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I love Dublin.
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00:00:10,680 --> 00:00:12,560
In fact, I'm here every two years
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00:00:12,560 --> 00:00:15,400
for the Ireland-England
rugby international.
4
00:00:15,400 --> 00:00:19,120
And this city's hospitality
is second to none!
5
00:00:23,480 --> 00:00:26,840
And for me, it's the music -
I just love it.
6
00:00:30,360 --> 00:00:32,840
And where do they combine the two?
7
00:00:32,840 --> 00:00:35,360
In one of the city's many pubs,
of course!
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00:00:36,880 --> 00:00:40,200
There are over 750 pubs in Dublin,
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and, along with
a vibrant atmosphere,
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00:00:42,360 --> 00:00:44,640
they're famous for serving stout -
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a dark, heavy-bodied beer with
a dry-roasted flavour.
12
00:00:49,560 --> 00:00:53,160
There's one Irish stout
you can't fail to recognise.
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00:00:53,160 --> 00:00:56,920
So, we've come to the factory
in the heart of Dublin
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00:00:56,920 --> 00:01:00,360
that's been making it since 1759.
15
00:01:05,640 --> 00:01:07,640
That's massive!
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00:01:07,640 --> 00:01:11,480
I'm Gregg Wallace - and tonight,
I'll be using my senses...
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00:01:11,480 --> 00:01:15,280
That is like smelling ten pints
of beer at the same time.
18
00:01:15,280 --> 00:01:16,720
..making discoveries...
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00:01:16,720 --> 00:01:19,640
So, the yeast is eating the sugar
20
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and producing alcohol?
21
00:01:21,880 --> 00:01:23,400
Exactly.
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00:01:23,400 --> 00:01:25,960
..and exploring this huge site...
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It's up here that you truly get
an idea of the mammoth scale
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of this production.
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00:01:31,320 --> 00:01:35,640
..to find out how brewing tradition
meets cutting-edge technology
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to produce the perfect pint.
27
00:01:37,320 --> 00:01:39,680
HE LAUGHS
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I'm quite excited!
29
00:01:40,720 --> 00:01:42,640
I'm Cherry Healey...
30
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..and I'm helping out at
this year's hop harvest!
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And learning how water is treated
so it's fit for a fine stout.
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It's like a huge sieve,
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but the holes are teeny,
teeny, teeny tiny.
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00:01:58,720 --> 00:02:00,200
And historian Ruth Goodman...
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00:02:00,200 --> 00:02:01,920
Oh, wow!
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00:02:01,920 --> 00:02:06,080
..is drinking in the fascinating
origins of the Irish pub.
37
00:02:06,080 --> 00:02:07,880
This little enclosed space -
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it's not just like
a respectable space,
39
00:02:10,520 --> 00:02:11,880
but it's for secret drinking!
40
00:02:13,680 --> 00:02:18,800
This factory makes 2 million
litres of stout every single day.
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00:02:18,800 --> 00:02:21,480
And we're going to reveal
just how they do it.
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00:02:21,480 --> 00:02:24,400
Welcome to Inside The Factory.
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00:02:49,320 --> 00:02:53,440
This is the St James's Gate
Brewery in Dublin.
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00:02:56,120 --> 00:02:58,360
Founded over 200 years ago,
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00:02:58,360 --> 00:03:02,960
this historic factory
stretches across 56 acres.
46
00:03:02,960 --> 00:03:07,320
That's as big as
112 football pitches!
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00:03:07,320 --> 00:03:09,880
It's a city within a city.
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00:03:10,960 --> 00:03:14,880
Here, they produce draught beers
to be sold in pubs and bars,
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from lagers to Indian Pale Ale.
50
00:03:18,160 --> 00:03:22,000
But there's no denying it's the
"black stuff" they're famous for.
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00:03:22,000 --> 00:03:24,280
So, you've guessed it -
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today, I'll be helping to produce
20,000 50-litre kegs
53
00:03:30,040 --> 00:03:32,280
of their Stout, Guinness!
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00:03:35,320 --> 00:03:38,920
Like most beers, one of the key
ingredients is malted barley.
55
00:03:40,520 --> 00:03:44,800
The factory receives up to 110
30-tonne deliveries
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00:03:44,800 --> 00:03:46,680
a week at intake -
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00:03:46,680 --> 00:03:49,480
where I'm meeting
Bulk Raw Materials Manager,
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00:03:49,480 --> 00:03:50,800
Richard Sturgess.
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00:03:50,800 --> 00:03:52,360
Richard, hello!
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00:03:52,360 --> 00:03:53,720
Oh, how are you doing, Gregg?
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00:03:53,720 --> 00:03:56,120
Pleased to meet you.
Mate, this place is enormous!
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This might be the biggest
factory I've ever seen.
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00:03:58,560 --> 00:04:00,520
This is one of the biggest
breweries in Europe.
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00:04:00,520 --> 00:04:04,160
And this is where we get all our
malted barley and barley delivered.
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HE LAUGHS
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00:04:04,160 --> 00:04:06,520
I'm quite excited!
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00:04:07,720 --> 00:04:09,480
That's great, PJ, thank you.
68
00:04:10,480 --> 00:04:12,880
Now, Gregg, there's a sample
of the malted barley.
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00:04:12,880 --> 00:04:16,000
Take it up there and
have a smell of it.
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00:04:16,000 --> 00:04:18,360
You get the sweet smell of it?
You do. Yeah.
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00:04:18,360 --> 00:04:20,120
It smells like a breakfast cereal.
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00:04:20,120 --> 00:04:23,280
What we have here is a load
of malted barley,
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00:04:23,280 --> 00:04:25,800
that comes from Irish fields.
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00:04:25,800 --> 00:04:30,040
That barley then goes through
the malting process.
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00:04:30,040 --> 00:04:33,800
To "malt" raw barley,
it's steeped in germination tanks
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00:04:33,800 --> 00:04:35,920
to encourage it to grow.
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00:04:35,920 --> 00:04:39,480
As the grain sprouts,
it starts to convert its proteins
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00:04:39,480 --> 00:04:43,080
and carbohydrates
into sugar-rich starch.
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00:04:43,080 --> 00:04:45,240
So, it's sweeter. Sweeter.
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00:04:45,240 --> 00:04:49,720
And the sugar and starch is
essential in our brewing process.
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What happens to it now?
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We put it in our silos
here behind us.
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00:04:56,120 --> 00:04:58,760
So, with the simple spin
of a handle...
84
00:05:02,640 --> 00:05:05,320
..the production of our
Irish stout begins.
85
00:05:06,480 --> 00:05:08,520
That's great, PJ.
Thanks very much.
86
00:05:08,520 --> 00:05:10,440
And the 30 tonne-load of barley
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00:05:10,440 --> 00:05:14,720
is transported to one of
12 huge storage silos.
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00:05:16,080 --> 00:05:18,400
Now, I've got my malted barley,
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00:05:18,400 --> 00:05:22,040
but the raw material that makes up
most of your pint down the pub
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00:05:22,040 --> 00:05:23,960
is actually water!
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00:05:25,960 --> 00:05:28,640
Cherry's heading straight
to the source.
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00:05:31,000 --> 00:05:34,320
I've travelled 20 miles
southwest of the factory
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00:05:34,320 --> 00:05:35,880
to County Wicklow...
94
00:05:37,120 --> 00:05:40,400
..home to Ireland's largest
man-made lake.
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00:05:44,560 --> 00:05:47,360
When it rains here,
which I'm told is quite often,
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00:05:47,360 --> 00:05:49,800
it falls up there over
the Wicklow mountains,
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00:05:49,800 --> 00:05:52,520
and then it runs down
and collects here at
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00:05:52,520 --> 00:05:55,280
this beautiful
Poulaphouca Reservoir -
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00:05:55,280 --> 00:05:58,720
which provides much of the water
needed for the city of Dublin,
100
00:05:58,720 --> 00:06:00,920
and also our stout brewery.
101
00:06:04,520 --> 00:06:07,720
Poulaphouca Reservoir
was created by the damming of
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00:06:07,720 --> 00:06:11,080
the River Liffey over 80 years ago.
103
00:06:11,080 --> 00:06:14,560
It's huge, covering 5,000 acres
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00:06:14,560 --> 00:06:16,240
with 50 miles of shoreline.
105
00:06:17,600 --> 00:06:19,960
This water looks good
enough to drink -
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00:06:19,960 --> 00:06:23,320
but actually, it has to go
through an immense process before
107
00:06:23,320 --> 00:06:26,040
it's fit for human consumption -
or stout-making.
108
00:06:28,440 --> 00:06:30,240
Purification takes place at
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00:06:30,240 --> 00:06:33,760
the Ballymore Eustace Water
Treatment Plant.
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00:06:33,760 --> 00:06:39,160
Every day, up to 316 million
litres are fed along three
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00:06:39,160 --> 00:06:44,240
1.6-metre diameter pipes,
to the inlet building...
112
00:06:44,240 --> 00:06:46,920
..where I'm meeting engineer
Eoin Walsh.
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Hi, Eoin, lovely to meet you!
Hi, Cherry. Nice to meet you.
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I've just come from
the stunning reservoir.
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I would like to know how you
make the water clean
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00:06:55,600 --> 00:06:57,120
and safe for us to drink.
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First, it's screened
to stop any plants or fish,
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00:07:00,000 --> 00:07:02,160
or larger objects coming through.
119
00:07:02,160 --> 00:07:04,560
You definitely don't want
any random swimmers in your
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00:07:04,560 --> 00:07:05,840
cup of tea, do you? No, no.
121
00:07:05,840 --> 00:07:08,320
But it looks really clean -
what would happen if I drank that?
122
00:07:08,320 --> 00:07:10,600
There's discolour and
suspended particles in it -
123
00:07:10,600 --> 00:07:14,280
that could indicate micro-organisms
and bacteria, parasites that could
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00:07:14,280 --> 00:07:17,520
make you very sick, so first,
we need to treat the water.
125
00:07:17,520 --> 00:07:21,240
All outdoor water sources
can contain dangerous levels
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00:07:21,240 --> 00:07:22,840
of micro-organisms.
127
00:07:23,840 --> 00:07:27,760
To begin the cleaning process,
the Liffey water travels through
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00:07:27,760 --> 00:07:33,000
a complex network of pipes to one
of 20 sedimentation tanks,
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00:07:33,000 --> 00:07:38,240
each one holding 1.45 million
litres of water.
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00:07:38,240 --> 00:07:39,760
This is like the biggest,
131
00:07:39,760 --> 00:07:42,080
most beautiful water feature
I've ever seen.
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00:07:42,080 --> 00:07:45,000
It's very calming,
but it is making me need the loo.
133
00:07:45,000 --> 00:07:48,040
This is the first real step
in process here.
134
00:07:48,040 --> 00:07:52,800
The sedimentation tanks take a lot
of the colour and the particles out.
135
00:07:52,800 --> 00:07:56,360
Sedimentation is the process
of removing materials
136
00:07:56,360 --> 00:08:00,360
like soil and algae, which contain
harmful micro-organisms.
137
00:08:01,480 --> 00:08:04,120
19 tonnes of aluminium sulphate -
138
00:08:04,120 --> 00:08:07,280
a salt that acts as
a coagulation agent -
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00:08:07,280 --> 00:08:10,080
is added to the water every day,
140
00:08:10,080 --> 00:08:12,840
binding together
the unwanted particles.
141
00:08:14,120 --> 00:08:16,880
So, that's the water from
the reservoir as it arrives here.
142
00:08:16,880 --> 00:08:20,280
After the aluminium sulphate
is added, you can see here that
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00:08:20,280 --> 00:08:22,880
the larger flakes are formed
and fall to the bottom.
144
00:08:24,800 --> 00:08:27,320
The sediment forms a sludge,
145
00:08:27,320 --> 00:08:31,640
which is dried out and used as
a filler in the cement industry.
