The mash vessel and lauter tun are only occupied for the duration of the mashing or lautering processes. In contrast, the wort kettle must be available from the moment the first wort is run in until the last wort is cast out, making it the vessel that is occupied for the longest time. This is not a significant issue when only a few brews are made per day. However, when multiple brews are boiled consecutively—often eight or more per day—problems can arise, as another batch of first wort is produced while the kettle is still in use.
To address this challenge, Tiantai recommends breweries choose a well-insulated, unheated underback wort collection vessel as a buffer, connecting it between the lauter tun and the wort kettle. This setup helps maintain a smooth casting-out cycle rhythm.
If a wort buffer vessel with a preheating function is added to the mash room, it can be used to collect the first wort of the next batch, as well as some of the washed wort, while the brew kettle is still in operation. This addition allows the occupied time of the brew kettle to be reduced to approximately 160 to 190 minutes, enabling it to be turned over 7.5 to 9 times a day.
Additionally, it is possible to warm the wort during its recirculation back to the wort kettle using a heat exchanger. A suitable heating medium for this purpose is hot water, which can be prepared using the kettle vapor condenser or by directly injecting cleaned fresh steam.
The wort brew kettle is the equipment that is used for the longest duration during the mashing process. The time it occupies is nearly equal to the combined time of the lauter tun and the wort boiling. However, the actual effective working time lasts only 90 to 120 minutes. Therefore, controlling the process conditions and minimizing the wort boiling time is crucial for efficient mash production. When configuring brewing equipment, it is advisable for breweries to include a wort buffer vessel.
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