How Is Our Beer Brewed

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1. We brew traditional Czech beer. We use a decoction way of mashing, slow bottom fermentation and long cold secondary fermentation.

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3. Our products are brewed with traditional Czech ingredients. No artificial colouring or hop extracts are used.

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2. We honour the so-called „Deutsches Reinheitsgebot“ - a 1516 act on beer purity, which has been the oldest valid regulation on the quality of ingredients used to this day.

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4. Each type of beer is made independently, having its own recipe.

Water – Artesian Wells

Nowadays, the brewery draws top-quality water from two artesian wells 312 and 320 metres deep. The water is of an invariable temperature of 12 – 14°C and needs no chemical treatment. It contains a minimum amount of nitrates - less than 3 mg per 1 litre of water. For instance, drinking water can contain up to 50 mg of nitrates per 1 litre of water according to the standards.

Breving House

The present brewing house comes from 1987. The technological equipment was made in Hradec Králové. The bottom parts where the technological processes take place are made of stainless steel, while the outer casing is made of copper. Two technological units are placed in the brewing house, each of which consists of:

» mash vat » mash pan » lauter tun » wort pan

I. Mashing

During the mashing, the insoluble and non-fermentable starch contained in the malt breaks down to simple fermentable sugars with the help of the malt´s enzymes. The process of mashing results in the creation of sweet non-alcoholic liquid called the wort.

Each batch takes 10 hours.

II. Lautering

Following the mashing, the product is drawn in the lauter tun, where residual grain and released proteins sink to the bottom during the so-called rest. The residual grain sedimented at the bottom of the tun creates a filtration layer. The lautering taps are open and the wort runs into the run-off tube and is drawn into the wort pan until only residual grain remains in the lauter tun (this wort is called ´first wort´). In order to utilise the maximum amount of the extract, the remaining grains in the lautering tun is sparged with hot water. The resulting wort is called ´after wort´. The lautering taps run into a run-off tube, where samples of the lautered wort are taken for an inspection. The grain residues are then drawn from the false bottom into a storage tank, the brewery subsequently selling it as a substantial fodder for livestock.

III. Boiling

The wort is brought to boil in the wort pan. Then hops are added in three rations; the amount depends on the brewing recipe. The hops and wort are boiled together, giving rise to so-called hopped wort, which is subsequently freed from sediments in a whirlpool.

Fermentation

The hopped wort is cooled down in plate coolers and then is drawn into cylindro-conical vessels (CCVs), where the primary fermentation takes place.

When the hopped wort with added yeasts is drawn into the CCVs, a process of fermentation begins, lasting around 10–15 days in accordance with the type of beer.

The yeasts are prepared by Budvar laboratory in their own propagator, which supplies the brewery with a new lot of yeasts every week. Some other breweries also purchase Budweiser Budvar’s yeasts. The used yeasts serve as a fodder for livestock thanks to their high content of vitamin B. Budweiser Budvar Brewery uses so-called bottom fermentation. Following the fermentation, the yeasts precipitate to the bottom of the tank and are drawn into storage tanks, subsequently being used for a next lot of wort.

Lagering Cellar–Secondary Fermentation

After the primary fermentation the young beer is drawn to the lagering cellar, where the secondary fermentation takes place and the beer conditions (or matures). During this time the beer gains the right flavour and aroma. The temperature in the cellar is maintained between 1–3°C all year round. The beer matures pressured by carbon dioxide. The maturing period depends on the type of beer: lager matures in 30–40 days, premium lager 80–90 days and Budweiser Budvar Czech Imperial Lager 200–250 days. During the process, the beer flavour balances and the beer matures. The conditioned beer is drawn to a filtration station, where it is filtered twice – first through a kieselguhr filter and subsequently though a cellulose (plate) filter.

Beer Filling

The bottling room consists of two filling lines, which fill 0.33 and 0.5 litre bottles. The bottles travel first to the bottle washer. Each bottle goes through a strict inspection - an automatic appliance checks how clean the bottles are after washing and if they are not defective. The beer is filled into the bottles in the filling appliance under carbon dioxide pressure. The bottles are then capped and head for a pasteurization tunnel, where they are showered with hot water. In the labelling machine the bottles are appropriately labelled.

The capacity of each filling line is
40 000 bottles an hour.

Put into operation in 2013, the can filling facility is fitted with the most modern equipment for filling 0.33, 0.44 and 0.5 litre cans, enabling also packing the cans into many practical and user-friendly packs into plastic wrap (4, 6, 8 or 12 packs) or into packaging with a carrying tape handle. The most important part of the technological unit is the filling monoblock using volumetric filling working in an aseptic environment.

HOW DO WE BREW OUR BEER