10 Secrets of Brewmasters

Being a brewmaster is about more than just sampling beer and coming up with new recipes. Maintenance and sanitation also play a huge role in the job.
Being a brewmaster is about more than just sampling beer and coming up with new recipes. Maintenance and sanitation also play a huge role in the job.
Stone Brewing

With roughly 7500 craft beer breweries in the United States—a number that continues to grow—it’s clear consumers like their ales and lagers. And as more of these breweries pop up in towns and cities every month, it’s up to brewmasters to constantly produce new beers to satisfy demanding (and evolving) palates, maintain a sterile workspace, and properly operate all the complex machinery that pumps out your favorite IPA. To find out what goes into owning and operating a brewery, Mental Floss spoke with a number of brewmasters about what their days entail. Here’s what they had to say about taste tests, oyster beer, and getting doused in hop sludge.

1. A lot of brewmasters started out as home brewers.

A brew kettle from Stone's Richmond, Virginia, location.Stone Brewing

While brewmasters sometimes attend college to study chemistry or even specific brewing courses, a fair number get their start in their own homes. “When I started, I would say about 50 percent [were home brewers],” Tom Kehoe, co-owner of Yards Brewing Company in Philadelphia, Pennsylvania, says. This was back when there were only around 649 breweries in the country, according to Kehoe. That number has only grown with time, and now he says as many as 90 percent of current brewers experimented with home brewing before moving on to larger productions.

While home brewing can be a good start, Kehoe says that there’s a limit to how much you can learn in a garage setting. “The basic knowledge of how beer is made is exactly the same. However, good brewing practices need to be learned on site. The environment working in a brewery is a lot different than brewing at home.”

One example? Size. According to Jeremy Moynier, brewmaster of Stone Brewing in San Diego, California, people are surprised when they see the scale of some brewing operations. "A home brewer is used to making a few gallons," Moynier says. "We could be making a 250-barrel batch [at Stone]. Each barrel is 30 gallons."

2. Brewmasters use sound almost as much as taste to evaluate the brewing process.

This is just a sample of the brewing equipment employed by Yards.Yards Brewing

Breweries come in all shapes and sizes, but all of them implement a lot of machinery, stainless steel vats, pumps, and bottling lines to concoct their brews. It becomes a symphony of sorts, according Moynier. And if one instrument sounds off, he can tell.

"You use all of your senses, from taste to sound," he tells Mental Floss. "Breweries are noisy, and there are sounds you get attuned to. If something sounds wrong, you know there’s a problem somewhere. Your senses being in tune are important."

Once, Moynier heard an unusual squeaking noise in the factory. He discovered that the tank that held the crushed malt was backed up, which would eventually ruin the conveyor belts if no one noticed in time. Thankfully, Moynier picked up on that change in noise, and the problem was corrected before the machine required a more expensive repair.

3. Brewmasters are always trying novel flavors. Even oysters.

There’s no shortage of creativity among brewmasters, with breweries constantly experimenting with different flavor profiles, from tea to chocolate to fruit. "There are so many different styles, flavor, and aroma profiles you can hit," Moynier says. "We’re constantly learning about new ingredients.” One that impressed Moynier recently was an oyster stout, a style that was originally billed as a beer that simply paired well with oysters more than a century ago, but has since evolved to include actual oyster meat and stock in modern recipes. This one came from Liberty Station, one of Stone Brewing’s locations in San Diego. "It was pretty fascinating," he says. "They got a real briny, oyster thing going."

4. Sanitation is one of the most important parts of being a brewmaster.

Stone's barrels hold 30 gallons of beer. Stone Brewing

The stereotype of brewmasters sipping beer all day and hovering over batches is slightly misguided. According to John Trogner, co-owner with brother Chris of Tröegs Independent Brewing in Hershey, Pennsylvania, most of the job is making sure beer is made in clean conditions. “People usually think you’re sitting around all day dreaming up recipes and tasting beer,” Trogner says. "That’s a very small component. Physical cleaning is probably 80 percent of it. Sanitation is paramount. It’s like a chef keeping a kitchen clean. Workers spend most of their time scrubbing."

Just because the breweries are kept clean doesn't mean the brewmasters are quite as lucky. Depending on the valve and your luck that day, that could sometimes mean an unintentional beer shower for workers. "I’ve taken baths in yeast and beer sludge," Trogner says of his early days, explaining it's a hazard you face when you're opening the valves on the brew tanks.

