In this concise walkthrough, Stuart from Iron John's Brewery details the end‑to‑end brewing workflow used at their facility. He begins with grain milling and mash tun operation, describing how milled malt is mixed with water, forms a grain bed, and is recirculated to maximize flavor extraction. After about 45 minutes the wort is transferred to a boiling kettle where it cooks for roughly an hour, with temperature and boil time monitored. The hot wort is then cooled rapidly through a glycol‑driven heat exchanger to around 70 °F, making it safe for fermentation. Fermenters are jacketed with glycol‑controlled temperature loops; ale fermentations run at 65‑68 °F while lagers and pilsners ferment at 30‑34 °F, each tank independently regulated. The fermented beer moves to bright tanks for final carbonation, where CO₂ is applied up to 15 psi. Finally, the beer is either filtered into kegs or sent to a newly installed canning line for packaging. The second speaker reacts with amazement, highlighting the brevity and completeness of the explanation.
Chapters
grain, malt, all that gets ground up and put through the top of here. We still have to set up our auger. And then it's basically in here, it's like a false bottom, kind of like a T-thing. So as the mash forms, it creates a bed basically, and the water forms through it, and that's where all the flavor comes. And then we use a pump and we pump it back over itself to get the most flavor. And once that process has happened, it normally takes about 45 minutes, then we transfer it into the kettle. Where we use a pump, pump it in, and it gets put in there for about an hour. It will cook, it'll boil basically until we get it to the point that we're looking for. You take some measurements, make sure everything's good, and it gets pumped through what's called a heat exchanger, which is this piece right here, which cools the boiling beer using glycol and cold water, um, to about 70 degrees, which then makes it safe to transfer into the fermenters. Um, the fermenters each have a jacket around the outside that, um, runs off of glycol. So cold glycol at about 28 degrees is flowing whenever it needs it using the control module. And, um, we— depending on the style of beer, like if it's like a, um, an ale, it's going to be warmer, so it'd probably stay in like this 65-68 range for for a couple weeks until it's fermented. And like colder beers like lagers and pilsners, um, uh, they take longer to ferment, but you ferment them at like a 30, 34, 32 degree range. Um, so basically what's coming down all the time is the same temperature, but each tank has its own control, so we can do several different styles all at once. And then the final process is it goes in the two end tanks, which are bright tanks., and those are where they get the finishing, basically carbonation. So we put CO2 in there up to 15 PSI, and it basically gives the beer its carbonation. And then from there we go to either kegs, through a filter into kegs, or directly into a canning line that we just purchased. And then that's the final packaging.
So. Wow. Goes all the way through. That was 2 minutes and you just explained the whole beer process. That was pretty amazing. There's more to it, but that's the simplest way of going through it all. That's pretty amazing.