Step 1 : Milling
Is the process
whereby malted barley and/or wheat grains are ground in a mill between rollers.
The husk of the grain is broken roughly while the core is crushed and exposed as
coarse flour. This is then known as grist.
Step 2 : Mashing
Is the second step
in the brewing process and consists of making a porridge of the grist and hot
water. This porridge is then taken up through different steps of temperature
change to facilitate the conversion of starch into fermentable sugars. Protein
decomposition (between 45 and 52°C), beta-amylase (between 62 and 65°C) and
alpha-amylase (between 70 and 72°C) are biological processes decisive for the
flavour and the appearance of the finished beer. This mashing process takes
about two hours.
Step
3 : Filtration
A fine stainless
steel mesh at the bottom of the mash tun separates the solid and liquid
ingredients. During this process this mesh forms a thick layer of grain husks.
The liquid (the wort) slowly seeps through using this layer as a filter. What is
left in the mash tun is the draff, which is used as high quality animal feed.
Step
4 : Boiling
The wort is
transferred to the boiling vessel where it is boiled for an hour and a half.
Here the hops are added and dependent on the recipe this may be enriched with
liquid candy sugar. During the boil the proteins form blooms like cauliflower
florets.
Step
5 : the cooling
At the start of the
cooling process these florets are filtered out at the hop sieve on a thick bed
of hops harvested in Meldert near Aalst. These fresh hop flowers contribute to
the fine, extra-hoppy aroma of the finished beer.
Cold water pumped through the heat exchanger is counterflowed with the hot wort
cooling it down to 25°C.
This cooled wort is then collected in the fermentation vessels.
Step 6 : the fermentation
The wort is sowed
with a pure culture of top fermentation brewers yeast and stored for four
weeks. During the first ten days the main fermentation is at 25°C. The young
beer lagers in the same tun for the rest of the period, after draining off the
fermented yeast.
At this stage of the procedure the tuns are cooled down to 7°C.
Step 7 : the bottling
The next step in the
process is pumping the young beer into the bright beer tank (buffer tank) and
mixing it well with a dose of liquid sugar and fresh yeast. It is then put into
brown 75cl Sekt-bottles by means of the bottling machine with an automatic crown
capping device.
After refermenting for two weeks in the warm room (26°C) the beer matures for
about a month before leaving the brewery.