5. Brewmasters know they're expected to bring beer to most gatherings.

Foeders are large wooden vats that age a beer to create a unique flavor profile. It's part of Tröegs's Splinter Cellar, and each foeder was custom made and shipped to the brewery. Tröegs Independent Brewing

Like any other profession, brewmasters can sometimes be greeted with an expectation that their services and goods are free for friends and relatives to enjoy at gatherings and family events. "If it’s appropriate to bring beer, I will," Kehoe says. "And sometimes when it is not so appropriate. I have brought beer to a business networking breakfast and somehow it turned out to be a great icebreaker. I find that people are disappointed if I don’t have at least some beer at the ready."

6. The job can make you critical of other beers and even food.

Working to perfect beers all day can have an effect on how brewmasters regard other beer options. "I still love beer, but it changes the way you approach it," Moynier says. "You pick out a flaw, and it will bother you. It might ruin your enjoyment. But if you find a beer you really like, it can also make it more enjoyable."

A brewmaster doesn’t just develop a sense of what makes for a good beer; they’re also constantly thinking about what type of food pairs well with certain beers. "It definitely affects the way you taste things," Moynier says. "It’s made me a pickier eater. You’ll think about how food will pair with beer sometimes, where you wouldn’t necessarily think about that before. It made me appreciate how things go together."

7. Brewmasters know names and logos can make or break a beer.

Tröegs's Mad Elf is one of the most recognizable beers around the holidays. Tröegs Independent Brewing

With so many beer options, it’s imperative for brewmasters to use marketing as a way of setting up a consumer’s palate before they sample anything. For Tröegs's Haze Charmer, which offers pineapple and grapefruit notes, the brewery went to great lengths to describe how the "haze" of the recipe carries hop oil into the mouth.

"Haze Charmer emerges from a soft, swirling cloud of oats and unmalted wheat. Vigorous dry-hopping adds a second phase of haze, propping up the oils of Citrus and El Dorado," the website description of the beer reads.

"The name is a critical component," Trogner says. "Consumers are getting to know it before they try it."

The right—or wrong—name and design can make all the difference. Trogner promoted a cherry, honey, and chocolate ale around the holidays and called it Mad Elf, with bottles and packaging decked out in cartoon images of a tipsy elf enjoying one too many. It's become a perennial hit.

"It’s a celebration of the holidays," Trogner says. "Mad Elf is kind of part of social webbing, which is nice to hear. Grandmothers come in and buy five or six cases for family coming over for the holidays."

Similar beers with different branding didn't fare as well. "We’ve done beers like Mad Elf out of season and it didn’t have near the fervor or excitement," he says.

8. A brewmaster associates a beer’s personality with color.

Yards's Philadelphia Pale Ale is lighter in color and far more citrusy than an amber lager.Yards Brewing

According to Kehoe, light and dark beers each give off a distinctive personality trait depending on their color, which comes from the grains used. "To me, the color of the beer is the mood of the beer," he says. "Light color is fluid and exciting; darker [is] slower and more filling and relaxing." Amber is more middle-of-the-road and more versatile. "[It] can be whatever personality that you want to project in the moment."

9. Smells are a big inspiration for new beers.

Don’t think brewmasters develop recipes based just on tasting other beers; it’s more of a multi-sensory experience. Trogner says that most beer ideas come from everyday life. “We’re not sitting around and looking at other types of beer,” he says. “It’s more about an experience, like having an amazing dish at a restaurant. Or you might be hiking and smell something floral in the air, like pine.”

10. Yes, brewmasters sometimes drink early in the morning.

While downing beer is probably not as common an occurrence as you might think, brewmasters are still expected to sample their wares before it goes out for distribution. According to Moynier, those executive samples can happen at odd times of the day depending on schedules.

"Tastings can happen at six in the morning," he says. "We also have structured tasting and daily taste panels to approve beer about to be packaged. Three times a week we have a brewmaster taste panel where we focus on new beers we’re trying out for release or changes to recipes. There’s an executive panel once a month with [Stone's founders Greg Koch and Steve Wagner]."

Or, as Kehoe puts it, “I don’t drink all day, but I do drink every day.”

10 Reusable Gifts for Your Eco-Friendliest Friend

Disposable tea bags can't compete with this pla-tea-pus and his friends.
Disposable tea bags can't compete with this pla-tea-pus and his friends.
DecorChic/Amazon

This article contains affiliate links to products selected by our editors. Mental Floss may receive a commission for purchases made through these links.

By this point, your eco-friendly pal probably has a reusable water bottle that accompanies them everywhere and some sturdy grocery totes that keep their plastic-bag count below par. Here are 10 other sustainable gift ideas that’ll help them in their conservation efforts.

