Zoedale explains the seven stage brewery process with an infographic.
ZOEDALE UNDERSTANDS BREWING
STAGE ONE: MALTING & MILLING
- Beginning In the brew house, different types of malt are crushed together to break up the grain kernels to extract fermentable sugars to produce a milled product called grist.
- Each beer has its own formulation with regards to the blend of different malts.
STAGE TWO: MASHING & LAUTERING
- This tank has a mixing paddle to ensure that the mix of water and malt is constantly agitated during mashing.
- The malt is mixed with hot water to allow the starch to be converted into sugar by enzymes.
- The temperature of the mixture is crucial, as the type of sugar converted is temperature dependent: some sugars are fermentable, while others are non-fermentable, giving a rich and smooth feel to the finished beer.
- The sweet liquid, now called wort, can pass through the screens of the false bottom, while the grain stays behind. The wort is then pumped into the kettle.
STAGE THREE: BOILING & WHIRLPOOL
- Once all the wort is in the kettle, the liquid is boiled for 60-90 minutes. This ensures that the wort is sterile
- Boiling also evaporates some water, concentrating the wort and intensifying the colour somewhat
- Hops are added to the kettle at the start of boil for bitterness and at the end of boil for aroma and flavour
- The wort is then recirculated through a whirlpool effect which ensures the residual hop product and proteins and enzymes are coagulated, and settle out of the liquid as a sludge called trub – This can be used as fuel for AD plants!
STAGE FOUR: COOLING THROUGH HEAT EXCHANGER
- Once boiling is complete, the wort is cooled to around 20 C through a heat exchanger on its way to the fermenter.
- By heat exchanging, we recover the energy used to boil the wort, i.e. cold water becomes hot water, and returned to the Hot Liquor Tank which is then used to brew more beer or for cleaning.
STAGE FIVE: FERMENTATION & MATURATION
- Once all the wort is in the tank, the yeast is added.
- The yeast will ferment the wort and turn it into beer.
- Primary fermentation will take about 3 – 4 days to complete.
- Fermentation temperatures will vary depending on beer styles, a lager is fermented below 16 C, ales are fermented above 20 C
- At the end of fermentation, the finished beer is chilled to around10 C and then 4 C and kept in the tank for maturation, usually around three weeks.
STAGE SIX: FILTERING INTO A BRIGHT BEER TANK
- When the beer is required for packaging, either in kegs or bottles, beer is earth filtered into a Bright beer tank (BBT)
- Filtering removes yeast, leaving the beer crystal clear.
- Some beers are not filtered at all, and still contain yeast
- The CO2 (carbon dioxide) is adjusted in the BBT and it is then ready to be packaged.
STAGE SEVEN: PACKAGING
- Beer is packaged into either kegs, casks, bottles or cans
See our valves and actuators for brewing section