Capstone design presentation

1. Samantha Wolfe
Amanda Dotseth
Kane Corbeau

2. OUTLINE
Background
Brewing Process
Modeling
Our Recipe
Brewing with Pilot System
Acknowledgements

3.  Evidence of beer dates back
to before 3400 BC
○ Oldest chemically confirmed
beer from 3500-3100 BC
found in Godin Tepe in the
Central Zagros Mountains of
Iran.
 Hymn to Ninkasi, the
Sumerian goddess of beer
 First known written
record
 Safer to drink
 Creative flavoring
 Olive oil, cheese, spices,
hemp, poppy seeds

4. According to the Brewers
Association:
 Small
 Annual production of 6 million
barrels or less (~3% of US annual
sales)
 Independent
 “Less than 25% of the brewery is
owned by a beverage alcohol
industry member which is not
itself a craft brewer.”
 Traditional
 majority of beers flavors derived
from traditional or innovative
brewing ingredients

5.  “The number of craft brewers
has gone from 8 in 1980, to
537 in 1994, to over 6,000 in
2018.”
 In 2017, 71 registered craft
breweries in SC
 Continuing to grow around 5%
by volume.
 12.7% of total beer
production in 2017 (=over
24.8 million bbls)
 Contributed $76.2 billion to
US economy in 2017

6.  Will McCameron
 Craft Microbrewery in Greenville, SC
 On site brewery and bar

7.  Design a beer
 Brew a beer at pilot scale
 Produce a great tasting
IPA

8.  R&D on brewing/ beer tasting
 Selection of ingredients/design (brewer’s friend)
 Homebrewing vs industrial
 Kegging
 Modeling
 Evaluate beer production
 Economics

10. Ions of Interest
Na+ - Metallic off flavor
Ca2+ - Lower mash pH, promotes clarity,
aids in flocculation
Mg2+ - Lower mash pH
HCO3
- - Raise mash pH
WATER QUALITY
Sulfate-to-Chloride Ratio
Sulfate - Expresses hop bitterness (2:1 ratio)
Chloride - Make beer taste sweeter and fuller (2:1
ratio)
 Low water hardness is preferred, giving brewers complete control in the mineral profile
by adding their own salts.

11. GREENVILLE WATER
QUALITY

12.  Malt is made from barley seeds
 germination/starch conversion
 kilning to dry seeds, end enzyme
activity
 Malt ranges in color depending on kiln
time
 Darker malts, fewer fermentable
sugars, higher finishing gravity
 Malt is a great source of free amino
nitrogen (FAN), needed for yeast
nutrition
 Other grains can be used as
fermentables to increase sugar content,
affect flavor

13.  Malted grain is steeped in hot
water
 Solubilization of sugars
 Further conversion of starch and
complex carbs into fermentable
sugars through temperature
activated enzymes
 Different mashing schemes cause
different sugar ratios
 Grain bed is established with
recirculation

14.  Separation of spent grain
and wort
 Hot water sparged on top of
mash while wort is filtered
through grain bed and
transferred to the kettle
 Must happen slowly so as
not to solidify grain bed
 Effluent sugar
concentration will decrease
with time

15. HOPS
 Historically used as preservatives for
beer
 Creation of IPA (India Pale Ale)
 Bittering agent and aroma addition
 Time Sensitive
 Alpha acids, beta acids, and volatile
fatty acids
 Bittering hops
 over 10% alpha acids
 45-90 min boil time
 Flavoring hops
 20-40 min boil time
 Finishing and dry hops
 lower alpha acids
 0-5 min boil time

16.  Sterilization step
 Bittering and some
flavoring hops added
 Must be allowed to vent
and allow evaporation of
sulfides (contribute to off
flavors)
 lasts around 1 hour

17.  Must happen quickly
 140 ͦF to 80 ͦF within 30
minutes
 Prevents microbial
contamination
 Prevents oxidation damage
 Helps proteins fall out of
solution
 Accomplished using heat
exchanger
 Plate or coil

18.  Reproduce asexually
 Sensitive and picky
 Temperature
 Alcohol concentration
 Nutrients
 Location
 Can live aerobically or
anaerobically
 Growth vs. alcohol
production

