Cereal based fermentation product

1. CEREAL BASED FERMENTED
BEVERAGES

2. Whiskey

3. INTRODUCTON
• spirit made from cereal starch.
• classified on the basis of the cereal used (wheat, barley, corn, rye), on
the degree of blending, and on the country of origin.
• In the raw cereals, the essential component for whiskey production is
the starch content, which is approximately 70% on a dry weight basis.

4. MANUFACTURE
• involves hydrolytic breakdown of the starch into fermentable sugars,
followed by fermentation, distillation, and maturation.

5. MALTING
• The barley is cleaned and then steeped in cold water for 2 to 3 days. The wet
grain is allowed to germinate at 24°C over a period of 8 to 12 days.
• Thus, increase in activities of enzymes α-amylase and β-amylase.
• The principal end product of the joint action of α- and β-amylases upon starch is
the fermentable sugar maltose.
• Malting also encourages the development of β glucanase and protease activities.

7. KILNING
• grain is heated gradually to approximately 52°C to stop germination but
not to destroy the enzymes.
• During kilning, the moisture level of the germinated barley (malt) is
reduced to approximately 5%.

8. MASHING
• The dried malt is milled to form the grist, which is then mixed with water at
approximately 68°C in mashtun for 0.5–1.5 hours.
• This process of mashing is characterized chemically by the continuing hydrolysis
of starch by amylase activity into fermentable sugars, chiefly maltose, with
smaller amounts of sucrose,glucose, and fructose.
• The other principal purpose of mashing is to bring into solution not only the
sugars but also amino acids, resulting from protease activity, which serve as a
nitrogen source for yeast growth during fermentation (Barnard 2008).
• At the end of the mashing period, the resulting liquor (wort) is recovered by
filtration, while theremaining residue (draff) is used as cattle feed.

11. DISTILLATION
GRAIN WHISKEY
• Batch distillation.
• All the contents of the
fermentation vat are
transferred to a large wash
still and boiled for 5–6
hours to produce a
distillate (the low wines)
that contains 20%–25%
ethanol.
MALT WHISKEY
• continuous distillation in a
special still.
• Usually, the incoming
material is the cold wash of
10% ethanol content, and
the principal product from
this process is raw spirit
containing 95% ethanol

12. DISTILLATION
Grain whiskey:
THREE FRACTIONS;
1. foreshots
2. whiskey (potable spirit
containing 63%–71% ethanol)
3. feints (approximately 25%
ethanol)

13. MATURATION
• The whiskey obtained directly from the distillation step is colorless
and has a harsh taste, and therefore, along period of maturation is
essential to develop the final flavor.
• a minimum maturation period of 3 years is mandatory for scotch
and Canadian whiskies.
Eugenol

14. BLENDING
• Malt whiskey by itself has a heavy flavor and is therefore frequently blended
with grain whiskey to increase its general acceptability.
• The most frequent composition of blended whiskey is 60%–70% grain whiskey
and 30%–40% malt whiskey

15. BOTTLING
• The matured spirit is diluted with
water to 40%–43% by volume of
ethanol (80°–86° U.S. proof) before
being bottled.
• Therefore, in terms of quantity, the
major component of whiskey is
actually water (approximately 60% by
volume).
• Once bottled, the whiskey does not
undergo subsequent change because
oxygen no longer has access to the
matured spirit.
• This represents the termination of
maturation, but on the other hand
there is no decline in whiskey quality
due to age.

17. Introduction
• Beer is fermented, alcoholic beverage made from
barley, wheat, rice etc. and flavoured with hops
• Third most popular drink overall, after water and
tea.
• Production of beer is termed as brewing
Component % of Beer based on barley
Protein 0.2-0.4
Carbohydrates 4.5
Water 88-91
Ethanol 3-9
CO2 0.4-0.45
Mineral salts 0.02

18. Ingredients
• Barley
• Hops
• Water
• Yeast

19. Barley Hops Water yeast
 Cheaply
available
 Not used as
staple diet
 Two enzyme:
CYSTASE
DIASTASE
• Flavours
• Preservative
• Aroma
• Clarifying agent
• 90% of water
• Six main salts:
• Bicarbonate
• Sodium
• Chloride
• Calcium
• Magnesium
• sulphate
• Cause the
fermentation

20. Production process
1. Malting
2. Mashing
3. Wort separation
4. Hops addition
5. Wort boiling
6. Trub removal
7. Wort cooling
8. Yeast pitching and aeration
9. Fermentation
10. Yeast removal
11. Aging
12. Clarification and adjustment
13. Pasteurization
14. packaging

21. MALTING

23. Mashing
• Cereal grist is mixed with hot water to extract
sugar for fermentation.
• The product of mashing is termed as sweet wart.
• The process of mashing involves:
• Dissolving the substances in the malt that are
soluble in warm water.
• Rendering the substances which are insoluble in
their natural state or soluble through enzymatic
action.

