A 30 barrel (bbl) brewhouse is a large-scale brewing system capable of producing 930 gallons per batch. 30 bbl systems are popular among microbreweries looking to expand production beyond the craft beer level.
Brewing Equipment Guide
A 30-barrel (bbl) brewhouse is a popular size for breweries aiming to distribute their beers, offering a larger production capacity than smaller setups while maintaining some flexibility compared to larger systems. Here’s a basic guide to the equipment you might find in a 30 bbl brewhouse:
Essential Equipment:
Hot Liquor Tank (HLT): Heats water to various temperatures needed throughout the brewing process.
Mash Tun: Where grains are mixed with hot water (mashing) to extract sugars and flavors.
Brew Kettle: Boils the wort (sugar water) to sterilize it, concentrate it, and add hops for bitterness and aroma.
Whirlpool: Separates the wort from the spent grain (trub) after lautering (draining the wort from the mash tun).
Heat Exchanger: Transfers heat between the hot wort and cold water to cool the wort down for fermentation.
Fermentation Tanks: Where yeast converts wort sugars into alcohol and carbon dioxide.
Brite Tanks: Used for conditioning, filtering, carbonating, and storing finished beer before packaging.
Optional Equipment:
Hopback: A vessel used to capture additional hop aroma and flavor from late and dry hops.
Wort Grant: A secondary vessel used to temporarily hold the wort while the lauter tun is being sparged (rinsed) with hot water to extract additional sugars.
Glycol Chiller: Provides chilled glycol to cool the jackets of tanks for temperature control during fermentation and storage.
CIP System (Cleaning In Place): A system for cleaning tanks and equipment without physically removing them.
Brewhouse System Sizing Table
| System Size | Max Batch Size | Annual Production |
|---|---|---|
| 7 bbl | 230 gallons | 1,500 bbls |
| 15 bbl | 465 gallons | 5,000 bbls |
| 30 bbl | 930 gallons | 10,000+ bbls |
| 60 bbl | 1860 gallons | 20,000+ bbls |
Vessel Sizes:
Hot Liquor Tank (HLT): Typically sized slightly larger than the brew kettle, around 35-40 bbls, to account for heating losses and potential hot water needs throughout the brewing process.
Mash Tun: Can be roughly equal to the kettle size (30 bbls) or slightly larger (35-40 bbls) depending on the desired grain bill size and lautering efficiency.
Brew Kettle: The core vessel, with a capacity of 30 bbls to accommodate the desired batch size.
Whirlpool: Typically sized around 10-15 bbls for efficient trub separation.
Heat Exchanger: Capacity is not defined by volume but by its ability to cool the wort to the desired fermentation temperature efficiently.
Fermentation Tanks: The number and size depend on your desired batch frequency, fermentation times, and beer styles. Typically, breweries use 2-4 tanks, each sized around 30-45 bbls.
Brite Tanks: Similar to fermentation tanks, the number and size depend on your needs. Usually, 1-2 tanks sized around 30-45 bbls are used.
Additional Considerations:
Wort Grant (Optional): Sized slightly smaller than the kettle, around 20-25 bbls, to hold the wort while lautering.
Glycol Chiller: Capacity depends on the number and size of jacketed tanks requiring cooling and the desired cooling speed.
Brewing Process Overview
The 30 bbl brewhouse brewing process contains the following major steps:
Milling – Cereal grains are crushed into grist to expose starch for mashing. Roller and hammer mills are commonly used.
Mashing – Grist is mixed with hot water in the mash tun. Enzymes convert grain starches to fermentable sugars over ~60 minutes.
Lautering – Sweet wort is separated from spent grains, which are discarded.
Boiling – The wort boils for 60-90 minutes with hops additions for bitterness, flavor, and aroma.
Whirlpool – Solids are settled out after the boil through a gentle swirling action.
Cooling – Heat exchangers quickly reduce wort temperature suitable for pitching yeast.
Fermentation – Yeast ferments sugars into alcohol and CO2 over 2-4 weeks.
Maturation – Green beer is conditioned in brite tanks before packaging.
30 Barrel Brewhouse Design and Customization
30 Barrel Brewhouse Design
A 30-barrel brewhouse is a mid-sized brewing system, larger than a typical nano-brewery but smaller than a regional brewery. It’s a good option for breweries looking to scale up production and distribution.
There are two main configurations for a 30-barrel brewhouse:
3-vessel system: This is the most common configuration and consists of a mash tun, lauter tun, and kettle/whirlpool.
