Beer Manufacturing and Design Capacity Calculation

BEER BREWING - The process of making malt beverages (as beer) which involves wort
production, fermentation and beer maturation, and bright beer processing.

MAJOR STEPS IN BEER BREWING:

• Wort production and treatment
• Fermentation
• Beer storage and conditioning

BEER PACKAGING - The process of transferring beer from bright beer tanks into suitable
containers without affecting its properties.

MAJOR STEPS IN BEER PACKAGING:

• Maintaining the beer properties in the container for a required period of time
• Facilitates handling and distribution
• Fills beer in a suitable container that is attractive and appealing to the customer

BEER BREWING PROCESS

Wort Separation
Malt milling Mashing
& Sparging
Steam

Yeast Sterilized Air

CO2 Recovery
Wort Wort Boiling
Fermentation
Treatment Steam
Refrigeration Refrigeratio n

Beer Filtration Packaging

maturation Refrigeration Refrigeration, Steam,
CO2 , & Air
Refrigeration

OTHER UTILITIES REQUIRED IN THE BEER MANUFACTURING:

• Water Treatment (It constitutes more than 90 % of the total beer volume )
• Grain Handling System and Storage (Silos)
• Yeast & Spent Grain Drying Facilities
• Waste Water Treatment Plant
• Power Supply (Electricity)
 NEW BREWERY
CAPACITY CALCULATION

(Based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

BREWHOUSE

a. Brews per day (actual) 8.0

b. Hl KO per brew 1,340

c. Hl KO per day = a x b 10,720

d. Net operating days per week 5.5

e. Hl KO per week = c x d 58,960

f. High gravity degree Balling 15.5

g. Regular gravity degree Balling 11.8

h. Dilution factor = f / g 1.314

j. Percent loss from brewhouse to packaging 10%

k. Hl packaged beer per week = e x hx (1-j) 69,703

l. Weeks per month =52 Weeks/12 Months 4.3

m. Hl packaged beer per month = k x l 299,722

n. Seasonality Factor , months per year 11.00

o. Hl packaged beer per year = m x n 3,296,938

p. Hl packaged beer per day = k /d 12,673

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

FERMENTING TANKS (FIRST SET)

a. Fermenting tank gross size, hl 10,000

b. No. of tanks 30

c. Hl. KO per brew 1,340

d. Maximum no. of brews per tank 5.5

e. High gravity deg. Balling 15.5

f. Regular gravity deg. Balling 11.8

g. Dilution factor = e ÷f 1.314

h. Percentage packaged beer recovery 90%

j. Hl packaged beer per CCT = c x d x g x h 8,713

k. CCT monthly cycle = 30 ÷ 21 1.43

l. Hl packaged beer per CCT per month = j x k 12,447

m. Total Hl packaged beer per month = b x l 373,407

n. Seasonality Factor , months per year 11.00

o. Hl packaged beer per year = m x n 4,107,481

NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

FERMENTING TANKS (SECOND SET)

a. Fermenting tank gross size, hl 1,000

b. No. of tanks 8

c. Hl. KO per brew 1,340

d. Maximum no. of brews per tank 3

e. High gravity deg. Balling 15.5

f. Regular gravity deg. Balling 11.8

g. Dilution factor = e ÷f 1.314

h. Percentage packaged beer recovery 90%

j. Hl packaged beer per CCT = c x d x g x h 4,752

k. CCT monthly cycle = 30 ÷ 21 1.43

l. Hl packaged beer per CCT per month = j x k 6,789

m. Total Hl packaged beer per month = b x l 54,314

n. Seasonality Factor , months per year 11.00

o. Hl packaged beer per year = m x n 597,452

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

FERMENTING TANKS (THIRD SET)

a. Fermenting tank gross size, hl 3,600

b. No. of tanks 18

c. Hl. KO per brew 1,340

d. Maximum no. of brews per tank 2

e. High gravity deg. Balling 15.5

f. Regular gravity deg. Balling 11.8

g. Dilution factor = e ÷f 1.314

h. Percentage packaged beer recovery 90%

j. Hl packaged beer per CCT = c x d x g x h 3,168

k. CCT monthly cycle = 30 ÷ 21 1.43

l. Hl packaged beer per CCT per month = j x k 4,526

m. Total Hl packaged beer per month = b x l 81,471

n. Seasonality Factor , months per year 11.00

o. Hl packaged beer per year = m x n 896,178

NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

TABULATED SUMMARY - FERMENTERS

Gross No. Hl. KO Max. Dilution % Pack. Hl. Pack. CCT Hls. Pack. Hls. Pack. Hls.
Fermenters Capacity of per brews Factor Beer beer per monthly beer/CCT beer Pack.
(hl) Tanks brew / tank Recovery CCT cycle per mo. per mo. beer/yr
1. First set 10,000 30 1,340 5.5 1.314 90% 8,713 1.43 12,447 373,407 4,107,481