24. Wort Filtration
• The process of separating the liquid part of mash(wort) from the
undissolved part (the spent grain) is called lautering.
• Two types of equipments are used to separate wort from mash solids,
these are:
• Lauter Tun: It is a vertical cylinder with a large diameter to depth ratio and
fitted into the tun is a wort collecting system.
• Mash Filters: The mash filters consist of a series of alternating plates and roller
frames in which a filter of polyethylene and polypropylene is suspended

25. Hops addition
• Hops are female flowers of the hop
plant, Humulus lupulus
• impart bitter, tangy flavor to beer,
balancing the sweetness of the malt
• Antibacterial properties

26. Wort Boiling
• Extraction of bittering compounds, oils and aroma
from hops
• Sterilization of wort: eliminates all bacteria, yeast
and molds that would competes with brewing yeast
and cause off-flavours
• Coagulation of excess protein and tannins to form
solid particles called trub : gives beer stability
• Color and flavor formation
• Removal of undesirable volatiles like dimethyl
sulphide by evaporation
• Water evaporation

27. Trub Removal
• Removed to give beer stability, and
since trub could potentially inhibit
fermentation
• Most common method is whirlpool,
other methods like straining,
sedimentation and decantation,
centrifugation filtration

28. Wort cooling
• Wort is sterilized, then cooled to fermentation
temperature through heat exchanger or cooling
coils
• Water used as cooling medium
• Fermentation temperature differ
• 7-15°C for lager
• 10-25°C for ale
• Cooled wort is now transferred to sterile
fermenter

29. Medium(wort) composition
• 90-92% of wort is composed of carbohydrates
• Nitrogenous compounds like amino acids formed from proteolysis
during mashing
• Vitamins like biotin, pantothenic acid, pyridoxine and thiamine

30. Yeast pitching and Aeration
• Air injection and yeast pitching done either
• Directly inside fermenter or
• En route to fermenter i.e., the wort is aerated/pitched with yeast before
being sent to fermenter
• Initial aeration required, as yeast cells reproduce quickly, producing
new cells. Also, they convert carbohydrates to organic acids, which
lower pH from 5.2 to 4, giving acidic taste. Significant amounts of CO2
are released at this step. Once all the O2 is used up, yeast start growing
anaerobically

31. Fermentation
• For ale production saccharomyces cerevisiae is inoculated and
for lager production saccharomyces uvarum is inoculated.
• As fermentation proceeds specific gravity is decreased due to utilization of
carbohydrate by the yeast
• There is production of ethanol and other compounds with density less than
water
• CO2 is also evolved during fermentation which is utilized for carbonation
• When yeast settles down, the beer obtained is called green beer which is
subjected to another storage tank having temperature 0-2°C. This stage is
called as facing

32. Biochemical
pathways

33. Fermenter Design
• Cylindroconical fermenters are used, as they allow easy separation of
yeast once they are flocculated

34. Yeast removal and Recovery of BEER
• When the desired ethanol concentration
is reached (3-9%), the yeast are
flocculated
• Isinglass, Kappa carrageenan and Irish
moss can be used to aid this process of
flocculation

35. Aging
• Beer is stored at lo temperature
(<0°C)
• For 2 days
• Polypeptides, polyphenols and
residual yeast from flocs called
chill haze, settling down – this is
removed in next step

36. Clarification and adjustment
• Coarse filtration uses diatomaceous earth or perlite to remove most
particles
• Fine filtration uses a cellulose filter sheet to remove finer particles
• Adjustments made to carbonation level by adding/removing CO2
• Adding color like caramel to correct color defect
• Adding hop products to correct bitterness and enhance foam
• Adding de-aerated water to correct final alcohol strength

37. Pasteurization and Packaging
• Flash pasteurization uses
temperatures of 71.5-74°C for 15-
30 sec for beer to filled in large
containers
• Large containers includes kegs,
casks, bulk tanks
• Small packs like bottle and cans
• Tunnel pasteurization carried out
by running beer-filled bottle/ can
under hot water spray inside a
tunnel at 60°C for 30 mins

39. BEER SPOILAGE
• Spoilage causing bacteria: lactic acid bacteria, acetic acid bacteria,
Zymomonas anaerobia, Pediococcus cerevisiae
• Spoilage causing yeast: Saccharomyces diastaticus, Candida lambica,
Dekkera intermedia

40. THANK YOU…