Beer production, bottling and canning line 

Transforming an abandoned barn into a state-of-the-art brewery and beer filling facility: this is the story of our collaboration with West Berkshire Brewery (WBB), a project that combines innovative brewing technology, efficient bottling and canning solutions, and long-term production planning.

From a barn to a modern brewery

Five years ago, in the green surroundings of Frilsham Park, about 85 km west of London, there stood a large disused barn covering more than 12,000 square metres. When we first visited the site, the structure showed clear signs of abandonment: rough concrete floors scattered with rubble, straw, old tools, and the unmistakable smell of a former agricultural building.

It was here that Tom Lucas, newly appointed CEO of West Berkshire Brewery, shared his ambitious vision with us: “We want to build a new brewery here to produce and bottle our beer.”

From the very first meeting, his enthusiasm and long-term perspective were clear. We accepted the challenge: to transform that empty space into a complete beer production, bottling and canning facility, equipped with cutting-edge technology and designed for future expansion.

In this video, West Berkshire Brewery chairman David Bruce presents the original project and the barn before conversion:

A complete and scalable solution by CFT

A few months later, our proposal was selected, standing out among other solutions for technical quality, operational efficiency and long-term scalability.

As we do for many complex installations, we developed a detailed Master Plan to:

• Optimize the use of available space
• Anticipate seasonal production peaks
• Streamline internal logistics
• Keep future development scenarios in mind

This strategic approach allowed West Berkshire Brewery to invest in a plant designed not only for immediate needs, but also for sustainable growth.

Beer production plant: efficiency, quality and automation

We designed the brewery for a production capacity of 50,000 hl/year, based on four 60-hl brews per day, with a total daily yield of 240 hl and an efficiency of 96%.

At the heart of the plant is a 3-vessel CFT brewhouse, capable of producing 4 brews per day and expandable up to 8. The system represents state-of-the-art brewing technology in terms of automation, product quality and energy efficiency.

Main features of the CFT brewhouse

• Malt handling system (1,500 kg/h) for receiving, storage, cleaning, milling and conveying, with vacuum transport to minimize explosion-risk areas
• 83-hl mash tun with low-oxygen static water–malt mixer, CO₂ protection and low-speed agitation to preserve wort quality
• 140-hl lauter tun with our balanced hydraulic filtration technology, ensuring high filtration speed, clear wort and solid content below 100 mg/l
• 108-hl brew kettle, optimized for high hop loads, with dual tangential wort inlets for efficient separation of volatile compounds
• External boiler with low evaporation rate and minimal temperature differential (0.7 °C)
• Automatic hop dosing system to reduce cycle times and operational risks
• Controlled hop aroma extraction system
• Three-tank CIP system, fully customizable and synchronized with brewhouse cycles

Before yeast pitching, the wort is cooled through a single-stage heat exchanger. We recover and reuse the thermal energy generated during this phase within the brewing process, significantly improving overall energy efficiency.

Cellar design for automated beer production

We engineered the fermentation and storage cellar specifically for a 50,000 hl/year output. Tank sizing was calculated according to production flow and fully aligned with the filtration, carbonation and storage phases.

All process stages are integrated and automated, allowing:

• Short production cycles
• High operational safety
• Consistent beer quality

This layout ensures flexibility while maintaining full process control.

Beer bottling and canning lines

For beer packaging, we supplied two complementary filling solutions, covering both bottle and can formats.

Counter-pressure bottling: MASTER RS GLASS / PET

The MASTER RS GLASS / PET filler is based on counter-pressure technology and is suitable for filling carbonated or still beverages in glass or PET bottles. It is an ideal solution for medium to high-capacity beer bottling lines.

Key features:

• Output from 3,500 to 60,000 bottles/hour
• High filling precision and excellent dissolved oxygen control
• PLC-managed filling phases
• Hygienic design
• Centralized decompression system

Beer canning: Master C Block monoblock

The Master C Block is an automatic can filling and seaming monobloc, capable of reaching speeds of up to 15,000 cans/hour. It is part of our premium range dedicated to craft and small-to-medium breweries.

Main advantages:

• Extremely compact footprint, ideal for limited installation space
• High-precision filling using advanced flow-meter technology
• Available in multiple configurations, including a 24-valve version

After filling, bottles and cans are labelled and palletized directly on site, completing a fully integrated packaging process.

Installation, commissioning and staff training

Installing advanced brewing equipment inside a historic structure required extremely accurate planning. We carefully positioned tanks, piping and utilities around the original pillars and roof trusses, taking into account the limited ceiling height.

In parallel with commissioning, we delivered three months of dedicated training for West Berkshire Brewery staff. Our intuitive control and monitoring systems allowed operators to quickly master the new technologies, resulting in:

• Faster and more efficient workflows
• Increased staff motivation
• Improved internal communication

Sustainability and future expansion

Beyond economic performance, the project delivered tangible benefits in terms of risk reduction and environmental sustainability. For us, eco-compatibility is a core principle of beer production: it means optimizing the use of natural resources and continuously monitoring energy and consumption parameters to identify and correct inefficiencies.

Thanks to the success of the project, West Berkshire Brewery soon decided to further expand the plant with additional tanks and equipment, increasing total production capacity to 100,000 hl/year.

A long-term partnership

Over the past 30 years, West Berkshire Brewery has grown significantly, recently completing its fourth and largest expansion. We designed and installed the new brewery, which includes:

• A 70-hl brewhouse with 5 vessels
• A modern cellar with multiple fermenters (60-hl, 120-hl and 240-hl)

This investment allows WBB to produce more beer while remaining flexible and creative.

Beer market outlook

Beer remains the most important segment of the global alcoholic beverage market in terms of both volume and value. Global market revenue reached $522.3 billion in 2020, with an expected average annual growth rate of 9.4% between 2020 and 2023. The United States alone generated over $101.8 billion in beer revenue in 2020.
Source: Statista

Project team

Matteo Avanzi – Sales Area Manager
Elio Poloniato – Brewing Process Engineering Specialist
Daniele Biancheri – Process Technical Manager
Cristiano Macrì – Packaging Process Manager