Getting the most out of malt!
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1 Getting the most out of malt! Aaron MacLeod Maritime Craft Malt Workshop November
2 Our Mission Support growth and innovation in craft food and beverage production through quality testing, technical support, & education.
3 Investment The Center was awarded a total of $1,125,000 in start-up funding from federal, state, and private sources Empire State Development USDA Rural Business Development Appalachian Regional Commission George Alden Trust
4 Grain Quality Testing Barley Selection Package (Moisture, Protein, Plump, Kernel Weight, Germination Energy, RVA, & DON) $75 Moisture & Protein $15 Starch $25 Germination (4mL, 8mL & Capacity) $20 DON (ELISA) $35 RVA (for pre-harvest germination) $25
5 Malt Quality Testing Full Malt Analysis (Moisture, Assortment, Friability, Fine Extract, Coarse Extract, F/C Difference, β-glucan, FAN, soluble protein, S/T, DP, α-amylase, color, filtration time, clarity) Basic Malt Analysis (Moisture, Fine Extract, β-glucan, FAN, DP, α-amylase, color, filtration time, clarity) $150 $75 Enzymes Only (Diastatic Power & α-amylase) $50 Specialty Malt Analysis (Moisture, Extract, Color) $25
6 Safety Testing DON $35 Aflatoxin $35 Ochratoxin $30 Total Aerobic Count $30 Yeast & Mold Count $30 EColi $30 Nitrosamines (NDMA) $250 Glycosidic Nitrile $225
7 Beer Quality Testing Alcohol (ABV) $15 Bitterness (IBU) $20 Free Amino Nitrogen (FAN) $20 Beer QC (ABV, SG, RE, OE, RDF, IBU, Color, ph) $50 Minerals (Ca, Mg, & Zn) $225 Beer Spoiler Alert $75
8 Micro and Pilot Scale Malting Micromalting assessment Variety & Agronomy Trials Cornell Penn State Virginia Tech UD Davis Oregon State University Washington State University AAFC
9 Using Third Party Labs Outsourcing some analysis can fill gaps in your quality assurance program by providing analysis that requires equipment you don t have or validation that your own analysis makes sense. Third party analysis can be used for: Identify high quality raw materials Feedback for process optimization Characterizing finished products Monitoring process variation Validation of in house test methods
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12 Malting barley quality selection criteria Characteristic Specification Protein content 9 12% dry matter Plumpness >85% (over 6/64 ) Varietal purity >98% Germination Energy >95% Rapid Visco Analyzer >120 stirring number DON <1.0ppm
13 Moisture Barley moisture < 13.5% to ensure good storability High moisture encourages microbial growth and germination loss Exercise caution when drying barley grain as it can destroy germination (max 100 F)
14 Grain Moisture
15 Maximum Number of Weeks % 12% 14% 16% 18% Storage Temperature ( F)
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17 Protein Related to growing environment, agronomic practice, and genetics High protein limits extract potential Low protein limits enzymes
18 Yield Grain Protein Nitrogen Management Nitrogen
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20 Protein % FRI % EX % SP % S/T % BG ppm DP L
21 Germination Will the barley germinate now? - Germinative energy
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23 Vitality versus Vigor Variety 24h 48 h 72h 3 Day Endeavor Puffin
24 Germination Will the barley germinate now? - Germinative energy Is it dead or just dormant? - Germinative capacity
25 Dormancy Dormancy is characterized by the absence of germination in the presence of favorable conditions Subsides after a period of grain storage Varies by variety
26 4 ml Germination % (at harvest) Germination & Dormancy
27 Dormancy Break
28 Germination Will the barley germinate now? - Germinative energy Is it dead or just dormant? - Germinative capacity Special care required for steeping? - Water sensitivity
29 Water Sensitivity the failure of seed to germinate in excess moisture Special case of dormancy, but may not improve on storage Steeping process parameters must be adjusted to overcome water sensitivity Shorter wet immersions Longer air rests
30 8 ml Germination % Water Sensitivity
31 Water Sensivity Barley A Barley B Day 1 Day 2 Day 3 Total 4 ml ml ml ml
32 Multi Step Immersion Steeping
33 Germination Will the barley germinate now? - Germinative energy Is it dead or just dormant? - Germinative capacity Special care required for steeping? - Water sensitivity Long term storability of the barley? - sprouting/pre-germination
34 Pre-Harvest Sprouting Caused by excessive moisture prior to harvest Can be visually detected at only at severe levels Pre-germination (early signs) can not be visually seen, but can be measured using Falling Number or Rapid Visco Anaysis (RVA)
35 Risk of loss of germination on storage RVA > 120 Barley is sound, high probability that germination will be retained on long term storage 50 < RVA < 120 Barley is moderately pre-germinated, medium risk of germination loss on storage. Risk can be reduced if storage conditions are cool and dry RVA < 50 Barley is severely pre-germinated, should be malted as soon as possible.
