The first day at any job is always full of nerves. Nerves of excitement and nerves wondering what you've gotten yourself into. There are always a million questions and thoughts flooding through your head. Lots of unanswered questions that will soon be answered. Is this what I really want to do? What types of things am I going to be doing? What have I gotten myself in to?
I definitely didn't know what it was going to be like working at a brewery. As I stated in my previous post, I think every beer drinker at some point has entertained the idea of working at a brewery. I was about to find out what it's like to work at a brewery.
My internship for this semester will take place at Adirondack Brewery in Lake George, NY. Adirondack is an award-winning brewery that produces all natural, fresh non-pasteurized beers. Currently their beers can be found at the Pub which is located on-site at the brewery, and throughout New York.
One of the things that makes Adirondack's beer unique is the fact that it is not pasteurized. The bulk of the beer you find in a supermarket or on the shelves at the grocery store is going to be pasteurized. This ensures that there is nothing in the beer that will allow it to spoil while it is sitting on the shelves, as well as extending it's shelf life considerably. Unfortunately, this also produces a product that in my opinion is not a tasty as a non-pasteurized beer. Basically, you are taking a living product and killing it.
Many people know the name Louis Pasteur and have heard about pasteurization. Most people think that Louis Pasteur was working on helping to figure out a way to extend the shelf life of milk. Actually Louis Pasteur was working on a way to extend the shelf life of beer and other fermented beverages.
I arrived at the brewery around 8am and things were already in full swing. Beer was being brewed. For a winter morning the place was steamy and warm, sort of like a sauna. I would soon realize that especially on brew days, this is the sort of atmosphere I would be working in. One where coming in from the outside, you can quickly work up a sweat and soon be working in a t-shirt, even when the temperature is below freezing outside.
I was introduced to the other employees at the brewery. Since Adirondack is a small brewery, there are only 6 employees that work in the brewery. I had toured the brewery previously, but was given a quick refresher so that I could begin to get accustom to the layout and where various equipment is located.
Today I would be working with Nate. Nate is a recent transplant from New Mexico. Before becoming a full-time brewer, he actually taught high school biology and chemistry. Having someone with that particular skill set is very useful in the brewery world. Most people don't think much about it, but making beer is all about chemistry. Various chemical reactions happen that allow you to take the simple ingredients: water, malt, hops and yeast; and soon they become beer.
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| Nate with several yeast brinks full of yeast |
One of the first things that I learned is that we try and reuse yeast as much as possible. Since healthy yeast which are provided with a good, clean environment and plenty of food (sugars that are converted in alcohol in the brewing process) can multiple and continue to thrive for several generations, we can reuse them again and again.
The first step in this process is to obtain one of the tanks that we use for collecting yeast (visible in the picture above). They look like kegs but have been converted so that they can be used for collecting and storing yeast. We then rinsed out the tank to ensure that there is not old yeast or any other material that could contaminate the yeast that will be going into the tank. Once we ensured that the tank is visibly clean, we then filled it completely with Perasan.
Perasan is one of several chemicals we use to ensure that we create a sanitary environment in order to ensure that the beer will not be exposed to unwanted bacteria, and potential spoilage. Perasan sanitizes on contact so it doesn't need to sit for very long in order to be effective. This product utilizes peroxyacetic acid and hydrogen peroxide to sanitize. It is often used in the dairy industry, just another reminder that there are parallels between agriculture and brewing.
Once we are confident that the tank had been sanitize, we made sure to sanitize the line that we would be using to collect yeast from the fermentation tank (seen in the above picture in orange). Once we sanitized the line, we were ready to collect yeast. There is a bit of an art to collecting yeast. Because of the conical shape of the bottom of the fermentation tank, if you open the valve that will release whatever is at the bottom of the cone too hard, you will pull beer from the middle of the cone, rather than collecting yeast.
Also you want to ensure that you are collecting healthy yeast. Inevitably there are going to be yeast cells that are unhealthy and that have died. These will settle at the very bottom of the cone. So the first thing that we do is make sure that we get rid of these dead yeast cells and any other bits of grain and other particles that have settled out during the fermentation process.
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| Trub, German for sediment that settles at the bottom of a fermentation tank |
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| Sight Glass |
You can see in the above picture that there is a viewing chamber, which is called a sight glass. This allows us to see whatever we are transferring to ensure that we are transferring only what we want, whether it is beer, moving sanitizer, etc. Once we have healthy yeast coming through the sight glass, we can open the valve and allow healthy yeast to flow into the yeast brink.
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| Me sampling healthy yeast. It packs quiet a bite. Not the difference in color between healthy yeast and the trub below it. |
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| Nate measuring out yeast for analysis |
Once we had collected 30 gallons of yeast, we then headed in offatory (office/laboratory) to make sure that the yeast that we had collected was healthy enough to ferment another batch of beer, and that there are enough yeast cells. Ideally we are looking for at least 1 Billion yeast cells per mL. It is not a terribly complicated process. Basically we make a dilution of yeast and water, and add a coloring agent in order to be able to view the cells under a microscope.
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| Hemocytometer which is used to count cells |
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| This is the grid on the hemocytometer that is used to count cells |
When we could out yeast cells under the microscope we count the bigger boxes (4x4 white boxes) in the corners of the grid and then we count the middle 4x4 box in the center. This number is then divided by 200 which gives us the total amount of yeast cells. This particular batch had 1.62 Billion yeast cells per mL. That is plenty of healthy yeast to ferment another batch of beer.
Once we had confirmed that this yeast was healthy and there were enough cells for our purposes, we could add it to the wort (unfermented beer). This process is very similar to collecting the yeast. We sanitized a line that was hooked up to the fermentation tank. Once this line was sanitized we pushed the sanitizer out and the yeast in with carbon dioxide that was hooked up to our yeast brink.
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| | The carbon dioxide line is visible at the top of the yeast brink which helps push the yeast into the fermentation tank |
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We were also preparing for an event at the brewpub, called the Festival of Barrels. This event featured a number of our beers that were aged in various whiskey barrels to impart depth and complexity to the beer. In the picture below, Nate is filling a firkin with beer. A firkin holds 1/4 of a barrel of beer.
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| Nate filling a firkin for the festival |
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| Several firkins lined up for the festival |
Additionally, throughout the day I began to familiarize myself with hooking up hoses and using the gaskets and clamps that hold them in place. I learned an invaluable lesson to make sure that the gasket and clamp are seated properly. I made this mistake which meant that we had to take apart our line and resanitize everything. Not the biggest mistake but took an additional 10 minutes out of our day.
Overall it was a great first day. Lots to do. Lots to learn and I look forward to many more days spent in the brewery.