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00:08:31,640 --> 00:08:34,600
After two hours
in the sedimentation tanks,
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00:08:34,600 --> 00:08:38,760
the next stage of the big clean
is the filtration station.
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00:08:38,760 --> 00:08:41,400
Eoin, water, water everywhere!
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Is any of this drinkable?
I'm so thirsty now.
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00:08:44,200 --> 00:08:46,040
No, this water's not drinkable yet.
151
00:08:46,040 --> 00:08:48,760
They filter it first,
to remove any small micro-organisms
152
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that are still not being removed.
How do you filter it?
153
00:08:51,960 --> 00:08:53,560
We have a big bed of sand.
154
00:08:53,560 --> 00:08:56,760
So, this sand here, the water comes
up through the top, slowly
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00:08:56,760 --> 00:09:00,160
moves its way down through
the tiny spaces left by the sand.
156
00:09:00,160 --> 00:09:03,360
I see. So it's like a huge sieve,
157
00:09:03,360 --> 00:09:06,440
but the holes are teeny,
teeny, teeny tiny?
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00:09:06,440 --> 00:09:08,200
Exactly, yeah.
159
00:09:08,200 --> 00:09:13,560
There are 36 of these
2.5-metre-deep filtration tanks.
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00:09:13,560 --> 00:09:17,400
They remove particles containing
micro-organisms as small as
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2 micrometres in diameter -
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that's around 30 times smaller than
the width of a human hair.
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The water then passes through a
filter to remove any residual sand,
164
00:09:30,600 --> 00:09:33,600
and on to the final stage
of the process.
165
00:09:33,600 --> 00:09:36,960
Oh, wow! Talk about saving
the best till last.
166
00:09:36,960 --> 00:09:40,520
It's a bit like a leisure centre.
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00:09:40,520 --> 00:09:43,720
It smells even a little bit
like there's chlorine.
168
00:09:43,720 --> 00:09:46,080
Yeah, we do add some chlorine
to disinfect the water.
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00:09:46,080 --> 00:09:48,560
After the process of taking
all the particles out,
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00:09:48,560 --> 00:09:51,280
there's nowhere for
the micro-organisms to hide,
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and the chlorine can find them
and finally disinfect
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and make the water safe.
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The chlorine is well within
safe drinking levels,
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00:09:59,520 --> 00:10:04,280
and is vital to kill off
any remaining harmful bacteria.
175
00:10:04,280 --> 00:10:06,680
We also add fluoride here,
in the pipes down below.
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00:10:06,680 --> 00:10:09,920
The fluoride's to help against tooth
decay, strengthen people's teeth.
177
00:10:09,920 --> 00:10:12,720
Really? It's like an added
service you provide.
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00:10:12,720 --> 00:10:15,120
It's an extra public health
measure we do here, yeah.
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00:10:15,120 --> 00:10:18,960
Water does contain small amounts
of natural fluoride -
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00:10:18,960 --> 00:10:23,400
but in Ireland, drinking water
must be between 0.6
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00:10:23,400 --> 00:10:26,000
and 0.8 milligrams per litre,
182
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to help prevent tooth decay.
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It's taken six hours for
the raw reservoir water to become
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clear, clean drinking water.
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And after some final tests,
it's ready to be pumped to the
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good people of Dublin and
the surrounding area.
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Plus, of course,
to our stout factory!
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00:11:00,800 --> 00:11:03,120
Back in Dublin,
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16 tonnes of my malted barley
travels from the storage silos...
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00:11:09,720 --> 00:11:10,960
..to the brewhouse.
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00:11:12,200 --> 00:11:14,360
First, a stainless steel mill
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00:11:14,360 --> 00:11:18,720
grinds it down to a fine
powder called "grist".
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00:11:18,720 --> 00:11:23,800
Then, it's pumped along with
72,000 litres of water into
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one of two huge brewing vessels...
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00:11:28,120 --> 00:11:29,160
Wow.
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00:11:29,160 --> 00:11:32,960
..where I'm meeting Quality and
Production Manager Eamonn Power.
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00:11:32,960 --> 00:11:36,040
Eamonn, hello. Gregg.
Gregg, nice to meet you.
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00:11:36,040 --> 00:11:38,880
This is very, very impressive.
Thank you.
199
00:11:38,880 --> 00:11:41,360
Out there, it's all 200-years-old.
200
00:11:41,360 --> 00:11:43,840
In here, it is like
space age, right?
201
00:11:43,840 --> 00:11:46,440
The brewhouse we're standing
in now is about ten-years-old.
202
00:11:46,440 --> 00:11:49,240
And it's still one of the most
modern brewhouses in the world.
203
00:11:49,240 --> 00:11:52,520
Explain to me, please,
what the brewhouse does.
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00:11:52,520 --> 00:11:54,880
OK, so the first vessel
we're standing beside,
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00:11:54,880 --> 00:11:56,600
it's called the mash
conversion vessel.
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00:11:56,600 --> 00:11:59,320
That takes the milled malted
barley and water.
207
00:11:59,320 --> 00:12:01,960
And if you look inside now,
you'll see it's being circulated -
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00:12:01,960 --> 00:12:03,560
or agitated, as we call it -
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00:12:03,560 --> 00:12:06,000
to ensure that everything is
being adequately mixed
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00:12:06,000 --> 00:12:07,240
throughout the vessel.
211
00:12:07,240 --> 00:12:09,360
What sort of volumes are
we talking about here?
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00:12:09,360 --> 00:12:11,920
Each holds about 100,000 litres,
213
00:12:11,920 --> 00:12:15,560
which equates to about
175,000 pints per brew.
214
00:12:17,160 --> 00:12:19,200
Like a colossal iceberg,
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00:12:19,200 --> 00:12:24,000
most of this 100,000-litre vessel
is hidden from view,
216
00:12:24,000 --> 00:12:28,080
stretching four storeys below
the floor we're standing on.
217
00:12:28,080 --> 00:12:32,080
Inside the giant structure,
the malted barley and water -
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00:12:32,080 --> 00:12:36,840
now called "mash" - is heated to
around 60 degrees Celsius.
219
00:12:36,840 --> 00:12:39,160
And tell me why
you're heating them up?
220
00:12:39,160 --> 00:12:42,400
To convert the starch within
the malt to sugars.
221
00:12:42,400 --> 00:12:45,800
And it's THAT sugar that
we then ferment into alcohol.
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00:12:48,080 --> 00:12:50,160
Inside the conversion vessel,
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00:12:50,160 --> 00:12:54,760
the milled malted barley contains
enzymes and grains of starch.
224
00:12:55,880 --> 00:13:00,240
The combination of water and heat
causes the starch to swell,
225
00:13:00,240 --> 00:13:02,720
then rupture...
226
00:13:02,720 --> 00:13:05,480
..releasing long chains
of sugar molecules.
227
00:13:06,720 --> 00:13:10,440
The enzymes then attach to
the long sugar chains,
228
00:13:10,440 --> 00:13:13,440
breaking them down into
shorter chains,
229
00:13:13,440 --> 00:13:16,200
which ferment more easily
into alcohol.
230
00:13:17,920 --> 00:13:21,080
How long is it going to take?
About two hours.
231
00:13:21,080 --> 00:13:24,240
Our next stage is to separate
the grain from the liquid -
232
00:13:24,240 --> 00:13:26,640
and that happens over here in
our separation vessel
233
00:13:26,640 --> 00:13:27,840
called the "lauter tun".
234
00:13:27,840 --> 00:13:33,320
97,000 litres of mash is pumped
into one of these 14-metre-diameter
235
00:13:33,320 --> 00:13:35,720
stainless steel beauties.
236
00:13:35,720 --> 00:13:37,080
That's massive!
237
00:13:39,000 --> 00:13:42,200
You've got big arms in there that
aren't just stirring, are they?
238
00:13:42,200 --> 00:13:44,440
They're dragging through the mix.
What's that?
239
00:13:44,440 --> 00:13:47,040
The purpose of that is to allow
the liquid within the grains
240
00:13:47,040 --> 00:13:50,040
to actually flow down through it.
So, where is the liquid?
241
00:13:50,040 --> 00:13:53,360
So, the liquid is actually beneath
our feet at the base of this vessel.
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00:13:53,360 --> 00:13:55,400
If you follow me over here,
I'll be able to show you
243
00:13:55,400 --> 00:13:59,080
a little bit more simply
what's going on in this vessel.
244
00:13:59,080 --> 00:14:03,000
So, in this jar, we have a liquid
that resembles what's in
245
00:14:03,000 --> 00:14:04,760
our mash conversion vessel.
246
00:14:04,760 --> 00:14:07,360
What's happening behind us
is like a giant sieve.
247
00:14:07,360 --> 00:14:09,400
On a much bigger scale, obviously.
248
00:14:09,400 --> 00:14:13,920
But what we want to do is be left
with a liquid that we call "wort".
249
00:14:13,920 --> 00:14:16,080
I've heard that term before.
250
00:14:16,080 --> 00:14:17,960
How would you describe wort?
251
00:14:17,960 --> 00:14:21,160
So, wort is a really
sweet-smelling, sugary liquid.
252
00:14:21,160 --> 00:14:24,680
So, at this stage, we've converted
the starch in the grains to sugars.
253
00:14:24,680 --> 00:14:27,840
And we want to extract as many of
those as possible into the liquid.
254
00:14:27,840 --> 00:14:30,880
And the liquid is then called
"wort"? Correct.
255
00:14:30,880 --> 00:14:33,480
The leftover grains are
used for animal feed,
256
00:14:33,480 --> 00:14:37,240
while the all-important wort
is continuously filtered
257
00:14:37,240 --> 00:14:39,680
until it becomes a clear liquid.
258
00:14:39,680 --> 00:14:42,400
This is what it looks like,
actually, when it's all collected.
259
00:14:42,400 --> 00:14:44,080
Have you taken that to the doctor?
260
00:14:44,080 --> 00:14:47,240
If you want to smell it, you'll see
that it's not what you think it is.
261
00:14:48,920 --> 00:14:51,960
Oh! It's like a really
strong herbal tea.
262
00:14:51,960 --> 00:14:53,040
In a way, yeah.
263
00:14:53,040 --> 00:14:55,560
So, that's your really sugary,
sweet-smelling liquid.
264
00:14:57,480 --> 00:14:59,960
Wow! That is really syrupy.
265
00:14:59,960 --> 00:15:02,600
That's delicious!
That'll cure what ails you.
266
00:15:02,600 --> 00:15:04,000
No alcohol in there yet?
267
00:15:04,000 --> 00:15:05,920
Correct, so fermentation
hasn't started.
268
00:15:05,920 --> 00:15:07,280
So, no alcohol yet.
269
00:15:07,280 --> 00:15:10,480
It's sweet, but it is nothing
like a pint, is it?
270
00:15:10,480 --> 00:15:11,520
Not yet.
271
00:15:12,760 --> 00:15:15,160
After filtering for
around two hours,
272
00:15:15,160 --> 00:15:19,200
97,000 litres of our
clear, sweet wort
273
00:15:19,200 --> 00:15:22,920
travels from the lauter tun vessel
into another huge cauldron
274
00:15:22,920 --> 00:15:24,880
called a kettle.
275
00:15:24,880 --> 00:15:27,120
Inside, it's boiled for two hours,
276
00:15:27,120 --> 00:15:31,920
killing any bacteria and
evaporating around 6% of the water
277
00:15:31,920 --> 00:15:34,200
to concentrate the sugary liquid.
278
00:15:35,480 --> 00:15:39,040
But there's another key ingredient
that many of us associate
279
00:15:39,040 --> 00:15:41,160
with the beer-making process.
280
00:15:41,160 --> 00:15:43,360
So, into the kettle, we'll add hops.
281
00:15:43,360 --> 00:15:45,240
I have some examples here.
