Characteristics of equipment for beer production. What equipment to buy for a microbrewery for business

Beer production consists of the following main processes:

• Malt preparation
• Preparation and fermentation of wort
• Beer aging
• Filtration
• Beer bottling

Beer production line. The preparation of malt begins with soaking and sprouting barley. During the germination process, soluble substances and enzymes accumulate in barley. After germination, the malt is dried. The result is light or dark malt, which is used to make light or dark beer.

To prepare wort, malt is crushed and mashed with unmalted materials and water. The finished mash is filtered and a wort is obtained, which is boiled with hops. Brewer's yeast is introduced into the cooled wort and fermented. After aging, the beer is filtered and bottled into consumer containers.

Light and dark beer is produced.
Light beers are characterized by a well-defined hop flavor and hop bitterness, while dark beers have a malt aroma and taste.

Beer is divided by color into light and dark, and by concentration into weak with the original wort 5%, medium up to 12% and strong over 14%. Depending on the fermentation method, it is divided into bottom-fermented beer and top-fermented beer. In rare cases, spontaneously fermented beer is found.

Beer concentrates and wort.

Recently, much attention has been paid to the production of beer concentrates. They can be produced during periods of reduced beer sales and stored for a very long time; During periods of increased demand for beer, they are diluted with water, carbonated and released as regular beer.

When producing concentrates, the finished beer is freed from water by freezing or specially designed vacuum distillation. Both methods are associated with certain losses of extract and alcohol.

When producing beer from concentrates, the taste differences in the resulting beer are negligible. Some tasters mistake beer made from concentrates for original beer.

Concentrates can be used as an additive instead of unmalted raw materials during the preparation of wort in the usual way.

But this is a really necessary purchase: without it, cooking will become tedious and time-consuming.

We also add a chiller here - it will also be needed, since There is no automatic cooling function in the microbrewery. Moving huge tanks into the bath for cooling is a dubious pleasure.

Opening your own beer production will cost 75 thousand rubles. (if you count all the necessary little things).

How to store?

Whether you prepare foam occasionally or regularly engage in this enjoyable activity, in any case you will be faced with the question: how to store the finished drink?

Previously, brewers preferred wooden ones. Today he has lost popularity: he was replaced by kegs. This is a convenient and capacious container: it allows you to comply with storage conditions, prevent spoilage of beer even in the heat, and in addition, it is well suited for transportation.

Making "dishes" made of metal and plastic. Metal “barrels” still hold the palm in popularity, but plastic products are increasingly coming on sale.

The former are durable and reliable, the latter as well, but at the same time they are also lightweight. True, there is debate about whether plastic affects the taste of the drink stored in such kegs.

Beer is poured from a keg using heads with which they are equipped.

The volume of containers is different - from five liters to one hundred. For home brewing, 20 liter gallons are suitable.

Your experience with storage is also interesting. Have you tried pouring the finished drink into plastic containers? Has the quality suffered?

There is no doubt: homemade beer is more pleasant and healthier than store-bought beer. It contains only and - and nothing superfluous.

If you set up a small home production (not for sale, but just for your own), you can always treat your friends to a glass of real “foam”.

Therefore, another necessary item, second in importance after brewing equipment, is set of beer mugs. Don't forget about it - it will come in handy too!

Beer production as a business is rapidly developing in our country. This is a popular and beloved drink. Using the example of a ready-made mini-brewery plan, we will consider the production process in detail.

The main advantage of a fresh drink over a long-life bottled drink is its special taste characteristics. High-quality beer from local producers will always be in demand in restaurants, clubs, bars and cafes. Before opening a business and purchasing the necessary equipment, the volume of future production is calculated. Small breweries can do:

• 50-500 l per day (micro-production);
• 500-15000 l (mini-brewery).

Enterprises that produce 1000 liters of beer per day are in demand.

Equipment

Prices from Chinese, Russian, Czech and global manufacturers differ. Equipment from Inyegral-Geha with a capacity of 1000 l/day costs $650,000, and the Russian manufacturer JSC Moskon offers a similar one for $170,000. The best option is to buy an inexpensive model of good quality. For smaller production volumes, equipment that prepares 80-100 l/day is suitable. The cost is approximately 900,000 rubles.

Production Features

To control the brewing procedure, you will need a qualified technologist. The business owner also needs knowledge about the features of the process. It is divided into stages:

1. Preparation of wort.
2. Yeast fermentation.
3. Pre-fermentation stage.
4. Filtration and pasteurization during final bottling.

