Brewery Setup Blog

How does one-pot fermentation work in craft beer?

In China, the vast majority of breweries today use conical fermenters for beer fermentation. The tank itself is equipped with a cooling device, which can easily control the fermentation temperature; the conical tank is easy to operate, saves labor, and is easy to clean, and can also perform yeast recovery. Many large breweries install conical tanks in the open air to save space; in craft beer, we generally don't use that large equipment, just indoors.

The so-called "one-tank fermentation" means that the entire fermentation process is carried out in a conical tank, and the pre- and post-fermentation is not strictly divided, and the production time is shortened compared with the traditional process. Next, we will introduce the operation method in detail.

1. Commonly used LAGER fermentation process operation
The yeast inoculation temperature of LAGER fermentation is generally 6-10 °C, and the maximum fermentation temperature is 12 °C. The time from inoculation to sealing is about 5-7 days. Seal the can when the sugar content drops to 3.8-4.2°P. After the pressure rises, the tank pressure is maintained at 0.12 MPa, and the temperature rises to 12 °C, and the temperature is maintained for 5-7 days to reduce diacetyl.

After that, the temperature was lowered to 5°C, kept for one day, and then lowered to 0°C. The cooling rate is different in different stages. In the 12°C-5°C stage, the temperature is lowered at a rate of 0.3°C/h, and in the 5°C-0°C stage, the temperature is lowered at a rate of 0.1°C/h. The post-ripening stage of lager fermentation is generally 5-7 days.

2. Commonly used ALE fermentation process operation
The fermentation inoculation temperature of ALE is generally 16-18°C, which is higher than that of LAGER, and its maximum fermentation temperature can reach 20-23°C. It is about 1-1.5 days from inoculation to sealing, which is shorter. Similarly, when the sugar content drops to 3.8-4.2°P, the cans are sealed. After the pressure rises, the can pressure is maintained at 0.12-0.15MPa. After the temperature rises to 20°C, the cans are kept and timed for 5-6 days to reduce diacetyl.
The cooling process of ALE fermentation is also lowered to 5°C, stays for one day, and then cools down to 0°C. In the stage of 20℃-5℃, the temperature is lowered at a rate of 0.3℃/h, and in the stage of 5℃-0℃, the temperature is decreased at a rate of 0.1℃/h. When stored at low temperature for 5-7 days, the beer is mature.

3. Process key control points

(1) The amount of yeast added
Dry yeast: ale 30-50g/100L, lager 20-80g/100L.

(2) Temperature
Controlling different fermentation temperatures has its own advantages and disadvantages. When using low temperature fermentation, yeast produces less by-products in the fermentation process, the beer tastes better, and the foam is in good condition, but the fermentation time is long; when high temperature fermentation is used, the fermentation speed of yeast is faster, the fermentation time is short, and the equipment utilization rate High, but more by-products are generated, and the beer taste is poor.Lagers are generally fermented at 8-12°C, ale 16-20°C. In addition, pay attention to the control of winter temperature.

(3) Hygiene
Hygiene plays a vital role in beer quality, and care should be taken when inoculating yeast or dry hops aseptically. Hands should be disinfected when opening the manhole, and the outer packaging around the manhole and the yeast inoculated should also be cleaned and disinfected. The disinfectant uses 75% alcohol and is sprayed with a watering can. Be safe and do not use an open flame when sterilizing.

(4) Fermentation pressure
The fermentation pressure of lager beer is generally controlled at 0.12MPa, and ale beer is 0.15MPa. The fermentation pressure mainly depends on the final taste requirements of the product. The higher the pressure, the lower the temperature of the liquor, the more fully the carbon dioxide is dissolved, the stronger the beer’s killing power, and the rich and lasting foam.

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