CASE STUDY
Customized solutions based on customer needs
ED-IT
EDIT – Eat, Drink, Innovate, Together – the venue has a fully operational bakery, a coffee bar sponsored by Lavazza, a ground floor kitchen area with shared dining space and innovative cocktail bar. The first floor dining area features a show kitchen operated by a Michelin starred chef. In addition there are four fully fitted professional kitchens that can be hired for demonstration cooking or just for your own use. This can be used with a private dining room area as well. To complete the experience there are also 20 apartments – with EDIT covering your food and drinks needs you may never need to leave the building!
However at the heart of this co-sharing economy is a lacquered stainless steel finish, show piece brewery, visible behind the bar. The 12 hectolitres high performance brewhouse from Simatec Srl of Turin is complete with 4 dpv’s or Unitanks and also one double batch dpv. Of the 19 taps on the bar some of them can be fed direct from one of four Simatec serving tanks giving a very fresh beer experience. The serving tanks are horizontal to save space but also fitted with internal bags to keep the beer in the best serving condition from the first taste to the final glass. Currently the brewery is producing three different beers that current includes a Pils, a bock and also an American Pale Ale. Over 80 different beers are available on site either on tap, in bottle or can.
Features of the brewhouse include a multifunction vessel and a separate lauter. The Simatec system is designed to as flexible as possible and easy to use. It is possible to rent the EDIT brewery as a gypsy brewer or just a group of friends. The results given by the brew house include low hot oxidation, much reduced filtration due to a cleaner wort and also a high extract rate due to the special design of the lauter. This also allows a wide variety of alternative or additional ingredients to be used in the brewing process such as fruit, nuts and plant material such as twigs!
A condensing column instead of a flue ensures that planning permission is more easily gained as there are no odours exhausting to atmosphere from the copper.
Another key feature of the system is the modularity. This allows you to double production on the existing plant but adding only one vessel. The process does not change either, as the new vessesl is operated as a separate brew stream…… with the larger brew houses we can produce up to 13 brews per day. The system can be upgraded in stages so that as the business grows the brew house grows but without disruption or changes of the plant or brewing process! A unique system called Top Modular only from Simatec who have their own award winning brew house established 15 years ago.
The cellar was supplied from Simatec with an isobaric hop injector to allow dry hopping in the Unitanks without wasting hops as so often happens when hops are just thrown in the top. A mobile CIP set, mobile filtration set along with a small kegging unit complete the processing and packaging supply. Simatec also supplied the steam boiler, chiller, interconnecting pipework and water treatment plant too to give a turnkey project.
All the EDIT spaces, can also be used by private individuals, professionals or amateurs. “These different experiences can all be lived within the same structure with the common denominator of sharing, which manifests itself in different aspects”, explains Giovanni Rastrelli, CEO of EDIT. “Sharing moments, experiences, ideas between enthusiasts, customers and professionals and among professionals themselves with mutual collaborations and inspirations.” The names of the curators of the various areas are synonymous with excellence: Pietro Leemann and Renato Bosco will give their own stamp on the Bakery and the Pub, the Costardi Bros. will take care of the restaurant with the usual creativity, the master brewers will best embody the spirit of sharing the Brewery and the Barz8 – the star of the “mixology” Salvatore Romano and Luigi Iula – will enliven the Cocktail Bar. EDIT is therefore a revolutionary approach to the world of work, doing business in the food & beverage sector and represents a further opportunity for redevelopment of the neighborhood in which it stands: not only rennovation of a former industrial area but also creation of opportunities of employment and construction of an attractive icon for the city.”
Further details of the EDIT experience can be found at www.edit-to.com
Source: https://www.enterprisetondelli.co.uk/case_study/brewpub-not-brewpub-edit/
HANDCRAFTED BEER AT BAYOU TECHE BREWERY, LOUISIANA
Today at Bayou Teche Brewing’s Brewery and on site Tap Room and Beer Garden near the banks of the Bayou Teche, innovative ales and lagers are being crafted true to the brewers’ original intent – beers that complement the unique foods and lifestyles of South Louisiana. A full list noted below or on the Bayout Teche website.
The original brew house has served them well for a number of years but now with an ever growing range of beers using a wide range of ingredients instead of the usual malt, water and hops a new automated modular brewhouse was required. Typical ingredients used by the brewery include, raw cane sugar, barley, rice, wheat and rye malt which can be a challenge for some filtration systems…
Brewery Equipment Selected
There were several key factors in the choice of brewhouse supplier one of which was modularity and flexibility. To achieve this a new brewhouse was ordered from Simatec Srl in Italy. Simatec as well as building brewhouses also have the added advantage of being brewers in their own right resulting in a perfect partnership of brewing and manufacturing excellence. Their award winning brewery “SorAlaMA” in Turin, Italy produces beers from berries, nuts as well as Pils etc all of which has given Simatec a great deal of experience in making flexible equipment for the brewer.
