By Kris McDowell
For the Oregon Beer Growler
Brewing craft beer is an art. Running a successful craft brewery is a balance of inputs and outputs. It’s the result of careful thought and planning, addressing each component of the business in the most efficient way possible. It’s undoubtedly a lot of work but one Oregon company has developed software that streamlines these processes, making it easier for craft breweries to focus on the part that we all love the most — the beer.
Beaverton-based Orchestra Software was started by Brad Windecker in 2008 to provide enterprise resource planning (ERP) software specifically for the craft beer industry. At the time, there were plenty of resources relating to brewing technology but nothing that addressed the business side of the equation — at least to the degree he intended. That intention was to provide true ERP, a comprehensive solution to run a business that would replace the various disparate tools and bootstrap solutions (i.e. QuickBooks, Peachtree, spreadsheets). Other companies were providing piecemeal offerings at a lower cost, but Brad aimed to offer a comprehensive package that was even more affordable as well as less complex — making it more approachable to craft breweries.
Identifying a need in the market is one thing and having the ability and know-how to implement a solution to address that need is another. So what put Brad in a position to go from idea to implementation? Growing up around a family business, Brad had always intended to be an entrepreneur and supported that plan by earning a business degree at San Francisco State University. Deciding not to take over the reins of the family business, it was somewhat of lucky chance that brought him into the craft beer fold. During his last year of college his girlfriend (and now wife) took him on a trip to Portland to attend the Oregon Brewers Festival. He was already enamored with craft beer, which could have landed him in a number of places, but during their visit he also fell in love with the city. From there, a path that combined his business background with a passion was forged.
The software Orchestra has created is similar to the kind that large enterprises utilize, but it has been brought down to an affordable level for small breweries or what Brad calls “democratizing technology.” It integrates purchasing and receiving, sales and shipments, production and packaging, quality control and inventory tracking while offering automated accounting and full reporting along with interfaces to third party systems.
Sound like a lot? It is, but it’s all part of what running the business side of a brewery entails. By addressing and successfully managing those things, businesses that utilize this software will not only run more efficiently, but will also have an advantage over those that are wasting time and resources on those same processes. By reducing the pressure of administrative tasks and allowing the focus to be placed on producing and selling product, Brad feels the industry as a whole is improving.
Starting with their early customers — Lazy Magnolia Brewery in Mississippi was the first, followed by Missouri’s Schlafly Beer and Firestone Walker Brewing Company in California — Brad says that, “word of mouth has been the biggest engine of growth since the beginning.” Brad sees an extension of that craft beer camaraderie in their Community Forum, an online resource where customers can ask for or offer help. It has not been uncommon for breweries that first connected in the Forum to go a step further and actually meet in person.
In addition to the always-available Community Forum, Orchestra offers an annual Orchestrate User Conference, yet another way to help their customers to get the most out of their software. At Orchestrate 2017: Level Up (Nov. 15-17), they are expecting 500 attendees who are there for the education and the networking.
Orchestra has come a long way since their inception and counts many Oregon breweries, including Buoy Beer Company, Cascade Brewing and Full Sail Brewery as customers. Their 40 percent year-over-year growth and 96 percent employee retention rate would make them highly attractive to many buyers, however, Brad isn’t interested in selling. He’s far more interested in continuing to grow and improve, changing craft beer on a global scale by expanding through the beer value chain. It may seem like a tall order, but based on how far they’ve already come it’s simply a matter of time before Orchestra is able to provide more avenues to help craft breweries run as efficiently as possible.
By Chris Jennings
For the Oregon Beer Growler
In the wondrous age we live in, it seems as though technology can’t get any better. Then the new-and-improved smartphone model that will call your mom and email your boss at the same time hits store shelves. As you know, we can use our phones to surf the web, solve crossword puzzles and check in all of the beer that you drink to earn badges. But you can also get assistance with developing your homebrew.
There is a vast array of apps that pop up with just a simple search for “brewing” in whatever app store you have. Some — not all — are helpful for making beer and can be used throughout the entire process. Naturally, free is the best price when it comes to acquiring anything, but you also get what you pay for. Some of the no-cost apps may not have features you’re looking for. Some of the free apps for Android products include Biermacht, Brewing Assistant, Brewing Calculator, Brew Timer, and Wort Homebrew Calculator.
