What are the 7 steps of the beer brewing process?

1.The long origin of beer and its connection with civilization

Beer is one of the oldest brewed alcoholic beverages of mankind. Its origin can be traced back to the Mesopotamia region around 5000 BC. At that time, the Sumerians used pottery jars to brew porridge-like beer and drank it with reed pipes, which became the earliest prototype of "fermentation vessel". Around 3900 BC, the brewing poem recorded in the "Nian Kasi Hymn" was regarded as the earliest "beer recipe" in the world, reflecting the initial systematic understanding of brewing technology at that time. At the same time, in ancient Egypt between 3000 BC and 2500 BC, pyramid workers could receive 4 to 5 liters of beer per day as "labor remuneration". Beer was not only a nutritional supplement, but also participated in religious sacrificial activities. Its production mostly relied on ceramic fermentation tanks and simple "fermentation equipment"

II. Overview of the global beer market and the rise of craft beer

1. Market size and future expectations

According to the Fortune Business Insights report, the global beer market size will reach US$851.15 billion in 2024, and is expected to increase from US$882.80 billion in 2025 to US$1,167.47 billion in 2032, with a compound annual growth rate (CAGR) of about 4.07%. As an industry upstart, craft beer has a market size of approximately US$102.6 billion in 2021, and is expected to double to US$210.8 billion by 2028, with a compound annual growth rate of 10.83%.

2. Regional distribution and consumption trends

The European market accounts for more than 30%, and North America and Asia-Pacific also show steady growth; China's high-end beer segment will maintain a sales growth of nearly 20% between 2023 and 2024. Heineken's sales have climbed to nearly 700 million liters thanks to its strategic cooperation with China Resources Beer. At the same time, zero-alcohol beer and functional beer are being driven by the trend of healthy consumption. AB InBev's newly launched "Corona Cero" aims to seize the market share of the alcohol-free segment with the opportunity of Olympic sponsorship.

3. Four classic brands: style and market performance

1. Budweiser

Founded in 1876, it is positioned as an American Lager and is widely known for its title of "King of Beers" - In 2023, AB InBev's first quarter revenue reached US$14.8 billion, of which Budweiser and high-end brands contributed significantly.

2. Heineken

A Dutch century-old brand, a representative of 5% ABV light lager; with a global distribution network of more than 190 countries, it continues to lead the high-end lager market in Europe and Asia Pacific.

3. Corona

Pilsner, a Mexican brand launched in 1925, has been deeply rooted in the hearts of the people with its image of "beer on the beach"; Corona Extra has become one of the best-selling imported beers in the United States and one of the top five best-selling brands in the world.

4. Guinness

Irish Stout, founded in 1759, is famous for its rich malt aroma and delicate and dense foam; it has long been the leader in the dark beer market.

These four brands not only show the diversity of beer flavors, but also put forward different requirements for equipment: pressure fermentation, temperature control accuracy, and automatic cleaning (CIP) of "fermentation vessel" and "stainless steel pressure fermenter" have become the basic guarantee for the brewing process of each brand.

4. Seven key steps in brewing beer (in-depth interpretation)

Each step depends on the precise coordination of brewery equipment and fermentation equipment to ensure the stability of beer flavor and quality.

1. Milling

The barley malt is crushed by an adjustable double roller or conical mill, with the goal of 70–80% of the grains passing through a 0.5–1.0 mm sieve hole to ensure that the inner membrane is not over-crushed and the enzymatic hydrolysis efficiency is taken into account.

2. Mashing

In a Mash Tun equipped with jacket heating and spiral stirring, protein rest (45–55 ℃), saccharification rest (62–68 ℃) and Mash-Out (75–78 ℃) are carried out in sequence, using the malt's own enzyme system to hydrolyze starch into fermentable sugars.

3. Lautering

Using the false bottom and adjustable raker of the Lauter Tun, combined with precise sparging (about 75 ℃), the solid spent grains are separated from the wort, and the residual sugar is recovered through the automatic reflux system.

