GRAIN HANDLING, MALTING,
AND MALT ANALYSIS PART 2
BREWING + DISTILLING CENTER, INC.
MALTING LOSSES
There is a substantial loss of weight and mass when barley is
transformed into malt.
100 pounds of barley will become 80 pounds of malt as in this example:
• The original 100 pounds has a moisture content of about 12%,
making the non-water weight 88 lbs.
• Trash plus foreign grains and broken grains account for about
2% of the weight.
• Respiration as the grain germinates accounts for 6%.
• Rootlets, which are removed, account for 4%.
• Final moisture content is about 4%.
Weight as malt = 100 x .88 x .98 x .94 x .96/.96 = 81.1 lbs.
MALT QUALITY AND ANALYSISCertificate of Analysis (COA) serves two purposes:
1. To document production in the Malthouse.
2. To predict the ultimate performance in the brew house.
TERMINOLOGY ON A COA• SRM = Standard Reference Method These two terms
refer to color
• EBC = European Brewing Convention
• MC = Moisture Content
• FG/CG = Fine Grind/Coarse Grind difference
• DP = Diastatic Power
• WK = Windisch-Kolbach
• TN = Total Nitrogen
• SP = Soluble Protein
• SNR = Soluble Nitrogen Ratio
• Mealiness (%)
• Friability
SRM & EBC
FORMULAS
• SRM = (1.3546 x °L) – 0.76 (to convert °Lintner to SRM)
• SRM = EBC x 0.508 (to convert EBC to SRM)
• EBC = SRM x 1.97 (to convert SRM to EBC)
• EBC = (°L x 2.65) – 1.2 (to convert °Lintner to
EBC)
• DP °Lintner = (°WK + 16) / 3.5 (to convert Kolbach
index to °Lintner)
FORMULAS c’d
• °L = (SRM + 0.6) / 1.3546 (to convert SRM to
degrees Lovibond)
• SG = 259 / (259 - °P) -- (to convert degrees Plato to
Specific Gravity)
• °P = (SG – 1) x 250 -- (to convert Specific Gravity to
degrees Plato)
• (DBCG / 1 + MC) – 0.002) x Brewhouse Efficiency
(to give actual brewhouse yield)
FORMULAS c’d
To determine pounds of extract per barrel of wort:
(Weight of a bbl of water + degrees Plato) X the
gravity = lbs. extract per bbl
Example using 12°P wort: (259 lbs. + 12) X .12 = 32.52
lbs extract/bbl
RECIPE DESIGN
Steps to successful recipe design:
1. Choose a beer style.
2. Review style guidelines for the beer you have
chosen.
3. Set target values for original and final gravities,
IBU’s, and color.
4. Identify malt types and determine the quantities to
use.
EXTRACT DETERMINATION STEPS IN WRITING A
RECIPE
1. Decide how strong the wort should be and the final volume.
2. Compute the total extract needed in the wort, using these two values (wort & volume).
3. Adjust the value of potential extract based on brewhouse efficiency.
4. Calculate, sum, and readjust the relative extract contributions of various malts to match the needed potential extract.
For example: We want to make 10 bbls of a 12°P medium colored beer with a full malty flavor---
Malt Grist Fraction
Pale Malt 80%
Munich Malt 12%
Crystal 7.5%
Black .05%
EXTRACT TABLE
By using our formula we find that a 12°P wort contains 32.52 pounds of extract per bbl.
10 bbls X 32.52 = 325.20 pounds of extract needed for the brew
Our brewery has an efficiency of 90%, so 325.20 / .90 = 361.3 pounds of potential extract required in the grist.
Example:
Malt Grist Fraction
Pale Malt 80%
Munich Malt 12%
Crystal 7.5%
Black .05%
The extract and color values for the malts as provided on the COA are:
Malt SRM CGAI Pale Malt 2 80%
Munich malt 10 78%
Crystal 35 72%
Black 500 50%
Example:
Malt Grist Fraction
Pale Malt 80%
Munich Malt 12%
Crystal 7.5%
Black .05%
We can determine the needed extract contribution from each malt by multiplying the grist percentage by the total extract available from the lauter tun (361.3 pounds):
Malt Grist % Extract Contribution
Pale malt 80% 289.0
Munich malt 12% 43.4
Crystal 7.5% 27.1
Black 0.5% 1.81
Total 100% 361.3
To calculate the grist weight needed of each malt we divide the extract contribution by the CGAI value.
