With the growing global demand for healthy beverages, kombucha has gained increasing attention due to its natural fermentation process, diverse flavor possibilities, and health-oriented positioning.
For many emerging beverage brands, the challenge of moving from small-scale production to commercial manufacturing is not simply increasing equipment capacity. A successful commercial system must also consider product strategy, available production space, process stability, operational efficiency, and future expansion.
In this project, the customer planned to establish a 500L/batch commercial kombucha brewing system capable of producing four different flavors. However, due to strict space limitations at the production site, a conventional equipment layout could not meet the customer’s requirements.
Therefore, the SDET engineering team worked closely with the customer to analyze production goals, process requirements, and site conditions. Through multiple rounds of optimization, we developed a highly customized kombucha production solution designed specifically for small-scale commercial manufacturing.
Part 1: Project Requirements: Upgrading from Small-Scale Production to Commercial Manufacturing
Before starting this project, the customer already had experience producing kombucha on a small scale using simple equipment for product development and market testing.
Based on this experience, the customer planned to upgrade to a commercial production system with the following requirements:
- Production capacity: 500L per batch
- Product range: Four different kombucha flavors
- Initial production plan: One batch per month, with future expansion to two batches per month
- A more stable and controllable commercial fermentation process
Traditionally, kombucha production involves several stages, including:
- Primary fermentation
- Flavor development
- Carbonation
The customer previously used natural carbonation through bottle fermentation to create carbonation.
After discussing production efficiency, product consistency, and commercial requirements, we recommended using pressure fermentation tanks for secondary fermentation combined with forced carbonation technology.
Compared with natural carbonation, forced carbonation provides:
- More accurate CO₂ control
- Better product consistency
- Shorter production cycles
- Reduced contamination risks
This solution is more suitable for stable commercial production.
Part 2: Main Challenge: Creating a Complete Production System Within a Limited Space
The biggest challenge of this project was the restricted installation area.
The available production space was:
- Length: approximately 6 meters
- Width: approximately 1.5 meters
- Height: approximately 2.6 meters
A conventional 500L kombucha system usually includes:
- 500L tea brewing tank
- 500L primary fermentation tank
- 500L pressure fermentation tank
However, the customer required four different flavors, which meant multiple independent secondary fermentation units were necessary.
A standard configuration could not provide:
- Enough space for installation
- Convenient operation access
- Easy maintenance
- Flexible flavor production
Therefore, the key engineering challenge became:
How to achieve multi-flavor commercial kombucha production within a highly limited installation space.
Part 3: Customized Solution: Redesigning the Secondary Fermentation System
To meet the requirement of producing four different flavors, the SDET engineering team redesigned the secondary fermentation system.
After primary fermentation, the 500L kombucha batch needed to be divided into four separate flavor production lines.
Considering:
- Different fruit additions for each flavor
- Additional volume required for ingredients
- Pressure fermentation requirements
- Operational space limitations
The final solution was:
4 × 150L Pressure Fermentation Tanks
Each 150L pressure fermentation tank is dedicated to one individual flavor.
Compared with a traditional single large pressure fermentation tank, this design provides:
- Independent flavor management
- Greater product flexibility
- Better suitability for small-scale commercial production
Part 4: Modular Design: Simplifying Transportation and Installation
Due to the limited production area, we further optimized the equipment structure to improve transportation and installation efficiency.
The four 150L pressure fermentation tanks were designed as:
- Two tanks installed on one common frame
- Pre-installed tank accessories
- Integrated piping connections
- Combined glycol cooling connections with a single outlet
This modular design provides several advantages:
- Reduced on-site installation workload
- Easier transportation
- Lower installation costs
- Faster commissioning
Before shipment, all equipment is clearly labeled with identification marks and installation instructions.
If required, SDET also provides free remote video guidance to support customer installation.
Part 5: Process Optimization: Redesigning the Cooling Method Based on Actual Conditions
A standard kombucha system normally uses a glycol cooling system for product cooling and fermentation temperature control.
However, during the project evaluation, we considered:
-The customer’s previous small-scale production experience
-Local environmental conditions
-Water availability and operating costs
After process analysis, we proposed using:
Tap water + single-stage plate heat exchanger cooling
instead of relying on a larger glycol cooling system for initial product cooling.
This optimization provides:
- Lower cooling system load
- Reduced investment cost
- Better space utilization
To improve water utilization, we also designed:
200L Water Recovery Tank
The recovered warm water after heat exchange can be reused for:
- Equipment cleaning
- Daily production support
The recovery tank is integrated below the 200L tea brewing tank, maximizing the use of limited space.
