A 1 bbl brewing system is designed to produce 1 barrel or 31 gallons of beer per batch. This small-scale system is popular for nano and microbreweries getting started with craft beer production.
A Primer on 1 bbl brewing system for Craft Beer Enthusiasts
In the world of commercial brewing, the standard barrel contains 31 US gallons. So a 1 barrel or 1 BBL brewhouse is designed to produce 31 gallons per batch. That may not sound like much compared to mass market megabreweries cranking out millions of barrels annually. But for microbreweries focused on quality over quantity, a 1 BBL nano setup allows meticulous attention to each small batch while building a local fanbase.
With the rising popularity of craft beers, these compact 1 BBL systems are an appealing way for homebrewers to transition into commercial production on a small scale. The relatively affordable investment of around $15,000 to $30,000 makes the leap towards owning your very own brewpub or taproom seem within reach. But beyond the budget, there are many factors to weigh before joining the ranks of nano craft brewers. Understanding the equipment, process, customization options and hands-on work required is essential.
Equipment Guide – Components of a 1 Barrel Brewery
While 2 to 3 fermenters and a few serving tanks may be enough to get your microbrewery off the ground, professional grade brewing requires a specific set of equipment for handling each stage of beer production. Here are the core components found in a basic 1 barrel brewhouse setup:
Mash Tun – Mashing Extracts Fermentable Sugars
The mash tun mixes hot water and milled malted barley or other grains to convert starches into fermentable sugars that yeast can turn into alcohol and carbon dioxide. Efficiency and consistency during this mashing stage sets the foundation.
Lauter or Separator Tank – Rinsing Sugars from Grains
After mashing, the grain pulp known as mash is transferred to a lauter tun or separator tank for rinsing the soluble sugars into the liquid “sweet wort”. Spent grains are discarded once sugars are extracted.
Brew Kettle – Boiling the Hopped Wort
The sweet wort moves to the brew kettle for boiling with hops added at different times to impart bittering, flavors and aroma. Vigorous boiling also sterilizes the wort and drives off volatiles.
Whirlpool Vessel – Settling Hops and Coagulants
A whirlpool tank uses a gentle spin cycle to separate hop debris, coagulated proteins and trub from the boiled wort. This clarifies the liquid prior to fermentation.
Fermenter Tank – Yeast Work Its Magic
After cooling, yeast is pitched into the aerated and clarified wort in a fermenter tank to convert sugars into alcohol, CO2 and flavors. Temperature controlled fermentation is critical for quality.
Bright Beer Tank – Maturation and Carbonation
Post fermentation, the “green” beer is transferred to a bright beer tank for clarifying, carbonating to desired volumes of CO2 and maturing prior to packaging.
Piping, Pumps and Valves – Liquid Transfer
A full array of piping, fittings, flow control valves and pumps tie all the vessels together to move liquids from one process stage to the next.
Control Panel – The Brewery Brain
Sensors, automation and an integrated control panel manage equipment, temperatures, valve states and material flow throughout brewing.
| Equipment | Function |
|---|---|
| Mash Tun | Mixes milled grains with hot water to extract sugars |
| Lauter Tun | Separates sweet wort from spent grains |
| Brew Kettle | Boils wort with hops to impart flavor |
| Whirlpool | Settles out hops and coagulated proteins |
| Fermenter | Ferments beer with yeast |
| Brite Tank | Carbonates and clarifies beer |
| Piping | Transfers liquids between vessels |
| Control Panel | Controls temperatures and pumping |
Typical 1 bbl brewing system Layouts
With a better understanding of the major equipment involved, let’s explore how it all fits together in a nano brewhouse. There are two primary configurations for a 1 BBL brewery regarding equipment layout:
Linear Layout From Start to Finish
A linear layout places equipment in sequence following the natural flow path of brewing from raw ingredients to finished beer. From grain handling at one end, vessels continue on in a line – mash tun, lauter tun, brew kettle, whirlpool, then fermentation and serving tanks. This straight through arrangement minimizes liquids transfer distances. However, the longer footprint may be tricky to fit in tight spaces.
Compact Triangle Setup Saves Floorspace
For small buildings and sites, a triangular 1 barrel brewhouse layout is more space efficient. Here vessels are interspersed, prioritizing height over linear length to reduce the floorspace. Tall mash and lauter tuns fit snugly in one corner, the brew kettle in another, fermenters along the third wall. Pumps connect them over shorter transfer pipe runs. This does mean lifts or platforms are needed for accessing upper components. And a compact triangle layout leaves less room for expansion.
