Posts Tagged ‘Expansion’


Previous Expansion Posts




Brewery Expansion – Part II

Thursday, May 16th, 2013

Part two of our brewery expansion blog post series. If you missed out on Part I, you can catch up here.

Phase VI
Expand glycol lines and install new fermentor

The first part of this phase involved Captain Chris driving the BT1 (Brewery Truck 1) down to San Marcos to pick up the new fermentor. This, of course, also involved staying down there for an extra night hobnobbing it with other breweries and having a few beers. Market research.

After we unloaded it at the brewery, it was time to use our good friend the rotohammer again and anchor the fermentor to the ground.

Then, we began Operation Frosty Pipes II and extended our glycol line down the wall with ports for several fermentors to come.

After we hooked our new fermentor up to the glycol lines, it was time to christen the new ferementor “Resi” right before we pumped our first batch over to her.


(pretty sure we’re still cleaning up glass after that)

Phase VII
Expand Brewery Barrel Program

With the increased storage over at the other location, we have the ability to store more barrels and expand our barrel aged beer program.

ebc-barrel-program-start

To start off we got 6 Jim Beam bourbon barrels, thanks to The Bruery ordering extra for us. We have four of these filled with Daniel Irons Oatmeal Stout, and one filled with Black Valkyrie.

What will we fill in the remaining barrel? At this point, only time will tell – but rumor has it, it could be an IPA.

Phase VIII
Acquire New Brite Tank from Ladyface

tax-determination-tank-2

This was a surprise expansion phase for us. While some phrases are banned from the brewery like “accidental validation” or “unmarked chemicals” (safety first!), “surprise expansion” is not – and is in fact welcomed. Ladyface Brewery is currently upgrading the size of their tanks, and we were fortunate enough to be offered one of the 7bbl tanks they are replacing. So we stopped by one afternoon, picked it up and delivered it to the brewery.

picking up tank from ladyface

It is currently named “Tax Determination Tank #2” – however we do have a planned renaming and christening ceremony like all new tanks at Enegren Brewing. Stay tuned…

It should also be noted that Fireman Dave purchased a new and improved roto hammer which cut our cement drilling time down from 5 hours to 10 minutes. May we never speak of the old roto hammer again.

Phase IX
Embiggen Tasting Room Area

In an effort to provide even more seating than previously imagined in Phase IV of our expansion plan – the brewery crew got creative and smashed down the wall separating the office and the tasting room.

We had several options of how to tear down the wall. The first was the classic move from The Shining – only problem is it didn’t tear down the wall completely and was just a little creepy.

the-shining-heres-johnny.

Our second option was to tear down the wall X-Men Juggernaut style – but we were afraid that we wouldn’t be able to stop before crashing into our brewery.

the_juggernaut

Our third and final option was to relive our childhood and attempt the classic Kool-Aid “OOOOHHH YEAAAAAHHH” wall breakdown.

Kool-Aid-Man-through-wall

After some debating, we decided to go for the Kool Aid wall breakdown – but it didn’t go quite according to plan. You can see for yourself in the video, but it turned out to be more of a cross between The Shining and Kool Aid.

Stay tuned for the third and final installment of our Brewery Expansion!

Brewery Expansion – Part I

Wednesday, April 10th, 2013

If you’ve stopped by the brewery over the past three months, you might have noticed some changes. And, as you might have surmised, we are expanding. While normally we post our upgrades as they happen – with all the time and effort we’ve put into the big brewery expansion we’ve found it hard to spare the few hours to write them all up. So, over our next few posts, we’ll catalog what’s happened at the brewery, and what is still to come.

The big brewery expansion plan’s goals are fourfold:
1) To increase current brewing capacity & barrel aging program
2) Lay the foundation for future brewing capacity expansion
3) Increase brewing efficiency
4) Expand tasting room

The project was broken into several phases spread over several months. Most of our expansion is complete, but there are still some upcoming changes.