Part 6: Cooling System Optimization: Improving Installation Flexibility
Besides the main production equipment, auxiliary systems also required customized solutions.
Because refrigeration units require good ventilation, and the production room had limited space, the cooling unit was installed in a better-ventilated location.
Considering the distance between the chiller and fermentation tanks, we specially optimized the glycol circulation system by increasing the lift head of glycol pump.
This ensures stable glycol delivery and reliable fermentation temperature control.
Part 7: Space Optimization: Engineering Design for Perfect Site Adaptation
Equipment layout was one of the most challenging aspects of this project.
The original standard configuration could not accommodate:
- Tea brewing tank
- Primary fermentation tank
- Four pressure fermentation tanks
- Necessary operating space
Therefore, the engineering team carried out multiple layout evaluations.
The final optimization focused on maintaining performance while reducing equipment footprint.
By adjusting:
- Insulation structure
- Tank dimensions
- Overall layout design
We successfully reduced the tank diameter by approximately 50mm while maintaining jacket cooling performance and insulation requirements.
This allowed the complete system to fit perfectly into the customer’s production area.
This project demonstrates the real value of customization:
Customization is not simply changing equipment dimensions. It is finding the best engineering balance between performance, space, and production requirements.
Part 8: Mobile Design: Improving Flexibility for Small Commercial Production
Considering the limited production space and the customer’s need for flexible operation, several mobile solutions were developed.
8.1 PLC-Controlled Mobile Transfer Pump
Traditional small-scale brewing transfer pumps usually use simple start/stop control.
However, the customer required:
- Preset transfer volume
- Automatic stop after reaching the target volume
Therefore, we upgraded the mobile pump with:
- Flow meter
- PLC control system
This allows accurate and automatic liquid transfer.
This design improves automation efficiency for small commercial brewing systems and represents an innovative application developed by SDET for compact beverage production.
8.2 Mobile Plate Heat Exchanger System
To improve flexibility and save space, the plate heat exchanger was designed as a mobile unit.
Features include:
- Mobile wheels
- Integrated pipeline filter
- Stainless steel fixed piping connection
A pipeline filter was added before the heat exchanger to reduce the risk of tea residue entering the heat exchanger and causing blockage.
During the factory visit, the customer also suggested arranging the filter and heat exchanger in a parallel layout to save additional space.
After engineering evaluation, this optimization was successfully implemented in the final equipment design.
Part 9: Detail Optimization: Improving Equipment Quality Based on Customer Feedback
During the factory visit, the customer paid attention to many equipment details and provided valuable suggestions.
For example, the customer noticed that the standard sanitary valves used food-grade plastic balls on the handles and hoped to achieve better material consistency throughout the system.
Based on this requirement, all product-contacting valves in this project were upgraded with stainless steel handle balls instead of food-grade plastic balls.
Although this was a small modification, it reflects the customer’s attention to long-term equipment reliability and hygiene standards.
It also demonstrates SDET’s commitment to responding to specific customer requirements.
Part 10: Packaging Solution: Compact 250ml Slim Can Filling System
In addition to the brewing system, the customer planned to package kombucha in 250ml slim aluminum cans.
Considering:
- Product positioning
- Production scale
- Available space
The final packaging solution included:
- Two filling heads
- One seaming head
- Mobile labeling machine
The packaging equipment was installed on a mobile working table, providing:
- Space-saving operation
- Flexible movement
- Better product demonstration capability
To meet the customer’s 250ml slim can requirements, SDET customized:
- Filling nozzles
- Can support components
and completed testing before delivery.
Part 11: Project Summary: Creating More Possibilities Through Custom Engineering
This project was not simply about manufacturing a 500L kombucha system.
It was about finding the best balance between:
- Limited production space
- Multi-flavor product requirements
- Commercial production stability
- Operational flexibility
From:
- Four-flavor fermentation system design
- Cooling process optimization
- Equipment layout improvement
- Mobile equipment solutions
- PLC automation upgrade
- Packaging system customization
every detail was developed based on the customer’s real production needs.
For beverage brands transitioning from product development to commercial manufacturing, the most suitable equipment solution is often more valuable than a standard configuration.
SDET is committed to providing completely customized solutions, including:
- Process analysis
- Equipment design
- Manufacturing
- Technical support
to help beverage producers achieve stable and efficient commercial production.
Part 12: Start Your Customized Kombucha Project with SDET
From small-scale production upgrades to commercial kombucha manufacturing systems, SDET provides customized equipment solutions based on your production goals, space limitations, and process requirements.
Our engineering team is ready to help you design a brewing system that fits your business needs.
Contact us today to discuss your project.
