Monday, February 13, 2012

Nanobrewery Interviews: Night Shift Brewing (Part 1)

While many of us have toyed with the thought of starting up our own nanobrewery, there are others who have taken the plunge.  To find out who these people are and what makes them do what they do, Tom and I embarked on a series of interviews with regional nanobreweris to get their stories.

Night Shift Brewing
Everett, MA

I recently had the opportunity to chat with the three owners (Michael Oxton, Robert Burns, and Michael O'Mara) of a new Boston nanobrewery that is on the verge of opening its doors.  Night Shift Brewing is setting up shop in an old WWII parts manufacturing facility in Everett, MA.  After signing the lease back in July 2011, the trio have been pushing hard to get their space in shape.  And with all the pieces finally coming together, the company was awarded their Farmer Brewery License just last month.  Brewing on a custom-built 3.5 bbl system, the brewery is planning to self-distribute to the Metro Boston area with targeted spots in the North and Southshore regions.

If Everett, MA sounds familiar, it might be because Night Shift Brewing is also the physical neighbor to one of our prior interviewees, Idle Hand Craft Ales.  With Night Shift tasting room almost complete and beer targeted to be ready to served toward the end of this month, a visit to the 3 Charlton Street facility in Everett to check out the two breweries should certainly be a worthwhile venture.

Below is the first part of our multi-part Q & A interview with Night Shift Brewing.  The conclusion of the interview can be found here.

*   *   *

Lug Wrench (LW): How long have you been planning the Night Shift nanobrewery?

Night Shift Brewing (NSB): Starting a brewery has been on our minds since we graduated college. Two of our three founders – Rob Burns and Michael Oxton – went to Bowdoin College in Maine, and were exposed to a lot of great craft beer from Allagash, Geary’s, Shipyard, etc. Rob actually brewed his first beer in college, looking to get deeper understanding of beer and its ingredients. After graduation, Rob and Michael. both moved to Boston, and began brewing more and more often. Honestly, it only took a few batches until the hobby of brewing became a total obsession.

During this time, our third founder and childhood friend of Rob, Mike O’Mara, had graduated from Philadelphia University and began brewing beer himself down in Philly. His exposure to some of the great PA/NJ breweries like Weyerbacher and Flying Fish definitely helped influence his perception of craft beer. In the summer of 2010, Mike moved to Boston when Rob and Michael (different person) began exploring the possibility of starting a nanobrewery.

Now homebrewing 1-2 times a week on our 15-gallon system, we also started developing this idea of Night Shift Brewing, a name we had given to our nocturnal brewing efforts. After some serious planning and organization, we incorporated Night Shift Brewing in January of 2011. Our business plan took shape soon after that, and it all escalated from there. About sixteen months of hard work and serious planning has led us to where we are now, on the verge brewing our very first official batch.

LW: When did you know this was something you were going to go for, as opposed to just just daydream material?

NSB: In our six-bedroom Somerville apartment, we began holding weekly beer tastings. Quite often, we’d have 10+ friends show up, each with 1-2 beers that would all get sampled, discussed and rated over the course of the night.  Over the years, we tasted and documented over 400 different beers this way, which became invaluable market research.  At the same time, we were just beginning our foray into homebrewing. Drawing inspiration from our many tastings, we experimented with our own recipes in an attempt to create beers that were equally unique, interesting and delicious. We often played with unorthodox ingredients and many strains of yeast, looking for flavors that were great, but also memorable.

Eventually, we began slipping homebrews into our weekly tastings, just to see how they stacked up. It wasn’t all positive at first, but after some improvements in our equipment, techniques and recipes, ratings for our homebrews went up. When they began tasting on par with certain commercial beers, the realization hit: we could actually do this professionally.

Fueled by this possibility, our brewing efforts increased even more. We bought better equipment and put as much time into brewing as we had available. With beer piling up around the apartment, we decided to start throwing tasting parties. These were a huge success – we’d usually have close too 100 guests show, all sampling 6-8 of our different beers on tap. We handed out rating cards to everyone, and collected feedback that way, and through conversation. When it became clear that many types of people with many different tastes thoroughly enjoyed and appreciated our product, we began developing serious ideas for the business.

