Homebrewing beer has experienced a surge in popularity in recent years. While beginner homebrewers often start with basic equipment kits, more advanced brewers look to customize their systems to match their specific needs and brewing goals.
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Customizing a brewhouse setup allows meticulous control over each phase of the beer production process. Carefully chosen vessels, valves, sensors and control systems enable brewers to fine-tune recipes and achieve consistency between batches. Commercial microbreweries also benefit from tailored equipment that streamlines operations at their production scale.
This guide will explore the key considerations and components involved in designing and building customized professional-grade brewing equipment.
A brewhouse setup includes the equipment used for mashing, lautering, boiling, fermenting, conditioning, filtering and packaging beer. While off-the-shelf systems are available, many serious brewers opt to customize their equipment.
Benefits of customized systems:
Customization does require significant planning, expertise and upfront costs. Key factors when designing a customized brewhouse include:
Brewing Volume and Floor Space
The batch size and annual production volume will determine the capacity requirements for vessels, storage tanks and packaging lines. The physical footprint should allow efficient workflows.
Power and Utilities
Electrical, water, steam and wastewater needs must be estimated for all equipment. Cooling systems may also be required.
Material Selection
Vessels and pipes must be constructed from food-grade and corrosion-resistant materials able to withstand high temperatures and pressure. Stainless steel is commonly used.
Automation Level
Consider the degree of manual versus automated control over material handling, temperature, valves, pumps and sensors.
Budget
Equipment costs, shipping, installation and customization services must align with budget constraints.
Aesthetics
Match brewhouse aesthetics and finishes to brand image and facility decor.
Careful planning and expert advice ensures a customized brewhouse that maximizes quality, efficiency and value over the long term.
Customized Brewhouse Equipment Guide
The main components and options for customizing a brewhouse setup are outlined below:
Mashing and Lautering
Equipment Key Features Mash tun Custom size and shape, single vs dual vessel design, material (stainless, copper), insulation, automated temperature control, automated rakes Lauter tun Custom dimensions, false bottom design, sparge arms, wort grant design, level sensors, automated valve control Mash filter Filter plate size and material, fully automated operation, front-to-back vs upflow configuration Pumps Custom flow rates, self-priming vs standard, impeller material, worm gear for high viscosity Piping Diameter, valves, sensors and insulation tailored to processWort Boiling and Cooling
Equipment Key Features Brew kettle Custom dimensions, direct vs indirect heat, automation of boiling, stirring and cooling steps Heat exchanger Type (plate, shell and tube), materials (stainless, copper), multiple units for multi-stage cooling Cooling jacket Custom jacket design for brew kettle walls, glycol chilling system Steam boiler Output matched to vessel sizes and boil rates, fuel type (gas, wood, electric) Flue gas condenser Heat recovery for pre-heating water, fully automatedFermentation and Conditioning
Equipment Key Features Fermentation tanks Custom size, shape, number based on batch size and annual production, cooling jackets, temperature control, stainless vs oak Brite tanks Custom size and number, glycol chilling jackets, pressure capability if carbonating, level sensors Yeast propagation Custom stainless tanks, fermenter turned propagator, temperature control, yeast handling system Racking and transfers Custom sanitary pipe diameters, automated valves and pumps, flow metersFiltration and Packaging
Equipment Key Features Filters Custom micron ratings, plates and housing material, fully automated operation Carbonation Inline or pre-tank, stone/diffuser vs surface diffusion Bottling/canning lines Custom throughput, bottle/can sizes, fill levels, labeling, 4/6/12 pack configurations Kegging Washer, filler and sealer matched to keg sizes and volumes Bundlers and palletizers Automated systems sized for packaging line and warehouse logisticsMonitoring and Control Systems
Subsystem Options Sensors Customized temperature, pressure, flow and level sensors PLC units Automated recipe control, batch tracking, CIP routines HMI interfaces User-friendly brewhouse control screens and settings Data logging Custom data storage and analytics reporting Alerts and notifications Text or app-based alerts for out-of-spec conditionsUtilities and Infrastructure
Utility Customization Hot liquor tank Sized to support mash and sparge water needs Glycol system Sized for fermenter and brite tank cooling loads CO2 system Match tank size, pressure and purity for carbonation method Steam system Boiler, piping, valves, and insulation sized for vessels Grain handling Conveyors, mills, storage bins and silos designed for recipe needs Clean-in-place Automated CIP balls, spray balls, pumps and chemical dosing Wastewater Sloped floors, collection system, pumps and treatment sized for volumes Electrical Panel, cables and outlets rated for all equipment loadsCareful selection of each brewhouse component based on brewing goals enables maximum quality and consistency between batches.