2. Second set 1,000 8 1,340 3 1.314 90% 4,752 1.43 6,789 54,314 597,452

3. Third set 3,600 18 1,340 2 1.314 90% 3,168 1.43 4,526 81,471 896,178

TOTAL 23,762 509,192 5,601,111

Note : Seasonality Factor = 11 months per year

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

FILTRATION

a. Filtration flowrate as HG (15.5 deg. B) 750

b. Filtration flowrate as RG (11.8 deg. B) = a x (15.5/11.8) 985

c. Percentage loss from Filtration to Packaging 2%

d. Hl packaged beer per hr = b x (1-c) 965

e. Net operating hours per day 12

f. Hl packaged beer per day = d x e 11,586

g. Net operating days per week 5.5

h. Hl packaged beer per week = f x g 63,721

j. Weeks per month 4.3

k. Hl packaged beer per month = h x j 273,999

l. Seasonality Factor , months per year 11.00

m. Hl packaged beer per year = h x j 3,013,992

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

BRIGHT BEER TANKS (FIRST SET)

a. Bright beer tank gross size, hl 3,750

b. Tank utilization 90%

c. No. of tanks 4

d. Hl packaged beer per day = a x b x c 13,500

e. Net operating days per week 5.5

f. Hl packaged beer per week = d x e 74,250

g. Weeks per month 4.3

h. Hl packaged beer per month = f x g 319,275

j. Seasonality Factor , months per year 11.00

k. Hl packaged beer per year = h x j 3,512,025

NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

BRIGHT BEER TANKS (SECOND SET)

a. Bright beer tank gross size, hl 1,000

b. Tank utilization 90%

c. No. of tanks 6

d. Hl packaged beer per day = a x b x c 5,400

e. Net operating days per week 5.5

f. Hl packaged beer per week = d x e 29,700

g. Weeks per month 4.3

h. Hl packaged beer per month = f x g 127,710

j. Seasonality Factor , months per year 11.00

k. Hl packaged beer per year = h x j 1,404,810

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

BRIGHT BEER TANKS (THIRD SET)

a. Bright beer tank gross size, hl 500

b. Tank utilization 90%

c. No. of tanks 6

d. Hl packaged beer per day = a x b x c 2,700

e. Net operating days per week 5.5

f. Hl packaged beer per week = d x e 14,850

g. Weeks per month 4.3

h. Hl packaged beer per month = f x g 63,855

j. Seasonality Factor , months per year 11.00

k. Hl packaged beer per year = h x j 702,405

NEW BREWERY
TABULATED SUMMARY - BRIGHT BEER TANKS
Gross Tank No. Hl PackagedHl PackagedHl Packaged Hl Packaged
Bright Beer Tanks Capacity Utilization of Beer Beer Beer Beer
(hl) Tanks per Day per Week per Month per Year
1. First set 3,750 90% 4 13,500 74,250 319,275 3,512,025

