High demand at drinktec 2009 in Munich, and the results of the subsequent market analysis, prompted GEA Brewery Systems to develop this innovative concept. The analysis of the brewing behaviour and the brewing capacity of medium-sized breweries resulted in the demand for brewing plants for quantities between 40 and 100 hl. Building large brewhouses only smaller was not the issue.
Cost-optimised new development
A cost-optimized development was the objective – this was achieved by using our standardized, production- and cost-optimized vessel sizes combined with proven products and technologies. The agitator paddle, with its optimum streamlined shape for gentle mashing, guarantees perfectly ’lump-free’ mashing-in of dry grist in conjunction with the pre-mashing system, which can be adjusted from the exterior. With the raking knives and flow-optimised run-off cones, elements of the LAUTERSTAR™ technology provides for short lautering times and worts of excellent quality. The hygienically-designed spent grains removal blade allows grain out in about 5 minutes. The wort kettle is equipped with the energy-optimised JETSTAR™ internal boiler system. Combined, these components make the most efficient brewing plants available.
CIP saves production time
The basic configuration COMPACT-STAR™ consists of a mash tun kettle, a lauter tun and a Whirlpool/wort kettle. With this combination up to five brews per day and a cast-out cycle of four brews per shift are possible. Either dry milling and wet milling with the MILLSTAR™ can be used. An infusion and decoction mashing process is available as standard.
The brewing plant, including product pipes, is cleaned using a consumption-optimised CIP concept from GEA Brewery Systems. If the brewery does not want to use the conventional day caustic brew or requiring a separate cleaning day, it’s possible to use highly-developed CIP systems commonly installed on bigger plants. These processes ensure reliable cleaning of the pipes while production continues in the downstream vessel.
Cost-effective pre-fabrication
COMPACT-STAR™ is provided largely pre-piped and pre-wired, in a modular design or for open installation without a frame. As a consequence, erection periods are minimised and the costs on site are reduced. In addition, there are no limits in relation to vessel finish and vessel appearance.
COMPACT-STAR™ is rounded off by the OTAS™ automation and visualization system from GEA Brewery Systems – a well-proven solution for the user-friendly control and monitoring of medium-sized plants.
Future expansion of the brewing plant is possible easily. For example, by integrating a pre-run tank, installing a separate Whirlpool or adding a MILLSTAR™, the brewing sequence can be increased to 12 brews per day.
Concept versions at a glance:
| Basic configuration with 3 vessels |
5 brews per day |
| Upgrade with a pre-run tank |
7 brews per day |
| Upgrade with a Whirlpool |
9 brews per day |
| Upgrade with a MILLSTAR™ |
12 brews per day |