Brewhouse. An exact weight of ground malt is mixed with a predetermined amount of corn grits and brewing water in the cooker. The enzymatic action of the malt solubilizes the starches during a precise time/temperature cycle. The solubilized starch is then transferred to the mash tun, which contains the main mash. Another precisely controlled time/temperature cycle converts the starches to fermentable sugars. The clear liquid, called wort, is separated from the grain by straining in the lauter tun. The wort is transferred to kettles and boiled. Hops are added in exact amounts to provide the distinctive flavor of beer. At the end of the timed boil period, the hot wort is pumped to a tank to allow settling of unwanted protein.
Fermentation. The wort is converted into beer during this stage. A small amount of brewer’s yeast and a quantity of air are injected into the cooled wort as it enters the fermentation tanks. The yeast grows, producing enzymes that convert the sugar in the wort to alcohol and carbon dioxide gas (CO2). Some of the CO2 is collected and saved for later use. Fermentation takes about one week. When complete, the beer is filtered to remove yeast and other solids, then pumped to the aging tanks.
Aging. “Green beer” is allowed to rest for an extended period in the aging tanks. When properly aged, the beer is filtered a final time; if the carbonation level is low, additional CO2 is added. Finished beer is then pumped to the packaging tanks.
Packaging, When the aging process has been completed, the finished beer is then packaged in bottles, cans, and kegs. After packaging, the bottle and can products are pasteurized over a period of approximately half an hour at a temperature that is allowed to rise to 140°F, then cooled down. Because it is pasteurized, packaged beer may be stored at room temperature without damage to the product


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