HomeHomeA well understood international unit of volume is the litre, eg 1L. In brewing the term barrel is used. But to the layman or newcomer a barrel is something that you put beer into, but to a brewer, a barrel (brl) is a unit of volume. So to avoid confusion, a barrel is a unit of volume, containing 163 litres, about 288 UK pints or 36 UK gallons. Beer containers can come in many different sizes, but the common ones in the UK are the 9 gallon firkin (40L), 18 gallon kilderkin (81L), 36 gallon barrel (163L). The larger sizes have almost disappeared, the UK industry seems to have standardised on the firkin.
To work out the size of brewery you need, estimate your weekly sales in litres. Convert this into barrels by dividing this figure by 163. The standard off the shelf microbreweries come with 2 fermentation vessels (FV's), this means that you can brew about twice per 7 or 8 day cycle. Now divide your estimated weekly sales figure by 2 (for 2FV's), does this now point to one of the standard breweries (pilot 1/2brl , 2.5 brl, 5 brl, 10 brl)?
Remember that brewing can be a wasteful process, eg sampling, spillage, raw material variation, so always allow for that. For example a single brew on a 2.5brl plant may yield 8 or 9 full firkins, and a part full cask that cannot be sold.
These are names for two different types of beer containers.
A cask is the traditional type of container in the UK, and is used for real ale and hand pumps. It has two openings. A small keystone hole on the end and a larger shive hole on the side (belly). Usually the beer is served from the keystone via a tap, the shive is broached (holed) to allow air in as beer is drawn off. A cask is usually dispensed when lying on its belly, sometimes they are used standing on their end, using a special tap called an extractor. Cask beer is usually sold by microbreweries, consumers tend to view it as traditional and hand crafted. Cask beer usually contains an unsaleable natural sediment. Cask beer is relatively short shelf life when opened. Bottle conditioned beer is similar to cask beer.
A keg is a relatively new type of container. In the UK it is the most common type of container, and is favoured by large companies. It is commonly used for lagers, cider, nitrokeg ales etc. A keg has only one opening, on the end. The opening is fitted with a valve. The valve allows beer to come out, and a compressed gas to go in. The gas drives the beer to the dispense head (tap) on the bar, instead of the handpump. A keg is always dispensed standing on its end (derived from the cask and extractor system above). Keg beer is usually sold by large companies; as it does not contain a sediment it is possible to sell 100% of the container (in some cases more!). Keg beer usually has a longer shelf life. It is viewed by consumers as mass produced and uniformly reliable. Can, bottle or tank beer is similar to keg beer.
Simply put, the equipment is used to extract sugars and flavours from vegetable raw materials, and convert these substances into a mildly alcoholic drink called beer.
The Brewery can be divided into 4 main areas, these are raw materials, brewhouse, fermentation room, processing and packaging. A microbrewery tends to concentrate on brewhouse and fermentation, and uses the bare minimum of the other two areas.
Raw Materials area. This covers the dry goods, malt, hops, adjuncts (processing aids) and the liquor system. Typically a microbrewery will use cereals eg malt, wheat, grains etc from 25Kg sacks, often stored on a pallet holding about 40 sacks. Some breweries use a mill for crushing grains, though in the UK precrushed grains are readily available. Larger breweries will store crushed grain in a grist case immediately before use. Microbrewers tend to pour the grain straight from the sack into the mash vessel. Hops are flowers, which come in large sacks called pockets, or in a compressed form in 14kg boxes. The boxed type are generally favoured, as they are more easily stored and transported. Adjuncts tend to come in a mixture of sacks and plastic buckets. The liquor system refers to the water supply, eg piped mains water or well water. In general, if the water is drinkable it is okay for brewing. A Cold liquor tank (CLT) is used for storing cold water. A hot liquor tank (HLT) is used for storing and heating hot water. It is possible to operate a small microbrewery without either a CLT or HLT, and so save costs of equipment. In this case, water is taken straight from a supply pipe and heated in the copper before use for brewing.
