BREWING WITH VARIOUS ADJUNCTS
BANGKOK BREWING CONFERENCE 2011
Christoph Kunzmann, CSA [email protected]
15th June, 2011
Motivation of adjunct inclusion
Processing of various adjuncts
Corn / corn starch / rice
Sorghum
Barley
Conclusion
TOPICS
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Corn and Corn Starch (35%)
Rice (20%)
Barley (15%)
Other (10%)
Syrups (20%)
One ton of maltose syrups provides the
same amount of saccharides as 1.15
tons of barley
Corn, rice and barley are the dominating adjuncts the choice of adjunct is driven by various factors
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CORN Cost Taste Availability
SYRUPCapacityCostColour
RICE CostTasteQualityCapacity
BARLEYCostLocal raw materialShortage of maltTaste wise closest to maltQuality
Source: Novozymes’ market intelligence
Processing of Adjuncts
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Cereal Cooking Infusion MashingSaccharified
Adjuncts
Penetration of adjuncts
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Penetration of adjuncts As % of beers produced in the region PenetrationAs average % of
adjuncts included in the recipeRegion Mashed-in
barley and wheat Cereal-cookedcorn and rice Syrups
Central & Western Europe 10 5 0 5-10
Eastern Europe 30 10 15 25
China 10 45 20 45
South East Asia 5 25 10 20
Latin America 10 30 25 25
North America 0 35 30 25
Source: Novozymes’ market intelligence
Corn &corn starch
Rice
Adjuncts are widely used around the world
Usage levels vary in the different regions as well as the choice of adjuncts
0
50
100
150
200
250
300
350
400
Malt, Europe
Barley, malting, Europe
Barley, feed,
Europe
Corn, Europe
Barley, feed, US
Corn, US Corn, Asia Rice, China Sorghum Africa
Raw material prices (EUR/t)Average 2010
Overall, cost is the strongest driver for the use of adjuncts, with corn and barley in particular representing significant cost reduction potentials
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Adjuncts where the starch has a high gelatinization temperature need to be separately cooked and liquefied
Starch granules swell
Viscosity increases
Starch gelatinizes
Then the enzyme can act
Gelatinization of corn
40
50
60
70
80
90
100
110
0 15 30 45 60 75 90
°C
Saccharification
Proteolysis
Transfer to lauter tun
52 °C
65 °C72 °C
78 °C
The starch gelatinization temperatures of some adjuncts, namely
Corn starch (GT of 62–75 oC)
Rice starch (68–85 oC)
Sorghum (70–78 oC)
... are above the inactivation temperature of the malt beta-amylase and consequently they need to be gelatinized before saccharification
Min
Typical mashing regime for cereal-cooked rice or corn
corn or rice is gelatinized and then liquefied by a thermostable alpha-amylase in a cereal cooker
70 °C
65 °C
85 °C
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Selecting the right amylase for cereal cooking
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A thermostable amylase is required
Comparison of the thermoactivity profile of malt alpha-amylase and a typical industrial liquefaction
amylase
Other important features
Viscosity as a function of pHA broad pH profile is desired
DE (%) at 88 oC. High efficiency at temperatures around 90 oC is preferred
Standard amylase (Termamyl)
Improved version(Termamyl SC)
Standard amylase (Termamyl®)
Improved version (Termamyl SC)
Vis
cosi
ty, f
allin
g ba
ll (s
ec)
Dex
trose
Equ
ival
ents
%
Quick-test for monitoring of liquefaction in practice
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DE = Ratio of reducing sugars in percent.
Calibration of LDA –
Kit with osmometer (or Fehling titration)
› optimal enzyme utilization through LDA-Kit.
Adjunct Brewing of the Future (high gelatinizing adjuncts)
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Sugar profile without proper enzymes leads to insufficient saccharide levels.
Sugar profile with experimental enzyme blend.
Background Challange
Tem
p.
Time
52°C
62°C72°C
MaltTgel 62-64°C
AdjunctTgel 70-78°C
Energetical improvement and OPEX/CAPEX reduction.
Simplification and shortening of mashing.
Debottlenecking.
Flexible adjunct use in infusion mashing.
.
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→
resulting attenuation levels (ADF%)
theo. ADF %= fermentables % * 0.9 / 0.81 (0.9 = empiric value sugar →
extract) (0.81 RDF to ADF)
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In general acceptable FAN levels for high adjunct inclusions. Can be highered by introducing a 52°C mashing step or an additional protease.
