How Many Fermentation Tanks Do I Need to Meet My Production Targets?

Determining the number of fermentation tanks required to meet your production targets is a critical decision for any brewery. It involves understanding your production goals, fermentation timelines, and operational workflow. This article will guide you through the key considerations and calculations necessary to determine the optimal number of fermentation tanks for your brewery.brewery equipment for sale

Understanding Production Targets

Before determining the number of fermentation tanks, it's essential to define your production targets clearly:

Annual Production Volume: The total amount of beer you aim to produce in a year, typically measured in barrels (BBL).

Batch Size: The volume of beer produced in each brewing session.

Brewing Frequency: How often you plan to brew (e.g., daily, weekly).

Key Factors to Consider

Fermentation Time

Different beer styles have varying fermentation and conditioning times. Ales typically ferment for 1-2 weeks, while lagers may take 4-6 weeks or longer. The fermentation time directly impacts tank availability.

Brewing Schedule

The frequency of your brewing cycles affects how quickly you need to free up tanks for the next batch. More frequent brewing requires more fermentation capacity to keep up with the production schedule.beer brewery equipment

Tank Turnover Rate

The turnover rate is how quickly a fermentation tank can be emptied, cleaned, and refilled with a new batch. Efficient turnover rates maximize the use of each tank.

Scaling and Flexibility

Consider potential future growth and the need for flexibility in your brewing operations. Investing in additional tanks can provide the capacity to scale up production as demand increases.

Calculating the Number of Fermentation Tanks

To calculate the number of fermentation tanks required, follow these steps:

Determine Annual Production Targets

Example: Your brewery aims to produce 1,000 BBL per year.

Define Batch Size

Example: Each batch produces 10 BBL.

Establish Brewing Frequency

Example: You plan to brew twice a week (104 batches per year).

Calculate Fermentation Time

Example: Average fermentation time is 2 weeks.

Calculate Tank Turnover

Turnover time includes fermentation time plus additional time for conditioning, cleaning, and preparation for the next batch.

Example: Total turnover time is 3 weeks.

Calculate Number of Batches Per Tank Per Year

Determine how many times each tank can be used in a year.

Example: 52 weeks per year / 3-week turnover time = 17.33 batches per tank per year.

Determine Number of Tanks Needed

Divide the total number of batches required per year by the number of batches each tank can handle per year.

Example: 104 batches per year / 17.33 batches per tank per year ≈ 6 tanks.

Additional Considerations

Buffer for Peak Production

Consider a buffer for periods of peak production or unexpected delays. Adding 1-2 extra tanks can provide flexibility and prevent bottlenecks.

Multiple Beer Styles

If brewing multiple beer styles with different fermentation times, calculate the tank requirements for each style separately and sum them up.

Tank Size Variability

Depending on your production goals, you may choose tanks of different sizes to optimize brewing efficiency and meet varying batch sizes.

Space and Budget Constraints

Ensure your facility has enough space to accommodate the required number of tanks. Also, factor in the cost of additional tanks and associated infrastructure.

Expansion Plans

If you plan to expand your brewery, consider future needs when purchasing tanks. It may be more cost-effective to invest in additional capacity upfront.

Example Calculation

Let's apply these steps to a hypothetical brewery:

Annual Production Volume: 1,000 BBL

Batch Size: 10 BBL

Brewing Frequency: Twice a week (104 batches per year)

Fermentation Time: 2 weeks

Tank Turnover Time: 3 weeks

Calculate Number of Batches Per Tank Per Year:

52 weeks / 3 weeks turnover time = 17.33 batches per tank per year.

Determine Number of Tanks Needed:

104 batches per year / 17.33 batches per tank per year ≈ 6 tanks.

To accommodate peak production periods and potential delays, the brewery might consider adding an additional tank, bringing the total to 7 tanks.