novel options for stabilization of beer mustafa rehmanji ashland inc. 1005 route 202/206...
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Novel Options for Stabilization of Beer
Mustafa Rehmanji
Ashland Inc.
1005 Route 202/206
Bridgewater, NJ 08807
Scope of Presentation
• Why should you Stabilize your Beer ?
• Implications of Colloidal Stability
• Mechanism of Haze Formation
• Option for Upstream Stabilization with Polyclar Brewbrite
• Combined Stabilization with Polyclar Plus 730
• Consumer expectations for better quality and product
consistency
• Expanded distribution areas: Beer travelling farther from the
brewery
• Challenge of producing quality products in developing markets
to compete with imports
• Need to reduce costs – production, return of beers
Drivers for Beer Stabilization
• Development of Haze in Beer – The colloidal stability of beer is a function of time and temperature.
• The end of useful shelf life of beer is defined in terms of haze.
• Total Haze of 2.0 EBC units is usually taken as the end of shelf life
Beer Haze Stability Definition
Beer Storage and Transport
Treatments
0
1
2
3
4
5
6
7
8
Haz
e E
BC
Store 0 C
Store 40 C
Cycled
Shaken 40 C
Data courtesy Brewing Research Institute, UK.
SimpleFlavanoids
Protein
ProteinOxidizedFlavanoids
Tannoids
Protein
No haze formation Chill haze Permanent haze
Model of Haze Formation
polypeptide Proline-rich region
polyphenol
Polyphenols are depicted as having two ends that can bind to protein. Proteins are depicted as having a fixed number of polyphenol binding sites.
Courtesy : Karl Siebert, Cornell University
Formation of Protein-Polyphenol Haze in Beverages, J. Agric. Food Chem. 1996,44, 1997-2005
Model for Protein – Polyphenol Interaction
Relative Haze FormationBeer stabilized with 100 g/hl PVPP to remove
reactive polyphenols
Catechin Haze EBCOxidized Catechin Tannic Haze EBC
0 10 20 30 40 500.8
1
1.2
1.4
1.6
1.8
2
2.2
2.4
0
5
10
15
20
25
30
Addition rate of reactive polyphenols in g/hl
CatechinOxidized CatechinTannic acid
Flavanoids & Tannoids in Beer
Shelf Life ModelCompare with PRIOR SLIDE
3 months
Haze-active Polyphenols & ProteinsBeer Model
9-12months
5-9months
Flavanols
TannoidsSensitiveProteins
Non-hazeactive
polyphenols
Non-hazeactive
proteins
Proteins Polyphenols
Balanced “As Needed” Stabilization
Raw Material & Process Strategies to Optimize Colloidal Stability
Process Polyphenol Reduction Protein Reduction Process Optimization
Raw materialselection
Low proanthocyanidinmalt
Hop extract
Low protein barley
Low malt modification
Coarse grind of malt
Brewhouse High adjunct ratio
Avoid weak worts
Mashing process pH, temperature
Good hot break
Vigorous kettle boil for>60 min.
