What makes a brewhouse worthwhile?
The purpose of a brewhouse is to make the brewer’s life easier. Firstly, the entire process is integrated in one place, allowing the easy, clean and hassle-free transfer of product from the HLT to the mash tun to the kettle. The brewer just taps a couple of buttons on the control panel, opens and closes the relevant valves, and the brewhouse does the rest. An intelligent feature of the full integration is the presence of an effective heat exchanger which uses the heat energy from the wort as it is pumped out of the kettle and into a fermentation vessel to heat the incoming water ready to enter the HLT.
Maintenance and cleaning is considerably less time consuming with a brewhouse; a CIP system combined with expert interior welding and a fully connected system results in effective and resource-efficient cleaning at the end of every brewing day. This level of sealed integration also means that very little maintenance needs to be completed on the machine aside from a yearly service, which should typically only involve the changing of the seals in the pumps and lubrication of any moving parts (such as handles or motors) with food grade grease.
The CIP system is commenced using the control panel, removing the labour typically involved in cleaning brewing equipment. Brewers can use the control panel to specify the thoroughness and length of time of the clean, and use either steam or chemicals to sterilise the interior of the brewhouse. The control panel can also be used to measure the status of each stage of the brewing process, including temperature, condition, volume, and time. This allows brewers to set an alarm via the brewhouse, and to continue with the more involved tasks around the brewery until the equipment prompts them to return to the product once ready.
Why use a brewhouse?
A brewhouse can be used to commence the brewing of a second batch before the first brew has been completed. The first brew has left the mash tun and whilst it brews in the kettle, a second batch can be added to the mash tun. This has the potential to increase production capacity by approximately 75%.
This strategy works best if the batches are all identical, particularly if they are due to share a fermentation vessel. For more experimental, smaller batches, the brewhouse is also very suitable. The clear hatches allow visual assessment of the condition of the product, and sample taps allow tasting throughout the process from any tank.
The insulation surrounding every tank and every pipe of the brewhouse retains as much heat energy as possible, plus the use of the heat exchanger to ensure that no energy is wasted between product entering and exiting the brewhouse. The control panel can also be used to instruct the brewhouse to behave in the most economical way, compared to using more power but reaching brewing temperature at a faster rate.
Where can a brewhouse be used?
Before considering investing in a brewhouse, brewers need to be aware of the supporting equipment required, along with the environmental requirements for storing and using a brewhouse. Firstly, the mash tun and the kettle need to be ventilated outdoors in the most direct way possible. Whilst a small cost, it must be acknowledged and planned to pay for the piping and installation to duct steam vapour outside.
Secondly, a brewhouse is an aesthetically pleasing piece of equipment, and many brewers choose to feature their brewhouse within their brew pub to add to the consumer experience. The main point to consider here is that a brewhouse reaches very high temperatures and despite being well insulated it will still burn to touch. Ensure that only qualified brewers are allowed within touching distance of the brewhouse.
Thirdly, in order to provide a source of heat to the brewhouse, a steam generator or a steam boiler must be connected and used. A steam boiler is quite a volatile item of equipment which can only be used by qualified personnel, so a steam generator is recommended. The specification of the steam generator depends on the size of the brewhouse, but space and a power supply must be taken into account during the planning process.
Lastly, as with any industrial equipment, placement on level ground is necessary. Whilst a brewhouse does feature adjustable feet for minor inconsistencies in the flatness of the flooring, it should not be placed on a slope as this could severely damage the machine, present a considerable health and safety risk, and compromise the effectiveness of the production.
“In Australia every brewer has a brewhouse. In Europe every brewer has a brewhouse. It was natural for Doghouse Distillery to invest in a brewhouse. The main benefit is the integration; everything is in one place and the process is very time-efficient to manage.” – Braden Saunders, Doghouse Distillery
Why not invest in a brewhouse?
Unfortunately, the British have a tendency to stubbornly stick to what we know. This is why most UK brewers are still brewing with individual tanks and pumps connecting each. This method allows a little more flexibility in terms of the quantities able to be produced, but it is wasteful of energy, product and often extremely time consuming.
Any brewers considering upgrading their brewery equipment should seriously consider investing in a brewhouse.
Spray ball CIP system visible from inside the tanks of a Letina brewhouse.
Who is a brewhouse suitable for?
A brewhouse is suitable for any brewer who would like to increase their brewing capacity, increase the efficiency of their brewing process, and save themselves some precious time, should consider a brewhouse as their next brewery investment. Suitable for brewers who follow the same recipe day in day out, but also suitable for those brewers who like to experiment and conduct some R&D, this equipment is an all round serious option for most UK brewers.