Delivering drinks in kegs is a cost-effective option. It is more profitable to brew beer with malt extract rather than with the starting material itself. The product is not subject to certification. A conclusion from the SES is required.

Raw materials and suppliers

To produce the drink, hops, brewer's yeast, malt, and water are used. The latter must be soft; special devices are purchased to improve its qualities. Raw materials are purchased in the following ways:

• deal with equipment supplier;
• purchase from a foreign company (beneficial when ordering a large batch);
• cooperation with large factories.

The price of one beer dispensing machine is approximately $600. At the same time, at the initial stage you will need an investment of 2 million rubles, which will bring a monthly income of 200,000.

Process

P Beer production is divided into several stages:

1. Malt preparation. Cereal grains are sprouted (usually barley), dried, and then cleared of sprouts.
2. Mashing the wort. The malt is crushed and then mixed with water. It turns out to have a sweetish taste.
3. Filtration of mash (mixture of crushed grain products and water). It is distilled into a special filter, where it is separated into spent grain (insoluble barley residues) and unhopped beer wort.
4. Boiling. Hops and other ingredients are added to the mixture and then boiled for 1 to 2 hours. During this time, aromatic substances are evaporated, which negatively affect the taste characteristics of the drink.
5. Lightening. To separate the remaining hop and barley particles, the wort is transferred to a hydrocyclone. Under the influence of centrifugal force, residues are collected along the radius of the apparatus. Then it settles for 20-30 minutes, and then it is separated from the sediment.
6. Cooling. At this stage, the wort is pumped into a special fermentation tank. It cools and is also saturated with oxygen.
7. Fermentation process. Brewer's yeast is added to the resulting composition. The solution sits for several weeks. The result is an opaque liquid that does not taste like beer. Therefore, it is sent for aging (fermentation) in closed barrels under low pressure of carbon dioxide. The period depends on the type of drink.
8. Filtration from remaining yeast particles. More often the process is carried out in industrial production. Certain methods can increase the shelf life of beer by destroying its microflora.
9. Pasteurization. Suitable for some varieties. The drink is heated to a temperature of 60 to 80°C, which also increases shelf life. It is believed that pasteurization negatively affects the taste.

Costs of organizing a microbrewery

You can start a business with a starting capital of $2500. What you need to do:

• Paper question. It is necessary to prepare and notarize the constituent documents and charter, undergo state registration, and register with statistical and tax authorities. The cost for this will be approximately $300. Next, you should obtain permission from the Housing Office, SES, Energonadzor and State Fire Supervision. A beer production license is not required, however, in some regions of our country such a requirement exists. To clarify this information, you should visit the Consumer Sector Coordination Office. Brewery products are subject to excise duty, which can be up to 400 rubles per liter. The brewery must obtain a hygienic certificate from the Sanitary and Epidemiological Supervision Authority.

• Purchase of equipment. Approximately 30 sq. m will be required to produce 50 liters of drink per day, and for 200 liters - 60 sq. m. One employee can monitor the process. To prepare 50 liters of beer you need 2 kg of sugar, 2 to 4 cans of concentrate and 14 g of yeast. The cost of organizing a micro-factory is $2500–7000. Profitability is 40%, and the payback period will be 2 months.

Costs of organizing a mini-brewery

1.5 million rubles will be required to start production of 100 liters per day. The money will be spent on certification, mandatory permits, purchase and installation of equipment, and preparation of the premises. The paperwork is similar to that of a microbrewery. The workshop area must exceed 60 square meters. m. Personnel composition:

• supervisor;
• accountant;
• specialist cook;
• electromechanic;
• cleaning woman.

It is profitable to purchase raw materials from large breweries. The choice of equipment is greater than in the case of a micro-enterprise. Devices from domestic companies can be purchased for 1-2 million rubles. A device for refilling a keg costs about 150,000. Profitability is 40%, payback occurs in 6-24 months. Monthly income can reach 600,000. The price of one glass of beer ranges from 100 to 200 rubles. The first year of activity will require additional investments in the amount of 4.5 million rubles. The annual income minus taxes will be equal to 2.5 million. In the next period, the business will bring 5 million rubles. The next stage in the development of the mini-brewery will be the opening of its own original pub.

One of the most popular types of entrepreneurial activity can be safely called the production of a foamy intoxicating drink. In Russia alone there are more than a hundred large beer production enterprises, about 300 medium-sized breweries and thousands of minimum-volume production facilities. In this article we will talk about how to open your own beer production business.

