Beer production is a complex process...

The brewer starts with malted barley that is then steeped in water until a chosen moisture level is reached. Under strictly controlled conditions, it is then allowed to germinate. Then it will be kilned to produce specific types of malt that the brewer will blend. The many varieties of malt allow a brewer to create his own texture for malt character for the beer he is brewing.

The next phase of the process is called "mashing". During the mashing process, the malt is ground into a powder-like material called grist. This process extracts and changes the composition of the sugars present and converts additional starches into sugars and carbohydrates which gives beer its body. This is done by using two different enzymes (alpha and beta), each working within a different temperature range. Alpha converts maltotriose into dextrins. Beta takes the converted dextrins and changes them to maltose and other elements.

There are two distinctly different processes a brewer can choose at this point:

Infusion Mash: This method is traditional to top-fermented beers and ales.

In a single vessel, mash is sprayed with hot water, which raises the temperature to between 149 and 160 degrees. The mash is then held at this temperature for one to two hours depending on the Brewmaster's preference.

The vessel used at this stage will have slotted holes in the base to drain the wort. The spent barley acts as a filter in the draining process.

Decoction Mash (Step Mash): This method is used for bottom-fermented beers.

This is a staged mash. The temperature level is raised in stages taking anywhere from 1 to 6 hours. This technique allows the brewer a very fine degree of control over the process.

Portions of the mash are taken from the kettle and heated, then returned to the kettle gradually raising the overall temperature to a maximum of 160 degrees.

Here the Brewmaster makes a choice: the higher, the temperature the more body and less alcohol; lower temperatures results in more alcohol and lighter body. Variations within the range are only limited by imagination.

The Finishing Touches - Maturation

At this stage top-fermented beers are virtually ready to go out the doors. They will have a short conditioning period that often revolves around a process called "dry-hopping", a process where whole cone hops are added to the beer to create more intensity of hop character in the nose and taste. This does not, however, add to the level of bitterness in the beer. According to the preference of the brewer, this can be done during conditioning in casks or barrels, or even in the primary fermenter after it has cooled.

In the case of bottom-fermented beers, this process can last from a few days to a year. The beer is held at 32 to 34 degrees, which slows the fermentation. Gradually, yeast and proteins in solution will precipitate out and leave a smooth tasting beer with no harshness in the back of the throat.

At this point most bottom-fermented beers that are filtered, go to a holding tank for bottling or kegging, and out of the brewery.

Some top-fermented beers go through a process called "bottle-conditioning". A dosage of live yeast is added to the bottle to create an additional fermentation in the bottle. This will add complexity and depth of character to the beer.

The approach to this process can vary:

German Hefe-Weizens: are top-fermented, but the dosage will be with a bottom-fermenting yeast strain.

The Belgian Classic Duvel: is processed much like a method champenoise sparkling wine. After dosage, the ale goes to a warm conditioning warehouse at 60 degrees for 11 days, then to a cold 40 degrees warehouse for three more weeks.

Belgian Trappists: have a dosage added. It can be a blend of single cell yeast strains.

In the Brew Kettle

At this point, the wort is boiled to create a further break down of sugar and starch.

Hops are also added. To obtain the hop bitterness, the resin (the source of the bitterness) which is not water soluble, must be boiled for breakdown into the wort. When this happens, hop character begins to appear. The spent hops are then extracted from the wort.

A centrifuge is the next stop for the wort. Here, the unwanted proteins that cause clarity problems and give beer harsh characters, are eliminated.

Now the hot wort is passed through a cooler bringing the temperature down to the optimum fermentation temperature for the style of beer being brewed and the Brewmaster's preference.

Now on to the fermentation vessel, where a yeast strain appropriate for the style of beer and the preference of the Brewmaster is added. Yeast uses the sugars and starches as food during their respiration cycle and gives off by-products of equal parts carbon dioxide and alcohol.

There are two types of primary fermentation:

Top Fermentation: The name is derived from the fact the yeast used rises to the top of vessel during fermentation.

This yeast works best at temperatures between 59 and 78 degrees and cannot work at all below 55 degrees. This fermentation is faster than bottom-fermentation, and has a higher tolerance to alcohol. It does not convert all the dextrins present, and therefore results in a sweeter beer with more body. This process takes about one week.

Bottom Fermentation: This style gets its name from the spent yeast sinking to the bottom of the vessel.

The primary fermentation takes place at temperatures between 40 and 50 degrees. The temperature is allowed to rise, and then fall back to its starting point. It is a process that can take as long as two weeks.

The secondary phase or "lagering" is a slow, cold fermentation held between 32 and 34 degrees from two days to as long as a year. The longer the lagering, the more expensive the beer. But what a difference it makes in the taste!