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Instrumentation and Control 2015

MALT PRODUCTION Page 1

INTRODUCTION

Malt is a natural food product that results from the transformation of a cereal grain. Barley is

the grain most used today, but wheat can also be used for making "white" beers. Malt is the main

ingredient used in brewing beer, along with water, hops, and yeast. Malts high enzyme content enables

the production of simple sugars and amino acids from the starch in the proteins. Thus malt is the source

of sugar, which is then transformed into alcohol and carbon dioxide gas in the beer. It also contributes

color and taste to the beer.

The main use of malt today is in brewing, for making beer. It is also used in distilling, to make

whisky. It can also be used as a component (as malt extract) in food manufacture (in making bread,

cereal bars, and energy drinks). Because of the products energetic and enzymatic potential, other uses

for it are emerging or could be developed. Various species of barley, both winter and spring barleys, may

be used in malt production. For a given species, different varieties are used.

The industry nowadays uses a modern technology to keep the best and high quality of the

products. In each of the process, Instrumentation and Controls manipulate the overall progression of

the manufacturing to ensure proper amount of mass or volume, temperature, speed, stress, force,

pressure, flow rate, movement, density and any other common measurement.



Brief Discussion of Old Malt Production

Step 1: The earliest known malt house was a simple structure located at the bottom of a hill

or mountain adjacent to a stream, which could supply low temperature water by gravity. These houses

had massive stone walls with floors of stone or mortar. Small windows set in these heavy walls were the

only means of ventilation. Barley would be received into the top of such a house, and dropped into deep

cisterns for steeping. From there, it would be deposited in a pile onto the stone floor of the house for

germination.

Step 2: As growth commenced and heat was generated, the malt was shoveled from this pile

and spread in a thin bed toward the front of the room. Any necessary further cooling could only be

accomplished during the cool evenings or night hours when experienced workmen shoveled the first

thin layer of malt forward to another spot on the floor, throwing it into the air, and allowing it to fall in a

thin shower. The proper moisture was applied by the simple old-fashioned sprinkling can.

Step 3: The process of shoveling to control temperature gradually moved the bed from the rear

to the forward end of the floor, and as each successive steep was deposited onto the floor from the

steeping cistern, it followed its predecessor down the length of the floor. In this way there were on each

floor, a number of beds of malt in varying stages of germination. When the malt reached the front of the

floor, its germination was completed, and it was shoveled by hand through a trap door into wheel

barrows beneath, by means of which it was transported to the kiln for drying.

Step 4: The kiln, at that time, was simply a room with a tile floor, under which were crude

furnaces. The ceiling of the room assumed the shape of a high tapered dome, in which was located a

large duct or chimney to pass off the moist hot air. After the germinated malt was spread on the floors,

the fires were started, and drying accomplished by simple heating. The malt was agitated from time to

tie by a shovel. Later the tile floors were perforated, so that the combustion gases could pass directly

through the grain.

Step 5: All ventilation was by natural draft, and, of course, was influenced greatly by weather

conditions. The art of malting under those conditions was one of the highest. The maltster personally

controlled all processes, and through highly developed manual skill maintained proper conditions. He

alone checked the temperatures, mostly by sense. It was he who determined when more moisture was

required. In short, it was exclusively his skill and experience which brought out a finished malt of the



proper character. Because temperature controls were dependent on atmospheric conditions, malting at

that time was confined to the cool months, which averaged about five months per year. During the rest

of the year, the house was completely closed. Naturally, with this short production season, volume was

very definitely limited.

Brief Discussion of Modern Malt Production

The basic principle of these early malt houses again prevailed for centuries, but always with the

search for new means of increasing production. It was not until the advent of steam, and later electrical

power, that any major change occurred in the malting process. Undoubtedly, someone at some time

drove ventilating bellows by water power in an effort to continue malting during the warmer weather,

but there is no definite record of such device.



Step 1: Mixing of Barley and Rye Malt, as the raw materials for Malt Production, from their

storage down to the soaking vessel.

Malted Barley Rye Malt

Barley and Rye Malt Composition

Rye Malt

Lovibond Flavor Unique Characteristics/Applications

3.7 Rye

DP 105. Another uniquely-Briess specialty malt, Rye Malt isn't

just for rye beer styles. Although brewing a traditional rye beer

is exceptionally rewarding, try adding Rye Malt to light- and

medium-colored and flavored beers for complexity. Or fire up

your new distillery and use it to make a single malt whiskey.

