Refrigeration for Breweries: Everything to Know

Refrigeration is one of the largest single contributors to a brewery’s operational costs, accounting for 40% of total electricity use. Whether it’s controlling fermentation temperatures or maintaining product quality in storage, refrigeration is essential across all stages of production. Yet it’s also a prime area for efficiency gains. With the right industrial refrigeration system design and regular maintenance through a preventative maintenance agreement for refrigeration systems, breweries can reduce energy consumption, improve reliability, and enhance beer consistency.

This guide covers system types, sizing considerations, energy-saving strategies, and maintenance practices. For breweries of any size, optimizing refrigeration can drive meaningful cost reductions and improve product quality.

Key takeaways

• Refrigeration accounts for roughly 40% of a brewery’s electricity use, making efficiency a top cost-saving opportunity
• System selection and sizing should align with production volume, ambient conditions, and expansion plans
• Direct ammonia systems can reduce refrigeration energy use by up to 14% in some facilities, but results vary by site and design
• Preventive maintenance and system zoning reduce downtime and extend equipment lifespan

Why refrigeration is critical in brewing

Refrigeration supports nearly every stage of the brewing process. Fermentation, in particular, relies on precise temperature control to produce desirable flavours and aromas. Ale yeasts typically operate around 18°C to 22°C, while lager yeasts require much cooler conditions, closer to 10°C. Any deviation can cause stalled fermentation, off-flavours, or microbial instability. Even small temperature swings can affect attenuation, flavour development, and fermentation timelines

After fermentation, refrigeration enables:

• Cold crashing, to clarify beer before packaging
• Conditioning, where beer matures at near-freezing temperatures
• Ingredient storage, especially for hops and yeast, which degrade rapidly when exposed to heat
• Cold storage and transport, preserving taste and preventing spoilage

Without reliable refrigeration, consistent beer quality becomes nearly impossible.

Main types of brewery refrigeration systems

Glycol chiller systems

Most craft and mid-sized breweries use glycol chillers. Glycol refrigeration systems circulate chilled propylene glycol through jacketed fermenters and brite tanks to manage temperatures precisely. Glycol chillers can handle multiple tanks with variable cooling loads. In most brewery setups, system performance depends as much on piping layout, flow control, and temperature control strategy as it does on chiller size.

Applications:

• Fermentation control
• Crash cooling
• Brite tank conditioning

Walk-in coolers

Walk-in units provide space-efficient cold storage for ingredients and finished beer. Their modular design allows for scalable installation.

Applications:

• Packaged product storage
• Yeast, hops, and keg conditioning
• Taproom cold storage

Blast chillers and flash coolers

Used primarily in larger breweries, these units rapidly cool beer post-boil or post-pasteurization. They’re effective in preserving quality, especially for beers with short shelf lives.

Ammonia vs. freon systems

Large breweries often use ammonia-based refrigeration for higher efficiency and environmental safety. Ammonia offers zero global warming potential and better thermal performance. In fact, direct ammonia cooling systems can cut refrigeration energy use by up to 14% compared to indirect glycol-based alternatives.

Smaller breweries typically rely on freon or low-charge ammonia systems, which are simpler to maintain and install but less efficient at scale. There is no universal production threshold where ammonia becomes the best option. System selection depends on brewery size, staffing, safety requirements, facility layout, and long-term growth plans.

Ammonia systems may be direct expansion or indirect (using glycol or other secondary fluids) depending on risk management and design goals.

How to size a refrigeration system for your brewery

Sizing is based on peak cooling demand. Key variables include:

• Batch volume and frequency
• Number of fermenters and brite tanks
• Desired temperature drop (e.g. crash cooling)
• Ambient heat load and insulation levels
• Fermentation heat generated by yeast activity
• Number of tanks operating simultaneously
• Seasonal temperature swings and ventilation impacts
• Planned future expansion

Simple sizing formula:

BTU/hr = Volume (gallons) × Temp change (°F) × 8.34 ÷ Cooling time (hrs)


Then convert to refrigeration tons (1 ton = 12,000 BTU/hr).

Example:
A 310-gallon batch requiring a 20°F drop over 6 hours:

310 × 20 × 8.34 ÷ 6 = ~8,628 BTU/hr ≈ 0.72 tons


Always size slightly above calculated needs to accommodate simultaneous tank cooling and future expansion. For most breweries, rule-of-thumb math is a starting point only. A professional load calculation is the best way to avoid undersizing (missed cooling targets) or oversizing (inefficient part-load cycling).

Energy efficiency strategies for brewery refrigeration systems

Because refrigeration accounts for up to 40% of a brewery’s energy use, improving efficiency offers one of the fastest paths to cost reduction. In one example, a UK brewery reduced its energy costs by 20%, saving £285,000 annually by consolidating its cooling loads onto its most efficient system.

Ways to increase brewery refrigeration efficiency:

• Use high SEER/EER-rated equipment for better energy performance
• Install variable-speed compressors that scale with cooling demand
• Choose natural refrigerants like CO₂ or ammonia with lower environmental impact
• Zone refrigeration systems to avoid cooling unused areas
• Add heat recovery systems to reuse waste heat for cleaning processes or hot water
• Optimize controls to reduce part-load losses, short cycling, and unnecessary compressor run time
• ‍‍Improve suction and head pressure control where applicable‍
• ‍Insulate tanks, glycol lines, and cold piping to reduce heat gain

Payback timelines depend on your operating hours and system condition. In many cases, control and optimization projects can deliver strong savings with modest capital investment.