Applications of customized beer brewing equipment
Customized brewing equipment enables excellent control over processes for:
With the right expertise, customized equipment can be designed to handle the specific needs of any brewing operation.
Custom Brewhouse Design Specifications
Key parameters and standards to consider when engineering a customized brewhouse setup:
Vessels and Tanks
Piping and Pumps
Controls and Automation
Electrical and Utilities
Following relevant codes and standards ensures the brewhouse will perform safely, efficiently and reliably long term.
customized beer brewing equipment Suppliers and Pricing
Many equipment manufacturers specialize in fully customized brewhouse design, fabrication and installation. Typical suppliers include:
Brewhouse Suppliers
Company Location Pricing JV Northwest Canby, Oregon, USA $$ to $$$ Craftwerk Brewing Systems Calgary, Canada $$ to $$$ Premier Stainless Systems Escondido, California, USA $$$ Malt Handling Buffalo, New York, USA $ to $$ Rolec Prozess & Brautechnik Panschwitz-Kuckau, Germany $$$$ Canadian Brewing Equipment Surrey, Canada $ to $$$Pricing Legend
Pricing varies widely depending on degree of customization, batch size, materials and automation. Get quotes from multiple vendors once system parameters are defined.
Installation and Operation of customized beer brewing equipment
Installing and operating a customized brewhouse system requires planning and training:
Taking the time to properly install and learn customized equipment results in years of optimized performance and great beer.
Maintenance of customized beer brewing equipment
To sustain optimal performance, customized brewing equipment requires ongoing maintenance:
Daily/Weekly
Monthly
Yearly
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Following prescribed maintenance schedules optimizes uptime and extends the usable life of the equipment.
Choosing a customized beer brewing equipment Supplier
Several criteria to consider when selecting a supplier of customized beer brewing equipment:
Experience
Offerings
Services
Quality
Value
Finding the right partner ensures a brewhouse optimized for a brewery's unique needs and long-term success.
Pros and Cons of customized beer brewing equipment
Pros
Cons
For many brewers, the benefits of customization outweigh the extra effort and costs required.
Conclusion
Customizing beer brewing equipment enables meticulous control over each production phase and ingredient. With careful planning and selection of components, brewers can engineer brewhouses fine-tuned to their specific recipes, batches and brewing philosophies. Finding an experienced equipment partner simplifies the process of achieving unique and efficient brewhouse designs. The ability to customize every vessel, valve, pump, and control system results in years of optimized brewhouse performance and exceptional beer.
FAQ
What are the main benefits of customized brewing equipment?
The main benefits are optimizing the system for your specific production goals, batch sizes, space constraints, and brewing processes. This customization provides more precise control and efficiency versus an off-the-shelf brewhouse.
What factors should you consider when designing a custom system?
Key factors are brewing volume, floor space, power utilities, automation level, materials, budget constraints, aesthetics, and flexibility to accommodate future growth or changes.
What are the core brewhouse vessels that can be customized?
The mash tun, lauter tun, brew kettle, fermenters, brite tanks, and hot liquor tank are all commonly customized to match specific needs. Piping, pumps, automation, and utilities can also be tailored.
What standards apply to commercial brewhouse design?
Brewhouses must meet food safety standards for materials and construction. Electrical, plumbing, ventilation, and wastewater codes also apply. Many suppliers adhere to ASME or ISO quality standards.
How much does a 10 barrel customized brewhouse cost?
A fully customized 10 barrel brewhouse typically ranges from $150,000 to $500,000 depending on materials, automation, and accessories chosen. Quotes from multiple vendors is recommended.
What maintenance is required on customized equipment?