Biermacht, Brewing Assistant and Wort Homebrew Calculator are all full-service brewing apps. You can use them to build recipes, add and edit ingredients, and even plan brew days in advance so that your phone will remind you when it’s time to brew (not that you really need to be reminded about something you’re looking forward to, anyway). The best way to decide which app will work for you is to install and play with each to figure out what suits your brewing habits.
The other two apps work better as a tool for your brew day if you already have brewing software or just a recipe on paper. Brewing Calculator is exactly that — you can calculate everything from alcohol content and IBUs to even how much sugar is needed to bottle condition a beer. The app is a quick and easy way to calculate all the little equations that may get a little fuzzy after you’ve had a few of those tasty homebrews. Brew Timer allows you to program in all of your different beers’ hop schedules and save them for later use. You create an “event” and set the minutes once you’ve entered all of the information and start the timer. Basically, this app replaces the kitchen timer or the need to constantly watch the clock so that you don’t miss an addition.
In the land of the free brewing apps, those mentioned will work for most applications. Of course, you can purchase options with more bells and whistles. BeerSmith 2 is a popular option. It works in conjunction with your desktop, allowing you to keep track of your brewing process, share and compare recipes with other users, get assistance or inspiration through a podcast and much more. The price for both Mac and PC is $27.95.
Apps aren’t just for making beer — there are plenty that exist for entertainment. Untappd is designed as a social network for beer drinkers. You can rate the beer you’re consuming, list where you’re drinking it and even chat with friends about the beers they’re trying. This app also keeps track of the beers you check in, so if you can’t remember whether you like a brew you can look up your rating from the past. There are also brewing games like Fiz: The Brewery Management Game where players build their own brewery from the garage up, SimCity-style.
Have fun exploring the world of beer apps where one thing is certain: as technology improves there will likely be more ways to improve our batches of homebrew in the future.
Bell Hop Porter [AG]
Bell Hop Porter [Extract]
By Anthony St. Clair
For the Oregon Beer Growler
Growing, harvesting and processing hops can be a finicky pain in the cask. That’s why scientists, farmers, processors and startups are looking at how technology might increase production and quality. From flyover drones to LED grow lights in hydroponic greenhouses, the market is filled with more experimentation and innovation than ever — but not all new tech is created equal.
The challenges are many, says Jim Solberg, CEO of Indie Hops, a Portland-based hop merchant dedicated to working with craft brewers. Here’s a breakdown of some of the tech being examined:
Unproven and Unlikely
Hops and cannabis are botanical cousins. Cannabis has a history of being grown in climate-controlled greenhouses with LED lights and hydroponics — nutrient-rich solutions — instead of soil. Could hops be grown the same way?
“People don’t necessarily think about the differences between the perennial nature of hops and the annual nature of cannabis,” says Solberg.
Hops have one growth and harvest cycle per year. “After the growing period, the rhizomes need a dormancy period,” explains Solberg. “There is a sort of cleaning up the rhizome does. It’s like us with how sleep helps us function. Hops need overwintering to help them do that. To take that same plant and force it through compressed growth and dormancy cycles at a commercial scale, there are just too many problems and costs to make it viable.”
Cannabis plants are often grown to only a few feet tall, but hops can easily surpass 20 feet. As a result, hops require exponentially more greenhouse space, nutrients, lighting and temperature control. Those factors add up to sky-high economic costs — plus, pests and disease could be an even greater problem in an enclosed space.
“For commercial hop growers, it makes no sense,” says Solberg, but he’s glad that people are trying things out on a small scale. “They might learn something that affects development in a big way.”
Not all ideas are duds though, and farmers and processors are willing to invest in new technologies.
Since farm labor continues to be a challenge, engineers are improving machines that aid with picking, cleaning, drying. At this point, expensive newer machines are only viable for large operations — but Solberg sees the potential to help farmers realize “big savings during the labor of the picking and cleaning process.”
Farmers are also working on how they monitor and adjust plant nutrition. Environmental conditions change every year, affecting both yield and brewing qualities. “You’re trying to optimize the plant’s health, influence its growth habits,” says Solberg. “Advances give more rapid testing of plant material that give a sense nutritionally of what’s going on in the plant. There have been improvements that help stabilize production from a hop standpoint. It doesn’t make it uniform, there are variations, but it does have a positive influence.”
