Turnkey brewing systems are basically, ready to use brewing set-ups delivered or installed at the doorstep. Built by one manufacturer, these systems encompass all the constituents and tools needed for a seamless and efficient operation of brewing activities. Turnkey brewing system is particularly beneficial for small to medium-sized breweries as well as brewpubs since it enables them to commence production without considerable installation or configuration.
Key Takeaways
- The turnkey system of manufacturing beer provides a complete brewery that is ready to be used immediately after delivery.
- A sole supplier designs and manufactures these systems thereby being responsible for the whole project.
- Key elements of turnkey brewing system include brew vessels, fermenters, heating/cooling equipment and controls including pumps, heat exchangers, piping etc.
- For this reason, small medium sized breweries can benefit from having turn – key systems which will help them start production very fast.
- Modular design of turn-key systems allow for expansion in future and scalability.
Understanding Turnkey Brewing Systems
1、Definition and Overview
A turnkey brewing system refers to a whole project, which is designed and produced by only one manufacturer who is responsible for all aspects of it: starting from designing and ending with installation and putting into operation. In this case the client receives a completely integrated and tested set that is ready to go with minimal settings or configuration. This equipment is usually used in small breweries or brewpubs that do not wish to spend time and resources to search for various vendors’ components.
2、Key Components
There are several key components of a turnkey brewery necessary for beer brewing:
Mash Tun
Lauter Tun
Brew Kettle
Whirlpool
Fermenters
Lagering Tanks
Working together, these parts help make the raw materials into finished beer thus making brewing process smooth.
3、Benefits of Turnkey Systems
Turnkey systems have some advantages including:
- Ease of Installation: As all parts come from one seller, installation becomes simple and fast.
- Cheapness in Buying: Purchasing complete system from single vendor can be more cost-effective than buying individual items off different suppliers.
- Scalability: Brewery growth requirements may be easily met by means of turnkey solutions.
Thus, turn-key brewery systems are more suitable for smaller self-made breweries than commercial breweries which aim at flavor production and brewing processes.
Key Components of a Turnkey Brewing System
A turnkey brewing system is an entire package with all necessary equipment needed to start producing beer. It provides flexibility so that any future expansion or customization could be done based on specific needs of a given brewery.
Advantages of Using a Turnkey Brewing System
1、Ease of Setup
Speed and Simplicity For instance, what if immediately after being handed the keys to a brewery, you could start making your own batch of craft beer? This is especially useful for people who desire to capture the market fast or do not have the technical expertise of opening a brewery.
2、Cost Efficiency
In some cases, small and medium sized breweries or brewpubs that are looking at starting up without having to bother themselves with time consuming equipment sourcing and assembling processes from different suppliers resort into turnkey brewing systems. They can also be a great choice for breweries seeking expansion or those planning to upgrade their existing systems.
3、Scalability
Several main beer brewing equipment that makeup turnkey brewery include mash tun, lauter tun, brew kettle and whirlpool thus enabling easier increase in production whenever required. This is particularly helpful for growing breweries needing a system that can grow them as well.
Turnkey brew systems from Blichmann Engineering provide almost everything needed for starting to brew and are designed specifically.
It’s really simple – experience true ‘turnkey’ brewhouse!
Installation and Commissioning Process
1、Pre-Installation Planning
The smooth running of installation will depend on pre-installation planning. Our team of experts has over 20 years’ experience in the brewing industry hence we can create any project regardless of how unusual it is: design, delivery, and commissioning. We collaborate with you, your architects and engineers to construct a right system for your space including system layouts with suggested workflows, process plans and spatial requirements. Brewmation can provide electric load specification sheets for permit applications and contractor support.
2、On-Site Installation
This involves close collaboration between us with your contractors like electrical, plumbers, HVAC technicians as well as steam fitters. Through Skype or FaceTime, Brewmation helps you install your system at times by visiting on-site. Also we work together with inspectors so that we review UL listing and other electrical details so that we meet regulatory requirements during this stage which ensures proper installation of this equipment by our company’s experts themselves.
3、System Testing and Training
Your turnkey brewing system will perform at its best only if it has been subjected to system testing and training. Training will be done through various platforms such as email, Skype, FaceTime etc. We will also provide replacement parts and technical support after installation is complete. This extensive approach helps you to operate the new system efficiently.
Proper planning and working with professionals can simplify the installation and commissioning process significantly thus allowing quicker start of your brewing operations.
