How to Brew Efficiently and Sustainably in 2025

This article is written in collaboration with Ashley Zerick and Kim Dalum. Ashley is a former craft brewer and raw material manager, now turned sales representative for DALUM Beverage Equipment. Kim Dalum, CEO of DALUM Beverage Equipment has more than 25 years of experience of executive positions at distinct global engineering firms and 10+ years of experience in CO₂ recovery.

Introduction

In Todays brewing industry efficiency and sustainability go hand in hand. Factors such as rising energy prices, tighter environmental regulations, and changing consumer expectations are pushing breweries to rethink how they operate.

At DALUM Beverage Equipment, we work with breweries worldwide to make production smarter, cleaner, and more profitable. From optimizing brewhouse processes and reusing water to integrating innovative technologies like CO₂ recovery, there are more ways than ever to improve both environmental impact and bottom-line results.

Here’s how breweries can brew efficiently and sustainably in 2025.

Read the article: What is a CO2 Recovery Plant?

1. Cut CO₂ Costs and Waste

CO₂ plays a significant role in brewing, from carbonation to purging, but it’s also an area where breweries lose efficiency and money.

Reduce Unnecessary CO₂ Losses

• Check for leaks: Inspect compressed air and CO₂ systems regularly.
• Install recondensing chillers: Capture CO₂ that would otherwise be vented from bulk storage.
• Use DO or O₂ meters: Prevent over-purging by measuring dissolved oxygen levels precisely.
• CIP under pressure: Clean tanks without venting excess CO₂.

Embrace CO₂ Recovery Solutions

CO₂ recovery systems offers many benefits for breweries, both to enhance sustainability, efficiency and reduce reliance on external suppliers. Capturing and reusing CO₂ produced during fermentation reduces reliance on purchased gas, avoids supply disruptions, and significantly lowers emissions. With DALUM’s Micro, Craft, Senior, and Hercules systems, recovery solutions are scalable and suitable for craft scale breweries.

2. Maximize Brewhouse Efficiencies

Brewhouse efficiency is the backbone of both cost control and sustainability. Small adjustments can have a big impact on resource use and overall yield.

Key Areas to Focus On

• Milling process: Keep your grain crush consistent and maintain mills regularly to improve extraction rates.
• Mash consistency and pH: Ensure the water-to-grain ratio and pH stay within spec for optimal enzymatic activity.
• Thorough vorlaufing: Proper wort recirculation ensures every grain is steeped and converted efficiently.
• Temperature control: Consistent mash and lautering temperatures improve yield and reduce waste.
• Hop extract usage: Reduce vegetal waste and improve consistency by supplementing or replacing raw hops with hop extracts.

Dialing in these processes ensures you get more from every batch while using fewer raw materials, less energy, and less water.

3. Reuse Water and Recover Heat

Water and energy costs are climbing, making reuse and recovery strategies essential:

Reclaim Heat Exchange Water

Redirect hot water from the heat exchanger into your Hot Liquor Tank. This not only saves water but also reduces energy costs when reheating.

Repurpose Process Water

Water used for cooling or cleaning can be reused elsewhere in the facility, from CIP cycles to washdowns, reducing overall consumption.

On-Site Wastewater Treatment

Breweries with higher output can invest in wastewater treatment systems to meet environmental standards while unlocking opportunities to reuse treated water safely.

4. Use Resources Smarter Across the Facility

Beyond brewing itself, sustainability comes from smart resource management:

• Spent grain reuse: Partner with local farmers to repurpose grain as livestock feed or compost.
• Chemical reuse in CIP cycles: Extend cleaning agents’ lifespan with closed-loop systems.
• Nitrogen integration: Replace CO₂ for purging where possible to cut costs and improve air quality.
• High-concentration brewing: Produce stronger wort and “water down” later to save energy and tank capacity.
• In-line carbonation: Streamlines operations and reduces CO₂ usage during packaging.

5. Leverage Renewable Energy and Efficient Equipment

Energy efficiency drives both environmental and financial gains:

• Solar or renewable energy: Offset electricity costs and reduce your carbon footprint.
• Ambient vaporizers: Replace energy-intensive electric vaporizers to handle CO₂ more sustainably.
• Steam heating: A highly efficient and widely adopted heating method for breweries.
• Energy-smart equipment: Choosing modern, efficient brewhouse systems ensures lower operating costs over time.

6. Source Ingredients Locally and Strategically

Sustainability also extends to sourcing and supply chains:

• Buy local ingredients: Reduce emissions from transportation and strengthen community ties.
• Grow your own adjuncts: Herbs, spices, and fruit can be cultivated on-site or nearby to ensure freshness and reduce imports.
• Optimize storage capacity: Fewer deliveries mean fewer emissions and better logistics.

Conclusion: Efficiency and Sustainability Go Hand in Hand

Brewing sustainably in 2025 is about more than reducing environmental impact – it’s about running a smarter, leaner, and more resilient brewery.

From optimizing brewhouse efficiencies and reusing water to reducing CO₂ waste and leveraging renewable energy, breweries now have countless opportunities to save resources and secure long-term growth.

At DALUM Beverage Equipment, we help breweries adopt innovative technologies like CO₂ recovery and CO₂ liquefaction while supporting a broader shift toward sustainability.

Ready to improve efficiency and sustainability in your brewery?

Contact DALUM today and explore how we can help future-proof your production with CO₂ recovery.

Contact Chris Lewington, founder of Brew Resourceful to learn how to optimize your brewery efficiency. You can start of using their free benchmarking reports or their free tools.