The Brewers Journal Nov-Dec 2017, iss 6 vol 3

The magazine for the professional brewing industry

Brewers J o u r n a l

November~December 2017 | Volume 3, issue 6 ISSN 2059-6669

Saltaire Investing in the future

40 | FOUNDERS: BREW, BUT DO IT FOR THE RIGHT REASONS

36 | LUDLOW BREWERY ON THE BEAUTY OF CASK BEER

44 | YEAST: REPITCH AND REAP THE BENEFITS

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le ad e r

improve yourself

T

he subject of quality assurance in brewing is, understandably, nothing new. But in recent weeks and months, it’s something that has come up time, and time, and time again. So it’s an issue that needs to be looked at in more detail, and it's a facet of the industry that needs collective action. This is required to ensure people’s hard work doesn’t go down the drain because some breweries aren’t paying it enough attention and people new to drinking, hopefully, good beer aren’t put off by a negative experience.

"As craft brewers become more and more ambitious with their beers, such as using Brettanomyces (a very latent yeast which can chew through almost anything) and adding fruit purees to beers, I believe it is key that they invest as much as possible in their QA system and learn as much as they can about their trade, before risking an idea on the general public, Rob Lovatt, head brewer and production director at Thornbridge tells us on page 21.

He stresses: “No-one wants to see more recalls, but let’s get something straight: a product recall is not ‘great QA’ as some devoted beer fans commented on social media, but a necessary procedure for a brewery to carry out when the brewery QA system has failed completely. What we do want to see are educated, skilled brewers creating innovative and exciting beers, brewed using the correct procedures – beers that excite the beer geeks whilst also making beer more accessible and attractive to all drinkers.”

His points are echoed in part by Moor Beer owner Justin Hawke, who recently spoke at our Brewers Lectures event in Bristol.

"Sure, if I could go back and see what I was doing in the early days and assess some of the assumptions I made with regards to brewing then some beers were probably not near the quality they are now. The same would apply to other breweries, too,” he says. “But people are opening cans and pouring out hop matter.

brewersjournal.info

editor's choice For Saltaire Brewery, it’s time to push on and further cement its positive reputation in the UK- page 30

That is not ok. Look at the whole mobile canning side of things, too. That is an issue for me. We fought, and continue to fight to get cans accepted. And while I appreciate the platform mobile canners give breweries, it also gives you a low quality platform to package beer of unknown quality.”

Hawke adds: “For so long we have had an industry where consumers thought that cans were shit. And if they now go to a market to try a canned beer and are let down in a very serious way then they are probably done with that for life. It’s very serious.”

And Alec Mull, VP of brewing operations at Founders takes the conversation towards packaging.

“Packaging is not sexy, let’s be honest. But when it comes to high-quality packaging lines," he says. "You simply have to invest. Brewers prefer to talk about IBUs and hops but it's critical to pay this area attention."

Tim Sheahan Editor

November~December 2017

3

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All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or any information storage or retrieval system, without the express prior written consent of the publisher. The Brewers Journal ISSN 2059-6650 is published bimonthly by Reby Media, 42 Crouchfield, Hemel Hempstead, Hertfordshire, HP1 1PA. Subscription records are maintained at Reby Media, 42 Crouchfield, Hemel Hempstead, Hertfordshire, HP1 1PA. The Brewers Journal accepts no responsibility for the accuracy of statements or opinion given within the Journal that is not the expressly designated opinion of the Journal or its publishers. Those opinions expressed in areas other than editorial comment may not be taken as being the opinion of the Journal or its staff, and the aforementioned accept no responsibility or liability for actions that arise therefrom.

Brewers Journal

STEINECKER

Brewing technology #GermanBlingBling #Steinecker

We do more.

co nte nt s

contents 30

40

44

21

36

Cover story 30 - Saltaire Brewery is a name synonymous with excellent cask beer. But for MD Ewen Gordon, it’s time for Saltaire to push on and further cement its reputation in the UK.

COMMENTS 21- Rob Lovatt, head brewer and production director at Thornbridge, on why breweries need to invest more in their QA systems 25- What does your quality assurance scheme achieve and what does it tell you?

David Gurr from InfinityQS asks the question 28- Un-malted cereal ingredients have been used in brewing for years, and there is renewed interest in them, says Crisp Malt

Meet The Brewer | lUDLOW 36- For somewhere like Ludlow, which has a long tradition and history of brewing, drinkers were bereft of locally, well-produced beer for decades. That was until Ludlow Brewery opened its doors in May 2006. Since then the brewery, owned by Gary Walters, has gone from strength-to-strength.

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November~December 2017

foreign focus | FOUNDERS 40- Founders exports to 25 countries across the globe with the UK its biggest export market. Its charge on these shores is led by All Day IPA, its session IPA that is popping up on an increasing number of keg fonts and in cans, too. We spoke with the team to get their views on exports, the NEIPA trend and the importance of packaging.

science | yeast 40- When most brewers are starting out, they rely on dry yeast cultures for the bulk of production. Dry yeast is very easy to use, and affordable to the point that it does not need to be reused. However, as breweries grow, they often find themselves seeking out the wider range of flavours available through liquid yeast cultures, or the other benefits of liquid yeast slurry reuse. explains Escarpment Laboratories.

Brewers Journal

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forge your own path, says MOOR B

reweries should concentrate on their own journeys

then, and that's when there were only 300 of us. My

and spend less time concerned with the wider

advice would be to focus on your own business and

changes in the industry, says Justin Hawke, owner of Moor Beer.

Hawke was speaking at the recent Brewers Lectures event, organised by The Brewers Journal, in Bristol.

During his motivational talk on leadership, Hawke

concentrate on your own path," he explained.

Hawke formed part of a industry-leading lineup of speakers that also included Chorlton Brewing Co founder Mike Marcus and Ernesto Salas, product development manager at Lallemand. The event was also completed

drew leadership principles from his time at West Point.

with compelling talks from Ed Mason, managing director

He offered a retrospect on his first 10 years in the industry

and owner of London's Five Points, Jim Wilson from

and also gave his views of where it's heading next.

Simply Hops, petainerKeg's Brett Lamont and Roger

Hawke gave examples of leadership to adopt both internally and externally, imploring attendees to know yourself and seek self improvement, be technically and

Ryman, master brewer and brewing director at St Austell Brewery & Bath Ales, In his talk, Ryman outlined the reasons behind the

tactically proficient while also taking responsibility for your

company's recent investment in a Lauter Tun for Bath

actions.

Ales.

Externally, he said brewery owners should know

He said: "Among the benefits the new equipment

their team and look out for their well being, to keep your

gives us is that it helps with competitive tendering with

team informed while also aiming to employ a team in

continental suppliers and the capital cost was actually

accordance with its capabilities.

less that the dual mash tun option.

Hawke also said those concerned with the increasingly

"There's also the desire to brew authentic European

competitive UK brewing landscape should look closer to

style lagers and it gives us flexibility to brew other beer

home before worrying about the bigger picture.

styles, alongside our traditional ales. Additionally, there

"So what if there are 1,700 breweries in the UK now?

Rewind a few years and people were also complaining

New chair in Brewing Science at University of Nottingham

T

is the opportunity to improve our extract to 98%, which is incredibly beneficial."

made David a well-known and respected face on the international brewing science circuit.

Professor Cook explained: ‘I am thrilled to have the

he University of Nottingham has announced the

opportunity to lead the highly talented team we have in

appointment of Professor David Cook to the AB InBev

the ICBS and to continue the excellent work done by my

Chair in Brewing Science, following the departure of Professor Joanne Hort earlier this year.

Cook has been an academic in the International Centre for Brewing Science (ICBS) at the University of Nottingham since its inception in 2005, working

predecessors.

"I am on record as saying that brewing research is of limited value if it is not both ‘applied’ in nature and responsive to the needs of the industry.

"Our work would have limited impact without a vibrant,

alongside former Chair Katherine Smart to help establish

profitable and technologically savvy brewing industry to

Nottingham as a global force in Brewing Science

work alongside; hence our aim is to work for the mutual

Teaching and Research.

good of the sector as a whole.

As Brewing Course Director David co-authored and

“For the University of Nottingham this means delivering

delivered the University of Nottingham’s ground-breaking

cost-effective research which delivers solutions to the

continual professional development courses for brewers,

key challenges faced by our partners in industry, as well

featuring state of the art e-learning, coupled with short

as producing highly skilled graduate brewers with the

intensive courses held at the University. His research

practical and technical knowledge to excel in their chosen

interests focus on the functionality of raw materials in

field.

brewing with particular expertise in their flavour and

"We have achieved much to be proud of in this regard

sensory impacts, as well as related topics such as the

over recent years and will continue to grow our teaching

flavour stability of beers. A successful publication

and research activities to deliver impact for the industry

record and high profile conference presentations have

and, of course, for our university.”

brewersjournal.info

November~December 2017

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Mondo sets sights on the big time with upcoming expansion M

ondo Brewing Company has cited growth from new and existing customers as the reasons behind its

latest expansion.

