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Process in beer production
the brewing of beer
2=the chemical details on the conversion of sugars into ethanol by fermentation

Brewing is the production of beer by steeping a starch source (commonly cereal grains, the most popular of which is barley) in water and fermenting the resulting sweet liquid with yeast. It may be done in a brewery by a commercial brewer, at home by a homebrewer, or communally. Brewing has taken place since around the 6th millennium BC, and archaeological evidence suggests that emerging civilizations, including ancient Egypt, Since the nineteenth century the brewing industry has been part of most western economies. The basic ingredients of beer are water and a fermentable starch source such as malted barley. Most beer is fermented with a brewer's yeast and flavoured with hops.]] Brewing has taken place since around the 6th millennium BC, and archaeological evidence suggests emerging civilizations including China, ancient Egypt, and Mesopotamia brewed beer. Descriptions of various beer recipes can be found in cuneiform (the oldest known writing) from ancient Mesopotamia. In Mesopotamia the brewer's craft was the only profession which derived social sanction and divine protection from female deities/goddesses, specifically: Ninkasi, who covered the production of beer, Siris, who was used in a metonymic way to refer to beer, and Siduri, who covered the enjoyment of beer. As almost any cereal containing certain sugars can undergo spontaneous fermentation due to wild yeasts in the air, it is possible that beer like beverages were independently developed throughout the world soon after a tribe or culture had domesticated cereal. Chemical tests of ancient pottery jars reveal that beer was produced as far back as about 7,000 years ago in what is today Iran. This discovery reveals one of the earliest known uses of fermentation and is the earliest evidence of brewing to date. In Mesopotamia, the oldest evidence of beer is believed to be a 6,000 year old Sumerian tablet depicting people drinking a beverage through reed straws from a communal bowl. A 3900 year old Sumerian poem honouring Ninkasi, the patron goddess of brewing, contains the oldest surviving beer recipe, describing the production of beer from barley via bread. The invention of bread and beer has been argued to be responsible for humanity's ability to develop technology and build civilization. The earliest chemically confirmed barley beer to date was discovered at Godin Tepe in the central Zagros Mountains of Iran, where fragments of a jug, at least 5,000 years old was found to be coated with beerstone, a by product of the brewing process. Beer may have been known in Neolithic Europe as far back as 5,000 years ago, and was mainly brewed on a domestic scale. Ale produced before the Industrial Revolution continued to be made and sold on a domestic scale, although by the 7th century AD beer was also being produced and sold by European monasteries. During the Industrial Revolution, the production of beer moved from artisanal manufacture to industrial manufacture, and domestic manufacture ceased to be significant by the end of the 19th century. The development of hydrometers and thermometers changed brewing by allowing the brewer more control of the process, and greater knowledge of the results. Today, the brewing industry is a global business, consisting of several dominant multinational companies and many thousands of smaller producers ranging from brewpubs to regional breweries.

There are several steps in the brewing process, which may include malting, mashing, lautering, boiling, fermenting, conditioning, filtering, and packaging. The brewing equipment needed to make beer has grown more sophisticated over time, and now covers most aspects of the brewing process. Malting is the process where barley grain is made ready for brewing. Malting is broken down into three steps in order to help to release the starches in the barley. First, during steeping, the grain is added to a vat with water and allowed to soak for approximately 40 hours. During germination, the grain is spread out on the floor of the germination room for around 5 days. When kilning is complete, the grains are now termed malt, and they will be milled or crushed to break apart the kernels and expose the cotyledon, which contains the majority of the carbohydrates and sugars; this makes it easier to extract the sugars during mashing. Mashing converts the starches released during the malting stage into sugars that can be fermented. The milled grain is mixed with hot water in a large vessel known as a mash tun. In this vessel, the grain and water are mixed together to create a cereal mash. During the mash, naturally occurring enzymes present in the malt convert the starches (long chain carbohydrates) in the grain into smaller molecules or simple sugars (mono , di , and tri saccharides). This "conversion" is called saccharification which occurs between the temperatures The result of the mashing process is a sugar rich liquid or "wort", which is then strained through the bottom of the mash tun in a process known as lautering. Prior to lautering, the mash temperature may be raised to about (known as a mashout) to free up more starch and reduce mash viscosity. Additional water may be sprinkled on the grains to extract additional sugars (a process known as sparging). The wort is moved into a large tank known as a "copper" or kettle where it is boiled with hops and sometimes other ingredients such as herbs or sugars. This stage is where many chemical reactions take place, and where important decisions about the flavour, colour, and aroma of the beer are made. The boiling process serves to terminate enzymatic processes, precipitate proteins, isomerize hop resins, and concentrate and sterilize the wort. Hops add flavour, aroma and bitterness to the beer. At the end of the boil, the hopped wort settles to clarify in a vessel called a "whirlpool", where the more solid particles in the wort are separated out. After the whirlpool, the wort is drawn away from the compacted hop trub, and rapidly cooled via a heat exchanger to a temperature where yeast can be added. A variety of heat exchanger designs are used in breweries, with the most common a plate style. Water or glycol run in channels in the opposite direction of the wort, causing a rapid drop in temperature. It is very important to quickly cool the wort to a level where yeast can be added safely as yeast is unable to grow in very high temperatures, and will start to die in temperatures above After the wort goes through the heat exchanger, the cooled wort goes into a fermentation tank. A type of yeast is selected and added, or "pitched", to the fermentation tank. or fined in the cask.

