Commercial Brewing Cost Saving Tips

I wanted to write an article covering some commercial brewing cost saving tips I’ve picked up over the years. As I think it could be valuable right now.

Across the globe brewers are seeing the cost of making beer rise. With the purchase of hops & malt, delivery costs and utility prices all on the rise.

I’ve also roped in a few of my brewing industry buddies on this one too. As it a conversation I’ve been having with them recently

Brewers need to look at their processes plus, take some time to look at available suppliers and chat with them.

I’ve been talking with many suppliers in the last couple of months. To see how we can work together, to keep costs as low as possible.

In this article, we’ll cover some easy to implement tips and processes which don’t require equipment upgrades or significant investment.

In brewing there are four main ingredients; water, malt hops and yeast. I think the natural starting point, is to look at water first.

Please note: Justin Fox the Flow Master for Bespoke Brewing Solutions, was kind enough contribute to this article…I’d like to thank him for his time.

Furthermore, he offered advice on a couple of different subjects. So, I’ll be dropping his nuggets of gold throughout.

Water Savings – Commercial Brewing Cost Saving Tips

When it comes to water there are a few basic tips we suggest. I’ve been brewing for over 25-years now. I admit in my early career, I picked up the bad habit of cleaning up many spills using a hose.

I’ve now changed; for example, if there is yeast slurry on the floor. I’ll squeegee as much as possible first. Although, I still may might to finish the job, with a quick rinse with water to get the last bits.

However, this practice over time will save money, using less water. Plus, I’ve found it’s often quicker this way, than trying to wash everything away with a hose.

High Pressure Low Flow Nozzle

When using a hose, it’s good to use a high-pressure low flow nozzle water gun. This may seem like a small detail to bring up, I know.

High-pressure low flow nozzle water gun

However, when you think how much water a brewery uses weekly, these small savings quickly add up. It’s like the old saying “look after the pennies and the pounds will look after themselves”.

Brewer joke, the job is 90% cleaning, well a lot of this cleaning involves using water. Small savings add up over time. In many countries you pay for water twice. Once when you use it and again when you send it down the drain.

Track Your Water Use – Commercial Brewing Cost Saving Tips

If you don’t measure it, you can manage it. If you measure your water usage regularly, and keep a record of it, then it can be tracked. Meaning any leaks or issues can be discovered more quickly and addressed.

Also, with this in mind, it worth taking time once a week for one employee to do a walk-through of all piping, looking for any possible leaks.

Over time leaks can present themselves, but be easily missed without regular checks.

Many breweries by design, have high water pressure. Pipes and particularly where there’s a connection (point of weakness) can start with a small drip, which becomes more severe over time.

Did you know if three taps leak one drip per minute, over a year it equates to 100-gallons of wasted water?

Glycol Too! Commercial Brewing Cost Saving Tips

As we said before; a once-a-week walk around the brewery, to check for leaks is good practice. Catching an issue early can save a brewery money. It’s the same with your glycol lines too.

Glycol system are notorious for leaks, you can actually get dyes which you add to your glycol system to help a brewer spot leaks. Use your favorite search engine and use the term “glycol leak detection dye” to find a suitable product.

Furthermore, make sure your glycol banks don’t run low. It will make for a more efficient system. One other tip I’ve shared before on this website, is to have an engineer check colling the system.

I like to have an engineer check the glycol system in the month of May (northern hemisphere), if possible. It’s before the weather gets too hot.

The main check is for the freon levels in the compressors. It’s also a good time to check the cooling fins too, ensuring they are clear of dust and other particles.

I like to check the cooling fins once a month. If there’s an issue use compressed air (plus wear a mask) to clean the fins out.

Compressor Cooling Fins for a Glycol System

On some compressors you can use water too but you need to check. If the fins are clean, the compressors work more efficiently, saving money.

Freon Gas

Most breweries I’ve worked with, use compressors working with freon gas. Now in the summer it’s hotter plus, it’s the busiest time of the year for most breweries.

So, making sure your glycol system is in tip-top shape before the summer months begin, is a logical preventive maintenance action.

Plus, in the height of summer, if your glycol system breaks down, engineers may be too busy to see you right away.

This may mean your system can’t run for a few days at the hottest time of the year, OR you have to pay a small fortune to get someone out ASAP. Neither scenario is ideal.

I think we’ve covered water and glycol enough for now. So, let’s move on to malt.

