MATURATION LAGERING TANKS – the maturation of beer
The main fermentation process of the young beer (or cider), which intermediate is called green beer, follows the process of the maturation of beer in the maturation tanks (also called lagering tanks). They are special beer production tanks designed only for second phase of the beer fermentation process. During this production phase, the beer maturates, or saturates with the carbon dioxide, which is formed from the remaining yeast activity. This way the beer acquires savour.
Maturation is the longest stage of the beer production process. The length of the beer maturation process depends on the chosen recipe, temperature and the set pressure in the maturation tank. Maturation of bottom fermented beer with EPM 10 % takes two to three weeks, light lager with EPM 12% at least 30 days, beer with special EPM above 12 % takes 60 days up to several months.
The length of the maturation process of beer, the batch size and frequency of its production is important for the decisions on the required number of maturation tanks in the brewery.
Equipment of maturation tanks :
Typical equipment of our maturation tanks
- Overpressure setting mechanism from 0 to 3 bar (over-pressure tanks with the maturation bottling function)
- Cooling channels – duplicators for circulating of coolant
- PUR insulation – thickness corresponding to the size of the tank and the environment
- Stainless steel jacket – with the customer selected surface finishing
- Guaranteed inner surface roughness of Ra = 0.8 microns (except in very small containers and terminating welds on intermediate vessels)
- Manhole on the bottom or on cylinder part (according to customer requirements)
- Outlet / inlet for beer or cider
- Outlet / inlet for dosing and discharge of yeast
- Sanitation shower – sprayball (static or rotary) – one or more pcs
- Cleanable and sanitizable sampling cock
- Double-acting air vent valve
- Independent safety overpressure valve
- Thermometer pocket
- Cleanable and sanitizable glass level indicator
Optional equipment of of our maturation tanks
- Frame or frame-system for positioning of horizontal tanks at several levels above each other
- Thermometer or thermo-sensor
- Automatic valves for regulation the coolant flow in the cooling channels
- Local thermostat unit (control valves duplicators, depending on the temperature)
- Control system for manual or automatic control of the fermentation and maturation process
- Carbonation stone – the special jet for carbonation of beverages from CO2 bottles
- Stainless steel ladder for easy access to the door of the tank
The Guide the four types of maturation tanks in our offer
We manufacture and supply lagering tanks in various designs with our microbreweries:
I. Types of beer maturation lagering tanks according to the the design of a cooling method:
1. Beer maturation lagering tanks with single-jacket (air-coolled)
Simple and cheap non-insulated tanks , cooled by cold air. The traditional way of cooling in a lager cellar . The advantage is low cost, but there is also number of disadvantages: high cooling energy demands (it can be affected by the quality of the thermal insulation of walls in the lager cellar) , the impossibility of controlling the maturation ( it is not possible to set different temperatures in individual tanks ), low comfort of work in the lager cellar ( cellar workers are working in very cold and humid environment which is not conducive to their health and working condition ).
It is necessary to note that for the brewery cellar with single-shell tanks it is needed to create a cooling box, a room with very good insulation of walls and ceiling and with a refrigerator door. The operating costs of cooling are particularly during the summer months, possibly year-round in tropical areas, significantly higher than the lager cellar with insulated tanks cooled by liquid. These increased costs to the building and operation usually outweigh the savings from buying cheaper technology brewery.
In contrast, the solution is usually advantageous for air cooling Microbrewery what need to create a refrigerated storage area for filled kegs or bottles of beer, and have not a dedicated storage room. In this case, together with the beer for sale are simultaneously cooled also lager tanks.
2. Beer maturation lagering tanks with double-jacket (liquid cooled)
– more elaborate insulated tanks, cooled by glycol or ice water circulating in the double jacket duplicators. The modern way of cooling a lager cellar, which is standard in modern breweries. Besides the apparent disadvantage of the higher initial cost, these tanks have only advantages: low cost of cooling operation (cooling only beer, not space), low demand at the place of installation (no need to insulate storage cellar, tanks can be in any room), comfortable operation (in the room with tanks is not need to regulate the teperature ). possibility to control maturation in each tank separately. The only suitable solution for automated management system of the brewery.
II. Types of beer maturation lager tanks according to the spatial orientation:
1. Beer maturation lagering tanks vertical
– tanks in a brewery are “standing”. Easy for cleaning and sanitation and there is also easy access to the tanks from all sides. The disadvantage is the space requirement both in height and in the area of beer cellar. Vertical maturation tanks are standard in modern breweries and this concept is preferred where small space is no fundamental limitation.
2. Beer maturation lagering tanks horizontal
The advantage is saving place. In the same area we can place a greater number of tanks, if they are arranged in the battery, i.e. several rows one above another. The disadvantage is the difficult cleaning and sanitation of the tanks stored too low or too high. Battery tanks are difficult to clean from outside – in inaccessible surfaces of tanks organic contaminants may accumulate and contaminate the produced beer.
