COMPLETE BREWING SOLUTIONS

“From malt to beer”

With the aim to accommodate your future plans and the full range of brewing styles, we can design and construct all units of your brewery.

1. Malt handling

Our team helps to design and install the most convenient and effective solution for the malt handling processes of your brewery. We produce malt mills, hoppers, conveyor systems, malt measuring and storage tanks and spent grain bunkers to cover most phases of the malt’s journey.

Malt milling

Malt is the base and one of the most valuable ingredients of your beer. Grinding the malt the proper way is key for the optimal mashing and lautering processes. Choosing equipment that guarantees the quality crush for your grains ensures consistent beers and pays your investment in the long run. We offer stainless steel malt grinders with 600 and 1200 kg/ hour capacities in 2 and 4 roller configurations.

Our ZIPMILL malt grinders are available in several setups depending on the requirement of the brewer. They can be mounted on legs as a stand alone unit, on top of a malt grist hopper, or built on a pre-mashing unit. ZIPMILLs are connected to other malt handling units with a proper chain conveyor system.

Pre-mashing

During the mashing process, it is important to ensure a homogeneous mixing that focuses on enhancing a proper enzymatic activation, heat and temperature distribution throughout the mash and avoiding malt clump formation. For this, we have developed two different pre-mashing setups that would complement the chosen malt handling solution.

We offer a pre-masher setup with a mixing tank and recirculation pumps to ensure a clump-free mash for systems up to 2000 liter. For bigger systems we offer a gravitational pre-masher, that will still enhance the clump-free mash and make the process easier by having the chance of getting a higher degree of automation.

2. Brewhouse solutions

The brewhouse as the most important part of every brewery plays a crucial role in determining the product’s quality, consistency, and yield. With our smart, highly automated technologies the brewing processes are cost, energy and time efficient. Our brewhouse units are designed to fit the specific productional needs of our partners, be it an industrial craft brewery, a spectacular brewpub concept or a small pilot brewery for recipe testing. Our brewhouses are available from 50 to 5000 liter per brew capacity with a wide range of configuration possibilities. Regardless of the model, the quality itself is always constant.

Industrial brewhouses

ZIP’s line of industrial brewhouses are designed for breweries with a production capacity over 1000 liter per brew. The development of industrial systems begins with a comprehensive consultation to determine the exact needs of the investor and the brewmaster including desired beer output, beer types and the sales and distribution method. Industrial breweries are equipped with cutting-edge technology to ensure seamless, efficient and repeatable production in the long term.

Brewpub system

A different kind of restaurant that is on pace with today’s trends in gastronomy, a brewpub restaurant features a brewing equipment on display for the guests. Beer is freshly brewed, fermented, served and consumed on premise. With 30 years of experience working in unique locations ranging from ancient cellars to floating ships, the team at ZIP understands multiple challenges you face when fitting a functioning brewery into your restaurant. We aim to combine form and function in the design so it results in an eye-catching product that isn’t simply a design feature, but also an active part of your business.

NANO pilot brewery

Our small but smart 50 liter NANO brewery is developed to serve:

The NANO pilot brewery can produce 50-55 liter cast out volume depending on the beer style. Similar to our industrial systems it can be operated with our self-developed, user-friendly software, the ZIPMATIC. The modern, automated control system ensures proper step-by-step implementation of the processes of mashing, lautering, sparging, boiling with hops, whirlpooling, chilling and CIP-cleaning.

3. Highly automated brewery control

Automation is a critical part of a modern brewery striving to work effectively and efficiently. It liberates the brewmaster from routine monotonic work, releasing more time and energy for creative pursuits, stabilizes quality throughout batches and provides accountability for owners / investors. Our self-developed software, ZIPMATIC offers control technology and automated solutions for the brewing processes, from the arrival of malt until the packaging of the finished beer.

The entire software is developed by utilising the expertise of brewmasters and technologists with the aim to create an all-in-one, user-friendly operating platform which is convenient and understandable for all brewers, while at the same time allowing the flexibility to tailor it to the individual needs. The high level of automation ensures that every step of our operation and our recipes can be tracked, saved and thus reproduced to guarantee constant product quality.

With the help of ZIPMATIC’s remote access, you can keep an eye on everything going on at the brewery even when you are not there. The software can be opened anytime and anywhere, from your computer or by our ZIPMATIC + application.

Features of full-automatic ZIP brewhouse

4. Heating by steam generator

ZIP electric steam generators provide the required steam for various brewing processes, such as mashing and hop boiling. The advantage of steam heating, besides high efficiency, is the uniform heating through latent heat transfer, which allows fast and precise temperature control in production processes. Our steam generators are compact, easy to use systems with small space requirement. As part of the brewery it is operated with automatic program control via the brewery PLC.

