























September 26th put me back at the wheel for creating new pilots. I brewed the Oatmeal Rye India Brown Ale. A glorious smell arose from the mash as we hefted over 24% rye into the mash tun. I realized that the grist bill accounts for less than 50% base malt and there is no doubt in my mind that this beer will be very complex. A monument of malt and hop rivalry that should result in a beer that is as busy as traditional jazz. I can imagine sipping this one in a jazz hall back in the 50’s with a cigar lit…the refreshing citrus/pine notes from the hops, the spiciness from the rye, the silkiness of the oats and the chocolate malt goodness meshing beautifully with my cigar and the sounds of the jazz hall reverberating down to my very soul. I am definitely looking forward to hearing feedback on this beer.
I spent Monday the 29th at St. Somewhere Brewing assisting Bob and crew in the bottling of their Lectio. Bob allowed me to break in our manual labeler there. After a few adjustments, it seemed to do a fine job. If they can put their front and back labels on one roll, this labeler would have removed two members of the labor team altogether. It won’t be the best labeler for labeling 3000 12 ounce bottles but it will do just fine for 750’s. One of the rewards of being at the brewery was a whole flower dry hopped Saison that Bob handed me. It was incredible to say the least. The whole flower Saaz helped to tame some of the brett aroma and made the brett overall mesh much better with the beer in the flavor profile. Don’t get me wrong, I like Bob’s beers anyway, but this was a special treat and I thoroughly enjoyed it. I also sampled some homebrews as well. One of them was a pumpernickel porter with caraway and poppy. Other than the yeast bite, this beer was well made…firm chocolate in the background with layers of rye and caraway. The last homebrew that I sampled before I left was some form of imperial stout or Belgian strong dark base with ripe banana added to the secondary. The aroma was lush with banana and this element paired well inside the flavor profile too. It made me wonder what this beer would have tasted like with an addition of caramelized raisins, figs and dates aged on oak. Thanks for letting me break in our labeler Bob.
I brewed
the Bleeding Heart Brown Ale on Tuesday. I finally received a break from all
the high gravity brewing. It made for an easier day and my anticipation for the
end of the day wasn’t because I was ready to go home but rather contemplating
the smell of the holiday tea that I put into the kettle after the boil was
over. The brown ale base already smelled great and quite malty but when those
tea bags hit the kettle, the brew pot told a completely different story. It
released the secrets of Christmas and winter in a voice that spoke through
aroma and vivid memories of my past winters and holidays came rushing back in a
warehouse that was 85 degrees. I can not adequately describe this to you but
only hope that you can experience it and tell me what you think personally. The
fermentation fridge was overloaded with the same aroma the following day. It
inundated the already active fermentation of the India Brown and reminded me of
my desire to be at home over the holidays with family and friends by the fireplace
or bonfire sipping this beer and laughing over the events of the year.
The Bleeding Heart recipe posing with a box of Celestial Seasonings Sugar Plum Fairy.
Wednesday brought about a different feeling. It was more in season than the Bleeding Heart was. The smell of baking pumpkin loomed as the mash rested and caramel malts gave up their sweetness underlying and supporting the pumpkin inducing a feeling of fall. The lauter however was another story. I used 10 pounds of pumpkin puree to 22 pounds of grain and this was a miscalculation. The puree clogged the spaces in between the grain and the husk and was intent upon not letting the mash release its sweet soul into the kettle. After much deliberation and physical manipulation, I was successful in gathering my pre boil volume of wort. I decided that the volume of puree will have to be reduced in future commercial batches in order to alleviate any stuck mashes on our equipment. When I was moving the wort from the kettle to the fermenter, I noticed quite a bit of solids coming out. I believe these to be caramelized bits of pumpkin puree and noticed that after fermentation began that these solids settled out to the bottom of the fermenter(it wasn’t cold break because I saw a similar thing happen at lauter). Fermentation is very active and the color is pale orange. The fermentation lock smells of unspiced pumpkin pie because I haven’t casted my pumpkin pie potion into it yet. Also, I was also able to ascertain the elements of Southern Tier’s Pumking and their Crème Brulee. I was right…they are using more than they tell you on the label and I hope that you will be able to determine what I have discovered as you are giving me feedback about this beer.
My techniques and precision have become much more efficient. I have dialed in mash efficiencies and total volume lost in the kettle on a standard one hour boil using a measuring tape and all just in time to make the last of the high gravity beers in this series of pilots. The Mayan Chocolate Imperial Stout, which I brewed on October 2nd, was even higher in gravity at my projected volume than I expected it to be. It finished at 26.8 degrees plato (11-12 ABV) at slightly over 5 gallons of yield. The mash looked like enough grain for a 10 gallon batch (28 lbs). The mash gave back mocha espresso with a multitude of dark caramel and toffee components. I was fortunate enough to have the foresight to put it into a larger carboy. It raged at the thought of being contained in any vessel during the process of fermentation and is still acting like a raptor even as I type…krausening 4 – 6 inches above the liquid surface (the raptors tested the shock gates in Jurassic Park). Eight different grains and 80 IBU’s are just the base of this beer. I can’t wait to get the chiles, raw cacao nibs, vanilla and cinnamon in there. Then it will be 10 – 14 days of contact time away from calling for a sacrifice on the temple steps as I hold the knife in one hand and this magical, historical elixir in the other. I guess it was all about population control back then and these guys were worse than that Cocoa Puffs’ bird (lol).

