BREWING

1
 INTODUCTION
 The process of making beer is known as brewing.
 A dedicated building for the making of beer is called a
brewery.
 The basics of brewing beer are shared across national and
cultural boundaries and are commonly categorized in to
two main types; the globally popular pale lagers, and the
regionally distinct ales which are further categorized into
other varieties such as pale ales, stout and brown ale.
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 The strength of beer is usually around 4% to 6% alcohol
by volume.
 A mixture of starch sources may be used, as
secondary starch source, such as maize (corn),
rice or sugar, often being termed an adjunct,
especially when used as a lower-cost substitute
for malted barley.
 Less widely used starch sources include millet,
sorghum and cassava root in Africa, potato in
Brazil, and agaves in Mexico among others. The
amount of each starch source in a beer recipe is
3

collectively called the grain bill.

RAW MATERIALS

 Malt
 Water
 Hops
 Yeast

4
 MALT
 Beer cannot be made without malt;
consequently malt production from barley is
the first step in beer production. It is of course
possible to make malt from other cereals, for
example wheat, rye, sorghum or millet, but
historically for various reasons, barley malt has
proved to be the most suitable malt for beer
production. 5
 Malted barley is ideally suited for brewing for
the following, reasons:
 barely has a high starch and protein content
which needed for yeast nutrition.
 It contains small amount oil (fat) which causes
foam damaging. The husk of barley malt
adheres to the grain; consequently it is able to
form the wort filtration layer required in wort
production stage (lautering).
6
 It has a high complement of enzymes for
converting its starch supply into simple sugars.
 Malted barley gelatinizes at low temperature,
relative to other cereals malts. This has an
advantage in lowering energy cost during
mashing.

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Barley dry malt has the following average chemical
composition:

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 2. HOPS

 The composition of the hops is extremely important for

the quality of the produced from them.
 The average composition of hop dry weight
approximately:

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BEER PRODUCTION PROCESS AND
TECHNOLOGY

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 1. MALTING
Malting involves the following steps:
1. steeping
2. germinating
3. kilning

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 Grain (usually barley) is malted
 Harvested grain is soaked in water until it germinates
 This activates amylases (and proteases)
 Grain is dried
 This halts the conversion
 Acrospires (sprouts) are removed

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 BARLEY MALTING
• Acrospires eat endosperm as they grow during malting
– Acrospire is the sprout, endosperm is its food source
(full of starch)
– Acrospires will continue to eat endosperm until it is
depleted or they are stopped by the maltster by
heating and drying
– Longer acrospire growth leads to:
• More endosperm consumed and less fermentable
sugar
• More amylases are activated
• More yeast nutrients released
• Clearer beer and more complete fermentation 18
 2. MALT
CLEANING
Initially, malt is often roughly screened (sieved) to remove
coarse and fine impurities, and is passed over magnetic
separators (of fixed or revolving magnet types) to remove
fragments of metal. Sometimes the malt is separated from
heavy contaminants' by passing it through a transverse airflow,
which deflects the comparatively light malt while allowing
denser objects to continue falling downward, to be collected
separately. The removal of metal items (`tramp iron') and
subsequent de-stoning are necessary to reduce wear on
conveying equipment and the brewery mills and to reduce
19 the

risks of sparks which can lead to fires or explosions.

3. MALT
MILLING

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 In order to give the malt enzymes the opportunity,
during mashing, to act on the malt contents and break
them down, the malt must be broken into small
fragments. This process is called milling. The degree of
size reduction has a decisive influence on the volume
and filtration efficiency of the spent grains.
 The finer the milling yields more extract and the
smaller the volume of spent grains,.

21
but the fine the grist, the less porous the filter
bed, the sooner it becomes pressed together
and so the longer the filtration time it takes
 Sieve analyses should be used regularly to
check that a mill's performance is not drifting.

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 23
Six roll mill
 4.MASHING AND MASHING
TECHNOLOGY
 Mashing is the process by which sweet wort is
prepared. It involves mashing in, the mixing of
the milled grist and the brewing liquor at the
correct temperature and in the correct
proportions to obtain the mash.
 the process of mixing the mashing liquor and the
grist is known as mashing in.
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Steel's mashing machine, used in traditional British infusion mashing.
In more modern Versions the rate of grist flow is regulated
mechanically and the slide valves prevent steam from the mash
travelling into the grist case. 25
Pre masher or Maitland grist hydrator,of atraditional main land
European type, used in Conjunction with decoction
mashing(afterNarziss,1992).Note that the grist falls past a
perforated tube, which delivers the mashing liquor.The mixture
pushes open a counter-balanced door and falls into the vessel26.
The grains are crushed into a fine powder, or grist, and
then soaked in water.

