Manufacturing process

As we saw in the History of beer chapter , the making of this natural beverage is based, since the time of the ancients, on a simple principle: natural fermentation of sugars and malted grain extraction with hot water. Nowadays, the whole process is complex, developed under the strict control of quality standards.


The process coordinator

Beer manufacturing process takes place in a completely closed system, using stainless steel equipment. This is fully automated, tracked and controlled from the “command and control room.” Process computers contain all the programs under which runs the brewing technology. On the monitors, there are followed all the technological parameters. Any deviation from the established levels is indicated by both optical and acoustic, so it is impossible its omission or failure to register in order of the immediate correction. All information related to the development process are recorded and stored, ensuring perfect traceability.


Beer wort production

The malt is crushed by a roller mill and it is mixed with water resulting the “leaven.” In the leaven-saccharification boiler the leaven is undergoing to a heating process at well defined temperatures, in precise intervals, so that the malt starch is converted into sugar molecules more easily metabolized by yeast.
In the furnace filter it is realised the liquid phase separation of the shells remaining from the malt grains. The equipment has a fine sieves system with which leaven filtering is done.
The clear malt wort is collected in a boiling cauldron with hops. In this equipment is added hops. An important role of this equipment is to sterilize the wort before yeast seeding. The plate cooler, the hot wort is cooled to about 10 degrees.


Yeast cell multiplication

The yeast cell is kept in sterile conditions and it is multiplied until the required amount of a batch of beer is achieved. After fermentation, the yeast is recovered from the fermentor, is stored in 27 special conditions of temperature and pressure in other sterile vessels . It is reused for another batch. Daily, it is checked the microbiological conditions and viability of yeast cells.


Fermentation

The leaven is fermented in some huge pots, fully enclosed, the wort turns into beer during 14 to 21 days. Each fermentor is equipped with three cooling areas, which automatically adjusts the temperature according to the technology requirements . After fermentation, the yeast is extracted in the bottom of the fermenter. This is equipped with automatic recovery system of carbon dioxide.


Filtering

All the yeast cells scraps, protein agglutinated debris or other fine particles are removed from beer by filtration , obtaining clear and bright beer .
Filtering is done in the filter with hundreds of horizontal plates. Beer is pumped under pressure through this filter layer which serves to retain any possible particle.
The process is always controlled by a device that measures the clearness degree of the final product, allowing beer passing only if it corresponds to the established purity level
Calming tanks
Filtered beer is stored in huge tanks where it takes place the calming and maturing process. After the required tests, the beer can be sent to bottling: bottle, can or barrel.