Beer

 Background

The family of beverages generally referred to as "beer" has been brewed for centuries. Beers are obtained by the yeast fermentation of malted cereal grains, to which hops and water have been added. Brewing has evolved from a cottage craft into a modern industry where large breweries export their beers worldwide.

                                                          Raw Materials

Beer requires these ingredients for brewing: properly prepared cereal grain (usually barley and corn or rice), hops (scientific name Humulus lupulus), pure water, and brewer's yeast. Each ingredient can affect flavor, color, carbonation, alcohol content, and other subtle changes in the beer. Grains are carefully stored and handled to promote highest quality. Hops are a form of cultivated perennial hemp, and the useful portions of the vine, the sticky cones, are developed from the bloom. About 35 pounds (16 kg) of barley malt and 15 pounds (7 kg) of grain are used to make each 31-gallon barrel of beer. Large quantities of pure water are extremely important not only as an ingredient, but for maintaining the cleanliness of the brewing equipment. In beer, water high in lime or iron can interfere with the fermentation process and discolor the final product. Yeasts are fungi, which are microorganisms that reduce sugars to alcohol by fermentation. Some types of brewer's yeast are closely guarded trade secrets.Outside of the beer itself, the process also requires various acids and cleaning chemicals to maintain and sterilize the brewing equipment. The finished product also requires packaging, which includes card-board products for boxes, aluminum for cans, glass for bottles, and stainless steel for kegs and other commercial dispensing equipment. The majority of the brewing equipment is stainless steel, with the exception of the brew kettles, which are copper.

The Brewing Process

Malting

1 Fully ripened barley grains are "steeped," or soaked in cold water until they are fully saturated. The water is changed once a day, and after 45-72 hours the grains are placed in shallow tanks. The grain is aerated and stirred, which causes it to germinate, releasing enzymes such as malt diastase. Malt diastase converts the starches contained in the grain to sugar for fermentation. As soon as the germination is adequately complete, usually six days, the grain is roasted to stop the germination process. The exact point at which the roasting starts and ends affects the flavor and color of the beer. The product at this point is referred to as malt.

                                                    Preparing the mash

2 The malt is crushed using iron rollers and transferred to the mash tank (or "tun"). This tank is a large copper or stainless steel vessel that mixes the malt with warm water until it is of porridge-like consistency. This mixture is called mash. After mixing with similarly prepared cereal grains, the temperature of the mash is raised incrementally from 100-170°F (38-77°C) so that the enzymes react. The enzymes break down the starch in the grain and convert it to simple sugars. Later, the yeast will convert the sugars into alcohol. Once complete, the mash is allowed to sit undisturbed so the solids can descend to the bottom of the tankBrewing the wort

3 The liquid contained in the mash is transferred into another tank called a lauter tun. This is accomplished by drawing the liquid out through the bottom layer of mash solids, which acts as a filter. Hot water is added to the top of the mash tank to rinse the remaining liquid, now called wort, from the mash. The solid remains of the grain are dried and sold by the brewery as animal feed. The wort travels on to the brew kettles, where it is boiled to sterilize it, and where the carefully prepared hops are added. The addition of the hops is important because they contribute to the bitterness of the beer. The brew kettles are the most impressive equipment in the process. Gleaming copper, they can be 7-12 feet (2-3.6 m) in diameter and two stories high. Steam usually provides the heating energy to the brew kettles. After brewing is complete, the finished wort is filtered again and pumped to the fermentation tanks.

Fermenting

4 In the fermentation tanks, the atmosphere must be carefully controlled to prevent any "rouge" bacteria from interfering with the yeast. Carefully maintained yeast (approximately one pound per barrel of wort) is added to the wort, and the temperature of the mixture is slowly reduced over a period of days to between 50°F and 60°F (10-15°C). In this temperature range, the yeast grows, consuming the sugar in the wort, and bubbles of carbon dioxide form. The wort has now become beer. The new beer is filtered and transferred once more into the aging casks, where the temperature is controlled at 33°F (°C) for 2-24 weeks. The shorter storage time produces a pale lager beer while the European lagers (called Pilsner) are aged longer to increase the alcohol content.

                                                           Pasteurizing

5 After aging, the beer can be pasteurized to kill the remaining yeast and prevent further alcohol production. This is accomplished by heating the beer above 135°F (57°C). This process, named after Louis Pasteur, is widely known for preserving milk. Interestingly, Pasteur originally developed this process to preserve beer in the 1860s. Pasteurization, however, is not used in the production of genuine draft beers. These beers are also known as "ice" beers, since they must be kept refrigerated to preserve their flavor and slow the remaining yeast sale to encourage the return of the bottles and cans.

When beer is dispensed from the keg, a pressure apparatus called a "tapper" is used to apply a light pressure of carbon dioxide (usually 2-6 PSI) to the tapper head for dispensing.

                                                               BEER BREWING AND STORING TANKS

 The tanks that are required for fermentation, maturing and storage of the product vary depending on the type of beer we choose to produce, the method of brewing and the further final processing of the product. The INOX MADE LTD provides all known brewing and maturing models, as well as tanks for beer storage / bottling and support tanks. The design, the selection of materials and the method of construction of the tanks guarantee hygiene, a decisive factor in quality assurance, but also high production efficiency. Tanks are equipped with a CIP device, all the required control and safety devices, and are certified in accordance with European standards. They can operate autonomously or be connected to the central control system of the brewery.