Industrial Unitanks

Reliable solution by Hypro Fermentation Tanks

Hypro designs and manufactures Fermentation Tanks (Unitanks) with capacities up to 5000 HL as a single-piece construction at its manufacturing facility. Where transportation constraints prevent the delivery of large tanks, Hypro offers an on-site assembly solution using prefabricated, surface-finished top dished ends, bottom cones, and shell sections.

Backed by an extended 5-year manufacturer warranty, our Fermentation Tanks deliver long-term reliability and peace of mind. Installation is executed by Hypro’s experienced engineering team, while the PLC-SCADA automation system is engineered with carefully selected sensors, controllers, and final control elements to ensure precise, dependable operation.

Product Description

Hypro Unitanks are designed to perform three key brewing processes within a single vessel:

Fermentation of wort to produce green beer
Cooling of green beer from fermentation temperature to maturation temperature
Maturation of beer to produce young beer

Wort Filling and Fermentation

Aerated cold wort from the brewhouse, pitched with fermenting yeast, is filled into the Unitanks batch-wise, typically 2-6 brews per tank. As fermentation begins, the fermentable extract is converted into alcohol and CO₂. Since the reaction is exothermic in nature, heat is generated and continuously dissipated by circulating glycol through the cooling jackets of the Unitank. The fermentation temperature is automatically maintained by a PC-PLC based control system in accordance with the predefined control logic.

First Stage of Cooling

Upon completion of the fermentation cycle, the first cooling stage begins. The green beer is cooled from the fermentation temperature to 4 Deg C. At this temperature, the yeast settles at the bottom of the Unitank and is collected before being pumped to the Yeast Plant for further processing.

Second Stage of Cooling

After yeast removal, the second stage of cooling begins, during which the beer is further chilled to -1 Deg C.

Beer Maturation

Once the beer reaches -1 Deg C, the maturation cycle begins. The beer is matured in the Unitanks for approximately 5-7 days to develop into young beer. During this period, CO₂ counter pressure is applied to maintain a CO₂ atmosphere within the beer and prevent oxygen pickup, ensuring product quality throughout the maturation process.

Features

Capacity: 50 L to 5000 HL
Designed in accordance with ASME Sec VIII, Div 1 and the latest hygienic design standards
Constructed using SS 304L – European mills
Complete cellar system with flow plates
Cooling rates designed to support 24-48 hour cooling cycles
Glycol circulation jackets designed for positive glycol flow and low pressure drop
Machine-ground surface finish of 0.8-0.4 Ra
TTP safety fittings and tank cleaning machine imported from Europe
Hygienic cellar process and utility piping designed to simplify brewery operations and facilitate efficient CIP over years of operation
Hot-dip galvanized platforms and walkways designed for easy on-site bolting, eliminating the need for welding during installation
Tanks with welded cladding on the bottom cone and top dish for extended insulation life and improved aesthetics
Ergonomically designed manholes and top plates for easy access during production and efficient cleaning, ensuring long-term surface hygiene
PLC-SCADA based automation with data logging, historical records, recipe management, and trend analysis
Brew iT Data Management Software for comparing trends and process parameters across multiple fermentation batches
Suitable for outdoor installation
Reduced operator dependency through advanced automation
High-efficiency tank cleaning machine designed for low water consumption

Functionality

Wort Transfer to Unitank
Connect the wort main line to the bottom of the Unitank using a Swing Bend. Keep the valve on the CIP-GAS line open to vent air during wort collection in the Unitank. Product-to-water or water-to-product changeover is carried out using a diverter valve with a sight glass arrangement.

CO₂ Collection
Connect the GAS line to the CO₂ collection header using a Swing Bend and open the respective line valves. CO₂ collection is typically initiated after the gas purity reaches 99.7% v/v, which normally occurs approximately 36 hours after the start of fermentation.

Yeast Transfer
Connect the yeast main line to the bottom of the Unitank using a Swing Bend. Keep the valve on the CIP-GAS line open to allow gas into the Unitank, maintaining positive internal gas pressure during yeast transfer. Product-to-water or water-to-product changeover is performed using a diverter valve with a sight glass arrangement.

Beer Transfer
Connect the beer main line to the bottom of the Unitank using a Swing Bend. Keep the valve on the CIP-GAS line open to maintain positive gas pressure inside the Unitank during beer transfer. A dedicated CO₂ supply line is provided and can be connected to the Unitank gas inlet using a Swing Bend. Product-to-water or water-to-product changeover is carried out using a diverter valve.

CIP of Unitank
The Unitank is cleaned after every production batch using the CIP system. During the CIP cycle, ensure that the cleaning solution is circulated at an adequate pressure of 5.0 Bar (as indicated on the CIP line pressure gauge) with a flow rate of 15-17 m3/hr. A separate provision is available for CIP of the Anti Vacuum Valve mounted on the top plate. The valve is fitted with a splash guard to prevent liquid splashing onto the top plate during cleaning.

