ESAU&HUEBERBrewery, Food & Beverage

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ESAU&HUEBER2

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Esau & Hueber offers 40 years of

experience in designing and building

of state-of-the-art processing equip-

ment from all stages of the value

chain of a brewery. We offer turn-key

solutions as well as solutions for

individual customer requirements.

ESAU & HUEBERWe build - You brew

As member of the BAUER Group,

we can draw on the infrastructure

of 110 subsidiaries and companies

worldwide and can handle interna-

tional projects with our well-known

competence and reliability

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Brewhouse TechnologyIt all starts with the wort preparation

The brewhouse, - the heart of any

brewery - can be manually cont-

rolled or equipped according to any

level of automation required. Industrial

brewhouses are built in the Esau & Hu-

eber production facilities. The SYSTEM

NERB optimally integrates tradition and

high-tech. Energy production and recu-

peration, fast brew cycles, automation

as well as simpler and safer cleaning

and maintenance are only a few key

features that facilitate effi cient high-

quality beer production and consistent

quality.

Water preparation

Different methods for obtaining high-

quality brewing water are required,

depending on the consistency of the

raw water and the beer types desired.

Esau & Hueber can implement individual

and economically sensible solutions

in all parts of the world together with

its sister company Bauer Water, an

internationally operating water-solution

provider.

Malt treatment/Milling

Correct handling of malt and grist in

the brewery is the basis of high-quality

beer production. Esau & Hueber offers

a suitable solution for each system size.

Individual solutions are planned and

implemented in cooperation with the

customer, whether dry or wet milling

or whether malt treatment should be

automated or manually handled.

Mashing

Key requirements regarding the

mashing process are low-oxygen,

clump-free mashing and very thorough,

homogenous mixing of the mash.

Esau & Hueber achieves this with its

premasher and with the geometry of

the agitator blades. An intense mixing

of malt and mashing water begins

just before the mash tun. A double-

pipe design, in which the outer pipe

transports the mashing water and the

inner pipe transports the grist, leads an

increase in iodine value and losses in

output can be avoided, dust formation

is made almost impossible.

The ideal geometry of the agitator blades

ensures an additional homogenization

of the mash. Consequently, demixing of

mash is avoided; smooth heat transfer to

the mash can be guaranteed – even with

very low mash volumes. In connection to

the bottom heating produced according

to the Thermplate® method, heating

can be provided under reduced steam

temperature having a positive effect on

the energy balance and thermal load of

the mash.

Lautering

The lautering process is usually the

limiting factor regarding the brewing

frequency. Reduced running time and

maximum extract yield are therefore

desirable. Lauter tuns made by Esau &

Hueber take both requirements into

account.

An optimized arrangement of the outlet

piping in connection with the spent

grain bunker being developed specifi -

cally for this reason ensures homogene-

ous and intense fl ow through the spent

grain mass. This results in an almost

complete leaching out of the extract

contained.

The design of the raking device with

differently formed raking knives guaran-

tees that the spent grain mass remains

porous at all times during the lautering

process, resulting in shorter lautering

times.

5-vessel brewhouse 70 hl Premium Series

Research brewery with a knockout

capacity of 2.5 hl

ESAU&HUEBER 53-vessel brewhouse

PROFESSIONAL SERIES with a

knockout capacity of 150 hl

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Brewhouse TechnologyEnergy saving and top quality

are compatible

Boiling systems

In contrast with most of the brewhouse

systems, SYSTEM NERB allows free

choice of the boiling system. The de-

sign concept of the wort kettle makes it

possible to choose an external boiler,

internal boiler or the VARIOBOIL va-

cuum system. While an internal boiler

with its consistent output volumes suits

perfectly with breweries, an external

boiler shows highest fl exibility features,

which is why they are the fi rst choice for

breweries with various different types of

beer and batch sizes. A fully automatic

hop dosing system can be integrated

into the wort boiling process. Moreover,

the energy used during the heating

process can be broadly recovered by

different additional installations. Esau

& Hueber is therefore able to provide

individual and cost-effective solutions

for every brewery.

VARIOBOIL

VARIOBOIL is an innovative wort boiling

option. The actual boiling process is

divided into a short phase of atmos-

pheric boiling in which all major thermal

degradation reactions (e.g. splitting of

DMS-P) take place, followed by a sub-

sequent vacuum evaporation phase.

This split reduces the total evaporation

process and leads to a strong reduction

in the primary energy consumption. The

high heat gain in the kettle vapour con-

denser provides an additional opportu-

nity for energy saving.

Any existing wort kettle can be retrofi t-

ted with the VARIOBOIL system. The

energy savings soon make up for the

investment costs.

