In the world of brewing, the brewhouse is the heart of the brewery—a central hub where the transformation of raw ingredients takes place. Here, we look at some of the latest innovations taking place in this space and more importantly, how your business can leverage these to your benefit.

The brewhouse is where the foundations of the beer are laid, dictating the potential of the final product.
A well-designed and meticulously operated brewhouse ensures that the beer has the desired characteristics, from colour and clarity to flavour and aroma.

The subsequent fermentation, maturation, and packaging processes can only enhance or preserve these qualities, but the brewhouse – arguably- defines them.

The brewhouse plays a critical role in a brewery, acting as the engine room where raw materials are converted into wort, setting the stage for the entire brewing process.

The precision and efficiency of the brewhouse operations are vital to producing consistent, high-quality beer. So let’s take a closer look at some of the businesses offering leading innovations in this essential, integral field. 

CO2 Recovery – The Time is Now

In recent years, the brewing industry has faced numerous challenges related to carbon dioxide (CO2) supply: from shortages in 2018 and 2021, to rising costs, and wider concerns around the environmental impact of CO2 production.

These issues have compelled many within the industry to consider future-proofing their operations by reducing their carbon footprint, becoming more self-sufficient, and gaining security over supply and affiliated costs.

SSV Limited are designers, suppliers and installers of brewhouses, fermentation tanks and all types of liquid processing equipment.

And in their experience, the time is now when to become more self-sufficient with subsidised CO2 recovery as they explain here.

CO2 generated during fermentation is a resource that can be recovered, purified and reused within the brewery, or sold on to wider industry.

As well as helping to reduce production costs and provide security over supply. CO2 recovery from fermentation means a sustainable process overall, with lower emissions and a reduced carbon footprint, yet many have been unable to take advantage of this quality by-product, unable to access the technology due to the capital costs involved and until recently equipment only being available for larger scale operations.

But utilising the Industrial Energy Transformation Fund (IETF), alongside the CO2 recovery offering from SSV Limited that has been recognised by the grant, can provide the potential for those within the industry to become CO2 self-sufficient, for as little as 15%* (depending on the location and size of company) of the capital outlay. 

“The IETF is a government grant that can financially support existing industrial sites to transition to lower energy/carbon futures, with the final round of funding opening in August/September 2024, explains Kate Stevens.

“The grant aids in the purchase, installation, and operational setup of CO2 recovery systems (including costs associated for staff involved in the project), providing a maximum subsidy of between 50–85% of the overall costs.” 

The partnership between SSV Limited and Hypro introduces cutting-edge CO2 recovery technology from Hypro to SSV Limited’s diverse product portfolio.

These innovative, efficient, compact, and user-friendly CO2 recovery systems are specifically designed for fermentation-based industries, crafted by globally recognized manufacturers, and supported by UK-based service teams.

When combined with a successful application for the IETF, these systems empower breweries, wineries, cideries, and distilleries to achieve CO2 self-sufficiency, offering an impressive return on investment (ROI) while significantly reducing their carbon footprint. 

The company’s expertise in bespoke installation ensures that the CO2 recovery systems can be tailored to fit any brewery setup.

The versatile skid-based units can be installed externally within a shipping container or internally, seamlessly integrating into existing cellar configurations to minimise disruption during the installation process. 

Stevens adds: “The CO2 recovery plants are designed for durability and longevity, constructed from high-grade materials like 304 stainless steel contact parts.

“The liquid CO2 storage tank is made from low-temperature carbon or stainless steel to prevent rust and impurities.

“The system features EU built compressors, known for their reliability and ease of maintenance, with widely available spare and replacement parts.

“The built-in intelligence and simplified monitoring systems all built on Siemens control architecture oversee CO2 quality and manage the recovery process automatically, eliminating the need for a dedicated operator.

“This system can be seamlessly integrated into SSV Limited’s automation software, enabling automatic recovery at predetermined times during the fermentation process, tank transfers, and packaging.

“By utilising various control methods—such as predetermined timers, pressure control, or gravity monitors—SSV Limited maximises efficiency in line with the technology available at the customer’s site.” 