282
00:15:45,240 --> 00:15:47,680
This is the hops
in their natural form.
283
00:15:47,680 --> 00:15:51,240
They will get concentrated either
into liquid form or pellet form.
284
00:15:51,240 --> 00:15:52,840
May I? Of course.
285
00:15:56,160 --> 00:15:57,720
Wow, that is really strong.
286
00:15:57,720 --> 00:16:01,600
That is like smelling ten pints
of beer at the same time.
287
00:16:01,600 --> 00:16:03,720
It is, isn't it?
That's the smell of a beer.
288
00:16:03,720 --> 00:16:06,400
Yeah. There's a very, very strong
flavour contribution
289
00:16:06,400 --> 00:16:07,720
from the hops.
290
00:16:07,720 --> 00:16:11,040
This, I'm guessing,
is the process to make any beer.
291
00:16:11,040 --> 00:16:12,280
Am I right?
292
00:16:12,280 --> 00:16:13,360
Very close, yes.
293
00:16:14,960 --> 00:16:21,240
Around 20kg of the concentrated
extract is added into the kettle.
294
00:16:23,040 --> 00:16:25,800
And it's boiled for two hours,
295
00:16:25,800 --> 00:16:28,400
until the distinctive hop flavour
296
00:16:28,400 --> 00:16:30,960
infuses into the wort.
297
00:16:34,240 --> 00:16:36,400
Hops are essential for giving us
298
00:16:36,400 --> 00:16:41,160
that bitter taste that we've come
to expect with beer and stout.
299
00:16:42,840 --> 00:16:46,320
And Cherry's been helping with
the annual harvest.
300
00:16:49,160 --> 00:16:51,240
Britain's blessed with not one,
301
00:16:51,240 --> 00:16:54,240
but two regions perfect
for growing hops -
302
00:16:54,240 --> 00:16:56,000
the south-east of England,
303
00:16:56,000 --> 00:16:58,640
and here, in the West Midlands...
304
00:17:00,280 --> 00:17:02,960
..where clay and sandstone store
more moisture than
305
00:17:02,960 --> 00:17:05,160
other types of soil -
306
00:17:05,160 --> 00:17:08,400
perfect for the thirsty hop plants.
307
00:17:08,400 --> 00:17:11,560
And I've come to a farm
that grows enough of them to make
308
00:17:11,560 --> 00:17:14,880
46 million pints of beer a year.
309
00:17:14,880 --> 00:17:17,120
And it's not at all what
I was expecting.
310
00:17:18,680 --> 00:17:21,520
The 200-acre Stocks Farm
in Worcestershire
311
00:17:21,520 --> 00:17:25,080
is in the throes of
this year's pick.
312
00:17:25,080 --> 00:17:28,840
Alongside her husband,
it's farmed by Ali Capper,
313
00:17:28,840 --> 00:17:33,000
who's also a Director of
the British Hop Association.
314
00:17:33,000 --> 00:17:35,640
Hi, Ali, lovely to meet you.
Hi, lovely to meet you, Cherry.
315
00:17:35,640 --> 00:17:38,400
What an extraordinary place!
I've never seen anything like it.
316
00:17:38,400 --> 00:17:40,840
It's like a jungle and a vineyard.
317
00:17:40,840 --> 00:17:42,480
Welcome to our hop yard.
318
00:17:42,480 --> 00:17:44,920
So, are these vines?
319
00:17:44,920 --> 00:17:47,680
They are bines, with a B.
320
00:17:47,680 --> 00:17:52,600
These bines - with a B -
grow up trellises in the hop yard.
321
00:17:52,600 --> 00:17:56,760
While vines use tendrils and
runners to grow up a structure,
322
00:17:56,760 --> 00:18:00,320
bines use stiff hairs to wrap
around their supports.
323
00:18:00,320 --> 00:18:03,200
They are about 18-foot tall.
324
00:18:03,200 --> 00:18:06,600
So, all the crop is at the top
where the sunlight is.
325
00:18:06,600 --> 00:18:08,480
Yeah. This is the hop.
326
00:18:08,480 --> 00:18:10,440
Wow. It's the flower of the plant.
327
00:18:10,440 --> 00:18:12,520
It's this that the brewer wants.
328
00:18:12,520 --> 00:18:16,080
So, that's a hop?
And the magic is inside.
329
00:18:16,080 --> 00:18:19,360
If you open it up,
see that lovely yellow?
330
00:18:19,360 --> 00:18:20,720
Looks like pollen.
331
00:18:20,720 --> 00:18:23,840
So, there are about
400 hop oils in there...
332
00:18:23,840 --> 00:18:25,720
Wow! ..in the lupulin gland.
333
00:18:25,720 --> 00:18:30,040
It's a bit like a tiny little sack
that contains the hop oils. OK.
334
00:18:31,600 --> 00:18:36,480
There are more than 250 varieties
of hop grown across the world,
335
00:18:36,480 --> 00:18:41,400
producing a cornucopia of flavours
to suit all types of beer.
336
00:18:41,400 --> 00:18:44,840
Today, they're harvesting a
variety called Target.
337
00:18:44,840 --> 00:18:48,520
It's full of oils that produce
a rich, slightly bitter flavour -
338
00:18:48,520 --> 00:18:50,280
perfect for stout.
339
00:18:50,280 --> 00:18:52,160
So, you can feel it...
Yeah, it's really oily.
340
00:18:52,160 --> 00:18:53,560
..and you can smell it.
341
00:18:53,560 --> 00:18:55,920
It's absolutely delicious.
342
00:18:57,960 --> 00:19:02,880
It would take around 130kg
of these oily hop cones to produce
343
00:19:02,880 --> 00:19:08,040
the amount of oil needed for
a batch of stout at the factory.
344
00:19:08,040 --> 00:19:11,800
And the man tasked with
harvesting this ten-acre field
345
00:19:11,800 --> 00:19:13,640
is farm hand Sam.
346
00:19:13,640 --> 00:19:14,960
Sam, I'm coming up!
347
00:19:18,280 --> 00:19:19,640
Well, this is cosy!
348
00:19:21,200 --> 00:19:23,480
As the tractor pulls us along,
349
00:19:23,480 --> 00:19:26,200
Sam cuts down the bines
with a simple hook.
350
00:19:28,080 --> 00:19:31,040
So, you need to cut them with
quite a lot of force?
351
00:19:31,040 --> 00:19:32,440
Yeah, you're right.
352
00:19:35,360 --> 00:19:38,200
It's action stations,
as there's a short window
353
00:19:38,200 --> 00:19:39,920
to pick the ripe hops -
354
00:19:39,920 --> 00:19:43,800
usually from the end of August
to early October.
355
00:19:43,800 --> 00:19:46,560
Do you want to try?
Yeah - ready, go!
356
00:19:46,560 --> 00:19:47,600
Got it!
357
00:19:47,600 --> 00:19:51,720
We carefully hold the blade to cut
through the 1cm-thick
358
00:19:51,720 --> 00:19:54,120
string holding the bines in place.
359
00:19:54,120 --> 00:19:55,760
They kind of ping off, don't they?
360
00:19:55,760 --> 00:19:58,080
And they go everywhere -
OK, this is a big one.
361
00:19:58,080 --> 00:20:01,600
At the peak of the harvest,
they cut 3 acres a day,
362
00:20:01,600 --> 00:20:04,200
producing 3 tonnes of dried hops.
363
00:20:07,640 --> 00:20:09,520
As soon as the trailer is full,
364
00:20:09,520 --> 00:20:13,120
it heads across the farm to
the processing area.
365
00:20:13,120 --> 00:20:17,120
It smells so
intensely green in here.
366
00:20:17,120 --> 00:20:20,120
By the end of the day in here,
you can literally taste
367
00:20:20,120 --> 00:20:21,880
the beer in the back of your throat.
368
00:20:23,040 --> 00:20:25,040
Everyone seems in a real hurry.
369
00:20:25,040 --> 00:20:26,960
Well, we are feeding a factory.
370
00:20:26,960 --> 00:20:31,920
We're trying to get 19 bines
a minute through the machine.
371
00:20:31,920 --> 00:20:35,760
So, speed is really,
really important? Yes.
372
00:20:36,800 --> 00:20:38,800
With time at a premium,
373
00:20:38,800 --> 00:20:43,160
this picking machine is designed
to make the job easier -
374
00:20:43,160 --> 00:20:45,080
at least, that's the idea.
375
00:20:45,080 --> 00:20:49,000
The bines are tied by hand
onto hooks hanging from
376
00:20:49,000 --> 00:20:51,360
a fast-moving conveyor belt...
377
00:20:51,360 --> 00:20:53,440
Oh, I see! Right.
378
00:20:53,440 --> 00:20:55,880
..which is easier said than done.
379
00:20:55,880 --> 00:20:58,240
I can't - my brain's gone weird.
380
00:20:58,240 --> 00:21:00,640
That way? And then, that one.
381
00:21:00,640 --> 00:21:02,480
OK. She's got it!
382
00:21:02,480 --> 00:21:03,760
Oh, my goodness.
383
00:21:03,760 --> 00:21:06,120
It's a bit of an arm workout,
isn't it?
384
00:21:10,840 --> 00:21:13,880
I think you've finished.
Well done! I think we fin...
385
00:21:13,880 --> 00:21:16,880
Hang on, what the...?
What?! No, I quit!
386
00:21:16,880 --> 00:21:18,640
I quit!
387
00:21:16,880 --> 00:21:18,640
THEY LAUGH
388
00:21:21,240 --> 00:21:25,240
After they're tied on, the bines
are carried along a conveyor
389
00:21:25,240 --> 00:21:28,120
to the picking machine's
plucker bank.
390
00:21:29,120 --> 00:21:33,120
A series of metal fingers gently
remove the hop flowers...
391
00:21:34,640 --> 00:21:37,880
..which are then spread onto
huge metal trays,
392
00:21:37,880 --> 00:21:40,120
and sent inside a kiln -
393
00:21:40,120 --> 00:21:42,880
just 20 minutes after
they were harvested.
394
00:21:44,360 --> 00:21:47,200
Hoo-hoo!
So, it's really hot in here!
395
00:21:47,200 --> 00:21:50,480
It is like a sauna!
Ooh, what temperature is it?
396
00:21:50,480 --> 00:21:52,720
It's about 60 degrees C.
397
00:21:52,720 --> 00:21:55,880
And we're trying to dry the hops
as fast as possible,
398
00:21:55,880 --> 00:21:59,200
but also as gently as possible.
399
00:21:59,200 --> 00:22:01,720
Damp hops are at risk of rotting,
400
00:22:01,720 --> 00:22:05,880
so drying them evaporates excess
water while leaving behind
401
00:22:05,880 --> 00:22:07,840
the crops' precious oil.
402
00:22:07,840 --> 00:22:12,280
It takes seven hours in the kiln
to reduce the moisture content
403
00:22:12,280 --> 00:22:14,080
from 80 to 10%.
404
00:22:15,560 --> 00:22:17,320
What's going on at the moment?
405
00:22:17,320 --> 00:22:21,280
So, when the hops come out of
the kiln and they're dried,
406
00:22:21,280 --> 00:22:24,440
they then need to be conditioned,
and we tip them...
407
00:22:24,440 --> 00:22:28,080
Woohoo! ..into these large hoppers,
408
00:22:28,080 --> 00:22:32,280
and here, they condition for
24 to 36 hours.
409
00:22:32,280 --> 00:22:37,280
And that enables the hop cone
410
00:22:37,280 --> 00:22:39,400
and the leaf of the hop cone
411
00:22:39,400 --> 00:22:41,320
to regain some moisture.
412
00:22:41,320 --> 00:22:44,680
Because we want to ensure that
what the brewer buys
413
00:22:44,680 --> 00:22:48,160
is a cone, not dust.
