Firstly, we source our 100% natural ingredients. We crush – or “mill” – the malt, which enables water to enter the malt during the next stage of the process. All our milling is completed at the Maltings.
The malt is mixed with water at a temperature of around 70°C and put into the mash tun. The mash is kept at 64-65°C for 90 minutes. At this point we collect spent grains, which local farmers can use as cattle feed.
The sweet liquid, called wort, is drained off and pumped into our copper, this process is called lautering. The mash is then sprayed with hot water (78°C) to rinse out as much of the sugars as possible.
Once we’ve reached the correct volume of wort in the copper we begin the boil. After 2 hours the bitter hops are added and one hour later come the aroma hops. After 10 more minutes the brew comes off the boil.
The whirlpool pump then creates a ‘swirling’ effect within the copper and results in a separation of the hops and ‘heat’ break in the middle of the copper, producing a very clear, clean and hot wort.
Before cooling the wort to 20°C oxygen is injected to prepare a happy environment for our yeast. Cold water enters the heat exchanger at 10°C and leaves at 70°C. The wort is then fed into the fermentation vessel.
As soon as all of the wort in the vessel has been collected, yeast is added. The temperature then slowly rises to 25°C over the next 4-5 days. The yeast is ‘cropped’ and stored for the next brew. We then chill the fermenting vessel.
Once the beer is cooled to 8°C it’s transferred into our maturation vessels where the sediment drops to the bottom. Over a 7 day period, the beer further ferments and forms carbon dioxide, giving the beer a little fizz.
We fill our casks directly from the maturation vessels.
Our second fermentation in the bottle produces what’s known as ‘bottle conditioned beer’. This process carbonates the beer naturally.