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The Case for Brewery Customization – Part 1
YOUR brewery is unique, YOUR beer is one of a kind, so YOUR equipment needs to help Brew YOUR Beer
By Derek Deubel
Founder and VP of TechniBlend and ProBrew
Brew YOUR Beer. These three simple words are some of the most important in the brewing industry, an industry that is constantly innovating and experimenting to produce the next great tasting drink for customers to enjoy. And while the flavors and trends may come and go, one thing remains constant, the commitment to creating something extraordinary.
That is why when it comes to equipment and operational procedures, breweries need customization, not something that is essentially “off the rack”.
Space is a premium
One of the biggest challenges for breweries is getting the most out of their current space. Naturally, the more popular the brewery is, the more space is needed to expand operations to keep up with demand. It’s this exact type of situation where one needs to have a customized operational line with equipment that fits exactly what they need.
One of the most unique projects ProBrew has handled had this exact issue. For Land-Grant Brewing, spacing for their operations needed to be a top priority. Their building, a 100+ year old elevator factory, had them “landlocked” and when it was time for them to expand their canning operation, they needed an individualized solution.
ProBrew’s answer for Land-Grant was to configure the line in a horseshoe shape. The line needed to be in this shape to enable crossover responsibilities going back and forth to different sides of the line. The brewery now enjoys one of ProBrew’s ProFill Rotary Can Fillers and achieves 85-90 cans per minutes, which was customized for their production needs.
The Production Manager had this to say when describing the newfound efficiency:
“One of our biggest runs, an 80 bbl batch, should take us about eight and a half hours and that’s the longest production day for us, now. That would have been two extremely long days on our old line, easily over two 10-hour days.”
Experimenting while expanding
Another common crossroads faced by breweries is making time for experimentation while meeting demand for their most popular beers. Breweries are founded by risk-takers and dreamers who have committed themselves to honing a craft and providing special experiences to visitors. However, it can be difficult to keep expanding into new, exciting flavors and styles while filling orders on flagship products.
This same issue popped up for Central Waters Brewing. This brewery, located in Amherst, WI, has been enjoying a massive amount of success over its 25-year history. However, with that success comes the need to expand operations and output of the most popular beers while still capitalizing on trends.
The solution? Have a small brewery within the main brewery. Central Waters was already utilizing a brewhouse capable of 50 bbl production alongside the ProFill 200 Rotary Can filler. However, to keep that spirit of innovation that birthed their brewery, they incorporated a new ProBrew 7-bbl pilot system to allow them to experiment and launch pilot beers.
“Our thought is, the pilot brewery gives us the flexibility to continue brewing as many beers as we want and to focus on in-house sales with that,” Paul Graham, president of Central Waters explains. “We’re in a town of 1,000 people, but we pushed almost 70,000 people through our tap room last year. For being in the middle of nowhere, that’s pretty good. We can run a beer on the 7 bbl system, throw it on tap, throw 30–40 cases worth in the retail cooler and get to see feedback from the general public.”
In other words, increased pilot capacity means increased ability to test the viability of new beers both in the tap house and out of the cooler. The production side creates space for experimentation, and the pilot side helps them make decisions one or two years out about limited-release beers that are worth putting into greater distribution. The custom-built ProBrew pilot brewhouse uses the same automation and controls as the 50-bbl and is hard-piped in, with CIP (clean-in-place) functionality, adding increased efficiency and convenience.
Case closed: Unique Brewing Calls for Customized Equipment
ProBrew believes that each craft beer reflects the hard work and long hours that each individual brewer puts in. That is why we are equally committed to providing customized equipment and solutions for what a brewery needs at this precise moment. From brewing to fermenting to carbonating and can filling, ProBrew’s customizable equipment empowers breweries to expand operations at their own pace.
If you’d like to further the conversation, fill out our form and a representative will be in touch as soon as possible! Otherwise, feel free to email us at firstname.lastname@example.org or call 262-278-4945.
About the Author:
Derek Deubel, Founder and Vice President
Derek has dedicated his career to developing some of the most innovative technologies to advance the beverage processing industry. Founding TechniBlend in 2008 and ProBrew a few years later, he has been an industry pioneer and trendsetter. Derek will be sharing his vast range of knowledge through commentary on industry trends on the Beverage Processing Post.
Accelerate Plant Production with the New ProFill V Series
VOLUMETRIC FILLERS ENABLE FAST-PACED PRODUCTION
The ProFill V series of Volumetric can fillers are accelerating plant production everywhere. These can fillers run at speeds between 100 – 600+ cans per minute while achieving precise and consistent filling volumes in multiple can sizes for a variety of beverages and liquids. Monobloc design gives customers a simple, single blocked unit consisting of the state-of-the-art ProFill V filling carousel integrated with a true tangential discharge to the integrated ProFill seaming system.