414
00:22:48,160 --> 00:22:51,040
Oh, I see. And if they
haven't been conditioned,
415
00:22:51,040 --> 00:22:52,680
they just go to dust.
416
00:22:54,040 --> 00:22:58,320
Retaining the moisture means
the valuable oils aren't lost.
417
00:23:01,040 --> 00:23:03,960
So, with the hops in
tiptop condition,
418
00:23:03,960 --> 00:23:07,280
they're packed into
60kg bales
419
00:23:07,280 --> 00:23:11,680
and travel to processing centres
for the oil to be extracted,
420
00:23:11,680 --> 00:23:14,520
ready to be delivered to breweries,
421
00:23:14,520 --> 00:23:19,440
where the small-but-mighty hops
will deliver a flavourful kick.
422
00:23:29,520 --> 00:23:31,600
Across the Irish Sea, in Dublin,
423
00:23:31,600 --> 00:23:36,520
20kg of liquid hop extract has
been boiling with our wort
424
00:23:36,520 --> 00:23:41,040
made from malted barley,
in the supersized "kettle".
425
00:23:42,240 --> 00:23:47,160
So far, the brewing process has been
much the same as making any beer.
426
00:23:47,160 --> 00:23:50,000
But all that's about to change...
427
00:23:50,000 --> 00:23:51,440
..at the roasthouse.
428
00:23:54,920 --> 00:23:57,600
Inside this 120-year-old building,
429
00:23:57,600 --> 00:24:00,720
they're preparing an
ingredient vital to transform
430
00:24:00,720 --> 00:24:05,920
our brew into rich, dark stout -
roasted barley.
431
00:24:05,920 --> 00:24:08,120
Whoa, it's getting warmer.
432
00:24:08,120 --> 00:24:09,920
Richard!
433
00:24:09,920 --> 00:24:12,120
How you doing, Gregg?
Good to see you again.
434
00:24:12,120 --> 00:24:13,480
Great smell!
435
00:24:13,480 --> 00:24:16,360
Oh, this is the place
where all the magic happens.
436
00:24:17,360 --> 00:24:19,200
We're roasting the barley.
437
00:24:21,000 --> 00:24:25,240
3,500 tonnes of barley is fed into
a hopper above the ovens.
438
00:24:25,240 --> 00:24:27,960
It then drops into
a rotating steel drum,
439
00:24:27,960 --> 00:24:31,920
where it's roasted at
232 degrees Celsius.
440
00:24:33,520 --> 00:24:36,000
Are you roasting the malted barley?
441
00:24:36,000 --> 00:24:39,000
No, we're roasting pure barley.
442
00:24:39,000 --> 00:24:41,400
This is raw barley from the fields.
443
00:24:41,400 --> 00:24:44,120
You pick up a handful of that
and smell it.
444
00:24:45,160 --> 00:24:46,800
It's a pure grass smell.
445
00:24:46,800 --> 00:24:49,880
Very clean, crisp, grass smell.
446
00:24:49,880 --> 00:24:52,120
That's what we use for roasting.
447
00:24:52,120 --> 00:24:55,040
What is it that the roasting
of the barley gives you?
448
00:24:55,040 --> 00:24:58,360
It gives us the colour
and also the flavour -
449
00:24:58,360 --> 00:25:00,800
that roasted flavour is what
we're looking for.
450
00:25:00,800 --> 00:25:04,280
So, the roasting the barley is
what makes the difference
451
00:25:04,280 --> 00:25:07,920
between a pint of beer and
a pint of Irish stout?
452
00:25:07,920 --> 00:25:09,160
It's the roasting?
453
00:25:09,160 --> 00:25:11,400
No doubt about it, Gregg.
454
00:25:11,400 --> 00:25:15,240
Hundreds of tonnes of barley
are roasted every week.
455
00:25:15,240 --> 00:25:19,400
The intense heat inside
the rotating ovens causes sugars
456
00:25:19,400 --> 00:25:23,440
and amino acids within the barley
to undergo chemical reactions,
457
00:25:23,440 --> 00:25:27,280
causing the grain to brown
and flavour.
458
00:25:27,280 --> 00:25:31,080
These browning processes are known
as the Maillard reaction.
459
00:25:31,080 --> 00:25:33,200
After two-and-a-half hours
of roasting,
460
00:25:33,200 --> 00:25:34,920
the barley is ready.
461
00:25:34,920 --> 00:25:37,120
We have a sample here in the drum.
462
00:25:39,320 --> 00:25:41,120
Just pour it into there, Gregg.
463
00:25:47,960 --> 00:25:49,760
You smell that roasted?
464
00:25:49,760 --> 00:25:52,760
That is the smell of ground coffee.
465
00:25:52,760 --> 00:25:56,160
That's a ground coffee,
there's a bitterness to that.
466
00:25:56,160 --> 00:25:58,800
It's almost like the bitter,
almost-burnt bit you get at
467
00:25:58,800 --> 00:26:00,960
the end of a joint of meat
that you can't resist.
468
00:26:00,960 --> 00:26:03,160
It's a good description, Gregg.
469
00:26:03,160 --> 00:26:06,560
Before my roasted barley can
move to the next stage,
470
00:26:06,560 --> 00:26:09,480
it must pass an important test.
471
00:26:09,480 --> 00:26:11,240
Using a dinky hand cutter,
472
00:26:11,240 --> 00:26:16,000
Richard checks that the barley has
the desired black colour.
473
00:26:16,000 --> 00:26:18,160
Each grain is cut in half.
474
00:26:18,160 --> 00:26:23,080
And you can see the samples of grain
are darker on the outside,
475
00:26:23,080 --> 00:26:25,280
and a little lighter on the inside.
476
00:26:25,280 --> 00:26:28,440
As a result, we can see that
this roast is completed
477
00:26:28,440 --> 00:26:29,680
and ready to go.
478
00:26:29,680 --> 00:26:31,880
If that wasn't roasted all
the way through,
479
00:26:31,880 --> 00:26:34,280
we might not have stout -
we might have a very pale ale.
480
00:26:34,280 --> 00:26:36,200
We wouldn't complete the roast.
481
00:26:36,200 --> 00:26:38,880
We'd leave the roast on for another
two or three minutes,
482
00:26:38,880 --> 00:26:43,720
because the roast really happens
in the last few minutes.
483
00:26:43,720 --> 00:26:46,240
We need one of these for
joints of beef.
484
00:26:46,240 --> 00:26:48,640
You need to be able to cut
through the middle and see that
485
00:26:48,640 --> 00:26:50,160
it's cooked all the way through.
486
00:26:50,160 --> 00:26:52,960
We'll adapt it, make a fortune.
You would do, yeah!
487
00:26:52,960 --> 00:26:55,120
If you do it,
I'll go shares with you.
488
00:26:56,680 --> 00:27:00,720
So, no roasted barley,
no black stout.
489
00:27:00,720 --> 00:27:03,360
I couldn't have said it
better meself, Gregg.
490
00:27:05,240 --> 00:27:08,720
The roasted barley's got
Richard's seal of approval -
491
00:27:08,720 --> 00:27:13,920
so 370 litres of cold water
is pumped into the drums,
492
00:27:13,920 --> 00:27:17,480
bringing the temperature down
to 110 degrees,
493
00:27:17,480 --> 00:27:19,040
stopping it from cooking.
494
00:27:20,240 --> 00:27:25,040
Then it's driven a mile across
the huge site to the brewhouse
495
00:27:25,040 --> 00:27:28,960
to be turned into wort,
just like my malted barley.
496
00:27:30,520 --> 00:27:32,680
So, I'm going back to
the brewhouse now?
497
00:27:32,680 --> 00:27:34,640
Yes, Gregg, that's where
you're heading now.
498
00:27:34,640 --> 00:27:36,640
My step count is going to be
through the roof.
499
00:27:36,640 --> 00:27:38,400
Good for you, Gregg!
500
00:27:36,640 --> 00:27:38,400
HE LAUGHS
501
00:27:38,400 --> 00:27:40,960
Cheers! God bless you.
502
00:27:40,960 --> 00:27:43,560
Fascinating place, but it's massive!
503
00:27:48,720 --> 00:27:51,280
The roasted barley
may be getting a lift,
504
00:27:51,280 --> 00:27:53,920
but I've got to find my way on foot.
505
00:27:55,320 --> 00:27:57,120
The factory's grown over the years,
506
00:27:57,120 --> 00:28:02,200
so there's a public road running
right through the middle of it.
507
00:28:02,200 --> 00:28:04,760
But that doesn't bother me -
oh, no -
508
00:28:04,760 --> 00:28:08,120
there's a handy
112-metre-long tunnel
509
00:28:08,120 --> 00:28:11,080
linking one side to the other.
510
00:28:11,080 --> 00:28:14,160
How many factories have a tunnel
in the middle of them?
511
00:28:16,240 --> 00:28:20,800
It was constructed in 1895 by
James Henry Greathead -
512
00:28:20,800 --> 00:28:24,760
the architect responsible for
some of London's Tube stations.
513
00:28:29,000 --> 00:28:31,840
Having resurfaced back
at the brewhouse,
514
00:28:31,840 --> 00:28:36,240
I head down four flights of stairs
and finally get a chance to see
515
00:28:36,240 --> 00:28:38,480
the massive brewing vessels
from below.
516
00:28:41,160 --> 00:28:44,840
Inside, there's a batch of
roasted barley wort,
517
00:28:44,840 --> 00:28:48,400
made using the same method
as my malted barley.
518
00:28:50,000 --> 00:28:51,920
Eh, Eamonn!
519
00:28:51,920 --> 00:28:55,080
Mate, it is tropical-hot
down here, innit?
520
00:28:55,080 --> 00:28:56,840
One of the warmer parts of Ireland.
521
00:28:56,840 --> 00:29:00,440
So, what we've got there is
another wort, but a black wort.
522
00:29:00,440 --> 00:29:02,560
Correct, and it's very, very hot.
523
00:29:02,560 --> 00:29:04,960
It's round about 80-90 degrees
at the moment.
524
00:29:07,520 --> 00:29:09,680
That's got a smell like caramel.
525
00:29:09,680 --> 00:29:11,240
Almost a burnt sugar.
526
00:29:11,240 --> 00:29:13,560
You do get that caramel note
in certain cases,
527
00:29:13,560 --> 00:29:16,080
I've got a cooled-down
sample from earlier.
528
00:29:16,080 --> 00:29:18,400
You can taste it, if you like,
but it is obviously a very,
529
00:29:18,400 --> 00:29:19,760
very strong-tasting liquid.
530
00:29:19,760 --> 00:29:22,840
Is it going to be sweet like the
other wort? Not as sweet.
531
00:29:26,880 --> 00:29:30,160
That's got a real bitter finish,
but that is toasty.
532
00:29:30,160 --> 00:29:34,840
Yeah. It almost tastes like the
smell of a wood barbecue.
533
00:29:34,840 --> 00:29:38,000
What's in your hand now is
effectively the special ingredient
534
00:29:38,000 --> 00:29:40,680
that converts our pale wort
into stout.
535
00:29:41,840 --> 00:29:43,840
Without this little thing here,
536
00:29:43,840 --> 00:29:46,000
we've got a pint of ale.
537
00:29:46,000 --> 00:29:48,280
With this, we've got a pint
of stout. Correct.
538
00:29:50,840 --> 00:29:54,320
The roasted barley wort is sent
to the huge kettle
539
00:29:54,320 --> 00:29:57,600
holding the malted barley wort
I saw earlier.
540
00:29:57,600 --> 00:30:01,720
It's blended at a ratio of
one part roasted barley wort to
541
00:30:01,720 --> 00:30:05,440
nine parts malted barley wort.
542
00:30:05,440 --> 00:30:08,280
So, this is where we combine
our roasted barley-wort
543
00:30:08,280 --> 00:30:09,400
with our pale wort.
