Brewing at Soul Barrel

Creating Rich Flavours

Our Brewing Process

The brewing process and the raw materials used both contribute equally to the flavour of the beer. This process has followed the same basic steps for thousands of years. While the technology available to us and our scientific understanding of this process has evolved, the steps involved remain the same. Here’s a glimpse into how we brew our artisanal beers…

Raw Materials

World-class beer starts with quality raw materials. A beer will only be as great as the potential provided by the ingredients. Most beer is made up of four ingredients: malt, hops, water, and yeast, although craft and Belgian brewing traditions embrace exploring any and all ingredients in the endless quest for flavour and innovation.

Mill, Mash Tun, Lauter

All alcohol is the product of yeast consuming sugar and converting it into CO2 and alcohol. Alcoholic beverages differ regarding where that sugar source comes from and how it is processed. In beer, the sugar comes from cereal grain starch that we convert into sugar in a process called mashing.

This begins with milling the grain, which exposes the internal part of the grain and grants us access to this starch. We then mix the milled grain with hot water, which activates enzymes from the malt that convert the starch into sugar. This process takes about an hour. Once all the starch has been converted into sugar, we separate the sweet sugar liquid called wort from the husks and other grain remains. This is accomplished in a draining and rinsing step called Lautering. Our spent grain then goes to local farmers to be used as cattle feed.

Kettle

Once we’ve collected all the sweet liquid in the kettle, we begin boiling. Centuries ago mankind discovered the beneficial properties of boiling which include sterilization, evaporation, protein precipitation and isomerization of the hops. It is at this step that we add hops to contribute a bitterness that balances the sweetness from the malt. Once the boiling is done we cool the wort down and pitch the yeast!

Hopback, Dryhopping

At Soul Barrel we are insane about hops! While we add hops at different stages during boiling to add bitterness, flavour and aroma, we also add hops at the end of the boil during whirlpool, on the way to the fermenter in our custom hopback, and during fermenting and ageing in a step called dry hopping. This enables us to capture the delicate aroma and flavour expressions of the hop blends that would otherwise be driven off during the boil.

Cellar

Once the beer has been boiled and cooled, it is mixed with yeast in the fermentation tank. This is where fermentation begins. The yeast will consume the sugars and produce CO2, alcohol and flavour by-products. Our custom-designed stainless-steel tanks are called cyndroconicals. Their unique shape enables us to ferment and age beer in the same tank. We have additional dedicated ageing and dry hopping tanks, and we also employ a cellar of used wine barrels to explore wood ageing techniques that merge winemaking methods with beer-making experimentation.

Explore the Ingredients

Click to learn more about our Raw Materials

Malt is sometimes referred to as the soul of beer. Malt refers to any cereal grain that has been malted. Malting is the process of changing the biological, physical and chemical properties of the raw grain to enable the brewer to make use of the starch within the grain. This starch is then converted to sugar in mashing during the brewing process.

 

The sugar is what the yeast consumes during fermentation to create alcohol and make beer! Most of the malt in brewing comes from special malting barley, but wheat, rye, oats and any other seeds can also be used. The use of malt as our sugar source is what separates us brewers from the wine, cider and mead maker.

 

At Soul Barrel most of our malt comes from specialty maltsters Simpsons in the UK and Weyermann in Germany. These malts cost double versus other options but we believe the quality is worth it. Rich malts are the foundation of beer flavour. This choice is consistent with our mission to brew South Africans the highest quality beer without compromise.

Brewers have been using hops to balance the flavours from malt since medieval times. Hops are the cones of the perennial hop vine and are added at many stages throughout the brewing process. Hops add a refreshing bitterness and their essential oils can also add grassy, citrus, and various other flavours to the beer. Hops are grown all over the world, including South Africa, but the majority come from the Pacific NW in the US and Germany.

 

At Soul Barrel, we are outrageously passionate about hops because of their unique fruit and citrus flavours and the crisp bitterness they contribute to beer. Hops come in numerous varieties that each have unique flavour profiles they display in beer. Even though it costs four times the price, we brew with a wide range of specialty hops from all over the world. Hops from the Yakima Valley in the US are particularly dear to our heart. We are also passionate about using South African hops and supporting our local hop industry. By blending the best international flavours with local passion and ingredients we aspire to brew the best beer in the world right here in South Africa.

Brewers make wort, a sugary malt liquid, which yeast consumes to make beer. Yeast is a single celled living organism that converts sugar into CO2 and alcohol during its reproduction cycle. Yeast is a fascinating organism that is one of the most universal and widespread organisms on earth.

 

Beyond creating carbonation and alcohol, yeast comes in a variety of different strains that each contribute unique flavours, which are an essential part of the flavour profile of a beer. We use a variety of different yeasts unique to our brewery and maintain a proprietary house-mixed culture of yeasts that goes into our farmhouse and Belgian style ales. This house culture gives our farmhouse ales a provenance unlike anything else in the world.

Water is ironically the unsung hero of brewing ingredients, even though most beers are 95% water! Beyond providing the medium to combine hops and malt, water contains dissolved minerals and ions that contribute to brewing performance, yeast health and beer flavour and mouthfeel.

 

At Soul Barrel, we use well water from the Simonsberg Mountain aquifer, which provides us with a fresh blank canvas with which we can create any beer within our imagination!
Wood – Almost all beer today is fermented and aged in stainless steel, but for centuries wood barrels were the only vessel used to brew and transport beer.

Our farmhouse and wild Belgian ales are aged and fermented in used wine barrels. These barrels infuse beautiful flavours from the wood and previous residence, as well as creating the perfect environment for a long, complex fermentation and aging.

Limiting ourselves to malt, hops, yeast and water would be boring! Throughout human history brewers have utilized what has grown around them to impart flavour, complexity, and depth. We get excited about using local fruits, fynbos and agricultural products in our beer.

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