FLAVOR & COLOR CONTRIBUTIONS

Malt Style: Rye Malt

Flavor: Spicy Rye

Color: Golden leaning toward orange hues

CHARACTERISTICS / APPLICATIONS

An often overlooked malt, Rye Malt has a unique spicy rye flavor for the production of great rye beer.

In addition, Rye Malt can help build flavor and develop complexity in many beer styles, all the way from

medium flavored lagers to dark ales.

We recommend you start light. Use in 5% increments until your desired flavor is achieved.



Rye Malt is fully modified. It performs well in a single temperature infusion mash if used at less than

20% of total grist.

Hulless and with a high beta glucan content, Rye Malt can result in a sticky mash and slow lautering.

We recommend adding rice hulls when usage levels approach 20% and supplementing with a

betaglucanase enzyme above 35% for manageable lautering.

1-3% Adds dryness and a touch of spicy rye flavor and interest to many beer styles, from medium

flavored lagers to dark ales

5% Rye Pale Ales, Wheat and Smoked Beers

10-35% Roggenbier (German Rye Beer), American Rye Beer

NOTE: Grains are pre-crushed in 1 lb. Bags

Malted Barley

Malted barley is the source of the sugars (principally maltose) which are fermented into beer.

The grain partially germinates, releasing enzymes in the aleurone layer (outermost layer of the

endosperm). New enzymes are created that break down the endosperm's protein/carbohydrate matrix

into smaller carbohydrates, amino acids and lipids, and open up the seed's starch reserves. The

endosperm is composed of large and small starch granules that are packed in a protein matrix. The cell

walls within the matrix holding the starch granules are primarily composed of beta-glucans (a type of

cellulose), some pentosans (gummy polysaccharide) and some protein. The degree to which the

enzymes unpack the starch granules (i.e. breakdown the endosperm) for use by the growing plant (or

brewers) is referred to as the "modification." It refers to all of the polymer-degrading processes that

occur during malting.

Barley is the worlds most nutritional crop and is recommended for beer brewing. This is

because barley contains many elements that are rich sources of health and energy for brewing yeast.

The composition of barley, including the percentage of minerals, gives a general idea about its uses in

brewing industry. Barley contains about

Starch 62 66 % Sugars 1 2 %

-glucan 3 5 % Other hemicelluloses (pentosans) 4 7 %

Cellulose 4-5 % Lipids 2 3 %



Protein 8 13 % Amino acids and peptides 0.5 %

Nucleic acids 0.2 0.3 Minerals 2 %

Other substances 5-6 %

Step 2: Soaking process of Malted Barley and Rye Malt into the soaking vessel with the addition

of water as the cleaning agent.

The process of malt production starts with dipping the grain in stainless steel tubs. The grain is

washed and soaked at the same time the soaking may last up to two days. The soaking process gives

the grain required amount of moisture and increases their vitality.

Step 3: Germination process of the soaked ingredient with a defined level of temperature.

After soaking, the grain is transferred to the germination chamber by hydrotransport.

In the germination chamber, air of necessary humidity and temperature is blown through the

grain mass. During the process of germination, the goal is to accumulate as much ferments as possible in

the grains.

Step 4: Roasting/Drying Process of the germinated ingredients from the previous process.

After germination, the grain is moved to the dryer/roaster.

The drying/roasting process is carried out, using warm air and applying specific modes of

temperature. Drying/roasting alters not only the moisture content, but also flavour, odour and aroma.

Step 5: Grounding and Cleaning Process of the roasted grains.

Dried grain (green malt) is transferred to the sprout breaking mechanism, where the sprouts are

removed, as they impart an unpleasant taste to beer.

The dried grain is cooled, weighed and transferred to elevator bins. After a period of ripening,

they become an ingredient for making good beer light malt.

Step 6: Pumping process of the malt into the large storage silos for storage and preparation for

delivery.

Step 7: Extraction of Beer from the storage tanks for the delivery and distribution to clients.



The Instrumentation and Control used for:

Mixing of the raw materials:

MicroTREK - (Guided Microwave) : LEVEL TRANSMITTERS

THERMOPOINT TM - (Multipoint temperature transmitter) : TEMPERATURE METERS

NIVOROTA-(Rotary Paddle): Level Switches

Soaking process for the mixed barley and rye.

