brewery

Special Cavallo Release Party Features Four Variants, Dessert Pairings And Two Special Guests On Friday & Saturday, November 6 & 7, 2020 At Stable Craft Brewing At Hermitage Hill

Good To Know

German Master Brewer Peter Bottcher and Catoctin Creek Distillery’s John Reed Shope Join Line-up for Entertaining Two Day Release Party! Central Virginia’s Stable Craft Brewing at Hermitage Hill, an authentic working farm brewery and winery, will celebrate the release of its popular Cavallo barrel-aged imperial stout on Friday and Saturday, November 6 & 7, 2020.  This […]

The post Special Cavallo Release Party Features Four Variants, Dessert Pairings And Two Special Guests On Friday & Saturday, November 6 & 7, 2020 At Stable Craft Brewing At Hermitage Hill appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Stable Craft Brewing At Hermitage Hill Salutes Our Veterans With Special Veteran’s Day Celebration On Sunday, November 8

Good To Know

Festive Day Features Special Veterans Day IPA Release with Yakima Chiefs Veterans Blend, Special Commemorative Glass, and Marine’s Cake-cutting Ceremony WAYNESBORO, VA – (November 2, 2020) – Central Virginia’s Stable Craft Brewing at Hermitage Hill, an authentic working farm brewery and winery, will honor the special men and women who serve our country, with a special Veteran’s […]

The post Stable Craft Brewing At Hermitage Hill Salutes Our Veterans With Special Veteran’s Day Celebration On Sunday, November 8 appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Gluten-Free Brewers Group Responds to FDA Final Rule on Gluten-Free Claims on Fermented Foods

Good To Know

In August 2020, the federal Food & Drug Administration (FDA) finalized the definition and labeling requirements of gluten-free fermented and hydrolyzed foods (including beer and other alcoholic beverages).  The ruling provides a clear delineation between products that are truly gluten-free and products that are not and how product labels communicate those differences to consumers.  In […]

The post Gluten-Free Brewers Group Responds to FDA Final Rule on Gluten-Free Claims on Fermented Foods appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Reserve Your Own Private Igloo At Stable Craft Brewing

Good To Know

Private Igloos Offer Perfect Answer for Outdoor Winter Dining WAYNESBORO, VA – (October 21, 2020) –Starting this November, Central Virginia’s Stable Craft Brewery at Hermitage Hill, an authentic working farm brewery and winery, will once again offer its private igloos for outdoor dining at its best. Stable Craft’s heated igloos are available by advance reservations only […]

The post Reserve Your Own Private Igloo At Stable Craft Brewing appeared first on CraftBeer.com.

... read more
by admin 0 Comments

World’s Fastest Pumpkin Carver Shatters Guinness World Record For Speed Carving A Single Pumpkin At Stable Craft Brewing’s Fall Harvest Party

Good To Know

WAYNESBORO, VA – (October 20, 2020) – Central Virginia’s Stable Craft Brewery at Hermitage Hill, an authentic working farm brewery and winery, was the site of a World Record record-shattering performance by Stephen Clarke, the World’s Fastest Pumpkin Carver on Saturday, October 17.  Clarke broke his Guinness World Record of 16.47 seconds for speed carving a […]

The post World’s Fastest Pumpkin Carver Shatters Guinness World Record For Speed Carving A Single Pumpkin At Stable Craft Brewing’s Fall Harvest Party appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Winners of 2020 Great American Beer Festival Competition Revealed During First-Ever Virtual Ceremony

Good To Know

272 medals awarded to 240 breweries in world’s most prestigious professional beer competition Boulder, Colo. • October 16, 2020 — The Brewers Association (BA) awarded 272 medals* to 240 breweries across the country during the 2020 Great American Beer Festival (GABF) competition awards ceremony. The best beers in 91 beer categories covering 170 different beer styles (including all subcategories) were awarded gold, silver, and bronze medals during a virtual ceremony hosted on The Brewing Network. Judges for the 34th edition of […]

The post Winners of 2020 Great American Beer Festival Competition Revealed During First-Ever Virtual Ceremony appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Fretboard Brewing and Branch & Bone Artisan Ales team up for “Dark Throne” Collaboration

Good To Know

Fretboard Brewing Company (Blue Ash, OH) isn’t known for their collaborations with other breweries. Over the course of their 3 year history, they’ve partnered with musicians like Bootsy Collins and The Cliftones, to foundations like ArtsWave, and even a bread company (Klosterman Baking), but they’ve never released a product brewed in partnership with another brewery. […]

The post Fretboard Brewing and Branch & Bone Artisan Ales team up for “Dark Throne” Collaboration appeared first on CraftBeer.com.

... read more
by admin 0 Comments

The Untold Benefits of Award-Winning Beer

Good To Know

For us homebrewers that enter a competition sanctioned by the Beer Judge Certification Program (BJCP), the goal is clear – we want feedback on our brews from trained tasters. And, if we win an award, we want to strut. As homebrewers progress to professional brewing, little changes in regard to competition goals. Professional brewers still […]

The post The Untold Benefits of Award-Winning Beer appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Experience Virginia’s Fall Foliage At Stable Craft Brewing’s Fall Harvest Party On Saturday October 17

Good To Know

World’s Fastest Pumpkin Carver Attempts New Guinness World Record, Pumpkin Drop, Grab the Oktoberfest Glass, Socially Distanced Stein Hoist and Many More Fun Fall Festivities   WAYNESBORO, VA – (October 5, 2020) – Central Virginia’s Stable Craft Brewery at Hermitage Hill, an authentic working farm brewery and winery, offers the perfect venue and party to celebrate […]

The post Experience Virginia’s Fall Foliage At Stable Craft Brewing’s Fall Harvest Party On Saturday October 17 appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Coin Toss Brewing Defies the Pandemic Odds, Announces Expansion of its Oregon City Brewery and Taproom

Good To Know

OREGON CITY, Ore.––Sept. 29, 2020––While 2020 has led to closures and downsizing for many small businesses, Coin Toss Brewing is thrilled to announce an expansion. The Oregon City brewery and taproom, located at 14214 Fir St., Unit H, is taking over an adjacent suite in its building complex. The new space is approximately 1,500 square […]

The post Coin Toss Brewing Defies the Pandemic Odds, Announces Expansion of its Oregon City Brewery and Taproom appeared first on CraftBeer.com.

... read more
by admin 0 Comments

Tracking Brewery Purchases, Crafty Beer, and Craft Conglomerates

Good To Know
In July 2018 I made a poster illustrating the connections between breweries. I've expanded and updated it a few times since then, both thanks to people who have commented with suggestions and because big breweries haven't stopped buying smaller breweries. Below is the most recent update. As always let me know if you see anything incorrect, but please include a source confirming it.

Higher resolution image - Prints are available from my web store.

The biggest change since my last update two months ago was the purchase of New Belgium (and Magnolia) by Kirin/Lion. Other big news included purchases by Legacy Breweries (Ninkasi's parent company) of Laurelwood, and Aspen in pursuit of buying 15 breweries by the end of 2020. AB InBev purchased the remainder of Craft Brew Alliance (Kona, Red Hook, Cisco, Widmer etc.) up from 31.5%.

I added some smaller ownership groups around the center box, both craft breweries who own other craft breweries, and private equity firms that own a brewery in their entirety. I've also tried to replace the bigger breweries outside the US with smaller breweries that would be more easily confused for independents.

As always my goal isn't to tell anyone what beer they should buy/drink, only to provide information. There are a wide variety of situations represented along the outside of the chart, and there is a big difference between a brewery owned by Duvel Moortgat and one owned by AB InBev. Personally I do my best to support small local breweries where the owner is personally involved. Then to independent regional breweries, then to independent national breweries, on to the private-equity-backed conglomerates, and finally those owned by big beer (whose interests, lobbying, and sales practices often hurt small breweries).

There are also a wide range of situations that I haven't found a way to represent on the chart. For example the breweries that are owned in part by private equity firms (Abita, Stone, Schlafly, Unita, Weyerbacher, and Lord Hobo).

