CEREAL BASED FERMENTEDBEVERAGES

Whiskey

INTRODUCTON• spirit made from cereal starch.• classified on the basis of the cereal used (wheat, barley, corn, rye), on

the degree of blending, and on the country of origin.• In the raw cereals, the essential component for whiskey production is

the starch content, which is approximately 70% on a dry weight basis.

MANUFACTURE• involves hydrolytic breakdown of the starch into fermentable sugars,

followed by fermentation, distillation, and maturation.

MALTING • The barley is cleaned and then steeped in cold water for 2 to 3 days. The wet

grain is allowed to germinate at 24°C over a period of 8 to 12 days.• Thus, increase in activities of enzymes α-amylase and β-amylase.• The principal end product of the joint action of α- and β-amylases upon starch is

the fermentable sugar maltose.• Malting also encourages the development of β glucanase and protease activities.

KILNING• grain is heated gradually to approximately 52°C to stop germination but

not to destroy the enzymes. • During kilning, the moisture level of the germinated barley (malt) is

reduced to approximately 5%.

MASHING• The dried malt is milled to form the grist, which is then mixed with water at

approximately 68°C in mashtun for 0.5–1.5 hours. • This process of mashing is characterized chemically by the continuing hydrolysis

of starch by amylase activity into fermentable sugars, chiefly maltose, with smaller amounts of sucrose,glucose, and fructose. • The other principal purpose of mashing is to bring into solution not only the

sugars but also amino acids, resulting from protease activity, which serve as a nitrogen source for yeast growth during fermentation (Barnard 2008).• At the end of the mashing period, the resulting liquor (wort) is recovered by

filtration, while theremaining residue (draff) is used as cattle feed.

DISTILLATIONGRAIN WHISKEY

• Batch distillation.• All the contents of the

fermentation vat are transferred to a large wash still and boiled for 5–6 hours to produce a distillate (the low wines) that contains 20%–25% ethanol.

MALT WHISKEY

• continuous distillation in a special still.• Usually, the incoming

material is the cold wash of 10% ethanol content, and the principal product from this process is raw spirit containing 95% ethanol

DISTILLATIONGrain whiskey:THREE FRACTIONS;

1. foreshots

2. whiskey (potable spirit containing 63%–71% ethanol)

3. feints (approximately 25% ethanol)

MATURATION• The whiskey obtained directly from the distillation step is colorless

and has a harsh taste, and therefore, along period of maturation is essential to develop the final flavor.

• a minimum maturation period of 3 years is mandatory for scotch and Canadian whiskies.

Eugenol

BLENDING• Malt whiskey by itself has a heavy flavor and is therefore frequently blended

with grain whiskey to increase its general acceptability. • The most frequent composition of blended whiskey is 60%–70% grain whiskey

and 30%–40% malt whiskey

BOTTLING• The matured spirit is diluted with

water to 40%–43% by volume of ethanol (80°–86° U.S. proof) before being bottled.

• Therefore, in terms of quantity, the major component of whiskey is actually water (approximately 60% by volume).

• Once bottled, the whiskey does not undergo subsequent change because oxygen no longer has access to the matured spirit.

• This represents the termination of maturation, but on the other hand there is no decline in whiskey quality due to age.

Introduction• Beer is fermented, alcoholic beverage made from

barley, wheat, rice etc. and flavoured with hops• Third most popular drink overall, after water and

tea.• Production of beer is termed as brewingComponent % of Beer based on barleyProtein 0.2-0.4

Carbohydrates 4.5

Water 88-91

Ethanol 3-9

CO2 0.4-0.45

Mineral salts 0.02

Ingredients

• Barley• Hops• Water• Yeast

Barley Hops Water yeast Cheaply

available Not used as

staple diet Two enzyme: CYSTASE DIASTASE

• Flavours• Preservative• Aroma• Clarifying agent

• 90% of water• Six main salts:• Bicarbonate• Sodium• Chloride• Calcium• Magnesium• sulphate

• Cause the fermentation

Production process1. Malting2. Mashing3. Wort separation4. Hops addition5. Wort boiling6. Trub removal7. Wort cooling

8. Yeast pitching and aeration9. Fermentation10. Yeast removal11. Aging12. Clarification and adjustment13. Pasteurization14. packaging

MALTING

Mashing• Cereal grist is mixed with hot water to extract

sugar for fermentation.• The product of mashing is termed as sweet wart.• The process of mashing involves:• Dissolving the substances in the malt that

are soluble in warm water.• Rendering the substances which are

insoluble in their natural state or soluble through enzymatic action.

