How to start a microbrewery project in 6 steps

Proyecto
Escrito por Alberto Leoni

Making a microbrewery or brewpub as a business model requires a lot of work, in this article we will explain the 6 main steps for the creation of a brewery.

  1. RESEARCH AND TRAINING

Craft beer is always more passionate to consumers, probably if you are thinking of setting up a microbrewery project you are one of them. Before starting the project you should think long and hard to be sure and avoid making false steps.

First of all, you need to acquire the necessary knowledge if you don't have it:

2. LOCATION

Before looking for a location you need to be clear about the amount of liters per year to be produced.

Finding a suitable location can be time-consuming, and we often have to adapt by waiving some non-essential requirement.

Opting for a location that is already in good condition can help us a lot in the start-up of the project. In any case, it will be necessary to adapt the facilities to convert the premises into a brewery that has to comply with the country's sanitary requirements.

This part of the project also has its cost, it is important to consider it together with the price of the equipment and the start-up costs of the project.

Let yourself be advised by experts to understand if the place you found is suitable to set up a microbrewery or a brewpub, a preliminary layout can be helpful to understand if the place is suitable to produce the estimated liters.

A good factorylayout can save you a lot of time, physical labor and additional expenses.

What should you pay attention to when choosing and preparing the location of the brewery?

  • Size: the site must be large enough (not only the surface area, but also the height).

  • Easy access: it is advisable to limit your work area to a single floor, without stairs or other height obstacles, to have sufficiently large doors and access for delivery, and to allow for forklift maneuvering.

  • Legal requirements: obtain all applicable and required permits (change or discharge of license, water supply, electricity, etc).

  • Sanitary requirements: maintaining hygiene is vital for the brewery, facilities should be designed to facilitate cleaning (smooth and washable floor surface, adequate drainage channels and ventilation of the brewhouse).

3. EQUIPMENT

Setting up a microbrewery requires a considerable investment, it is essential to have a clear idea of the type of project (size) you want to carry out and to develop a good feasibility plan.

How much are you willing to invest?

How much beer do you want to produce?

If you have the possibility visit a brewery so you can get an idea of what equipment you need to brew the estimated liters. Study the various brewhouse options.

What equipment do you need to set up your own microbrewery?

  • Malt mill: scaled on the basis of production volume, capacity in kg/h

  • Brewhouse: for wort production, there are smaller electric or steam models with larger capacity.

  • Hot and cold water storage tanks: support the processing process and optimize water consumption

  • Adequate number of fermentation and maturation tanks according to expected annual volumes

  • Cooling equipment and temperature controller: controls the fermentation temperature, the cold water tank and is used for cold settling.

  • Steam generator: in case of steam cooking room, it is a relevant part of the budget.

  • CIP pump or CIP station

  • Flexible hoses: for product transfer and CIP cleaning

  • Barrel, bottle or can filler: according to the chosen format

  • Labeler: according to the chosen format

  • Water treatment equipment: dechlorinator mandatory, osmosis optional depending on local water quality

4. RAW MATERIALS AND PACKAGING

Knowing the ingredients and sourcing suppliers is a fundamental step for a successful start-up of the project.

The main ingredients of beer are barley malt, hops, yeast and, of course, water.

Water

Beer is mainly composed of water. Chlorine-free water is used to brew beer; a dechlorinator is the minimum and indispensable water treatment in every brewery.

Water can be used as an ingredient to accentuate malt or hop flavors, and to control the pH during mashing. Depending on the area and type of water supply, osmosis treatment can be used to lower the mineralization of the water.

In order to evaluate the type of treatment required, a water analysis form can be requested from the water supply company or a sample can be taken to a laboratory. The most relevant parameters for processing water are: chlorine, sodium, sulfates, chlorides, chlorides, bicarbonates, magnesium, calcium, pH,

The pH value is very important and should be systematically controlled during the brewing process, especially during the mashing phase. A correct pH value during this phase benefits the enzymatic activity, color and flavor of the beer, as well as helping the stability of the finished product.

Hops

Hops are a climbing plant whose buds are used in brewing beer. Hops contribute bitterness, flavor and bitterness to the wort, and also help the stability and preservation of the finished product thanks to their antiseptic and antioxidant components.