36 Germination Energy Germination Loss sound moderately pre-germinated Severely pre-germinated Storage Time
37 Germination loss during storage At Harvest July/Aug December Moisture Germination Germination RVA % Energy % Energy % Scala Synergy Synergy Scala Conlon Newdale
38 Fusarium & DON Mycotoxin produced by fusarium mold Can survive the brewing process Fusarium is implicated in gushing and PYF Maltsters reject >1.0 ppm
39 Fusarium and malting Highly infected barley can produce additional DON during malting Fusarium growth and DON production more likely after harvest then after long term storage Fusarium viability declines during storage The mold produces enzymes which cause damage to the protein structures Excessive soluble protein, FAN Elevated wort color
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41 Solutions - Grower Variety choice Look for varieties with resistance Rotation Do not follow corn or small grains Fungicide & Timing Tillage
42 Solutions - Maltster Screen barley and malt for DON Have a do not accept level for incoming barley Cleaning DON is difficult to clean out of barley Small reductions in damaged kernels might be possible Storage Fusarium losses viability and is less likely to grow
43 Solutions - Maltster Malting Practice Increased overflow in steep may help to rinse surface contamination Chemical Control (e.g. bleach, ozone) Research is inconclusive on safety or effectiveness Microbiological Control Adjusting steep water ph (alkaline or acidify) Protective cultures (lactic acid bacteria or geotricum yeast)
44 Best practices to maintain high quality Harvest malting barley in a timely manner, ideally in good conditions when both grain and straw are mature. Dry grain gently (<100 F) to < 13.5% moisture Obtain an accurate/representative sample for testing Handle harvested grain gently to avoid breakage and hull abrasion
45 Keys to success Know your market Discuss variety choice, quality specifications, & price with maltster in advance Plan for alternative markets if quality isn t met Know your product Send a representative sample for testing Monitor quality during storage Keep a representative sample
46 What Is Quality? Fitness for use functional characteristics Meets customer expectations Free from defects Preforms well in the brewery Safe Brand Values the art of malting Distinctive, innovative, local, sustainable, flavorful
47 Understanding Malt Analysis What do we use it for? Process quality control Comparing different malts Predicting brewing performance specifications
48 What do brewers need? High BrewhouseYield high extract
49 Endosperm Modification Barley genetics Kernel hydration Germination moisture/temperature/time
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51 Ease of modification Beta-Glucan (mg/l)
52 What do brewers need? High BrewhouseYield high extract Efficient conversion Adequate alpha amylase
53 α-amylase Important enzyme for rapid degradation of starch during mashing Is produced during malting process Promotes fast wort conversion Influenced by variety and malting conditions Specifications: Moderate: D.U. High: D.U. Very High: >70 D.U (distillers)
54 Action of α-amylase
55 a-amylase Activity Steep
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57 What do brewers need? High BrewhouseYield high extract Efficient conversion Adequate alpha amylase Good wort separation low β-glucan, good hull retention
58 wort viscosity (cp) beta-glucan (mg/l)
59 What do brewers need? High BrewhouseYield high extract Efficient conversion Adequate alpha amylase Good wort separation low β-glucan, good hull retention Fermentability adequate DP, adequate FAN
60 Diastatic Power Represents total activity of starch degrading enzymes Primarily related to β-amylase activity which produces fermentable sugars Influenced by variety and protein content Specification ranges: High > 150 L Moderate L Low < 100 L
61 Action of β-amylase
62 Impact of mash temps on enzymes
63
64 Malt Sensory ASBC Hot Steep
65 Developing flavor in pale malt Use higher protein barley Promote modification Higher steep out moisture Extend germination time Higher cure temp (195 vs 185 F) Raise temperature ( F) at higher moisture Increasing color will reduce DP
66 Nitrosamines NDMA in barley malt at levels greater than 10 ppb is considered avoidable contamination under section 406 of the Federal Food, Drug, and Cosmetic Act. The action level of 10 ppb NDMA in barley malt applies to all barley malt produced after October 1, 1980 Actionable if a composite of 10 subsamples of finished product barley malt contains greater than 10 ppb NDMA Action levels represent limits at or above which FDA can take legal action to remove products from the market.
67 Nitrosamines Risk Factors Direct fire kilning Industrial emissions Mitigation Indirect fire kilns Low NOx burners Burn sulfer in the kiln
68 Glycosidic Nitrile Risk Factors Barley genetics All malt spirit production Copper in descending vapor phase Mitigation Non-GN producing or Low GN varieties Malting conditions (low temp, low moisture, short germination)
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70 Malt Quality Characteristic Adjunct Brewing All Malt Brewing Total protein (%) >11.5% <11.5% Soluble/Total protein (%.) 40-47% 38-45% Extract (%) >80.0% >81.0% Diastatic power ( o L) > Free Amino Nitrogen
71 Spring 2-Row Spring 6-Row Winter 2-Row Protein, % Extract, % β-glucan, % FAN, mg/l Diastatic Power, L
72 Crisp Marris Otter Simpsons Golden Promise Weyerman Pale Ale Rahr 2-Row Moisture, % Extract, % Protein, % Friability, % Color, L Kolbach, S/T % FAN β-glucan. % Diastatic Power, L α-amylase, DU
73 Beyond the numbers
74 Growth in Craft Beer Market Share Source: Brewer s Association
75 Projected malt usage Source: Brewer s Association
76 North American Craft Maltsters Guild Craft Malt is made using a majority (greater than 50% by weight) of locally grown grains Craft Malthouse producing minimum 5 metric tons & maximum 10,000 metric tons product/year Ownership by non-craft malt company does not exceed 24%
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78 Find a craft malthouse near you!
79 February Bozeman, Montana
80 If you want something different, then it isn t going to be the same -Jason Sahler, Strong Rope Brewery
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