Product Guide GEA Brewery Systems

engineering for a better world

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The competence center 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 center 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 long-

term sustainability and designed for a successful economic

future. We develop innovative solutions considering

customers' local conditions and their economic and

ecological requirements.

J Minimized consumption of natural resources like water,

energy and raw materials J Making the brewing process as efficient and predictable

as possible J Reduced odour emissions by up to 100 % J Recycling of by-products or waste products J Tailored energy management

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Content

Engineering is our competence

MILLSTAR™

LAUTERSTAR™

JETSTAR™

HOPSTAR™ Iso

CRAFT-STAR™

COMPACT-STAR™

CIP concept – brewhouse

GEA brewhouse 2.0

HEAT-STER™

Energy storage system

Beer mix beverages

COMPACT-STAR™ Keller

GEA piping concepts

Flash pasteurizer ECO-FLASH™

YEAST-STAR™

ECO-FERM™

CIP concept – cold process area

Utilities

SolarBrew concept

GEA Process automation solutions

Servicenext level

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. 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.

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MILLSTAR™ – All advantages on its side.

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 J Hygienic design for efficient cleaning J Positive displacement pump for mashing-in: malt to water

ratios of up to 1:2 (without rinsing) J Level control in mash hopper for low oxygen uptake J Optimized spray geometry to avoid mash flotation J Quality automation system: feed roller speed control J Temperature and flow of steeping water individually adjustable

(standard for MILLSTAR™ 5 – 40 t) J Precise and easy adjustment of the crushing roller gap J Mash acidification possible directly in the mill J On request, available with equipment for inert gas flushing J Less ATEX protection measures required due to the wet grist

Sizes: 2.5 t/h – 5 t/h – 10 t/h – 16 t/h – 20 t/h – 25 t/h– 40 t/h

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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.

TCO: Advantages of the LAUTERSTAR™ compared to a

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

Typical features of the LAUTERSTAR™ J Safety system in accordance with EU directives J Indestructible spent grains flaps without any wort loss J Mash intake through the bottom seat valve with little oxygen

pick-up J Sealless center column with gentle central intake of the wort

during circulation J Spent grains removal blade with mechanical actuation

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JETSTAR™ – Technology and energy management hand in hand.

The JETSTAR™ allows a completely innovative process in

atmospheric kettles: the two-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.

Your benefits at a glance J More flexible wort boiling technology with two-phase

boiling: Thermal conversion processes and evaporation are

independent from each other J Homogeneous wort mixing in the wort kettle J Technological flexibility J Economical and technological advantages J Energy savings due to low evaporation

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HOPSTAR™ Iso – Efficient treatment methods.

We offer efficient treatment methods for higher alpha acid yields

in combination with significantly reduced energy expenditure for

wort boiling.

The HOPSTAR™ Iso equipment for homogenization and

isomerization of hop extract suspension is characterized by the

efficient and sustainable use of hops, especially the alpha acid:

J 30 % Reduction of hop dosing J 50 % Energy savings during wort boiling

HOPSTAR™ Iso equipment at a glance J Hop extract dosing unit J Heating unit plate heat exchanger or J Direct steam injection J Hop receiving tank with high speed mixing unit J Homogenizer J Heat treatment pipes J Suspension cooler plate heat exchanger J Collecting and dosing tanks

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CRAFT-STAR™ – Innovation for artisan craft brewers.

The new Huppmann brewhouse CRAFT-STAR™ for artisan craft

breweries is a skid-mounted brew system, designed for a flexible

batch size from 25 to 40 hl (20 to 35 U.S. bbl).

The 2-vessel configuration with mash/lauter tun and Whirlpool/

wort kettle is ready for single-step infusion mashing and the

efficient solution for ale breweries.

The 3-vessel configuration with mash tun, lauter tun and

Whirlpool/wort kettle for up to 5 brews/day is ready for all infusion

and decoction mashing regimes and thus allowing to brew a wide

range of international beer styles.

