In order to ensure perfection in every pint, Bays have a 5 stage brewing process described below:
The malted barley (sourced locally from Tuckers Maltings, Newton Abbot) is mixed with hot water to form a mash in the Mash Tun. This process usually takes between ten and twenty minutes, then the mash is left to stand for one hour. At this stage the Enzymes in the malt break down the starch in the grain into fermentable sugars.
Here the malt extract, called wort, is boiled to ensure sterility. During the boil hops are added, which help to create the bitterness, flavour and aroma of the beer. The boil lasts for exactly 1 hour 15 minutes.
After this, the wort is pumped to the open cooler before being chilled through a heat exchanger.
Yeast is added to the wort and the fermentation takes place. It is during this stage that the sugars from the malt are transformed into alcohol and carbon dioxide. This is the point at which the product is first called beer! Fermentation takes roughly 4 days.
The beer is transferred from the fermenting vessel into the conditioning tank and left to rest for a day or two. From here it is filled into casks with the addition of finings which help to clear the beer of yeast.
This is the fun part! Samples of each brew are set up on a stillage and checked by the team to assess quality and flavour throughout the life of the beer.