5. Complete cooling systems

Our compact, integrated cooling system contains all the necessary elements to provide stable cooling throughout the brewing processes, minimizing energy costs and microbiological concerns. The glycol is used to chill both the fermentation and serving tanks, while the ice water – to chill the wort rapidly prior to yeast pitching. A network of insulated copper piping is soldered to fit the individual brewery site during installation to oversee the cooling of the fermentation and serving tanks. All operational data on the cooling system is collected and saved in the central automation system. ZIP chillers have an environmentally friendly construction, and they fully comply with the latest Ecodesign regulations.

6. Fermentation and storage tanks

The quality of the final product is determined not only by the brewing process but also by the proper fermentation and storage. We provide an all-in-one solution for the cold area including fermentation and storage tanks in various sizes and flexible configurations together with complete stainless steel piping, cooling and CIP solutions.

7. Hop technology

Modern times and modern trends are demanding higher efficiency and complexity related to hops. With the increasing and leading popularity of beers with unimaginable loads of hops, our goal is to provide our customers with the most flexible and efficient solutions to achieve the desired hoppiness profiles, in terms of bitterness, flavor and aroma. From the hot side of production to the cold area, we have developed different solutions that could be adjusted to our customers requirements. All these solutions could be adjusted onto a unique setup to produce any style of beers with ease.

8. Separation

Beer losses have always been a concern in the brewing industry, and mainly nowadays with new brewing trends developing every day. Due to the high loads of dry hopping, fruits and spices and the regular yeast growth, a decrease in production yield could be foreseen. To improve performance, we offer separation solutions powered by our partner Alfa Laval. With these separators, we have the flexibility of focusing mainly on recovering beer from surplus yeast and hops or any insoluble compounds, while also complementing yeast management by the gentle recovery of useful yeast as well, reducing raw material costs. This equipment also aids to have a more efficient filtration of the finished product due to the extraction from the mix of already some undesired compounds, increasing yield and reducing time and filtering costs.

9. Pasteurization

Our self developed flash pasteurizer ensures the sterilization and preservation of the finished beer by destroying any deteriorating yeast and bacterial cells present in the beer with the help of heat treatment. In the pasteurization process, the beer is heated through a heat exchanger, held for a pre-set time span to reach the desired pasteurization units, and then cooled. Our flash pasteurizers are highly automated for better efficiency and process control and they are available with capacities from 1 000 to 10 000 liters per hour in two configurations:

Based on the customers’ request and the size, the equipment can be heated electrically or by steam. The system is equipped with a heat recovery unit resulting in low energy consumption and saving over 90-95% of the heat energy.

10. CIP cleaning

A CIP (Clean In Place) system is a crucial part of any production line to ensure cleanliness, sanitation and hygiene for a microbiologically safe operation, consistent product quality and the prevention of contaminations. We offer a wide range of CIP solutions for the cleaning of the entire brewery including brewhouse, fermentation area, pipelines, filling lines, etc. Depending on the specific needs for the cleaning process, our CIP systems are available in different configurations, number of vessels and level of automation offering maximum flexibility to carry out this important task in the simplest, most convenient way while saving water, detergents and your equipment.

11. Serving and packaging of ready beer

Depending on your productional and business concept, we offer different solutions for the serving and packaging of your finished beer.

Tapping systems

In case of brewpub systems, we have the expertise of constructing complete tapping systems with appropriate cooling and CIP cleaning. In our palette we can offer bar or table tap configurations. The level of automation of the system could be designed on demand, with tracking tools such as flowmeters (for inventory and interactive experiences with the customers), touch screens and POS compatible systems. In order to enhance the guest experience, our tapping systems can be complemented with creative solutions such as:

KEG cleaning filling machines

ZIP KEG machines are available with different functions such as: only cleaning, cleaning and filling and only filling. Depending on the number of KEGs to be handled, we can offer 1 and 2 head constructions. These machines have a fully programmable operator interface for optimal cleaning flexibility and efficiency. The processes are automatic, except for the loading of the KEGs onto the working platform. The whole structure, including all of the single parts and pipelines are made of stainless steel with a construction that is easy to maintain. Each of our machines are conditioned with two tanks with an alkaline solution and an acidic solution, two independent pumps (to avoid any chemical cross contamination), automatic control (with a different set of sensors), optionally a steam generator for sterilization and counterpressure filling.

Our team offers maximum support in the configuration of your individual system from the first idea to the brewing of the first batch and beyond. We can support your brewery project with:

technical consultation for building construction (electrical, water, canalisation, air, steam connection plans)
preparation of layout drawings, P&ID plans
3D plans of the future brewery in the building, upon request
beer technology consulting
flexible approach for individual requests, specification.

Are you planning to open your own brewery?

We are here to help you during the whole process of building your brewery step by step.