1. Reusable Produce Bags; $13

No more staticky plastic bags.Naturally Sensible/Amazon

The complimentary plastic produce bags in grocery stores aren’t great, but neither is having all your spherical fruits and vegetables roll pell-mell down the checkout conveyor belt. Enter the perfect alternative: mesh bags that are nylon, lightweight, and even machine-washable.

Buy it: Amazon

2. Animal Tea Infusers; $16

Nothing like afternoon tea with your tiny animal friends.DecorChic/Amazon

Saying goodbye to disposable tea bags calls for a quality tea diffuser, and there’s really no reason why it shouldn’t be shaped like an adorable animal. This “ParTEA Pack” includes a hippo, platypus, otter, cat, and owl, which can all hang over the edge of a glass or mug. (In other words, you won’t have to fish them out with your fingers or dirty a spoon when your loose leaf is done steeping.)

Buy it: Amazon

3. Rocketbook Smart Notebook; $25

Typing your notes on a tablet or laptop might save trees, but it doesn’t quite capture the feeling of writing on paper with a regular pen. The Rocketbook, on the other hand, does. After you’re finished filling a page with sketches, musings, or whatever else, you scan it into the Rocketbook app with your smartphone, wipe it clean with the microfiber cloth, and start again. This one also comes with a compatible pen, but any PILOT FriXion pens will do.

Buy it: Amazon

4. Food Huggers; $13

"I'm a hugger!"Food Huggers/Amazon

It’s hard to compete with the convenience of plastic wrap or tin foil when it comes to covering the exposed end of a piece of produce or an open tin can—and keeping those leftovers in food storage containers can take up valuable space in the fridge. This set of five silicone Food Huggers stretch to fit over a wide range of circular goods, from a lidless jar to half a lemon.

Buy it: Amazon

5. Swiffer Mop Pads; $15

For floors that'll shine like the top of the Chrysler Building.Turbo Microfiber/Amazon

Swiffers may be much less unwieldy than regular mops, but the disposable pads present a problem to anyone who likes to keep their trash output to a minimum. These machine-washable pads fasten to the bottom of any Swiffer WetJet, and the thick microfiber will trap dirt and dust instead of pushing it into corners. Each pad lasts for at least 100 uses, so you’d be saving your eco-friendly friend quite a bit of money, too.

Buy it: Amazon

6. SodaStream for Sparkling Water; $69

A fondness for fizzy over flat water doesn’t have to mean buying it bottled. Not only does the SodaStream let you make seltzer at home, but it’s also small enough that it won’t take up too much precious counter space. SodaStream also sells flavor drops to give your home-brewed beverage even more flair—this pack from Amazon ($25) includes mango, orange, raspberry, lemon, and lime.

Buy it: Amazon

7. Washable Lint Roller; $13

Roller dirty.iLifeTech/Amazon

There’s a good chance that anyone with a pet (or just an intense dislike for lint) has lint-rolled their way through countless sticky sheets. iLifeTech’s reusable roller boasts “the power of glue,” which doesn’t wear off even after you’ve washed it. Each one also comes with a 3-inch travel-sized version, so you can stay fuzz-free on the go.

Buy it: Amazon

8. Countertop Compost Bin; $23

Like a tiny Tin Man for your table.Epica/Amazon

Even if you keep a compost pile in your own backyard, it doesn’t make sense to dash outside every time you need to dump a food scrap. A countertop compost bin can come in handy, especially if it kills odors and blends in with your decor. This 1.3-gallon pail does both. It’s made of stainless steel—which matches just about everything—and contains an activated-charcoal filter that prevents rancid peels and juices from stinking up your kitchen.

Buy it: Amazon

9. Fabric-Softening Dryer Balls; $17

Also great for learning how to juggle without breaking anything.Smart Sheep

Nobody likes starchy, scratchy clothes, but some people might like blowing through bottles of fabric softener and boxes of dryer sheets even less. Smart Sheep is here to offer a solution: wool dryer balls. Not only do they last for more than 1000 loads, they also dry your laundry faster. And since they don’t contain any chemicals, fragrances, or synthetic materials, they’re a doubly great option for people with allergies and/or sensitive skin.

Buy it: Amazon

10. Rechargeable Batteries; $40

Say goodbye to loose batteries in your junk drawer.eneloop/Amazon

While plenty of devices are rechargeable themselves, others still require batteries to buzz, whir, and change the TV channel—so it’s good to have some rechargeable batteries on hand. In addition to AA batteries, AAA batteries, and a charger, this case from Panasonic comes with tiny canisters that function as C and D batteries when you slip the smaller batteries into them.

