Dec. 02, 2024
Machinery
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I wanted to discuss buying a custom brewery from China after receiving a message from Eric in The Philippines. He expressed regret at not finding my website sooner.
Eric had been searching for a "200L custom brewery system from China," but Google had not provided him with useful results. Eric is a homebrewer interested in transitioning to his first commercial system and required some guidance.
My clients often echo Eric's sentiments as many of them are new to commercial brewing. They seek assistance not only with sourcing equipment but also in making their new brewery operational.
I assist new brewing ventures in starting up, analyzing cost-per-liter metrics, establishing standard operating procedures (SOPs), and plotting production schedules. Today, however, our focus will be on the process of buying a custom brewery from China.
Whether you are planning a brewery, customization will always play a role.
Please note: The insights shared in this article are applicable to any brewery project, not solely for equipment sourced from China.
As I've repeated on various occasions, conducting thorough research is crucial (or contact me for assistance). The multitude of Chinese manufacturers can be daunting.
New manufacturers are emerging at a rapid pace, making it overwhelming with constant emails and messages arriving in your inbox.
The challenge is that not all manufacturers have experienced brewers on their teams or are up-to-date with the latest brewing advancements.
The information available to brewers regarding the brewing process and technological innovations has never been richer. Each brewing project is unique, requiring specific customizations.
I’m currently engaged in several other projects, but these presented specific challenges that required careful navigation. None of these cases could have effectively utilized a simple off-the-shelf solution.
Finding a Chinese brewing equipment manufacturer who truly understands the nuances of your specific project is the second essential step. Do you know what the first step is?
When clients initially reach out, I provide them with a comprehensive questionnaire to fill out. It’s perfectly fine if they cannot answer all the queries; any shared information is helpful.
I review their responses and pose additional questions for clarity, after which we schedule a video call to discuss further.
This preparation ensures that our initial conversation is productive. It all contributes towards crafting a detailed list outlining why each piece of equipment is necessary.
Below are several critical elements to convey to an equipment manufacturer for any brewing project.
The beer styles you plan to brew will inform the necessary vessel configuration. For instance:
Primarily Brewing Lagers – This may require a suitably sized cold liquor tank (CLT) for a large brew day, instead of a two-stage heat exchanger.
Hazy IPAs – A client I’m currently collaborating with prefers to implement hop baskets in both the brewhouse and fermentation vessels, believing that this method reduces hop burn and minimizes beer losses.
Strong Ales – For brewing robust beers, especially those with an all-malt grain bill, larger mash and lauter tun size is necessary to handle higher volumes efficiently.
If a brewery executes just one brew per day, planning becomes straightforward. Typically, a two-vessel system suffices, combining mash/lauter and kettle/whirlpool.
This setup works effectively for a 500-liter (or smaller) brewpub. If correctly designed, it allows brewers to complete two batches in a 10 to 12-hour span for a 1,000-liter unit tank.
However, planning becomes more complex when multiple beer types are involved, each requiring different-sized unit tanks.
Consider a 1,000-liter brewery with various tanks sized 1, 2, 4, and 6,000 liters; such a setup requires multiple brewhouse vessels.
Brewing multiple batches on a single system within a day is referred to as “turns.” A practical way to boost production and expedite brew days is to add a whirlpool.
This setup fosters an efficient flow: Mash mixer → Lauter tun → Wort holding tank → Brew kettle → Whirlpool → Heat exchanger → Fermentation vessel.
Larger breweries might necessitate additional brewhouse vessels to accommodate 10 or more turns daily, particularly for filling extensive unit tanks and brewing various beers within one day.
It’s crucial for a brewery to project its volume needs for both the present and potential future expansions, particularly when increasing fermentation capacity is in the cards. Preemptively investing in an appropriately sized glycol/cooling system can yield long-term savings.
While this might incur higher initial costs, it ultimately saves time and resources as breweries can seamlessly integrate new fermenters into the existing glycol system during expansion.
