Short, Simplified Explanation
Crushed barley is combined with hot water in a large tank where the grain’s carbohydrates are turned into sugar. After about an hour, the barley and water are separated (our barley is composted) and the water is boiled in another tank for almost an hour. Hops are added during the boil. The water is cooled and is transferred into a fermentation tank with yeast. It will ferment for 7-12 days during which time the yeast releases carbon dioxide which creates carbonation. The beer is then stored for a couple months in different tanks until it’s put in kegs or bottles.
More detailed brewing process specific to the Dave’s Electric brewery in Tempe
(Probably more than you wanted to know about how to brew beer. But if this isn’t enough, visit the brewpub and ask Dave or Scott for a brewpub tour.)
The system for Dave’s Electric Brewpub is a seven barrel package (1 barrel equals 31 gallons or 2 kegs). A 7 barrel tank is approximately 42 inches in diameter and 80 inches tall. The brewhouse consists of a hot liquor tank (HLT), a mash tun, a kettle, and various pipes, valves and controls. The HLT and mash tun can be stacked to reduce the space required. Fermentation tanks are vertical tanks with a cone shaped bottom specially designed for this process. Brite (storage) tanks are utilized to store the finished beer until served at the bar. Brewpub systems are a fraction of the size of standard brewing operations. Tanks, fittings and hose clamps are stainless steel, and all hoses and pumps are food grade.
Tap water is filtered, heated and placed into an HLT. Barley is milled (off-site) and combined with the hot water in the mash tun. Temperature and time are critical and vary depending on the type of beer being produced. After certain conditions are met, the liquid (the spent barley stays in the mash tun) is directed into the kettle where it is boiled for 45 to 60 minutes. Hops are added during the boil. The liquid is then pumped through a heat exchanger into a fermentation tank. Yeast is added to start the 7-12 day fermentation cycle. After a conditioning period, the beer is transferred into brite tanks for storage until served.
The spent grain is pulled out of the mash tun for proper disposal. All materials (tanks hoses, fittings, etc.) that come into contact with beer after the boil are cleaned using a sodium hydroxide solution, rinsed with water and then sterilized using a mild bleach solution (sanitizer). The rinse water is directed into a special process tank where solids can settle out. The ph of the water is neutralized as necessary before being released into the city sanitary sewer.
Occasionally, we add extra hops in a process called dry hopping. Brewers add bittering hops during the boil to counteract the sweet wort (water and barley). Hops are also added at the end of the boil for flavor. Dry hopping is a third addition for additional flavor in the fermentation tank.