Commercial Brewing Cost Saving Tips – Malt

With malt I’d like to start with an example please, I took over the running of a small production brewery in Shanghai, China last year. It was in some disarray when I took over.

I mean the brewery had 3 bags of malt, only one-third of the tanks had beer in them and some of the beer was infected.

Please see the pictures of how the mash/lauter tun looked before and after I got to work. In four-years the lauter plates had not been taken out, according to the assistant brewer onsite.

The Lauter Tun Before and After I’d Cleaned It – They’d Not Cleaned It For 4-Years!!!

Furthermore, the raw material costs per liter, for all beers was high. Oh! And they had stupid amounts of many varieties of hops. Twenty kilos of Sorachi Ace anyone!

Quite frankly it was carnage…

As I spent time cleaning with the team, I also reached out to raw material suppliers I know, to get their pricing.

My aim was to substitute for some cheaper malts, or to use similar malts with greater extract potential, to bring the production costs of beer per liter down.

When looking to reduce costs by using cheaper raw materials, breweries must ensure this process, doesn’t result in a significant flavor change.

It wasn’t much of an issue for me, as the beer being brewed before me, wasn’t great. My aim was to cut costs, revamp the beers and improve beer quality.

Malt Chat – Commercial Brewing Cost Saving Tips

If you’re making a beer using 100% Marris Otter Pale malt. The chances are, switching out a percentage of the grain bill, will not change the overall sensory of the finished beer in a recognizable way.

Please note: When discussing “sensory” in this article, I talking about the color, aroma and taste of the beer.

When looking to change the raw materials, it’s time to experiment. There are two main ways to approach this:

1. Use a pilot system and play around with percentages
2. Slowly replace a growing percentage of the malt, for the cheaper malt option, on your main system.

Humdingers manual pilot system

A lot of breweries may not want to experiment directly their main system, I can understand this. However, if you don’t have a pilot, it might be the only option.

If you’re a production brewery, then you should also have a pilot system. If you’re a brewpub then why not get a small home-brew set up or better yet a small 50-liter system.

See the picture below of the pilot system my friend has at it his brewpub in Kunming, China. It makes 50-liter of beer per batch.

Such a system doesn’t take up much space and ideal for a brewpub to experiment on.

Look these are only my suggestions, from my experiences, switching in 20% standard pale ale for Marris Otter doesn’t impact overall flavor. Start at 10% and then keep increasing in 10% steps.

Sven Shared Some Commercial Brewing Cost Saving Tips With Us – Click Here To See Them…

Most Drinkers Won’t Notice the Difference

Honestly the chances of your customers noticing any real difference are negligible. Do you know who will notice? Your accountant. Look the only way to know, is to try it yourself.

Experiment and test…however, as I say if you’re not comfortable with this, then I understand.

The process is to check the COA’s (the link is good guide to how to read them), trial batch and use small amounts in your recipes.

If all goes well then, it’s possible to push the percentage of cheaper base used higher, for more savings.

If you felt you’ve gone too far then dial it back. As always, whatever changes you make, keep good records of them. Plus, only change on thing at time, otherwise you’ll not know which tweak changed the sensory.

Likewise, when looking through those COA’s, check the extract yield potential, like in the picture below. The extract potential of some suppliers can be significantly higher than others.

Side note: It’s always worth checking this value of each malt before purchasing, and again before accepting delivery too.

For Those Using Imported Malt – Commercial Brewing Cost Saving Tips

For those who read my articles, and use imported malt…this section is for you.

Unfortunately, the craft beer market right now, is proving tough for breweries around the globe. It’s leading to some breweries having to default on their malt contracts or unable being unable to meet their forecasts.

For example, as I write this, I’m in lockdown in Shanghai and several of the brewery staff cannot leave their living areas too. Our sales this week were 440L across the 10 venues, as many bars are closed as well.

When breweries suffer, so do the suppliers. There might be some room to work with, or possibility of substitution for lowers costs.

Recently one supplier I buy from, had some Marris Otter close to expiry date and was offering it at a reduced rate.

The malt was still good, but I don’t use Marris in my house beers. So, I had to pass on the opportunity. As ever peeps; test, test and test!

Commercial Brewing Cost Saving Tips – Let’s Talk About Hops

I’ve spoken about this before; asking you what hops you’re using for bittering additions. If you’re using the same hops for bittering as you do for aroma, for example Citra. Then you’re doing it wrong.

Bittering Additions

Granted Citra is high in alpha acids (10 to 15%) but they aren’t cheap. You need to be using suitable lower cost high alpha hops.