PROFESSIONAL and PREMIUM

The NERB SYSTEM is available in two

different product lines. The PROFES-SIONAL SERIES offers everything

an industrial brewhouse needs. The

design is, as far as possible, based

on standardized modules, which makes

planning, production and commis-

sioning much simpler and cheaper.

Additional savings result from the use

of standardized automation hardware

and software and the omission of costly

fi nishing of the outer surfaces.

Customers interested in more individua-

lity can choose the PREMIUM SERIES.

It allows for individual solutions down to

the smallest detail. Third-party solutions

can also be used to provide automa-

tion, extend sensor systems or create

special surface fi nishes according to

customer requirements.

Reconstruction in existing facilities

Reconstruction activities in existing

facilities require the knowledge of

experienced experts - especially if

sensitive areas are to be repositioned

which need to be ready for operation

within the shortest time. Works in old

buildings, however, could sometimes

be particularly demanding. Additionally,

it is often the case that areas of activity

need to be connected to each other

where the structural requirements can

be disadvantageous in the fi rst place.

For this task, instinctive feeling and a

reliable project management is needed

to solve such a complex task. Esau &

Hueber has gained experience in this

fi eld in a multitude of projects comple-

ted in the last few years and is therefore

able to provide individual solutions

down to the smallest detail.Vacuum wort boiling system VARIOBOIL

Hop dosing unit and external calandria

ESAU&HUEBER 73-vessel brewhouse PREMIUM SERIES

with a knockout capacity of 35 hl

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Fermentation and storage cellar systems

Wort turns into beer

The Esau & Hueber brewery pro-

gram also includes all the process

steps in the cold sections of a

brewery. The construction of a com-

plete fermentation and storage cellar is

one of the core skills of our company.

Numerous patents and other copyright-

protected documents generated over

the last few decades are proof of our

continuous development work. The

company is a global technology leader

in the fi elds of wort aeration and yeast

management.

HOSE-FREE AREA

Finding the right balance between the

costs of installation and an appropriate

level of automation in the fermentation

and storage cellar is often diffi cult,

particularly for medium-sized compa-

nies. The HOSE-FREE AREA concept

of Esau & Hueber provides the perfect

solution. It is a piping system based

on a pipe grid with articulated joints.

Two tank exits are linked to a joint valve

combination for routing purposes.

This approach halves the number of

disk valves as compared to the con-

ventional switching panel technology,

leading to a signifi cant reduction of the

investment and maintenance costs. The

user clearly benefi ts from this (partial)

automation due to increased produc-

tion, increased product security and a

reduction in staff requirements.

TURBO AIR

Good fermentation requires yeast in

top condition and the correct aeration

of wort and yeast before pitching. The

TURBO AIR two-component jet has

proven track record and corresponds

to the latest state of technology for this

application. The construction complies

with all aspects of hygienic design and

therefore offers increased safety for this

sensitive area of beer production.

Its design results in the formation of

ultra-fi ne air bubbles immediately after

the nozzle. Low oxidation of anti-

oxidants, as compared to conventional

systems, results in an improved taste

stability of the fi nished beer.

MICRO AIR

Correct yeast aeration is important for

industrial breweries as well as for small

and micro-breweries. Esau & Hueber

covers this performance range with the

MICRO AIR complete modular system

for home breweries. The MICRO AIR is

equipped with an aeration device, re-

gulation valve, sterile fi lter, fl ow quantity

limiter and pressure reducer, mounted

on a stainless steel panel and provides

a cost-effi cient but reliable and complete

solution for brewers with low wort

volumes.

HOSE-FREE AREA piping system in a German mid-size brewery

The TURBO AIR two-component jet is

the centrepiece of Esau & Hueber wort

aeration systems.

ESAU&HUEBER 9A piping system with an attractive

appearance in a mid-size brewery

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V igorous and strongly fermenting

yeast in a physiologically fl awless

state is an essential requirement

for high and consistent beer quality. It

also contributes to biological safety.

The aerobic phase in the yeast life cycle

is particularly important for vitality later,

as it is used to synthesize all the essen-

tial components of the cells.

CONTI PROP

High fermentation strength and the vita-

lity of the yeast cells obtained charac-

terizes the CONTI PROP system for ae-

robic yeast propagation developed by

Esau & Hueber. The removable quantity

can be adapted to the production re-

quirements by adjusting the propagation

time, temperature, aeration volume/

aeration intervals for the start cells and

the residual cells in the propagator.

Aeration with the TURBO AIR yeast

aeration system and the resulting ultra-

fi ne distribution of air ensures optimal

yeast growth. The construction strictly

follows the specifi cations for hygienic

design and ensures biological safety, so

that the brewery always has a reliable

supply of fresh propagation yeast.

