The Process Technology
of
Beverage Industries
(Beer, winery, Distillery..)
Gizachew Shiferaw
Column1 Production (106 hl/year) Consumption (106 hl/year) Per capita consumption
(litter per year)
China 289.9 288.8 22.1
United states 214.4 241.3 84.3
Germany 108.8 97.8 118.5
Brazil 89.6 89.3 50.3
Russia 81.4 82.3 56.3
Japan 65.3 65.6 51.6
United Kingdom 56.2 59.9 100.1
Spain 31.3 34.2 82.8
France 16.8 20.2 33.8
Europe 533 512.8 58.3
Americas 480.8 493 56.9
Asia/Pacific 460.1 461 12.9
Africa 72 76 7.1
World Total 1543 24.1
RAW MATERIALS
The main raw materials for beer production are:
• Cereals Malt ,mainly barley
• Water
• Hops and
• Yeast
Malt plant or
Malt house
Brew house
Fermentation
house (Beer processing)
Finishing
0peration
Finishing
0peration
Grain
• Barley
– Higher extract, less husk
– Preferred by both home and
Industrial breweries
• Other Grains
– Wheat, Oats, Corn, Rice
Malting
• Grain (usually barley) is malted
– Harvested grain is soaked in water until it
germinates
• This activates amylases (and proteases)
– Grain is dried Barley Amylase
• This halts the conversion
– Acrospires (sprouts) are removed
– Grain is cured
• usually at least one month
Barley Malting
• Acrospires eat endosperm as they grow
during malting
– Acrospire is the sprout, endosperm is its
food source (full of starch)
– Acrospires will continue to eat
endosperm until it is depleted or they are
stopped by the maltster by heating and
drying
– Longer acrospire growth leads to:
• More endosperm consumed and less
fermentable sugar
• More amylases are activated
• More yeast nutrients released
• Clearer beer and more complete
fermentation
Water:The medium for fermentation
• 3 main concerns
– Flavor of water
– Nutrients for yeast
• Can’t use distilled water
– pH effects how well enzymes make maltose
• Keep mash pH 5-5.5
• Ion concentration important
– e.g. Ca2+, Mg2+, CO32-
• Darker malts lower pH more than lighter malts
– Areas with water with natural higher pH produced
darker beers than areas with water with lower pH
Hops
• Humulus lupulus (family = Cannabinaceae)
• Perennial Bitter herb grown on a vine and
composed of leaflike bracts and bracteoles
• Bracteoles have lupulin glands that produce
resins containing alpha acids
• Alpha acids – provide bitter taste/flavor and
preservative
• Oils from the plant add flavor and aroma
• According to studies the average
composition of hop dry weight is
approximately
• Bitter substances or hop resins 18.5 %
• Hop oil 1.0 %
• Polyphenols 3.5 %
• Protein 20.0 %
• Inorganic 8.0 %
• cellulose and other materials 49.0%
Yeast fermentation catalyst
• The most important and mysterious ingredient
turns wort into beer and produced more of itself
• Through anaerobic respiration, it converts the malt
sugar into alcohol, CO2, and other by-products
• Often removed after fermentation, and can be re-
uesd
• Yeast is essentially a fermentation catalyst
• The word “enzyme” (meaning biological catalyst)
Yeast
• 2 main types (for brewing purposes)
– Saccharomyces cerevisiae (ale yeast)
• Prefers warmer temperatures (20-25°C) and will
flocculate on top of the beer
– Saccharomyces uvarum (lager yeast)
• Prefers cooler temperatures and will flocculate at the
bottom of the beer (~5°C)
• MALTING: The first ingredient to come into play
is barley, which is grain (or, in other words, a
seed). The seeds are soaked in water for about
two days and allowed to begin their development
into plants. Enzymes are released that break
down the proteins and starches in each grain into
simple sugars meant to nourish the baby plant.
However, once this process has begun, the barley
is cooked in a kiln, arresting the growth process
while the enzymes are at their peak of
production. This is called malting.
Malt
• Germinated and crushed grain
• Amylases (and proteases) accessible but
inactive
• Starches from endosperm partially broken
down
Column1 Moisture content (wt/%) Volume (hl) Mass (kg)
Malting barley 14 100 100
Steeped barley 41 145 145
Green malt 48 220 147
Stored malt 3.5 118 79
4.7 120 80
Alpha Acids
• Humulone R = CH2CH(CH3)2
• Cohumulone R = CH(CH3)2
• Adhumulone R = CH(CH3)CH2CH3
• MASHING: In the mashing stage, the grain is actually transformed
into sugar. The grains are crushed into a fine powder, or grist, and
then soaked in water. Proteins are broken down
• . Starches are broken down into simple sugars that nourish the
yeast. Complex sugars remain to give the beer its malty taste. The
mash is heated and strained to yield a substance called wort.
Next, the wort is brought to a boil and the flowers of the female
hop plant are added. Bitter resins and aromatic hop oils are
released. The variety of hop, the amount added, and the point or
points in the boil at which they are added all contribute to the
flavor of the beer. They add bitterness when added early to the
boil, flavor if added in the middle, and aroma when added at the
end.