Brewhouse. This area is a cleanable, but not necessarily a hygienic area. Typically in a simple microbrewery it consists of a mash vessel, copper, heat exchanger, pump(s) and pipe work. The mash vessel can be one of many sub-types (eg mash tun, lauter tun, hybrid, mash filter etc), but usually consists of a tank containing a mesh false bottom. It is used to contain a mixture of crushed grains and hot water, called the mash. After a standing period, the liquid part of the mash is drained off the grains, using the false bottom as a sieve. The liquid part is called wort, a sugary liquid, and will become the beer. The residual spent grains are usually dug out and given or sold as cattle food. The copper, also called a kettle, is a vessel used to boil wort with hops. This serves several purposes that you can read about in a text book. The most important of which are to extract the bitter flavour from the hops, and sterilise the wort. The heat exchanger (Hx) is used to cool the boiling wort to ambient (room) temperatures, so that yeast, a living creature, can be added. A brand name of Hx is "paraflow", like hoover is a brand name.. The heat exchanger is the border between the clean and hygienic areas. The liquids in the process are moved around by pumps and pipes.
Fermentation Room. This is a clean and hygienic area. The fermentation vessels (FV's) are used to store a mixture of wort and yeast. The yeast converts the sugar in the wort to alcohol. Gradually the wort changes into beer. The fermentation vessels, internally, should be smooth and easily cleanable. Do not be tempted to buy FV's with sharp internal corners or rough welds, as these are very difficult to clean and sterilise, resulting in failed brews later in your project's life. FV's can be cleaned manually, or, more usually, by a semi automatic process called CIP (cleaning in place). FV's are usually cooled at some point in the process, to below 13C. This can be achieved in several ways, typically a cooling coil is introduced into the beer, or the FV's are fitted with external cooling jackets. The cooling system is usually driven by a chiller; typically a standard cold water unit in the UK microbreweries, or a dedicated fridge plant in bigger breweries.
Processing and Packaging. UK microbrewers usually produce cask beer. This is the simplest technology. Beer is run from the FV's, via a flexible pipe, into casks. The beer matures in the cask for about a week before being offered for sale. The beer can also be further processed to increase the shelf life. For example, keg beers are stored in maturation vessels (MV's), which act like large casks. The mature beer can be packed now, or filtered (and pasteurised) into kegs, cans, bottles or serving tanks.
In the UK, the market for microbrewery beers is almost exclusively cask beer, sold to real ale orientated pubs, as hand crafted, traditional products. In 1997 there where approximately 60,000 pubs, of which about 5,000 sold real ales. Both numbers will decline in coming years, but will the ratio?. The technology to make cask beer is relatively cheap and simple to use. Some microbrewers in the UK have made a success out of bottled, canned and keg beers, sold via pub chains, supermarkets, off licences and mail order. The technology and marketing techniques for these types of beer are relatively expensive and complicated. Hence most brewers start with cask beer first. In 2002, UK microbrewers were given a major boost from the government, by allowing a 50% discount on beer duty, the tax on beer.
As the remaining UK major brewers rationalise and regroup, it is likely that microbrewers will take a larger share of the market, at least in the pub sector, as small pack beers need more marketing and distribution spend. Most customers will try at least one glass of guest beer in a pub, but will stick to what they know in a club or at home.
Microbrewers tend to develop a "bread and butter" trade in their local region, and also a national trade using the well established network of beer wholesalers. The guest beer market is sometimes called the "tickers" market, referring to a person who collects beer samples. To maximise the tickers opportunity it is better to bring out seasonal beers, which are variations on standard recipes.
Outside the UK there are developing markets for cask beer, notably in France and the USA. In other countries it is possible that cask beer may be a novelty, or that a large bar/restaurant/hotel/nightclub/gym could sell sufficient volumes to make a short shelf life beer feasible.
You need somewhere to operate your plant. For a pilot brewery you need a shed or large cupboard. For a larger plant you will need about 10 square metres or more, for example a living room sized area (or bigger).
Ideally, the brewery will be near to a bar, or somewhere where people can buy the product by retail. The secondary option will be a building that you already own, and so do not have to pay additional overheads on. Alternatively a low cost industrial unit. In these two latter cases you will probably sell the beer by wholesale, that is to someone else like a pub or wholesaler.
