Crisp Malt Craft Distilling Seminar
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Crisp Malt share insights into the Craft Malting and Distilling Process including the company introduction. Barley growing and malting process and the importance of non-glycosidic nitrile (GN) barley varieties in Distilling. Distillers requirements. Plain Pot Distilled Malt, Peated Malt and High Diastatic Malt. Scottish Whisky and American Whiskey (mixed grains) are explored. Other malts including highly kilned, roasted and heritage malts are explored alongside unmalted cereals - flaked and torrefied.
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Crisp Malt Craft Distilling Seminar
- 1. Malting & Distilling Malts
- 2. Agenda Introduction Barley Malting Process Distilling Malts Other Malts Non-Malted Cereals
- 3. Introduction
- 4. • Frederick Smith started malting in Gt Ryburgh, Norfolk in 1870 • Malt exports started in 1888 • John Crisp joined the business in 1962 • Now owned by group of private investors • 3 maltings in England, 2 in Scotland, 1 in Germany and 1 in Poland • Now producing 432 000 tonnes of malt • Head Office at Gt Ryburgh, North Norfolk • More than 85% of barley used is sourced locally • Still operating a traditional floor malting at Gt Ryburgh • Leading supplier to the global craft distilling sector Crisp Malt – introduction
- 6. Barley
- 7. Barley Facts • Barley is a cereal crop • Cereals are grains produced by grasses for food • Other cereals are maize (corn), rice, wheat, rye, oats, sorghum, millet & triticale • Malting barley grows well on lighter, sandy land • Well suited to the drier eastern regions of the UK
- 8. UK Barley Growing Regions Why are these regions most suitable? • Drier, warmer climate better suited to arable crop production • Farm land particularly suits cereal cropping • Soil types suit barley production • Malting plants predominantly located in barley growing regions
- 9. Barley types – 2-row or 6-row
- 10. Barley types – 2-row or 6-row 2-Row Larger grains 6- Row Smaller grains Twisted grains
- 11. Winter or Spring Sown September / October Plant Winter Malting Barley February / March Plant Spring Malting Barley Late July Harvest Winter Malting Barley Mid August Harvest Spring Malting Barley
- 12. Barley Growing October April May June July July HarvestPlanting SeptemberWINTER April May June July August AugustMarchSPRING Ripening
- 13. Growing Malting Barley • Alternative cropping options • Barley – winter or spring, feed or malting • High risk crop • Quality specifications/premiums • Chemical restrictions – BBPA list • Fertilizer restrictions – yield/quality implications • Harvesting/storage requirements
- 14. Sowing
- 15. Growing season - Ear emergence
- 16. Maturing
- 17. Harvesting
- 18. Maltsters Requirements • Approved malting barley variety • High viability (minimum 98% live grains) • Appropriate protein/nitrogen content • Low level of small grains • No admixture with other grains • No moulds or smells • No skinned, split or damaged grains
- 19. Malting Process
- 20. What is Malting? • Partial germination of cereals Barley, wheat, rye, oats, sorghum etc • Under controlled conditions Moisture, temperature and time • Raw material for further processing Brewing, distilling and food uses • Value added products Provides extract, enzymes, colour and flavour
- 21. Barley vs. Malt Barley Malt
- 22. Why Malt Barley? • Retains its husk • High starch content • Cell walls degradable • Good enzyme production
- 23. The Barley Corn Embryo Living tissue Source of new plant Scutellum & Aleurone Living tissues Site of enzyme synthesis Endosperm Dead tissue Embryo’s nutrient reserve ‘Modified’ during malting Husk Dead tissue Protective covering Scutellum Aleurone layer Husk Embryo Endosperm
- 25. What Does it Require? • Suitable barley variety • Water • Oxygen • Temperature • Time
- 26. The Malting Process Steeping 2 days Germination 4 - 6 days Kilning 1 -2 days BARLEY MALT
- 27. Steeping • Objective • Hydrate the grain, increasing the moisture content from around 12% to 44-46% • Initiate uniform germination This is achieved by successive wet and dry periods in steeping vessel with careful control of water and air temperature
