For more than 200 years, Brauerei C. & A. Veltins has combined brewing tradition with a continuous commitment to innovation. To further improve efficiency and secure long-term production reliability, the German premium brewer partnered with GEA to modernize a critical process step in its brewery: beer clarification.
By replacing two existing separators with new GEA Westfalia Separator GSE 400 units, Veltins achieved measurable energy savings, improved process performance and created additional capacity for future growth – all while maintaining ongoing production.
A modernization project without production interruptions
Beer clarification plays a key role in ensuring consistent product quality and efficient downstream filtration. When the existing separator technology approached the limits of its lifecycle, Veltins evaluated different modernization options.
Rather than investing in extensive refurbishment work, the brewery chose a future-oriented solution with new separator technology. Together, GEA and Veltins developed an implementation strategy that allowed the replacement to be completed efficiently and with minimal disruption to operations.
"The collaboration with GEA was cooperative and solution-oriented from the very beginning. From planning and implementation through to commissioning, both teams worked closely together. The result is a modernization project that delivers clear benefits for us, both technically and economically."
Moritz Zipro
Head of Brewing Technology, C. & A. VELTINS Brewery
Improving efficiency across the process
At the heart of the project was the replacement of two existing HSA 200 separators with two new GSE 400 units.
The new separators operate at reduced rotational speed while maintaining the required separation performance. This enables energy savings and contributes directly to the brewery's sustainability objectives.
In addition, the cooling water used by the system is fully recovered and reused, further improving resource efficiency.
The separators are fully integrated into the brewery's automation environment and can be monitored and controlled centrally from the control room, providing operators with complete process transparency.
Better clarification, stronger filtration performance
The benefits extend beyond the separator room.
Improved pre-clarification has a positive impact on downstream filtration, resulting in longer filter runtimes, lower kieselguhr consumption and highly reproducible process results. This helps Veltins maintain consistent beer quality while reducing operating costs and process variability.
The combination of stable clarification and optimized filtration contributes to a robust and reliable brewing process, even during seasonal production fluctuations.
"We see the advantages extending far beyond the separator room. The improved pre-separation performance leads to longer filter runtimes, reduced diatomaceous earth consumption, and highly reproducible results. This creates greater stability throughout the entire brewing process."
Moritz Zipro
Head of Brewing Technology, C. & A. VELTINS Brewery
Designed for long-term reliability
When making investment decisions, Veltins takes a long-term perspective.
The new GSE 400 separators were selected not only for their current performance but also for the operational security they provide over decades of use. Spare parts availability for the next 25 years gives the brewery confidence that the investment will continue delivering value well into the future.
Additional reserve capacity was incorporated into the system design, ensuring flexibility for changing production requirements and future growth.
Partnership beyond technology
For both companies, the project demonstrates the value of close collaboration.
From engineering and service to automation specialists, maintenance teams, brewers and project managers, experts from Veltins and GEA worked together throughout the project. The result was not only a successful installation but also a solution tailored to the brewery's operational needs.
The modernization highlights how technology, expertise and partnership can come together to create measurable business value.
"This project demonstrates what can be achieved when a customer and a technology partner work together toward a common goal. Through the close collaboration of both teams, we were able to integrate the new separators seamlessly and rapidly into the existing production environment while laying the foundation for long-term efficiency gains."
Ingo Schmitt
Senior Sales Manager, GEA
Kevin Bauer Senior Technical Trainer, GEA | Ingo Schmitt, Senior Sales Manager, GEA | Moritz Zipro, Head of Brewing Technology, C. & A. VELTINS Brewery
Customer benefits at a glance
Full cooling water recovery and reuse
Improved process stability
Longer filter runtimes
Reduced kieselguhr consumption
Highly reproducible product quality
Additional capacity reserves for future growth
Full integration into the brewery automation system
Spare parts availability for the next 25 years
Implementation without interrupting ongoing production
"For us, the key was to find a solution that not only delivers outstanding performance today but also provides long-term security and reliability. With the new GSE 400 separators, we benefit from improved energy efficiency, stable processes, and the confidence that we are well prepared to meet future requirements. "
Moritz Zipro
Head of Brewing Technology, C. & A. VELTINS Brewery