Battersea-based Mondo Brewing Company will boost capacity by 80% following the investment in a new brewhouse setup later this year.

The brewery, co-founded by Todd Matteson and Tom Palmer, is replacing its existing Zip Technologies setup with a new system from the Hungarian manufacturer.

It is also adding a Gruber kegging system; a two-head cleaner, one-head filler setup with output speeds up to 45 kegs per hour.

The move coincides with the addition of a new unit that Mondo will use as its cold store, freeing up significant space in the existing site that is currently used for that purpose.

This space will allow Mondo to investigate the

contributed massively to expansion at Mondo. Our Dennis

addition of a canning line to bring the process in-

Hopper IPA has performed really well for us and I’m

house, something that is currently and ably handled by

excited about how consumers will take to it now we are

Bermondsey’s Fourpure.

canning that beer. Alongside that, our All Caps American

Matteson is enthused by the brewery’s growth, which he attributes to a number of factors.

He explained: “We have been running at capacity for a while now and had planned to expand. It’s just happening sooner than we initially anticipated.

“New accounts and growth with existing clients has

New fungal chitosan aims to replace isinglass

Pilsner and Little Victories beers will follow into can, too.”

Matteson added that it has been a year of evolution for Mondo.

“We bought out our early investors in February of this year so now this business is family-owned, which we are very proud of,” he added.

been excellent.”

Plater Bio manufactures novel biostimulants and micronutrients for the agriculture and horticulture

A

new flocculant, Chitosan, is aiming to revolutionize

industries. All our products are manufactured exclusively

real ale clarification and replace isinglass

on-site in Glossop, North Derbyshire.

It is manufactured by UK-based Plater Bio and is

extracted from specially cultured fungi.

Plater Bio the only manufacturer of fungal chitosan

It manufactures natural extracts using a unique manufacturing system without the use of synthetic chemicals, heat or pressure. Unlike the vast majority of

outside of China and aims to have the new material taken

chitosan imported from Asia, Plater Bio said its chitosan is

up by the industry as a replacement for isinglass as it is

not made from prawn heads and crab shells.

more effective and is suitable for vegan and organic uses, they said.

Dr Russell Sharp, Plater Bio technical director, explained: “At Plater Bio we are very excited about

This is claimed to make the new material suitable for applications where animal waste is prohibited or where ingredients need to be vegan/halal/kosher.

Plater Bio’s Fungal Chitosan is also REACH regulation

the benefits of this revolutionary product. Initial trials

exempt as it is a natural polysaccharide, the company

have shown that fungal chitosan is a far more powerful

said.

flocculant than crab chitosan for clarifying real ale.

“We have worked with unclarified samples of beer from Pot Belly Brewery in Kettering and the results have

12

November~December 2017

In addition, this substance’s uses include removing humates and other contaminants in water treatment and protecting crops from fungi and bacterial diseases.

Brewers Journal

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Fourpure rebrands can range F

ourpure, the London-based brewery, has said it wants to make craft beer “more accessible to new

audiences” following its new can redesign.

The new cans feature extended tasting notes designed to help beer drinkers identify which beer they’d like to try.

The range will also features a creative representation of their ‘brewed and canned in London’ proposition.

Daniel Lowe, co-founder of Fourpure, explained: “Provenance is increasingly becoming a key factor in the purchasing decision for beer drinkers so we wanted to make it clear that we still brew and can in London, our home.

“Beer drinkers are increasingly knowledgeable with regards to the different flavours across beer styles -

upgraded centrifuge, a carbonation module, additional

we wanted to reflect this in our new style descriptors

indoor/outdoor chillers, malt and spent grain silos and 12

and tasting notes, and crucially make craft beer more

x 200hL fermentation tanks.

Speaking at the time, Lowe said: “We are funding this

accessible to new audiences.”

Earlier this year Fourpure announced it was to follow

most recent expansion of our business in a traditional

2016’s £1.6m investment in a canning and packing line

way through a combination of lending, borrowing and

with a new four vessel Craft-Star brewing system from

reinvestment. We are delighted that so many people

GEA and additional new equipment.

enjoy our beer and this investment will help us to

The Craft-Star brewing system is the first of its kind to hit the UK, while the £2m spend also includes an

continue this exciting path to becoming one the UK’s leading craft brewers.”

Layer Board Now Available!

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brewersjournal.info

November~December 2017

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Murphy & Son unveils new impact resistant layer board M

urphy & Son has launched a new layer board, produced in collaboration with Hallam Plastics, that

is more durable, weather resistant safe and strong than existing products.

Layer boards are a staple in every brewery and used throughout the supply line. They’re not, however, without their bugbears; prone to cracking in frosty conditions, warping under heavy use and collecting rain water.

Murphy & Son said the new layer board is designed with the brewer and brewery in mind.

It is compatible with numerous automated systems and manufactured from High Density Polyethylene (HDPE), a superior non-brittle plastic that won’t crack or split in sub-zero temperatures and is impact resistant.

It is manufactured using engineered structural foam

the company added.

Murphy & Son added: “The board’s superior manufacture is coupled with business acumen. It’s

(ESF), the board boasts a high strength to weight ratio,

100% recyclable and returnable for supply chain cost

compared to conventional injection moulding techniques.

effectiveness.

“Plus, we’ve even added a simple drainage system so rain water can no longer collect. HDPE is stronger, more durable, more rigid and more resistant to the sunlight’s

"Plus, our boards can be customised; available in a range of colours and with the option to add a logo.

“A radio-frequency identification tag facility is also

UV rays than conventional polypropylene, ensuring safer

available upon request, to enable accurate tracking, deter

loading and unloading for draymen and fewer breakages,”

theft and enhance security. We’ve left no stone unturned.”

Magic Rock “fully-committed” to indy retailers, says MD Richard Burhouse

to put out specials, the weird and wonderful beers that seem to resonate with people. It is important to keep that going.

“We still really enjoy our core, and it’s necessary to

S

ecuring a major listing at Marks & Spencer gives

keep things ticking over. But in my eyes it’s the special

Magic Rock security while allowing it to stay “fully-

stuff that keeps us relevant. It’s fun for the brewers here

committed” to independent retailers, says managing director Richard Burhouse.

Magic Rock has secured a nationwide listing with Marks & Spencer for its High Wire, Salty Kiss and Inhaler beers, a move that has resulted in the brewery significantly increasing production capacity.

An additional 500hl has been installed, increasing capacity to 1,200hl. Burhouse expects this to come online this month.

“Much of that will be taken up by the beer we will be producing for Marks & Spencer but it also means we can start to supply beers to accounts we’ve previously had to turn down, too,” he said.

The brewery’s managing director also added the

as well.”

Burhouse said that Magic Rock had been approached by major retailers in the past, but the possibility of that jeopardising existing accounts put paid to the idea.

“This new relationship allows us to secure future volume and when you’re asked who you’d like to partner with, Real Ale and M&S would be the ones. It’s a really good fit,” he said.

Burhouse was also keen to stress that the new listing would not impact its relationship with independent retailers.

He said: “I did think about it a lot. We are committed to them, the M&S listing is limited to those three beers and the opportunity to get those beers to the far flung corners

decision to supply Marks & Spencer would not impact its

to the country was really attractive. It helps our forward

production of other beers.

planning and gives us confidence and security.

He explained: “We don’t want to disrupt our ability

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November~December 2017

“It’s a consequence of us maturing as a business.”

Brewers Journal

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Fuller’s team up with six breweries for 'fuller's and friends' project

W

est London-based Fuller’s has teamed with breweries including Thornbridge, Fourpure and

Cloudwater for a new collaboration project.

Fuller’s has also worked with Moor Beer, Marble and Hardknott on the new collaboration six-pack.

The beers, which will be available at Waitrose later this year, are the result of six members of the Fuller’s brewing team partnering up with each brewer.

Together, they have created new recipes, worked through the whole brewing process from beginning to end, as well as designing the artwork and came up with about agreeing a recipe then brewing a beer, it is a great

a name.

The six pack includes a dry-hopped lager with Fourpure, a New Zealand Saison with Marble, a red

way to make friends.

“So Georgina and I asked Rob at Thornbridge, Dave

rye ale with Thornbridge, a New England IPA with

at Hardknott, Dan at Fourpure, Justin at Moor, James at

Cloudwater, a smoked Porter with Hardknott and a

Cloudwater and JK at Marble, all of whom I knew, some

homage to Extra Special Bitter with Moor Beer.