Mayan Chocolate Imperial Stout Recipe

Peppers & Nibs
The final pilot (of these 5) was the Saison. It was brewed on October 3rd. This brew day was a walk in the park and a nice final pilot to brew due to its lower gravity. The mash was dominated by the smell of pils malt with underlying hints of wheat. The interesting part was adding those scuppernongs to the boil. We removed the skin and the seeds and added them during the last fifteen minutes of the boil. The orange peel, pils malt and hops dominated the smell of the boil. It wasn’t until after we moved all the sweet wort to the fermenter that we smelled the unique smell of the grapes. It was wild and almost vegetal. During my rush to get the heat exchanger set up, it slipped my mind to add the aroma hops to the kettle post boil so I had to make a hop tea at home and add it back to the fermenter. I wasn’t able to administer the tea until after the weekend. By this time, the eccentric Saison yeast had started to become much less active and this means that since there will be less carbon dioxide scrubbing of the aroma hops, we should get a little brighter hop aroma. The yeast has that classic Saison smell (apple pie) and after I added the tea to the fermenter, the aroma took on more of what I am used to smelling in respected commercial interpretations of the style. This beer still has to go through secondary on even more grapes and then it will come off the grapes and go through a “garding” period for another 4 weeks. A lengthy process that will lead to some interesting if not captivating results.
Thanks are in order to Ben for stopping by several times to help me out with brew days. Thanks to Dave and Todd for stopping by on your lunch breaks to see what we were up to. Thanks to Christian and Greg for sharing the homebrews and helping with the Imperial Pumpkin (that crazy hop filter beer blew my mind you guys…I can still remember the aroma, flavor and the lack of hop astringency amidst all the big aroma and flavor…great job). Thanks to Justin for stopping by on Friday and lending a hand with the Saison and also discussing our packaging and distribution options (and for lunch). Thanks to Tracey for the pictures of the brew house delivery day. And thanks to anyone else that I might have left out.
Our t-shirts and glasses came in today (10/06/08). They look great! If you look at an earlier post you can see them. The glassware came out exactly like the proofs on the web site (not to size on the web site) and the shirts are a darker blue but other than that just like you see them on our web page.
I guess that wraps it up for the last week and a half or so.
Take care,
Wayne Wambles
Head Brewer
Cigar City Brewing