FERMEX

The aerobic FERMEX system developed

by Esau & Hueber is capable of vitalizing

the harvesting yeast. CO² stored in

the yeast cells is gently removed after

the yeast harvest. Before pitching, the

propagation phase of the operating

yeast is activated by adding fresh wort

as a nutrient substrate and by more

aeration of the yeast suspension. This

has a positive effect on the vitality and

fermentation strength of the pitching

yeast.

FERMEX reduces the disadvantages

of multiple-use yeast (tendency to

autolysis, bad fl occulation, slow start of

fermentation etc.) and leads to smoother

and better reproducible fermentation

processes.

FLEXI PROP

Modern yeast management for breweries

of any size requires strongly-fermenting

harvesting yeast as well as suffi cient

amounts of fresh propagation yeast at

any time. The ingenious FLEXI PROP

yeast management system by Esau &

Hueber makes it possible to manage

FLEXI PROP yeast propagation system

both yeast fl ows in an effective manner

to ensure a consistent yeast supply and

therefore a consistent beer quality.

FLEXI PROP mainly consists of a

CONTI PROP propagation system and

a FERMEX harvesting yeast vitalization

system.

YEAST PROPAGATION MANAGER (YPM)

The newly developed YPM is based on

situation-orientated process control,

which differs from the strictly recipe-

based controller systems previously

used. It continuously monitors all

process-relevant parameters in real

time and intervenes when they deviate

from the ideal values. The software

logically evaluates the entire process

and can therefore autonomously learn

to optimize the process conditions.

The software simply runs on top of the

existing controller and can be com-

bined with all systems. The YPM can

be integrated while the production is

running, without any down-time or

production losses.

Esau & Hueber´s MICRO PROP – consis-

ting of one or several Carlsberg Flasks of

up to 150 l with an aeration unit – offers

the ideal yeast propagation system for

small breweries.

Yeast TechnologyVitality and fermenting strength

ESAU&HUEBER 11Modern yeast management

with both a FLEXI PROP and a

YEAST PROPAGATION MANAGER

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The TURBO AIR two-component jet can be used both for aeration of wort and in the

carbonation system of TURBO CARBO.

Process TechnologyConsidering the whole system

Several brewery applications, in

addition to the main process of

actual beer production, require

attention in order to ensure high and

constant beer quality. Esau & Hueber

provides its customers with a series of

solutions for these processes, too.

CONTI FLASH

The CONTI FLASH short-term heating

system with continuous control of the

variably reselectable pasteurizing units

makes use of the latest and most gent-

le process for biological preservation of

beer, fruit drinks and juices with up to

1.2 mm fi bre length. The functional unit

with hygienic design according to DIN

1164 is delivered on a solid base frame,

already wired up and ready for connec-

tion. Permanent monitoring and control

of the effective pasteurizing units by

adjusting the heating temperature pro-

vides the user with maximum biological

safety and minimum thermal damage to

the product.

AIREX

Various amounts of air may be dissol-

ved in water, depending on its tem-

perature. Different application such as

blending according to the high-gravity

method, separation of alcohol-free be-

verages, fi lter sedimentation or rinsing

of product lines requires completely

gas-free water. Esau & Hueber has

developed the AIREX water degassing

system, a reliable and economic solu-

tion, in cooperation with specialists at

Bauer Water.

Blending systems

Reliability, simple operation and pro-

tection against oxygen uptake are the

requirements for modern blending block/

blending systems. The in-house blending

solutions made by Esau & Hueber fully

comply with these requirements.

These systems are available in all sizes

from manual to fully automated operating

modes. The construction of these

systems obviously complies with the

guidelines for hygienic design - as can

be expected of all process systems

made by Esau & Hueber.

TURBO CARBO

Esau & Hueber provides the TURBO

CARBO system for the carbonization of

beverages and correction of the CO²-

content, for example after blending. The

CO² is added through tried and tested

Esau & Hueber two-component jet.

CONTI FLASH short-term heating system with a capacity of 55 hl/h

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CIP-SYSTEMS from Esau & Hueber can be assembled in every required

confi guration.

SEMI-fi ll systems can be delivered as a single machine and as an AUTO-fi ll system

with ancillary equipment.

It ensures that the content in the fi nal

drink remains constant. The TURBO

CARBO can obviously also be used to

dose nitrogen into the beer, which is, for

example, required for stout beers.

FLEXI-fill

Differentiation in the market is now

more important than ever. Filling special

containers in small numbers provides an

opportunity for differentiation. This can

be achieved with the FLEXI-fi ll system

by Esau & Hueber, a reliable system

for manual fi lling of bottles of any size

and neck form as well as 5-litre party

barrels.

The FLEXI-fi ll can be produced as a

mobile or stationary solution and in a

counter-top version to enable pub bre-

weries to bottle beer in the pub directly

for their customers.

