1. To make ten barrels (310 gallons) of beer, approximately 500 pounds of malted barley is crushed in the mill. This grain is a mixture of two row pale malt and darker roasted malts, which vary with the type of beer being made.
2. The crushed malt is mixed with hot water in an insulated tank called the "mash tun". The resulting mixture, the consistency of hot cereal, sits at 155 degrees F for one hour. During this time, enzymes in the grain convert starch into sugars. A liquid extract called "wort" is drained off the bottom of the mash tun while hot water is sprayed on the grain from above. This process, called "sparging" takes 1 1/2-2 hours, during which the wort is pumped into the brew kettle, and when finished the spent grain is removed for cattle feed.
3. Wort from the mash tun is pumped into the brew kettle and brought to a steady, rolling boil for 90 minutes. Shortly after, bittering hops are added to the boil. After 90 minutes the boil is concluded after which a second addition of hops, "the aromatic hops", are added. After the boil, sediment "trube" is allowed to settle and the hot wort is pumped through a heat exchanger, reducing its temperature to 55 degrees F for lagers, and 65 degrees F for ales.
4. Cool wort is pumped from the heat exchanger into a fermenting tank where it is mixed with pure yeast slurry. Fermentation is the metabolic process of the yeast as it consumes the simple sugars in the wort producing alcohol and carbon dioxide as byproducts. This fermentation takes 5-7 days for ales, and 14-21 days for lagers, after which the temperature of the beer is dropped to 35 degrees F. The yeast becomes dormant and settles to the bottom of the tank. Some is harvested and used to start other fermentations the rest is discarded.
5. The beer is clarified using two traditional methods. The first is passing the beer through a plate and frame filter to remove suspended yeast; the second is a traditional English form of clarification called "finings". The clear ""bright" beer is placed in a conditioning tank.
6. In the conditioning tank the beer is allowed to mature, 1 week for ales and 2-4 weeks for lagers. At this point the beer is ready to be served on tap at the bar.