The Brewing Process: 3) All-Grain Brewing

1) Basic Equation -- The foundational definition of making beer.
2) Extract Brewing -- The process used by beginning home brewers.
3) All-Grain Brewing -- The full process which is used in breweries, but at home.
4) Production Brewing -- Some key differences between the experiences of home brewing and working in a microbrewery.


In my explanation of the all-grain brewing process I will be using my process as the example.  It should be noted that terminology or methods vary widely and this is just how I brew.  Take this for what you will and enjoy!


Step 1:  Dough-In  Mixing the Grain and Hot Water
Step 2:  The Mash  Letting the Grain soak, producing Sugar
Step 3:  Recirculation  Circulating the contents of the Mash for clarification
Step 4:  The Run-Off  Extracting the Sugar and Filling the Kettle
Step 5:  The Boil  The liquid is boiled with hops
Step 6:  Cooling  The liquid is rapidly cooled and aerated as it is transferred into the fermentor


The Brewing Rig

  --Hot/Cold Liquor Tank:  This vessel holds a large volume of water which is heated by a gas burner for mashing and Lautering and filled with cold water and ice for cooling the finished wort.  I have a keg with the top cut out and a valve installed near the bottom.  For ease, this vessel has been elevated so that it will use gravity to feed to other vessels.

  --Mash/Lauter Tun:  A Mash Tun is a vessel in which the grain soaks and allows the enzymes to convert the starches from the grain into sugars.  A Lauter Tun is a vessel used to separate the grain from the sugars and other desired products of the grain.  Most homebrewers have a combined vessel.  Mine is a 5 gallon cooler with a false bottom and a sturdy valve below the false bottom.

  --Kettle:  A 5 gallon batch requires a brewing pot between 8 and 10 gallons in capacity to account for water which is boiled off and the boiling up of the wort.  I have a Blichmann brewing pot which has a valve, graduated volume scale on the side, and a thermometer.  The scale is one of the most useful features, but if you do not have one, you can use a measured bucket and as you add a gallon to your brew pot mark the water level on a stick or stirring paddle.

  --Pump:  With 5 gallon batches a pump is not required, but definitely helpful.  The usefulness of a pump is most noticed during recirculation.  Brewing pumps are magnetic impeller pumps which do not expose the wort or beer to the workings of the pump.  It is important to have a valve on the output as you can run it with the output closed, but not the input.  The valve on the output is how you regulate the speed of the transfer of liquid.  If you don't use a pump, you will need to make sure all three vessels gravity feed from Liquor Tank to Mash/Lauter Tun, to Kettle.

  --Chiller:  Most home brewers invest in immersion chillers which are copper coils through which cold water is run.  The cold water draws the heat out of the wort, but can take 30 minutes or more.  A plate chiller is what professional breweries use and they are also made for home brewers.  Plate chillers are highly efficient in the transfer of heat and can cool 6 gallons of wort to pitching temperature (approx. 70F) in under 10 minutes.

  --Burner:  There are many burners which will do the job.  Some people convert them for natural gas, but I use propane with consistent success.  On my setup the Hot/Cold Liquor Tank uses two small, inexpensive propane burners and the kettle uses the Blichmann burner.  The Banjo Burner is also very good, but has to burn off its own paint before use.


The Process

Step 1:  Dough-In

Doughing-in is the process of mixing the cracked (milled, crushed, etc.) grain with hot water in order to begin the mashing proces.  The grain is usually at room temperature so you will have to experiment with water temperatures to achieve a final temperature between 149F and 157F.  Because of how I mash I mix the grain with temperature which is approximately 10F hotter than my target mash temperature.  I usually also add water and grain at a ratio of [1G/3lb].

              So:  1 Gallon of water @ 164F   PER   3 Pounds of milled grain = 154/155F Mash

Stir in the grain and water until all the grain is soaking in the water with no clumps.

Step 2:  The Mash

Mashing is the process by which grains soak in water between 149F and 157F so that the enzymes are allowed to convert the starches to sugar.  149F will produce a drier beer as more sugars are broken down to a greater degree and are easier for the yeast to ultimately devour.  Lower temperatures around 149F also require between 60 and 90 minutes to complete.  Higher mash temperatures around 157F will result in a higher proportion of more complex sugars which will remain past fermentation, resulting in a sweeter or maltier beer.  Higher temperature mashes can usually complete in 45 to 60 minutes.   I mash around 153F and let it mash for at least 75 minutes to be sure it has completed.

               So:  149F = Drier = 60-90 min. mash    /////    157F = Sweeter = 45-60 min. mash

Step 3:  Recirculation

Recirculation (German: Vorlauf) is used to settle the grain bed so that it may be used as a filter by which to clean the liquid moving into the kettle.  This may be done by pouring off from the bottom of the mash tun into a cup or other vessel and pouring it back, carefully, into the top of the mash tun.  The most convenient way to accomplish this is to use a magnetic impeller pump with the valve on the exit side of the pump barely open.  Once the liquid has been carefully and slowly recirculated and is running relatively clear of particulate it is time for the Run-Off.

