To make a good quality beer “we always require Pure water”. So, Brewers give focus to the main source i.e. water and its purification of the main content for their brewing process. Pure and quality water sets the standards of the brewing process and taste of beer. If it doesn’t have the proper calcium or acidic content for maximum activity of the enzymes in the mash, we must bring it up to that standard. So, quality water plays the main role in the brewery process.
The Malted barley, renowned for Malt World, is used to create malt for brewers. The grain is first permitted to germinate to produce malt. Whole malted grain (portioned and cracked) is milled to allow it to absorb water, which helps to extract sugar from the malt. The malt will darken in color, depending upon how long the roasting method takes. This affects the beer’s color and flavor.
Malt is now added to heated, purified water, and malt enzymes break down the starch into sugar through a closely regulated method of time and temperature, and the malt’s complicated proteins break down into simpler nitrogen compounds. The mashing takes place in a large round tank called a “mash mixer” or “mash tun,” requiring careful control of the temperature. The malt is then supplemented by starch from other cereals such as maize, wheat or rice, depending on the required beer.
The malt barley’s milling is a very significant move. Milling is performed to improve access to the barley core by the mashing liquor. This enables the enzymes to behave on the starchy endosperm that is secreted by the aleurone layer. It is important that the grain husk remains intact, as the husks are used to form a filter bed during lautering, the process where the sweet wort (pronounced as “Wert”) is runoff from the mashed grains.
Lautering plays a significant role in the manufacturing of beer. In the lautertun, the mash is filtered as the husks sink and the wort is separated from the solid (spent grains) substances. The wort is then used in the brewing process, while the grains spent are usually used as cattle fodder.
Hops Separation & Cooling
After the beer has taken on the flavor of the hops, the wort then goes to the hot wort tank. It’s then cooled, usually in an apparatus called a plate cooler. As the wort and coolant flow past each other on opposite sides of stainless steel plates, the temperature of the wort drops from boiling to about 50°F to 60°F (a drop of more than 150°F) in a few seconds.
Boiling & Hopping
Boiling takes place in a huge cauldron like brew kettle that holds up to 1,000 hectoliters under carefully controlled conditions. The process to get the desired extract from the hops usually takes about two hours. The hop resins contribute to flavor, aroma, and bitterness to the brew. Once the hops have flavored the brew, then we can remove from it. Sometimes, if required highly fermentable syrup may be added to the kettle. They coagulate undesirable protein substances which have survived the journey from the mash mixer, leaving the wort clear.
This is where all the magic happens- where the (yeast those living, single-cell fungi) breaks down the sugar in the wort to carbon dioxide and alcohol, and here a lot of the vital flavor occurs. In all modern breweries, we take elaborate precautions to ensure that the yeast remains pure and unchanged. Through the use of pure yeast equipped plants, they can maintain a particular beer flavor from time to time. During fermentation, which lasts about 7 to14 days, the yeast multiplies until a creamy, frothy head appears on top of the brew. When the fermentation is over, we remove the yeast. Finally, at last, we get The Fresh beer!
Bright Beer tank to Dispensing Tap
For one to three weeks, the beer is stored cold and then filtered once or twice before it’s ready for bottling/Dispensing or “racking” into kegs. Overall, for one batch production/Maturation/cellaring and up to dispensing taps Beers usually takes 14 to 20 days. Then we say Cheers to beer!