Author: Henry Chen Publish Time: 2026-02-02 Origin: Jinan Cassman Machinery Co., Ltd.
A shiny new brewhouse is a thing of beauty, but a well-maintained brewhouse is a profit-generating machine.
For brewers using Direct Fired Brewhouse Systems, consistency in the glass starts with consistency in the flame. While gas-fired systems are renowned for their robust heating power and simplicity, they require specific operational protocols to ensure safety, efficiency, and longevity.
Whether you are a startup brewer or a veteran brewmaster, this guide covers the essential "Standard Operating Procedures" (SOPs) for keeping your Cassman gas system firing on all cylinders.
Operating a direct fired kettle is slightly different from steam or electric. It involves managing a live flame. Here is how to optimize your brew day.
The most common fear with direct fire is "scorching" (burning the wort on the bottom).
The Golden Rule: Never fire the burner unless the kettle is full and the agitator (mixer) is running.
Why: The bottom of the kettle gets extremely hot. The agitator ensures the wort moves constantly across the heated surface, distributing heat evenly and preventing sugars from sticking and burning.
Soft Start: When you first ignite the burner, start at a lower percentage (if modulating) for 1-2 minutes to allow the steel to expand gradually.
Full Power: Once the flow is established, you can ramp to 100% to reach a boil quickly.
The Cassman Advantage: Our Direct Fired Systems come with pre-programmed PID controllers that manage this ramp-up automatically, reducing the margin for human error.
Simmer Control: Once you hit the boil, dial the burner back. You only need enough energy to maintain a rolling boil (usually 30-50% power). Running at 100% during the boil wastes gas and increases evaporation too much.
Preventative maintenance is cheaper than emergency repairs.
Visual Flame Inspection: Look through the sight glass. The flame should be blue and steady. A yellow or orange flame indicates poor combustion (lack of air) and will create soot.
Internal Rinse: After the brew, inspect the bottom of the kettle. If you see "beer stone" or protein buildup, perform a hot caustic soak immediately. A dirty bottom acts as an insulator, reducing efficiency and causing hot spots.
Check Air Intakes: Ensure the blower fan on the burner is free of dust and grain flour. Blocked air intakes are the #1 cause of burner failure.
Inspect Gas Lines: Use a soapy water solution to check for micro-leaks at connection points. Safety is paramount.
Burner Calibration: Just like a car, a gas burner needs tuning. Have a local HVAC technician check the gas pressure and air-to-fuel ratio.
Flue Inspection: Check the exhaust stack for any obstructions or soot buildup.
Even the best machines have occasional hiccups. Here is how to solve common direct fire issues.
Issue | Possible Cause | Solution |
Burner won't ignite | Air in gas line / Low Airflow | Purge the gas line. Check if the blower fan is spinning. Reset the controller. |
Soot on Kettle Bottom | "Rich" mixture (Too much gas, not enough air) | Adjust the air damper on the burner to increase oxygen flow. |
Wort Scorching | Agitator off / Heat too high | Always run the mixer. Lower the max output percentage on the VFD/Controller. |
Slow Heating | Low Gas Pressure | Check your facility's regulator. Ensure other equipment isn't starving the line. |
One of the biggest worries for brewers is, "Where do I get parts?"
When you buy from a reseller, you often have to wait for them to contact the manufacturer. When you choose Cassman Factory Direct, you have a direct line to the source.
Spare Parts: We recommend purchasing a "Critical Spares Kit" (igniters, flame sensors, relays) with your initial order.
Remote Support: Our engineers can guide you through troubleshooting via video call, helping you diagnose burner codes instantly.
A Direct Fired Brewhouse is a workhorse. With simple, regular maintenance, it will serve your brewery reliably for decades. By keeping the burner clean, the agitator running, and the kettle polished, you ensure that every batch of beer tastes exactly as you intended.
Maintenance isn't a chore; it's an investment in your product quality.
Whether you need a spare part or advice on burner tuning, we are here to help. Contact Cassman Support.
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