„JAASTRA – WAM“ delivery of complete plants both for newly built breweries, and already operating enterprises under reconstruction or modernization. New breweries, as well as their manufacturing and technological complexes are designed for installation in existing customer’s premises or completely new buildings.
Usually industrial breweries are designed for productive capacity of 20,000 gl/year to 3,000,000 gl/year. However on customer‘s request delivery of equipment with higher productive capacity is possible. Standard breweries are equipped with 2 and 4 vessel brewhouses for brewage of decoction beer, as well as cone tanks for beer fermentation and settling-down. Brewhouses are offered in typical sizes, however other sizes are available. The size of tanks depends on brewhouse‘s nominal brewage (it is limited only by possibilities of transportation to their installation place). In case a customer needs other kind of beer manufacturing technology, e.g. use of unmalted materials (so called substitutes), single decoction brewage, infusion brewage, etc., we can offer all this within the framework of our manufacturing program. Power saving equipment is installed in our breweries, e.g. a plant for brewage of hopped wort under low pressure or secondary steam condensers, thermal energy of which is further used for wort preheating before its boiling process or even for water heating. It is generally accepted that every brewage is a purely individual technical solution, therefore its configuration is executed in compliance with specific customer‘s requirements, as well as basing on our many years‘ experience. Besides, our company executes delivery of other non-technological complexes (so called final delivery) required for operation of a brewery. We acquire the equipment from famous manufacturers who we’ve cooperated for many years with.
Layout of manufacturing complexes in industrial breweries
- PS 01 – Acceptance and warehousing of raw materials (wort and substitutes)
- PS 02 – Crushing division
- PS 03 – Brewhouse
- PS 04 – Wort cooling
- PS 05 – Supply of hot water
- PS 06 – Manufacturing of a pure yeast culture
- PS 07 – Yeast warehousing
- PS 08 – Fermentation of hopped wort and beer settling-down. Cone tanks.
- PS 09 – Washing and disinfection
- PS 10 – Beer filtration and filling tanks
- PS 11 – Spent grains bin
- PS 26 – Pipelines
Final deliveries
- PS 12 – CO2 collection including cleaning and liquefaction
- PS 13 – Beer filling into casks (KEG), including acceptance, washing, etc.
- PS 14 – Beer bottling, including acceptance, washing, palleting, etc.
- PS 15 – Cooling unit
- PS 16 – Electrical equipment
- PS 17 – Control and measuring instruments
- PS 18 – Laboratory
- PS 19 – Workshop
- PS 20 – Compressor station
- PS 21 – Boiler room, including water processing
- PS 22 – Insulation
- PS 23 – Diesel aggregate
- PS 24 – Water processing for achievement of composition required for beer boiling
- PS 25 – Wastewater cleaning units
- PS 27 – Alcohol content reduction in beer for manufacturing of nonalcoholic (0.5%) and alcohol-less beer (0.05%)
- PS 28 – Filling of beer into cisterns
- PS 29 – Adjustment of beer density (HGB), high density beer dilution with specially processed water
- PS 30- Beer filling into tins
- PS 31 – Production of syrups and their filling into PET bottles
- PS 32 – Production of lactic acid
PS 01 – Acceptance and warehousing of raw materials
Manufacturing complex for acceptance and warehousing of raw materials allows storage and handling of raw materials for beer manufacturing, besides, in this case it refers not only to wort, but also to barley, maize, rice, etc. The complex is designed by strictly following customer‘s requirements and conditions considering available premises, the kind of raw materials foreseen for usage, the way of their acceptance (from trucks, in bags from railway wagons, etc.). During acceptance raw materials are weighed and pre-cleaned. Afterwards raw materials are transported to silage containers with the help of screw and bucket conveyors (from concrete or mounted from steel panels). In silage containers raw materials are periodically mixed in order to avoid their caking and temperature increase, and they are further transported in an analogous way to crushing division according to the needs of the manufacturing process. Raw material acceptance line will satisfy the needs of breweries with any productive capacity.