Daily inspections, weekly operation tests, monthly calibrations and sensor validations, and yearly deep cleaning and preventative maintenance are best practices.
How can you evaluate and select a good brewhouse equipment supplier?
Look for years of proven experience, recommendations, flexible and inclusive offerings, quality manufacturing and materials, services like delivery and installation, and competitive pricing.
What are the downsides to a customized brewhouse?
The main limitations are higher upfront costs, longer lead times, reliance on the supplier's expertise, and difficulty predicting resale value. Ongoing tweaks may be needed as well.
What types of breweries benefit most from custom-built systems?
Craft breweries desiring unique recipes and specialty brewing processes benefit greatly from customization. Highly automated custom brewhouses also suit large production breweries.
Know More Brewing equipment
Brew your beer. These three simple words are some of the most important in brewing, an industry that is constantly innovating and experimenting to produce the next great-tasting drink for customers to enjoy. While the flavors and trends may come and go, one thing remains constant: the commitment to creating something extraordinary.
That's why when it comes to equipment and operational procedures, breweries need customization, not something that is essentially 'off the rack.'
One of the biggest challenges for breweries is getting the most out of their current space. Naturally, the more popular the brewery is, the more space it needs to expand operations and keep up with demand. It's exactly this type of situation that calls for a customized operational line with equipment that fits exactly what the brewers need.
One of the most unique projects that ProBrew has handled was for a brewery facing this exact issue. For Land-Grant Brewing in Columbus, Ohio, spacing for their operations needed to be a top priority. Their building, a 100-plus-year-old elevator factory, had them 'landlocked.' When it was time for them to expand their canning operation, they needed an individualized solution.
ProBrew's answer for Land-Grant was to configure the line in a horseshoe shape. The line needed to be in this shape to enable crossover responsibilities, going back and forth to different sides of the line. The brewery now enjoys one of ProBrew's ProFill Rotary Can Fillers and achieves 85 to 90 cans per minute, customized for their production needs.
The production manager had this to say when describing the newfound efficiency: 'One of our biggest runs, an 80-barrel batch, should take us about eight and a half hours, and that's the longest production day for us, now. That would have been two extremely long days on our old line, easily over two 10-hour days.'
Another common crossroads faced by breweries is making time for experimentation while meeting demand for their most popular beers. Breweries are founded by risk-takers and dreamers who have committed themselves to honing a craft and providing special experiences to visitors. However, it can be difficult to keep expanding into new, exciting flavors and styles while filling orders on flagship products.
This same issue popped up for Central Waters Brewing. This brewery in Amherst, Wisconsin, has been enjoying a massive amount of success over its 25-year history. However, with that success comes the need to expand operations and output of the most popular beers while still capitalizing on trends.
The solution? Have a small brewery within the main brewery. Central Waters already was utilizing a brewhouse capable of 50-barrel production alongside the ProFill 200 Rotary Can filler. However, to keep that spirit of innovation that birthed their brewery, they incorporated a new ProBrew seven-barrel pilot system to allow them to experiment and launch pilot beers.
'Our thought is, the pilot brewery gives us the flexibility to continue brewing as many beers as we want and to focus on in-house sales with that,' says Paul Graham, president of Central Waters. 'We're in a town of 1,000 people, but we pushed almost 70,000 people through our taproom last year. For being in the middle of nowhere, that's pretty good. We can run a beer on the seven-barrel system, throw it on tap, throw 30 to 40 cases worth in the retail cooler, and get to see feedback from the general public.'
In other words, increased pilot capacity means increased ability to test the viability of new beers both in the taphouse and out of the cooler. The production side creates space for experimentation, and the pilot side helps them make decisions one or two years out about limited-release beers that are worth putting into greater distribution. The custom-built ProBrew pilot brewhouse uses the same automation and controls as the 50-barrel and is hard-piped in, with CIP (clean-in-place) functionality, adding increased efficiency and convenience.
ProBrew believes that each craft beer reflects the hard work and long hours that each individual brewer puts in. That is why we are equally committed to providing customized equipment and solutions for what a brewery needs at this precise moment. From brewing to fermenting to carbonating and can filling, ProBrew's customizable equipment empowers breweries to expand operations at their own pace.
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