Pumping Success Into Your Brewery or Distillery

By: Gerald Dlubala

For breweries and distilleries, the beer and spirits that flow within drive business, but the pumps used to move that product can easily be considered the heart of production. If a pump fails, product flow stops and downtime eats away at production and delivery schedules. Having a quality pump lessens the chances of failure, so reliability and quality are key.

  Taking the time and effort to research the best pumps for the money and making a quality investment will make all the difference. “With the risk of sounding glib, you really do get what you pay for,” said Ross Battersby, Sales & Design contact for Carlsen & Associates. “There is usually a bit of a conflict between what the business accountant says is affordable and what the winemaker, distiller or brewmaster really wants and needs. The accountant almost always wins, but there is an inherent danger in selecting a pump on the basis of cost alone. Cheaper pumps may look fine on the outside, but they’re usually outfitted with cheaply made, low-quality blades and impellers, leading to a lot of internal shear that damages the product as it passes through the pump.”

  Carlsen & Associates started as a portable pump manufacturer for the wine industry, but now manufactures pumps for breweries, distilleries, meaderies, kombucha, soy sauce manufacturers, honey producers and various cannabis-related businesses. Their many years creating and tweaking pumps for multiple industries makes them uniquely qualified in recommending the right pump for a business’s needs.

  “We recommend a double diaphragm air pump with grounding tag for distilleries,” said Battersby. “With distilleries and high proof alcohol, you first and foremost need explosion-proof pumps. Compressed air powered pumps easily deliver the necessary amount of power for distilleries, and they’re perfectly fine for fluids, but if the distiller uses any botanicals, the pumps need to be screened off. You can safely use electrical-based pumps too, but they have to be rated explosion-proof, which sometimes makes them quite costly for what is really needed.”

  “With breweries, you’re talking about moving wort and heavier fluids with temperatures up to 210 degrees, so you’ll likely be looking at positive displacement pumps. Ours are Waukesha pumps, using winged rotors resembling ice cream scoops that spin around, scoop the optimal amount of product, and move it along without causing any crush or damage. They have capabilities of pumping as little as 30 gallons per minute up to 130 gallons a minute using one to three-inch lines.”

  Brewery systems and structures are more rigid and fixed, so the pumps tend to reflect that and perform better as a fixed system as well. Battersby told Beverage Master Magazine many brewers favor smaller centrifuge pumps that fit into these systems. In contrast, wineries will make better use of portable pumps that are on carts so they can move them around the different areas of the winery where needed.

  As far as new technology on the forefront, Battersby said hybrid pumps made by combining air and impeller pumps are currently being manufactured, but he doesn’t feel they will significantly change the industry. The real trend, according to Battersby, is what he calls “right-sizing.”

  “You can’t really get away from the tried and true technology,” says Battersby. “Business owners tend to go with whatever will give them the least amount of downtime. Many newer brewers don’t possess the type of physics background that allows them to know the best ways of moving liquids. They tend to think that more horsepower is always better, but that’s not true. It’s better to match your specific needs. So the new trend, as far as we are concerned, is right-sizing. We match the equipment up to whatever it is that you need to move.

  We educate brewers and distillers in the physics behind what they are trying to do, and why one piece of equipment is preferred over another, even if it’s not the most powerful. Additionally, we stress that the pumps are only as good as the hoses, clamps and fittings that connect to them. Right-sizing incorporates a quality pump with appropriate matching parts that are easily serviceable and repairable in the least amount of time.”

Matching Pumps To Product

  Paul Hail, CEO of Affordable Distillery Equipment, knows what reliability means in the brewing and distilling industry, so only offers quality equipment made to last a lifetime. Although based in the rural hills of the Missouri Ozarks, Affordable Distillery’s pumps are used in nearly 20% of craft spirit distilleries across the U.S. Hail recommends a few options for spirits production.

  “If you try to use a centrifugal pump with corn mash, the lifespan of that pump is probably going to be less than a year,” said Hail. “When moving corn mash, you have better options available. A double diaphragm air pump will work, but it will take a lot of air and a minimum of 1 ½  diameter connecting hoses. The pump is cheap, but the big expense—sometimes an additional $2,000-$3,000—comes with the need for a larger air compressor. A flex impeller type of pump is a great, moderately priced choice, but the impeller is a normal wear part, and depending on what type of material it’s manufactured from and the amount and type of use it receives, it could last months or only weeks. The loads it’s put through determines the wear and replacement needs. Your best choice would be a rotary load pump, but they are incredibly expensive so generally not an option for every smaller or startup distillery.”

  Hail, like Battersby, mentions the importance of safety when using a pump in the distillery. “You must remember, though, when moving high proof alcohol, you’ll need a grounding terminal on the pump to make it explosion-proof,” said Hail. “It’s not a likely scenario, but there is a minute chance that the rushing of a product while being pumped will manufacture enough static to potentially release a tiny spark. Couple that with high proof alcohol and we all know where that leads.”

  As Hail continues to run an industry-leading pump manufacturer, he told Beverage Master Magazine that it’s hard to come up with new ideas when pump technology has barely changed in generations.

  “You’ll hear about new things being tried around the industry, but when properly researched, those bright new ideas were usually already attempted by those before us. The reason that they’re not being done today is that they just didn’t work or weren’t economically feasible. Any new technology or methods would likely be groundbreaking if valid, and that’s what we are working on here at Affordable Distilling. Hopefully more about that in the future,” said Hail.