Even if you aren’t entirely certain of your brewhouse needs, the more detailed information provided to a knowledgeable Chinese equipment manufacturer or brewing consultant will enhance the likelihood of designing a suitable brewing setup.
A competent brewery consultant will typically pose questions such as:
Choosing the optimal heating method for your brewery can lead to significant cost savings. Certain locations bear higher electricity costs, thus opting for a gas boiler instead of an electric steam generator could be prudent.
If water pressure is subpar and not easily adjustable, relocating may be essential.
If persistence is key, installing a CLT for wort cooling might be the best solution. Furthermore, utilizing mains water buffer tanks coupled with an on-demand pump can simplify operations for brewing teams.
Should your water analysis reveal poor quality, characterized by a high total dissolved solids (TDS) count, installing a reverse osmosis (RO) machine, treatment buffer tank, and an on-demand pump would be advisable.
As labor costs evolve, automation has become an appealing consideration for many brewing facilities. For instance, I am currently in discussion with a brewery in France regarding a project.
Due to anticipated shifts toward a 4-day work week next year, my client recognizes the value of minimizing employee count while maintaining competitive salaries.
If you need guidance regarding customized brewing equipment, our seasoned sales team is ready to assist in identifying the best options for your requirements.
The significance of process flow is often underestimated in brewery projects. Production staff engage in considerable movement during brewing, cellaring, and packaging.
A well-designed brewery layout can save time and drastically reduce labor costs, benefitting everyone involved.
I believe in visualizing a triangular layout encompassing three primary areas: the brew deck, keg washing station, and sampling points.
Is it feasible to design a brewery such that employees reduce their travel distance between these three locations? Yes, by understanding operational needs and incorporating this knowledge into brewery design.
Hot Side: Milling → Mashing → Lautering → Boiling → Whirlpool → Wort cooling → Fermentation Vessel
Cold Side: Fermentation → Free Rise → Crashing → Separation → Carbonation → Packaging
While the processes outlined are simplified, they effectively communicate the complexity involved in assembling a custom brewery.
The first recommendation I always make to clients considering the procurement of packaging equipment from China is to contemplate sourcing options elsewhere.
Historically, small-scale packaging solutions from China have been inconsistent in quality.
To secure a packaging license in China, breweries previously needed to establish a capacity of 12,000 units per hour. This far exceeded the requirements or capabilities of smaller enterprises.
Although circumstances have evolved and some Chinese manufacturers are now addressing the global market, issues such as dissolved oxygen (DO) levels on craft lines continue to pose challenges.
Several brewers have reported DO levels exceeding acceptable ranges, leading to concerns with freshness and quality. In fact, I’ve had feedback indicating variability over 3,000ppb on older Chinese bottling lines.
Conversely, I’m aware of a canning line capable of achieving DO levels below 30ppb, demonstrating reliability while maintaining operational efficiency at approximately 400 cans per hour.
My role in assisting clients with buying custom breweries from China is ongoing.
The importance of process flow cannot be overstated regarding labor efficiency and benefit to brewing staff.
Establishing a successful brewery involves numerous complexities. However, based on input from previous clients and manufacturers across various projects, the above principles have proven pivotal.
This framework will empower a brewing equipment manufacturer in China—or any supplier—to better tailor a custom brewery to meet specific project needs.
If you're seeking assistance through this process, please reach out. I can guide you as I have for numerous clients before, from conceptualizing an idea through to executing a turnkey brewery order.
My name is Neil, a British brewer residing in China, and I possess an in-depth understanding of the brewing equipment market here.
The journey begins by completing this questionnaire and sending your answers via email to: [email address].
Feel free to connect with me directly on WeChat by scanning the relevant QR code. Once added, you can send a message to initiate the conversation.
I'm eager to discuss your brewing project or expansion plans. Thank you for reading, and have a great day!
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