Brewing process

Introduction

The beer production with Brewiks can be divided into various phases, and here each phase is explained individually. These phases are first described in general terms, so that the brewing process applies to all types of beer and recipes. Before you start brewing, it is best to first get an overview of the individual steps that lead to the finished drink. To ensure that you do not skip any steps and also have an overview of your brewing procedures later on, it is recommended to take notes.

Preparations

Get the necessary ingredients (hops, malt, and yeast) in time. It is important that the grain is freshly malted. After milling (breaking the grains - not too fine), the malt should be used as soon as possible. The quantities may vary slightly depending on the recipe. Hops are usually available in compressed form (as pellets). For fermentation, dried yeast is recommended as it is easy to store and lasts longer. These ingredients can be purchased at homebrew shops or online. A third option to obtain the ingredients is from a brewery near you.

Mashing

The mixing of ground malt with water is called mashing. The aim of the entire mashing process is to extract the starches stored in the malt and convert them into sugar with the help of the enzymes contained in the malt. The different enzymes act at different temperatures, which is why the different temperature stages follow one another.

The malt is placed in the Brewiks mash tun.

During the protein rest, the large protein molecules in the malt are broken down into smaller components. The protein rest is important for the clarity and fullness of the beer, especially for the foam stability and the beer's ability to bind carbon dioxide.

During the second phase, the maltose rest, the starch molecules are converted into fermentable sugars by other enzymes present in the malt. This phase is an important part of the brewing process for alcohol production, as this is where the largest amounts of sugar are produced. Extending the rest period means more sugar in the wort, resulting in a stronger beer. A shortened time leads to a fuller beer taste due to more dextrins.

In the third mashing phase, other starch components are broken down with the help of enzymes that become active at this temperature and dissolve in the wort.

In the final phase, remaining starches are saccharified, creating even more unfermentable extracts that make the beer fuller-bodied. An iodine test can determine if there is still residual starch in the wort. To do this, a few drops of wort are placed on a white plate and some iodine is added. If the sample turns brown-red or yellow, the saccharification level is sufficient. If this is not the case, the last temperature stage must be maintained longer.

Mixing in the mash tun is done with the following valve settings:
1. Inlet - OFF
2. Outlet - OFF
3. Mixing inlet - ON
4. Mixing outlet - ON

Once the valves are set, the pump can be turned on and set to 60% speed.

Everything at this stage takes place in the mash tun.

Recirculation / Wort Pumping

Recirculation is the process of forming a fine grain layer in the lauter tun. This enables us to achieve a clear wort before the lautering process. The first step is to transfer the mash from the mash tun to the lauter tun and then start the recirculation process.

First, pump the mash into the lauter tun. Turn off the pump and connect the valve "2. Outlet" to "5. Whirlpool" with a flexible hose. The valves must be set as follows:

1. Inlet - OFF
2. Outlet - ON
3. Mixing inlet - ON
4. Mixing outlet - Half ON during transfer. Use water before the end of the transfer to flush the remaining mash to the outlet, and then close the valve.
5. Whirlpool - ON

Turn on the pump and increase the speed. The hose connection is shown in the next figure.

After the mash has been transferred to the lauter tun, the recirculation process can begin. The pump is off and the valve "2. Outlet" is connected to "6. Side" with a flexible hose. A sight glass is attached to "8. Bottom" and then connected with a second flexible hose from "1. Inlet" to "8. Bottom". The valves must be set as follows:

1. Inlet - ON
2. Outlet - Half ON
3. Mixing inlet - OFF
4. Mixing outlet - OFF
6. Side - ON
8. Bottom - ON

Turn on the pump and set the speed to 60%. The hose connection is shown in the next figure.

Clarification

Clarification is the process of separating the ground malt from the wort. For safety reasons, it is recommended to always wear heat-resistant gloves, as some parts can be extremely hot.