Step-by-Step Guide to Brewing Process with a 1 bbl brewing system
Now that we know what equipment enables those 31 gallons of craft beer let’s walk through how they operate in harmony during the full production process:
Milling – Whole kernel grains must first be cracked open or milled to make starches accessible for enzyme conversion in mashing. A roller mill or hammer mill crushes grains down to grits without excessive flouring.
Mashing In – The milled malt is mixed with hot water around 150°F to activate enzymes that convert grain starches into fermentable sugars over a 60 minute mash rest. This takes place in the mash tun.
Lautering – After mashing, the sweet wort is separated from spent grains which are discarded. Sparging rinses any remaining sugars from grain pulp in the lauter or separation vessel.
Boiling the Wort – The hopped up brew kettle boils the wort vigorously for 60-90 minutes. This extracts bitterness and flavor from hops while sanitizing and stabilizing the wort.
Settling Out Trub – The hot boiled wort spins in a whirlpool tank for about 30 minutes, using centrifugal force to settle hops and coagulants.
Cooling and Aerating – Before yeast can thrive, the hot wort must chill down rapidly to 65-68°F while absorbing oxygen. This occurs via plate heat exchangers and air infusion.
Primary Fermentation – Yeast is added to aerated, cooled wort in a fermenter for 4-7 days converting sugars into CO2, alcohols and flavor compounds.
Maturation – Freshly fermented “green beer” mellows in conditioning tanks allowing flavors to meld and yeast to settle out.
Carbonation and Fining – The bright beer tank carbonates, clarifies and cleans up beer with filtration prior to serving.
Packaging and Serving – After processing, beer moves to the tasting room for pouring pints or heads into the canning line to take out the door!
Factors to Consider When Designing Your 1 bbl brewing system
Beyond a basic 3 vessel brewhouse, crafting your own 1 barrel nano dream system allows customizing features to your vision, space constraints, budgets and future growth plans. Let’s explore what design options are on the table:
More Advanced Mashing Options
Infusion Mashing – Simple single temperature mash tuns are most affordable
Multi-Step Mashing – Continually adjustable mash tuns allow proteins and starches to be extracted at different temperatures over time for better efficiency and body. Useful for more complex beer styles.
Integrated Grant Design – Specialized lauter tun bottom draining directly into the brew kettle saves time and equipment. But this ties the grant and kettle sizing together.
Types of Brew Kettles
Direct Fire – Burners heating kettle bottom directly but less control over scorching.
Indirect Heat – Steam jackets or heat exchangers allow fine tuning temperatures without marring delicate worts. Useful for more technique-driven beers.
Fermenter Vessel Options
Open Fermentation – Allows direct yeast and CO2 interaction but increased risks of contamination. Provides distinctive flavors.
Closed Fermentation – Closed cylindrical conical tanks are easier to control and clean but require venting pressure buildup.
Custom Alloys and Metallurgy – Stainless steel is standard but premium grades or exotic metals can improve performance, longevity, and output quality.
Automation Levels
Manual – Completely hand operated valves and equipment. Lower cost but very labor intensive.
Semi-Automated – Compromise with automated temperature controls but manual transfers.
Fully Automated – Programmable controllers regulate entire brewhouse including valves between vessels and cleaning cycles. Requires specialized engineering and equipment.
Key Specs and Price Ranges of 1 bbl brewing system
Okay so with a grasp on equipment and operations, what can you actually expect to spend when purchasing a 1 barrel brew system? Costs vary between suppliers from entry-level basic 3 vessel setups starting around $15,000 up to elaborate premium rigs pushing $30,000 or above. Let’s break down determining factors:
Dimensions And Layout
Footprint restrictions play a major role – compact triangular rigs take up less floorspace but may require platforms and lifts to access vertically stacked components. Linear layouts allow walkable workflow but can stretch over 25 ft long. Ceiling height should accommodate boil kettles up to 8 ft tall.
Level of Automation And Controls
Fully automated 1 BBL breweries with programmable PLCs, actuated valves, and self-cleaning come at a premium. Semi-automatic functionality offers a compromise, but 100% manual operation requires far more hands-on labor.
Power, Utilities, And Infrastructure
mistress steam boiler, cooling water, drains, compressed air, ventilation and multiple electrical connections suited to a wet indu
Degree of Customization
An off-the-shelf 1 BBL turnkey system gets you brewing fast by keeping custom options limited. Unique layouts, exotic alloys, upgraded automation or niche accessories add cost but help match equipment to brewing goals.
Ancillary Equipment Extras
Pricing also depends on add-ons like fermentation temperature control, heat exchangers, grain handling, bottle fillers and clean-in-place (CIP) systems to ease cleaning labor. And don’t forget the tasting room furnishings!
