Stainless steel plant construction for dealcoholization: Precision under specific physical conditions
Alcohol-free beer presents microbiological challenges. At the same time, the processes used to remove alcohol place stress on the piping system through negative pressure and pressure pulsations. STW GmbH manufactures stainless steel skids and piping systems that withstand the physical stresses of dealcoholization.
Are you planning to integrate a dealcoholization plant into your existing brewery?
Talk to us as your partner for the prefabrication and installation of the systems.
Control of vacuum and system pressure in the pipe network
The dealcoholization processes place different demands on the pipelines and welded joints. Clean workmanship is essential for mechanical operational reliability and protection against contamination.
Vacuum distillation and reduced pressure: This process puts the system under negative pressure. If pipes are not properly welded, the pressure difference leads to the ingress of air. In the case of non-alcoholic beer, the intake of unsterile ambient air means immediate microbiological contamination. We manufacture pipe sections for vacuum systems with precision and execute the welds in such a way that they permanently guarantee this tightness.
Reverse osmosis and pressure pulsations: This process uses high system pressure (often over 30 bar) for membrane separation. The high-pressure pumps generate pressure pulsations in the pipe network. To protect the material from fatigue and cracking, we rely on precise seam preparation and stress-free welds.
Modular skid manufacturing for structurally limited brewery cellars
Dealcoholization plants often need to be retrofitted into existing brewery cellars, which are frequently limited in size. To prevent skids from not fitting through the passageways or requiring on-site welding, we manufacture them to fit the specific conditions:
Modular segment construction
The prefabricated skid construction allows the individual modules to be adapted to the existing gate dimensions and paths on site, thus optimizing the installation.
Disassemblable installation
System components are prefabricated in modules and segments. This allows them to be brought into the basement and assembled there without any additional rework.
Are there structural limitations in your brewery cellar?
We construct your dealcoholization skids in precisely fitting modules.
Microbiological safety for non-alcoholic beer
Since alcohol, a natural preservative, is absent in beer, the product is susceptible to microbiological spoilage. Furthermore, no residues may remain in the pipe during CIP cleaning, as cleaning residues would directly contaminate the non-alcoholic beer.
We perform our welds in accordance with DIN EN ISO 5817 standards and EHEDG requirements (Hygienic Design):
No root resorption (sagging)
The seam must not form a depression inside the pipe, as this creates classic dead spaces for germs and cleaning agents.
No root overhang (overhang)
Excessive inward projection of the seam into the pipe interior is avoided in order to keep flow resistance low and not disrupt the CIP process.
“Flat” design
A properly executed weld ensures that the cleaning chemicals are completely rinsed away and the product can flow without significant resistance.
Ergonomics through stress-free assembly
The effects of a system installed under tension are often evident in older breweries at manual interfaces, such as with swing arch panels. If the system was not designed and installed without tension, the arches are difficult to adjust during operation. This significantly complicates manual repositioning for the operating personnel. For STW, tension-free installation is therefore standard practice – it protects the material and ensures ergonomics in daily operations.
Rely on microbiological safety and stress-free plant construction for your non-alcoholic beer. We implement your requirements in stainless steel.
FAQ: Frequently asked questions about plant construction for dealcoholization
Vacuum distillation creates a negative pressure. If a system is not 100% airtight, air will enter. The intake of unsterile ambient air leads to immediate microbiological contamination of non-alcoholic beer.
Reverse osmosis operates at high system pressure (often >30 bar). High-pressure pumps can generate pressure pulsations that lead to cyclic stresses in the stainless steel. These alternating stresses promote material fatigue and cracking. We prevent this through precise weld preparation and low-stress, high-quality welds.
The systems are built in modules to match the installation routes, in order to integrate them into the existing network on site without additional welding.
Non-alcoholic beer is susceptible to microbiological contamination. STW prevents contamination through standard-compliant welds without root recession (depressions where germs can collect) and without root protrusion, ensuring complete rinsing during CIP cleaning.
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