Note: Descriptions are shown in the official language in which they were submitted.
1336271
A process for the production of beer
The invention relates to a process for the
production of beer by partially replacing malt with a
starch-contAining mixture, a so called secondary frac-
tion or fraction B obtained as a side fraction from a
barley starch process, as such or in the form of a
syrup.
Beer is conventionally made from barley. In
general, barley is malted mainly with the purpose of
forming enzymes in germin~ting barley. In mashing, the
enzymes hydrolyze starch and other macromolecules into
water-soluble form. A generally known practice is to
replace malt with a so called brewing adjunct or at
least use it in addition to malt as a beer raw ma-
terial. Suitable brewing adjuncts include maize, rice,
barley, sugar and various syrups. A brewing adjunct to
be used in the production of wort, such as maize, is
usually mashed (hydrolyzed) separately from the malt
mash by adding enzymes (The Practical Brewer 1977, ed.
H.M. Broderick). Prehydrolyzed products can be mixed
with the malt mash, and syrups can be added to the
wort at the cooking step.
It has now been found that malt can be partial-
ly replaced with a starch-cont~ining mixture obtained
as a side fraction from a barley starch process while
the mashing water is partially replaced with the water
contained in the mixture. The pH of the mixture is
low, so the normal addition of acid at the mashing
step is not necessary. Malt usually contains an ex-
cess of amylolytic enzymes, whereby even 30% of the
malt can be replaced with a starch fraction at the
mashing step without enzyme addition. If necessary,
glucanase or cellulase enzymes can be added for im-
proved filterability.
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It is also possible to produce barley syrup
from the above-mentioned starch-contAining mixture in
a manner known per se by liquefying, saccharifying,
filtration and concentration. The resultant barley
syrup can also be used as raw material in a brewing
process. An advantage of barley syrup is that it has
good storage properties and can be added to the wort
at the beginning of the fermentation step. This in-
creases the capacity of the brewery and makes it easy
to increase the concentration of the wort in a so
called high gravity process.
FI Patent 56552 describes a process for the
production of pure starch from barley. Also, a process
is known for the production of starch from wheat, in
which pure fraction A contAining large starch granules
and fraction B contAining more impurities and small
starch granules can be separated (see Selley & Wookey,
Glucose Syrups and Related Carbohydrates, ed. Birch,
Green & Coulson, Elsevier Publishing Company Ltd.,
London, 1970). In the barley starch process, it is
also possible to separate fractions A and B on the
basis of the purity of starch. The total yield of the
process is improved with respect to starch when frac-
tions A and B are separated, as compared with the sep-
aration of a single fraction contAining pure starch.
The production of syrup from cereals for use in
fermentation is known per se (GB Patent 1 203 623). It
is also known to use various cereals and syrups in
brewing (Canales, Brewing Science, ed. J.R.A. Pollock,
Academic Press, London, 1979).
Economically, the use of fraction B in a brew-
ing process is advantageous over malt and pure starch.
As compared with the use of barley, many technological
advantages are obtained: better dosing properties,
better filterability of wort, decreased demand for
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addition of mashing water, natural pH adjustment by
addition of an acid fraction, and more efficient
extraction. Surprisingly enough, the use of fraction B
gives beer of a very high quality and excellent taste.
Syrup manufactured from fraction B has a
greater purity than malt extract with respect to
proteins, colour, ash and polyphenols. It improves the
stability of beer and the resultant beer is lighter. It
nevertheless contains barley-originated taste and
flavour substances typical of beer. The sugar
composition of the syrup can be adjusted as desired. A
typical sugar composition resembles that of conventional
wort, i.e. contains mainly maltose.
The use of the starch-containing mixture of
the invention in a conventional process does not require
any substantial modifications or further investments.
The use of the mixture as beer raw material is a major
economical and technological advantage when the starch
plant is located in the immediate vicinity of the
brewery, e.g., in an integrated barley starch/starch
sweetener/soft drink/beer factory.
In accordance with the present invention,
there is thus provided a process for the production of
beer by mashing malt to obtain a mash, extracting a wort
from the mash and fermenting the extracted wort. The
process of the invention is characterized by:
a) adding to the mash during mashing a mixture
obtained as a side fraction from a barley starch process
and containing
protein 2 to 15 weight % on a dry
substance basis,
starch 60 to 98 weight % on a dry
substance basis, and
r~
3 a 1 3 3 6 2 7 1
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water 60 to 85 weight %, and
having
a pH of 3.5 to 6,
in an amount of 5 to 50% by weight based on the total
weight of the extracted wort; or
b) adding to the wort prior to fermentation or at
the beginning thereof a barley syrup containing
protein 0.1 to 3 weight % on a dry
substance basis,
fermentable sugars 60 to 90 weight % on a dry
substance basis, and
water 25 to 35 weight %, and
having
a pH of 3.5 to 6,
in an amount of 5 to 60% by weight based on the total
weight of the extracted wort.
According to a preferred embodiment of the
invention, the mixture obtained as a side fraction from
a barley starch process has a pH of 4 to 5 and is added
in an amount of 10 to 30% by weight, based on the total
weight of the extracted wort.
The composition of the mixture added may vary
remarkably with the process conditions and mode of
operation. Essential is that fraction A containing
starch as pure as possible (more than 98% on a dry
substance basis) and fraction B containing more
impurities are separated separately. The proportions of
fractions A and B may also vary; a typical proportion
being 70% of starch A and 30% of starch B, calculated on
a dry substance basis.
