Professional Documents
Culture Documents
Brewery LayoutEquipment Selection 2021 Briggs PB 07 Jan 2021 Issue
Brewery LayoutEquipment Selection 2021 Briggs PB 07 Jan 2021 Issue
Equipment Selection
Paul Banham & John Hancock
Our Global Offices
Briggs of Burton, Inc.
• Pittsford, NY
Briggs Asia
• Shanghai
Our UK Offices
Briggs of Burton PLC
• Burton on Trent
• Objectives
• Process
• Equipment Selection
• Factory Layout
• Practical Examples
7
Objectives
B
e
e
r
i
n
b
o
t
t
l
e
,
c
an
,
k
e
g
o
r
c
as
k
Equipment Selection
Hot process
Factors Affecting Cold
Equipment Selection Layout
process
Operation/
Scale
Automation
Equip.
Operational selection Throughput
1 or 2
Cost
streams
Product
Capital Cost
quality
Visitor site
Flexibility
or not
Malt
Equipment Selection Example 1 :
Water
Trub
Hot Wort
Cold wort
Infusion Mash Tun
Layout =
Cold process
Compact
Scale =
Smaller Operation/
Automation =
throughputs typically more
& longer manual
TAT
Infusion
Mash Throughput
Operational
Cost = Low Tun 1 or 2
streams
Product
Capital Cost quality = Good
quality but
= Low lower extract
yield
Flexibility =
Visitor site Requires good
or not malt/ very
limited grains
Lauter Tun
• Large diameter
• Slotted False Bottom
• Mash Distribution
• Sparge Distribution
• Lauter knives
• Grains Discharge
• Plough Bar
• Grains Valves
• Lauter Drive
Hot process
Layout =
Conversion
Cold process
vessel
required
Scale = Operation/
Small to Automation
large = Fully
automatic
Lauter
Operational
Cost = Tun Throughput
1 or 2
Medium streams
Product
Quality =
Capital Cost Control wort
= Medium clarity and
good extract
Flexibility = yield
OK with
Visitor site
poor malt
or not
but limited
grains
Mash Filter
Mash
Operational
Cost =
Medium
Filter Throughput
1 or 2
streams
Product
quality =
Capital Cost Clear wort
= High only &
highest
extract yield
Flexibility =
Visitor site OK with poor
or not malt and
many grains
Visual appearance/Finish
Bed Loading and Cycle Time (10 Te Malt )
Infusion Mash Tun Lauter Tun
2 2
4 Brews /da y 420 kg/m 8 Brews /da y 200 kg/m
Mash Filter
2
12 Brews /da y 30 kg/m 0.04 m wort (200 hl)
Bottoms : Cooling
Yeast & Cold Break Beer to Filtration
Standard Single Unitank Process
Lower room with most of vessel Smaller vessels can be located Completely open top and
external – improved operator indoors bottom – OK for warmer
working environment, especially in
colder climates climates
Mature Beer
• Number of streams
• 1, 2 or more Beer Yeast & Cold Break removal
Filtration
• Equal or different sized streams PVPP
Spent Filter aid
PVPP Dosing (Not for X-flow)
• DE Filtration Flitered Beer
• Batch
• Disposal costs / sustainability PVPP PVPP Stabilisation,
Re-generaton Stabilisation Shelf life.
• Membrane (Crossflow) Filtration
• Lower losses Sterile Removes Microbes
• Lower O2 pickup Filtration
De-aerated Water
• Higher capital costs CO2
High GravityBright Beer
Blending
• Lower running costs & Carbonation
Cooling
• 470 hl/h Membrane Filter Stream • 400 hl/h Membrane Filter Stream
• One of 2 streams installed in 2007 • One of 2 streams installed in 2015
• Pall Membrane technology • Pentair Membrane technology
• Continuous system • Batch system
Membrane Filtration vs DE
Minimising material
Supports all
movement within
necessary functions
boundary
What makes a
successful
layout?
Cost effective – Minimising people
minimise foot print movement
requirements
Safety
Equipment Operation/
type Automation
Brewery
Layout
Logistics &
Scale
supply chain
Utilities People
Expansion/
Future Environment
requirements
Process requirements
Straight-line Flow
Filter/ Utilities
Pro’s: Con’s: R
BH
YR/
CR/
Blending Pack.
• CR & Lab cannot be close to BH & M Lab Fermentation/
• Simple process flow Conditioning
Packaging
• Simple building design (shed)
• Workshop not close to C/R
• Small building span
• Utilities location extends beer flow RM = Raw Materials
• Utilities engine room close to FV’s BH = Brewhouse
distances YR = Yeast Room
Utils = Utilities Engine room
C/R = Control Room
’Dog-leg’ Layout W/S = Workshops (+Stores)
Utils BBTs = Bright beer tanks
Filt/Blend
BBTs
Pro’s:
• Control Room, Lab, Workshops close to all plant Ferm
• Utilities does not extend beer flow distances, and close to FV’s &
Cond.
Con’s: YR Pack
• Building design more complex C/R; Lab
Pack
• multiple inter-linking buildings
RM BH W/S
Process requirements
U-Shape Flow
Pro’s: Filt/Blend
Utils
• Control Room, Lab, Workshops close to all plant YR
• Utilities does not extend beer flow distances, and close to FV’s
C/R Lab
Pack
Con’s: BH RM W/S
RM = Raw Materials
BH = Brewhouse
YR = Yeast Room
Utils = Utilities Engine room
C/R = Control Room
W/S = Workshops (+Stores)
BBTs = Bright beer tanks
Good process flow &
effective space use
means minimal
pump & conveyor
power use.
14m
• First floor included
• Raw material handling
• Steam generator
• Control room
• Hop store
• Large process area relative to
packaging
• Limited room for expansion
(although designed for research so
key process units are all skid Process Packaging Utility
mounted) area area area
Large Scale – Example 1 USA Brewery
250m
3. Use of existing equipment & buildings
4. Expansion
1. Future constructability taken into account
2. Raw Material Storage, FVs, MVs, BBTs
5. Logistics
1. Malt in via rail
2. Access to site
3. Security
450m
1. Access to site
2. Security
3. Lorry Park/holding area
4. Goods in/out via Road
7. Expansion
1. Future constructability taken into account
2. Raw materials storage/Uni-tanks/ BBTs
• People • Visitors
• Production team • Does there need to be a visitor route?
• Segregation of certain areas from visitors?
• Maintenance Team
• Sales/Admin location • Good site location (relative to market)
e.g. Courage Berkshire Brewery
• Operation/Automation • Replaced old town centre brewery
• Fully automated/manual • Originally on greenfield land close to Motorway
junction
• Central control location/dispersed • Over time area developed, land became high value
• CIP manual/Automatic - site sold and production relocated.
• Objectives
• Process
• Equipment Selection
• Factory Layout
• Practical Examples
46