LW: How did you gather the required capital to start the brewery?

NSB: Our start-up capital came from our friends, our family, and ourselves. As a business with no credit history, banks or traditional lenders would never have given us the necessary loans. So, we wrote a strong business plan and convinced friends and family members that our strategy and product had real potential for success. The business plan itself took a lot of work and many, many drafts, but it was hugely helpful and ultimately quite successful.

LW: As you began to plan the nanobrewery, what resources did you use to gather information?

NSB: Starting the brewery has been a long and painfully slow process. Everything has taken longer than expected. Perhaps most helpful to us were conversations we had with other brewers and breweries - we tried to learn as much as we could from them. We were also lucky to have Idle Hands Craft Ales directly next door to us, and 6 months ahead of us in terms of licensing and build out. Chris Tkach, the owner of Idle Hands, was a fantastic resource.

We also read a number of beer blogs to help us navigate the mess. The Bruery’s blog was one of our best resources, as they fully documented a large part of their start-up. Another great site is Probrewer.com. There are a lot of active discussions on there, and many people who will answer your questions.

LW: Night Shifts initial plan is to self-distribute. Why is that?

NSB: We chose self-distribution because (a) we simply cannot afford a distributor right now (b) we don’t really need one until our production increases, but also (c) we’d much rather become familiar with our accounts as we start. Being able to speak personally with the beer buyer or restaurant manager about our own product is really important to us, and that relationship is something we want to cultivate before we grow too big.

Eventually, we would like to expand to other New England states, as well as more of the east coast (especially Pennsylvania, where two of our founders are from). For now, though, given our small size, our focus is on Massachusetts.

LW: How are you planning to differentiate your beer from all the other offerings that are out there?

NSB: Night Shift Brewing is really trying to be an innovative brewery. Each of our beers will incorporate unusual ingredients, processes, or inspiration from rare styles. Our goal is to fuse these ideas into beers that are truly memorable and interesting. But we’re not looking to make gimmicky beers or put out extreme flavors. Rather, we want to build unique, complex flavor profiles that create a product that, above everything else, is simply great beer. People will hopefully find intricacies in our beer, but the focus is a drink that people will enjoy, and remember.

When possible, we also plan to source ingredients from local businesses. Two of our three initial offerings use a locally sourced product – our Bee Tea uses organic green tea from Somerville’s Mem Tea, and our Taza Stout uses organic roasted cacao nibs from Somerville’s Taza Chocolate.

Finally, it is our belief that beer and food are a natural combination. While our beers should be worth appreciating on their own, they should also pair well with the right complementary dish. Our labels will details “Suggested Food Pairings” for each beer, and our blog will have an ongoing focus on both eating and cooking with beer. We also plan to work with various restaurants in and around Boston in hopes of uniting great craft beer with great food.

* * *
Part 2 of our interview with Night Shift Brewing can be found here.

If you want to find out more about Night Shift Brewing, check out their website, or better yet, if you are in Boston, stop by the brewery.

Slainte!

-JW


"Work is the curse of the drinking class."
-Oscar Wilde

Thursday, February 9, 2012

Westmalle Trappist Dubbel

I am extremely fortunate to have kind co-workers who travel to far away places and bring me back beer and beer-related items.  One of them recently returned from a trip to Belgium and left a bottle of Westmalle Trappist Dubbel on my desk.

Westmalle is one of six Trappist monasteries that still brew beer in Belgium.  The others include Achel, Chimay, Orval, Rochefort, and Westvleteren.  Westmalle is located in the central Northern part of Belgium and started brewing in 1836.  According to Hieronymus' Brew Like a Monk, Westmalle was founded by monks who fled France in 1802.  The brewery has expanded several times since 1836, mostly to finance different Trappist ventures.  However, unlike older days, Westmalle monks no longer actively participate in daily brewing, which is done by lay employees.  The monks do sit on the brewery's board and set the rules for its output, capped at 120,000 hetoliters annually, and its recipes, which remain unchanged over the years.  The brewery produces a dubbel and a tripel and is the only Trappist brewery to label its beers with those traditional names.

