MEC132
CRAFTING BREWS:
A JOURNEY INTO
THE ART OF
Beer Making
Noelle Gwendolyn G. Dana
Let’s jump in!
WATER:
Comprising up to 95% of beer, water's composition – mineral content, pH,
and even its source – significantly impacts the final brew. Soft, low-mineral
water is ideal for lighter styles like Pilsners, while harder water brings out the
malt character in darker beers.
THE FOUR PILLARS OF
BEER:
A LOOK AT BREWING
ESSENTIALS
MALT:
Malt, the very soul of beer, provides the fermentable sugars that fuel the
yeast's magical alchemy and define the brew's body and sweetness. Crafted
from germinated grains, primarily barley, malt manifests in diverse forms,
each imparting its unique signature. Pale malt, the cornerstone of many
styles, lends a light, biscuity character, while caramel malt unveils warm
notes of toffee and toast. For bolder expressions, roasted malts, such as
chocolate and black, contribute rich, coffee-like undertones.
HOPS:
Hops, the floral cones of the Humulus lupulus plant, provide bitterness,
aroma, and preservation for beer. They offer a wide range of aromas and
flavors, from citrusy and piney to floral and earthy. Adding hops during the
brewing process determines the bitterness level, while dry hopping (adding
hops later) infuses intense aromas. Hops also act as a natural preservative,
extending the shelf life of beer.
YEAST:
Yeast, the microscopic marvel, is responsible for the magical transformation
of sugars into alcohol and carbon dioxide through fermentation. Different
yeast strains thrive at various temperatures and produce distinct flavor
profiles. Ale yeasts, preferring warmer temperatures, create fruity esters,
while lager yeasts, at home in cooler conditions, result in cleaner, crisp
flavors.
UNVEILING THE
MALTING PROCESS
In the grand orchestra of brewing, malting
plays a crucial role, transforming humble
grains into the soul of beer – malt. It's a
delicate dance of germination and drying,
unlocking the magic within each seed that
ultimately fuels the fermentation process.
Veer
Making
1. AWAKENING THE GRAIN:
The journey begins with barley, the most common star of the malting
show. Cleaned and sorted, the grains are immersed in cool water,
soaking up moisture and kickstarting the slumbering embryo within.
Think of this as a wake-up call for the tiny plant-to-be. After a period of
rest and aeration, enzymatic activity intensifies, breaking down starches
and proteins within the grain.
2. GREEN SHOOTS TAKE FLIGHT:
With newfound vigor, the embryo erupts, sending green shoots
skyward in a process called germination. These sprouts, aptly
named "acrogens," play a vital role in producing the enzymes
needed for fermentation.
Imagine tiny factories springing up within each grain, churning out
essential tools for unlocking the sugars that will later feed the
yeast.
3. TIME TO REST AND RECHARGE:
However, this growth spurt can't go on forever. Just as the acrogens reach
their peak, the malting process is gently halted. The grains are dried in kilns
using carefully controlled temperatures to ensure even drying and develop
unique flavor profiles. This final step not only stops germination but also
concentrates the sugars and aromas within the malt, setting the stage for
its starring role in the brewing process.
1. Malting
It all starts with barley, the most common grain used for brewing. The
barley kernels are soaked in water, which triggers the germination
process.
Germination releases enzymes that convert the starches in the barley
into sugars, which will later be fermented by yeast.
After a few days, the germination is stopped by drying the kernels in a
kiln. This process also develops the characteristic flavors and aromas of
malt.
BEER MAKING PROCESS
2. Milling
The dried malt is then crushed into a coarse flour-like consistency
called grist. Dry malt, especially in the form of malted barley, contains
starches that need to be converted into fermentable sugars during the
brewing process. Milling the dry malt breaks down the malt into smaller
particles, exposing a greater surface area. This increased surface area
facilitates the enzymatic conversion of starches to sugars during the
mashing process.