2. Second set 1,000 90% 6 5,400 29,700 127,710 1,404,810

3. Third set 500 90% 6 2,700 14,850 63,855 702,405

TOTAL 21,600 118,800 510,840 5,619,240

Note : Seasonality Factor = 11 months per year

 NEW BREWERY
CAPACITY CALCULATION

(Based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

PACKAGING

I. HIGH SPEED BOTTLING LINES 1, 2 & 3

a. Bottles per hour line capacity =500 BPM x 60 Mins/Hr 30,000

b. Package size, liter 0.32

c. Net operating hours per day 16

d. Net operating days per week 5.5

e. Weeks per month 4.3

f. Net operating days per month = d x e 23.65

g. Seasonality Factor , months per year 11.00

h. Bottling line efficiency 88%

j. Hl packaged beer per hour = (a x b x h)/100 84

k. Hl packaged beer per day = j x c 1,352

l. Hl packaged beer per week = k xd 7,434

m. Hl packaged beer per month = l xe 31,967

n. Hl packaged beer per year = m xg 351,640

NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

PACKAGING

2. CANNING LINE

a. Cans per hour line capacity 30,000

b. Package size, liter 0.330

c. Net operating hours per day 16

d. Net operating days per week 5.5

e. Weeks per month 4.3

f. Net operating days per month = d x e 23.65

g. Seasonality Factor , months per year 11.00

h. Canning line efficiency 85%

j. Hl packaged beer per hour = (a x b x h)/100 84

k. Hl packaged beer per day = j x c 1,346

l. Hl packaged beer per week = k xd 7,405

m. Hl packaged beer per month = l xe 31,842

n. Hl packaged beer per year = m xg 350,266

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

PACKAGING

3. KEG RACKING LINE

a. Kegs per hour line capacity 60

b. Package size, liter 50

c. Net operating hours per day 16

d. Net operating days per week 5.5

e. Weeks per month 4.3

f. Net operating days per month = d x e 23.65

g. Seasonality Factor , months per year 11.00

h. Keg racking line efficiency 90%

j. Hl packaged beer per hour = (a x b x h)/100 27

k. Hl packaged beer per day = j x c 432

l. Hl packaged beer per week = k xd 2,376

m. Hl packaged beer per month = l xe 10,217

n. Hl packaged beer per year = m xg 112,385

NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

PACKAGING

4. LITER BOTTLING LINE 4

a. Bottles per hour line capacity 30,000

b. Package size, liter 1.00

c. Net operating hours per day 16

d. Net operating days per week 5.5

e. Weeks per month 4.3

f. Net operating days per month = d x e 23.7

g. Seasonality Factor , months per year 11.00

h. Bottling line efficiency 85%

j. Hl packaged beer per hour = (a x b x h)/100 255

k. Hl packaged beer per day = j x c 4,080

l. Hl packaged beer per week = k xd 22,440

m. Hl packaged beer per month = l xe 96,492

n. Hl packaged beer per year = m xg 1,061,412

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

PACKAGING

5. MULTI-PRODUCT BOTTLING LINE 5

a. Bottles per hour line capacity 30,000

b. Package size, liter 0.33

c. Net operating hours per day 16

d. Net operating days per week 5.5

e. Weeks per month 4.3

f. Net operating days per month = d x e 23.7

g. Seasonality Factor , months per year 11.00

h. Bottling line efficiency 80%

j. Hl packaged beer per hour = (a x b x h)/100 79

k. Hl packaged beer per day = j x c 1,267

l. Hl packaged beer per week = k xd 6,970

m. Hl packaged beer per month = l xe 29,969

n. Hl packaged beer per year = m xg 329,662

TABULATED SUMMARY - PACKAGING

Package Line Net Net Net Hls. Hls. Hls. Hls. Hls.
Line Capacity per
Packaging Line ID Size hour Eff. OperatingOperating Operating Pack. Pack. Pack. Pack. Pack.
(liters) hrs/day days/wk wks/month beer/hr beer/day beer/wk beer/mo beer/yr *
1. HS Lines 1, 2, & 3 0.320 30,000 bot. 88% 16 5.5 4.3 84 1,352 7,434 31,967 351,640