Improving On Current Equipment

  Based on their successful history with marine and industrial applications, AmpCo Pump Company in Glendale, Wisconsin, began manufacturing pumps specifically for the brewing, distilling and wine industries (https://www.ampcopumps.com).

  One chronic issue with pumps has been a tendency for the seals to leak eventually. Tony Krebs, Marketing Manager for AmpCo Pumps, said they have successfully addressed that issue in one of their most popular pumps, the CB+ Craft Brew Pump, specially designed for hot wort transfer.

  “Over time, the material being moved through the pump typically crystalizes, and that buildup will eventually cause traditional seals to leak,” said Krebs. “AmpCo’s CB+ Craft Brew Pump possesses an internal, submersed seal to promote cooling. Because it’s internally seated, any pressure increase caused by heat or flow creates an increased closing force on the seals to minimize any potential buildup. Additionally, the pump has an internal spring that acts as an agitator to reduce the solids buildup, thereby reducing crystallization on the seals. It’s an excellent choice for all sizes of breweries, but it’s an especially great match for the smaller brewpubs because on a cart, mobile and multi-functional. It can be used as a transfer pump in many areas around the facility, but it performs equally well as a clean-in-place pump. It’s not the cheapest pump you’re going to find, but when choosing a pump, it’s extremely important to be able to find certified, readily available parts and quality people to install those parts and repair your equipment. Downtime costs money, and when pumps are down, so is your brewing or distilling process.”

  AmpCo also makes pumps for the wine industry, offering their L series centrifugal pumps with the same exceptional quality, efficiency and durability as their counterparts designed for the craft breweries and distilleries.

  Krebs told Beverage Master Magazine that AmpCo is always at the forefront of pump technology, and regularly on the leading edge of trends in the craft brewing, spirits and wine industries. Krebs has recently noticed the need and increased demand for their portable hop induction units. This machine simultaneously induces dry hop pellets directly into the beer stream while recirculating the fermenter. It features AmpCo’s SBI Shear Pump and provides the brewmaster everything necessary to dry hop beer efficiently and safely within a single unit.

  “You can’t ignore the creative side of distillers, winemakers and brewmasters. They like to continuously mix flavor and ingredient profiles and provide experimental flavor combinations for signature blends, special tastings or customer trials,” says Krebs. “Blending pumps provide a better and more efficient way to get this done.”

How to Choose the Right Packaging Machine for Your Brewery

By: Alyssa Ochs

©Mitch Wojnarowicz Photographer
Schneider Packaging Equipment Co in Brewerton NY for ABC Creative group, Schneider Packaging Equipment Co and OEM Magazine


Craft beverage consumers are often quick to judge a book by its cover, or in this case, a beer by its packaging. The quality of beer comes first and foremost, but how a beer looks on retail shelves can also drive or sink a brewery’s profits. Packaging machines are useful to breweries for many reasons, including efficiently and attractively packaging beer and cans in cartons. Depending on the size of a brewery’s operations and its goals, these machines range from small hand machines to huge mass production models.

Uses of Brewery Packaging Equipment

These days, very few breweries are packaging their products by hand. Manual processing isn’t fast enough to keep up with demand, but unlike mechanization in the wine industry, there isn’t a strong stigma regarding breweries using machines.

For breweries, packaging equipment comes in the form of case packers and uncasers, can cartoners, case erectors and partition inserters. Innovative companies have developed robotic case packers to pack products into cases and trays, as well as multi-lane diverters to configure cans in the desired format for multi-packs. It may save time and labor if breweries use cartoners that convey, collate, and package cans into multi-pack cartons that are built and glue-sealed.

Meanwhile, other packaging machines work as case and carton sealers, stretch and shrink wrappers, and label applicators. Wrap-around tray packers are commonly used for beer bottles and cans, tray-formers are used for rollover locking, and open-top glue trays are used for 24-count trays of bottles or cans. Large brewery operations typically rely on fully integrated systems that include many of these features including product conveyors, uncasing, single-filling conveyors, lane dividers, dividing wheels, star wheels and sealing equipment.

Benefits of Packing Machines for Breweries

In the early stages of operations or for small and niche breweries, manual packaging may be the preferred operational method, or at least a good starting point. Packaging bottles and cans manually can serve as a preliminary method before growing and saving up for a more automated system. Temporary and transitional packaging services are available for breweries looking to outsource this type of work. However, having your own packaging line typically saves money in the long run and gives brewers greater control over their products.

Packaging machines provide breweries with speed, consistency and efficiency on their packing line, saving employees time and the brewery money. Packaging machines also help a brewery reduce packaging costs, ensure a more consistent appearance, and promote good hygiene to prevent beer contamination. Consistent, well-placed packaging can reinforce and strengthen a brewery’s particular brand and help establish brand recognition and loyalty among consumers.

Top Packaging Machines in the Industry

Packaging machines are used in a wide variety of industries, including food, beverages, pharmaceuticals, industrial products, and non-food consumer goods. In a market with so many choices, some companies now cater to the highly specific needs of breweries.

