The Brewery

The Happy Goblin Brewery uses a small custom built brewing system, that has been assembled by Colin and Mike. It is continually being upgraded and scaled up as the brewery grows.

The System
The Mill

The Mill - A homebrew mill with a motor attached. Grinds more than a kilo of malt per minute. The grain is just cracked, rather than ground completely. The husks need to be intact. After grinding the malt is called the grist. This is added to the mash tun.

 

Mash Tun

Mash Tun - A well insulated 400L stainless steel tank with a false bottom made of perforated stainless sheet that acts as a strainer and a large gauge valve in the centre of the sloped floor. The grist is mixed with hot water and left to soak for one hour while the starch in the malt is converted to sugar by various malt enzymes. The water (with the dissolved sugars) is strained off and more hot water added to rinse as much of the sugars out as possible, this water is called sweet wort (pronounced wert). The wort drains out into a small tank, and is then pumped up into the kettle.

 

The Kettle

Kettle - 240L stainless steel kettle, heated by a 4-ring propane burner. The sweet wort is brought to the boil and hops are added. Hops are the flowers of the hop plant and contain bitter compounds that are extracted into the wort by boiling. After an hour or more of boiling the heating is stopped and the wort is allowed to settle, all the hops sink to the bottom along with much of the protein from the malt which has reacted with compounds from the hops to form an insoluble material known as trub. The clear, hopped wort is the run off through the heat exchanger.

 

Fermenters

Fermenter - The primary fermenter is a 300L flat bottomed, stainless steel tank. The fermentation process starts with the yeast being added to the chilled wort. The primary fermentation lasts 5 days after which the beer is transferred to the maturing vessels. During primary fermentation most of the available sugars are used by the yeast to make alcohol. Much of the yeast drops to the bottom of the tank after fermentation slows down, and is left behind when the beer is transferred.

 

Maturing

Maturing - The beer matures in 54L glass demijohns that are usually used for winemaking. During maturation the last of the available sugars are fermented slowly and the flavour of the beer develops. More yeast also drops to the bottom leaving the beer clearer.

 

Maturing

Kegging - The demijohns containing the finshed beer are raised on a pulley system, and the beer siphoned into either 18L or 50L kegs. The kegs are chilled and carbonated and the beer is ready to be served.

 

Packaging

Packaging - All of our bottling is done by hand into either 330mL or 650mL bottles. A small amount of uncarbonated beer is packaged in 2L and 5L flagons, straight from the maturing vessels.