Overview of Conical Fermenters

Conical fermenters, sometimes referred to as uni-tanks or uni-vessels, are a type of fermentation tank used in brewing beer and other alcoholic beverages. They get their name from their conical shape, with a broad base that tapers to a narrow top.

Key Features and Benefits

Some of the main features and benefits of conical fermenters include:

• Efficient design allows for combined fermentation and conditioning in one tank
• Cone-shaped bottom makes it easy to collect yeast and trub
• Integrated cooling jackets or glycol coils for temperature control
• Sample valves for taking hydrometer readings and testing beer
• Can modify tank pressure for fermentation, carbonation, transfers
• Available in different materials like stainless steel and plastic
• Range of sizes from 3 gallon homebrew models up to 5000 gallon industrial scale
• Lower risk of oxidation and contamination compared to transferring between multiple vessels

Equipment Guide – Conical Fermenter Types

Type	Description	Typical Uses
Plastic Conical Fermenters	Inexpensive, lightweight, translucent plastic allowing visibility. Available in 3-15 gallon sizes.	Homebrewing, pilot systems
Stainless Steel Uni-tanks	Commercial-grade stainless steel conicals ranging from 30-5000+ gallons. Jacketed, pressure-rated.	Pro and commercial breweries
Half-Barrel Conicals	~15 gallon stainless mini-conicals designed for homebrewers. Combine features of uni-tanks in a smaller format.	Advanced homebrewing
Open Top vs Closed Top	Open top models have large openings for loading fruit, dry hops. Closed top have smaller ports.	Breweries choose based on process requirements
Cooling Options	Glycol/recirculating chilling	Temperature control during fermentation
Pressure-rated	Rated for pressurization	Carbonation, transfers under pressure

Conical Fermenter Sizes

Conical fermenters are available in a wide range of volumes to meet different brewing production requirements:

Size	Capacity	Typical User
3-30 gallons	Homebrew batches up to ~10 barrels	Homebrewers and nanobreweries
30-300 gallons	Pilot batches up to ~60 barrels	Pilot systems, pub breweries
500-5000+ gallons	Full brew lengths for production breweries	Production craft breweries
3000-30000+ gallons	Large batch fermentation	Industrial breweries

The dimensions, height, and footprint increase proportionally with capacity based on the conical design. Options are available for tank customization.

Conical Fermenter Design and Layout

Conical fermenters have an internal cone-shaped bottom and cylindrical top half. This shape allows sedimentation of yeast and trub during fermentation and conditioning.

Key design elements and parts of a conical fermenter include:

• Cone base tapering to collection ball valve
• Cylindrical upper tank with dish or domed lid
• Sample valve, sight glass, air vent ports
• Integrated cooling jackets or glycol in/out ports
• Pressure rating for pressurization
• Solid or screen false bottom to separate trub
• Sanitary fittings – valves, ports, connectors
• Stand/frame with adjustable feet

Many custom options are available:

• Manways for access
• Spray balls/nozzles
• Integrated heaters
• Variable volume marker
• Casters for mobility
• Ladder and platform for tank access

Choosing a Conical Fermenter Supplier

Reputable conical fermenter manufacturers and suppliers include:

Company	Location	Price Range
Ss Brewtech	USA	80-9000
Spike Brewing	USA	90-500
Blichmann Engineering	USA	999
Uni-Tank	Canada	9-700
ABE/Maverick	USA	999
Rolec	UK	999
Paco/Andino	Spain	9-9999

Key factors when selecting a conical fermenter supplier:

• Budget – Prices range widely depending on size and features
• Quality and durability – Stainless steel thickness, welding, finishing
• Lead time – Production time and availability
• Customization options – Support for special options
• Customer service – Responsive support representatives

Be sure to get multiple quotes before purchasing as prices can vary significantly.

