Instruction Brewhouse Calculation

Instructions for use of the calculation
tool:
Brewhouse calculation complete
Instruction manual for the brew.tech calculation tool Basic formulas 1

Instructions for use of the calculation tool: Complete brewhouse design and calculation
• Contents of the manual:
1. Recipe
2. Mash calculation
3. Grist and pre-mashers
4. Mash pan
5. Raw fruit stove
6. Lauter tun
7. Lauter wort heater
8. Wort pan
9. Whirlpool and wort cooling
10. Water
buttons of the instruction manual:

One click on the enter key: Go one page further
• Go to next page
• Go to previous page
• Go to this table of contents
• Go to the beginning of the chapter
Meaning of the colors of the individual cells:
• A cell in which a value must be entered
• A cell which outputs a calculated value
• A cell where you have to choose between given options
2
Instruction manual: Complete brewhouse design and calculation
1. Recipe:
The following pages of this calculation tool are based on each other and have to be filled in following the order of their
numeration because the later values depend on the former ones.
The starting point is the recipe of the mash which is entered in the first chapter.
BASIC TECHNOLOGICAL DATA OF THE RECIPE
Wort quantity
Hot wort quantity kettle full 100 hl

Cold wort quantity 96 hl
Original wort content of the cast wort 14,0 °P

Specific gravity (20/4) 1,0549 g/cm³
Original wort content at the start of
14,8 GV% = weight/volume
fermentation
In this case, 100 hl of hot wort are to be produced, which is entered in the corresponding Hot wort field. The corresponding quantity of 96 hl of cold wort is
automatically calculated from this.
The second value is the desired wort concentration that is entered, in this case 14 degrees Plato, automatically the specific gravity (here 1.0549 g/cm³) and
the cold wort concentration before the start of fermentation in weight/volume % (here 14.8 GV%) is calculated.
3
Extract composition
% from extract
Total extract [kg]
Malt
Barley malt 70 992
Wheat malt 0 -
Rye malt 0 -
Sorghum/malt of millet 0 -
Raw fruit
Rice 30 425
Broken rice 0 -
Corn 0 -
Rice starch 0 -
Barley 0 -
Sorghum/Millet 0 -
Sugar Concentration Volumen
Liquid sugar 0 - 0,65 kg/l - l
Granulated sugar 0 -
Total extract 100 1.418 Extrakt korrekt Zusammensetzung ändern
Total extract 14,77 GV% = Weight/Volumen

Possible statements
Spec. weight (20/4) 1,05490
Original wort real 14,00 °P
In the following table, the composition of the extract is now determined according to the beer recipe, in this case the recipe should consist of 70% barley
malt extract and 30% travel extract.
If the recipe calls for the use of sugar, the required amount of liquid sugar can be determined directly via the concentration of the liquid sugar (in this case
0.65 kg/l or 65 ° Brix).
In the following it is checked whether the total amount of the extract corresponds to 100 % of the recipe, if yes, extract appears correct, if no 100 % is
reached, Change composition appears.
Likewise, the real amount of kg of total extract is calculated regardless of whether 100% has been reached or not.
In the last three lines, the real weight/volume concentration of the wort (here 14.77), the real specific gravity and the real degree Plato of the wort are
displayed, which should be identical to the recipe (in this case 14°P).
4
Raw materials composition
Yield difference between laboratory and brewhouse yields 3 %
Calculated
extract Selected extract Share of Plausibility
Laborausbeute quantity quantity total extract check
[%] [kg] [kg] %

Malt
Barley malt 78 1.327 1.330 70 OK
Wheat malt 80 - 0 - OK
Rye malt 82 - 0 - OK
Sorghum/malt of millet 73 - 0 - OK
Raw fruit
Rice 81 543 540 30 OK
Broken rice 82 - 0 - OK
Corn 77 - 0 - OK
Rice starch 98 - 0 - OK
Barley 66 - 0 - OK
Sorghum/Millet 60 - 0 - OK
Total - 1869 1870 - OK
Selected quantity 1.870 kg OK
Possible statementszu große Abweichung
In the following section, the necessary raw material quantities are now calculated from the extract quantities.
In the column "Laboratory yield", the yield determined in the laboratory for the individual raw materials used must now be entered, in this case 78% for
the barley malt and 81% for the rice. A correction factor between the laboratory yield and the real yield (here 3%) must also be entered. The result in
the "Calculated quantities" column is now 1,327 kg for the necessary barley malt and 543 kg for the necessary rice. In the following column "selected
quantity", the quantity used for the further calculation process is now entered, which is subjected to a plausibility check in the last column with the
result "O.K." or "large deviation", in which case the selected raw material quantity should be checked again because the desired extract cannot be
achieved.
In the last column, the selected quantity is subjected to a final plausibility check as described.
5
2. mash calculation:
Based on the parameters entered in the previous chapter "Recipe", this chapter now calculates the design of the quantity
and throughput parameters for mash production.
Mash layout
Front wort 19,0 °P Standard value: original wort of cold wort +5%.
Main cast 63 hl
Raw fruit mash

