Author: Cyndi

By: Cheryl Gray 

Whether a small craft brewery or a large-scale operation, pumps play a vital role in making beer. While breweries large and small understand the invaluable relationship between pumps and products, such a capital investment begs the question, “Which pump is best?”  

  Pumps are used in breweries for a wide range of functions, from handling yeast to managing filtration to dispensing measured doses of additives. According to industry experts, the most popular pumps are the most versatile, meaning they can be used in multiple areas of a brewery operation. That math adds up to money spent that can result in a solid return on investment when it comes to improving a product, boosting productivity and lowering operating costs.     

  FLUX Pumps Corporation has spent 70 years being a global leader in making pumps used in virtually every industry, including craft brewing. Its six subsidiaries and a huge roster of distribution centers give FLUX the capability of servicing customers in more than 100 countries.    

  The company’s innovation streak began in 1950 when it earned a patent for the world’s first electric-powered drum pump. A year later, FLUX introduced the first explosion-proof drum pump designed to be used in hazardous areas. In the years since, FLUX has firmly established itself as a frontrunner in drum and container pumping technology. The company’s global headquarters and manufacturing plant is located in  Maulbronn, Germany. It also operates corporate offices in the United States, India, Thailand, France, United Kingdom and Belgium.  

  Glenn Mulligan is the President of FLUX. His product advice, he says, is the same for all craft breweries, no matter whether it is a start-up or an established operation.    

  “Whether a new or old facility, I would offer the same advice to both customer types: Product longevity and performance is critical. Performance keeps your process running efficiently, perhaps even helping to increase productivity by moving away from tasks operators had to complete by hand. Product longevity helps to keep operating expenses low, which increases the bottom line. When you are using a pump, which offers an overall cost of ownership second to none, you know you have the right equipment in place. Don’t let drum pumps become ‘throwaway’ equipment.” 

  Mulligan shares why FLUX products are a versatile choice for breweries:   

  “By default, the most popular products in the brewing industry are those which conform to sanitary and hygienic standards. Brewing customers need to meet the strict sanitary standards of food and beverage processors, but typically also need the flexibility to use their equipment in various areas of the facility. Simple product disassembly, assembly and cleaning are crucial to minimize downtime and increase productivity.  

  From versions that can handle thin, water-like products, to models which can pump honey, fruit purees and products as thick as peanut butter, FLUX has the solution you need. Some models can quickly and easily be broken down into two main components for cleaning. This allows a pump to be used in multiple areas of the facility.”   

  Mulligan cautions craft breweries against investing in pumps that may seem simple to operate and don’t cost much. What might be a bargain at first sight, he says, can quickly become a drain on finances as well as valuable production time.    

  “It is a common misconception that air-operated, double-diaphragm pumps are best suited in these applications due to their cheap costs and simple operating principle. However, these pumps can very quickly become expensive to maintain as well as run with compressed air. A recent brewing customer had purchased one of our units to move a fruit puree from 55-gallon drums into their process. They were using 1.5” air-operated, double-diaphragm pumps to transfer the puree, which would take about an hour to empty the drum. When they switched over to FLUX progressive cavity drum pump technology, this transfer time was shortened to under six minutes.” 

  Watson-Marlow Fluid Technology Group is another global leader in providing pumps to the craft brewing industry. The company, based in the United Kingdom with operations worldwide, was founded in 1956. It entered the United States market in 1991 by establishing Watson-Marlow, Inc. The company offers a broad range of peristaltic and sinusoidal pump products designed to handle nearly every pump requirement for every stage of brewing.    

  Among other features, the products boast a rapid cleaning time and simplicity of use. Watson-Marlow explains that by reducing CIP cycles, along with the amount of water and cleaning agents needed, its pump designs save breweries money over time.    

  Pumping brewer’s yeast is a tricky business. One wrong move can ruin the delicate yeast and, in turn, an entire batch of beer. That’s why a number of breweries are looking for the latest technology in pumps that offer features that provide, among other things, low shear and low pulsation, which experts say is ideal for transferring yeast. Watson- Marlow offers its MasoSine Certa 100 pump. The product is fully portable and mounted on a specially designed cart for easy transfer of yeast. Unlike more traditional pumps with rotors cutting through the fluid, Certa’s sinusoidal rotor gently moves fluid through the pump to significantly reduce shear. Russell Merritt is the company’s marketing manager. 