I had already brewed with but all were friends, to get

John Keeling, Fuller’s global ambassador, said: “It has

involved. What better way to get the team at Fuller’s to

been a privilege to be able to welcome these six brewers

experience the full meaning of collaboration than for

to Fuller’s home to create these new beers.

them to work with these great brewers?

“I have always enjoyed doing collaborations and to

“The levels of enthusiasm and creativity in our first

extend this to include brewers from other breweries all

meeting was so inspiring and it did not take long for

over the country seemed like it would be such fun for

recipes and trial brews to follow.

everyone.

“Collaborating on beers is much more effective when meeting a brewer face to face. Collaboration is not just

New canning facility for BAD Company

“I am looking forward to tasting all the final brews and to continue the legacy of Fuller’s and Friends with other brewers in the future.”

the same design as high speed lines. Additionally an ecologically minded water conservation tank and filtration system was installed. The line was cleverly designed by

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orkshire-based BAD Company has invested in a

Enterprise to allow integration of an existing bottling line

new canning facility that will enable the business to

already supplied from Enterprise Tondelli to maximise

can their own beers in-house, as well as offer contract facilities for other breweries.

The Dishforth brewery has called on Enterprise

labour utilisation with easy access.

The addition of a new BRB Globus Mega ADE rotary bottle labeller means that it can be used for can as well

Tondelli for a canning facility that would enable the

as bottle labelling. With the minimum print run of cans

business to meet the growing demand for its beers from

being around 50,000 and with an economic cut off point

nationwide customers.

of around 150,000 this will allow short runs to be carried

The brewery commissioned Enterprise Tondelli to provide the can filler/seamer along with the canning line ancillaries including all conveyors.

The can line starts with a high level all stainless steel can depalletiser that can handle both short and tall stacks of cans for cost saving on bulk can transport costs.

This feeds to a gravity can rinser with two channel for future can sizes such as 440 ml or 500ml and using

16

November~December 2017

out for specialist beers or local craft breweries entering the can market but seeking quality production.

The labeller can run either wraparound body labels or body and back label for maximum versatility In phase two it will be possible to run the two packaging facilities independently but without moving any of the equipment installed in phase one allowing sustainable and modular growth for the future.

Brewers Journal

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Element equipment brings Premier Stainless Systems to UK market

U

S manufacturer Premier Stainless Systems, which produces brewhouses, tanks and keg washers has

started selling it’s equipment to the UK through Element Equipment and Consultancy.

Element, which was established in April 2017 by Jon Clatworthy, will act as Premier’s distributor, providing sales and technical support to UK breweries.

California’s Premier Stainless Systems have supplied more than 600 breweries to customers including Mikkeller, Cloudwater, Stone Brewing, Pirate Life, Ballast Point, Garage Project, White Labs and Edge Brewing.

Brewing systems are available from 2-10 BBL pilot systems, or 10-40 BBL systems. These are a bespoke design, with 2-4 vessel systems, complete with HLT, CLT,

represents a great option for anybody looking for brewery equipment.”

Rob Soltys, president of Premier Stainless Systems,

pumps, heat exchanger, wort aeration, FVs, Brite tanks,

added, “At a time when the UK craft brewing industry

temperature control systems.

is flourishing, it made a lot of sense for us to work with

Jon Clatworthy, director of Element Equipment, explained: “We are naturally delighted to establish

Element to make it easier for brewers to access our range.

“We have worked with Cloudwater and Lovibonds

a partnership to supply Premier’s range of brewery

breweries in the UK, and we look forward to the

equipment to craft brewers across the UK.

opportunity of working with more British breweries in the

“The UK craft beer market is in an extremely exciting phase, and I know that brewers will welcome the

future”.

Element also offers added distillation systems for

opportunity to consider Premier equipment for their

craft spirits. The business is the European agent for HBS

businesses.

Copper, based in Barlow, Kentucky. They supply stills for

“Premier’s reputation for quality equipment at pricing

commercial and hobbyist distillers, all made from high

which offers real value for money, along with the

grade copper and Element is seeing a lot of breweries

service and backup which can be provided by Element

taking an interest in these systems.

Wimbledon Brewery launches three new beers

The first beer in the Winter Collection, which launched in October, is the XK Autumn Ale 3.5%. Prentice said the XK as the “baby brother” of the XXXK barley wine. Using

W

imbledon Brewery has announced the

the residual weaker sugar wort from the brewing of the

introduction of three beers, inspired by the

high strength barley wine, Wimbledon have brewed this

original Brewery which burned down in 1889. The origin

‘small beer’, adding chocolate and caramel malts to add

of the idea was the discovery of a price list from the old

further body and depth of flavour.

brewery, then based in Wimbledon Village.

Master Brewer Derek Prentice explained: "Traditionally,

The XK was followed by a bigger brother in the shape of Wimbledon’s XXK Winter Ale, 4.8%, with a spice and

beer strength was denoted by Xs – so an ‘X’ beer would

dried fruit character. The XXK incorporates malted wheat

be a ‘mild’, ‘XX’ a stronger brew and ‘XXX’ the strongest

to add a silky texture and give a creamy head. In keeping

(often also known as a barley wine) – typically at between

with the Winter theme,

8-13% alcohol. XXXK – the K denotes a ‘keeper’ – could be kept and aged for many months or even years.

"Since (Wimbledon Founder) Mark Gordon showed

Finally the big beast itself, the XXXK (circa 10%) Barley Wine, which will be put into bottles and casks in mid-November to mature. Once Prentice and his team

me the old price list, I’ve wanted to make our own

are happy with the results, the finished bottles will be

interpretation of an XXXK. This led us to the beers we’re

released – just in time for Christmas. The remainder of the

releasing this Autumn.”

brew will slumber in cask until 2018.

18

November~December 2017

Brewers Journal

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Q uality

assurance

co m m e nt

A rising tide It is key breweries invest as much as possible in their QA system, and learn as much as they can about their trade, before risking an idea on the general public, explains Rob Lovatt, head brewer and production director at Thornbridge.

five brands of bottle conditioned beers available in the UK. I suspect yet again that the reason to shy away from bottle conditioning was to ‘allow the brewers to sleep at night’. Bottle conditioning certainly brings something to the table, namely improved resilience to oxidation and a softer, more natural form of carbonation.

Here is a relatively detailed explanation of bottled conditioning and the various ways to approach it: https:// beerandbrewing.com/dictionary/iKSxvCoDdk/bottle-

by rob lovatt

conditioning/ At Thornbridge, we centrifuge the beer bright, measure the CO2 level, then calculate the correct

A

amount of sugar solution we need to add to obtain the

but the entire UK craft brewing industry. Until I received

bottle conditioning. Namely these are:

few days ago, I was sent an e-mail by a head brewer from a regional brewery

desired level of in-pack carbonation.

Finally, we inoculate the beer with 0.75-1.0 million

commenting on the spate of exploding

cells/ml of Champagne yeast. We approach wheat beers

cans and product recalls that has hit the

slightly differently, by ‘krausening’ each batch of wheat

craft brewing industry recently.

beer from a lager fermentation, but again making the

One of his main concerns was that these product

recalls would tarnish not just the breweries involved, this e-mail, I hadn’t really considered it from this angle.

necessary calculation to hit the desired level of CO2.

I mentioned earlier about the ‘inherent’ problems of u Introducing an infection into a previously

However, after ‘chewing the cud’, I believe he has a valid

microbiological clean beer. This could be either during

point, particularly if somebody was injured as a result of

the dosing of the yeast or sugar or a very small number of

an exploding vessel.

bacteria which, under bright conditions, wouldn’t cause

One thing I have always advocated and pushed for is

problems, but as soon as there is any form of autolysis

fresh beer. Not only fresh beer, but beer which has had

from the yeast it acts as a food source, reinvigorating the

minimal processing and certainly has not pasteurised. As

latent bacteria.

a brewer once said to me, ‘Pasteurisation allows brewers

u The refermentation of the sugars stalling, resulting

to sleep at night’. What makes pasteurisation so attractive

in an under carbonated beer ( this is one of the reasons

from a QA and safety point of view is that it doesn’t matter

I would suggest always using fresh healthy yeast, rather

what has gone on upstream.

than tired, stressed yeast from the primary fermentation).

Even a beer infected at the last possible moment

u The brewer incorrectly calculating the level of

during packaging would have no issues, as it is heated

fermentable sugars, resulting in over carbonation, and in

sufficiently in its final container to kill any yeast or bacteria

the worst case scenario – exploding bottles or cans.

which may have been inadvertently introduced. I know

Out of the three scenarios, it’s the latter which would

for a fact that some breweries in the past have not really

give most brewers cause for concern. At first glance, it

worried too much about infections upstream, as they are

might seem that the obvious mistake would be to get the

relying on the pasteurisers dealing with bacteria once the

sugar calculation wrong, which of course could happen if

beer is packaged.

a brewer was to get his decimal point in the wrong place

Bottle conditioning used to be fairly common practice, but because of the inherent problems of bottle conditioning, it became a rarity. This blog here:

or the sugar wasn’t weighed out or mixed correctly into the beer.