544
00:30:09,400 --> 00:30:10,640
I took a sample earlier.
545
00:30:12,080 --> 00:30:14,600
That's looking like a glass of
stout without the head.
546
00:30:18,920 --> 00:30:22,600
Ooh, that, I like.
It's getting there. Ohh!
547
00:30:22,600 --> 00:30:25,440
That starts off treacly-sweet.
548
00:30:25,440 --> 00:30:28,680
But it finishes with
that Irish stout bitterness.
549
00:30:28,680 --> 00:30:31,080
So you should be able to see
everything starting to come
550
00:30:31,080 --> 00:30:32,560
together in this one.
551
00:30:32,560 --> 00:30:34,680
Nice to meet you, Gregg.
You're a fine man.
552
00:30:39,840 --> 00:30:42,360
Ireland's known around
the world for its pubs!
553
00:30:42,360 --> 00:30:44,640
But when did this tradition start?
554
00:30:44,640 --> 00:30:47,760
Ruth's pulling up a bar stool
to find out.
555
00:30:52,640 --> 00:30:56,120
RUTH: Ireland is home to
more than 6,000 pubs.
556
00:30:57,480 --> 00:31:01,560
And over 750 of them are in the
busy capital of Dublin.
557
00:31:03,320 --> 00:31:07,360
So what better place to start
my crawl through their history?
558
00:31:07,360 --> 00:31:12,360
And to help me, I've enlisted pub
historian Eamonn Casey.
559
00:31:12,360 --> 00:31:14,320
Throughout the centuries in Ireland,
560
00:31:14,320 --> 00:31:18,360
there were always a hodgepodge
of unregulated taverns,
561
00:31:18,360 --> 00:31:21,160
coaching inns, ale houses,
562
00:31:21,160 --> 00:31:24,920
many of which
sold questionable brews.
563
00:31:24,920 --> 00:31:26,280
SHE LAUGHS
564
00:31:28,440 --> 00:31:33,440
But from 1635, these early public
houses had to obtain a licence -
565
00:31:33,440 --> 00:31:36,640
and there were some very strange
and surprising ways to get one.
566
00:31:38,360 --> 00:31:41,200
Why are we meeting here on
the edge of Dublin?
567
00:31:41,200 --> 00:31:45,040
That pub you see over there
commenced life as a family home
568
00:31:45,040 --> 00:31:48,280
with absolutely nothing to do
with the licence trade.
569
00:31:52,600 --> 00:31:55,840
The house received its licence
to sell alcohol at a time
570
00:31:55,840 --> 00:31:57,800
of national tragedy.
571
00:31:57,800 --> 00:32:00,960
In the 1840s,
the Irish potato crop failed,
572
00:32:00,960 --> 00:32:04,280
and it's estimated that the
subsequent famines resulted in
573
00:32:04,280 --> 00:32:07,120
the death of more than
a million people -
574
00:32:07,120 --> 00:32:10,000
commemorated by this memorial.
575
00:32:10,000 --> 00:32:14,280
In 1847, as the bodies piled up,
576
00:32:14,280 --> 00:32:18,840
John and Catherine Howe
developed a community morgue.
577
00:32:18,840 --> 00:32:22,240
And, as a consequence of that,
they also received a licence.
578
00:32:22,240 --> 00:32:24,960
So, that people can have
a wake, presumably?
579
00:32:24,960 --> 00:32:28,720
Yes. Its history totally evolved
from of a community morgue
580
00:32:28,720 --> 00:32:30,920
to a prosperous licensed premises.
581
00:32:30,920 --> 00:32:33,880
So, it's a home, a morgue, and a pub
582
00:32:33,880 --> 00:32:37,880
as a result of this tragic
episode in history? Absolutely.
583
00:32:39,920 --> 00:32:43,920
By 1870, 800 premises which
had become morgues
584
00:32:43,920 --> 00:32:46,960
also obtained licences
to act as pubs
585
00:32:46,960 --> 00:32:49,680
at the heart of their communities.
586
00:32:49,680 --> 00:32:51,800
Shall we go and look at some
other pubs? Yes.
587
00:32:51,800 --> 00:32:52,840
SHE LAUGHS
588
00:32:59,120 --> 00:33:02,680
Whilst the number of
licensed pubs was growing,
589
00:33:02,680 --> 00:33:06,480
Victorian Dublin was still
the centre of religious
590
00:33:06,480 --> 00:33:08,800
and moral values...
591
00:33:08,800 --> 00:33:12,240
..which frowned upon
the consumption of alcohol.
592
00:33:13,960 --> 00:33:15,720
Oh, wow!
593
00:33:15,720 --> 00:33:17,440
So, where have you brought me, then?
594
00:33:17,440 --> 00:33:19,160
We're outside the Palace Bar,
595
00:33:19,160 --> 00:33:21,720
one of the iconic
Victorian pubs of Dublin -
596
00:33:21,720 --> 00:33:23,680
and one of my own favourites.
597
00:33:25,400 --> 00:33:29,600
The battle for more licensed
premises took place at a time
598
00:33:29,600 --> 00:33:34,520
when both church and state were
supporting a Temperance movement -
599
00:33:34,520 --> 00:33:36,120
to stop drinking.
600
00:33:37,120 --> 00:33:41,000
This campaign in Ireland,
the Irish Temperance Campaign,
601
00:33:41,000 --> 00:33:43,280
was to convert souls to sobriety.
602
00:33:43,280 --> 00:33:46,160
To a life of total abstinence.
603
00:33:46,160 --> 00:33:50,960
Yes, but people found ways
to have a little tipple,
604
00:33:50,960 --> 00:33:53,880
and drinking continued in the pubs,
605
00:33:53,880 --> 00:33:57,800
and also in the grocery shops.
606
00:33:57,800 --> 00:34:00,040
The grocers' shops? Yes.
607
00:34:01,520 --> 00:34:03,760
Flying in the face of Temperance,
608
00:34:03,760 --> 00:34:06,480
enterprising grocers
saw an opportunity
609
00:34:06,480 --> 00:34:08,960
to increase their business.
610
00:34:08,960 --> 00:34:12,760
They were only supposed to sell
alcohol to customers to take home,
611
00:34:12,760 --> 00:34:16,280
but quickly found a way
round the licensing laws.
612
00:34:16,280 --> 00:34:19,560
What they were doing was actually
erecting screens within
613
00:34:19,560 --> 00:34:23,960
their premises and allowing the
public to drink alcohol illegally
614
00:34:23,960 --> 00:34:25,360
behind that screen.
615
00:34:25,360 --> 00:34:27,440
I can see the publicans
wouldn't have liked that.
616
00:34:27,440 --> 00:34:30,200
I mean, if you were running a pub,
and then the bloke down the road
617
00:34:30,200 --> 00:34:33,480
selling the groceries is suddenly
in competition... Absolutely.
618
00:34:33,480 --> 00:34:37,240
Well, there was a bitter feud
between the licensed publicans
619
00:34:37,240 --> 00:34:41,480
and the grocers,
which lasted for 25 years.
620
00:34:41,480 --> 00:34:46,160
By the 1860s, the Temperance
campaign had lost momentum.
621
00:34:46,160 --> 00:34:50,160
And in 1862, the publicans and
grocers put aside their differences
622
00:34:50,160 --> 00:34:53,080
to form a trade association.
623
00:34:53,080 --> 00:34:57,360
At that time, pubs like
the Palace Bar could commence
624
00:34:57,360 --> 00:34:59,160
to sell groceries.
625
00:34:59,160 --> 00:35:03,840
And the grocers were able
to adapt their premises
626
00:35:03,840 --> 00:35:05,920
to become licensed premises.
627
00:35:05,920 --> 00:35:09,760
That is a really creative way of
solving an argument, isn't it?
628
00:35:09,760 --> 00:35:11,920
So, if you're going to nick my
business, I'm going to nick
629
00:35:11,920 --> 00:35:13,880
your business. We'll both share
both businesses.
630
00:35:16,600 --> 00:35:21,320
So, as well as morgues,
grocery shops became pubs, too.
631
00:35:21,320 --> 00:35:25,760
And the 1870s saw a boom in
the number of licensed premises.
632
00:35:25,760 --> 00:35:29,240
And with it, a whole new
clientele was born.
633
00:35:29,240 --> 00:35:34,360
It became respectable for women to
visit and sit in a snug like this...
634
00:35:34,360 --> 00:35:35,760
Cosy, isn't it?
635
00:35:35,760 --> 00:35:38,120
..while collecting their shopping.
636
00:35:38,120 --> 00:35:43,200
The first purpose of the
Victorian snug in Dublin was for
637
00:35:43,200 --> 00:35:47,840
the Victorian ladies who came in
here in order to buy tea.
638
00:35:47,840 --> 00:35:51,560
Back in the 1880s,
tea was a far more desirable
639
00:35:51,560 --> 00:35:54,240
and expensive item than coffee.
640
00:35:54,240 --> 00:35:57,240
Oh, we mean loose tea?
Loose tea, yes.
641
00:35:57,240 --> 00:36:01,040
This new brand of pub customer -
the middle-class housewife -
642
00:36:01,040 --> 00:36:04,800
found there was another advantage to
doing their shopping in a pub.
643
00:36:06,120 --> 00:36:07,960
She would just press that bell.
644
00:36:07,960 --> 00:36:10,600
The publican would appear,
and she might say,
645
00:36:10,600 --> 00:36:13,880
"Could I have a half-pound of
your beautiful tea, please"?
646
00:36:13,880 --> 00:36:16,000
And he would say,
"Would you like a little beverage
647
00:36:16,000 --> 00:36:18,360
"while you're waiting"?
Oh, no, I couldn't possibly!
648
00:36:18,360 --> 00:36:21,440
But on second asking,
she would consent and say,
649
00:36:21,440 --> 00:36:23,040
"Oh, maybe a gin". "Oh, well!"
650
00:36:23,040 --> 00:36:25,240
So, you've got this
little enclosed space -
651
00:36:25,240 --> 00:36:29,360
it's not just a respectable space,
but it's for secret drinking!
652
00:36:29,360 --> 00:36:31,600
FIDDLES PLAY
Ooh, hang on, listen, listen!
653
00:36:31,600 --> 00:36:33,800
That's music!
Shall we go and have a listen?
654
00:36:35,040 --> 00:36:36,840
By the turn of the 20th century,
655
00:36:36,840 --> 00:36:40,160
Dublin was home
to more than 1,500 pubs.
656
00:36:40,160 --> 00:36:44,640
And nowadays, you can find so-called
Irish bars around the world -
657
00:36:44,640 --> 00:36:48,680
trying to emulate the warmth
and welcome of a place like this.
658
00:36:48,680 --> 00:36:51,200
But you can't beat the real thing.
659
00:36:51,200 --> 00:36:53,560
The Irish pub - we have to think
of it as a grocers,
660
00:36:53,560 --> 00:36:55,080
it's a place for music,
661
00:36:55,080 --> 00:36:56,840
it's a place for the community.
662
00:36:56,840 --> 00:36:58,760
And yet, despite everything,
663
00:36:58,760 --> 00:37:01,480
this is the place you come
for the craic.
664
00:37:04,920 --> 00:37:06,440
MUSIC ENDS
665
00:37:18,000 --> 00:37:19,400
GREGG: Back at the factory,
666
00:37:19,400 --> 00:37:22,200
we're nine hours and 50 minutes
into production.
667
00:37:23,280 --> 00:37:26,440
My dark, bittersweet liquid -
or wort -
668
00:37:26,440 --> 00:37:30,120
is packing an increasingly
rich flavour.
669
00:37:30,120 --> 00:37:32,280
But it's not stout yet.
670
00:37:32,280 --> 00:37:34,320
For that, we need yeast.
671
00:37:36,120 --> 00:37:38,960
So, I'm heading to
the microbiology lab...
