Empowering High-Volume Production with a CASSMAN 8000L Brewhouse in China

Project Title: Turnkey 8000L Automated Brewhouse for a Leading Regional Brewery

Client: A prominent and rapidly growing brewery in China.

Location: Shandong Province, China

Introduction

As the demand for consistent, high-quality craft and commercial beer continues to surge in the Chinese market, established breweries are faced with the challenge of scaling their production without compromising quality. A leading regional brewery in Shandong Province, known for its popular flagship lagers and expanding portfolio of ales, approached CASSMAN with a critical need: to dramatically increase their production capacity and modernize their brewing process.

The Challenge: Scaling Up for Market Dominance

The client's existing brewhouse was struggling to keep pace with market demand. The system was labor-intensive, offered limited process control, and had become the primary bottleneck in their production chain. Their key objectives were:

1. Massive Capacity Increase: To install a new brewhouse capable of producing multiple batches per day to meet their annual output targets.

2. Unwavering Consistency: To achieve superior batch-to-batch consistency through precise process automation.

3. Improved Efficiency: To reduce utility consumption (steam, water, electricity) and minimize wort loss.

4. Future-Proofing: To invest in a durable, reliable system that could serve their needs for years to come.

CASSMAN's Solution: A Custom-Engineered 8000L 4-Vessel Brewhouse

After a thorough consultation and analysis of the client's facility, recipes, and production goals, the CASSMAN engineering team designed and manufactured a state-of-the-art 8000L 4-Vessel Automated Brewhouse.

This turnkey solution was engineered for maximum efficiency, throughput, and control.

Key System Features:

• Configuration: 4-Vessel System (Mash Tun, Lauter Tun, Kettle, Whirlpool) allowing for continuous brewing cycles and maximizing daily output.

• High-Grade Materials: Constructed entirely from certified SUS304 stainless steel, with meticulous attention to sanitary welding and a polished interior finish (≤ 0.4μm) to ensure product purity.

• Advanced Automation: Integrated with a Siemens PLC control system and a user-friendly touchscreen HMI. This allowed for the automation of the entire brewing process, including temperature control, step-mashing, pump operation, and valve management.

• Efficiency-Driven Design:

• Steam-jacketed vessels with optimized surface areas for rapid and uniform heating.

• A specially designed lauter tun rake and false bottom system to achieve high wort clarity and extract efficiency.

• Variable Frequency Drives (VFDs) on all pumps for precise flow control and energy savings.

• Integrated Peripherals: The project also included the supply of oversized fermentation tanks, brite tanks, a fully automated CIP (Clean-In-Place) station, and a high-capacity glycol chilling system to support the new brewhouse.

Project Execution: From Design to First Brew

CASSMAN managed the project from end to end, ensuring a seamless experience for the client.

1. Collaborative Design: Our engineers worked closely with the client's brewmaster to customize the system, ensuring it was perfectly tailored to their brewing philosophy and physical plant layout. 3D models were provided for review and approval.

2. Precision Manufacturing: The entire system was fabricated in our modern manufacturing facility in Jinan. Rigorous quality control, including pressure testing and weld inspections, was performed at every stage.

3. On-Site Installation & Commissioning: A dedicated CASSMAN technical team managed the on-site installation, including vessel placement, process piping, and utility connections. Following installation, our team commissioned the entire system, running water brews and fine-tuning the automation programs.

4. Comprehensive Training: We provided in-depth training for the brewery's staff, empowering them to operate the new system confidently and efficiently.

The Result: A New Era of Production

The new 8000L CASSMAN brewhouse transformed the client's operations.

• Production capacity increased by over 300%, enabling them to meet market demand and explore new distribution channels.

• The brewing cycle was significantly shortened, allowing for up to 5-6 brews per 24-hour period.

• The automated system delivered exceptional batch-to-batch consistency, elevating the quality and reputation of their core products.

• The client reported a significant reduction in labor costs and utility consumption per hectoliter of beer produced.

The head brewer commented, "The CASSMAN brewhouse has been a game-changer for us. The level of control and consistency we now have is incredible. We are not just making more beer; we are making better beer, more efficiently than ever before."

Conclusion

This project stands as a testament to CASSMAN's capability in delivering large-scale, industrial brewing solutions. By combining robust engineering, advanced automation, and a deep understanding of the brewing process, we empower our clients to achieve their most ambitious production goals.

Are you ready to scale up your brewery? Contact the CASSMAN team today to discuss your project and receive a custom quote.