A few common questions:

How did you choose which breweries are in the center box?
  • I tried to include a range of sizes and locations, focusing on my favorites, friends, and those that had been generous with their time. There are tens of thousands of breweries and not enough room for all of them.
Why is Sol under Heineken, isn't it owned by MillerCoors?
  • The poster shows ownership, MillerCoors has a 10-year distribution deal for Sol in the US. My goal is to show ownership, so I ignore contract brewing. This is different than the overlap between Groupo Modelo and Constellation where brands like Corona and Dos Equis are owned/brewed separately for the US.
What is that weird symbol above the Trappists?
  • It's the logo of the Holy See (Vatican). Certainly not the same as the corporate relationship depicted elsewhere, but it is certainly a connection between them and the other monastic orders of the Catholic church.

... read more
by admin 0 Comments

How to Win Untappd (or any Online Beer Rating)

Good To Know
Like it or not, online beer ratings have been one of the big drivers of craft beer over the last 20 years. As a brewery, you don't need to cater to them, but high scores can drive sales and excitement.

I spent a good deal of time on BeerAdvocate during my first few years of beer drinking (2005-2008). Reading other's reviews was beneficial for my palate and beer vocabulary. I reviewed a couple hundred beers, which gave me confidence to "review" my homebrew for this blog. However, there were aspects of trying to track down all the top beers that made it not entirely healthy. Whether it was fear of missing out on a new release, or the thrill of the catch outweighing the enjoyment of actually drinking the beer. I  find how many new beers there are now freeing, there is no way to try them all, so I don't try!

Untappd Logo

Now that Untappd is the dominant player I'll glance at reviews (especially for one of our new releases), but I don't rate. It's rare to see a review that has much insight into the beer. Even the negative ones are rarely constructive. As an aside, I find it a bit weird when people in the local beer industry rate our offerings. Generally they are kind, but it just seems strange to publicly review "competing" products.

For four or five years I maintained a spreadsheet to track the beers I drank and those I wanted to try. I weighted the beers not just on their average BeerAdvocate score, but on the score relative to their style. That's to say I was more interested in trying a Czech Pilsner rated 4.2 more than a DIPA at 4.3 because Pilsners generally have lower scores. If all you drink are the top rated beers, you'll be drinking mostly the same handful of styles from a small selection of breweries. Why is that though?

My homemade beer ranking spreadsheet

Whether it is the BeerAvocate Top 100, Rate Beer's Top 50, and Untappd's Top Beers they all show a similar bias towards strong adjunct stouts, DIPAs, and fruited sours. I don't think the collective beer rater score aligns with what the average beer drinker enjoys the most or drinks regularly. It is a result of a collection of factors that are inherent to the sort of hedonistic rating system.

So what makes beers and breweries score well?

Big/Accessible Flavors

People love assertive flavors. Once you've tried a few hundred (or thousand) beers, it is difficult to get a "wow" response from malt, hops, and yeast. This is especially true in a small sample or in close proximity to other beers (e.g., tasting flight, bottle share, festival). So many of the top beers don't taste like "beer" they taste like maple, coconut, bourbon, chocolate, coffee, cherries etc. If you say there is a flavor in the beer everyone wants to taste it... looking at reviews for our Vanillafort, it is amazing how divergent the experiences are. Despite a (to my palate) huge vanilla flavor (one bean per 5 gallons), some people don't taste it.

Vanillafort and vanilla beans

Sweetness is naturally pleasant. It's a flavor our palates evolved to prefer over sour/bitter because it is a sign of safe calories. That said, too much can also make a beer less drinkable. I enjoy samples of pastry stouts, but most of them don't call for a second pour. Balance between sweet-bitter or sweet-sour makes a beer that calls for another sip, and a second pour.

Even the most popular IPAs have gone from dry/bitter to sweet/fruity. They are beers that are less of an acquired taste. More enjoyable to a wider spectrum of drinkers. I'm amazed how many of the contractors, delivery drivers, and other non-beer nerds who visit the brewery mention that they are now into IPAs.

If you want a high brewery average, one approach is simply to not brew styles that have low average ratings. That said, for tap room sales it can really help to have at least one "accessible" beer on the menu. For us that has always been a low-bitterness wheat beer with a little yeast character, and a fruity hop aroma. Their scores drag our average down, but it is worth it for us.

Exclusivity

The easier a beer is to obtain, the more people will try it. The problem is that you don't want everyone rating your beer. To get high scores it helps to apply a pressure that causes only people who are excited about the beer to drink (and rate it). This can take a variety of forms, but the easiest is a small production paired with a high price-point and limited distribution. You can make the world's best sour beer, but if it is on the shelf for $3 a bottle at 100 liquor stores you'll get plenty of people sampling it that hate sour beers. Even with our relatively limited availability we get reviews like "My favorite sour beer ever!" 1.5 stars... The problem with averages is that a handful of really low scores have a big impact.

I'll be interested to see how our club-exclusive bottles of sour beer rate compared to the ones available to the general public. The people who joined self-identified as fans of ours and sour beers. My old homebrewing buddy Michael Thorpe has used clubs to huge success at Afterthought Brewing (around #20 on Untappd's Top Rated Breweries). In addition to directing his limited volume towards the right consumers, clubs allow him to brew the sorts of weird/esoteric (delicious) beers that might not work on a general audience (gin barrels, buckwheat, dandelions, paw paw etc.).

Jeff pitching Afterthought dregs


As noted above some styles have higher average reviews than others. Simply not brewing low-rated styles goes a long way towards ensuring a high overall brewery average. Anytime I feel like one of our beers is underappreciated, I go look at the sub-4 average of Hill Farmstead Mary, one of my favorite beers. Afterthought recently announced a new non-sour brand, which will prevent beer styles with lower averages from "dragging down" the average for Afterthought.

I remember there being debate over the minimum serving size for a review on BeerAdvocate. I think a few ounces of a maple-bacon-bourbon imperial stout is plenty. However for session beers, can you really judge a beer that is intended to be consumed in quantity based on a sip or two? We don't do sample flights at Sapwood Cellars. We sell half-pours for half the price of full pours. Not having a flight reduces people ordering beers they won't enjoy just to fill out a paddle. It also means that more people will give a beer a real chance, drinking 7 oz gives more time for your palate to adjust and for you to get a better feel for the balance and drinkability. What kills me is seeing people review one of our sessions beers based on a free "taste."

Another option is physical distance. Most trekking to Casey, De Garde, or Hill Farmstead are excited to be going there and ready to be impressed. It helps that all three brew world-class sour beers, but I'm not sure the ratings would be quite as good if they were located in an easily-accessible urban center.

The trick to getting to the Top Beer lists is that you need a lot of reviews to bring the weighted average up close to the average review. So having a barrier, but still brewing enough beer and being a big enough draw to get tens of thousands of check-ins and ratings. Organic growth helps, starting small, and generating enough excitement to bring people from far and wide. Lines (like those at Tree House) then help to keep up the exclusivity, not many people who hate hazy IPAs are going to wait in line for an hour to buy the new release - unless it is to trade.

My only visit to Tree House brewing

Shelf Stability/Control 

Many of the best rated beers are bulletproof. Big stouts and sours last well even when not handled or stored properly. This means that even someone drinking a bottle months or years after release is mostly assured a good experience. Most other styles really don't store well and are at their best fresh.

Conversely, hazy IPAs are one of the most delicate styles. I think it's funny that some brewers talk about hiding flaws in a NEIPA. While you sure don't need to have perfect fermentation control to make a great hop-bomb, they are not forgiving at all when it comes to packaging and oxygen pick-up. That's partly the reason that the best regarded brewers of the style retail most of the canned product themselves. Alchemist, Trillium, Tree House, Tired Hands, Hill Farmstead, Aslin, Over Half etc. all focus on direct-to-consumer sales. That ensures the beer doesn't sit on a truck or shelf for a large amount of time before a consumer gets it. Consumers seem to be more aware than they once were (especially for these beers) that freshness matters.