Example:
Malt Grist Fraction
Pale Malt 80%
Munich Malt 12%
Crystal 7.5%
Black .05%
CALCULATING
GRIST WEIGHT
Malt/Grist lbs. Extract Contribution CGAI
Pale Malt / 289.0 80%
361.3
Munich Malt / 43.4 78%
55.6
Crystal / 27.1 72%
37.6
Black / 1.81 50%
3.6
Total
458.1
*************************************************************
We now have a rough grist bill for our brew and can next check the
calculated wort color by multiplying the color contribution of each
malt by the total weight used.
Example:
Malt Grist Fraction
Pale Malt 80%
Munich Malt 12%
Crystal 7.5%
Black .05%
FIGURING SRM (COLOR)
Malt Grist lbs. SRM SRM•lbs.
Pale Malt 361.3 2 723
Munich Malt 55.6 10 556
Crystal 37.6 35 1316
Black 3.6 500 1800
Total 4395
The total is then divided by the total number of gallons to determine
the wort color:
4395 SRM•lbs. / 310 gallons = 14 SRM
BREWING SOFTWARE PROGRAMS
• Spreadsheet
• Beer Smith
• Brewers Friend
BEERSMITH
IN-CLASS PROJECT
We want to brew a high gravity Winterfest Ale.
We need to calculate a grain bill using the following
information and the formulas we have discussed:
20 bbl quantity. S.G. = 1.090. Brewery efficiency = 85%
Malt Grist Fraction CGAI
Pilsner malt 72% 83%
Caramunich III malt 15% 79.5%
Munich malt I 6% 82.5%
Carahell malt 3% 83%
Wheat malt 3% 86%
Carafa II malt 1% 69%
Determine pounds of extract per bbl of wort
First, we need to convert specific gravity to
degrees Plato:
°P = (SG -1) X 250 = (1.090 – 1) X250 = 22.5 degrees
Plato
Using the weight of water per bbl and the degrees
Plato we get:
(259 lbs. + 22.5) = 281.5 X .225 = 63.34 lbs. of extract
per bbl
IN-CLASS PROJECT
Determine pounds of extract needed for the brew
# of bbls X lbs. of extract per bbl = pounds of
extract needed for the brew
20 bbls X 63.34 lbs extract per bbl = 1266.8 lbs
extract needed for the brew
IN-CLASS PROJECT
Use brewery efficiency to figure potential extract
Our brewery has an efficiency of 85%
Lbs. extract needed for brew / brewery efficiency =
lbs. of potential extract required in the grist
1266.8 / .85 = 1490 lbs potential extract required in the
grist
IN-CLASS PROJECT
Figuring contribution of each malt in the grist
Multiply grist percentage of each malt X total extract
available = extract contribution of each malt.
Malt Grist Fraction Total Extract Available
Pilsner Malt .72 X 1490 = 1072.8 lbs extract contributed
Caramunich III .15 X 1490 = 223.5 “ “ “
Munich Malt I .06 X 1490 = 89.4 “ “ “
Carahell Malt .03 X 1490 = 44.7 “ “ “
Wheat Malt .03 X 1490 = 44.7 “ “ “
Carafa II Malt .01 X 1490 = 14.9 “ “ “
Total = 1490 lbs. total extract
IN-CLASS PROJECT
Calculating grist weight of each malt
Now that we know the extract contribution of each malt we need to calculate the weight of each malt using the CGAI. This is done by dividing the lbs. extract by the CGAI:
Malt
Pilsner 1072.8 / .83 = 1293 lbs. grist
Caramunich III 223.5 / .795 = 281 lbs. grist
Munich 89.4 / .825 = 108 lbs. grist
Carahell 44.7 / .83 = 54 lbs. grist
Wheat malt 44.7 / .86 = 52 lbs. grist
Carafa II 14.9 / .69 = 22 lbs. grist
Total = 1810 lbs. grist
IN-CLASS PROJECT
MILLING THE MALT
MILLS:
• 2 –Roll mills
• 6-Roll mills
GRIST CASE
MALT MILL ROLLERS
DIAGRAM OF 6 ROLLER MILL
WET MILLS
WET MILL SIERRA NEVADA, NC
IDEALLY CRUSHED MALT
Ideally crushed malt:
1. No uncrushed kernels
2. Majority of the husks split end to end with no
endosperm particles adhering
3. Endosperm reduced to a uniform small
particle size
4. Minimum of flour
IDEALLY CRUSHED MALT
PROPER MALT CRUSH