2-vessel system: This system combines the mash tun and lauter tun into a single vessel, and is less common but can be more cost-effective.
The specific design of a 30-barrel brewhouse will vary depending on the brewer’s needs and preferences. However, some common elements include:
Mash tun: Where the grain is mixed with hot water to convert the starches into sugars.
Lauter tun: Where the wort (sugar water) is separated from the grain.
Kettle/whirlpool: Where the wort is boiled, hops are added, and the wort is clarified.
Hot liquor tank: Stores hot water for use throughout the brewing process.
Fermenters: Where the wort is fermented by yeast to produce beer.
Brite tanks: Used to store and condition the finished beer before it is packaged.
Control panel: Allows the brewer to monitor and control the brewing process.
The layout of a 30-barrel brewhouse will also vary depending on the available space. However, it is important to ensure that there is enough space for all of the equipment, as well as for the brewer to move around safely and efficiently.
30 Barrel Brewerhouse Customization
The craft beer industry is booming, and for ambitious brewers looking to scale up production, a 30-barrel brewhouse is a significant milestone. However, with a standard system comes the question: how can you make this equipment truly your own and optimize it for your specific brewing needs and brand identity? This is where the power of 30 barrel brewerhouse design customization comes in.
Tailoring Functionality:
Beyond the core brewing vessels (mash tun, brew kettle, etc.), customization allows you to refine the setup for efficiency and specialized brewing styles. Here are some key areas:
Number and Size of Vessels: Opt for additional kettles for simultaneous boils or dedicated sour beer production. You can also adjust the size of specific vessels based on your dominant beer styles. For example, a larger hop back can be beneficial for IPAs requiring extensive dry hopping.
Heating and Cooling Systems: Choose from steam, direct fire, or electric heating based on your energy preferences and budget. Similarly, explore options for hot and cold liquor tanks tailored to your brewing process and water needs.
Automation and Controls: Integrate automated brewing control systems to ensure recipe consistency and streamline production. This can range from basic temperature controls to full-fledged automation managing the entire brewing process.
Enhancing Aesthetics and Brand Identity:
A customized brewhouse isn’t just about functionality; it can also be a visual representation of your brand. Consider these possibilities:
Polished Stainless Steel: This classic choice exudes a professional and clean aesthetic.
Copper Accents: Copper kettles add a warm, vintage touch, perfect for breweries aiming for a traditional feel.
Custom Cladding: Incorporate branded elements like your logo or signature color scheme onto the brewhouse cladding to create a unique and memorable visual statement for your visitors.
Collaboration is Key
To achieve the perfect customized brewhouse, collaboration with an experienced manufacturer is crucial. They will work with you to understand your brewing specificities, space constraints, and budget limitations. They can then guide you through the design process, offering valuable insights and ensuring your vision translates into a functional and aesthetically pleasing brewhouse.
Brewhouse Installation, Operation and Maintenance
For aspiring brewers, the heart of their craft lies in the brewhouse – the specialized equipment responsible for transforming raw ingredients into the wort, the foundation of your favorite beer. But the journey from dream to draft involves more than just brewing passion. Setting up, operating, and maintaining a brewhouse requires careful planning, technical knowledge, and meticulous upkeep.
Brewhouse Installation: Planning is Paramount
Before the first batch simmers, thorough planning is crucial. Here are some key steps:
Define your brewery’s scale and production goals. This will determine the size and complexity of your brewhouse.
Choose a reputable equipment supplier. Seek companies with experience in your desired production capacity and offer installation services.
Secure a suitable location with proper utilities and space for the brewhouse and additional equipment.
Obtain necessary permits and licenses for operating a brewery in your region.
The installation process itself is often complex, involving:
Foundation preparation: Ensuring the weight of the equipment is properly supported.
Equipment placement: Positioning vessels, pumps, and piping according to the manufacturer’s specifications.
Electrical and plumbing connections: Setting up power supply and ensuring proper water flow.
Commissioning: Testing and calibrating all equipment before the first brew.
Operating Your Brewhouse: Brewing Magic in Action
Once installed, operating your brewhouse involves a series of well-defined steps:
Milling: Grinding the malted grain to release starches for conversion into sugars.
Mashing: Mixing the milled grain with hot water to allow enzymes to break down starches into fermentable sugars.
Lautering: Separating the sweet wort from the spent grain husks.
Boiling: Adding hops to the wort for bitterness, aroma, and preservation.
Whirlpooling: Removing hop trub (sediment) from the wort before fermentation.
