Product Guide

GEA Brewery Systems

engineering for a better world

The competence centre for breweries all over the world

GEA Brewery Systems combines the hot and cold process
technology in one company and is the globally unique
competence centre for sustainable brewery equipment.
Our range of services includes everything from engineering,
manufacturing, delivery, installation and automation
up to the servicing of plants and components. Our core
competence is in process optimization, modernization and
extension. Upon request, we realize complete greenfield
projects.
Focus on green breweries
Reduce customers' environmental footprint and go green
our equipment and processes are optimized for longterm sustainability and designed for a successful economic
future. We develop innovative solutions considering
customers' local conditions and their economic and
ecological requirements.
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Minimized consumption of natural resources like water,

energy and raw materials
Making the brewing process as efficient and predictable
as possible
Reduced odour emissions by up to 100 %
Recycling of by-products or waste products
Tailored energy management

Contents
Engineering is our competence

MILLSTAR

LAUTERSTAR

JETSTAR

COMPACT-STAR

CIP concept brewhouse

HEAT-STER

10

Energy storage system

11

Beer mix beverages

12

ECO-MATRIX

13

ECO-FLASH

14

YEAST-STAR

15

ECO-FERM

16

CIP concept cold process area

17

Refrigeration and CO2 recovery

18

Solar brew project

19

Automation

20

Servicenext level

21

GEA Innovations

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Engineering competence from a single source.

Breweries require comprehensive, complete services today: from the

planning phase to the technical plant specification right up to the
handing-over of a turnkey, fully operational brewery.
From the Plant Manufacturer to the Engineering Company
For a long time already, service has been as important for us as classical
plant engineering and construction. This service encompasses the
calculation of economic efficiency of an investment, the organization
of project financing, the management of a large building site up to
the management of a new brewery for a certain period of time.
With our broad range of engineering competence we assume all
tasks of planning and implementing complete plants for beer and
soft drinks anywhere in the world. Our engineers plan the process.
They select the equipment, supervise the delivery and ensure the
correct installation and commissioning. They remain with the entire
brewery project up to the final handing-over and also undertake the
training of the brewery staff during and also after commissioning to
guarantee the successful operation of the brewery.
Our joint ventures with internationally leading engineering and
contracting companies places us in a better position than any other
company in the industry to set up, manage and keep overall control
of large-scale brewery projects.

MILLSTAR All advantages on its side.

A successful system - with all its technical advantages the MILLSTAR is

the ideal system for a milling process that requires high flexibility. Thanks
to its unique technical features, the customer can take essential measures
already during mashing-in to ensure the high quality of his beers.
What makes the MILLSTAR so special
Hygienic design for efficient cleaning
Positive displacement pump for mashing-in: malt to water
ratios of up to 1:2 (without rinsing) can be reliably handled
Level control in mash hopper for low oxygen uptake
Optimized spray geometry to avoid mash flotation
Quality automation system: feed roller speed control based on
power consumption of crushing rollers, providing adjusted
steeping time for harder malt batches
Temperature and flow rate of steeping water individually
adjustable
Precise and easy adjustment of the crushing roller gap
Large-dimensioned rollers for optimal crushing and perfect
husk conservation
Mash acidification possible directly at the mill
On request, also available with equipment for inert gas flushing
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Sizes:

2.5 t/h 5 t/h 10 t/h 16 t/h 20 t/h 40 t/h

LAUTERSTAR
A milestone in lautering efficiency.

Maximum extract yields and efficient use of resources are one thing.
With the LAUTERSTAR our customer will benefit in every way. The
lautering time is reduced, flushing and cleaning times are minimized.
Operating and maintenance costs are low. The LAUTERSTAR works
so efficiently that the investment pays off within a short period of time. A
wise decision regarding life cycle costs.
Typical features of the LAUTERSTAR
New safety system of the vessel in accordance with EU
directives
Indestructible spent grains flaps without any wort loss
Sealless centre column
Gentle distribution of cloudy wort in the centre
New spent grains removal blade with feedback signal and
mechanical actuation
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TCO: Advantages of the LAUTERSTAR compared to a

mash filter
Lower debt service associated with the acquisition
Savings of electric energy during milling
Lower CIP costs
Operator-free spent grains removal and cleaning
Lower maintenance costs

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JETSTAR
Technology and energy management hand in hand.