There are several hops’ brewers in the industry typically use for bittering, which don’t break the bank. Plus, offering decent/smooth bitterness.

If you don’t use all your hops, it’s good to vacuum pack the leftovers

Columbus is a good substitute for Citra, I’ve actually been using this hop for part of my dry-hopping regime, for my house IPA too.

It’s a under appreciated hop these days, as people look for “joose” in their IPA and NEIPA’s. Some of other bittering hops brewers use are; Chinook (good for some “dankess”), Nugget (one I use a fair bit), Magnum and Warrior.

Whirlpool and Dry-Hopping

It’s the same with whirlpool and dry-hopping…test, test and test.

I’ve been looking at some of the new German hop varieties; like Callsita, Ariana and using some more established ones like Mandarina Bavaria. They are cheaper for me to source and use in China.

So, they can be added into the mix to bring the overall price down of the hop load. Furthermore, they offer some great aromas and really add to the total sensory of the beer.

I’m a big fan of Ariana as it can add some real nice tropical notes. So, please explore and experiment with other hops out there. If it was easier for me, I’d really be leaning on some of the Polish and Slovenian varieties out there.

When I was in Armenia, this Polish hop farm sent me some great samples of different Polish hops to try. Unfortunately, I can’t get them in China otherwise I’d be using them for sure.

Depending where you are these hops maybe cheaper to source but also make your beers interesting and possibly unique if nobody else is using them.

Hop Extracts

I’m brewing in Shanghai, as many of you know. So, pretty much all of the hops I use are imported. Hop prices are expensive for Chinese brewers, compared to many other countries.

I like to use Flex, which a CO2 extract for bittering. I’ve run the numbers and it works well, proving cost effective for me to add IBU’s as a bittering addition.

Using Flex might not be economical to all brewers. You need to check the figures, to see if the number of milliliters needed to reach your target IBU’s (using Flex), works out cheaper than the gram added equivalent using bittering hops.

Hop Cannons and Aroma Extracts

I’ve written about hop cannons in the past having, in article such as “Hop Cannons – Issues and Fixes” and “Hop Cannon – FAQ’s”. Modern breweries, producing a lot of hop forward beers are using hop cannons, as they can increase hop utilization rates.

As Justin Fox says,” When looking for cost savings in a brewery, the tangible expenses stand out as the easy wins, for example recovering cleaning solutions by way of a CIP cart, or increasing hop utilization via a hop cannon”

It’s believed using a hop cannon, you can reduce your hop loads by 25 to 30%. Your mileage may vary. Not all brewers are convinced by hop cannons. However, I’m a fan, as are many people like me are.

Chinese Made Hop Cannon for my client

When it comes to extracts, I’m new to them as well. There are hop extracts for aroma, both for the whirlpool (like Incognito) and to use in dry-hopping (Spectrum).

Please note: I know I’m discussing mostly Bath Haas products for hop extract examples. However, it’s because I’ve most experience with these products, as they are easier to source in China.

I prefer to write about products I’ve had experience with. However, there are other hop extracts you can try like Hopzoil from Glacier hops.

I’m not realty a fan of Hopzoil however, the aroma they produce seems fake to my colleagues and I, when we did some sensory bench trials.

Still, it’s worth trialing them yourself, if you can get some samples.

Hop Extracts and Trialing

Like we’ve said before, when it comes to using hop products it’s all about trialing and experimenting with them.

Most of the more established hop products can be “Googled”, to find forums where brewers discuss their experiences and results using them.

For example, from my own research (using in experiments and some “Google Fu”), it seems when using Spectrum only replace up to 50% of the dry-hop, with this product. It’ll not replace pellets entirely.

Furthermore, you need to work out if using these extracts make economic sense and determine if you like the sensory too.

Another reason brewers turn to products like Incognito and Spectrum, is they lead to less vegetative matter and trub in beer production. Resulting in lower beer losses, when compared to using all hops.

Commercial Brewing Cost Saving Tips – Yeast

Yeast is a bit trickier than the other main brewing ingredients, when it comes to cost savings.

Still, we’ll look at a few options here…

Buying Smaller Pitches and Propagating

Now propagating yeast isn’t an option open to everyone. You need to have some technical know-how, the right equipment and proper sanitary conditions.

There’s a more “ghetto” way to do this if you’ve a decent sized pilot system to feed you main brewhouse.

At the current brewhouse I’m running, we can buy a one-liter wet yeast pitches, and make a 150-liter starter with them. We then brew the main batch on the big system, then push starter we’ve made to the big batch in FV.

