A 500L commercial brewing system was installed for an education-focused brewing and distilling center looking to expand its teaching capabilities and enhance on-site demonstration activities. The goal was to create a facility where training, hands-on operation, and small-batch production could be carried out in a flexible, safe, and user-friendly environment.
This installation supports three core functions:
- Educational demonstrations for brewing and distilling students
- Pilot-scale beer and distilled liquor production
- Interactive visitor experiences, including tasting events and on-site workshops
To meet these requirements, the system needed to be reliable, easy to operate, and adaptable to both teaching scenarios and diverse small-batch production needs.
Delivered System Configuration
1. Brewhouse System
- 500L 3-vessel brewhouse (mash tun, lauter tun, kettle/whirlpool)
- Heat exchanger + sanitary pump
- 1000L hot water tank with pump
2. Fermentation System
- 500L stainless steel fermenters × 9
3. Cooling System
- 1500L ice water tank + pump
- 5HP glycol chiller
4. Control System
- Brewing and fermentation control panel for real-time process management
5. Kegging System
- 20L stainless steel kegs × 30
- 2-head automatic keg washer
This configuration creates a complete brewing workflow—from mashing and boiling, through fermentation and cooling, to packaging and serving.
Implementation Highlights
Teaching-Friendly Brewhouse Operation
The 3-vessel brewhouse layout provides a clear process flow for educational demonstrations:
- Mashing — precise temperature control for enzyme activity
- Lautering — efficient wort separation with visible operations
- Boiling & Whirlpool — stable heating and easy demonstration of hop additions
A simplified control panel allows instructors to walk students and visitors through each stage step-by-step. The design is ideal for classrooms, brewing experience programs, and distilling introductions.
Flexible and Scalable Fermentation Capacity
Nine 500L fermenters allow the facility to run:
- multiple beer styles at once
- small-batch distilled liquor bases
- recipe trials for workshops
- production of tasting samples for events
The setup is highly suitable for environments that require experimentation and rapid turnover of batches.
Integrated Cooling & Kegging for Better Workflow
A 1500L ice water system and 5HP chiller ensure rapid cooling during wort production and stable fermentation temperatures—critical for product consistency during training sessions.
The kegging system (20L kegs + 2-head washer) completes the loop from production to serving, enabling the center to offer:
- fresh samples for visitors
- packaged batches for classes
- controlled small-scale distribution for internal events
How a 3-Vessel Brewhouse Works (Mash–Lauter–Boil/Whirlpool)
A 3-vessel system is widely used in commercial craft breweries and educational facilities because it separates key brewing steps:
- Tunnel di ammostamento: converts starches into fermentable sugars
- Tunnel di raffreddamento: filters wort through the grain bed
- Boil Kettle/Whirlpool: sterilizes wort, extracts hop components, and clarifies it
This configuration improves efficiency, reduces downtime, and allows students to clearly understand each function, which is why it is preferred for teaching environments.
Why Fermentation Temperature Control Matters
Fermentation temperature is one of the most important variables affecting beer and spirits:
- Too warm → ester and fusel alcohol overproduction
- Too cold → slow fermentation and off-flavors
- Stable temperature → consistent flavor profile
The combination of a glycol chiller and insulated ice water tank creates a stable thermal system for precise temperature regulation.
How a Keg Washer Improves Quality and Safety
Automated keg washers are a common topic in brewery technical searches. Key benefits include:
- Consistent sanitation between batches
- Reduced risk of contamination in small-scale production
- Faster turnover for tasting sessions and classes
- Lower labor intensity compared to manual rinsing
For facilities running frequent workshops and tastings, automated keg cleaning dramatically improves efficiency.
Why a 500L System Is Ideal for Education and Small-Batch R&D
500L is one of the most popular capacities for:
- teaching centers
- pilot breweries
- recipe development labs
- product innovation teams
It is large enough to mimic commercial processes yet small enough to run economically, making it an excellent teaching and demonstration size.
Conclusione
This 500L brewing system provides a balanced combination of teaching functionality and practical production capability. With a clear brewhouse layout, flexible fermentation capacity, and a complete cooling and kegging workflow, the setup enables hands-on learning, small-batch trials, and engaging visitor experiences—all within one integrated system.
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