evidence of beers created over 5,000 years ago beer has been an integral part of society sustenance:...
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The History, Science, and Engineering of
Brewing
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Brief History• Evidence of beers created over 5,000 years ago
• Beer has been an integral part of society• Sustenance: Low alcohol (1%), high gravity beers
• Energy storage• Liquid meal – Egyptians, Colonists
• Safe water supply• Sterilization inherent of making beer
• Hops and Boiling• I.P.A’s
• Religion and Health• Blood of Christ – Church Brewed• Monastic Beers• Anesthetic - Surgery
• Today – 39 Billion gallons of beer brewed annually
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Beer: Unit Operations• Barley is grown, harvested, and dried (Malting)
• Malt is milled and steeped in water to create sweet wort (Mashing)
• Sweet Wort is boiled and hops are added to create bitter wort (Boiling)
• Wort is chilled to fermentation temperature and yeast added
• Fermentation takes 2-6 weeks depending on beer style yeast
• Wort has now become beer. It is filtered, carbonated, and packaged
• Shipped and Consumed
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Barley Harvest and Malting
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Specialty Malts
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Milling
Milling: Husk crushed to increase surface area to improve saccharification
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Mashing
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Mashing: Grain to Water ratio (Grist Ratio) and time of mash determines extract efficiency
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Mashing Chemistry
• Starches given, sugars needed– Enzymes are found naturally in grain
• Generate needed fermentable sugars from starches (saccharification)
Alpha-AmylaseBeta Amylase
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EnzymesEnzyme Optimum
Temperature
Range
Working pH
Range
Function
Phytase 86-126°F 5.0-5.5 Lowers the mash pH. No longer used.
Debranching (var.)
95-113°F 5.0-5.8 Solubilization of starches.
Beta Glucanase 95-113°F 4.5-5.5 Best gum breaking rest.
Peptidase 113-131°F 4.6-5.3 Produces Free Amino Nitrogen (FAN).
Protease 113-131°F 4.6-5.3 Breaks up large proteins that form haze.
Beta Amylase 131-150°F 5.0-5.5 Produces maltose.
Alpha Amylase 154-162°F 5.3-5.7 Produces a variety of sugars, including maltose.
Major Enzyme Groups and Functions
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Boiling Kettle• Wort is boiled for an hour
• Energy Intensive
• Hops are added:• Bittering • Flavoring• Aromatic
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Chilling/Aerating• Wort is cooled to fermentation temperature
• Heat Exchangers
• Oxygen solubilized into wort• Allows yeast to perform aerobic respiration to grow and
multiply
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Fermentation
• Wort pumped to fermentation tank• Yeast is added
• Wort maintained chilled• Fermentation exothermic
• more heat exchangers
• 2-6 week wait• Gravity Checked
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Fermentation
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Yeast Fermenter. Imperial Chemical Industries, Billingham,UKVolume: 98,000 Ft^3
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Filtration/Carbonation/Bottling
• “Green” Beer Filtered• Diatomaceous Earth
• Brightening Tank• Chilling to precipitate out proteins
• Carbonation• Bottling/Kegging• Shipped!
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Summary
Malting
KilnMill Mash Tun
Boiling Kettle
FermentationFiltrationCarbonationPackaging
Barley Water
HopsFinnings
Salts
Spent GrainsWater
Solids YeastCO2
YeastO2
Hops
Trub
CO2
Bottles/Cans/ Kegs
Moisture Dust
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What about Wastes?• Spent Grain/Trub
• Fertilizers/Cow Feed
• CO2 Production during Fermentation• Capture and use for carbonation?
• Spent Yeast• Protein Powder• Adsorbent for waste in another industry
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Q & A?
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