Manufacturing complex consists of following parts:
- a weighing device (truck scales)
- receiving devices (the number of boxes is in compliance with productive capacity of the brewery and quantity of substitutes)
- vertical conveyors (bucket elevators)
- horizontal conveyors (screw conveyors), possible usage for pneumatic transportation of raw materials
- silage containers
- closing and regulation elements (valves, flaps)
- cleaning equipment
- dosing units
- gravity pipeline
- exhaust units
PS 02 – Crushing division
Manufacturing complex of crushing division is designed for preparation of raw materials by crushing them for further processing in a brewhouse. First of all grains pass a cleaning unit, afterwards they are weighed and crushed in malt crushers. If in beer production substitutes are used, they are analogously processed on a parallel line. Received extraction cake is transported into buffer bins, where it further goes to a brewhouse for mixing with water from. A crushing line may also be designed as a direct line, it means that wort after crushing directly goes to the process of mixing with water. Wort processing applying dry crushing with conditioning possibility is preferred. We produce malt crushers with four or six axles, productive capacity of which is 2.5 to 4 t/h and 4 to 5.5 t/h. In crushing division there is installed suction equipment for dedusting; the dust later is collected into bags together with waste of cleaning machines.
Manufacturing complex consists of following parts:
- cleaning devices (vibrating cleaning sieves)
- a weighing device (bucket or flow scales)
- vertical and horizontal conveyors (bucket and screw conveyors)
- malt crushers
- crushers of substitutes
- closing and regulation units (valves, flaps)
- dosing units
- gravity pipeline
- exhaust units
PS 03 – Brewhouse
Manufacturing division of brewhouse is the heart of a brewery. There is manufactured wort which is transferred to fermentation process after cooling. Standard equipment of brewhouses is designed for 8 boiling cycles per day producing high-quality beer of Czech type with double decoction, and for 10 boiling cycles producing hopped wort by single decoction or infusion boiling. The whole process is computer controlled according to a set program. In order to increase productive effectiveness, modern technologies are applied, for example, boiling of hopped wort under low pressure and under temperature of 102 to 104°C, as well as secondary power usage using condensers of secondary steam and preliminary wort warming before wort boiling in a wort copper. Brewhouse is equipped with independent devices for equipment washing and disinfection which are connected to washing heads installed in all boiling containers.
A classical four-vessel brewhouse.
General types of brewhouses:
Two-vessel brewhouse, productive capacity of which is 2.5 brewages per 24 hours with standard nominal productive capacity JV 50÷200 gl.
A classical four-vessel brewhouse with wort collector (see above), standard nominal productive capacity is JV 50, 80, 100, 160, 200, 250, 320, 350, 400, 500 and 600 gl.
A block four-vessel brewhouse (for limited spaces), where vessels are layout in two blocks one over another; such structure is also called gravity – flowing, whereas liquid may flow from upper vessel into lower vessel; the range of standard nominal boiling is analogous to classical structure.
Standard brewhouse consists of following parts:
- devices designed for mixing of crushed wort with water (a pump may also used)
- a mash copper with a heated surface for warming (it is usually installed on a supporting structure and has a mixer)
- a boiler with mashing possibility (double mashing in both vessels is preferred), it is usually equipped on a supporting structure and has a mixer.
- a filter tank with an expansion plant and permanent regulation
- a wort collector (may be heated)
- a wort copper designed for wort boiling under atmospheric or low pressure,with internal boiling device, it is installed on supporting construction
- a device for washing and disinfection of equipment (two washing liquid vessels are used usually)
- pumps
- connecting pipelines and fittings
- automatic computer-aided control and operator's workplace (usually with two monitors)
Standard construction of vessels:
Usually boiling vessels are manufactured from stainless steel with processed decorative surface and plated cylindrical section. All units installed inside of vessels are also manufactured from stainless steel, as well as pipelines, fittings and pumps. Examples of standard boiling vessels are provided below.
