BREWING WITH VARIOUS ADJUNCTS - VLB Berlin WITH VARIOUS ADJUNCTS CORN Cost Taste Availability SYRUP...

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

BREWING WITH VARIOUS ADJUNCTS2 6/15/2011

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


CORN Cost Taste Availability

SYRUPCapacityCostColour

RICE CostTasteQualityCapacity

BARLEYCostLocal raw materialShortage of maltTaste wise closest to maltQuality

Source: Novozymes’ market intelligence

Processing of Adjuncts


Cereal Cooking Infusion MashingSaccharified

Adjuncts

Penetration of adjuncts


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


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


Selecting the right amylase for cereal cooking


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


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)


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.

.

→

resulting attenuation levels (ADF%)

theo. ADF %= fermentables % * 0.9 / 0.81 (0.9 = empiric value sugar →

extract) (0.81 RDF to ADF)


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)


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


NOVOZYMES PRESENTATION30 6/15/2011

YOU CHOOSE THE RAW MATERIAL…..

Thanks

for

your

attention!

BREWING WITH VARIOUS ADJUNCTS - VLB Berlin WITH VARIOUS ADJUNCTS CORN Cost Taste Availability SYRUP...

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