Luckily, Kunze's "Technologie Brauer und Mälzer" has a pretty detailed description.
The initial brew was the same as for ordinary Malzbier.
6.1.2. Special Features in the Production of Doppelkaramelmalzbier and Malzbier
In most breweries, both beers are produced using the same process up to the lagering cellar.
Both beers are 6% Plato dark beers; in the case of Doppelkaramelmalzbier, the extract difference of up to 12% is later achieved by adding sugar.
The grist contains 3–6% Farbmalz and often another 6–8% Karamelmalz. Part of the colour is always achieved by adding caramel colouring (see p. 92). The hop addition is minimal (see TGL) and serves only to round out the flavour.
"Technologie Brauer und Mälzer" by Wolfgang Kunze, VEB Fachbuchverlag Leipzig, 2nd edition, 1967, page 451.
Around 6º Plato of gravity came from sugar. Making sugar, effectively, 50% of the grist. Which is ridiculously high. Especially as it wasn't really fermented at all.
Several methods were used.
There are several ways to achieve the desired wort concentration:
The wort is drawn off at approximately 6% Plato; reducing the grist size decreases the brewhouse capacity in fully utilized brewhouses. A blind plate must be used in the mash filter.
With a normal grist size, the wort is drawn off at approximately 6% Plato; However, significantly more wort needs to be drawn off to achieve 6% Plato in the wort. This amount exceeds the kettle's capacity, and some breweries boil the additional quantity in the mash tun. This, however, ties up the brewing equipment for longer and results in unnecessary water boiling.
The wort is drawn off at 9-10% Plato, as far as the kettle's capacity allows. During racking, it is then blended with water to approximately 6% Plato (converted to pitching wort).
Advantages: Time savings in the brewhouse, fewer vessels in the fermentation cellar, and energy savings, as the blending water is not boiled.
"Technologie Brauer und Mälzer" by Wolfgang Kunze, VEB Fachbuchverlag Leipzig, 2nd edition, 1967, page 451.
A sort of high-gravity brewing, then, the last method. though 9-10º Plato isn't exactly a very high gravity.
For Doppelkaramelmalzbier, the finished beverage, based on an 11.7 to 12.2% Plato pitching wort, must contain 6 kg (Figure 259) of sugar per 1 hl of retail beer. This sugar is added in a concentrated aqueous solution as sugar syrup before bottling. Since the syrup water dilutes the beer, the double caramel malt beer is blended slightly stronger beforehand (7-8% Plato). The 7-8% Plato beer is mixed with the syrup by repeatedly transferring it between pressure tanks. At the same time, several liters of thick yeast slurry are usually added to initiate a second fermentation, which is intended to generate a higher carbon dioxide pressure in the Doppelkaramelmalzbier.
Doppelkaramelmalzbier is not filtered, but pasteurized.
The added sugar introduces a significant amount of fermentable extract into the Doppelkaramelmalzbier. If the existing and added yeast were able to ferment this extract, all the bottles would burst due to the ever-increasing carbon dioxide pressure.
"Technologie Brauer und Mälzer" by Wolfgang Kunze, VEB Fachbuchverlag Leipzig, 2nd edition, 1967, page 451.
The sugar was added after primary fermentation. However, by the addition of yeast as well, ther was a short secondary fermentation, which was designed to increase the CO2 content.
But that fermentation had to be stopped, given the massive content of unfermented sugar. Hence the pasteurisation. A bit strange that it wasn't filtered, though.
However, slightly higher pressure produces a more appealing head (see p. 434). To generate this increased pressure, the temperature is raised to 30–35°C for approximately 2–4 hours at the beginning of pasteurization. Then, the temperature is increased to about 65°C, thereby killing the yeast cells and preventing further fermentation and carbon dioxide production.
"Technologie Brauer und Mälzer" by Wolfgang Kunze, VEB Fachbuchverlag Leipzig, 2nd edition, 1967, page 452.
All in all, pretty weird. Doppelkaramel does still exist. But does anyone still brew it this way?
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