Mashing & Lautering
• Mashing
– Malt is soaked in hot water
– ~155°F (~68°C)
– Amylases re-activated
– starches broken down to sugars
• Primarily maltose = 2 glucose joined by α(14) linkage
– Proteins also broken down
– Processing of proteins and starches highly dependent
on temperature
– pH also important for amylase activity
• Lautering
– Grains are rinsed until water comes through clear
– Extract all ingredients into wort to be boiled
Alpha Acid Isomerization
• FERMENTATION: The wort is then cooled and
moved into a fermentation vessel. Yeast is
added and allowed to consume most or all of
the sugars in the wort. This is the
fermentation process during which alcohol is
produced. The process takes about ten days.
Each brewery has its own strains of yeast, and
it is the yeast that determines the character of
the beer.
Pitching Yeast
• Addition of yeast to allow fermentation
• Wort must be at proper temperature for yeast
to survive and flourish
– Slightly off temperatures lead to off flavors
– Far off temperatures lead to stuck fermentation
• Oxygen must be kept out
– Yeast only converts sugars to alcohol and CO2
under anaerobic respiration
– With oxygen present, aerobic respiration will
dominate
Fermentation
• Yeast absorbs oxygen and sugar, and reproduces
asexually
• When oxygen is used up, reproduction stops and
fermentation (anaerobic respiration) begins
• Each glucose produces two molecules of ethyl
alcohol and CO2
C6H12O6 2 CH3CH2OH + 2 CO2 + 118 kJ (2 ATP)
• Large amounts of CO2 are produced and must be
removed without letting oxygen in
– Airlock or water bubbler
Fermentation
• When all fermentable sugars have been
consumed, fermentation stops and yeast
begins to go dormant
• Yeast settle out and the beer clarifies
• This yields a “young beer”
– Bad taste and smell
– High concentrations of diacetyl and other organic
byproducts
• STORAGE: The beer is then separated from the yeast
(racked). Once the yeast is removed the beer is passed
from fermentation to storage vessels. During transfer
the beer is cooled to minus one degree centigrade. The
beer stays in storage at this temperature, and any
material which might impair the appearance, flavour
and shelf-life of the beer settles out.
• FILTRATION: Following a set time in storage, carbon dioxide
gas collected during fermentation is added to give beer its
characteristic head and sparkling taste. The beer is then
passed through a filtration system to remove surplus yeast
and protein.
Conditioning
• Small amounts of remaining yeast continue to
consume byproducts of initial fermentation
– Conditioning or aging, development of flavor
• PASTEURISATION: This is a process of heating
and rapid cooling which prolongs shelf-life and
destroys any bacteria or other organisms in the
beer. Canned and bottled beers are pasteurised
in their containers, while draught beer is
pasteurised by means of a special heat exchanger
called a flash pasteuriser.
• PACKAGING: The filtered and sparkling beer is
packaged into bottles, cans and stainless steel
casks, or kegs, ready for distribution.
Packaging
• Flat beer is packaged (bottle or keg) and must
be carbonated
– Add extra sugar for natural carbonation by
fermentation
– Artificially carbonate from gas source
Beer Characteristics
• Alcohol Content
• Flavor
– Malt, Hops, Yeast, Water
• Aroma
• Clarity
• Head
• Preservation
Alcohol Content
• Measured by density
– Original gravity – density of wort prior to
fermentation
– Final gravity – density of beer after fermentation
– Dissolved sugars lead to high density
– As sugars convert to ethyl alcohol, the density
decreases
– The decrease in the density is directly
proportional to the amount of alcohol present
Flavor
• Sweet flavors from malt
– Dependent on types of grain and on grain
modification
• Bitter flavors from hops
– Isoalpha acids balance sweetness of grain
• 15 – 100 ppm depending on beer type
– Aroma from hop oils mainly from later additions
of hops
Aroma
• Hop oils
– Small organic molecules
• Often aromatics
• Polyphenols Phenol
• Mainly from late addition of hops
– Aroma hops boiled for a short time (~5 minutes)
– Dry hops (added after wort has cooled or just
before packaging)
Clarity
• Filtering, siphoning, settling, racking
• Yeast
– Flocculency of yeast
• Polyphenols from hops
– Larger polyphenols become insoluble and form a
“permanent haze”
– Small polyphenols agglomerate when chilled to
form a “chill haze”
Head
• Protein from grains
– Wheat proteins stabilize head
• Isoalpha acids
– Tensioactive properties of isoalpha acids stabilize
head
Preservation
• Alcohol is a natural preservative
• Alpha acids
– Act as a preservative by inhibiting the growth of
bacteria
– Beta acids (also from hops) also help
• Decomposition on exposure to light
– Isoalpha acids are
light sensitive
– Skunky flavor
– Only a few ppb
http://www.scielo.br/scielo.php?pid=S0100-4042
2000000100019&script=sci_arttext
Outline
• History
• Ingreedients
– Barley, Hops, Yeast, Water
• Brewing process
– The processing, and what effects we expect them
to have on properties of the final product
• Beer characteristics
– The properties that we observe, and how they
were derived from the processing of the
ingredients
• Conclusion & links for more info
More Info
• Stephen Snyder, The Brewmaster’s Bible, New
York: HarperPerennial, 1997
• http://www.scientiaevitae.de/gb/2/5/beer.ht
m
• Hop Chemistry:
http://www.scielo.br/scielo.php?pid=S0100-4
0422000000100019&script=sci_arttext
Drink!
• And be merry
• Happy Memorial Day!
