From the idea of a differently designed lautering technology NESSIE by Ziemann (detailed professional article DBMB no. 2 / 2017), via the development work in the company-owned pilot brewery in Ludwigsburg, up to the first brews in a commercial brewery environment in Switzerland and France; this development culminated in the completion of the core component NESSIE with its upstream and downstream process steps, which were finally combined to the unprecedented brewhouse solution OMNIUM by Ziemann and which has already been implemented in two well-known breweries: the Schlossbrauerei Reckendorf near Bamberg and the Ratsherrn Brauerei in Hamburg. But let us start from the beginning:
Article created by:
Dr.-Ing. Verena Blomenhofer, Technology / Research & Development / Patent system
In 1852, August Ziemann established his coppersmith workshop in Stuttgart. Entrepreneurs like him made the former Kingdom of Württemberg a pioneer in efficiency and innovation, which the federal state of Baden-Württemberg continues to be today. He observed the market and customers in detail, soon sold his brewhouses all over the world and made brewery plants from Germany the dream of every brewer. Today, more than 165 years later, nothing has changed in Ziemann’s attitude. It is still important to observe the market and its customers and to develop the right pioneering brewery plants and systems of the future. In this respect, a significant change could have been noted in recent years. Customers value regional and individual products and they are willing to pay for the added value. The “cheap-is-cool” mentality has had its days, at least when it comes to enjoyment and quality. This fact is reflected in the development of prestigious craft beer breweries. In order to comply with their creative and innovative approaches, the brewery plants of the future must be extremely flexible, especially with regard to recipes and quantity of the brewed beer. This leads to a rethinking regarding the previous approach. On the other hand, people today rightly attach importance to ensuring that companies treat raw materials, energy and the environment as gently as possible. After all, we also want to ensure future generations a thriving, liveable planet. The company Ziemann has been driving this idea since its first days – and this issue is more topical than ever.
The Ziemann development team faced up to this great challenge and, together with high-ranking scientists from all over Germany, found the answer to the question of the brewery of the future: OMNIUM by Ziemann. It combines century-old processes and procedures with state-of-the-art technology – see Figure 1.
So far, especially the lautering systems decided on the type and quantity of the beers to be produced in a brewery. OMNIUM does not have these restrictions and limitations. Four successive, flat cylindrical wheel chambers – lovingly named NESSIE by ZIEMANN by its developers – allow almost any batch size and almost complete freedom in the type and composition of the malt mixture, see Table 1. It is not just about the recipes. While the classic brewery must rely on special barley that has been bred for optimal usability in current brewhouses, all types of grain can be used in the OMNIUM brewhouse – as it was the case in the founding years of Ziemann. Comparable to a piano on which only eight notes were to be played, but now the entire instrument can be used.
|NESSIE||Mash filter||Lauter tun|
|Wheat malt||ü||ü||max. 70 %|
|Rice||ü||<60 %||max. 40 %|
|Sorghum||ü||ü||max. 50 %|
|Cassava||ü||max. 50 %||max. 30 %|
|Corn||>80 %||<60 %||max. 40 %|
|Starch||>80 %||<60 %||max. 30 %|
Table 1: Possible use of raw materials with the three different lautering systems
Never before has it been possible to process such a high proportion of raw materials in a lautering system. NESSIE paves the way for the elimination of the time-limiting process step of lautering. The mash transfer time corresponds to the lautering time and the lautering is basically a transfer step of the wort boiling and can therefore be carried out continuously. With NESSIE by Ziemann, the identical plant can process strongly varying original extract contents (up to 32 °P), depending on the variety, as well as different starch sources or smallest batch sizes. With the effective counterflow extraction, NESSIE always achieves high yields with the usual sparging water quantities of 2.5 to 3.5 l/kg malt. Process times can be reduced by up to 30 %. The spent grains are discharged continuously after passing the fourth module with a residual moisture of < 78 %. Overall, the system produces more particle-rich and more turbid worts due to the dynamic filtration principle, the viscosity of which plays no role for the separation. (Figure 2)
The separate vessel ALADIN by Ziemann succeeds in extracting partial worts for an optimized malt utilization. Between one and two percent of the lautering volume is initially collected into ALADIN by Ziemann as enzyme extract for the post-saccharification of wort. The system essentially consists of an insulated, cylindro-conical stainless steel tank. The malt alpha-amylase, buffered in this tank at approx. 72 °C, ensures a subsequent complete saccharification of the boiled wort. For dosing the enzyme extract, the wort is cooled down to 83 to 90 °C. (Figure 3)
While the innovative JANUS by Ziemann, a hop isomerization vessel with about 40 % of the beer wort, helps the brewer to effortlessly and flexibly give the beer the required hop aroma and bitterness, 60 % of the beer wort boil in parallel in the wort boiling process. This means that the process of wort boiling and the hop isomerization are decoupled process steps in the OMNIUM brewing process. Modules 3 and 4 are suitable for the hop isomerization due to the lower bitter substance losses resulting from the reduced protein load. The low original extract of about 2 °Plato and the higher pH value of this wort fraction have a positive effect on the conversion of the hop bitter substances. The dosing possibilities of the isomerized wort of the JANUS are manifold and cover both the brewhouse and the sterile hop addition in the cold block. (Figure 4)
By using the separate hop isomerization vessel JANUS, the tasks within the wort boiling process by means of the internal boiler SHARK by Ziemann or the external boiler DOLPHIN by Ziemann are the same as before, only the isomerization is no longer considered in this process step. Both processes can be optimized separately. It is possible to transfer hop trub from the JANUS into the wort kettle. This supports the protein precipitation by the polyphenols of the hops. (Figure 5)
After the boiling process, the wort is cooled down to 83 to 90 °C. At this temperature, the first wort extract ALADIN is dosed. In the whirlpool WORTEX by ZIEMANN, the hot trub is separated, which consists of about 80 % water, a mixture of insoluble proteins, carbohydrates, lipids, tanning agents, minerals and hop components.
