Methods for Breweries To Improve Brewing Efficiency

Scientific Definition and Calculation of Brewing Efficiency

Brew efficiency refers to the ratio of potential fermentables to a wort of target volume and specific gravity (also known as boil efficiency). Professional brewers typically use software such as Beersmith and ProMash to calculate efficiency at each stage.

Calculation Formula:

• Brew efficiency = Actual grain extract / Potential grain extract

• Actual grain extract = Wort volume (L) × Specific gravity (sg) × Plato value / 100

• Potential grain extract = Grain weight (kg) × Crush extract percentage

Three Core Processes Affecting Efficiency

Grinding Process

• Quality Standard for High-Quality Malt: Over 95% of Particles > 2.5mm

• Grinding Balance: Ensures sufficient separation of kernel and husk while avoiding excess flour

• Common Mistake: Over-grinding results in a tight filter bed, affecting filtration speed

Mashing Process

• Optimal Temperature Range: 63-80°C (Full Conversion)

• Critical pH: 5.5-5.6 (Measured at Room Temperature)

• Data: A pH deviation of 0.2 will reduce efficiency by 2%

Filtration Process

• Goal: Maximize Extraction from Malt Grind

• Technique: Initially filter slowly, then gradually increase the speed to prevent channeling

Six Practical Strategies for Improving Efficiency

1. Raw Material Selection

• Use high-friability malt (easy to grind)

• Focus on the difference in extract levels between grinded and unmilled malt

2. Equipment Optimization

• Mashing Kettle Design: Prefer a cylindrical shape, ensuring that the grain bed depth aligns with the width

• False Bottom Design: Fully cover the kettle bottom and minimize dead space

• Filtration System: Increasing the sieve plate area increases speed

3. Automation

• Precisely control variables such as temperature, pressure, and flow

• Benefits: Improve consistency and reduce batch-to-batch time

4. Energy Integration

Establish a heat exchange network to recover waste heat

Typical Examples:

• Recover steam heat from the wort kettle for preheating

• Recover hot water from the wort cooler for the next mash

5. Process Control

• Avoid excessive agitation during mashing

• Varied temperatures primarily affect flavor, not efficiency

6. Energy Storage

• Use buffer tanks to store energy

• Benefit: Reduce peak loads and reduce utility requirements

Key points for efficiency monitoring

• All volume measurements must be temperature corrected

• Regularly check the particle size distribution

• Monitor the filtration rate curve