Installing and Operating Conical Fermenters

Proper installation and operation ensures safety, efficiency and beer quality:

• Review manufacturer instructions for setup and cleaning requirements
• Level and secure tank on stand allowing access
• Connect cooling and glycol lines per spec
• Attach sanitary fittings; check for leaks under pressure
• Test sample valves and ports during cleaning cycles
• Monitor fermentation temperature and make adjustments
• Use calibrated yeast pitch rates based on batch size
• Ensure stable fermentation before crash cooling or transferring

Conical Fermenter Maintenance

Routine maintenance is required for longevity and proper performance:

• Inspect seals and gaskets; replace worn parts
• Verify accurate pressure gauges and sensors
• Describe cleaning procedures and schedules in SOPs
• Follow passivation procedures after wetted surface exposure
• Check sample valves and ports for signs of build up
• Monitor cooling system functionality and glycol concentration

Pros and Cons of Conical Fermenters

Pros	Cons
Efficient fermentation and conditioning in one vessel	More expensive upfront cost than cylindrical tanks
Compact footprint conserves space	Larger units require hoists or cranes for handling
Easy collection of yeast and trub	Additional training needed to leverage features
Flexible pressurization capabilities	Requires more planning for cleaning and maintenance
Lower risk of oxidation and contamination	Potential for foaming with some beer styles

Choosing Between Conical and Cylindrical Fermenters

Conical Fermenters are best suited for:

• Breweries with space constraints necessitating a compact design
• Beers requiring yeast harvesting like lagers and high-gravity beers
• automated or semi-automated brewhouses with integrated transfers
• Budget is less constrained and quality is top priority

Cylindrical Fermenters tend to be preferable when:

• Cost savings is key priority
• Facility has space for multiple vessels
• Brewing ale styles not requiring yeast harvesting
• Manual brewing process without integrated automation

FAQ

What size conical fermenter should I choose?

Choose a size approximately 1.5-2X your target batch size to allow sufficient headspace for active fermentation.

Should I get a cooled vs non-cooled conical?

Temperature control is critical for quality beer, so a cooled/glycol jacketed conical is highly recommended unless you already have a glycol system plumbed externally.

How many turns/openings are needed on sample valves?

Look for 3-4 turns or openings needed to fully open sample valves. This slows valve opening to prevent violent outrush of beer and foaming.

What material should I choose – stainless or plastic?

For commercial or serious homebrewing look for stainless steel conicals which are more durable, pressure capable, and sanitize better. Plastics can scratch over time.

Any suggestions on conical fermenter manufacturers?

Top manufacturers include Ss Brewtech, Spike, Blichmann, Rolec, Uni-tanks, and Paco based on reputation and customer experiences in homebrew forums. Always verify certifications.

Know More Brewing equipment

Frequently Asked Questions (FAQ)

1) What cone angle is optimal for Conical Fermenters?

• A 60° cone (half-angle ~30°) is common; it compacts yeast well while allowing reliable racking. Steeper cones aid harvest; shallower cones risk trub carryover.

2) How much headspace should I leave in a pressure-capable conical?

• Target 15–30% headspace for ales (top-cropping strains closer to 30%), 10–20% for lagers. Insufficient headspace increases PRV lifts and blow-off losses.

3) Do I need a pressure-rated uni-tank for spunding and carbonation?

• Yes. Choose vessels rated ≥1.5–2.0 bar (15–30 psi) with certified PRV and vacuum relief. Non-rated plastics or thin-walled steel are unsafe for pressure fermentation.

4) What internal finish (Ra) should I specify?

• Aim for Ra ≤0.6–0.8 μm with proper passivation. Smoother surfaces reduce biofilm formation and shorten CIP time.

5) What ports are “must-haves” for modern conicals?

• Top CIP with rotary spray ball, thermowell, sample valve with purge, racking arm, carb stone port, 1–2 jacket zones, pressure/vacuum relief, and a large manway for inspection.