A more latent problem can be when the primary

http://zythophile.co.uk/2010/01/15/a-short-history-of-

fermentation hasn’t reached its limit of attenuation, even

bottled-beer/ quotes that in the 1970’s, there were only

though the brewer thinks the fermentation is complete.

brewersjournal.info

November~December 2017

21

Co m m e nt

Q uality

assurance

So, if for example a fermentation stalled at 3 Plato and

been a huge number of new breweries start up within the

the brewer thought that his fermentation was complete,

last two years and many of them are trying to run before

but for one reason or another the true level of attenuation

they can walk, with no QA system and guided only by

was 2.0 Plato, this could equate to a significant increase in

generic homebrew books and a desire to impress social

carbonation once the beer had fermented out.

media forums with wacky beer ideas and cool branding.

The problem would only rear its head when the fresh,

In addition, I have just heard a story from another

healthy yeast is added to the beer. At Thornbridge, part

country where a brewer added pure fruit puree to a beer

of our QA system involves a limit of attenuation test of

and assumed because the beer had been filtered, there

every batch of beer we produce. Fermentations are a

was nothing to worry about! Can you imagine if Coca-

fairly hostile environment for yeast cells, with high levels

Cola had this attitude? An even worse scenario would

of CO2, alcohol and pressure, and therefore there is

be an exploding keykeg due to refermentation after

always the chance a fermentation won’t reach its true

packaging and this could have disastrous consequences.

level of attenuation. In the limit of attenuation test, we

As craft brewers become more and more ambitious

provide optimal conditions, a high yeast count, constant

with their beers, such as using Brettanomyces (a very

agitation at a steady 20c for between 24 hours and 48

latent yeast which can chew through almost anything)

hours. The result from this test in theory would be the

and adding fruit purees to beers, I believe it is key that

level the fermentation in question should attenuate to, all

they invest as much as possible in their QA system and

being well.

learn as much as they can about their trade, before risking

If we find a fermentation has a level of attenuation which doesn’t match the limit of attenuation test, then we

an idea on the general public.

No-one wants to see more recalls, but let’s get

have numerous weapons in our arsenal to complete the

something straight: a product recall is not ‘great QA’ as

fermentation. These include rousing, krausening, or using

some devoted beer fans commented on social media,

a different yeast strain to complete the fermentation.

but a necessary procedure for a brewery to carry out

However, a beer would never be signed off for packaging

when the brewery QA system has failed completely.

without it reaching its limit of attenuation, or as near as

What we do want to see are educated, skilled brewers creating innovative and exciting beers, brewed using the

damn it.

Although it appears that the number of product recalls

correct procedures – beers that excite the beer geeks

within the industry have calmed down, I still don’t believe

whilst also making beer more accessible and attractive to

that the problems have been fully solved. There have

all drinkers. A rising tide lifts all boats!

22

November~December 2017

Brewers Journal

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Join us at:

Q uality

C ontrol

co m m e nt

How Brewers can gain QA wins What does your quality assurance scheme achieve? What does it tell you?

And what would you like it to tell you? asks David Gurr from quality control software business InfinityQS

process is going wrong – and if so, allow you to dump that batch before it disappoints your hard-won customers.

But, crucially, pass/fail checks don’t tell you how right things are going!

Pass/fail data don’t show you how close to the limit you are. They don’t show trends. They don’t show you how likely you are to be able to brew a consistent quality product again in the future. You gain these benefits only

by rob lovatt

by recording the actual values (for lab data and sensory) over multiple batches, over time. Once you start doing

A

ny commercial craft brewer would say they

this you can gain some key insights.

First up, you can view a histogram distribution of

care about quality (if you’re a craft brewer

data at each stage (see chart below). This tells you how

and disagree with this statement, please let

frequent each value is, where the outliers are and where

me know so that I can stop drinking your

the majority of the values lie.

beer).

But let’s dissect that a little. What does your quality

assurance scheme achieve? What does it tell you? And what would you like it to tell you?

Even the simplest QA schemes will cover raw ingredients checks, and process automation for steadystate processes such as mashing, boiling, fermentation and conditioning temperatures.

You’ll be adjusting the length of some processes based on measurements, such as extending vorlauf based on wort clarity or extending (or curtailing) fermentation based on gravity.

Then, between each stage in the process, you’ll be doing simple pass/fail checks. Is the liquid clear enough

Then, you can start to look at the capability for each

and the correct colour? Does it taste and smell right? Is

check at each step in the process. This allows you to

the gravity good and the pH pukka? In latter stages, does

answer what should be a key question for any brewer:

it have the correct level of dissolved O₂ and CO₂?

“How capable is my production process of producing the

These checks are vital and tell you whether the

brewersjournal.info

right result?”

November~December 2017

25

Co m m e nt

Q uality

C ontrol

You can do this separately for each stage: brewhouse, fermentation, conditioning, and packaging. You can even assign a numeric score to capability. In essence, it’s a score of how easily your histogram fits within your specification limits.

Moving on, you can look at statistically significant trends within your data. If your dissolved O₂ is within acceptable limits but steadily rising over time then you may have an emerging problem in conditioning. Pass/ Fail checks won’t show this. If you have a number of OG values near the lower or upper spec limit it might be time to run your own lab check on the malt you’re buying.

Finally, you could even start to compare quality parameters between different brews. Is the process capability for the ABV of your DIPA a problem, where it’s fine for your Saison?

Managing the amount of data required for this type of analysis on paper or spreadsheets is near impossible.

26

November~December 2017

Brewers Journal

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C ereal

I ngredients

Uncovering the Mysteries of Un-Malted Cereal Ingredients Un-malted cereal ingredients have been used in brewing for hundreds, if not thousands, of years, and there is a renewed interest in them, according to Carl Heron of Crisp Malt. by carl heron

T

here is a renewed in interest in un-malted

Torrefied whole or crushed wheat

cereal ingredients, which follows decades

Torrefied wheat improves head retention, especially in

of relative indifference among smaller

wheat beers. It’s great for use as a nitrogen diluent as

brewers This has perhaps been a reaction

it adds very little soluble nitrogen to wort. It also adds

to the way international players have set

subtle depth of flavour and body.

their store by inclusions of maize or rice at the rate of over 20%. However, brewers in the craft sector are increasingly

Torrefied flaked barley

adventurous,They’re experimenting extensively with the

Torrefied flaked barley has similar benefits to torrefied

rich range of malts, but also visiting some of the excellent

wheat, but with a stronger and slightly harsher flavour.

un-malted cereals on offer.

Torrefied and micronized wheat, barley, oats, rye,

Micronized flaked maize

maize and rice all offer the opportunity to play tunes on

Micronized flaked maize adds up to 20% of grist to

the flavour notes of beer. They impact on colour, head

the tun with normal malt, and even more with high

retention, body, smoothness and mouthfeel, and can

diastatic power malt. On top of this, it improves body and

therefore offer significant help in orchestrating the overall

mouthfeel, and is gluten and nitrogen free, allowing it to

characters of beers.

be used as a diluent in coeliac-friendly beers.

Clearly brewers can’t use raw grains. In the past, those that weren’t malted might be passed through a stream of

Micronized flaked rice

hot sand by grain merchants or had to be put through a

Micronized flaked rice also adds grist to the tun, and adds

cereal mash by brewers (using up precious space in the

a greater perception of refreshment. It also accentuates

mash tun).

hop aromas, without adding taste.

The processes of torrefication and micronization have provided much more satisfactory answers. They

Micronized flaked oats

involve rapid cooking of cereals at high temperatures to

Micronized flaked oats improves mouthfeel and increased

gelatinise the starchy endosperm.

body, but also imparts a smoothness and a pleasant oaty

Torrefication, rather like the sand-based methods of

flavour on the beer.

the past, involves passing the grains through a fluidised bed of very hot air at 750 - 780°F. The cell walls of the

Both torrefication and micronization can be applied to

grains are disrupted. The grains expand, their density

many cereals, including barley, wheat, rice, maize, oats,

changes, they’re aspirated to remove dust and chaff,

and rye, creating grains ready to be used for brewing,

then sized and cooled in the ambient air. Micronization

providing their own benefits. With these products you

involves using infrared waves to rapidly heat grains until

will be able to develop a brew that consists of your

they ‘pop’. The molecules within the grains vibrate and the

preferred colour, head retention, body, smoothness, and

molecular friction causes the fast increase in temperature

mouthfeel. Of course, experimenting with malts is crucial

and rise in water vapour pressure. Once the cellular

to developing a fantastic brew, but if a beer needs a

structure has been disrupted, the starch gelatinises.

little boost in a certain area, there’s usually an un-malted cereal which can be used to save the day.

