Production Process

Brewing is a completely natural process. Simply put, beer brewing is based on an ancient and simple principle: that natural fermentable sugars are extracted from malted barley (or other grains) using hot water.

1. Barley Malting

During malting, the barley is left to germinate for about 5 days. After this period, germination is stopped by kilning.

In this short interval, we achieve:

• the development of enzymes, which are necessary in the later stage (brewing).
• the breakdown of the natural walls of the starch in the grain, so that it is more readily available in the later stage (brewing).

The malting process involves three stages: Steeping, Germinating, Kilning. Malting usually takes 7 days.

2. Brewing

Brewing is a particularly important process for the production of beer and involves the following stages:

2.1 Milling

Malt is ground in a special mill. Milling achieves better extraction of the starch and other components, as well as separation of the bran from the endosperm.

2.2 Mashing

• The ground malt is mixed with hot water. The starch is converted into fermentable sugars (saccharification). The gradual increase in temperature activates enzymes (present in the malt and created by the natural malting process) that convert the carbohydrates and peptides in the malt into forms that are metabolised by the yeast (sugars and proteins) during alcoholic fermentation.

2.3 Lautering

In traditional brewing, the mash is transferred to a special container with a perforated bottom (Lauter Tun). The grains are the natural filtration medium. This is how the wort is separated from the grains. Wort clarification is a very important process because it affects the quality of the beer to be produced. After lautering, the wort is transferred to the boil kettle.

2.4 Boiling

After adding hops, the wort is boiled. At the boiling stage the hop essential oils are released, which give the beer its signature hop aroma and are, at the same time, the substances responsible for the bitterness of beer, while also acting as natural preservatives. At this stage, the wort is sterilised, the enzymes are deactivated, protein complexes and polyphenols are aggregated and precipitated, the pH of the wort is reduced, the colour is developed and unwanted volatile substances are removed.

2.5 Wort Treatment

This is followed by natural clarification of the wort by centrifugation in a special cylindrical container (Whirlpool). The wort is introduced tangentially into the vessel, creating a circular motion that causes the clumps created during boiling to form a cone in the centre of the container. After settling, the wort is removed through an outlet on the side of the container. This is how further clarification is achieved.

Then, the wort is cooled, aerated and inoculated with yeast.

3. Fermentation

During fermentation, yeast converts sugars into alcohol and carbon dioxide and other substances that give it its characteristic taste and aroma. The two types of fermentation are:

• Fermentation in modern cylindrically conical tanks.
• Fermentation in traditional open horizontal tanks.

4. Maturation/Aging

After fermentation is complete, the yeast is removed, the fermented wort remains at the fermentation temperature for a certain period of time and is then frozen at 0 °C.

At this stage, the following is achieved:

• The Fermentation of the few remaining fermentable sugars that have not yet been fermented.
• The Carbonation of beer with carbon dioxide (CO2).
• The Maturation of beer and the development of substances that contribute to its organoleptic properties.
• The further Clarification of beer.

5. Filtration

Even though there are types of beer that are unfiltered (e.g. Weiss), which owe their characteristic cloudiness to the natural ingredients of beer and yeast, filtering is usually an important part of the production process because:

• It removes the yeast and other substances that could cause clouding later on, during storage. At this stage, the beer acquires its final density and the required carbonation.
• The filtered beer is clear and ready to be packaged in bottles, cans and kegs.

6. Packaging

With the right packaging, beer remains unaltered until it reaches the consumer.

• Oxygen is an enemy of beer, so bottling is done in the presence of carbonate. Before being filled, the bottle is emptied of the air it contains, which is replaced by carbonate. The bottle is then filled.
• For reasons of biological stability, pasteurisation or sterile filtration follows. This stage is not required, but if omitted, the beer will have a shorter shelf life.