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BEER BREWING-Notes.pptx

The key stages of milling are: 1. Receiving and storage of malt in silos 2. Passing the malt through rollers to crack the husk and grind the endosperm 3. Sieving to separate the grits from husk particles 4. Adjusting the gap between the rollers to achieve the desired grind size A roller mill is commonly used, consisting of two or more rollers that crack and grind the malt. The grist composition for lauter tun separation typically has 70-80% of particles passing a 0.5mm sieve. Safety precautions when milling include lockout procedures and guards to prevent contact with moving parts.

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1 BEER BREWING
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 What is beer? • Fermented by yeast • Fermented sugar derived from a cereal starch source • There are lots of different strengths and styles • 0 to 20% ABV - Ale, lager, stouts, porters • Wheat, fruit, spiced, smoked • Lite beers to pale ales to strong ales • Doppelbocks, maibocks, schwartz and dunkel • Kolsch and Dortmund • Trappist, lambic, gueuze • Native beers
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 Beer is an alcoholic beverage produced from the fermentation of sugars by yeast to produce alcohol. Most of the sugar in brewing comes from barley, which has to be malted to release the sugars before fermentation can occur DEFINITION OF BEER S u g a r C a r b o n D i o x i d e A l c o h o l + Y E A S T + C O 2
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 Beer flavour is derived from.. • Alcohol, residual sugars, hop aroma and bitterness • Salts • CO2 or N2 • Esters, higher alcohols • Dimethyl sulphide ( DMS ) • and a host of other biochemicals measured in ppb
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 Beer faults include... • Stale • Diacetyl • Aldehydic • Sulphury • Grainy • Sunstruck • Phenolic • Catty • Acidic • Metallic
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 THE MALTING & BREWING PROCESS BARLEY MALTING MALT BREWHOUSE FERMENTATION MATURATION & FILTRATION PACKAGING WORT GREEN BEER BRIGHT BEER CANS & BOTTLES CASKS & KEGS WATER HOPS Cask
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 BREWING MATERIALS BARLEY Gibberellic acid Bromate MALTING BREWHOUSE FERMENTATION MATURATION & FILTRATION PACKAGING WATER ELECTRICITY STEAM AIR used in all areas HOPS Leaf Extracts Pre Isomerised Isinglass Auxiliary finings Post FV bitterness Hop aroma Flavourings Beechwood chips pH adjustment PVPP Tannic acid Silica hydrogel Proteolytic enzymes Primings Krausen Antioxidants Heading agents Filter powder Recovered beer Salts Sugars Coloured malts Roasted barley Caramel Copper finings Glucanase Antifoam Yeast food Oxygen ZnSO4 CO2 and N2 Bottles and cans Ends Crowns Hicone Labels Shrinkwrap Glue Foils Trays and cartons Pallets Casks and kegs Keg caps Cask bungs Dry hops
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 CO PRODUCTS and WASTES MALTING BREWHOUSE FERMENTATION MATURATION & FILTRATION PACKAGING Culms Screenings Spent grains Spent hops Spent filter cake Spent alcohol CO2 Yeast Packaging waste Glass cullet Crushed cans EFFLUENT IS PRODUCED BY ALL AREAS Animal feeding Distilling Yeast tablets Horticulture Vinegar Glass paper Recycling
Brewing materials • Water • Malt and adjuncts • Hops and hop products
USE of WATER in BREWING Brewing requires a plentiful supply of good clean water. Water accounts for approximately 94% of the total beer volume. Water is used for: brewing & process dilution  treated brewing water cleaning & CIP  softened water bottle washing & past.  mains/untreated water general cleaning e.g. floors  mains boiler feed water.  demineralised water
To be suitable for brewing, water must be: • Clear & Colourless • Tasteless & Odourless • Not acidic or alkaline ( pH 7 or slight acid ) • Correct salt composition ( varies by beer type ) • Free from residues ( heavy metals, nitrates organic residues ). • Microbiologically pure ( coliform bacteria absent ) Water Quality - Appearance & Taste.
Effect of pH • Lower pH •  amylase and peptidases work at optimum pH • encourages break formation • less polyphenol extracted from malt and hops leads to cleaner flavour • less tannins but more protein breakdown gives lower haze potential • improves foam by reacting with lipids • in beer discourages the growth of spoilage organisms • Calcium itself stabilises alpha amylase • helps precipitate oxalates and • helps yeast flocculation • Higher pH encourages • extraction of undesirable polyphenols from the last runnings from the mash • increases hop utilisation • increases colour formation
Barley is the principal source of carbohydrate. The energy is stored as starch in the endosperm Enzymes, produced during malting, convert starch to sugar. Malt. PRINCIPAL RAW MATERIAL - BARLEY
Malting barley • Variety should be approved for malting. It should be short strawed to counter wind damage and give a good yield per hectare • There is always a trade off between adding nitrogenous fertilisers to increase yield but with a protein content unsuitable for malting • The more protein, the less starch so the brewer gets a lower extract from his mash • The more protein, the more prone the beer to haze formation and the more amino acids etc available to beer spoilage organisms • Brewers talk of nitrogen levels. Protein = nitrogen x 6.25 so 1.5% nitrogen = 9.4% protein • In the UK there is a malting premium. • Lighter chalky soils will not retain added nitrogen so produce the best malting barley
Each individual batch of barley should be assessed prior to malting for: • Uniform size and colour • Bold grain with few screenings ( smaller corns ) • Freedom from smell, mould growth and insects • No admixture with other cereals or barley varieties • Absence of split skinned or pre-germinated grains • Moisture - freshly harvested around 18% - storage at 12% • Capable of growing with a germinative capacity greater than 95% • Total nitrogen less than 1.8% • for some barley used to produce ale malt the total nitrogen should be below 1.6%. BASIC REQUIREMENTS OF A MALTING BARLEY VARIETY.