Hot CIP of Process Lines
As standard practice, Hot CIP is carried out for all process headers, including the Wort, Yeast, and CIP Return (CIP-R) headers. All process headers are cleaned and chased using Hot CIP and standard CIP cycles while maintaining the required flow rates and an operating pressure of 3-4 Bar.

CO2 Supply
A dedicated CO₂ supply line is provided for the Unitank. The line can be connected to the Unitank gas inlet using a Swing Bend whenever CO₂ supply is required.

Technical Specification

Cylindroconical Unitanks are complete with shell, top dish, and bottom cone.
Cooling jackets are of embossed/dimpled type on the shell portion and petal/embossed type on the cone portion.
Thermowells with shrouds are provided on both the shell and the cone.
Cooling section zones (as per the design) are provided on the shell and the bottom cone.
Membrane-type sample valve (Keofitt make) with keyring, shrouds, and shroud drain.
CIP supply pipe routed from the operating level in the cellar to the tank top through the insulation.
Dome drain pipe routed from the tank top to the top of the slab through the insulation.
Cable conduit pipes routed through the insulation.
Glycol supply and return piping from the tank to the supply headers in SS 304, routed through the insulation.
Glycol supply and return piping from the main headers to the supply headers in SS 304 with PUF insulation and SS 304 cladding.
Lifting lugs with a detachable arrangement for platform installation at site.
Skirt with leg supports in hot-dip galvanized MS.
Unitank platform in hot-dip galvanized material, complete with railings.
Hygienic process piping, fittings, and butterfly valves (wherever required) in OD-based SS 304 for wort, beer, yeast, CO2, air vent, CIP Supply (CIP-S), and CIP Return (CIP-R).

Process Automation & Control

Cooling jackets are provided on both the shell and cone portions of the tank.
The tank temperature is monitored by temperature transmitters located at the top of the shell and the top of the cone.
Actuated butterfly valves are provided to control the tank temperature.
In Profile/Auto mode, the valves automatically open or close to maintain the set temperature.
A manual ON/OFF facility is also provided and can be operated from the SCADA screen.
The entire temperature control system is fully automated and operates through SCADA based on a predefined control logic program.
The CIP Return Pump is trolley-mounted and starts/stops automatically according to the steps defined in the Cellar CIP and Line CIP programs.
The Yeast Cropping Pump is also trolley-mounted and is operated automatically through SCADA.
Yeast harvesting from the Unitank and transfer to the Yeast Section are performed through cycle selection in SCADA.

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Fermentation Tanks

Optimum conditions with automaton

Frequently Asked Questions.

How do I clean a tank before first time use?

This is an easy process. DO NOT use acid first. To remove any chemicals or welding lubricants from your new tank, you must first run a cleaning cycle with a caustic solution. We recommend running two separate cycles for absolute cleaning. Do not use an acid first, as a white residue will form. You must always clean your tank after receiving it from the factory.

Do the Unitanks come equipped with a CIP Spray Ball?

The Unitanks do not have a spray ball included. The Unitanks come equipped with a 3″ TC Accessory port in which you could place a 3″ Spray Ball.

Do the Unitanks have internal gallon markings?

No, Unitanks do not have internal volumetric markings.

Can you serve beer from a Unitank?

Although Unitank has the capability to serve beer directly, it is recommended that you transfer the beer to a dedicated serving vessel like a Brite Beer Tank or Keg to avoid the inadvertent contamination of fermentation by-product in the finished brew.

What is the warranty exactly?

We test all our tanks for optimum quality before placing our 5-year warranty on them. This covers any issues with the tank’s function that would be considered a factory error. We also replace broken or faulty parts should this occur in the 5 year warranty period. We require photos of the damaged part(s) before helping with warranty related issues. If we determine it is an operator error we will not cover replacements or fixes. The warranty becomes absolutely void if you make any alterations or fabrications to the tank after purchase. We do not guarantee other people’s handy work.

Often Combined with

Hypro Fermentation Tanks provide exactly those assured conditions. They are tailored to the diversity of types and the specific system of fermentation parameter control operated by your brewery. Our vessels are designed with versatility, allowing all the brewery functions to be combined in fewer vessels for the economy, or separated into several vessels for increased capacity.

Industrial Unitanks

Reliable solution by Hypro Fermentation Tanks

We would love to see you on social media!

Fermentation Tanks

Optimum conditions with automaton

Manholes & Top Plates

Internal Surface finish

Cellar Process & Utility Piping

Platforms / Walkways

Tank Top Fittings

Cladding

Frequently Asked Questions.

Often Combined with

Industrial Brewhouse

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