Why do Brewhouse Systems Vary in Price?

Many beginners or brewers transitioning from homebrewing to commercial brewing may have questions when considering brewery solutions. What are the differences between two-, three-, four-, and five-vessel brewhouse systems? How should I choose the right system for my needs? This article provides a detailed analysis of the brewhouse to answer your questions.

1. Two-Vessel Brewhouse System

The two-vessel brewhouse typically consists of a Mash/Lauter Tun and a Kettle/Whirlpool. This is the preferred option for many small and medium-sized commercial breweries. They typically brew one batch per day, with each batch taking approximately 6-7 hours to brew (before entering the fermenter), and time must be allocated for cleaning. This type of equipment is also the most economical and offers the best value for small and medium-sized craft breweries.

Two-vessel brewhouse

Let me analyze the typical design of each tank in a typical two-vessel brewhouse system.

Mash/lauter tun

The mash/lauter tun is generally double-layered with insulation, and it has a manway on top. The types of manways include glass manway, stainless steel manway, and a combined type with a glass center and stainless steel frame — the prices vary accordingly. We also install spotlights inside the tank for easy observation.

If heating is required during mashing, the vessel will include the corresponding heating components, such as: electric heating elements for electric systems；steam jackets and steam components for steam-heated systems；combustion chamber and burner for direct-fire systems. If heating is not required, the mash/lauter tun will not include these components.

Agitator is also required during the mash. In a two-vessel design, we typically use a rotating arm system (raking system) to agitate the mash and loosen the grains during lautering. Depending on customer preference, the raking system can be designed as an upper rotating arm or bottom rotating arm. The mash/lauter tun also includes a sieve plate, also known as a false bottom, to filter the wort. The spent grains above the sieve plate are discharged through a side-mounted spent grains manway. We usually provide a manual rake for removing spent grains, while some customers choose to add a scraper or even a fully automatic grain-out system, though this increases cost.Optional wort collection rings are available for better wort collection, and a backwash system can be used to clean the tank. Typical tank accessories include a PT100, sparging ball, and side vent stack.

Kettle/Whirlpool

Kettle/Whirlpool is also double-layered with insulation, and it has a manway on top. Heating is typically required during the boiling process, and the necessary heating equipment is also required depending on the heating method. The whirlpool process requires a tangential whirlpool Inlet, high and low position discharging outlets, a wort outlet on the slope of the bottom, and a discharging port at the center of the bottom. Accessories typically include a PT100, a split-type light, a sparging ball, a side vent stack, a glass level tube with a SUS scale plate, and an indoor vapor condensation device.

2. Three-Vessel Brewhouse System

A three-vessel brewhouse can be configured as: Mash Tun + Lauter Tun + Kettle/Whirlpool, or Mash/Lauter Tun + Kettle + Whirlpool. Some countries also refer to a Mash/Lauter + Kettle/Whirlpool + Hot Water Tank combination as a three-vessel system.

Three-vessel brewhouse system

This setup is usually chosen by breweries that plan to brew two batches per day, as multiple vessels can operate simultaneously to save time.

3. Four-Vessel Brewhouse System

A four-vessel system includes: Mash Tun, Lauter Tun, Kettle, and Whirlpool.This is suitable for larger equipment or brewing multiple batches per day.

Four-vessel brewhouse

• The Mash Tun includes an agitator and, if step mashing is required, heating components.
• The Lauter Tun includes a raking system, sieve plate, spent grain outlet, and manual or automatic grain-out system.
• The Kettle includes a heating system; for larger capacities, we recommend a cylindrical internal calandria for higher heating efficiency.
• The Whirlpool, for larger systems, can be equipped with a diffuser and rotary jet device to remove hot solids effectively.

4. Other Configurations: Five-Vessel, Six-Vessel, and More

Some customers require five- or six-vessel designs, often including a cooker if they brew beer with corn or other ingredients. Sometimes, a holding tank is also required. These are special configurations designed for particular brewing needs.

5. Special Design: Two-Body Three-Vessel System

Another popular configuration is the Two-Body Three-Vessel System, such as: Mash/Kettle + Lauter Tun + Whirlpool, where the lauter tun and whirlpool are separate tanks but share a common body (the bottom of the lauter tun and the top of the whirlpool). Other options include Mash/Lauter Tun + Whirlpool + Kettle, or Mash Tun + Lauter Tun + Kettle/Whirlpool.

Two-body three-vessel brewhouse

This configuration allows parallel operations with one additional tank compared to a two-vessel system, improving efficiency. Compared to three- or four-vessel systems, it has fewer tanks, smaller footprint, and lower cost.

6. Auxiliary Equipment

In addition to the vessels, several auxiliary components are essential for a complete brewhouse system.

• Manual/automatic water mixing station: controls the temperature of the brewing water entering the mash tun.
• Grant tank: provides buffering, stability, and monitoring of wort flow during lautering;
• Plate heat exchanger: cools the wort before it enters the fermenter.
• Y-filter: filters hops and solids.
• Thermometry and oxygenation combination: ensures proper oxygenation and temperature of wort entering the fermenter.
• Wort tester: measures wort gravity.
• Pipelines, pumps, and working platform: essential for a complete and efficient brewing process.

These optional items greatly improve brewing stability and convenience during production.

I hope this article helps you gain a better understanding of brewhouse system design. If you still have questions, would like to learn more details, or have already decided on your brewhouse configuration and need a quotation, please feel free to contact us anytime!