A 24 hl brew house was installed capable of automatically producing up to 6 batches per day in phase 1. As the business continues to grow and demand increases for their great beers a further two vessels can be added that will allow up to 13 brews per day to be produced – automatically and with only two transfers of each batch thus reducing hot oxidation and increasing shelf life. This ensures future proofing of the production and means as so often happens that in years to come they will not need to replace their plant with all the disruption this can cause.
Bayou Teche Analysis
C.J. McFaul, head brewer at Bayou Teche has been very impressed with the brewhouse from Simatec and commented on some of the key benefits they are enjoying:-
“Thus far I have been thoroughly impressed with the system. We’ve done around twenty batches and here are the immediate benefits I’ve seen:
The Simatec Lauter Tun (not all lauters are equal) – The design is second to none. In my experience this is one of, if not the, biggest short comings of most brew houses. The wort that runs off is the clearest I’ve ever seen it. You’re going to notice a large drop in astringency from husk material that would otherwise make it’s way into the kettle. We have also noticed a decrease in time spent clarifying bright beer. Time of lautering itself has, in some cases, been cut in half. Ours came with a pressure gauge which regulates the amount of negative pressure under the false bottom. If it gets to -0.5 bar it will stop temporarily to allow differential pressure to equalize. Of course I’ve only been told this. It has never gone under -0.17 and most cases it stays at or a little bit above zero (no stuck mashes!)
Recipe Design – Set your numbers and you’re done. It does give you many parameters to adjust; 7 mash rests, 5 hop additions, any temperature control you can think of. Our 12 Plato Lager came out at 11.9 and unless I change a parameter it will always come out the same.
Steam – This is not an all or nothing system. I’ve never seen the actual mash temperature venture more than +-0.3 degrees Fahrenheit. In addition you can tell it to go from step to step in degrees per minute. I’ve been toying with a lot of protein rests as a result. So I’m not just getting an alpha rest here and a beta rest there. I’m getting the whole spectrum in between, as fast or as slow as I’d like. And of course the consistency from batch to batch.
Multi Functional Tanks – To me the best thing about these is that now I can decoct and cereal mash. The paddles are awesome. they stay on for the duration of both the mash and the boil, so no hot spots. It allows you to mash very thin to increase efficiency and have more control over final gravity. I’ve been able to get our corn lager down to 0.8 Plato from 12, something I could have otherwise not achieved. The vent stack is narrow and allows for a hotter boil. we typically boil at 214 and since those paddles are always turning, there’s just not a hot spot. We use pilsner malt so the hotter boil has allowed me to drive off DMS in 60 minutes rather than the traditional 90. Lastly our hot break has improved because those large chunks of protein are not being chopped up at the whirlpool due to being sucked up by a pump. Instead the paddles whirlpool.
Manual Mode – This is where things really get fun. While I think what Simatec has achieved in automation is second to none, I really like the fact that you can Pause, run Semi-Automatically, or just run the thing Manually. This is where decoction and cereal mashing come in. Is there a program to decoct? No. Does that prevent you from doing it? Absolutely not. To decoct: write your recipe, mash in, go into Manual Mode, transfer however much mash you want from one multi-function tank to another, boil, transfer back, go back into automatic and it will pick up right where you left off. Want to cereal mash? Before you start, put in Manual Mode, transfer hot liquor to you tank, throw the grain of your choice in (this is Louisiana so for us it is rice), rest, boil, and start your mash in (you probably want to compensate for the near boiling porridge in the tank. The point is that you can do a lot more than just press start.
Thank you Simatec!”
Simatec Srl of Turin work with Enterprise Tondelli for the UK market and have a number of installations already in the UK. The range of brew houses is from 3 hl to 96 hl brewhouse – always with an expandable or modular approach. As part of their production they also supply all types of vessel, hot/ cold liquor tanks, chilling plant, steam raising etc to give a turnkey brewhouse solution. Inovation includes the isobaric hop injector that reduces dry hop consumption and saves money and time…
SOURCE: https://www.enterprisetondelli.co.uk/case_study/new-brewery-bayou-tech-louisiana/
BIRRASALENTO ONE OF THE LARGEST CRAFT BREWERIES IN ITALY
With an area of 1600 square meters Birrasalento is the largest craft brewery in Puglia and also one of the largest in Italy. At the grand opening the provenance of the brewery was in evidence with such activities as the Italian medieval flag throwing or Sbandieratori along with Corde lisse or rope acrobatics and a band playing Pizzica music which is very typical of the region. The new brewery which is the brainchild of Mr. Maurizio Zecca was inspired by letters from his father who left Italy in 1963 to look for work and found it in a brewery in Switzerland. Reading those letters as a young man planted a seed that was later to find its realisation in the new Birrasalento Brewery.