The construction of maturation tanks depending on allowed overpressure and using
The standardized maturation tanks which we product and deliver with our breweries and cider houses are usually designed for max. overpressure 3.0 bar and we test them for overpressure 4.0 bar in our works. Notice : These tanks are classified as pressure vessels according to PED (Directive 97/23/EC).
According to customer request we can replace all the maturation tanks by combi-serving tanks with a maximum allowed overpressure of 3.0 bar tested by PED with combined functionality both lager and bright beer tanks – then the microbrewery operator can bottle and serve beer from any pressurized lager tank without pumping beer into dedicated serving tanks.
Variations of maturation tanks according to their quality and equipment :
According to requirements and financial possibilities of customers we recognize the maturation tanks with three classes of quality and equipment:
- HQ – HIGH Quality – High quality workmanship of all parts, welded joints and surfaces. The inner surface has a guaranteed roughness Ra<0.8 μm – glossy design. The outer surface is unified. All functional armatures and fittings that have an impact on the reliability and safety of the products are made in Europe or in the USA. Luxury equipment of the tanks. The main advantages are the savings of sanitizing solutions, water and energy, minimized losses of beverages, shorter work time, reduction of production costs. Three years warranty for stainless steel main parts and also for the fittings. The quality class for the most demanding customers.
- SQ – STANDARD Quality – Standard quality workmanship of all parts, welded joints and surfaces. All functional armatures and fittings that have an impact on the reliability and safety of the products are purchased from approved suppliers from Europe or USA. Inspection of all critical welds and joints. The inner surface has a guaranteed roughness Ra=0.8μm – semi glossy design. Usual equipment af the vessels, usual set of fittings. Tanks in this quality class comply with all European regulations for pressure vessels and food processing plants. Two years warranty for stainless steel main parts, two year for the fittings. It is the most often ordered quality variaton of tanks for our customers.
- LQ – LOWER Quality – Lower quality workmanship of all parts, welded joints and surfaces. The most of functional armatures and fittings are purchased from approved suppliers from Asia. The inner and outer surface are not unified. Not guaranteed surface roughness on the inside of the containers. This solution is interesting only for starting small breweries because it saves an investition costs. Unfortunatelly, this brings higer beverage production costs. Longer period of sanitation, greater consumption of the sanitizing solution, energy, labor and hot water. High losses of produced beverages. We don´t offer this quality class for our products, because the equipment with the LQ quality class does not comply with the European regulations for pressure vessels and food processing plants. It is the quality of tanks of very cheap world producers of the tanks.
MLT - Maturation lagering tanks : Quality + Equipment
Specification and equipment HQ SQ LQ
Production of the Czech Mini Breweries optional standard we don´t offer
Competitors' production (usual reality) rarely optional standard
Main fittings producers Europe Europe Asia
*** Inner surface - roughness Ra < 0.8μm Ra = 0.8μm Ra > 0.8μm
*** Inner surface - sheen glossy semi glossy matte
Outer surface - united design yes no no
* Connections of outer plates welved welved riveted
* PU insulation > 50 mm > 40 mm < 40 mm
Thickness of the inner plates > 3 mm > 3 mm < 3 mm
* Thickness of the outer plates > 1,5 mm > 1,5 mm < 1,5 mm
* Penetration test yes yes no
Design quality 100% 100% unspecified
Function quality 100% 100% unspecified
* Pressure relief valve - adjustable range 0 - 3 bar 0 - 3 bar 0 - 2 bar
* Pressure relief valve - with adjusting scale yes extra charge no
Level indicator - sanitable yes yes no
Level indicator - with scale yes extra charge no
Vacuum-overpressure aeration valve yes yes yes
** Independent safe overpressure valve 3.3 bar 3.3 bar no
Rotary shower - pressurizing nozzle yes yes extra charge
Inlet / outlet valve yes yes yes
Yeast draining valve yes yes yes
Sampling valve - removable yes yes no
* Overpressure manhole (upper or side) yes yes yes
* Cooling area of duplicators > 60% > 60% < 60%
Manometer yes yes yes
Thermocouple for each cooling zone yes yes yes
PED 97/23/EC certificate yes - always yes - always rarely
ASME / GUM / GOST-R certificate optionally optionally rarely
Warranty 36 months 24 months 12 months
Asterisks: *= only for insulated tanks cooled by glycol **= only for pressure tanks > 1000L ***= only for pressure tanks > 300L
Our quality Ten: Why to buy maturation tanks just from us?
(why we can not to be the cheapest …)
- We design, manufacture, mounted and testing of all vessels (excluding non-pressure) in accordance with the strict standards and guidelines for pressure vessels (EU Directive PED 97/23 / EC Pressure Equipment). I.e :
- Each pressure vessel contains a double-acting air vent valve (prevents against an over pressurization or implosion of the tank during its charging / discharging)
- Each pressure vessel also contains an independent overpressure safety valve (prevents against a very dangerous overpressurization of the vessel and the subsequent explosion during a malfunction or insufficient capacity of the double acting air vent valve)
- Each pressure vessel is designed by certified designer who is qualified for the designing and calculation of pressure vessels.