4. Boiling

Boil in a Brew Kettle for 60–90 min, add bitter flowers to extract alpha acid in the early stage, add fragrant flowers to extract volatile oil in the middle and late stages, and use vacuum or film boiling technology to improve energy efficiency and aroma retention if necessary.

5. Cooling & Fermentation

After the wort is quickly cooled to 10–25 ℃ by a plate or shell and tube heat exchanger, it is transferred to a stainless steel pressure fermenter or unitank fermenter for main fermentation in a controllable temperature and pressure environment; lager is fermented at 8–12 ℃ for 7–14 days, and ale is fermented at 16–22 ℃ for 5–10 days, and the temperature is raised at the end (Diacetyl Rest) to optimize the flavor.

6. Filtration & Conditioning

Use plate and frame, centrifugal or vacuum filtration systems to remove suspended matter, and cold age at 0–2 ℃ for 3–14 days in Unitank or Brite Beer Tank to achieve final adjustment of stability, clarity and carbonation.

7. Filling and Packaging

The fully automatic filling line combines aseptic flushing, nitrogen/CO₂ replacement, back pressure filling and online pressure testing to ensure that bottles, cans or bulk containers are capped and labeled in an oxygen-free environment.

V. Advantages of Shandong Tonsen's commercial brewing system and equipment

Shandong Tonsen Equipment Co., Ltd. (Shandong Tonsen) takes "full process, integration and intelligence" as the core, and provides a comprehensive solution for commercial brewing system covering raw material processing, brewing and fermentation, filtration and conditioning, and filling and packaging.

1. Integrated Brewhouse System

Modular configuration: 2–5 brewhouses, capacity 1000 L–20000 L;

Heating method: optional steam or electric heating;

Control system: PLC+SCADA centralized monitoring, supporting one-button programmed operation of water distribution, temperature rise, flower throwing, slag discharge and CIP.

2. High-end fermentation and Unitank series

CCT (conical fermentation tank): SUS 304/316 material, Dimple jacket insulation and refrigeration integrated, cone bottom automatic slag discharge, support 0–2.5 bar pressure fermentation.

Unitank multi-function tank: integrates primary fermentation, secondary fermentation and carbonization, equipped with gas circulation mixer and CIP arm in the tank to reduce pipeline and tank transfer losses.

3. Intelligent CIP and cleaning system

Automatic liquid preparation module: programmed circulation of alkaline washing, acid washing and disinfectant;

Multi-angle spray ball: covers the inside and outside of the tank body and the jacket, and the cleaning efficiency is increased by 30% without dead corners;

Closed-loop monitoring: real-time feedback of temperature, flow and pH to achieve a formulated cleaning curve.

4. Customized process support and global service

Process R&D center: small test-pilot-scale test full process process optimization and flavor adjustment;

Global technical team: localized support in Europe, North America and Southeast Asia, rapid response within 48 hours

Financial leasing plan: cooperative financial institutions provide installment and leasing to optimize "brewery equipment cost" and return on investment.

5. Sustainability and energy saving and environmental protection

Waste heat recovery system: saccharification and cooling waste heat recovery is used for preheating or plant heating, which can save 15% energy per year; wastewater and solid-liquid separation: integrated anaerobic/aerobic treatment and solid-liquid separation, up-to-standard emissions;

Biomass and solar energy compatibility: support renewable energy access, help breweries achieve carbon neutrality.

Through a comprehensive explanation of brewing technology and equipment solutions, combined with Shandong Tonsen's continuous innovation and service support in core equipment such as "fermentation vessel", "stainless steel pressure fermenter", "best conical fermenter", and "unitank fermenter", a panoramic view of the modern beer industry from history to technology, from brand to equipment was presented, highlighting the cutting-edge trend of industry technology evolution and equipment upgrades. It also provides career ideas for those who want to expand the beer market.