In the mashing stage, the grain is actually

transformed into sugar. Proteins are broken
down. Starches are broken down into simple
sugars that nourish the yeast. Complex sugars
remain to give the beer its malty taste. The
mash is heated and strained to yield a
substance called wort(sweet wort).
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• Mashing
– Malt is soaked in hot water
– ~155°F (~68°C)
– Amylases re-activated
– starches broken down to sugars
• Primarily maltose = 2 glucose joined by α(14)
linkage
– Proteins also broken down
– Processing of proteins and starches highly
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dependent on temperature
 5. WORT SEPARATION
Wort and spent grain can be separated by:
 Mash tun
 Lauter tun
Mash filter
etc

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 After a period, with or without temperature
changes, during which the necessary
biochemical changes occur, the liquid sweet
wort, which contains the extract, is separated
from the residual solids, the spent grains or
draff.
 Some extract remains in the draff, and as much
of this as possible is recovered by sparging',
washing the grains with hot brewing liquor.
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Sweet wort

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 TYPES OF MASHING
SYSTEM
The major mashing systems are:

a)The simplest, nearly isothermal, infusion mashing

system, (traditional for British ale brewers);

(b)The decoction system, traditional for mainland

European lager brewers);

(c)the temperature programmed infusion mashing

system that is being widely adopted in the UK and
mainland Europe
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 1.INFUSION
MASHING

 Single (isothermal) mashing

 Suitable for all types of malt and low
gelatinization temperature adjunct grist.
 Usually associated with mash tun.
 Mash conversion and the separation of the
sweet wort from the spent grains take place in
this vessel.
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The coarsely ground grist, made with a high proportion of
well-modified malt, is mashed in to give are relatively thick,
porridge-like mash at 63-67 oC. After a stand of between30
minutes and two and a half hours the wort(liquid) is with
drawn from the mash. The first Worts are cloudy and are re-
circulated, but as the runoff is continued the wort
becomes bright(clear), because it is filtered through the
bed of grist particles. When bright the Wort is either
collected in a holding vessel (an under back) or it is moved
directly to a Copper to be boiled with hops. Most of the
residual extract, initially entrained in the wet grains ,is
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washed out by sparging (spraying) hot liquor, at 75-80oC
over the goods.
 2. DECOCTION MASHING

Decoction mashing is carried out with more finely

ground grists, originally made with malts that were
under modified. These mashes are relatively `thin', so
they may be moved by pumping and can be stirred.
Decoction mashing uses three vessels, a stirred mash
mixing vessel, a stirred decoction vessel or mash cooker
and a wort separation device either a lauter tun or a
mash filter. In one traditional mashing programme the
gristis mashed into give an initial temperature of around
35

35oC.
After a stand decoction is carried out, that is, a
proportion of the mash, e.g., a third, is pumped
to the mash cooker, where it is heated to
boiling. The boiling mash is pumped back to the
mash mixing vessel and is mixed with the
vessels contents, raising the temperature to,
e.g., 50oC. After another stand a second
decoction is carried out, increasing the
temperature of the mixed mash to about 65oC.
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A final decoction increases the mash temperature to

about 76oC.The mash is then transferred to a lauter

tun or a mash filter. The sweet wort and spargings
are collected, ready to be boiled with hops.

The grits, mixed with a small proportion of ground

malt and/or a preparation of microbial enzymes, are
mashed in a separate vessel called a cereal cooker.
The contents are carefully heated with mixing, and
are st at about 70ëC(158ëF), to100ëC (212ëF) to
disperse the starch and partly liquefy it. 37
TRIPLE DECOCTION MASHING

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DOUBLE DECOCTION MASING

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3. TEMPERATURE PROGRAMMED
INFUSION MASHING

Temperature programmed infusion mashing is increasingly

displacing older mashing systems. The grist is finely
ground and the mash is made `thin‘ to allow it to be
stirred. The grist is mashed in to a stirred and externally
heated mash-mixing vessel to give an initial temperature
of 35oC for a poorly modified malt or 50oC or more,for a
better modified malt. The mash is heated, with `stands‘
typically at 50oC,65oC and 75oC. Then the sweet wort is
40
collected using a lauter tun or a mash filter.
 1.MASH TUN

The mash tun(`kieve') is the simplest device for

mashing and preparing sweet wort. Mash
conversion and wort separation from the spent
grains take place in one vessel, and so mash
tuns should be distinguished from the mash
mixing and incubation vessels which are used to
carry out the mash conversion step only, wort
collection being carried out in a separate
41

device, usually a lauter tun or a mash filter.