28

November~December 2017

Brewers Journal

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B r e w e ry

To u r

S altaire

Staying true to yourself Saltaire Brewery is a name synonymous with excellent cask beer, whether that’s the flagship Saltaire Blonde, its Cascade Pale or the rich Cascadian Black. But for Ewen Gordon, managing director at Shipley business, it’s time for Saltaire to push on and further cement its strong reputation in the UK brewing industry.

transformed in the years since I joined. Saltaire was something resembling a hobby that got out of hand in the early days but it was underpinned by a passion for making really, really good beers,” he says. “As the years have passed, the industry has gone off in all directions and grown exponentially but we’ve somewhat restricted ourselves, until now."

To cater for demand, the business was required to frequently add new tanks to their portfolio. But they had barely been installed when capacity limits were hit once again. So recently, Saltaire Brewery invested more than

by tim sheahan

£1m in new kit following ongoing growing demand for its beers. The new equipment more than doubles the

I

company’s brewing capacity to more than 100,000 pints

in new kit. But he is also realistic about the challenges

business was founded 12 years ago and the rise in the

they need to overcome to get the Saltaire name where he

popularity of craft beer has almost certainly played a

wants it to be.

significant part of that," says Gordon.

t’s time to breath more life into our creativity, to produce even more beers that we want to drink

per week.

The spend follows continued and growing demand

and draw further inspiration from the myriad

for its beer, especially from ASDA, Morrisons, Sainsburys

of styles we all enjoy,” explains Ewen Gordon,

and Co-op, companies that have significantly increased

managing director at Saltaire Brewery.

distribution both in terms of new lines listed and

Gordon is excited about the journey ahead for Saltaire,

and he has every right to be thanks to a £1m investment

Saltaire Brewery was established in 2005 and is

increased store availability.

“We’ve enjoyed year-on-year growth since the

"The new brew kit will be instrumental in allowing us to

dedicated to the production of high quality ales with a

grow more ambitiously over the next year, we’ve got our

contemporary twist. The Brewery is close to the UNESCO

sites set on a number of other significant developments

World Heritage site of Saltaire Village, famous for its

and additions to the business which will also support our

Victorian industrial heritage. Gordon joined the business

growth plans and enable us to get our beer out there

back in 2011 then later, taking on the role of managing

to more and more people. It’s a really exciting period of

director when Tony Gartland, owner and previously head

growth for the business, and the investments we’ve made

brewer of Saltaire, took a step back.

so far will only go to support the demand for our products

“The business and industry as a whole has truly

30

November~December 2017

on a national level.”

Brewers Journal

saltaire

brewersjournal.info

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to u r

November~December 2017

31

Saltaire has returned to equipment manufacturer Moeschle for its new kit, a 40bbl setup on which the team

for at least the next five to 10 years.

“We have worked with Moeschle for many years so

are currently outputting 320 brewers barrels a week but

when it came to investing, we wanted to return to them.

have the ability to move up to 1,000. Gordon is confident

We like longterm relationships with businesses and with

the new setup that comprises a 40-barrel infusion mash

people. Working with Moeschle has shown that,” says

tun, Copper with unique pillow-plate steam jacket and

Gordon. “With their know-how they have managed to link

also a combined whirlpool and hopback, allowing use of

the new bespoke kit into the old setup and we can also

both pellets and whole hops, will keep the brewery going

pipe beer from the new unit to the existing site. It’s a great

32

November~December 2017

Brewers Journal

relationship and the equipment is of the highest quality.”

The manufacturer added: “Moeschle UK Ltd. is honoured to have worked in close partnership with

Gordon is enthused that the new equipment setup will open new doors for the business.

“This new investment will breath life into our creativity,

Saltaire to create a state-of-the-art brewery, which we are

allow our five-strong brewing team to create new beers

sure will contribute hugely to the expansion of the Saltaire

we want to drink and draw from our inspiration. The new

brand. We look forward to supporting Saltaire in getting

kit is fantastic, it’s an exciting place to be and it will allow

the very most from their investment, and to playing a part

us to experiment,” he explains.

in their continued success.”

brewersjournal.info

Gordon wants Saltaire to experiment, and also sees

November~December 2017

33

B r e w e ry

To u r

S altaire

“

We have faith in what we do, and in this industry Ewen Gordon, Saltaire Brewery

a subtle rebrand as a possibility in the future, but not if it comprises the brewery’s reputation in the market.

“We want to rebrand and we will do it for the right reasons. I’m not interested in imposing ourselves into a new market. It would be more to freshen ourselves up.

The core of the business is changing, but it’s priorities and ethics have not. However, we are probably a much younger set of people here now, so the opportunity is there to inspire and refresh but while staying true to ourselves," he says.

Saltaire’s permanent range is based around its bestselling Saltaire Blonde and the Cascade Pale Ale. Blonde is a soft, creamy, continental style ale with a gentle hop spiciness. Cascade is an American pale ale packed with resinous, piney, grapefruit flavoured Cascade hops. The brewery splits some of the brews into blending tanks and add essences, syrups and a “bit of magic” to create flavoured fruit brews such as Raspberry Blonde and the popular black IPA, Cascadian Black.

For Gordon, he is satisfied, but not unsurprised by the ongoing success of the brewery’s core.

He says: “In Yorkshire, Blonde established itself as one of those beers that hit the nail on the head for the time. We appreciate that and built on it, and now it’s a permanent in 120 pubs in Yorkshire, sitting along as a mainstay with Timothy Taylor’s Landlord pale ale. We are in good company!”

Elsewhere, Saltaire recently celebrated the success of its Kala Black IPA 6.2%, which was awarded the Championship Trophy in the International Dark Beer competition at the 2017 International Brewing Awards.

34

November~December 2017

Brewers Journal

saltaire

b r e w e ry

to u r

“We were immensely proud to have received this amazing accolade. It recognises the creativity, skill and commitment of our brewing team to produce world-class

Core Beers

beers for drinkers to enjoy. It also pays tribute to all those that have inspired, challenged and supported Saltaire to become an international award-winning brewery – our colleagues, customers, fans, suppliers and competitors make this a tremendous global industry to be part of,” he said at the time.

Cascade Pale Ale American style pale ale with the floral aromas and strong bitterness of Cascade and Centennial hops.

(4.8 % ABV)

But now, Gordon is only looking forward and he’s excited about the new beers Saltaire can produce, and the new drinkers it can attract.

“We’ve produced many, many different beers. More than people would expect. We’ve produced 9.5% Double IPAs to Belgian Reds but each time, it has to be for the right reasons. Sometimes I feel that we’re not that far from

Cascadian Black A black IPA with the roast malt flavours of a stout and the bitterness and fresh pine and citrus grapefruit flavours of the Cascade hop. Currently unavailable.

(4.8 % ABV)

someone throwing an old shoe or sock into the beer and at that point, things will have to get back to basics,” he says. “But we’ll never be part of that conversation. Fair enough, others do what they want and they can do it well but it’s not for us. I’m more interested in the finer details, quality and consistency. You can push the envelope, sure.

Saltaire Blonde A straw coloured light ale with soft malt flavours, delicately hopped with Czech and German hop varities.

(4.0 % ABV)

Just make sure the beer is still good with it."

He adds: “The brewing industry had developed into this fantastic thing. People are pushing boundaries and there is a real enthusiasm for beer. We want to help add to that because we can sit within a number of camps. We don’t need a sub-brand, to sit in with newer breweries.

“We’ve had an intense period of investment and it is

Saltaire Pride A classic English pale bitter, with light malt base and spicy fruitiness from the Challenger, Bramling Cross and Cascade hops.

(3.9 % ABV)

going to be a nice place to be in 18 months time. We’ve done this because we have such faith in the industry and what we do. That will lead us forward.” u

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November~December 2017

35

M e e t

th e

B r e w e r

L udlow

B rewery

Going for Gold For somewhere like Ludlow, which has a long tradition and history of brewing, drinkers were bereft of locally, wellproduced beer for decades. That was until Ludlow Brewery opened its doors in May 2006. Since then the brewery, owned by Gary Walters, has gone from strength-to-strength but Walters’ views, and approach to brewing, have remained constant. And that's to produce a wellmade range of core beers that people can rely on each and every time.

Ludlow Gold is the brewery’s biggest selling beer, accounting for 65 per cent of its sales. Walters heads up the 20-barrel plant, which produces 3,200 litres per brew.

Of the five times it brews, ably assisted by brewers Chris Davies, and Joe Jacks, three of those are Gold.

Gary, who designed Gold, believes the beer’s popularity lies in it being a classic British ale.