Each step requires specific temperature control, proper timing, and adherence to sanitation protocols to ensure consistent and high-quality beer.
Maintaining Your Brewhouse: Ensuring Smooth Operations
Regular maintenance is vital for optimal performance and longevity of your brewhouse. Here are some key practices:
Cleaning and sanitation: Thoroughly cleaning all equipment after each brew to prevent contamination and maintain hygiene.
Preventive maintenance: Regularly inspecting and servicing equipment to identify and address potential issues before they escalate.
Calibration and adjustment: Ensuring all instruments and controls function accurately for precise brewing control.
Selecting a 30 bbl brewhouse Supplier
For passionate brewers ready to scale up their craft, acquiring a 30-barrel brewhouse marks a significant milestone. This equipment represents the heart of your operation, directly impacting beer quality, production efficiency, and ultimately, your brand’s success. Choosing the right supplier, therefore, becomes a critical decision with long-lasting implications.
This guide equips you with the knowledge and tools to navigate the selection process, ensuring you choose a partner that empowers your brewing journey.
Know Your Needs:
Production Goals: Assess your desired annual output and potential future growth.
Space Constraints: Measure your designated brewery space and ensure chosen equipment fits comfortably.
Customization: Determine if a standard model suits your needs or if specific modifications are crucial.
Budget: Set a realistic budget and anticipate potential add-on costs like automation features or fermentation tanks.
Research and Compare:
Industry Reputation: Explore established suppliers with a proven track record of delivering high-quality equipment and reliable service. Look for positive customer testimonials and industry awards.
Equipment Specifications: Compare details like material construction, heating systems, automation capabilities, and warranty coverage.
Customization Options: Investigate the level of customization offered by different suppliers. This could include modifications to vessel size, pump capacity, or integration with specific control systems.
Engage with Suppliers:
Request Quotations: Obtain detailed quotes from shortlisted suppliers, ensuring clarity on pricing, lead times, and payment terms.
Visit Facilities (if possible): Tour manufacturing facilities, if feasible, to assess production processes, equipment quality, and meet the team behind your potential brewhouse.
Ask Questions: Don’t hesitate to ask detailed questions about the supplier’s expertise, experience with similar projects, and post-sale support offerings.
Beyond the Equipment:
Installation and Commissioning: Inquire about installation and commissioning services, ensuring a smooth transition from delivery to operational readiness.
Training and Support: Evaluate the availability of training programs and ongoing technical support to equip your team with the knowledge and resources to operate and maintain the equipment effectively.
Building a Partnership:
Choosing a 30-barrel brewhouse supplier goes beyond simply acquiring equipment. It’s about establishing a long-term partnership with a company that aligns with your vision, understands your needs, and shares your passion for brewing exceptional beer. By carefully considering these factors, you’ll be well on your way to selecting a supplier who will not only provide the tools but also become a valuable partner in brewing your future, one successful batch at a time.
Comparing 30 Barrel Brewing Systems
| Pros | Cons |
|---|---|
| High degree of automation | Complex programming and controls |
| Labor savings at scale | Equipment cost is relatively high |
| Efficient utilization of ingredients | Signficant footprint required |
| Consistent quality control | Requires an experienced brewer |
| Expansion possible in future | Long lead time for delivery |
In conclusion, 30 barrel brewhouse systems enable medium to large scale commercial beer production while requiring substantial capital, floorspace, and operations expertise. Careful planning for this capacity expansion is vital for overall brewery success. Many equipment suppliers and options exist so companies should evaluate choices closely when selecting a system best matching their budget and brewing needs.
FAQ
Q: What throughput can a 30 bbl brewhouse produce annually?
A: Approximately 10,000-15,000 barrels per year assuming 5 brews per week and 75% uptime.
Q: Does the brewhouse come fully automated?
A: It depends on the supplier and options chosen, but many 30 bbl systems have at least some manual operation required. Higher cost can provide full touchscreen automation.
Q: What size building is needed to house a 30 bbl system?
A: Allow for at least a 800 – 1,200 sq ft footprint plus room for fermentation cellar and brite tanks. High ceilings are also required.
Q: Can I expand capacity in the future?
A: Yes, adding additional fermenters and brite tanks can increase annual capacity. The brewhouse itself can sometimes be expanded but may ultimately become the production bottleneck.
Q: What are the power and utility requirements?
A: Significant electrical (400+ amps at 480V, 3-phase), steam, glycol and CO2 consumption are needed, which adds operating expenses.