Main pour factor 3,8 hl/100kg guide value: 3,8 - 4,5 hl/100kg (corn: 3,8hl, rice min. 4hl)
540
Pouring raw fruit kg
Malt content 81 kg approx. 15% of the total raw fruit quantity
Evaporation 1,0 %
The starting point is the desired concentration of the mash to the lauter tun (the influence of this concentration on the wort quality is
explained in the Brew-Tech course Mashing), in this case 19° Plato (usually about 5% above knockout wort concentration).
This results in a mash volume of 63 hl which is now used for further calculation of the mash parameters.
Since a raw fruit content of 30% rice was specified for the wort in the recipe, the raw fruit mash is now calculated here. For the quantity
balance, the desired mash concentration for the raw fruit is first necessary (here 3.8 hl/100kg), suggestions for this concentration can be
found to the right of the values or in the Brew-Tech course Maceracion.
The necessary amount of raw fruit is taken from the given recipe (in this case 540 kg), furthermore the necessary amount of malt for
enzymatic liquefaction of the raw fruit sugar is calculated (usually 15% of the raw fruit amount). If technical enzymes are used, this quantity
can be replaced by the corresponding quantity of raw fruit.
Finally, the expected amount of evaporation of the raw fruit mash during mash cooking must be taken into account (here, 1% was selected).
6
Raw fruit kg Volumen in hl
In the further now the quantities and Voluminas resulting from the recipe calculated. Bulk 540 2,2
First, the quantity in kg and the volume in hl for the raw fruit, the water used and the Main cast 2.011 20,5
Mash volume 2.551 22,7
resulting totals for the raw fruit mash are calculated.
Likewise, the ratio 100 kg of raw fruit per hl of water quantity,and the specific density is Mash ratio 4,20 hl/100kg
Density of mash 1,1248 kg/hl
given.
Lastly, the total masses and quantities of raw fruit mash before and after cooking the kg Volumen in hl
raw fruit mash are also given. Amount of raw fruit mash before boiling 2.632 25,8
Amount of raw fruit mash after boiling 2.606 25,6
Malt mash
Malt kg Volumen in hl
Pouring 1.330 9,3
Main cast 4.149 42,3
Analogous to the raw fruit mash, the values for the malt mash are shown below. Mash quantity 5.479 51,6
In addition, the ratio of the malt to the total mash is indicated (here 3.88 100kg/hl ). Main pour factor 3,18 hl/100kg
Mash ratio 3,88 hl/100kg
Density of mash 1,0609 kg/l
Total mash
kg Volumen in hl
Bulk 1.870 11,5
Main pour 6.159 62,9
Mash quantity 8.029 74,3
Finally, the masses in kg and the volumes in hl of the total mash are calculated.
Mash ratio 4,0 hl/100kg
Density of mash 1,0804 kg/l
7
At the moment, the amount of brewing water required to push the mash from the mash tun
Calculation of discharge water from mash tun to lauter tun
to the lauter tun is still missing from the volume calculation. This results from the diameter
Diameter of the mash line in DN 200,0 mm
of the mash removal line (here DN 200 = 200 mm), the length of this line (here 15 meters), Length 15,0 m
and a safety margin from practice to ensure complete flushing of the mash tun (here 3 hl). Safety margin 3,0 hl
Required quantity of discharge water 7,71 hl
The resulting discharge volume of 7.71 hl of brewing water is taken into account in the
further calculations.
In the following, the resulting liquid quantities for Extract recovery in lautering
approx. 16% wort concentration--->48-52%;
the lautering work and the brewing process are Front wort yield 40,0 % approx. 22% malt wort concentration--->40%.
calculated from the existing recipe and the design of Front wort quantity 37,32 hl
the mashing work. Depending on the desired mash Evaporation rate per hour 6,0 %/h
Boiling time 70 min
yield (here 40%, reference values are given on the Total evaporation 7,0 hl
right), the mash quantity is calculated. The amount Total evaporation in 7,00 %
Ladle full volume 107 hl Rezept 103 hl
of water to be evaporated (7 hl) is calculated from Wort concentration at kettle full 13,80 GV% WW% 13,08 %
the evaporation rate of the wort kettle (here 6 %, Water content in spent grains 18 hl
Ladle full volume at 12.5 ° plato 122 hl WW% 1,0510 kg/l
depends on the kettle manufacturer) and the boiling Water content in spent grains atP 15 hl
time, and the kettle full of wort amount of 107 hl is Total amount of water 130 hl
Amount of post-pour water 68 hl
calculated with the wort removal quantity of the
recipe.
Furthermore, the recipe and the pan full volume result in the pan full concentration of the wort of 13.8 °P.
Furthermore, the pan full of wort at 12.5 °P (= 122 hl) and the amount of water remaining in the spent grains at 12.5 °P (=15 hl) are calculated as reference
values.
Finally, the total amount of brewing water needed for this brew is calculated (=130 hl) as well as the amount needed for spiking (=68 hl).
8
The quantities and flow rates of the individual mash components are
then calculated. Raw fruit mash calculation
In the first section, the malt content for the enzymatics in the raw mash Malt content in raw mash
Casting factor for the malt portion 3,8 hl/100 kg
is calculated. The water/malt ratio defined above (3.8 in this case) is used Grist time for the malt portion according to the selected mill 1,6 min
as a basis. After the mill is set up on the next tab "Mill_PreMasher", a Volume of the malt portion 3,1 hl
Steeping water (0.65hl/dt) 0,5 hl
time of 1.6 min is calculated for the milling of this part of the malt. The Flow rate of soaking water 20 hl/h
total amount of mash (here 3.1hl) is also specified by the water/malt Post-pressing water Wet grist mill->raw malt kettle 2 hl
Additional water 0,6 hl
ratio. Flow rate additional water 16 hl/h
The other values apply to wet or conditioned grist and are not applicable
Raw fruit content in raw fruit mash
to dry grist: A volume of 0.5 hl is required as water quantity for the Casting factor for the raw fruit portion 3,8 hl/dt (preselected by: main casting factor)
average value of 0.65 hl/100kg, and a volume flow of 20 hl/h is required Water quantity for the raw fruit portion 20,5 hl
Post-pressure water wet grist mill->raw fruit digester 1,0 hl (measured)
here for the shot duration of 1.6 min. The post-rinse water is either a Post-pressing water raw fruit digester->mash pan 1,0 hl (measured) to rinse out residues
practical value or can be set so high that the value for the remaining Missing water quantity for the raw fruit mash 18,5 hl
Flow rate of water addition 69 hl/h 2,0 t/h Raw fruit mill capacity
water required in the next line is zero (in our example, 2 hl of post-rinse Duration to mix in raw fruit mash 16,2 min
water results in a residual quantity of 0.6 hl, which must be added Total volume raw fruit mash 23,3 hl
directly to the raw mash. Total volume of raw fruit mash plus post-push water 24,3 hl
Ratio raw fruit+B72:B105r 1: 3,76
In the second section, we will now look at the raw fruit part in the raw fruit mash.
The ratio of water to raw fruit is also taken from the value entered in the oven. This again results in the total amount of water required (here 20.5 hl). If it is a wet
mill, a volume for the rinsing water from the mill to the raw fruit stove is entered here again, for dry grist this is =0. Likewise, the quantity of discharge water must
be entered again in order to empty the raw fruit stove to the mash tun (here 1 hl). The next value is the amount of water to be added to the raw fruit digester.
After the capacity of the raw fruit mill (here 2 t/h) has been entered, the time for mashing in the raw fruit (here 16.2 min) and the water throughput for raw fruit
boiling (here 69 hl/h) are calculated.
Finally, the total volume in the raw fruit digester during raw fruit mashing is now displayed (here 23.3 hl) as well as the volume of raw fruit mash plus the
replenishment water finally pumped to the total mash (here 24.3hl) and the ratio of water/total raw fruit corrected by the replenishment water. In order to
deviate as little as possible from the target value defined above, the replenishment water should be kept as low as possible.
9
In the following, the values for the malt mash are determined. Malt mash (according to recipe and without raw fruit mash)
Again, the malt quantity defined under "Recipes" is used as a Malt quantity 1.249 kg
basis (here 1249 kg). The concentration of the malt mash must Malt/water ratio 4,00 hl/dt
now be determined (here 4.00). The effects of this relation on Water quantity 50 hl
Power of the mill 3 t/h
the wort composition and beer quality are explained in the Duration of milling 25,0 min
Brew.Tech course "Mashing", a relalistic value is important here For wet grist: ratio of soaking water/grist 0,65 hl/dt at least 0.65 hl/t for wet grist,
for the entire further calculation. Quantity of soaking water 8,1 hl 0 hl/t for dry grist
Water flow rate for soaking water 18,9 hl/h
Based on this concentration, a total necessary brewing water Water flow rate for soaking water Wet grist mill-> Mash tun 1,0 hl
quantity of 50 hl results here. With a grist mill capacity of 3 t/h Post-pressing water mash tun-> lauter tun 1,0 hl
(this value is taken from the mill size selected in the "Lauter tun" water to fill lauter tun with approx. 4 cm above bottom 4 hl
tab), the required grist time is 25 min. In the case of wet milling, remaining water in malt mash 36,1 hl
the required quantity of water per kg of malt must now be Water flow rate for mashing water 84,0 hl/h
specified here (here the minimum of approx. 0.65 hl/100 kg); for Total volume of malt mash 53,9 hl
dry milling, this value is equal to 0. Ratio malt mash water/malt 1: 3,62 hl/100kg
Depending on the entered concentration, the volume of the brewing water (here 8.1 hl) and the flow rate (here 18.9 hl/h) are calculated to completely mix in the
malt during the milling time.
The amount of rinse water to empty the wet mill must also be entered (here 1 hl), which is 0 for dry grist. As well as the amount of rinse water from the mash tun
to the lauter tun. Both quantities should be kept as low as possible to keep the mash concentration as close as possible to the setpoint.
Next, the amount of water necessary to cover the bottom of the lauter tun by 4 cm is taken into account, this value is calculated from the tab
"Lauter tun" adopted (here 4 hl).
Finally, the amount of brewing water that must be added to the mash tun during mashing, in the case of dry grist this is the amount of water in the mash tun (in
this example 36.1 hl with a throughput of 84 hl/h to mash in the given 25 min).
Finally, the total volume of the malt mash (53.9 hl in this case) and its final concentration of 3.62 hl/100 kg are obtained.
10
3. mill and pre-masher:
Grist mill (at example wet grinding)
In this chapter, the malt grist mill and the pre-masher Basic data
Malt pouring according to recipe 1.330 kg
are now designed and dimensioned. Grist time 18 min max.20 at 10 brews/day
Example data of wet milling

