Overview of 3 BBL Fermenter
3 BBL Fermenters are a common size for nano and microbrewery operations. Matching fermentation capacity to brewhouse size allows efficient beer production workflows.
This guide covers key considerations in selecting, designing, installing and operating 3 BBL Fermenter – variables that impact quality, throughput and scaling capacity cost-effectively.
Types of 3 BBL Fermenter
Standard 3 BBL fermenter vessels choices:
Type | Details |
---|---|
Conical Fermenters | Cone-shaped bottom collects yeast for easy removal. Accessories like cooling, carbonation. |
Cylindroconical Fermenters | Hybrid allows some yeast removal. Conical add-on option. |
Unitanks | Combined fermentation and conditioning tank. One vessel beer processing. Customizable. |
Open Fermenters | Simple design usually square or circular. Cannot remove yeast easily. Lower cost. |
Conicals and cylindroconicals allow yeast handling benefits but higher capital costs. Open top fermenters provide basic functionality at lower prices. Unitanks offer flexibility through integrated processing.
![3 BBL Fermenter](https://yolongbrewtech.com/wp-content/uploads/2018/06/Full-automatic-CIP-station-1030x773.jpg)
3 BBL Fermenter Design Factors
Key design considerations for 3 barrel fermenter systems:
Parameter | Recommendations | Customization |
---|---|---|
Dimensions | 24-36″ diameter, 84-96″ straight side height typical | Varies with aspect ratio, conical bottom design |
Material | Stainless steel (304, 316L) | Choose finish, thickness, insulation |
Volume | Adjust to match brewhouse batches & yeast pitching rates | 2-4 turns weekly ideal utilization |
Cooling | Glycol/steam jackets; cooling coils; chilling units | Balance cost, precision and response times |
Temperature Control | Automated PID controllers | Set multi-step profiles, alarms, monitoring |
Pressurization | Pressure rated up to 15 PSI | Certify >5 PSI for reliable carbonation |
Yeast Handling | Blow-off lines; carbonation stones; yeast dump valves | Level of automation vs manual operation |
CIP Systems | Spray balls; cleaning heads; foam retention basket | |
Other features | Thermowells; stands; racks; walkways; stairs |
Fine tune fermenter design and functionality based on existing infrastructure, beer types, production targets and budget.
3 BBL Fermenter Sizing
Properly size the fermentation system to match brewhouse capacity:
- For a 3 BBL brewhouse, have 10-15 BBLs total fermentation volume
- Allows 2-4 turns per week with proper yeast pitching and turnover
- With 12 BBLs fermentation space, produce 1250 bbls annual output from a 3 BBL brewhouse
- Scale horizontally adding more 3 BBL fermenters as needed
- Budget $2000-$4000 per barrel of fermentation capacity
Inadequate fermentation space bottlenecks beer output. Optimize vessel utilization through workflow scheduling before expanding.
Buying New 3 BBL Fermenters
When investing in new 3 barrel fermenter systems, buyers evaluate:
Consideration | Details |
---|---|
Price | $6000 – $12000 per 3BBL fermenter |
Lead Times | 14-18 weeks from order to delivery |
Vessel Choices | Conical, cylindroconical, unitanks, open tops |
Fabrication | Stainless steel grade and finish quality – 2B, electropolish etc |
Cooling Systems | Glycol, steam, chilled water; cooling jackets vs internal coils |
Automation Level | Manual operation vs automated temperature controls, monitoring etc |
Customization | Modified dimensions, addition of carbonation stone, yeast dump etc |
Warranties | Workmanship, parts replacement, service response terms |
Get multiple quotes. Choose balance of functionality, quality and budget fitting current and future production based on market research.
Buying Used 3 BBL Fermenters
Used and reconditioned fermenters can significantly reduce startup costs:
Sourcing – Check online listings regularly for availability. Be ready to act quickly if finding a functional used 3BBL system.
Evaluation – Carefully inspect vessel interiors and exterior for damage. Review maintenance logs if possible.
Refurbishing – Budget cleaning, passivation, cosmetic touch ups, replacement of worn parts like cooling jackets, fittings, gaskets etc.
Pricing – Condition significantly impacts used market value. Expect to pay 40-60% of a new 3 BBL fermenter if no major issues.
Transportation – Coordinate equipment dismantling, rental trucks for pickup and professional re-installation.
Testing – Validate cooling precision, pressure rating, seals etc before starting fermentation.
Though used vessels need more upfront effort, they can kickstart profitable 3 BBL brewery operations on a tight budget.
Popular 3 BBL Fermenter Manufacturers
Among the many 3BBL fermentation tank suppliers across the United States:
Brand | Description |
---|---|
[Brand 1] | Leading US manufacturer of uni and conventional fermenters for craft breweries |
[Brand 2] | German engineered stainless steel conical and unitank import |
[Brand 3] | Custom fabrication from Oregon specializing in high quality finishing |
[Brand 4] | Budget, made in China import conicals and open fermenters |
Also research local stainless steel fabrication shops able to make simple open or closed 3 BBL fermenters at reasonable costs from scratch per your specifications.
Installing 3 BBL Fermentation Tanks
To safely install 3 barrel fermenters:
- Space Planning – Arrange vessels conveniently for transfers but allow operator movement. Mark locations.
- Flooring – Reinforced concrete to support heavy loads. Slope gently to drains.