Mashing is the process of combining a mix of milled grain (typically malted barley with supplementary grains such as corn, sorghum, rye or wheat), known as the "grist" or "grain bill", and water, known as "liquor", and heating this mixture in a vessel called a "mash tun". Mashing is a form of steeping, and defines the act of brewing, such as with making tea, sake, and soy sauce. Technically, wine, cider and mead are not brewed but rather vinified, as there is no steeping process involving solids. Mashing allows the enzymes in the malt to break down the starch in the grain into sugars, typically maltose to create a malty liquid called wort. There are two main methods – infusion mashing, in which the grains are heated in one vessel; and decoction mashing, in which a proportion of the grains are boiled and then returned to the mash, raising the temperature. Mashing involves pauses at certain temperatures (notably ), and takes place in a "mash tun" – an insulated brewing vessel with a false bottom. The end product of mashing is called a "mash". Mashing usually takes 1 to 2 hours, and during this time the various temperature rests activate different enzymes depending upon the type of malt being used, its modification level, and the intention of the brewer. The activity of these enzymes convert the starches of the grains to dextrins and then to fermentable sugars such as maltose. A mash rest from activates various proteases, which break down proteins that might otherwise cause the beer to be hazy. This rest is generally used only with undermodified (i. e. undermalted) malts which are decreasingly popular in Germany and the Czech Republic, or non malted grains such as corn and rice, which are widely used in North American beers. A mash rest at activates β glucanase, which breaks down gummy β glucans in the mash, making the sugars flow out more freely later in the process. In the modern mashing process, commercial fungal based β glucanase may be added as a supplement. Finally, a mash rest temperature of is used to convert the starches in the malt to sugar, which is then usable by the yeast later in the brewing process. Doing the latter rest at the lower end of the range favours β amylase enzymes, producing more low order sugars like maltotriose, maltose, and glucose which are more fermentable by the yeast. This in turn creates a beer lower in body and higher in alcohol. A rest closer to the higher end of the range favours α amylase enzymes, creating more higher order sugars and dextrins which are less fermentable by the yeast, so a fuller bodied beer with less alcohol is the result. Duration and pH variances also affect the sugar composition of the resulting wort.

Lautering is the separation of the wort (the liquid containing the sugar extracted during mashing) from the grains. This is done either in a mash tun outfitted with a false bottom, in a lauter tun, or in a mash filter. Most separation processes have two stages: first wort run off, during which the extract is separated in an undiluted state from the spent grains, and sparging, in which extract which remains with the grains is rinsed off with hot water. The lauter tun is a tank with holes in the bottom small enough to hold back the large bits of grist and hulls (the ground or milled cereal). The bed of grist that settles on it is the actual filter. Some lauter tuns have provision for rotating rakes or knives to cut into the bed of grist to maintain good flow. The knives can be turned so they push the grain, a feature used to drive the spent grain out of the vessel. The mash filter is a plate and frame filter. The empty frames contain the mash, including the spent grains, and have a capacity of around one hectoliter. The plates contain a support structure for the filter cloth. The plates, frames, and filter cloths are arranged in a carrier frame like so: frame, cloth, plate, cloth, with plates at each end of the structure. Newer mash filters have bladders that can press the liquid out of the grains between spargings. The grain does not act like a filtration medium in a mash filter.

After mashing, the beer wort is boiled with hops (and other flavourings if used) in a large tank known as a "copper" or brew kettle – though historically the mash vessel was used and is still in some small breweries. The boiling process is where chemical reactions take place, Finally, the vapours produced during the boil volatilise off flavours, including dimethyl sulfide precursors. At the end of the boil, solid particles in the hopped wort are separated out, usually in a vessel called a "whirlpool". The simplest boil kettles are direct fired, with a burner underneath. These can produce a vigorous and favourable boil, but are also apt to scorch the wort where the flame touches the kettle, causing caramelisation and making cleanup difficult. Most breweries use a steam fired kettle, which uses steam jackets in the kettle to boil the wort.

