The Brewery
Mikrobryggeri.
Kommentar.

The Brewery

Well my interest for Brewing.

The tradition of brewing beer and mead here in Norway is virtually ancient and at one of the village?s Stave churches they found brewing logs dated back to the year 800 with the recipes neatly in scripted into a great big log.  Luckily for us Historians have translated the inscriptions from ancient Norwegian and into a readable form, as the inscriptions of the old Viking?s are hard to go by.

  From the year1100 the Gulatings law obliged all the farmers in Norway to brew a certain amount of Beer and produce a sufficient amount of barley and hops for this purpose if not it carried heavy sentences, the church in the name of the Bishop would take half their land and the King would take the rest so one can see that the locals wanting to hang on to their land had to brew a good beer. One can still find these Hop plantations and their wild offspring?s growing on the hillsides.

Several entries such as the following are found, this one dated back to 1786 the Bishop Wille describes the importance of the beer being strong enough. ?If the guests didn?t become drunk, there should rest a course upon them?. So many a guests acted drunker than they were to please their host and to show that they did not deserve the curse in doing shame to one of Gods gifts.

 Norse legend says that Odin, disguised as an eagle, spilled the secret of beer from the sky. The Norwegian brewers learnt that, if they kept the stick they had stirred their previous brew with; it would help to start the next fermentation. Coated with sticky residue, the "magic sticks" harbored millions of living yeast cells. Later called "yeast logs" some have been kept as family heirlooms.

Today, in the rural valleys of the mountainous west, almost every farmer keeps a supply of liquid yeast for home-brewing, and all say that this precious resource has been in the family "for as long as we can remember?, probably from Viking times.

 

In 1820 Norway had their first commercial brewery and by 1850 there was 343 breweries scattered around Norway.

  

All this caught my interest in 1982 when I was 14 and going to church for our christening perpetrations.

 

Worship to the ancient Gods had to be carried out and the recipes that were discovered at the Stave church had to be tried so a friend and I started gathering the equipment needed for the upcoming adventure of our first brew.  First things first we needed a "yeast log? the last Sunday of each month we had christening school so we planned to borrow one of the churches ancient "yeast logs" as the Priest was a strict old man we thought it be best not to let him in on our upcoming plans as we could easily return the log on the following class.

The log was safely secured and having Easter holidays we went on with our plans the following day using the exact recipe and instructions from the year 800.

  We thought this exiting venture went quite well; of course it took 3 days before the brew started fermenting but other than that the making of beer seemed easy bare in mind that temperature control was dome by sticking your hand in and feeling how hot it was during the various stages.  My friend scolded himself when he stuck his elbow into the still very hot wort.  All the details were described in that old recipe  (it did say to use your elbow for finding the correct temperature needed before stirring the ?borrowed magic log?.

 We let our finished brew sit in a keg until summer holidays not daring to taste it at our young age we ended up giving it to some older boys at a village summer party.

 Norwegians having Viking in their bloodline drank it all. They seemed very pleased with us right there and then, but as they ended up really sick and encountering a runny next day in addition to their killing headaches.

  They decided to settle the score, with this we were both rounded up for a good beating that following week.  Some of the same guys are good friends now and they enjoy my beer with fellow villagers.

 

This was my introduction to the fine art of brewing and it has grown on me ever since. The first few years it was hard to find information about the secrets of brewing as most of the old brewers kept their magic to them selves always keeping their skills close at hand so that no one could steal their secrets.

One always craves for more information on a serious hobby and I have been upgrading my skills and brewery ever since that first Easter day.

 

When fine magazines like BYO and Internet came along, achieving good information has become easy and it gives people a great way of being introduced to the skills and techniques of brewing.  For me it was a super upgrade from my first book on brewing dated back to 20.06.1900.

 

I can highly recommend a book called Technology Brewing and Malting in the international edition by Professor Kunze.

 

 

My latest brewery was a major upgrade and I finally ended up throwing out all the old equipment that had been put together through out the years. My first decision in planning a new setup was to use the same detergents as commercial brewers use, the only problem is that these detergents corrode copper and more or less eat aluminum.