Your benefits J GEA pre-masher and water mixer J GEA lauter technology with differential-pressure measuring J GEA Whirlpool/wort kettle with external boiler and wort

spreader J GEARBOXX™ automation with recipe database and WLAN

mobility J Short manufacturing times and cost advantages due to

standardized concept J Fast project realization due to pre-assembly and commissioning

in GEA workshops

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COMPACT-STAR™ – Brewhouse concept for 40 to 115 hl.

The COMPACT-STAR™ is a customized brewhouse for the

increasing requirements of medium-sized and specialty breweries

with a cast-out quantity from 40 to 115 hl (35 to 100 U.S. 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.

Your benefits J Individual brewhouse concept for customer’s needs J High flexibility due to modular design J User-friendly control and monitoring by an GEA automation

and visualization system

Concept versions at a glance J Basic configuration with 3 vessels 5 brews per day J Upgrade with a pre-run tank 7 brews per day J Upgrade with a Whirlpool 9 brews per day J Upgrade with a MILLSTAR™ 12 brews per day J Ale-brewery with 2 vessels

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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. 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.

Your benefits at a glance J Upgrade of CIP processes results in a time advantage of at least

3 hours and thereby reduces labour costs J Production processes and CIP processes in the brewhouse can

run simultaneously J Reduced consumption of cleaning agents due to elimination of

caustic brew J Reduced power consumption during cleaning J As product-safety is ensured in the complete pipe system,

production can start earlier – additional capacity is created J Useful instrument to boost production – with only few

mechanical modifications J Maximum equipment utilization, particularly in peak times

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The perfect brewhouse 2.0 – Go news ways with GEA.

Given ever rising energy costs and with our focus on green

breweries we have developed a brewhouse aimed at reducing

operational expenditure (OPEX) and investment required for

utility plants.

The perfect brewhouse 2.0 consists of a traditional mashing and

lautering process with a mashing in cycle of 40 min. This reduces

batch sizes and thereby utility peaks.

The wort treatment is continuous incorporating a boiling step with

a minimum evaporation rate, a trub separation step, a stripping

process for the removal of volatiles and last but not least a wort

cooling process.

This process design allows reduction of the steam peak by 80 %,

a reduction of peak electrical power by 20 % and gives rise to

optimum utilization conditions for a combined heat & power plant.

Summary J Ideal concept for sustainable energy supply J Perfect combination with combined heat & power plants J Significantly reduced steam peak J Flexible evaporation strategy with a minimum evaporation rate

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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.

Your benefits J Optimal spent grains combustion system J Fluidized bed technology J Covers up to 60 % of the heat demand in the production process J Energy demand and spent grains availability go hand-in-hand J Reaches all demands of TA Luft

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Energy storage system (ESS) – More effi ciency 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 hectoliters of beer per year.

Two reasons are responsible for this success: the reduced total

evaporation rate in combination with atmospheric boiling and the

more effi cient energy recycling in the brewhouse.

Effi ciency of the energy storage system by using the installed

calorimeter at vapour condenser and wort heater

J Data are recorded and archived by the control system J Ad hoc information displayed on the screen of the PLC J Operation time of vapour condenser is shown as percentage of

total boiling time, if evaporation rate is above balance

Energy transferred at wort heaterEnergy leaving vapour condenser ƞESS =

Energy storage tank

Whirlpool

Heat exchanger

Pre-run tank

Vapourcondenser

Wort kettle

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Process technology for beer mix beverages – 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 fl exible manner and make them fi t for the

future.

Your benefi ts at a glance J GEA Brewery Systems uses modern technology enabling the

fl exible and effi cient production of high-quality beer mixes J The combination of proven and well-engineered process steps,

a sophisticated tailored control system and precision measuring

instruments ensures a consistently high quality J Our customized plant concepts are individually tailored to the

needs of our customers and the space available on site J The brewery benefi ts from full automation of the core processes

of dosing and mixing, high mixing accuracy, minimum product

loss

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COMPACT-STAR™ Keller – Building blocks for your individual brewery.

