Brewing

BEER BREWING
Why brewing?
• Because everybody loves beer!
• Is the largest alcohol segment nationwide,
accounting for roughly 85% of all alcohol
volume sold in US.
CONTENTS
Overview
 Main ingredients (raw materials)
Outline of brewing process
Genetic engineering in brewing
Objectives
• Describe the importance of main raw
materials used in beer brewing
• Give an outline of the brewing process
• Explain the fate of the by-products of beer
brewing
• Discuss the impacts of genetic engineering in
brewing industry
OVERVIEW
• One of the oldest fermentation (first
archeological evidence 6000BC).
• Louis Pasteur, first to study beer production
(1850’s).
• Discovered that all fermented materials contain
yeast.
• Raw materials can sugary materials, fruit juices,
plant saps, starches-grains and roots.
• These provide carbon source.
• Basic principle- starch contained in grains (mainly
barley) is released from the grain & fermented by
yeast to an alcohol.
• Products include CO2, glycerol & ethanol
Beer
• The fermented extract of malted serial grains
principally barley.
• Involves adding yeast to water extract of germinated
barley (barley wort).
• In brewing the following xristics are important: flavor,
aroma, clarity, foam production, foam stability &
%alcohol.
• Arise from malt, hops & products of fermentation.
• By varying malt ingredients & process of fermentation
several styles of beer produced. In its ranks include
porters, ales, steam beers, lagers & stouts.
Lager type
• Clear-amber-coloured
• Fermented with strain of S. cerevisiae and S.
uvarum @ low temperature.
• Strains called bottom yeasts-
sediment/flocculate to the bottom.
Ale
• Fermented at 18-20˚C by to strains of S.
cerevisiae.
• Darker in colour, produced using darker malt.
• Stout-very dark and malt roasted.
Brewing medium composition
• Medium- source of C & N substrates, vits,
growth factors,etc .
• Contribute to the aroma, flavor, foam xristics,
color, clarity & stability.
• Main raw materials/ingredients include:
1. malted barley 2. water 3. hops 4. malt
adjuncts 5. yeast
Water
• Components affects flavour & quality
properties of product.
• Properties of good water quality: MgCO3<
100ppm, pH (6.5-7), CaSO4 (250-500ppm), NaCl
(200-500ppm), Fe (1ppm), MgSo4 (traces), etc
• CaSO4- allows for light flavoured beers with no
harshness.
• High carbonates- heavy flavoured, dark colored
prdct and increased extraction of hops during
mashing.
Barley
• Provides sugar for alcoholic fermentation.
• Provides N-source (a. acids) which support
yeast growth.
• In raw barley these are present as starch
(amylose & amylopectin) and proteins, cannot
directly be metabolized by S cerevisiae.
• Starch has to be degraded to maltose, glucose
but some must remain as dextrins ( by
amylases).
• Proteins first degraded to a. acids & short
chain peptides but some must remain as
peptones and larger peptides for flavor &
foam (by proteases).
Malt adjuncts
• Used in conjunction with barley malt, malt
agents are fermentable substrates.
• Include meal from maize, rice, corn, sugar
syrups, dextrose, wheat, sorghum.
• Used to dilute malt protein & provide
additional carbohydrate for ethanol
production.
Hops
• Dried female flowers (cones) of hop vine
plant, Humulus lupilus.
• Provide beer with aroma, pungent xristics
• Has a stabilizing effect to beer.
• Provide tannins, substances which coagulate
proteins.
• Provide α and β resins which contribute to
bitter flavor of beer & which act as
preservatives against Gram +ve bacteria.
Microbes/ yeasts
• S cerevisiae and S uvarum,top or bottom fermenting
strains used : descriptive of where fermentation takes
place.
• Most fermentations employ bottom yeasts –easy to
separate.
• During fermentation fresh inoculum not used from one
batch to another but cells from previous fermentation
used.
• Cells first washed in tartaric acid or ammonium
persulphate: prevents contamination.
• NB: contamination results in overcarbonation, strange
flavours and all other fermentation peculiarities.
OUTLINE OF BREWING PROCESS
Malting
Mashing
Wort separation
Wort boiling
Fermentation
Post fermentation
Malting
• If not buying in the malted barley prepare it as follows:
• The grain is graded, washed and cleaned
• Steeped for 2 days in water at 15-20 ̊C –to increase
water content from 15-16% to 42-45%
• Water is drained & grain germinate/sprout for 4-6 days.
oC
• Diastatic enzymes (α and β amylases & proteolytic

enzymes activated
• Process ended with kilning @ 80 ̊C to reduce water
content
• Grains costly ground/cracked by rollers & stored
• Can manipulate the process to get darker malt
Mashing
• Water & malt adjuncts added to ground malt.
• malt mixed with malt adjuncts @ the ratio of ⅔
to ⅓ respectively
• Malt adjuncts cooked to gelatinize starch in meal
(making soluble much of the valuable portions of
malt and malt agents)
• Mixture heated and maintained varied
temperatures and pH.
• Enzyme activity is terminated by raising the
temperature to 75-80°C
Mashing cont’d
Enzyme Opt Temp Opt pH Mashing effect
α-amylase 60-70 5.7-6.3 Dextrinization

