How it’s made – brewing Cayman’s new beer

It takes nearly three weeks to make Cayman’s newest beer, Caybrew.

That’s one day brewing, seven days fermenting, 10 days lagering and one day in the bottling tank.

Brewing beers

Michael Russell and TJ Ebanks check the empty bottles. Photo: Jewel Levy

Then you can pop the cap on a refreshingly smooth, full-bodied premium larger with a crisp, clean taste.

Brewed and bottled in the Cayman Islands to international standards, Caybrew alcohol content is five per cent.

Cayman Brewery, located on Shamrock Road, recently launched its new beer, Caybrew, after a year of preparation including a multi-million dollar overhaul to the brewery and the installation of bottling and canning facilities.

General Manager Allen Chu Fook, who has more than 40 years of brewing experience, said the company was pleased to deliver a 100 per cent Cayman-made product to the bars and liquor stores of the islands.

There are six steps to brewing a refreshing Caybrew – brewing, fermentation, storage, filtration, packaging and pasteurizating.

Ingredients

The grain comes in one ton bags which are stored and then poured into a huge 25 ton malt silo. This holds the malt until the start of brewing.

Brewing

A huge pipe chain conveyer transports the malt from the silo into the weighing bin. Then it is taken to the mill and crushed.

After the malt is crushed it goes to the mash kettle. There, it is mixed with water and heated to different stages to get the sugar out. After the heating processes, it is transferred into the lauter tank.

There the grain is separated from the liquid and the brew kettle boils the mixture. The hops are added to the brew kettle. In the whirlpool, particles not used in the beer will be removed at this stage.

Then the beer is cooled before the fermentation process.

On the way to the fermentation tanks the yeast is added.

Fermentation

Fermenting takes one week and lagering two weeks. In the first week yeast transfers sugar water into alcohol and carbon dioxide.

Filtration

After the fermentation process the beer is ice cold, filtered and stored in a bright beer tank.

Before bottling, filtration is need to remove residual yeast and protein in the beer. This helps prevents hazing.

Bottling

It takes just as much time to wash and clean beer bottles as it does to fill them with beers.

At Cayman Brewery, thousands of empty bottles pass through a bottle washing machine each day.

Hot water loaded with a detergent, removes labels, cigarette butts, sand, chipped bottles or any other foreign substance in or on the bottle.

After a through cleaning, bottles are inspected electronically and visually and given a stamp of approval.

Throughout the washing process, a technician does adjustments on a multi panel computer. This shows the insides of the machine and what functions it is performing.

Filling

Then the bottles are moved along to the 18-tube filling machine. This tube removes the air from the bottle, fills it with carbon dioxide and aligns 18 bottles at a time to be filled with beer.

Capping

After the bottle is filled with the beer, it moves on down the line to the capper machine. This machine caps each individual bottle of beer which is decorated with the Caybrew logo.

Pasteurisation

In the pasteurisation process the beer is heated at various degrees Fahrenheit. This insures the quality of the beer will stay the same over a period of six months.

Emerging from the pasteurizer, the bottles and caps labelled with the Caybrew logo are placed in boxes, stacked on pallets and await delivery to various shops.

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