BH-BWCL-400 : BREWORX CLASSIC 400 liters : Wort brew machine / Brewhouse

The wort production machine (brewhouse ) BREWORX CLASSIC 400 is a compact food machine which includes all necessary equipment to produce 472 liters of wort (it is an optimal volume for production approximately 400 liters of beer) in one brew batch from malt (or malt extract or wort concentrate), hops and drinking water. The BREWORX CLASSIC is a three-tank equipment, some tanks have more functions :
1st tank = mashing tank (tank to mixing malt in water) + wort boiling tank (tank to boiling of wort), 2nd tank = wort filtration tank (tank to filtration of wort) + 3rd tank = whirlpool (tank to separation of hop from wort + tank to temporary storage of hot wort) . The operation platform, measuring and control system and supporting frame are also parts of the machine.
The historical design of this wort production machine, which is based on the traditions of Czech brewing, predetermines this type of brewing equipment for its location in the interior of the restaurant of the brewery. It is not only a marketing efficient, technically interesting element of the interior, where it becomes the center of attention of the guests, but it is also a functional facility on which the restaurant guests can watch the the specialist during a production of beer when they spend their time in the restaurant and they are drinking just this beer which is served them by waiters.
This wort production machine is the main part of the BREWORX CLASSIC 400 microbreweries. Primary function of this machine is the production of wort using either infusion (infusion) or decoction boiling method (decoction). Wort is an intermediate necessary product in production of beer. Beer then arises from wort after its fermentation and maturation in special pressure tanks – fermenters.

The singleblock brewhouse BREWORX CLASSIC 400 is a compact machine which includes all necessary equipment to produce 400 liters of beer wort in one batch. It is three-vessels brewhouse wherein two containers are integrated into one cylinder. This we have achieved full functionality brewing while we retained the traditional design of the Czech type brewhouse which is ideal for producing of world-famous Czech type beer. However, this brewhouse is fully capable for manufacturing all types of beer, which is produced anywhere in the world.

 

The brewhouse BREWORX CLASSIC 400 includes in standard :

• mashing tank – kettel for boiling
• wort filtration tank – for filtering
• whirlpool – for separation of hop dregs from wort
• laboratory sink
• control panel
• platform with steps
• all pipes and wires connections
• all mechanically and automatically controlled valves and armatures
• electric switchboard cabinet
• control computer (only version with SA control system)

 

Main advantages of the BREWORX CLASSIC 400 compared with brewhouses of other manufacturers:

1. The BREWORX CLASSSIC 400 is a compact standardized wort machine, which is based on a common frame. The brewhouse is easily transportable in one unit, or it can be broken down into 3 smaller parts.
2. Our brewhouse allows the production of almost all types of beers, which are known in Europe and the USA. The BREWORX CLASSIC 400 brewhouse allows the production of beer using both infusion or decoction method.
3. The whirlpool is integrated under the wort filtration tank. This solution saves space in the brewery (only for brew house volumes lower than 1000 liters)
4. The dosage of the raw materials is carried out at the beginning of the brewing process. Brewer does not need to intervene in the brewing process (only automatic version).
5. Two options of wort lautering – gravitational (first phase) and by pump (second phase).
6. The electrical switchgear and the control computer are integrated in the body of the brew house. This solution greatly eliminates the required amount of electrical wiring and electrical work on site.
7. An elimination of the negative influence of water conductivity on beer quality using the deionization belt.
8. The brewhouse construction allows you to start mashing of the second batch during a last phase of the first batch – it speeds up the double brewing process.
9. The placement of the lower engine agitator under the bottom of the brewhouse prevents dripping of grease into the brewhouse.
10. Easy access to all controls and flaps.
11. The unique glass single-hand doors on both tanks. Overpressure manholes may not be opened during wort production, while a slight overpressure in the brewhouse accelerates the brewing process.
12. Exactly calculated sizes of containers to minimize oxidation of wort.
13. An automatic ejection of waste grains.
14. Removable segment sieve with trapezoidal holes allows the perfect lautering of wort. High load capacity of the sieve
15. The possibility of producing beer from barley malt and wheat malt. The brewhouse allows also production beer from malt extract or wort concentrate.