Buy it: Amazon

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12 Secrets of Spirit Halloween Employees

Spirit Halloween stores are a sign Halloween has arrived.
Spirit Halloween stores are a sign Halloween has arrived.
Mike Mozart, Flickr // CC BY 2.0

When Joe Marver founded Spirit Halloween in 1983, he probably didn’t have any idea his seasonal Halloween store would eventually grow to over 1300 locations in the United States and Canada. But now, seeing a Spirit pop-up materialize in a vacant building has become as much of a Halloween tradition as pumpkin carving.

In order to assist shoppers with Halloween costumes, decorations, and animatronic creatures, Spirit employs a small army of seasonal workers. To get a better feel for what goes into this spooky vocation, Mental Floss reached out to several current Spirit Halloween team members. Here’s what they had to say about everything from customers making a mess to the hazards of trying on a mask during this pandemic-heavy Halloween.

1. Most Spirit Halloween employees really, really love Halloween.

Why take on a seasonal job with no potential for year-round work? If you love Halloween and the macabre, it’s a dream job. “I've never once worked with an employee that didn't love Halloween,” Kota, a five-year veteran of Spirit Halloween in Kentucky, tells Mental Floss. “It's something that all employees have in common from my experience … It's a perfect place to meet people with the same interests.”

2. Spirit Halloween employees are supposed to open costume packages for customers.

Spirit Halloween employees are happy to help with your costume selection.Courtesy of Spirit Halloween

If a Spirit Halloween employee is eyeing you with a little bit of consternation, it might be because you ripped open a costume package. Owing to issues of loss prevention and hygiene—even before COVID-19 struck—Spirit’s policy is to let employees open items and then package them back up. But not every customer is willing to wait.

“Our employees are supposed to deal with opening and closing each and every package,” Kota says. “This way we don't have to worry about things coming out or going into the packages that aren't supposed to. Although we try hard to make it as easy and friendly as possible, some customers would rather do it themselves wherever they may be standing in the store.”

3. Spirit Halloween employees can’t keep astronaut helmets in stock.

Every season brings a different phenomenon to Halloween shopping. In 2018, it was the popular video game Fortnite. This year, it’s an astronaut helmet. Not the suit, just the helmet. The trend is due to the popularity of a smartphone game titled Among Us, which puts the player in the role of a space explorer.

“Despite what you might think, the suits themselves seem significantly less popular than the helmets themselves for reasons beyond my comprehension,” Derek, a Spirit Halloween employee in New Jersey for the past three years, tells Mental Floss. “It's still just a bit too early to say, but if the helmets keep shipping out at the rate they are, in-store stock will probably remain at a near-constant zero. If I'm recalling it right, all of the stores in my area currently have one helmet if any, and no more than five are being shipped to each store.”

4. Spirit Halloween employees can’t believe customers are still trying on masks.

It's probably not a good idea to try on Halloween masks this year.Mike Mozart, Flickr // CC BY 2.0

Despite newfound concerns over touching surfaces or being exposed to infectious particles, customers are still willing to try on masks in the store, even though someone else may have already been wearing it. “Ultimately the pandemic hasn't affected my store, aside from everyone needing to wear face masks while they're inside,” Jayme, a Spirit Halloween employee in Florida who’s worked there for four years, tells Mental Floss. “But people still ask to try things on and … they do still put masks on despite orange signs everywhere saying not to.”

Derek agrees. “If you've bought a mask from Spirit in any of the past seasons, there's a very high chance you're one of at least five people who’s worn that mask, and that's a conservative estimate for some of the masks. Despite the rule, I think I've seen that many people trying on [fictional creepypasta internet character] Jeff the Killer masks just in this past week.”

5. Spirit Halloween employees have seen some spooky things.

While a store full of scary costumes and props is a Halloween lover’s dream, some Spirit Halloween employees say it can also be the site of some spooky events. “An associate and I have both seen things swaying on the shelves as if someone walked by it, though nobody else is in the store,” Jayme says. “We've seen a few shadow movements as if people were hiding behind [a] corner. The funniest one [was] at closing time. One of my associates yelled ‘whoo’ and we heard a guy's voice say something in response. It totally freaked him out. It was one of our sound-activated hanging [animatronics].”