The brewery is rooted in the landscape and region with the barley being grown a stone’s throw from the brewery. Trials were carried out on barley varieties with the University of Salento over a number of years before finally settling on Concert and Odyssey after 5 years of experimentation. Water is sourced from a private well adjacent to the plant and with the inclusion of local spices and ingredients. The only item not found locally is the hops which cannot grow in the local climate.
Piccante Beer Style
The brewery produces a range of interesting beers including the flagship Pizzica which has hot chilli peppers in the recipe. This beer is inspired by the local Pizzica music typical of the region and part of the Tarantella family of music. The dance starts off slow and increases in speed and tempo to a finale – a bit like the beer with hot chilli peppers in it that are not overpowering but very subtle and distinctive. Originally danced to cure spider bite whilst working in the olive groves and vineyards……..
Other brews include Taranta, Beggia, TIPA, Fresca and Nuda & Cruda which include a Belgian style fruit beer, Hellas, pils and a blanche IPA. With such a wide range of beer styles beer being produced it was imperative to have a very flexible and modular brew house. This would allow shorter runs but on a regular basis so the beer is always fresh.
Modular Brewery With Traditional Italian Roots
A “Top modular” 48 hectolitre Simatec brewhouse was installed which as has can produce 12 brews per day using a unique five vessel system that transfer the wort only twice thus reducing hot oxidation. Simatec work with Enterprise Tondelli in supplying brew houses / breweries in the UK markets as well as some international markets where they are active. Already Enterprise Tondelli have a number of Simatec brew houses in the UK market ranging from 12 hl to 24 hl.
The patented system which is common to all Simatec brew houses feature a multi-function vessel that acts as the mash vessel/copper and whirlpool with a special lauter tun. The Simatec “Top modular” range is aimed at the 48 – 96 HL brewhouse market for large flexible volume production. The modularity comes from the fact you can start with one multi-function vessel and one lauter tun and then as the volumes grow additional multi-function vessels can be added up to a total of four – always using the one lauter. The pipework is pre-engineered for minimum disruption when adding a further module so that very little down time is experienced. This modular system can also be applied to the craft range of brew houses from 3HL – 36HL to rationalise capital investment and maximising future proofing. The Birrasalento brewhouse is arranged with four 48 hectolitre multi-function vessels with one 48 hectolitre lauter tun for maximum optimisation.
Extract efficiency and speed is critical for all brewers and our control system maintains a constant flow through the Lauter Tun. Using a pump to positively draw down the filtered wort through the grain results in keeping a fixed head of wort above the grain. This combined with the large surface area results in a yield of up to 85% with very low heat oxidation. Another benefit is that the filtration is rapid, normally taking less than 75mins even when using other cereals. High gravity brewing is also possible with the system where we employ a larger diameter lauter.
The complete system if fully automated and PLC controlled from grain feeding to discharge and everything in between. Particular attention was taken for the hopping events with the hot wort being taken from the copper during the boil cycle and sent to a special hop injection tank which has three hop dosing units on it. The timing and dosing of these is fully automatic and the cone shaped unit also feature a very special patented mixing system and nitrogen environment to control hot oxidation….. A further hop back with automatic dosing and removal gives maximum flexibility for flavours. All of these items are located on the same level as the brew house for ease of operation and also for health and safety considerations. Cooling of the wort is with a tubular heat exchanger which much more flexibility in the types of ingredients that can be used in the brew without blocking plates.
Malt Handling
The grain handling system was supplied by Simatec including bulk silo, 1 tonne bag feed, special ingredient feeding and milling equipment along with feed conveyor to the brew house. The hot and cold liquor tanks from Simatec also controlled by the central PLC to give maximum energy recovery and reduction of energy costs. With the system configured with four mfv’s these are sized at 3 times the brew length to ensure liquor is available at all times. Spent grain is automatically discharged outside to a line of waiting specially constructed carts arranged in a train.
Cleaning
With a fully automatic brew house cleaning is a key consideration and Simatec supplied a three tank automatic CIP set adjacent to the plant. As well as CIP spray balls for instance in the lauter there are also CIP spray nozzles below the lauter plates as well as a special cleaning cycle for the spent grain removal arm using a high pressure water curtain.
Simatec Srl themselves started some years ago as an aspiring brewer. Not finding the technological solution they wanted in their own brewhouse to achieve the goals of low hot oxidation, increased extract performance, fresh taste profile and low filtration inspired them to start manufacturing brew houses as well. Thus was born the perfect partnership between equipment manufacturer and the brewer. This partnership has been ongoing resulting in continual development and improvement of the product over time. One recent example is the trend for dry hopping which can cause some challenges for both costings and tank hygiene. Simatec developed the “isobaric hop injector” or IHI for short. This unit utilised with the conditioning vessel reduces hop consumption by around 50-60%, can reduce tank time by 2 days and results in a conditioning tank easier to clean. It can also be used for special ingredients addition such as spices, peppers, sugars, raisins etc. and oxidation too.
Source: https://www.enterprisetondelli.co.uk/case_study/birra-salento-automatic-modular-brewhouse/
