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PHASE 1: EXTENSION TO 35.000 HL/A
On-site-assessment; basic- and detail engineering incl. equipment supply of milling plant, lauter tun and 8 fermentation- and storage tanks.
PHASE 2: EXTENSION TO 70.000 HL/A
Engineering and delivery of a weak wort tank, whirlpool, hop dosage, hop- and fruit strainer, flash pasteurizer, mixing plant (syrup and dry yeast for bottle conditioning), yeast propagation and storage, CIP-plant.
PHASE 3: EXTENSION TO 130.000 HL/A
Delivery and implementation of DAW plant including distribution piping and dosage station for disinfectant. Modernization, extension and delivery of components for existing refrigeration plant incl. glycol piping. Holistic project management, execution of the site management and complete commissioning for all 3 phases.
BREWERY AUTOMATION WITH BRAUMAT V7.0 INCLUDING ELECTRICAL PLANNING AND INSTALLATION OF ALL CONTROL COMPONENTS
Concept design for the integration of a dealcoholization plant as well as a new cold block area to produce small batch sizes of new, innovative products. Engineering, interface coordination to the existing brewery, preparation of P&IDs and installation plans as well as elaboration of a detailed cost overview of investment costs.
Feasibility study and engineering for a greenfield brewery with soft drink production including comprehensive marketing study for entry strategies into a new market. Production and expansion planning from 300,000 to 750,000 hl/a in 3 phases.
Site evaluation
Capacity calculation
Consumption data
Layout concept
3D-planning concept
Realization plan
Budget indications
Return of investment calculation
Planning of a new brewery plant with a view to energy-efficient and ecologically construction and production. Consistency and symbiosis between state-of-the-art brewery process technology in intelligent combination with advanced civil technology. Detailed insights into the brewing process under the aspect of a "crystal brewery" - insights for the visitor from raw materials intake, through the production process to the filling and packaging of the final product. Further planning including event catering with beer garden and bar area as well as souvenir and sales store to complete the visitor experience. Elaboration of a customized construction and process concept considering seasonal production peaks, from which defined expansion stages for an increase in output and capacity were determined.
We are pleased to announce the successful commissioning for the expansion of the fermentation and storage cellar at Brewdog in Berlin.
The turnkey project included from process planning, to delivery of components, electrical and mechanical installation, commissioning with integration into the existing automation system (BOTEC), FATs, training and the complete project documentation.
Through our holistic approach and the integration of our process optimization in the fermentation and storage cellar, we not only enabled an optimized cooling, reduction of hose connections, simplification of operation through intelligent swing bend arrangement, but also achieved, through the integration of a new pipe fence, maximum flexibility for processes which can run in parallel, such as cleaning and filling of the tanks, as well as the feeding of two different filling lines.
Tailor-made engineering, insertion and erection also required the integration of 3 new CCTs to expand the current capacity with special structural challenges for tank installation in the existing historic building complex. After successful expansion in the pilot brewery with new fermentation and bright beer tanks, increased fermentation volumes are available for smaller batches as well as enhanced flexibility for product varieties.
A summary of our project can be found here:
Beertec develops a tailor-made overall concept, optimized in terms of efficiency and effectiveness, which meets the requirements of an efficient and energy-efficient brewery. Taking into account the medium and long-term development of the annual output for the individual products and the corresponding seasonal production peaks, Beertec designed a master plan that focuses on all necessary areas such as raw material reception, production, filling & packaging and warehouse and considers later, further expansion stages and allows them to be realized in a simple manner.
In the course of an individual production plant tailored directly to the customer's needs, Beertec developed a CAPEX-friendly overall concept with maximum flexibility through the integration of flexible malt silos, BigBag special malt stations, dry hopping options, fermentation tanks with double outlets, space for barrel storage, spacesaving filling (barrels & cans) including secondary packaging, and process-cooled storage rooms.
The building design with an independent gallery tour provides visitors with a detailed insight into the brewing process, from the receipt of raw materials and the production process to the filling and packaging of the final product.
Engineering, equipment supply and installation of two filling lines for a Greenfield brewery with an annual output of up to 150.000 hl. Design engineering of can filling line (330 ml and 500 ml - filling speed 6.000 - 8.000 cans per hour) and bottle filling line (330 ml and 630 ml crown cork - filling speed 2.800 - 6.000 bottles per hour). Variable applicable bottle filling for 750 ml champagne bottles with cork closure.
Expansion and modernization of a refrigeration plant for an existing brewery with an annual output of 2.100.000 hl. Planning and design of the plant and components as well as coordination of all interfaces between all disciplines.
PHASE 1:
Supply and installation of a 5,500 kW refrigeration plant (ammonia on glycol) including integration of process components into the existing system. Site management for connection to the existing tanks.
PHASE 2:
Supply and installation of process components for the integration of 24 new CCTs. Site management for the connection to the new tanks.
Turnkey project to implement a new yeast management system to integrate new yeast strains (ale yeast).
Additional expansion of the cold block area with a hop dosing system. Layout, design concept and delivery of the process optimizing equipment, development and implementation of the software, as well as turn-key installation and commissioning of the entire plant.
Process optimization resulting in significant savings of raw materials after replacement of the previous dry mill by the mill individually tailored to the customer incl. steep conditioning.
Project management, software engineering and implementation into the existing process control system (beraBREW), delivery of the mill and all peripheral components, installation and commissioning.
Development of defined tender packages including detailed technical specifications, scope of work descriptions and commercial comparisons for the overall project scope. Detailed and distinct overview of the overall tender as well as, sending tender documents to suppliers, which are specialized in the specific sub-areas (silos, milling plant, brewhouse, etc.). Definition and coordination of the interfaces between the tender packages to avoid later interfacing problems between the individual plant parts and components.
System expansion to BRAUMAT V8.0 with integration and replacement of hardware in the brewhouse and cold block area for an existing brewery.
On-site system analysis
Software configuration
System upgrade to BRAUMAT V8.0
Functional test and optimization
Commissioning
Training, parameterization and configuration of the individual areas
Beertec developed a holistic concept on the feasible capacity and product expansion through the integration of a new glass bottle line at the existing site, with the aim to increase the output by 25%.
Taking into account a logistics concept for the handling of disposable, reusable, full, terta packs, boxed goods and consumables, Beertec developed the complete project planning of a maximally flexible overall line with the option of later expansion to automated warehouse design with high-bay warehouse and fully automated truck loading.
In addition, Beertec developed a tailor-made and customized conceptual design of the blending processes for lemonades, juices, energy drinks and organic products.
The overall scope of the project covered process planning, building design, supplier tender management, and supplier coordination under the heading of project management.
In the existing adjacent old warehouse, Beertec's goal was to combine parts of the installed filling line from the existing production building with new state-of-the-art technology and to implement the complete line with as minimum conversion work as possible.
The project aimed to increase glass bottle capacity and integrate a new bottling line with different capping systems (crown cork and swing top) to increase output and sales and reduce currently high downtimes.
The resulting space in the production building was used to expand production, integrate a new keg line, a future canning line and expand the warehouse.
Beertec created an individually tailored master plan based on process and building technology requirements and taking into account optimized investment costs – CAPEX and OPEX savings.