  “Certa sine pumps accurately dose the yeast while maintaining its quality. Certa pumps reduce shear damage to yeast cells by eliminating backflow seen with screw and lobe pumps. Also, with the high suction capability of the sine pump, even challenging yeast strains can be transferred at full capacity. Due to the virtually pulsation-free flow, the transfer rate at the yeast harvesting pump can be accurately controlled. Certa pumps can handle variable viscosities with ease, which means the yeast dosing process is under control regardless of the type of beer and yeast strain.” 

  Another key function of pumps in brewery operations is resolving wastewater, which is often injected with chemicals not environmentally friendly. As such, that wastewater has to be filtered and purified before it is discharged.  

  Blue-White Industries, Ltd., based in Huntington Beach, California, touts a solution through its Flex-Pro A2, a peristaltic chemical metering pump designed to tackle the kind of harsh chemicals found in brewery wastewater.    

  Among the company’s success stories in helping brewery clients achieve optimal wastewater treatment is California’s Stone Brewing, the ninth-largest craft brewery in the U.S. With brewery operations on both coasts, Stone Brewing celebrates its 25th anniversary this year. It recently installed four of the Flex-Pro A2 pumps. Blue-White says that the product’s ease of use and electronic features offer the kind of precise chemical metering that Stone needed to meet industry-standard wastewater purification requirements.    

  Carlsen & Associates, a family-owned business based in California’s Sonoma Valley, services wineries, distilleries and craft breweries. The company, founded in the 1980s by Jim Carlsen, is a manufacturer, fabricator and customer service enterprise with representatives covering all 50 states. Carlsen & Associates thrives on the industry knowledge base of its founder, whose background as a manager and electrician helped to distinguish the company’s products as those with precision and ease of use at the forefront of all design.   

  Jon Johnson, who has been with Carlsen & Associates for 24 years, is well-versed in the pump needs for brewery clients. He offers some recommendations from the company’s extensive product line, starting with the Waukesha 30, which features single o-ring seals for easy cleaning and replacement, stainless steel housing and rotors, along with 50-foot remote speed control.  Additional options include pressure, float and timer controls.   

  The  features a flow of up to 90 GPM, variable speed control, pressures up to 20 psi and auto cavitation correction. Options for this pump include float and timer controls as well as remote start and stop. Johnson says that both products rate high with craft brewery clients.   

  “For brewing, the Waukesha 30, for barrel work and transfer, is very popular. The Waukesha 2045 Centrifugal is primarily for transfers. A less expensive option for start-ups is the NDP-25 air diaphragm pump. Both will provide about 30 GPM of flow. The Waukesha 30 and the Centrifugal 2045 are electric and can be used in single or three-phase applications. The NDP-25 does require an air compressor to provide its power. For distilling applications only, the air pump can be used in the explosive environment. Please check your local codes for these restrictions. We also offer a full line of valves, fittings and hoses for either application.”  

  Time spent on research is one of the most critical investments for craft breweries when deciding which pump is best for any operation, large or small. Experts agree that a full consultation with an industry specialist is by far the wisest upfront investment that a brewery can make before any money is spent. This important step ensures that the brewery can fully assess pump needs for the long and short term and, with the help of an expert, can objectively navigate through the innumerable pump options on the market. It is the best way to look forward to a return on investment into an essential equipment item that should operate to maximize production efficiency and product quality. 

By: Gerald Dlubala

An engineer, architect and brewmaster walk into a brew space. No, this isn’t the beginning of a joke, but rather the start of a multi-point approach in laying out a successful and reliable grain handling and storage system.

  ABM Equipment works with brewery owners and brewmasters to develop their projects from concept to completion. They use collaborative teamwork and deliver cohesive systems integrated to work together as a complete unit rather than a group of individual machines pieced together. 

  “When you understand the effects that your grain handling and storage system has on your entire brewing process, you realize how important it is to be one of the initial items discussed when laying out a brewery,” said Adam Dubose, Operations Manager at ABM Equipment. “Proper grain handling and storage planning include considering the entire brewhouse and production plans while remaining aware of available space. When all of these things get included early in the planning process, it becomes easier to determine the needed specifications regarding storage options, handling capabilities and system speeds versus available space. Then you factor in expected growth and go from there.”

