pilot brewing system

Types of Pilot Brewing Systems

A pilot brewing system is a small-scale brewing facility that allows brewers to produce limited quantities of beer for testing purposes. The main aim of these systems is to enable brewers to fine-tune recipes and experiment with different flavors before moving to larger commercial-scale production. While every pilot brewing system comes with its own unique feature set, they typically include the following:

• Small Batch Brewhouse:

  The small batch brewhouse is the heart of the pilot brewing system. It is where raw materials such as malt, hops, yeast, and water are transformed into wort and, eventually, beer. Unlike larger commercial-scale brewhouses, the small batch brewhouse is more compact and consists of smaller vessels.

• Micros fermentation tanks:

  Just like brewhouses, fermentation tanks in a pilot brewing system are much smaller, too. Micros fermentation tanks are where the wort produced in the brewhouse is fermented and converted into beer. One little difference between micros fermentation tanks and larger commercial-scale fermentation tanks is that the latter has conical bottoms. This makes it easy to drain the beer off the yeast once fermentation is over.

• Maturation vessels:

  After undergoing fermentation, beer typically has a harsh taste. Maturation vessels are where beer is stored and allowed to mature, developing a smoother and more refined flavor. These vessels are usually made of stainless steel to prevent contamination and are often refrigerated to control the maturation process more precisely. In a pilot brewing system, maturation vessels are ideal for aging small quantities of beer to see how the flavors change over time.

• Control System:

  Modern pilot brewing systems are usually fitted with an advanced control system that lets users program brewing parameters such as temperature, pressure, and time precisely. Some control systems even have touchscreen interfaces and automated functions that make it easier for operators to monitor and adjust the brewing process in real time.

Specifications and maintenance of pilot brewing systems

Breweries use different pilot brewing systems according to their needs. Thus, the specifications of pilot brewing systems vary depending on the configuration and components of the equipment.

• System capacity

  It usually ranges from 1 barrel (31 gallons or 117 liters) to 10 barrels (310 gallons or 1,175 liters), which is smaller than commercial brewing systems. Common capacities are 1bbl, 3bbl, 5bbl, and 7bbl.

• Core components

  Pilot brewing systems typically consist of key components, such as mash tanks, boil tanks, fermentation tanks, carbon dioxide systems, filtration systems, filling systems, control systems, etc. The exact setup will differ based on the specific purpose and requirement of the brewing.

• Heating source

  The method used to heat the wort in the mash tank and boil tank also varies, such as internal electric heating tubes, steam heating jackets, gas burners, induction heating, etc.

• Control methods

  Modern pilot brewing systems often incorporate automated control systems, which can precisely manage the parameters and processes of brewing. Some smaller systems may adopt manual control methods for flexible operation.

Maintenance

Regular maintenance is required so that the pilot brewery system can run efficiently. It will help brewing control, product quality, and equipment reliability.

• Regular cleaning

  Cleaning brewing equipment, such as fermentation tanks and pipelines, thoroughly is a crucial step in maintaining a pilot brewing system. Residues must be removed and then disinfected to prevent bacterial contamination or off-flavors in subsequent brews.

• Regular inspections

  A round of inspection of the key components, such as mash tanks, boil tanks, fermentation tanks, heating systems, valves, and pipes, should be performed. Users need to check for signs of damage, blockage, or leakage, and any issues discovered should be addressed immediately to prevent potential risks.

• Calibration of control system

  Control systems and sensors in a pilot brewing system must be periodically calibrated to ensure accurate measurement and control of brewing parameters, such as temperature, pressure, and time.

• Regular maintenance and repair

  Routine maintenance is required for the control system, valves, and pumps, as well as repairing or replacing components that have been worn or damaged.

Scenarios

The pilot brewing systems are useful in different scenarios in the brewing industry. They are essential for training brewers. Breweries seeking to train their brewers on the brewing process will use the pilot systems to safely train their staff without having to impact the entire brewing process. The small scale of the brewing systems makes them ideal for hands-on training.