Based in Brewerton, New York, Schneider Packaging provides case and tray packaging, case sealing, palletizing, and complete end-of-line solution services for its customers. For the beverage industry, Schneider’s gable top packing solution is the stand-out solution designed to run at speeds matching the fastest filling systems. Meanwhile, Schneider incorporates FANUC robotics to create flexible palletizing solutions to meet facility and production requirements. The latest innovations used include ProAdjust technology to increase uptime, patent-pending Intelligent Illumination to maintain case packers, and the proprietary OptiStak software to optimize and simplify pallet generation. Other industries Schneider serves are dairy, food, industrial/chemical/household, paper, personal care/cosmetics, pharmaceuticals, and plastics.

Douglas Machine Inc., a packaging solutions company based in Alexandria, Minnesota, specializes in high-quality automated packaging solutions for paperboard, corrugated and shrink-film. Douglas is a 100 percent employee-owned company that has installed more than 9,000 machines in at least 30 countries.

“Douglas provides paperboard horizontal cartoning, RSC, and wrap-around case-packing and tray, shrink, pad/film and film only packaging machinery for the brewery industry at a variety of line speeds and configurations,” said Brenda Larson, Marketing Communications Manager at Douglas Machine.

Meanwhile, in Eugene, Oregon, PakTech is a full-service manufacturing company that delivers environmentally sustainable packaging solutions to the craft beer industry.

“Our handles are simple to grab, carry, and remove your product using a 100 percent recycled handle,” PakTech Sales Manager, Keenan Hoar, told Beverage Master Magazine. “PakTech’s minimalistic design and extensive color options highlight your brand and eliminate the need for obscuring artwork with other types of packaging.”

Hoar also said PakTech offers automated application versatility for flexible production requirements.

“You can apply the handles by hand if you’re a startup or have a limited volume requirement,” he said, “or you can utilize their automated applicators ranging in speed from 120 cans per minute to over 1,500 cans per minute if you have a higher speed operation.”

 Accutek Packaging Equipment Companies, Inc. is headquartered in Vista, California but has locations in Irving, Texas and Fort Myers, Florida as well. One of the largest privately-held packaging machinery manufacturers in the U.S., Accutek is a leading manufacturer and developer of complete turnkey packaging solutions. It offers consumers everything from filling to capping machines, conveyors, labeling and sleeving machines, and complete packaging systems.

Vice President Drake Chocholek told Beverage Master Magazine that Accutek often helps start-up companies make the best decisions for their operations. By partnering with a company experienced in this field, brewery owners can better assess whether potential packaging machines are easy to maintain, clean, adjust and upgrade.

“For example, a lot of new producers don’t know there are different grades of quality for glass bottles, or they may not know about bottle washers or rinsers used for cleaning containers before filling,” Chocholek said.

To take this a step further, Chocholek told us about the essential checklist his company uses to help new customers understand their full scope of operations and to make packaging simpler and more affordable.

“After we find out the product and container sizes, we ask them what their budget is, how fast they want the machinery to go, and if they’re in the market for more than one piece of machinery,” he said.

What Breweries are Using and Why

Aaron Williams of Monday Night Brewing in Atlanta, Georgia told Beverage Master Magazine his brewery specializes in brewing balanced beers for weeknights that pair well with food. Monday Night Brewing opened up its second facility, The Garage, in September 2017 to feature its barrel-aged, sour, and experimental beers. This addition came with an upgrade in equipment.

“We recently upgraded to a 24/4 CFT canning line that we are running at about 250 cans per minute,” Williams said. “We use hi-cone rings packed into trays because it uses the least amount of packaging.”

Meanwhile in Albuquerque, New Mexico, Marble Brewery’s president and brewmaster, Ted Rice, told us about the packaging system that his team currently uses.

“We use a 12-head CFT for canning,” Rice said. “From the CFT, the 12-ounce cans run to a Switchback cartoner for six or 12 packs. The cans can also run to an American Canning Machine PakTech applicator.”

However, finding the best options for machines that carton beer bottles and cans seem to be more of a challenge for breweries.

“Right now, we don’t do any bulk beers in cartons but are actively looking at machines to handle this in a more automated system,” Williams of Monday Night Brewing said. “There are many machines, but it doesn’t seem there is a clear winner based on conversations with other breweries. We currently hand-package our limited sampler packs.”

Douglas Machine may have the solution, however, since they offer a variety of cartoning machinery models that fit a wide range of canning and bottling line speeds and pack configurations.

“For lower speed lines, the intermittent motion Vantra offers an unparalleled speed of 40 plus cartons per minute with range capabilities offering of four to 24 count flexibility,” Larson said. “For higher speed lines, Douglas offers the Spectrum in many models for mid-high-speed lines with speeds up to 250 cartons per minute. The Vantra and Spectrum Center Select offer flexibility to run different diameter and height cans, while the cost-effective Spectrum Center Select offers mid-high-speed capability on a single can diameter capability at a very cost-effective price.”

How to Choose the Right Packaging System

As with every decision made in a brewery, owners must make considerations before investing in a packaging system. Short-term and long-term costs, ease of ongoing maintenance, opportunities for customizable design, integration with existing bottle and can filling systems, as well as choosing the correct machine size are only a handful of things to analyze before purchasing.

Breweries can also reduce their carbon footprint and sustain more eco-friendly operations if they choose packaging products made from 100 percent recycled materials.

