In today’s competitive craft beer market, breweries must balance stable commercial production with continuous innovation. One effective solution is the implementation of a dual-scale brewing equipment, combining a full-size production line with a pilot brewing system for recipe development.
This case study highlights how a Dutch craft brewery partnered with our company to design and install a 1000L commercial brewing system alongside a 100L pilot brewing system, creating a future-ready brewing operation that supports both consistency and creativity.
Project Overview: Why a Dual-Scale Brewing System?
The brewery’s objective was clear:
- Maintain efficient, stable commercial production
- Reduce risks when developing new recipes
- Enable seasonal, experimental, and limited-release beers
- Ensure smooth and predictable scale-up from pilot to production
By installing a pilot system that mirrors the commercial brewing process, the brewery established a reliable pathway from small-batch trials to full-scale production, minimizing guesswork and raw material waste.
1000L Commercial Brewing System Configuration
The 1000L brewing system serves as the backbone of the brewery’s daily operations. It is designed for high efficiency, consistent beer quality, and operational flexibility, supporting both flagship products and future expansion.
Brewhouse & Utilities
- 1000L Combined Three-Vessel Brewhouse
- 2000L Hot Liquor Tank (HLT)
- 250L Cold Water Tank
- Система управления
The combined three-vessel brewhouse optimizes floor space while maintaining complete brewing functionality. Integrated lautering ensures high extract efficiency, while boiling and whirlpool stages deliver stable wort quality and effective trub separation.
The 2000L HLT provides sufficient hot water for multiple brews per day, CIP cleaning, and temperature stability—significantly improving overall brewhouse efficiency.
Fermentation & Beer Conditioning System
- 8 × 1000L Fermentation Tanks
- 1000L Bright Beer Tank (BBT)
The fermentation cellar is carefully sized to match brewhouse output, creating a balanced production rhythm. This configuration allows:
- Continuous weekly brewing schedules
- Parallel fermentation of multiple beer styles
- Adequate fermentation and maturation time without tank pressure
The Bright Beer Tank ensures precise control over clarification, carbonation, and short-term storage, delivering consistent flavor, clarity, and CO₂ levels before packaging.
100L Pilot Brewing System Configuration
To support innovation, the brewery installed a 100L pilot brewing system designed to replicate the commercial brewing process—not a simplified test setup.
Pilot System Components
- 100L Pilot Brewhouse
- 2 × 150L Fermentation Tanks
- 150L Bright Beer Tank
The pilot system follows the same brewing logic, temperature control strategy, and process flow as the 1000L system. This ensures that recipes developed at pilot scale can be scaled up accurately and predictably to commercial batches.
The Role of a Pilot Brewing System in Craft Breweries
A pilot brewing system is no longer a luxury—it is a strategic asset for modern craft breweries.
Ключевые преимущества
Recipe Development & Validation
Test new hop varieties, yeast strains, adjuncts, and mash schedules without occupying commercial tanks.
Risk Reduction
Identify potential flavor or process issues before committing large volumes of raw materials.
Seasonal & Limited-Release Beers
Develop taproom-exclusive beers or test market acceptance with small batches.
Process Optimization & Brewer Training
Fine-tune brewing parameters and train staff using real production workflows.
By closely matching the commercial system, the pilot brewhouse eliminates scale-up uncertainty and significantly improves production confidence.
Central Control System & Process Consistency
Both the 1000L commercial system and 100L pilot system are built around a unified central control philosophy, allowing brewers to precisely manage:
- Temperature profiles
- Brewing time and sequencing
- Fluid transfer and process logic
This consistency improves:
- Batch-to-batch repeatability
- Data tracking and process transparency
- Operational efficiency and staff training consistency
As a result, the brewery benefits from improved product stability and reduced operational variability.
Why Choose a Dual-Scale Brewing System?
A dual-scale brewing system offers the ideal balance between production efficiency and innovation capability.
By designing the pilot system to mirror the commercial brewing process, breweries can validate recipes, yeast performance, hop utilization, and key process parameters before scaling up. This approach:
- Reduces production risk and raw material waste
- Prevents unnecessary occupation of fermentation capacity
- Maintains stable output of core beer styles
- Enables continuous development of new and seasonal beers
Ultimately, a dual-scale system supports sustainable growth without sacrificing creativity.
Project Results & Long-Term Value
With the installation of both systems, the Dutch brewery achieved:
- Stable and efficient daily production
- Reliable scale-up from pilot recipes to commercial batches
- Improved consistency across multiple beer styles
- A future-ready platform for innovation and expansion
This project demonstrates how thoughtful brewery equipment planning can drive both business growth and brewing creativity.
Заключение
Brewing equipment defines more than production capacity—it shapes workflow, beer quality, and long-term development potential.
By combining a 1000L commercial brewing system with a 100L pilot brewing system, this brewery has built a flexible, efficient, and scalable operation tailored to the demands of modern craft brewing.
Our engineering team specializes in custom brewery equipment solutions, helping brewers confidently move from idea to full-scale production.
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