Research and development projects in brewing companies also look for pilot brewing systems to use. The systems enable the teams to experiment with new recipes and fine-tune the ingredients and brewing techniques before scaling up the process.

Start-up breweries looking to enter the market can use the pilot brewing system to produce small quantities of beer and test the current market before fully investing in larger brewing equipment. The system will help the start-up breweries know what works for the market and what does not in terms of flavors, styles, and packaging.

The system also allows more established breweries to quickly respond to the shifts and trends in the market. Instead of going all out and making a full-scale shift in their production, the pilot brewing system allows them to test and taste new styles and flavors before making any larger changes to the production process.

Collaborative brewing projects between two or more breweries can also use the pilot brewing system. The system provides a way for the different breweries to experiment with unique blends and flavors together without having to invest in larger brewing equipment.

Because the pilot brewing systems are small, they are also ideal for use in brew pubs and taprooms to supplement larger brewing systems on-site. They can produce limited-edition offerings for the on-site suppliers in the pubs and taprooms.

How to choose pilot brewing systems

When choosing a pilot brewing system, the first step is to determine the brewing capacity. Brew houses for pilot brewing range from systems that brew 1 pint all the way up to 500 gallons per batch. The capacity of the brewing system should fit the amount of beer that the brewery will need for each batch of brewing. Brewing efficiencies will improve as the system gets larger, but this may lead to excess beer that the brewery will not be able to sell. Calculate the ideal batch size by considering system brewhouse losses, fermentation capacity, and how much of the beer will be used for sampling vs. actual sales.

Consider the design of the pilot brewing system. Some systems are fully automated, while others require human intervention during the brewing process. Determine how much staff time is available to devote to pilot brewing. If the system is being used to develop recipes that will ultimately be scaled up to a production brewing system, it may be worthwhile to invest in a system that is automated so that the same brewing parameters are used on both brewing systems.

The energy source for heating the brewing vessel and wort chiller are also important factors in selecting a pilot brewing system. Different energy sources may be more economical, reliable, or environmentally friendly depending on the location of the brewery. The type of kettle and metal used to construct the brewing system can affect heat retention and distribution, as well as how resilient the system is to corrosion.

Another important consideration is the functions of the brewing system. Some pilot brewing systems also include fermentation, filtration, carbonating, and kegging capabilities. If the main goal of the pilot brewing system is to test recipes and small-scale brewing, the fermentation, filtering, carbonating, and kegging will probably be unnecessary and be better left to the larger production brewing system.

Finally, the price of the pilot brewing system and the budget for this part of the brewing process are important. Prices for pilot brewing systems can be as low as $20,000 up to more than $800,000 for more extensive parts and more features. Try to determine which parts of the system are essential and which optional features are more crucial before ordering a system. It is also good to know what the system's delivery time is and to be aware of any additional setup and installation costs.

Pilot brewing system Q & A

Q: Who needs a pilot brewing system?

A: Small-scale, innovative breweries use them for testing new recipes. Educational institutions like brewing colleges also use pilot brewing systems for training students in a hands-on environment. Craft breweries that want to minimize risk before scaling up to full production use the pilot brewing system.

Q: What is the difference between pilot brewing systems and full-scale brewing systems?

A: Pilot brewing systems are scaled-down versions of commercial brewing equipment. The pilot brewing system uses a kettle of 50-500 liters, while the full-scale brewing system has a kettle of more than 1,000 liters.

Q: Can users brew any beer style with the pilot brewing system?

A: Yes, users can brew any beer style with the pilot brewing system. The system is flexible and can adjust the brewing process to create different beer styles.

Q: Can users scale up beers brewed in the pilot brewing system to a larger production?

A: Yes, one of the pilot brewing system's main benefits is the ability to replicate successful small-batch recipes on a larger scale.

Q: Can buyers customize the pilot brewing system?

A: Yes, some suppliers of the pilot brewing system allow buyers to request specific customizations to fit their needs.