The following statistics on the Westmalle dubbel come from Brew Like a Monk:

  • Original Gravity: 1.063
  • ABV: 7.3%
  • Apparent Degree of Attenuation: 87%
  • IBU: 24
  • Malts: Pilsner, caramel, and dark malt
  • Adjuncts: Dark candi sugar
  • Hops: Tettnang, Styrian Goldings, Saaz
  • Yeast: Westmalle, which is also used for bottle conditioning (commercially, WLP 530 Abbey Ale or Wyeast 3787 Trappist High Gravity)
The beer pours a deep amber red color with high amount of carbonation and makes a distinctive hiss as it hits the bottom of the glass.  The carbonation supports a off-white colored head with coarse bubbles that fade after two or three minutes.  The foam does leave a nice Belgian lacing as the beer moves down the glass.  The dubbel's aroma has hints of dark fruit, perhaps raisin or prunes.  It also smells of dark caramel sweetness, with a slight herbal/basil note.

The first taste of the dubbel reveals the prickle of carbonation evident during the pour.  This subsides into dark caramel flavors, but without the sweetness.  The mid-palate includes evidence of the dark fruit flavors hinted at in the aroma, but again without any sweetness.  The flavors finish very dry and almost evaporate off the tongue within seconds.  The 7 percent ABV is completely hidden in the beer, without any burning or harsh characteristics.

I brought a lot of expectations to this tasting, based on my experiences with other, mainly American, dubbels.  I anticipated a beer with large flavor components, featuring layered sugar and caramel characteristics.  I certainly expected some degree of sweetness and a lingering palate that encouraged slow sipping.  What I experienced, instead, was a very dry beer with subdued flavors that appeared almost flat compared with my expectations.  Even after knocking out a good amount of the carbonation, I still did not find more complex flavors.

In an ideal dubbel, I would like something between my expectations and what I tasted in the Westmalle dubbel. The beer I tasted was very well brewed, without any apparent faults or mishandling, but I would like some more robust and interesting flavors.  On the other hand, I found the Westmalle example more drinkable than many American dubbels, which often end sweet and are too big to truly want more than one glass.

Thanks to my co-worker, John, for bringing me a Trappist beer direct from Belgian.  I truly appreciate his generosity.

Cheers,

TW

Monday, February 6, 2012

RFP - Jeff's Initial Recipe and Brewing

I realize that it has been over a year since we initially announced our Recipe Formulation Project (RFP) and while there was a lot of energy around it, the chatter died off after Tom completed his first beer for the project.  While I had every intention of brewing my beer, 2011 did me in with very few brew days, which caused my contribution to the project to get procrastinated.... seriously procrastinated.  However, with a new head of steam for brewing in 2012, I got back on the horse, compiled my recipe, and brewed the beer this past weekend.

As a quick synopsis, the RFP idea was a way for Tom and I to explore new ingredients that were outside our comfort zones.  Each of of us selected three randomly generated ingredients and had to brew a beer with two of the three.  For my beer, I was allotted rye malt, cardamom, and extra special malt (see the Beer Concept post for all the details).  My ingredients took me down the path of Danish dark rye bread, which was the inspiration for the recipe below.

The final recipe that was brewed is very similar to what was discussed in the beer's concept phase.  However, I did make a few modifications that should be noted:
  • Rice hulls were added because of all the rye and oats in the recipe.
  • Cardamom was kept out of the boil as I decided I'll add it at bottling/kegging.  I'll be using a a manner akin to the method Tom described, which will give me the ability to dial in the cardamom flavor and potency.
  • The late addition of centenial hops was increased but pushed closer to flame out.
  • WLP001 was used as the yeast in lieu of the English or lager strains I initially contemplated.  This yeast would be easy and have a clean character that would allow the other ingredients to take center stage.

Other than a slow sparging process and letting the wort get too cold during chilling (~45 F) which slowed the initial yeast activity, the brew day was a success.  In about 2-3 weeks, the beer should be ready for cardamom dosing.  I should be able to do a side by side with the spiced and non-spiced version to really understand how the spicing is complementing the end result.