“It’s a very traditional pale gold recipe made with old Noble Variety Hops, Goldings and Fuggles, which are grown locally at Little Lambswick Farm, Tenbury Wells.

The Gold’s popularity shows there’s still a strong call for a really good traditional golden ale. It’s well-balanced with subtle aromas,” he explains.

Walters adds: “I designed all the beers, using a tasting panel. I can’t pick a favourite beer as they are all so

by tim sheahan

different, sometimes I want to drink a pale hoppy beer, other times I might feel like a nice dark malty stout so

W

it changes from week to week! I think the beauty of our e don’t normally bother with

range of six ales is that they are varied enough to suit all

awards, to be fair. I’m too busy

tastes; we offer a couple of pale modern ales, which are

brewing beer, pottering away

more citrussy, and also the more traditional style.”

doing my own thing. That’s where I’m more comfortable if I’m honest,”

explains Ludlow Brewery owner Gary Walters.

With that in mind, you have to assume Walters has

Ludlow Brewery has come a long way since Gold marked the team’s first brew back in May 2006. Started

by Gary and Alison Walters, it only took until September of that year for the brewery to pick up its first awards at

been feeling a little uncomfortable of late. Gold, which

the CAMRA Severn Valley Railway beer festival. Walters

is brewed by the south Shropshire-based brewery, took

followed on the release of Gold with beers that included

bronze in the prestigious Golden Ale category of the

The Boiling Well, Best and a Black Knight that also

Champion Beer of Britain 2017 awards.

scooped accolades across the country.

These awards took place at the Campaign for Real

But after having successfully established the brewery

Ale (CAMRA’s) Great British Beer Festival in London and

in an old malting building on Corve Street, it became

Ludlow’s success was the latest accolade it has picked

apparent during 2008 that capacity and space were

up for its beers in recent years.

becoming issues. However, an abandoned railway shed

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Brewers Journal

Gary Walters: "I'm most comfortable brewing beer"

ludlow

on the same site as the current building presented an opportunity that was too good to ignore. A planning application swiftly followed and work on creating the new brewery began during the summer of that year.

The project was supported with assistance from The

brewery

M e e t

th e

b r e w e r

And in bottle is where Walters wants his small-pack sales to stay.

“I’m not convinced by cans, if I am honest. I have had too many cans that I haven't finished and it just seems that many of them are generally poor quality. My feeling

Rural Development Programme for England and the

is that a lot of the beers haven’t got the specification to

EU and a Shropshire Tourism Business Grant (funded

be canned, which is a mistake. But when you couple

by Shropshire Council) and brewing started at the new

that with a canning process that isn't up to scratch, then

brewery in December 2010.

something is going to give. Of course, there are some

Walters is a carpenter by trade. He had spent 20 or so years in the building trade and, in his own words, “always loved a good beer with my wife”. Time spent at pubs and beer festivals drove him on to start brewing in his garage where he developed his passion for beer.

“Like many people I took that route and went on

amazing looking cans on the shelves these days, but it’s whats inside that counts,” he stresses.

Walters’ uncertainty over cans also extends to keg beers, too.

He explains: “Too many people drink a so-called craft beer in keg and just because it is chilled, they can’t pass

from there. But it didn’t take long for me to get fed up

a negative comment on it. Like in can, there is a lot of

of brewing every Saturday to only end up with 44 pints

poor quality beer around but people are simply afraid to

though to be honest, I think I only did that five times or so

be critical of it. To put it bluntly, too many recipes haven’t

before deciding enough was enough!” he proclaims

been developed properly but they are still sent out to

By his own admission, Walters said the first day after

market regardless. It’s not on. When you are producing

deciding upon his new career, things seemed “bloody

beer, regardless of its intended vessel, you shouldn’t

crazy”.

mess around. Simply as that.”

He explains: “For a whole day, it seemed bloody crazy.

It’s that no-nonsense approach that applies to how

I was looking at converting a old immersion tank but it

Ludlow sells its beers, too. Opting to market the bulk of its

was such a palaver that we went for a 6bbl plant instead.

beers in a roughly 50-mile radius.

That was the best move we probably made early on. We

“It’s something I am very passionate about as I am anti

were very lucky finding that original maltings and all we

beer miles. That’s why we’ve never done anything on the

had to do was to persuade the site owner that a brewing

export side of things, either. It’s crazy, I don’t want to go

operation was a good use for it. It was a beautiful old

abroad and drink UK beers. I want to go and enjoy what it

place but after four years we simply ran out of space. I

is produced there,” he says.

found myself making little box rooms within other little

“There is enough diversity in global brewing not to

box rooms and there were barrels all over the yard. It was

require me to drink UK beers when I am on holiday. Look,

craft as well as graft! So the time came that we had to

I haven’t even enjoyed everything from this country yet,

move on.”

I don’t see the point of going to another place and not

The current Ludlow site is an aesthetically-pleasing facility characterised by high-arched ceilings, wooden beams and a setup that gives visitors an in-depth insight

wanting to sample the diverse numbers of beers they are likely to have on offer.”

You’d be hard-pushed though to work out when

into the brewing operation. The building houses a

Walters will next find the time to enjoy a trip overseas

20-barrel Moeschle brewhouse while bottling is handled

though, with him and the team working as hard as the day

by Edwin Holdens Bottling.

the brewery opened.

“We used to do our own bottle conditioning but it was

“We want to continue going steady while taking deep

very difficult because you could go to a local cafe and see

breathes. We’re doing 75 barrels a week and we continue

the beer wasn’t being poured right. That really jarred with

to grow. The business is profitable but we all work really

me so we decided to down the pasteurised route with

hard. I was here at 6am last Saturday, and the same on

Holdens, which is a great family run business,” he says.

Sunday. We are all hands-on but that’s the way we like it.” u

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November~December 2017

39

Fo r e i g n

Fo cu s

founders

Brew for the right reasons Founders has quietly and confidently become the 10th largest craft brewery in the US. On course to output 445,000 US brewers barrels in 2017, it exports to 25 countries. We caught up them in the biggest of these export markets, the UK, to hear about the road ahead.

much bigger celebration.

Mull was debating the issue with Dave Engbers, who co-founded the Michigan brewery with Mike Stevens some 20 years ago. A brewery that is now the 10th largest craft brewery in the US, on course to output around 445,000 US brewers barrels in 2017.

However, as Founders continues to enjoy great success in the US, the duo have made a brief visit to the UK to catch up with some key accounts, meet some new faces and to simply enjoy some new beer while at the

by tim sheahan

same time, introduce more people to their own brews.

Founders exports to 25 countries across the globe with the UK its biggest export market. Its charge on these

"Did you get that email this morning?”

shores is led by All Day IPA, its session IPA that is popping up on an increasing number of keg fonts and in cans, too.

“The one about the Harvest Ale on tap? Yeah, I did. I didn’t know it was due on just yet!”

But it’s not just the UK that has taken to the beer, which joined the brewery’s year-round lineup in 2012. Only this summer, the beer was the most ‘checked-in’ beer of

“Yeah, me neither. But I suppose we’d normally tap it for the

the summer on popular beer info sharing app Untappd,

Harvest party but we’re not having that this year.”

notching an impressive 64,795 check ins.

“True, but I want to try it. I’m p*ssed!”

growing presence in the UK, to drinkers relating to styles

D

that have resonated with UK tastebuds for many years.

Mull attributes the beer’s popularity, especially its

ave Engbers and Alec Mull are in London

“The UK has been responsible for inspiring a lot of US

but at that moment, the only place they

breweries. All we’ve done is Chuck Norris the s**t out of

want to be is back home at their brewery

them and made them our own,” he says wryly.

sampling the anticipated annual release of Harvest Ale, its 7.6% wet-hopped beer.

See, as Alec Mull, vice president of brewery operations

at Founders points out, the special beer would normally be poured for the first time at the annual harvest party.

“But I think drinkers, especially in the Northern hemisphere have often been able to relate what we’ve done in the US and vice versa. That’s one reason while All Day IPA has proved popular and we’re thankful for that.”

Other overarching reasons Mull and Engbers agree

But that particular occasion in 2017 is making way for

on us that quality, consistency and reliable packaging

the brewery’s 20th anniversary which will be, arguably, a

that has ensured the beer Founders sells, especially its

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Brewers Journal

Founders: Mike Stevens & Dave Engbers Photo: Founders brewing Co

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November~December 2017

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Fo r e i g n

42

Fo cu s

founders

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Brewers Journal

founders

fo r e i g n

fo cu s

session IPA, reach drinkers in the way they intended, even

before it all got up and running the following year. Since

if consumption is taking place two or three months after it

then, it has introduced the 15-pack to the craft market,

was packaged.

formats that have included its PC Pils, Mosaic Promise

“Packaging is not sexy, let’s be honest. But when it comes to high-quality packaging lines, when and where

and Azacca beers.