At the end of the boil, solid particles in the hopped wort are separated out, usually in a vessel called a "whirlpool" or "settling tank". Whirlpool systems vary: smaller breweries tend to use the brew kettle, larger breweries use a separate tank, The principle in all is that by swirling the wort the centripetal force will push the trub into a cone at the centre of the bottom of the tank, where it can be easily removed.

A hopback is a traditional additional chamber that acts as a sieve or filter by using whole hops to clear debris (or "trub") from the unfermented (or "green") wort, as the whirlpool does, and also to increase hop aroma in the finished beer. It is a chamber between the brewing kettle and wort chiller. Hops are added to the chamber, the hot wort from the kettle is run through it, and then immediately cooled in the wort chiller before entering the fermentation chamber. Hopbacks utilizing a sealed chamber facilitate maximum retention of volatile hop aroma compounds that would normally be driven off when the hops contact the hot wort. While a hopback has a similar filtering effect as a whirlpool, it operates differently: a whirlpool uses centrifugal forces, a hopback uses a layer of whole hops to act as a filter bed. Furthermore, while a whirlpool is useful only for the removal of pelleted hops (as flowers do not tend to separate as easily), in general hopbacks are used only for the removal of whole flower hops (as the particles left by pellets tend to make it through the hopback). The hopback has mainly been substituted in modern breweries by the whirlpool.

After the whirlpool, the wort must be brought down to fermentation temperatures A plate heat exchanger has sereral ridged plates, which form two separate paths. The wort is pumped into the heat exchanger, and goes through every other gap between the plates. A good heat exchanger can drop wort to while warming the cooling medium from about to The last few plates often use a cooling medium which can be cooled to below the freezing point, which allows a finer control over the wort out temperature, and also enables cooling to around After cooling, oxygen is often dissolved into the wort to revitalize the yeast and aid its reproduction. While boiling, it is useful to recover some of the energy used to boil the wort. On its way out of the brewery, the steam created during the boil is passed over a coil through which unheated water flows. By adjusting the rate of flow, the output temperature of the water can be controlled. This is also often done using a plate heat exchanger. The water is then stored for later use in the next mash, in equipment cleaning, or wherever necessary. Another common method of energy recovery takes place during the wort cooling. When cold water is used to cool the wort in a heat exchanger, the water is significantly warmed. In an efficient brewery, cold water is passed through the heat exchanger at a rate set to maximize the water's temperature upon exiting. This now hot water is then stored in a hot water tank. After the wort is cooled and aerated – usually with sterile air – yeast is added to it, and it begins to ferment. It is during this stage that sugars won from the malt are converted into alcohol and carbon dioxide, and the product can be called beer for the first time. Most breweries today use cylindroconical vessels, or CCVs, which have a conical bottom and a cylindrical top. The cone's angle is typically around 60°, an angle that will allow the yeast to flow towards the cone's apex, but is not so steep as to take up too much vertical space. CCVs can handle both fermenting and conditioning in the same tank. At the end of fermentation, the yeast and other solids which have fallen to the cone's apex can be simply flushed out of a port at the apex. Open fermentation vessels are also used, often for show in brewpubs, and in Europe in wheat beer fermentation. These vessels have no tops, which makes harvesting top fermenting yeasts very easy. The open tops of the vessels make the risk of infection greater, but with proper cleaning procedures and careful protocol about who enters fermentation chambers, the risk can be well controlled. Fermentation tanks are typically made of stainless steel. If they are simple cylindrical tanks with beveled ends, they are arranged vertically, as opposed to conditioning tanks which are usually laid out horizontally. Only a very few breweries still use wooden vats for fermentation as wood is difficult to keep clean and infection free and must be repitched more or less yearly. Brewing yeasts are traditionally classed as "top cropping" (or "top fermenting") and "bottom cropping" (or "bottom fermenting"); the yeasts classed as top fermenting are generally used in warm fermentations, where they ferment quickly, and the yeasts classed as bottom fermenting are used in cooler fermentations where they ferment more slowly. Yeast were termed top or bottom cropping, because the yeast was collected from the top or bottom of the fermenting wort to be reused for the next brew. This terminology is somewhat inappropriate in the modern era; after the widespread application of brewing mycology it was discovered that the two separate collecting methods involved two different yeast species that favoured different temperature regimes, namely Saccharomyces cerevisiae in top cropping at warmer temperatures and Saccharomyces pastorianus in bottom cropping at cooler temperatures. As brewing methods changed in the 20th century, cylindro conical fermenting vessels became the norm and the collection of yeast for both Saccharomyces species is done from the bottom of the fermenter. Thus the method of collection no longer implies a species association. There are a few remaining breweries who collect yeast in the top cropping method, such as Samuel Smiths brewery in Yorkshire, Marstons in Staffordshire and several German hefeweizen producers. Modern quantitative genomics has revealed the complexity of Saccharomyces species to the extent that yeasts involved in beer and wine production commonly involve hybrids of so called pure species. As such, the yeasts involved in what has been typically called top cropping or top fermenting ale may be both Saccharomyces cerevisiae and complex hybrids of Saccharomyces cerevisiae and Saccharomyces kudriavzevii. Three notable ales, Chimay, Orval and Westmalle, are fermented with these hybrid strains, which are identical to wine yeasts from Switzerland.

