Brewing the Hooky way

Brewing from top to bottom

Life starts early in every brewery and Hook Norton is no different. 

toursWhat sets our brewery apart is the way that it is done.  No automated systems leap into action here. Instead, someone will be here to coax the steam engine into life and then climb the stairs in order to rouse the beer by hand, using a paddle, 365 days of the year. At every stage of the process we are close to our product as it rises and falls through the brewery building, so we can be confident that all the systems and processes are working as they should be to help us produce our award-winning beer.

  • Stage One
  • Stage Two
  • Stage Three
  • Stage Four
  • Stage Five
  • Stage Six
  • Stage Seven
  • Stage Eight
  • Stage Nine
  • Stage Ten
 
 
 
 
 
 
 
 
 
 
The factory image
barrel image
 
 
 
 
 
 
 
 
 
 

Stage one

Liquor is pumped from the well

Brewing begins with the liquor (water) being pumped from a well below the brewery up to the cold liquor tank which is right at the very top of the tower.

Brewing from top to bottom

Stage two

Checking and crushing the malt

Next comes the malt. First of all the mill is checked to ensure that it has the correct crush characteristics.  The mill rolls have to be set to give the desired blend of husk, grits and flour to allow good extract and efficient run off from the mash tun.

Once it has been checked, the malt is crushed in the Grist mill from where it travels to the masher and then on to the mash tuns.

Brewing from top to bottom

Stage three

Grist Hopper

The malt that has been crushed in the mill (grist) is stored in the grist hopper ready for use. Cold water (liquor) then travels from the cold liquor tank into the hot liquor tank where it is heated in preparation for mashing with the grist.

 

 

Brewing from top to bottom

Stage four

Mashing

The first job of the day, usually at about 6am, is mashing. The crushed malt is mixed with hot liquor through a Steeles masher which then feeds down into one of the two mash tuns.

Mashing-in itself takes 10 minutes, then the mash is allowed to stand for 90 minutes to allow the conversion of starch to fermentable sugars to take place.

This is a process at Hook Norton Brewery that has not changed in 100 years. After standing for 90 minutes, the sweet sugary solution that is created (called wort) is drained from the mash tun, and is run by gravity to one of the two coppers.

The mash is then sprayed with hot liquor through a rotating sparge arm, this allows all of the sugars to be washed from the malt to maximise the extract. The run off process takes approximately 2 ½ hours.

Brewing from top to bottom

Stage five

The Copper

The next step is to check the quality of the hops prior to them being added to the copper.

The choicest hops are used in Hook Norton Beers. Traditional varieties such as Fuggles, Goldings & Challenger dominate with First Gold & Styrian Goldings also being used in some seasonal ales. Late Copper hopping is key to the hop characteristic found in Hook Norton Beers. In addition all beers are dry hopped in cask with Goldings Hops.

In the 2 ½ hours it takes the wort to run off the mash tun, the copper is gradually filling and coming to the boil. Our chosen blend of hops is added and the copper is then boiled for 1 hour 15 minutes. This process allows the bitterness to be extracted from the hops.

Brewing from top to bottom

Stage six

The Hop Back

After boiling the copper is "cast" to the Hop Back where the hops settle and the wort is strained through them.

Brewing from top to bottom

Stage seven

Cooling System

The bitter/sweet wort is pumped to the top of the brewery for cooling before being chilled through a place heat exchanger and allowed to flow into the fermentation vessel.

Brewing from top to bottom

Stage eight

Fermentation

Yeast is then added to the collected wort in the fermenting vessel (a process called ‘pitching’) and fermentation then commences. Hook Norton Beers will remain in the fermenting vessel for a full 7 days. In that time the sugars from the malt will be converted into alcohol by the yeast, with carbon dioxide being evolved as fermentation proceeds.

After 4 days the yeast is removed, using the parachute system, then the beer is gently cooled to accelerate the flocculation and sedimention of the yeast. Gravity and temperature are checked throughout the fermentation process to monitor and control the speed of fermentation. A saccharometer is used to measure the specific gravity.

Brewing from top to bottom

Stage nine

Storage Tank

After fermentation the beer is cooled and checked for aroma, palate, colour, alcohol and trueness to type before being transferred to a Storage Tank reading for racking.

Brewing from top to bottom

Stage ten

Cask Racking

Finally the beer is run into casks, a process called racking. Secondary fermentation then takes place.

Then follows the most important check of all! Representative samples of each rack are taken and set up on a stillage. They are checked to assess quality and to monitor flavour throughout the life of the beer.

The beers are checked each day and the assessments are recorded.

Brewing from top to bottom