The JETSTAR from GEA Brewery Systems allows a completely

innovative process in atmospheric kettles: the 2-phase boiling. This
method with two separate steps makes wort boiling with an internal
boiler using natural circulation much more gentle and energy-efficient.
In the first phase, the conversion process, the subjet system provides
for a more homogeneous circulation with minimum thermal stress. In
the second phase, the two-level wort spreader ensures very intensive
evaporation and stripping of volatiles. Intermediate cleaning during a
brewing week can be reduced to a minimum.
The best thing is: The JETSTAR can be retrofitted to existing plants
without much effort.
Key characteristics
2-Phase boiling
Adjustable opening
Low evaporation rate
Natural circulation with high circulation rates
Patent protected two-level wort spreader
Efficient stripping of undesirable volatiles
Atmospheric and dynamic low pressure boiling
Always hygienically safe
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COMPACT-STAR
Brewhouse concept for 40 hl up to 100 hl.

The COMPACT-STAR is a customized brewhouse for the increasing

requirements of specialty and medium-sized breweries with a cast-out
quantity from 40 hl (34 bbl) up to 100 hl (85 bbl).
The brewhouse has a modular design and the brewing vessels are
connected as independent units, the later integration of additional
vessels to increase the capacity of the brewhouse is possible without any
problems. The basic configuration consists of a mash tun kettle, a lauter
tun and a Whirlpool/wort kettle.
The COMPACT-STAR can be equipped with an internal boiler system
with JETSTAR technology and the CIP concept. The COMPACTSTAR is completed with OTAS, a well-proven automation solution
for medium sized plants.
Key characteristics
Individual brewhouse concept for customers needs
High flexibility due to modular design
Future expansion without any problems
From 5 up to 12 brews per days
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Concept versions at a glance

Basic configuration with 3 vessels
Upgrade with a pre-run tank
Upgrade with a Whirlpool
Upgrade with a MILLSTAR
Ale brewery with 2 vessels

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5 brews per day

7 brews per day
9 brews per day
12 brews per day

Brewhouse CIP concept

Increased plant availability in the brewhouse.

The top priority drivers in the decision matrix for a new brewhouse are
high brewhouse yields, optimum occupation times of the vessels and a
minimum consumption of primary energy. Our CIP concept uses special
mixproof valves for a safe separation of vessel groups and pipes. This
allows independent cleaning of vessels and pipes, even if production is
still on-going in other brewhouse vessels. This saves time and increases
the plant availability. On top of that, our CIP concept uses combined
vessel and piping cleaning which eliminates the need for a caustic brew,
thus reducing the consumption of cleaning agents and water as well.
We guarantee product safety at every point of the process. Our upgrade
considers all individual local conditions and customer requirements and
leads to noticeable savings.
Customer benefits at a glance
Upgrade of CIP processes results in a time advantage of at least
3 hours thus reducing labour costs
Production processes and CIP processes in the brewhouse can
run simultaneously
Reduced consumption of cleaning agents and water due to
elimination of caustic brew
Reduced power consumption during cleaning
As product safety is ensured in the complete pipe system,
production can start earlier additional capacity is created
Useful instrument to boost production with only few
mechanical modifications
Maximum equipment utilization, particularly in peak times
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HEAT-STER
Sustainable energy production.

The energy-efficient brewery concept for the future is available. We

have developed the HEAT-STER technology in cooperation with
the Fraunhofer Institute for Factory Operation and Automation IFF in
Magdeburg. Thus, a competent team is available to plan and realize a
sustainable energy supply for customers' breweries.
Key characteristics
Optimal spent grains combustion system
Fluidized bed technology
Covers up to 60 % of the heat demand in the production process
Energy demand and spent grains availability go hand-in-hand
Reaches all demands of TA Luft
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Energy storage system

More efficiency with less fuel heat.