BEER MAKING PROCESS
3. Mashing
The grist, crushed grains used in the mashing process, is mixed with hot
water in a large vessel called a mash tun. The specific temperature and
time of mashing determine the types of sugars extracted from the malt,
which in turn influence the final beer's flavor and body.
During mashing, the enzymes break down the starches into fermentable
sugars, mainly maltose, and unfermentable sugars like dextrins.
4. Lautering and Sparging
The sweet liquid extract from the mash, called wort, is separated from
the spent grain (draff) using a lauter tun. This can involve a lautering
plate or a false bottom, allowing the wort to drain through while retaining
the larger grain particles. Additional water is then sparged over the
draff to rinse out any remaining sugars, maximizing the wort yield.
BEER MAKING PROCESS
5. Boiling and Hopping
The wort is then brought to a boil in a kettle. Hops, the flower
cones of the Humulus lupulus plant, are added at different
stages of the boil. Hops contribute bitterness, aroma, and
preservative qualities to the beer.
6. Cooling and Fermentation:
After boiling, the wort is cooled down and transferred to a
fermentation tank. Yeast, the single-celled fungi responsible for
the magic of fermentation, is then pitched into the wort. The
yeast consumes the sugars in the wort and converts them into
alcohol and carbon dioxide. The type of yeast used (ale or lager)
and the fermentation temperature determine the final beer style.
BEER MAKING PROCESS
7. Conditioning and Packaging
Once fermentation is complete, the young beer undergoes a
conditioning period. This allows for further flavor development and
maturation, and also removes any remaining yeast and sediment. The
beer is packaged in bottles, kegs, or cans, and it's ready to be enjoyed!
BEER MAKING PROCESS
EQUIPMENT USED IN
BEER:
PRODUCTION
Malt Mill
Crushes the malted barley into a grist for better access to
starches during mashing.
Mash Tun
A large vessel where the grist is mixed with hot water to
convert starches into sugars.
Lauter Tun
Separates the sweet liquid wort from the spent grain (draff)
using a lautering plate or false bottom.
Brew Kettle
Boils the wort and adds hops for bitterness, aroma, and
preservation.
Fermentation Tanks
Vessels where yeast ferments the wort into beer. These can
be open or closed, and come in various shapes and sizes.
Pumps
Transfer liquids between different vessels.
Piping and Valves
Direct the flow of liquids throughout the brewery.
Cleaning and Sanitation Equipment
Ensures cleanliness and hygiene throughout the brewing
process.
ENVIRONMENTAL
CONSIDERATIONS USED IN
BEER
PRODUCTION
Beer Production
A Thirsty Process: Beer production is notoriously waterintensive. From barley irrigation to mashing, boiling, and
cleaning, every stage guzzles H2O. An average pint of beer
requires around 70 liters of water!
Conservation Efforts: Breweries are implementing water-saving
measures like rainwater harvesting, wastewater treatment and
reuse, and efficient equipment upgrades. Choosing breweries
with such practices can make a difference.
WATER USAGE
Beer Production
Fueling the Brew: Heating water, running machinery, and
keeping beer cool all require energy, often generated from
fossil fuels. This contributes to greenhouse gas emissions and
air pollution.
Renewable Options: Forward-thinking breweries are switching
to renewable energy sources like solar panels, wind turbines,
and biogas to reduce their carbon footprint. Look for beers
brewed with renewable energy!
ENERGY CONSUMPTION
Beer Production
Barley Blues: Barley, the main ingredient, is often grown with
conventional methods that rely on chemical fertilizers and
pesticides. These can harm soil health, pollute water bodies,
and reduce biodiversity.
Sustainable Farming: Supporting breweries that source barley
from organic or regenerative farms minimizes environmental
impact. These practices promote soil health, biodiversity, and
reduce reliance on harmful chemicals.
AGRICULTURAL PRACTICES
Beer Production
Spent Grain and Beyond: The brewing process generates
various waste products like spent grain, yeast, and wastewater.
