We have a simple, yet elegant steam-fired 10 bbl brewhouse (310 gallons).
We have 57 bbls of fermentaion capacity.
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The Basic Process
Step One - Mash-in Conversion
This is the initial stage of the brewing process where the milled malted barley and grains are mixed with hot water to form the mash. The mash is held to cook in the mash/lauter tub at temperatures of approximately 150 degrees fahrenheit. At this temperature, enzymes in the malt convert the starches into sugars, which the yeast will ferment later in the brewing process (this stage takes about 60 minutes).
Step Two - Recirculation
The mash is sitting on a false bottom in the mash/lauter tub. The false bottom is a screen with hundreds of small slots in it. The slots are small enough to hold the mash, but large enough to allow liquid to seep through. We use the mash (milled malted barley mixed with hot water) as its own filtration system. Draining off a few gallons and recirculating clears up the sweet liquid from opaque to translucent.
Step Three - Sparging and Wort Collection
This process involves the sugars we've created from the malt in the mash bed. We pump hot water (175 degrees fahrenheit) over the top of the mash. As it percolates through, it picks up the sugars formed during the initial mash-in and conversion stage. The sweet liquid is called wort and it is collected in the brew kettle, where the boil will soon start.
Step Four - Boil
Here's where we apply the heat to our wort. While we collect the wort, we begin heating it in the brew kettle. After we reach boiling temperature, we add our hops at three to four different times (the boil lasts from 60-90 minutes). The hops add the spicy, slightly bitter flavor to the beer, and also give it its pleasant aroma. We take great care to add just enough hops, enough for flavor and to offset the sweetness of the malt, but not too much to make it bitter. The boil also serves to sterilize the wort, so that the yeast can do its job without any risk of other, unwanted microorganisms.
Step Five - Run-off and Yeast Pitching
No, the yeast doesn't play baseball. Pitching refers to adding the yeast to the boiled, but cooled wort. After boiling, we cool the wort through a plate heat exchanger, and pump it into cone-bottomed fermenters (cooling of the wort takes about 60 minutes). During the beginning of this process, we pour the yeast into the fermenter so that the yeast and wort mix well. It is here where the wort actually becomes beer. We call it green beer, because it is so young
Step Six - Fermentation and Aging
It may look like things are quiet in the brewery, but there's a lot happening in the fermenters. During fermentation, the yeast will eat the sugars we provided for them in the brewing process and transform it into alcohol and carbon dioxide. After 5-7 days, the yeast has eaten all the available sugars. We then cool the tanks causing the yeast to precipitate to the bottom of the cone, where we can draw it off into a sanitized container, and reuse this yeast on our next batch. After the yeast is removed, the beer is left to age at this cooler temperature, This process allows for a smoothing and maturing of the beer. as well as...DRY HOPS!!!!!!!
Step Seven - Packaging
The last step in the brewing process is packaging and carbonation. Next the beer is either bottled, caned or moved to a holding tank where it carbonated and kegged.
Brewing Innovative Ales
in Small Batches / Erie PA
We focus on quality and innovation. We are an American Craft Brewery: happy to 'borrow' processes and techniques from British, German and Belgian traditions.
Contact us with any questions/comments and be sure to follow us on Facebook.
Where To Buy
Too many locations between Pennsylvania, New York, Delaware & New Jersey so ask for Lavery Brewing Company at your local Grocery, Pub, Bottle Shops and beyond.
Penn Beer Company
1825 E. 12th St
Erie, PA 1651
85 36th St
Pittsburgh, PA 15201
139 N. Patterson St
State College, PA 16801
1800 Pennsylvania Ave
York, PA 17404
Bella Vista Specialty Beer Wholesale
755 S. 11th Street
Philadelphia, PA 19147
Mid State Beverage
1805 East 3rd Street
Williamsport, PA 17701
800 South 4th Street
Hamburg, PA 19526
Try It Dist
4155 Walden Ave,
Lancaster, NY 14086
2 Commerce Drive,
Moorestown, NJ 08057
Lavery Brewing Co.
128 W. 12th St
Erie, PA 16501
Phone: (814) 454 0405