We make sure the cell count is appropriate. Typically, a 1-liter wet pitch goes into 150-liter starter. It’s then later pushed into a 1,500-liter main size batch. Typically, the big beer batch has an original gravity below 15° Plato.

Other Yeast Tips

Also look at yeast strains, you can use too. For example, a lot of breweries are using Kveik strains more. Kveik and high-pressure lager strains can complete fermentations quicker and/or at higher temperatures.

This will lead to energy savings and money saved. I know of several breweries who have switched from using US-05 to using Kveik Lutra. Furthermore, Kviek strains are hardy.

So, easier to keep and reuse. The more you can reuse yeast, the greater the savings to be had. It maybe time to speak with your yeast supplier and assess the situation.

Commercial Brewing Cost Saving Tips – Processing

When I talk about processing, I’m talking SOPs (Standard Operating Procedures). These are the procedures put in place as rules to follow when brewing, cellaring and packaging a beer.

When it comes to processing and finding those marginal gains to save money, Justin sums it up really well. So, over to Mr. Fox…

“It’s important to not lose sight of the indirect costs, which can rapidly increase when things go wrong. For example, extract efficiency has a direct correlation with how much malt you need to buy to make the beer, and driving this up will obviously reduce costs.

The watchout is, chasing a high extract can bring with it issues which will very quickly negate any realized cost savings. 

Consider the tangible benefit of driving extract efficiency in the lauter tun, going from 85% to 90% will save you less than a kilogram of base malt per HL.

Malt Being Milled Ready For Brewing

Lautering times can quickly blow out, when adjusting mills to crush finer, extended labour costs countering the malt savings.

Increasing sparge water volumes and temperatures will increase efficiency, but will also increase the amount of malt tannins in your wort.

Every cost saving is a compromise in some shape or form

So, always think of what you are giving up in order to save money.

The best target for cost saving is to eliminate (or at least reduce) any instances of producing beer that is not up to scratch, which will either damage the brand, or worse, need to be dumped.

It’s these events that are often never seen in the budget and cause the real headaches to the bottom line. “

This partially falls back to our last article on “How to Make a Good Commercial Beer”. Where we talk about how “beer quality is important” and long with value too.

Recommended Beer Processing Articles – Commercial Brewing Cost Saving Tips

I’ve written several articles on this site, looking into the different parts of the brewing process. Sharing tips on being more efficient. So, instead of writing it all out here, I’ll link to them for further reading:

Brewing Boiling Tips – Kettle Reactions – Looking at the science of the boil, offering tips along the way.

Mash Thickness Tips – We do a deep dive into the mash, explain what’s going on and how your actions effect the finished beer including efficiencies.

The Brewing Process Step-by-Step with Pictures – More of a top-down view of the brewing process, with some nuggets about beer processing thrown in.

This is a diagram I made for a client to help explain a possible system set-up for him

Stages of Beer Fermentation – We look what happens to beer in the cellar, offering tips along the way.

Spunding During Fermentation – One of my most popular articles, explains how to capture the CO2 created in the fermentation process, to naturally carbonate your beer. Leading to CO2 usage savings.

These articles go into some detail, about different processes to produce beer. They are sprinkled with tips on how to potentially save money in the brewery too.

Commercial Brewing Cost Saving Tips – Conclusions

Thanks for reading; I hope you’ve been able to pick-up some actionable content along the way. It was a fun article to write and thanks again to Justin and Sven for contributing.

Again, for Sven’s cost savings tips please see this addendum post we made. As the price of raw materials rise, due to a number of outside factors. I felt this article on commercial brewing cost savings tips, was at timely one to write.

As brewers we should always keep a close eye on the raw materials market, as well as for new companies entering the space.

For example, I recently got approached by the company called Amédée and hope to try their products soon. Thanks to Stephane for sending us some samples. I’ll be writing about them at a later date, when I’ve had the chance to trial them

Likewise, we should always be looking to improve/tweak our processes to see if we can save money without loss in beer quality. Certain techniques like “DIP hopping”, could actually improve sensory and save money too.

Anyway, thanks for reading and as ever, if you’ve any feedback or follow-up questions please feel free to email me at:

neil@asianbeernetwork.com

Or if you’d prefer to send me a message on your preferred network. Simply, scan the appropriate QR code in the image below, add me, then send me a message.

Need Help with Your Brewing Project?

