Large-Scale Brewery Design & Installation Guide | DEGONG Turnkey Solutions

Building a large-scale brewery requires a clear plan, reliable equipment, and a strong understanding of sanitary design, layout, utilities, and automation. DEGONG has supported hundreds of brewery projects worldwide, and this guide summarizes the key principles to help you build a high-performance, expandable, and compliant production facility.

1. Capacity Planning: Brewhouse, Fermentation, and Cooling Systems

Every successful brewery starts with a balanced production plan.

Begin with the brewhouse size, then calculate the required number of fermenters, brite beer tanks, and cooling capacity. A common rule is to size the cellar at 4–6 times the brewhouse volume to maintain a steady brewing cycle. A practical formula often used:

Annual output = brewhouse size × batches/day × brewing days per year

Early planning should also include:

• Steam, electricity, water supply, glycol chiller load

• Drainage slope, trench positions

• Expansion zones for future tanks

DEGONG recommends reserving at least 20–30% spare space for expansion, to avoid expensive reconstruction later.

2. Brewery Layout: Clean, Safe, Efficient

A professional layout clearly separates workflow zones:

Raw materials → Brewing area → Fermentation area → Packaging line → Utilities zone

Good layout design improves hygiene, reduces contamination risk, and simplifies daily operations. Key considerations for DEGONG brewery projects include:

• Anti-slip flooring and correct slope toward drains

• Proper spacing between tanks for access and CIP

• Forklift lanes and safe pedestrian pathways

• QA laboratory and chemical storage areas

• Adequate ventilation and exhaust in hot areas

A clean, organized layout directly contributes to long-term efficiency and product consistency.

3. Brewhouse System: Mashing, Lautering, Boiling & Whirlpool

The brewhouse is the heart of the brewery. DEGONG offers 2-vessel, 3-vessel, 4-vessel, and fully automated systems depending on your required productivity and recipe diversity. Core features of a modern brewhouse include:

• High-efficiency mash mixing system

• Optimized lautering plates for fast run-off

• Stable steam jackets for strong boiling intensity

• Low-oxygen design for improved wort quality

• Precise flowmeters, pumps, valves, and temperature control

• Platforms designed for operator comfort and efficiency

A 4-vessel configuration significantly increases throughput and consistency for mid- to large-scale breweries.

4. Automation & Central Control System

Automation ensures product stability, safety, and repeatability. DEGONG’s control platforms can integrate:

• Brewhouse automation

• Fermentation temperature control

• CIP sequences

• Packaging line synchronization

• Data logging and batch reports

With interlocks, alarms, and recipe management, operators follow a clear workflow—reducing human error and improving product uniformity.

5. Hygienic Piping, Valves & CIP System

Hygiene is the foundation of quality. DEGONG designs all pipelines with proper slope, minimal dead zones, and sanitary welding. Essential elements include:

• Hygienic valves and automated actuators

• Spray balls for tanks

• CIP supply & return loops

• Sight glasses and sample ports

• Verified weld quality (inside & outside)

A well-designed CIP system allows safe, reliable cleaning without disassembling tanks or pipes, saving labor and minimizing contamination risk.

6. Cooling, Temperature Control & Utility Integration

The cold side defines beer flavor stability. DEGONG designs complete glycol systems that include:

• Correct pipe sizing and insulation

• Balanced loops across all tanks

• Backup circulation pumps

• Accurate glycol temperature control

Utilities such as steam, compressed air, water treatment, and power distribution must be engineered early and recorded in detailed drawings for future expansions.

7. Packaging System & Material Flow

Packaging is the final critical stage before the beer reaches consumers. DEGONG provides turnkey filling and packaging solutions for:

• Cans

• Bottles

• Kegs

Important design considerations:

• Linear product flow

• Buffer zones between machines

• Clean, segregated packaging environment

• Adequate space for palletizing and storage

A well-engineered packaging area ensures high throughput and protects beer quality.

8. Small vs. Large-Scale Breweries: Key Differences

Although brewing principles are the same, scale brings additional complexity:

• Larger vessels

• Higher steam and cooling demand

• Longer piping distances

• Strict ventilation and wastewater regulations

• More complex utilities and automation

But at any scale, DEGONG follows the same principles:

Cleanability, accessibility, process efficiency, and long-term expandability.

9. Upgrading or Expanding an Existing Facility

For renovation projects, DEGONG first evaluates:

• Floor loading capacity

• Power supply capability

• Drainage system and trench location

• Ventilation and exhaust

• Space for tanks and piping routes

Drainage is often the most challenging part—insufficient slopes or poorly placed trenches can cause operational issues for years.

10. Installation, Commissioning & Minimizing Downtime

DEGONG installation usually follows a phased approach:

• Equipment delivery and inspection

• Tank placement and anchoring

• Utility connection (steam, glycol, water, electricity)

• Piping installation

• Commissioning tests (water test → wort test → full production)

We recommend performing water brewing trials first to verify pumps, valves, automation, and CIP sequences before moving to real production.

11. Staffing, Training & Spare Parts

A strong system needs a strong team. DEGONG provides on-site or remote training for:

• Brewhouse operation

• Fermentation management

• CIP cleaning

• Preventive maintenance

• Quality control basics

We also supply recommended spare parts lists to ensure smooth operation.