 42
Mash tun
Appearance of sweet wort

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Mas tun false bottom

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 2. LAUTER
TUN
Lauter tuns have been used for many years to separate
worts from decoction mashes. Now they are also used
with temperature-programmed infusion mashing
systems.

There are significant differences between mash tuns and

lauter tuns. In particular the Grists used in the mashes
that are filtered in lauters are more finely ground, the
mashes are more dilute, `thinner', and because more
rapid wort filtration is desired the bed depth is
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Comparatively shallow, so it provides a less good filter
Maximum bed loadings may be in the range 339-
153kg/m2 for cycles allowing 6-12
brews/24h(Wilkinson,2003).

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 6. WORT BOILING

Wort boiling may be regarded as the turning point

in the brewing of beer. Sweet wort is boiled
with hops in a copper (kettle, hop-boiler).

The boiling vessels were originally made from

copper so are often called coppers although
today they are more likely to be made of
stainless steel.
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Sometimes, if the copper is not immediately available,
the wort is held in an intermediate vessel, or
under back, before it is boiled. It is held hot (75-
80oC); to minimize the risk of microbial infection. For
many years the hop-boil, which usually lasted for
1.5-2 h but sometimes longer, was regarded as a
simple process, the only variations being the
duration of the boiling, the choice of hops, the
hopping rate and whether the hops were added at
the start of the boil, in the middle or near the end
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(late hopping, when aroma hops are added).
The principal changes that occur during wort
boiling:

1.Inactivation of malt enzymes

2. Sterilization of the wort

3. Extraction and isomerization of compounds derived

from hops

4. Coagulation of protein material in the wort

5. Formation of protein/polyphenol complexes

6. Formation of flavour and colour complexes

7. Formation of reducing substances to give the wort

reducing potential, which is thought to protect the 51
wort
from oxidation later in the process
8. Fall in wort pH

9. Concentration of wort gravity through

evaporation of water

10. Evaporation of volatile compounds in wort

derived from mashing

11. Evaporation of volatile compounds in wort

derived from hops.

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 TYPES OF COPPERS
 1. An internal heater and `fountain' for coppers in which
the wort moves up the steam- heated tubes by
convection, its flow is constricted, then it emerges from
beneath the wort level and strikes the deflector plate
which directs it down onto the wort surface (Various
sources).

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2. A copper heated by a comparatively small external
shell-and-tube calandria heater (Hough et al., 1982).
This is an older design in which the pump initiated wort
circulation but which relied on the circulation being
driven by the thermosyphon effect once boiling was
established.

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3. In newer designs the wort flow is directed around the
pump in a bypass loop when boiling is occurring. Wort
from the EWH may be discharged above or at the wort
surface. (Courtesy of Briggs of Burton, plc.).
Alternatively, the wort may be discharged through a
`fountain', as in the older pattern.

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 7.WORT CALRIFICATION
After the beer has taken on the flavor of the hops, the
wort then proceeds to the "hot wort tank“. at the
end of the boil the wort should be absolutely clear
(`bright') but contain, suspended in it, the remains
of hops and flocs of trub or hot break.

The trub will be in the region of 0.21-0.28 kg/hl wet

weight and will contain 80-85%water (Hough et al.,
1982). Hot break contains roughly 50-60% crude
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protein, 20-30% tannin, 15-20% resins and 2-3% ash
The hot break should be removed from the wort as
thoroughly as possible, and this is most easily achieved
with large particles. Consequently boiled wort should
be handled gently and shear should be avoided to
minimize damage to the trub.