Maintenance and Support for Turnkey Brewing Systems
For the long life span of your brewing equipment, regular maintenance as well as cleaning is important. There are specific manuals provided by most manufacturers which can help in servicing of these systems; they are very useful when it comes to maintaining such systems. Furthermore, after sales support and training sessions can be so helpful.
1、Routine Maintenance
Preventive maintenance entails several primary tasks:
- Regular cleaning of fermentation tanks and brewing vessels to avoid contamination.
- Checking control systems for correct operation.
- Lubricating moving parts for reduced wear and tear.
- Check for signs of damage or wear out and deal with them promptly.
2、Troubleshooting Common Issues
Maintenance on a regular basis does not guarantee that no issues will arise. Common problems include:
Inconsistent temperature control
Pipe or valve blockages
Faulty sensors or controls
For any of these, refer to the manufacturer’s manual for troubleshooting procedures. Quick customer service can also be of great help.
3、Supplier Support Services
Most suppliers provide complete support services for customers such as:
After-sales support services in order to address any post-installation problems that may come up.
Training programs to help your team understand how to operate and maintain the system properly.
Availability of spare parts and replacement items.
Maintenance-friendly design: consider equipment that is easy to clean and maintain for uninterrupted brewing operations.
Case Studies of Successful Turnkey Breweries
1、Small-Scale Breweries
The turnkey systems have changed everything in small-scale breweries. This way they could open quickly while making top-quality beer with modest upfront costs. The ease of setup and the ability to produce consistent brews have made turnkey systems a popular choice among small-scale brewers.
2、Medium-Sized Breweries
When it comes to medium-sized breweries, turnkey systems help them increase their production capabilities in the most efficient manner. They make it possible for new equipment to be incorporated into the operations of a brewery without any hindrance and this guarantees that brewing goes on smoothly. Turnkey systems are versatile and offer solutions for medium-sized breweries with different needs as they seek to scale up.
3、Brewpubs
Turnkey systems are also applied in brewpubs where both a pub or restaurant and a brewery are combined into one establishment. Customer experience is enhanced by making a variety of beers onsite hence driving sales. Brewpubs can have an opportunity to taste out new flavors and styles while using finished systems thus becoming more adaptable which helps them cope with ever changing customer’s tastes.
They promote diverse businesses; therefore, they may fill various different roles like satisfying beer drinkers wherever they might be found since these aren’t fancy brothels but customers want good booze.
Conclusion
In short, a turnkey brewing system gives breweries a total and no-stress solution that helps them with operations and quick production. When such systems are bought from one manufacturer, all these complications of sourcing and putting together individual components are removed. This makes them perfect for small to medium-sized breweries and brewpubs wishing to expand their production capacity or improve their existing set-ups. Thus, brewers can concentrate on the most important thing –making high-quality beer more so if they have an integrated and tested system that is easy to operate.
FAQ
- What does it mean when we say it is a turnkey brewing system?
A turnkey brewing system referrers to fully functional brewing setup in which all functions are ready for use upon installation or delivery. This includes equipment for making various types of beers like fermenters, heat exchangers, pumps, pipes and controls among others.
- What are the major parts of a complete turnkey brewing system?
Commonly, mash tun, lauter tun, brew kettle, whirlpool, fermenters,lagering tanks,bright tanks,pumps,piping systems ,control systems,and heat exchangers are key elements found in such full kits.
- Why should we use a ready-made brewing system?
The advantages of using a turnkey brewing system include easy installation, cost-effectiveness, and scalability. This mean it can be incorporated easily into existing systems.
- Who benefits from having a ready-made brewing system?
Turnkey brewing systems are useful for small to medium-sized breweries or brewpubs that want to start producing beer quickly without the hassle of sourcing and assembling equipment from different vendors. They are also suitable for breweries who would like to increase their production capacity or upgrade their current equipment.
- How do I choose the right turnkey brewing system?
When choosing the correct turnkey brewing system, you need to look at your brewery’s needs and evaluate suppliers while considering your expansion plans. It is essential that you choose one which will satisfy your present production requirements but with adequate room for growth.
- What does the installation and commissioning process involve in case of a turnkey brewing system?
Usually, there is always pre-installation planning, on-site installation, system testing, training during installation and commissioning process. The supplier ensures that the complete functionally awaits onward functioning.