THE BREWING PROCESS
1. Milling and brewing
Malt is carefully stored in big silos. From there it is milled and mixed with water in the mash tun. The heating process is realised very carefully in order to get as much maltose out of the milled malt grain as possible.
2. Filtering and boiling
Once all the starch has been transformed into sugar, the spent grains are filtered out. This is called the wort. The sediment is called "draff" and is often a useful product for the feedstuff industry. The filtered wort is pumped into the brew kettle where hops are added to provide the aroma and the bitterness. This stage will also determine the strength of the beer, on which excises will be levied.
3. Clarification, cooling and fermentation
Protein flakes arise during the boiling procedure. These have to be removed as soon as possible in order to avoid turbidity in the finished beer. The brew is therefore clarified. Then the wort is cooled down to a temperature of 8-12°C (low fermentation) or to a temperature of 18-25°C (high fermentation). At these temperatures yeast is added to the wort. After five to twelve days the fermentation of the green beer is completed and the sugars are converted into alcohol and carbon dioxide. At the end of the fermentation procedure the yeast is recovered, purified and used again for the next brew.
In order to ferment the last sugars and to allow the residual yeast to settle, the green beer is stored in tanks in the stock cellar thus allowing the taste to ripen. This procedure is called lagering of beer. In this stage the last sugars are converted into carbon dioxide, which remains in the beer.
5. Final filtering
The residual yeast cells are removed by way of a second filtering, which renders the beer crystal-clear, perfectly pure and sterilized before being packed in kegs, cans or bottles.
After the laboratory has realised the necessary checks, the different types of beer are filled in kegs, bottles or cans. Tankers are also used to deliver beer to big cafes or for events. The principle stays the same: before the filling, a carbon dioxide gas is used to provide counter pressure on the bottle, the keg, the can or the tanker in order to avoid the loss of carbon dioxide or froth from the beer.
After bottling, the products are loaded on trucks.