QUICK CHANGEOVER MEANS MORE VOLUME
The ProFill V Series utilizes a sophisticated electronic HMI interface for recipe-based changeovers and simple and repeatable filler operation. This means that there are shortened changeover times, leading to more overall production capability. Hygienically designed, stainless steel can handling and change parts allow for easier cleaning, quick changeover, and super smooth can transport in and out of the filler & seamer.
REDUCE MANUAL INTERACTION WITH AI
ProFill V’s embedded AI (Artificial Intelligence) digital filling technology means manual interaction is rarely needed due to the ProFill V’s AI error correction algorithms always monitoring and optimizing each filling valve’s performance.
EASILY CONNECT WITH OTHER BEVERAGE PROCESSING SOLUTIONS
Plus, the process system integration with industry leader TechniBlend, known for world-class beverage blending, carbonation or nitrogenation, deaeration, flash pasteurization, and any other up-stream process is fully integrated into the ProFill V filling system.
At TechniBlend, we’ve proven our capabilities in service to Fortune 500 beverage companies through our innovative technology and equipment. Learn precisely how the Profill V can advance your plant’s operation – Contact us.
TechniBlend Helps Beverage Powerhouse Move Towards RTD Production
One of the top wine and spirits producers is quickly expanding into the ready-to-drink (RTD) beverage market, and they’re using TechniBlend’s superior equipment and technology to do it.
The global beverage company kicked off their expansion plans in the summer of 2021 with a $4.5 million investment in beverage processing equipment from TechniBlend that will allow them to produce a brand-new line of canned RTD cocktails from start to finish.
Comprehensive systems & technology
The beverage giant purchased a custom-designed TechniBlend Ingredient & Concentrate Batching System and a TB-404, 4-Stream Blend System. The combination of these TechniBlend systems is well known in the beverage industry for its precise ratio control and variable speeds that generate continuous production at a high rate of speed.
The beverage company followed up their new batching & blending systems with other key pieces of RTD equipment engineered by TechniBlend including a Membrane Deaerator, Flash Pasteurizer, and two CIP OnDemand systems.
TechniBlend will test every system in their all-new facility before shipping the equipment, which is set to be delivered at the end of Spring 2022. Following installation, the TechniBlend team of service professionals will initiate onsite training and startup of each system, ensuring the customer is running at peak performance.
Why choose TechniBlend?
This is a first-time partnership for TechniBlend and the global beverage maker, who were introduced by a mutual business partner.
Several factors sealed the deal, including TechniBlend’s proven reputation for professionalism, reliability, and commitment to customer success on similar projects with other large scale beverage manufacturers. TechniBlend’s high-quality beverage processing systems offer customers improved production speed and efficiency; superior systems and service; and a more consistent final product.
At TechniBlend, we’ve proven our capabilities in service to Fortune 500 beverage companies through our innovative technology and equipment. Contact us to help your company expand into the ready-to-drink market with industry-leading beverage systems and solutions.
FlashPAS-10 Pasteurization System Helps Fabrizia Grow in Competitive RTD Market
As consumers continue to thirst for ready-to-drink (RTD) cocktails, beverage producers are eager to grab their share of an expanding market – one that shows no signs of slowing down. In fact, according to Grand View Research, the global RTD cocktails market is expected to see a compound annual growth rate of 12.1 percent through 2027.
But taste and eye-catching packaging aren’t enough to stay competitive. With such a crowded playing field, companies are looking for the most efficient and cost-effective ways to make their products.
Finding a partner in pasteurization
Fabrizia Spirits in Salem, NH, asked TechniBlend and its sister company, ProBrew, to develop a highly efficient pasteurizing system for their new line of premium, 100% natural RTD canned cocktails. Fabrizia Spirits did their research and found that many flash pasteurizers on the market have trouble maintaining carbonation levels after pasteurization, but TechniBlend’s systems offered integrated ProCarb inline carbonation technology that allows for stable, consistent and repeatable gassifcation after pasteurization.
The result was the creation of the new FlashPAS-10, a fully-automated, easy to use, inline HTST flash pasteurizer with integrated ProCarb technology. The system has and the option for multiple hold times to quickly and effectively pasteurize all the different styles of RTD cocktails Fabrizia has to offer.
Fabrizia executives are pleased
The FlashPAS-10 delivers unprecedented pasteurization technology, including precise pasteurization unit control for a variety of bottled, canned or kegged products. The fully automatic, stainless steel, skid-mounted pasteurizer incorporates the latest PLC control technology to deliver a high-level of control and accuracy. Systems are available in a variety of sizes and modifications for production speeds ranging from 10 to 200 gallons per minute.
With the FlashPAS-10, Fabrizia has instant and efficient thermal pasteurization control, which provides energy and cost savings without sacrificing a drop of product quality. Cheers to their continued success!
Contact us to learn how FlashPAS-10 can help modernize and improve your pasteurization processes.