Dark Side of Denmark Rye
Style: Spice, Herb, or Vegetable Beer

Recipe Specifications
---------------------
Batch Size: 6.00 gal
Boil Size: 7.0 gal
Measured OG: 1.046
Measured FG: 1.011
Estimated SRM: 17.5
Estimated IBU: 24.8 (Rager)
ABV: 4.6%
Brewhouse Efficiency: 73%
Boil Time: 60 Min

Grain / Extract / Sugar
----------------------
5.50 lb GlobalMalt Light Munich Malt (53.66%)
1.56 lb Weyerman Rye Malt (15.22%)
1.50 lb Rahr US 2-Row Malt (14.63%)
0.56 lb Flaked Oats (5.46%)
0.50 lb Crisp Crystal 45 Malt (4.88%)
0.38 lb Chocolate Rye Malt (3.71%)
0.25 lb Rice Hulls (2.44%)

Hops
-------
0.70 oz Sterling (6.0% alpha) at 60 minutes
0.80 oz Centennial (8.4% alpha) at 20 minutes

Extras
-------
40 drops of Foam Control in the boil


Yeast
------
1 vial of WLP001 (Cal Ale yeast) in a 1000 ml starter

Mash Schedule
---------------
60 min at 151 F

Notes
------
Brewed on 2/3/2012 by JW

Whirlfloc was left out of the brew by accident as I found out I had no more tablets when it came time to add it.

Aeration was accomplished via an aquarium pump and diffusion stone, run for 30 minutes.

Yeast was pitched into cold wort (45 F) and allowed to ramp up to the targetted 67 F fermentation temperature.  The low initial temperature caused a delay in the first signs of fermentation activity.

Cadamom, one of the required ingredients, will be added after fermentation at the type of packaging.

Feb 19, 2012 - All signs of fermentation activity have completed.  Dropped the temperature of the beer to 40 F to cold crash  prior to kegging.

March 25, 2012 - After being lazy with this beer and letting it sit in cold temp for 5 weeks, I finally got around to kegging it.  When I was pulling the carboy out, the carboy was under negative pressure (from when the beer got cold I guess) as the blow-off tube had sealed itself.  In my attempt to relieve the pressure in the better bottle carboy, the blow-off tube unsealed itself and sucked 1-2 cups of star san into the beer :(  The beer was kegged and put under Co2 gas to carbonate.

* * *

Slainte!

-JW


"Beer is the Danish national drink, and the Danish nation weakness is another beer"
-Clementine Paddleford

Recipe Formulation Project - Reference Guide
Tom's Recipe:
Jeff's Recipe:

Thursday, February 2, 2012

Poll: New Year's Beer-Related Resolution?

Like all our prior blog polls, this post takes a moment to memorialize the results we recieved on the most recent blog poll.  The readers' responses to the question "What Beer-Related New Year's Resolution Is Most Appealing To You?" are presented below.

Total Votes: 23

Bring on the new kettle, march pump, temp control, etc .... it seems everyone is looking to improve their homebreweries this coming year.  I'll have to admit that I fell into this category too.  With any homebrew mail order, I find myself always trying to add one or two items that will improve my process.  Whether its an oxygenation kit, a diffusion stone, or a refractometer, I can never pick up just a few ingredients.  However, as I mentioned in my 2011 wrap-up, my next homebrewery improvement needs to be a second chest freezer so I can keep beer on tap when I'm fermenting a new one.

One of the categories I was hopeing to see get a bigger turn out was for "Take a beer-related trip", as this was a close second for me.  I am sure most beernuts are like me and unconsciously do this anyways (heading to city X?  What breweries/brewpubs/beer bars are there?), but taking a serious trip to beer-meccas like Belgium or Germany have always been on the short list.  I've got to move that up on the priority list for sure. 

Let us know what your thoughts are on the topic.  And if you are reading this, our next blog poll is up and awaiting your participation.

Slainte!

-JW


"If God intended us to drink beer, He would have given us stomachs."
-David Daye
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