EchoTREK for liquids - (Ultrasonic Compact) : LEVEL TRANSMITTERS

NIVOSWITCH for liquids - (Vibrating Fork) : LEVEL SWITCHES

NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL TRANSMITTERS

Germination process.

THERMOCONT TT - (Temperature transmitter) : TEMPERATURE METERS


Roasting process.


THERMOCONT TT - (Temperature transmitter) : TEMPERATURE METERS

Storing the malt product into vessels before to distribute to its customer and buyers.



NIVOROTA - (Rotary Paddle) : LEVEL SWITCHES

NIVOCONT R - (Vibrating Rod) : LEVEL SWITCHES



Tables References


FEATURES

APPLICATIONS

SPECIFICATIONS

Two-wire TDR Technology Digital communication High accuracy: 5 mm High pressure range High temperature range Extremely low dead band Large Dot-Matrix graphic display Local programming feature Text-based menu system Plastic coated stainless steel probes (PFA, FEP, PP), Aluminium and plastic housing Wide range of probes Explosion-proof models

Level, volume measurement Liquids, powders and granular mediums with Er>1.4 Medium with turbulent surface, dense dust, vapour or pressurized gas layers above the product surface For all tank shapes, for narrow vessels Heavy industrial applications

Power supply: 18-35 V DC Accuracy: 5 mm Medium temperature: -30...+ 200 C Pressure: max. 40 bar Measuring range: up to 24 m Output: 4-20mA, loop powered Communication: HART Process connection: 1'' 1 1/2'' or flanges Ingress Protection:IP 65 ATEX approval: II 1 G Ex ia IIC T6...T3 II 1 G Ex ia IIB T6...T3 II 1D iaD A20/A21 IP65 T100C



THERMOPOINT TM - (Multipoint

temperature transmitter) :

TEMPERATURE METERS

FEATURES

APPLICATIONS

SPECIFICATIONS

2-wire multipont temperature Transmitter Max. 30m probe length Max. 15 sensors Max 35kN tensile force Digitally addressed sensors HART communication Ex ia or Dust Ex protection APPLICATIONS

For normal and hazardous materials Temperature measurement of liquids ,or powdered, granular or free flowing solids Grain industry Feed industry Food industry

Power supply: 12-36 V DC Measuring range: For liquids: -40C.+125C For solids: -10C.+85C Accuracy: -10C...+85C: 0,5C -40C...-10C and +85C...125C: 2C Max. tensile force: 35kN Probe length: 5-30m Output: HART Protection: IP67 Approval: ATEX Ex II 1 G Ex ia IIB T6..T4 ATEX Ex II 1 D Ex iaD A20/A21 T85C IP67 ATEX Ex II 1 D Ex ta/tb IIIC T85C Da IP67



NIVOROTA - (Rotary Paddle) : LEVEL SWITCHES

FEATURES

APPLICATIONS

SPECIFICATIONS

Two-wire TDR Technology Digital communication High accuracy: 5 mm High pressure range High temperature range Extremely low dead band Large Dot-Matrix graphic display Local programming feature Text-based menu system Plastic coated stainless steel probes (PFA, FEP, PP), Aluminium and plastic housing Wide range of probes Explosion-proof models

Level, volume measurement Liquids, powders and granular mediums with Er>1.4 Medium with turbulent surface, dense dust, vapour or pressurized gas layers above the product surface For all tank shapes, for narrow vessels Heavy industrial applications

Power supply: 230/120/24 V AC, 24 V DC Temperature: - 30C to 200C Pressure: max. 3 bar Output: SPDT Relay 250V AC, 15A Process connection: mouniting plate, or BSPT 1'' / 11/2'' Ingress protection: IP67 Ex marking: ATEX II 1/2 D Ex tb IIIC T__C IP67 Da/Db



EchoTREK for liquids - (Ultrasonic Compact) : LEVEL TRANSMITTERS

FEATURES

APPLICATIONS

SPECIFICATIONS

2- or 4-wire compact transmitters Non-contact level metering Narrow 5 beam angle Fully temperature compensated Excellent signal processing via QUEST+ software PP, PVDF, PTFE, stainless steel or foam faced Transducers Optional field indicator and plug-in programmer /display Optional switching relay Built-in DataLogger Plastic or aluminium housing * HART + * PROFIBUS PA + Secondary lightning protection Explosion-proof models

Almost any liquids

Level, volume and open channel flow measurement

Reliable measurement in challenging applications such as vapour/fume, stirrer, foam with liquids

