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Beer Production

Not a lot of people realize it but actually beer and whiskey are the same thing. The only difference is that beer is fermented and whiskey is distilled, but at the end of the day they both have the same basic ingredients, which are malted grain, yeast and water.

Let’s start with the barley (grain). Barley is a tall grass plant with seeds on the top of the stalk. It comes in different varieties, which ultimately influences the taste of the final product. The first part of brewing includes malting the barley. The first step is steeping the barley in water for forty hours and spreading them to dry for three to five days. This will produce a substance called “Starch”. This first part is called the germination process.

Germination can be quickly halted by drying the barley in a Kiln, which is a thermally insulated chamber. At the end of the malting process you get the final product called green malt. The green malt continues its journey to the Grinding Mill, where the milling process starts. The malt is cracked into flour called grist, which makes it easier for it to absorb water and extract the sugars from the malt.

After the milling comes the mashing. The grist is mixed with hot water in the Mash Tun to create a cereal mash. This vessel contains thin perforations at the bottom to let the sugared liquid, resulting from the brewing operation, flow out. The sugared liquid is called wort, which is subsequently boiled with Hops to add flavor. Ok, let's give you some background information before we go on. Hops are green herbs related to dope. Yes, that’s right. Hop plants produce sticky buds that make you feel peaceful and relaxed. They’ve been added to beer for hundreds of years for a euphoric effect. Also because hop oils contain a natural preservative that keeps the beer from spoiling. Now, let’s get back to the brewing process.

The boiling process takes place in a Copper. It is during the boiling process that most decisions about flavor, color and aromas are made. At the end of the boil, the “hopped wort” settles to separate the more solid particles. Afterwards the wort is transferred inside a tube of cold water to start the cooling process. It is important that this process be done quickly in order to add yeast. When yeast is added to the wort, the fermentation process begins.

During fermentation, the mixture of wort and yeast will produce alcohol and carbon dioxide. After two to three days, fermentation is complete. The beer is then racked and aged, to develop a smoother flavor. After one to three weeks, the fresh beer is transferred into conditioning tanks. The conditioning part lasts for a week to several months and if needed, the beer is filtered. The filtration gives the beer its natural polish and color. Filtration is also done to stabilize the flavor of the beer. After carbonation the beer is moved to a holding tank until bottling.