Brewery Setup Blog

In an ideal world, we would all have purpose-planned, well-designed, and constructed breweries that allow a smooth flow of products from start to finish without hindrance. This not only reduces the risk of cross-contamination but optimizes process efficiency. It’s also expensive.

Whatever we choose it is important that both the brewery design and that of other facilities allow not only efficient production but also proper cleaning/sanitation and maintenance. Plus of course, it must be fabricated and fitted out with suitable materials for food production. So, what should we be looking for in terms of brewery design and a clean working environment? The building itself needs to be in an area suitable for access to large delivery vehicles or outgoing goods. Access is also important if you want to have visitors for brewery tours or events. Whilst it might be romantic to brew in the “old dairy” or similar ancient buildings they are not always the best or easiest sites. Modern purpose-built units are far more suitable with good lighting, usable space, and high ceilings. Also, check out what the neighbors are doing. Avoid sites next to businesses that might be a possible source of contamination. Obviously, you also need to ensure the building has:

• A clean and consistent water supply not only for brewing but also for cleaning down. It needs to be at the pressure and flow rates you need

• Efficient effluent removal

• A consistent and sufficiently specified power and gas supply. Usually single phase up to 4BBL and 3-phase above that but make sure you have, for example, the electrical power to supply all the kit you will be using plus a bit extra Starting with the flooring. Ideally, it should be constructed from concrete to at least 15 cm depth with a suitable protective coating on top. Any unprotected concrete will suffer greatly due to the various acids and alkalis used across production and packaging and of course the very nature of beer itself.

• The flooring has to withstand repeated and thorough cleaning and sanitizing, which is usually of a chemical nature, constant wetting, and steam

• The flooring may also be subject to physical abuse e.g. movement of casks, kegs, and pallet trucks so must have properties to withstand such loads and abrasion

• Slips and trips are one of the main sources of industrial injury so all flooring must provide a safe working surface, in both wet and dry conditions, for personnel and handling equipment e.g. sack barrows and forklifts

• Ideally, wall-to-floor skirting should be a continuation of the floor coating up to a height of 15 cm or so. This provides a smooth seal for cleaning and maintaining floor integrity by minimizing seepage

• Floors should slope down to drainage points. This will prevent puddles of water from developing after cleaning. The drains should be of the correct size for the requirement in the area and fitted with traps. These ensure any solids, e.g. spent grain and broken glass, are held and can be removed for disposal

Which now leads us to the walls and the ceiling. Most of us will choose to use anti-fungal/anti-mold paints or coatings which must be capable of being washed. Part of your maintenance program may well include a specified interval for repainting key areas. Natural ventilation or air-conditioning should supply sufficient air movement to help prevent mold growth.

Pest proofing is essential so all process areas should be protected against the entry of rodents, birds, and where possible insects. Pest control will be part of your PRP program.

Staff facilities such as the kitchen, toilets, and shower/changing rooms must be positioned away from the process area, and fitted with appropriate sinks, lockers, etc. Toilets should have a double-door entry. Ventilation whether by window or extractor fan should ensure sufficient air movement to eliminate odors.

In summary, the design and maintenance of a brewery should prioritize efficiency, cleanliness, and safety to ensure a smooth and safe production process while meeting all necessary regulatory requirements.