The brewery located in the deli building where we have our own cheesery, bakery and sausage making facility. We also have a smoke house where we cold smoke some of our meats and fish. I built this building in 2010 and with up and downstairs it is a 1000 square meters. Took 65 weeks to complete using a local builder and devoured cement at an alarming rate. The supporting walls had to be very thick as to the engineers specifications.
We are an all grain brewery using only malted barley to make our beers. Our pale malt comes from SAB Maltings and our speciality malts are from Weyermanns. The milling machine is from Germany and is overkill for what I do but still a great machine. Only thing is that it does not have a gauge for the roller gap so you cannot help a friend by telling them what setting you have it on.
Our 1200 liter hot liquor tank with temperature controller behind mounted on the wall. The tank is very well insulated and only loses a degree or so over a night when not switched on. We vary our mash in temperatures depending on the beer and also take into account the temperature of the grain. I set the sparge water temperature at 76 celsius.
The mash tun can hold about 900 liters when making a low ABV beer. It is very well insulated and loses no heat during the 90 minute mash. It has a false bottom and the hydrator is lying on top of the cover. I have a squeaky sparge arm which is a must. I do single infusion mashes as I am not able to heat the mash tun.
This is a clever little device and helps when transferring the wort from the mash tun to the kettle. It has an auto on and off switch depending on the level of fluid that controls the transfer pump. Just makes the transfer that much easier not having to do everything manually.
The kettle can hold 1200 liters and has 2 three phase elements inside the tank. It produces a nice rolling boil without the cover on and in fact I do not use the cover once it is boiling. Means there is a lot of steam in the brewery but I feel the funnel system supplied is not adequate and does not let enough wort evaporate off during the boil. I only boil for 60 minutes and being a hop head put in loads of flavour and aroma hops. Boils pretty quickly if you keep the heat trapped in while it is getting up to speed.
My heat exchanger works very well and cools the wort from 98 celsius down to my pitching temperature of 18 celsius with no problem. My cold liquor tank sits at around 6 celsius and the exchanger allows the hot energy from the boiling wort to exchange with this cold water. The stainless device you can see on the left is the in line hop filter which sieves out most of the hop debris from going into the fermentor. Normally clean the heat exchanger after every seventh brew and this takes about an hour.
The cold liquor tank holds 1200 liters and once this water has passed through the heat exchanger it runs into the hot liquor tank at around 70 celsius. This is ideal as it allows you to brew again without waiting for the hot liquor tank to get to a suitable temperature for your strike temperature. Ideally you need a much bigger cold liquor tank if you are going to do successive brews. This is a limiting factor in this set up.
The fermentors are 1000 liter tanks with water jackets that allow you to control the temperature of the beer. Initially when they came from England they had small water jackets on them. This I had modified on 2 of the 3 tanks so that the water jacket now runs right around the whole tank on these 2 tanks. I can cold crash my beers to around 6 celsius and once I have insulated the tubes carrying the cold water I expect it will go lower than this.
Two of my fermentors are temperature controlled by this device. It works really well and keeps the temperature within a degree of the set temperature. It allows me to keep better control of the yeast and I also hold my tanks at 12 celsius for 2 days before I cold crash the beer.
The brewery walls are solid cement and are about half a meter thick. The beer aging room has no windows and only one access and the temperature is very stable because of this. It holds at about 18 celsius for most of the year and this is where the newly bottled beers sit for 3 weeks before going into storage.