The makers of Iron City Beer are brewing on a large scale now in the Alle-Kiski Valley.
The Pittsburgh Brewing Co. is settling in at its state-of-the-art brewery in the Creighton neighborhood of East Deer. It’s more than 150,000 square feet. Brandon Mayes, director of brewing and quality, watched Thursday as 400 cans of beer per minute rolled through the automated production line.
“I brew the beer and make sure it’s the highest quality,” Mayes said.
400 cans of beer per minute happening now at Pittsburgh Brewing Company in East Deer. ?@VNDNews? ?@TribLIVE? pic.twitter.com/teCdVgCRSU
— Joyce Hanz (@hanz_joyce) September 8, 2022
Mayes brings more than 26 years of brewing experience to the iconic Pittsburgh Brewing Co., which was founded in 1861.
He relocated from Maine to Pittsburgh in 2021 and noticed the Steel City’s penchant for hops.
“I love Pittsburgh. They love their beer. It’s a wonderful, wonderful city,” Mayes said.
Iron City Beer is the top seller, and it takes about 21 days to produce a can of it, he said.
Other beers brewed on site include IC Light, Old German and American.
A limited-edition Pittsburgh Iron City Bill Cowher Lager is being produced, featuring a black-and-gold image of the Hall-of-Fame Steelers head coach on every can.
The 42-acre property, once home to Pittsburgh Plate Glass’ Works No. 1 glass factory, features state-of-the-art, high-tech brewing equipment along the Allegheny River. Brewing began there in late April and became fully operational in June.
Before April, the beer was brewed in Latrobe.
General Manager Todd Zwicker stood Thursday among gleaming stainless-steel brewing tanks — 25 in all — as he touted the highly automated facility.
“Everything was designed and made for this facility in Germany,” Zwicker said. “This is one of the most automated breweries on the East Coast.”
Workers are required only for loading raw materials and to monitor the machines, which can operate 24/7.
Pittsburgh Brewing Co. beers are sold in a dozen states, mostly in Pennsylvania, Ohio, West Virginia, and Maryland.
“I jump out of bed every day,” said Zwicker on what it’s like to work at Pittsburgh Brewing Co.
Zwicker has 33-plus years working in the beer business.
The company, previously based out of Pittsburgh’s Lawrenceville neighborhood, closed its plant there in 2008.
The former Pittsburgh Glass Works closed in 2018 and was purchased in 2019 by Cliff Forrest, owner of the Kittanning-based Rosebud Mining Co..
The brewery has bragging rights.
“For the city of Pittsburgh, this is the biggest production — with about 100,000 barrels a year,” Mayes said. “And I’m hoping we’re going to see a bit of a boost now that we’re open and operational.”
Cora Marchand of Bethel Park works as a quality assurance technician. She scoots around the large facility on a company-provided bike.
photos: Joyce Hanz | Tribune-Review
Pittsburgh Brewing Co. quality assurance technician Cora Marchand rides her bike from one area of the facility to another.
One of her jobs is to collect sterile IC Light beer samples from the line for testing.
“We test every beer before it goes to get packaged,” Marchand said.
Future plans
The brewery’s future plans, expected to be completed next year, include a public area that will include a store that sells specialty beers, a restaurant and an outside courtyard area. The company plans to host brewery tours.
“We’re going be bringing jobs to the local community, and it will eventually be a tourist attraction,” Mayes said.
Additionally, a rickhouse for rye and bourbon will house as many as 4,000 barrels later this year that will age for two to four years before they’re ready to be sold.
It will be called Iron City Distillery.
With automation provided by GEA, a German-based engineering company, the brewery can handle all operations with just 36 employees.
Some people might assume all Mayes does is drink beer for a living.
“That’s kind of true, but it’s a lot more than that. We’re yeast farmers, basically,” he said.
Mayes began as a home brewer but has a science background.
“It’s amazing. Seeing this from dirt floors (as the dormant glass plant) to stainless steel and automation — it’s pretty breathtaking,” Mayes said.
Zwicker would not reveal the exact amount of money spent on renovations but confirmed it was more than $50 million.
East Deer Commissioner Anthony Taliani praised the news of the brewery’s production status.
“We’re very excited, and we’re committed to helping them in any way we can,” Taliani said “They’re a real asset to the entire Alle-Kiski Valley.”
Taliani brushed off concerns that the large facility will employ fewer than 60 people.
“The brewery is state-of-the-art, and that’s the times,” Taliani said. “Right from the beginning, they told us, maybe, there would be a max of 60 employees.”
East Deer can expect to profit from the brewery because all of the water used for production is purchased from the township. Such revenue was lost when the glass plant ceased operations.
Last month, the brewery used about 1 million gallons of water, resulting in about a $12,000 water bill, Taliani said.
Joyce Hanz is a TribLive reporter covering the Alle-Kiski Valley. A native of Charleston, S.C., she graduated from the University of South Carolina. She can be reached at [email protected]