|
JV 50гл. |
JV 80гл. |
JV 100гл. |
JV 160гл. |
JV 200гл. |
JV 250гл. |
JV 320гл. |
JV 350гл. |
JV 400гл. |
JV 500гл. |
JV 600гл. |
VP |
D2000 H2360 |
D2400 H2700 |
D2400 H3160 |
D3000 H3500 |
D3000 H4000 |
D3550 H4100 |
D3750 H4450 |
D3750 H4700 |
D4000 H4800 |
D4750 H4900 |
D4750 H5400 |
RP |
D1500 H2100 |
D2000 H2200 |
D2000 H2600 |
D2400 H3000 |
D2400 H3260 |
D2800 H3400 |
D3000 H3760 |
D3550 H3700 |
D3550 H3900 |
D4250 H4150 |
D4250 H4400 |
SK |
D2600 H2260 |
D3150 H2460 |
D3550 H2700 |
D4500 H2900 |
D5000 H3000 |
D5600 H3150 |
D6300 H3300 |
D6700 H3400 |
D7100 H3800 |
D8000 H4000 |
D8500 H4100 |
MP |
D2000 H3050 |
D2400 H3500 |
D3000 H3600 |
D3550 H4150 |
D3550 H4400 |
D4000 H4650 |
D4500 H5150 |
D4750 H5150 |
D4750 H5300 |
D5000 H5950 |
D5600 H5850 |
VP – a mash copper
RP – a decoction boiler
SK – a filter tank
MP – a wort boiler
D – internal diameter of vessels
H – height of vessels (without supporting construction)
Measures, measuring units of which aren't indicated, are provided in mm
PS 04 – Wort cooling
Manufacturing complex for wort cooling is designed for separation of solid materials from hopped wort (in a turbulent tank), i.e. so called waste of hopped extract and hot residuals, as well as cooling of hot wort up to the temperature required for fermentation process. A turbulent tank with a bottom of lightly conical shape is equipped with a bypass channel, a stationary washing head and a rotating atomizer equipped on the bottom of the tank which serves for elimination of slurry sludge. A turbulent tank is equipped with a sludge collector and a pump. Hot wort is cooled in a cooling device – a plate heat exchanger. Refrigerants may be supplied in two ways – for single-phase wort cooling which is executed using industrial water cooled up to 2-3°C, and for two-phase wort cooling which is executed using industrial and iced water or non-freezing liquid. In both cases quantity of refrigerants is calculated industrial water to warm up to the temperature of 80°C. An advantage of single-phase cooling is that extreme consumption of frost is eliminated, and in case of fluctuating temperature of cooling industrial water power consumption also reduces. Washing and disinfection of equipment is performed by the way of attachment of the installation to the brewhouse.
Main types of turbulent tanks are following:
- measures of turbulent tanks (as well as manufacturing complexes for cooling of hopped wort) are usually designed in compliance with standard nominal boiling scope JV 50, 80, 100, 160, 200, 250, 320, 350, 400, 500 and 600 gl.
- Two types of turbulent tanks are manufactured – designed for installation outside the brewhouse, it means that external section is not plated and only has brushed surface or is designed for installation in the brewhouse, in this case processing of their surface is analogous to processing of boiling vessels.
- Tanks may be installed on a metal construction or on concrete surface.
Standard version consists of following parts:
- a turbulent tank
- a sludge collector
- a wort cooler
- pumps
- connecting pipelines and fittings
- automatic computer-aided control (devices are controlled from the brewhouse)
|
JV 50гл. |
JV 80гл. |
JV 100гл. |
JV 160гл. |
JV 200гл. |
JV 250гл. |
JV 320гл. |
JV 350гл. |
JV 400гл. |
JV 500гл. |
JV 600гл. |
WK |
D2400 H2250 |
D3000 H2400 |
D3150 H2700 |
D3750 H2950 |
D4000 H3400 |
D4250 H2250 |
D4750 H3800 |
D4750 H4050 |
D5000 H3900 |
D5600 H4000 |
D5600 H4500 |
D – internal diameter of vessels
H – height of vessels (excluding supporting construction)
Measures, measurement units of which are not indicated, are provided in mm
PS 05 – Supply of hot water
Manufacturing complex of hot water supply is designed for production and storage of water necessary for operation of the whole brewery. It is referred to tanks with corresponding measures, where water is heated or cooled up to the temperature required for operation of further manufacturing technological complexes. There is collected water received from technological process (e.g. warm water from wort cooling process and hot water from condenser of secondary steam) which is repeatedly prepared for technological process (e.g. tank of cooled water for single-phase cooler). So, integral parts of this manufacturing complex are heat exchangers used for warming. All devices of this manufacturing complex are manufactured from stainless steel. Hot water tanks are insulated and plated with aluminium.
