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planning | delivery | installation | enrollment | beers
The successful path to your own brewery.
Pub brewery serving beer or craft brewery with beverage bottling and keg filling.
Why invest in a custom-built brewery?
Growth sector? Passion for beer? Affordable investment? Market niche: craft beer? Or simply because it’s fun?
… All of these reasons combined make the perfect mix! No matter if you are looking for a restaurant and pub brewery or a craft brewery as production facility – FLECKS offers the complete package: Design, planning, construction, montage, operator training, beer recipes, online maintenance of the brewery and support for the brewer.
Planning of your brewery
1.1 Determination of the size of your brewery
When customizing a new microbrewery first of all it is important to define the size of the brewhouse.
A “BRAUHAUS 300” for example is a small brewhouse with 300 litres of wort per brew = about 8 hours (3HL). Further options are:
- BRAUHAUS 500 (5 HL) or
- BRAUHAUS 1000 (10 HL) or
- BRAUHAUS 1500 (15 HL) or
- BRAUHAUS 2000 (20 HL) or
- BRAUHAUS 4000 (40 HL)
Depending on the size of the brewery you can determine how often to brew per week. The possibility of subsequent extension of the brewery allows you to double and even quadruple your daily production.
Our pricelist offers a detailed investment cost breakdown for various capacities.
This measure shows size and number of fermentation and storage tanks that will be needed. Therefor it is necessary to define the annual amount of beer that should be sold. Due to the fact that your business might grow over time, space for an extension and additional tanks is always included in our plans.
There are various types of fermentation and storage cellars that are determined by the range of beers produced.
Planning of your brewery
The smallest capacity starts at 30.000 litres beer per year and peaks at several million litres per year.
Our pricelist offers an overview of beginning investment costs.
1.2 Planning and space requirements
We have already planned and realised a great number of various different installations and formations when it comes to our breweries.
No matter if “all in one room” or “divided between several rooms” – we have done it all.
Based on a layout plan of the building we develop several different installations and formations with our clients. Entrance widths and ceiling heights are important to consider during this process.
Minimum space requirements in m2:
1.3 Required brewery – infrastructure
- BRAUHAUS 300 30 kW
- BRAUHAUS 500 40 kW
- BRAUHAUS 1000 80 kW
- BRAUHAUS 1500 120 kW
- BRAUHAUS 2000 160 kW
- BRAUHAUS 4000 320 kW
- Water and water treatment
Water is an essential ingredient when brewing beer. Referring to the amount of beer produced, you will need about three to four times the amount of water. If you send us water analysis data of your home town, we are able to provide information about what kind of water treatment is the most appropriate for you.
wastewater:
Wastewater produced by microbreweries is just slightly contaminated (less than wastewater produced by gastronomy) and can easily be disposed by municipal sewage plants. However, the daily procedure of brewing and the related water use of a microbrewery have a great impact on the overall water consumption – and therefore also on the amount of wastewater produced by the brewery.
For this reason we try to focus on teaching our clients and brewers how to work efficiently and sustainably in this area.
Exhaust air:
The exhaust air mainly consists of exhaust steam from the brew kettle. FLECKS breweries have a built in steam condensation unit that vacuums and then condenses steam beginning with temperatures at 85°C..
Waste:
Solid waste consists of draff which is about 1,8 times heavier than the weight of the used malt.
This residue of the malt (wet grains) remains in the lauter tun and is then removed through the FLECKS draff discharge device (lateral discharge over a slide into storage units or with a draff pump into transportation facilities and hangers)
The optimal exploitation is to use the draff as fodder for pigs, cattle or sheep. Therefore farmers are often very happy to receive this brewery “waste”.
Furthermore it is possible to make a special draff bread, containing about 20 to 30 percent of this malt residue.
1.4 Design
Basic Designs - Optical design variants for brewhouse
Full stainless steel, wonderfully brushed surface
Stainless – copper – brass Mix
Full copper version
1.5 Automation
Semi-automatic
A partially automated brewery is controlled by hand vales, while various mash, cooking, and fermentation programmes are automated.
Full-automatic
All valves and drives are regulated and controlled by a simatic S7 control system.
Grinding malt, mashing, mash programmes (infusion and decoction), purifying, boiling of wort, hop dosages, whirlpool and cooling of wort and cleansing are all fully automated.
Furthermore fermentation and storage tanks are also fully automated when it comes to controlling (temperature and pressure). Simultaneously the produced amount of carbon dioxide is being recorded.
Temperature, quantities and error system reports are being created and saved automatically. In case of a disturbance the brewer is informed via sms.