But not all employees get creeped out. “As much as I want to say that I've experienced anything creepy or paranormal, the store's about as creepy as a former Circuit City can be,” Derek says. Still, he's seen some strange things. “The lights used to turn off at the exact same time every day for about a month, there's always been the occasional inexplicable bang or creak, and some of the aisles do get messy a bit too quickly. One time, I was working at the fitting room. I sent a kid back with a previously unopened, dry Morphsuit costume [a full-body spandex outfit] and it came back warm and moist.”

Wet costumes aside, Derek won’t declare any paranormal activity just yet. “If I see a kid go flying across the store, I'll let you know.”

6. Spirit Halloween employees wish customers would stop making a huge mess.

Spirit Halloween employees like to keep stores neat.Courtesy of Spirit Halloween

Owing to the nature of pop-up stores or the excitement over the holiday, customers at Spirit Halloween stores tend to make messes. Big ones. “You could've just finished putting every mask neatly back on the racks, and half of them will be back on the floor before you've caught your breath,” Derek says. “It seems like everyone takes a little pride in the sections they helped set up and the animatronics they built, and that definitely manifests in how we feel about customers messing with those things.”

7. Spirit Halloween employees would prefer you not use the aisle as a dressing room.

Some customers like to try on outfits in the aisle instead of the dressing room, a habit that predated the current pandemic. (Spirit Halloween fitting rooms are closed this season.) Employees would still prefer you not try to dress—or undress—in the middle of the store. “It's very common to find people, mostly kids, trying on costumes in aisles,” Kota says. “We [did] have multiple fitting rooms to try to stop this from happening, but once again, people would rather do things themselves sometimes.”

8. Spirit Halloween employees move a lot of licensed animatronics.

Animatronics are a popular item at Spirit Halloween.Courtesy of Spirit Halloween

Among the most popular items in Spirit Halloween locations are the life-sized animatronics that provide a scary atmosphere for homes or parties. “Animatronics are one of our largest-selling items,” Kota says. “There's a certain group of people that love them and look forward to them annually. Some of our buyers buy them and use them for their haunted attractions. It's always nice to go to one and see a familiar face.”

While Spirit offers a number of original animatronic concepts—the Harvester of Souls being among the more popular—Kota says that customers usually gravitate toward licensed characters. “I've noticed that the most popular animatronics are our licensed ones. Pennywise [from 2017's It] and Sam [from 2007's Trick 'r Treat] have been huge sellers this year as was Michael Myers a few years ago. I've also noticed the ones that stay behind at the end of the season are almost always the swinging animatronics. I think they're interesting, but they don't sell as often as the others do.”

9. Spirit Halloween employees might sell you a used animatronic, but you need to get lucky.

Come the end of the season, Spirit Halloween locations often unload animatronics that were on display and no longer being manufactured. “Older animatronics, if I recall correctly, will stop being manufactured and then sold until it runs out,” Jayme says. “As for the displays, we do sell those at the end of the season. It's just a matter of putting your info on a waiting list.”

10. Spirit Halloween employees meet a lot of cosplayers.

Cosplayers are frequent shoppers at Spirit Halloween.Mike Mozart, Flickr // CC BY 2.0

It’s not just Halloween customers that Spirit Halloween stores service. According to Kota, cosplayers looking for that perfect accessory sometimes show up. “Spirit actually gets quite a bit of cosplayers and I personally think it's a great place to go for more specific items,” Kota says. “I'm sure we get even more cosplayers than I'm aware of since some customers like to talk about it and others don't say much about it.”

11. Spirit Halloween employees get a steep, steep discount once Halloween is over.

Between the standard employee discount and the after-Halloween fire sale available to customers, Derek says that he can go shopping in November and save a considerable amount of money. It’s one reason he keeps coming back. “It's hard to say no to an 80-percent discount during the November clearance sale,” he says. (The regular discount is 50 percent, and employees get an additional 30 percent.) “There's nothing like rewarding yourself after a busy season by spending $150 on, like, five or six things.”

12. Spirit Halloween employees sometimes get holiday shoppers.

Halloween means holiday shopping for some people.JJBers, Flickr // CC BY 2.0

For some customers, a Spirit Halloween store is a perfect place to start their holiday gift shopping. “I made a friend last year with a kid who comes in weekly to see if we have anything new in yet,” Kota says. “He's maybe about 7 years old and [he] and I go around the store almost every time he comes in and talk about new things and animatronics we have. His parents then secretly go around and buy him animatronics and props as Christmas presents. It's so nice to see his love for Halloween all year round. It reminds me of myself when I was his age.”