I’ve been brewing for over 25-years in different parts of the world. I’ve overseen several installs and brewed on a number of systems. I worked in brewpubs and production breweries.

I now use the experience and knowledge I’ve gained to help other people, as a brewing consultant. If you’d like to chat about a project; to see if I might be able to offer assistance, then feel free to get in touch.

I can help in a number of ways:

• Assess your brewing needs over a FREE initial consultation call
• Assist with putting an equipment list together
• Work with you to communicate with brewing equipment suppliers, to get quotes
• Help evaluate quotes and choose the right supplier for your budget and needs
• Be in communication during the fabrication process
• If needed; visit the supplier factory to sign off on equipment before shipment

Plus, a whole lot more. I can also help with brewery processing to improve in-house SOPs. For example, I recently helped a client add spunding capabilities to their existing set-up.

For now, thanks for reading everyone, have a great day and happy brewing.

Synopsis

**Latest update: April 2023** Commercial brewery equipment cost is changing rapidly. After the COVID-19 pandemic, the global economy and trade gradually recover, with shipping costs stabilizing. In the new economic environment, craft beer projects indeed have the potential for good opportunities. On one hand, with the growing demand for high-quality and distinctive products among consumers worldwide, the craft beer market is expected to continue expanding. On the other hand, during the pandemic, people’s consumption habits have changed, with more and more people enjoying food and drink at home, bringing new demand to the craft beer market.

Breweries around the world come in different sizes and types. Some are big while some are operating on a small level. Their operations, cost, and revenues depend on their size mainly. Let’s say a microbrewery would fit only in one room and all procedures will be handled by only one person. As for a large commercial multinational brewery, they will have many employees working in different departments. Each department in this brewery will be dedicated to one type of operations and the employees working in that particular department will make sure their operations get done for their phase only. Despite the variability in size, the basic biochemical process is the same for beer brewing. Recently, before the outbreak of the coronavirus, people from different backgrounds have been establishing large breweries in their towns enjoying the low interest rates at the banks. These are not as big as the multinational brewing companies, but they certainly have made their cut in nearby bars and pubs. If you are thinking to opening a large brewery in your area then you need to buy commercial brewing equipmentcommercial brewing equipment , because large brewery need to handle different scale of operation. But how much does commercial brewery equipment cost? *We haven’t blogged yet about microbrewery equipment cost so if you are interested to know how much new or used microbrewery equipment cost or will cost you, feel free to ask our sales reps, or alternatively visit our microbrewery equipment page for more info.

The cost of commercial brewing equipment

The cost of commercial brewing equipment can vary widely based on several factors, such as the size of the brewery, the type of brewing system, and the specific components you require. Here is a general breakdown of costs for various types of commercial brewing systems:

Nano Brewery

(1 to 3 barrels): $10,000 to $50,000 Nano breweries are small-scale operations, typically producing less than 1,000 barrels per year. These systems are a popular choice for startups or brewpubs due to their lower upfront costs.

Microbrewery

(5 to 15 barrels): $50,000 to $200,000 Microbreweries typically produce between 1,000 and 15,000 barrels per year. These systems are popular among small to medium-sized independent breweries that distribute their products regionally.

Regional Brewery

(15 to 60 barrels): $200,000 to $1,000,000 Regional breweries produce larger volumes of beer, generally between 15,000 and 500,000 barrels per year. These systems are more complex and require a more significant investment.

Large-scale Brewery

(60+ barrels): $1,000,000 and up Large-scale breweries produce high volumes of beer, usually over 500,000 barrels per year. The costs for these systems can run into the millions of dollars, depending on the size, technology, and automation involved.

Keep in mind that these costs are rough estimates and can vary depending on factors such as the specific equipment and components you choose, as well as any customizations, shipping, and installation costs. It’s essential to work closely with brewing equipment manufacturers to get accurate quotes based on your specific needs and requirements.

Basic factors that affect brewing equipment cost

3 basic factors affect brewing equipment cost in 2021, which includes:

• What kind of brewery equipment material you use?
• Do you take brand new brewery equipment or second hand?
• What is the size of your brewery business plan?

Brewery equipment material:

Let’s talk about the 1st factor which is brewery equipment material. Just like in a kitchen, we have utensils of different materials, like we have glass, china clay, stainless steel, and nonstick utensils for different purposes, the same way, a brewery has kettles made from either copper or stainless-steel material.