Malting is a controlled germination process • Steps of malting: • Steeping • mimics the corn getting wet and growth starts • Germination • under controlled conditions • Kilning • arrests growth by killing the embryo but temperatures are carefully controlled so that enzymes are not denatured ( inactivated ) • Colour and flavour compounds develop
Other malted cereals • Any starch source can be malted • Can be used to impart subtly different flavours • Oats • enhance dryness - oatmeal stouts • Rye • Increase palate fullness at high levels but rye has no husk so wort run off can be difficult • Wheat • At 4% addition will improve head retention with no effect on flavour • Wheat beers at up to 60% wheat have a dry refreshing clovey taste
Adjuncts BREWING WITH ADJUNCTS Adjuncts come in two forms • Solid starch adjuncts which have to be converted to sugar in the brewhouse during mashing • Malt enzymes convert the starch to sugar • May require heat treatment to gelatinise or liquefy the starch to allow enzymes to convert it • Liquid adjuncts are already in the form of sugar • Conversion from starch has taken place at the suppliers plant • The sugars are ready for fermentation but are generally added directly to the kettle so they benefit from sterilisation. • Usually derived from maize, different acid and enzyme treatments can produce different fermentabilities
ADVANTAGES OF USING ADJUNCTS • Cost and availability • Control of fermentability • Colour and flavour contribution • Beer presentation • Process benefits/development – Increased brewing capacity through shorter brewing cycles and more uniform wort quality. – Ease of handling and usage – Cleaner fermentation - better yeast heads – Improved hot and cold breaks – Shorter maturation times.
TYPES of LIQUID ADJUNCTS Cereal Syrups - • Produced with various sugar compositions • Direct source of extract added to the copper Raw Sugars - • Cane sugar is the principal component in most primings • Invert sugar a mixture of glucose and fructose syrup, ( liquid or solid block form ). Priming Sugars • Add sweetness, fermentability or colour after the end of primary fermentation & to act as a source of sugar for a secondary fermentation. Colouring Products - • Hot water extracts from roasted and coloured malts • Caramel produced by the controlled heating of food grade sugars with ammonia • Class 3 - Ammonia caramel is used for brewing - must not react with beer component to form hazes:
Hops FUNCTION of HOPS in BREWING • Hops provide the bitter taste in beer (with alpha acid the principal precursor) • The oils provide aroma. • Hops contribute to beer texture (mouthfeel) • Hops have bacteriostatic properties which protects beer against some biological spoilage organisms.
FUNCTION of HOPS in BREWING • Hops reduce over foaming during wort boiling. • Hops aid in protein coagulation during the boil. • Hops are a foam active agent in beer.
23 The brewhouse receives the malt and uses the natural enzymes produced in the malt to convert the starch to sugar. The sugar solution ( wort ) is separated from the solids, boiled to increase its stability along with hops which add bitterness and flavour to the beer. The boiled wort is clarified and cooled, from where it goes on to act as the nutrient for yeast to fuel the fermentation. Purpose of Brewhouse operation.
24 THE BREWING PROCESS - BREWHOUSE Milling Malt Mash Conversion Water Mash Separation Wort Boiling Adjunct (optional extra) Wort Clarification Wort Cooling Hops Oxygen Co-products Malt dust Spent grains Trub Cold wort fermentation
25 Purpose: to expose the extract for conversion. Students should have a basic knowledge of the key stages of milling. • They should understand the reason for milling. • Know and describe one type of mill. • Know the grist composition for one type of mash separation system. • Be familiar with hazard and safety requirements when milling. Milling
26 BREWHOUSE PROCESS - MILLING OBJECTIVE: Malt is received from the maltsters and stored (usually in silos on site). Before brewing the malt has to be milled which involves splitting the husk and grinding the endosperm into small grits. It is necessary to keep the husk as whole as possible since it will be used to form the filter bed during run off. The endosperm must be broken down to allow the enzymes to attack the starch. • Too coarse grind - poor extract & starch carry-over. • Too fine grind - run off problems & set mash.
