Small-Batch Brewing Kettle Recirculation for Even Mash Extraction

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Solution Overview

Problem

Existing small batch beer brewing systems face challenges in achieving efficient extraction of carbohydrates and flavor from malt due to uneven heating and clogging issues, leading to 'dead zones' in the mash and reduced yield, as well as difficulties in maintaining a homogeneous distribution of wort during the mashing process.

Innovation Solution

A brewing kettle system with multiple filters and a recirculation system that includes a pump arrangement, distribution unit, and adjustable nozzles to ensure even distribution and penetration of wort throughout the mash, minimizing clogging and enhancing extraction efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single filter is used to separate wort from mash, then the device complexity is reduced, but clogging occurs and creates dead zones reducing extraction efficiency

Engineering Contradiction:

Improvefilter arrangementVSAvoidextraction efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The single filter is segmented into multiple filters arranged at different heights in the kettle. The first filter is positioned at a first height and the second filter at a second height, creating multiple separation zones. This segmentation prevents clogging by distributing the filtration load and eliminates dead zones by ensuring continuous wort flow through multiple filtration stages, thereby maintaining high extraction efficiency without excessive complexity.

Inventive Principle:

Principle #1Segmentation

2Productivity

If wort circulation is increased to improve extraction, then productivity increases, but clogging of the pump and tubes occurs

Engineering Contradiction:

Improveextraction rateVSAvoidpump operation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary filtration by passing wort through the first filter before it reaches the pump, and through the second filter before recirculation. This preliminary action removes particulate matter that would otherwise cause clogging in the pump and tubes, allowing increased wort circulation rates to improve extraction without compromising pump reliability.

Inventive Principle:

Principle #10Preliminary action

3Use of energy by moving object

If heating is concentrated at the bottom of the kettle, then energy efficiency improves, but uneven heating creates dead zones reducing mash efficiency

Engineering Contradiction:

Improveheating efficiencyVSAvoidmash efficiency

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

The system uses hydraulic circulation to pump wort from the bottom heating zone through filters and back into the mash. This creates continuous fluid motion that distributes heat evenly throughout the mash, eliminating dead zones while maintaining bottom heating efficiency. The circulating wort acts as a heat transfer medium, ensuring uniform temperature distribution without sacrificing energy efficiency.

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Reliability

If multiple filters are added to prevent clogging, then reliability improves, but device complexity increases

Engineering Contradiction:

Improveflow continuityVSAvoidfilter system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The multiple filters serve multiple functions: the first filter provides primary filtration before pumping, the second filter provides secondary filtration before recirculation, and together they prevent clogging while maintaining flow continuity. This multi-functionality justifies the increased complexity by delivering reliable operation and high extraction efficiency simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system ensures homogeneous distribution and extraction of carbohydrates and flavor from the mash, reducing clogging and maintaining consistent brewing results, thereby improving mash efficiency and quality.

Implementation Method 1

a pump arrangement arranged with the kettle for pumping the wort, the pump arrangement having an inlet arranged between the first filter and the fixed bottom of the kettle and an outlet arranged in position between the first filter and the second filter

Methodology Applied

Scientific EffectPumping: Pump

Implementation Method 2

a heater arranged with the kettle in such a way that it can supply the kettle with heat

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

a first filter arranged inserted in a first height above the fixed bottom for separating the mash and the wort and a second filter and/or a third filter arranged inserted in a second height above the fixed bottom for separating the mash and the wort

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentEP4685220A1An enhanced system for small batch beer brewing

Publication Date: 2026.01.28 MORT HLDG APS

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AI summary

A kettle for small batch brewing of beer with an enhanced efficiency of preparing the wort and avoiding clogging of filters, tubing and pumping arrangement. The kettle features a sprinkler arranged between a bottom filter and a top filter that facilitates the extracted wort to flow in both a downward and/or upward direction in the kettle for a more efficient recirculation in the mash which ensures a better exploitation of the malt.