Improper disposal can pollute landfills and waterways.
Circular Economy: Innovative breweries are finding creative
ways to reuse or upcycle these waste products. Spent grain
can be used for animal feed, biogas production, or even baking!
Supporting such breweries encourages a circular economy in
the industry.
Bottles, Cans, and Beyond: Beer packaging, from glass
bottles and aluminum cans to cardboard boxes, generates
waste and requires resources to produce and transport.
Sustainable Packaging: Breweries are exploring reusable
options like growlers and refillable kegs, using recycled
materials for packaging, and minimizing transportation
distances to reduce their environmental footprint. Choosing
local beers can help.
WASTE MANAGEMENT
SAFETY CONSIDERATIONS
USED IN
BEER
PRODUCTION
Physical Hazards
Slips and Falls: Wet floors, spills, and uneven surfaces
can lead to slips and falls, particularly common in
areas like brewhouse and kegging stations.
Lifting and Straining: Manually moving heavy kegs,
bags of grain, and cleaning equipment can cause
muscle strains and back injuries.
Burns and Scalds: Hot surfaces like kettles, steam
pipes, and boiling wort pose a risk of burns, especially
during brewing and cleaning.
Falls from Heights: Climbing ladders to access tanks
or work on platforms can lead to falls if proper safety
measures are not in place.
Confined Spaces: Working in tanks, bins, or other
confined spaces presents risks of oxygen depletion,
suffocation, and entanglement.
S A F E T Y
CONSIDERATIONS
Chemical Hazards
Cleaning Chemicals: Caustic cleaning agents and sanitizers can cause skin
and eye irritation if not handled properly. Proper PPE and training are crucial.
Compressed Gases: Carbon dioxide and other compressed gases used in beer
production can pose explosion risks if not handled and stored correctly.
Mold and Bacteria: Inadequate sanitation and improper temperature control
can lead to the growth of mold and bacteria, contaminating the beer and
posing health risks.
S A F E T Y
CONSIDERATIONS
Mechanical Hazards
Unguarded Machinery: Exposed gears, belts, and moving
parts of equipment can cause cuts, crushing injuries, and
amputations if proper guards and precautions are not
taken.
Electrical Hazards: Faulty wiring, exposed outlets, and
improper use of electrical equipment can lead to shocks
and electrocution.
S A F E T Y
CONSIDERATIONS
Safety Measures
Personal Protective Equipment (PPE): Providing and ensuring the proper use
of gloves, goggles, respirators, and safety footwear is essential to minimize
risks.
Training and Education: Comprehensive training on safety procedures, hazard
recognition, and emergency response is crucial for all brewery personnel.
Risk Assessments and Inspections: Regularly assessing potential hazards and
implementing preventive measures can minimize risks before incidents occur.
Safe Work Practices: Establishing proper lifting techniques, lockout/tagout
procedures for equipment maintenance, and clear guidelines for working in
confined spaces are essential.
S A F E T Y
CONSIDERATIONS
Beer Manufacturers in the
Philippines
San Miguel Brewery Inc.
Established in 1890, it's the oldest and largest brewery in the Philippines with its
main brewery in Mandaluyong City. This historic brewery is the company's flagship
facility and produces iconic brands like San Miguel Pale Pilsen.
Asia Brewery Inc.
Founded in 1982, it's the second-largest brewery in the Philippines with its
flagship brewery located in the bustling Libingan Hills Industrial Complex,
Muntinlupa City, Metro Manila.
Beer Manufacturers in the
Philippines
Anheuser-Busch InBev
his Belgian-American brewing behemoth controls over 27% of the global beer
market. They are responsible for iconic brands like Budweiser, Stella Artois,
Beck's, Corona, Leffe, and Hoegaarden.
Heineken Holding
Based in the Netherlands, Heineken represents around 12.4% of the global
market. Their portfolio includes Heineken, Amstel, Birra Moretti, Desperados, Tiger
Beer, and Cruzcampo.
Thank you!