After the recirculation in the lauter tun is completed, the clarification process begins. Turn off the pump and connect the valve "8. Bottom" to "1. Inlet" via a flexible hose. The valves must be set as follows:

1. Inlet – ON
2. Outlet – OFF
3. Mixing inlet – OFF
4. Mixing outlet – Half ON
8. Bottom – ON

Turn on the pump and reduce the speed to 60%. Close the valve "4. Mixing outlet" slightly. The hose connection is shown in the next figure.

During clarification, the heaters must be turned on to warm the wort.

Sparging

Sparging is the process of washing the sugar out of the malt. This increases the brewing efficiency. The amount of water needed for rinsing depends on the beer recipe. (Heating the water for rinsing is optional).

Connect cold water to the valve "12. Inlet for sparging". Connect "13. Outlet for sparging" to "14. Sparging" on the lautering tun. If the heater in the mash tun is on and the valve "12. Inlet for sparging" is on and connected to cold water, hot water will enter the lautering tun through a built-in special nozzle under the lid of the lautering tun. The hose connection can be seen in the next illustration.

Boiling Hops

Adding hops to beer originally served to make the beer last longer. The hops remain in the wort until the end of the boiling time, as their substances only unfold their effects after a longer boiling time and transfer the specific bitterness to the beer. Resins and oils in the hops are also released, which, together with the malt aroma of the wort, give it its full-bodied character.

The amount of hops varies depending on the recipe and type of beer. This also depends on the hop varieties themselves, as they can vary from year to year and growing region. Hops can be added as pellets or dried hops. The bitterness of beers is expressed in bitter units (BU).

For boiling in the mash tun, the following valve setting is used:

1. Inlet - OFF
2. Outlet - OFF
3. Mixing inlet - ON
4. Mixing outlet - ON

Once the valves are set, the pump can be turned on and set to 60%, until the wort begins to boil, after which the pump is turned off.

At this stage, everything happens in the mash tun.

Whirlpool

The whirlpool is used at the end of the cooking process to separate larger particles before cooling. After cooking, the wort is pumped from the mash tun to the lauter tun through the valve "5. Whirlpool". After a few minutes, the wort is pumped back into the lauter tun through the valve "7. Side bottom" to cool down.

The whirlpool is performed by pumping the wort into the lauter tun. Turn off the pump and connect the valve "2. Outlet" to "5. Whirlpool" via a flexible hose. The valves must be set as follows:

1. Inlet – OFF
2. Outlet – ON
3. Mixing inlet – ON
4. Mixing outlet – OFF
5. Whirlpool – ON

Turn on the pump and set the speed to 100%. The hose connection can be seen in the next figure.

Wort cooling

The Wort is cooled using a tubular heat exchanger built into the wall of the Brewiks mash tun.

Turn off the pump and connect the valve "7. Side bottom" to "1. Inlet" using a flexible hose. Connect valve "2. Outlet" and "9. Hot wort inlet" with a second flexible hose. Connect valve "10. Cold wort outlet" and the fermenter with a third flexible hose. The valves must be set as follows:

1. Inlet - ON
2. Outlet - ON
3. Mixing inlet - OFF
4. Mixing outlet - OFF
7. Side bottom - ON
17. Cold water inlet - ON

Connect cold water to "17. Cold water inlet" and open the cold water. Turn on the pump and reduce the speed. The cooling time depends on the temperature of the cold water, the flow of the water, the temperature of the wort, the flow of the wort, and the amount of wort.

Hot water from "18. Hot water outlet" can be returned to the mash tun or directed to another tank for collecting hot water. The hose connection is shown in the next figure.

Cleaning

After brewing, it is best to put the Brewiks in the cleaning position and dilute and pump out all the fine solids with water. Pay attention to the correct valve position. Residues from brewing can now be removed from the inner surfaces of the kettle with a brush and water (via a hose). Pump out the dirty water in the meantime. Also pump clean water through the inlet into the kettle to flush out this connection and the valve. Don't forget to clean the outlet and the inlet.