The devices most often installed for hot wort clarification

in modern breweries are whirlpool tanks or copper
(kettle)-whirlpools. A whirl pool consists of a vertical,
cylindrical vessel, with a preferred height/width ratio of
0.7-0.8/1.Hot wort is injected tangentially, at about 30
57
degree to the tangent to the vessel wall, often at a rate
of about 3.5 m/s.
Whirl pool

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 8. WORT COOLING
After clarification the hot wort must be cooled to the
temperature at which it is pitched (inoculated) with
yeast. Traditionally this is about 15-22 oC for ales and
6-12oC for lagers, but other temperatures are used. The
cooling should be carried out rapidly and under aseptic
conditions to stop chemical reactions continuing and to
minimize chances of growth of any contaminating
microbes. As the wort cools it becomes hazy as a cold
break forms. 59
By far the most common coolers are plate heat
exchangers, which are compact, efficient and
versatile. Being enclosed microbes are excluded, and
cleaning and sterilization are simple. In these coolers
numerous stainless steel plates are suspended
vertically from a strong metal frame and are clamped
together.

60

.
Gasketed plate- and-frame heat exchanger 61
62
 As the wort cools it becomes cloudy as the cold break or
trub separates from solution. This material contains
about 50% protein, 15-25% polyphenols and 20-30% of
wort carbohydrates.
 Unlike the hot break this material does not flocculate,
and occurs as small particles, <1μm, in amounts
reported to be 40-350 mg/l.

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64
 9.WORT
AERATION/OXYGENATION

 In the initial stage of `fermentation' the freshly

pitched yeast needs to be in wort that contains
dissolved oxygen. The concentration of oxygen
required is critical, and depends on the wort, for
example, the availability of sterols and unsaturated
fatty acids, and the variety and history of the
yeast. In the past it seems that saturating wort with
oxygen from air (approx. 21% O2) was sufficient, but
now saturation with pure oxygen is often required. 65
 Wort may be injected with air or oxygen at
the inlet to the cooler, part-way through the
Cooler, or after the cooling process is
complete. Adding the gas to hot or warm wort
allows the oxidation of wort components,
causing flavor changes and darkening, which
are usually undesirable.

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 10.FERMENTATION

 The cooled wort is moved into a fermentation

vessel. Yeast is added and allowed to consume
most or all of the sugars in the wort. This is the
fermentation process during which alcohol is
produced. The process takes about ten days.
Each brewery has its own strains of yeast, and it
is the yeast that determines the character of the
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beer.
 PITCHING
YEAST
 Addition of yeast to allow fermentation
 Wort must be at proper temperature for yeast to survive
and flourish
 Slightly off temperatures lead to off flavors
 Far off temperatures lead to stuck fermentation

Oxygen must be kept out

 Yeast only converts sugars to alcohol and CO2 under
anaerobic respiration 68

 With oxygen present, aerobic respiration will

 There are two main types of yeasts (for
brewing purposes)
1. Saccharomyces cerevisiae (ale yeast)
 Prefers warmer temperatures (20-25°C)
and will flocculate on top of the beer.
2. Saccharomyces uvarum (lager yeast)
 Prefers cooler temperatures and will
flocculate at the bottom of the beer
69
(~5°C)
• Yeast absorbs oxygen and sugar, and reproduces
asexually
• When oxygen is used up, reproduction stops and
fermentation (anaerobic respiration) begins
• Each glucose produces two molecules of ethyl alcohol
and CO2

C6H12O6  2 CH3CH2OH + 2 CO2 + 157kJ/mole

etoch

• Large amounts of CO2 are produced and must be

removed without letting oxygen in 70

– Airlock or water bubbler

 One of the most significant advances in
fermenter design was the move to closed
fermenters following the work of Leopold
Nathan who in 1908 and in 1927 patented
designs of enclosed vertical cylindrical vessels
with conical bases. These vessels are usually
3-4 times taller than their diameter and work
at pressures of 1-1.5 bar above atmospheric.

71
72
Fermented wort
Fermented wort

Fermented wort
73
 11. BEER MATURATION
 Beer, at the completion of primary fermentation
is said to be `green'. It contains little entrained
carbon dioxide, it is hazy and its taste and
aroma are inferior to beer that is ready for
sale. In order to refine green beer it must be
matured or conditioned. This maturation
process takes place in closed containers in the
brewery and beer treated in this way is called
74
 Green beer is hazy as well as having an
unacceptable flavour. During maturation,
clarification of the beer takes place. This is by
natural sedimentation in the cold (≤1oC) of
protein and polyphenol complexes, but this
process can be enhanced and considerably
hastened by physical and chemical means and
this is now common brewery practice.
Stabilization of the beer is also an important
75
aspect of maturation.
 The objective is to ensure that turbidity owing to
chemical precipitation or growth of micro-
organisms does not occur or, in the case of
chemical precipitation, does not recur when the
beer is clear and stable.
 During maturation, treatments can be made to
the beer to adjust its flavour and colour by the
use of caramel or other colouring materials and
by the use of various post-fermentation hop
76

treatments for both bitterness and aroma.