Standard version consists of following parts:
- cold water tanks
- a tank of hot water (80°C) and a heat exchanger for warming
- a tank of hot water (96°C) (using preliminary wort heating with secondary steam from wort boiler)
- a tank for water cooled up to +2°C (using a single-phase cooler of hopped wort)
- pumps
- connecting pipelines and fittings
- automatic computer-aided control (devices are controlled from the brewhouse)
PS 06 – Manufacturing of pure yeast culture
Manufacturing complex for pure yeast culture growing (so called station for pure yeast culture growing) is designed for supply of pure yeast culture (white pats) for beer fermentation process. This station consists of two fermentation and sterilizing tanks. Proportion of these tanks is 1:5. The station produces white pats with an interval of three days. The size of pure yeast culture growing station is determined by the quantity of white pats produced during one cycle. Primary charge of yeast is transferred from laboratory in a Carlsberg tin. In both tanks sterilization of hopped wort may be performed, afterwards its fermentation is performed, whereas both vessels have warming and cooling zones. All devices are produced from stainless steel. External surfaces of tanks are processed. For washing of the whole manufacturing process a device for washing and disinfection of equipment is used which is an independent technological complex PS 09.
Standard version consists of following parts:
- a Carlsberg tin
- a fermentation and sterilization tank I (RST I)
- a fermentation and sterilization tank II (RST II)
- a pump
- connecting pipelines and fittings
- automatic computer-aided control (devices are controlled from the brewhouse)
Productive capacity of the device
Size of tanks
Произв.установки Размер танков |
0,5м3 |
0,95м3 |
1,9м3 |
3м3 |
4,8м3 |
8м3 |
(RST I) |
D600х2380 |
D600х2380 |
D700х2550 |
D800х2960 |
D1000х2990 |
D1200х3510 |
(RST II) |
D800х2960 |
D1000х2990 |
D1200х4010 |
D1400х4340 |
D1600х4970 |
D1900х5960 |
Provided tank measures: internal diameter x total height
Measures, measuring units of which aren‘t indicated, are provided in mm
PS 07- Warehousing of yeast
Manufacturing complex for yeast warehousing is designed for yeast collection after beer fermentation process, its cleaning, rinsing and warehousing for fermentation in subsequent fermentation cycle. Yeast of several generations may be used. Yeast excess which forms during fermentation process is collected in tanks for used yeast and is further used in preparation of fodder. Manufacturing process is equipped with a device for yeast cooling which also has the function of a water cooler for yeast rinsing in collecting tanks. Collecting tanks are equipped with mixing and cooling devices. As a device for yeast dosing during fermentation process there is used a volumetric pump securing regulation with the help of measuring consumption, as well as in the way of measuring quantity of cells or living cells. All equipment is produced from stainless steel. Exterior of the tanks is subject to surface processing. The whole manufacturing complex is washed by a device designed for washing and disinfection of equipment which is an independent technological complex PS 09.
Standard version consists of following parts:
- yeast warehousing tanks (usually 3 units)
- a tank for used yeast
- a plate cooler of yeast and rinse water
- pumps
- connecting pipelines and fittings
- automatic control of required temperatures
Nominal volume of tanks
Size
Номинальный объем танков |
0,5м3 |
1,1м3 |
2,2м3 |
3,5м3 |
4,5м3 |
6,7м3 |
Размер |
D700х3140 |
D1000х3170 |
D1100х4200 |
D1400х4330 |
D1500х4580 |
D1600х5420 |
Provided tank measures: internal diameter x total height
Measures, measuring units of which aren‘t indicated, are provided in mm
PS 08 – Beer fermentation and settling-down
Manufacturing complex for beer fermentation and settling-down consists of cylindrical and conical tanks, where both processes take place not repumping beer into other vessels. These tanks are equipped with modern single-phase fermentation process technology, however a double-phase fermentation process is possible. A single-phase method significantly accelerates the whole process, positively influences separation of residual sludge and improves its elimination during filtration. Useful volume of ordinary cylindrical – conical tanks is 1 m3 to 420 m3. Tanks have a steamtight insulation layer from polyurethane foam. A cylindrical part of the tank is sheathed with trapezoidal aluminium plates from outside, and the conical part – with stainless steel sheets. The size of tanks is determined by productive capacity of the brewery and transportation conditions. Maximal volume of the tank which may be conveyed by railway is 118 m3. Tanks may be cooled in two ways. For cooling there may be used ammonia or anti-freezing liquid applying direct steaming. Standard size of cooling surface of the cylindrical and conical section is calculated for beer cooling from 14°C to 2°C within 30 hours. Tanks are equipped with an emergency device, as well as a device for washing and disinfection of equipment. The manufacturing complex usually has two cylindrical – conical fermentation tanks, the volume of which makes 1/3 - 1/2 of the volume of the cylindrical – conical fermentation tanks. In these tanks fermentation of hopped wort up to formation of white pats transferred from the pure yeast culture growing station takes place. All devices are manufactured from stainless steel. Washing of the whole manufacturing complex is performed by a unit designed for washing and disinfection of equipment which is an independent technological complex PS 09.
