Efficiency and quality in the brewhouse: increased the production with remarkable results
The next-generation GEA Lauterstar 2.0 sets a new benchmark for efficiency and quality in the brewhouse. Proven through practical trials in breweries across Austria and the Netherlands, this advanced lautering technology delivers remarkable results: net lautering times have been reduced to just 70 minutes, with extraction efficiency reaching an impressive 98.7%. In one project, the Lauterstar 2.0 enabled up to 14 brews per day, while an upgrade to an existing lauter tun increased production from 5 to 8.5 brews per day for another customer. This innovation redefines productivity and brewing excellence.
Productivity in the brewhouse: the lauter tun as a bottleneck
Lautering separates the solid components of the mash, the grains, from the dissolved substances of the malt kernel. Lauter tuns (here at Bushmills) are considered bottlenecks for brewing productivity. GEA’s latest lautering technology, GEA Lauterstar 2.0, increases lautering quality and significantly reduces processing time. (photo: GEA)
In the brewhouse, the capacity of the lauter tun time and again proves to be a bottleneck for productivity and efficiency. Large international breweries in particular are looking for ways to unburden the lautering process: “Brewers have grown used to filtration taking a lot of time. We scrutinized these processes and found that we can lauter faster if the filter cake can be prevented from clogging. The GEA Lauterstar 2.0 achieves a productivity increase of ten percent and an extract efficiency of 98.7%,” explains Peter Sterk, Product Manager for Brewhouse Technology at GEA. Additionally, the new lauter tun is smaller, which results in material savings of ten percent.
Technical Innovations for faster lautering processes
To increase the efficiency of the Lauterstar 2.0, GEA optimized the geometry and drainage points of the wort run-off cones. A larger distance between the false bottom and the lauter tun bottom ensures a more uniform wort flow and faster extraction. In addition, the new raking machine, equipped with special double-shoe knives, prevents compaction in the spent grain bed, thereby eliminating filter blockages. These compactions were previously responsible for two to three percent of wort losses.
Clear worts without solids, as produced in the GEA Lauterstar 2.0, are particularly advantageous for energy-saving high-gravity brewing. With this method, higher concentrated worts are produced, which can be subsequently diluted. This allows breweries to increase their capacities without additional resources.
Optimized lautering thanks to GEA Multifunctional Lautering Management (MLM)
A crucial element of the Lauterstar 2.0 is the raking machine, equipped with double-shoe knives that ensure low resistance in the grain bed and prevent channel formation caused by compactions. (photo: GEA)
Depending on the raw material quality, net lautering times of 70 minutes can now be achieved while maintaining high lauter tun yields. For continuous optimization, the MLM software monitors the lautering process in real-time. It automatically compensates for fluctuations in raw material quality and relieves the brewmaster from manual interventions. This software makes dynamic adjustments to the lautering process, ensuring constant production times and consistently high extraction efficiency.
Upgrade of existing lauter tuns for cost efficiency
For the ideal run-off geometry, GEA experts have fine-tuned the distance between the false bottom and the lauter tun bottom. The raking machine of the Lauterstar 2.0 is lowered later to loosen the grain bed. This extends the vitality of the grain bed and avoids clogging and thus wort losses. Customer tests showed extract yields of up to 98.7 percent. (photo: GEA)
Another option is to upgrade existing lauter tuns to the Lauterstar 2.0, which for many breweries makes economic sense. The investment pays for itself after just a few months, as demonstrated by the example of an Austrian brewery that was able to increase its production from five to 8.5 brews per day.
