Appendix A

Beer-Making Process

Beer is the overall generic term for fermented malt beverages.There are only two kinds of beer: ale and lager.Within those two broad categories there are many styles.Major ale styles are pale ale, India Pale Ale (IPA), porter, stout, and barleywine. Among the major lager styles are pilsner, Mrzen, bock, and dunkles (dark lager).TM makes two ales (Saguaro Pale Ale and Sedona Stout) and two lagers (Ocotillo Amber Pilsner and Bisbee Bock).

It is the yeast that is the significant difference between the ale and the lager.Ale yeasts coagulate loosely at the top of the fermentation tank.Given the type of yeast, ales ferment best between 64 to 70 degrees Fahrenheit.Lager yeasts are more successful at colder temperatures, typically 50 to 55 degrees Fahrenheit and coagulate closer to the bottom of the fermentation tank.Lager yeasts also tend to ferment more aggressively, leaving behind less residual sweetness and flavor than ales.

Direct Materials - Beer primarily consists of four ingredients:water, barley, hops, and yeast.A clarifying agent is also used in the beer-making process.The different types of beer require different proportions of these ingredients and even slightly different ingredients (e.g., pale ale uses a pale malted barley while stout is made using a darker roasted barley).

Brewing Process - Work in the brewery is typically divided into eight steps:mashing, lautering, boiling, fermenting and conditioning, filtering, filling, and aging.

Mashing - Mashing is the first process in brewing.The barley grains are mixed with water in a large vessel.This mixture is heated with periodic breaks, or rests, at certain temperatures to allow enzymes in the malted grains to break down the starch in the grain into sugars.

Lautering - Lautering is when the mash is separated into a liquid and the residual grain.There are two stages to lautering.In the first stage, called Wort Run-Off, a liquid (or extract) is separated in an undiluted form from the used grains.The second stage is called sparging.During sparging, the extract that remains with the grains is rinsed off with hot water.The results of these two stages are combined and the result is a dark, sugary liquid called Wort.This is returned to the original mashing vessel.

Boiling - Boiling the Wort in the vessel ensures that the mixture is sterile and prevents infection.During the boiling step, hops are added to the Wort.The hops contribute bitterness, aroma, and flavor compounds to the beer.The boiling must be continuous and intense (rolling boil) and typically lasts between 60 and 120 minutes, depending on its intensity, when the hops are added and the amount of Wort expected to evaporate.The Wort is then cooled before the fermentation stage.

Fermenting and conditioning - The cooled Wort is put into a fermentation tank and yeast is added, which starts the fermentation process.This is also the point at which the product is first called beer.It is during this stage that fermentable sugars are metabolized into alcohol and carbon dioxide (the bubbles in beer).As noted above, fermentation temperatures are very different for ales versus lagers.

Fermentation takes about a week.When the sugars in the fermenting beer have been almost completely digested, the fermentation slows down and the yeast cells will naturally start to die off and begin to settle to the bottom of the tank.At TM, the fermentation tanks are equipped with cooling jackets.Therefore, conditioning can take place in the same tank as fermentation.Conditioning (also called "maturation") is when beer is cooled in the tanks to allow the yeast to settle to the bottom of the tank.Conditioning allows the flavor of the beer to become smoother and is a natural filtration process (removing cloudy material from the beer).

Filtering - The beer that comes out of the fermentation tank must be filtered prior to bottling.Filtering the beer stabilizes flavor and gives beer its gloss or "shine."Filtering removes much of the yeast and any solids (e.g., hops and other grain particles) that remain in the beer.

Filling - The filling process (also called "packaging") is putting the beer into bottles in which it will leave the brewery.At this point, carbon dioxide is added to the bottling process to increase the carbon dioxide in the beer.Cases of beer (consisting of 24 bottles) are then put into aging.

Aging - Beer is stored (aged or "lagered") in the refrigerator unit and the temperature and length of the aging will vary based on the type of beer.Ales are usually aged no more than a few weeks.The aging process is generally done at 40 to 55 degrees Fahrenheit.Lagers are similarly aged but at much lower temperatures, 32 to 45 degrees Fahrenheit, and for a much longer time (typically months).Lagering creates a cleaner, clearer beer.The refrigeration unit allows for different temperatures in different areas of the unit.

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