Features of doing business

Entrepreneurs who decide to open their own modest production of a foamy drink should know all the features of this type of business.

First of all, you should decide on the type of organization, because in this small market segment there are two main types:

1. Microbrewery, the production volume of which is only 50-500 liters of intoxicating drink per 24 hours.
2. – an enterprise with a production volume of 500-15,000 liters of finished product per day. It is these enterprises that usually specialize in the production of live, unfiltered beer. There are several classifications of mini-sized brewers.

Depending on the type of production activity, such organizations can be divided into:

1. Restaurant type brewery, based on catering enterprises.
2. Production type brewery, individual or separate production.

Depending on the technology used to brew the drink and the raw materials used, the following can be distinguished:

1. Full cycle brewing production.
2. Short cycle brewing production.

When organizing a mini-brewery, an entrepreneur should choose a full-cycle production technology only if he already has some agreements, verbal or on paper, with restaurants or beer bars. The use of a shortened technology is a more economical solution, since its implementation will require renting a smaller premises, and it will also be possible to save on equipment and filtration devices. This type of production involves the use of malt extracts, which are a highly evaporated substance and hopped beer wort ready for fermentation.

Brewery

Organization of this type of activity

Organizing your own brewing business is a rather interesting idea, requiring the entrepreneur to have a creative approach and attention to every detail. The profitability of this business is associated with the unique taste of a freshly brewed drink, which is simply incomparable to the taste of a store-bought bottled drink with a long shelf life. If beer from local producers is of good quality, then it will certainly be in demand by the population, which means that various bars, cafes and restaurants will buy it both retail and wholesale.

Registration of hop production

To open your own business, a future brewer needs to register the organization legally. In order to go through this procedure, you must submit the necessary package of documents to the tax office and select a material and legal form of entrepreneurship, usually an individual entrepreneur or LLC.

It is important that the registration certificate or the charter of the enterprise itself mentions that the organization will be engaged in the production and retail sale of alcoholic and non-alcoholic drinks.

According to modern legislation of the country, the activities of breweries do not require mandatory licensing. But local licensing centers themselves determine the need to obtain licenses for enterprises of this kind, and they also issue the appropriate documents.

To coordinate activities with the sanitary service, the following documents must be completed:

• Hygienic certificate– issued based on the results of analyzes and examinations of finished products carried out by accredited laboratories. Such a certificate is issued for a period of one to 5 years.
• Certificate of Safety or Compliance– a document confirming the finished product’s compliance with regulatory requirements.

Beer is an excisable product, so for each liter of drink the entrepreneur will have to pay excise tax in the amount established in 2005, 1.75 rubles. Payment of excise tax is a mandatory procedure for any form of enterprise.

Brewery equipment

1. Water filters. Water quality can affect such parameters of the final product as:
   1. color;
   2. ability to foam;
   3. taste;
   4. best before date.
2. Cooking kettle. This container is necessary for pasteurization of syrup and boiling of wort. In microbreweries, pans of various sizes or ordinary food boilers are used as such a boiler.
3. Fermenter– a container for main fermentation, which is a huge stainless steel cauldron, polished from the inside. The fermenter must be equipped with a water seal, which is used to remove excess carbon dioxide during the fermentation process. As additional equipment, the fermenter can be equipped with a tap, which allows you to drain the yeast, take samples and pour the finished product.
4. Containers for post-fermentation, in which young beer completes the fermentation process and matures. The role of such containers can be:
   1. bottles made of glass or plastic;
   2. stainless steel kegs;

In the same containers, the finished product is supplied for sale.

1. Mixing and pouring devices. A set of this type of equipment includes:
   1. mixing blade made of food-grade plastic;
   2. electrical appliances for maintaining the temperature of the wort during the fermentation process;
   3. electric pump;
   4. hoses for water, detergents and beer.
2. Laboratory instruments:
   1. hydrometer – measures the density of the wort and the alcohol content in the finished product;
   2. thermometer for temperature control;
3. Equipment for cleaning and sterilization:
   1. in order to wash and sterilize large containers, a large stainless steel bath is required;
   2. To clean bottles, the simplest and most inexpensive means are sufficient;
   3. To sterilize air in production, bactericidal ultraviolet lamps will be required.
4. Auxiliary equipment:
   1. devices for capping glass bottles;
   2. devices for screwing caps on polyethylene bottles;
   3. device for packaging a batch of bottles in polyethylene;
   4. scales for weighing ingredients;
   5. tables, shelves, racks for storing raw materials and finished products.
5. Refrigeration equipment. Beer production technology involves maturing the drink in a cool place. For this purpose the following can be used:
   1. natural premises such as a cellar or basement;
   2. air conditioned room;
   3. refrigerator or cabinet.