Engbers says exports, moving into cans has aided

possible, you simply have to invest in them. I know

Founders’ growth further, as has its tie-up with Mahou

brewers prefer to talk about IBUs, hops and other fun

San Miguel, which acquired a 30% stake in the business in

things rather than packaging but it is so critical to pay that

December 2014.

attention if you intend your beer to get to the consumer the way you intended,” explains Mull.

He adds: “We need to change the dialogue so that the

He says: “We’ve grown from a Michigan Brewery to a national brewery. We’re still young and we’ve been growing at a pretty aggressive clip. But a few years ago

brewing community focuses on packaging and I admit,

we looked at things and knew maintaining growth in

that is not a simple issue that can be changed overnight

excess of 60% would become a challenge as the growth

for many, many reasons. However if you have the money,

rate in the US was slowing down.

look at that side of things.

“I argued many years ago that we needed to invest

“That’s why we started looking more at the export side of things and now we export to around 25 countries. The

in a good packaging line rather than expand on the

partnership with San Miguel made sense for all parties

brewhouse side. And we’ve never looked back.”

because they knew how much expertise we had in the

Mull argues that quality packaging processes are imperative and Engbers adds that the type of beer you package is all-important, too.

US craft beer market while their knowledge in many other fields has been incredibly beneficial.”

And although Founders itself is celebrating its 20th

“I was in the UK a few months before this visit and I

anniversary, Engbers says it’s significantly easier to open

simply love the pubs here. The culture is very different

a brewery in 2017 than it was for him and Stevens back in

to what we have in the US. But I also visited a number of

the late nineties.

smaller breweries too and each one was talking about their latest New England-style hazy IPA,” he says.

Engbers adds: “Hey, this is great if you’re serving

“Access to market makes it a hell of a lot easier to open a brewery nowadays but unfortunately with that, we’re seeing people open breweries for the wrong reasons.

that beer over the bar from the brewery, or if it’s being

They are just trying to make money as quickly as possible

consumed shortly after. But for a brewery like us,

in case this whole thing could disappear,” he says.

packaging a beer like that makes me really nervous and

However, Mull has more faith in his brewing brethren.

we wouldn’t do it because if you’re packaging beers that

“I’d hope that it’s only a very small percentage that

are going to be good for up to 120 days, that isn’t a style

have that mindset when it comes to opening a brewery.

you should be looking at.

The people I know started brewing because it’s what

“I think the New England phase will be a short-lived

they wanted to do for the rest of their lives. But equally, it

trend, just don’t ask me where the next one is. Pale Ales,

amuses me when people tell me that they are opening

maybe? Either way, we won’t jeopardise quality and

a brewery but only plan to do it part-time. You’re soon

consumer experience either way by putting out beers we

going to realise that that will simply not be the case,” says

shouldn’t.”

Mull with a laugh.

Mull believes Founders are not alone in this approach either, he says.

“Working for Founders has made me feel really good that we don’t compromise on what we do. But nobody wants to take the opposite approach to things. The vast

He adds: “It’s a lot of hard work and it’s a labour of love.

Some people don’t realise how difficult it will be. But it you really want to do it, go ahead, give it your all and give it your best.

“That’s why we spent a massive amount on packaging

majority of brewers are passionate people that want to

because we made the decision to compete with the

make the best beer they can. They may not always have

Sierra Nevadas, New Belgiums and Bell’s. That would

right tools to do so, or even the knowledge at times but

help acheive our goal.

underneath it all, they want to do the best,” he adds.

Founders made the decision to move into cans in 2014

brewersjournal.info

“We knew what we had to do and we did it. So have your own goals and go for them.” u

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s c i e n c e

yeast

Repitch and Reap the Benefits

When most brewers are starting out, they rely on dry yeast cultures for the bulk of production. Dry yeast is very easy to use, and affordable to the point that it does not need to be reused. However, as breweries and brewers grow, they often find themselves seeking out the wider range of flavours available through liquid yeast cultures, or the other benefits of liquid yeast slurry reuse.

R

eusing yeast presents possible benefits to both the brewer and the owner. The most obvious reason to reuse yeast is to reduce the cost of each brew. There are several other practical benefits to reusing yeast

within the brewer - many yeast strains exhibit increased fermentation performance, flocculation, and enhanced flavour compound production when reused (repitched).

This improvement is most often observed in the 2nd to 3rd generation of the yeast. For reference, the 2nd generation of a culture is the batch of beer made with cells harvested from the initial pitch.

If performed correctly, there are no downsides.

by Nate Ferguson

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However, poor/incorrect practices in yeast management

Brewers Journal

yeast

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s c i e n c e

yeast

can cause problems. The most notable issues are

harvested. Tunneling is when the yeast cake does not

contamination and yeast health & pitching

slide into an opening below the cone and instead forms

Contamination: If a beer is contaminated, then the

a passage in which beer begins to travel through causing

yeast culture will also be contaminated. If you harvest

a loss of beer and a reduced yield of yeast. Tunneling is

the contaminated culture and use it to inoculate another

more prominent in some yeast strains and is impacted by

batch, then the contamination will be present in the

tank design and cleaning regime.

repitched beer. Sources of contamination can be from

Collecting the yeast into a brink: Now that you are

process, equipment failure, or contaminated ingredients (fruit, etc).

Yeast Health & Pitching: Ensuring healthy yeast is critical for brewers. Without a microscope and viability stain, it is not possible to directly assess the quantity and

yeast cropping

quality of a yeast culture. As a general rule, it is always better to overpitch than underpitch since underpitching is more likely to produce unpleasant flavours than overpitching.

Escarpment Laboratories recommends using proper microscope technique to count and analyze your yeast

Method 1: Crop very slowly, allowing for gravity to induce tunnel collapse. This method is slower and does not ensure as complete of a crop, but it is much easier in practice.

culture and can advise where to acquire the equipment to do so.

Three main stages of Yeast Management

S

tage 1: Yeast Cropping. Understanding the Layers: Yeast is often cropped from the bottom of the conical fermentor cone after fermentation

and cooling to ensure that fermentation has come to completion and cells have flocculated out of the beer and sedimented at the bottom. This practices ends up

Method 2: Remove the beer from the top of the cake via a racking arm or standpipe and then remove the yeast cake (this process is often benefited with CO2 agitation after beer has been removed). This ensures near complete removal of the yeast cone however more labour is required. If you have yield problems with method 1, then we recommend method 2.

pro tips

producing “3 layers� within the yeast cone which need to be managed. Layer 1 is the Trub/Dead Yeast at the bottom which contains trub (protein) which precipitates from the wort during fermentation, as well as the earliest flocculating yeast.. This portion of the cone is normally darker brown to beige in colour and must be dumped from the cone before harvesting. Layer 2 is the Ideal & Healthy Yeast which is composed of healthy, fit for fermentation and dense to moderately dense culture.

This region will be a light beige to tan in colour in lighter beers and darker in stouts/porters. This is the section of the cone you will harvest. Layer 3, the top layer, is the Poor Flocculating and Thin Yeast which is normally less useful for repitching.

Methods for removing the yeast: Removing the yeast

u Yeast slurry contains CO2 which causes the yeast to expand/foam. It is never recommended to fill a brink to the top to account for expansion. u If tunneling occurs, stopping the flow and allowing for settling will mitigate the issue. Make sure while settling occurs that the end of the collection hose is capped or shut and the brink is covered/ free of environmental contamination. u When removing yeast from a tank it is always recommended to ensure 1-4 PSI of CO2 pressure to ensure a vacuum or oxidation of beer does not occur.

from the tank is easy, however there is one variable you must keep in mind to ensure enough cells can be

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yeast

s c i e n c e

ready to harvest you need a device to hold the yeast -

meaning that the longer you store your cells the less

commonly called a brink. A yeast brink is simply an easily

nutrients the cells will have when they are added to

sanitizable container used to contain the cropped yeast

the next fermentation. Cells with low nutrients reserves

under CO2 but not under pressure. This can be as simple

when pitched have a higher risk of producing off flavour

as a clean and unscratched sanitized plastic bucket, a

and/or stuck fermentation and due to this it is always

stainless steel bucket with tight fitting lid, a converted

recommended to use the cells as soon as possible.

Cornelius or Sanke keg up to expensive custom built

Different cells will be impacted by storage different. Yeast

sanitary brinks.

strains like Saisons can be stored for long periods of time while other strains such as English Ale yeasts cannot.

Yeast storage

Using the yeast sooner is always better.

When do I know when the cells are no longer useful?