2. Canning Line 0.330 30,000 cans 85% 16 5.5 4.3 84 1,346 7,405 31,842 350,266

3. Keg Racking Line 50 60 kegs 90% 16 5.5 4.3 27 432 2,376 10,217 112,385

4. Liter Line 4 1.000 30,000 bot. 85% 16 5.5 4.3 255 4,080 22,440 96,492 1,061,412

5. Multi-Product Line 5 0.330 30,000 bot. 80% 16 5.5 4.3 79 1,267 6,970 29,969 329,662

TOTAL 530 8,477 46,625 200,488 2,205,364

Note : Seasonality Factor = 11 months per year

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

REFRIGERATION PLANT

a. Ammonia compressor capacity, TOR 900

b. No. of ammonia compressors 0

c. Ammonia compressor capacity, TOR 500

d. No. of ammonia compressors 5

e. Total ammonia comp. capacity, TOR = (a x b) + (c x d) 2,500

f. Percentage efficiency 90%

g. Refrigeration capacity, TOR = e x f 2,250

h. Design TOR per hl KO/day 0.15

j. Daily wort hl KO per day = g/h 15,000

k. Dilution Factor, DF = 15.5/11.8 1.314

l. Percentage beer recovery 90%

m. Hl packaged beer per day = j x k x l 17,733

n. Net operating days per week 5.5

o. Hl packaged beer per week = m x n 97,532

p. Weeks per month 4.3

q. Hl packaged beer per month = o x p 419,387

r. Seasonality Factor , months per year 11.00

s. Hl packaged beer per year = q x r 4,613,253

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

COMPRESSED AIR PLANT

a. Air compressor capacity, SCFM 1,500

b. No. of air compressors 2

c. Air compressor capacity, SCFM 600

d. No. of air compressors 1

e. Total air compressor capacity, SCFM = (a x b) + (c x d) 3,600

f. Percentage efficiency 90%

g. Compressed air system capacity, CMH = e x f x 1.7 5,508

h. Design CMH per hl KO (regular gravity, RG) 5

j. Net operating hours per day 16

k. Daily wort hl KO per day = g x h / j 17,626

l. Percentage beer recovery 90%

m. Hl packaged beer per day = k x l 15,863

n. Net operating days per week 5.5

o. Hl packaged beer per week = m x n 87,247

p. Weeks per month 4.3

q. Hl packaged beer per month = o x p 375,161

r. Seasonality Factor , months per year 11.00

s. Hl packaged beer per year = q x r 4,126,770

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

CO2 RECOVERY PLANT

a. CO2 compressor capacity, kg/hr 2,000

b. No. of CO2 compressors 0

c. CO2 compressor capacity, kg/hr 1,000

d. No. of CO2 compressors 1.5

e. Total CO2 comp. capacity, lb/hr = [(a x b) + (c x d)] x 2.205 3,308

f. Percentage efficiency 90%

g. CO2 Recovery Plant capacity, lb/hr = e x f 2,977

h. Design lb CO2/hr per hl KO/day 0.265

j. Daily wort hl KO per day = g/h 11,233

k. Dilution Factor, DF = 15.5/11.8 1.314

l. Percentage beer recovery 90%

m. Hl packaged beer per day = kx l x m 13,280

n. Net operating days per week 5.5

o. Hl packaged beer per week = m x n 73,038

p Weeks per month 4.3

q. Hl packaged beer per month = o x p 314,065

r. Seasonality Factor , months per year 11.00

s. Hl packaged beer per year = q x r 3,454,717

 NEW BREWERY
CAPACITY CALCULATION

(based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

STEAM PLANT

a. Steam boiler capacity, Bo.Hp 800

b. No. of steam boilers 0

c. Steam boiler capacity, Bo.Hp 600

d. No. of steam boilers 5

e. Total steam boiler capacity, lb/hr = [(a x b) + (c x d)] x 34.5 103,500

f. Percentage efficiency 85%

g. Steam plant capacity, lb/hr = e x f 93,150

h. Design lb steam/hr per hl KO/day 6.50

j. Daily wort hl KO per day = g/h 14,331

k. Dilution Factor, DF = 15.5/11.8 1.314

l. Percentage beer recovery 90%

m. Hl packaged beer per day = j x k x l 16,942

n. Net operating days per week 5.5

o Hl packaged beer per week = m x n 93,180

p. Weeks per month 4.3

q. Hl packaged beer per month = o x p 400,676

r. Seasonality Factor , months per year 11.00

s. Hl packaged beer per year = r x s 4,407,431

 NEW BREWERY

SUMMARY OF CAPACITIES
Capacity
AREAS (Hl packaged
beer per year)

a. Brewhouse 3,296,938

b. Fermenters 5,601,111

c. Filtration 3,013,992

d. Bright Beer Tanks 5,619,240

e. Packaging 2,205,364

f. Refrigeration 4,613,253

g. Compressed Air 4,126,770

h. CO2 Recovery System 3,454,717

j. Steam Plant 4,407,431

Note : No stand-by equipment for the utilities included in the computation.

Assumptions:

1. Seasonality factor of 11.0 months per year.

2. Net operating days per week of 5.5 days.
3. Weeks per month of 4.3 weeks.
 NEW BREWERY
CAPACITY CALCULATION

(Based on KO Balling of 15.5 deg. B and Packaged Beer OG of 11.8 deg. B)

SUBSTATION

a. Design brewery capacity, Hl. Per year 3,250,000

b. Power consumption per Hl., kWh (@ 100 % production level) 9.50

c. Net operating days per week 5.5

d. Weeks per month 4.3

e. Seasonality Factor , months per year 11.00

f. Yearly production days = c x d x e 260

g. Average monthly load factor 0.706

h. Average power factor 0.85

j. Max. operating hours per day 24

k. Average Load, kW = (a x b) / (f x j) 4,945

l. Maximum demand, kVA = k / (g x h) 8,240.40

m. Design size of Substation, MVA 7.5

n. No. of Units 3

o. Total installed capacity, kVA = m x n x 1000 22,500

p. Primary voltage, kV 69

q. Secondary voltage, kV 4.16

r. System Secondary Selective