Production premises

In order to open your own brewery, premises can be obtained in two main ways:

• purchase of necessary space;
• renting the necessary premises.

Whatever route the entrepreneur takes, he must choose areas that fully comply with the standards of sanitary and fire services that apply to catering establishments.

Separate production facilities may be located:

1. on one floor;
2. on different floors;
3. in basements;
4. in semi-basements.

The requirements for brewery premises include the following:

• ventilation system;
• spaciousness;
• electricity;
• water supply;
• sewerage with floor drain;
• the walls in the technological workshops are decorated with ceramic tiles;
• ceiling height of at least 2 meters;
• ceilings should be painted with water-based paint;
• floors can be covered with tiles or synthetic turf.

The brewery should consist of the following areas:

1. pre-wash:
2. preparation of raw materials;
3. fermentation and post-fermentation;
4. beer maturation;
5. raw materials warehouse.

The total area of ​​the brewery should be 20-100 square meters.

Raw material base

The raw materials for this type of production are:

• Water. For production, you cannot use ordinary tap water; it must be purified and softened.
• Brewer's yeast. This type of raw material is purchased from large breweries or wholesale suppliers.
• Malt. This ingredient comes in three classes (first, second and highest). Foreign malt is considered to be of the highest quality, while domestic malt has an acceptable cost.
• Hop. To purchase this foamy drink ingredient, you can use one of the following methods:
  • buy American hops at the border for $59/kg, but you will have to buy at least 50 tons;
  • purchase hops from large breweries or wholesale suppliers of raw materials;
  • team up with other private entrepreneurs and buy hops from wholesalers in large quantities.

A tasty and popular foamy drink can only be obtained from high quality raw materials.

Recruitment

The brewery staff consists of the following positions:

• supervisor;
• highly qualified cook (Brewer);
• technologist;
• electromechanic;
• manager;
• accountant;
• delivery driver;
• cleaning woman.

Raw material suppliers

Typically, raw materials for a brewery are purchased in the following ways:

1. supply agreement with the equipment supplier (usually companies that sell technical equipment for breweries also sell raw materials);
2. acquisition of large quantities from foreign organizations;
3. contractual relations with large breweries.

Production technology

The beer brewing process consists of the following steps:

1. malt preparation related to the germination of cereals, drying and cleaning of sprouts;
2. mashing the wort (Mash). The malt is crushed by mixing it with water. The resulting wort has a sweetish taste;
3. mash filtration. At this stage, the created mash is cleaned of undissolved grain residues and unhopped wort;
4. boiling. The wort is supplemented with hops and boiled for several hours;
5. lightening. At this stage, the wort is purified by passing through a hydrocyclone;
6. cooling. The wort is poured into a kettle, where it is cooled and oxygenated;
7. fermentation. Yeast is added to the composition, after which the cauldron is closed and left to ferment;
8. further fermentation. The almost finished drink is kept in closed containers, where it acquires the required taste under the pressure of carbon dioxide;
9. filtration. Yeast residues are removed from the drink;
10. pasteurization. The drink is heated to 60 degrees, increasing its shelf life.

Finished product

Implementation of the final product

Beer is a product that does not have a long shelf life, especially when it comes to a live drink. This fact complicates sales issues, so the entrepreneur should take care of the markets for the products even before starting production. Selling beer to grocery stores can be complicated due to not only its short shelf life, but also the restriction of its sale during night hours. All this suggests that restaurants, cafes and bars that have beer on their menu are the main wholesale buyers of breweries.

You can also get additional customers by holding presentations of a new product and tasting varieties, which will also allow the entrepreneur to find out the consumer reaction to new experimental products.

Financial aspects

The cost of 1 liter of fresh beer is about 60 cents, while the minimum cost of this product in a bar or store is 1 dollar 20 cents. As can be seen from these figures, the profitability of the business for producing a foamy drink will be quite high.

Moreover, this type of production can be organized starting with minimal volumes, gradually increasing production volumes and profits from the brewery. Each brewer, starting with minimal start-up costs and modest volumes, gradually establishing sales markets, can become the owner of an expanded production facility with a large set of equipment and serious volumes of finished product production.