Calculating brewery equipment output is a key step in ensuring production efficiency and optimizing resource allocation during the brewing process. The output of beer brewing equipment depends on the type and size of brewing equipment, the batches brewed per day, the size and number of fermentation tanks, and the fermentation cycle of beer. Different equipment has different requirements for site size, height, water, and electricity, and varies from place to place. When brewing beer, understanding how brewery equipment calculates beer output is crucial for any brewer who wants to optimize production and maintain consistency.
All beer is not created equal
One thing to consider when calculating your brewery’s annual production is time in the can. How long does beer sit in the can before it can be packaged? If you brew beer, it will probably sit in the can for 4-6 weeks before it’s ready. The longer the beer sits in the can, the less beer you can brew.
Overview of beer production equipment
mash tun
A mash tun is a device that mixes malt with water and heats it to extract the sugar. The efficiency of the mash process directly affects the sugar content and volume of the final wort.
Calculation method: The mash efficiency can be calculated by measuring the volume and sugar content of the wort before and after mash. This usually involves the difference in specific gravity and volume change of the wort before and after mash.
Boiling kettle
The boiling kettle is used to boil the wort and add hops. During this process, the wort will decrease due to evaporation, which will affect the final yield.
Calculation method: The boiling loss can be estimated by monitoring the boiling time, temperature, and the change in the volume of the wort in the kettle. The evaporation rate is usually used to calculate the final wort volume.
Fermentation tank
The fermentation tank is used for primary fermentation and post-fermentation. The volume of beer during the fermentation process will change due to the generation of gas and sediment.
Calculation method: The final beer yield can be calculated by measuring the volume at the beginning and end of the fermentation, combined with the record of fermentation losses. The volume monitoring system of the fermentation tank usually provides real-time data.
Filters
Filters are used to remove solid matter from beer after fermentation to ensure clarity and stability of the beer.
Calculation method: During the filtration process, the volume of beer will decrease due to the removal of solid matter. Recording the volume change before and after filtration can help calculate the filtration loss.
Packaging equipment
Packaging equipment fills beer into bottles, cans, or barrels and seals them. There will also be certain losses during the packaging process.
Calculation method: By recording the volume before packaging and the actual filling volume, the packaging loss can be calculated. Usually, the metering system of the packaging equipment will provide accurate data.
Key factors in beer yield calculation
- Wort yield: The first step in calculating beer yield is to measure the amount of wort produced during the brewing process. This is usually done using a volume sensor or flow meter integrated into the brewing equipment.
- Specific gravity: Specific gravity measures the density of wort relative to water and helps estimate the amount of fermentable sugars. Brewers use tools such as hydrometers or refractometers to measure specific gravity before and after fermentation.
- Alcohol content: The alcohol content of beer is calculated based on the difference in specific gravity before and after fermentation. This difference indicates how much sugar is converted to alcohol during the brewing process.
- Brew efficiency: The efficiency of the brewing process affects the extraction and utilization of sugars.
- Yeast strains and fermentation conditions: Different yeast strains and fermentation temperatures can affect the development of flavor and the characteristics of the final beer.
Brewery production calculation
For simplicity, we will calculate 20 fermentation and conditioning production cycles per year. Fermentation and maturation/storage in CCT unit tanks.
We calculate: average cycle fermentation + conditioning takes 17-18 days, 350 days per year divided by 17 days = 20 production cycles per year.
Calculating Brewery Capacity – Cellar Tanks
There are several types of tanks you can use in your brewing process:
- Fermentation tanks
- Clear beer tanks
- Horizontal maturation tanks
- Serving tanks
The beer tanks you choose will affect your brewery’s output and labor costs. For example, if you run a brewpub, then tanks are a viable option. Some breweries keep beer tanks in a cooler and pour beer directly from these tanks at the bar. This saves labor, so keg beer is not used for draft beer.
The number of vessels in the brewery
The design of the brewery will also affect the amount of beer that can be brewed on-site. The types of home brewing equipment and craft beer brewing equipment used in hotels, bars, breweries, and restaurants generally use 500L or 1000L 2 vessel, 2 tank 3 vessel, two-vessel + hot water boiler. 1-2 batches are saccharified per day. Considering factors such as labor and labor intensity, one batch is used per day.
The most common setup:
- 3-vessel system: combined mash/filtration tank and kettle/vortex tank
- 3-vessel system: combined mash/filtration tank with separate kettle and vortex tank, or separate mash and filtration tank with combined kettle/vortex tank
- 4-vessel system: separate mash, filtration, kettle, and vortex tank
The more vessels a brewery has, the more beer can be brewed in a day. In a 2-vessel system, it may be possible to brew 2 times, but that will be a long day. Some breweries have 5 or 6 vessel systems and can brew more than 6 times a day. During the brewing process, it is not the number of cellar tanks that limits a brewery’s output, but the brewery’s design.
Brewery output calculation process
Data collection
- Raw material data: record the input amount of each raw material, including malt, hops, and water.
- Process data: record the volume and quality data during mash, boiling, fermentation, filtration, and packaging. Modern equipment is usually equipped with sensors and automatic recording systems to collect this data in real-time.
Data calculation
mash efficiency calculation: calculate the mash efficiency based on the volume and sugar content of the wort before and after mash.
- The formula is: mashefficiency = the amount of soluble sugar extracted ÷ the amount of sugar put into the malt
- Boiling loss calculation: estimate the boiling loss by measuring the volume difference of the wort before and after boiling and combining the evaporation rate.
- Fermentation loss calculation: record the change in the volume of beer before and after fermentation, and calculate the fermentation loss by combining the gas and sediment produced during the fermentation process.
- Filtration loss calculation: calculate the filtration loss based on the volume difference before and after filtration.
- Packaging loss calculation: calculate the packaging loss by measuring the volume before packaging and the actual filling volume.
Data analysis
- Yield forecast: predict future production output by combining historical production data and current production conditions.
- Quality control: Analyze production data to ensure the efficiency of each link to maintain product consistency.
- Cost control: Optimize production process and cost management based on loss data of each link.
Conclusion
Understanding how brewery equipment calculates beer output is essential for brewers to improve efficiency and maintain quality standards. By mastering these calculations and utilizing advanced brewing techniques, breweries can achieve consistent results and satisfy the needs of beer lovers around the world. For those looking to build or upgrade a brewery, Micet Group offers a comprehensive range of brewing equipment and auxiliary systems to meet different brewing needs. From malt grinders to bottling and keggers, Micet Group provides the tools needed for brewing success.