Visitors to a hop field may also see drones flying overhead. Drone-snapped aerial images help farmers evaluate stresses on plants and make adjustments to irrigation or nutrients.
A persistent challenge is field testing hops to know when they are at the optimal condition for harvesting. “In the wine world, they focus on refractometers — they measure the sugar. It’s quick, but there isn’t anything like that for hops,” says Solberg. While there is still no “quick-and-dirty field instrument” for hops, Solberg is hopeful that one could be developed.
Most exciting to Solberg are advances in hop drying and processing. U.S. commercial processors usually dry hops in a 24–30-inch thick layer, laid on a screen floor. Furnaces below the mesh put out heated air that rises, drying the cones. Monitoring moisture levels and temperature has been difficult. “If you let it get too hot, the hop oils can degrade,” explains Solberg. “And these thick beds of hops, there’s not a way to have them mixed through the process. Hops on the bottom don’t get moved, so the bottom of the bed gets warmer than the top, so you have uneven drying.”
Large-scale, variable-speed fans, sensors and mode cells placed on and in the hop bed and along the floor connect to software and provide crucial data. “They can record the weight of the whole floor of hops, and then factor in the weight change for an accurate view of how much moisture has evaporated,” says Solberg.
Hop breeding programs such as Oregon State University’s are also testing varieties that can thrive in drought conditions and still provide a brewing-quality crop. “Water is a larger and larger issue,” says Solberg. “If new hop varieties have both great brewing characteristics but take less water to grow, that could be compelling.”
At a recent global hops symposium at OSU, experts from around the world presented new findings on some of the hundreds of compounds — most as yet unresearched — that comprise any given hop cone.
“Hops are way more complex and interactive than anybody would have imagined. The contribution hops give to beer isn’t just a linear thing,” says Solberg. “There are a lot of so-called hop aroma precursors that don’t contribute in their natural form. During the brewing process and during fermentation, the yeast can help the hop release an aroma component. It’s not present before brewing, but later it releases a clear flavor or aroma component in the beer. Some hops actually do release their aroma compounds during boil, which we used to think wasn’t the case.”
The symposium has given brewers “tremendous ideas,” says Solberg, just as he, farmers and other processors are hopeful for new ideas and innovations.
“Science, research and tech will have some big impact over the next five to 10 years,” he said. “Over time, new things will come of it.”
By Holly Amlin and Pete Dunlop
For the Oregon Beer Growler
Already deep in the Oregon beer weeds with Bailey’s Taproom, The Upper Lip and Brewed Oregon, Geoff Phillips wasn’t quite satisfied. He had recurring visions of a taproom where he could take his young family to enjoy good beer in a pleasant atmosphere.
The result of his thinking is Level Beer, which opened over the summer in the space formerly occupied by produce outlet The Barn in Northeast Portland. Level is situated on roughly 2 acres and features a brewery, taproom, beer garden, food carts, hop yard, gaming and more.
“My original vision was a family-oriented taproom outside the downtown core,” Phillips said. “As I searched for a spot, I was looking at expensive retail space. That led me to the brewery idea because industry property is a lot less expensive. Then I stumbled on this place.”
Owners of The Barn have been looking for a buyer for several years. The property, fairly atypical for a brewery in this area because of its size, appealed to Phillips due to its potential to host a variety of events and activities.
“When I found this place, I was sold on its utility,” Phillips said. “I figured, OK, I can do a brewery. I know something about beer, but I don’t brew and I don’t have any interest in brewing. So I put out feelers that I was looking for a brewer or brewers.”
Soon enough, Jason Barbee entered the picture. Barbee worked at Deschutes’ Portland brewery for five years before moving to Ex Novo Brewing Co. in 2014. There he developed a line of respected beers during the next two years.
“Leaving Ex Novo was tough in some ways,” Barbee says. “I had built something I was proud of and had good momentum. But my ultimate goal had always been to have my own place. Getting to know Geoff, this seemed like an ideal opportunity.”
Barbee and Phillips found a third partner in Shane Watterson, who Barbee had worked with early on at Deschutes. After leaving Deschutes, Watterson spent six years at Laurelwood Brewery, eventually reaching the role of head brewer there.
