Implementing a turnkey brewery system is complex in the brewing industry. To gain a competitive advantage, you need to determine production capacity, develop a unique brewing line, and select the right brewing equipment. A turnkey brewery is an integrated brewing solution that usually includes the entire process from equipment procurement to installation and commissioning. For investors who want to enter the beer industry but lack brewing experience, turnkey breweries provide an efficient and convenient option.
What is a turnkey brewery?
A turnkey brewery is a complete brewing system that includes all the necessary equipment and components required to brew beer. Therefore, the term “turnkey” indicates that the system is ready to use immediately after installation, and you only need to do minimal setup. Such systems are designed to simplify the brewing process by providing everything from wort barrels to fermentation tanks and control panels in one package.
One of the main advantages of a turnkey solution is its easy and quick setup. Imagine that after handing over the keys to the brewery, you can produce your batch of craft beer almost immediately. This is especially beneficial for those who want to quickly enter the market or lack the technical knowledge to set up a brewery.
Turnkey Brewery Components
- Brewing Kettle: Used to boil wort, add hops, and sterilize. Usually made of stainless steel, equipped with a heating device to control the temperature and boiling time. During the boiling process, the aroma and bitterness of the hops are released, and impurities in the wort are removed.
- Fermentation Tanks: Used to ferment wort and convert it into beer. Usually made of stainless steel, equipped with a temperature control system and a pressure release device. Fermentation is a crucial step in the brewing process and directly affects the flavor and aroma of the beer.
- Storage tanks: Used to store fermented beer and prepare it for packaging. Generally have a high-pressure tolerance and are equipped with a cooling system. It can ensure that the beer is stored under suitable conditions to improve quality and taste.
- Malt Mill: Grind the malt to increase the masheffect, and use different grinding methods to control the particle size.The finer the grinding, the better the mash effect, which ultimately affects the taste and alcohol content of the beer.
- Water Treatment System: Filter and treat the brewing water to remove impurities. Including technologies such as activated carbon filtration, reverse osmosis, and ion exchange. Water quality directly affects the taste and quality of beer, and ensuring the purity of water is crucial.
- Filling machine: Fills beer into bottles, cans, or barrels. Usually has a high-speed, precise filling system. Efficient filling can reduce the entry of oxygen and maintain the freshness of beer.
|
Equipment Name |
Function Description |
Approximate Price (USD) |
|
Brewing Kettle |
Used to boil the wort and add hops |
15,000 – 100,000 |
|
Fermentation Tank |
Used for the fermentation process, converting wort into beer |
10,000 – 50,000 |
|
Storage Tank |
Stores the fermented beer, ready for packaging |
5,000 – 30,000 |
|
Malt Mill |
Crushes malt for the subsequent mashing process |
5,000 – 20,000 |
|
Water Treatment System |
Ensures water quality meets brewing standards, removes impurities |
3,000 – 15,000 |
|
CIP Equipment |
Cleans and sanitizes brewing equipment, ensuring hygiene |
10,000 – 30,000 |
|
Used to fill and seal beer bottles or cans, preparing for sale |
20,000 – 150,000 |
What are the types of turnkey breweries?
- Small turnkey breweries: usually small in scale, with a production capacity between 1 and 5 barrels. More suitable for start-ups, small brewers, or home brewers. The brewing equipment is simple, mainly including basic brewing pots, fermentation tanks, and storage tanks. The investment is small and the risk is low, which is suitable for testing the market and developing new flavors.
- Medium-sized turnkey breweries: The production capacity is between 5 and 20 barrels, and the equipment configuration is relatively complete. Craft breweries or small commercial brewers who want to expand their production scale. Including more advanced brewing equipment, packaging equipment, and water treatment systems, it can meet the needs of a larger market and has high flexibility.
- Large turnkey breweries: The production capacity is more than 20 barrels, suitable for large-scale production. Large commercial breweries or investors who want to enter the market quickly. Contains comprehensive brewing, fermentation, and packaging equipment, as well as automated control systems. High efficiency and production capacity, suitable for a wide range of market distribution.
Brewing Process at a Turnkey Brewery
- Mashing: Ground grains (primarily malted barley) are mixed with hot water in a mash tun. The heat activates enzymes that convert the starches in the grains into fermentable sugars, creating a thick, porridge-like mixture called mash.
- Filtration: Once mashing is complete, the liquid is transferred to a container called a lauter tun. Here, the wort is separated from the solids and the liquid is now called wort.
- Boiling: The wort is then boiled in a brew kettle, which usually lasts about an hour. Hops are added during this process to add bitterness, flavor, and aroma to the beer. Boiling also sterilizes the wort, ensuring that no harmful microorganisms interfere with the fermentation process.
- Cooling: After boiling, it is critical to quickly cool the wort to a temperature suitable for yeast fermentation. Heat exchangers are often used to achieve this rapid cooling.
- Fermentation: The cooled wort is transferred to a fermentation tank and yeast is added. The yeast consumes the fermentable sugars in the wort, producing alcohol and carbon dioxide in the process.
- Packaging: Once fermentation is complete and the beer is mature, it is ready for packaging. Depending on the brewery’s capabilities, beer can be packaged in bottles, cans, or kegs.
Why choose a turnkey brewery system?
One stop solution
The turnkey system provides one-stop services from demand analysis, design, equipment procurement to installation and commissioning. Businesses no longer need to spend time and energy coordinating among different suppliers, simplifying project management. Suppliers usually customize the equipment according to the customer’s needs and space layout to ensure the equipment is properly configured and operates efficiently.
Device compatibility
All brewing equipment (such as brewing pots, fermenters, packaging machines, etc.) are carefully selected to ensure that they can be seamlessly connected to minimize technical bottlenecks in production. Since the equipment itself is designed to be compatible with each other, debugging and testing time is significantly reduced, helping companies quickly enter the production stage.
Reduce risk
Turnkey systems use proven technology and equipment, reducing the risks associated with new technology or equipment instability. Suppliers often provide detailed operating manuals and technical support to help companies deal with potential problems and reduce the risk of production downtime due to equipment failure.
Professional support
Suppliers usually provide employee training, including operating procedures, equipment maintenance, and troubleshooting, to ensure that winemakers are proficient in using the equipment. Good after-sales support can provide timely solutions when equipment problems arise, reducing production interruption time.
Flexibility
Many turnkey systems can be adapted to a company’s specific needs, allowing companies to flexibly adjust production capabilities as market demand changes. Companies can quickly launch new products based on consumer preferences and enhance market adaptability.
Scalability
Many turnkey systems allow businesses to expand over time, such as adding production lines or introducing new equipment, to adapt to changes in the market. The design of the system also usually takes into account future technology upgrades, allowing companies to introduce new technologies without significantly changing the overall structure.
FAQ
What is a turnkey brewery?
A turnkey brewery is a system that provides a complete beer production solution, usually including services such as equipment procurement, design, installation, commissioning, and training.
How much does a turnkey brewery cost?
The cost of a turnkey brewery varies depending on the scale, equipment configuration, and market demand. Generally speaking, the initial investment may range from tens of thousands to millions of dollars.
How long does it usually take for a turnkey brewery to be put into production?
The time to put into production usually depends on the scale and complexity of the project. Generally, it may take several months from signing the contract to completing the installation and commissioning.
How to choose the right turnkey brewery supplier?
When selecting a supplier, factors such as its industry experience, customer evaluation, technical support capabilities, equipment quality, and customized service capabilities should be considered.