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Flying Fish

Flying Fish Brewery - Factory Tour Presentation

Jessica Joyce

on 1 March 2011

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Transcript of Flying Fish

Flying Fish Materials Quality Brewing Proudly brewed in New Jersey. You got a problem with that? History 1995
April - Flying Fish Brewing Company created
August - Flying Fish became the 1st “virtual” microbrewery on the web

April - Moved into building
June - Brewing equipment arrived
September - Released first 2 beers — XPA and ESB (draft only)

April - Added new fermenters; increases capacity by 40%

November - First Flying Fish truck unveiled

October - Flying Fish Porter voted "Best of Philly" by Philadelphia Magazine

May - Flying Fish brews its one millionth gallon
November - Flying Fish starts shipping to Delaware

February - Add new fermenters - increase capacity by 22%
Brewing has taken place since around the 6th millennium BC, and archeological evidence suggests that this technique was used in ancient Egypt. Brewing Steps: malting, milling, mashing, lautering, boiling, fermenting, conditioning, filtering, packaging. Mashing converts starches into sugars that can be fermented. The grain is dropped into a hot water masher where it’s mixed with water to create a cereal mash. The leftover sugar rich water is then strained through the bottom of the mash in a process known as lautering. At this point the liquid is known as wort. The wort is moved into a large kettle where it is boiled with hops to add flavor and aroma to the beer. Next, the hopped wort settles in the whirlpool, where solid particles in the wort are separated out. After the whirlpool, the wort is cooled in a heat exchanger. It is very important to quickly cool the wort to a level where yeast can be added safely. The wort then goes into a fermentation tank. A type of yeast is selected and added and the fermenting process begins, where the sugars turn into alcohol. Conditioning of the beer is the process in which the beer ages and the flavor becomes smoother. Filtration gives beer their natural polish and color and helps to stabilize the flavor. After the beer is filtered, it undergoes blending and carbonation, and is then moved to a holding tank until bottling Malt & Hops Light malt Chocolate Malt Hops Interesting fact The Masher The whirlpool The Fermenters The Brightbeer Tanks This is Chuck - our tour guide. Material handling is the art and science involving the movement, handling and storage of materials during different stages of manufacturing. PRINCIPLES OF MATERIAL HANDLING •Space utilization principle: Make optimum use of cubic space. At Flying Fish, they stack their cases to the ceiling for optimal storage capacity. For more info, check out their website: http:\\www.flyingfish.com
•Flexibility principle: Use methods and equipment that can perform a variety of task and applications. They utilize a bottling machine that can bottle any type of beer they brew, and it can fill kegs or bottles. Let's check out their brewing process... Material Handling Equipment *Conveyors are useful for moving material between two fixed workstations, either continuously or intermittently. At Flying Fish, a conveyor is used to move the empty bottles into the bottler where they are filled, and out of it where they are labled. *If the flow is fairly constant between two fixed positions that are not likely to change, fixed equipment such as conveyors or chutes can be successfully used. Quality is a measure of how closely a good or service conforms to a specified standard. Quality begins with the design of a product in accordance with the customer specification. When Flying Fish was founded as a virtual brewery back in 1995, they used the web as a way to find out what people wanted in a micro-brew. Hands down, most said a pale ale. And that's why the very first beer made at Flying Fish was Extra Pale Ale. CENTRALIZED INSPECTION
Inspection is conducted in a central location. Samples are brought to the inspection floor for checking.
Flying Fish has an on-site lab for all testing and inspection. They keep samples from all batches so if they get a complaint about a beer, they can track it back to a batch by the number code on the bottle. The variation in quality in any manufacturing process is broadly classified as:
(a) Chance causes - Causes which are inherit in the manufacturing process
(b) Assignable causes - Causes that create ordinary variation in the production quality.
A little known fact: skunking is not caused by change in temperature. Exposure to sunlight causes skunking - that's why the bottles are dark! Most quality issues pertaining to beer are not caused during the making of the beer. They usually have to do with storage of the beer after its been brewed.
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