Brewery refrigeration installation tips and challenges

Designing and installing refrigeration for breweries involves more than simply placing units. It requires careful planning to handle temperature zones, heat output, and building layout.

Key installation considerations for breweries:

• Zoning: Create separate cooling zones for fermentation, packaging, and cold storage
• Ventilation: Ensure compressor and condenser units have proper airflow to avoid heat buildup
• Drainage: Prevent mould and structural damage by directing condensation away from surfaces
• Ambient temperature extremes: Design systems to perform reliably in both summer and winter
• Redundancy: Add backup capacity or contingency planning for critical fermentation cooling
• ‍Future growth: Leave room in mechanical design for more tanks and expanded production

Partnering with HVAC-R professionals experienced in brewery installations helps prevent undersizing, poor airflow design, and premature equipment failure.

Learn more about food and beverage refrigeration

Brewery refrigeration maintenance and performance checks

Routine maintenance keeps refrigeration systems running efficiently and avoids costly downtime. Neglecting even minor issues can impact beer quality or disrupt production schedules.

Daily maintenance tasks:

• Monitor tank and cooler temperatures
• Check glycol fluid levels and pressure
• Watch for ice buildup or fluid leaks on lines
• Review alarm notifications and control setpoints

Weekly checks:

• Clean condenser coils and fans
• Inspect pump operation and electrical components

Monthly or quarterly tasks:

• Calibrate temperature sensors and thermostats
• Inspect insulation and glycol line integrity
• Test safety features like alarms and emergency shutoffs
• Perform refrigerant leak checks and verify proper charge levels (licensed technicians only)
• Inspect and tune control sequences for stable temperatures and efficient cycling
• For ammonia systems, complete scheduled safety system testing and documentation

Warning signs include fluctuating temperatures, compressor short cycling, and visible frost—indicating a need for professional service.

Looking for reliable brewery refrigeration contractors in Toronto and across Ontario? Contact Enns Industrial Refrigeration

Brewery refrigeration system costs (one-time installation)

Installing a refrigeration system is a significant capital expense for breweries. One-time costs include equipment, installation, and commissioning. The final amount depends on system type, brewery size, and complexity.

Estimated upfront costs for brewery refrigeration sytems (CAD):

• Small brewery (up to 10 BBL): $5,000–$15,000
  Includes compact glycol chillers and basic walk-in coolers.
• Medium brewery (10–30 BBL): $15,000–$40,000+
  Covers mid-sized glycol systems, zoned cooling, and expanded storage.
• Large brewery (30+ BBL): $40,000–$100,000+
  May involve direct ammonia systems, multi-zone temperature control, and custom integrations.

These are one-time, upfront investments. Long-term cost savings often come from choosing high-efficiency systems during the initial setup.

Ongoing brewery refrigeration operating costs

Beyond installation, refrigeration systems require regular maintenance and energy input. Operating costs vary based on system efficiency, usage patterns, and ambient temperature.

Typical ongoing expenses:

• Energy use: Refrigeration can account for 35–40% of a brewery’s electricity costs
• Maintenance and servicing: $500–$2,000 annually for inspections, cleaning, and minor repairs
• Component and refrigerant replacement: Includes pumps, fans, and refrigerant top-ups as needed

Efficient design choices, such as load consolidation and proper zoning, can significantly reduce ongoing costs.

Brewery refrigeration compliance and safety requirements

Canadian breweries must meet strict safety and environmental regulations when installing and operating refrigeration systems.

Key compliance areas:

• CFIA food safety standards for temperature control and equipment cleanliness
• Refrigerant regulations under Environment and Climate Change Canada
• OHS requirements for ammonia systems, including leak detection and emergency ventilation
• Certification: All refrigeration technicians must hold a valid Ozone Depletion Prevention (ODP) Card
• Provincial pressure equipment and mechanical safety codes that apply to refrigeration plants and pressure systems‍
• ‍Ammonia requirements may include additional safety systems, operator training, and documented emergency planning

Failure to comply can lead to fines, operational shutdowns, or product recalls—making compliance a critical part of refrigeration planning.

Frequently asked questions (FAQs) about brewery refrigeration systems

What size glycol chiller does a 10-barrel brewery need?‍

Typically between 3 to 5 tons, depending on tank count and climate conditions.

Can I use a standard commercial fridge for beer storage?‍

Yes, for small batches. For larger volumes, a walk-in cooler offers better control and capacity.

How often should I service my brewery refrigeration system?‍

Daily checks in-house, with quarterly inspections by licensed industrial refrigeration technicians.

Is it worth investing in an energy-efficient brewery refrigeration unit?‍

Yes. Efficiency upgrades often pay for themselves within 1–2 years and reduce electricity bills significantly. Actual payback depends on your production schedule, local energy rates, and the condition of your existing system.

What refrigerants are best for sustainable brewing?‍

Ammonia and CO₂ offer low or zero global warming potential. Ammonia is especially efficient but requires specialized safety protocols.