In general, yeasts such as Saccharomyces cerevisiae are fermented at warm temperatures between , occasionally as high as , while the yeast used by Brasserie Dupont for saison ferments even higher at They generally form a foam on the surface of the fermenting beer, which is called barm, as during the fermentation process its hydrophobic surface causes the flocs to adhere to CO2 and rise; because of this, they are often referred to as "top cropping" or "top fermenting" – though this distinction is less clear in modern brewing with the use of cylindro conical tanks. Generally, warm fermented beers, which are usually termed ale, are ready to drink within three weeks after the beginning of fermentation, although some brewers will condition or mature them for several months.

When a beer has been brewed using a cool fermentation of around , compared to typical warm fermentation temperatures of , then stored (or lagered) for typically several weeks (or months) at temperatures close to freezing point, it is termed a "lager". During the lagering or storage phase several flavour components developed during fermentation dissipate, resulting in a "cleaner" flavour. Though it is the slow, cool fermentation and cold conditioning (or lagering) that defines the character of lager, the main technical difference is with the yeast generally used, which is Saccharomyces pastorianus. Technical differences include the ability of lager yeast to metabolize melibiose, though these technical differences are not considered by scientists to be influential in the character or flavour of the finished beer, brewers feel otherwise sometimes cultivating their own yeast strains which may suit their brewing equipment or for a particular purpose, such as brewing beers with a high abv. Brewers in Bavaria had for centuries been selecting cold fermenting yeasts by storing ("lagern") their beers in cold alpine caves. The process of natural selection meant that the wild yeasts that were most cold tolerant would be the ones that would remain actively fermenting
in the beer that was stored in the caves. A sample of these Bavarian yeasts was sent from the Spaten brewery in Munich to the Carlsberg brewery in Copenhagen in 1845 who began brewing with it. In 1883 Emile Hansen completed a study on pure yeast culture isolation and the pure strain obtained from Spaten went into industrial production in 1884 as Carlsberg yeast No 1. Another specialized pure yeast production plant was installed at the Heineken Brewery in Rotterdam the following year and together they began the supply of pure cultured yeast to brewers across Europe. This yeast strain was originally classified as Saccharomyces carlsbergensis, a now defunct species name which has been superseded by the currently accepted taxonomic classification Saccharomyces pastorianus.

Lambic beers are historically brewed in Brussels and the nearby Pajottenland region of Belgium without any yeast inoculation. The wort is cooled in open vats (called "coolships"), where the yeasts and microbiota present in the brewery (such as Brettanomyces) are allowed to settle to create a spontaneous fermentation, and are then conditioned or matured in oak barrels for typically one to three years.

Brewing by products are "spent grain" and the sediment (or "dregs") from the filtration process which may be dried and resold as "brewers dried yeast" for poultry feed, or made into yeast extract which is used in brands such as Vegemite and Marmite. The process of turning the yeast sediment into edible yeast extract was discovered by German scientist Justus von Liebig. Brewer's spent grain (also called spent grain, brewer's grain or draff) is the main by product of the brewing process; it consists of the residue of malt and grain which remains in the lauter tun after the lautering process. It consists primarily of grain husks, pericarp, and fragments of endosperm. As it mainly consists of carbohydrates and proteins, Spent grains can also be used as fertilizer, whole grains in bread, as well as in the production of flour and biogas. Spent grain is also an ideal medium for growing mushrooms, such as shiitake, and some breweries are already either growing their own mushrooms or supplying spent grain to mushroom farms. Spent grains can be used in the production of red bricks, to improve the open porosity and reduce thermal conductivity of the ceramic mass.

The brewing industry is a global business, consisting of several dominant multinational companies and many thousands of other producers known as microbreweries or regional breweries or craft breweries depending on size, region, and marketing preference. More than are sold per year—producing total global revenues of $294.5 billion (£147.7 billion) as of 2006. SABMiller became the largest brewing company in the world when it acquired Royal Grolsch, brewer of Dutch premium beer brand Grolsch. InBev was the second largest beer producing company in the world and Anheuser Busch held the third spot, but after the acquisition of Anheuser Busch by InBev, the new Anheuser Busch InBev company is currently the largest brewer in the world. Brewing at home is subject to regulation and prohibition in many countries. Restrictions on homebrewing were lifted in the UK in 1963, Australia followed suit in 1972, and the US in 1978, though individual states were allowed to pass their own laws limiting production.