• Copper brewery equipment: Copper brewery equipment has been used in beer brewing for centuries because of its properties. It transfers heat quickly and evenly in the kettle to boil the wort. Traditionally, people started off making beer in copper utensils because it is highly desirable for boiling wort at high temperatures.

But copper tends to react with other chemicals easily and give a metallic taste in beer. Also, different cleaning and sanitization processes can change the color of beer made in copper kettles. Copper is a way cheaper option in comparison to stainless-steel.

• Stainless-steel brewery equipment: In the modern world where we are all about the end product, all big commercial breweries use stainless-steel brewery equipment in the modern times.. Although the kettles used in there are not completely made of stainless steel, they have copper cladding on each kettle to ensure the traditional appearance, but it doesn’t interfere with the taste unless it’s the bleach.

Stainless-steel material doesn’t actively react with chemicals, but it tends to react with chlorine, so proper sanitization won’t affect the quality of beer made in stainless-steel brewing equipment. Also, stainless-steel is a stronger material than copper, so it doesn’t get pressurized when worts are boiled at high temperatures. Stainless-steel is expensive but it will be a durable choice in a brewery.

New or secondhand brewery equipment:

The production costs of commercial brewery equipment also depends on whether you buy the new equipment or used brewery equipment for your startup. The new equipment will be expensive than the secondhand equipment, of course, but it won’t affect your brewing at all if your used commercial brewing equipment is in good shape (make sure you check it before paying that guy from craigslist). Despite the copper and stainless-steel boilers and kettles, major equipment in a commercial beer brewing systems includes the following.

• Fermentation tanks: Fermentation is the next step after your wort is been boiled. Fermentation tanks hold the wort while yeast converts into sugar in the wort along with alcohol and carbon dioxide.  They usually have a cone-shaped bottom. The jacketed fermenter is best in use, A ½ bb non-jacketed cost about $400 and jacketed fermenter of 1 bb can cost you $3,200
• Kegs: Kegs are important because you need to store beer in a keg before moving it into the bottles or cans. A ½ bbl. The keg is the most common size, it cost you $125 and buying them in a bulk will get you discount. They need to be washed properly so you will need a keg washer which comes under $300.

Other equipment include refrigerators, bottling, filters, and cleaning supplies.

Size of your brewery:

The size of the brewery is a major factor in determining the cost of commercial brewery equipment. If you have a larger operation going on, you will be needing the bigger equipment and bigger brewhouse. A brewhouse features a mash mixer, hot liquor tank, whirlpool, boiling kettle, and lauter tun. Usually, the capacity of the brewhouse is determined in barrels (bbl.) unit. Different companies like us manufacture the brewhouse in different barrel capacities depending on the client’s needs. The retail prices of brewhouses are also different from size to size. The smallest brewhouse costs about $50,000.

Cost of commercial brewing startup:

Depending on your brewery size, acquiring a license and buying the good quality commercial brewing equipment, we can roughly estimate that it can go from $100,000 to $1million easily. Again, this is only a ballpark figure. For a person who is new to this brewing, the microbrewery option is far better. It is slightly smaller, but you will oversee everything in your own space. You can produce less than 15,000 barrels and 75 % of beer will be sold offsite. It will be a commercial venture and you can buy all the commercial equipment for a microbrewery in less than $100,000. The small equipment will take less space in the house. This will save you some major real estate costs and tax amounts. Your license cost will certainly get reduced. The further plumbing, electrical works, and flooring cost will eventually reduce because you are renting a small space. Day to day operation will be easy to handle, you can take a few employees to help you out as well. Finally, starting your brewery is an expensive and challenging task, you need to be committed and have a plan to manage the hurdles on the way. But good business always flourishes so hope for the best.

Customization of Commercial Brewing Equipment

In the brewing industry, each brewery has its unique needs and objectives. Therefore, customized commercial brewing equipment has become an increasingly popular choice. Customized equipment can better meet the specific needs of the brewery, improve production efficiency, and also create unique products. Here are some major considerations for customizing commercial brewing equipment.

1. Equipment Type

The first thing you need to determine is what type of equipment you need. This will depend on the scale of your brewery, the type of product you produce, your production volume, and other factors. For instance, if your brewery is small-scale, you might need a compact brewing system. If you plan to brew a variety of craft beers, you might need a versatile mashing system that can handle different brewing methods. If you have a large production volume, you might need a fermenter with a large capacity. In a more detailed scenario, if you are a small-scale brewery that focuses on producing a variety of craft beers, you might need a brewing system that is compact yet versatile. This system should be able to handle different brewing methods, such as infusion mashing, decoction mashing, and step mashing. It should also be equipped with a variety of brewing vessels, such as a mash tun, a lauter tun, a boil kettle, and a whirlpool. Each of these vessels should be designed to handle different brewing tasks, and they should be easy to operate and clean.