               So:  Circulate the liquid from the bottom of the mash tun to the top to clarify and set up the grain as a filter

Step 4:  The Run-Off

Running-Off means running 170F water through the mash tun with the grain (which is now set up as a filter) and extracting the sugars into the kettle.  This basically means washing the grain.  170F water flows from the Hot Liquor Tank, through the grain, and into the kettle.  Make sure the water level stays above the grain so that the grain doesn't collapse and cause your run-off to clog.  Also make sure not to open the valves too much and, again cause the run-off to clog; take your time with this.  Fill the kettle to a volume which allows for a gallon or more to boil off during the boil.

                 So:  Wash the sugar from the grain and into the kettle

Step 5:  The Boil

The boil sterilizes the wort and allows the hops to impart their bitterness.  Boils are usually 90 minutes long with the main bittering hop addition occurring between 60 and 70 minutes.  The longer hops are in the boil, the more bitterness they impart.  Flavor from hops diminishes considerably beyond 15 minutes while aroma dissipates quickly after 5 to 8 minutes.  A good, roiling boil will produce the most efficient and predictable results.

                 So:  Make a timeline and add hops at your specified times

Step 6:  Cooling

(Everything at this point must be sanitized prior to use)

Cooling the wort quickly is very important as chemical and bacterial process can and will be occurring as the wort sits out in the open at warm to hot temperatures.  A wort chiller, through which you run cold water, can be placed in the kettle shortly before the end of the boil so that it is sanitary when you terminate the boil and begin to circulate water to cool the wort.   A plate chiller is the most efficient way to cool wort quickly as it provides for the maximum exchange of heat so long as you monitor the wort output temperature and regulate the speed of the wort to maintain a temperature around 70F.  Breweries aerate their wort after going through the plate chiller with bacteria-free oxygen to provide the yeast with optimal circumstances.
                 
                   So:  Get the wort to pitching temperature (70F) ASAP
               

This is just an overview.  In time you will find what works for you.  ENJOY!!!

The Brewing Process: 2) Extract Brewing

1) Basic Equation -- The foundational definition of making beer.
2) Extract Brewing -- The process used by beginning home brewers.
3) All-Grain Brewing -- The full process which is used in breweries, but at home.
4) Production Brewing -- Some key differences between the experiences of home brewing and working in a microbrewery.



 2) Extract Brewing

I recommend getting a Brewer's Best kit and following their instructions, but this is an overview of the process:


1-  Steep Specialty grains in water between 150F and 157F.  These grains add character and flavor, but do not provide sugars.  Make sure grains are in a bag which can be used to remove the grains before the boil.

2-  Remove Specialty Grains and bring pot to a boil.

3-  Add Malt Extract and stir to avoid initial scorching. 

4-  Add hops at the times noted by the recipe.  Timer starts after extract is added and boil resumes.

          Ex.)          1:00 PM    (60 min)      add 1 oz. of Kent Goldings
                           1:30 PM    (30 min)      add 1 oz. of Fuggles
                           1:55 PM    (5 min)        add .5 oz. of Fuggles
                           2:00 PM    (0 min)        Terminate Boil

5-  Remove the pot from heat and add cold water to bring the final volume to 5.5 gallons (assuming a 5 gallon batch).

6- If the temperature is close to 70F, it is safe to transfer it into the fermenting vessel (bucket, etc.) and add yeast.

7-  Allow your creation to ferment and, after one or two weeks, bottle or keg for consumption.  Don't forget to add a measured amount of sugar which will create carbonation.

The Brewing Process: 1) Basic Equation

1) Basic Equation -- The foundational definition of making beer.
2) Extract Brewing -- The process used by beginning home brewers.
3) All-Grain Brewing -- The full process which is used in breweries, but at home.
4) Production Brewing -- Some key differences between the experiences of home brewing and working in a microbrewery.



1) Basic Equation

        [Sugar from Malted Barley] + [Water] + [Boiled Hops] + [Yeast] = Beer

The German Purity Law (which is no longer technically in effect) defined the ingredients of beer to be Barley, Hops and Water.  Later, when yeast was discovered to cause the fermentation, yeast was added to the common definition.  This is THE basic equation.

Asheville - Barley's Taproom

 

The "Beer City" Flight

Barley's Taproom is a fantastic destination for food, drink and entertainment in a setting which feels like an "authentic pub."  They have a broad selection of food on their menu which should satisfy all tastes and my favorite is their New York style pizza by the slice for $2 a slice.  They have in excess of thirty taps which include local and rotating selections.  They offer several different flights, including the "Beer City" flight which showcases several staple beers from Asheville breweries.  Their downstairs is a beer hall/restaurant, while the upstairs has billiards and other games along with slightly fewer than half of their 30+ taps.  Barley's is a place of comfort and enjoyment which can not be overlooked.  Enjoy!