Trillium, Aslin, and Alchemist

Of course the margins are best when selling direct too, so any brewery that is able to sell cases out the door will. It can turn into a positive feedback loop, where the beer is purchased/consumed fresh which makes the beer drinker more likely to return. This worked well for Russian River, not bottling Pliny the Elder until there was enough demand that it won't sit on the shelf for more than a week.

Sure the actual packaging process (limiting dissolved oxygen) is important. But generally an OK job on a two-week-old can will win out over a great job on a two-month old can.

The ultimate is to have people drink draft at your brewery. That way you can control the freshness, serving temperature, glassware, atmosphere etc. That said, I notice the scores for our beers in growlers are usually higher than draft. I suspect that this is about self-selection, people who enjoyed the beer on draft are more likely to take a growler home and rate it well. It might also be a way for people to appear grateful to someone who brought a beer for them to try.

Reputation

This is one area where blind-judged beer competitions have a clear edge over general consumer ratings. When you know what you're drinking, that knowledge will change your perception. Partly it is subconscious, you give a break to a brewery that makes good beer. Or after a lot of effort to procure a bottle you don't want to feel like you wasted money/time. It can be more overt. I've had friends tell me that they'll skip entering a rating for our beer if it would be too low. I remember boosting the score of the first bottle of Cantillon St. Lamvinus I drank, it was so sour... but I didn't want to be that 22 year old who panned what people consider to be one of the best beers in the world.

I could also be cynical, but I can imagine someone buying a case of a new beer to trade and wanting to make sure they get good "value" by helping the score for the beer. Might be doubly true for a one-off beer with aging potential!

Sapwood Cellars has done pretty well in our first year. Out of more than 100 breweries in Maryland, we have the third-highest average score (4.06) on Untappd. That isn't even close to meaning that our beer is "better" than anyone below us though. In addition to being solid brewers, we're helped by our selection of styles (mostly IPAs and sours) and by selling almost all of our beer on premise. Hopefully that feeds a good reputation, which further drives scores as we continue to hone our process.

Rum, Apple, Apple tripel



... read more
by admin 0 Comments

Dark Funky Saison – A Retrospective

Good To Know
Since 2008 my friend Alex and I have been brewing dark funky saisons. Each year we come up with a new concept, usually involving dried fruit and/or spices. We've been a bit lax the last couple years, the ninth iteration was brewed a year ago, and neither of us has bottled our share yet.

For my birthday a couple weeks ago, Alex came over to the brewery and we opened bottles of all the versions (including a few variants). I shot a video of our discussion, enjoy!




2009 Funky Dark Saison with Black Cardamom

2010 Fig Honey Anise Dark Saison

2011 American Farmhouse Currant Dark Saison

2012 Dark Saison with Quince Paste

2013 Cranberry Dark Saison

2014 Dark Saison Etrog

2016 Dark Saison Date and Pomegranate


... read more
by admin 0 Comments

The Economics of Opening a Brewery

Good To Know
The excitement over hazy/NE IPA is the best thing that has happened for local breweries in a long time. They are expensive to brew, difficult to package, a nightmare to distribute long distances, and get beer drinkers excited! When we put a juicy Double IPA on tap it flies. Our recent 7-barrel-yield of Snip Snap lasted less than three days, while an IPA might last three weeks, and a pale ale five. Having a beer that draws increases growler sales, and helps sell all of our other beers as people end up trying other similar beers when they come in.

Snip Snap DIPA

Here is a graph of the scores of 13 of our hoppy beers (pale ales, IPAs, and DIPAs) showing the Untappd score compared to the ABV. The formula for the trend line is y = 3.2008+.1392*x. That suggests if we brewed a 0% ABV hoppy beer it would score a 3.20 and to get a score of 5 would require 14.31% ABV. The R-squared value of the correlation is .71, so the most important factor in the consumer's opinion of our hoppy beers is strength (granted that typically comes with a higher dry hopping rate, sweetness etc.).

Impact of ABV vs. Untappd Score.

Driving business to your tasting room is job #1 for a small brewery because that is where the profit is highest. When you buy a beer at a bar or restaurant, most of the money goes to them rather than the brewery. While a ½ bbl keg of a pale ale might sell to a bar for $150-175 (a portion of which might go to a distributor), at even $5 pint the bar makes $620 in revenue. At our scale, it is almost impossible to make a profit only  selling beer at wholesale. It requires a tight reign on expenses with a premium price point, not to mention low overhead.

It is no coincidence that local brewery booms seem to follow when a state or city allows production breweries to serve/retail their own beer. In the case of Maryland this has created backlash from distributors, and a lesser extent bars and liquor stores who see more consumers cutting them out.

Sapwood Cellars Holiday Party

Ingredient Cost

We aren’t doing a great job controlling ingredient costs. We don’t reuse our yeast nearly as much as we "should" (3-4 batches per pitch), we pay as much as $35/lb for hops that are difficult to get on the spot market, we buy our malt pre-milled by the bag, we use expensive “real” ingredients for our variants (and usually don’t up-charge over the base beers) etc. That said, having a tasting room that is busy covers all of those sins.

Great Western Full Pint Malt

10 bbls – Pillowfort
$484 – 2-row
$137 – Malted Oats
$40 – Chit Malt
$50 – Milling Fee
$11 – Glucose
$.80 - Whirlfloc
$.06 - Zinc Sulfate Heptahydrate
$1 – Calcium Chloride
$1 – Gypsum
$.25 – Epsom Salt
$2.00 – 350 ml 75% Phosphoric Acid
$125 – Liquid yeast
$150 – Dry yeast
$77 – Columbus
$99 – Centennial
$396 – Citra
$264 – Azacca
~$100 – CO2/Gas/Electric/Chemicals
 ($1950/batch - $1.11/pour)

Let’s say we put more effort into yeast management and that gives us confidence to reuse the yeast for 20 batches. Bringing the proportional cost down from $125 to $25 per batch. The net savings to us would be $.05 per pour. What if we moved to a silo for 2-row, and cut our base malt cost down to a third and added a mill? $.14 per pour. That would make Pillowfort ~$.92/pour. Granted these recurring costs add up over the course of a year and both might yield improvements to the consistency and quality of our beer. But selling just one 1/2 bbl keg to a bar, even charging $250, loses us more money per batch then we’d save from making those moves. It also speaks to how important yield on these heavily dry-hopped beers is.

Most of our IPAs and DIPAs work out to $100-150 per ½ bbl keg. Self-distributing these beers for $200-250 there would be no way to make enough to cover rent, pay ourselves, and fund expansion. However, being a retailer of our own beers means we get $800-900 for that same keg sold by the glass and growler. It makes sense for us to charge a reasonable price ($7-8 for a 14 oz pour in a 17 oz glass) and have consumers return rather than charge a dollar or two more and end up having to self-distribute kegs (with the added effort).

When we do send kegs out, we try to get as much of a push out of it as we can (fests, tap-takeovers, beer dinners etc.). We don't pay for any traditional advertising, but we view the "losses" from self-distributing as a form of marketing. That also means not always sending beer to the same bars, as we want people to feel like they have to come to us to try our beers regularly.

Beer Festival

Most bars use a flat percentage markup to price their draft. If a beer costs twice as much for them to purchase, they’ll charge twice as much to the consumer. That means that they’ll make a much larger dollar-per-ounce profit on more expensive beers. The same isn’t true at most breweries, an IPA with Nelson Sauvin or Galaxy is easily twice as expensive as a session wheat beer (especially considering the lower yield with high dry-hop rates), but we don’t double the price. Still, charging $7 for IPA and $6 for the session wheat makes the IPA more profitable per pour. When you visit a brewery and buy beer, you’re allowing them to spend more money on the ingredients and make better beer. Not to mention that the brewery will care more about their beer and have better control over the product.

Overhead

After ingredient cost, our next biggest expense is rent. Scott and I debated where to open and toured spaces with a wide range of looks and costs. While a beautiful rustic plot with room for outdoor events and a small orchard was appealing… either running on a septic or paying hundreds of thousands of dollars for a municipal sewer connection was not. Conversely, opening in a vibrant downtown with plenty of foot traffic would have meant easier retail sales, but would have tripled our rent. Brewing is a space-intensive manufacturing business (especially with barrel aging), it is difficult for me to justify paying $30+ sq ft for the parts of the business that aren’t customer facing.