672
00:37:41,800 --> 00:37:45,520
..where I'm meeting group
microbiologist Dan Kerruish.
673
00:37:49,080 --> 00:37:51,400
Hey!
674
00:37:51,400 --> 00:37:53,160
Dan, I've got these, as well.
675
00:37:53,160 --> 00:37:54,680
Come on, high five.
676
00:37:54,680 --> 00:37:58,040
All right. I didn't expect the
next stage to be a lab.
677
00:37:58,040 --> 00:37:59,800
Not only a lab, but a library.
678
00:37:59,800 --> 00:38:00,840
Let me show you.
679
00:38:02,480 --> 00:38:03,960
In here...
680
00:38:05,240 --> 00:38:07,480
..we have hundreds and
hundreds of yeast.
681
00:38:07,480 --> 00:38:09,800
What? And we use these yeast...
682
00:38:11,200 --> 00:38:12,880
..to make beer.
683
00:38:12,880 --> 00:38:15,840
The yeast we're using today
dates back from 1903.
684
00:38:15,840 --> 00:38:17,960
Wow! That's incredible.
685
00:38:19,720 --> 00:38:22,520
Yeast is a single-celled
living micro-organism
686
00:38:22,520 --> 00:38:24,160
from the fungus family.
687
00:38:26,240 --> 00:38:29,040
There are around 1,500 species,
688
00:38:29,040 --> 00:38:32,840
and some are better than others
for creating stout.
689
00:38:32,840 --> 00:38:37,280
This one, dating back to 1903,
is unique in that it ferments
690
00:38:37,280 --> 00:38:41,200
quickly without imparting its
own "yeasty" flavour.
691
00:38:41,200 --> 00:38:43,480
Is that liquid nitrogen?
Liquid nitrogen.
692
00:38:43,480 --> 00:38:45,000
Why do you store them in that?
693
00:38:45,000 --> 00:38:47,480
So, we keep it at
-196 degrees Celsius,
694
00:38:47,480 --> 00:38:50,080
because we know that the yeast
will keep. Right, OK.
695
00:38:50,080 --> 00:38:52,440
Stick that back, cos that's
scaring me a little bit.
696
00:38:52,440 --> 00:38:56,000
We normally only get that
in a MasterChef final.
697
00:38:56,000 --> 00:38:58,720
At -196 degrees Celsius,
698
00:38:58,720 --> 00:39:02,320
the yeast can be stored
indefinitely and used to create
699
00:39:02,320 --> 00:39:05,280
"daughter" cells that are
young and active.
700
00:39:05,280 --> 00:39:06,520
Bit like me.
701
00:39:06,520 --> 00:39:09,680
Could you explain to me,
please, the job that the yeast
702
00:39:09,680 --> 00:39:11,480
is doing inside the stout?
703
00:39:11,480 --> 00:39:14,080
So, the yeast is there.
It's producing the alcohol.
704
00:39:14,080 --> 00:39:16,160
It's producing carbon dioxide,
as well,
705
00:39:16,160 --> 00:39:18,120
and it's also producing
some of the flavours.
706
00:39:18,120 --> 00:39:19,160
How is it doing that?
707
00:39:19,160 --> 00:39:21,000
It does that by feeding
on the sugar.
708
00:39:21,000 --> 00:39:23,920
So, it takes that sweet wort,
and it converts it to alcohol
709
00:39:23,920 --> 00:39:24,960
and carbon dioxide.
710
00:39:24,960 --> 00:39:27,920
So, the yeast is eating the sugar
711
00:39:27,920 --> 00:39:30,160
and producing alcohol?
712
00:39:30,160 --> 00:39:32,840
Exactly. Clever little thing.
713
00:39:32,840 --> 00:39:34,280
So, what do you do?
714
00:39:34,280 --> 00:39:36,400
You just tip that into a vat
of wort, do you?
715
00:39:36,400 --> 00:39:37,600
Oh, no, no, no.
716
00:39:37,600 --> 00:39:39,840
We take the sample of yeast,
and then, we grow it up
717
00:39:39,840 --> 00:39:41,080
into different stages.
718
00:39:41,080 --> 00:39:43,240
So, we put it into
this conical flask,
719
00:39:43,240 --> 00:39:44,600
which has sweet wort in it.
720
00:39:44,600 --> 00:39:47,360
We leave it for 24 hours,
and it starts to grow.
721
00:39:47,360 --> 00:39:49,600
We then transfer it to
a larger flask.
722
00:39:49,600 --> 00:39:53,720
So, we've gone from a million
cells here to roughly
723
00:39:53,720 --> 00:39:55,520
50-60 million there.
724
00:39:55,520 --> 00:39:58,520
And then, we put it into what
we call a Carlsberg flask.
725
00:39:58,520 --> 00:40:02,480
We need roughly between
10-15 million cells per mil.
726
00:40:02,480 --> 00:40:05,360
This thing's extraordinary!
It is indeed.
727
00:40:06,520 --> 00:40:09,200
It takes about a week for
the yeast to grow enough to be
728
00:40:09,200 --> 00:40:11,520
ready for my sweet wort.
729
00:40:11,520 --> 00:40:14,440
This is one we prepared for you
to take down to the brewery.
730
00:40:14,440 --> 00:40:16,520
Not far away? Not too far.
731
00:40:16,520 --> 00:40:18,920
Mate, everything around here
is far away.
732
00:40:18,920 --> 00:40:21,000
Thank you, Dan.
You are a clever man.
733
00:40:21,000 --> 00:40:22,960
DAN LAUGHS
734
00:40:21,000 --> 00:40:22,960
I'll look after your yeast.
735
00:40:26,040 --> 00:40:29,880
The factory gets through one
Carlsberg flask every three weeks.
736
00:40:29,880 --> 00:40:32,120
And this one will eventually
help to ferment
737
00:40:32,120 --> 00:40:34,880
28 million litres of stout.
738
00:40:34,880 --> 00:40:38,920
So, if I drop it, that's 50 million
pints down the drain.
739
00:40:41,000 --> 00:40:44,760
Thankfully, I've got it safely
to the fermentation plant -
740
00:40:44,760 --> 00:40:48,120
and Brewing Production Manager
Neale Young.
741
00:40:50,080 --> 00:40:52,480
Neale? Ah! Gregg.
742
00:40:52,480 --> 00:40:54,680
Delivery of yeast for you,
my friend. Great stuff.
743
00:40:54,680 --> 00:40:57,640
Thanks very much.
Very precious, this.
744
00:40:57,640 --> 00:41:00,480
My yeast is added to yet more wort
745
00:41:00,480 --> 00:41:04,760
held inside a 9,000-litre tank
called a propagator vessel,
746
00:41:04,760 --> 00:41:08,280
where it multiplies even further.
747
00:41:08,280 --> 00:41:12,320
Then the 9,000 litres is pumped
into one of the factory's
748
00:41:12,320 --> 00:41:17,520
290,000-litre fermentation tanks...
749
00:41:20,800 --> 00:41:24,240
..which is full to the brim
with sugary wort.
750
00:41:26,280 --> 00:41:32,600
The factory has 52 of these colossal
28-metre-high containers
751
00:41:32,600 --> 00:41:35,320
spread across the site -
752
00:41:35,320 --> 00:41:40,680
all dedicated to transforming
wort into stout!
753
00:41:42,920 --> 00:41:45,400
Are we going up there?
All the way to the top, yeah.
754
00:41:45,400 --> 00:41:46,440
Ooh-ho-ho!
755
00:41:50,040 --> 00:41:52,040
Lucky I'm OK with heights!
756
00:41:55,440 --> 00:41:57,960
Whoa! Right, Gregg, here we are.
757
00:41:57,960 --> 00:41:59,560
Whoa-ho-ho!
758
00:41:59,560 --> 00:42:02,880
It's up here that you truly get
an idea of the mammoth
759
00:42:02,880 --> 00:42:05,760
scale of this production.
Yeah, absolutely.
760
00:42:05,760 --> 00:42:08,560
As impressive as they look,
they're doing a job, right?
761
00:42:08,560 --> 00:42:11,240
What's happening in here?
These fermenters, right,
762
00:42:11,240 --> 00:42:13,480
they're taking the wort over from
the brewhouse, OK?
763
00:42:13,480 --> 00:42:16,640
And that wort's...it's laden with
sugar. And, once the yeast goes
764
00:42:16,640 --> 00:42:18,640
inside, it's going to start the
important job
765
00:42:18,640 --> 00:42:20,720
of creating the alcohol.
766
00:42:20,720 --> 00:42:25,480
Inside the tanks, my sugary wort
finally becomes stout.
767
00:42:25,480 --> 00:42:27,200
But it's not a quick process.
768
00:42:27,200 --> 00:42:29,680
Over the course
of two-and-a-half days,
769
00:42:29,680 --> 00:42:32,280
the yeast feasts upon the sugars,
770
00:42:32,280 --> 00:42:34,800
expelling alcohol and
carbon dioxide.
771
00:42:36,840 --> 00:42:41,480
The yeast is removed and re-used to
help ferment other vessels...
772
00:42:41,480 --> 00:42:43,560
..while the carbon dioxide rises
773
00:42:43,560 --> 00:42:46,320
and is captured at the top
to be extracted.
774
00:42:48,040 --> 00:42:50,880
All the carbon dioxide that
comes off the fermentation,
775
00:42:50,880 --> 00:42:54,640
we recover that, and we use it
within the plant itself.
776
00:42:54,640 --> 00:42:57,720
We also collect it and purify it,
and we use it in our packaging
777
00:42:57,720 --> 00:43:00,480
plants and in the keg plant to
carbonate some of the beers.
778
00:43:00,480 --> 00:43:02,240
So, it's fully utilised.
779
00:43:02,240 --> 00:43:05,400
So, inside one of these,
you've got how many pints?
780
00:43:05,400 --> 00:43:09,360
There's enough stout in here
to make 950,000 pints.
781
00:43:09,360 --> 00:43:12,040
And how many of these have
we got up here? 52.
782
00:43:13,720 --> 00:43:16,480
I can't fathom it.
It's an incredible scale.
783
00:43:16,480 --> 00:43:19,200
Well, we normally have about
35 million pints at
784
00:43:19,200 --> 00:43:20,880
any one point in time.
785
00:43:25,000 --> 00:43:27,880
As stunning as
the view of Dublin is,
786
00:43:27,880 --> 00:43:32,400
I want to know what the fermentation
process has done to my stout.
787
00:43:32,400 --> 00:43:36,440
So, we're heading down 28 metres,
788
00:43:36,440 --> 00:43:40,160
to the base of
the colossal containers.
789
00:43:40,160 --> 00:43:42,880
Gregg, this is one of
our fermentation tanks.
790
00:43:42,880 --> 00:43:47,160
It's actually the one that we were
on top of just earlier on.
791
00:43:47,160 --> 00:43:49,120
So, if you like,
I'll pour you a sample.
792
00:43:49,120 --> 00:43:51,240
Yeah, can I? Yeah, go on!
793
00:43:55,680 --> 00:43:57,880
Taking longer than a pint
takes in the pub, Neale.
794
00:43:57,880 --> 00:44:00,920
Well, you've got to wait for it,
Gregg.
795
00:44:00,920 --> 00:44:03,600
Now, before you try this,
Gregg, I've got to warn you,
796
00:44:03,600 --> 00:44:05,560
it's 7.2% alcohol.
797
00:44:06,680 --> 00:44:08,800
That's nearly double the strength
of the beer
798
00:44:08,800 --> 00:44:10,360
that I would drink at home.
799
00:44:10,360 --> 00:44:11,960
Absolutely, it's very strong.
800
00:44:16,080 --> 00:44:18,000
Whoa, that is strong, innit?
801
00:44:18,000 --> 00:44:19,560
That is seriously strong!
