19th century marks the beginning of industrial breweries being established in Kaunas. One of these was a brewery of Swiss citizens Max and Henrietta Blumental, built by back then St. Petersburg road (now Svanoriu street). The capacity of the brewery, which belonged to the Blumental family, was remarkable and the original plot of land owned by the company was constantly expanded, new facilities were built and factory equipment was renewed.
After the First World War in 1922 the company was sold. In the same year the new owners set up a joint-stock beer and soft drink company Ragutis, owned by Wolf Frenkel, Martynas Ycas, Adomas Prusas and Jokubas Sernas. The company mainly sold its products in the temporary capital, but beer brewed in Ragutis was not only valued in the country but also in Europe.
In 1940 the company was nationalized. Still operating as an independent company after the war, in 1959 the brewery Ragutis was merged with another Kaunas brewery Raudonoji Pasvaiste into one Kaunas Beer and Non-Alcoholic Beverage enterprise Ragutis. Not only did Ragutis give the name to Kaunas beer enterprise, turned to simply a Factory No.2, but also the brand.
At the beginning of the 1990s, the former brewery Ragutis split up from the merger and was called Zalsvytis, which comes from the name of “zalsviai” sort of peas, back then used in the beer production.
The revival of the brewery began in 2000, when the company still called Zalsvytis was acquired by the new owners. It was them who set out to preserve and modernize the oldest brewery in the country and thus to open a new page in the history of Lithuanian beer.
In 2001 the name of the brewery was changed to AB Kauno alus. Throughout the renovation procedure modern beer filtration facilities and new technological pipelines were installed, a wet grinding mill was built, the production premises were renovated, the latest glass container washing and labeling lines were installed. Kaunas brewery inherited beer maturation cellars excavated on the slope of Žaliakalnis Hill, which were adapted for the maturation of all beers produced in a modernized brewery.
The company is constantly expanding its product range, soft drinks production facility has been set up, production of beer cocktails was begun, beer in barrel section has been modernised.
Cooling
In the refrigerator, the wort is cooled to the temperature required for the fermentation process and then aerated.
Šaldymas
Šaldytuve misa atšaldoma iki reikiamos fermentacijos procesui temperatūros ir aeruojama.
Bottling
Filtered beer goes into the containers where it is kept until it is bottled. Then the beer is poured into the barrels (KEG) and glass bottles. To ensure longer life, beer is pasteurized with a flush pasteurizer and bottled into glass or PET tare.
Beer in barrels (KEG) can be also both non-pasteurized and non-filtered.
Išpilstymas
Filtruotas alus paduodamas į saikininkus – talpas, kuriose alus laikomas iki pilstymo. Iš saikininkų alus išpilstomas į statines (KEG-us), ir stiklo tarą. Kad užtikrinti ilgesnį galiojimo laiką alus pasterizuojamas sroviniu pasterizatorium ir išpilstomas į stiklo butelius ir PET tarą.
Į statines(KEG-us) alus išpilstomas ne tik nepasterizuotas bet ir nefiltruotas.
Storing
Bottled or barreled, the beer is stored in ventilated warehouses, which are protected from the sunlight, the air humidity of which does not exceed 75% and the temperature is 10-20 degrees.
Sandėliavimas
Išpilstytas į prekinę tarą, alus yra laikomas vėdinamuose, nuo saulės spindulių apsaugotuose sandėliuose, kuriuose esanti oro drėgmė ne didesnė kaip 75 proc., o temperatūra 10-20 laipsnių.
Milling
The malt is ground in a special wet grinding mill. The malt grains are crushed and mixed with the required amount of water. It is very important to preserve the grain shell, which is later used as natural filtration layer.
Quality control
Beer production quality is checked at all technological process stages. Physical-chemical and microbiological analysis is carried out.
Filtration
Mature beer is not lucid. In order to remove any beer yeast residues and any other residues, to provide better appearance and stability, the beer is filtered.
Maturating in cellars
During the maturity period, the main beer features are formed: flavor, smell, color, the bitterness and aroma of hops develops and natural carbon dioxide forms. Beer clears and its flavor stabilizes.
Open fermentation
Cool wort is taken to an open fermenting vessel. Beer yeast is added into a flowing wort. During the fermentation process, fermentation sugars turn into ethyl alcohol and carbon dioxide.
Mash filtration
From a mash tun, mash goes into a filtration bin where a liquid part – wort – and insoluble parts – draff – are separated. The insoluble wort material forms a natural filtration layer.
Mashing
Malt is cleaned and any impurity is removed, then it travels into in a wet mill. Milled malt and specially purified water are stirred together until a smooth paste-like material is received, this is called mash. Mash undergoes several processing stages with every stage-specific temperature and time while malt starch turn into fermentation sugars.
Lautering
Boiled wort is pumped into a precipitation container. There a whirlpool effect is produced, which separates all insoluble particles that have formed a cone. Then wort cools down until it reaches a fermentation temperature and finally it is aerated.
Brewing
Lucid filtered wort is boiled for 90 min in a brewing kettle. During the brewing process, hops are added: the bitter flavoring is released from the hops, wort takes over the aromatic hop components and any water excess is boiled down.
Virimas
Skaidri išfiltruota misa yra verdama virimo katile. Į virimo katilą yra dozuojami ir apyniai, kurie suteikia misai aromatą ir kartumą. Taip pat virimo metu misa yra sterilizuojama, išgarinamas vandens perteklius.
Brandinimas rūsiuose
Brandinimo metu susiformuoja visos pagrindinės alaus savybės: skonis, kvapas, spalva, išryškėja apynių kartumas ir aromatas, natūraliai formuojasi angliarūgštė. Alus nuskaidrėja, jo skonis stabilizuojasi.
Filtracija
Subrandintas alus nėra skaidrus. Alaus mielių liekanoms, bei kitoms drumstumą sukeliančioms dalelėms atskirti, prekinei išvaizdai suteikti ir stabilumui išlaikyti alus filtruojamas.
Atvira fermentacija
Atšaldyta misa paduodama į atviros fermentacijos talpas. Alaus mielės įmaišomos į atitekantį misos srautą. Rūgimo metu fermentuojami cukrūs esantys misoje virsta į etilo alkoholį ir anglies dioksidą.
Nusistovėjimas
Išvirta misa paduodama į nusodinimo indą. Jame susidaro sūkurio efektas, atskiriamos visos, į taisyklingą kūgį sušokusios, netirpios dalelės.
Užmaišymas
Sutraiškytas salyklas užmaišymo katile maišomas su vandeniu, gaunams vienalytė tešlos pavidalo masė-mentalas. Veikiant salykle esantiems fermentams, tam tikroje temperatūroje ir tam tikrą laiką, salyklo krakmolas suskaldomas iki fermentacijai tinkamų cukrų (sacharozė, maltozė).
Malimas
Salyklas sumalamas specialiame drėgno malimo malūne. Salyklo grūdai yra sutraiškomi ir maišomi su reikiamu kiekiu vandens. Labai svarbu išsaugoti grūdo lukštą, kuris vėliau naudojamas kaip natūralus filtracijos sluoksnis.
Mentalo filtracija
Iš užmaišymo katilo mentalas paduodamas į filtravimo katilą, kuriame misa yra atskiriama nuo netirpiųjų grūdo dalių ir lukšto – salyklojų.
Kokybės kontrolė
Alaus gamyba kontroliuojama visose technologinio prpceso stadijose. Atliekami fiziko-cheminiai ir mikrobiologiniai tyrimai.