Some popular nano-scale 1 BBL brewhouse equipment manufacturers include:
- ABS Commercial – $18K to $25K base price
- JV Northwest – $22K to $27K
- Marks Metalworks – $15K to $21K
- Premier Stainless – $19K to $23K
- SS Brewtech – $17K to $28K
- Stout Tanks – $20K to $30K
With such wide variability in pricing, you must carefully balance functionality, technology, customization and operating costs over future production goals. A good equipment supplier understands this balance and your aspirations. Which leads us into choosing the ideal 1 BBL system partner for your brewery.
How to Select the Best 1 BBL Brewhouse Manufacturer
Launching any commercial beer making operation is no small venture, so selecting the right equipment and integration partner can make all the difference between brewing success and headaches. Beyond comparing bids, consider these decision factors when choosing a 1 barrel brewhouse supplier:
Craftsmanship Quality
Build construction, welds, finishing and compliance with brewery quality certification standards indicate attention to detail that prevents problems down the road. Get references and visit existing installations when possible.
Customization Capabilities
Even at nano-scale capacities, no two breweries are alike. Choose a 1 bbl brewing system vendor with engineering know-how to adapt equipment specifications, dimensions and functionality to your goals rather than off-the-shelf packages.
responsive and Knowledgeable Support
From design consultation and equipment questions to installation help and operator training, find a supplier invested in smooth ongoing operations, not just the initial sale. Ask about service response times, parts availability and included manuals.
Testing and Proven Reliability in the Field
There will inevitably be some trial and error when commissioning a new 1 BBL system, but battle-tested manufacturers have worked out most kinks. Ask for uptime reliability stats, customer reviews and how they improved early systems.
Lead Times and Delivery Logistics
Whether 4 weeks or 6+ months, equipment build schedules vary dramatically between vendors. factor in your brewery opening timelines, financing and potential delays when assessing quotes.
Upgradability And Expansion Options
While nano-scale systems focus on small batches, successful microbreweries eventually grow. Discuss how easily 1 BBL components and infrastructure could support doubling or tripling capacity down the road.
Pros, Cons and Limitations of 1 BBL Brewhouses
Before committing to purchase your own mini 1 barrel brew system, honestly weigh benefits against practical drawbacks that could affect daily operations and profitability:
Pros
- Lower upfront capital investment than larger systems
- Highly customizable to unique space and brewing requirements
- Learn the art and science of commercial brewing hands-on
- Foster personal connection with local craft beer fans
- Innovation opportunities with experimental small batch recipes
Cons
- Equipment costs per barrel are higher than larger brewhouses
- Very hands-on manual labor – less automation increases staff workload
- Niche consumer base limits sales volume capabilities
- Expansion requires replacing major components
- Consistency and efficiency challenges until mastered
Limitations
- 1 barrel per batch sets strict ceiling on production volumes
- Extremely tight spaces makes equipment flexibility difficult
- Staff likely wearing multiple hats in each job function
While not insurmountable, these realities should be thoroughly considered before embarking on the 1 BBL nano-brew dream. Delve into the nitty gritty operational and financial details rather than getting bedazzled by shiny tanks! Now let’s answer some common questions from aspiring nano-brewers.
FAQ
What is a good brewhouse efficiency level for a 1 BBL system?
Target 50-65% mash efficiencies extracting fermentable sugars from grain when designing your 1BBL setup. This measures how much sugars make it into the wort compared to total grain weight. Efficiency improves with precise milling and mashing mastery.
Can I expand production capacity in the future beyond 1 barrel batches?
While 1 BBL systems allow some modular add-ons to grow, scaling beyond 10 barrels capacity likely requires replacing core mash tuns, kettles and fermenters. Carefully plan max size before installing or ensure your buildout space, utilities and budgets facilitate upgrades.
How many staff are needed to operate a small 1-2 BBL microbrewery?
For a nano scale startup, 1-2 skilled brewers can likely handle the hot side brewhouse operations and cold side fermentation cellars. But as production goals or varieties expand, more cellar workers, tasting room, sales, delivery and administrative staff will surely be needed. Start conservatively and scale up judiciously.
What additional equipment is required to package 1 BBL batches into cans, crowlers and kegs?
Basic brewing equipment produces only bulk beer. Packaging into cans, bottles, kegs or to-go containers requires further processing – cleaning, purging oxygen, filling, seaming and labeling. Both manual as well as modular automated equipment options exist for capping 1 BBL volumes.
How do direct fire vs indirect heat brew kettles compare?
Direct fire kettles feature burners right underneath for aggressive boiling but temperature control is trickier. Indirect heating uses embedded steam jackets or external heat exchangers to gently heat the wort avoiding scorches – better for delicate beer recipes but less vigorous boiling action.