 

Every thing had to be Stainless 316L steel with food grade quality.

Second dream was to have a brewery with that magic 1000 Liter capacity.

 

I started searching for this material and calling different companies that sell stuff a brewer could need but soon encountered that this task would take an investment much larger than any hobby brewer could even dream of so I started roaming dump sights diary plants and other factories in the food production business for used or out graded materials by this my stock of 316L grew and grew.

 When I told them that I was building a small countryside brewery they all got interested and by this day I do not know how much beer I promised the guy?s working in the mechanical and developing departments of the food industry all over Norway. I know I am sending out beer steadily.

Bare in mind there is only 4.5 million people in Norway and most things are pretty spread over great distances ?compare it to the great state of Montana?

Getting all my valuables here also took a lot of beer bribing in the trucking industry but as long it?s about beer they?re all helpful.

 

Finally I ended up with a Stainless Steel craze and lots of it.

 

The layout of the brewery had to be planned thoroughly as the space in my brew room is very limited only 3 by 4 m with a door located at each end; therefore it had to be built into the room.

At the beginning I started out and hired a welder to weld the parts that I had prepared but after 20 hours I could already feel the budget screaming so I ended up buying his tig and rod

Welder and had him instruct me in the mystique of welding after 10 hours of professional instruction I went on reading and practicing on my own.

Again this was partially paid for in the upcoming brew.

 

There were lots of obstructions and failures encountered on the way but as you can see I ended up with a 99.9% Stainless steel brew house (the lid on the boil kettle is aluminum and a stainless cone is under construction). Although not 100% finished it works very well with high brew house yields and the possibility to brew any beer one could think of.

My steam fired 3-kettle setup lets me prepare any adjuncts I wish to add to the mash or do a decoction brew with any desired percentage of the mash.

I have furnished CIP units in all the vessels witch gives me as clean vessels and transfer lines as any brewer could wish for.

 

The only parts of the brewery intended for beer are the two 1000 L high-pressure tanks. I bought these from the company that developed the bag in tank concept although expensive I purchased them with a 45% discount and the promise of 200 L beer being delivered to the company?s Christmas party. They have already pre tested the product and were so pleased that they sent me 40 pieces of their1000L Mylar liner beer bags for my tanks.

They work great as the beer is always contained in a sterile environment and it allows me to transfer beer with air pressure.

 

 

Brewery over view.

 

 

 

 

 

Mash Vessel is 800 L Farmers diary/milk cooler from 1961 in witch I have installed a slotted false bottom a powerful mash stirrer with two big paddles a circulation pump with outflow holes on top for gentle return of the wort under the clarification process at the mash out. The pump is also used for transferring the wort to the boil kettle The CIP rotor is used as the sparge sprayer for the final rinse. 

 

 

 

 

Mash Tun heat generator. The mash tun is heated by a high-pressure pump circulating 120 degrees Celsius water under low pressure 1 bar through the old cooling jacket in the fully  Insulated vessel. This gives me the ability to raise the temperature with 1 degree Celsius pr minute. Hot water is generated in an auxiliary vessel holding 30 KW of heating elements.

 

 

 

 

Adjunct and Decoction boilers.   300 L external steam heated boilers are used in case I want to do a decoction mash or add any other adjunct's.

 

 

 

 

Boiling Kettle an old Farmers diary/milk cooler from 1975. It?s slightly bigger than the mash vessel and holds 1000L this one has been stripped completely from its outer coat, foam insulation and cooling jacket surrounding the sides and bottom.  It gave me the opportunity to weld all the needed connections, this being wort inn/out and a whirlpool unit. Heating is done by gas as it gives the option of burning/caramelizing some of the wort for both taste and coloring adjustments. The boiling vessel is fitted with a Stirrer/ CIP unit and has 50 KW gas burners it all sits nicely in two concrete drainage rings normally used for creek pas through under farmland or roads.

