Author: CASSMAN Publish Time: 2025-09-05 Origin: CASSMAN BEER BREWING EQUIPMENT
Project Title: Engineering a Custom Direct Fired Brewhouse to Master the Art of Caramelization for a Bruges Brewpub
Client: "Brouwerij De Leeuw" (The Lion Brewery), a new brewery launched by a family with a multi-generational history of running a famous beer café in the heart of Bruges.
Location: Bruges, Belgium
In Belgium, brewing is not just a process; it's a cultural heritage. The founders of "Brouwerij De Leeuw" spent decades serving the world's finest Trappist and Abbey ales in their historic café. When they decided to create their own house beers, their goal was not to imitate, but to honor this tradition. They knew that the key to the rich, complex malt profile of a classic Belgian Dubbel or Tripel lay in the boil—specifically, in the intense, flavor-creating reactions that only a direct fired kettle can provide. They sought a partner who understood this art and could engineer a modern system around this ancient technique.
Creating a world-class Belgian ale system required a delicate balance of tradition and technology, facing four main challenges:
Mastering Kettle Caramelization: This was the soul of the project. Direct fire heating can produce beautiful Maillard reactions and caramelization, but it also carries a high risk of scorching the wort, especially with the high-gravity, sugar-rich worts used in Belgian brewing. The kettle's design had to maximize flavor development while completely preventing scorching.
Honoring Complex Brewing Processes: Belgian brewing often involves complex, multi-step mashes to activate different enzymes and develop a highly fermentable wort. The system needed precise temperature control and the ability to handle very thick, dense mash profiles.
Full European Compliance (CE/PED): As a European installation, the entire system, particularly the pressure-rated fermenters and brite tanks, had to be designed and documented to meet the stringent requirements of the Pressure Equipment Directive (PED) and carry the CE mark for legal operation.
Aesthetics of a "Showpiece" Brewery: Located in historic Bruges and intended to be a feature of their brewpub, the system needed to be not only functional but also visually stunning—a true "showpiece" that reflected the quality of the beer it produced.
CASSMAN delivered a solution that was both a tribute to tradition and a feat of modern engineering: a 1000L 2-Vessel Direct Fired Brewhouse with custom features for crafting perfect Belgian ales.
Key System Features:
The "Caramelization Kettle": The heart of the system was a custom-engineered direct fired kettle. It featured:
A purpose-built, high-efficiency firebox that provided intense yet evenly distributed heat.
A concave, recessed bottom to promote strong convection currents, ensuring the wort was constantly moving and preventing any hot spots or scorching.
A low-shear, high-flow agitator, designed to keep the wort circulating during the boil without damaging the delicate proteins, further ensuring an even boil and preventing scorching.
Precision Step-Mashing Tun: The Mash/Lauter Tun was designed to handle the stickiest of Belgian mashes, with powerful, variable-speed rakes and an automated control system for programming precise, multi-step temperature rests.
CE/PED Certified for Europe: CASSMAN managed the entire compliance process, providing a full technical file, certified manufacturing procedures, and all necessary documentation to ensure the system was fully PED compliant and CE marked, guaranteeing a smooth path to permitting.
Optional Copper Cladding & "Bruges Polish": To meet the client's aesthetic requirements, the brewhouse was offered with beautiful, hand-worked copper cladding and a mirror-polish finish on all stainless steel surfaces, making it a stunning centerpiece for their new brewpub.
Our approach was centered on collaboration and a shared passion for great beer.
Flavor Profile Consultation: We began by discussing the exact flavor profiles the client wanted to achieve. We talked about the specific notes of caramel, toffee, and dark fruit they were looking for, which directly informed the engineering of the kettle.
Custom Kettle Engineering: Our engineers used thermal modeling to design the firebox and kettle geometry, ensuring the heat transfer would be powerful enough for vigorous caramelization but gentle enough to avoid any off-flavors.
Factory Acceptance & Training: The client visited our facility to inspect the finished system. We fired up the kettle with water to demonstrate the powerful convection and the effectiveness of the agitator, giving them complete confidence before shipment.
On-Site Commissioning & Boil Calibration: Our technician traveled to Bruges for the first brew. They worked alongside the Belgian brewer to calibrate the gas burners and dial in the boiling process, achieving the perfect level of caramelization on the very first batch of their house Dubbel.
The "Brouwerij De Leeuw" launch was a triumph, validating their decision to embrace direct fire.
Signature Flavor Achieved: The first batches of their Dubbel and Tripel had the exact rich, complex malt character they had dreamed of. The direct fired kettle performed flawlessly, delivering deep caramel and toffee notes without a hint of scorching.
Instant Local Hit: The house-brewed ales were an immediate success, earning praise from discerning locals and tourists alike. The beers stood proudly alongside the legendary Belgian ales they had served for years.
A Destination Brewpub: The stunning "showpiece" brewery became a major attraction, drawing in customers who wanted to see where the magic happened. It transformed their café into a true brewing destination.
The Brewer's Endorsement: The owner expressed his satisfaction: "CASSMAN understood that for us, the fire is part of the recipe. They didn't just sell us equipment; they engineered a tool that allows us to paint with flavor. They helped us create a beer with a true Belgian soul."
The "Brouwerij De Leeuw" project demonstrates CASSMAN's ability to create highly specialized, custom solutions that honor the world's deepest brewing traditions. We understand that the choice of heating method is a critical creative decision, and we possess the engineering expertise to build systems that masterfully execute on that vision. For brewers who believe that the process defines the product, CASSMAN delivers the tools to forge a legacy.
For brewers who seek to master tradition, CASSMAN provides the fire.