With the gentle, efficient and aroma-enhancing OMNIUM brewing process, substantially more of the valuable ingredients from hops and malt are obtained for the beer. The brewmaster has full control of the action and is able to brew beers exactly according to his ideas. With the OMNIUM brewhouse solution, Ziemann pushes the door to a new world of brewery plants. Beer can be beer again: full-flavored thanks to the high yield of ingredients, fully aromatic thanks to the gentle brewing process and individual thanks to the almost complete freedom of the brewmaster in producing creative beers.
The new brewhouse concept has already been implemented in two breweries that could not be more different – in the traditional brewery Schlossbrauerei Reckendorf and the well-known Ratsherrn Brauerei in Hamburg. Never before have there been so many control variables in a brewing process and thus never before has there been such a great potential for flexibility in the brewing process, which is reflected in the enormous variety of beer types.
Pioneering role – Schlossbrauerei Reckendorf
The Schlossbrauerei Reckendorf with its brewing tradition since 1597 combines modern brewing technology and strong brands. Only in 2016, the brewery won the International Craft Beer Award for its Weizenbock. Therefore, no one was surprised that the Schlossbrauerei Reckendorf took the pioneering role in 2018 and installed the first OMNIUM brewhouse. The existing mill and the whirlpool were continued to be used, everything else was planned and built by Ziemann Holvrieka GmbH. The first brew in the new brewhouse in Reckendorf was produced early in April 2018. Instead of the original two brews per day, each with 105 hl cast-out wort, the OMNIUM brewhouse was designed for three brews per day with 70 hl each, filling the 210 hl fermentation tanks. (Figure 6)
Despite the expansion to three brews in Reckendorf, the new overall process is faster than the old brewhouse (only 4.5 hours per brew).
However, according to graduate process engineer and brewmaster Dominik Eichhorn, who is at the helm of the family-owned brewery in the third generation, speed as such has never been the primary objective of the Schlossbrauerei Reckendorf. “The decision in favour of the OMNIUM brewhouse is essentially based on the greater flexibility. Brewhouse processes are subdivided into part processes and thus optimized. We are thus in a position to process a greater variety of raw materials such as old cereal varieties that are nowadays considered as rather unsuitable for industrial production processes”, explains Eichhorn.
Dominik Eichhorn confirms that the previous results and practical experience are very good. “This applies both to the commissioning and to worts and beers”. In the first step of the “flavour matching”, the new brews were blended in the fermentation cellar with conventional worts. The wort aeration could be significantly lowered in order to keep the yeast propagation within the required limits. Currently, only one of the three brews is aerated for ten minutes in order to achieve an oxygen concentration of 1 ppm. This results from the yeast vital substances such as zinc or fatty acids, which have a positive influence on the fermentation process.
In Reckendorf, both the worts and the beers were analysed chemically and analytically down to the last detail. The fact that the analyses of the OMNIUM beers are flawless is shown in Table 2 and Table 3 as a comparison with the old brewhouse (ASH).