 

Options and properties

 

Two raw materials for production of beer wort :

• Classical raw materials : Malt + hops + drinking water + brewer’s yeast + (optionally other ingrediences)
• Beer concentrates : Malt extract + hops + drinking water + brewer’s yeast + (optionally other ingrediences)

 

Four production capacities of the brewhouse :

• 472 liters of beer wort per day – one batch within 12 hours – source raw materials are malt or malt extract, hops, drinking water and brewer’s yeast
• 944 liters of beer wort per day – two batches within 24 hours – source raw materials are malt or malt extract, hops, drinking water and brewer’s yeast
• 1416 liters of beer wort per day – three batches within 24 hours – source raw materials are malt extract, hops, drinking water and brewer’s yeast
• 1888 liters of beer wort per day – four batches within 24 hours – source raw materials are malt extract, hops, drinking water and brewer’s yeast

 

Two available designs :

• SD – Stainless steel design – all vessels are fully made of stainless steel AISI 304
• CD – Copper design – all main parts are made of stainless steel AISI 304, only outer sheath and hats of containers are made of copper.

 

Brewlock – the practical door-lock system :

 

• BLMS – Brewlock quick door-lock system – simple BLMS system allows very quick locking and unlocking of all upper doors of the tanks by only one hand (with the glass door design)

 

Powerful heating system :

• SH – Steam heating – the heating of the tank kettles is performed by hot steam produced by the steam-generator. Heating by hot steam significantly speeds up the boiling process. This is the best and very safety system for the heating of wort without danger caramelization of malt. This system requires a connection of the brewhouse to electric, gas or pellet steam-generator that is not included in the wort brew machine (see an optional accessories).

 

Heating the wort with a special convectional turbular heating chamber

A special turbular heater is integrated into the mashing tank. Its function is the intensive convectional heating of wort in the wort boiling process. How the special convectional heating of wort works :

 

Two available control systems :

• SACS | Semi-automatic control – The semi-automatic control of the brewhouse with the support of PLC with most operations controlled from the central control panel with controls and sensing elements. The control panel is designed as a touchscreen – centrally are controlled motors, heating and opening and closing several important valves on the media pipes. The most valves and flaps on the brewhouse pipe system is controlled manually.
• FACS | Automatic control – automatically controlled brewhouse supported by industrial computer which automatically controls the production of wort and requires little user´s interaction. Features such as heating of the brewhouse, stirrer speed, pumps running, valves and control valves are computer controlled and adjusted to a central control panel with touchscreen.

 

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SACS : semi-automatic control system :

The semi-automatic control system is part of the wort brew machine in the basic version (manual control) and it is included in the price of the brewhouse.

In semi-automatic mode, the operator can adjust the exact amount of water to fill the brewhouse.

• The operator can set up to 4 different heating steps (temperature in ° C). Everything is showed and controled simply on the touchscreen.
• The PLC system also controls the brewing pump speed.
  The operator can adjust the volumes of liquids and mashes that he needs pump into containers.
• The operator can adjust the amount of water he needs to fill into the boiling vessel.
• In the wort filtering process, the system automatically senses the underpressure under the sieve and controls the suction speed of the pump to prevent malt spent grains from being squeezed on the sieve – preventing sieve clogging.
• In the wort cooling process, the system automatically regulates the wort flow rate across the plate heat exchanger to achieve a constant desired wort temperature at the cooler outlet to the fermenters.
• The centrifugal pump is equipped with an induction flow meter connected to the PLC.
• Pneumatic valves are fitted to the water inlet and steam inlet in the brewhouse, they can be operated from the touch screen.
• A pulse flowmeter is installed at the water inlet of the brewhouse.
• All remaining valves and flaps are operated manually by the operator. Their current status is not shown on the display.

 

The control system may work in two modes :

1. Fully manual control
2. Semi-automatic control

The operator can freely switch between the two modes.