With the energy storage system invented by GEA Brewery Systems it is

possible to recover energy during wort boiling and to use this energy in
the brewhouse. This is achieved by combining a vapour condenser with
an energy storage tank as well as a wort pre-run tank and a wort heater.
The low-pressure energy storage system is used worldwide for producing
more than 120 million hectolitres of beer per year. Two reasons are
responsible for this success: the reduced total evaporation rate in
combination with atmospheric boiling and the more efficient energy
recycling in the brewhouse.
Efficiency of the energy storage system by using the installed
calorimeter at vapour condenser and wort heater

ESS =
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Energy transferred at wort heater

Energy leaving vapour condenser

Data are recorded and archived by the control system

Ad hoc information displayed on the screen of the PLC
Operation time of vapour condenser is shown as percentage
of total boiling time, if evaporation rate is above balance

Energy storage tank

Vapour
condenser

Wort kettle

Whirlpool

Pre-run tank
Heat exchanger

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Beer mix beverages

Process technology for the perfect mix.

Beer variations are the latest trend today, as mixed beverages or as new
beer specialties. We provide comprehensive solutions for the economical
production of high-quality beverages. Whether batch production or
continuous production in the multi-blender, we adapt the systems exactly
to customer requirements in an individual and flexible manner and make
them fit for the future.
Key characteristics
Complete range of products for mixing and dosing in the
brewery
Ensuring a consistent plant concept
High quality standard for hygienic design prevents ingress of
air into the product and guarantees constantly high product
quality
Modular skid mounted design
Very high dosing accuracy for each beverage component
Product losses are reduced to a minimum
Product changeover: Fully automatic, fast and uninterrupted
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ECO-MATRIX
Piping system with the focus on quality.

The fully automatic pipe connection system ECO-MATRIX is based

on a compact tank outlet tree. The short vertical pipe below the tank in
combination with the ECO-MATRIX double-seat valves guarantees
good cleaning conditions and minimum product losses. With the new
ECO-FENCE system, the ECO-MATRIX concept is now also applied
to manual piping technology.
To sum up: our cellar piping concepts improve the foam and taste stability
of your beers at minimum life cycle costs.
Benefits at a glance
With regard to plant investment costs
Minimized space requirement due to compact tank outlet
tree below the tank
Fewer valves than comparable systems with valve matrix
Easier installation (less valves)
Easier automation (less valves)
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With regard to running costs

Less flush-out losses due to favourable valve arrangement and
shorter pipes
Less CIP losses due to the integrated LEFF module
Lower cleaning agent losses
Less maintenance work
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Additional benefits with intangible values

Highest flexibility
Ecologically sound operation
Fail-safe operation
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ECO-FLASH
Beer pasteurization for highest demands.

Quality and shelf life cannot be separated in the brewing process. With
our flexible modular ECO-FLASH systems, we are the ideal partner
for breweries. We have developed a safe and cost-effective method to
optimize the biological preservation by pasteurization. Thanks to the
recuperative design of the ECO-FLASH system, as much as 96 %
(optimum between heat recovery and investment) of the heat input can
be recovered. This makes flash pasteurization the most cost-effective of all
heat treatments used today.
The ECO-FLASH systems inspire confidence with their
reliability and the following advantages
Low investment and operational costs
Precise PU control, online monitoring is possible
Minimum product losses
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The ECO-FLASH system is available

In four sizes
Size

Capacity range
DN 50
50 hl/h to 150 hl/h
DN 65
> 150 hl/h to 250 hl/h
DN 80
> 250 hl/h to 370 hl/h
DN 100
> 370 hl/h to 600 hl/h
With two levels of automation semiautomatic or fully automatic
In modular design for future extension.

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YEAST-STAR
The yeast management concept.