β-amylase 57-65 5.0-5.5 Saccharification
protease 38-50 4.0-5.0 Proteolysis
Mashing cont’d
• Done to make soluble much of valuable
portions malt & malt agents.
• Degree of hydrolysis depends on pH & temp.
• High temp-non-fermentable dextrins &
oligosaccharides by α-amylase.
• The non-fermentable dextrins remain in beer
causing sweetness, richness & foam retention.
• Low temp-saccharification by β-amylase to
give fully fermented beer.
• Adequate proteolysis-gives sufficient protein
for yeast & reduces hazeness in final product.
Mashing cont’d
• Remaining peptones & peptides (inadequate
proteolysis) provides flavour & foam to final
product.
• pH control for optimum enzyme activity.
• Can be done using lactic acid, sulphuric acid,
phosphoric acid, etc.
• End result is wort with fixed gravity (OG), a set
ratio of fermentable and non fermentable
sugars, and proteins (soluble & non soluble)
that affect physical & biochemical changes
during fermentation.
Separation of wort/Straining
• Husks and grains in wort, precipitated protein
and other solids are removed through
straining/filtration (husks or diatomaceous
earth of silica or sand filters)
• Clear liquid is produced during the separation
of wort
Wort boiling
• Filtered wort is boiled with steering and agitation
for 1-2 hrs with hops addition.
• Sterilization.
• Hops’ bitter acids extracted during boiling –flavor
• Tannins also extracted- precipitate/ coagulate
protein which if not removed causes turbidity in
final product
• The hop material & coagulated material removed
• Wort aerated & cooled asceptically
Fermentation
• All important step in brewing.
• is a process by which enzymes produced by yeast
convert glucose in wort into CO2 and alcohol.
• Wort cooled to btwn 10-11 ̊C and placed in a closed
fermentation tank.
• Yeast added, a process called pitching/ inoculation to
wort.
• Temp controlled @ btwn 5-12 ̊C
• Tank stirred for 7 days
• Foaming is evident after 24 hrs- caused by carbon
dioxide evolution
• Rapid yeast cell multiplication btwn 40 & 60 hrs after
pitching
Fermentation cont,d
• By day 5, carbon dioxide evolution decreases
and foam collapses
• 7-9 days is the last phase of fermentation, the
yeast become inactive and flocculates
• After fermentation, yeasts can be reused
Changes during fermentation
• Ethanol formed together with other alcohols
• Specific gravity decreases, nitrogen content
reduced, pH falls, acetate; pyruvate;
succinate; malate are formed
• Yeast flocculate and sink
• Final ethanol concentration is btwn 2.6-5.2%
depending on the mashing regime
Fermentation cont’d
Post fermentation processes
• The final steps:
cold storage maturation
carbonation
clarification
packaging
Cold storage maturation
• Completed fermentation is run into storage
vessels & is conditioned to remove harsh flavor
• Storage is @ btwn 0-3 ̊C for 3 wks
• Nitrogenous substances, resins, insoluble
phosphates & yeast cells sediment from the beer
• Anti-oxidants (SO2 & ascorbic acid) are added to
prevent later oxidation processes in beer- flavor
Carbonation
• Achieved by carbon dioxide injection or the
Krausen process or priming
• Krausen process- addition of actively fermenting
yeast to provide the natural carbonation
• Priming- addition of simple sugars so as to be
fermented by residual yeast to provide CO2
• CO2 injection up to 0.5%
• Helps in foam retention & has preservative
effect( weak carbonic acid formed to prevent
contamination)
Clarification
• Beer filtered to give brilliance i.e a clear bright
colour
• Occurs by settling protein-tannin complexes
• Can be achieved also by addition of fining
agents and enzymes
• Also by centrifugation
Packaging
• Bottles, cans and pressure keys are filled- air is
excluded in the process
• Bottles are pasteurized after capping for 15-30
mins @ 55-60 ̊C
By-products of brewing
• Spent grains- for animal feed as wet or dried
grains ; provide prot, fat, carbohydrate, crude
fibre & vit B in animals
• Brewer’s yeast- has high B-Vits for humans &
animal feed
Genetic engineering in brewing
industry
• New properties introduced into brewer's yeast by
rDNA technology has been used for production of
experimental beers
• This has been done by adding new enzyme activities to
those of the yeast which include β-glucanase from
Bacillus subtilis which reduces haze & filtration
problems
• Amyloglucosidases reduces dextrin content of beer
• Acetolactate decarboxylase from Enterobacter
aerogens reduces the time required for maturation of
beer
Beer quality control
• A combination of methods used i.e physical,
chemical, microbiological, sensory evaluation,
and so on.
• Parameters for quality control include: specific
gravity, alcohol content, sweetness, bitterness,
colour, haze or turbidity, contaminants.
• Cultural/microbiological examination for
Acetobacter, Acetomonas, Lactobacillus.
• Microbial beer contamination produces haze,
acidification,pellicles, undesirable flavours.
Summary
Barley
MALTING
cracking
Ground malt
Water MASHING
Malt agents
straining Spent grains
Wort
Hops BOILING
wort cooling (10-11˚C)
FERMENTATION
Pitching yeast
POST FERMENTATION PROCESSES
Final product

Brewing

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BEER BREWING

• Diastatic enzymes (α and β amylases & proteolytic

α-amylase 60-70 5.7-6.3 Dextrinization

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