|Beer production process|
Barley must undergo a germination process to convert its insoluble starch into soluble sugars used in the brewing process. Barley is stored for 2-3 months after harvest before it can enter the malt workshop to start malt production.
In order to obtain clean and consistent high-quality malt, barley needs to be air-selected or screened to remove impurities, permanent magnet drums are removed, stone removed by a specific gravity stone remover, and graded by a concentrator.
The main process of malting is: barley enters the soaking tank to wash the wheat, absorb water, and then enter the germination box to germinate and become green malt. The green malt enters the drying tower/furnace for drying, and the root remover is used to remove the roots to make finished malt. It takes about 10 days from barley to malt.
The main production equipment of the malting process is: sieve (air) separator, classifier, permanent magnet cylinder, stone remover and other impurity removal and grading equipment; wheat soaking tank, germination box/wheat turning machine, air conditioner, drying tower ( Furnace), root removal machine and other wheat making equipment; bucket elevator, screw/scraper/belt conveyor, dust collector/fan, vertical warehouse and other conveying and storage equipment.
Raw materials such as malt and rice are transported to the top of the saccharification building from the feeding port or vertical warehouse via bucket elevators, screw conveyors, etc., and after stone removal, iron removal, quantification, and crushing, they enter the gelatinization pot and saccharification pot for saccharification and decomposition into mash Liquid, filtered through a filter tank/filter press, then add hops to boil, remove heat coagulum, cool and separate
The malt is sent to the crushing tower before being sent to the brewing workshop. Here, the malt is lightly crushed to make malt for brewing. Gelatinization process The crushed malt/grain is mixed with water in a gelatinization pot. The gelatinization pot is a huge swirling metal container equipped with hot water and steam inlets, stirring devices such as stirring rods, stirring paddles or propellers, and a large number of temperature and control devices. In the gelatinization pot, the malt and water boil after heating. This is the natural acid that converts the insoluble starch and protein into a soluble malt extract called'wort'. The wort is then sent to a filtration vessel called a separation tower. Before the wort is pumped into the boiling pot, the malt husk must be removed in the filter tank, and hops and sugar are added.
Boiling: In the boiling pot, the mixture is boiled to absorb the taste of hops, and is colored and sterilized. After boiling, the wort added with hops is pumped into the cyclone sedimentation tank to remove unwanted hop residues and insoluble proteins.
Gelatinization pot: first put a part of the auxiliary materials such as malt, rice, corn and starch into the gelatinization pot and boil.
Saccharification tank: Add appropriate warm water to the remaining malt, and add the auxiliary materials boiled in the gelatinization pot. At this point, the starch in the liquid will be converted to maltose.
Wort filter tank: After filtering the puree in the saccharification tank, a transparent wort (syrup) is obtained.
Boiling pot: Add hops to the wort and boil it to give off the unique aroma and bitterness of beer.
Fermentation tank maturation tank: Add brewer's yeast to the cooled wort to make it ferment. The sugar in the wort is decomposed into alcohol and carbon dioxide. After about a week, a "tender beer" can be produced, and then it will mature after dozens of days.
Cooling and fermentation: After the clean wort is pumped out of the whirling sedimentation tank, it is sent to the heat exchanger for cooling. Subsequently, yeast is added to the wort and the fermentation process begins. During the fermentation process, the artificially cultivated yeast converts the fermentable sugars in the wort into alcohol and carbon dioxide to produce beer. Fermentation takes place within eight hours and proceeds at an accelerated rate, accumulating a high-density foam called'wrinkle foam'. This bubble reaches its highest stage on the 3rd or 4th day. From the 5th day, the fermentation rate slowed down, and the froth began to spread on the surface of the wort, which must be skimmed off. After the yeast fermented all the fermentable materials in the wort, it began to form a thick sediment on the bottom of the container. The temperature gradually decreases, and the fermentation is completely over after 8 to 10 days. In the whole process, strict control of temperature and pressure is required. Of course, different beer and different production processes lead to different fermentation times. Generally, the fermentation process of lager beer takes about 6 days, and the fermentation process of lager beer takes about 5 days. After the fermentation, most of the yeast settles on the bottom of the tank. The brewers recycle this part of the yeast for use in the next tank. After the yeast is removed, the product "tender beer" is pumped into the post-fermentation tank (or called the maturation tank). Here, the remaining yeast and insoluble protein further settle down, making the beer style gradually mature. The maturity time varies with beer varieties, generally 7 to 21 days. After the post-fermentation and mature beer, all remaining yeast and insoluble protein are filtered out in the filter, and it becomes the sake to be packaged.
Bottling and canning machine: The brewed beer is first filled into beer bottles or beer cans. Then, after strict inspections such as visual inspection and liquid inspection machine, it is packed into beer crates and shipped out of the factory.
Bottle washing machine: wash recycled beer bottles.
Empty bottle inspection machine: Very small scars will not be let go.
Sensory inspection: The newly brewed beer every day is actually tasted by a dedicated person in charge. Only after ensuring its quality, will the delicious beer be presented to you.
Before packaging, each batch of beer will pass strict physical and chemical inspection and sensory evaluation by the taster before it can be sent to the packaging line. The packaging of finished beer often has several packaging forms: bottled, canned and barreled. Coupled with the difference in bottle shape and capacity, the difference in labels, neck sleeves and caps, and the diversification of outer packaging, this constitutes a dazzling array of beer products in the market. Bottled beer is the most popular form of packaging, and it also has the most typical packaging process, that is, bottle washing, wine filling, sealing, sterilization, labeling and boxing.
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