Ideally the premises will have washable walls, floors etc. A water and power supply. The smaller breweries work on single phase domestic electricity, the larger systems use 3 phase, gas or steam. If you have the building, it is possible to modify it to take the brewery.
My best tip for premises is "easy in, easy out, everything reversible". This is because you never know if you need to quit the business or expand it.
Most, if not all businesses, trades etc are regulated in some way. In the UK, incredibly, we are the least regulated. A 'phone call is the best way to check that you comply.
To sell beer by wholesale you do not need a license. To sell beer by retail you do need a license, eg a pub or off license. A wholesale quantity can be as low as 12 litres, or a case/crate of beer. A retail license is granted by a local magistrates court.
All microbrewers require a customs and excise license. This is granted to the premises, not the person. It is obtained by 'phoning the local excise office, see VAT in the 'phone book. They will send you a small booklet and application form. This license is likely to be granted, as a way of collecting tax, unless you have previously done something that customs and excise dislike. It is free.
A microbrewery is a food production premises. As such you will need to obtain a license/consent from the local environmental health department, see Town Hall in the 'phone book, again free. Generally the EHO is very helpful. Beer is a low risk product. Standards on surfaces in food production areas are being increased inline with other EU countries. Use of timber surfaces has to be carefully considered. Food hygiene rules stipulate washable surfaces in food production areas. In the past EHO's have exercised discretion in the use of timber surfaces, eg roof trusses and cosmetic vessel cladding. In line with other EU countries, this discretion is being narrowed. It is strongly advised that clients considering a timber cosmetic finish on brewing vessels seek written advice from the local authority EHO before ordering. No liability can be accepted if the EHO does not issue an operation certificate. The likelihood is that existing installations will be allowed to continue, new installations will be subject to stricter enforcement proceedures. This will also affect the resale value of plant when the business ceases to trade.
Your premises should comply with planning consent. For example, light industrial use, business appropriate to a residential area, ancillary to the storage and sale of beer, agricultural purposes etc. Generally pubs and industrial units have this consent already, for other premises you may have to ask. Microbrewing, as it is now called, was once a major widespread industry 100 years ago. It is best to always check with the local town hall.
Water Company. A microbrewery produces effluent, in the order of that produced by a small restaurant. You will have to comply with water by laws (quite simple). If you have come under the planning consents, then it is likely that you have complied with the water company requirements. However, once you have grown you may have to check, a `phone call is all it takes.
Always remember, if bureaucracy stands in your way, there will be valid reasons laid down by law. If the reasons are a matter of opinion, discretion or interpretation, they can usually be overcome by negotiation.
Outside the UK? Europe is meant to be a free market, but local laws still exist. Outside Europe? I can't say. Perhaps consent is given on receipt of a fee???
A simple and transparent process, starting with a phone call or email . Two main ways.
1. Come to the showroom in Burnley, Lancashire. See a plant. Test it. Pay for it. Take it away. Of course a little more involved than this but basically that's it.
2. Plant built to order. Ask for the FAQ microbrewery.doc sheet. Agree a specification either custom or standard. Read Terms of business. Pay a deposit. Pay an instalment on collection/delivery. Complete payment on tasting first Brew.
Training. Training can be given on site, for example as part of an installation package. A less expensive option is to take our course at the Ministry of Ale in Burnley, Lancashire.
After sales support. The equipment is designed to be low maintenance or simple self maintenance. Free, discretionary, after sales support is available to all customers who remain in credit, via email, fax, telephone or visit to our sites. On site visits may be free if travelling locally in that area, ie courtesy visits..
In broad terms, the cost of setting up a microbrewery, will be about the same as buying a new car (in the UK). Currently new cars cost in the range £6000 to £30,000 (GBP), or more if you want all the extras! The pilot brewery is a little lower in price. Please ask for a price list, we will try to beat any genuine competing offer. As a rule of thumb allow a factor of 2 x plant costs to cover the approximate project start up costs
The brewing equipment will last a very long time. But how long will the business project last? That is difficult to say. But, consider the status 3 years from start up. At that time you may have one of three options; 1. Sell up, 2. Expand, 3. Stay still.