Necessary power according to entered data 4,4 t/h Tipo molino Capacidad [t/h]
The grist mill is chosen here as wet grist mill. selected power 3 t/h 3 3
The initial value is the malt quantity selected in the previous Actual output 3 t/h 8 8
The malt grist is treated in a continuous steeping and milling process with the following ram data:
recipe (here 1,330 kg). The calculated output of the grist mill
Width 600 mm 20 20
(here 4.4 t/h) results from this quantity plus the desired or Height 950 mm
required grist duration (here 18 min.). Depth 420 mm
In order to obtain design data for the mill, dimensions and
Roll diameter 600 mm
outputs for four different mill outputs have been stored in the Drive power 238 mm
system. Via the green pop-up field, a mill size should now be Output speed 8 kW
1.450 1/min
selected which comes closest to the calculated capacity (here 3
Mash pump
t/h). Dimensions, electrical connected loads of mill and pump Delivery head 15 m³/h
as well as the brewing water throughput for this mill type are DN 8 m
Input power 80
automatically displayed.
Output speed 4 kW
1.450 1/min
Finally, the size of the malt buffer in front of the mill is
grist bin
suggested (here 29 hl).
Total Volumen 29 hl
11
In the following, the pre-mixer is now laid out.
The initial values are again the quantity of malt and raw fruit which were defined in the recipe (here 1,330 kg and 540 kg). As a further step,
the existing temperature of the cold and hot brewing water is now entered (here 15 °C and 80°C).
The right-hand section of the table contains suggestions for the mashing time to be expected for the malt mash and the number of brews
per day. In this case, 15 minutes were selected. Since the raw fruit mash is less time-critical, the duration can be longer (here 25 minutes).
The desired mashing temperature is also specified (here 49°C and 50°C).
From this information, the output of the mash tun, the diameter of the mash tun, and the possible belt width of this mash tun are now
calculated.
The quantity of mashing water for the malt and raw fruit mash is taken from the chapter Mash calculation (here 42 hl as well as 21 hl).
Pre-masher
Brews/day Mashing time Malt min.
Basic data 4 15
Pouring malt 1.330 kg 6 12
Pouring raw fruit 540 kg 8 10
Temp. brewing water cold 15 °C 10 8
Temp. brewing water warm 80 °C 12 6 till 8
Malz Rohfrucht
Mashing time 15 min 25 min
Mashing temperature 49 °C 50 °C
Output pre mashers 5,32 to/h 1,30 to/h
Premash mixer DN 150 mm 150 mm
(for pouring from - to) 0-2500 kg 0-2500 kg
Premash water 42 hl 21 hl
12
With the values now entered, the brewing water supply of the single mashers can be designed in the following.
First, the main line to the macerator is calculated. The desired flow velocity (here 2 m/s, guide value is 1.5 to 2.5 m/s) is specified. The pipe
diameter is then calculated from the known quantities and times. In the next step, the pipe diameter closest to this calculated value is
entered (here DN 50 and DN 32), from which the system then indicates the flow velocity to be expected in real terms.
In addition, the required amount of cold and hot water is calculated, as well as the pump capacity to deliver this in the specified time. From
these values, the necessary cold and hot water lines to the water mixers can now be designed.
First, the flow velocity for the hot water pipes is again taken as an example (here 2.0 m/s), the pipe diameter is calculated from this and then
the next available pipe diameter is selected (here DN 40 and DN 25) and then the real flow velocity is again calculated).
Main water line to the mixer
Flow rate 2,0 m/s 2,0 m/s
This process is now repeated analogously for the cold water DN calculated 55 mm 30 mm
DN selected 50 mm 32 mm
supply, whereby a somewhat higher flow rate can generally be Flow rate actual 2,40 m/s 1,70 m/s (ideal 1.5 till 2.5)
selected for cold water.
Finally, the connection diameters for the water mixer of the Water quantity
Hot water quantity 22,1 hl 11,0 hl
malt and raw fruit mixers are calculated and shown.
Cold water quantity 20,2 hl 9,5 hl
Also displayed is a summary of the various pipe diameters Hot water supply 8,9 m³/h 2,7 m³/h
selected. Feed cold water 8,1 m³/h 2,3 m³/h
Water mixer Hot water supply

Diameter hot water valve 32 mm 25 mm
Diameter cold water valve 32 mm 25 mm Flow rate 2,0 m/s 2,0 m/s
DN calculated 40 mm 22 mm
Summary of the pre-mixer piping DN selected 40 mm 25 mm
Malt Raw Fruit real flow velocity 1,96 m/s 1,50 m/s
Mash mixer diameter 150 mm 150 mm
Main water pipe to the mixer 50 mm 32 mm
Hot water line 40 mm 25 mm Cold water pipe
Cold water pipe 32 mm 25 mm Flow velocity 3,0 m/s 3,0 m/s
Diameter hot water valve 32 mm 25 mm
Diameter cold water valve 32 mm 25 mm DN calculated 31 mm 16 mm
DN selected 32 mm 25 mm
real flow velocity 2,8 m/s 1,3 m/s
13
4. mash tan:
In this chapter, the malt mash tun is dimensioned and designed.
The starting values for dimensioning the mash tun are the volume of the malt mash as calculated in the chapter Premasching (here 74 hl); 15% safety
margin is now added to this calculated value and the calculated volume of 85 hl is obtained. A reference table is now automatically searched for the
suitable mash tun for this volume and the corresponding diameter, the total volume and the contents of the bottom of the mash tun up to the frame
are specified.
The diameter relevant for the further calculations must then be entered; the reference diameter of 2500 mm was used here. This now results in the
ratio of the pan diameter to the height of the level of the malt mash of 1 : 1.7.
Mash pan
Dimensions
Mash quantity 74 hl
Total content of mash pan 85 hl
Mash pan diameter 2500 mm
Mash pan capacity 95,6 hl
Bottom mash pan capacity 7,2 hl
Actual safety factor 1,29
Diameter selected 2500 mm

Ratio diameter/mash height 1,7
14
The starting point for the calculation of the heating surfaces is the desired heating rate, this is usually in the range of 0.5 (for older pans) to 1.8
°C/min (for newer ones) here a value of 1.5 °C/min m²K was used, newer pans reach a K value above 2000, for our example we used 1300 which
corresponds to a value of 1512 W/m²K which is displayed below.
Furthermore, the available steam pressure at the ladle (it is assumed that saturated steam is the heating medium) must be selected, here the
value of 3, 4, 5 or 6 bar can be selected, the corresponding steam condensation temperature then appears in the cell below.
Furthermore, the initial and final temperature of the mashing process is necessary.
These values are then used to calculate the required heat output, in this case 778 kw.
Now the calculation of the total required heating surface (here

