For many large breweries, the production requirements are relatively high, and usually multiple batches need to be brewed every day. Here, the brewing capacity of the brewhouse is very important. There are also many customers who ask how to improve the utilization rate of the brewhouse. The key here is to improve the turnover rate of the equipment, that is, to reduce the use time of a single tank, so that we can increase the number of daily feeds in the brewhouse. The following are some specific methods and strategies to optimize the utilization rate and turnover efficiency of the brewhouse.

Key methods to improve brewhouse turnover rate

1. Boil kettle optimization

The boiling kettle takes up the longest time in the mashing process. Although its actual effective working time is 90 to 120 minutes, the total occupancy time is almost equal to the use time of the lauter tun plus the wort boiling time. We can take the following measures to reduce the occupancy of the boil kettle:
 
**Precisely control the process conditions: avoid extending the boiling time of the wort, thereby shortening the total occupancy time of the boil kettle.
**Add a wort storage tank: Receive the first wort of the next batch and part of the washed wort while the boiling kettle is working, which can shorten the use time of the boiling kettle to 60 to 990 minutes, thus achieving 7 to 9 turnovers per day.

2. Optimization of Lauter tun

The occupancy time of the Lauter tun is long, especially when lautering is difficult, the time may reach 4 to 5 hours, which greatly affects the work efficiency of the brewhouse. Here are some solutions:
 
**Improve the lautering process: In-depth understanding and application of countermeasures when lautering is difficult, so that the total occupancy time of the lauter tun does not exceed 180 minutes, thus achieving 8 turnovers per day.
**Use a wort filter: The wort filter can shorten the filtration time to about 120 minutes, greatly increasing the number of daily feedings.

3. Optimization of cooker and mash tun

Although the use time of cooker and mash tun is usually no more than 240 minutes, if we want to increase the number of daily feedings to more than 8 times, we need to further shorten their occupancy time. Specific methods include:
** Raise the feeding temperature of auxiliary materials: Use 65~70℃ to feed, and use high-temperature resistant bacterial amylase instead of malt liquefaction auxiliary materials, which can directly heat up the mash and shorten the heating and insulation time.
** Adopt efficient mashing method: Use one-time mashing method, fast mashing method or leaching mashing method, which can save a lot of mash separation, heating and boiling time.
** Optimize the amount of auxiliary materials and enzyme addition: Appropriately reduce the amount of auxiliary materials, or add protease, glucanase and mashing enzyme, and use a protein resting temperature of 45~48℃ to shorten the protein resting time and mashing time, so that the turnover of cooker and mash tun reaches 8 to 9 times a day.
 
Any interested information about beer brewing or brewery equipment, please feel free to contact Tiantai. We would be more than happy to do our best to support you.
 
 
Edited by Cassie
E-mail：[email protected]