1 BBL Brite Tank

30 BBL Brewing Equipment

30 BBL brewing equipments are optimized for rapidly scaling craft brewers aiming to expand distribution while retaining quality. This guide covers considerations for planning and operating 30 BBL brewhouses.

Overview of 30 BBL brewing equipments

With an annual capacity approaching 10,000 barrels, 30 BBL brewhouses position growing craft breweries for wider retail reach and added wholesale accounts.

Complete 30 BBL brewhouse package contains major equipment like:

  • 30 BBL Mash Tun
  • 30 BBL Lauter Tun
  • 30 BBL Kettle
  • Whirlpool
  • Heat Exchanger
  • Fermentation Tanks
  • Brite Tanks
  • Piping, pumps and controls

Additional equipment like grain handling, CIP, air compressors, chilling systems and wastewater are also included in turnkey configurations by reputable vendors.

When evaluating and designing 30 BBL brewhouses, key considerations include:

Production Volume

Carefully match brewhouse capacity to forecasted annual barrelage to ensure good utilization rates rather than over-building. A rule of thumb is 120-250 barrels output per batch.

Infrastructure Requirements

Larger equipment and batches drive up ancillary infrastructure needs – boiler capacity, chilling, wastewater, etc. Plan for added capital costs for these systems…

30 BBL Brewing Equipment
2vessel Brewing equipment

Types of 30 BBL brewing equipment

The major vessels and components in 30 BBL commercial brewing systems include:

EquipmentDescription
Mash TunMixes crushed malt with hot water for starch conversion to sugars via natural enzymes
Lauter TunSeparates wort from spent grains after mashing
KettleBoils wort with hops for bitterness, flavor and aroma
WhirlpoolSettles out particulates after boil for clear wort
Heat ExchangerRapidly cools hot wort to pitching temperatures
FermentersFerments cooled wort into beer over 5-7 days on average
Brite TanksCarbonate, clarify and store beer prior to packaging
PipingFood-grade stainless steel pipes transferring liquids
PumpsCentrifugal, rotary or piston pumps for fluid transfer
ControlsAutomated measurements, valves and record-keeping

30 BBL Brewing Process

A typical 30 barrel four vessel brewhouse utilizes the following modular process flow:

Milling – Barley malt is dry milled with roller mills or hammer mills for grain crushing to expose starch for mashing while controlling flour.

Mashing – Milled grains are mixed with hot water in the mash tun for natural enzymatic conversion of starches into fermentable sugars. Usually conducted in staggered temperature rests targeting various sugar profiles.

Lautering – The mash seperates into sweet wort and spent grain in the lauter tun. Spent grains are discharged while clear wort recirculates before transferring to the brew kettle.

Boiling – In the brew kettle, wort is sterilized and hopped for bitterness, flavor and aroma at rolling boil. Evaporation concentrates sugars and inhibits microbial growth.

Whirlpool – Coagulants help sediment settle as a cone in the whirlpool vessel when rotated after boiling, allowing transfer of clear wort to the heat exchanger.

Cooling – Plate heat exchangers rapidly cool hot wort to prevent contamination and prepare for fermentation yeast pitch.

Fermentation – Yeast converts sugars in cooled wort to CO2, alcohol and flavors over approximately one week before transferring to conditioning tanks.

Conditioning – Beer is carbonated to style specifications and clarified in conditioning tanks prior to packaging.

Packaging – Bright beer moves to bottling, canning or kegging lines for packaging final product.

30 BBL System Suppliers and Pricing

SupplierPrice Range
AAA Metal Fabrication$350,000 – $1,100,000
MW&L$400,000 – $1,200,000
Premier Stainless$375,000 – $1,250,000
Psycho Brew$450,000 – $1,400,000
Portland Kettlehouse$550,000 – $1,500,000
JV Northwest$425,000 – $1,350,000

Pricing varies based on materials (stainless vs. carbon steel), valves and automation selected along with any customization needs. Get quotes from multiple vendors.

Key Price Factors:

  • Stainless adds ~30% versus steel clad carbon steel vessels
  • Grain handling systems $30,000+
  • Automation controls from ~$75,000+
  • Installation, shipping and taxes additional..

Operation, Cleaning and Maintenance

ActivityDescriptionFrequency
CalibrationEnsure sensors and measurements are accurate.Monthly
InspectionsCheck vessels, valves and pipes for damage/leaks.Daily
CIPAutomated clean-in-place cycles.Each batch
Tank purgingCO2 line clearing prevents oxidation.Quarterly
Preventative maintenanceTunings, lubrication and adjustments.Annual

How to Choose a Brewhouse Supplier

Key factors in selecting 30 BBL brewing system partner:

CriteriaConsiderations
BudgetEquipment pricing, installation fees, shipping costs
Lead timeProduction planning schedules, financing
CustomizationMatch layout, dimensions and flow requirements
AutomationLevel desired for operation, cleaning and record-keeping
ExperienceYears in business, number of systems built
ServiceInstallation help offered, maintenance contracts
CertificationsASME, UL, OSHA, CRN conformance to North American standards
WarrantyCoverage terms for labor, components, vessels
ReferencesFeedback from existing customers

Get quotes from at least 3 vendors to balance price, construction quality and service reputation. Prioritize suppliers accommodating custom options tailored to your brewhouse needs…

Pros and Cons of 30 BBL Systems

ProsCons
Optimized batch size for rapidly growing breweriesLarger batches risks quality control vs. smaller batches
Enables wider production diversitySignificant infrastructure investment needed
Economies of scale improve marginsSeasonal demand fluctuations can hurt utilization
Headroom for continued growth before maxing out capacityHeightened QA/QC discipline critical
Option to sell excess capacity via contract brewing

Key Takeaways

  • Match 30 BBL system capabilities to production plan and expansion roadmap
  • Carefully evaluate brewery infrastructure upgrades required
  • Gets growing brewers to ~10,000 BBL annual capacity

FAQs

Q: What size batches can 30 BBL breweries produce?

A: With ~200 barrels per batch, 30 BBL breweries can reach nearly 10,000 barrels annual capacity operating at reasonable utilization rates.

Q: What raw materials are needed for 30 BBL brewhouses?

A: Key consumables are malt, hops and yeast. A 30 BBL system requires ~900-1500 lbs per batch plus filtration media, cleaners, lubricants etc. Proper storage space is necessary.

Q: Should breweries buy new or used equipment?

A: High quality new 30 BBL equipment ensures longevity, efficiency and ease of maintenance for rapid growth phase breweries. But used systems with upgraded components can also offer big cost savings.

Q: How many people are required to operate a 30 BBL brewery?

A: Excluding the taproom, a 30 BBL production scale brewery can be operated by head brewer plus 4-6 employees handling cellar, packaging, inventory, distribution and assistant brewing. Use contractors to assist with seasonal spikes or large expansion projects.

Q: What quality control is needed for 30 BBL batches?

A: Increased lab testing and record-keeping for raw materials, in-process metrics and finished beer become essential at this scale. Tighten SOPs and implement lean manufacturing techniques to ensure consistency.

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