Whirlpools deliver a clear, trub-free wort with minimal capital investment. Smaller craft breweries can use a single vessel for boiling and whirlpooling. Optimal design targets trub compaction over shorter durations.
Wort Cooling Equipment
Chilling hot wort rapidly below fermentation temperature is critical to maximize beer quality and production efficiency.
Table 17: Wort Cooling Equipment
| Type | Description |
|---|---|
| Plate heat exchanger | Compact cooling via conductive plates |
| Shell & tube heat exchanger | Inline cooling through tubing bundle |
| Wort cooler | Single-pass cooling unit |
| Glycol chiller | Refrigerant-based cooling system |
Table 18: Wort Cooler Specifications
| Parameter | Typical Range |
|---|---|
| Cooling medium | Glycol, ammonia, Freon |
| Coolant temperature | -8°C to 2°C |
| Cooling time | 15 – 60 minutes |
| Heat exchange rate | 500 – 5000 kW |
| Exit wort temperature | 12°C – 18°C |
Table 19: Wort Cooling Suppliers and Pricing
| Supplier | Equipment | Price Range |
|---|---|---|
| JVNW | Plate heat exchanger | $8,000 – $15,000 |
| Blichmann Engineering | Therminator cooler | $3,500 – $4,500 |
| DME Process Systems | Glycol chiller | $20,000 – $60,000 |
| GEA Group | Wort cooler | $100,000 – $250,000 |
Plate heat exchangers provide rapid single-pass cooling in compact units. Larger breweries use a combination of plate and shell & tube exchangers. Budget 5-15% of capital for wort cooling equipment.
When selecting equipment, balance cooling rate, wort oxidation risk, and maintenance needs based on production scale. Automated sensors help optimize cooling water usage.
Fermentation Equipment
Fermentation tanks allow yeast to convert wort sugars into alcohol, CO2, and flavor compounds. Temperature control, agitation, and yeast handling systems are critical.
Table 20: Fermentation Equipment
| Equipment | Description |
|---|---|
| Fermentation tanks | Stainless steel pressure vessels |
| Yeast pitching system | Adding yeast to start fermentation |
| Temperature control | Cooling jackets and chilling units |
| Agitator/rouser | Keep yeast in suspension |
| CO2 capture | Collecting CO2 from tanks |
Table 21: Fermentation Tank Specifications
| Parameter | Typical Range |
|---|---|
| Volume | 10 – 6000 hectoliters |
| Height to diameter ratio | 2:1 – 3:1 |
| Cooling system | Glycol, ammonia, Freon |
| Temperature | 12°C – 22°C |
| Pressure rating | 1 – 2.5 bar |
| Cell density | 15 – 150 million cells/ml |
| Yeast pitch rate | 0.5 – 2 million cells/ml/Plato |
Table 22: Fermentation Suppliers and Pricing
| Supplier | Equipment | Price Range |
|---|---|---|
| JVNW | 10hl UniTank | $15,000 – $22,000 |
| Ss Brewtech | 7bbl Fermenter | $15,000 – $22,000 |
| ABE | 600hl Closed Fermenter | $180,000 – $350,000 |
| GEA Group | Yeast pitching system | $35,000 – $100,000 |
Highly flexible fermentation systems allow multiple beer varieties. Closed, hygienic vessels reduce risk of contamination. Jacketing and cooling represent around 15% of capital costs.
Optimize yeast vitality, fermentation kinetics, and tank utilization through wort aeration, nutrient levels, yeast cropping, and repitch rates.
Maturation Equipment
Maturation or conditioning tanks improve beer flavor clarity through a secondary fermentation and clarifying process.
Table 23: Maturation Equipment
| Equipment | Description |
|---|---|
| UniTanks | Combined fermentation and maturation |
| Brite tanks | Pressurized vessels for clarifying |
| Dry hopping system | Hop aroma addition |
| Filtration | Removing yeast and haze particles |
Table 24: Maturation Tank Specifications
| Parameter | Typical Range |
|---|---|
| Volume | 50 – 2000 hectoliters |
| Temperature | -2°C – 4°C |
| Pressure | 1 – 3 bar |
| Residence time | 7 – 30 days |
| Yeast settling rate | 0.5 – 2 cm/day |
Table 25: Maturation Suppliers and Pricing
| Supplier | Equipment | Price Range |
|---|---|---|
| JVNW | 10hl UniTank | $12,000 – $18,000 |
| Ss Brewtech | 7bbl UniTank | $10,000 – $15,000 |
| GEA Group | Horizontal tank | $70,000 – $200,000 |
| Alfa Laval | Centrifugal separator | $35,000 – $150,000 |
UniTanks streamline operations through single vessel fermentation and maturation. Horizontal tanks optimize clarity and labor. Budget 10-20% of capital for conditioning and clarifying systems.
Balance residence time, temperature ramps, yeast settling, and filtration to achieve desired beer stability, clarity, and quality attributes.
Filtration Equipment
Filtration provides stabilized shelf life by removing yeast, proteins, and tannins. Filters clarify beer for packaging.
Table 26: Beer Filtration Equipment
| Type | Description |
|---|---|
| Plate and frame filter | Filter sheets compressed between plates |
| Lenticular filter | Stacked disks enclosed in housing |
| Rotary drum filter | Rotating drum with filtration screen |
| Centrifugal separator | Spinning conical chamber sedimentation |
Table 27: Filtration Specifications
| Parameter | Typical Range |
|---|---|
| Filter size | 1 – 500 square meters |
| Filtration rating | 0.5 – 10 microns |
| Flow rate per filter | 5 – 250 hl/hr |
| Total suspended solids | 50 – 500 ppm |
| Turbidity reduction | 70 – 90% |
Table 28: Filtration Suppliers and Pricing
| Supplier | Equipment | Price Range |
|---|---|---|
| GEA Group | Plate filter | $35,000 – $120,000 |
| JVNW | DE Filter | $4,000 – $8,000 |
| Alfa Laval | Centrifuge | $35,000 – $150,000 |
| Pentair | Lenticular filter | $80,000 – $250,000 |
Combinations of coarse, fine, and sterile filtration provide cost-effective clarification based on product requirements. Sterile filtration enables longer shelf life.