19.  Lager Yeasts
 Bottom fermenting
 Saccharomyces
pastorianus
 Ale yeasts
 Top fermenting
 Saccharomyces
cerevisiae
 Prefer warmer temps.
 More diverse
 Flavors
 Esters = fruity
 Phenols = Spicy
 Ketones =
Buttery/Butterscotch
 Attenuation
Ale
Yeast
Lager Yeast

20.  Aerobic respiration consists of
 Glycolysis
 Citric acid cycle
 Electron transport chain
 Oxidative phosphorylation
 C6H12O6+ 6O2 ⇒ 6CO2 + 6H2O + 38ATP

21.  Glucose + 2 NAD+ + 2 ADP + 2 P → 2
pyruvate + 2 NADH + 2 ATP + 2 H2O
+ 4 H+
https://www.google.com/url?sa=i&source=images&cd=&cad=rja&uact=8&ved=2ahUK
Ewi19baojMjeAhXImeAKHYH2CS4QjRx6BAgBEAU&url=http%3A%2F%2F27.109.7.67
%3A1111%2Fecontent%2Frespiration%2Fdifferent-pathways.php&psig=AOvVaw3To-
KIP9iLCU-Dyd9FwKzT&ust=1541879863766845

23.  Creates proton motive force

24.  Phosphorylation of ADP to ATP
using proton gradient created by
ETC

25.  Anaerobic process
 Also starts with glycolysis
 C6H12O6 + 2ADP => 2C2H5OH + 2CO2 +
2ATP

26.  Three main phases
 Adaptive
 enzyme synthesis
 O2 utilization, population
growth
 preparation for fermentation
 Attenuative
 rapid fermentation, conversion of
sugar to ethanol
 krausen (foam) forms
 Conditioning
 sedimentation, flocculation,
fermentation of unused
intermediates, clarification of
beer

27.  yeast population begins to die
off/settle
 some continue to break down more
complex sugars and intermediates
 acetaldehyde ⇒ ethanol
 fusel alcohols ⇒ esters
 sedimentation
 flocculation of yeast
 tannins + phenols bind to
proteins

28. FLOCCULATION
 Clumps together and drops out of
solution
 Cheapest and easiest way to clarify
beer
 Too early = under attenuated and
sweet
 Too little = cloudy with strong
yeast flavor

29.  First Practiced in Munich Germany
in 1880
 Pump through porous medium
 Polypropylene

30.  Kegs, bottles, cans
 Prevent “skunking”

31.  Alcohol by volume (%) – ABV
 𝐴𝐵𝑉 = 𝑂𝐺 − 𝐹𝐺 ∗ 131.25 @ RT
 Where,
 OG = original gravity
 FG = final gravity
 International Bittering Units – IBU
 IBU = AAU x U x 75 / V
 AAU = Weight (oz) x % Alpha Acids
 Gives coefficient of alpha acids present
 Utilization (U) = f(G) x f(T)
where:
𝑓 𝐺 = 1.65 ∗ 0.000125(𝐺𝑏−1)
𝑓 𝑇 =
1 − 𝑒−0.04∗𝑇
4.15
 Based on specific gravity and boiling time,
predicts extent of isomerization

32.  ABV, IBU
 Flavor
 Aroma
 Color
 Crushability
 Overall Rating

33. Beer ABV IBU Rating */10 Notes
SweetWater
IPA
6.30% 50 7.4 Sweeter after taste. Doesn’t finish bitter.
. SW Triple Tail 5.50% 57 7.5 Less hoppy finish. Fruitier.
Terrapin Hi-5
IPA
5.90% 80 4.75 No aroma. Not smooth just all bitter hops.
Dogfish Head
Flesh and Blood
IPA
7.50% 45 7 Heavier. Slightly maltier. Starts sweet finishes hoppy.
Wicked Weed Lt.
Dank
6.50% 60 5 Similar to SW IPA but more subtle flavors.
Wicked Weed
Napoleon
Complex
5.20% 47 7.5 Smooth than Lt. Dank. Good level of hop flavor.