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ExamPle 1
Production of a barley starch process side
fraction
1000 kg of dry barley was dehulled with a re-
sultant weight loss of 10~. Resultant barley was
soaked for 12 hours in water having a temperature of
30C (approx. 1000 1), and then the kernels were
ground by stone mills and the slurry was screened by
means of a screening device in a manner described in
FI Patent 56552. After screening a starch-cont~;ning
fraction was separated in a hydrocyclone into starch A
having a greater purity and starch B containing pro-
teins and other slowly settling substances. Starch
fraction B was concentrated by centrifugation.
The substance balance of the process appears
from the following formula:
Barley 1000 kg (dry substance)
~ barley hull 100 kg
> screening surplus 320 kg (d.s.)
~ ~ starch fraction A 400 kg (d.s.)
Starch fraction B
140 kg (dry substance)
Analysis of starch fraction B:
Protein 11.5% on dry substance
Starch 67.1% on dry substance
Water 79.3%
pH 4.6
Reducing sugar (DE) 5% (DE=dextrose equivalent)
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Example 2
Production of beer from fraction B obtained
from a barley starch process
Starch fraction B was added to the brewing pro-
cess at the mashing step so that about 25% of the
wort extract originated from the starch fraction and
the remaining 75% from the malt.
100 1 of wort was prepared as follows:
Malt 14.4 kg
Starch fraction 16.8 kg (20.7% of d. s.)
Calcium chloride 30 g
Water 85 1
The malt was crushed and mixed with water sim-
ultaneously with the starch fraction. The mash was
stirred and its temperature was risen by about 1C/min
with the pauses held as follows:
50C 30 min
63C 20 min
72C 30 min
78C 10 min.
After mashing, the mash was filtered by means
of a vessel of the same type as the lauter tun used in
breweries. Solid matter was separated from soluble ma-
terial and washed at three steps with 78C water.
The resultant wort was introduced into a cook-
ing vessel and was cooked and flavoured with hops ac-
cording to a conventional brewing process. The sedi-
ment formed during the cooking step was separated in a
whirlpool; the wort was cooled and aerated for fermen-
tation.
Analysis of wort:
Extract concentration11.0% by weight
Alpha-amino nitrogen 204 mg/l
Bitterness 31 EBU
Colour 4.5 EBC
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pH 5.4
Conventional bottom fermenting layer yeast was
added to the wort (VTT-A-63015, Technical Research
Centre of Finland, Biotechnical Laboratory). The main
fermentation took place at 10C and lasted seven days,
whereafter a secondary fermentation followed (10C, 4
weeks). The beer was tested for its quality by ana-
lytical and sensory evaluation.
Analysis of beer:
Alcohol 3.70% by weight
Extract
apparent 2.15~ by weight
real 3.85% by weight
Degree of
fermentation
apparent 80.5~
real 65.0%
pH 4.45
Colour 3.5 EBC
Bitterness 22 EBU
Example 3
Production of barley syrup
The pH of fraction B obtained from a barley
starch process (1000 l, 20% of dry substance) was
risen to 6.2 by a 3% potassium hydroxide solution, and
fraction B was liquefied in a jet cooker at 100C for
five minutes and thereafter in a liquefaction reactor
at 85C for two hours. The enzyme used was a thermo-
stable alpha-amylase (SPEZ~ME* AA 20,manufacturer Cul-
tor Ltd) at a dose level of 1 l!tn on a dry substance
basis. After liquefaction the amount of the reducing
sugar (DE) was 20%.
Protein sediment was removed from the resultant
slurry by centrifugation and the surplus was cooled to
58C. The pH was adjusted to 5.7. Beta-amylase derived
* Trade mark
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from barley ( SPE~YME BBA 1500, manufacturer Cultor
Ltd) was added. Saccharification time was 24 hours.
The syrup was filtered by means of a vacuum
drum filter through a layer of diatomaceous earth, and
was then passed through a cation exchanger (DOWEX 88,
manufacturer Dow Chemicals) and through an anion ex-
changer (DOwEX* 66, manufacturer Dow Chemicals). The
syrup was concentrated by evaporation.
Analysis of the syrup:
Dry substance 69.1%
Reducing sugar (DE) 48.8%
pH 4.2
Colour 1295 ICUMSA
Ash 1.0% on d.s.
Protein 0.2% on d.s.
Glucose 22.7% on d.s.
Maltose 43.1% on d.s.
Maltotriose 13.9% on d.s.
Example 4
Production of beer from barley syrup
In the experiment, 49~ of the beer extract was
replaced with the barley syrup described in Example 3.
Wort was prepared by mixing crushed malt (10.5
kg) with water (50 1) and by mashing the solution in
accordance with the following temperature program:
48C 15 min
72C 50 min
78C 10 min
The mash was filtered as usually and the wort
was introduced into a wort copper to which barley
syrup, too, (10.2 kg, 69.1% of dry substance) was
added. As compared with conventional all-malt wort,
hops were added to the wort copper in an amount of 70%
with respect to the bitterness concentration. After
the cooking the precipitate was separated in a whirl-
* Trade mark
- 133627l
pool, the wort was cooled, aerated and yeast was
added for fermentation.
Composition of the wort was as follows:
Extract 12.3% by weight
Bitterness 28 EBU
Colour 7.5 EBC
pH 4.8
Free alpha-amino nitrogen121 mg/l
Coagulating nitrogen 21 mg/l
Fermentation rate
apparent 86.1%
real 69.7%
The fermentation step was carried out similarly
as in Example 2. Both analytical and sensory evalu-
ation showed that the qualities of the finished beer
were equal to conventional all-malt beer.
Analysis of beer:
Alcohol 4.20% by weight
Extract
apparent 2.15 "
real 4-05 "
Degree of fermentation
apparent 82.5%
real 66.5%
Bitterness 14 EBU
Colour 6.0 EBC
Sensory evaluation:
Mark 4 (very good; scale from 1 to 5)