COMPACT-STAR™ Keller is a modular concept for the cold process

area. Processes are grouped together on prefabricated and pretested

units. Thus, the installation time and the commissioning on site can

be optimized and costs reduced.

Consistent, comprehensive and future-proof –

that's our COMPACT-STAR™ Keller

With a prefabricated modular design, the COMPACT-STAR™

Keller is our concept for the cold process area for breweries

with an annual output from 10,000 to 300,000 hl (8,500 to

256,000 U.S. bbl). The modular design allows for easy and individual

expansion.

Your benefits at a glance J Simple and flexible design J Technically proven modules J Flexibility in capacity planning J Minimum requirements on the place of installation J Fast availability is beneficial for ROI considerations J Consistent and reproducible high beer quality

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GEA piping concepts – Efficient systems with the focus on quality.

We have the right solution for the wide variety of tasks in your

brewery, from pipe fence solutions and the manual system

ECO-FENCE™ up to the fully automated ECO-MATRIX™ piping

system.

Individual and ideal piping concepts, which improve the foam and

flavor stability of your beer – with minimum life cycle costs.

Your benefits

With regard to plant investment costs J Fewer valves J Easier installation J Easier automation

With regard to running costs J Less flush-out losses due to favorable valve arrangement and

shorter pipes J Less CIP losses due to the integrated LEFF® module J Less maintenance work

Additional benefits J Highest flexibility J Ecologically sound operation J Fail-safe operation

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Flash pasteurizer system ECO-FLASH™ – Beer stabilization for highest demands.

With our flexible modular ECO-FLASH™ systems, we are the

ideal partner for breweries when it comes to beer stabilization

for highest demands. GEA Brewery Systems has developed the

microbiological stabilization by flash pasteurization into a safe and

cost-effective method ensuring uncompromised quality. Thanks to

the recuperative design, as much as 96 % of the heat input can be

recovered. This makes flash pasteurization the most cost-effective

of all heat treatment methods today.

The ECO-FLASH™ system is available in five sizes and with two

levels of automation – and, on request, in modular design for

future extension.

Possible options J Fully automatic monitoring of the positive pressure gradient J Fully automatic control of the CO2 pressure in the buffer tank J Pasteurization pressure control J Heat recovery rate up to 96 % J Heat insulated buffer tank

Size Capacity range

DN 25/40 20 hl/h to 80 hl/h

DN 50 80 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

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YEAST-STAR™ – The yeast propagation concept for breweries.

YEAST-STAR™ is the tailor-made concept for your yeast

management – from a simple unit to a complex plant.

Features of YEAST-STAR™ J Vigorous, actively fermenting yeast J Less equipment required J Optimal aeration rates J Gentle circulation loop J Sterile air station with candle filter and product trap J Optional: In-line alcohol measurement, automatic

determination of yeast cell count, etc.

Your benefits at a glance J Maximum microbiological process safety because the EHEDG

guidelines are followed J High constant beer quality due to especially vigorous and

viable yeast cells J Essential nutrients are preserved as additional wort treatment

is avoided J Little foam formation and homogeneous mixing J Highest possible flexibility in the process J Optimized concept in terms of space requirements and costs

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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 J Shorter fermentation and maturation time; the total occupation

time of a tank is thus reduced by up to 25 % J Consistently high degrees of final attenuation J Uniformity of the fermentation means better scheduling of

tank occupancy J Homogeneous temperature distribution in the fermentation

tank during warm maturation and cooling J Improved yeast vitality due to reduced sediment formation in

the tank cone J Constantly high beer quality and unchanged flavor profile J More fermenting capacity with the same number of tanks

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Cold process CIP concept – Increased plant availability and savings.

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 by

means of equipment optimization certain criteria have to be met.

When it comes to the cleaning of equipment, vessels and pipes in a

brewery, the major criterion can only be perfect cleanliness.

The intelligent combination of energy efficient components and

cleaning processes results in improved plant availability, which

ultimately means a higher capacity.

