How to make Heineken beer in Russia
What is beer? Barley malt, hops, water and yeast. In the world of 40 thousand beers, made from the same four ingredients, and everyone has different tastes. How it all to mix and prepare to get a tasty beer?
The branch of "Siberian Heineken Brewery" is part of the HEINEKEN in Russia since 2004. The plant was built in 2003 and is equipped with ultra-modern German equipment. According to the level of automation "Siberian Heineken Brewery" is considered one of the best in Russia.
The plant produces 8 brands: "Zlaty Bazant", "Bochkarev", "Three Bears", "Zhiguli", "Free Siberia", "Hunting", "PIT" in 2012 - "Ostmark Helles Beer". In 2011, we started production of new beers "Three Bears Crystal", "Three Bears Alpine", "Hunting the Dark."
Oddly enough, but the "Siberian Heineken Brewery" does not let himself "Heineken". To create a Heineken beer need horizontal tanks, and "Siberian Heineken Brewery" is equipped with a vertical. But more on that below.
Production capacity is 1, 7 million hectoliters of beer per year.
It begins with malt.
The history of beer Heineken started at a time when the company's founder was able to fundamentally improve the beverage preparation formula applied brewery, which by that time had already existed for 251 years. Then developed the recipe and still persists in the strictest secrecy, but the requirements to ensure that the excellent properties of beer are still valid until now: high-quality ingredients and strict control at all stages of production. Beer Recipe company HEINEKEN involves the use of only natural ingredients. Ingredients are all 4 major components: barley, hops, yeast and water. At the same time, every kind of beer has its own flavor, color and aroma. This is the magic brewing.
The brewing process:
Stage №1. Malting
Malting - a process of soaking and germinating barley, germinating malt drying and removing germs. Malting is necessary that the substance could barley go into the water and turned the wort - the basis of fermentation.
In the photo a ready-to-use malt, delivered to the "Siberian Heineken Brewery" by rail from various Russian suppliers.
The next stage of the malting - crushing malt. Grain paved in solododrobilku to grind, to result in a husk, grits and flour. There are several ways of crushing: dry, dry grinding and crushing conditioned with the addition of water.
In the photo silos that store malt and barley.
silos with malt.
In the "Siberian Heineken Brewery" used the latest style - grain after this treatment becomes soft, loose and easy. In addition, this method is safer than others.
In the photo podrabotochnoe branch brewery, where the crushing of malt.
Step №2. Preparation of the wort
It consists of 4 stages - mashing, filtration, boiling and cooling lighting.
Mashing - that the process is kept secret brewers. In fact, beer is invented at this stage. The bottom line is that the mashing occurs when heated with a certain temperature range. The secret temperature and heating time. In the photo mash kettle, in which the process of mashing.
After that, the wort is filtered in a special tank.
The filtration process wort - release from the shell and grains grains.
The photo shot filtration process through the "window" vat.
At this stage it is important to achieve transparency of the filtered wort. The clear wort, better get a beer. Purification boiled wort from 60 to 120 minutes and added to it hops. On the same production step the wort adjusted to a certain density which the label is expressed as a percentage and called "extractive density Wort".
The taste varies depending on when the hops are added at the beginning or at the end of boiling. After boiling, the wort is clarified and cooled.
In the picture: the resulting wort is pumped into a hydrocyclone for lightening weighted by depositing fine particles of hops and protein.
This happens wort boiler.
Step №3. Fermentation
The resulting beverage is injected sterile compressed air, then added brewer's yeast. The air needed to the yeast can rapidly multiply the first 12-24 hours of fermentation of beer wort.
Yeast separation. The tanks are growing the yeast used in the brewing of beer.
CCT (cylindro-conical tanks) - the device main fermentation. The fermentation lasts from 6 to 8 days (for different grades) at a temperature of 9-18 degrees Celsius. On termination of fermentation "green beer" was cooled to 3 degrees Celsius, deposited yeast is removed from the bottom of CCT.
The total brewing time - not less than 14 days! The beer must CCT is at least 2 days (depending on the beers).
Technological corridors. Since the brewing process is fully automated, technological corridors are necessary in order to minimize the people's participation in the preparation of beer.
Step №4. Filtering
This final filtration of particles causing the turbidity of the beverage. After filtration, the beer is saturated with carbon dioxide gas and sent to storage.
The beer is filtered using diatomaceous earth - the sediment with a porous surface through which the liquid passes, and fine particles remain.
Through the glass you can see the still unfiltered beer.
And this is a filtered beer.
The filtration unit.
Step №5. Filling
The most spectacular stage. Beer comes to filling lines in different types of packaging for "Siberian Heineken Brewery" has three lines: Line of glass, PET line and a keg line.
Bottling - is to prepare containers (washing and sterilization), filling into containers, beer pasteurization, gluing labels and packaging.
First, wash the bottle.
Bottle washing machine.
Filling bottles of beer.
Many, many bottles of beer are going to receive their labels with the name of the brand and grade.
Already labeled. After that, the beer is packaged and sent to the warehouse.
Beer "Zlatý Bažant".
Beer "Three Bears."
Line PET. Here of such blanks are blown bottles.
is already filled with beer.
Automated inspector checks bottles on the filling quality. If the level of filling does not meet the standard, discarded bottles and beer - drained.
Line keg. On the "Siberian Heineken Brewery" beer is poured into kegs capacity of 30 and 50 liters.
This warehouse - a place where beer is awaiting its shipment to stores.
Laboratory. They conduct various analyzes of samples from different stages of beer making - from the malt, and the last beer, already bottled.
Beer is analyzed not only by the physical-chemical, but also in terms of microbiological indicators.
Power unit - here produce heat and steam for brewing beer.
Boiler room - one of the most energy efficient and environmentally friendly in Russia.
Thank you all for your attention.