“Our products provide an end market for recycled HDPE, helping the economy and environment by providing jobs and keeping plastics out of the landfills and oceans while providing a second life for recycled HDPE plastic,” said Gary Panknin, PakTech’s Sustainability Officer. “Our handle recycling program also provides the opportunity for breweries to participate in keeping our products in the recycling stream and out of the waste stream.”

According to Panknin, 102,592,428 milk jugs were kept out of landfills and repurposed into PakTech handles in 2018, and that’s only the tip of the iceberg. “In total, we have diverted 338,267,223 milk jugs from entering the waste stream, kept 20,973 tons of plastic out of the landfills and oceans, and saved 17.90-acre feet of land from being used as landfills for waste,” he said.

PakTech’s system isn’t merely a sustainability badge of honor, however. “The PakTech applicator makes our line far more efficient, and our operators do not experience wrist fatigue from manually applying the PakTech,” said Rice of Marble Brewery. “Having the Switchback cartoner allows our brands to have a clean billboard on the shelves. Using the PakTech allows us to run smaller volumes of seasonals in shrink sleeve cans without designing a carton with its associated costs and minimums.”

Williams of Monday Night Brewing suggests brewers ensure that any company they partner with for packing is credible and trustworthy.”I think the key is to really do your homework and ask around,” he said. “Find out who uses the equipment you’re interested in, what the manufacturer support is like, and if the manufacturer really will stand behind it for the long term. I’ve talked to many breweries that got a great up-front price on their equipment only to find the supplier didn’t really stand behind it.”

With this in mind, Mike Brewster of Schneider Packaging Equipment advises breweries “to do their due diligence on what they foresee their operation looking like in the future. Today, more than ever, consumer trends in the marketplace are changing at a rapid pace. With that, it is critical to align with a manufacturer who offers flexible and scalable solutions to assist you as your operation encounters changes.”

Concerning functionality, Hoar of PakTech said that his team looks at the fill rate when helping a brewery choose the right application for its operations. “It is extremely easy to manually apply PakTech carriers, yet the feasibility of doing so is all dependent on volume,” he said. “It is necessary to look at the cost of utilizing employees to apply the handle against the return on investment of our automated solutions.”

Hoar emphasizes the importance of packaging presentation as well because “by focusing on originality and creative expression, breweries have turned artwork into brand identity.” He also points out the need to know your brewery’s customers and consider portability and sustainability when choosing packaging products because many customers care about these things.

“We understand that many customers have a ‘pack it in, pack it out’ mentality, and we need to support the idea of a circular economy in any capacity,” Hoar said.

Finally, Larson of Douglas Machine recommends that breweries consider future packing patterns and configurations when specifying packaging systems for canning and bottling lines.

“Too often, brewers will select machinery based upon their immediate pack patterns or speeds, therefore buying a machine that cannot handle future pack patterns and speeds due to a lack of flexibility in some machinery offerings,” Larson said. “Additionally, the robustness of machinery is critical as brewers grow their operation and volumes increase to the point they need to add production shifts. It is imperative to consider the design and build design to ensure that a packaging system they purchase is robust enough to run multiple shifts, seven days per week. Initial low costs are long forgotten when experiencing poor or inconsistent performance.”

Customization Fosters Innovation: Choosing the Best Brewing Tanks

By: Tracey L. Kelley

Head Brewer Joe Kesteloot of Peace Tree Brewing Co. in its Des Moines, Iowa-based innovation brewery. Photo courtesy of Peace Tree Brewing Co.

The long game of brewing isn’t always obvious in the glass. Some producers spend up to two years evaluating what to brew and what equipment will craft the best product. There’s absolutely nothing wrong with this approach, but for brewers eager to get started or respond to an expansion demand, it’s critical to have a long-term mindset to produce creatively with fiscal responsibility.

When choosing tanks, especially fermentation tanks, there are numerous questions to answer before snapping up a standard model and placing it in the rack. The equipment in the brewhouse reflects as much about your approach as the end result: attention to detail and processes, ease of production and quality standards.

Patrick Mears is the sales and marketing manager for Marks Design and Metal Works, operating in Vancouver, Washington. Since 2008, Marks Design has specialized in designing custom stainless steel fermenters to brewers’ unique specifications but also fabricates brite tanks, cider tanks and other stainless steel vessels. Mears told Beverage Master Magazine the brewer’s personality, and approach helps inform his company to meet your needs.

“We’ve happily helped many groups who didn’t have a clue what they needed other than a produced volume and a budget. However, our expertise can be more useful if you’ve had a chance hammer out your vibe,” Mears said. “I know that sounds crazy, but it tells us a lot! Are you nerdy about beer and want extreme control over every aspect of the process and log all the data to look for trends? Are you super laid back and simply want to provide your neighborhood with an alternative to Applebee’s? Do you want to be innovative, or are you looking to perfectly reproduce old world beers?  Your brewhouse is an extension of you.”

For new producers, knowing what’s needed beforehand can be difficult. Evaluating potential tank requirements by nebulous considerations of volume, beverage, processes and other factors sometimes makes the choice more challenging.

  Joe Kesteloot is the head brewer at Peace Tree Brewing, Co. based in Knoxville, Iowa. Peace Tree, established in 2010, now has three taprooms in Iowa and an extended retail presence. They produced approximately 5,500 barrels in 2018. Kesteloot agreed the decision is tough, especially when “you don’t know what your flagship beer(s) may be yet,” but offered particular sources of insight. “It helps to get out in your market and talk to your potential customers, and weigh that information with your strengths. If you have a distributor, you ask what the market needs are. You can also look at the current market trends, but those trends are always evolving.”