Lease Signing Day

If we are able to brew enough to outstrip tasting room demand, we’ll look into opening a small taproom someplace other than an industrial park. For the time being, our location is close enough to residential for the tasting room and inexpensive enough for 4,000 sq ft of production. Luckily the power of Google Maps, Untappd, and social media has been enough for us to draw people in.

In addition to the ability to sell beer by the glass, a tasting room opens up the way for merchandise sales, private events, packaged beer, and even food sales (working on that now). It has been essential for us to have a space and offerings that attract customers, even those who aren’t beer nerds. A fantastic staff, and enough of them working for short waits also improves the customer experience.

Salaries are the third big expense. Scott and I have done 100% of the brewing, tank cleaning, kegging, and keg washing up to this point. Financially speaking, our labor has been free, but we certainly could have kept our day jobs and paid less-per hour than our lost wages to hire brewers and cellar-people. That said, it didn’t seem right to trust something we’d worked so hard for to other people. As I learned from consulting, the people who are physically there have the biggest effect on the results. We’ll be looking to hire someone in the brewhouse soon, but we’re still trying to figure out what the role will be (cleaning and cellar duties, or someone who already has the skill-set to be a lead brewer eventually). We were willing to pay for front-of-house, as that is where we didn’t have experience (or the time to learn).

Other Income Streams

I posted about Brewery Clubs a few months ago. As a brewery that didn’t take on outside loans or investors, the extra money we brought in from club sales was essential. It gave us the breathing room to buy more expensive equipment, ingredients, not to mentions barrels for beers we won’t sell for months or years, and dump most of a batch that we didn’t love. Padding in the bank account helped with our sleep those first couple months too.

We’re now “paying” some of that money back. We made it through the club holiday events, for which we created 16 sixtels of variants that we didn’t sell a drop of. Not to mention paid employees to work (and at $15 an hour as tipping was light without tabs). Most of that cost was in our time, but we’ll continue to incur costs as we give bottles, decanter baskets (below), and events that club members paid for last year. Not only do we want to ensure that customers (and many friends) are happy they joined, we’d like to over-deliver so many consider re-upping for 2020!

Decanter Baskets

The rest of this year our biggest focus will be on packaging. Direct sales of canned and bottled beer should give us the chance to increase total revenue, but it will also lower our per-ounce revenue. While many people are willing to pay $8 for a 14 oz pour of DIPA... $5 for a 16 oz can of the same DIPA is about the top of the market. Cans have higher costs associated with them as well, both in terms of labor and materials (especially when you don't own a canning line). That really slims down the margins, and will dictate which beers are more likely to be canned (e.g., Pillowfort with Azacca rather than Snip Snap with Galaxy). The most important thing for us will be avoiding turning draft sales into can sales. Ideally cans are an add-on to tabs or an additional trip for a release rather than a replacement for draft consumption and growlers.

Shared Kingdom at Black Flag

What makes sense for a brewery will depend on the types of beer they brew and their goals as a company. If you want to be a large production brewery, it may make sense to start fighting for draft accounts early. We don’t have any resources dedicated to outside sales, in fact we turn down most offers to put our beer on tap. We’d rather have an excess of demand, and be in strong position rather than fight for a limited number of tap handles with an ever-increasing number of breweries.

Having the huge catalog of homebrew recipes between the two of us has been a big advantage too. On Saturday we tapped a scaled-up version of Atomic Apricot. The price difference on the apricot puree was particularly stark, $1.71 per pound at the commercial scale vs. $7.84 for the same product (Oregon Fruit/Vintners Harvest). I haven't been doing much homebrewing or test batch brewing so most of my social media posting has moved to the Sapwood Cellars Facebook and Twitter accounts (Scott does Instagram because I usually avoid posting from my phone).

... read more
by admin 0 Comments

Am I a Better Craft Brewer or Homebrewer?

Good To Know
We're doing pretty well at Sapwood Cellars so far. Our most recent batch of Snip Snap (Citra-Galaxy DIPA) only lasted 2.5 days on draft, about 200 gallons drained by the pour and growler fill. Ratings on Untappd were stellar. Is this how good Scott and I were at homebrewing or is our new 10 bbl brewhouse and temperature controlled fermentors making our beer better than it was?

I shot video of the big batch of Snip Snap and brewed a small batch at the brewery with my old pots and fermentor. We tried to keep them as identical as possible, using malt/hops/yeast from the same bags for both batches. I sampled both beers blind, and we served them to 49 customers in the tasting room to see which they preferred for this Video!




... read more
by admin 0 Comments

Is American Homebrewing Dying?

Good To Know
Brewing beer at home changed the course of my life. At first it was merely a fun way to explore my drink of choice, and an excuse to hang out with friends. As time passed it became a larger part of my life, a side-hustle, a reason to travel, altered who I am. I always hated public speaking… until I figured out that I’m engaging when I care about the material. I was never passionate about reading, researching, and writing, until they meant I could learn to brew better beer and share my passion. I met many of my friends at homebrew club meetings, through this blog, and homebrewing forums. I worked a boring government desk job for 12 years, until brewing allowed me to open a business!


That’s why I'm sad that homebrewing is on the decline in America. I see it at DC Homebrewer’s meetings, where there aren’t nearly as many fresh faces as there were five years ago. The closures of retailers, like the recent announcement from Love2Brew. The surveys from the American Homebrewer’s Association gives hard numbers: from 1.2 million homebrewers in 2013, to 1.1 million in 2017.

Anecdotally over the last 30 years, American homebrewing has experienced three similar dips. Roughly the early-1990s, early-2000s, and the last few years. These coincide with three pivotal moments in commercial beer availability.

By the early 1990s most parts of the country had a selection of bottled craft beer from the likes of Sierra Nevada, Boston Beer, not to mention a few local breweries. No longer were beer drinkers limited to macro lagers and stale impotrs, because hoppy pale ales, malty browns, and roasty stouts were available coast-to-coast. I've met a few former homebrewers who thought that was enough selection to make homebrewing superfluous. There were still plenty of people who wanted to drink a wider range of styles though, and that still meant brewing their own.


A decade later with the opening and expansion of breweries like Allagash, Dogfish Head, New Belgium and hundreds more, the selection and availability of craft beer had exploded. You could find wit, kolsch, imperial stouts, apricot pale, IPA and a multitude more everywhere. Most cities had stores where you could pick from hundreds if not thousands of bottles. Again, some homebrewers didn’t see the need to keep brewing when they could drink a solid example of pretty much any style. Still though, many homebrewers wanted greater variety, unique flavors, and ua-fresh beer.


Now we’re in another slide. With more than 6,000 breweries spread across the country, most Americans can take a short drive to visit a different brewery tasting rooms every week for a few months without repeating. Not only that, but the old model of four core beers, four seasonals, and a couple special releases is  gone. Many breweries are producing 50 or more beers each year. The variety is staggering, and again many former homebrewers are happy to reduce their risk/effort and sample as many new beers as they desire. Not only is homebrewing suffering, but so are many of the breweries from those previous waves… Smuttynose, Green Flash etc.


In the chart below, the red line represents Google searches for "Brewery" the blue is "Homebrewing." December 2008 is the closest they have been (29 to 13), while July 2018 was the furthest (100 to 5). That's to say that while search interest in breweries has more than tripled over the last ten years, during the same time interest in homebrewing has dropped in half.


Where does homebrewing go from here?

There have always been different types of homebrewers, different reasons they brew. There will always be homebrewers. Those who brew not to save money, or drink the “best” beer, but who love the process. Those who are passionate about recipe design, microbiology, botany, community. engineering, culinary techniques, and experimentation. For them craft beer is a source of inspiration, but not a replacement for the hobby!