- Lifting & Positioning – Use jacks, lifts or rigging beams operated by qualified technicians to place vessels.
- Anchoring – Bolt conicals securely to stands. Brace cylindrical tanks. Ensure stability before use.
- Platforms – Install sturdy catwalks and stairs for top access on stacked fermenters.
- Plumbing – Connect cooling lines, glycol piping, electrical for temperature controllers and sensors.
- Commissioning – Clean and passivate tanks. Calibrate valves and instrumentation. Verify seam welds.
Safety – Confine space training. Warning signs. Emergency stop buttons.
Leave no shortcuts – professional installation prevents damage and enables safe operations.
Operating 3 BBL Fermenters
Consistent procedures operating 3 barrel fermenters maximize quality:
Cleaning – Follow CIP protocols before yeast inoculation to avoid contamination
Wort Transfer – Carefully move cooled wort from whirlpool vessel into fermenter. Aerate thoroughly.
Yeast Pitching – Ensure viability of correct yeast strains and precise pitching rates. Document cell counts.
Monitoring – Track density, temperature and yeast activity daily through fermentation. Log fermenter conditions.
Temperature Control – Maintain optimum profile over full fermentation cycle from active primary fermentation to conditioning phase.
Sampling – Pull taste samples aseptically to check flavor profile development and make recipe adjustments.
Yeast Handling – Remove yeast on schedule for harvesting or disposal. Follow safety procedures.
Hygiene – Strict sanitation between fermentation turns in all vessels, fittings and transfer hoses.
Consistent fermentation protocols result in clean, flavorful beers with the desired characteristics reliably batch after batch.
Maintaining 3 BBL Fermenters
To sustain performance and longevity of 3 barrel fermentation vessels:
- Gaskets – Replace door seals, lid gaskets and o-rings annually
- Welds – Inspect internally and externally for cracks or pits annually. Repair immediately.
- Pressure Test – Validate mechanical integrity and leaks above maximum pressure rating biannually.
- Valves – Actuate valves regularly. Rebuild sticky valves preventing wort and yeast flow issues.
- Instrumentation – Calibrate temperature sensors and density meters every 2-3 months for precise control.
- Cleaning – Descale tanks with acid cleaners quarterly. Inspect spray balls and CIP heads.
- Coatings – Re-passivate stainless steel periodically to prevent corrosion especially if caustic cleaning frequently.
Prevent issues through proactive maintenance – avoid stuck fermentations or contamination during peak brewing season.
Choosing Fermenter Manufacturers
Factors to consider when selecting fermentation tank suppliers:
Technical Expertise – Experienced engineering and stainless steel fabrication specializing in brewery vessels from simple to sophisticated automation.
Platform Offerings – Range of fermenter types and volumes using quality materials to suit current needs and future growth.
Manufacturing Standards – Consistent workmanship and finishing. Passivation, electropolish options. Verifiable sanitary welding procedures.
Customization Skills – Offer variety of fittings and accessories like cooling or carbonation upgrades tailored to needs.
Quality Control – Thorough inspection, cleaning, testing and documentation of vessels before shipping.
Services – Provide transportation coordination, site preparation advice and installation guidance.
Warranties – Clear coverage terms on both components and labor issues. Check service response reputation.
Evaluate company engineering competence, manufacturing standards and services when investing in new or used fermentation vessels.
![3 BBL Fermenter](https://yolongbrewtech.com/wp-content/uploads/2022/01/fermentation-tanks-1030x644.jpg)
Key Fermenter Supplier Comparison Factors
Parameter | Importance |
---|---|
Reputation & Experience | High |
Platform Scalability | High |
Price for Quality Ratio | High |
Lead Time | Medium |
Customization Range | Medium |
Automation Sophistication | Low |
Warranty Coverage | High |
Installation Support Services | Medium |
FAQ
Q: What size batch can a 3BBL fermenter handle?
A: A 3 barrel fermenter can effectively ferment a standard U.S brewers barrel batch of 31 gallons or 117 liters, allowing about 15% headspace. Some oversize a 3BBL tank closer to 4-5 barrels capacity.
Q: How many 3BBL fermenters are needed for a 3BBL brewhouse?
A: For a 3BBL brewhouse, have 10-15 barrels total fermentation capacity. So about 4 to 5 units of 3BBL fermenters is recommended to allow 2-4 turns weekly and smooth workflow.
Q: Can 3BBL fermenters be stacked?
A: Yes, 3 BBL conical and cylindrical fermenters can be safely stacked up to 2 high using stands. Ensure the floor can support the total weight load per square feet. Install rails, cages and platforms for safe operations.
Q: What temperature range can 3BBL fermenters support?
A: Most 3 BBL fermenters cool down to 32-34°F for cold crashing and carbonating if needed. Heating ranges vary more widely from ambient up to 80°F though usual maximum fermentation temperature needed is 68-72°F.
Q: How much do new vs used 3BBL fermenters cost?
A: New 3 BBL fermentation tanks cost $6000 – $12,000 each installed. Used reconditioned 3BBL vessels average $2500 – $7000 depending on type, configuration and refurbishment needed.
Q: How long do 3BBL fermenters last?
A: Well maintained stainless steel 3 barrel fermenters have a typical lifetime of 15-20 years in commercial production settings. Replacing cooling jackets, valves and gaskets can extend lifespan further.