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Process technology


the banke internal calandria

The banke Wortifier internal calandria guarantees the best quality wort with reduced energy usage.

TheWortifierdesign allows for the flow to be carefully maintained at any stage of the process and at any fill level in the wort kettle. This prevents scorching of the wort and fouling, which can negatively impact quality, particularly while the wort is heating up to boiling. Gently heating the wort produces better quality beer while also saving time, energy and cleaning costs.

The Wortifier system provides a consistent level of flexibility for any batch size from 40 – 110 % of the nominal output of the brewhouse.

The low level of thermal stress over the entire boiling process is accompanied by technical benefits for the finished beer with regard to shelf life and foam stability.


Key facts

  • energy efficient elimination of DMS
  • improved foam formation and head retention as well as flavor stability
  • a low thiobarbituric acid index (TBI)
  • low energy requirements – both thermal and electrical
  • specific wort evaporation rates < 4%
  • no pulsing while the wort is heating to boiling
  • 30 batches between CIP intervals
  • retrofitting and upgrading is simple
  • flexible batch sizes

Phase optimized heating and boiling

A number of factors with the Wortifier system allow production of wort of the highest quality with very low energy consumption:

The wort boiling process is optimized by dividing it into discrete stages: the wort can be held at a constant temperature near boiling but can also be vigorously boiled. A combination of this kind of heating efficiently removes unwanted aroma compounds, such as DMS, while saving significant amounts of energy.

Whether the wort can flow at the highest possible rate through a calandria with the heat transfer medium set at a low temperature is entirely a question of the tube bundle design. The tube geometry in the banke internal calandria is perfectly matched for any size brewhouse. An hourly circulation rate of 30 to 50 times per hour ensures maximum homogeneity of the wort.

Cleaning in place only after the production of 30 batches of wort? This is not a problem because fouling of the heat transfer surfaces is greatly reduced with the Wortifier compared to conventional boiling systems.

Brewhouse brewing technology wort boiling

Boiling small batches

At lower fill levels, the wort is pumped through the central pipe of the Wortifier internal calandria. The system feeding the calandria distributes the wort evenly as a thin film over the tubes, creating a falling film which covers the entire heat transfer surface enclosed in the calandria. This gradually heats the wort and produces a gentle boil. The Wortifier design allows heating to commence while the wort is entering the kettle, even before the entire heat transfer surface is covered. Peaks in steam usage can thus be reduced.

Wortifier in operation:

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1. Heating the wort

Heated wort is pumped into the tube bundle through the central pipe. The cooler wort is carefully metered into the calandria by the pump and heated without producing a pulsing motion.

2. Boiling

  • When boiling commences, the wort circulates through the Wortifier system purely through natural convection. The recirculation pump can be turned on to enhance the DMS vaporization and elimination.
  • The stages of the boil are optimized for maximum evaporative efficiency and energy savings.

Boiling small batches

  • The wort is pumped into the Wortifier through well designed piping. The wort flows uniformly down as a thin film into the heating tubes, even at low fill levels.
  • In this way, the smallest volumes can be boiled, and heating is feasible even with a minimal volume of wort.