Heating surfaces
7.40 m²) is performed as well as the specification from a
Heating rate 1,5 °C/min
reference table of the possible distribution of the heating k-value 1300 kcal/m² K hReference value: 1000 bis 1500
surfaces in the base and frame for this ladle. 1512 W/m² K
Next, the number of heating rings (where one heating ring Steam pressure absolute 3 bar
Temperature steam 133,55 °C
requires 13 cm of cylindrical height) is specified to achieve this Temperature min mash at start 50 °C
cylinder heating surface. Temperature max mash at end 78 °C
The actual number of heating rings to be installed must now be
Heating power 778 kW
specified (if dimple plates are to be installed instead of heating
rings, the number must be selected so that the desired m² is Heating surface required 7,40 m²
achieved). Bottom heating surface available 3,55 m²
Now the effective quantity of mash according to the recipe is Frame heating surface required 3,85 m²
Heating rings quantity 3,8 (1ring corresponds to 13 cm cylinder height)
calculated in the cylidric section (here 67.11 hl) as well as the Number of heating rings selected 4
filling height of the mash in the cylindrical section (here 1.37 m). Frame heating surface selected 4,08 m²
The filling height of the mash above the uppermost heating Heater frame height selected 0,52 m
Heating surface selected 7,63 m²
surface segment is now displayed (here 85 cm).
If no bottom heating surface is provided, the entire heating Frame content 67,11 hl
surface must be accommodated in the frame; if this is not Frame height required 1,37 m
possible for this recipe, the message "no factible" appears. The
Mash over heating frame 0,85 m
heating rate must now be reduced or the recipe changed.
15
Furthermore, the necessary connection to the lauter tun is designed. First of all, the mashing time must be determined in order to comply with the
brew schedule; here, 10 min was selected, which results in the necessary mashing speed (here 45 ³/h).
The next value to be entered is the speed of the mash on the suction side of the pump, this should not exceed 1.5 m/sec, here 1.2 m/sec was selected.
This results in a calculated pipe diameter of 115 mm, the next available pipe diameter in this case was a DN 125 which was selected, finally this results
in a flow velocity on the suction side of 1.01 m/sec.
Mashing to lauter tun
The necessary steam and condensate connections are designed. Mashing time 10 min
Capacity 45 m³/h
From the required heating energy of 778 kw, the steam energy of 845 kW is
calculated. Taking into account the preselected steam pressure at the ladle, this Flow velocity on suction side 1,2 m/s (not over 1,5 m/sec)
steam energy results in a mass of 1407 kg/h with a volume flow of 851 m³/h. DN required 115 mm
DN selected 125 mm
For these steam quantities, a steam regulating valve with a diameter of 65 mm is Flow velocity real 1,01 m/s
proposed to reduce the high pressure steam coming from the steam boiler to the
preselected steam pressure at the ladle. Steam supply to mash tun
Energy demand 778 kW = 668.896 kcal/h
For the steam line to the ladle, the desired flow velocity is now selected (reference Steam consumption 845 kW = 727.060 kcal/h
velocities can be found in Brew.Tech "General calculations"). A selected velocity of Steam mass flow 1407 kg/h
30 m/sec results in a pipe diameter of 100 mm, since this corresponds to an existing Steam volume flow 851 m³/h
pipe diameter, 100 mm is entered in the next field as the selected diameter, which Control valve DN 65 mm
then results in the real flow velocity of 30.1 m/sec.
The same procedure is followed for the condensate piping. The selected condensate Flow rate steam selected 30 m/s
Steam line required 100 mm
flow velocity of 1 m/sec results in a calculated pipe diameter of 22 mm, the next Steam line selected 100 mm
available pipe has a diameter of 25 mm which corresponds to a real flow velocity of Flow rate steam real 30,1 m/s
0.8 m/sec.
Flow rate Condensate selected 1 m/s
Finally, the required steam traps are suggested: Here 2 traps with a nominal width of Condensate line required 22 mm
40 mm, as well as the volume of the condensate tank of here 9 liters. Condensate line selected 25 mm
Flow velocity condensate real 0,80 m/s
Number of steam traps 2 x DN 40

Condensate pot 9l
16
In the final step, the piping and pump selection for mashing down to the lauter tun are designed and checked again.
First, the previously defined mashing time of 10 min and the calculated mashing speed of 45 m³/h are adopted.
Next, the actual pump capacity is entered, here 55 m³/h has been entered as the real pump capacity.
We see that the calculated mash speed was 1.01 m/s, to keep to this a pipe diameter of 139 mm would now be necessary, but the selected pipe
diameter is 125 mm, resulting in a flow speed of 1.24 m/s. Since this is still below the maximum speed of 1.5 m/s, the message "Pump OK" appears.
For the pressure side of the pump, a desired speed of 2.3 m/s was selected, resulting in a necessary pipe diameter of 92 mm, the selected pipe
diameter is 80 mm, which in turn results in a flow speed of 3.04 m/s. After this is above the maximum speed of 3.0, the message "Change pump"
appears. In order to set the flow velocity below 3.0, either the flow rate of the pump must be reduced or the pipe diameter of the pressure side must be
increased.
Mash pump
Mash duration 10 min
Mash pump capacity calculated 45 m³/h
Mash pump capacity selected 55 m³/h
Flow rate mash suction side 1,01 m/s maximum 1,5 m/sec
Required pipe diameter 139 mm
Selected pipe diameter 125 mm
Real flow velocity 1,24 m/s Pumpe OK
Flow velocity mash pressure side 2,3 m/s maximum 3,0 m/sec
Required pipe diameter 92 mm
Selected pipe diameter 80 mm
real flow velocity 3,04 m/s Pumpe ändern!
17
5. raw fruit stove:
In this chapter, the raw fruit cooker is dimensioned and designed.
This design is largely analogous to the design of the mash pan.

At the beginning it must be determined whether it is a pressure cooking (necessary for installations at high altitude where the atmospheric pressure
does not allow a sufficient cooking temperature above approx. 95 °C) or normal atmospheric cooking, depending on this, a conical or dished bottom
must be installed.
The initial values for dimensioning the raw fruit digester are the volume of the raw fruit mash as calculated in the chapter Mash calculation (in this
case 26 hl); a safety margin of 50% is now applied to this calculated value and the calculated volume of 38 hl is obtained. The suitable pan for this
volume is now automatically searched for in a reference table and the corresponding diameter, the total volume and the contents of the pan bottom
up to the frame are specified.
The diameter relevant for the further calculations must then be entered; the reference diameter of 2000 mm was used here. This now results in the
ratio of the pan diameter to the height of the level of the malt mash of 1 : 2.5
Raw Fruit Cooker

Pressure cooking nein
Dimensions
Raw fruit mash quantity 26 hl
Total capacity raw fruit cooker 38 hl
Diameter raw fruit cooker 2000 mm
Raw fruit digester cooker 48,9 hl
Contents bottom raw fruit cooker 3,7 hl
Actual safety factor 191%
Selected diameter raw fruit cooker 2000 mm

Ratio diameter / liquid height 2,5
18
The starting point for the calculation of the heating surfaces is the desired heating rate, this is usually in the range of 0.5 (for older pans) to 1.8
°C/min (for newer ones) here a value of 1 °C/min m²K, newer stoves reach over 2000, for our example we chose 1250 which corresponds to a
value of 1453 W/m²K which is displayed below.
Furthermore, the available steam pressure at the stove (it is assumed that saturated steam is the heating medium) must be selected, here the
value of 3,4,5 or 6 bar can be selected, in the cell below the corresponding steam condensation temperature appears.
Furthermore, the start and end temperature of the boiling process is necessary, here the start of boiling was specified at 50°C and the start of
boiling at 95°C.
These values are then used to calculate the required heat output, in this case 178 kw.
Heating Surfaces
Now the calculation of the total required heating surface (here 2.01 m²) is Heating rate 1 °C/min
k-value 1250 kcal/m² K h:
reference value 1100 bis 1300
performed as well as the specification from a reference table of the possible 1453 W/m² K
distribution of the heating surfaces in the base and frame for this ladle. Steam pressure absolute 3 bar
Next, the number of heating rings (where one heating ring requires 13 cm Temperature steam 133,55 °C
Temperature min raw fruit mash at start 50 °C
of cylindrical height) is specified to achieve this cylinder heating surface.
Temperature max raw fruit mash at end 95 °C
The actual number of heating rings to be installed must now be specified (if
dimple plates are to be installed instead of heating rings, the number must Heating power 178 kW
be selected so that the desired m² is achieved).
Heating surface required 2,01 m²
Now the effective quantity of mash according to the recipe is calculated in Bottom heating surface available 2,00 m²
the cylidric section (here 21.87 hl) as well as the filling height of the mash in Frame heating surface required 0,01 m²
the cylindrical section (here 0.70 m). The fill level of the mash above the Heating rings quantity 0,0
Number of heating rings selected 1
uppermost heating surface segment is now displayed (here 0.70 m).
Frame heating surface selected 0,82 m²
If no bottom heating surface is provided, the entire heating surface must be Heater frame height selected 0,13 m
accommodated in the frame; if this is not possible for this recipe, the Heating surface selected 2,82 m²
message "no factible" appears. The heating rate must now be reduced or
Frame content 21,87 hl
the recipe changed. Frame height required 0,70 m
Mash over heating frame 0,57 m
19
Furthermore, the necessary connection to the mash tun or lauter tun is designed. First of all, the mashing time must be determined in order to comply
with the brew schedule; here, 10 min was selected, resulting in the necessary mashing speed (here 15 m³/h).
The next value to be entered is the speed of the mash on the suction side of the pump, this should not exceed 1.5 m/sec, here 1.4 m/sec was selected.
This results in a calculated pipe diameter of 62 mm, the next available pipe diameter in this case was a DN 80 which was selected, finally this results in a
flow velocity on the suction side of 0.85 m/sec.
The necessary steam and condensate connections are designed.
Steam supply of the raw fruit cooker
From the required heating energy of 178 kw, the steam energy of 194 kW is Energy demand 178 kW = 153.401 kcal/h
calculated. From this steam energy, taking into account the preselected steam Steam consumption 194 kW = 166.740 kcal/h
Steam mass flow 323 kg/h
pressure at the stove, a mass of 323 kg/h results at a volume flow of 195 m³/h. Steam volume flow 195 m³/h
For these steam quantities, a steam regulating valve with a diameter of 32 mm is
proposed to reduce the high pressure steam coming from the steam boiler to the Control valve DN 32 mm
preselected steam pressure at the ladle. Flow rate steam selected 30 m/s
For the steam line to the ladle, the desired flow velocity must now be selected Steam line required 48 mm
Steam line selected 50 mm
(reference velocities can be found in the Brew.Tech "herramienta básica"). A selected
Flow rate steam real 27,61 m/s
velocity of 30 m/sec here results in a pipe diameter of 48 mm, the next available
pipe diameter is a DN 50, in the next field 50 mm is therefore entered as the Flow rate Condensate selected 1 m/s
Condensate line required 11 mm
selected diameter, this again results in the real flow velocity of 27.6 m/sec. Condensate line selected 25 mm
The same procedure is followed for the condensate piping. The selected condensate Flow velocity condensate real 0,18 m/s
flow velocity of 1 m/sec results in a calculated pipe diameter of 11 mm, the next Number of steam traps 1 x DN 40
available pipe has a diameter of 25 mm which corresponds to a real flow velocity of Condensate pot 4l
0.18 m/sec.
Finally, the required steam traps are suggested: Here 1 trap with a nominal diameter
of 40 mm, as well as the volume of the condensate tank of here 4 liters.
20
6. lauter tun: Total pouring 1870 kg
Pouring malt 1330 kg
Pouring raw fruit 540 kg
In this chapter, the lauter tun is dimensioned and designed. specific pouring 180 kg/m²
Base area 10,4 m²