Sensory Analyses:
Wort/Beer Quality (rice / corn in infusion mashing)
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Rice/Corn as Adjunct – FAN Levels
Grouping of amino acids (aa’s) grouped in relation to how well yeast can utilize and absorb the aa:
A: Fast
B: Intermediate
C: Slow
D: None
50% of maize/rice inclusion results in a comparable amino acid profile of the FAN as a 100% WM malt.
FAN Levels
SORGHUM Brewing
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Processed malted and
un-malted
Processable in any ratio up to
rd 70% in LT
Processable in any ratio up to
100% in MF
Several proteases
Xylanases
Glucanases
Alpha-Amylases
Processable with combination
of Cerezyme® Sorghum and
Fungamyl® BrewQ
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SORGHUM brewing
Mix & mash Brew & blend
The standard solution for barley brewing
Malt and barley are mixed and mashed together
Other adjuncts can be added as cooked adjunct or syrup
Typically the barley inclusion is 15–35%
The requirement of the enzyme system increases as the barley inclusion increases
Two strategies for brewing with barley
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Separate mashing and fermentation of malt and 85–100% barley
Blending to the target barley:malt ratio
Other adjuncts can be added in any of the mashings
A flexible solution where the malt- and barley- based brews can be optimized separately
Can also be applied for a 100% barley beer
This solution was enabled by the Novozymes Ondea® Pro technology launched in 2010
Attenuation is ensured through a synergistic action between
Endogenous barley beta-amylase
Exogenous added pullulanase and alpha-amylase
The fermentable amino acids are provided by a synergistic action between
Endogenous exopeptidases
An added protease
Good lautering with a clear wort is provided by a combination of well- adjusted mills and
A filtration enzyme system including both beta-glucanase and xylanase components
A lipase to ensure wort clarity
The Novozymes Ondea® Pro enzymatic solution for brewing with up to 100% unmalted barley
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The synergies between the enzymes are ensured by
A three-temperature step-infusion mashing profile
pH 5.6–5.8
Time
54 °C / 30 min
64 °C / 45–75 min
78–82 °C / 10 min
Temperature
Mashing profile
The barley must be food grade
according to local regulations
It is not necessary to use spring
barley matching malting specifications
Parameters especially necessary for a
successful malting process (e.g.,
germination energy, water sensitivity,
relationship between cytolytic and
proteolytic degradation) are less
important
The Novozymes Ondea® Pro brewing concept allows the strict malting barley specifications to be broadened
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The barley performance can be
checked using a barley quality test,
which is a modified Congress mash
with enzymes, measuring turbidity,
throughput, FAN, sugar profile
(HPLC), viscosity, and pH
The barley’s endogenous enzymes
(exopeptidases and beta-amylase)
must be active. So far only one
barley sample has shown
insufficient activity
100% barley wort can be processed with the same or lower viscosity than for malt wort
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1
1.5
2
2.5
3
3.5
50 60 70 80 90 100
mP
a*
s
% Barley
Wort viscosity as a function of barley inclusion (%)
no enzyme 2 kg/t Ondea® Pro
Viscosity in mPas (12% oP base)
N= Ave- rage
Min Max Spec.
Total 36 1.52 1.42 1.82 1.60
0.2 18 1.50Adjust:N =10.8 18 1.55
The wort viscosity in lab-scale mashing trials was measured at different barley inclusion levels with
and without the addition of Novozymes Ondea® Pro
The viscosity-reducing component
The viscosity reduction is ensured by the choice of the right xylanase and beta-glucanase
Barley specification test
Only one sample was out of specification
Viscosity is usually not a limiting factor in the selection of grain
The turbidity-reducing component ensures low turbidity and facilitates lautering
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The turbidity-reducing component Barley specification test
Almost all critical samples are obtained when analyzing coarse grist
High turbidity can be solved by the addition of 5–15% malt or by a higher enzyme dose
020406080
100120140160
Barley Barley with lipase
NTU
Turbidity after lautering
Lipase added to laboratory mashing. The turbidity was measured during filtration/lautering
The lipase used reduces the turbidity
of the wort to regular standards
The free fatty acids in the mash are at the same level as for malt with an expected similar amount of lipid oxidation products
Wort turbidity
N= Ave- rage
Min Max Spec
Total 36 33 2 222 80 NTU/20 EBC
0.2 18 24AdjustN=30.8 18 41
Synergy with barley peptidases provides good yeast performance
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0123456789
10111213
0 2 3 4
mg F
AN
/l/P
lato
kg Ondea® Pro per ton of barley
Without inactivation With preinactivation of barley enzymes
Novozymes Ondea® Pro’s proteolytic component works in synergy with the endogenous enzymes of barley