Avoid excess mineralsalts
Cold wort filtration
Fermentation/
Maturation
Rapid onset tofermentation
Early yeast removal
Minimum 7 days maturation at -1OC
Filtration Low solids count
Filter at -1OC
Avoid O 2 Pick up
Admixture of Kappa-Carrageenan and micronized PVPP- Polyclar Brewbrite
Marine polysaccharide of galactose & galactose sulfate monomers
OCH
2O
OH
OO
CH2OH
OSO-3O
OH
O
n
ß-D-galactose 4 sulfate 3,6-anhydro-α-D-galactose
ONON N O
Cross-linked polyvinylpyrollidone
n
2-pyrrolidinone,1-ethenyl-, homopolymer
Kappa Carrageenan PVPP
Function/Purpose
The addition of Admixture of Carrageenan/PVPP to the boiling wort has the following functions:
• To stimulate coagulation of the proteinaceous particulates
• To promote the cohesion of the coagulated protein particles and of other protein-carbohydrate complexes into bigger flocs which can settle to the bottom of the tank faster (whirlpool), or are more effectively removed by a mash filter
• To facilitate upstream adsorption of polyphenols, particularly, TANNOIDS from the wort
Effect of Cold Wort Clarity on Beer Clarity
Courtesy of Murphy-Savilles Clarification
wort clarity is very important and is related to beer clarity
Bright(<3 EBC)
Hazy(>4 EBC)
Cloudy(>8 EBC)
ClarityRating
Filtered Beer Haze (EBC)
0.7 1.4 2.1
0
1
2
3
Increase in Wort Yield - Commercial TrialBrewbrite gave 3.2% increase in cold wort collected in FV as compared to untreated wort
Also, Brewbrite gave a higher throughput on the centrifuge and longer filter run lengths
Vo
lum
e o
f W
ort
at
colle
ctio
n,
hl
15.2
15.3
15.415.5
15.6
15.715.8
15.916.0
16.1
Untreated Carrageenan,alone 3.9g/hl
Brewbrite15g/hl
Fer
men
tat i
on
Tim
e , h
ou
rs
Decrease in Fermentation Time –
Commercial Trial Brewbrite gave 10 % reduction in
fermentation time as compared to untreated
120
125
130
135
140
145
Carrageenan alone,
3.9g/hl
Untreated Admixture
15g/hl
Analysis of Packaged Beer - Commercial TrialAccelerated Forcing Test
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
Initial Cycle 1 Cycle 2 Cycle 3 Cycle 4 Cycle 5
Admixture
15g/hl
Untreated
Cycle = 24 hours at 600C followed by 24 hours at 00C
No. of Cycles (to reach 2.0 EBC Units) = month of predicted shelf life
To
tal
Ha
ze,
EB
C U
nit
s
Trial AMalt- Adjunct Lager
Control Beers• Average cold wort
collection = 501 hl
• Wort clarity = 4.3 EBC• Total haze at end of
shelf life = 7.1 EBC
Brewbrite Trial Beers• Average cold wort
collection = 506 hl (+1% volume)
• Wort clarity = 1.2 EBC
• Total haze at end of shelf life = 4.5 EBC
Trial B – All Malt LagerDosage Evaluation
0
20
40
60
80
100
120
0 5 10 15 20 25 30
Brewbrite Addition Rate (g/hl)
Tannoid
s (m
g/l)
0
5
10
15
20
25
30
35
Wort C
larity
(E
BC
)
Tannoids (mg/l) Wort Clarity (EBC)
OptimumAddition Range
Dosage Evaluation-Trial B
Dosage Evaluation
0
20
40
60
80
100
120
0 10 15 20 25
Brewbrite Addition Rate (g/hl)
Tannoid
s (
mg/l)
Tannoids (mg/l) Wort Clarity (EBC)
OptimumAddition Range
Trial-B 100% Malt Lager
Polyphenol Reduction
0
50
100
150
200
250
300
350
400
Pre-addition Post addition
Sample Stage
mg
/l
Tannoids Total Polyphenols
Tannoid reduction = 49%
Total Polyphenol reduction = 21%
South America Brewery TrialsBrewery Wort Yield
(%)Beer Stability
A +2 Slight increase
B +2 Similar to 40 g/hl SHG + wort stabiliser
C 0 Similar to 60 g/hl SHG + papain
0
10
20
30
40
50
60
70
80
90
100
110
0 25 50 75 100 125 150
Sample as is
Segregation BEGIN
Segregation MIDDLE
Segregation END
Will the Materials Segregate?