802
00:44:19,560 --> 00:44:21,960
It's got the nice
kind of toasty flavour,
803
00:44:21,960 --> 00:44:24,200
and it finishes with
a lovely bitter finish,
804
00:44:24,200 --> 00:44:26,160
but that is seriously strong.
805
00:44:26,160 --> 00:44:30,400
That's a little bit like someone's
put a whiskey in my stout.
806
00:44:30,400 --> 00:44:33,480
It is, yeah.
Why do you make it so strong?
807
00:44:33,480 --> 00:44:36,120
Well, you see, we've got
to make different stout products
808
00:44:36,120 --> 00:44:37,480
for different countries.
809
00:44:37,480 --> 00:44:39,880
So, you start with
the strongest, and then, you...
810
00:44:39,880 --> 00:44:42,720
Start off strong and then we can
adjust it down depending on
811
00:44:42,720 --> 00:44:44,000
what we want to do with it.
812
00:44:44,000 --> 00:44:45,960
Neale, thanks for that.
Thanks, Gregg.
813
00:44:45,960 --> 00:44:48,200
I can't have too much of that.
I really can't.
814
00:44:50,720 --> 00:44:54,560
After two-and-a-half days
fermenting, the stout is transferred
815
00:44:54,560 --> 00:44:57,960
to a maturation vessel where it
spends another two days
816
00:44:57,960 --> 00:45:01,560
and seven hours to allow
the flavour of the stout to mature.
817
00:45:02,920 --> 00:45:04,360
Once you've got your pint,
818
00:45:04,360 --> 00:45:07,640
the perfect accompaniment is
often a good pub game.
819
00:45:07,640 --> 00:45:10,840
Ruth's been investigating
their surprising role
820
00:45:10,840 --> 00:45:12,320
during the Second World War.
821
00:45:20,600 --> 00:45:23,240
RUTH: From darts...
822
00:45:23,240 --> 00:45:26,600
..to board games,
and even playing cards,
823
00:45:26,600 --> 00:45:31,080
we seem to love getting competitive
alongside our favourite tipple.
824
00:45:31,080 --> 00:45:36,240
But apparently, there was also
a secret role that these played
825
00:45:36,240 --> 00:45:38,240
during the Second World War.
826
00:45:42,160 --> 00:45:46,040
In search of facts,
I've arranged to meet a contact -
827
00:45:46,040 --> 00:45:48,000
historian Dr Helen Fry,
828
00:45:48,000 --> 00:45:50,520
an expert in the history
of spy craft.
829
00:45:51,920 --> 00:45:54,000
Helen, hello!
830
00:45:54,000 --> 00:45:55,720
Hi, how lovely to see you!
831
00:45:55,720 --> 00:45:59,360
I want to know what espionage
and pub games have got
832
00:45:59,360 --> 00:46:00,720
to do with each other.
833
00:46:00,720 --> 00:46:05,160
Well, there was a top-secret section
of military intelligence
834
00:46:05,160 --> 00:46:09,120
that was doing all kinds of
interesting things with pub games,
835
00:46:09,120 --> 00:46:13,800
and it was as top-secret
as MI5 and MI6.
836
00:46:13,800 --> 00:46:17,240
This was a branch of military
intelligence called MI9.
837
00:46:21,960 --> 00:46:26,440
During the Second World War,
more than 170,000 British service
838
00:46:26,440 --> 00:46:29,600
people were captured and kept
as prisoners by German
839
00:46:29,600 --> 00:46:31,000
and Italian forces.
840
00:46:32,560 --> 00:46:35,320
Under the leadership of
Brigadier Norman Crockett,
841
00:46:35,320 --> 00:46:38,240
it was MI9's job to help
them escape.
842
00:46:42,880 --> 00:46:46,440
And there was one group of highly
skilled people on whom their efforts
843
00:46:46,440 --> 00:46:48,320
were particularly focused.
844
00:46:48,320 --> 00:46:51,160
SHE LAUGHS
Now, that's a plane-and-a-half.
845
00:46:51,160 --> 00:46:53,880
What sort is it?
Oh, it's a Mosquito bomber.
846
00:46:53,880 --> 00:46:56,360
So this would have been used
by Bomber Command in missions
847
00:46:56,360 --> 00:47:00,280
over Nazi Germany and other
enemy-occupied territories.
848
00:47:03,560 --> 00:47:07,280
Pilots were in high demand,
so it was vital that any shot
849
00:47:07,280 --> 00:47:11,520
down and captured were returned
to the skies as quickly as possible.
850
00:47:12,800 --> 00:47:17,800
The problem was how to get help
to those who were caught.
851
00:47:17,800 --> 00:47:20,240
How did Crockett come up
with the plan?
852
00:47:20,240 --> 00:47:24,160
Well, he enlisted a former pilot,
Christopher Clayton Hutton.
853
00:47:24,160 --> 00:47:28,080
He was interested in illusionism,
in escapology.
854
00:47:30,240 --> 00:47:33,640
During the war, Christopher
Clayton Hutton worked mostly
855
00:47:33,640 --> 00:47:36,160
as an intelligence officer
for MI9,
856
00:47:36,160 --> 00:47:39,280
but his interest in magic
tricks inspired him to devise
857
00:47:39,280 --> 00:47:42,360
an ingenious plan
858
00:47:42,360 --> 00:47:45,080
involving pub games, of all things.
859
00:47:45,080 --> 00:47:49,440
Ah, well, you couldn't get a much
more traditional pub game
860
00:47:49,440 --> 00:47:52,400
than a dartboard, could you?
No, exactly.
861
00:47:52,400 --> 00:47:54,200
Well, this is a modern version,
862
00:47:54,200 --> 00:47:56,040
but, of course, what we've done
863
00:47:56,040 --> 00:48:01,080
to show you is that this comes out
here and between there, this comes
864
00:48:01,080 --> 00:48:03,440
apart and there's a hidden
compartment.
865
00:48:03,440 --> 00:48:06,400
So this would have been,
as in the picture here,
866
00:48:06,400 --> 00:48:08,800
Clayton Hutton's original design.
867
00:48:10,880 --> 00:48:14,480
Equipment to aid escape,
like hacksaws, screwdrivers
868
00:48:14,480 --> 00:48:17,800
and compasses could easily
be hidden inside the dartboard.
869
00:48:17,800 --> 00:48:21,960
But the most amazing trick
of all was pulled off with a humble
870
00:48:21,960 --> 00:48:24,440
deck of cards.
871
00:48:24,440 --> 00:48:26,800
Surely, nothing can be hidden
in a pack of cards?
872
00:48:26,800 --> 00:48:28,520
Well, you'd be surprised.
873
00:48:28,520 --> 00:48:30,200
These are incredibly rare,
874
00:48:30,200 --> 00:48:34,000
actually, there aren't many
of these that survive.
875
00:48:34,000 --> 00:48:36,160
If you slice this open,
876
00:48:36,160 --> 00:48:38,480
look, you've got part of a map.
877
00:48:38,480 --> 00:48:39,520
This is Westphalia,
878
00:48:39,520 --> 00:48:42,040
part of what was then Nazi Germany.
879
00:48:44,320 --> 00:48:48,520
Chessboards were also adapted,
hiding everything from magnifying
880
00:48:48,520 --> 00:48:51,880
glasses to silk maps.
881
00:48:55,080 --> 00:48:59,520
How did MI9 manage to get
this sort of equipment to people
882
00:48:59,520 --> 00:49:01,800
who were stuck in
prisoner-of-war camps?
883
00:49:01,800 --> 00:49:05,920
Well, the Geneva Convention allowed
for parcels to be sent to
884
00:49:05,920 --> 00:49:08,000
prisoners-of-war by their families,
885
00:49:08,000 --> 00:49:12,720
and MI9 came up with fictitious
charities, and they would send
886
00:49:12,720 --> 00:49:15,240
this into prisoner-of-war camps.
887
00:49:15,240 --> 00:49:18,800
What we've got here is a letter
from 1941
888
00:49:18,800 --> 00:49:21,360
from the Licensed Victuallers
889
00:49:21,360 --> 00:49:24,840
Sports Association... So this
is completely fictitious... Yes.
890
00:49:24,840 --> 00:49:27,920
..there was no Licensed Victuallers
Sports Association?
891
00:49:27,920 --> 00:49:29,840
No, this doesn't exist. OK.
892
00:49:29,840 --> 00:49:32,040
And it says, "Owing
to the difficulties in the present
893
00:49:32,040 --> 00:49:37,440
"situation of obtaining new supplies
of sporting goods using our various
894
00:49:37,440 --> 00:49:41,080
"public houses and inns, your name
has been published as a
895
00:49:41,080 --> 00:49:43,840
"prisoner-of- war, and our committee
896
00:49:43,840 --> 00:49:45,960
"feel that no better purpose
can be found
897
00:49:45,960 --> 00:49:50,320
"for the use of our present stock
of goods than to distribute them
898
00:49:50,320 --> 00:49:54,000
"to those unfortunate members
of the services who are at present
899
00:49:54,000 --> 00:49:55,320
"in prisoner-of-war camps."
900
00:49:55,320 --> 00:49:58,920
And here it says, I really
like this, "Parcel number 14361,
901
00:49:58,920 --> 00:50:02,680
"containing five records, one
dartboard, one chess set, one
902
00:50:02,680 --> 00:50:04,120
"shove ha'penny board."
903
00:50:04,120 --> 00:50:06,440
So the Germans would see
this and think
904
00:50:06,440 --> 00:50:10,800
it was just a charitable act,
sending surplus pub games
905
00:50:10,800 --> 00:50:12,240
to blokes in prison?
906
00:50:14,600 --> 00:50:18,640
Under this cunning guise, pub games
were sent across enemy lines
907
00:50:18,640 --> 00:50:22,840
into Germany and Italy,
giving their recipients
908
00:50:22,840 --> 00:50:25,080
a very pleasant surprise.
909
00:50:25,080 --> 00:50:28,760
I've got an example for
you of a naval prisoner,
910
00:50:28,760 --> 00:50:30,840
Sub Lt John Pryor.
911
00:50:30,840 --> 00:50:33,600
And look what he's written,
"A parcel
912
00:50:33,600 --> 00:50:36,800
"from the Licensed Victuallers
Association."
913
00:50:36,800 --> 00:50:39,160
But look what it says,
it actually says what's inside.
914
00:50:39,160 --> 00:50:40,440
Can you see what...?
915
00:50:40,440 --> 00:50:42,840
"When we opened it, it contained
a chessboard..." Yes.
916
00:50:42,840 --> 00:50:45,320
"..and a beautiful set of chessmen
in a polished wooden box.
917
00:50:45,320 --> 00:50:48,000
"When we split open the chessboard,
it contained
918
00:50:48,000 --> 00:50:49,680
"Reichsmark, hacksaw blades." Yeah.
919
00:50:49,680 --> 00:50:51,000
SHE LAUGHS
920
00:50:51,000 --> 00:50:54,160
So here we have proof that somebody
has received one
921
00:50:54,160 --> 00:50:57,400
of these from the made-up Licensed
Victuallers... Yes.
922
00:50:57,400 --> 00:50:59,080
..and has found it useful.
923
00:50:59,080 --> 00:51:03,880
Lt John Pryor, along
with 35,000 other prisoners-of-war,
924
00:51:03,880 --> 00:51:08,000
used these cleverly concealed
tools to plan their escape.
925
00:51:10,640 --> 00:51:14,200
And the pilots who found their way
back home bravely took
926
00:51:14,200 --> 00:51:17,120
to the skies again,
927
00:51:17,120 --> 00:51:19,680
helping to secure victory.
928
00:51:29,680 --> 00:51:30,920
GREGG: Back at the factory,
929
00:51:30,920 --> 00:51:35,000
I'm uncovering some secrets
of my own.