27 Purpose: to mix the ground malt with a set amount of water at a given temperature thus allowing the natural enzymes from the malt to convert the starch in the endosperm to sugar. Students should have a basic knowledge of the steps in mashing. They should: • Understand the changes which occur to the malt during mashing. • Know the times and temperatures of the mashing regime • Be able to define when mashing is complete • Be able to describe a mash mixing vessel Mashing
28 Mashing • To mix the crushed grain evenly with the correct amount of water at the correct temperature • To allow other additions such as brewing salts and enzymes to be evenly mixed in • To allow the enzymic conversion of protein to amino acids and starch into simpler sugars in the correct amounts to give consistent fermentation and the right %ABV and Original Gravity • To extract colour and flavour from any coloured malts and adjuncts used
29 Enzymes involved in mashing Amylases - alpha & beta - convert starch to sugar Proteases - break proteins to peptides & amino acids Beta glucanase - degrades beta glucans The factors which control the enzyme activity are TIME TEMPERATURE ACIDITY - pH
30 BIOCHEMISTRY - PROTEIN BREAKDOWN H N AA AA AA AA AA AA OO H 2 2 3 2 1 n-1 n-2 aminopeptidase carboxypeptidase n Endo-peptidase Exo-peptidase Mechanisms for Enzymic attack of proteins and polypeptides Produces: Proteins - insoluble precipates in spent grains & break Polypeptides - foam & haze Amino Acids - yeast growth
31 BREWING PROCESS - MASHING During mashing the ground malt is mixed with water at a specific temperature to allow the enzymes to convert the starch to sugar. It normally takes about an hour to convert all the starch and completion can be checked with the Iodine test.
32 Purpose: once all the starch has been converted to sugar and dissolved in water (wort) it has to be separated from the solid material – husk and acrospire etc. Students should have a basic knowledge of the steps in mash separation. They should: • Know the operation of one type of wort separation system. • Know the principle elements of control – flow rate, pressure, wort haze, etc. • Know the principle factors which effect extract recovery. • Be able to describe a mash separation vessel Mash Separation
33 BREWHOUSE PROCESS - WORT SEPARATION OBJECTIVE: Wort separation involves filtering the wort (sugar solution) through a filter bed made up of the spent husk material. The purpose is to produce clear bright worts free from solids, it is also important not to extract compounds such as polyphenols and lipids from the husk. Effective Wort separation Means: • High extract recovery (around 98% to 100%) • Bright worts - free from suspended solids • Worts free of starch.
34 Types of wort clarification systems The three principal methods: • Mash Tun • Lauter Tun • Mash Filter Use the same basic principals: • Husk material acts as filter bed • Filter bed supported by screen or plates. • Strong worts extracted first followed by sparge water to wash out remaining extract. • Extraction flow is controlled to maximise clarity and extract recovery.
35 BREWING PROCESS - SEPARATION The sugar solution ( wort ) has to be removed from the spent grains. It is filtered through a bed made up of the the husk from the malt. Wort must be clear and produced with minimum effluent. Oxygen should be excluded In ale breweries filtration is carried out in the same vessel as mashing - the mash tun. In modern breweries a separate lauter tun or mash filter for wort filtration. The solids left behind are called spent grains and are fed to cattle.
36 Purpose – to stabilise the wort and to extract and isomerise the bitter compounds from hops. Students should have a basic knowledge of the process of wort boiling. They should • Know the reasons for wort boiling. • Know the principle elements of control – time, temperature, vigour etc. • Know the principle factors which effect hop utilisation and to be able to calculate a hop charge. • Be able to describe a wort boiling system. Wort Boiling
37 WORT BOILING After wort separation the clarified wort is boiled. Hops and sugar adjunct (if required) are added at this stage Wort boiling is the most energy intensive stage of the brewing process. Not only does the wort have to reach boiling point, but it is usual to evaporate between 5 and 10% of the kettle contents. A successful boil must be vigorous. Usually 60 -90 minutes
38 BOILING The clarified wort is boiled for about an hour in a kettle or “copper” Hops are added during the boil to provide bitterness and aroma. Boiling also improves the physical (haze) stability of the beer and kills any micro- organisms which could infect the beer and cause flavour problems.
39 BENEFITS OF WORT BOILING • Inactivation of malt enzymes • Sterilisation of the wort • Extraction and isomerisation of compounds derived from hops • Coagulation of proteinaceous material in the wort • Formation of proteinaceous/polyphenol complexes • Formation of flavour and colour complexes. • Fall in wort pH • Concentration of the wort gravity through evaporation of water. • Evaporation of volatile compounds from the wort.
40 Control of dimethyl sulphide - DMS DMS has a sweetcorn flavour and is a component of finished lagers. Excess quantities are undesirable DMS is formed from the breakdown of DMS precursor (S-methyl methionine) from malt due to heating. DMS is highly volatile and is rapidly lost during boiling. It build up during the hot wort stand and this should be kept to a minimum if DMS control is required. S-methyl methionine DMS BOILING ½ life 35 minutes HEAT DMS is volatile and is readily removed from beer during boiling. Formation of DMS during wort boiling.
