PROCESS

From the farm to the brewery, the malting process can be explained in 3 steps

The seeds must soak for 40 hours prior to germination to increase their moisture content

The seeds absorb all the oxygen in the water, so carbon dioxide is periodically pumped into the water.

STEP 1 – STEEPING

The first and most important part of the malting process begins with the steeping phase; were all grain types are cleaned and sorted by kernel size, and immersed in our steeping tanks for a period of 40-48 hours where the grain is allowed to uptake water. The process itself is executed by a series of soaking periods, followed by resting periods with no water, where the grain swells in size and moisture within the kernel is increased from roughly 12% to as high as 48%. This process allows for hydration of grain cell walls and proteins, required for uniform germination. Steeping is complete when the barley has reached a sufficient moisture level, to allow uniform breakdown of the starches and proteins that occur during the germination phase.

STEP 2 – GERMINATION

All of our grain germination takes place via the traditional method of floor malting. The germination phase can take as little as 3 and sometimes as long as 7 days to ensure that the grain has been allowed to fully modify. This modification allows for the break-down of protein and carbohydrates, and the degradation of the seeds starch reserves; all resulting in the formation of fermentable sugars which can then be consumed by yeast in the brewing process. The grain bed is manually raked every 4-6 hours by our Maltster to prevent matting, along with visually and physically inspecting the grain to determine when full modification has taken place.
The germination process is a precise science.

The seeds must be raked every 4-6 hours to prevent the rootlets from becoming entangled.

The seeds go through a precise drying process before shipping.

The seeds are precisely dried to the customers desired moisture content.

STEP 3 – KILNING

The germination phase is halted by the drying process and it is essential that this process takes place quickly. Continued growth of the seed would eventually consume the seeds food reserves and reduce the extract efficiencies within brew houses and distilleries. The grain is further dried with higher temperatures that create complexities and flavors in the finished malted product. With a sufficient amount of aging time, the grain is now ready to be used by breweries and distilleries across New York State.