“We always like to see a brewer mill their grain if possible,” said Dubose. “Pre-milled grain is crazy expensive, so even a small mill with a flex auger is better than using a pre-milled product. You can control crush, increase safety and improve your time and labor costs. Instead of shouldering bags and risking physical injury, you push a button. Most breweries now have a grist case as well. Then you can start talking about bulk storage to cut costs even more dramatically – sometimes in half – over the use of bulk bags. Your return on investment includes cutting physical labor, saving workers’ shoulders and the savings on buying at bulk prices.”

  In terms of brewery installations, almost all of their projects use either flex augers or chain discs for conveyance. “Flex augers are the usual choice for entry-level applications because they are the low cost, reliable choices,” said Dubose. “Their downside includes higher required maintenance, meaning that they need to be oiled more often and will likely require routine elbow replacement after about six months, depending on use. We remind our clients that if they don’t schedule a little downtime to maintain their equipment, the equipment will schedule it for them. Chain discs are a popular go-to method for grain and malt conveying because they’re versatile, run a little quicker, maneuver tighter corners and are gentler on the product while moving it from place to place. Chain discs can connect silos, handle long runs, vertical climbs, bulk bag unloaders or specialty hoppers. The same chain disc line can carry infeed to mill and then loop back around and go from mill to mash. They are also lower friction options, so that translates into lower wear in parts.”

  Dubose told Beverage Master Magazine that silos provide the most significant savings and return on investment when considering grain storage options. Larger bulk purchases translate to a lower price point, offer more opportunities for system automation, better grain consistency, longer storage times and the chance to free up some valuable indoor floor space.

  “We recommend silos with a minimum 65,000-pound capacity so a brewer can receive a typical 48,000-pound grain delivery without having to run their silo dry,” said Dubose. “Larger capacities are available if desired. Bigger may be better when it comes to needing only limited grain deliveries, but it’s more common to link silos for the additional capacity and then use an automated sourcing system. With more than one source available, a brewmaster can mix the contents of multiple sources for new, seasonal or different mixtures and recipes. We can link up to eight sources from one system, allowing the brewmaster to choose which product is needed and from which source. Quality stainless-steel silos have a minimum 20-year life expectancy with proper maintenance, which usually means keeping them touched up with paint to reduce any chance of corrosion. Silos situated closer to saltwater or in coastal locations normally get a paint upgrade to help reduce the corrosive effects of saltwater. Our silos feature smooth walls to deter any grain from getting stuck and deteriorating or rotting, and we manufacture our gates for excellent dust inhibition. We reduce the need for ladders with built-in level indicators, and we help navigate any municipal restrictions by using creative workaround strategies. For brewers that use bulk bag grain, bulk bag unloaders are available in an easily installed, low-profile form. They can use a hoist and trolley configuration to help reduce grain costs and labor through efficient use of super sacks.”

  Spent grain is a related yet separate issue, requiring its own storage area. Spent grain storage should alleviate the mess of raking or shoveling the spent grain into totes and moving them to outside storage by forklift or pallet jack. The type of storage needed depends on the number of daily brew cycles and anticipated spent grain pickups. Spent grain silos are also constructed of stainless steel to fight corrosive contents, but they’re usually not polished like the more visible grain storage units and are elevated for truck access either underneath or along the side. If using a silo for spent grain storage, the brewery may require an additional pump at the mash discharge to get the spent grain over to the silo.

  Dubose told Beverage Master Magazine that it’s crucial for a brewer to partner with a grain handling and storage provider that works within the brewery’s desired layout and approaches it in a complete system mode versus a supplier that sells and provides only equipment and nothing else.

  “We look at all facets of the operation and the speed and throughput of your process to make sure it all works in unison. Control panel automation helps brew consistency and labor control, but it’s also a way to keep your equipment from damaging itself. A brewer has to know their limitations regarding their knowledge in certain areas, and they have to partner with a supplier that will work with them as if it is their own business. Another thing to look for is a supplier that carries spare parts in their inventory like chains and gearboxes to help out when the OEMs don’t have the part. We at ABM Equipment will do that for our clients.”

  “It’s really about taking the brewery’s concept, including the amount of storage or bulk bag storage needed and projected, and then providing the proper mix within the space allotted,” said Dubose. “A workable and successful layout within a brewery’s space and allotted budget ultimately dictate our recommended conveyance and storage design.”