41 KETTLE ADDITIONS Main addition is hops - various forms • At beginning of boil - for bitterness only • 15 - 5 min. from end - hop aroma - late hopping • Pre-isomerised hops added towards end of boil • Hops help prevent over foaming • Syrup adjunct & colour added early in boil - avoid burning caramelisation on heating surfaces • Kettle finings to improve break added 5 minutes before the end of boil. (Carragheen /Irish Moss - seaweed) • Mineral salts or acid to adjust wort acidity pH
42 Purpose – to separate the coagulated protein (trub) and hop debris from the hot wort. Students should have a basic knowledge of the process of wort clarification. • They should know reasons for wort clarification. • The effects on duration on quality. • The use of kettle finings. • Describe a wort clarification system. Wort Clarification
43 BREWHOUSE PROCESS - FUNCTIONS OF WORT CLARIFICATION The principal changes during hot wort clarification: • Coagulation of protein/polyphenol complexes. • Precipitation and separation of hot break • Temperature dependent chemical reactions started in the boil continue during the hot stand in the wort clarification stage, e.g. colour formation & oxidation. • Temperature dependent reactions which produce flavour active volatiles (e.g. DMS) can build up as they can not be removed in a vigorous boil.
44 KETTLE FININGS ADDITION TO A STANDARD BOILED WORT Addition of kettle finings improves the settlement of solids and the clarity of the wort. Best results occur with maximum settled solids and brightest (lowest) cold wort haze.
45 Purpose: to cool the clarified wort after boiling prior to fermentation. Candidates should have a basic knowledge of wort cooling. They should know • Mechanisms for wort cooling. • Typical cold wort temperatures for ale and lager beers • Reasons for aeration • About the formation of cold break. • About microbial risks. Wort Cooling
46 FUNCTIONS OF WORT COOLING The clarified wort has to be cooled to the fermentation temperature. Wort cooling is carried out using a heat exchanger. The cooling medium is brewing water which is recovered ( as warm water ) for the following brew. For low temperature cooling involves a glycol or cooled water stage. Wort is oxygenated on the cold side
47 BREWING PROCESS - COOLING After boiling the protein and hop debris precipitates have to be removed. They are often mixed with the spent grain. The hot sugar solution (wort) is then cooled to the required temperature for fermentation. Yeast is added to the cool wort along with a small amount of air or oxygen to promote vigorous growth at the start of fermentation.
48 ADDING OXYGEN • Usually on the cold side • to avoid colour pick up • hot side if aerating will sterilise the air • Aeration will add around 8ppm O2 • Oxygen must be used for higher gravity worts • More gas dissolves in colder and lower density liquids • Gas must be sterile and dissolve before reaching the fermenter
49 OTHER ADDITIONS • Nutrients • Zinc sulphate or yeast foods • Enzymes • Antifoam • Salts
50 KEY POINTS FOR BREWHOUSE • The stored malt is ground to produce “grist”. • During mashing the grist is mixed with an appropriate amount of brewing water to produce a mash at pre-set temperature (or temperatures). • The mash is allowed to stand until all the starch from the malt is converted to sugar. • The sugar solution (called wort) is then separated from the malt solids, during wort separation. • Wort separation occurs in a single vessel or Mash Tun in traditional ale breweries. A two vessel system – mash mixer with either a lauter tun or mash filter is used for lagers. • The collected wort is boiled with hops. It is clarified (hot break removed) and cooled ready for fermentation.
Microbial contamination  Bacteria - very small organisms, only a very limited range live in beer - pathogens will not survive in beer  Wild Yeast - organisms of the same basic type as brewing yeast but giving rise to flavour defects in beer  Fungi/Moulds -organisms similar to yeasts growing in old beer or unclean containers
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 Potential for contamination • Raw materials • Taints, pesticide residues, grain weevils. Mycotoxins • Dust, wood etc in cans, plastic in crowns and can lacquer • Broken glass • Water supply • Nitrates, spillages, trihalomethanes • Plant cleaning • Residual detergent, residual chlorine • Poor road tanker cleaning • Process • Coolant ingress via plate heat exchanger leaks • Plastics • Oil or grease • Microbiological.
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001 Water borne contamination • Pathogens will not grow in beer • Pathogens will grow in water • Water must be checked for pathogens eg Escherichia Coli, the presence will indicate sewage contamination • Other coliforms can adapt to life in a non hygienic brewery. All can reduce nitrate to nitrite but do not survive in finished beer • Legionella can also exist in mist sprays in air conditioning systems • Cryptosporidium Water borne protozoan - causes diarrhoea Destroyed by boiling but not by chlorine Does not live in beer

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BEER BREWING-Notes.pptx

  • 1.
