Getting the most out of malt! Aaron MacLeod Maritime Craft Malt Workshop November 30 2018
Our Mission Support growth and innovation in craft food and beverage production through quality testing, technical support, & education.
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
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
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
Safety Testing DON $35 Aflatoxin $35 Ochratoxin $30 Total Aerobic Count $30 Yeast & Mold Count $30 EColi $30 Nitrosamines (NDMA) $250 Glycosidic Nitrile $225
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
Micro and Pilot Scale Malting Micromalting assessment Variety & Agronomy Trials Cornell Penn State Virginia Tech UD Davis Oregon State University Washington State University AAFC
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
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
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)
Grain Moisture
Maximum Number of Weeks 100 90 80 70 60 50 40 30 20 10% 12% 14% 16% 18% 10 0 32 41 50 59 68 77 86 Storage Temperature ( F)
Protein Related to growing environment, agronomic practice, and genetics High protein limits extract potential Low protein limits enzymes
Yield Grain Protein Nitrogen Management Nitrogen
Protein % FRI % EX % SP % S/T % BG ppm DP L 9.1 95 82.3 4.3 44.6 45 116 9.6 91 81.5 4.3 43.0 78 128 10.5 86 81.1 4.4 42.0 114 132 12.2 76 80.0 4.5 37.1 150 152 13.0 67 79.4 4.6 36.4 270 160
Germination Will the barley germinate now? - Germinative energy
Vitality versus Vigor Variety 24h 48 h 72h 3 Day Endeavor 70 27 1 98 Puffin 9 32 57 98
Germination Will the barley germinate now? - Germinative energy Is it dead or just dormant? - Germinative capacity
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
4 ml Germination % (at harvest) Germination & Dormancy - 2017
Dormancy Break
Germination Will the barley germinate now? - Germinative energy Is it dead or just dormant? - Germinative capacity Special care required for steeping? - Water sensitivity
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
8 ml Germination % Water Sensitivity - 2017
Water Sensivity Barley A Barley B Day 1 Day 2 Day 3 Total 4 ml 47 51 2 100 8 ml 95 3 0 98 4 ml 33 91 3 97 8 ml 31 22 8 61
Multi Step Immersion Steeping
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
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)
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.
Germination Energy Germination Loss sound moderately pre-germinated Severely pre-germinated Storage Time
Germination loss during storage At Harvest July/Aug December Moisture Germination Germination RVA % Energy % Energy % Scala 13.2 99 65 93 Synergy 13.3 98 75 98 Synergy 14.1 97 55 91 Scala 15.3 97 50 73 Conlon 15.3 94 30 73 Newdale 16.1 98 20 48
Fusarium & DON Mycotoxin produced by fusarium mold Can survive the brewing process Fusarium is implicated in gushing and PYF Maltsters reject >1.0 ppm
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
Solutions - Grower Variety choice Look for varieties with resistance Rotation Do not follow corn or small grains Fungicide & Timing Tillage
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
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)
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
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
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
Understanding Malt Analysis What do we use it for? Process quality control Comparing different malts Predicting brewing performance specifications
What do brewers need? High BrewhouseYield high extract
Endosperm Modification Barley genetics Kernel hydration Germination moisture/temperature/time
Ease of modification Beta-Glucan (mg/l)
What do brewers need? High BrewhouseYield high extract Efficient conversion Adequate alpha amylase
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: 40-55 D.U. High: 55-70 D.U. Very High: >70 D.U (distillers)
Action of α-amylase
a-amylase Activity Steep 1 2 3 4 5
What do brewers need? High BrewhouseYield high extract Efficient conversion Adequate alpha amylase Good wort separation low β-glucan, good hull retention
wort viscosity (cp) 1.70 1.65 1.60 1.55 1.50 1.45 1.40 1.35 0 100 200 300 400 500 600 beta-glucan (mg/l)
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
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 100-150 L Low < 100 L
Action of β-amylase
Impact of mash temps on enzymes 110 120 130 140 150 160
Malt Sensory ASBC Hot Steep
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 (130-150 F) at higher moisture Increasing color will reduce DP
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.
Nitrosamines Risk Factors Direct fire kilning Industrial emissions Mitigation Indirect fire kilns Low NOx burners Burn sulfer in the kiln
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)
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) >150 100-120 Free Amino Nitrogen 180-220 120-180
Spring 2-Row Spring 6-Row Winter 2-Row Protein, % 11.8 12.7 9.5 Extract, % 80.0 79.0 82.0 β-glucan, % 120 260 70 FAN, mg/l 200 230 150 Diastatic Power, L 130 140 110
Crisp Marris Otter Simpsons Golden Promise Weyerman Pale Ale Rahr 2-Row Moisture, % 3.1 4.4 4.8 4.8 Extract, % 81.8 81.2 81.0 81.8 Protein, % 9.4 9.6 11.0 11.6 Friability, % 94.3 94.5 87.2 85.6 Color, L 4.3 3.2 3.95 2.2 Kolbach, S/T % 47.1 46.7 39.5 43.0 FAN 154 192 148 187 β-glucan. % 212 64 114 118 Diastatic Power, L 75 100 105 140 α-amylase, DU 40.0 53.2 59.5 63.0
Beyond the numbers
Growth in Craft Beer Market Share Source: Brewer s Association
Projected malt usage Source: Brewer s Association
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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February 2-3. 2019 Bozeman, Montana www.craftmalting.com
If you want something different, then it isn t going to be the same -Jason Sahler, Strong Rope Brewery