The heavy 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 smaller was not
the issue.
Cost-optimised new development
A
new cost-optimised development was the objective – this was achieved by
standardised, production- and cost-optimised vessel sizes combined with proven
products and technologies from GEA Brewery Systems. 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, the LAUTERSTAR™ technology provides for short
lautering times and worts of excellent quality. The spent grains removal blade
of hygienic design allows spent grains removal in times of around 5 minutes.
The wort kettle is equipped with the energy-optimised JETSTAR™ internal boiler
system. These components combine to make small state-of-the-art brewing plants.
CIP saves production time
The basic
configuration COMPACT-STAR™ consists of a mash tun kettle, a LAUTERSTAR™ and a
Whirlpool/wort kettle. With this combination up to 5 brews per day and a
cast-out cycle of 4 brews per shift are possible. Dry milling and also wet
milling with the MILLSTAR™ are not a problem for the small brewing plant, both
methods can be used. An infusion and decoction mashing process is set up as
standard.
The small brewing plant including product pipes is cleaned
using a consumption-optimised CIP concept from GEA Brewery Systems. If the
brewery wants to do without the conventional cleaning day and the caustic brew,
highly-developed CIP philosophies as used on the "big" plants are possible.
These processes ensure reliable cleaning of the pipes while production is still
going on 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 reduced. In
addition, there are no limits in relation to vessel finish and vessel
appearance.
COMPACT-STAR™ is rounded off by the GEARBOXX™ 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 also possible without any problems. 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 |