  • 2.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 What is beer? • Fermented by yeast • Fermented sugar derived from a cereal starch source • There are lots of different strengths and styles • 0 to 20% ABV - Ale, lager, stouts, porters • Wheat, fruit, spiced, smoked • Lite beers to pale ales to strong ales • Doppelbocks, maibocks, schwartz and dunkel • Kolsch and Dortmund • Trappist, lambic, gueuze • Native beers
  • 3.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 Beer is an alcoholic beverage produced from the fermentation of sugars by yeast to produce alcohol. Most of the sugar in brewing comes from barley, which has to be malted to release the sugars before fermentation can occur DEFINITION OF BEER S u g a r C a r b o n D i o x i d e A l c o h o l + Y E A S T + C O 2
  • 4.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 Beer flavour is derived from.. • Alcohol, residual sugars, hop aroma and bitterness • Salts • CO2 or N2 • Esters, higher alcohols • Dimethyl sulphide ( DMS ) • and a host of other biochemicals measured in ppb
  • 5.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 Beer faults include... • Stale • Diacetyl • Aldehydic • Sulphury • Grainy • Sunstruck • Phenolic • Catty • Acidic • Metallic
  • 6.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 THE MALTING & BREWING PROCESS BARLEY MALTING MALT BREWHOUSE FERMENTATION MATURATION & FILTRATION PACKAGING WORT GREEN BEER BRIGHT BEER CANS & BOTTLES CASKS & KEGS WATER HOPS Cask
  • 7.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 BREWING MATERIALS BARLEY Gibberellic acid Bromate MALTING BREWHOUSE FERMENTATION MATURATION & FILTRATION PACKAGING WATER ELECTRICITY STEAM AIR used in all areas HOPS Leaf Extracts Pre Isomerised Isinglass Auxiliary finings Post FV bitterness Hop aroma Flavourings Beechwood chips pH adjustment PVPP Tannic acid Silica hydrogel Proteolytic enzymes Primings Krausen Antioxidants Heading agents Filter powder Recovered beer Salts Sugars Coloured malts Roasted barley Caramel Copper finings Glucanase Antifoam Yeast food Oxygen ZnSO4 CO2 and N2 Bottles and cans Ends Crowns Hicone Labels Shrinkwrap Glue Foils Trays and cartons Pallets Casks and kegs Keg caps Cask bungs Dry hops
  • 8.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 CO PRODUCTS and WASTES MALTING BREWHOUSE FERMENTATION MATURATION & FILTRATION PACKAGING Culms Screenings Spent grains Spent hops Spent filter cake Spent alcohol CO2 Yeast Packaging waste Glass cullet Crushed cans EFFLUENT IS PRODUCED BY ALL AREAS Animal feeding Distilling Yeast tablets Horticulture Vinegar Glass paper Recycling
  • 9.
    Brewing materials • Water •Malt and adjuncts • Hops and hop products
  • 10.
    USE of WATERin BREWING Brewing requires a plentiful supply of good clean water. Water accounts for approximately 94% of the total beer volume. Water is used for: brewing & process dilution  treated brewing water cleaning & CIP  softened water bottle washing & past.  mains/untreated water general cleaning e.g. floors  mains boiler feed water.  demineralised water
  • 11.
    To be suitablefor brewing, water must be: • Clear & Colourless • Tasteless & Odourless • Not acidic or alkaline ( pH 7 or slight acid ) • Correct salt composition ( varies by beer type ) • Free from residues ( heavy metals, nitrates organic residues ). • Microbiologically pure ( coliform bacteria absent ) Water Quality - Appearance & Taste.
  • 12.
    Effect of pH •Lower pH •  amylase and peptidases work at optimum pH • encourages break formation • less polyphenol extracted from malt and hops leads to cleaner flavour • less tannins but more protein breakdown gives lower haze potential • improves foam by reacting with lipids • in beer discourages the growth of spoilage organisms • Calcium itself stabilises alpha amylase • helps precipitate oxalates and • helps yeast flocculation • Higher pH encourages • extraction of undesirable polyphenols from the last runnings from the mash • increases hop utilisation • increases colour formation
  • 13.
    Barley is theprincipal source of carbohydrate. The energy is stored as starch in the endosperm Enzymes, produced during malting, convert starch to sugar. Malt. PRINCIPAL RAW MATERIAL - BARLEY
  • 14.
    Malting barley • Varietyshould be approved for malting. It should be short strawed to counter wind damage and give a good yield per hectare • There is always a trade off between adding nitrogenous fertilisers to increase yield but with a protein content unsuitable for malting • The more protein, the less starch so the brewer gets a lower extract from his mash • The more protein, the more prone the beer to haze formation and the more amino acids etc available to beer spoilage organisms • Brewers talk of nitrogen levels. Protein = nitrogen x 6.25 so 1.5% nitrogen = 9.4% protein • In the UK there is a malting premium. • Lighter chalky soils will not retain added nitrogen so produce the best malting barley
  • 15.