 MATURATION AND SECONDARY FERMENTATION

Secondary fermentation permits continued

activity by the yeast at a reduced rate limited by
the low temperature and the lower yeast count
in the beer. There are many temperature
regimes which are subsequently applied, and
they represent compromises between promoting
production of carbon dioxide and hence
providing condition to the beer and allowing77the
removal of undesirable flavour compounds.
 Flocculent yeasts separate easily at the end of
primary fermentation and conditions can be
adjusted such that sufficient yeast can be
retained in the beer to effect the flavour
changes required in maturation.

78
MATURATION AND IMPORTANT FLAVOUR
CHANGES
 Several important groups of compounds have been
identified as changing during the maturation of beer
with consequent positive effect on beer flavour. The
most important are: diketones (especially diacetyl),
sulphur compounds, aldehydes, and volatile fatty
acids.

79
MATURATION VESSELS

80
 12.BEER FILTRATION

 The final process to consider in beer treatment, prior

to packaging, is filtration. This is the clarification of
the beer to a standard that is acceptable for sale.
The process involves the removal of any
remaining yeast cells and the removal of
precipitated protein and poly phenol haze
material. The beer must be rendered stable so that
visible changes do not occur during its commercial
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(shelf) life, which could be up to 52 weeks from the
A very important factor in successful filtration
is the chilling of the beer. The lower the
temperature the more cold break(trub) and
chill haze will form. Filtration will remove
this material, provided that the beer
temperature does not rise emerging from
maturation must therefore be maintained at -2
to -1oC through filtration.

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 13. CARBONATION
 Carbon dioxide is a very important constituent of beer. It
imparts sparkle and `mouth feel' and sharpness
associated with its properties as an acid gas. The
concentration of carbon dioxide in beer for sale is
carefully controlled to ensure that consumers of the
beer can drink a consistent product. Beers that lack
carbon dioxide, particularly lager beers, are dull and
lifeless and are said to lack condition and be flat. The
carbon dioxide is the gas produced naturally in primary
83

and secondary fermentation and that added to the beer

 the carbon dioxide level is possibly between
2.2 and 2.8%v/v for bottled and canned
products. The carbon dioxide levels for kegged
beer typically range from 1.5 to 2.5 %v/v .
Such is the control now demanded for the
precise level of carbon dioxide in finished beer
that the gas levels are frequently adjusted after
primary and/or secondary fermentation. The
amount of carbon dioxide that will dissolve in
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beer depends on temperature and pressure.
 14. BEER
PACKING
 Beer packaging encompasses four steps:
1. Bottle washer
2. Bottle filler
3. Bottle pasteurizer
4. Bottle labeler

85
 PASTEURIZATIO
N

This is a process of heating and rapid cooling

which prolongs shelf-life and destroys any
bacteria or other organisms in the beer. Canned
and bottled beers are pasteurized in their
containers.

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89
 BEER
CHARACTERISTICS
 Alcohol Content
 Flavor

 Malt, Hops, Yeast, Water

 Aroma

 Clarity

 Head

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 ALCOHOL CONTENT

 Measured by density
 Original gravity(OG)– density of wort prior to
fermentation
 Final gravity(FG) – density of beer after
fermentation
 Dissolved sugars lead to high density
 As sugars convert to ethyl alcohol, the density
decreases
 The decrease in the density is directly proportional
91

to the amount of alcohol present

 FLAVOR

 Sweet flavors from malt

 Dependent on types of grain and on grain
modification
 Bitter flavors from hops
 Iso alpha acids balance sweetness of grain
 15 – 100 ppm depending on beer type
 Aroma from hop oils mainly from later additions of
hops

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 AROMA

 Hop oils
 Small organic molecules
 Often aromatics
 Poly phenols
 Mainly from late addition of hops
 Aroma hops boiled for a short time (~5 minutes)
 Dry hops (added after wort has cooled or just before
packaging)
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 CLARITY

 Filtering, settling, racking

 Yeast

Flocculency of yeast
 Poly phenols from hops
Larger poly phenols become insoluble and
form a “permanent haze”
Small poly phenols agglomerate when chilled
94

to form a “chill haze”

 HEAD
 Protein from grains
 proteins stabilize head
 Isoalpha acids
 properties of iso-- acids stabilize head

95
 E
E N D

D
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