When designing a brewhouse, the traditional choice of heat sources has been between direct fire and steam. However, for breweries operating systems up to 10 barrels, electric heating presents a compelling alternative. Increasingly, brewers are turning to electric elements for heating strike water, sparge water, and boiling wort due to advancements in precision temperature control and efficiency.
Electric brewing is not a new concept. In fact, brewers have been utilizing electricity to power their brewhouses for over two decades. What has changed in recent years is the level of precision that modern electric elements and control systems can offer, making electric brewing a more attractive and viable option.
How Electric Brewing Works
Unlike direct-fire burners or steam jackets, which apply heat externally, electric brewing systems heat liquid internally. This is achieved by immersing stainless steel-sheathed electric elements directly into the hot liquor tank and/or brew kettle via triclover ports. Because these elements are submerged in the liquid, nearly 100% of the applied energy is efficiently transferred, minimizing heat loss and optimizing energy consumption.
In basic electric brewing setups, the elements are controlled manually with simple on/off switches. However, to leverage the full potential of electric brewing, many brewers integrate a control panel. This allows for precise regulation of each element’s output, achieving temperature accuracy within 1 degree Fahrenheit.
Advanced Control Systems for Precision Brewing
One of the key advantages of electric brewing is the ability to precisely control mash temperatures, particularly in single-infusion and step-mash schedules. Most electric brewing systems utilize either Recirculating Infusion Mash Systems (RIMS) or Heat Exchange Recirculating Mash Systems (HERMS):
RIMS: Wort is recirculated through a heated tube where an electric element maintains or raises the temperature as needed.
HERMS: Wort passes through a coil submerged in the hot liquor tank, with temperature adjustments made by controlling the water temperature in the tank.
These systems rely on temperature probes inserted into thermowells within the tanks. The probes feed data to Proportional-Integral-Derivative (PID) controllers, which regulate solid-state relays (SSRs) to adjust the power output of the heating elements. The control panel can also manage variable-speed wort pumps, ensuring smooth circulation in both RIMS and HERMS configurations. In larger HERMS setups, a water pump is often added to prevent stratification within the hot liquor tank.
Benefits of Precision Temperature Control
Temperature regulation is not only critical during mashing but also in the brew kettle, where it helps prevent boilovers and controls evaporation rates. Brewers typically aim for an evaporation rate of 7-10% per hour. With an electric control panel, they can precisely program the energy input to achieve consistent results batch after batch.
The heating capacity of an electric brewing system depends on the number and wattage of the elements. Common brewing elements are available in 5,500-watt and 10,000-watt configurations. To prevent scorching, these elements operate at ultra-low watt densities, distributing heat evenly and efficiently. For optimal performance, recommended power capacities are:
12 kilowatts for a 1-barrel system
60 kilowatts for a 7-barrel system
By carefully selecting the appropriate number and wattage of elements, brewers can optimize heating efficiency without compromising wort quality.
Electric brewing has evolved into a reliable and efficient alternative to traditional heating methods for small to mid-sized breweries. With near-total energy transfer efficiency, advanced temperature control, and reduced risk of scorching, electric brewing systems offer consistency and precision unmatched by direct-fire or steam options. As technology continues to advance, electric brewing is poised to become an even more prominent choice for brewers looking to maximize efficiency and control in their brewing process.