- 28. Steeping process 0 4 8 12 16 20 24 28 32 36 40 44 48 Time (Hours) Moisture Content (%) 12 16 20 24 28 32 36 40 44 48 Continuous steeping Broken steeping Water drained Water replaced Water drained Water replaced
- 29. Germination • Objective • Synthesis and release of enzymes • Degradation of endosperm cell walls • Limited solubilisation of endosperm storage protein This is achieved by effective control of grain temperature by the application of attemperated, humidified air
- 31. Barley Germination Progress From steep 24 hrs 48 hrs 96 hrs
- 32. Barley Structure
- 33. Barley Structure Husk Aleurone Endosperm Large starch granules Cell wall Small starch granules Storage protein
- 34. Barley Structure – Cell walls stained
- 35. Toluidine Blue Stained EndospermBarley Structure – Protein stained
- 36. Modification
- 37. Malt Structure
- 38. Modification – key objectives • Degradation of endosperm cell walls • Solubilisation of appropriate amount of endosperm storage protein • Synthesis and release of starch-degrading enzymes Supply distiller with package of accessible starch and necessary enzymes to degrade to fermentable sugars plus other desired attributes
- 39. Kilning • Objective • Halt germination • Reduce moisture content to 3-6% • Develop required colour and flavour characteristics This is achieved by passing heated air (55°C-100°C) through the grain bed. Malt type will dictate applied air temperature used.
- 40. Kilning process
- 41. Traditional Floor Malting Advantages • Flexibility • Low capital cost • Heritage Disadvantages • Labour intensive • High energy • Low output • Process control
- 42. Traditional Floor Malting Steeping, germination & kilning Steep Tanks Germination Floors Kiln
- 44. T r ad it ional F l oor M al t ing
- 49. Distilling Malts
- 50. Distilling malts • Plain pot still • Peated pot still • High diastatic Common to all is the use of non-glycosidic nitrile (GN) barley varieties in their manufacture
- 51. Non-GN barley varieties • Glycosidic nitrile issue arises from hydrolysis of epiheterodendrin to produce isobutyraldehyde cyanohydrin and ultimately ethyl carbamate • Distillery sensitivity varies by still design • Only non-GN producing varieties now selected for approval • Optic last of GN-producing varieties and older varieties all GN-producers
- 52. Distillers requirements • Plain pot still Easily processable malt that produces highly fermentable wort that leads to expected spirit yield after distillation of wash • Peated pot still As plain pot still with the additional attribute of providing desired phenolic character to distilled spirit • High diastatic Provision of sufficient starch degrading enzymes and processing potential to convert up to 90% unmalted starch source for grain spirit production
- 53. Plain pot still • Typically produced from low nitrogen spring barley • Concerto, Laureate and Diablo • Gentle kilning to preserve enzymes and maximise fermentability of finished malt Parameter Typical Analysis Moisture (%) Maximum 4.5 Extract (% soluble, as is) Minimum 78 Colour (EBC) 2.5 – 3.5 Total nitrogen (%) 1.30 – 1.55 Soluble nitrogen ratio 35 - 42 Predicted spirit yield (LAA/t) 410
- 54. 0 10 20 30 40 50 60 70 80 90 100 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018* %oftotalspringbarleycrop Crop year KWS Sassy Laureate RGT Planet Moonshine Chronicle Odyssey Concerto Propino NFC Tipple Quench Oxbridge Belgravia Westminster Decanter Optic Golden Promise *estimated from certified seed production from harvest 2017 Spring Malting Varieties As % of total Scotland spring barley crop
- 55. The Malting Barley Committee Approved List harvest 2019 Brewing Use Malt Distilling Use Grain Distilling Use Winter Varieties Full Approval Flagon, Venture, Craft Winter Varieties Full Approval None Approved for distilling use Winter Varieties Full Approval None Approved for distilling use Spring Varieties Full Approval Concerto, Propino, RGT Planet, Laureate Spring Varieties Full Approval Concerto, Laureate, KWS Sassy, Sienna Spring Varieties Full Approval Fairing, Olympus Winter Varieties Provisional Approval 2 Spring Varieties Provisional Approval 2 Chanson Spring Varieties Provisional Approval 2 Spring Varieties Provisional Approval 2 Winter Varieties Provisional Approval 1 Electrum Spring Varieties Provisional Approval 1 LG Diablo, RGT Asteroid Spring Varieties Provisional Approval 1 LG Diablo, RGT Asteroid Spring Varieties Provisional Approval 1 RGT Asteroid