Gudger's Easy Home "Monk's Meal"

On occasion I enjoy what I call a monk's meal.  It's as simple as it sounds, but can be a nice repast during a long week, or just because the desire strikes.  All of these things can be found at most supermarkets and the price depends on their selection and your taste.  The staples for my meals are bread, cheese, and Belgian beer.  I prefer rosemary bread, aged gouda cheese, and one of the Chimay beers.  A foundation like this is perfect for adding fruit or some kind of meat and can be enjoyed over an evening (raspberries...).  Take some time and enjoy!


Making cheese, bread, and beer are all very doable things in your own kitchen (as you already know) and could be an event if you were to time all three to be ready around the same time.  Beer requires the most investment to make a palatable product.  Cheese requires a couple special ingredients, but is still relatively simple.  You may want to check out a home brewing or winemaking shop in search of the cheese making ingredients.  Look up recipes for interesting and simple breads as you probably have most of the ingredients already.  Have fun with it.

Asheville - The Thirsty Monk

This is my watering hole of choice.  As a matter of fact it has received many notations in beer publications of its status as a world class beer bar.  You can find this list on some of the tables next to their specials.

If you feel like enjoying American craft brews they have the upstairs which is adorned with signs of the craft brew industry.  The upstairs has about twenty taps which rotate at a fairly quick pace from breweries around the country and a few from here in Western NC.

The downstairs has sixteen or seventeen taps which are usually flowing with tripels, strong ales, barley wines and other high gravity brews.  The downstairs is partially below ground level and decorated with dark woods and makes you feel as if you're in a cave of beer greatness (you are).

The way to go is to pick either the upstairs or the cave downstairs and order a flight of four smaller pours of beers with which you are not familiar.  This is the perfect amount of beer for a full sampling of each and provides a better chance to enjoy a greater variety of these beers which will quickly be moving on.  To order you get a pencil and a card and give it to the bartender with your selections.  I enjoy the process of reading the descriptions on their menu and picking out my dream team of brew greatness.  The card includes an area for each beer where you can make comments and even helps you out with suggestions for the tasting process.  The bartenders are knowledgeable and will be happy to pick out a flight based on your taste.

The people at the Monk are proud to serve pub fare which integrates ingredients from several local breweries.  You can find pizza, pretzels, sandwiches, and even a cheese plate with which to complement your beer tastings.

You can find their menu and beer listings complete with descriptions online at www.monkpub.com.  The beer lists are updated daily and are usually accurate to within one or two taps (sometimes less accurate on the weekend because of the increased business).  They have regular specials and events which are worthwhile and can also be found on their website.  They have a second location now in South Asheville at which they brew some of their own beer in smaller batches.  I haven't experienced enough of their house brews to comment.  I personally believe it's worth the effort to make it out to the original location downtown as it has a wider selection and more authentic ambiance.  Now that I've called your attention to this wonderful place, go to their website or better yet to the Thirsty Monk itself!

Asheville, NC - Beer City USA

I am fortunate to have been raised in one of the greatest cities in the world.  Downtown has great restaurants, accessible shopfronts, unique cafes and coffee shops, and plenty of other destinations.  Just outside the downtown area is the Blue Ridge Parkway, the Pisgah National Forest, and lots of hiking trails.  The liberal culture of the city juxtaposes well with the traditional mountain culture 10 minutes away and provides a spectrum of experiences.  We even have the nation's largest privately owned home; the Biltmore Estate, which can easily take an entire day to explore.  There are many reasons the Vanderbilt family came here and constructed a huge Gothic mansion. 

Asheville is also Beer City USA for the fourth year now!  Each year there is a poll administered by Charlie Papazian and Examiner.com in which anyone can log on and vote for their favorite beer culture.  I'm personally pleased that so many cities have recently been stepping up their efforts and supporting their city's vote. 

On June 1st Asheville had its annual Beer City Festival which showcases its many breweries and some from surrounding states as well.  It's one of the few festivals which only has one long 6-hour session as opposed to two or more 4-hour sessions.  There are few experiences more like adult Christmas than this single afternoon in June.  If you live far from Asheville, it is worth a pilgrimage.  Buy tickets early and make it happen next year.

I work the school years in Kentucky, but I've been back home in Asheville for the summers interning at various breweries and enjoying the culture.  Over this summer I will be reporting on, among other topics, each of the breweries and a few of the more notable beer destinations.  (If you are in Asheville, go to the Thirsty Monk Downtown.  That's at the top of my list of beer bars.)


The culture for great brew has grown so much here that both Sierra Nevada and New Belgium are moving into the area over the next couple years.  Get with it Sam.