Hops are available in several formats: unprocessed (fresh or dried flowers), in pellet or liquid extract. There are many varieties of hops, the flavor and aromas they provide differ according to type and production area. Depending on the time of addition during the production phase, more bitterness, flavor or aroma can be added.

Packaging

The choice of packaging format is something to consider from the first phase of the project, as it influences the initial investment, space management, image and commercial strategy.

The most commonly used containers in breweries are:

  • Barrels

  • Bottles

  • Cans

The barrels can be reusable (stainless steel or plastic) or disposable. Capacity can vary from 10 to 50 liters.

The bottles can be of 0.25/0.33/0.5/0.75cl, you can choose a more identifying shape to differentiate yourself from the competition.

The cans give a more modern image, they have several advantages over the bottle format and there is also the possibility of choosing the format between 0.33/0.44/0.50cl.

It is important to contact a supplier to ensure that the supply chain is not interrupted and to check what is the minimum order required.

 
 

Malta

Malt is a malted cereal used for brewing beer. The malting process lasts approximately 8 days and takes place in specialized centers called malting plants.

Brewers mainly use barley malt, but wheat, rye or other cereals can also be used. Different barley varieties and malting methods (humidity, temperature, roasting time) produce different types of malt. Malt contributes aroma, flavor, color and sugars.

The malt must be milled before use in the mash to promote the decomposition and transformation of the starches into sugars.

During this process it is important that the grains are broken without turning into flour, preserving the husk intact, which will be of great help during filtering.

Yeast

Yeast is a single-cell fungus used for beer fermentation: it metabolizes the sugars extracted from malt and converts them into alcohol and carbon dioxide.

Yeast can also characterize the flavor and aroma of beer. There are two main types of yeast used in brewing, depending on the type of fermentation, they can be divided into two groups:

  • top-fermenting ale yeasts, which ferment at higher temperatures and act at the top of the fermenter during this process

  • bottom-fermenting lager yeasts start fermenting at lower temperatures; these yeasts ferment more slowly and settle to the bottom of the fermenter during the process.

Brewer's yeast is available in various forms:

  • dry yeast (dehydrated)

  • liquid yeast

  • cream yeast

5. PREPARATION AND RECIPES

Once the documentation and facilities are in place, the installed team can start the most creative and fun part of this business: brewing.

Brewing beer requires a lot of knowledge, experience and creativity. We advise you to prepare for this moment months or years in advance in case you have decided to be the brewmaster who will run the brewery. Alternatively, you can hire a professional as head brewer or count on his support for the initial accompaniment. From our Institute there are people who could be integrated in your project, you can ask us if we have a brewer available.

Numerous tips and recipes can be found on the internet and in professional literature. Start with something easy, a tried and true recipe. Once you gain more experience and confidence, you can start adding new flavors and create your own beer. Write down your recipes, technological procedures, measurements and important observations. Always evaluate your recipes, also taking into account the feedback you receive for each beer.

This information will help you later on to find the best combinations for your recipes. Having a direct point of sale, taproom or brewpub, is essential to talk to customers and know their preferences.

The beauty of craft brewing lies in the fact that it always offers something new, a different combination of ingredients, new flavors, creative and innovative solutions, as well as a continuous flow of new challenges. Once you are clear about the recipes you can proceed with the order of raw materials that will have to be properly preserved.

6. BRANDING

To sell your beer it is essential that it is recognizable. You need a name for your brand, a logo and a coordinated design. You can set up an online store that also serves as a presentation of your company and where your products will be sold. Nowadays it is also essential to have a presence in the networks as a marketing tool to position the brand and increase sales. If you feel that you lack creativity, we recommend you to hire a graphic designer to help you establish the corporate identity of your brewery.

This brief guide outlines the main steps to set up a microbrewery project, to deepen the topics and complement the information you can participate in our specific course for microbrewery entrepreneurs.

We recommend that you start gradually with a smaller brewery or a beerfirm. Raise capital and form a secure sales network. Make sure your brewery is recognizable. Once all these factors show steady and increasing progress and growth, it may be time to increase your production capacity.

Alberto Leoni
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