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SOP — Malt Loading

FUERST WIACEK Version 1.2 | Brewhouse — brew day | Frequency: per brew

Purpose

This SOP covers the preparation and loading of malt into the grist case on brew day. Correct malt preparation and loading order ensures accurate recipes, traceability, and safe handling.

PPE Required

  • Ear protection (during milling)
  • Dust mask recommended when handling grain

Risks

Hazard Risk
Grain dust Respiratory irritation — turn on Absaugung (dust extraction) before handling
Heavy bags Back injury — lift correctly

Equipment

  • Printed recipe
  • Pen
  • Yellow brush (malt room only — for cleaning top of grist case)
  • Vacuum cleaner (for malt room)

Process

1. Prep Malt

  1. Pull all malts as specified in the recipe. Double-check you have the correct types and correct total weight in bags.
  2. Write down the lot numbers for all malts on the printed recipe — this is required for traceability.
  3. If any malt looks or smells off — unusual colour, damp, mouldy smell — stop and inform the team before proceeding.

2. Activate Dust Extraction

  1. Return to the Botec computer and set the mill to Stop.
  2. Turn on the Absaugung (dust extraction) manually. This runs the extraction system in the malt room, pulling dust away when you handle grain bags. It keeps the room clean and protects your respiratory health.

3. Load the Grist Case

  1. Open the grist case.
  2. Add malts in the following order — this affects colour extraction and milling behaviour:
    • First: Acid malt
    • Second: Specialty malts — darkest malts first
    • Last: Base malt
  3. When done, take the yellow brush and clean the top of the grist case to remove any loose grain. Close the grist case.

4. Clean Up

  1. Vacuum the malt room.
  2. Throw away all empty bags and rubbish.
  3. Remove empty pallets and place them outside for the farmer to collect.

5. Return to Botec

  1. Return to the Botec computer and set the mill back to Play (automatic mode).
  2. Tick off the malt loading task on your todo list.

Checklist

  • [ ] Malts pulled and verified — correct types and total weight
  • [ ] Lot numbers written on printed recipe
  • [ ] Any off-specification malt flagged to team
  • [ ] Mill set to Stop in Botec
  • [ ] Absaugung (dust extraction) turned on
  • [ ] Grist case opened — acid malt first, dark specialty malts, base malt last
  • [ ] Grist case top brushed and closed
  • [ ] Malt room vacuumed
  • [ ] Empty bags and pallets removed
  • [ ] Mill set back to Play in Botec
  • [ ] Task ticked off todo list