|Parameter||Omnium by Ziemann||ASH||Reference values |
|Total N [mg/100 ml]||74,1||72,7||70-80|
|Foam number [SKZ)||127||121||>105 (according to DLG)|
|Polyphenols [mg/l]||111 /167**||120||150-200|
|Anthocyanogenes [mg/l]||27 /50**||40||50-70|
|Tanning agents [mg/l]||5/25**||20||10-40|
|Bitter units [EBC-BE]||22,4||18,7|
|Forcing test 0/40/0 [WT]||>>20 /(>20)**||8||>2 (according to DLG)|
Table 2: Practical values of the beer quality with the OMNIUM brewhouse in direct comparison to the lauter tun operation (ASH), the beers are stabilized on the protein and tanning agent side, average values calculated to 12 %, chemical-technical analyses, * without colour correction, ** without stabilization
The nitrogen contents, the viscosity, higher alcohols and DMS/DMS-P are within the usual ranges. The parameters colour and TBZ are only conditionally meaningful, since the brewery has made a colour correction by adding caramel malt. The OMNIUM worts and beers contain reduced tanning components. The beer remains stable, since the polyphenols are missing as reactants for the turbidity formation. In general, OMNIUM beers do not necessarily have to be additionally stabilized. The predominance of the protein fraction promotes the good foam stability with 127 SKZ. The increase in the yield of bitter substances by approximately 10 percent up to the finished beer is also remarkable.
The fatty acid content C6-C18:1,2,3 of OMNIUM beers is low, which can be attributed to the nutrient supply of the OMNIUM worts, because only a low level of fatty acid synthesis is required at the beginning of the fermentation process, fewer medium-chain fatty acids (C6-C12) are released into the beer as by-products and the long-chain, saturated and unsaturated fatty acids are completely metabolized (see Table 3). These conditions also lead to a good foam stability.
|Omnium by Ziemann||ASH||Reference values|
|DMS/DMS-P [µ/l]||40/34||34/42||∑ < 100|
|Ethyl acetate [mg/l]||6,9||15,8||8-32|
|Isoamyl acetate [mg/l]||0,4||1,3||0,3-3,8|
|Amyl alcohols (2-,3-Me-bu-ol) [mg/l]||72,4||64,0||38-100|
|Diacetyl, total [mg/l]||0,05||0,03||< 0,10|
|2,3- Pentandion, total [mg/l]||0,05||0,02||< 0,05|
|Capronsre. C 6:0 [mg/100ml]||–||–||0,05-0,2|
|Caprylsre. C 8:0 [mg/100ml]||0,09||0,21||0,2-0,5|
|Caprinsre. C:10 [mg/100ml]||0,03||0,06||0,01-0,2|
|Laurinsre. C:12 [mg/100ml]||0,01||0,03||0,01-0,05|
|C 16 – 18_1/2/3 [mg/100ml]||0,09||0,1||–|
Table 3: Practical values for beer quality with the OMNIUM system in direct comparison to a lauter tun system (ASH), gas chromatographic analyses
The good zinc and fatty acid supply leads to a vital yeast and thus to a very good fermentation activity. Other small, measured differences are irrelevant for the quality of the beer. Here, it becomes clear that in a lauter tun process, nutrients are strongly absorbed by the trub and are no longer available in the subsequent fermentation process.
Brewing technologists and beer lovers can therefore look forward to Reckendorf with great anticipation. The graduate process engineer summarizes his new brewhouse as follows: “Fewer malt polyphenols, gentle hop isomerization and vital fermentation will certainly produce an ideal Pilsner beer.” It is therefore no wonder that the acceptance test of the brewhouse was successful.
Ratsherrn Brauerei in Hamburg
Ratsherrn Brauerei, a trendy urban brewery in Hamburg’s district Sternschanze, opened its plan to implement OMNIUM by Ziemann in the Hamburg brewery already at the trade fair BrauBeviale 2018 in Nuremberg. In February 2019, the Hamburg team came to Ludwigsburg in order to carry out trials with NESSIE in Ziemann’s pilot brewery. The Hamburg-based medium-sized brewery, founded in 2012, implemented the new brewhouse solution (50-hl brewhouse) as a so-called brownfield project: OMNIUM is running in parallel to another lauter tun brewhouse. The decision in favour of OMNIUM was simple and was based on the fact that NESSIE can be used to produce also very small batches. In this way, the impressive variety of the scene brewery – about 30 different, partly seasonal or even limited beer types – can be covered. In addition, the newly gained independence of the lautering process results in product development advantages when upscaling new beer types. With regard to the viscosity parameter, barley varieties such as oats and rye can now be processed efficiently. The wort kettle with shell and bottom heating zones has been equipped with the external boiler DOLPHIN by Ziemann in order to be able to reproduce the different batch sizes. Ziemann’s hop isomerization vessel JANUS by Ziemann is used for dosing very different high amounts of hops, which can also be dosed in the cellar. (Figure 7)
On July 3, 2019 the first brew of the beer type Ratsherrn Pilsner was produced successfully and with great enthusiasm of all participants. The following excerpt includes the description of the beer sommelier Birgit Rieber, which she wrote after tasting the first “NESSIE” Pilsner.
|Light gold, crowned by a fine white foam head. The noble hop blossom in the nose is followed by a scent of lime blossom with a hint of lemongrass. The initial taste is smooth and fresh, the perlage finely chiselled.|
A Pilsner – Amazing what happens with the first sip on tongue and palate. Tart, but highly cultivated bitterness is noticeable. The bitterness is there immediately – not just in the aftertaste, as we passionate Pilsner lovers are used to. The hops line the mouth right from the start: present, dominant, but still soft. The fine bitterness remains, which does not want to disturb, only enchant the senses. In the aftertaste, the lime blossom suddenly reappears. The Pilsner leaves behind traces of blossom and spicy Elbe air.
