Know-how for the world's largest malting plant built in one piece

Maltaria Campos Gerais: Zeppelin Systems built a malting plant of superlatives in Brazil

The go-ahead for the super project was given in October 2021: Zeppelin Systems was commissioned with the planning, construction and commissioning of the world's largest malting plant (built in one piece) in Ponta Grossa, Brazil. On June 6, 2024, the “Maltaria Campos Gerais (MCG)” plant was officially handed over to the operators. MCG can produce up to 240,000 tons of malt per year - this corresponds to around 14.5 million hectolitres of beer and therefore around 15 percent of Brazilian demand. The customers for the malt are international breweries.

Exceptional solutions - impressive dimensions

In Ponta Grossa, Zeppelin Systems engineers have realized a plant that exceeds all dimensions of previous malting projects. Around 550 million euros were invested here. The entire site extends over 800,000 m2 and the malt production facility covers an area of 21,000 m2.

Um optimale und reproduzierbare Backergebnisse zu erzielen, ist es entscheidend, die Rahmenbedingungen konstant zu halten. Die Teigtemperatur, maßgeblich von den Rohstoffen wie Mehl und Wasser beeinflusst, spielt dabei eine wesentliche Rolle. Das Pneumotherm-Batch-Verfahren zur Mehlkühlung bietet eine wirtschaftliche Lösung für diese Herausforderung. In Großbäckereien, die eine breite Palette von Backwaren herstellen, ist es wichtig, dass die Teige nach dem Kneten eine bestimmte Zieltemperatur erreichen, um eine konsistente Qualität zu gewährleisten. Eine effektive Methode dafür ist das gleichmäßige Temperieren der Mehle und Flüssigkeiten vor der Verarbeitung, insbesondere wenn Mehle in Außensilos gelagert werden.

SITE AREA 800.000 SQM

240.000 T MALT PRODUCTION PER YEAR

BATCH SIZE 400 T BARLEY

UP TO 800 T MALT PRODUCTION PER DAY

MALTARIA CAMPOS GERAIS I Oct 2022

MALTARIA CAMPOS GERAIS I Dec 2023

Up to 800 tons of malt per day

At full capacity, the plant produces between 700 and 800 tons of malt per day. For the three areas of malt production - steeping, germinating and kilning - a steeping building with a total of 24 steeping tanks was built on two levels. In addition, there are two germination towers, each with five germination units and a diameter of 30.5 m, as well as two single deck kilns - each with a diameter of 40 m - with a central middle section for energy recovery.

The mechanical conveyor systems for transporting barley and malt are around 750 m long - approx. 510 m horizontally and 240 m vertically. The finished products are stored in two dry malt silos, each with a capacity of 900 m3

Regional production

Large parts of the system were manufactured at the Zeppelin site in São Bernardo do Campo. From there, the components were transported overland to Ponta Grossa and precisely installed on site. Up to 1,700 people from 50 different companies were working on the construction site at times, including around 180 employees from Zeppelin Systems.

Trust in competence

The fact that Zeppelin Systems was entrusted with the complete realization package is certainly also due to the satisfaction of the clients with the performance and competence of Zeppelin Systems. This is because the clients - a consortium of various agricultural cooperatives under the leadership of Cooperativa Agrária Agroindustrial - already operate a malting plant in the region using Zeppelin Systems technology. This is where brewing know-how meets development expertise. The malting plant project in Ponta Grossa once again confirms the wide-ranging expertise of our planners and engineers. And it proves that nothing is impossible. We Create Solutions!

Think big – The key data of the malthouse at a glance

Total investment:	3 Bln R$ ≈ EUR 550 Million
Site area:	800.000 m²
Area of malt production:	21.000 m²
Construction time:	approx. 2 years
Time period:	10/2021 - 11/2023
Nominal capacity malt production:	240,000 t/a, equivalent to approx. 14.5 million hectoliters of beer production
Barley silo capacity:	90,000 t (5 x 6 = 30 silos)
Malt silo capacity:	75,000 t (5 x 6 = 30 silos)
Malting plant construction:	Tower malthouse
Soaking tank system:	24 steep tanks on 2 levels 2 x 5 germination units ø30.5 m, 727 m² Two kilns (side-by-side) ø 40.0 m, 1,256 m²
Batch size	400 tonns barley

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GREAT OPENING IN PONTA GROSSA