2025 Industry Trends for Conical Fermenters

• Oxygen control by design: more conicals ship with inert gas purge manifolds, low-DO valves, and DAW-compatible ports.
• Smart sensing: integrated temp/pressure/level DO ports and Bluetooth gateways for cellar-wide monitoring.
• Efficiency-first finishes: Ra ≤0.6 μm internals and improved spray devices cutting CIP time 15–30%.
• Energy optimization: thicker insulation and multi-zone jackets to reduce glycol load in warm climates.
• Small-scale pressure fermentation: growth of 5–15 gal pressure-rated stainless conicals for home and pilot systems.

Conical Fermenter Benchmarks (2024–2025)

Metric	Typical Range	2025 Best Practice Target	Notes / Sources
Working pressure (uni-tanks)	1.0–1.5 bar	1.5–2.0 bar	Supports spunding/carbonation
Internal surface roughness (Ra)	0.8–1.2 μm	≤0.6–0.8 μm	Faster CIP; less biofilm
CIP cycle time per tank	45–75 min	30–50 min	Rotary spray ball + validated flow
Packaged DO (ppb)	30–80	≤30 (draft ≤20)	ASBC methods
Insulation thickness (shell/cone)	50–80 mm	80–100 mm	Cuts glycol energy use
Brite-to-filler hose length	10–25 m	≤10 m	Lower O2 pickup/foam

Authoritative sources:

• Brewers Association (cellar/CIP/sustainability): https://www.brewersassociation.org/
• ASBC Methods of Analysis (DO, QA): https://www.asbcnet.org/
• EHEDG hygienic design guidelines: https://www.ehedg.org/

Latest Research Cases

Case Study 1: Spunding and Closed Transfer on 30 bbl Conicals (2025)
Background: Regional brewery reported oxidative staling in hoppy SKUs at 90 days.
Solution: Implemented spunding (0.8–1.0 bar) in pressure-rated conicals, CO2-purged hoses/valves, and DO checks at brite and filler inlet.
Results: Packaged DO dropped from 52–70 ppb to 18–26 ppb; shelf life extended ~60 days at 20°C; purchased CO2 reduced 20% due to natural capture.

Case Study 2: Surface Finish Upgrade Reduces CIP Time (2024)
Background: Older conicals (Ra ~1.2 μm) required long CIP and saw intermittent ATP fails after dry-hopping weeks.
Solution: Replaced two tanks with Ra ≤0.6 μm uni-tanks, added rotary spray balls and conductivity/temperature-controlled CIP.
Results: CIP time cut 30%; caustic use down 22%; ATP fails <1% of swabs for 6 months; improved tank availability increased monthly cellar turns by 0.3.

Expert Opinions

• Dr. Tom Shellhammer, Professor of Fermentation Science, Oregon State University
  “Cone geometry and oxygen management around conicals heavily influence yeast performance and flavor stability—keep transfers closed and surfaces clean.”
• John Mallett, Brewing Operations Expert; author of “Malt”
  “Specify the right ports—PRV, vacuum relief, racking arm, sample valve you can sanitize—and validate your CIP. Good conical details prevent bad beer.”
• Ashton Lewis, Technical Support Director, BSG
  “Trend DO, temperature, and pressure. Conical Fermenters become predictable when you monitor the variables that drive fermentation and pickup.”

Practical Tools/Resources

• Brewers Association cellar/CIP and sustainability resources: https://www.brewersassociation.org/
• ASBC Methods (DO, CO2, microbiology, sensory): https://www.asbcnet.org/
• EHEDG guidance on hygienic tank design and validation: https://www.ehedg.org/
• DOE Better Plants energy tools for process optimization: https://www.energy.gov/
• Vendor technical notes (GEA, Alfa Laval, Pentair) on spray devices, jackets, and passivation

Last updated: 2025-08-29
Changelog: Added focused FAQs, 2025 trends with benchmark table, two conical-focused case studies on spunding/closed transfer and surface finish/CIP, expert viewpoints, and vetted resources.
Next review date & triggers: 2026-02-28 or earlier if BA/ASBC/EHEDG update DO/CIP guidance, new PRV/vacuum standards are issued, or packaged DO exceeds 30 ppb for two consecutive audits.