“Jason and I stayed in touch after Deschutes,” Watterson said. “We had the same ultimate goal and were working on a plan. It’s fair to say the three of us are on the same page in terms of what we think a brewery should be. Level Beer seemed like a good fit for me.”
The family-friendly aspect of Level Beer means they’ll focus on brewing lower-ABV beers. They’d like visitors to feel comfortable enjoying a few pints and food with their kids in a laidback setting.
“Honestly, the lighter stuff is what we like to drink,” Watterson said. “We all have young kids and we appreciate less alcohol. That doesn’t mean we won’t make barleywines and double IPAs. But most of our beers will be on the lighter side in terms of ABV.”
One of their standards is Let’s Play!, a dry-hopped pilsner. They’re still tinkering with the hops, but the beer already has a following. Another standard will be Ready Player One, a dry-hopped saison. Both beers clock in at about 5% ABV.
“Of course, we’ll always have an IPA on, probably two,” Barbee added. “We’ll take a traditional approach, but also do some hazy stuff to please those who search for that. We’ll definitely have some heavier beers and barrel stuff, particularly during the cooler months.”
One of Level’s cool factors is its beer garden, formerly a greenhouse. Seating inside the brewery building is dark and sparse, so the expansive beer garden is a necessary and highly desirable feature.
“The beer garden is unique and we intend to use it year-round,” Phillips said. “We’re in the process of getting overhead gas heaters installed, looking ahead to winter. We’ll close off the sides and make it a comfy space. It was one of the big selling points.”
Possessing a 20-barrel brewery and some fairly large fermenters, Level will have the ability to crank out some volume once the system is fully up to speed. They also have a 2.5-barrel pilot system for experimental and small-batch brews.
“The great thing about the pilot system is we can make small-batch stuff that doesn’t have mass appeal,” Barbee said. “You’re always going to have some beers that don’t move very fast, like a mild. We can make small batches of beers like that and know they won’t be around forever.”
While most startup breweries self-distribute early on to get the best return on what they sell outside their taproom or pub, Level decided to go another route. They chose to partner with Running Man, a boutique Portland-based distributor that represents a handful of craft brands. They have their reasons.
“We didn’t want to self-distribute,” Phillips said. “Shane and Jason want to brew. I want to run these businesses. We don’t want to hit the streets. We would have had to buy trucks, hire salespeople, develop logistics. We didn’t want to go there. Running Man will be our salesperson.”
Running Man may be a good fit. Level Beer isn’t looking to get into big-box grocers. They’re selling draft and packaged product to beer bars and bottle shops and expect to get cans and bottles into New Seasons and other premium stores.
Level Beer branding elements were designed by Hood River-based Jeremy Backer. Backer has several years of experience in branding, packaging and user interface design working with Ex Novo, Final Draft Taphouse, Fortside Brewing Company and others.
An ‘80s video game theme is apparent in the stylistic elements, as well as the bright color scheme. Some design elements can be seen in the taproom, such as the large “LEVEL” display above the taps. But the branding will be most apparent on packaged product.
“We realize there’s a contradictory aspect to the branding,” Phillips said. “The ‘80s theme doesn’t really fit with The Barn. The logo is more for our packaged stuff, less for the pub. We’re super stoked with the branding. And we have a barn. We’ll make it work.”
Phillips didn’t do a formal market analysis. But the area around the brewery, a mix of industrial and residential, is desperately underserved and in dire need of good beer.
“There’s no brewery within 7 miles in any direction,” he says, “and very little here in terms of food and beverage. Besides people living nearby, we hope this will be a destination for people passing by on I-84 or flying in and out of PDX.”
Indeed, the steady flow of PDX traffic in the skies above Level Beer makes rooftop advertising a viable option.
“We’re considering it,” said Phillips. “That might be fun.”
5211 NE 148th Ave., Portland
By Jim McLaren
For the Oregon Beer Growler
The sparkling idea old Joe Priestley had back in 1767 didn't reach its most useful purpose until 2014.
It was 247 years ago when the chemist, who lived next to a brewery and began experimenting with their gas in Leeds, England, made carbonated water. But he stopped there. Making draft beer portable would have to wait.
