ESAU&HUEBERBrewery, Food & Beverage
en
glish
ESAU&HUEBER2
ESAU&HUEBER 3
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
ESAU&HUEBER 13
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.
2 08
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ESAU & HUEBER GmbHKapellenweg 1086529 Schrobenhausen, GermanyTel.: +49 8252 8985-0Fax: +49 8252 [email protected]