Forged Stout Production - Here To Take Over

Now challenging the biggest names in the brewing ring with Forged Irish Stout – big on flavour and bold as brass. They may be the new kid on the block, but they have got their eyes on the prize and won’t settle for second best. “They are not here to take part, they are here to take over”.
The Forged brewery is based in Glasnevin, Dublin, Ireland and here they brew the ‘Forged Irish Stout’ and then package on their new Enterprise Tondelli canning line.

Enterprise Tondelli are very proud to be associated with this exciting project and provided a complete packaging line that met all the challenges of packaging a world class nitrogenated stout. The most significant is the filling process and the special requirements for the widget can. To meet the challenge Enterprise Tondelli supplied a ‘state of the art’ rotary Matrix volumetric can filler.

Infeed wormscrew feeds cans into the filling machine

The Challenge of Nitrogenated Stout

For widget cans the cans must first be purged by high pressure nitrogen supplied from a separately controlled manifold to reduce dissolved oxygen and aid in the widget preparation. Secondly a different pressure Nitrogen is then used to counter pressure the cans before filling. Cans are filled using individual flow meters mounted on the rotary carousel without the vent tube touching the product giving a very calm fill with no drips. This also ensures the fill level in the can as too much beer will mean the widget is flooded with beer and not nitrogen when inverted. All functions of the filling valve are controlled by electro pneumatically actuated valves so any regulation can be done from the panel during running, this includes de-pressurisation so that the correct amount of small bubble head is left on the can by controlling bowl pressures. Cans are immediately inverted on the seamer discharge to ensure that the widget is charged with nitrogen to give that lovely creamy cascade affect.

High level view of a tunnel pasteuriser for beer

The Canning Gear

The total line supplied by Enterprise Tondelli consists of a very compact automatic bulk can de-palletiser manufactured in stainless steel from EuroSistemi Srl. High level conveyors feed to a gravity ionised air can blower. This multichannel blower means that change over from one can size to another is by means of a pneumatically actuated gate. Ionised air also means no water consumption thus reducing the environmental footprint of the line whilst maintaining product integrity.Located after the filler Enterprise supplied a fill level and pressure check inspection system to ensure that nitrogen has been dosed.A six zone all stainless steel tunnel pasteuriser with very low water consumption was installed by Enterprise. The low water consumption is achieved by all water from all zones and conveyors being collected and used in a ring main to recharge the pasteuriser with cooling water via a tower as required. Energy is also saved by the use of plate type heat exchangers which are more reactive and used in a closed loop around each zone only. The small reservoirs in each tank also ensure reduced water consumption along with low energy use as the water volume heated is comparatively small. An easy to use touch screen allows the customer to easily add new recipes.

Stainless steel high level depalletiser for cans with a low level control panel.

Iain Wood, Operations Director at Forged Stout Production Ltd, said: “ Before going with Enterprise we checked around, made reference visits and heard good things. We have not been disappointed in our decision as they have followed the project with great diligence, both in planning, commissioning and ongoing support. We would certainly use them again”

Enterprise Tondelli were established in 1977 and supplying equipment in over 40 countries. The Forged Irish Stout project is just one of the latest projects by Enterprise who supply canning lines 1,500 to 72,000 cans per hour and bottling from 600 to 60,000 bph.

Forged Stout Production – Here To Take Over

The Challenge of Nitrogenated Stout

The Canning Gear

More Case Studies

Talk to our experts today.