34. Kettle
Mash Tun
Hot Water
Control System

35. Fermentables:
Amount
American 2-Row Pale Malt 35 lbs
Weyermann Barke Munich Malt 5 lbs
Flaked Wheat 2 lbs
Briess Caramel 80L Malt 2 lbs
Mash Guidelines:
Conversion at 150 °F
Batch Sparge at 170 °F

36. Yeast:
Wyeast - American Ale
Fermentation temperature at 65 °F
Hops: Amount Boil Time
Chinook 2.25 oz 60 mins
Columbus 3 oz 20 mins
Cascade 3 oz 5 mins
Mosaic 1 oz 0 mins
Simcoe 3 oz
Dry hop after 5
days
Goldings 3 oz
Dry hop after 5
days

38.  Mash
 44lb malt (fat, fibers, minerals, proteins, starch,
water)
 20 gal hot water
 0.9 Starch + 0.1 Water ⇒ Glucose (90%)
 Lauter
 15 gal 172 F water,
 filter 20% fats, 99% fiber, 20% proteins
 Boil
 14.25 oz hops
 duration (60 min)
 Hops ⇒ 0.1 AA + 0.9 Spent Hops (90%)
 Proteins + Spent Hops ⇒ Trub (100%)
 Heat exchange
 input T = 180F, output = 77 F
 Fermentation
 Set T = 65F
 45.3 g yeast pitched
 1.055 Glucose ⇒ 0.05 Yeast +.0463 CO2 + .049
Ethanol + 0.052 H2O (88%)

39.  Inlet stream: 12.05% Glucose (1.0486
SG)
 Outlet: 5.016% Ethanol

40.  Software used to calculate
theoretical values

41. OUR YEAST
 American Ale Strain
 Saccharomyces Cerevisiae 1056
 Wyeast Laboratories
 Desired temperature 60-72
 Maximum ABV of 11%

42.  Mash at 150 °F for 20
minutes
 grain temp: 78 F
 water temp: 164 F
 Recirculate for 30 minutes
 creates grain bed which
acts as filter
 Sparge at 170 °F (lautering)

43.  Use 15 gal water
 Slow transfer to prevent
solidification of grain bed
(~45 minutes)

45.  “Rolling” Boil
 Addition of hops at
intervals
 Addition of
 Fermcap for boilover
 Yeastex for nutrients
 Whirlfloc for settling
Hop
% Alpha
Acid
Amount Hop Usage
Chinook 12.8 2.25 Bittering
Columb
us
12.8 3 Flavoring
Cascade 6.3 3 Finishing
Mosaic 10.1 1 Finishing
Simcoe 13.4 3 Dry Hop
Goldings 5.1 3 Dry Hop

46.  Dual layer copper coil heat
exchange
 77 °F effluent temperature

47.  Rubber Mesh
 Increases surface area of
the flow
 Aerate as beer is poured

48.  Optimum temp: 65 F
 Needed to sit and cool more
before pitching
 Cooling mechanism
 Fans
 Heating
 Heating pad inside
insulation

49. Date Plato
Specific
Gravity
ABV pH
11/2 14.8 1.060 0 % -
11/5 8.7 1.035 3.28 % 4.53
11/8 (dry
hop)
6.3 1.025 4.59 % 4.57
11/13 2.3 1.009 6.69 % 4.65
Date Action
11/3 Pitch yeast
11/8 Dry hop (Goldings and
Simcoe)
11/11 Resting (clean up)
11/16 Cold conditioning
11/27 Dump yeast
11/28 Keg (carbonation taking
place)
12/5 Beer is ready

50.  Total Ingredient Cost: $166.32
 The 15.5 gallon keg can pour 124
16oz beers
 Sale of beers at 4$ would net a
$496.00 revenue
 Profit: $329.68
 Margin: 66.47%
 Labor at 15$/ hour increases
Expenses to $299.32
 New profit: $196.68
 New margin: 39.65%
Actual Hypothetical

51. Will McCameron & Brewery
85
Dr. Darnault
Jasmine Taylor
Clemson University
Cheers!

52. Questions?