2. Equipment Functionality

What functionalities do you want your equipment to have? This will depend on your brewing process and your product requirements. For example, if your brewing process involves multi-step mashing, you might need a mashing system that can handle different temperature rests. If your product requires fermentation at low temperatures, you might need a fermenter that can accurately control the temperature. To elaborate, if you are brewing lagers, which require a multi-step mashing process and fermentation at low temperatures, you might need a mashing system with advanced temperature control features. This system should be able to accurately maintain different temperature rests, such as protein rest, beta-amylase rest, and alpha-amylase rest. It should also be equipped with a powerful heating system to quickly raise the temperature between rests. For the fermenter, it should be well-insulated to maintain low temperatures for extended periods, and it should be equipped with a reliable cooling system to quickly cool down the wort after boiling.

3. Equipment Material

What material do you want your equipment to be made of? The material of the equipment will directly affect its durability, cleanability, and the quality of the beer brewed. For example, stainless steel equipment is corrosion-resistant and easy to clean, making it a common material for brewing equipment. Copper equipment can provide a unique visual effect but requires more maintenance. For instance, if you prioritize durability and cleanability, you might want your equipment to be made of stainless steel. Stainless steel is highly resistant to corrosion, which is important for brewing equipment as it is often exposed to acidic wort and cleaning chemicals. It is also easy to clean, which can help prevent contamination and ensure the quality of your beer. If you want your brewery to have a traditional look, you might want some of your equipment, such as the brew kettle, to be made of copper. Copper has excellent heat conductivity, which can help achieve a more even boil. However, it requires regular polishing to maintain its shiny appearance, and it needs to be lined with tin or stainless steel to prevent the beer from coming into contact with the copper, which can cause off-flavors.

4. Equipment Design

What design do you want your equipment to have? The design of the equipment can not only affect its operation and maintenance but can also affect the visual appeal of your brewery. For example, you might want your equipment to have a user-friendly control panel for easy operation. You might also want your equipment to have a unique appearance to attract customers’ attention. For instance, if you want your equipment to be easy to operate, you might want it to have a control panel with clear labels and intuitive controls. The control panel should display all the important information, such as temperature, pressure, and flow rate, and it should allow you to easily adjust the settings. If you want your brewery to stand out, you might want your equipment to have a unique design. This could be a sleek and modern design with clean lines and polished surfaces, or it could be a rustic and traditional design with copper accents and wooden details.

5. Equipment Supplier

Choosing a reliable commercial brewing equipment supplier is key to customizing equipment. A good supplier can not only provide high-quality equipment but can also provide professional customization services, helping you design and manufacture equipment that meets your needs. When choosing a supplier, you need to consider their experience, technical capabilities, service quality, and other factors. For example, you might want to choose a supplier with many years of experience in the brewing industry. They should have a deep understanding of the brewing process and the needs of breweries, and they should be able to provide valuable advice on equipment design and selection. They should also have strong technical capabilities, with a team of skilled engineers and craftsmen who can design and manufacture high-quality equipment. In terms of service, they should provide comprehensive after-sales service, including installation, training, maintenance, and repair, to ensure that your equipment operates smoothly and efficiently.

Layout and Design of Commercial Brewing Equipment

The

layout and design of your commercial brewing equipment can significantly impact the efficiency of your brewing process, the quality of your beer, and the overall operation of your brewery. A well-planned layout and design can streamline your workflow, reduce labor and energy costs, and improve safety and cleanliness. Here are some major considerations for the layout and design of commercial brewing equipment.

1. Workflow Efficiency

One of the primary considerations for the layout and design of your brewing equipment is workflow efficiency. The arrangement of your equipment should facilitate a smooth and logical flow from one stage of the brewing process to the next, minimizing unnecessary movements and delays. In a more detailed scenario, you might want to place your milling equipment near your grain storage area for easy grain handling. Your mash tun should be located near your hot liquor tank for efficient heat transfer. Your fermenters should be placed close to your brewing vessels for easy transfer of wort. Your packaging equipment should be located near your cold storage area for quick and easy packaging and storage of finished beer.

