Nitrogen is an effective solution for pressure build-up in your brewery and offers significant advantages compared to CO2. By installing a nitrogen generator, you can produce your own nitrogen from ambient air, independent of external suppliers. This gas is inert, meaning it doesn’t react with your beer, and it helps with moving beer through lines without affecting the taste. Moreover, nitrogen is more cost-effective than CO2 and provides consistent pressure for a reliable brewing process.
Why is nitrogen important for pressure build-up in breweries?
Nitrogen plays a crucial role in pressure build-up in breweries because it is an inert gas that doesn’t react with beer, unlike CO2 which can dissolve in the product and influence the taste. This makes nitrogen ideal for moving beer through lines and tanks without affecting quality.
When you use nitrogen for pressure build-up, you can achieve higher pressures without the gas being absorbed into the beer. This is particularly useful when transferring beer from tanks to filling lines or tap systems. While CO2 increasingly dissolves in beer at higher pressure (leading to over-carbonation), nitrogen largely remains outside the beer.
Other advantages of nitrogen over CO2 or compressed air include:
- Better control over the carbonation level of your beer
- Reduced dependence on external CO2 suppliers
- Lower operational costs in the long term
- Constant availability of gas for pressure build-up
- More environmentally friendly (no CO2 emissions from transport)
Nitrogen is also very safe to use, provided appropriate precautions are taken, and is free from contaminants that can occur in compressed air.
How does a nitrogen generator work in a brewery?
A nitrogen generator in a brewery extracts nitrogen from ambient air through a process called Pressure Swing Adsorption (PSA) or membrane technology. This system makes breweries independent of external gas suppliers by continuously producing nitrogen when needed.
In the PSA process, the generator works as follows:
- Compressed air is compressed and filtered to remove contaminants
- The filtered air passes through carbon molecular sieves that adsorb oxygen, moisture, and other gases
- Pure nitrogen (typically 99.5% to 99.999% pure) passes through the sieves
- The adsorbed gases are then expelled during a regeneration phase
In membrane technology, compressed air flows through hollow fibers with semi-permeable walls. Oxygen and other gases diffuse through these walls, while nitrogen is retained and collected.
A complete nitrogen generation system for your brewery consists of:
- Air compressor for the supply of compressed air
- Pre-filters for removing contaminants
- The nitrogen generator itself (PSA or membrane)
- Buffer tank for nitrogen storage
- Control system for automation and monitoring
- Post-filters for optimal gas quality
This system can be seamlessly integrated into your existing brewery infrastructure, giving you access to nitrogen whenever you need it for pressure build-up.
What benefits does nitrogen offer for beer quality?
Nitrogen offers significant quality benefits for beer, both during the production process and in presentation to the consumer. Unlike CO2, nitrogen preserves the original flavor characteristics of your beer through minimal interaction with the product.
For your beer’s quality, nitrogen use means:
- Less oxidation as nitrogen displaces oxygen, resulting in longer shelf life
- Preservation of delicate aromas that would otherwise evaporate or break down
- More consistent carbonation levels because nitrogen doesn’t dissolve in beer like CO2
- Ability to create a creamy, fine head (especially in stouts and nitro beers)
- Reduced acid formation in the final product
In nitrogen-dispensed beers, such as the famous Irish stouts, the high nitrogen content in the gas creates the characteristic creamy texture and durable head. This cascading effect and smooth mouthfeel are impossible to achieve with CO2 alone.
Additionally, nitrogen ensures more stable product quality by providing constant pressure when transferring beer with nitrogen during brewing between tanks and to the filling line, without the risk of excessive carbonation that could disturb your carefully balanced product.
What are the safety considerations when using nitrogen?
Adequate safety measures are essential when using nitrogen in your brewery, despite nitrogen being an inert and non-flammable gas. The primary risks concern oxygen displacement in confined spaces, which can lead to asphyxiation hazards.
Implement these safety measures:
- Install oxygen monitors in spaces where nitrogen is used or stored
- Ensure adequate ventilation in all areas where nitrogen is present
- Train staff to recognize symptoms of oxygen deficiency and proper emergency procedures
- Place clear warning signs at nitrogen storage and usage locations
- Conduct regular safety inspections on your nitrogen installation and lines
- Use appropriate personal protective equipment when working on the system
Regular maintenance of your nitrogen generator and distribution system is important not only for efficiency but also for safety. Leaks can go unnoticed because nitrogen is odorless and colorless, but they can lead to dangerous situations in enclosed spaces.
In the UK and US, you must comply with specific regulations for industrial gases, including standards for pressure equipment. Work with a certified installer who is familiar with these requirements to ensure your system is fully compliant.
How do I choose the right nitrogen pressure system for my brewery?
Selecting the right nitrogen pressure system for your brewery depends on various key factors specific to your situation. Begin by determining your nitrogen needs by analyzing your production volume, working pressure, and peak usage.
Consider these important factors:
- Production volume – How much beer do you produce per week/month?
- Purity level – What nitrogen purity do you need? (99.5% is usually sufficient for pressure build-up)
- Flow rate – How much nitrogen do you need per hour during peak usage?
- Required pressure – What working pressure is needed for your specific processes?
- Available space – Do you have sufficient room for the generator and buffer tank?
- Power supply – Is your electrical infrastructure adequate?
For smaller craft breweries, a compact membrane system with lower capacity may be sufficient, while larger operations might need a PSA system for higher volumes and purity.
Also consider future growth: it’s wise to choose a system with 20-30% more capacity than your current needs, giving you room for expansion. Additionally, pay attention to the energy consumption of different systems – more efficient models may have higher acquisition costs but lower operational costs in the long term.
A buffer tank is essential to handle peaks in demand and ensure continuity, even if the generator is temporarily offline for maintenance.
What are the key insights for effective nitrogen use in breweries?
For optimal nitrogen use in your brewery, it’s important to understand both technical and practical aspects. Proper implementation can deliver significant operational benefits, including cost savings and quality improvements.
Essential insights for effective use:
- Monitor nitrogen consumption regularly to detect inefficiencies and leaks early
- Implement a preventive maintenance schedule for your nitrogen generator
- Regularly check the purity of your nitrogen to ensure consistent quality
- Optimize pressure settings for different applications within your brewery
- Train your staff in efficient nitrogen use and basic maintenance
- Consider heat recovery from the compressor to reduce energy costs
An integrated approach where your nitrogen generator is connected to your brewing management system can yield further efficiency improvements through automatic pressure control and consumption optimization.
The investment in a nitrogen generator typically pays for itself within 1-3 years, depending on your current CO2 costs and consumption volume. With rising CO2 prices, the payback period is becoming increasingly shorter, making nitrogen generation an increasingly attractive alternative.
We understand the challenges breweries face in pursuing quality and efficiency. By implementing the right nitrogen solution, you can improve the continuity of your brewing process while saving costs. If you have questions about the possibilities for your specific situation, please feel free to contact us for tailored advice.