SEMI-fill/AUTO-fill

The semi-automatic party barrel fi llers of

the SEMI-fi ll type are built and delivered

with 2, 4 and 6 fi lling points and a ca-

pacity of 100 to 300 5-litre party barrels

per hour.

The fi ller can be delivered as a single

machine and as an AUTO-fi ll system

with transport conveyors, dust cap

remover, ink jet printer, semi-automated

or fully automated closing system and a

washing and turning system.

BIOSTAR CIP SYSTEMS

Esau & Hueber is highly skilled and has

many years of experience in cleaning

technology and offers CIP systems that

are custom-made for specifi c appli-

cations. They are individually adjusted

according to parameters such as the

content of the container to be cleaned,

height differences, nominal diameters,

pipe lengths and, in particular, the type

of impurity to be removed. Adaptation to

the specifi c requirements saves cleaning

agents as well as energy and water. CIP

systems made by Esau & Hueber can

be delivered for all automation levels

required, from manual to fully automatic.

With BIOSTAR, Esau & Hueber offers a

particularly cost-effective and safe way

of clearing CIP. By making use of this

clearing method, the required room and

investment can be signifi cantly lowe-

red when compared to conventional

CIP systems. Furthermore, BIOSTAR´s

advantage lies in its increased fl exibility

and biological safety. What is more,

BIOSTAR is an environmentally-friendly

procedure thanks to its low consumption

of detergents.

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WINBREW® allows the user to control the entire operating sequence with a single platform.

Automation with WINBREW®Controlling, monitoring, logging

Reliable automation software is

essential for controlling, monitoring

and logging complex opera-

tions - not only for beverage systems.

Esau & Hueber has therefore included

WINBREW® in its portfolio, which is a

proven and trusted solution for many

years. It allows the user to control the

entire operating sequence, from malt

removal to the pressure tank, with a

single platform.

These freely programmable controllers

are typically used with WINBREW® and

are provided complete with all the

modules required, e.g. remote main-

tenance. Logging of operating data is

optionally available.

The high-resolution visualization sys-

tem displays the complete production

process at a plant. The function of

regulators, counters and loggers is dis-

played on the monitors instead of using

conventional hardware controllers. The

system is based on a SIMATIC S7

(and also link to TIA portal possible)

controller that checks the plausibi-

lity (locked manual level) of manual

intervention, which might be necessary

from time to time. This prevents dama-

ge to the product and the machinery.

Esau & Hueber also offers the

WINBREW®-S for stand-alone projects

or partial automation. The user inter-

face and the control components are

adapted to the budget, the individual

needs and the task at hand without

restricting the availability or reliability

of the plant. Since there has been an

increase in demand for programmable

controlling units in the north of America

offered by the US manufacturer Rock-

well / Allen Bradley, Esau & Hueber

developed the WinBrew-AB alternati-

ve. This version complements Esau &

Hueber´s product range and is availa-

ble from now on. Ask our automation

specialists!

„READY FOR WS-BREW AND TIA PORTAL“„READY FOR WS-BREW AND TIA PORTAL“

ESAU&HUEBER 15

ServiceAiming for satisfied clients

Each production chain is only as

strong as its weakest link. If

components or entire systems

fail, it always means that there is a

signifi cant detrimental effect on the

overall production. To prevent the

likelihood of such a scenario, Esau &

Hueber offers a comprehensive range

of services. This includes, among other

things, a telephone hotline, a 24 hour

service centre and remote maintenance

(online service). These components are

an important part of Esau & Hueber’s

corporate philosophy. Its aim is to

develop a long-term partnership, which

includes safe and reliable maintenance

of systems during their entire life cycle.

The objective is to maintain the operational

safety of plants and components, so as to

guarantee the effi ciency of the systems.

The self-understanding of Esau &

Hueber is not to be just a plant con-

structor, but, above all, also a service

provider. It takes a number of steps to

fi nd the perfect solution for the clients.

First and foremost, the initial situation

is analyzed in detail on-site. Thereafter,

model processes can be designed and

tested in the laboratory and in pilot

projects. In this way, optimal process

steps can be developed and the most

suitable plant designed and implemented

for that particular task.

Esau & Hueber possesses all the

required competencies, from defi nition

of tasks to start-up and complete

after-sales service. The company is also

equipped to handle modernization and

optimization of existing plants. This very

often involves the task of customizing

plants according to new parameters

or requirements.

Customization is usually necessitated by

the ever-growing demand of regulations.

Also products manufactured with the

available and proven systems change

over time.

905.

070.

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ESAU & HUEBER GmbHKapellenweg 1086529 Schrobenhausen, GermanyTel.: +49 8252 8985-0Fax: +49 8252 8985-85info@esau-hueber.dewww.esau-hueber.de