3 vessel brewhouse for small and medium breweries

Increased Production Capacity

A 3 vessel brewhouse consists of three key components: a mash tun, a lauter tun, and a kettle. This configuration allows breweries to expand their production capacity while maintaining a manageable scale, which is great for small and medium breweries. Typically, a 3 vessel brewhouse can produce around 10 to 20 barrels (310 to 620 gallons) of beer per batch, depending on the specific equipment and brewing techniques employed.

Mash Tun:

The mash tun is where the mashing process takes place, converting starches from malted grains into fermentable sugars. In a 3 vessel brewhouse, the mash tun usually has a capacity ranging from 1,000 to 2,000 liters (264 to 528 gallons). This size allows for efficient mixing of grains and water, ensuring optimal extraction of sugars during the mashing process.

Lauter Tun:

The lauter tun is responsible for separating the liquid wort from the spent grain material after mashing. It typically has a similar capacity to the mash tun, ranging from 1,000 to 2,000 liters (264 to 528 gallons). The lauter tun is designed with a false bottom or other filtration system to allow the wort to flow through while retaining the grain solids.

Kettle:

The kettle, also known as the brew kettle or boiling kettle, is where the wort is boiled and hops are added for bittering, flavor, and aroma. In a 3 vessel brewhouse, the kettle is usually larger than the mash tun and lauter tun, with a capacity ranging from 1,500 to 3,000 liters (396 to 792 gallons). This larger size allows for a vigorous boil and accommodates the addition of hops and other ingredients.

Batch Size and Production Capacity:

The specific batch size and production capacity of a 3 vessel brewhouse can vary depending on factors such as equipment design, brewing techniques, and recipe formulation. Here are some rough estimates:

1. Batch Size: A 3 vessel brewhouse can typically handle batch sizes ranging from 10 to 20 barrels (310 to 620 gallons) per brew. This translates to approximately 2,000 to 4,000 liters of beer.

2. Production Capacity: Depending on the number of brews per day or week, a 3 vessel brewhouse can produce around 20 to 40 barrels (620 to 1,240 gallons) of beer per week. This is a significant increase in production compared to smaller brewing systems.

It's important to note that these numbers are general estimates, and the actual production capacity will depend on various factors, including equipment efficiency, brewing practices, and the desired beer styles.

Overall, a 3 vessel brewhouse provides breweries with the capability to produce larger batches of beer while maintaining control over the brewing process. The increased production capacity allows small and medium breweries to meet the growing demand for their craft beers and potentially expand their distribution reach.

Enhanced Process Control

Precise control over the brewing process is crucial for consistently producing high-quality beers. With a 3 vessel brewhouse, small and medium breweries have better control over mashing, lautering, and boiling, leading to improved efficiency and repeatability. For instance, the mash tun enables efficient extraction of sugars from malted grains, while the lauter tun facilitates effective separation of the wort from the spent grains.

Recipe Development and Experimentation

Small and medium craft breweries thrive on innovation and experimentation, and a 3 vessel brewhouse provides the necessary flexibility for recipe development. Brewers can explore a wide range of malt varieties, hop combinations, and yeast strains to create unique flavor profiles. By tweaking the brewing parameters, such as mash temperatures and hop additions, brewers can fine-tune their recipes and achieve desired flavor characteristics.

Case Study: "Hops & Barrels Brewery"

Let's take a closer look at a real-world example of a small and medium brewery, Hops & Barrels Brewery, that successfully implemented a 3 vessel brewhouse.

Hops & Barrels Brewery, a small and medium brewery, located in a bustling city, experienced growing demand for their craft beers. To meet the market needs and maintain consistent quality, they decided to invest in a 3 vessel brewhouse with the following specifications:

Mash Tun: 1200 liters (317 gallons) capacity

Lauter Tun: 1200 liters (317 gallons) capacity

Kettle: 1500 liters (396 gallons) capacity

With their new brewhouse, Hops & Barrels Brewery increased their production capacity by 60%. They were able to brew 12 barrels (372 gallons) per batch, resulting in approximately 6,000 bottles of beer.

The enhanced process control provided by the 3 vessel brewhouse allowed Hops & Barrels Brewery to consistently produce beers of exceptional quality. They fine-tuned their IPA recipe by experimenting with different hop varieties and adjusting the mash temperature to achieve the desired balance of bitterness and aroma.

The versatility of the 3 vessel brewhouse also enabled Hops & Barrels Brewery to introduce seasonal and specialty brews. They experimented with unique ingredients like fruits, spices, and barrel aging techniques, which captivated beer enthusiasts and expanded their customer base.

In conclusion

A 3 vessel brewhouse is an ideal choice for small and medium breweries. Its increased production capacity, enhanced process control, and recipe development flexibility make it a valuable asset for breweries aiming to meet market demands, maintain consistency, and foster innovation. Hops & Barrels Brewery's success story demonstrates how a well-designed 3 vessel brewhouse can empower breweries to thrive in the ever-evolving craft beer landscape.