- Production documentation for each pressure vessel containing static strength calculation, the exact description of a right manufacturing process, including the required types of welds, thickness of material, critical points solutions.
- All the manufactured pressure vessels are subjected to rigorous testing of tightness and porosity of welds, using a special liquid that detects even the slightest unwanted leaks, pores or micro-cracks = The Penetration Test
- Pressure vessels are tested at overpressure which is at least 1 bar higher than the overpressure, for which containers are certified.
- The Protocol on the tightness and pressure tests and the EU declaration of conformity are issued to all pressure vessels. We also attach the Pressure vessel passport, at the request of the customer.
- Manufacturing processes, design drawings, manufacturing, tightness and pressure tests are supervised by an inspector of TÜV SÜD Czech or another certified company, supplying quality control and compliance with European standards.
- Each pressure vessel contains an indelible nameplate with the obligatory name of the manufacturer, the ultimate pressure or other data that uniquely identifies the concrete pressure vessel in accordance with EU PED 97/23 / EC
- Optionally we can produce the pressure equipment according to the conditions and standards of ASME, GOST-R or GUM certification rules. In this case, we charge an extra surcharge for the special certification :
- PED certification … is included in the price
- ASME certification … surcharge 10%
- GUM certification … surcharge 5% – We ensure all necessary technical equipment of the tank (GUM compliant), a customer pays and handles the certification process for the tank on site.
- GOST-R certification … surcharge 10%
- We produce food containers fundamentally from food stainless steel that fully comply with the Regulation of the European Parliament and Council Regulation EC no. 1935/2004. These materials do not release their constituents to food in quantities which could endanger human health or bring about an unacceptable changes in the composition of food or a deterioration in their organoleptic and sensory characteristics in contact with food under normal or foreseeable conditions. We do not use cheap stainless steel with lower quality, which will soon lose their corrosion resistance and indifference to food, especially after repeated contact with the sanitation solutions.
- We are looking into suppliers of construction and installation materials and components from which we produce equipment for food production and handling. We do not buy any material from importers who are unable to prove its European origins and characteristics.
- All the tanks, which we design for maturation, maturation and storage of beverages, have optimized dimensions for the maturation processes, maturation process, carbonation, carried out in accordance with technological standards for beverages production. We do not set the dimensions of the containers by an unqualified “eyeball” estimate .
- All containers that are made in HQ quality class, are produced with the guaranteed inner surface roughness of Ra < 0.8 microns , containers that are made in SQ quality class, are produced with the guaranteed inner surface roughness of Ra = 0.8 microns (except in very small containers and terminating welds on intermediate vessels), which is the European standard prescribed roughness of the inner surfaces of the containers that come into contact with food and carried with their sanitation alkalis and acids. Guaranteed roughness of the inner surface of the vessel is extremely important to ensure thorough cleaning and sanitation tanks. This is an essential prerequisite for achieving purity and sterility of food production equipment. We guarantee this limited roughness for 100% of the interior surface . We repeatedly do measurements of all internal surfaces of tanks with the special oughness-meter TR-130 during all their manufacturing process. We polish the inner surface of the tank until the desired roughness is reached.
- Each container is designed and manufactured in such a way as to ensure easy cleaning and sanitizing of all surfaces that come into contact with food. Therefore, the vessels are equipped with at least one sanitation shower, removable and sanitizable level-indicators and sample cooks. We do not use any cheap fittings, for which the manufacturer has failed to sanitary design and cleanability.
- Tanks in HQ quality class have an united outer surface. All joints of the outer sheets (thickness at least 2 mm) are either welded or completely sealed. This is important to prevent ingress of moisture into the double casing, moistening the insulating material and the loss of insulating ability. This ensures a consistent quality and insulating capacity of the tanks. For containers in LQ quality the external sheets are usually riveted and they have a thickness of at least 1 mm.
- We isolate all the pressure vessels by quality PU foam. The insulating polyuretan foam is professionally applied to the insulating space of the container so as to avoid formation of thermal bridges, unisolated empty space or deformation of containers.We do not use cheap little functional replacements for the isolation of containers such as insulating wool, polystyrene beads, inexpertly applied foam.
- Diameters of nozzles, valves and piping are sized correctly according to the volume and vessel function – we do not mount underpowered functional elements on the tanks.
- The warranty for the tanks produced in HQ is at least 24-36 months. The warranty on vessel in SQ quality is 18 months. The practical life of the vessels is usually several decades, while elements with lower lifetime (dampers, valves, seals, etc.) can usually to be easily replaced with a new standardized elements of the same or another manufacturer.
If you are comparing our prices with competitors, please always make sure that any other manufacturer guarantees the same quality as we offer.
Technical data of lager tanks – four variants maturing vessels:
- Maturation vertical tanks – insulated, liquid-cooled
- Maturation vertical tanks – non-insulated, air-cooled
- Maturation horizontal tanks – insulated, liquid-cooled
- Maturation horizontal tanks – non-insulated, air-cooled