WORT PRODUCTION BREWING + DISTILLING CENTER, INC - PowerPoint Presentation

WORT PRODUCTION BREWING + DISTILLING CENTER, INC.

Wort Production WORT Solution of fermentable sugars Glucose Maltose Maltotriose Produced by MASHING Solution that YEAST is added for FERMENTATION

Wort Production Begin with PROPER MILLING of malted barley

Wort Production Begin with PROPER MILLING: Separate the outer husk material from the grain with minimal damage, while crushing the endosperm to small, but uniform, particle size. Maximize surface area of the endsoperm for greatest amount of starch conversion, while leaving larger undamaged pieces of husk.

Wort Production Begin with PROPER MILLING: Larger pieces of grain husk contribute to : P roper grain bed structure Better lautering porosity Smaller, damaged pieces of husk can release elevated levels of polyphenols, such as tannins, that can add astringency to the finished product. *Review any milling topics as needed

Wort Production Malting enzymatic reactions continue during MASHING MASHING: The ‘cooking’ of grist to enzymatically convert unfermentable starch/sugars to fermentable simple sugars Increased temperature and water hastens enzymatic activity

Mashing Mashing is the process of turning the complex carbohydrate— starch —of the malted barley, into simple sugars —glucose, maltose, and maltotriose —that yeast can eat (to produce ethanol and carbon dioxide through fermentation ). Malted barley + hot water + enzymes simple sugars (glucose, maltose, maltotriose ) (Starches)

Mashing simple sugars/carbohydrate *enzymes *ENZYMES: Alpha Amylase + Beta Amylase STARCH: complex sugar/carbohydrate

Alpha amylase Beta amylase Mashing Mashing ENZYMES (naturally occurring in barley seed) :

Alpha amylase : chops starch molecules in the middle of the starch molecule (initially forming DEXTRINS)Works best at: 150 o F – 167 o F pH of 5.6 – 5.8 Dextrins - sugars larger than 3 glucose molecules Mashing ENZYMES

Mashing ENZYMES Beta amylase : chops single glucose molecules from the ends of starch and shorter sugar molecules Works best at: 145 o F – 150 o F pH of 5.4-5.6

Mashing Alpha and beta-amylase activity in MASHING : Undigestible starch is converted into “chewable” simple sugars yeast can eat so they can ferment and produce ethanol and CO2 There are 3 steps of Mashing: 1. Gelatinization Liquification 3. Saccharization

Mashing STEPS Step 1: GELATINIZATION Separation of the large, long, flat starch molecules from each other To start increasing the surface area for the amylase enzymes to start working The hot water (about 150 F) breaks down the bonds between the starch molecules to separate them.

Mashing STEPS Step 1: GELATINIZATION stacked starch molecules separated starch molecules hot water

Mashing STEPS Step 2: LIQUIFICATION The amylase enzymes begin chopping the starch molecule into smaller dextrin molecules. T up to 167 F.

Mashing STEPS Step 3: SACCHARIZATION The beta-amylase finishes chopping the sugar molecules into single glucose molecules. Temperature down to 150 F. pH = 5.2-5.4.

Mashing STEPS Step 3: SACCHARIZATION maltotriose maltose dextrin

Mashing Maintaining correct temperatures and pH is vital Incorrect temps and pH: 1. Incomplete mashing not enough simple sugars produced for yeast to eat less ethanol produced wasted money 2. Off-flavors

Mashing Maintaining correct temperatures and pH is vital

Tending to Your Mash Take all precautions to help maintain rest temperature Regular mixing of mash Helps enzymatic activity Avoid temperature gradients Confirm mash temperatures Check mash depth Use Iodine test to confirm completion of starch conversion Mashing

Mashing The result of mashing: WORT (The simple sugar solution) The wort is now separated from the grain and hull and other solid particles (spent grain) The wort is boiled to sterilize it to get rid of any bacterial or wild yeasts that can contaminate beer Hops is added during the wort boil (as discussed)

Different Mashing Schedules Single Step Infusion Primarily British and American brewing Multi-Step Infusion Primarily Continental European Brewing Decoction Mash Step by Steam Mashing

p H and Your Mash Enzymatic activity is dependent on proper pH Mash pH ranges... 5.0-5.2 for best hop character, and optimize hot break 5.2-5.6 for greatest extract yield 5.3-5.4 for obtaining most fermentable wort 5.3-5.6 for fastest conversion Stop collecting wort when run-off pH is 5.8-6.0 Mashing

If Your Mash pH is Too High: Increase in dextrin production Higher extraction of polyphenols (e.g. Tannins) Colloidal instability Slow run-off Turbid run-off Mashing

Vorlauf Also known as recirculation Helps separate sugars from grain Clarifies wort from gain particles Stabilized grain bed for proper wort run-off Watch your speed Mashing

Vorlauf - precautions Mashing Make sure vorlauf discharge is not oxygenating the wort Running too fast can compact the grain bed, leading to a stuck mash . A stuck mash can also develop in the initial milling and mashing steps .

Lautering Collecting your wort run-off - Do not run too fast, especially in the beginning - Avoid oxidation of wort - Avoid loss of extract efficiency Things to check while lautering - Gravity of Sweet wort - pH of sweet wort - pH towards end of lauter - Gravity of wort's last runnings

Sparging Adding additional hot liquor water to mash to extract as much brewing sugar as possible

Copper Full and Time to Boil Copper full is the final amount of wort you wish to collect before boil. Determined by recipe Ideally, heating the wort should be occurring while lautering . Once a boil is achieved, it is a good time to check the “pre-boil” gravity of the wort.

Proper Boiling A proper boil should be as vigorous as possible without boiling over . - Controlling your heat source -Manipulating venting areas * During the boil , there should, at least, be a small surface area of exposed boiling wort

Boil Activites /Functions Drives off unwanted flavor volatiles (e.g. DMS) Lowers pH through precipitation of Calcium Phosphate Denatures malt enzymes Sterilizes the wort

Boil Activites /Functions Denatures and coagulates proteins Concentrates wort gravity Increases wort color, and flavor characteristics through caramelization, formation of melanoids , and oxidation of tannins Changes hops alpha acids to iso-alpha acids

End of Boil End of boil volume/also known as Copper Cast -Check wort volume -Check wort gravity -Determine if dilution is needed: If so... Current Volume x Current Specific Gravity/Specific Gravity Desired = Diluted Volume *Once calculations are complete, proceed with whirlpool.

Wort Cooling Wort cooling is achieved by passing hot wort through a heat exchanger , while counter flowing a cold liquid through the heat exchanger's alternating plates. -Ground Water -Cold Liquor Water -Glycol

Oxygenation O 2 is added to the cooled wort -I n line during cast out, -O r to the wort in the fermenter O 2 is necessary to stimulate YEAST TO REPRODUCE (will be covered in detail in FERMENTATION CHEMISTRY ) *Pure oxygen should not come into direct contact with yeast

Pitch that yeast baby! Introduce the yeast into the fermenter with the cooled, oxygenated wort -Directly through an opening in the fermenter -Inline from a propagator -Inline from another fermenter - Injecter from a “yeast brink”