30 Barrel Brewhouses
30 bbl brewhouses are medium-sized professional beer production systems with an output capacity of 930 gallons or 3,510 liters per brewing batch. They are popular among expanding craft breweries looking to upgrade from pilot systems to higher volume commercial scale setups.
30 Bbl Brewhouse Equipment Guide
Main Components:
- Mash tun – Stainless steel vessel where grist is steeped in hot water to extract sugars
- Lauter tun – Separates sweet wort from spent grains
- Brew kettle – Wort is boiled with hops here
- Whirlpool – Settles out proteins, hops and coagulated particles
- Heat exchanger – Cools hot wort to fermentation temperature
- Fermenters/Brite tanks – Fermentation and carbonation
Auxiliary Equipment:
- Grist case, mill, auger – Handles raw ingredients
- Piping, pumps, valves, sensors – Fluid transfer
- Control panel, software – Automated process operation
- Grain handling system – Removes spent grain
- CIP system – Interior cleaning
Optional:
- Filtering system – Enhanced wort clarity
- CO2 recovery – Saves on gas usage
- Steam generation – Internal heating unit
30 Bbl System Sizing
| Feature | Typical Specifications |
|---|---|
| Total footprint | 700 – 1300 sq.ft |
| Ceiling height | 16 – 24 feet |
| Floor weight loading | 1500 – 3000 lbs/sq.ft |
| Electrical load | 100 – 250 kVA |
| Peak water demand | 30 – 50 GPM |
| Drain size | 4″ minimum |
| Compressed air | Up to 30 CFM |
30 Bbl Brewhouse Design and Customization
Commercial 30 bbl brewhouses are mostly custom fabricated to match specific production goals, space constraints, and budgets.
Key design choices include:
- Vertical vs. horizontal layout
- Single vs. double brewing process
- Direct vs. indirect heating
- Level of automation
- Made to order vs. modular construction
- Material choice – stainless steel, copper, etc.
- Type of fermentation – open vs. closed tanks
- Serving tanks – brite vs. traditional
- Additional functions like wort aeration, filtering, steam generation, etc.
Within a fixed footprint, prioritizing taller tanks yields higher capacity while shorter widths improve access. Tradeoffs are made between initial cost, production efficiency, consistency, labor requirements, maintenance needs and other factors.
Choosing a 30 Bbl Brewing System Supplier
Reputable equipment manufacturers for medium scale breweries are:
American:
- JV Northwest
- Premier Stainless Systems
- Specific Mechanical Systems
- Psycho Brew
- AAA Metal Fabrication
German:
- Kaspar Schulz
- Keg King
Italian:
- MME
- MCC
Chinese:
- Tiantai
They supply pre-built or custom fabricated breweries costing $100,000 to $250,000 depending on dimensions, materials, features and accessories selected.
Key Selection Criteria
| Parameter | Importance |
|---|---|
| Build quality and durability | Very high |
| Dimensional accuracy | High |
| Welds and finishes | High |
| Automation capabilities | High |
| Brand reputation and reviews | High |
| Customization flexibility | Medium |
| Hop utilization and yield | Medium |
| Order lead time | Medium |
| Affordability | Medium |
| Operator training support | Low |
| Warranties and service contracts | Low |
Installing and Operating a 30 Bbl System
Proper installation and maintenance helps achieve safe, efficient functioning and maximize equipment lifetime.
Facilities Setup
- Flooring with good drainage and chemical resistance
- Load-bearing walls and ceilings
- Sloped surfaces to avoid fluid accumulation
- Access platforms and catwalks if height over 6 feet
- Ventilation hoods over boil kettles
- CO2 venting system with sensors
- Lighting fixtures – LEDs avoid breakage
Daily Operation
- Follow manufacturer instructions for each process stage
- Track brew sheet calculations and measurements
- Inspect functioning of valves, motors, sensors
- Monitor flow rates, pressures and temperatures
- Collect samples and record analytics
- Perform problem diagnosis for unexpected readings
- Coordinate grain handling, transfers, cleaning with teams
Maintenance
| Task | Frequency |
|---|---|
| Interior/exterior cleaning | Each batch/weekly |
| Gasket inspection | Monthly |
| Replace fluid filters | Quarterly |
| Sensor calibration | Biannual |
| Valve and pump overhaul | Annual |
| Tank/pipe passivation | Every 2-3 years |
Comparing Pros and Cons of 30 Bbl Setups
Advantages
- Large batch volumes improve efficiency
- Height allows gravity flow transfers
- Automated operation possible
- Flexible customization options
- Higher output meets market demand
- Prevents bottlenecks in production
Disadvantages
- Expensive equipment and installation costs
- Large floor space requirement
- Height impacts maintenance access
- Complex troubleshooting required
- Long lead times for custom fabrication
FAQ
Q: What is the best 30 bbl brewhouse brand?
A: Premier Stainless Systems, Specific Mechanical Systems and JV Northwest have excellent reputations but choice depends on specific brewery requirements.
Q: How long does it take to produce 930 gallons of beer?
A: Around 8 to 12 hours depending on the recipe and automation level.
Q: What problems can occur with 30 bbl systems?
A: Improper wort aeration, unplanned pressure buildups, temperature fluctuations outside critical limits, pump failures blocking transfers.
Q: How many people are needed to operate a 30 bbl brewhouse?
A: 2-3 trained personnel can manage the full production process efficiently.