With YEAST-STAR we offer a method that ensures that the yeast is

growing in the log phase during the entire propagation process. Yeast
propagated under these conditions provides high stability in taste and
head retention. The reproducible quality guarantees a true pleasure in
beer production.
YEAST-STAR: the tailor-made concept for your yeast management
from a simple unit to a complex plant.
Characteristics
Vigorous, actively fermenting yeast
Wort sterilization as an option in the propagator (additional
heat exchanger)
Optimized temperature control
Optimal aeration by lance with spray ball in the bottom
Homogenization by circulation loop
Sterile air supply with product trap incl. automatic cleanout
In-line alcohol measurement
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Customer advantages
High and constant beer quality
Gain of essential nutrients (good wort properties)
Fast growth rates
Reduced formation of foam
Optimal homogenization, easy cleaning-in-place
Highest microbiological process safety
Determination of the optimal point of time for initiating
further propagation steps
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ECO-FERM
Optimized quality and higher capacity.

With ECO-FERM we have developed a system that reduces the

fermentation time by supporting the natural processes during
fermentation. Significant time savings can be achieved without
compromising beer quality.
ECO-FERM is the revolutionary system for jet mixing in fermentation
tanks. A mixing organ without any movable parts ensures stable support
of the natural bubble column in the tank resulting from the formation
of CO2 during fermentation. Thus, much more active yeast cells are kept
in suspension, conversion processes during fermentation are accelerated
and temperature homogeneity in the fermentation tank is increased
considerably.
ECO-FERM provides numerous advantages
Shorter fermentation and maturation time; the total
occupation time of a tank is thus reduced by up to 25 %
Consistently high degrees of final attenuation
Uniformity of the fermentation means better scheduling of
tank occupancy
Homogeneous temperature distribution in the fermentation
tank during warm maturation and cooling
Improved yeast vitality due to reduced sediment formation
in the tank cone
Constantly high beer quality and no changes in the flavour
profile
More fermenting capacity with the same number of tanks
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Cold process CIP concept

Increased plant availability in the cold process.

Today, modern breweries cannot be imagined without CIP systems. In

view of rising costs, particularly for fresh and waste water, CIP systems
have recently been in the focus of interest to identify possible saving
potentials. However, for reasonable savings, that means optimization of
equipment, certain criteria have to be met. When it comes to the cleaning
of equipment, containers and pipes in a brewery, the major criterion can
only be perfect cleanliness.
The CIP system is used to clean the parts with product contact of the
apparatus, pipes and vessels of the plant. It consists of several storage
tanks, e.g. for caustic, acid and disinfectant solution, including the
required valves, pumps, measuring devices and heat exchangers.
The intelligent combination of energy efficient components and cleaning
procedures results in improved plant availability, which ultimately means
a higher capacity.
Customer benefits at a glance
Individually engineered for your needs
Reduced consumption of cleaning agents and water due to
use of high performing components and innovative cleaning
procedures (small water barrier between the different
cleaning agents)
Minimized energy consumption
Easy handling and minimized service intervals for long life
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Utilities Refrigeration and CO2 recovery.

To realize functional and economical refrigeration and CO2 recovery

plants, expertise from both worlds, refrigeration technology and the
brewing process, is essential. For over 80 years we have been active in
the refrigeration sector world-wide. We have built complete units with
a refrigerating capacity ranging from 100 to 10,000 kW and can provide
excellent references for the modernization and optimization of existing
plants.
Refrigeration plants
Optimum operating conditions
Extremely efficient operation by multi-temperature circuits
Intelligent control system for optimized processes
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Refrigeration plants
CO2 audit to determine the amount of CO2 produced and
required
Precise calculation of the CO2 produced
Upgrade of existing plants
Sustainable investment thanks to industrial type components
Made in Germany
Use of natural refrigerant (ammonia)
Flexible integration into the control system
International experience and approvals
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Solar brew concept.

The project aim is to show the practicability in terms of integrating big

solar thermal systems in the brewing process.
Brewing industry processes qualify themselves for the integration of
solar heat because of their process temperature levels. Processes with
temperature ranges between 50 to 100 degrees C are very capable for the
integration of solar thermal plants as the efficiency of solar collectors (flat
plate and vacuum tube) in this temperature range is high.
To accumulate experience in this field of technology the construction
of three solar thermal plants in three different European locations of
HEINEKEN Supply Chain B.V. is planned. The total installed capacity of
these three plants will be 5.08 MWth corresponding to total of 7,270 m
collector area.
GEA project management: Dr. Ludwig Scheller
Progress: on-going
GEA Project partner:
HEINEKEN Supply Chain B.V., NL; www.heineken.com
AEE Intec, A; www.aee-intec.at
SUNMARK A/S, DK; www.sunmark.com

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Automation and process control systems.

