BACKGROUND
Flexigen has worked with 4 Pines for approximately a decade, delivering energy and process efficiency projects that have improved energy productivity and brewing capabilities. In 2024, cracks in the existing brewhouse’s steam jackets prompted an assessment of replacement options. Alternatives, including an external wort heater, were investigated, but full replacement offered better long-term value.
DESCRIPTION
Flexigen worked with 4 Pines to define and deliver a new brewhouse at its Brookvale brewery, combining brewing flexibility, automation and energy efficiency with compatibility for future electrification of the brewing process.
The selected BrauKon system replaced the existing 65 hL brewhouse with a faster, more automated 50 hL system, designed to accommodate current production and future growth. It incorporates vapour heat recovery, thermal storage and wort preheating, with the recovery system designed to reduce brewhouse heating energy consumption by up to 20%. Wort precooling provides additional control over the brewing process and product quality.
A pressurised high-temperature hot-water network supplies the new brewhouse’s heating duties. Initially heated through a heat exchanger connected to the existing steam system, this network enables future integration of electric heat pumps.
Flexigen supported equipment selection, site layout, utility integration and installation coordination, working with 4 Pines, BrauKon and local contractors. Existing vessels and infrastructure were retained where practical. Installation took place during the summer production peak, with the first brew completed in January 2026.