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FACS :  fully-automatic control system

More about the fully-automatic control system …

BHAC1 automatic control system for the brewery includes:

1. Automatically controlled hot process of brewing – fully automatized management of the entire processes of production beer wort
2. Automatic system for time-control of temperatures in fermentation and maturation process
3. Automatic system for control of media

 

The control system may work in two modes :

1. Fully manual control
2. Semi-automatic control

The operator can freely switch between the two modes.

 

 

Control of operations and processes when the automatic control system is choosed :

Automatic processes	Manual processes
Filling the mashing tank and filtering tank with water	Grinding the malt
Heating cycles	Malt dosing
Pauses for saccharization
Mashing
Filtering
Hops brewing + hops dosing (the hop granulat must be ready in the hops dosers before the process)
Swirling the wort
Wort cooling and aeration
Throwing out of malt residues from the filtering tank
Rinsing and sanitation of the brewhouse

 

Why choose AC system for brewing control ? Main reasons are :

• Elimination of human errors – machine accurately and timely perform necessary tasks
• Costs saving for owner – only one worker is necessary for manipulating in the brewery
• Minimize the number of error conditions in the brewery – everything is still under control
• Monitoring and registration of the production process into the computer memory
• Minimization of requirements for constant operator attention – early reaction of machine
• Stable quality of beer – standard manufacturing procedures are always observed
• Six pre-programmed recipes – for production of the most known types of beer : Pils, Lager, Black, Weissenbeer, Ale, Special
• Manual brewing mode – for production of all other types of beer
• Special sanitation mode – for automatic cleaning,sanitizing and sterilization of the brewhouse, wort pipes, armatures and other brewery equipment

 

 

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Recommendation :

We emphatically recommend choose the automatic brewhouse control system for this type of brewhouse and also the automatic control system for media and fermentation & maturation process !

The computer brewhouse automatic control system always ensures the right brewing operations timing without damaged wort batches.

The automatic control system for media and fermentation & maturation process allows automatic monitoring and controlling of the most important parts of beer fermentation and maturation process (from 1 to 30 tanks max) and operations with media.

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Technical specification

Mashing tank / Wort boiling tank

• Usable capacity 653 L
• Dimensions Ø 800 mm, height 1 300 mm
• Steam bottom area 1.05 m2
• Steam jacketing area 0,38 m2
• Steam valve ASCOjucomatik DN 20
• Steam condensate discharge DN 20
• Four-arm agitator with gearbox output power 120 Nm, input power 0.63 kW
• Lighting 12V 35W
• 1x Sanitary rotating shower RTS 25
• Steamer DN 100, 3x spraying device
• Insulation 40 mm plasticized cotton,
• external jacketing copper 1 mm (only for CD – Copper Design version)
• Top cover in copper + steamer imitation DN 200 (only for CD – Copper Design version)
• Measuring rod with ČMI-cz certification/directive 71/316/EEC

Filtering tank

• Usable capacity 352 l
• Dimensions Ø 800 mm, height 700 mm
• Filtration bottom 6 segments with 12% permeability
• Nozzles for rinsing under wire 3 pc
• Stirrer 2 arms, 8 blades
• Gearbox 190 Nm, input power 1300W
• Lighting 12V 35W
• Mechanical temperature indicator 0-120ºC stainless steel
• 1x Sanitary rotating shower RTS 25
• Three-way setting valve with sight glass DN 50
• Brewer’s grains discharge 286*240
• Equipment for automatic grains discharge
• Insulation 50 mm plasticized cotton,
• external jacketing copper 1 mm (only for CD – Copper Design version)
• Top cover in copper + steamer imitation DN 100 (only for CD – Copper Design version)

Whirlpool – swirl tank

• Usable capacity 402 l
• Dimensions Ø 800 mm, height 800 mm
• Sanitary manhole 285*245 mm
• 1x Sanitary rotating shower RTS 25
• Tangential nozzle DN 20
• Level indicator DN 20
• Fermenting valve 2x DN 25
• Insulation 50 mm plasticized cotton,
• External jacketing copper 1 mm (only for CD – Copper Design version)

