The exclusive 2-row barley malt that we import is first stored in our silo upon arrival.

Milling is where the malt is crushed without destroying the husk and is collected in the malt bin for mashing. This milled grain mixture is called “grist.”

To extract the best from what nature offers us, we use a 6-roller mill crusher from Kunzel-Germany – characterised for its robust construction and renowned for its operational reliability.

The milled malt is collected in the grist bin before being sent for mashing.

The brewing process officially starts when the crushed grains are mixed with water to form a porridge-like mixture called the “mash”. Here, sweet unfermented beer called “wort” is created at 58°C when the malt and other cereal starches are transformed into sugars and proteins.

Lautering is the process by which the sweet liquid wort is separated from the solid spent grain. To extract the right amount of protein, sparging water is added at 76°C. This process is known as sparging. Then the separation of solid and liquid is ushered by the raking arms present inside the lauter tun while the false bottom enables clear filtration of the wort from spent grain.

Later, to optimally utilise all the raw materials we have, the spent grain that is not filtered through the lauter tun’s false bottom is transferred to the spent grain silo and is used as a favourable feed for the animals.

The holding tank’s function is as its name implies. It holds the wort before it is sent to the wort kettle for boiling.

The wort kettle works to sterilise and stabilise the wort at 100°C, which halts the sugar-to-starch conversion. This then allows us to add hops into the mixture, giving our beer its fruity, earthy, and aromatically bitter taste.

Whirlpooling is then used to separate hop pellets and trub from the wort after the wort boil. For better efficiency, our wort kettle also doubles as the whirlpool vessel through internal mechanical distinction. Here, the wort is pumped into the whirlpool vessel at a rapid velocity, usually about 15 feet per second, to cause the wort to start spinning like a whirlpool, prompting the desired separation.

EQUI-THERM TECHNOLOGY

Since a lot of heat is generated during wort boiling, we re-use the heat by re-circulating it to be used during the mashing process through Krones Equi-Therm technology leading to a higher efficacy with 30% lower energy usage.

Fermentation happens in 2 sections: primary fermentation and secondary fermentation (conditioning). During the primary fermentation process, the sugar in the wort is broken down into alcohol and carbon dioxide through yeast activity, while the second fermentation process conditions the beer to taste finer.

We also dry hop our beer by adding noble hops during the fermentation process.

The smart membrane units are self-foreseeing beer filters that filter and clean independently of one another to ensure hygienic, consistent and uncompromised beer flow.

Here the fermented and filtered beer is stored and is the stage present right before the bottling process. Filtered beer is kept at 0C until it is taken.

CO2 RECOVERY PLANT

Carbon dioxide (CO2) is essential in beer during botting to give it a crisp feel, and since it is also a bi-product of yeast activity, we use a CO2 Recovery Plant to collect the CO2 that is generated during fermentation and reuse it in the bottling process. This allows us to stay in check with our sustainable goals by enabling us to reduce our carbon footprint.

Before reaching the filling unit, bottles coming along the conveyor are checked for defects like moisture content and breakage in front of the sight light.

Our KHS filling machines that work through counter pressure filling.

We conduct a tunnel pasteurisation process to ensure a better shelf life. The pasteurisation zones of temperature vary between 35°C, 45°C, 55°C, 61°C, 63°C, and 28°C.