Design Report on Brew Brothers Pty Ltd

Vulcan Smart
June, 2016
U1089522
Omar Alkhataimi

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Executive Summary
Brews Brothers Pty Ltd is a brewpub business that works as a bar, microbrewery and jazz club. Brew
Brothers are looking for preliminary analysis and to have a new design for the brewing process.
Brews brothers have proposed an effective system to construct an effective brewing structure that
consist if six main processes and can help them to increase the supply for the demand of customers as
well as will be efficient and economical. This report contains the technical analysis for each of the six
main processes and set of derived relation regarding limiting parameters. Moreover, this report will
discuss the findings related to design and process of brewing and recommendation for the final design
of the system based on the analysis.

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Table of Contents
Executive Summary

Introduction

Technical Analysis

2.1

Tank Sizes and Capacity........................................................................................................4

2.2

Plant Layout...........................................................................................................................8

2.3

Lautering and Pump A.........................................................................................................10

Costing 12

Conclusions

12

References

13

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1 Introduction
Brew Brothers Pty Ltd is seeking designs for a proposed brewing process facility. This design
proposal, has been developed by Vulcan Smart in response to the specifications outlined in client brief
V2.0 (Brew Brothers Pty Ltd). This report will summarise the following design aspects with a short
technical analysis for each aspect.
1. Maximising the productivity of the Brewing systems.
2. Minimize the capital cost of the brewing systems.
3. Providing the capability to brew and store more types of beers.
4. Costs associated with Brewing systems.
The report will identify a number of solutions, modelled to comply with the requirements and
constraints detailed in the brief. It will conclude with a final recommendation that will meet specific
goals detailed within the client brief.

2 Technical Analysis
The technical analysis has been split into four different sections as specified by the design section of
the client brief V2.0. The analysis starts with the storage capacity (volume) then the capacity of
fermenter, followed by the copper boiler, then the mash/lauter tun, and finally a cost analysis for the
complete facility.
Brewing process is based on six main sections whose technical analysis is needed to be done. These
six processes mainly involve mashing, lautering, boiling, cooling, fermenting and storing. In order to
provide the actual assessment of the each of the section, we need to develop the correlation between
all of the major equipment and machinery and define the limiting parameters to optimize the
production and economize the cost of the design of the system.

2.1 Tank Sizes and Capacity

The major equipment of the project includes; mash, copper with gas heater, fermenters, storage tanks
and pumps.
First of all the tank sizing and production capacity is need to be determined in order to achieve the
economical production and storage capacity.
The first is mash/ lauter tun which is a cylindrical closed tank and its parameters are;

Mash tun volume = VM (m3)

Mash tun Diameter = DM (m)
Mash tun Height = HM (m)
Parameters of the Copper cylindrical closed tank are
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Copper volume = VC (m3)

Copper Diameter = DC (m)
Copper Height = HC (m)

Parameters of the fermenter which is a cylindrical closed tank having conical based are;

VF Copper volume (m3) total volume (including conical base)

= 450 (conical angle)
Fermenter Diameter = DF (m3)
Fermenter Height = HF (m)
Fermenter Cone Height= hF (m3)
Parameters for the storage tank, which is the closed tank, are given below;

Storage Tank Volume = VS (m3)

Storage Tank Diameter = DS (m)
Storage Tank Height = DS (m)
Following are the relationship between the sizes.

Vf = Vs / 0.9

(Equation No.1)

Vc = Vf / 0.93

(Equation No.2)

Vm = Vc / 0.75

(Equation No.3)

The relationship between volumes of beer brewed per batch (Vbpb) to the average weekly
production/ consumption rate (Vb) depends on the time to brew each batch (Tb) and the
number of fermenters (Nf).

Vbpb = Vb x Tb / Nf

(Equation No.4)

The volume of beer brewed per batch = volume beer to be stored in each tank
Therefore,
Vs = 1.1 x Vbpb
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(Equation No.5)

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Quantity

Name

Unit

Number of fermenters

Nf

Volume of beer stored in

each tank

Vbpb

Volume of storage tank

Vs

Volume of fermenter

3200

1600

1067

800

3520

1760

1173

880

Vf

3911

1956

1304

978

Volume of copper

Vc

4205

2103

1402

1051

Volume of mash/lauter
tun

Vm

5607

2804

1869

1402

Time each beer is stored

weeks

8.00

4.00

2.67

2.00

Table 1. Volumes of tanks for a few batch sizes at minimum production.