This is demonstrated by a comparison between the effect of Ondea Pro on barley with and without inactivation of the endogenous enzymes
Barley wort needs only 9 mg FAN/L/Plato to ensure good fermentation
The inactivation of the endogenous enzymes was done by a heat treatment at 75 °C for 30 min The mashes were carried out at 50 °C
Barley wort produced with Novozymes Ondea® Pro has a significantly higher amount of fast-absorption amino acids
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0%10%20%30%40%50%60%70%80%90%
100%
Malt wort Barley wort
D
C
B
A
The amino acids are often
divided into 4 groups according
to their absorption by the yeast
cell
The amino acid profile of 100%
barley wort differs from that of
malt wort
The barley wort contains
relatively more of the easy-to-
ferment amino acids and
relatively less of the harder-to-
ferment amino acids, especially
proline
Average of 10 barley samples with the malt from the corresponding barley
Relative amino acid composition of malt and barley wort according to amino acid fermentability groups
100% barley wort shows comparable fermentation performance with less FAN
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Lab fermentation of 12 oP malt wort and barley wort (made with Ondea® Pro). Fermentation temperature 12 °C, Yeast strain W34/70
The FAN recommendations for malt brews are 10-18 mg/l/Plato
The FAN from 100% barley wort is lower; 9-14 mg/l/Plato
The barley worts have good fermentability
This leads to less unfermented FAN at the end of the fermentation
The pullulanase ensures around 70% RDF with a high maltose sugar profile
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The starch is degraded by a synergistic action between the added pullulanase and alpha-amylase and the beta-amylase from the barley
The selected pullulanase is especially essential for the attenuation performance
Sugar profileExperience from successful pilot and plant trials
Glucose and fructose 5–10%
Maltose 45–60%
Maltotriose < 15%
Dextrins (DP4+) < 22%
Unique pullulanase added
Alpha- amylase added
Barley beta- amylase
StarchFermentable sugars
Glucose
Maltose
545658606264666870727476
52545658606264666870
0 1 2 3
RD
F
Maltose and RDF as a function of enzyme dose
Maltose % RDF%kg Ondea® Proper ton of barley
Results from lab-scale mashing trials
The gelatinization temperature influences the starch degradation and the level of dextrins
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Correlation between the dextrins and the gelatinization temperature measured by RVA
Dextrins (DP4) as function of the gelatinization temperature of grains
Correlating attenuation Barley specification test
The final attenuation can be adjusted via the dosage and the duration of the 64 °C rest
High gelatinization temperatures reduce the amount of fermentable sugars and are hard to adjust
Dextrins (DP4+) as % of total sugar profile
N= Ave- rage
Min Max Spec
Total 56 21.3 14.8 29.7 22
0.2 18AdjustN=70.8 18
Linear Fit
Barley Quality Test barley specification
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Congress mash with a dose of 2 kg/t Novozymes Ondea® Pro on define mash profile
Fine grist for mash filter application (0.2 mm)
Coarse grist for lauter tun application (0.8 mm)
Sample database
Worldwide we tested more than 100 barley samples and conducted over 50 pilot and industrial trials
As the database for the barley quality test we used 18 dedicated barley samples
Parameter Unit Standard Adjust Reject
Extract °P 14–15
Dextrins (DP4+)
% < 22 < 27 > 27
Gelatinizationtemperature
°C < 64.5 < 67 > 67
Viscosity mPas < 1,560 < 1,600 > 1,600
FAN mg/L/°P > 9 7–9 < 7
Total protein % 10–13 < 10
pH 5.7–5.9 > 6
Turbidity NTU < 80 > 80
Filtrationperformance
ml after 10 min
> 50 < 50
Market response to beer from Ondea brewing
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Breweries impressed by variety and taste
High scores in testing
Consumers like taste
No beer defects
Excellent foam
Good shelf life
Confirming..
Brewmasters can make desired beer type and quality
New beer claims are possible
Adjuncts are widely used, with corn, rice, and barley being the global dominant adjunct. Sorghum is broadly used in Africa.
The penetration of adjuncts is mainly driven by cost and availability, but quality parameters also play a role.
The adjunct penetration is being facilitated by the development of enzyme technology.
Corn and rice are currently cooked and liquefied with thermostable amylases as these starches have high gelatinization temperatures. Future developments are expected to enable mashing-in of corn and rice after infusion mashing steps.
Ondea Pro technology enables brewing with up to 100% barley; this technology is based on a synergy between the endogenous enzymes of barley and a complex enzyme mixture.
The innovative effort of enzyme suppliers is likely to continue, facilitating brewing with the inclusion of different adjuncts for cost savings as well as product development utilizing the different quality attributes of the adjuncts.
Conclusion
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NOVOZYMES PRESENTATION30 6/15/2011
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