With option 1, a Mossbrew plant should still be in good condition, and so you could sell the plant on to someone else. With option 2 you could purchase more FV's to increase output, or trade up to a larger system. Option 3 means you are happy with the work load and the income it generates. Good Luck.
Recipe Formulation
The most important issue. We can devise a recipe to match your requirements. Light beers, dark beers, ales, lager, stout, porter, RTD's etc
Stainless Steel Construction
All vessels are made of food grade Stainless steel. This is indestructible in normal use and vessels will last for ever until manually destroyed, unlike plastic vessels. All vessels thermally stable at high temperatures, unlike plastic vessels. Stainless steel has low surface roughness (a microscopic property), unlike plastic, and so microbiologically safer. (Note that plastic vessels can break, can become brittle, shorter lifespan, unstable at CIP temperatures, surface roughness promotes microbial growth, plastic vessels are inferior to stainless steel vessels). At the end of your "project" you will still have something of value.
Where appropriate, Quality rolled angle rings are used, eg mash vessel false bottom. These resist distortion and so reduce passing of grain into the process. Mash False bottoms are made of perforated stainless steel with correct hole size. (Note that excess grain husk passing into the copper and boiled may promote haze in beer, also false bottoms fashioned from plate steel will distort).
Hygienic Welding
Any internal welding of vessels or pipe work is by TIG (Tungsten inert gas) welding. Also called GTAW (Gas Tungsten arc welding). Internal welds are pickled, ground and polished to avoid bug traps. Avoid selecting vessels with rough (uncleanable) welds.
Safe Pipe Work
All pressurised product pipe work is stainless steel. Hoses are not used (not needed) for dangerous operations such as hot pressurised cleaning. (Note that hoses become unstable when hot and so are liable to burst, or separate, potentially causing injury). A novel "rigid" swing arm is used for CIP and FV filling. Hoses are only used in low pressure situations such as CIP return and racking.
Ease of Cleaning
All pipe work and Fermentation Vessels (FV's) are "automatically" cleaned by CIP (Cleaning In Place). This system operates in excess of 80 Celsius, providing a thorough clean and avoids entry into confined spaces. (Note that FV's contain a dangerous/fatal atmosphere high in CO2, and so entry and/or manual cleaning should be avoided). "Tees" are avoided in product pipework, as the branch presents a shadow that cannot easily be cleaned. Only hygienic valves eg butterfly or diaphragm, are used in product pipe and vessels. Ball valves represent a serious risk of infection to the product as it is difficult to clean the "face" of the ball. A build up of soil on the face of a ball valve may infect subsequent brews. Ball valves on product systems are best avoided. (This section excludes pilot breweries for reasons of size).
Ease of Installation
Most pipework is preassembled in the workshop, making installation extremely easy (standard systems). All the customer needs to do is connect the water supply and connect the electricity supply (or pay someone to do it), and little else. This means that a standard system can be operational less than 24hours after delivery. Also the system can be easily relocated in the future. Additionally, a Stainless Steel pipe work system can be supplied that can be assembled by the client with basic skills!
Insulation
By using technology from "other industries" the basic insulation on MossBrew systems is extremely efficient. The insulation used is 8mm thick, BUT, it has the same performance* as over 3 inches of polystyrene! It is attractive, and can be easily renewed if damaged. Cosmetic finishes (embellishment) can be applied over the basic insulation eg stained timber, brass rings, decorative laminates, Coloured uPVC etc. (* overall heat transfer coefficient is 0.44 W/m2K for 8mm std material and for 84mm of polystyrene). Surfaces in food production areas are assessed by EHO's, and standards on use of timber are being increased inline with other EU countries, see below.
