COMMERCIAL BREWING EQUIPMENT

WHAT ARE COMMERCIAL BREWING STARTUP COSTS?

If you want to budget commercial brewery equipment costs, we can help you focus on the main items you will need to purchase in order to achieve maximum output in the minimum amount of time.

Every detail must be reviewed and finalized based on the different characteristics of the individual brewery. Additionally, different design details will affect the total cost, especially relative to the level of automation desired.

• Malt Handling System

The first step in the commercial beer production process is creating malt from barley. The grains are steeped in a malt handling system for one to two days, and then cooled in humid air conditions in order for germination to occur over the next 3 – 7 days. 

The grains are then dried out in a kiln for up to one week, with a following rest period of 3 weeks. This is when the barley grain becomes malt. Depending on how much grain you are dealing with, the size of the malt handling system will correlate to it.

YoLong designs and produces commercial malt handling systems for a range of budgets and uses; one size does not fit every commercial brewery setup. Please contact us if you need help gauging which size malt handling system is best for your setup.

Individual setups and commercial brewery equipment for distillers and brewers has to be treated on a unique case by case basis. Using a repurposed malt handling system is never advisable; trace residue and microscopic debris could impact the flavor profile of your end product. A new malt handling system must be commissioned and designed for your individual requirements and within your established budget.

If you want a malt handling system that has been designed to go the distance, factoring this vital piece of equipment into your budget and inventory is essential.

• Custom Brewhouse

YoLong custom brewhouse equipment ranges from 20bbl up to the greatest volume size commercial vessels available, customized to your specifications. Malt developed in a custom malt handling system is best positioned close to the brewhouse, because that is where the malt is added to brewhouse mash tuns, (as many as the production volume requires: 3,4, and 5 vessel configurations). The mash is subsequently heated for two to three hours.

After the heating process, the malt passes into the lauter tun. It is here that the malt grains are processed and the mix converts into a liquid called wort. The wort is sieved by the lauter tun before the mix passes into the wort kettle, where it is boiled. 

During this process, the wort separates out from the grain over 2 – 4 hours. The grain residue is not left to waste: as part of YoLong’s commitment to sustainability, the grain is recycled and sent to local farmers to feed their cattle.

• Cellar Tank

The wort is now ready to be placed into fermentation vessel cellar tanks that range in size from 20bbl to 200bbl, depending on the production volume required by the commercial brewery. 

These vessels can hold hundreds of thousands of litres/gallons of liquid. The fermentation process takes between 18 to 28 days. Having more cellar tanks means increased production across the board.

• Water Stations

The scaled system that YoLong uses to make each independent water station, includes HLT, CLT, Glycol Tanks, and chiller units. Cold liquor tanks in a brewery are used as buffer tanks. They contain cold water used as a cooling mechanism to bring the boiling wort down to the ideal temperature for fermentation to occur. 

Cold liquor tanks for commercial use are essential to any brewery and must be produced by experienced commercial brewery equipment manufacturers. YoLong sizes both hot and cold liquor tanks precisely, so you know each tank is sufficient to support the brewing system with the correct quantities of water, at the correct temperature. 

For the chiller and glycol reservoir, which provides and stores the cooling capacity for the CLT, cooling down and fermentation temperatures can then remain constant.

Ready to discuss your commercial brewing equipment idea? Contact our project engineers!

• Fully Automatic CIP Stations

Commercial breweries deal with huge volumes of product every day. In addition to this, the area and the equipment have to reach the highest standards of hygiene + efficiency. No one understands this process better than YoLong Industrial. 

We design, manufacture, and install fully automated brewing systems for commercial CIP (Cleaning In Place) stations that clean the interior surfaces without the need for disassembly.

The interior of all tanks, pipes, and vessels are cleaned automatically without manual labor. This is a major labor and cost-efficient commercial equipment to install. Because the brewing vessels, pipes, and packaging equipment are closed systems, frequent cleaning is necessary to maintain the chemical and microbiological quality of the beer.

YoLong Industrial presents an automatic cleaning process that is extremely comprehensive and elaborate. This provides your commercial brewery with sufficient energy control, running costs, time management, and product consistency.

• Yeast Propagation System

Commercial yeast propagation equipment produced by YoLong Industrial is engineered to produce ideal yeast propagation under the most sterile conditions. This is an essential component of the beer production process. 

