Beer production has been long associated with clouds of steam and long hours of energy consumption. Could we ever imagine brewing beer without the need for boiling at 100 degrees for hours? A new Italian technology made that possible by offering breweries a way to cut their energy costs, reduce emissions and create a greener future by making the entire process more sustainable.
The new method has been developed by Cavitek SRL, an Italian company that acquired the patent from Italy’s National Research Council (CNR) in 2021. The innovation, known as Cavibeer, is not about brewing beer itself but about changing the way it is made. It aims to support the whole industry by making production processes more efficient and environmentally friendly. The idea is as simple as it is revolutionary: using the power of microscopic bubbles to replace the traditional boiling, which represents one of the most energy-intensive stages of beer production.
The magic of tiny bubbles
Instead of heating the wort – the sweet liquid extracted from malted grains – to a roaring 100 degrees for 90 minutes, breweries using Cavibeer can gently heat it to around 94 degrees, enough to ensure product safety and 100 per cent compliance with standard specifications, without the need for a full boil. Specially controlled bubbles do the rest, breaking down unwanted compounds and preparing the beer wort for fermentation. This innovative process allows producers to save up to 80 per cent of the energy which would be normally required using conventional methods.
Boiling the wort has always been seen as an essential part of brewing, mainly to remove dimethyl sulphide – a chemical that can cause unpleasant flavours. But by using a method known as hydrodynamic cavitation, where tiny bubbles form and collapse inside a liquid, this unwanted compound can be eliminated without traditional boiling.
The research behind Cavibeer was led by Francesco Meneguzzo, a senior scientist at CNR’s Institute for Bioeconomy. “We succeeded in producing wort ready for fermentation without boiling, preserving its chemical and sensory qualities,” he explained. The findings were recently published in Beverages, a leading scientific journal.
While the concept of hydrodynamic cavitation may sound a little technical, the principle is extremely simple: when a liquid passes through a narrow channel and then widens again, it creates areas of low pressure where tiny vapour bubbles form. When these bubbles collapse, they release bursts of energy strong enough to break down molecules like the precursor to dimethyl sulphide.
Sustainable innovation and fresher flavour
Although these technical details are fascinating, what matters most to brewers and beer lovers is the impact. Cavibeer drastically cuts down energy consumption and improves stability as well as the aroma of the final product. Early tests showed beers made with this new technology had fresher flavours and longer shelf life compared to those made with traditional methods.
The environmental benefits are enormous too. Traditional brewing usually relies on gas to power large boiling tanks. Cavibeer runs entirely on electricity, meaning breweries can potentially operate using renewable energy sources like solar or wind. That could make a real difference in reducing the carbon footprint of the beer industry, which is under increasing pressure to become more sustainable.
Maria Carmela Basile, who heads the CNR’s research valorisation unit, points out that switching from gas to electricity for brewing is a tangible step towards decarbonisation. “Hydrodynamic cavitation marks a real shift for one of the food sector’s most energy-intensive processes,” she says.
Ready to scale for industrial production
Is this technology ready for the big stage? According to Meneguzzo, yes. Trials carried out using a 230-litre pilot plant – roughly the size used by craft brewers – showed that Cavibeer can be easily expanded for industrial production. Essentially, breweries would need a steel tank, pumps and the cavitation reactor to get started.
Should one of the world’s top five multinational beer companies – which together account for more than 50 per cent of global production – decide to adopt this new technology, hydrodynamic cavitation could have a revolutionary impact on the global brewing industry.
Although the initial focus has been on beer, hydrodynamic cavitation could possibly find wider applications across the food and beverage industry, wherever heating and energy usage are priorities.
With the industry currently facing inflation, rising costs and soaring bills, Cavibeer can offer a much-needed solution which combines both quality and sustainability, making production greener and more affordable for brewers.
Beer has been brewed for thousands of years with the ancient Egyptians seen as the pioneers of brewing, and its basic steps of fermentation largely remained unchanged over the centuries. This innovative technology reminds us that while old traditions can be preserved, they can also evolve, allowing us to look at the future while honouring the past and ultimately transform one of the world’s oldest drinks into a more sustainable industry leader. Sometimes, all it takes is just a tiny bubble.