The starting point for this design is again the recipe created in the Mash Calculation tab. Diameter 3637 mm
The total quantity of raw material of 1870 kg, as well as the partial quantity of malt of
1330 kg and the partial quantity of raw fruit of 540 kg are taken from this. Diameter selected 3600 mm
Now, the desired specific sagging load must be selected; this is responsible for the Actual base area 10,2 m²
minimum achievable filtration time and is therefore selected as a function of the specific fill actual 157 kg/m²
Frame height 2000 mm
maximum desired brew number and the type of grist. On the right-hand side, there is a Actual volume 192 hl
selection table in which the possible specific particle sizes are given as a function of the
grist and the number of brews, as well as the resulting pouring height. The lower the Volume of spent grains in the lauter tun 27,5 hl
specific apparent density, the larger and therefore more expensive the lauter tun will be. Height of spent grains in lauter tun 0,29 m
In this case, a bulk density of 180 kg/m² was selected. 8 9
brews brews
The required filter area of 10.4 m² and the theoretical lauter tun diameter of 3637 mm pure dry grist 165-175 155-165 kg/m²
are now calculated from this. The effective real or next possible lauter tun diameter is spent grain height 29-32 27-29 cm
now entered, here a lauter tun with a diameter of 3600 mm was selected. With the real cond. Dry grist 175-185 170-175 kg/m²
spent grain height 32-33 30-32 cm
diameter, the real filter area of 10.2 m² and the real specific bulk density of 157 kg/m² cond. Wet grist 220-230 205-215 kg/m²
are calculated. spent grain height 30-41 36-38 cm
The next step is to enter the cylindrical height, which should be at least 50 above the
maximum volume of the lauter tun contents. Here a height of 2000 mm was selected 10 12
which results in a volume of 192 hl. brews brews
pure dry grist 150-160 140-150 kg/m²
Finally, the spent grains volume of 27.5 hl and the spent grains height of 0.29 meters are spent grain height 26-28 25-26 cm
calculated. cond. Dry grist 165-175 150-160 kg/m²
cond. Wet grist 195-205 185-195 kg/m²
21
The calculation of the entry openings for the mash into the lauter tun is now Pump in mash
carried out. The total mash has already been calculated at 74 hl, the duration of Total mash 74 hl
Duration of pumping 10 min
the mashing process has also been set at 10 min and the required flow rate of Necessary power of the pump 55 m³/h
55 m³/h has been defined. To ensure air-free mashing into the lauter tun, the
inlet velocity should be less than 1 m/s. In this case, 0.5 m³/h was used. In this Rushing speed 0,5 m/s < 1 m/s
case, 0.5 m/s was selected, resulting in a required inlet opening into the lauter Resulting size of inlet port(s) 306 cm²
tun of 306 cm² or 30,556 mm². In this case, inlet valves with a diameter of 100 30.556 mm²
Selected diameter of inlet valves 100 mm
mm were selected, resulting in a calculated number of valves of 3.9. For this Resulting number of inlet valves 3,9
case, 4 valves are now used and entered. Selected number of inlet valves 4
Sparging time
In the following, we will now calculate the mechanism of sparging or anschwänzen. Sparging time 45 min
The initial value is the maximum time allowed for precoating. This is estimated Precoat quantity 68 hl
Precoating temperature 77 °C
from the attached table in which the maximum total filtration time and the
Temperature of cold brewing water 15 °C
maximum possible time for tarnishing are given for the maximum number of brews
Temperature of warm brewing water 80 °C
of 8, 10 and 12 brews per day.
A time of 45 min was specified here. The amount of preweaning water of 68 hl has
already been calculated. The temperature of the preheating water is specified as 8 brews 10 brews 12 brews
77°C to ensure saccharification. Ma ximum la ute ring time 140 110 90
The cold water temperature of 15 °C and the hot water temperature of 80 °C Ma ximum spa rging time 60 50 40
available in the brewery have already been specified and are adopted here. Pre coa ting qua ntity 5,3-5,8 6,0-6,3 6,4-6,6
m³/t*h m³/t*h m³/t*h
22
The piping of the water mixer can now be designed from the entered and Water mixer
calculated values of the lauter tun. Main line
2m/s is selected as the flow velocity for the main supply line to the Flow velocity 2 m/s
DN calculated 40 mm
preweakening device, this results in a calculated pipe diameter of 40 mm, this is
DN selected 40 mm
also entered as the selected diameter and the real flow velocity of 1.99 m/s is Actual flow velocity 1,99 m/s
shown.
Water quantity
In order to achieve the selected precoating temperature at the specified water Hot water quantity 64 hl
temperatures and quantities, 64 hl of hot water and 3 hl of cold water are Cold water quantity 3 hl
required, which corresponds to a throughput of 8.6m³/h of hot water and Hot water supply 8,6 m³/h
0.4m/h of cold water at the selected times. Cold water supply 0,4 m³/h
For the hot water supply of the water mixer, a pipe diameter of 39 mm is Hot water supply 2 m/s
Flow rate 39 mm
therefore calculated at a selected flow velocity of 2 m/s. The real pipe diameter
DN calculated 40 mm
is assumed to be 40 mm. The real pipe diameter is assumed to be 40 mm, DN selected 1,90 m/s
which results in a real flow velocity of 1.90 m/s. Actual flow velocity
For the cold water supply of the water mixer, a pipe diameter of 9 mm is Cold water pipe 2 m/s
calculated at a selected flow velocity of 2 m/s. The real pipe diameter is Flow velocity 9 mm
assumed to be 25 mm. The real pipe diameter is assumed to be 25 mm, which DN calculated 25 mm
results in a real flow velocity of 0.24 m/s. DN selected 0,24 m/s
23
Finally, the lautering of the filtered wort is calculated.
First, the required number of lauter tun openings is calculated; here, approx. 1 wort filtration
m² of lauter tun surface per opening applies, resulting in 10 lauter tun openings
Number of wort outlets 10
here.
According to the recipe, a total of 107 hl of wort is lautered. This quantity must
Vessel full quantity 107 hl
be subtracted from the lauter tun in the effective lautering time, i.e., total
lautering time 130 min
lauter tun occupancy time minus lautering time minus transfer time minus Lauter pump capacity 5 m³/h
stripping time. In this case, 130 min were entered. This results in an average Lauter pump capacity selected 8 m³/h
flow rate of the wort of 5 m³/h.
A pump with a capacity of 8 m³/h was selected to draw this off from the lauter Flow rate 1,5 m/s
tun. DN calculated 43 mm
The flow velocity of the wort should be 1.5 m/s, from which a tube diameter of DN selected 50 mm
43 mm is calculated. A tube diameter of 50 mm was selected and thus a real Actual flow velocity 1,13 m/s
flow velocity of 1.13 m/s was achieved.
GEARING
Finally, there is an indication of the rotation speed of the chopping unit. Speed chopping 0,2 UpM
During blowdown, this should be 0.2 revolutions per minute. Speed spent grains removing 9,5 UpM
During scouring, this should be 9.5 revolutions per minute.
24
Now the spent grains handling is calculated.
The recipe results in a spent grains quantity of 1933 kg with normal residual wort spent grain removal
content. In the next step, the desired spent grains time of 15 min is entered here, Spent grains quantity 1933 kg
resulting in an output for the spent grains unit of 129 kg/min. Sparging time 15 min
Spent grains conveyor capacity 129 kg/min
If the spent grains are to be stored temporarily in a silo, a silo volume of 3.31 m³ is
spent grain silo
required for this quantity of spent grains; if several brews are to be stored in this
Spent grains quantity circa 3,31 m³
silo, this volume must be multiplied by the desired number of brews.
Sparging time 20 min
In the next step, the required stripping time from the silo is entered, in this case 20
Output of spent grains conveyor calculated 124 kg/min
min, and the required line of the stripping unit, in this case 124 kg/min, is displayed. Output of spent grains conveyor selected 100 kg/min
Air consumption circa 1,5 m³/min
Consumption data for a comparable pneumatic spent grains conveyor are now given at 2 bar
below. A comparable conveyor would have a capacity of 100 kg/min and would Engine aprox. 4 kW
require 1.5 m³/min compressed air at 2 bar with an electrical connected load of 4
kW.
25
7. lauter wort heater:
In this chapter, a lauter wort heater is dimensioned and designed.
A lauter wort heater is connected between the lauter tun and the wort kettle in order to reduce the
occupancy time of the wort kettle (the time required for the wort to heat up is reduced) and to have
the option of using regenerative energy.
First of all, the total volume of filtered wort of 107 hl, the total effective flow time of the wort of 130
min and the resulting throughput of 49 hl/h are the key data that have already been specified.
The effective inlet temperature of the wort into the heater must now be specified (here 74 °C) as well
as the desired outlet temperature (depending e.g. on the boiling temperature at the site, or the
available hot water temperature in the energy storage tank) here 92 °C.
In the following, the size of the heat exchanger is now designed for the use of hot water from an
energy storage tank.
The inlet temperature of the hot water into the energy storage tank is entered (here 96 °C) as well as
the desired return temperature (usually 3 to 6 °C above the inlet temperature of the wort).
This now results in a required heat output of the heat exchanger of 110 kW with a hot water
throughput of 59 hl/h.
Furthermore, the heat transfer or K-value of the heat exchanger must now be specified, this value is
usually specified by the manufacturer of the heat exchanger, for older types this can be 1200 to 1800
for newer around 2000 - 2500, in this case a value of 2000 was selected.
With these values, the average temperature difference between the two media (here 4.9 k) and, as a
result, the size of the heat exchanger is given as 11.1 m² (without safety margins !).
26
If no hot water tank is available for heating the wort, the water can also be generated
by means of saturated steam in a steam-driven hot water generator; here is the design
of the corresponding steam supply. Heating medium steam (indirect for hot water production)
The size of a corresponding hot water generator can be designed with brew.tech -> Steam pressure 4 bar
Steam temperature 143,64 °C
Brewing calculations -> General calculations. k-value 800 kcal/K m² h
The starting point is the steam pressure used (here 4 bar), which results in a saturated k-value 930 W/m² K
steam temperature of 143.64 °C.
Furthermore, the K value of the hot water generator is entered as specified by the Steam consumption
manufacturer (here 800) at the same time it is specified in the unit W/m²K (here 930). Energy demand 110 kW = 94.247 kcal/h
The demand for thermal energy with 110 kW is taken over, this corresponds to a steam Steam consumption 119 kW = 102.443 kcal/h
Mass flow 201 kg/h
energy of 119 kW and this with the given steam pressure a steam quantity of 201 kg/h Volume flow 93 m³/h
corresponding to a steam volume of 93 m³/h.
Steam line
Flow rate Steam 25 m/s
The steam supply line and condensate drain can now be designed. Steam line required 36 mm
Steam line selected 40 mm
Flow rate steam actual 20,53 m/s
With a specified steam velocity of 25 m/s (reference values can be found in brew.tech -
> Brewing calculations -> General calculations), a steam tube diameter of 36 mm is Condensate line
Flow rate Condensate 2 m/s
calculated. A tube diameter of 40 mm was selected, resulting in a steam velocity of Condensate line required 6 mm
20.53 m/s. Condensate line wt. 25 mm
Flow rate Condensate actual 0,11 m/s
With a given condensate velocity of 2 m/s (reference values can be found in brew.tech
-> Brewing calculations -> General calculations), a condensate tube diameter of 6 mm
is calculated. A tube diameter of 25 mm was selected, resulting in a condensate
velocity of 0.11 m/s.
27
In order to make the wort transfer from the lauter tun to the wort kettle independent
of the occupancy of the wort kettle (regardless of whether a lauter wort heater is used
or not), a buffer vessel can be connected in between which is designed here.
Basically, the orientation can be selected (here vertical, alternatively horizontal) as
well as the type of floors (here normal curved, alternatively dished floor).
The volume of the kettle full of wort with 107 hl is again already given and from this,
with 15% surcharge, the required volume of the buffer tank is 123 hl.
A diameter of 2000 mm was selected for this upright buffer vessel with normally
arched bottoms. This results in a bottom capacity of 5 hl and a cylinder capacity of 118
hl with a frame height of 3.76 m. The actual height of the frame was now selected as
3.90 m, resulting in an actual total height of 4.19 m with a cylindrical volume of 123 hl
and a total usable volume of 127 hl.
The time selected for pumping the wort from this buffer vessel into the wort kettle
was 12 min, which requires a pumping speed of 54 m³/h, and a pump with a speed of
80 m³/h was selected.
The suction speed of this pump was selected to be a maximum of 1.4 m/s, resulting in
a calculated pipe diameter of 142 mm. A pipe with a diameter of 150 mm was
selected, resulting in a speed of 1.26 m/s.
The speed of the discharge side of this pump was selected with a maximum of 1.7 m/s,
resulting in a calculated pipe diameter of 129 mm, a pipe with a diameter of 150 mm
was selected, which also results in a speed of 1.26 m/s.
28
8. wort pan:
The starting point for the calculation is again the hot seasoning quantity at the end of
boiling of 100 hl specified in the recipe. A surcharge of 50% is now applied to this
quantity for the necessary total volume, resulting in a total volume of 150 hl.
Next, the ladle diameter is selected here 2800 mm (the ratio of ladle height to ladle
diameter should be about 1:1 to 1:1.5, also depending on whether a function as a
whirlpool ladle is intended, here see the later chapter "Whirlpool").
Furthermore, the type of bottom is selected; a dished bottom is required for pressure
cooking, otherwise a normal curved bottom. Depending on this, the bottom volume
(here 13 hl) as well as the necessary cylindrical volume of 137 hl and the resulting
calculated cylinder height of 2.22m are calculated.
The next step is to enter the actual cylindrical height, here 2.4 m was selected, this now
results in an actual total height of 2.8 m (without gearbox and lower piping!), an actual
cylinder volume of 148 hl and a total volume of 161 hl.
The next step is to design the heating system. In the first step, you need to choose
between indoor or outdoor stove.
The parameters set in the recipe are then displayed: Hot seasoning quantity at end of
boil of 100 hl, an hourly evaporation rate of 6%, a total boiling time of 70 min, the hourly
evaporation segments of 6 hl and from this the total evaporation quantity of 7 hl and the
total evaporation rate of 7% which in turn gives the pan full quantity of 107 hl.
The last parameter to be entered here is the time in which the wort preheated to 92 °C
by the lauter wort heater is to be heated to the boiling temperature of 99 °C; 10 min
have been provided here.
29
With the previous data, the heating of the pan can now be designed. In the kettle, a
distinction is made between the warm-up phase and the boiling phase, both of which must
be considered separately. In the heating phase, the start temperature of the wort heating
must first be entered at 92 °C as it comes from the previously designed lauter wort heater, as
well as the temperature of the start of boiling of 99 °C in this case, from which a heating rate
of 0.70 °K/min is then calculated, taking into account the specified heating time of 10 min.
Likewise, the temperature of the start of boiling is specified under Boiling and the maximum
desired wort temperature is specified under Exit temperature (from the internal or external
boiler) in order not to overheat the wort (103 °C in this case).
Next, the steam pressure in the heat exchanger must be selected (here 3 bar) and this results
in the saturated steam temperature of 133.55 °C in this case.
Furthermore, the K-value of the heat exchanger must be entered (here 1650), which is
specified by the manufacturer (older exchangers 1500 - 2000, newer ones 2000 - 2500). Here
1650 was selected, and at the same time the K-value is specified in W/m²K (here 1919).
Furthermore, a safety factor for the heat exchanger surface area is necessary, since the K
value decreases due to the occupation and incrustation of the surface between the cleaning
intervals and the surface area would be too small; here, 30 % was selected. This results in a
heat exchanger surface area of 8.61 m² for the cooking process and 10.23 m² for the
reheating process. Since only one heat exchanger can be installed, the larger value must be
selected for the design.
Now the steam supply can be designed. Based on the previous data, the energy requirement
during the cooking phase is 323,640 kcal/h and for the heating phase 449,400 kcal/h. The
next step is to correct this value for steam losses due to radiation, etc. Here, these were
assumed to be 4%. Next, this value is corrected for steam losses due to radiation etc., here
these were assumed to be 5%. This gives the mass of steam of 659 kg/h for boiling and 915
kg/h for heating, as well as the corresponding steam volume for boiling of 399 m³/h and for
heating of 554 m³/h, and also the calorific heat output of the exchanger for boiling of 396 kW
and for heating of 550 kW. Finally, the nominal diameter of the steam reducing valve must be
designed according to the larger nominal diameter of 50 mm.
30
The steam supply line from the regulating valve to the wort kettle can
now be designed using the previous information. First, the steam
velocity of 20 m/s in the steam line is specified again. This results in a
pipe diameter of 84 mm for the boiling phase and 99 mm for the
heating phase. Since the larger diameter must be selected, a pipe
with 100 mm was chosen. Again, we obtain the real steam velocities
of 14.1 m/s during the boiling phase and 19.6 during the heating
phase.
The condensate is treated in the same way.
First of all, the condensate velocity of 1 m/s in the condensate line is
specified again. This results in a pipe diameter of 15 mm for the
boiling phase and 18 mm for the heating phase. Since the larger
diameter must be selected, a pipe with 25 mm was chosen. Again, we
obtain the real condensate velocities of 0.37 m/s during boiling and
0.52 during heating.
Furthermore, in the case of an external boiler, the necessary capacity