As you know, beer naturally carbonates during fermentation; yeast eats sugar, making alcohol and carbon dioxide. Problem is that when you take the beer out of the barrel, air gets in and spoils the brew. So to take Joe’s discovery a step further, someone would need to fill that empty space in a barrel with what was called “fixed air” and preserve the freshness. Eventually this would lead to kegs — big kegs for taverns and pubs, pony kegs, Cornelius kegs, none of which are very portable. They are heavy and require attached external devices to get the beer out. But jump ahead to modern times at a bar in Portland and you’ll find another option.
“To keep good beer from going bad.” That’s what I told the guy on the stool next to me when he asked why I paid $149 for the stainless steel uKeg the ponytailed bartender at the Widmer Pub in North Portland was filling with Altbier. When I went on to explain that the uKeg is easy to use and keeps beer fresh for up to two weeks, he chuckled and said, “Who keeps beer around that long?” So, I asked him, “Haven't you ever had a beer you wanted to enjoy a little at a time, a seasonal release or, maybe, after you fill a growler you don’t feel like drinking it all in a couple of days?” “Well,” he said, “how do they keep beer fresh in that big can?”
This is where a trip to an Oregon beach comes in.
“I brought a glass growler and a cooler.” Standing in the front office of GrowlerWerks in Southeast Portland, Shawn Huff recalls how inspiration for the uKeg came from the good beer he’d put in his glass growler. “It was a Boneyard RPM IPA. I drank it one day, put it down, didn't drink the second day and then pulled it back out on the third day. It was flat. It was oxidized. All the work the brewer put into that IPA was ruined.”
So, I was thinking — pressurized growler,” Shawn Huff explains. “I saw some other people were doing it, but no one really from an engineering design perspective.”
Engineers! Brewers get a lot of attention. But who knows the engineers? Meet three you should know: Huff, Brian Sonnichsen and Evan Rege. (Evan was at a manufacturing plant in China when I visited the GrowlerWerks research-and-development warehouse.) Brian explains they met while working for ClearEdge Power, an alternative-energy company. He says Shawn’s idea for a pressurized growler came at just the right time.
“ClearEdge Power went out of business as we were working on this as an after-hours hobby, trying to figure out how to make it work.” Brian has a degree from Massachusetts Institute of Technology and 13 patents to his credit. Evan has a UC Berkeley degree in mechanical design and knows how to build fuel cells. Shawn owns four patents and is a chemical engineer; but, just as important, he won a business plan competition in college. All of that schooling and experience set them up for a dive into entrepreneurship. Brian says they figured, “What the heck? Let’s try this for six months because we can. There’s a program in Oregon that will let you start a business and you don’t have to look for a job for six months. It worked out fantastically.”
Some of the technology involved in making the uKeg is confidential and now being patented in both the U.S. and overseas. But when Brian and Shawn share what they can about how the uKeg works, it sounds simple.
“This is a double-walled, insulated vessel, so it keeps beer cold.” Shawn points out the first thing you’ll probably notice about the uKeg is a brass pipe climbing from the bottom of the vessel to a mini-tap at the top. “We go through the vessel so the beer exits from the bottom.”
Putting the tap on top means they can store a CO2 cartridge inside the variable pressure-regulation cap. “What that allows is you can put the top on, and once it is on you can set this dial and it automatically maintains your carbonation level. So all you have to do is pour.”
Thumbing through the owner’s manual that comes with the uKeg, Brian points out various carbonation settings, from 6 pounds per square inch (PSI) for stout, porter and cream ale to 12 PSI for lager, pilsner or even kombucha. A window on what they call the “sight tube” shows how much beer is in the uKeg. You can check it before you grab the brass handle provided for making your fresh draft beer portable.
“Our brand,” Brian reminds us, “is keeping beer fresh and being able to take it with you.”
Joe Priestley would be proud.
The GrowlerWerks trio has encountered some interesting liquor laws as they’ve moved into new markets. In Florida, there was a law allowing for gallon-sized growler fills, but not half-gallon sizes. In another state, the tap on a freshly filled growler had to be shrink-wrapped to prevent customers from pouring while driving. And when beer drinkers in Japan received the growlers they were due as part of the Kickstarter campaign, they found that Japanese law does not allow for growler fills.
For more information on the uKeg, go to growlerwerks.com.
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