Author: CASSMAN Publish Time: 2025-09-05 Origin: CASSMAN BEER BREWING EQUIPMENT
Project Title: Engineering a 7BBL "Production Pro" System with ASME Certification for a Colorado Brewery's Expansion
Client: "Elevation Brewing Works," a partnership of experienced brewers ready to scale up from a small pilot system to a full production facility focused on canning and local distribution.
Location: Boulder, Colorado, USA
In the craft beer heartland of Boulder, Colorado, simply making good beer isn't enough. To succeed, a brewery must produce exceptional beer with relentless consistency and efficiency. The founders of "Elevation Brewing Works" knew this well. After perfecting their recipes on a small pilot system, they were ready to launch their brand into the competitive local market. Their business plan depended on a production brewery that could not only produce high volumes but do so with precision and reliability, enabling them to secure distribution deals and keep the shelves stocked.
Scaling from a pilot batch to a 7BBL production system introduces a new level of complexity and higher stakes. The client's success hinged on overcoming these critical factors:
Throughput for Distribution: To be profitable, they needed to brew multiple times a week, often performing two batches in a single day ("double-batching") to fill their larger 15BBL fermenters. This required a brewhouse designed for speed and efficiency, not just capacity.
ASME Certification for Safety and Compliance: The brewery planned to use a powerful steam heating system. In the US, steam-jacketed pressure vessels often require an ASME (American Society of Mechanical Engineers) stamp for insurance and state regulatory approval. This is a rigorous certification that signifies the highest level of industrial safety and build quality.
Consistency Through Automation: With a small brewing team, manually hitting precise mash temperatures for multiple batches a day is a recipe for inconsistency and burnout. They needed a system with smart automation to ensure every batch of their flagship IPA was identical.
Planning for Future Growth: Their initial plan included four fermenters, but they knew they would need to add more within two years. The brewhouse, glycol chiller, and overall layout had to be designed to accommodate this future expansion without requiring a costly overhaul.
CASSMAN delivered a comprehensive solution engineered specifically for efficient, repeatable production brewing.
Key System Features:
High-Efficiency 3-Vessel Steam Brewhouse: The core of the system was a 3-vessel configuration: a dedicated Mash Tun, a dedicated Lauter Tun, and a combination Kettle/Whirlpool. This design is built for speed. It allows the brewer to begin mashing a second batch while the first batch is still boiling, making double-batching in a 10-hour day a standard procedure.
ASME Stamped & Registered Vessels: The steam jackets on both the Mash Tun and Kettle were engineered, inspected, and stamped in accordance with ASME code. We managed the entire process, providing the client with the official "U-1" forms required for registration with the National Board, ensuring a smooth and successful state inspection.
Semi-Automated Brewhouse with Step-Mash Programming: The Siemens PLC control panel allowed the brewers to program and save their entire mash schedule. The system automatically controlled steam flow, pumps, and rakes to execute complex multi-step mashes, hitting temperature ramps and rests with digital precision. This freed up the brewer to focus on other critical tasks during the brew day.
Future-Proofed Utility Sizing: We supplied a glycol chilling system with the capacity to handle eight 15BBL fermenters, double their initial cellar size. The brewhouse layout and utility drops were also planned to make the addition of future tanks a simple "plug-and-play" operation.
Our process was designed to de-risk the client's expansion and set them up for success.
ASME Compliance Management: We worked hand-in-hand with the client and their consultants from day one, ensuring the vessel designs and documentation would meet Colorado's specific requirements. This proactive approach prevented any last-minute compliance headaches.
Detailed Utility and Layout Schematics: We provided a full set of P&ID (Piping and Instrumentation Diagrams) and 3D layout drawings. This allowed the client's local contractors to prepare the facility's steam, water, drain, and electrical connections perfectly before the equipment arrived.
Hybrid Installation & Commissioning: To provide the best value, the client used a local rigging company to set the tanks. We then flew in a CASSMAN-certified US-based technician for three days to perform the critical final commissioning of the steam system and PLC, and to provide hands-on training for the brewing team.
Workflow Optimization: The system layout was designed with a logical flow from grain-in to packaging, placing the brite tanks in close proximity to their future canning line to minimize beer loss and labor.
The CASSMAN system became the engine of Elevation Brewing Works' successful launch and growth.
Production Targets Exceeded: The 3-vessel brewhouse allowed them to easily produce 14BBL of wort (two batches) in a single day, enabling them to keep their fermenters full and their production on schedule.
Passed Inspections, No Delays: With the official ASME documentation in hand, the brewery passed its critical pressure vessel and safety inspections on the first attempt, a major victory that kept their opening timeline on track.
Unwavering Product Consistency: The automated mash profiles resulted in highly consistent wort, which was crucial for building brand loyalty for their canned beer. Their flagship IPA quickly became known for its reliable quality.
A Foundation for Growth: The founder commented, "In a market like Boulder, efficiency isn't a luxury; it's a survival tool. CASSMAN delivered a brewhouse that is our production engine. The ASME certification was seamless, and the ability to double-batch consistently is the reason we were able to sign with our distributor in our first year. This system was built for a real production brewery."
The Elevation Brewing Works project showcases CASSMAN's expertise in engineering brewing systems for growth. We understand that scaling up requires more than just bigger tanks—it requires a smarter workflow, uncompromising compliance, and a clear path for future expansion. By providing high-efficiency, ASME-certified systems with intelligent automation, we give ambitious brewers the powerful and reliable tools they need to compete and win in the demanding American craft beer market.
For brewers ready to scale, CASSMAN engineers the pathway to production.