 

Piping, armatures

• Primary line DN 40, 5x flap valve DN 40
• Drain line DN 40, 3x flap valve DN 40
• Sanitary line DN 25, 4x valve DN 25
• Water supply and additional lines DN 25, 5x valve DN 25
• Beer wort filter 2000l/h/DN 80
• Mashing  pump DWO 150 Ebara
  • Input power 640W
  • H max. 2.2 bar
  • pump controlled by frequency converter Fronic 0.75 kW

 

Electric installation

• Main switch 3x25A with central stop button
• Motor starter 3×2,5-4A
• 1x Frequency converter Fronic mini 1,5 kW
• 2x Frequency converter Fronic mini 0,75 kW
• Digital temperature regulator of mash kettle Dixel XR20D
• Digital regulator of beer wort output temperature Dixel XR20D
• Circuit breaker 6A 230V
• Circuit breaker 10A 230V
• Circuit breaker 4A 230V
• Plastic DIN switchboard, 36 modules
• Wiring
  • 5x 1,5 18 m
  • 5x 2,5 10 m
  • 3x 1 48 m

 

 

 

 

Dimensions and weight

• Weight 406 kg
• Basic size minimum height 1 800 mm
• Width 2 500 mm
• Depth 1 500 mm

This boiling equipment is mounted in a rigid frame made of 1.4301, 8 pc adjustable supports installed in its bottom part.

 

Connections:

• Beer wort discharge DN 25
• Cold water supply DN 25
• Hot water supply DN 25
• Drain line DN 40
• Electro 5*2,5 5000 W

 

Auxiliaries:

• Wash basin with combined lever taps assembly
• Cooling device for samples
• Flow meter DN 25 of water supply
• Water filter
• Combined water taps assembly with digital indication of temperatures
• Steps to service bridge 750*730*585 mm

 

Transport

This equipment is usually shipped in assembled state with exception for copper covers, steamer for steam condensation, steps of service bridge and electric switchboard.

 

 

Optional accessories

• ACS – Automatic control system – automatic brewing process of wort fully controlles by computer
• STG – Steam generator – necessary only for version with SH heating system
• WCS – Wort cooling system – equipment for controlled hot wort cooling to the fermentation temperature (7°C or 25°C depending on the type of beer)
• MMG – Malt mill – equipment for grinding of malt – necessary only for production of wort from malt (not necessary for production of wort from malt extract)
• LEA – Laboratory equipment and accessories – saccharimeters, alcoholmeters, graduated cylinder, wooden rod for manual level measurement
• HWT – Heat water tank – insulated vessel for storaging of heat water purchased from wort cooling process. It is necessary to have hot water available for some parts of boiling cycle in the brewhouse.
• ITWT – Ice treated water tank – insulated vessel for cooling, storaging and pumping of ice water which is necessary in wort cooling process. This treated drinking ice water is heated in wort cooling process and becomes then hot water storaged in HWT. If is not available drinking water with requested chemical composition, it is needed to use some equipment for water treatment – WTS. Available for breweries with one-level wort cooling system – we recomment it for brewhouses with production capacity above 1000 liters of wort per one brew instead ICWT.
• ICWT – Ice cooling water tank – insulated vessel for cooling, storaging and pumping of ice water which is necessary in wort cooling process. This treated drinking ice water is heated in wort cooling process and then is comming back to the cooling system. Available for breweries with two-level wort cooling system – we recomment it for brewhouses with production capacity max.1000 liters of wort per one brew instead ITWT.
• WTS – Water treatment systems – equipment for treating of cold water that has not requested chemical composition available for brewing of choosed type beer. It is needed a chemical analysis for assessment of suitable water chemical composition.

 

 

 

 

Optional services

BTS – Brewer´s training services for starting of a new microbrewery and also for already operating microbreweries – all courses are teached by certificated Czech brewer in Czechia or in the country of the customer.