930
00:51:35,000 --> 00:51:38,360
My stout's been fermented
with yeast, giving it an alcohol
931
00:51:38,360 --> 00:51:41,040
content of 7.2%.
932
00:51:42,280 --> 00:51:43,800
From the maturation vessel,
933
00:51:43,800 --> 00:51:47,320
it's pumped through a series
of pipes where it's pasteurised
934
00:51:47,320 --> 00:51:51,160
by blasting it with steam to prolong
shelf life,
935
00:51:51,160 --> 00:51:55,400
before finally reaching
the kegging plant.
936
00:51:55,400 --> 00:51:59,680
Here, it's blended with water,
bringing down the alcohol content
937
00:51:59,680 --> 00:52:04,800
to a more palatable 4.2%
for the Irish market.
938
00:52:04,800 --> 00:52:08,680
Guiding me through this muddling
maze of pipes is packing
939
00:52:08,680 --> 00:52:11,120
manager, Patricia Gormley.
940
00:52:11,120 --> 00:52:13,400
So here, Gregg, we are the first
step of the process here
941
00:52:13,400 --> 00:52:15,120
in the keg plant.
942
00:52:15,120 --> 00:52:18,560
What happens to it here? I thought
you just put it in barrels.
943
00:52:18,560 --> 00:52:21,480
Yeah. Here's where we add
the nitrogen to the stout.
944
00:52:21,480 --> 00:52:22,760
Nitrogen? Yeah.
945
00:52:22,760 --> 00:52:24,360
Nitrogen's all around us.
946
00:52:24,360 --> 00:52:26,800
It makes up 78% of the world's
atmosphere.
947
00:52:26,800 --> 00:52:29,920
So we're breathing nitrogen anyway?
We're breathing nitrogen anyway.
948
00:52:29,920 --> 00:52:31,840
Right, right, two things I need
to know.
949
00:52:31,840 --> 00:52:36,520
The first one is, why are you
putting nitrogen into the stout?
950
00:52:36,520 --> 00:52:40,960
Nitrogen gives the stout
that smooth, creamy head height.
951
00:52:40,960 --> 00:52:43,760
So it's the small bubbles
that are naturally forming
952
00:52:43,760 --> 00:52:45,080
in the nitrogen.
953
00:52:45,080 --> 00:52:48,960
They give it a subtle fizz
that makes the beer a creamy
954
00:52:48,960 --> 00:52:51,040
and a heavy taste.
955
00:52:51,040 --> 00:52:53,280
So the bubbles aren't big enough
to make it like bubbly
956
00:52:53,280 --> 00:52:54,640
like a lager? No.
957
00:52:54,640 --> 00:52:58,160
The nitrogen gives it that creamy,
distinguishable head.
958
00:52:58,160 --> 00:53:00,160
Compared to carbon dioxide,
959
00:53:00,160 --> 00:53:04,240
nitrogen has a much smaller
molecular size, so the bubbles
960
00:53:04,240 --> 00:53:06,880
it forms are packed closer together.
961
00:53:08,000 --> 00:53:10,200
So how are you putting it in?
962
00:53:10,200 --> 00:53:13,720
We're actually injecting
it in at 9 bar pressure.
963
00:53:13,720 --> 00:53:15,040
That's a lot of pressure.
964
00:53:15,040 --> 00:53:19,800
That's four times the pressure
that's in your car tyre.
965
00:53:19,800 --> 00:53:24,080
The pressurised nitrogen gas is fed
directly into the stout,
966
00:53:24,080 --> 00:53:26,320
where it dissolves into the liquid.
967
00:53:29,320 --> 00:53:30,640
So, all right, let me say
968
00:53:30,640 --> 00:53:33,240
I put nitrogen at pressure
into a coffee,
969
00:53:33,240 --> 00:53:35,120
would it make the coffee
thick and creamy?
970
00:53:35,120 --> 00:53:36,400
Yeah, it would, yeah.
971
00:53:36,400 --> 00:53:38,080
And without that, what would it be?
972
00:53:38,080 --> 00:53:40,360
Just...? You'd have a flat head.
973
00:53:40,360 --> 00:53:41,680
Excuse me? You'd have a flat...
974
00:53:41,680 --> 00:53:43,520
Oh, not me... No, not you.
975
00:53:45,280 --> 00:53:49,600
My nitrogen-rich stout is finally
ready to be put into kegs.
976
00:53:49,600 --> 00:53:53,080
MACHINES HISS AND CLANK
977
00:53:53,080 --> 00:53:55,280
It's loud, innit?
It's very loud, yeah.
978
00:53:55,280 --> 00:53:57,000
Crashing heavy metal!
979
00:54:02,520 --> 00:54:04,400
It's no wonder it's noisy.
980
00:54:04,400 --> 00:54:10,520
An average of 15,000 metal kegs come
through here every day!
981
00:54:10,520 --> 00:54:11,800
I don't know why,
982
00:54:11,800 --> 00:54:14,360
I just thought they might still
be, like, wooden barrels.
983
00:54:14,360 --> 00:54:18,080
Oh, the last wooden barrels
were used in the 1960s.
984
00:54:18,080 --> 00:54:20,280
HE CHUCKLES
985
00:54:18,080 --> 00:54:20,280
Right.
986
00:54:22,320 --> 00:54:25,080
Metal kegs are more durable
and easier to sterilise,
987
00:54:25,080 --> 00:54:29,040
and that's important because
they're part of a continuous cycle.
988
00:54:29,040 --> 00:54:33,480
Each week, more than 100,000 kegs
are collected from pubs
989
00:54:33,480 --> 00:54:36,840
across Ireland and the world,
and brought back here where
990
00:54:36,840 --> 00:54:41,240
they're washed, ready to be filled
with stout all over again.
991
00:54:42,760 --> 00:54:44,840
This is a big old operation.
992
00:54:44,840 --> 00:54:46,880
Yeah, it is.
993
00:54:46,880 --> 00:54:50,160
So you'll see that the kegs are
being fed on into the filler, one
994
00:54:50,160 --> 00:54:52,680
by one, and as they turn
around the carousel,
995
00:54:52,680 --> 00:54:54,720
they're slowly being filled.
996
00:54:57,920 --> 00:55:01,480
Grippers grab the kegs
25 at a time.
997
00:55:01,480 --> 00:55:06,080
The stout is pumped inside and held
under pressure of 4 bar
998
00:55:06,080 --> 00:55:09,560
to maintain the level of nitrogen
in the liquid.
999
00:55:10,680 --> 00:55:13,280
How long does it take
you to fill a keg?
1000
00:55:13,280 --> 00:55:15,760
We can fill a keg in about
30 seconds.
1001
00:55:15,760 --> 00:55:19,400
And what volume of liquid's in
there? 50L.
1002
00:55:19,400 --> 00:55:20,640
How many pints is that?
1003
00:55:20,640 --> 00:55:23,600
88 pints. 88 pints? 88 pints.
1004
00:55:23,600 --> 00:55:28,560
We have the capacity a day
to do 48,000 50L kegs.
1005
00:55:28,560 --> 00:55:33,400
So that's 2.4 million
pints a day, which is about
1006
00:55:33,400 --> 00:55:34,800
25 million pints a week.
1007
00:55:35,800 --> 00:55:38,040
It's a lot of pints.
It's staggering!
1008
00:55:38,040 --> 00:55:39,800
It's staggering volumes.
1009
00:55:41,200 --> 00:55:43,800
I find this stuff sort of quite
hypnotic.
1010
00:55:43,800 --> 00:55:46,080
You know the steel balls
on the streets? Yeah.
1011
00:55:46,080 --> 00:55:48,760
This is like watching
one of them.
1012
00:55:50,560 --> 00:55:54,640
The full barrels exit the filler
and travel along computer-controlled
1013
00:55:54,640 --> 00:55:59,000
conveyors where a shrinker melts
caps onto the tops to keep
1014
00:55:59,000 --> 00:56:00,560
the connectors clean.
1015
00:56:02,800 --> 00:56:07,200
Then they're transported 30 kegs
at a time to the dispatch yard...
1016
00:56:09,320 --> 00:56:13,520
..where I'm meeting logistics
manager, Ciara McGowan.
1017
00:56:13,520 --> 00:56:15,160
Ciara, hello. Hi there, Gregg.
1018
00:56:15,160 --> 00:56:17,440
Good to meet you.
Nice to meet you, Gregg.
1019
00:56:17,440 --> 00:56:20,720
From this depot, do
you distribute all over the world?
1020
00:56:20,720 --> 00:56:22,880
Yes. This area you're in here,
1021
00:56:22,880 --> 00:56:25,680
this is for distribution
within Ireland only.
1022
00:56:25,680 --> 00:56:27,400
So in Ireland itself,
1023
00:56:27,400 --> 00:56:29,840
how many trucks are you sending out
every day?
1024
00:56:29,840 --> 00:56:33,880
From this site, we're sending out 40
vehicles on average every day.
1025
00:56:33,880 --> 00:56:37,000
So how many kegs of stout
are going out of here every day?
1026
00:56:37,000 --> 00:56:39,720
On average, about 6,500 kegs
of stout.
1027
00:56:39,720 --> 00:56:42,760
How many pints is that, do you know?
Over half a million pints, Gregg.
1028
00:56:42,760 --> 00:56:45,800
These two trucks you just loaded,
where are they going?
1029
00:56:45,800 --> 00:56:48,320
They're going to make deliveries
in Dublin City Centre.
1030
00:56:48,320 --> 00:56:49,920
So not far? Not far at all.
1031
00:56:49,920 --> 00:56:51,760
Would you like to get in one?
Could I?
1032
00:56:51,760 --> 00:56:54,400
Yes, absolutely.
What, make a delivery?
1033
00:56:54,400 --> 00:56:56,160
Let's get you safely onboard.
1034
00:56:57,720 --> 00:56:58,840
Hello, sir.
1035
00:56:58,840 --> 00:57:00,440
This is Pat.
1036
00:57:00,440 --> 00:57:02,480
Wahey, come on!
1037
00:57:02,480 --> 00:57:03,680
Cheerio.
1038
00:57:07,920 --> 00:57:11,760
Seven days and five hours after
the start of production,
1039
00:57:11,760 --> 00:57:16,120
we're delivering Irish stout
to a pub in the heart of Dublin.
1040
00:57:18,800 --> 00:57:21,760
The equivalent of 7,500,000 pints
1041
00:57:21,760 --> 00:57:25,120
are delivered every week throughout
Ireland and the UK,
1042
00:57:25,120 --> 00:57:29,800
and they're supped as far afield as
South Africa, the USA and Japan.
1043
00:57:33,000 --> 00:57:36,280
It's amazing to think that something
that looks so simple has gone
1044
00:57:36,280 --> 00:57:38,680
through so many processes
before it's pulled into a pint
1045
00:57:38,680 --> 00:57:40,760
for us to enjoy.
1046
00:57:44,000 --> 00:57:46,320
From space-age brewing
1047
00:57:46,320 --> 00:57:48,800
and sci-fi yeast,
1048
00:57:48,800 --> 00:57:52,080
to phenomenal fermentation,
1049
00:57:52,080 --> 00:57:54,920
and a cacophony of kegs.
1050
00:57:56,040 --> 00:57:57,960
One final test.
1051
00:57:57,960 --> 00:57:59,000
Cheers!
1052
00:58:06,320 --> 00:58:08,640
The factory has come a long
way since its first
1053
00:58:08,640 --> 00:58:10,400
early assembly lines.
1054
00:58:10,400 --> 00:58:13,840
But how did we get from there
to where we are today?
1055
00:58:13,840 --> 00:58:16,720
Explore the history and future
of the factory
1056
00:58:16,720 --> 00:58:18,680
in an interactive timeline.
1057
00:58:18,680 --> 00:58:19,880
Go to...
1058
00:58:23,400 --> 00:58:26,280
..and follow links
to The Open University.
137637
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