of the wort circulation pump is specified as 81 m³/h in order to be
able to achieve the corresponding heating capacity.
31
Here, the heating of the wort kettle by means of hot water instead of saturated
steam is now calculated.
The starting point is again the pan full amount of 107 hl.
The heating rate of 0.7 °K/min is now preselected. Furthermore, it is assumed in this
example that no lauter wort heater was used. The initial temperature of the wort at
the start of lautering is therefore entered as 74 °C and the temperature at the end of
lautering (= temperature at the start of boiling) is again entered as 99 °C.
Furthermore, the available hot water is entered with a temperature of 130 °C as well
as the return temperature of the hot water with 100 °C. In order not to damage the
wort by overheating, a mixing temperature of 120 °C is specified at the inlet of the
boiler (by adding the outgoing water with 100 °C to the incoming water with 130 °C
at the inlet of the heat exchanger).
The K value of the heat exchanger is assumed to be 1500, furthermore heat losses of
5% and a safety factor for the heat exchanger of 10% for fouling.
This results in a calculated heat demand of 523 kW as well as including the
previously entered loss of 550 kW (alternatively, the values are given in kcal/h). This
now results in a calculated heat exchanger area of 25.49 m² as well as including the
safety factor of 28.04 m².
Furthermore, the mass flows as well as the volume flows corresponding to the
temperature result. The flow through the heat exchanger (with the mixing
temperature of here 120 °C) is 23,373 kg/h or 24.8 m³/h, the hot water inlet (of here
130 °C) is 15,582 kg/h or 16.7 m³/h, the hot water return (of here 100 °C) is 15,582
kg/h or 16.3 m³/h and the necessary mixed water circulated at 100 °C from the heat
exchanger outlet to the heat exchanger inlet is 7,791 kg/h or 8.1 m³/h.
32
Accordingly, the piping of the hot water supply can now be calculated.
First, the flow velocities of the three water streams are specified again,
in this case this is entered as 1.5 m/s.
As in previous examples, the calculated pipe diameter is 61 mm for the
hot water flow and return, which is then designed with 65 mm, and 43
mm for the circulation or mixing line, which is designed with 50 mm.
Now the hot wort deflection pump is still being dimensioned.