 

 

 

Whirlpool uses the outflow for suction and has wort return angled at 90 degrees in the vessel a valve enables me to adjust the speed during whirl pooling.

 

 

 

Hop back and Wort collector is refitted as the whirlpool effect treads in place. The wort collector is furnished with a hop back for the adding of fresh aroma hops after the initial boil. Pump outlet is mounted at a 90-degree angle from the inlet ensuring a nice flow of the wort from the kettle not causing suction of the throb cone centered nicely in the kettle.

Wort Pump a powerful Alfa Laval pump serves in transporting the wort through the temperature-adjusting valve and wort filter on its way to the plate heat exchanger from where it goes on to the fermentation tank.

 

Wort Temperature control is done by adjusting an inlet valve inn front of the plate heat exchanger thereby achieving the desired fermentation temperature.

 A Wort Filter makes sure that no particles pas through the plate heat exchanger and also serves as a wort clarifier. Wort aeration is done by submerging a 30 cm Stainless steel aeration stone in the fermentation tank   high pressure 200 bar sterile oxygen is used for this task and is done at such an extent that it filters and raise/converts the cold break throb into a thick foam that is allowed to overflow the fermentation vessel through a vacuum pump.

 

Plate Heat Exchanger is an APV H17 with a capacity of 1.5 m3/h.  I got hold of it when I bought a used CIP machine from the local Diary plant. This CIP machine was used for cleaning the tanks sitting on the Diary collector trucks. They sold it as they had just bought a 125.000 US Dollar fully automated CIP unit.  God knows how much the one I bought had cost in 1989.  It had 2 800 Liter tanks 1 heat exchanger 11 Pneumatic butterfly valves 2 pumps 1 computer control board a steam generator and a bunch of 32 mm tubing.

Everything in SS 316.

 

Fermentation Tank 1000L also a farmers diary/ milk tank only that this one is a fully closed vacuum tank fitted with a vacuum pump. (This is how they transfer milk at the farms; vacuum is introduced to the tank at one end with a milk line inn at the other end milk is hereby sucked into the tank from the milking machine?s holding tank). This serves me greatly as a sterile way of getting the produced co2 out of the fermenter and out of the room leaving no hazard gas in

the brewery. Keep in mind that 1000 L fermenting wort produce approximately 4 KG pure co2 0.3 KG of this remain in the beer the rest rises out of the fermentation vessel the

Remaining 3.7 KG rising into the room is more than enough to pollute a small brewing room to a hazardous level. Especially if you have a fan running mixing the heavy co2 into the air.

  In my case I have a cooler circulating the air in the brewery letting me set the desired temperature down to +2 Celsius.

The fermenting temperature is monitored by a digital PID controller witch controls a solenoid valve that lets ice water flow through the old cooling jacket and keeps temperatures to the chosen level.

 

 

 

 

Top left: Secondary Fermenter 1000 l high-pressure tank is the one sitting on top of the other 1000L Bright beer tank. Secondary fermentation temperature is controlled by the brewery cooling unit letting me set the desired temperature down to +2 Celsius.

 

 

 

Filter  a converted steam filter graded to 12 bar working pressure. I totally rebuilt the interior to take round Kieselguhr plate filters of any micron rating desired. And it can now hold 32 plates I normally install coarse filters in the first 8 columns followed by finer filters towards the end.  Most folks around here though prefer the beer unfiltered.

 The filter is partially gravity fed but if high pressure is wanted I hook up the air compressor to the holding tank.

 

 

 

Bright Beer Tank a 1000L double insulated beer tank with a cooling jacket this pressure vessel allows me to keep the lagering temperature at any given temperature (first hookup froze a water test to a solid block of ice taking 10 days to thaw out)

Here the bright beer is carbonated with a 30 CM Stainless steel carbonation stone. Before transfer to bottles or kegs.

 

 

 

Finnaly me in my Brew House.

Brew kettle

Fermenter

Pressure tank

External Heater

Mark in Brewery

Mash tun

Plate heat

Filter

Pressure Tank

Steam Kettles

Whirlpool

Wort colector