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24/10/2017
1
Scaling Up Production
Dick Murton
www.murtonbrewing.com
dickmurton@aol.com
Why upsize?
• Successful business – Insufficient brewhouse capacity
• Mash tun too small
• Insufficient or no chilled liquor
• Insufficient HLT capacity
– Insufficient tank capacity • FVs, CTs, BBTs
– Insufficient packaging capacity
– Paying for excessive hours for additional revenue
– No personal time outside work
http://www.murtonbrewing.com/http://www.murtonbrewing.com/
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Other example drivers • Need to replace equipment anyway
– Unsafe – Poor quality or damaged equipment – Not suitable for beer / yeast types used – Cannot produce consistent quality beer
• Lack of insulation • Cannot control liquor or beer temperatures accurately • Infection prone • Cannot pressurise tanks for carbonation
• Poor extracts • Need to move anyway
– lease expiring – limited space for existing capacity – limited access – permit problems
Possible alternatives
• Contract brew
• Cuckoo brew
• Double brew and rent larger FVs / CTs
• e.g. ninkasi tank rentals
• Use contract packager for bottles / cans
– separate company
– mobile packager
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Deciding what you need
For a given brewery size and style, the brewing recipes should be used to determine brewery design, e.g.
• Turnaround time
• Numbers and capacities of vessels
• Vessel dimensions and design features
• CIP facilities
• Extract performance
• Cask, keg, bottle, can storage
– empties, secondary packaging materials
– full packages
Level of spec
• Detail the required performance criteria • Will the kit you are considering achieve these? • Make sure you can safely and effectively clean &
sanitise it
• Automation, welded cladding will cost extra capital, but probably save revenue costs, physical effort, time
• Will probably improve consistency & quality and possibly extract performance
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Grist preparation
Pre-ground malt • Convenient, but some consider it inconsistent
Own mill • Optimised grist fractions can
– Improve extract efficiency – reduced malt costs – Increase runoff rates / reduce set beds – Reduce debris in wort
Grist case • Large enough for maximum grist weight • Pre-ground malt, or • Mill night before • Can also mash in directly from mill – no GC req’d
– But max 20 minutes to mash in
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Mash system
• To cope with largest grist weight, e.g. – Maximum volume & normal gravity, e.g. 5% – Reduced volume at higher gravity, e.g. 10%
• Mashing in – Manual mixing OK up to 10 brl / 400 kg – Mash mixer essential above this for most people – Mashing time – 20 mins max
• Mashing profile – Isothermal with simple MT – Rising temperature infusion with MT – not controllable – Decoction & rising temp mashes – additional kit
• How are you going to remove spent grains?
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Liquor tanks
• Incoming water supply flow and quality
• Break tank?
• Chlorine removal
• Acid treatment?
• CLT working capacity = > 1.3 x maximum wort volume
• HLT working capacity > 1.3 x maximum wort volume
• Temperature and time control of HLT
• Handling different mash and sparge temps
Wort copper / kettle
• Flexible heating to allow full / reduced volumes
• Ability to vigorously boil entire contents
• Ability to handle hop formats being used in copper – WP – pellets only
– Hopback – whole hops only
• Heating – Direct flame to bottom of kettle – rare
– Electric heating elements
– Direct gas fired – internal heating coil
– Steam heated jackets / calandria
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FVs / CTs
• Bottom / top cropping yeast ?
• “Flat” bottom should still be sloped
• CCVs - 60 deg internal angle
– require extra vertical height for cone
• Top access for top cropping
• Lower side access for bottom cropping
• Cooling / temperature probes for full and part brews
• Temperature control system
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Cooling
• Common glycol cooling system better if =>10 brl
• Sizing – supplier will need volumes, times, rates of
– Fermentation attemperation
– FV crash cooling
– CLT cooling
– CT / BBT cooling
– Cold store conditions – size, temperature
Pipework
• Generally 10 brl (1635 litre) kit can / should use 25 mm pipe
– Ideal flow = 2,900 –> 3,800 litres / hr
– Mashing in 350 kg @ 3:1 = 3,150 l / hr (20 min mash)
• Many suppliers use 1.5 inch (36 mm), but not cleanable with the pumps often supplied
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Cleaning
• Manual cleaning not practical for enclosed vessels – access, safety, confined working space
• Simple CIP system particularly beneficial at 10 brl +
• Typically single use
• Vessels must not be continuously ponded
• Pipe flows must be turbulent
Packaging
Cask / keg washing • For 10 brl kit, at least 2 head
– More heads reduces attention required
Bottling, canning, kegging ? • Filtered? Unfiltered? Package conditioned? • How much of each to determine size, and level of
manual input
Outsource • But need sensible minimum quantities - costs • Agree quality expectations
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Other considerations
• Filtration?
– KG, sheet, lenticular?
– How are you going to clean and sterilise?
• Carbonation
– “Natural” – krausening, primings – time required
– “Forced” - in tank sinter
– “Forced” - in-line
Brewery space requirements
• Individual pieces of kit
• Working space for each item
• Storage space for materials and packaged beer
• Admin
• Lab
• Mess room & toilets
• Bar / food ?
• Off sales area
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The building
• Do NOT compromise on structural safety
– Floor and wall strengths / loadings
• Access to get tanks in
• Sufficient height for tank installation
• Insulated
• Outside space for access, parking waste storage
10 brl FV – large brewery ratio
3.65 metres 3.3 metres
3.0 metres
10 brl FV – smaller brewery ratio
3.1 metres
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Hygiene – non negotiable
• You are producing food products
• Non porous walls / ceilings – tiles / plastic / polypropylene boarding
– impermeable paint
• Non porous surfaces (floors and vessels) essential
• Good falls / gullys not essential
• Ventilation – for moisture & CO2
• Pest control
• Toilet / washing / personal kitchen facilities
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