Wort Filtration• The process of separating the liquid part of mash(wort) from the

undissolved part (the spent grain) is called lautering.• Two types of equipments are used to separate wort from mash solids,

these are:• Lauter Tun: It is a vertical cylinder with a large diameter to depth ratio and

fitted into the tun is a wort collecting system.• Mash Filters: The mash filters consist of a series of alternating plates and roller

frames in which a filter of polyethylene and polypropylene is suspended

Hops addition• Hops are female flowers of the hop

plant, Humulus lupulus• impart bitter, tangy flavor to beer,

balancing the sweetness of the malt• Antibacterial properties

Wort Boiling• Extraction of bittering compounds, oils and aroma

from hops• Sterilization of wort: eliminates all bacteria, yeast and

molds that would competes with brewing yeast and cause off-flavours• Coagulation of excess protein and tannins to form

solid particles called trub : gives beer stability• Color and flavor formation• Removal of undesirable volatiles like dimethyl

sulphide by evaporation• Water evaporation

Trub Removal• Removed to give beer stability, and

since trub could potentially inhibit fermentation• Most common method is whirlpool,

other methods like straining, sedimentation and decantation, centrifugation filtration

Wort cooling• Wort is sterilized, then cooled to fermentation

temperature through heat exchanger or cooling coils• Water used as cooling medium• Fermentation temperature differ• 7-15°C for lager• 10-25°C for ale

• Cooled wort is now transferred to sterile fermenter

Medium(wort) composition• 90-92% of wort is composed of carbohydrates

• Nitrogenous compounds like amino acids formed from proteolysis during mashing• Vitamins like biotin, pantothenic acid, pyridoxine and thiamine

Yeast pitching and Aeration• Air injection and yeast pitching done either• Directly inside fermenter or• En route to fermenter i.e., the wort is aerated/pitched with yeast before

being sent to fermenter

• Initial aeration required, as yeast cells reproduce quickly, producing new cells. Also, they convert carbohydrates to organic acids, which lower pH from 5.2 to 4, giving acidic taste. Significant amounts of CO2 are released at this step. Once all the O2 is used up, yeast start growing anaerobically

Fermentation• For ale production saccharomyces cerevisiae is inoculated and for lager production saccharomyces uvarum is inoculated.• As fermentation proceeds specific gravity is decreased due to utilization of

carbohydrate by the yeast• There is production of ethanol and other compounds with density less than

water• CO2 is also evolved during fermentation which is utilized for carbonation• When yeast settles down, the beer obtained is called green beer which is

subjected to another storage tank having temperature 0-2°C. This stage is called as facing

Biochemicalpathways

Fermenter Design• Cylindroconical fermenters are used, as they allow easy separation of

yeast once they are flocculated

Yeast removal and Recovery of BEER

• When the desired ethanol concentration is reached (3-9%), the yeast are flocculated• Isinglass, Kappa carrageenan and Irish

moss can be used to aid this process of flocculation

Aging• Beer is stored at lo temperature

(<0°C)• For 2 days• Polypeptides, polyphenols and

residual yeast from flocs called chill haze, settling down – this is removed in next step

Clarification and adjustment• Coarse filtration uses diatomaceous earth or perlite to remove most

particles• Fine filtration uses a cellulose filter sheet to remove finer particles• Adjustments made to carbonation level by adding/removing CO2

• Adding color like caramel to correct color defect• Adding hop products to correct bitterness and enhance foam• Adding de-aerated water to correct final alcohol strength

Pasteurization and Packaging• Flash pasteurization uses

temperatures of 71.5-74°C for 15-30 sec for beer to filled in large containers• Large containers includes kegs, casks,

bulk tanks• Small packs like bottle and cans• Tunnel pasteurization carried out by

running beer-filled bottle/ can under hot water spray inside a tunnel at 60°C for 30 mins

BEER SPOILAGE• Spoilage causing bacteria: lactic acid bacteria, acetic acid bacteria,

Zymomonas anaerobia, Pediococcus cerevisiae• Spoilage causing yeast: Saccharomyces diastaticus, Candida lambica,

Dekkera intermedia

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