    Each individual batchof barley should be assessed prior to malting for: • Uniform size and colour • Bold grain with few screenings ( smaller corns ) • Freedom from smell, mould growth and insects • No admixture with other cereals or barley varieties • Absence of split skinned or pre-germinated grains • Moisture - freshly harvested around 18% - storage at 12% • Capable of growing with a germinative capacity greater than 95% • Total nitrogen less than 1.8% • for some barley used to produce ale malt the total nitrogen should be below 1.6%. BASIC REQUIREMENTS OF A MALTING BARLEY VARIETY.
  • 16.
    Malting is acontrolled germination process • Steps of malting: • Steeping • mimics the corn getting wet and growth starts • Germination • under controlled conditions • Kilning • arrests growth by killing the embryo but temperatures are carefully controlled so that enzymes are not denatured ( inactivated ) • Colour and flavour compounds develop
  • 17.
    Other malted cereals •Any starch source can be malted • Can be used to impart subtly different flavours • Oats • enhance dryness - oatmeal stouts • Rye • Increase palate fullness at high levels but rye has no husk so wort run off can be difficult • Wheat • At 4% addition will improve head retention with no effect on flavour • Wheat beers at up to 60% wheat have a dry refreshing clovey taste
  • 18.
    Adjuncts BREWING WITH ADJUNCTS Adjunctscome in two forms • Solid starch adjuncts which have to be converted to sugar in the brewhouse during mashing • Malt enzymes convert the starch to sugar • May require heat treatment to gelatinise or liquefy the starch to allow enzymes to convert it • Liquid adjuncts are already in the form of sugar • Conversion from starch has taken place at the suppliers plant • The sugars are ready for fermentation but are generally added directly to the kettle so they benefit from sterilisation. • Usually derived from maize, different acid and enzyme treatments can produce different fermentabilities
  • 19.
    ADVANTAGES OF USINGADJUNCTS • Cost and availability • Control of fermentability • Colour and flavour contribution • Beer presentation • Process benefits/development – Increased brewing capacity through shorter brewing cycles and more uniform wort quality. – Ease of handling and usage – Cleaner fermentation - better yeast heads – Improved hot and cold breaks – Shorter maturation times.
  • 20.
    TYPES of LIQUIDADJUNCTS Cereal Syrups - • Produced with various sugar compositions • Direct source of extract added to the copper Raw Sugars - • Cane sugar is the principal component in most primings • Invert sugar a mixture of glucose and fructose syrup, ( liquid or solid block form ). Priming Sugars • Add sweetness, fermentability or colour after the end of primary fermentation & to act as a source of sugar for a secondary fermentation. Colouring Products - • Hot water extracts from roasted and coloured malts • Caramel produced by the controlled heating of food grade sugars with ammonia • Class 3 - Ammonia caramel is used for brewing - must not react with beer component to form hazes:
  • 21.
    Hops FUNCTION of HOPSin BREWING • Hops provide the bitter taste in beer (with alpha acid the principal precursor) • The oils provide aroma. • Hops contribute to beer texture (mouthfeel) • Hops have bacteriostatic properties which protects beer against some biological spoilage organisms.
  • 22.
    FUNCTION of HOPSin BREWING • Hops reduce over foaming during wort boiling. • Hops aid in protein coagulation during the boil. • Hops are a foam active agent in beer.
  • 23.
    23 The brewhouse receivesthe malt and uses the natural enzymes produced in the malt to convert the starch to sugar. The sugar solution ( wort ) is separated from the solids, boiled to increase its stability along with hops which add bitterness and flavour to the beer. The boiled wort is clarified and cooled, from where it goes on to act as the nutrient for yeast to fuel the fermentation. Purpose of Brewhouse operation.
  • 24.
    24 THE BREWING PROCESS- BREWHOUSE Milling Malt Mash Conversion Water Mash Separation Wort Boiling Adjunct (optional extra) Wort Clarification Wort Cooling Hops Oxygen Co-products Malt dust Spent grains Trub Cold wort fermentation
  • 25.
    25 Purpose: to exposethe extract for conversion. Students should have a basic knowledge of the key stages of milling. • They should understand the reason for milling. • Know and describe one type of mill. • Know the grist composition for one type of mash separation system. • Be familiar with hazard and safety requirements when milling. Milling
  • 26.
    26 BREWHOUSE PROCESS -MILLING OBJECTIVE: Malt is received from the maltsters and stored (usually in silos on site). Before brewing the malt has to be milled which involves splitting the husk and grinding the endosperm into small grits. It is necessary to keep the husk as whole as possible since it will be used to form the filter bed during run off. The endosperm must be broken down to allow the enzymes to attack the starch. • Too coarse grind - poor extract & starch carry-over. • Too fine grind - run off problems & set mash.
  • 27.
    27 Purpose: to mixthe ground malt with a set amount of water at a given temperature thus allowing the natural enzymes from the malt to convert the starch in the endosperm to sugar. Students should have a basic knowledge of the steps in mashing. They should: • Understand the changes which occur to the malt during mashing. • Know the times and temperatures of the mashing regime • Be able to define when mashing is complete • Be able to describe a mash mixing vessel Mashing
  • 28.