The starting point is the 100 hl of hot cast wort produced. A deflection
time of 15 min is assumed, resulting in a calculated pump capacity of
40 m³/h.
A pump capacity of 50 m³/h was selected.
The flow velocity on the suction side of the pump should not exceed
1.3 m/s, which results in a pipe diameter of 117 mm. A pipe with a
diameter of 125 mm is selected, which corresponds to a real flow
The flow velocity on the discharge side of the pump should not exceed
2.4 m/s, which results in a pipe diameter of 86 mm. A pipe with a
diameter of 100 mm is selected, which corresponds to a real flow
33
9. whirlpool:
The design of the whirlpool and the wort cooling system is now carried out.
The initial value is the volume of hot wort at the end of boiling of 100 hl from the
recipe. A safety factor of 20 % is now added to this to obtain the calculated whirlpool
volume.
The next value is the diameter to height ratio, as a guide this should be between 2.5
to 3.0 to 1, here a ratio of 2.5:1 was chosen.
From this ratio, a calculated diameter of 3,169 mm was selected as the real diameter
of 3,200 mm, resulting in a wort level of 1,243 mm and a real diameter to height ratio
of 2.57:1.
This results in a calculated cylinder height of 1,492 mm; a cylinder with a height of
1,500 mm was selected, resulting in a total volume of 121 hl.
If the whirlpool is also used for wort boiling, the calculation is similar. In this case, an
external boiler should be used so that the diameter is not too small due to the height
of the internal boiler.
The starting point is again the 100 hl of hot wort at the end of boiling, but now a
safety margin of 40% is added due to the boiling motion, resulting in a total capacity
of 140 hl.
The diameter to height ratio is assumed here to be 2.0:1 (in order to clarify whether
an internal boiler can be installed). This results in the calculated diameter of 2,942
mm and a diameter of 3,000 mm was selected, giving a wort level of 1,415 mm and a
real diameter to height ratio of 2.12:1.
This results in a calculated cylinder height of 1981 mm; a cylinder with a height of
2000 mm was selected, resulting in a total volume of 141 hl.
34
Now the pumps of the spa are laid out.
In total, the hot holding time of the wort should not exceed 120 min (transfer/rotation time + settling time of
approx. 30-40 min + cooling time).
A transfer/rotation time of 30 minutes is assumed here, since the same pump is used to supply the wort cooler,
wort cooling also takes 30 min.
This results in a calculated pump capacity of 200 hl/h, a pump capacity of 200 hl/h is also selected.
The tangential entry speed of the wort into the whirlpool should be between 10 and 15 m/s in order to achieve
the centrifugal effect of the whirlpool. A velocity of 15 m/s is selected here, which means that the entry into the
whirlpool must be reduced to a calculated 22 mm, a reduction to 25 mm is selected, which now results in a
tangential velocity of 11.32 m/s.
The inlet velocity of the wort on the suction side is selected as 1.5 m/s, a tube diameter of 69 mm is calculated, a
tube diameter of 80 mm is selected, resulting in a real inlet velocity of 1.11 m/s.
The outlet velocity of the wort on the pressure side is selected as 2.0 m/s, a pipe diameter of 59 mm is calculated,
a pipe diameter of 65 mm is selected, resulting in the real outlet velocity of 1.67 m/s (applies to the piping up to
the inlet nozzle into the whirlpool and the piping to the wort cooler and fermentation cellar).
Now the calculation of the trub discharge. The average amount of trub to be expected is 1.0 m³ (varies depending
on hop input and type). From this, a pump capacity of 10 m³/h is suggested, a pump with 12 m³/h is selected.
The inlet velocity of the trub on the suction side is selected as 1.4 m/s, a pipe diameter of 55 mm is calculated, a
pipe diameter of 65 mm is selected, resulting in a real suction velocity of 1.00 m/s.
The outlet velocity of the trub on the pressure side is selected as 2.0 m/s, a pipe diameter of 46 mm is calculated,
a pipe diameter of 50 mm is selected, resulting in a real outlet velocity of 1.70 m/s.
35
The data of the wort cooler are now calculated.
The previously determined capacity of the deflection pump of 200 hl/h is assumed. The
entry temperature of the wort into the wort cooler is determined to be 97 °C (after cooling
down the boiling temperature in the whirlpool), furthermore the wort should leave the
wort cooler at 8 °C . The entry temperature of the ice water is 3°C and this is to be heated to
80°C in a single-stage cooler (for the design of a two-stage cooler, brew.tech -> Brewing
calculations -> General calculations can be used).
As K value of the cooler we assume 2500 (cooler of newer design).
The efficiency of the chiller is set at 95%, which then results in a theoretical heat output of
2,024 kW and an effective one of 1,924 kW.
From these general conditions, a required ice water flow rate of 217 hl/h and a necessary
heat exchanger area of 82.57 m² are calculated.
Taking into account a safety reserve of 10% (to prevent deterioration due to e.g. occupancy
between cleanings), the heat exchanger area to be selected is 90.83 m².
Now the pressure in an approximation is calculated which the deflection pump must
overcome.
Output are again the output of 200 hl/h.
The resistance of the wort aeration system is usually specified by the manufacturer
(different systems use their own booster pump) here we chose 2 bar.
Furthermore, the maximum pipe/hose length to the most distant fermentation tank is
entered, here 140m. With an estimated pressure loss of 0.1 bar/100 m, this results in a pipe
level of 0.14 bar (still depending on the number of bends/t-pieces and other installations).
Finally, the maximum wort height above the spa floor is given, in this case 25 m, and then
the total pressure to be overcome is 4.6 bar.
36
10. water:
This area represents a summary of the flow rates, volumes, and temperatures of the various water streams.
At the beginning, the different temperatures of the water available in the brewery are displayed: Hot water with 8 Cold water with 15 °C and ice water
with
The water required for mashing-in is then shown: A total of 63 hl of water with a mixing temperature of 49 °C is required in a mashing-in period of 10
min. The mixing temperature is achieved by mixing 30 hl of cold water with 33 hl of hot water. This requires a flow rate of 2.00 hl/min or 12.0 m³/h for
the cold water and a flow rate of 2.19 hl/min or 13.2 m³/h for the hot water.
Now the water required for precoating is shown: A total of 68 hl of water with a mixing temperature of 77 °C is required in a precoating period of
45 min. The mixing temperature is achieved by mixing 3 hl of cold water with 64 hl of hot water. This requires a cold water flow rate of 0.07
hl/min or 0.4 m³/h and a hot water flow rate of 1.43 hl/min or 8.6 m³/h.
37
Next, the quantity balance of a possible pan vapor condenser is shown if the energy of the evaporated wort water should be recovered.
Assuming the specified evaporation rate of 6 hl/h and the boiling time of 7 min, 56 hl of cold water (from 15 °C) can be heated to hot water (with
80 °C). The volume of 56 hl of cold water results in a volume of 58 hl of hot water by expansion. This requires a flow rate of 0.80 hl/min or 4.8
m³/h for the cold water, which results in a flow rate of 0.83 hl/min or 5.0 m³/h on the hot water side.
Now the condensed wort water is still considered.