Good Planning Leads To Proper Handling Equipment and Right Sized Grain Storage

  “In so many cases, having adequate space to store enough grain inside the brewery is often overlooked, and you see a variety of bags and pallets placed wherever they can fit,” said Dave Ewald, Director of Sales for Bratney Companies, providers of state-of-the-art equipment, processes and solutions for their clients. “The layout and choices for grain handling and storage should be done in the initial planning stages of the brewery. Then, with more planning and forethought, an area can be designed to store the brewery’s grains in an organized and efficient manner.”

  Knowing what your planned and projected grain usage will be in conjunction with what the expected lead times are for deliveries goes a long way to dictating what type of storage is necessary. Upgrades can include silos, conveyors with floor dump hoppers, bulk bag dump stations, and more. These save time and minimize physical labor like bag hauling and ladder or stair climbing.

  “Conveyor types range from simple, flexible conveyors to chain disc systems to drag or screw-type conveyors. Conveyor mechanics typically include either a screw type, helical coil type or disc system that runs by chain or cable. Each has benefits and treats the grain differently while conveying,” said Ewald. “The key factors in determining the best conveyance solutions come back to the capacities needed, distances to convey, the number and complexity of the rises and runs to get the malt from point-to-point, and the ability to still facilitate a good cleanout between malt types. For example, leftover dark malts mixed in with pilsner malts will affect the color and taste of the beer.”

  “The capacity needed by any brewery is largely determined by the brewery size and the capability of their roller mill,” he said. “Many mills run between 1,500 and 3,000 pounds per hour and run a simple flex conveyor or chain disk system. Flex conveyors are quite simple in their design and construction, usually featuring tubing constructed from PVC or steel. It is fair to say that many breweries only operate their conveyors once or twice a day for a couple of hours, so the system’s longevity is naturally extended. On the other hand, breweries that run several batches would look for longer-lasting and more durable solutions. It really is a balance between needs and overall cost.”

  Ewald told Beverage Master Magazine that storage most often falls into the use of a hopper-bottomed silo to hold a truckload of malt. Suppose a brewery can get their grain by the truckload. In that case, they enjoy the economic advantages of buying in bulk, and the higher initial investment in the equipment is usually recovered in a relatively short time. Likewise, with conveyors, the brewer can slow a conveyor system down to handle lesser capacity if needed. For example, if the conveyor runs 4,000 pounds per hour, the brewer can alter and decrease that through a frequency variator or drive system change. Conversely, the brewer can’t modify a 2,000 pound an hour conveyor to run twice the speed, so if they can afford the higher speed systems upfront to match their planned production increases, it’s a better option.

  “Most applications are pretty straightforward,” said Ewald. “Working with an equipment provider on the head end of your brewery planning and knowing what considerations need addressing upfront goes a long way in ensuring a successful, properly sized and reliable system. For example, a case in point might be if the conveyor runs overhead across the taproom or restaurant portion of a brewery. The last thing you want in an area where patrons should be enjoying themselves with your food, conversation, and your beer is an excessively noisy conveyor.”

  When the economics of buying in bulk versus bags make sense, that’s generally when changes, including expansion, take place. Ewald said it’s not too difficult to make a case for a brewery producing as little as 1,500 to 2,000 barrels per year to justify the expense of a silo and slab and be able to recoup that cost in less than a year. From that point on, the cost savings goes right into the brewery’s bottom line. A brewer should inquire with their malt providers to confirm the exact savings point on a per pound basis and see if there are any partnership incentives available through the supplier to help obtain a grain storage silo.

  “I suggest that a brewer engage a company that has the history and knowledge to be able to discuss overall plans and can look at their entire grain handling and milling systems,” said Ewald. “Being able to provide and take responsibility for a total solution versus looking at one piece from one manufacturer, another from a different supplier and so on, is critical. It is often the little things in a brewery’s overall flow that get overlooked, like transitions, gates, spouting and the system control interface.”

  “Another consideration,” said Ewald, “Is after all the fun that comes with grain conveyance, milling, and brewing, you’re then going to have to deal with the spent grain. So it’s best to have an idea of how much spent grain will be stored, the time that it will be in storage, how it is going to be moved out and where it will be going. [These are] all things to think through before you brew that first batch of goodness.”