    28 Mashing • To mixthe crushed grain evenly with the correct amount of water at the correct temperature • To allow other additions such as brewing salts and enzymes to be evenly mixed in • To allow the enzymic conversion of protein to amino acids and starch into simpler sugars in the correct amounts to give consistent fermentation and the right %ABV and Original Gravity • To extract colour and flavour from any coloured malts and adjuncts used
  • 29.
    29 Enzymes involved inmashing Amylases - alpha & beta - convert starch to sugar Proteases - break proteins to peptides & amino acids Beta glucanase - degrades beta glucans The factors which control the enzyme activity are TIME TEMPERATURE ACIDITY - pH
  • 30.
    30 BIOCHEMISTRY - PROTEINBREAKDOWN H N AA AA AA AA AA AA OO H 2 2 3 2 1 n-1 n-2 aminopeptidase carboxypeptidase n Endo-peptidase Exo-peptidase Mechanisms for Enzymic attack of proteins and polypeptides Produces: Proteins - insoluble precipates in spent grains & break Polypeptides - foam & haze Amino Acids - yeast growth
  • 31.
    31 BREWING PROCESS -MASHING During mashing the ground malt is mixed with water at a specific temperature to allow the enzymes to convert the starch to sugar. It normally takes about an hour to convert all the starch and completion can be checked with the Iodine test.
  • 32.
    32 Purpose: once allthe starch has been converted to sugar and dissolved in water (wort) it has to be separated from the solid material – husk and acrospire etc. Students should have a basic knowledge of the steps in mash separation. They should: • Know the operation of one type of wort separation system. • Know the principle elements of control – flow rate, pressure, wort haze, etc. • Know the principle factors which effect extract recovery. • Be able to describe a mash separation vessel Mash Separation
  • 33.
    33 BREWHOUSE PROCESS -WORT SEPARATION OBJECTIVE: Wort separation involves filtering the wort (sugar solution) through a filter bed made up of the spent husk material. The purpose is to produce clear bright worts free from solids, it is also important not to extract compounds such as polyphenols and lipids from the husk. Effective Wort separation Means: • High extract recovery (around 98% to 100%) • Bright worts - free from suspended solids • Worts free of starch.
  • 34.
    34 Types of wortclarification systems The three principal methods: • Mash Tun • Lauter Tun • Mash Filter Use the same basic principals: • Husk material acts as filter bed • Filter bed supported by screen or plates. • Strong worts extracted first followed by sparge water to wash out remaining extract. • Extraction flow is controlled to maximise clarity and extract recovery.
  • 35.
    35 BREWING PROCESS -SEPARATION The sugar solution ( wort ) has to be removed from the spent grains. It is filtered through a bed made up of the the husk from the malt. Wort must be clear and produced with minimum effluent. Oxygen should be excluded In ale breweries filtration is carried out in the same vessel as mashing - the mash tun. In modern breweries a separate lauter tun or mash filter for wort filtration. The solids left behind are called spent grains and are fed to cattle.
  • 36.
    36 Purpose – tostabilise the wort and to extract and isomerise the bitter compounds from hops. Students should have a basic knowledge of the process of wort boiling. They should • Know the reasons for wort boiling. • Know the principle elements of control – time, temperature, vigour etc. • Know the principle factors which effect hop utilisation and to be able to calculate a hop charge. • Be able to describe a wort boiling system. Wort Boiling
  • 37.
    37 WORT BOILING After wortseparation the clarified wort is boiled. Hops and sugar adjunct (if required) are added at this stage Wort boiling is the most energy intensive stage of the brewing process. Not only does the wort have to reach boiling point, but it is usual to evaporate between 5 and 10% of the kettle contents. A successful boil must be vigorous. Usually 60 -90 minutes
  • 38.
    38 BOILING The clarified wortis boiled for about an hour in a kettle or “copper” Hops are added during the boil to provide bitterness and aroma. Boiling also improves the physical (haze) stability of the beer and kills any micro- organisms which could infect the beer and cause flavour problems.
  • 39.
    39 BENEFITS OF WORTBOILING • Inactivation of malt enzymes • Sterilisation of the wort • Extraction and isomerisation of compounds derived from hops • Coagulation of proteinaceous material in the wort • Formation of proteinaceous/polyphenol complexes • Formation of flavour and colour complexes. • Fall in wort pH • Concentration of the wort gravity through evaporation of water. • Evaporation of volatile compounds from the wort.
  • 40.
    40 Control of dimethylsulphide - DMS DMS has a sweetcorn flavour and is a component of finished lagers. Excess quantities are undesirable DMS is formed from the breakdown of DMS precursor (S-methyl methionine) from malt due to heating. DMS is highly volatile and is rapidly lost during boiling. It build up during the hot wort stand and this should be kept to a minimum if DMS control is required. S-methyl methionine DMS BOILING ½ life 35 minutes HEAT DMS is volatile and is readily removed from beer during boiling. Formation of DMS during wort boiling.