2. Space Utilization

Space utilization is another critical factor in the layout and design of your brewing equipment. You should make the most of your available space, arranging your equipment in a way that maximizes capacity while allowing for easy access and movement. To elaborate, you might want to consider the vertical space in your brewery. For instance, you could stack your fermenters or use tall, slim fermenters to maximize your fermentation capacity. You might also want to use mobile equipment, such as portable pumps or mobile CIP systems, which can be moved out of the way when not in use. You should also leave enough space for cleaning, maintenance, and future expansion.

3. Safety and Ergonomics

Safety and ergonomics should also be considered in the layout and design of your brewing equipment. Your equipment should be arranged in a way that minimizes safety risks and promotes comfortable and efficient work conditions. For instance, you might want to place your brewing vessels at a height that allows for easy monitoring and cleaning without the need for ladders or platforms. You should also ensure that there is enough space around your equipment for safe operation, and that all safety devices, such as pressure relief valves and emergency stops, are easily accessible. You should also consider the ergonomics of your equipment, such as the height of control panels and the placement of valves and handles, to reduce physical strain and improve efficiency.

4. Cleanliness and Maintenance

Cleanliness and maintenance are also important considerations for the layout and design of your brewing equipment. Your equipment should be arranged in a way that facilitates cleaning and maintenance, preventing the buildup of dirt and bacteria and prolonging the life of your equipment. For example, you might want to place your brewing vessels with enough space around them for easy cleaning and inspection. You should also consider the drainage of your brewery, ensuring that all areas can be easily rinsed and that wastewater can be efficiently drained away. You should also consider the maintenance of your equipment, ensuring that all parts are easily accessible for servicing and replacement.

5. Aesthetics and Visitor Experience

If your brewery is open to the public, you should also consider the aesthetics and visitor experience in the layout and design of your brewing equipment. Your equipment should be arranged in a way that is visually appealing and provides an engaging and educational experience for your visitors. For instance, you might want to arrange your brewing equipment in a way that allows visitors to follow the brewing process from start to finish. You could also use visually appealing equipment, such as copper-clad brewing vessels or glass fermenters, to enhance the aesthetics of your brewery. You could also provide viewing areas, information boards, and guided tours to educate your visitors about the brewing process. In conclusion, the layout and design of your commercial brewing equipment is a complex task that requires careful planning and consideration. It involves balancing workflow efficiency, space utilization, safety and ergonomics, cleanliness and maintenance, and aesthetics and visitor experience. By investing time and effort in the layout and design of your brewing equipment, you can create a brewery that is efficient, safe, clean, and engaging for both your staff and your visitors.

How can we help you?

Yolong, as a professional brewing equipment supplier from China, can offer a variety of solutions to visitors interested in commercial brewing equipment. These solutions can include:

1. Comprehensive product range: Yolong can provide a wide range of brewing equipment for different sizes and types of breweries, such as nano breweries, microbreweries, regional breweries, and large-scale breweries. This includes brewing vessels, fermentation tanks, heat exchangers, pumps, filtration systems, and more.
2. Customized solutions: Yolong can work closely with customers to design and manufacture customized brewing equipment tailored to their specific needs and requirements, taking into account factors such as available space, desired production capacity, and unique brewing processes.
3. Quality and materials: Yolong is committed to using high-quality materials, such as stainless steel, in the construction of their brewing equipment. This ensures durability, ease of maintenance, and compliance with industry standards.
4. Advanced technology and automation: Yolong can incorporate advanced technology and automation options into their brewing systems to help improve efficiency, consistency, and control in the brewing process.
5. Shipping and installation: Yolong can provide support with shipping and installation of the brewing equipment, ensuring that customers receive the necessary assistance throughout the process.
6. Technical support and customer service: Yolong offers ongoing technical support and customer service to help customers maintain and troubleshoot their brewing equipment, as well as providing guidance on how to optimize the brewing process.
7. Training and consultation: Yolong can offer training and consultation services to help customers better understand the brewing process and how to effectively use and maintain their equipment.
8. Ancillary equipment and accessories: In addition to the main brewing equipment, Yolong can also supply ancillary equipment and accessories, such as kegging systems, bottling lines, and laboratory equipment, to provide a complete brewing solution.
9. Regulatory compliance assistance: Yolong can help customers navigate local, regional, and national regulations, ensuring that their brewing equipment meets the necessary health, safety, and environmental standards.

By offering these solutions, Yolong can cater to the diverse needs of visitors seeking commercial brewing equipment and provide them with reliable, high-quality, and cost-effective options for their brewing ventures.