Brewers should consider tank choices and sizes by determining, “some multiple of the brewhouse size,” said Bryan Boynton, Ph.D., brewer for Snake River Brewing, a brewery and pub located in Jackson, Wyoming. Established in 1994, Snake River is the state’s oldest brewery, and they now sell their beer throughout the U.S. The company produces an average of 8,000 barrels annually. “A 15 barrel brewhouse would lead to 30 or 60 barrel fermenters, bright tanks and serving tanks.” He suggested, “top manway tanks are ideal for all brewing styles, and especially important for ease of dry hopping; and tanks with racking arms that can rotate in the tank are ideal again for all styles, allowing for ease of transfer and filtering.”

Another consideration that factors into tank selection is the potential for multi-purpose use. William Stacy is the managing director of THIELMANN, a European company with U.S. headquarters in Houston. THIELMANN has produced containers for all types of products for more than 275 years, now with a particular focus on aseptic stainless steel tanks and kegs. In his brewery visits, Stacy said he’s continually impressed with the way producers ask double-duty of the company’s fermenters to maximize their investments.

“Some popular applications for our fermenter include brite tank, carbonation vessel and also a yeast propagation vessel. Large breweries use it for running small batches and test samples, and some even as a serving tank,” Stacy said. “This versatility and competitive price allow for the breweries to afford accessories and customization for the applications they require.”

Kesteloot sometimes takes this approach in the brewhouse. “One of my small-scale tanks doubles as a fermenter and a brite tank. However, I always transfer from fermenter to brite: I don’t ferment in it and leave it in there as brited beer. That tank rotates as one or the other function,” he said. “With most of my beers, I like to make sure they are off as much yeast and sediment as possible before serving or especially packaging.”

“I personally believe using fermenters as unitanks provides the most flexibility,” Mears said. He suggested buying the same amount of tanks as if you were pairing with brites, “but all the tanks would be conical fermenters. This way, your production doesn’t have to slow down because one of your brites are still full—you can just flip the fermenter to brite mode.”

While Boynton believes tanks can be multi-purpose in some instances, he offered a word of caution: “A fermentation tank doubling as a serving tank only works for certain styles of beer,” he said. “Most styles don’t allow for this combination. The removal of old yeast, dry hops and sedimentation that will push through to a consumer usually needs to be avoided.”

Stacy added that some producers intending to diversify their product lines often shop for tanks that can provide the most versatility. “Similar to root beer, sparkling or bubbling water is another offering brewers are moving into—filtering the water and just adding C02 to the tank prior to canning or bottling,” he said. “This is why we encourage brewers to think ahead about tank use and talk with their vendor about what type of kit specifications to accommodate other needs.”

Peace Tree Brewing Co. also crafts root beer, and often uses existing tanks for the process—but carefully. “We have designated hoses, carbonation stones and filler parts for root beer only. Many of those flavors can carry over to other brews, so we keep those pieces of equipment completely separate,” he said. “Even a mixing tank other than our brew system is used for root beer ingredients. Any tank used for root beer goes through a rigorous cleaning to remove any residue. This also applies to any sour beer we make with wild yeast.”

“If I Knew Then What I Know Now….”

The camaraderie of the brewing industry means the portal to quality information is always open. We requested our experts provide candid insight into tank, fitting and equipment decisions, and how they influence processes.

Boynton of Snake River Brewing stressed the significance of many factors. “Pressure Relief Valves (PRV) are very important for safety. If possible, buy tanks that are larger than expected brews to allow for a vigorous fermentation and not clog PRVs—which can lead to an explosion with grave consequences,” he said.

“Also, temperature probes that control the fermentation temperature need to be placed where one brew from the brewhouse is within its contact. If the first 15 bbl brew goes into the 60 bbl fermenter and doesn’t reach a temperature probe to turn on the cooling system, you have an uncontrolled fermentation,” Boynton said. “Finally, ease of cleaning without shadows, which are areas that the clean-in-place system doesn’t connect with well; and multiple zone cooling controls are the most important.

When asked what he wouldn’t do again, he replied: “No side manway tanks would have been purchased, and there was no need for conditioning tanks.”

Kesteloot of Peace Tree Brewing Co. seconded Boynton’s reference to temperature probes. “Probe location in fermenters and brite tanks are important. If you’re brewing multiple brews in a single fermenter, make sure the temperature probe is able to read the first brew, or maybe add multiple probes,” he said.

He also explained why tank shape and cooling jackets might matter to your processes. “We look at height-to-width ratios and cone pitch. Yeast can react differently in certain shape vessels. The right cone angle is necessary to collect healthy yeast,” Kesteloot said. “Even the way the cooling jackets are spaced or separated can help with certain applications. If you’re packaging from a brite tank and unable to finish the tank, the cooling jackets need to be located in the right spot to keep beer cold until packaging can resume.”

He added that learning how to accommodate Peace Tree’s expansion pointed to one crucial detail: “Anticipating the amount of cold storage we needed was a big challenge. It seems like we could always use more. Maximize the efficiencies in your processes as much as possible, so you have more wiggle room to be flexible later.”

