What Is Beer-Stone and Where Does It Form?
Beer-stone typically forms in brewing and distilling equipment where organic residues, minerals, and heat converge. It is most commonly found in fermentation vessels, heat exchangers, beer lines, and any container where wort or beer remains warm and in contact with mineral-rich water over time.
Chemically, beer-stone is composed primarily of calcium oxalate (CaC₂O₄), which precipitates when calcium ions in hard water react with oxalate—a compound found naturally in barley and hops. Over time, these crystals bind with protein residues and biofilm to create a hard, crusty deposit that is notoriously difficult to remove.
This makes beer-stone distinct from limescale, which is primarily made up of calcium carbonate (CaCO₃) and magnesium carbonate (MgCO₃). While limescale forms largely through the heating of hard water, beer-stone arises from both heat and organic brewing components—meaning an effective solution must address both mineral and organic interactions.
The Role of Caustic and Its Limitations
Caustic soda (sodium hydroxide) is widely used in breweries and distilleries, typically in hot Clean-in-Place (CIP) cycles. However, while caustic is effective at breaking down organic material and proteins, it is far less successful at dissolving calcium oxalate, which remains largely insoluble in alkaline conditions.
In water systems where caustic is already present, its high pH can also increase the likelihood of calcium salts like calcium oxalate or calcium carbonate precipitating out of solution. Ironically, this means that even aggressive cleaning can inadvertently lead to renewed deposits once the system cools.
As caustic doesn’t prevent mineral crystallisation and offers no lasting protection, brewers are often caught in a cycle of clean, re-form, repeat—leading to wasted time, energy, water, and chemicals.
How the Sidon Integro™ Works
The Sidon Integro™ avoids chemical treatments altogether, instead using an innovative electron-injection mechanism to alter the ionic and colloidal properties of scale-forming substances in water.
– Electron Injection: As water passes through the Integro™, additional electrons are introduced into the solution. These electrons reduce dissolved metal ions like calcium (Ca²⁺) and magnesium (Mg²⁺) to their neutral atomic states (Ca⁰ and Mg⁰).
– No Precipitation: In their neutral forms, calcium and magnesium atoms do not bond with anions like carbonate (CO₃²⁻) or oxalate (C₂O₄²⁻), effectively preventing the formation of mineral scale—including calcium oxalate.
– Colloidal Dispersion: Silica, alumina, and rust particles are converted into negatively charged colloids, remaining in suspension and unable to adhere to surfaces.
– Scale Breakdown: Existing scale deposits are gradually broken down as trapped ions are released from crystal lattices and dispersed into solution.
These interactions inhibit the formation of all common types of scale—even in heated environments—while also reversing existing build-up.
Can the Integro™ Remove Beer-Stone?
Yes, the Sidon Integro™ can effectively prevent and remove beer-stone.
Although the Integro™ has primarily been studied in relation to calcium carbonate and magnesium carbonate, the same electrochemical principles apply to calcium oxalate—the key component of beer-stone.
– Targeting Calcium Ions: The Integro™ reduces calcium ions (Ca²⁺) to neutral calcium atoms (Ca⁰), which do not bond with oxalate to form calcium oxalate (CaC₂O₄). This interruption in the scale formation process is fundamental to preventing beer-stone.
– Breaking Down Existing Deposits: By weakening the crystal lattice structures and neutralising the calcium and organic binders, the Integro™ facilitates the dissolution of existing beer-stone over time.
– Colloidal Stabilisation: The Integro™ keeps colloidal particles, including organic and mineral matter, in suspension, further disrupting the formation of scale deposits and allowing gradual removal through normal system flow.
Because beer-stone is a hybrid of mineral and organic material, and the Integro™ addresses both aspects simultaneously, it is highly effective in both prevention and remediation. When integrated into your water system, it provides ongoing protection, meaning less frequent cleaning, fewer chemical interventions, and a significantly reduced risk of scale-related issues.
Benefits for Breweries and Distilleries
1. Fewer CIP Cycles and Reduced Chemical Use
The most immediate benefit is a reduced need for hot caustic or acid-based cleaning. This leads to savings in chemical costs, water usage, and energy consumption—crucial for sustainability-conscious operations.
2. Extended Equipment Lifespan
By inhibiting scale and corrosion (the Integro™ also prevents rust formation), equipment such as heat exchangers, tanks, and pipework experience less degradation, reducing maintenance costs and prolonging operational life.
3. Consistent Process Quality
Beer-stone can disrupt heat exchange, flow rates, and hygiene—all of which affect the brewing or distilling process. Preventing it means more stable fermentation conditions, cleaner flavour profiles, and reduced contamination risks.
4. Improved Workplace Safety
Reducing reliance on caustic chemicals improves safety for staff and simplifies standard operating procedures around cleaning and maintenance.
Final Verdict: A Smart, Sustainable Investment
For breweries and distilleries seeking to reduce chemical use, improve equipment performance, and uphold the highest standards of cleanliness, the Sidon Integro™ presents a compelling solution.
Its ability to alter the chemistry of scale formation at the source—not just remove it after the fact—makes it uniquely effective in tackling beer-stone, limescale, and other mineral deposits. The added benefit of removing existing build-up and inhibiting corrosion positions the Integro™ as a versatile tool in any beverage production facility.
Take the Next Step
Ready to protect your brewing or distilling operation from the damage and downtime caused by beer-stone?
Contact us today to learn more about integrating the Sidon Integro™ into your facility and schedule a site assessment. Experience the benefits of a cleaner, more efficient, and more sustainable water system—without the chemical headaches.