Table 4: Description of the Ratsherrn Pilsner of wegro-Institut für Bierkultur gmbh / in Vienna / Austria
Up to now, five beer types have already been successfully brewed in the OMNIUM brewhouse. From Matrosenschluck, an oat white IPA with oat malt and orange peel, via the classic IPA up to the Noctopus Imperial Stout with 9.7 vol. %. This year’s Hamburger Senatsbock of the Ratsherrn Brauerei was also brewed in the OMNIUM brewhouse. This has been ceremonially tapped on January 24, 2020 in the Grundsteinkeller of the Hamburg City Hall in the course of the Senatsbock event.
Technological advantages result in principle from a shortening of the fermentation time, the reduction of yeast addition as well as the extensive omission of wort aeration. However, the fermentation can be controlled individually and flexibly and, due to the optimized pitching conditions, can be selected as desired by the brewery. The constant lautering time of about 40 minutes is remarkable and is completely independent of the beer type. This time saving is particularly noticeable when brewing special beers, as lautering times using a lauter tun of more than four hours were previously necessary.
- Becher Tobias, Ziller Konstantin, Wasmuht Klaus (2017) Die Läuterarbeit in Brauereien mit Läuterbottich, Maischefilter und der innovativen Neuentwicklung Nessie, DBMB Nr. 2, Seiten 24-26
- Schwill-Miedaner Annette, Miedaner Heinz (2018) Sudhauskonzept OMNIUM Teil 1: Technologische Fakten und ihre Folgen, Brauwelt Nr. 45, Seiten 1321-1324
- Schwill-Miedaner Annette, Miedaner Heinz (2018) Sudhauskonzept OMNIUM Teil 2: Technologische Fakten und ihre Folgen, Brauwelt Nr. 51-52, Seiten 1557-1559
- Wasmuht Klaus, Eichhorn Dominik (2018) Revolutionäres Sudhausdesign erstmals im Einsatz, Brauwelt Nr. 30, Seiten 856-858
- Gehrig Klaus (2019) OMNIUM by ZIEMANN Handbuch, 1. Auflage, Ziemann Holvrieka GmbH
- Mitteleuropäische Brautechnische Analysenkommission, MEBAK Wort Beer Beer-based Beverages, Freising-Weihenstephan: MEBAK, 2013
Figure 1: The new brewhouse solution: OMNIUM by ZIEMANN – schematic process diagram
Figure 2: The new mash filtration NESSIE by ZIEMANN – implemented in the Schlossbrauerei Reckendorf
Figure 3: ALADIN by ZIEMANN, the buffer vessel for enzyme extract – implemented in the Schlossbrauerei Reckendorf
Figure 4: The hop isomerization vessel JANUS by Ziemann – implemented in the Schlossbrauerei Reckendorf
Figure 5: The external boiler DOLPHIN by Ziemann – implemented in the Schlossbrauerei Reckendorf
Figure 6: The Schlossbrauerei Reckendorf Dirauf GmbH Co. KG – both from inside and from outside
Figure 7: Ratsherrn Brauerei in Hamburg
Picture credit: ZIEMANN HOLVRIEKA GmbH
The high-resolution pictures can be downloaded here.
About ZIEMANN HOLVRIEKA
Since 1852 ZIEMANN HOLVRIEKA has been providing innovative and tailor-made solutions for craft breweries as well as for large-scale breweries – from the malt intake to the bright beer tank cellar. The product range in the area of the wort treatment extends from the malt intake, via grist mills, mash vessels, lauter tuns, mash filters, wort kettles and whirlpools up to wort cooling systems. In the area of the cold block ZIEMANN HOLVRIEKA offers fermentation and storage tanks, bright beer tanks, yeast tanks and all required CIP tanks. ZIEMANN HOLVRIEKA plans, engineers and automates the process and the cleaning technology in all production areas, including the installation of process pipework and the integration of all required utilities. For modernizations, capacity expansions as well as for completely new brewery plants – ZIEMANN HOLVRIEKA provides innovative solutions and is a valued expert. Last but not least, ZIEMANN HOLVRIEKA is a competent and reliable partner for craft breweries and large-scale breweries in the field of research and development. ZIEMANN HOLVRIEKA supports its customers, for example, in developing individual beer recipes.