Manufacturing experts Mears from Marks Design and Stacy from THIELMANN highlighted a fundamental but critical factor: bad tank quality reduces output and increases contamination.

“We offer field services in addition to tanks and systems, and have spent many field hours fixing tanks from other manufacturers that took shortcuts during fabrication or used low-quality material,” Mears said. “Within the past year, we fixed four 240 bbl fermenters at a single location! The tank manufacturer took shortcuts during fabrication, causing cracked welds on the inside of the tank within just a few years of purchase. Those cracks not only caused the tanks to leak precious revenue but also put the tank at risk of producing off-flavors due to the now unsanitary environment.”

Stacy echoed choosing a quality product and encouraged producers to “specify in tank selection aseptic characteristics and polished welds. This assures breweries that if operated properly, these aspects can reduce the risks of contamination. THIELMANN tanks, for example, are a fully aseptic design for easy cleaning with a simple spray ball,” he said. “We’ve recently seen some poorly-welded vessels in breweries and wineries. This substandard welding and lack of polished welds allow for severe risks with contamination.”

Invite the Vendors to Come to You

The nuts and bolts of tank decisions come down to what your vision is, and how well you communicate this to your equipment vendors.

Each producer has a different purchasing method—some buy tanks outright, using finance options that make sense within the guidelines of individual business plans. Others may lease or rent—an especially popular choice for seasonality spikes, short runs or additional product lines.

What does the typical fermentation tank cost? It depends. Establishing a base of $6,000-$7,000 or more per unit provides a launch pad, but what if the tank is multi-purpose? A standard brite tank may start at $2,500, but be as high as $6,000. Does this leave more wiggle room for additional equipment or change what you’ll produce? Should you utilize a turnkey system and work from that for a while?

Mears told Beverage Master Magazine that customization is what saves money in the long run. “The biggest mistake I see over and over is a brewer simply sending an email or filling out an online form and asking for a standard quote on a system,” he said. “If you take the time to have a conversation with us, we can put together a real quote that fits your specific needs. Explain what you really want, and if it isn’t in your current budget, we can help you decide what comes now vs. later.”

Stacy added: “We find budgets are a large factor, especially for new breweries. I would suggest they ask about the versatility of the systems. To be able to buy one piece of equipment and get three or four different uses out of it is a rare find,” he said. “For specification purposes, we have added many of the popular fittings and connections to make a tank a versatile, multi-use vessel. We also can customize the manways and connections to meet the specific needs.”

Producers that take advantage of customization find it allows for better operations. “We had vendors come to look at our space, and scale our square footage vs. ceiling height to maximize the most volume possible,” Kesteloot said. “They also examined our layout to see if things were going to flow from tank to tank, to packaging and out the door.

Based on increased demand, Boynton at Snake River Brewing said the company scaled up as needed. “We have a hodgepodge of tanks purchased through different sources.  The new large 60 barrel tanks we purchased are very nice.”

While no one can predict the future, these experts suggested using your objectives to determine tank needs. “Right now, with the popularity of IPAs, there are many specialized tanks for dry hopping as well as techniques for dry hopping in standard tanks,” Kesteloot said. “Breweries are using this equipment to maximize flavors and aromas. These are some things we’ll take into account in future expansions. We may even go backward in some applications and add some old, traditional methods.”

Maximizing budget. Providing quality products. Preparing for growth. It’s incredible to think your tank selection is a primary catalyst to accomplish these and other objectives. So take time and let the experts walk you through a set-up that fits your needs. “It’s important to brewers to be innovative, but it’s also important to be consistent and crank out the moneymakers,” Mears said. “Why not have a system that can do both?”

Canning Your Craft Brew

By: Robin Dohrn-Simpson

Marty Jones of Cask Global Canning Solutions has worked tirelessly for nearly twenty years convincing brewers that cans were the right way to package craft beer. He was one of the founders of Oskar Blues Brewery’s “Canned Beer Apocalypse” and remembers the pioneer days of canned craft beer. “I would serve canned beers at fests, and folks would walk by and wave and say ‘I don’t drink canned beer,’ and follow that remark with some additional misinformed comment, such as ‘Cans are bad for beer,’ or ‘Cans impart metallic flavors to beer.’ Many brewers thought we were nuts, heathens, committing sacrilege by questioning the long-revered brown bottle. A few breweries wished misfortune upon us! I always made a point to talk about the benefits of cans, not the negatives of bottles, and that helped to temper some of the backlash. Most consumers loved the idea.”

Many of those benefits include fitting in with into the younger generation’s more environmentally conscious and active lifestyle.

“Cans are welcome in loads of places where bottles are not,” Jones said. “They dramatically shrink shipping costs and energy consumption for shipped beer. They are Mother Nature’s preferred beer package and the most recycled beverage package on the planet. They make it super easy to take goose-bumping beer to the beach, the boat, the backcountry, the bathtub, and other places where beer is a treasured life enhancer.”

Cans also provide protection that isn’t necessarily guaranteed with bottles.

“Cans lock in the flavor of beer better than even dark glass bottles,” according to Mother Road Mobile Canning’s website, motherroad.com. “In glass bottles (especially green and clear ones) beer can become lightstruck, a condition caused when ultraviolet light breaks down hop-derived isohumulones, breaking them apart and allowing them to bind with sulfur atoms, creating a skunky, off-flavor. This flavor is so common that some people think the skunky character is a normal flavor in some beers. Oxidation is another problem for bottled beer. Bottle caps allow oxygen to pass into the beer making it stale.”