I don't view automated homebrewing systems as a threat to traditional homebrewing or a big boon for the hobby. If I hear one more new product that bills itself as the “Keurig” of beer… I’m going to lose it! It isn’t even like Keurig is synonymous with high quality coffee. I just don’t see any product that makes brewing that easy gaining a strong foothold because brewing beer involves more care than coffee and to-the-minute freshness isn't as important. You can buy a six pack at the store for less than it takes to brew these, and enjoy a bottle each night. The automated systems will always make beer that isn't as good as commercial, at a higher price-point. Not that automated wort production isn't appealing (and useful) for homebrewers looking to devote less time to the process.

If this time is like the previous two lulls, homebrewing is due for another bounce. Maybe the continual push for novelty in craft brewing, extra-bold flavors, and lack of true originality turns people off. Lack of quality, high prices, poor quality control, beer that sits too long before being sold… honestly now that I know how good IPA tastes within a month of brewing, I rarely buy a six-pack off the shelf. Hopefully as more consumers become accustomed to really fresh beer at tasting rooms, they get interested in brewing it for themselves! Maybe the greater number of people drinking craft beer simply gets more people interested in brewing.

The second option is decline. As quality beer becomes more accessible the price will be pushed down, making it an even more attractive option for marginal-homebrewers. Homebrewing becomes an even more specialized/nerdy hobby, and we lose out on the vibrancy that new hobbyists bring.

My best guess is that we're reaching stasis. There won't be a return the levels of excitement and engagement we saw ten years ago. There will still be plenty of people who drink craft beer, and try their hand at homebrewing, but only enough to replace all of the homebrewers who stop to drink craft beer or join the industry.

Homebrewing Matters

Drinking beer wouldn't have done the same thing for my life as homebrewing. An active engagement with brewing is the best way to really understand and appreciate beer. It caused me to learn and grow in areas that aren't really connected to beer or brewing. I understand that drinking a beer and checking in on Untappd is no-risk (I wrote a couple hundred reviews on BeerAdvocate), but it doesn't really lead to anything. Drinking beer is a diversion, brewing beer can change your life!


... read more
by admin 0 Comments

Foraged Staghorn Sumac Beer

Good To Know
My homebrewing frequency has taken a nosedive recently (surprise), but I still try to find time to brew a weird batch when I can. In August, when Scott and I drove to pick-up our first hop order in western Maryland, I noticed that Staghorn Sumac was in full bloom along I-270 . I’d read about flavoring beer with it in The Homebrewer’s Almanac, but never actually tasted a beer brewed with it. Sumac is tart and fruity, traditionally used in a tart lemonade-like beverage.

Staghorn Sumac "Berries"

I pulled over and harvested about a pound. The range I’d read was 1-5 lbs per 5 gallon batch. Without a beer ready for them, I took the clusters of dusty berries off of the central twig, vacuum sealed them, and froze. That was enough of an excuse to brew a batch of Berliner weisse (fermented with US-05 and Omega Lacto Blend - similar otherwise to this recipe). After primary fermentation I racked 1 gallon onto the resulting .75 lbs of sumac, and another onto .5 oz of dried Turkish sumac from Penzeys for a month. Obviously if the dried version is just as good, it certainly would be easier!

Me, harvesting sumac


Dried Turkish Sumac Berliner

Smell – Aroma is light, doughy-grain, lightly citrus and roasted pear. An odd note of cinnamon as well.

Appearance – Clear pale yellow. It’s almost so pale that yellow isn’t the right word, it looks washed out, faded. Retention isn’t great, but the tight, white head sticks around for much longer than the other half of the batch.

Taste – Bright acid without being obnoxious. The finish has an odd fall-spice note as in the nose that I suspect is from the sumac. Dry without being a desert.

Mouthfeel – Classic Berliner, light and spritzy.

Drinkability & Notes – The not-entirely-pleasant musty-herbal flavor the dried sumac provided when the beer was young seems to have mostly faded to a light spiciness. I’m not sure I’d even pick it out if I didn’t know it was in there.

Changes for Next Time – Maybe a different/fresher source of dried sumac would provide a better flavor and aroma?

Staghorn Sumac Berliner

Smell – Aroma has the generic fruitiness of Hawaiian Punch, or Hi-C, but with an herbal hint of a Ricola cough drop. I don’t get any of the base beer, at this elevated rate it is all sumac. Certainly in the same sort of flavor-family as hibiscus.

Appearance – To go along with the aroma, it has the color of Hawaiian Punch. Similar head retention too…

Taste – The same fruit flavor from the nose, but more pronounced cherry candy. It’s a really fun flavor, that doesn’t stray into cloying. Acidity is snappy, sort of Vitamin-C, quick and punchy. No sweetness, finally breaks the comparison to "fruit" beverages.

Mouthfeel – Light, medium+ carbonation, but not excessively thin or harsh.

Drinkability & Notes – Staghorn sumac is a foraged ingredient that has a real chance for broader appeal. The flavor is fun, quenching, and somewhat familiar. The color certainly doesn’t hurt either. With how much it took, a mild base beer like this makes the most sense.

Changes for Next Time – I was sort of hoping this one wouldn’t be delicious so that I didn’t have to source a couple hundred pounds to put into a beer next summer. Likely could drop down closer to .5 lbs/gallon for a more balanced beer, but it is delicious as is!


I’m hopeful I can get this formula approved by the TTB for Sapwood, as there are already a few commercial beers from the likes Sumac Sour from Four Quarters, Backroads from Suarez Family, and of course several sours and saisons from Scratch. That said, it seems like they are clamping down as I had both acorns and Eastern Red Cedar rejected already. I’ve had several brewers tell me that the step isn’t necessary unless you are getting label approval (not true) or that it is better to ask forgiveness than permission…

I'll be making the trip down to Asheville, NC March 22-23 for another round of BYO Boot Camps! As usual I'll be talking about Wood/Barrels one day and Sour Beers the other. I said it before, but this really is looking like the last one of these for me given how much time running a brewery takes!
... read more
by admin 0 Comments

Craft Cleaning: Cylindroconical Fermentor CIP

Good To Know
Brewers often joke that they spend more time cleaning than on any other aspect of the job. That isn't quite true at Sapwood Cellars, but the cleaning aspect has been the biggest change from homebrewing. By comparison, wort production hasn't been that difficult or different. Sure it took a few batches to acclimate to the efficiency and losses on our 10 bbl Forgeworks brewhouse (as with any new brewing system), made more challenging by an unreliable flow meter. Even 15 batches in despite hitting our target mash temps, wort fermentability seems to be lower than expected. We're also still dialing in hop utilization given the thermodynamics involved with large wort volumes. Still, the concepts, ingredients, and techniques are all pretty similar to homebrewing.

When it comes to cleaning and sanitizing though, we've had to relearn the entire process. You really can't fill a fermentor with 360 gallon of Oxiclean Free and soak overnight or swirl and scrub... I miss those days. First, let's talk about chemicals and what they do. Our main supplier is AFCO, but Berko, Five-Star, and Loeffler all have fans. Prices seemed similar, we just didn't think about ordering until a couple weeks before we started brewing and picked the one with the quickest turnaround time. We buy most of the chemicals in 5 gallon jugs, and pump them into beakers to measure and dose.

The chemicals we use to clean and sanitize our brewery.

Chemicals

Caustic (5229 Caustic) - Caustic is the primary cleaner used by most breweries. Usually sodium hydroxide based and heavily alkaline. It is ideal for breaking down and removing organic deposits (e.g., krausen rings). You can do a bit of trading-off between time, temperature, pressure, and concentration. That said, 2-3% caustic at ~150F (66C) for 20-30 minutes through the sprayball has been a pretty good place to start for us. Caustic is dangerous because it is capable of breaking down your skin (the lye used in soap making is similar). We started with a powdered caustic (Wash-It), but given the price and efficacy we transitioned to liquid.

Phosphoric-Nitric Acid Blend (5397 Microlex Special 30) - Acid helps to remove inorganic deposits, i.e., beerstone (calcium oxalate). It also helps to neutralize any residual caustic (not that there should be any with adequate rinsing) and to passivate stainless steel. Acid blend is used at similar temperatures and cycle lengths as caustic, although slightly cooler, ~130F (54C).