A total of 8 hl of hot condensate is produced, which can now be cooled in a heat exchanger, resulting in 7 hl of cold water. This requires a flow rate
of 0.11 hl/min or 0.6 m³/h for the cold water, which results in a flow rate of 0.11 hl/min or 0.7 m³/h on the hot water side.
38
Now the water required for wort cooling is shown: A total of 100 hl of hot wort is cooled to a pitching temperature of 8 °C during a cooling period
of 30 min. This requires a quantity of 117 hl of ice water (of 3 °C) which expands to 120 hl of hot water (with 80 °C) by heating. This results in a
throughput of 3.90 hl/min or 23.4 m³/h on the ice water side and a throughput of 4.02 hl/min or 24.1 m³/min on the hot water side.
In the water balance that follows here, the previous flow

rates are again summarized in a table in different units.
39
Finally, the calculated minimum cross-sections are
displayed again in order to achieve the maximum flow
velocities required in the previous tables on the suction
and discharge side of the respective pumps.
In the following overview, the respective pipe diameters

can now be freely selected and the resulting flow velocities
on the suction and pressure side of the respective pumps
appear.
40

Instruction Brewhouse Calculation

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instruction Brewhouse Calculation

Uploaded by

Copyright:

Available Formats

Instructions for use of the calculation

Brewhouse calculation complete

Instruction manual for the brew.tech calculation tool Basic formulas 1

buttons of the instruction manual:

• A cell in which a value must be entered

• A cell which outputs a calculated value

• A cell where you have to choose between given options

Hot wort quantity kettle full 100 hl

Original wort content of the cast wort 14,0 °P

Total extract 100 1.418 Extrakt korrekt Zusammensetzung ändern

Total extract 14,77 GV% = Weight/Volumen

Yield difference between laboratory and brewhouse yields 3 %

[%] [kg] [kg] %

Raw fruit mash

Example data of wet milling

Water mixer Hot water supply

In this chapter, the malt mash tun is dimensioned and designed.

Diameter selected 2500 mm

Now the calculation of the total required heating surface (here

Number of steam traps 2 x DN 40

In this chapter, the raw fruit cooker is dimensioned and designed.

This design is largely analogous to the design of the mash pan.

Raw Fruit Cooker

Selected diameter raw fruit cooker 2000 mm

Mash over heating frame 0,57 m

Base area 10,4 m²

In this chapter, a lauter wort heater is dimensioned and designed.

Furthermore, in the case of an external boiler, the necessary capacity

Now the hot wort deflection pump is still being dimensioned.

Now the condensed wort water is still considered.

In the water balance that follows here, the previous flow

In the following overview, the respective pipe diameters

You might also like