Premium Craft Brewery Complete Fit-out

Project Overview

Stone & Wood Brewing Co., one of Australia’s most respected craft breweries, needed to significantly expand their production capacity while maintaining the quality and consistency that has made their Pacific Ale a household name. FabEng delivered a comprehensive brewery expansion that tripled production capacity while incorporating the latest in brewing technology and automation.

Project Scope

Fermentation Systems

• 8 × 6,000L conical fermentation tanks with glycol cooling
• Advanced temperature control systems with ±0.5°C accuracy
• Integrated CO2 recovery and carbonation systems
• Automated pressure relief and monitoring systems

Bright Beer Tank Systems

• 4 × 8,000L bright beer tanks with specialized finishes
• Integrated sampling ports for quality control
• Automated transfer systems with flow measurement
• Temperature-controlled conditioning capabilities

Clean-in-Place (CIP) Systems

• Automated 3-tank CIP system with programmable cycles
• High-efficiency spray balls for thorough cleaning
• Chemical dosing systems with precise concentration control
• Water recovery and reuse systems for sustainability

Process Integration

• Automated control system integration with existing brewery operations
• SCADA system for real-time monitoring and control
• Data logging and reporting for quality assurance
• Remote monitoring capabilities for 24/7 oversight

Technical Innovation

Advanced Surface Finishes All tanks feature electropolished surfaces achieving Ra values of 0.4μm for optimal cleanability and sanitation:

• Fermentation Tanks: Mirror-finish interiors with specialized yeast collection systems
• Bright Beer Tanks: Ultra-smooth surfaces for clarity and stability
• Transfer Lines: Orbital welded sanitary piping throughout
• CIP Components: Self-draining design with no dead legs

Automation and Control State-of-the-art automation systems provide precise control:

• Temperature Management: Multi-zone cooling with individual tank control
• Pressure Monitoring: Continuous pressure monitoring with automated relief
• Transfer Control: Automated beer transfer with density monitoring
• Quality Assurance: Integrated sampling and testing protocols

Sustainability Features

Resource Efficiency The system incorporates multiple sustainability measures:

• CO2 Recovery: 95% recovery of fermentation CO2 for reuse
• Water Conservation: CIP water recovery reducing consumption by 30%
• Energy Efficiency: Variable speed drives and heat recovery systems
• Waste Reduction: Automated yeast collection and processing systems

Environmental Compliance Full compliance with environmental regulations:

• Wastewater Treatment: Integrated pH balancing and solids removal
• Air Quality: Vapor recovery systems preventing atmospheric emissions
• Noise Control: Sound dampening for residential area compliance
• Chemical Management: Automated chemical handling reducing manual exposure

Quality Assurance

Food Safety Compliance Comprehensive food safety measures throughout:

• HACCP Implementation: Complete hazard analysis and control points
• Sanitary Design: All equipment designed for thorough cleaning
• Material Certification: Full traceability of all food-contact materials
• Validation Testing: Comprehensive cleaning validation protocols

Quality Control Integration Advanced quality control capabilities:

• Inline Monitoring: Continuous monitoring of critical quality parameters
• Automated Sampling: Representative sampling for laboratory analysis
• Data Recording: Complete batch history and traceability
• Alarm Systems: Immediate notification of process deviations

Installation Excellence

Phased Implementation Careful planning minimized disruption to ongoing operations:

• Phase 1: Site preparation and utility installations
• Phase 2: Tank fabrication and delivery
• Phase 3: Installation and piping connections
• Phase 4: Automation commissioning and testing

Safety Management Comprehensive safety protocols throughout installation:

• Site Safety: Zero harm achieved across 15,000 work hours
• Risk Assessment: Detailed hazard identification and control
• Training Programs: Specialized training for all installation personnel
• Emergency Procedures: Comprehensive emergency response protocols

Commissioning and Validation

System Testing Extensive testing ensured optimal performance:

• Pressure Testing: Hydrostatic testing of all pressure vessels
• CIP Validation: Complete cleaning cycle validation with microbiological testing
• Automation Testing: Comprehensive control system functionality testing
• Performance Verification: Capacity and efficiency verification testing

Operational Training Comprehensive training for Stone & Wood personnel:

• System Operation: Training on all system components and controls
• Maintenance Procedures: Preventive maintenance training and scheduling
• Troubleshooting: Problem diagnosis and resolution procedures
• Quality Control: Integration with existing quality assurance protocols

Results and Impact

Production Enhancement The expansion delivered significant operational improvements:

• Capacity Increase: 300% increase in total brewing capacity
• Efficiency Gains: 25% reduction in labor requirements per batch
• Quality Consistency: Improved batch-to-batch consistency and quality
• Flexibility: Enhanced ability to produce seasonal and specialty beers

Business Growth The expansion enabled Stone & Wood to pursue new opportunities:

• Market Expansion: Increased capacity for interstate distribution
• Product Innovation: Dedicated tanks for experimental and seasonal brews
• Contract Brewing: Capacity for contract brewing partnerships
• Export Potential: Production capacity for international market entry

Long-term Partnership

Ongoing Support FabEng continues to support Stone & Wood’s operations:

• Maintenance Contracts: Comprehensive preventive maintenance programs
• Technical Support: 24/7 technical support and emergency response
• Upgrades and Modifications: Ongoing system improvements and expansions
• Training Updates: Continuing education for operational personnel

Future Expansion The system was designed for future growth:

• Modular Design: Easy integration of additional tanks and systems
• Utility Planning: Infrastructure designed for future expansion
• Control System Scalability: Automation platform capable of handling growth
• Site Preparation: Master planning for additional production capabilities

Industry Recognition

The project has received significant industry recognition:

• Engineering Excellence Award: Engineers Australia Queensland Division
• Food Safety Recognition: Queensland Food Industry Association
• Sustainability Award: Green Building Council of Australia
• Innovation Award: Australian Institute of Food Science and Technology

This project demonstrates FabEng’s capability to deliver complex, integrated systems that support business growth while maintaining the highest standards of quality, safety, and sustainability. The success at Stone & Wood has established a template for brewery expansions across Australia’s growing craft brewing industry.

---

Interested in expanding your brewing operations? Contact our brewing specialists to discuss how FabEng can support your growth plans.