  • 41.
    41 KETTLE ADDITIONS Main additionis hops - various forms • At beginning of boil - for bitterness only • 15 - 5 min. from end - hop aroma - late hopping • Pre-isomerised hops added towards end of boil • Hops help prevent over foaming • Syrup adjunct & colour added early in boil - avoid burning caramelisation on heating surfaces • Kettle finings to improve break added 5 minutes before the end of boil. (Carragheen /Irish Moss - seaweed) • Mineral salts or acid to adjust wort acidity pH
  • 42.
    42 Purpose – toseparate the coagulated protein (trub) and hop debris from the hot wort. Students should have a basic knowledge of the process of wort clarification. • They should know reasons for wort clarification. • The effects on duration on quality. • The use of kettle finings. • Describe a wort clarification system. Wort Clarification
  • 43.
    43 BREWHOUSE PROCESS -FUNCTIONS OF WORT CLARIFICATION The principal changes during hot wort clarification: • Coagulation of protein/polyphenol complexes. • Precipitation and separation of hot break • Temperature dependent chemical reactions started in the boil continue during the hot stand in the wort clarification stage, e.g. colour formation & oxidation. • Temperature dependent reactions which produce flavour active volatiles (e.g. DMS) can build up as they can not be removed in a vigorous boil.
  • 44.
    44 KETTLE FININGS ADDITIONTO A STANDARD BOILED WORT Addition of kettle finings improves the settlement of solids and the clarity of the wort. Best results occur with maximum settled solids and brightest (lowest) cold wort haze.
  • 45.
    45 Purpose: to coolthe clarified wort after boiling prior to fermentation. Candidates should have a basic knowledge of wort cooling. They should know • Mechanisms for wort cooling. • Typical cold wort temperatures for ale and lager beers • Reasons for aeration • About the formation of cold break. • About microbial risks. Wort Cooling
  • 46.
    46 FUNCTIONS OF WORTCOOLING The clarified wort has to be cooled to the fermentation temperature. Wort cooling is carried out using a heat exchanger. The cooling medium is brewing water which is recovered ( as warm water ) for the following brew. For low temperature cooling involves a glycol or cooled water stage. Wort is oxygenated on the cold side
  • 47.
    47 BREWING PROCESS -COOLING After boiling the protein and hop debris precipitates have to be removed. They are often mixed with the spent grain. The hot sugar solution (wort) is then cooled to the required temperature for fermentation. Yeast is added to the cool wort along with a small amount of air or oxygen to promote vigorous growth at the start of fermentation.
  • 48.
    48 ADDING OXYGEN • Usuallyon the cold side • to avoid colour pick up • hot side if aerating will sterilise the air • Aeration will add around 8ppm O2 • Oxygen must be used for higher gravity worts • More gas dissolves in colder and lower density liquids • Gas must be sterile and dissolve before reaching the fermenter
  • 49.
    49 OTHER ADDITIONS • Nutrients •Zinc sulphate or yeast foods • Enzymes • Antifoam • Salts
  • 50.
    50 KEY POINTS FORBREWHOUSE • The stored malt is ground to produce “grist”. • During mashing the grist is mixed with an appropriate amount of brewing water to produce a mash at pre-set temperature (or temperatures). • The mash is allowed to stand until all the starch from the malt is converted to sugar. • The sugar solution (called wort) is then separated from the malt solids, during wort separation. • Wort separation occurs in a single vessel or Mash Tun in traditional ale breweries. A two vessel system – mash mixer with either a lauter tun or mash filter is used for lagers. • The collected wort is boiled with hops. It is clarified (hot break removed) and cooled ready for fermentation.
  • 51.
    Microbial contamination  Bacteria- very small organisms, only a very limited range live in beer - pathogens will not survive in beer  Wild Yeast - organisms of the same basic type as brewing yeast but giving rise to flavour defects in beer  Fungi/Moulds -organisms similar to yeasts growing in old beer or unclean containers
  • 52.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 Potential for contamination • Raw materials • Taints, pesticide residues, grain weevils. Mycotoxins • Dust, wood etc in cans, plastic in crowns and can lacquer • Broken glass • Water supply • Nitrates, spillages, trihalomethanes • Plant cleaning • Residual detergent, residual chlorine • Poor road tanker cleaning • Process • Coolant ingress via plate heat exchanger leaks • Plastics • Oil or grease • Microbiological.
  • 53.
    INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATEIN BREWING & PACKAGING 2001 Water borne contamination • Pathogens will not grow in beer • Pathogens will grow in water • Water must be checked for pathogens eg Escherichia Coli, the presence will indicate sewage contamination • Other coliforms can adapt to life in a non hygienic brewery. All can reduce nitrate to nitrite but do not survive in finished beer • Legionella can also exist in mist sprays in air conditioning systems • Cryptosporidium Water borne protozoan - causes diarrhoea Destroyed by boiling but not by chlorine Does not live in beer