Five Star Peroxyacetic Acid (PAA) - While there are many sanitizers available, PAA is the most popular for breweries. At the right concentrations it is a robust sanitizer with high effectiveness. It breaks down to acetic acid, so it can be used no-rinse. It is a powerful oxidizer, which makes it important to drain any residual before fermented beer enters a tank or keg. Our bucket was leftover from the old brewery in our space, so we bought a pack of test strips and it still reads the expected concentration after dilution.

Five Star PBW - We have a bucket of this alkaline powered cleaner for soaking hot-side equipment and other gear where we don't want to have to be as careful as we would with caustic. We both used it at home, so were more comfortable with it than the Chlorinated Manual Cleaner we started with.

Iodophor (4330 Spark I2) - Similar to the PBW, it is nice to have a less hazardous sanitizer for spraying ports or soaking fittings. It is only effective on clean surfaces, so it is important to remove of detritus before expecting it to work.

Grain Alcohol - Given its quick kill times and evaporation ethanol is the ideal sanitizer for spray bottles and any surfaces that are highly sensitive (e.g., yeast culturing). Isopropyl alcohol is another option.

General Concepts

Pre-Heating - At this scale a tank has so much thermal mass that you can't simply put 15 gallons (57 L) of hot water to a tank and expect it to still be hot after circulating. As a result if you want the caustic or acid to stay hot, you need to pray hot water into the tank. A tank with an electric element (like our keg washer has) helps too.

Sprayball - Most tanks have a port that leads to a sprayball, a small metal orb that spins and sprays when liquid is forced through. These aren't always perfect, and can have blind spots, especially in ports and above it. In addition, it isn't effective at cleaning its own exterior.

A sprayball from our kettle.

Passivation - This is what makes stainless steel stainless, a thin layer of chromium atoms at the surface that prevents iron from rusting or leeching into the beer (which weakens the equipment and shortens its lifespan). With a pristinely clean surface, the oxygen in the atmosphere is enough to accomplish this, but acids (especially nitric) are more effective.

Safety

 These chemicals aren't anything to joke about. Many brewers have scars gained from caustic or acid dripping onto their skin . Safety glasses, long gloves, chemical resistant boots and pants are a must when handling them. Read the safety data sheet for each chemical you are using and know what to do if some gets on your skin or in your eyes. I don't get to drink as much beer as I used to because the end of the day is usually the most dangerous time.

Scott and I prefer to have all of the tank's arms connected from the start, allowing us to use valves to direct the flow of the cleaning and sanitizing solutions. We started off using a manifold coming off the pump, but have changed to daisy-chained T's between the arms. Many brewers prefer to simply move a single output line from the pump between the arms. This requires less setup time, but more active effort once cleaning begins (moving the hose from arm to arm ~10 times through the process). It also carries additional risks if you move the hose without closing a valve.

Our Fermentor CIP Process

1. Once the beer is out of a tank, we turn off the glycol jackets and open the dump valve. We then shoot high-pressure cold water through the sprayball to remove most of the hops/yeast struck to the sides and bottom.

2. We use our on-demand hot water heater to generate 130F (54C) water to spray through the sprayball and manually through a hose to dislodge the bulk of the crud stuck to the sides/top of the fermentor. We'll run it through the pump to get good coverage.

Tankless on-demand hot water heater.

3. We briefly remove the lower fittings on the tanks (including manway, racking arm, thermometer, sample port) to spray out the trub caught in them.

4. We blow compressed air through the sprayball at ~30 PSI with the bottom valve open for 30 minutes. CO2 neutralizes caustic, so best to remove as much as possible before proceeding. This long is likely overkill for a 10 bbl tank, but can't hurt.

5. We assemble our cleaning rig, usually a pump running to the sprayball, with a T to connect it to the racking arm and another to the blow-off.

The pump we use for cleaning.

The fermentor during the cleaning process.

5. We preheat the tank for a couple minutes by spraying 160F (71C) water in and letting it drain. We hook the water line in right before the pump so we can immediately go to cleaning once it is preheated. Our goal is to get the tank to read ~130F (54C).

6. We then use the hot water heater's built-in meter to send 10-15 gallons of 160F (71C) water into the tank. We dose in 3 oz of caustic per gallon (2.3%) using a stainless steel elbow on one of the ports (chasing the caustic with water to ensure it get in). We then turn the elbow down to allow that port to equalize the pressure inside the tank, while preventing caustic from spitting out.

7. I like to send a little flow through the blow-off and racking arm first to soak them during the 20-25 minutes sprayball at full pressure (60 hz on our pump - or a bit slower if it cavitates). Then five minutes through the other arms, before a final five through the sprayball.

6. Dump the caustic. Rinse each arm with hot water, then burst rinse 10 times for 10 seconds at 130F (54C) through the sprayball, allowing it to drain before each successive rinse. I'll often put 10-15 gallons (38-57 L) into the tank once or twice and recirculate at the end to make sure there is enough pressure to spray all the surfaces. You can check the pH of the drained rinse water to ensure it has returned close normal before proceeding.

2. We then take off all of the fittings (including the sprayball itself), soak them in PBW or caustic. We inspect the fittings and gaskets, rinse and put into a bucket of iodophor. For the ports we spray, scrub and spritz with iodophor before reassembling. We also take the chance to inspect the interior with a flashlight to ensure there are no deposits.

7. We run acid blend at 2 oz per gallon (1.5% by volume) using roughly the same process and times as the caustic. Significantly higher concentrations should be used on new equipment and once a year to ensure adequate passivation.

8. Usually we'll air-dry at this point unless we need the tank the following day. In that case we'll rinse and then sanitize with peroxyacetic acid in cool water at 200 PPM using the same rig, and pressurize the tank to 4 PSI of CO2 to ensure it holds. The next morning we'll dump any residual sanitizer from each port before running wort or beer in.

The whole process including sanitation takes three hours, but most of that time isn't active (just waiting for a purge, or cycle). Going longer on any of the times isn't a big deal, so it is easy to run while working on other things if you keep track of your progress and don't miss a step.

We haven't gotten a CIP cart with dedicated vessels and pump, so our biggest issue currently is that it is difficult for one of us to clean a tank while the other person brews because they require some of the same equipment. Luckily our current schedule of two batches a week doesn't make that too much of an issue.

I am by no means holding this up as a perfect or ideal process. It'll likely be viewed as overkill by some, and inadequate by others. But if you have constructive suggestions, I'd love to hear them! I'd rather err towards overkill because we're dealing with several yeast strains (including killer wine yeast, Saccharomyces cerevisiae var. diastaticus, not to mention Brettanomyces and Pediococcus in a dedicated tank), although we do have the advantage of only dealing with kegs stored cold.

Other Pieces

We addition we'll pump the same chemicals through our heat exchanger and carbonation stone. For the heat exchanger we also heat pasteurize by running 180F (82C) water for 20 minutes inline once we assemble our knock-out rig (we discard the water until we see wort before sending to the fermentor). Our keg cleaner automatically does the same process on our sanke kegs, including air and CO2 purges to recapture the caustic and sanitizer.
... read more
by admin 0 Comments

Rings of Light – Hazy Pale Ale

Good To Know
Cleared by the final runnings.

My homebrewing-rate has slowed dramatically the last couple months, not coincidentally we brewed our first batch at the brewery around that time (House Saison brew day). Part of that is brewing 10 bbls about twice a week, the rest is how much time I spend at the brewery doing other stuff. My plan for The Mad Fermentationist is to keep up the same style of post, with recipes and tasting notes for occasional Sapwood Cellars beers. I'll still document homebrew batches when I can, mostly test batches or experiments with impractically weird ingredients.

The first beer I wanted to cover is my favorite of the initial four clean batches, Rings of Light. For those interested the name, is a subtle The Fellowship of the Rings reference: "They watched the pale rings of light round his lanterns as they dwindled into the foggy night." It is exactly the sort of beer I love drinking, moderate alcohol (4.8% ABV), but with a huge hop flavor and aroma and a surprisingly luscious mouthfeel. Luckily Untappd reviews have been pretty positive, and it is our tasting room's top seller so far!