Compliance
Since 1995 goods sold within the European Union have to comply with European Directives (where appropriate). Items that comply with European Directives are allowed to carry the "CE" mark. This is to allow freedom of trade and demonstrates compliance with Harmonised European Standards. Goods which do not comply with standards, or are exempt cannot be "CE" marked (this would be illegal). On request, MossBrew can provide certification on items that come within the scope of European Directives. Items that are not "CE" marked may need to be approved locally by environmental health officers (local EHO) eg by demonstration of low risk, safe working procedures, etc. As a result of recent experiences in Europe, application of EU regulations is becoming more tightly enforced. Future use of Exposed Timber in food production premises has to be carefully considered. See Permits etc above.
Free After Sales Support
All customers that conduct their account satisfactorily can rely on after sales support. This is free if done by email, telephone or a visit to our site (other methods may incur a charge notified in advance). A wide range of spares and accessories can be purchased and mailed to the customer if requested.
Presales advice may be important to a customer. Eg advice on plant size, costs of brewing, values of effluent if needed for planning consent etc. This web site contains useful information, and other presales requests will be dealt with sympathetically. We cannot give specialist advice away to our competitors for free. For larger projects clients may like to consider purchasing a training course or 4 week advice pack, before committing to a large (and possibly wrong) purchase.
Excellent Manual, Statement of Practise
Every brewery system comes with a comprehensive manual. Topics covered include; Brewery Design, Brewing Method, Shopping and Suppliers list, Suggested recipes, Business Issues. For example it tells you what the equipment is made of, it tells you where to buy your malt, hops and casks, it talks about the product lifecycle (will your project last more than 3 years?). Also included are a set of "Brewing Tables" needed to operate the system. This manual represents a competitive advantage. The manual/retainer can be purchased in advance, and a credit can be given for against a subsequent brewery purchase. Some EHO's are now asking for written statements of practise and written Risk Assessments, examples will be provided in future manuals. This is part of due diligence.
Why Plastic is not So Good
Professional Brewery Plants do not use plastic vessels. Home brew equipment does use plastic vessels, and the difference in quality of beer between the two ends of the industry is widely appreciated. So why is plastic avoided in professional equipment, when it appears to be so inexpensive. All materials have a property called "surface roughness" (Ra). This is a measure of the height between the valleys and peaks of the surface. For some textured surfaces Ra is very high, and you can feel it with your fingers. For smooth surfaces Ra is very small and you cannot feel it with your fingers. Some plastics have a finger smooth surface, but, a higher Ra than stainless steel. Bacteria are smaller in size than Ra for plastics, but bigger in size than Ra for most stainless steel surfaces. In simple terms this means that bacteria become lodged in the valleys and peaks of plastics, but are rinsed off stainless steel during cleaning. In practicality this means that a film of spoilage bacteria soon builds up in plastic vessels which cannot be removed, leading to spoilage of the wort. This build up occurs after the first brew, and may soon become a quality problem. Plastics cannot withstand heat sterilisation. For these two reasons professional brewing systems do not use plastic vessels. Remember that wort ( no alcohol, neutral pH) is very vulnerable to infection whereas beer (high alcohol, low pH) is resistant to infection. This is a fundamental design criteria.
Speedy Service
Usually microbrewery systems are available for delivery 6 to 8 weeks after placing an order. In that time the client could adapt their premises, order their raw materials and buy their casks (because the manual will tell you where to buy them, sent in week 1). The brewery could be operational soon after delivery. If you did not have the microbrewery manual, or the technical support, how long do you think it would take to get going? 3 months? 6 months? Delays represent missed beer sales.
We Know What We are Talking About!
Remember that the proprietor, Graham Moss, is a Master Brewer of the Institute of Brewing, has a Thesis in Process Engineering( Univ Birm), is an MBA (Business Masters degree, Univ Hull), is a biochemist (Univ Sheffield) and also a Publican! He has over 18 years experience in the industry, including production management in brewhouse, maturation, filtration, kegging, cask racking, bottling and canning. He has brewed millions of pints of beer! Our competitors may know about some of these subjects, but only one supplier can cover them all in the same package! That's MossBrew for MicroBreweries.
Copyright © 2003 Graham Moss. All rights reserved.
Revised:
January 15, 2007
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