Power supply: - 2-wire: 12.5-36V DC - 4-wire: 24 V AC/DC; 230 V AC 11.4-40V DC / 11.4-28V AC Ambient temperature: -30 C to +70 C Medium temperature: -30 C to +100 C Pressure: 0.3 - 3 bar Measuring range: -0.2 to 25 m for liquids Outputs: 4-20 mA, relay, HART, PROFIBUS PA Protection: IP 67 Approvals: ATEX II 1 G EEx ia IIB T6



NIVOSWITCH for liquids - (Vibrating

Fork) : LEVEL SWITCHES

FEATURES

APPLICATIONS

SPECIFICATIONS

No moving parts Self-cleaning for most media High immunity against vibrations Stainless steel and coated (PFA) probes Solid rod extension up to 3 m Various output configurations Selectable density High or low fail-safe mode Plastic, aluminium or stainless steel housing Explosion-proof models

Most liquids with min. 0.7 kg/dm3 density and max. 10,000 mm2/s viscosity Corrosive, thick, turbulent, flowing liquids

Power supply: 20-255V AC, 20-60V DC Ambient temperature: -40 C to +70 C Medium temperature: -40 C to +130 C Medium pressure: max. 40 bar Process connection: 1'', 11/2'' or flanges or hygienic fittings Output: 1 or 2 SPDT relays, 2-wire AC or DC, transistor (PNP, NPN) Ingress protection: IP 65/68, IP 67 Ex marking: -ATEX II 1 G Ex ia IIC T4...T6 Ga -ATEX II 1 G Ex ia IIB T4...T6 Ga Approvals: -Germanischer Lloyd (GL) only for Compact type (RF-400) instruments



NIVOPRESS D - (Hydrostatic level /

pressure) : LEVEL TRANSMITTERS

FEATURES

APPLICATIONS

SPECIFICATIONS

Two-wire compact transmitter Stainless steel diaphragm Measuring range: 0.1-400 bar, -1 bar Scalable analogue output Programmable damping Level and pressure management Secondary lightning protection High overload capability High accuracy



THERMOCONT TT - (Temperature transmitter) :

TEMPERATURE METERS

FEATURES

APPLICATIONS

SPECIFICATIONS

2-wire compact temperature indicator, Transmitter Integral Pt 100 probe Plug-in type indicator and programming unit Measurement range: -50 C .. +600 C Resolution: 0.1 C up to 200 C HART communication Probe length upto 3 m Aluminium or plastic housing Fully programmable Heavy duty field mountable housing Explosion-proof models

Normal and explosive mediums Temperature indication and transmission Signal transmission to large distances

Power supply: 10...36 V DC Ambient temperature: -20 C .. +88 C Medium temperature: -50 C .. +600 C Pressure: max. 25 bar Output: 4...20 mA, HART Process connection: M20x1.5, 1/2'', flange Protection: IP 65 ATEX II 2 G EEx d IIB T6-T1 II 2(1) G EEx d ia IIB T6-T1 II 1/2 G EEx d ia IIB T6-T1 II 2(1) G EEx ia IIC T6-T1 II 1/2 G EEx ia IIC T6-T1



NIVOCONT R - (Vibrating Rod) : LEVEL SWITCHES

FEATURES

APPLICATIONS

SPECIFICATIONS

No moving parts Self-cleaning for most media Stainless steel vibrating section Solid rod or flexible cable extension up to 20 m Plastic or aluminium housing Selectable density High or low fail-safe mode Selectable switching delay Dust-Ex models

Almost any granular material and powder with min. 0.05 kg/dm3 bulk density Grain, flour, plastic granules, cement, fly ash

Power supply: 20255 V AC/DC Ambient temperature: -30 C to +50 C Medium temperature: -30 C to +160 C Pressure: max. 25 bar Process connection: 11/2'' Output: relay (SPDT) or electronic switch (SPST) Protection:IP65, IP 67 (housing) Ex marking: ATEX 1/2 D tD A20/21 IP67 T*



References:

http://oregonstate.edu/instruct/css/330/five/BarleyOverview.htm

http://www.brewps.com/rye-malt-1-pound.html

http://www.probrewer.com/library/malt/the-maltingprocess/

http://www.maltosa.lt/en/production_of_malt,step.2

http://nivelco.com/egyeb/swf/malata_eng.html

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