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Thermal Processes in a Brewery

Last updated on July 25, 2025

Modernisation and efficiency in beer production processes.

The main objective of this project was to reduce energy costs, pollutant emissions, and ensure the continuous operation of production processes, avoiding downtime due to failures.
The initial starting point was to calculate the heat demand for each process, disregarding the power of combustion boilers, as current heat generation technology using electricity is more efficient and the power of electrical equipment is lower, as is the demand on the electrical grid.
The thermal processes analysed: Beer pasteurisation; Beer fermentation; Bottle cleaning; and Fermentation tank cleaning.
BEER PASTEURISATION AND FERMENTATION
The power required for the pasteurisation process is calculated by multiplying the number of litres pasteurised per hour by the thermal increase from 10 to 70 °C, with a correction factor of 60%. The beer exits the pasteuriser at 33 °C.
As an example, if 10,000 litres of beer are pasteurised per hour, the required power is 279 kW. Other processes are calculated in a similar way, taking into account volumes, temperatures, and operating time.
BOTTLE AND FERMENTATION TANK CLEANING
For bottle washing with water at 80 °C, 10 water tanks are used, each with a flow rate of 2.5 litres per minute. The total power required is 104 kW.
Fermentation tank cleaning, using 3 tanks with a flow rate of 25 litres per minute and a cleaning time of 20 minutes, requires 26 kW. It is recommended to install a 1,500-litre tank that will be heated from 20 to 80 °C in 4 hours, requiring 26 kW.
art. Processos Térmicos em uma Fábrica de Cerveja 1
CALCULATION EXAMPLES
Pasteurisation (279 kW): 10,000 litres/hour x 60 °C = 600,000 kcal/h. 40% of the heat must be supplied (240,000 kcal/h or 279 kW).
Fermentation (697 kW): Several tanks of 200,000 litres at 33 °C, losing 3 °C/hour. 200,000 litres x 3 °C = 600,000 kcal/h or 697 kW.
Bottle washing (104 kW): 10 tanks with 2.5 litres/minute each at 80 °C. 1,500 litres/hour x 60 °C = 90,000 kcal/h or 104 kW.
Fermentation tank cleaning (26 kW): 3 tanks with 25 litres/minute for 20 minutes. A 1,500-litre tank is recommended, heated from 20 to 80 °C. 22,500 kcal/h or 26 kW.
FOR THESE THERMAL PROCESSES, THERE ARE TWO ALTERNATIVES
Separate equipment: Distinct equipment with specific power ratings for each process.
Single unit: for pasteurisation, fermentation, and bottle washing processes with a total power of 1,080 kW.
When installing a single heat generation unit, it is necessary to add 10% for network losses. The equipment may be either steam generators or closed-loop superheated water systems, both operating at 3 bar and 137 °C. Superheated water systems are more economical and have lower maintenance costs.
CONCLUSION
In summary, modernising the thermal processes in the factory will contribute to environmental sustainability, save energy, and reduce operational costs.
This case study highlights the importance of modernising thermal processes in industrial facilities, not only to improve energy efficiency but also to achieve long-term environmental and sustainability goals.

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