You'll likely recognize most of the elements of the recipe as things Scott and I have been doing for years. Golden Naked Oats, Chit malt, Boddington's yeast (RVA Manchester), moderate-high chloride and sulfate, less expensive hops in the boil (Cascade and Columbus), and Citra dry-hopping. We added mid-late fermentation additions to several of our other batches, but this one was soft-crashed to 58F before dry hopping so we could harvest the yeast for re-pitching into an IPA (Cheater Hops) and DIPA (Uncontrollable Laughter). 

Scott dry hopping Rings of Light.

The process tweaks have mostly been to account for the differences related to the physics of working at scale. For example, usually I'd add a small dose of hops at 15 minutes to up the bitterness, but in this case the extended contact after flame-out makes that unnecessary (between whirlpool, settling, and run-off near-boiling wort is in contact with hops for more than a hour). In fact, we added one barrel of cold water at flame-out to lower the whirlpool temperature to reduce isomerization. Beersmith 3 includes the capability to specify the average temperature of the wort during the whirlpool, still the estimate seems to be wildly higher than the perceived bitterness. I wonder if the hops settling, mixing with the proteins in the trub-cone slows the isomerization rate?

It has taken a little time to dial in our Forgeworks brew house. We achieved slightly lower efficiency and attenuation on this batch than expected for example. We've made a few mistakes and miscalculations along the way, but given neither of us had brewed frequently at a commercial scale I'm happy to report that things have been relatively smooth. Our biggest issues have been with the durability of the equipment itself. For example the rakes in the mash tun detached from the motor twice, and our burner shorted after a boil-over. What is taking the most effort to optimize is our cleaning and sanitation regimen. 

Kegging pale ale.

Thanks to everyone who came out to our grand opening last weekend! I didn't expect as many fans of the blog to drive from an hour or more away to try the beers and say hello. Either Scott or I will be there most of the time we're open, so let us know! Happy to show you around and talk brewing. For those further away, I'm also running the brewery's Twitter and Facebook accounts for now (Scott took Instagram because I couldn't figure it out).

Rings of Light in the tasting room.

Rings of Light

 Smell – Pleasantly mango-melon hop aroma. As it approaches room temperature I get a slightly toasty-vanilla-richness thanks to the yeast playing off the Golden Naked Oats. Otherwise a pretty clean/fresh aroma.

Appearance – Pleasantly hazy yellow, glowing in the right lighting. I guess we did an adequate job avoiding oxygen pickup during transfers and kegging as it hasn’t darkened! We certainly pulled some hop matter into the bright tank, but it mostly settled out and stayed behind when we kegged, as I don’t see any particulate in the pour. Head is really thick, but could have better retention.

Taste – I really love the flavor on this, really saturated with juicy hops. Similar to the aroma, the tropical flavors from the Citra dominate the Cascade and Columbus. We were surprised how hop-forward it was even before dry hopping (perhaps thanks to the deep kettle slowing the evaporation of the oils?). Bitterness is pleasant, but restrained. Well below the estimated 70+ IBUs, more like 40-50 to my palate.

Mouthfeel – Full bodied, especially for a  sub-5% beer. That is thanks to the oats, and low attenuation (which allowed for more malt for the given alcohol). As usually the substantial texture of the head from the chit malt really enhances the perception of creaminess.

Drinkability & Notes – Glad this beer ended up as an early-fall release. It is a little full for a quenching summer pale ale, but it is perfect for temperate weather. The hops are well balanced, and provide enough interest to demand each additional sip. The malt mostly stays hidden, while providing adequate support.

Changes for Next Time – We’ve already got a new batch of this fermenting with the same grist and kettle-hops, although given the tweaks (higher original gravity and different yeast: Lallemand New England and S-04) it may receive a different name.

Recipe

Batch Size: 315.00 gal
SRM: 4.9
IBU: 73.7
OG: 1.052
FG: 1.018
ABV: 4.8%
Final pH: 4.54
Brewhouse Efficiency: 68%
Boil Time: 60 Mins

Fermentables
-----------------
75% - 495 lbs Rahr 2-Row Brewer's Malt
16.7% - 110 lbs Simpsons Golden Naked Oats
8.3% - 55 lbs Best Chit Malt

Mash
-------
Mash In - 60 min @ 153F

Hops
-------
11 lbs Cascade (Pellets, 7.20% AA) - Steep/Whirlpool 75.0 min
11 lbs Columbus (Pellets, 15.70% AA) - Steep/Whirlpool 75.0 min
22 lbs Citra (Pellets, 12.00% AA) - Dry Hop Day 10

Other
-------
40 g Whirlfloc G @ 15 mins

Water
-------
200 ml Phosphoric Acid 75% @ Mash
1.00 lb Calcium Chloride @ Mash
0.70 lb Gypsum (Calcium Sulfate) @ Mash
50 ml Phosphoric Acid 75% @ Sparge

Calcium
Chloride
Sulfate
Sodium
Magnesium
Carbonate
120
150
100
20
5
100

Yeast
-------
RVA Manchester Ale #132

Notes
-------
Brewed 8/29/18

Collected 315 gallons of water.

All salts and 100 ml acid right after mash-in. Ran rakes for 15 minutes, started recirculation 10 minutes after mash in. After 10 min of recirculation, measured temp at 152.8F.

Measured mash pH at 5.42, add 50 mL more acid. 5.39, add 50 mL more acid. 5.34.

Sparge water 183F, pH 6.47 with acid addition - more next time

Start of boil with 11 bbls of 1.055 runnings.

Added 1 bbl of cold water at the start of the whirlpool. Combined temperature 196F, added hops.

Run-off started at 66F. .5L/min of O2 through in-line stone.

Ended up with a wort temperature of 64F. Set tank to to 66F. By the next morning the glycol chiller had popped the breaker and the tank was at 69F... Reset and lowered to 67F.

8/31 Raised set-point to 69F to ensure finish.

9/3 Fermentation appears nearly complete from lack of CO2 production. Tastes good, better hop aroma than expected. Up to 70F to ensure it is done before soft crashing.

9/6 Harvested yeast. Left blow-off open so no dissolved CO2.

9/7 Dry hopped with 22 lbs of Citra through the top port while running 25 PSI of CO2 and blow-off arm closed. Closed everything and add 5 PSI as head pressure.

9/8 Pushed 15 PSI through racking arm for 1 minute to rouse, 18 hours after dry hopping. Dropped temperature to 54F.

9/9 Pushed 15 PSI through racking arm for 1 minute. Dropped temperature to 50F.

9/10 Crashed to 36F.

9/12 Moved to bright tank. 3 L/min of CO2 set to 16 PSI got to ~11 PSI at 36 F. 2.6 volumes of CO2 prior to kegging.

9/15 Kegged, 17 kegs with the last almost full.

I get a commission if you buy something after clicking the links to MoreBeer/Amazon/Adventures in Homebrewing/Great Fermentations!
... read more
by admin 0 Comments

I, Beer: What Goes Into Brewing

Good To Know
I, Pencil is a classic economics essay from 1958 by Leonard Read about the complexity of making a pencil. The iconic yellow #2 seems so simple, yet no one person could make it on their own (e.g., harvest the rubber, synthesis the polymers and pigments for the eraser, create the yellow paint, precisely cut the wood and graphite, mine and forge the metal band etc. ). The global economy doesn't have any person or group coordinating all of this activity, but to earn money people and companies fill niches, specialize, and compete to buy and sell in ways that creates things of immense complexity requiring the sum work of hundreds of people across continents so you can buy a pencil for $.25. This video gives a more hands-on view of what it takes to make a chicken sandwich when you don't buy anything from a supermarket.

It is tempting to say that beer isn’t like that. After all, each all-grain batch starts with the four basic ingredients and we do the rest… sure it would be a challenge to grow and malt barley, harvest and dry hops, isolate/propagate wild yeast, and haul water from a local stream, but what vessels would you use to boil/ferment? What about sanitizer, minerals, clarifiers, compressed CO2?