Standard version consists of following parts:
- cylindrical – conical tanks for beer fermentation and settling-down
- cylindrical – conical tanks for fermentation
- a service platform including stairs
- pumps
- distribution panels for pipelines
- connecting pipelines and fittings
- automatic computer-aided control with operator‘s workplace (usually with one or two monitors)
PS 09 – Washing and disinfection
The device for washing and disinfection of equipment is designed for washing of so-called cold processes. These processes include fermentation and settling-down of hopped wort (cylindrical –conical tanks PS 08), production of pure yeast culture (PS 06), yeast warehousing (PS 07), filling tanks (PS 10) and, if it is necessary, filtration (PS 10). Tanks are washed with so-called cold acid and alkaline washing liquid. Pipelines are washed with warm alkaline and cold acid washing liquid, and rinsed with disinfection liquid. Productive capacity of the manufacturing complex depends on tanks washed, as well as size and quantity of devices (i.e. on the length of pipelines). Quantity of separate vessels is determined according to customer requirements and wishes. Usually three or four tanks for preparation of washing solutions and tanks for concentrators are used. For warming up to required temperature a flow heater is used. All devices are produced from stainless steel. External surfaces of tanks are processed. The tank for hot rinse water is insulated and sheathed with stainless steel sheets.
Standard version consists of following parts:
- a tank for cold rinse liquid
- a tank for hot rinse liquid
- a tank for acid rinse liquid
- a tank of water used for preliminary rinse
- a rinse liquid filter
- a device for warming of rinse liquid
- tanks for concentrated washing liquids
- devices for dosing of washing liquids
- pumps
- pipeline distribution panels
- connecting pipelines and fittings
- automatic computer-aided control with operator‘s workplace (control from cylindrical – conical tanks)
PS 10- Filtration and filling tanks
Beer filtration and filling tanks is the last manufacturing technological process. Beer received from cylindrical – conical tanks is filtrated here up to necessary purity, i.e. solid particles reducing beer clearness are caught. It is referred mostly to residuals of yeast and cooled sludge which is settled down in cylindrical – conical tanks. Thanks to it beer validity term is prolonged. For the process single-phase filtration is usually used which on customer‘s wish may be supplemented with plate sterilization filters with special filtration paper. Final part of complex delivery consists of filling tanks which filtered beer is delivered to; it is later poured into vessels (barrels, bottles, etc.). Filling tanks may be supplied with a cooling system or without it. Volume of these tanks usually is two times smaller than volume of cylindrical – conical tanks, and their number has to allow beer settling down after filtration and before filling. Tanks are equipped with an emergency device, a device for washing and disinfection of equipment, steamtight insulation from polyurethane foam, plated with trapezoidal aluminium sheets. All devices are produced from stainless steel. For washing of the manufacturing complex a device for washing and disinfection of equipment is used which is an independent technological complex PS 09.
Standard version consists of following parts:
- filtration stations including kieselguhr precoat candle filters with a set of accessories (e.g. kieselguhr dosers, leveling tanks, etc.)
- filling tanks
- service area with stairs (depending on size and layout of tanks)
- pumps
- pipeline distribution panels
- connecting pipelines and fittings
- automatic computer-aided control with operator‘s workplace
PS 11- Mash cases
In mash cases there are collected mash residuals which are eliminated from a filter tank during boiling process. Mash residuals are transported from an intermediate tank located under filtration tank directly into the tank of mash residuals located outside next to the building of the brewhouse, where a freight car may approach to. Mash residuals are transported through pipeline using a pump and steam or air pressure. Tank‘s bottom is cone-shaped and has a latch which a dosing device is usually equipped on (a metering spiral conveyor with heating which protects against freezing) and which mash residuals are spilled into vehicle through and removed for production of fodder. Over a tank outlet there is installed an expansion unit with the help of which mellow grains are manufactured seeking for the best discharging. Sludge residuals which are collected from a turbulent tank into a special collector for sludge are released into the mash tank. The tank has an insulation layer which usually is produced from carbon steel with a special varnish coat. Special washing heads are used for washing of internal spaces. The size of mash tank depends on the size of the brewhouse, the number of boiling cycles per day and possibilities of mash removal.
Standard version consists of following parts:
- a mash tank
- supporting tank construction
- an expansion device
- a dosing device
- connecting pipelines