H

This is very strain-dependent, however there are a few

ow to Store Yeast: Once yeast is collected, the

general rules. We recommend using a microscope and

slurry must be kept cold in a walk in fridge (we

viability stain (either methylene blue or trypan blue) to

recommend between 0ºC and 5ºC) and away

determine viability. If the culture is less than 60-80%

from oxygen and sunlight. While in storage it is important

viable (strain dependent) it is likely time to dump the cells.

to prevent yeast stress: Head Pressure - Yeast should

Pitching yeast

not be stored under excess CO2 pressure. If using a pressurized brink, we recommend 5psi at most. Oxygen contact - Oxygen is a trigger for the cells to reenter respiration and leave dormancy. Exposing cells to oxygen will prime the cells for fermentation before it occurs, reducing the lifespan of the cells. Alcohol - Alcohol

H

ow to Pitch yeast and how much to use: How you pitch yeast is going to be based on what you are storing the yeast in - kegs are great for this

will stress out yeast cells and due to this it is normally

reason as you can push the yeast with CO2; It is important

recommended to harvest yeast from beer in the 4-6%

to depressurize the remaining yeast after use. If using

ABV range; there are some exceptions.

buckets that cannot be pressurized then your options

Can I store yeast in the cone of my fermentor? If your fermentor has glycol jackets on the cone, yes you can. A brink is however usually recommended as the

become limited to pouring yeast into the fermentor via a manway.

There are two main ways brewers pitch yeast: Pour

additional head pressure from the liquid above the tank,

yeast into the ferment (before or after wort is present; Or

residual CO2, low nutrients, higher alcohol and IBU

inject yeast into the brew during transfer

content of the cone make it a non-ideal place for yeast

Pouring yeast into the fermentor. This is the most

to remain dormant. Harvesting the cells into a brink is

common method for small breweries as it is simple, does

recommended to reduce these issues.

not require a complex system or stainless and allows

How long can I store my yeast? The main question

for sanitary buckets to be used instead of a costly yeast

everyone has when storing yeast is “how long can I store

brink. There are a few measures that must be taken into

my yeast before it is no good”

account for this method so that you do not harm the cells.

This question is best answered when you relate it to

If adding yeast before knocking out make sure your

food. If you asked “how long is my soup in the fridge good

wort cooling is on max and slowly bring the wort online. If

for” the answer is always “sooner is better”; same goes for

wort cooling is not on or is not sufficient as soon as wort

yeast.

enters a yeasted fermentor the wort will heat and kill

To explain why this is you must realize that yeast is

some or all of the yeast. A way to consistently get around

not frozen or still while dormant - it is still alive and still

this is to add your yeast after the tank has been filled.

consuming its own nutrient reserves. Yeast cells have

However, if the fermentor does not have a top manway

2 main nutrient reserves - glycogen and trehalose.

or your yeast pitch is large, then this becomes infeasible

Glycogen is the main nutrient source, while trehalose

and/or dangerous.

provides rigidity to ensure physical stability. As the yeasts cells are dormant they will consume these nutrients,

brewersjournal.info

Inject yeast in the brew during transfer. This is the most common method for adding yeast to large tanks

November~December 2017

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of wort. To do this you must pressurize the yeast brink, attach a valve to the brink and connect it to the chilled wort entering the fermentor. It is recommended for

about the author

this applications that a pump is not used however if unavoidable a positive displacement or diaphragm pump are appropriate. To ensure flow it is important to pressurize the tank to the proper PSI; if your pump places

Nate Ferguson is the co-founder of Escarpment Laboratories and an instructor at Niagara College, Canada.

10PSI onto the line and your brink is pressurized to 10PSI then no yeast will leave the device. If no yeast is leaving then it is recommended you increase the pressure on the brink. A scale is normally used to measure the amount

what you as a brewer are trying to do and how the strain

of slurry entering the wort - as the slurry is removed the

you are working with operates. In general English and

weight will decrease allowing for controllable pitching.

Belgian strains are comfortable at the lower end of the

How much yeast should I pitch? In order to determine

range, while high gravity beers and Lagers should be

the amount of yeast to add to the tank we need to first

pitched at the high end of the range, especially when

determine a few parameters of the yeast - Its viability and

repitching.

its concentration. Viability is the % of the cells within the

What else can/should I do while pitching yeast? While

population that are alive. For example, if I have 100 cells

repitching yeast it is very important to oxygenate your

however only 90 of them are alive our culture is said to

wort just prior to or during yeast pitching. Oxygenation is

be 90% viable. Concentration is the quantity of cells per

commonly performed with a sintered stone (carbonation

mL of slurry. This is important as different cultures will

stone) in the wort stream between heat exchanger and

flocculate more or less intensely resulting in different

the fermentor. The biggest problem that occurs with this

slurry thicknesses.

process tends to be a lack of a flow meter for oxygen gas

For example, English strains will becomes much more compact and tightly flocced than Lager strains. If we are working with a thin slurry then we will have to add more

volume determination; normally a PSI gauge is all that is present.

A common technique in many breweries is

litres of slurry to equal the same cell count of a thick

acid washing for the removal of potential brewery

slurry.

contaminations from the yeast culture. Resources for

The general rule of thumb is 1L of slurry per hL of beer,

yeast washing can be found online, and typically involve

however this is not an accurate measure as it does not

exposure to phosphoric acid or chlorine dioxide to help

take into account viability or cell concentration. For these

reduce bacterial load. In general, if good sanitation

reasons cell counting is highly recommended as part of

practices are followed and yeast reuse is limited to 10-15

the brewery yeast management program.

generations, yeast washing is not necessary.

You should only harvest yeast from beers that

How much yeast?

turned out the way you wanted them and are free of fermentation off flavours. If the beer has noticeable off flavours, do not collect yeast from that tank. Additionally,

T

he amount of cells you need to add for a brew is

yeast should not be harvested from sour beers as the low

going to be different for each brew. A formula for

pH environment is non-ideal for yeast health.

the amount of cells needed for a ferment is given

Using the information in this guide, any brewer should be able to familiarize themselves with the best practices

here:

0.5-1.25 million cells/mL/â °P

and practical considerations to yeast repitching. Yeast

With this equation we can see that the larger the

repitching, when implemented properly, can reduce costs

volume of wort (mL) the more cells we are going to need.

if yeast is used for multiple, and significantly reduce tank

As we increase the gravity of the brew we will also need

time, which also creates greater operational efficiency in

more cells. The rule of 0.5-1.25 million cells is based on

the cellar.

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Brewers Journal

DISCOVER LALLEMAND BREWING’S FULL RANGE OF PREMIUM BREWING YEAST

FERMENTATION RANGE 15 to 22°C (59 to 72°F) AROMA & FLAVOR Fruity, especially stone fruits BEER STYLES East Coast Style Ales ATTENUATION Medium to High

NEW ENGLAND LALBREW

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ENTER A NEW YEAST ADVENTURE

fruits like peach.

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The CANPRO filling system is a state-of-the-art, high-speed, mechanically controlled can filling system designed around proven European counter-pressure-gravity filling technology and can seaming technology. The CANPRO is designed to fill beer in a variety of can sizes and volumes offering today’s craft brewers a wide range of flexibility.

The CANPRO filling systems achieve filling speeds ranging from 80 cans per minute with (330ml cans) up to 600 cans per minute while delivering very precise fill levels, very low O2 pickup and minimal product loss.

Please contact us at info@moravekinternational.com for further information.

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Tel: (44) (0)1427 890098

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date s

&

e v e nt s

events

Brewers C ON G R E S S

The inaugural Brewers Congress, presented by The Brewers Journal, takes place in London this November

3/11/17 - 5/11/17

Celtic Beer Festival

Northern Monk, Leeds www.northernmonkbrewco.com

St Austell Brewery www.staustellbrewery.co.uk

10/11/17 - 11/11/17

Working Beer Festival Woking Leisure Centre www.wokingbeerfestival.co.uk 16/11/17 - 17/11/17

hull real ale festival Hull Minster www.hull.camra.org.uk 24/11/17 - 25/11/17

Bath Beer Festival Widcombe Social Club, Bath www.bathandborderscamra.org.uk

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25/11/2017

Dark City

November~December 2017

27/11/17

brewers congress One Great George Street, London congress.brewersjournal.info 05/12/17 - 09/12/17

Pig's Ear Beer & Cider Festival The Round Chapel, Hackney www.pigsear.org.uk 16/12/17 - 21/12/17

Essen Christmas Beer Festival Essen, Belgium www.kerstbierfestival.be

Brewers Journal

QUALITY Amazing hops from around the world and the best support for the craft brewers of Europe. enquiries@simplyhops.com +44 (0)1892 833 415

www.simplyhops.com

The premier gaThering of The professional brewing indusTry

Brewers C O N G R E S S

27 November 2017 - 8am to 5pm oNe great george street, LoNdoN

congress guide