What follows is a high-level overview of what is required to brew a single batch of beer at Sapwood Cellars. Obviously, you could keep digging deeper into each one of these, peeling back layer-after-layer to the inputs of each input (e.g., the shoes that the hop harvester was wearing). I’ll arbitrarily stop where I lose interest. Needless to say though, the work of thousands in not millions of people goes into each of our batches. Scott and I just get the credit (or blame) because we're the ones at the end of the chain!

Ingredients

Water

Our water comes from Liberty Reservoir. From there it goes to Baltimore’s Ashburton water treatment plant. Baltibrew posted a nice series on the Baltimore water system. Luckily for us the existing minerals are mostly beneficial to the character of our beer. The carbonate is a bit higher than we’d like, but not by enough to require the waste of reverse osmosis.

Once pipes take it to the brewery it passes through a carbon filter to remove chlorine, and then an on-demand hot water heater. The fuel is natural gas piped into the brewery by BG&E (by way of fracking or older methods, and then refining). From there the water travels through a hose to our hot liquor tank where an electric element allows us to adjust the temperature. The electricity comes from a mix of fossil fuels, nuclear, and ~5% renewables.

To adjust the mineral content of the water, we add calcium chloride (from limestone-hydrochloric acid reaction or natural brine concentration) and calcium sulfate (harvested and refined from gypsum rock deposits). In addition, we add 75% phosphoric acid to adjust the pH of the water. Phosphoric acid is usually produced by combustion, hydration, and demisted from three ingredients: phosphorus, air, and water.


Grains

The grain we mash is a mixture of barley, wheat, oats, and rye depending on the beer. These are grown primarily on farms in North America and Europe. It is then soaked, sprouted, dried, and kilned by a maltster. The precise equipment required varies by malt and producer. In some cases it is a large industrial operation, in others the malt is still manually turned. The bulk of our base malt is Rahr brewer’s 2-row from Minnesota, but in our first order we also had sacks from Briess, Chateau, Simpsons, Crisp, Best etc. Most of the unmalted flaked grains (steamed and rolled to gelatinize their starches) are from Grain Millers.

We decided to hold-off on buying our own mill, to save the cost at the start… but after a few brews I can say a mill and auger are in our near future. We order our grains from Brewers Supply Group, which pre-mills the grain. We also occasionally add a few sacks to a Maryland Homebrew order from Country Malt.

Once we’re done with the now “spent” grain, they are picked-up by Keith of Porch View Farms. He feeds it to his animals as most of the carbohydrates are extracted into the wort, but proteins remain.


Hops

Our hops are grown throughout the higher latitudes of the globe, primarily the Pacific Northwest of the United States, but also Australia, Germany, and Czech Republic. The hops are first stripped from their bines, dried in an oast, and then baled. After selection, various lots are blended to create a consistent product and the hops are pulverized and pelletized. They are then vacuum-packed in mylar and stored cold to preserve their aromatics. Our hops primarily came from Hop Havoc, but we’re working on getting contracts for the upcoming harvest.


Yeast

Most of the yeast we’re using are the decedents of yeast that have been fermenting beer for hundreds or thousands of years. A couple hundred years ago their ancestors were part of a mixed-culture at breweries in England and Belgium, only to be lucky (and talented) enough to be isolated as a pure culture that gained success. Our Saccharomyces cerevisiae so far has come from RVA, Fermentis, and Lallemand for our “clean” beers. These needed to be isolated, propagated, and in some cases dried.

The sour and wild beers are too complex to track. They come from labs, bottle dregs, and a house culture. They may have come via a barrel, the breeze, an insect, or any number of other vectors into a brewery or labs. For example the Hanseniaspora vineae we are fermenting a hoppy sour for Denizen's Make It Funky festival came from Wild Pitch Yeast which isolated it from tree bark.


Fruit

We don’t have any beers far enough along for fruit, but we’re planning to source as much of it as we can directly from local farms and orchards. Most fruit is at its best when it is picked ripe and used quickly. I'm sure we'll use dried fruit, aseptic purees, juices, and freeze-dried fruits depending on quality, availability, and desired results as well. The first batch will probably be a tart saison on grape pumace (the pressed skins) from a local natural winery.


Other Consumables

Gas

Carbon dioxide is usually produced as a byproduct of some other activity (e.g., hydrocarbon processing). Our CO2 is stored in a 750 lb tank in a liquid state. We use it to carbonate and serve beer. It isn't economical at our scale to recapture the CO2 released by fermentation. Our supplier is Robert’s Oxygen.

As the air on Earth is 70% nitrogen it is usually concentrated with the use of a nitrogen generator. These rely on a membrane that allows nitrogen through. We need nitrogen to help push the beer through the long-lines from our walk-in to the tasting room (pure CO2 would lead to over-carbonation at those pressures). As the second most abundant gas in the atmosphere, oxygen generation uses similar technologies. We pump .5L/minute into the wort as it exits the heat exchanger, the yeast quickly uses it to create sterols for healthy cell walls when they bud. We get these two gases in large cylinders that are swapped out.

Chemicals

We need cleaners like caustic (sodium hydroxide) to remove organic deposits, and a phosphoric-nitric acid blend to remove inorganic beer stone and passivate the stainless steel. For sanitation we use iodophor for fittings in buckets, and peracetic acid for the tanks. These are made in a variety of industrial processes that I’m totally unaware of. Our chemicals are provided by Zep/AFCO.

Clarifier

Whirlfloc G helps proteins clump together in the last 15 minutes of the boil to be left behind. It is derived from Irish moss (seaweed) that is dried and granulated. As a vegan brewery, no gelatin or isinglass for us.

Barrels

Oak barrels start as oak trees. They are processed into planks, and then purchased by a cooperage which dries (either in a kiln or naturally). They are then assembled into barrels with metal hops, toasted, and sealed. From there they go to vineyards and distilleries that age their products in them. Beer is best in barrels that have already lost much of their oak character, so we buy them from other producers. A small amount of the wine or spirit is still present in the wood, providing a moderate contribution to the first batch, diminishing with each additional batch.


Equipment

The stainless steal for the vast majority of our equipment comes from China. Our brewhouse was constructed by Forgeworks in Colorado. Our fermentors and bright tank from Apex and DME in China. Our keg washer from Colorado Brewing.

The cooling of the fermentors is accomplished by a glycol chiller from G&D Chillers in Oregon. The ethylene glycol itself comes from ethylene and oxygen. The chiller also assists chilling the wort with our two-stage Thermaline heat exchanger (primarily more stainless steel). The copper pipes that carry the glycol are insulated with Armaflex. The flow of the glycol to individual tanks is controlled by electronic temperature sensors and solenoid valves.

Other equipment includes hydrometer, refractometer, pH meter, hoses, gaskets, and all manner of other valves and fittings.

For the space itself there was already plenty of concrete, bricks and metal. We hired Kolb Electric and B&B Pipefitters to do the installation of the bulk of the wires, pipes, and connections.

There is also everything that goes into serving a beer once it is ready. Kegs (Corny kegs for the sours and infusions, sanke for the standard clean beers), stainless steel fittings, beer lines, glasses (including the printed logo and the glasswasher) etc.


What’s the Point?

I don’t really have one. To me it is just remarkable how much of the complexity of brewing a batch of beer is now hidden in the inputs. I know how to brew beer at my house or a brewery, but if you put me out in the woods even with all the ingredients, I couldn’t brew a batch. Thinking about what is required for each batch makes me appreciate how nice it is to live in a time when I can brew beer as simply as going online and ordering the equipment and ingredients I want. It also shows me how much I still have to learn about making beer.

At the same time, it means that beers everywhere are mostly separated by the choices the brewer makes rather than the availability of ingredients. The exchange of information accelerated by the Internet. I hope there continue to be regional variations, specialties, and preferences. Traveling isn't as exciting when everyone brews NEIPA and pastry stouts.


... read more
by admin 0 Comments