The Physical sizing of the tanks can be determined from the general equations.
Vcylinder

= H x pi x (D/2)2

Where H is the height, D is the diameter

Vcyl +cone = H x pi x (D/2)2 + 1/3 x h x pi (D/2)2

Where h is the height of conical section and D is the diameter
To determine the height of cylindrical tanks using equation
H = 4 x V/ (pi x D2)

(Equation No.6)

And for the fermenter with conical section

H = [4 x (V- 8/3 x pi x D3 ) / (pi x D2 )] +D/2
We can plot the height of the tanks for the production volumes

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(Equation No.7)

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2.2 Plant Layout

As per the specification of the plan layout of the system in client brief

Any tank located on the floor is on a stand 0.5 m high and is required to have a 1 m clearance above.
The height of the roof varies from 4 m to 5 m, so the maximum height (Hs, Hf, Hc, Hm) of the tank
itself can between 2.5 m and 3.5 m, depending slightly on its diameter. For example a 1 m diameter
tank located on the floor closest to the walkway (but not on the walkway) can actually only has a
maximum height of approximately 3.1 m.

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For efficient production 4 fermenters and 5 storage tanks are used.

Tank Type

Number

Diameter
(m)

Mash/lauter tun

Copper

0.7

3.0

Fermenter

0.75

2.58

Storage

0.70

2.51

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0.9

Height (m)
2.42

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2.3 Lautering and Pump A

Time needed to lauter the wort = the volume of mash tun over the volume flow rate. In the next slide
we will show that the volume flow rate = the flow velocity by the cross sectional area.
The flow velocity has been provided in the Client Brief, which is 0.01 m/s, and as the tank is
cylindrical, then the cross sectional area would be Pi multiplied by the radius of the mash tun squared.
This is best demonstrated by example. To produce 1600 L of beer / week, say the volume of mash tun
= roughly 2804 L and the radius of the tank = 0.5m,
then the time taken to lauter the wort and transfer it to the copper would be 2800 over the flow
velocity which is 0.01 m/s by the cross sectional area which is pi r 2.
This would be 356507 seconds = 99 minute = 1.65 hours which is almost an hour and a half.

(Equation No.8)

2.3.1 Volume Flow Rate

As the mash tun is cylindrical, the cross sectional area would be pi multiplied by the radius of the
mash tun squared,
Therefore, volume flow rate = the average velocity of 0.01 m/s 2 times the radius squared, and the
result is multiplied by 1000 to convert the volume to Liter. Of course we know that the radius = half
of the diameter.
If we take the previous example and we say that the diameter = 1.08 m, then the VFR would = 9.16
L/s

(Equation No.9)

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2.3.2 Head Required for Pump

We can derive the height of the head from 2 pressure equations:
The first one is that: Pressure = force / area, and we know that force = mass times gravity
And the second one is: Pressure = density times gravity times height.
If we mix the 2 equations together and cancel out gravity, we get height = mass over density times
area.
We know that mass = density times volume, if we cancel the 2 densities, we conclude that the height
of the pump head = the volume of the mash tun over the area of the mash tun.
So for example if we take the previous example, where the volume of the mash tun =
or
3
2.804 m , and its diameter = 1.08m, the the height of the pump head would be = 3.06m, which seems
reasonable if compared to the tank parameters in section 1, which shows that the mash tank height is
almost 3 m.

Therefore,

(Equation No.10)
Therefore,
(Equation No.11)

2.3.3 Power Output

WE know that power = work over time, and work = force * distance, while force = mass times
acceleration due to gravity.
As we were not given the time, then we can say that mass over time = mass flow rate. Since we know
the volume flow rate from previous slides, then we could say that MFR = VFR*density.
Therefore, we conclude that the pump power = VFR times the density of the malted beer times gravity
* distance.
Distance here would be the height of the pumps head, which we found in the previous slide.
To illustrate this in example, from the previous 2 slides, we found that the VFR =
, converting
that to cubic meter/ second we get 9.16 times 10 to the negative 3, and the height of the head =
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3.06m, therefore, the pump A power would be 9.16 times 500 times 9.81 time 3.06, that would give us
the power in Watt, we divide the result by 1000 to convert it to kW, and we get approximately 0.138
kW.

Therefore,
(Equation No.12)

3 Costing
Sr No

Structure

No of
Units

Heigh
t

Diame
ter

Mash
Luter

2.42

0.9

Copper

0.7

2.58

0.75

2.51

0.7

3
4

Fermente
r
Storage
Tank

Cost
5057.
38
3683.
53
13313
.27
15723
.71

Chiller

2000

Filter

500

Pump

1500

Heater

2500

Total

44277
.89

4 Conclusions
One fermenter requires large tank sizes, which may fit, but do not utilize
height well whereas using four fermenter reduces the size requirement for all
tanks. Using four fermenters allowed smaller tanks to be placed above the
walkway.

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Heights of tanks on the floor are limited to 2.5m (up to about 3.1 m near
right side). Heights of tanks above the walkway are limited to about 1.8m.
Depending on the numbers of fermenters i.e; with 4 fermenters tanks of D >
0.75 m may work.
Based on the volumetric flow and time required economical pumps has
also been selected. Using five storage tanks and four fermenter it will give us
economical design with total cost $44277.

5 References
Brew Brothers Pty Ltd n.d., Ver2.0, Client Brief, University of Southern Queensland,

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