A commercial yeast propagation system plays a critical role in how the beer end product will taste, its quality, and how easily the mix can be filtered. Choosing the correct strain of yeast, propagating healthy yeast cells, and utilizing the surplus yeast is possible with a YoLong commercial custom automated yeast propagation system.

• Hop Storm: The Hop Delivery System

The hop storm is the ultimate hop delivery system. Brewers are forever reinventing the palate of how beer should taste, and therefore, the mechanisms through which hops are added to the beer are changing all the time as well. 

When hops are added to the mix after the boil, they contribute a far more aromatic flavor. There are many names for the different hop delivery systems used by commercial brewers today. But they all add up to a fragrant, less bitter beer product that is helping change the profile of modern beer tastes.

• Portable Pumps and Flowmeters

The flow and thermal energy measurements for the commercial beer brewing process are necessary in both the cold process areas and the brewery. This equipment carries out systematic checks on every installed component and measures the process’s performance and inspection parameters. 

Commercial portable pumps and flowmeters are indispensable tools to optimize water consumption and thermal energy.

• Beer Filtration Commercial Equipment and Supplies
• Energy Saving Devices

YoLong Industrial produces state of the art energy devices that enable the recycling of thermal energy during the brewing process. This can save on energy costs and the use of government funded power sources, as well as contributing to the sustainability of commercial beer production. 

Utility optimization in the commercial brewery process is based on modern energy-integration methodology. It’s best for the commercial brewery and the environment. Lowering the carbon footprint of the beer-making process is constantly being improved upon at YoLong.

• Keg Washing and Filling Line/Bottle Washing and Filling Line Purchase and Installation

While commercial beer is fermenting, the interim period can be utilized for other tasks: commercial beer production continues.

Bottles must be prepared to receive the final beer product. YoLong Industrial commercial bottle washer and filler line can process between 40,000 to 45,000 bottles per hour. That is sufficient to fulfill the production needs of any commercial brewery.

Both bottles and kegs are inspected for quality and cleanliness by a bottle inspector or a PVI machine. They are picked up and sent back if they do not meet the production health and safety parameters. YoLong commercial grade machines are part of the automation of this system.

• Filling Up and Sealing the Kegs/Bottles

When the bottles are ready, and the beer has fermented to perfection, the last steps in a commercial brewery beer production line is to label the bottles. Over 1,500 bottles can be labeled every minute. 3 checks take place concurrently:

• Bottle contents fill height is correct
• Labels are straight
• The bottle caps are checked for attachment security and fastness

Now the only thing left is to pack the beer into crates and load them into the transport trucks, awaiting delivery to the eager distributors and consumers all over the world.

How to choose the Right Commercial Brewing Equipment?

When selecting commercial brewing equipment, there are several factors to consider:

Scale of Production

The size of your brewing operation will determine the size and capacity of the equipment you need. Brewhouses are typically sized in terms of barrels (1 barrel = 31 US gallons), with systems ranging from 1-barrel nano-breweries to 50-barrel production facilities.

Budget

Commercial brewing equipment can be a significant investment, so it’s essential to set a realistic budget. Prices vary depending on the size, quality, and complexity of the equipment. Be sure to factor in not only the initial cost of the equipment but also installation costs, ongoing maintenance, and any future expansions. You can read this blog to learn more about brewing equipment costs. Or you can contact our expert to get the price!

Space Constraints

Consider the available space in your brewery when selecting equipment. Make sure there is enough room for your brewhouse, fermentation tanks, bright beer tanks, and other essential components, as well as adequate space for workers to move around comfortably and safely.

Flexibility and Customization

Choose equipment that offers flexibility and customization options to accommodate your unique brewing needs and future growth. Look for modular systems that can be easily expanded or reconfigured as your production needs evolve.

Energy Efficiency

Energy-efficient brewing equipment can help reduce your utility costs and lower your environmental footprint. Look for energy-efficient heat exchangers, pumps, and other components to minimize energy consumption.

Automation and Control Systems

Modern commercial brewing equipment often includes advanced automation and control systems, which can help streamline the brewing process, improve consistency, and reduce the risk of human error. Determine the level of automation that suits your needs and budget.

Equipment Manufacturer

Choose a reputable equipment manufacturer with a proven track record in the brewing industry. Look for companies that offer excellent customer support, warranties, and after-sales service to ensure you get the most out of your investment.