Cans provide a full 360 degrees chance for advertising as well, which according to Sarah Brennan, Marketing and Sales Coordinator for Palmer Canning Systems, “is a draw when you want your product to stand out on a shelf.”

Canned Beer Apocalypse

While working at Oskar Blue’s in 2002, Jones recalls, “We purchased Cask’s original tabletop one-can-at-a-time seamer/filler and became the first U.S. craft brewer to brew and can their beer. At that time a couple of craft brewers had beer in cans that was brewed and canned by others under contract.”

Jones and Oskar Blues went out of their way to make cans exciting, crushing stereotypes and creating the kind of beers that consumers wanted, attracting a following of beer drinkers who helped change the industry.

“For the first few years, I spent most of my time debunking the myths about aluminum cans and talking about the many wonders of cans, rather than talking about the beers we squeezed into those cans. That helped change the perceptions. We made a point of putting especially luscious beers into those cans, to inspire more craft beer lovers to give them a chance. That was super helpful, too,” said Jones. “Slowly, other risk takers took the chance on cans and started to reap the benefits and fast-rising sales. Nowadays the perception of cans in comparison to bottles has changed about 180 degrees. There are still a few can cynics and doubters out there, and people who simply prefer the feel and time-tested merits of bottles. But the most maligned and scorned package a craft brewer could once consider has now become the package of choice for many discerning brewers and beer drinkers. Brewers who swore they would never put their beer in a can have now added the mighty aluminum can to their packaging, or tossed out their bottles completely.”

Purchase vs. Mobile Canning Lines

There are many considerations when deciding whether to purchase, lease or rent a mobile canning unit. Mobile canning services are a great way to get into cans without any capital outlay. Many brewers start with a mobile canner and then eventually move to purchase their own canning lines.

Mobile canning lines offer the convenience of coming to you, no matter the size of your brewery. Every state has a variety of companies to assist you. The advantages of their systems are that they have provided the capital outlay for the equipment. Most mobile canning companies will help with inventory management of cans, ends, handles, case flats and off-site storage options. They focus on the canning so you can focus on the brewing.

However, with the rise in cans and use of mobile canners, some brewers find the service not quite worth it.

“While they can make your packaging very easy, their service comes at a cost. We often hear complaints that busy mobile canners are hard to schedule, and their quality control in terms of dissolved oxygen and product loss rates can be lacking, depending on the quality of the operator. Many brewers also don’t feel comfortable turning something as crucial as their packaging over to someone else,” said Jones.

For those canning less than 300 cases a month, mobile canning is often a great choice. However, for those filling 300 cases or more each month, it may be more beneficial to buy an in-house canning line. Often, an in-house system pays itself off within one to two years, and brewers have complete control over all aspects of packaging and filling.

“If you plan to put your product in cans for the long term, the point to purchase your own canning line is right away. The payback period on a purchase is two years at 300 cases a month and one year at 500 cases a month. On top of that, you’ll have full control over your packaging schedule and quality control program. At 500 cases a month, we have literally saved some customers thousands of dollars per month by helping them buy or finance their own canning system,” said Russell Love, President of Cask Global Canning Solutions.

Creating Your Canning System

Canning system manufacturers like Cask Global and Palmer Canning Systems work with breweries to ensure they make the right choice of canning line for their size, output and budget.

“As you build the system that works for your brewery, keep in mind that Cask offers systems that cater to all budgets down to the nano-brewery level and an entire range of systems from manual systems with as little as a two, three, six or 10-head fill stations systems. We can customize canning systems and accessories for just about any beverage type, and we also provide brite (unpainted) or printed aluminum cans to our customers as well,” Love said.

Palmer Canning System’s Brennan told Beverage Master Magazine that they can customize a system for beverages from beer, wine and coffee to energy drinks and infused juices. “The market is really dictating the rise of canning now. There has been so much data to support that canning your beverage is the better process for quality in things like total package oxygen and DOs. Canning is the way to go, we have just been a part of the steady incline of cans,” she said. “We fabricate fully customizable entire systems at our manufacturing facility in Lafayette, Indiana. We have no problem working with other vendors to incorporate ancillary items to a line, although we also design things like weight checkers and date coders in house.”

Palmer Canning offers fixed and mobile versions of Craft-in-Line can filling and seaming systems, as well as Craftbulk, an empty can de-palletizer; Wavegrip, an auto carrier applicator; Propurge, can filling valves; Craftrinse, an empty can rinser; and Craftdry blower systems.

Cleaning Your Cans

Whether you purchase a custom designed system or put together a variety of components that fit your brewery or a combination thereof, Carleton Helical Technologies has created a can and bottle cleaner suited for existing production lines.

“Our equipment is very versatile. We can easily integrate it into existing lines which is easier than developing a new line,” said Nick Carleton, President of Carleton Helical. “The beauty of our cleaner is that it is very simple to install and operate. It is very rare that we have to install or do start-ups, although we do offer the service. Our cleaner has been used in both can and bottling lines, providing easy change-over with our proprietary HP Inverters [that flip] the cans over for cleaning and back.”

