La Crosse



Brewing

The Brewhouse in La Crosse is the kitchen of the brewery, which cooks the grains and hops, according to recipe, to produce a sweet fermentable liquid called wort which, after undergoing fermentation, will become beer. Our twin stream Brewhouse is capable of producing 16 brews per day at 1,100 barrels each for an annual capacity of nearly 7 million barrels of beer. City Brewery currently brews approximately 40 different brew recipes for ourselves and over a dozen contract brewing customers.


Fermentation

  • La Crosse has 70 fermentation tanks
  • Fermentation tanks are horizontal temperature controlled
  • Our brewing yeast strains are managed in a dedicated Yeast Room and grown in the Yeast Propagation Room

The Finishing Process

  • Beer is transferred to storage tanks for aging
  • Our aging cellars hold 70 storage tanks and are a mix of horizontal and vertical tanks of various sizes
  • Aged beer is centrifuged prior to filtration
  • This is carried out using a 900 barrel per hour centrifuge system, which supplies a 1,000 square foot US Filter

Filtration

  • The single-pass filtration process is performed after the storage beer has been centrifuged
  • Filtration is through a 1,000 square foot, vertical leaf, US Filter. Process speed is 750 finished barrels per hour
  • Finished beer is filtered into the Package Release Cellar

Blending

At La Crosse, our state-of-the-art, computerized batching/blending room utilizes Rockwell Software's RS Batch program suite capable of batching and blending alcoholic, non-alcoholic, carbonated and non-carbonated beverages. We have four blend loops, each separately controlled through isolated terminals.


Batch Sizes

  • Minimum of 7,750 gallons
  • Maximum of 24,800 gallons
  • All batches are single strength to the filler

Storage and Transfer

  • Stainless steel and Glass lined storage tanks
  • Stainless steel piping
  • Re-circulating finish tanks available for juice products

Ingredients

  • Bulk truck and rail unloading stations
  • Bulk liquid, tote and drum storage
  • Storage for dry bag and drum ingredients
  • Both heated and refrigerated storage space available

Packaging

The La Crosse Packaging Center has the capability to package a multitude of glass, aluminum can configurations, and kegs. The center consists of three glass bottling lines and three aluminum can lines with a total capacity to package over 50 million cases. Ask us about our latest addition to the facility: a Rainbow Line!


Glass Packaging

Three Lines Featuring

  • Bulk glass depalletizers
  • H&K bottle fillers
  • Carbonated or non-carbonated filling capability
  • Tunnel warming and/or pasteurization for various products, including beverages containing natural juices
  • Cold Glue Labelers with back labeling capability
  • Pressure Sensitive Labeling (PSL) with back labeling capability

Crown and Closure Capabilities

  • Twist-off or Pry-off 26mm crowns on 11 oz., 12 oz., 22 oz., 24 oz., 32 oz. and 40 oz. bottles. A specific bottle size of the customer's choice is an option
  • 28mm and 38mm ROPP aluminum bottle closures

Glass Package Configurations

  • 24 bottles per case in 4-pack or 6-pack basket carriers
  • 2/12-pack cartons in a tray
  • 12,15 and 24 bottles per case loose packed with a partition

Rainbow Line

  • Bottle diameters 2.50" (+- .10), heights up to 9.00"
  • 12 pack "battery boxes" packed in a tray or 1-24 pack case with a partition insert
  • "Rainbow" flavor mixes - up to and including 6 flavors in the 12-pack or 24-pack cases

Can Packaging

Three Lines Featuring

  • Bulk can depalletizers
  • H&K fillers with Angelus Seamers
  • Carbonated or non-carbonated filling capability
  • Cold-Fill and HTST Hot-Fill capability (HTST Hot-Fill 24oz only)
  • Nitrogen injection systems
  • Tunnel warming and/or pasteurization for various products, including beverages containing natural juices

Capabilities

  • 211 diameter cans with 202 ends industry standard
  • 300 diameter cans with 209 ends

12 oz. Package Configurations

  • 12/15/18/20/24 cube/30 stack/36 stack cartons
  • 4-pack/6-pack/8-pack/12-pack rim and side applied Hi-Cone in a tray
  • 24 cans loose in a shrink wrapped tray

16 oz. Package Configurations

  • 4-pack/6-pack/8-pack/12-pack rim and side applied Hi-Cone in a tray
  • 6/4-pack cartons in a tray
  • 24 cans loose in a shrink wrapped tray

24 oz. Package Configurations

  • 12 cans loose in a shrink wrapped tray
  • 24 cans loose in a shrink wrapped tray

Quality

Quality Assurance is achieved through integration of quality control, auditing, measurement method validation, and data validation. In our Production/Quality Assurance Program, quality checks by Production and QA occur at key receiving, blending, filling and finished goods locations. A state-of-the-art laboratory backs up the staff with chemical, physical and microbiological testing capabilities.


Analytical Lab

  • Anton Paar alcolyzer
  • DMA 4500 Densitometer
  • BRIX and Refractive index
  • Hewlett Packard 5890 Series II Gas Chromatograph

Package Lab

  • Package Fills; Air and CO2
  • Secure Seal Test for ROPP closures
  • Crown closure torques
  • Double Seam Full Teardowns and evaluation
  • PU monitoring (Pasteurization Unit)

Micro Lab

  • Total plate count
  • Yeast and mold count
  • Water plating
  • Juice testing
  • CIP Validation/Sanitation Monitoring

Other QA Functions

  • Plant Sanitation, GMP, HACCP and Food Safety Audits
  • Sanitation Program Management
  • GMP and HACCP Program Management
  • Analytical and Packaging Data Reporting
  • Retain Sample Library
  • Sensory Evaluation

Warehousing & Logistics

Our warehouse, distribution and logistics experience is extensive. Careful handling and inspection at our warehouse ensures product leaves in excellent condition. Proper loading by our experienced personnel provides damage-free shipping for both domestic and international shipments.


Warehousing and Distribution

  • 500,000 square feet of ambient warehouse space
  • 8,000 square feet of refrigerated cooler space
  • 80 truck loading dock doors
  • 4 separate rail sidings for box cars, tanker cars and grain cars used on both inbound product and outbound shipments
  • 200 trucks per day capacity, with rail car access
  • 24/7 loading available by appointment
  • Inter-modal and container loading
  • All product is stretch wrapped and palletized
  • International and domestic freight expertise
  • Inter-modal, container, trailer and rail car cross docking system
  • 300 space drop trailer capacity
  • Spotting service available

Logistics and Inventory

  • Modern Warehouse Management System, including bar code scanning
  • 3 million cases of product and hundreds of SKUs easily tracked and maintained
  • Strict adherence to FIFO and shipping accuracy
  • Timely inventory reporting
  • Conveniently located in the Midwest along the interstate system, making shipping to both coasts easy and affordable
  • Local BNSF hub leads directly into our facility. Two other Class I rail companies also have local hubs
  • LTL and TL freight companies have terminals within the area
  • Proven load pattern designs