- 56. Determination of Predicted Spirit Yield 1. Standard IoB mash and collect wort 2. Determine original gravity of wort - soluble extract 3. Ferment wort with standard yeast for 44 hrs at 33C 4. Determine final gravity of wash - fermentability 5. Calculate fermentable extract 6. Calculate PSY = fermentable extract x 6.06 Distillery efficiency often based on achievement of actual yield relative to lab PSY value, i.e. PSY = 410 laa/t, distillery yield 405 laa/t Efficiency = (405/410) x 100 = 98.8%
- 57. Peated pot still • Green malt directed to peating kiln and peat smoke ducted into kiln during pre-break drying • Aiming to ‘smoulder’ peat to generate highly phenolic smoke • Peat sources; Islay, St Cyrus (Aberdeenshire)
- 58. Peated pot still • Crisp lab determines total phenol content using colorimetric method after steam distillation of malt • Heavily peated malt deliveries at 45-55 mg/kg (ppm) • Higher levels are possible! • Fermentability can be suppressed, but not in all distilleries
- 59. High Diastatic Malt • Enzyme source for conversion of unmalted cereals (usually maize or wheat) for grain spirit production • Specialist high nitrogen non-GN barley varieties • Olympus • Fairing • Asteroid • Specification typically:- • minimum 60 Dextrinising Units (DU, dry) • minimum 160 Diastatic Power (DP, dry) • TSN/FAN levels also important
- 60. Definition of Whisky/Whiskey The Scotch Whisky Regulations 2009 REGULATION (EC) No 110/2008
- 61. Other Malts
- 62. Coloured malts There are three categories of coloured malts: • Those produced from green malt on normal kiln • Those produced from green malt in roasting facility • Those produced from kilned malt in roasting facility
- 63. Coloured malts Products from green malt on normal kiln • Kilning conditions promote formation of colour precursors leading to increased final colour and flavours • Vienna malt 6-10 EBC • Munich malt 25-60 EBC • Provide richer ‘malty’ flavour
- 64. Coloured malts Products from green malt in roasting facility • First phase of process ‘stews’ grain leading to liquifaction of endosperm • Second stage of roasting dries and forms colour & flavour compounds • Crystal malt 160-480 °EBC • Crystal malts provide sweet, caramel flavours
- 65. Crystal malt 100 EBC 170 EBC 200 EBC 70 EBC
- 66. Coloured malts Products from kilned malt in roasting facility • Dry raw material introduced into drum • Product temperature close to combustion temperature for black malt and roast barley • Amber 60-80 EBC • Brown 120-150 EBC • Chocolate malt 900-1100 EBC • Black malt 1300-1400 EBC • (Roast barley) 1300-1400 EBC
- 67. Malt roasting drum 1. Raw material inlet 2. Product outlet 3. Weighing hopper 4. Roasting drum 5. Burner 6. Exhaust air fan 7. Cooling fan 8. Cooler 9. Utilities
- 68. New roasting technology - RevTech
- 69. Heritage Malts
- 70. • Chevallier - first selected in 1820’s • Plumage Archer – first commercial hybrid barley (1905) • Maris Otter – continuous production since 1965 • Coming soon! • Long Eared Nottingham • Hanna Heritage varieties
- 72. Other malted cereals • Wheat malt • Rye malt • Naked oat malt
- 74. Non-malted cereals • Range of Torrefied cereals available • Produced by processing through a Cabot cooker or microniser • Cooking results in starch gelatinisation • Flaked products can be added directly to the mash • Provide opportunity for product differentiation
- 75. Non-malted cereals • Torrefied • Whole Barley • Whole Wheat • Torrefied and flaked • Maize • Rice • Oats
- 77. Australia Importers & Distributors BeerCo.com.au Unit 1 / 1-3 Disney Avenue, Keilor East, VIC 3033 Tel: +61 400 040 195 Inquiries to: service@BeerCo.com.au Orders to: orders@BeerCo.com.au Social: @BeerCoAU #InsistonCrisp