Where a brewery loses heat — and what it costs

A small-to-mid brewery loses tens of kilowatts continuously from bare kettles and tuns, the boiler door and valves, pasteuriser roofs and feed-water lines. On the canonical model used here (ISO 12241, convection + radiation, lightly-ventilated hall at 25 °C with 0.5 m/s air) a bare wort-kettle face loses ≈1,100 W/m² at 99 °C, and a Bosch steam boiler's bare fittings alone ≈25 kW. Removable insulation cuts each by ~90–95%.

Wort (brew) kettle ≈99 °C at the boil, mash tun ≈68 °C, lauter tun ≈77 °C at mash-out, whirlpool ≈92 °C, cereal/adjunct cooker ≈95 °C; steam and condensate lines and boiler fittings run 120–300 °C. The surface temperature drives the loss — each is modelled at its real operating temperature.

The hottest, longest-running surfaces: the boiler door and steam-side fittings (≈180–300 °C), then the wort kettle and whirlpool, then the pasteuriser roof and feed-water pumps. The boiler house usually shows the fastest payback.

Up to 96% heat-loss reduction, with the cover surface dropping to a touch-safe ≤45 °C. For a full brewery (brewhouse + packaging + boiler house) payback is typically around 13 months on the figures in this tool, and well under 2 years for most single items.

Inzonex is an engineered modular system — not a loose jacket. Each cover is templated to the exact geometry (valves, PRVs, heat exchangers, boiler doors, irregular shapes) — the complex spots where flat blanket suppliers stop. Stainless snap-button fasteners close it by hand: no tools, no fixings drilled into the equipment, and access in seconds. The form-fitting build follows the surface, so there are minimal folds or creases where water, dust or CIP chemicals could collect. The insulating core (PAROC stone wool, fully certified) is independently replaceable; the outer shell is silicone (standard) or PTFE (chemical / caustic-resistant) in a range of colours. The result looks tailored and professional — not a sack, which matters for visitors, auditors and stakeholders — with high day-to-day usability: unclip, clean, refit every cycle.

No. We do not rip out or replace rigid sheet-metal cladding or hard lagging. Inzonex sits alongside it and covers what cladding can't — the valves, doors, flanges, manholes and irregular fittings that are usually left bare. The first step on most sites is an audit of those bare spots, not a rip-and-replace.

Yes. Less radiant and convective heat enters the hall, so the ambient temperature falls. That improves working conditions and helps avoid overheating nearby electronics, sensors and control panels — on top of the touch-safe ≤45 °C cover surface.

Yes. Inzonex modular covers unclip in minutes for CIP, inspection or valve access and refit exactly — no hard lagging to cut off and rebuild. Snap buttons give routine access; the core unzips for replacement and washing.

End-to-end — production + delivery + installation — about 4–6 weeks in Europe and 8–12 weeks worldwide (sea freight). As a breakdown: production 2–6 weeks, EU delivery under a week, sea delivery roughly 4–6 weeks. Minimum order 100 pieces.

The outer shell lasts on the order of 15 years; the PAROC stone-wool core is independently replaceable, so a cover is renewed rather than scrapped. In harsh climates covered hardware has been documented lasting 15–25 years. Rated for service up to +600 °C. Covers carry a 3-year warranty (excluding leaks and similar process faults), and an optional annual paid service keeps them performing year after year.