The recovery plants are described highly energy-efficient, using as little as 0.17–0.24 kWh of electrical energy per kilogram of liquefied CO2, based on the site’s climatic conditions.

The design features fewer pumps than standard recovery units and includes built-in energy recovery, where the energy expelled during CO2 evaporation is recaptured into the customer’s existing cooling systems, further reducing net electrical input.

The captured CO2 is liquefied and stored at 16–20 bar, allowing the use of existing CO2 infrastructure without the need for additional high-pressure storage vessels.

A key advantage of this lower-pressure storage is the significantly reduced flashing losses due to a lower differential between storage and operating pressures, resulting in higher overall plant efficiency. 

When purified liquid CO2 is needed, the built-in evaporator converts it into usable gas while recapturing any flashing losses.

The energy used in the evaporation process is not wasted; it is recovered and reintegrated into the customer’s cooling systems, such as glycol or ammonia plants, allowing it to be utilised in other processes throughout the facility, like cellar glycol systems for tank cooling. 

She continues: “SSV Limited, in partnership with Hypro, offers units ranging from 15 to 8,000 kg/hr of liquid CO2 recovery, producing hygienic, food-grade CO2 with 99.998% purity and minimal oxygen pickup.

“Beyond incorporating world-class technology from Hypro, SSV Limited provides a turnkey service covering sales, installation, integration, commissioning, and aftercare, all supported by UK-based service teams.” 

“Adopting CO2 recovery systems with the support of the IETF grant presents a viable solution for breweries and other producers to mitigate supply issues, reduce costs—with the possibility of covering as little as 15% of the capital outlay—and enhance their self-sufficiency.

“SSV Limited’s tailored, energy-efficient, and technologically advanced systems enable breweries to leverage high-purity CO2 from fermentation, ensuring a secure and sustainable CO2 supply for future operations.

“With the final round of applications opening in August/September 2024, there is no better time to invest.”

Whiskies, vodkas and gins – from a brewery

While CO2 Recovery is one of the hottest subjects in brewing, so is that of diversification. But how can breweries leverage their existing equipment to distil spirits such as whisky, vodka and gin? Briggs, a sister company of Ziemann Holvrieka, has developed the a new technology for this purpose, which makes it possible to produce a variety of beverages using common raw materials.

Many beer brewers are broadening their range and are also entering the distilled spirits market with their own products.

This is a trend that is becoming increasingly apparent. In the USA in particular, distilled beverages such as whisky, vodka and gin are challenging beer’s market share.

To support breweries in this process, the UK based engineering company Briggs of Burton offers BrewStilleries, an engineered solution that makes it easy for brewers to diversify into distilled spirits.

A BrewStillery can transform ‚wash‘ (fermented wort) or beer into various spirits, making efficient use of their existing resources.

Production can be flexibly adapted to demand, and producers can also develop new flavors. The system is seamlessly integrated into existing operations – providing they have the additional space.

The Briggs BrewStillery uses a hybrid distillation process that combines the best of pot and column distillation processes. 

The traditional pot still technology takes place in copper stills. The copper material, as well as the shape and size of the still, influence the taste, as a large proportion of the sulphur compounds are removed from the spirit during distillation. This can have a positive effect on the aromas. 

Depending on the spirit alcohol strength, either the ‚wash‘, beer or new make spirit flows through different rectification columns.

This allows drinks with a higher alcohol concentration to be produced continuously and effectively. Each tray in a column corresponds to a batch distillation step. More trays are required for higher alcohol strengths.

The hot steam removes the alcohol and various aromatic substances from the wash at each bubble cap tray in the column. The result is a refined, high-quality spirit that, after condensation, can be bottled or matured in wooden barrels.

The US-based Spoetzl Brewery in Shiner, Texas, has recently installed a Briggs BrewStillery. In addition to beer, the brewery can also use it to produce its own ‚Shine‘ (legal Moonshine Whiskey).

The distillation process there consists of a copper pot still and series of rectification columns. The brewery and distillery work closely together in the company, with both teams using the same raw materials – malt, yeast and water. 

Working together Briggs of Burton are typically involved in the planning and construction of distillation systems such as this BrewStillery, while Ziemann Holvrieka typically provides the tanks and can support with installation.