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1.8 Costs of investment
Our price lists are updated regularly to enable a realistic insight into costs of investments.
Many of our current clients value this transparency when it comes to our pricing and profit from our rapid processing of the lists when prices change.
- Price list
- Cost efficiency calculator
1.6 Marketing concept
Choice of type of brewery/viewing brewery with pub/ sole production brewery.
We support you when it comes to realizing your concept and are eager to help with our experience in implementing pub and restaurant breweries or production breweries.
After having installed and developed over 110 breweries in 35 different countries worldwide, we have acquired a lot of know-how that we want to share.
Choice of beer type
You probably already have an idea about the type of beer you want to brew. You might even have recipes and varieties that work well for you. Our task is to adapt your recipes for our FLECKS breweries.
Distribution of bottled beer, kegs or directly served to customers.
We provide keg cleansing machines and small bottle fillers or recommend an integrated bottling line (Labelling, cleansing, evacuating, filling and capping)
1.9 time schedule
Starting with your order up until the opening of your brewery, a project usually takes 4 to 6 months.
1.7 Personnel Requirement – we make brewers
The required personnel depends on whether your brewery is fully or partially automated and on the annual production quantity.
Small breweries (3-10 HL) usually simply require one brewer with occasional support staff. Fully automated breweries only need half as much personnel. Bottling the beer is the task that demands the most additional support.
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We help you become a successful brewer
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We give you all the know-how you need
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We show you how to do necessary maintenance work
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Furthermore we offer an online service (modification of recipes, new beers, support)
1.10 State approval
Different in all countries, but definitely doable:
Technical approvals/ CE, TÜV, trade authority
We deliver technical documents and certificates for local permits.
Beer tax/ customs authority
We recommend to register at the responsible tax authority for beer tax earliest possible.
Hygiene check
Inspections of the hygienic situation by the government are very common. Therefore we offer support when creating your HACCP concept (Hazard Analysis and Critical Control Points).
2. Outstanding beers
Our contribution to sophisticated beer culture . Automatic brewing and controlled fermenting guidance guarantee the highest quality .
The outstanding and full-bodied taste of our beers is the result of our very own FLECKS mash technology. It offers a great variety of possibilities when brewing. Traditional and modern brewing processes enable a great diversity of varieties, regional variations, creative styles of beers and a healthy, aromatic, natural and organic yeast clouded beer.
Our unique FLECKS beer recipes have allowed us to implement a great number of various standard and special types of beers at our clients’ breweries.
Currently over five million litres of craft beer are being produced annually by FLECKS breweries worldwide.
3. Successful brewery projects
We have established over 110 breweries in 35 countries worldwide over the past 18 years. Almost all of these microbreweries (even the oldest ones) are still active. We would like to introduce you to a number of our most successful projects: :
4. FLECKS brewing technology
Innovation for highest beer quality and easy operation
3 mashing processes are available with Flecks brewery systems:
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Pure Infusion for easy drinkable pale lager
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Infusion/Calandria system for outstanding pils and ales beers.
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Decoction for beers especially rich in taste and colour.
Brewing of beer
The brewing process according to the German purity law ( Deutsches Reinheitsgebot ) from year 1516:
( Deviations from the German purity law are of course possible and will be applied according to local requirements )
1. Water + malt + hops + heating energy = wort
Within the brewery best brewing water and light/dark barley malt or wheat malt are being mashed, heated in several steps and finally purified.
The result of this process is sugary wort which is then cooked with bitter and aroma hops. The brew is done after about 7 to 8 hours.
2. Wort + yeast + cooling energy = beer
Within the fermentation tank, cooled wort is mixed with top-fermented and bottom-fermented yeast which then leads to the sugar being transformed to alcohol and carbonic acid.
The typical beer aroma forms during maturation at about 6 degrees under pressure. Your beer is ready for consumption after three to four weeks. It can also be filtrated if needed.
Our highlights
FLECKS external mash boiler system with overheated hot water.
This system enables a heating of mash without causing any burns. Furthermore the external system ensures a constant temperature of 104°C within the boiler.
Solar and hybrid heating
In order to prevent investment costs for expensive power connections we have developed a solution that combines several sources of energy to enable a highly efficient overall energy use. The process allows us to work with several environmentally friendly sources of energy such as solar power, geothermal energy, distinct and local heat.
FLECKS Mixer - mash mixing system
with the help of a patented, non-rotating, lifting and mixing system maximum efficiency is achieved: FLECKS Mixer
High end brewing systems
Our fully automated concept, which is based on an industry-proven measuring and data acquisition system, is one of the most modern of its kind worldwide.
