For a reliable gas supply in your brewery, you need at least three types of backup systems: a secondary gas supply system (such as a cylinder bank or a second generator), an automatic switchover system that activates upon pressure loss, and an alarm system that warns of malfunctions. For nitrogen supply, a combination of a primary nitrogen generator with a backup cylinder bank is ideal, while for CO2, a secondary storage tank is essential. These systems guarantee continuity in your brewing process, prevent production loss, and protect your tanks from implosion during cleaning.
Why are backup systems for gas supply in breweries essential?
Backup systems for gas supply in breweries are essential because even brief interruptions in the gas supply can have serious consequences for the brewing process and product quality. If your gas supply fails, you risk production loss, quality reduction, and in some cases even damage to your equipment.
Gases such as nitrogen and CO2 fulfill various critical functions in the brewing process. Nitrogen is used to prevent oxidation when brewing beer with nitrogen, purge tanks, and build pressure without affecting the beer. CO2 is crucial for carbonation, pressure build-up, and moving beer between tanks. A sudden interruption can lead to:
- Unwanted oxidation of the beer, which affects shelf life and taste
- Disruption of the fermentation process
- Problems when bottling or filling kegs
- Damage to tanks during cleaning processes due to pressure loss
By installing adequate backup systems, you ensure the continuity of your brewing process, save costs through reduced production loss, and guarantee consistent product quality. Moreover, you prevent the frustration and stress associated with sudden failures in your gas supply.
What types of backup systems are available for nitrogen supply?
For nitrogen supply in breweries, various backup systems are available, each with its own advantages and disadvantages. The choice depends on your specific needs, space, and budget. The most common backup systems are:
A secondary nitrogen generator forms the most complete backup solution. It functions as a full reserve installation that can automatically take over when the primary generator fails. Benefits include complete independence and capacity, but this solution requires a higher investment and more space.
Cylinder banks or cylinder packages are a more compact solution. These consist of multiple high-pressure nitrogen cylinders that can automatically engage when pressure drops. Advantages include relatively low acquisition costs and limited space requirements. Disadvantages are the periodic replacement of cylinders and higher operational costs in the long term.
Automatic switchover systems form an essential component of any backup solution. These systems continuously monitor the pressure of your primary gas supply and seamlessly switch to the backup source when pressure is too low. Modern systems are equipped with:
- Accurate pressure sensors
- Advanced controllers for smooth switching
- Alarm functions that warn upon activation
- Remote monitoring capabilities via smartphone
For smaller breweries, a simple backup with nitrogen cylinders and manual switching may suffice, but for medium to large operations, an automated system is strongly recommended to ensure continuity.
How does an automatic switchover system for gas supply work?
An automatic switchover system for gas supply works as an intelligent guardian that continuously monitors gas pressure and switches to a backup source without human intervention when necessary. The heart of this system consists of pressure sensors, controllers, and electronic circuits working together to ensure an uninterrupted gas supply.
The operation follows a clear process:
- Pressure sensors continuously measure the outgoing pressure of your primary gas supply
- Upon detecting a pressure drop below a preset threshold (for example, 90% of normal operating pressure), the system sends a signal to the switchover valve
- The switchover valve opens the supply from the backup source (such as a cylinder bank)
- Simultaneously, an alarm signal is generated via a local alarm, SMS, email, or app notification
- When the primary gas supply functions again and delivers sufficient pressure, the system automatically switches back
Modern switchover systems offer additional functionalities such as data logging, consumption monitoring, and preventive warnings when pressure begins to drop slowly. This helps you identify potential problems before they become critical. For breweries, it’s important to choose a system specifically calibrated for the gases used (nitrogen and CO2) and that meets the required food-grade standards.
What are the safety requirements for gas backup systems in a brewery?
Gas backup systems in breweries must meet strict safety requirements to ensure employee safety, product quality, and regulatory compliance. The main safety requirements include both legal standards and practical measures.
For food production environments such as breweries, HACCP requirements (Hazard Analysis and Critical Control Points) apply to all systems that come into contact with the product or influence the production process. For gas systems, this means:
- All materials in contact with the gas must be food-safe
- Systems must be free from contaminants and oils
- Regular microbiological controls of the gas are required
Additionally, all equipment must comply with specific quality marks and certifications:
- CE marking for all pressure systems
- PED (Pressure Equipment Directive) certification for pressure vessels
- ATEX certification for equipment in potentially explosive environments
For backup systems specifically, additional safety requirements apply such as periodic inspection of pressure vessels, cylinder banks and pipes, regular calibration of pressure sensors and alarm systems, and clear emergency procedures. It’s also important to consider the placement of gas cylinders and generators in well-ventilated spaces, especially for CO2 which can be asphyxiating in high concentrations.
How do I determine the right capacity for my backup gas supply?
Determining the right capacity for your backup gas supply is a crucial step to avoid both underprovisioning (insufficient backup) and overprovisioning (unnecessary costs). The calculation requires a systematic approach based on your specific production processes.
Start by mapping your average and peak gas consumption per hour. Measure this for all relevant processes in your brewery, including:
- Tank purging with nitrogen (volume × frequency)
- Pressure build-up in tanks and pipes
- Transfer of beer between tanks
- Bottling, filling kegs and cans
Next, determine how long your backup system should be able to function in case of a failure. For most breweries, 24-48 hours is a reasonable autonomy period, but this can vary depending on your specific situation, such as the reliability of your primary system and the response time of service providers.
The formula for calculating the required capacity is: Capacity = Average hourly consumption × Desired autonomy in hours × Safety factor (usually 1.2-1.5).
For smaller breweries (up to 1,000 hl/year), a backup capacity of 10-20 m³ of nitrogen is typically sufficient. Medium-sized breweries (1,000-10,000 hl/year) often need 20-50 m³, while larger operations require a customized calculation that takes into account the complexity and scale of production.
What are the key considerations when choosing backup systems for my brewery?
When choosing backup systems for your brewery, various factors play a role in determining effectiveness, reliability, and total costs. A well-considered choice begins with a thorough analysis of your specific situation.
Capacity requirements come first: the system must be able to supply enough gas to keep your critical processes running during an outage. It’s important to look not only at your current but also your future production levels, especially if you have growth plans.
Space constraints can be an important consideration, especially in smaller or older brewery buildings. Some backup solutions, such as secondary generators, take up more space than, for example, a compact cylinder bank. Weigh the available space against the desired capacity and autonomy.
The degree of automation of the switchover system determines how quickly and reliably the backup activates. Fully automated systems offer the highest operational reliability but are more expensive than manual or semi-automatic alternatives. For larger breweries, full automation is usually the best choice.
Maintenance requirements and operational costs differ significantly between different systems. A cylinder bank has higher operational costs due to periodic replacements, while a secondary generator requires a higher initial investment but has lower ongoing costs. Make a realistic calculation of the total cost of ownership over a period of 5-10 years.
Finally, it’s important to choose a solution that grows with your business and can be flexibly adapted to changing needs. We understand better than anyone that each brewery is unique and has its own challenges. For tailored advice, you can always contact us without obligation.