Carleton Helical’s cleaners provide customers the option to clean with ionized air, water or any cleaning solution, starting at 10 cans per minute. “This system is also being used for code dating, flipping the can over for the code date and inspection. This provides a very simple method to place the cans in position for the code date,” said Carleton.

What’s on the Horizon

A trend that’s already common in the brewing world seems to be reaching out into the canning world as well: collaboration.

“We are seeing a real interesting growth in the collaboration space where breweries are partnering with other local craft beverage producers (coffee, cider, Kombucha, craft sodas or craft spirits, etc.) to provide affordable co-packing,” said Cask Global’s Jones. “We design all our canning systems to be very easy to switch between slim, sleek and standard diameter cans which allows a brewery the ability to run 250 mL slim nitro cold brew coffee cans or 12-ounce sleek Kombucha cans one day a week. It’s a great model for cool collaborations and also financial efficiency.”

Stop Contamination at the Door With Disinfectant Mats

By: Nelson Jameson

PRESS RELEASE

CONTACT: Melissa Pasciak | Director of Marketing

m.pasciak@nelsonjameson.com | 715-387-1151

FOR IMMEDIATE RELEASE

Stop Contamination at the Door with Disinfectant Mats™ from Nelson-Jameson

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To learn more about preventing cross-contamination in your plant with innovative selection of Disinfectant Mats and accessories, visit nelsonjameson.com or call one of our product specialists today!

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Petition for a Writ Far-fetched? Nope!

By: Dan Minutillo, APC

If a state regulatory agency with jurisdiction over the craft brew industry makes a decision that appears to be arbitrary and capricious, having a direct effect on your business, then, you have the right to petition a court for relief using a Writ of Administrative Mandamus. An unnecessarily fancy phrase meaning that a court of law reviews the administrative decision and decides if, under applicable law, the decision is not rational. Most times a writ is requested by an association or group of companies that are affected by the agency decision so that a positive result will affect many companies in the association or group.

STATE ADMINISTRATIVE AGENCIES

State administrative agencies with jurisdiction over the craft brew industry create policies that can affect your business. I recently wrote in this magazine about a Tennessee agency which passed a regulation indicating that only people domiciled in Tennessee for a certain time could get a permit to sell alcoholic beverages in the State.

For the purpose of this article, let’s say that an administrative agency in California, like the California Department of Alcohol Beverage Control (ABC), passed a regulation indicating domicile restrictions to get a permit to sell craft beer om the State; that a company had to be in business in the State for ten (10) years and then that company could sell alcoholic beverages. This regulation is then challenged by you as arbitrary and capricious at the agency level, and the agency denies your challenge.  You argue that this domicile restriction is illogical, with no purpose other than to discriminate against out of state craft brew companies. You lose at the agency level, that is, the ABC reviews your challenge and denies it.

THE APPEAL; THE WRIT

That administrative decision (the denial of your challenge) by the ABC can be appealed to a court by “writ”, and you, the appellant, will win and ensure that this decision and underlying regulation is stricken if you can prove that the decision and underlying regulation is arbitrary, that is, without a rational basis.

So, there are a few criteria to get you into court to have the ABC decision (the denial of your challenge) reviewed and to win on your writ:

  1. That the decision/regulation was made by an “administrative agency” of a state (or of the Federal government), like the California ABC;
  2. Normally, that you have exhausted your administrative remedies. This means that if there is a method of appeal at the ABC, then you must first make that appeal and follow all other procedural rules regarding an appeal at the ABC before you bring a writ.
  3. That all of your ABC remedies have been exhausted and denied, and this denial must usually be in writing by the ABC (evidentiary issue).
  4. That you have standing to be heard by a court. Standing means that you are a “party in interest” which usually means that you, that is, your business has been affected by this ABC regulation/decision. You have standing if you will be or have been damaged by the regulation or decision. For example, if I teach math to high school students in a local school, I would not have standing to bring a writ in this circumstance because the ABC regulation/decision does not affect me. But, if you make or sell craft beverages, this regulation/decision does affect you, so, you have standing to bring the writ.
  5. That any applicable statute of limitation has not run. Most actions brought in a court of law must be brought to the court before a certain time period, that is the statute of limitations. Various statutes limit the time in which you can bring certain actions. Some statutes are as short as ninety (90) days from the time of the ABC denial of your challenge.
  6. That you can prove that the decision/regulation was made by the California ABC in an arbitrary and capricious manner, that is, there is no basis in fact or law to support the decision (the denial). It was whimsical and therefore an abuse of discretion by the ABC. The case law language is that a court on a writ will not disturb the ABC’s decision absent an arbitrary, capricious, or patently abusive exercise of discretion by the ABC.

THE STANDARD

Some courts call this a “rationality review”. Is the regulation/decision rational, that is, justified in fact and in law. No matter how you look at this, the key here is that the ABC did something that has damaged you and, after exhausting your administrative remedies, you are able to prove that the ABC’s decision is arbitrary and capricious—and you win.

THE REMEDY

I will discuss remedies, that is, what decision a court could make on a writ and how it could affect you, in a later article for this magazine.

Dan Minutillo has lectured to the World Trade Association, has taught law for UCLA, Santa Clara University Law School and their MBA program, and has lectured to the NPMA at Stanford University. Dan has lectured to various National and regional attorney associations about Government contract and international law matters. Dan has provided input to the US Government regarding the structure of regulations. He has been interviewed by reporters for the Washington Post and other newspapers.