Monday, 21 September 2026
HSF System is constructing a new malt-processing facility within Plzeňský Prazdroj’s brewery complex in Plzeň, expanding production capacity while introducing technology designed to reduce water consumption. The contractor is delivering the building together with connections to the brewery’s existing infrastructure and production systems.
The partly basement-level building will have five floors and rise to almost 30 metres. It will provide approximately 1,895 sqm of floor space on a footprint of around 588 sqm, with an enclosed volume of approximately 11,750 cubic metres. The project also includes two connecting bridges, utility relocations, water and electrical systems, drainage infrastructure and links between the new installation and the existing malt house.
Construction inside an operational brewery requires building works to be coordinated with continuing production and the installation of specialist equipment. The structure is being founded on piles measuring 800 and 1,000 mm in diameter and extending as deep as 12 metres, supporting a 500 mm reinforced-concrete foundation slab. The steel structure will be assembled in stages so that large pieces of production technology can be installed before the building is fully enclosed, while BIM modelling using Autodesk Revit is being used for the project documentation and digital building model.
At the centre of the new operation will be eight conical stainless-steel vessels, each measuring 5.7 metres in diameter and designed to accommodate approximately 62.5 tonnes of barley. The equipment will handle the initial steeping stage of malt production, including washing, aeration and the removal of carbon dioxide generated during the process.
Once operational, the facility is expected to increase the malt house’s steeping capacity by approximately 15%. The new installation will also introduce enclosed vessels with automated cleaning, while changes to the grain-washing process are intended to reduce water consumption and improve working conditions within the production operation.
Plzeňský Prazdroj expects the new technology to save approximately 500 litres of water for every tonne of barley processed. Based on annual production of around 87,000 tonnes of malt at the Plzeň facility, the projected reduction amounts to approximately 43,500 cubic metres of water per year. The brewery separately reported that its Plzeň malt house produced 87,000 tonnes of malt in 2025, providing the production baseline for the calculation.
The development represents a further modernisation of Plzeňský Prazdroj’s established industrial complex, where new production infrastructure is being incorporated into an operating manufacturing site rather than developed on a greenfield location. Alongside the planned increase in capacity, the investment demonstrates how upgrades to existing industrial properties can combine additional production capability with lower resource consumption.