Particle Size in m
% T
ota
l Par
ticl
es
The potential for Polyclar Brewbrite to segregate due to a sifting mechanism is low
Enhances clarity of wort & beer
Increases wort production
Decreases fermentation time
Improves total productivity of plant
Extends shelf life of packaged beer
Longer shelf life requires PVPP treatment at filtration
PVPP helps reduce astringency in beer** Measuring Astringency of Beverages using a Quartz-Crystal Microbalance
J.Am.Soc. Brew. Chem. 61(3):119-124, 2003
Summary of Trial Results
A composite of micronized
Polyvinylpolypyrrolidone (PVPP) and
selected Silica Xerogel- Polyclar® Plus 730
Optimized ratio for preventing chill and permanent haze High adsorptive capacity for haze- forming precursors Improved handling and performance characteristics
Key Features
Inversions required to re-disperse 10% slurries after 24 hours of sedimentation
Improved dispersion results in a more homogeneous dosing into the beer
Greater than 2000
PVPP Xerogel PVPP/Silica Admixture
8057
Re-dispersion PVPP/Silica Admixture
Polish FilterTrap/Bag
Filter
Dosing Tank
InletBufferTank
DE Filter
ToPackaging
DEStabilizer
Buffer Tank
Bright BeerTank
Possible Injection Points
0
2
4
6
8
10
Si hydrogel95 g/hl
Si hydrogel95 g/hl
+ PVPP20 g/hl
AdmixturePVPP/Silica
xerogel40 g/hl
Cyc
les
to 2
EB
C (
War
m D
ays)
60°C
/24
hr.
- 0
°/24
hr.
Forced Haze Development in Packaged Beer - Trial A
AdmixturePVPP/Silica
xerogel60 g/hl
AdmixturePVPP/Silica
xerogel80 g/hl
200 bbl of American lager treated Stabilizer dosed in-line, before buffer tank Dosage rate of PVPP/silica xerogel
admixture - 10 lb/100 bbl (38.5 g/hl)
US Microbrewery Trial B
0
1
2
3
4
5
Untreated Admixture
Predicted Shelf-Life in Months
I week @ 370C with total haze @ 2 EBCis equivalent to I month of shelf-life
0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40 50 60 70 80 90 100
Increasing Polyphenol Stability ==>(ml T125/100 ml Beer to 2 EBC Additional Haze
Incr
easi
ng
Pro
tein
Sta
bil
ity
==
>(m
l P
40/1
00 m
l B
eer
to
5 E
BC
Ad
dit
ion
al H
aze
Stabilized - 10 lb/100 bbl
Unstabilized Region
Trial B Stabilization ResultsPVPP/Silica Xerogel Admixture
Objective to increase product shelf life Normal regime - silica hydrogel on transfer to MV &
PVPP at filtration Admixture of PVPP/Silica Xerogel (40 g/hl) dosed
on transfer from FV to MV (900 hl) Beer cold stored for 7 days PVPP (20 g/hl) added with DE body-feed - very
short contact time ~3 min.
Ale Stabilization- 2 Stage : Trial C
• Stage 1 - complete tannoid removal & substantial protein and flavanoid reduction •Stage 2 - further flavanoid reduction
BBT FV MV
Tannoids 35.0 <12 <12 (mg/l) T125 Polyphenols 11.9 55.0 123.0 (ml/100ml) P 40 Proteins 21.2 49.4 51.6 (ml/100ml) Admixture PVPP/Silica Xerogel (40 g/hl) PVPP (20 g/hl)
T125 & P40 - high values indicate better stabilization
Ale Stabilization- 2 Stage : Trial C
Brewery Trials – Filter Pressures, Run Lengths & Beer Stability
Admixture PVPP/Silica Xerogel
PVPP only
Xerogel only
Stabilizer
33.0
12.6
35.8
Dose rate
g/hl
12.0
7.4
6.4
Filter Run Time (hr.)
1.2
3.6
6.9
Total Haze**
(EBC)
0.25
0.35
0.49
P/hr*
*Pressure increase at steady state**Total haze measured at 0oC after 5 days incubation at 60oC