1/ crushing the malt
The grains of malt are crushed between precisely adjusted rollers to release the starch and the flavours and aromas of the malt for the subsequent brewing stages. The crushing process is fine-tuned to the size of the grain to preserve the bran, which will function as a natural filter.
2/ producing the mash
Water is added to the ground malt or grist, and the resulting mixture, now called mash, is gradually heated from 50°C to 80°C so that enzymes released from the malt can get to work converting the starch into sugars.
The mash has now been mixed with water and is pumped into a filtration basin. At this stage, the liquid wort is separated from the solid bran. The bran will be used as cattle feed and the wort, with its valuable sugars and flavours, is carefully pumped into the boiling kettle.
The wort now boils for an hour-and-a-quarter at a temperature of 100°C. At this stage the hops are added in quantities determined by how bitter the brewer would like the finished beer to be. The blend of wort and hops is now cooled down with the aid of a plate cooler.
5/ main fermentation
In the fermentation tanks the yeast will provide the beers of Brasserie de Silly with their unique flavour as they morph sugars into alcohol. The length of this stage depends on the type of beer: 10 to 11 days at 12°C for bottom fermentation (Pils, Pils Bio), or five to six days at around 22°C in the case of top fermentation.
6/ cold storage
The beer is now maturing and will spend between three weeks and a month at a temperature of 0°C depending on the fermentation method. In the cold storage phase the beer undergoes a moderate fermentation that converts the residual sugars into alcohol.
A number of Silly beers, including the Pils, are filtered to improve clarity. The beer is now ready to be bottled or pumped into barrels.
Specific beers make their way to the refermentation chamber after bottling so they can re-ferment in the bottle.
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The last stage uses several bottling lines. The beer now goes into bottles of 25, 33 or 75cl or 1.5 l or is used to fill barrels with volumes of 20, 25, 30 or 50 l.