Your benefits at a glance J Individually engineered for your needs J Reduced consumption of cleaning agents and water due to the

use of high-performance components and innovative cleaning

procedures (small water barrier between the different cleaning

agents) J Minimized energy consumption J Easy handling and minimized service intervals for a long life

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Utilities – Refrigeration and CO2 recovery.

To realize functional and economical solutions, expertise from

both worlds, refrigeration technology and the brewing process, is

essential. For over 80 years GEA Brewery Systems has 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 J Optimum operating conditions J Extremely efficient operation by multi-temperature circuits J Intelligent control system for optimized processes

CO2 recovery plants J CO2 audit to determine the amount of CO2 produced and

required J Precise calculation of the CO2 produced J Upgrade of existing plants J Sustainable investment thanks to industrial type components

“Made in Germany” J Use of natural refrigerant (ammonia) J Flexible integration into the control system J International experience and approvals

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SolarBrew Concept – Go new ways with GEA.

The project aim is to show the technological and economic

practicability in terms of integrating big solar thermal systems in

the brewing industry.

Brewing processes qualify themselves for the integration of solar

heat because of their process temperature levels. Processes with

temperature ranges between 50 to 100 °C are very suitable for

the integration of solar thermal plants as the effi ciency of solar

collectors (fl at plate and vacuum tube) in this temperature range

is high.

To gain experience in this fi eld of technology the construction of

three solar thermal plants in three diff erent 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 a

total of 7,270 m² collector area.

GEA Project Manager: Dr. Ludwig Scheller

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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GEA Process Automation Solutions – Diversity in process control engineering.

We offer proven field-tested solutions that are individually tailored

to your processes. Our process control experts select the right tools

from the software available on the market and adapt them to your

needs. The combination of our experience in process engineering

and brewing technology, and our extensive knowledge of the

industry-specific requirements is the key to making the right

decisions.

As system integrator we combine our knowledge of process

and plant engineering with software products from

the market leaders (e. g. Siemens WinCC & BRAUMAT,

Wonderware InTouch, GE Intelligent Platforms iFIX, ProLeiT

brewmaxx).

Our control systems at a glance J GEARBOXX™ – efficient process automation of plant sections

and units J OTAS™ – Open Technology Automation Solution for SCADA

systems and for fully integrated plant wide process control J brewmaxx™ – process control solution for breweries, MES

included J BRAUMAT – the process control system for the entire beverage

production process

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Servicenext level – Partnership for optimum plant efficiency.

Together with our customers, we design intelligent solutions aimed

at fully exploiting the potential of your brewery and achieving a

continuous and cost-effective production process.

We provide intelligent service concepts - flexible and future-

oriented.

Servicenext level stands for J Technical service modules ensuring high plant availability for

increased production safety J Technological service modules ensuring high efficiency for

optimized production costs J Audits for transparency to make informed decisions J Energy efficiency check – mobiles Energiedatenmanagement J Spare parts service and emergency service – 24 h / 365 days– J Training programs

Servicenext level − the results speak for themselves J High plant availability J Excellent system efficiency J Spare parts availability as required

Optimized operating costs (TCO)

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Further GEA Group innovations for breweries

J Decanter for the beverage industry

Westfalia Separator® ecoforce gMaster CF 6000

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

J 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

J Beer recovery with nozzle separator

J Beer recovery with ceramic membrane filtration

J Flavored Alcoholic Beverages (FAB)

J Clear Malt Base Beverages and FAB

Purification techniques (flavour/colour)

Nanofiltration units

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J Dealcoholization of beer

J Solutions for sustainability

Consumption reductions of energy, water, etc.

J New energy saving centrifuges

J Westfalia Separator® directdrive + hydrostop

The new separator generation

J VARIVENT® Valve Technology

Single-seat, divert, control and mixproof valves

J GEA Breconcherry

Cleaning devices according to todays

hygienic standards

J GEA Tuchenhagen®-VARIFLOW TPS

Hygienic self-priming centrifugal pump

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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 2–10, 21514 Büchen, Germany Phone +49 4155 49-0, Fax +49 4155 49-2770

gea-brewerysystems @ gea.com, www.gea.com

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

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