We offer solutions that are specific to our clients processes and are
thoroughly tested in that environment. Our process control specialists
select the right tools from the software available on the market and
adapt them to customer requirements. Experience in process technology,
the brewing business, and a clear knowledge of the industry-specific
requirements are the key elements in taking the right decisions.
As system integrators we bring our knowledge from process technology
and plant engineering together with software products from market
leaders (e.g. Siemens WinCC & BRAUMAT, Wonderware InTouch,
GEFanuc iFix, Proleit brewmaxx, Rockwell Automation RSView).
When other solutions are required, we have the flexibility to adapt to meet
the local conditions.
Our control systems at a glance
GEARBOXX for the efficient process automation of plant
sections and units
OTAS basic Open Technology Automation Solution for
small plants and first steps in automation.
OTAS 9 Open Technology Automation Solution for
SCADA systems and for fully integrated plant wide process
control
brewmaxx process control solution for breweries, MES
included.
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Servienext level Partnership for efficiency.

With GEA Brewery Systems you can benefit from increased efficiency
and higher capacity due to optimization, modernization and expansion of
existing plants. In combination with technological and energy efficiency
audits we can even offer a guaranteed return on investment. We provide
intelligent service concepts - flexible and future-oriented.
Together with customers we develop intelligent solutions in order to take
full advantage of their breweries potentials. For this purpose, we have
designed flexible service modules, which can be individually adapted to
specific production conditions to keep production costs at an optimum
level.
Servicenext level stands for
Technical service modules ensuring high plant availability
for increased production safety.
Technological service modules ensuring high efficiency for
optimized production costs.
Energy efficiency check - mobile energy data management
Spare parts service
Emergency service - 24 h / 365 days
Training programs
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Further GEA Group innovations for breweries

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Solutions for continuous brewing

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Vessel Safety Solution (according to 98/37/EG & 2006/42/EG)

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Yeast cropping with centrifuge for repitching

E.g. the first separator generation

GSC 200i GSC 250i, GSI 200

GSI 300 GSI 400 and PROFI 300i

PROFI 400i with the innovative drive concept

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Beer recovery with nozzle separator

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Beer recovery with ceramic membrane filtration

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Decanter for the beverage industry

Westfalia Separator ecoforce gMaster CF 6000

Clear Malt Base Beverages

Purification techniques (flavour/colour)
Flavored Alcoholic Beverages (FAB)
Clear Malt Base Beverages and FAB

Nanofiltration units

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Dealcoholization of beer
Solutions for sustainability

Consumption reductions of energy, water, etc.
New energy saving centrifuges
Westfalia Separator directdrive + hydrostop

The new separator generation
VARIVENT Valve Technology

Single-seat, divert, control and mixproof valves
VARIPURE
Cleaning devices according to todays
hygienic standards
GEA Tuchenhagen -VARIFLOW TPS

Hygienic self-priming centrifugal pump

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We live our values.

Excellence Passion Integrity Responsibility GEA-versity

GEA Process Engineering

GEA Brewery Systems GmbH
Huppmann Tuchenhagen

Locations:
Heinrich-Huppmann-Str. 1, 97318 Kitzingen, Germany
Phone +49 9321 303-0, Fax +49 9321 303-603
Am Industriepark 210, 21514 Bchen, Germany
Phone +49 4155 49-0, Fax +49 4155 49-2770
gea-brewerysystems@gea.com, www.gea.com

Product Guide.E.08.12 / GEA Brewery Systems GmbH / All rights reserved / Subject to modifications

GEA Group is a global engineering company with multi-billion euro sales

and o
perations in more than 50 countries. Founded in 1881, the company
is one of the largest providers of innovative equipment and process
technology. GEA Group is listed in the STOXX Europe 600 Index.