From grain to bottle
Brewing begins early in the morning with the weighing of several different types of malted barley. The resulting mixture, known as the ‘grist’ is mixed with hot water in a vessel known as a ‘mash tun’.
This is steeped for upwards of ninety minutes to extract the sugar from the resulting porridge-like mix known as the ‘mash’.
The sweet liquid produced – called ‘wort’ – is filtered out of the mash tun leaving the spent grain behind and is then pumped to a secondary vessel known as the ‘brew kettle’. The wort is then brought to the boil for between 60 – 90 minutes where whole hops are added to provide bitterness and flavouring at different stages during the boil.
After boiling the wort is pumped from the kettle through a heat exchanger which drops the temperature to 15-20 degrees Celsius. It is then it is pumped on to an open vessel called the fermentation tank where yeast is added. This is located in a dedicated room.
The wort is left to ferment for between four and seven days, after which it is transferred to a conditioning tank, where it is kept at a colder temperature for a second week to ensure it clarifies and settles. After a week the beer is sent to another tank via a filter where a small amount of sugar is added to aid carbonation and the ale is pumped from the conditioning tank and bottled and packaged.
The bottles are then transferred to a warm room to condition and to allow the remaining particles of yeast to settle for a further two weeks after which they are ready to be boxed up and sent out into the world!