Phase I
Secure a new unit close to the brewery for increased dry and cold storage.

After months of searching, and trying hard to get the unit directly across the alley, we found a new place about a block away from the brewery off Zachery Street. The building, roughly the same size and shape as our brewery & tasting room, is a perfect size and shape for our storage needs.

Our lease started December 2012, and we quickly moved to utilize our new-found space and implemented phase II of our expansion.

Phase II
Move Dry storage to new unit to free up space in brewery and tasting room

As soon as the new unit was ready (nicknamed The Grainery), we started moving over all of our dry storage. This included our grain and grain racks that were sitting in the tasting room. We also moved over our keg washer and all empty kegs – all of which are now cleaned over at the new unit. Lastly, we moved over our workbench and all of our brewery odds-and-ends (spare parts, extra tools, etc.).

the-grainery-post-move-in

The Grainery – Post Move In

Combined, this opened up a lot of space in our tasting room which allowed us to expand seating (see Phase IV).

Phase III
Buy and install a second kettle to decrease brewing time.

One of the big limiters in how much beer we are able to produce is time. The less time it takes us to brew a batch of beer, the more we can make.

Every batch we brew, we double brew (two mashes, two lauters, two boils). After we finished the first lauter, the wort would sit in a holding tank until our mash-kettle was clear. This holding tank was insulated, but did not heat our wort.

With the second kettle, we no longer have to go into a holding tank. Instead we lauter into the new kettle and it heats our wort as we fill it. Believe it or not, this extra heating cuts our brew day by 5-6 hours. This saved time enables us to brew two batches on weekends instead of just one without killing ourselves.

Like a new ship, all new tanks in the brewery must be properly christened. It would be bad luck to brew in an un-christened tank, so right before we pumped our first wort into our new kettle we did it proper:


Phase IV
Expand brewery tasting room with tables, chairs & fancy lighting

One of the main goals of this expansion was to expand the tasting room with more tables and seating. We wanted people to be able to come in, sit down and relax while they have a brew. The increased table space would also allow customers to easily bring in some outside food – whether a sandwich from Custom Melt, some chips and salsa from home, or some pastries from Carrara’s.

new-table

So we asked Fireman Dave, who you may remember from such construction projects as Bathroom Upgrade II, Build a Brewery Bar and Super Work Day to build us up some tables for the tasting room in a style similar to tables Chris and Matt saw on their trip to Germany in Dusseldorf, home of the altbier. Stop on by the brewery to check them out if you haven’t seen them yet. Also, keep an eye out for Dave’s hidden Easter Eggs in his construction.

new-tables-and-stools

If you’ve stopped by during the evening after sunset – you also might have noticed that we’ve moved away from standard warehouse florescent light. The primary reason for this change is because florescent lighting makes Captain Chris depressed and angry. Not wanting him moping around the brewery, and because we wanted to provide a more enjoyable experience to our customers, we replaced these lights with soft lighting on dimmer switches over the bar – and accent lighting over the brewery.

new brewery lights

New lights above the bar

Phase V
Operation Frosty Box III – Move and expand fridge, buy and install new fridge

More difficult than Operation Frosty Box I & II combined, this was the most daunting task for the EBC. In one weekend we had to disassemble the entire fridge in the brewery, move it and all of our kegs to our new unit, rebuild the fridge at twice the size, hook it up and load with all of our kegs. Simultaneously, we had to build up a new, smaller, fridge in the brewery while still being able to serve beer to customers.

It was a long weekend with little sleep, but thanks to the help of some friends, the Brew Chief’s brother Mike, and a few patient customers who didn’t mind waiting a few minutes for us to finish installing the taps Sunday morning, the plan went smoothly.

The new fridge we installed in the brewery is just big enough to hold kegs, gaining us a lot of extra space – extra space for things like more fermentors.

new-small-fridge-brewery

The new, smaller, fridge in the brewery

Stay tuned for part II of this exciting brewery expansion review!