The 26th Nordic Meeting on Brewing Technology, 12 to 14 SEP, 212 in Stockholm Current and Future Materials for Beer Making according to VLB Dr. Roland Folz Translating breakthrough technology application into reality
Raw Material Sustainability Three pillars: Economic Social Ecologic Water- and CO 2 footprint Reduced energy consumption Less waste
Lean Manufacturing Lean production: practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. "value : any action or process that a customer would be willing to pay for. lean : centered around creating more value with less work. (origin: Toyota Production System, 1953) Lean is an integrated set of principles, tools and techniques designed to improve operational performance Avoiding unnecessary costs could be more profitable than increasing sales: "A penny saved is two pence clear. A pin a-day is a groat a-year. Save and have. (Benjamin Franklin Poor Richard's Almanac )
Overall process time Just-in-time production Current Time from Grain into storage to Package out of warehouse =? Days Value Added Time =? % Culture of continuous improvement and learning Kaizen 5S
Future Green Fields Capex: plan (supply, demand, inventory, design) buy (sourcing location, warehouse capacity) grain storage Raw material types Supplier process capability Raw material quality storage vessels, site footprint, Opex make (location, schedule, labor) deliver (delivery schedule, route, transportation mode) Example brewhouse Excess capacity inefficient in terms of energy consumption individual vessel utilisation
World Grain Production Corn: 87,45 Million Tons Wheat : 692,9 Million Tons Rice: 463,31 Million Tons Soya Been: 236,87 Million Tons Barley: 133,7 Million Tons Source: USDA Report May 212
Barley Total : 133,7 Million Tons Feed Barley: 18,7 Million Tons Malting Barley: 25, Million Tons Malting Barley is a niche -> Niche markets are a characterized by differently structured supply and demand sides
World Wide Supply /Demand Producers Import Countries = Balance Country Export Import Australia 2,8 Canada 1,1 EU 27,4,4 Argentina 1,3 China 2, o. Asia,9 Africa,14 o. Europ/CIS,5 USA+Mexico,65 Russia+Ukr.,7 South Am.,7 Turkey,6 total 5,6 5,6
Malting Barley Production It requires many controls that are not needed for other grains Seeds must be certified Varietal purity must be maintained Many parameters (germination, protein, moisture, etc.) are controlled, and an out of specs value results in rejection Perfect storage is needed (low humidity, controlled temperature, good ventilation) Traceability has to be applied
Malting Barley Cocerns Needs to compete for land with: Biofuel Feed grains (cattle, pigs, poultry, horses) Human food Needs special attention from farmers, therefore, a premium is required (if compared with wheat and feed barley)
Malting Barley Breeders Work in order to develop new varieties that are suitable for every member of the supply chain Usually, characteristics that are good for one, are bad for the other productivity and high yield usually mean lower quality
Raw Material Choices Agricultural land and water availability will continue to be an issue in the supply of basic brewing materials Africa 211: Corn became 95% higher in price than it was the previous year -> importance of local raw materials will modify standard European brewing techniques, with attention to: adaption of fermentability adaption of filterability and turbidity adaption of FAN adaption of yield
Flexible supply chain Being able to meet changing customer demands: Understand the key variables that impact the supply chain Faster product changes Greater process flexibility Look for volatility across core elements Minimum of raw materials Minimise the number of mother beers by late customisation BBT Hopderivates Alginates Colour CO2 To Packaging
Heat Resisant Enzymes by the Brewing Raw Materials: A possible future Way?
New Breeding Aims for Malting Barley on the Basis of Economic Factors Use of malts with thermo-stable enzymes e.g. thermo-stable beta-amylase = alignment of the temperature optima amylolytic enzymes = better combination of alpha- und beta-amylases = shortening the mashing process (74 C mash?) e.g. thermo-stable beta-glucanase = higher residual activity of the enzymes in malt/mash = high molecular weight glucans released will still be broken down Problem: sufficient biodiversity for glucanases questionable present heat stability of the ß-Amylase only ca. +4 C
Current scheme of the quality evaluation of new malting barley genotypes in Germany Berliner Programm (part II) Industrial-scale malting Industrial scale brewing Berliner Programm (part I) Standard malting scheme 45 % / 14,5 C / 6 d + variations Congress mash + 65 C isothermal mash Standard malt analyses + glucan + FAN + amylases Official testing of new varieties (year 1 to year 3) Standard malting scheme 45 % / 14,5 C / 6 d Congress mash Standard malt analyses Breeders trials Standard malting scheme 45 % / 14,5 C / 6 d Congress mash Standard malt analyses
Thermostability of the Beta-Amylase from Various Spring Barleys 1, Enzyme Activity [ % rel.] 8, 6, 4, 2, Alexis Barke Derkado Korinna Renata Europ. land race, 4 45 48 5 52 54 55 56 Temperature Temperature [ [ C C ] C
Variation of the beta amylase activity after a treatment of the malt extract with increasing temperatures (relative 1 = 4 C treatment) Standard
Part 2 Thermo-stable beta glucanase
Background: ß-glucanase activity and its impact on the brewing process Enzyme Temp. [ C] ph Substrate Product β-glucan Solubilase Endo 1,3 β-glucanase Endo 1,4 - β-glucanase Exo β- Glucanase 62 65 6,8 β - Glucane bound to matrix < 6 4,6 Soluble high molecular β-glucane < 4 4,5 4,8 Soluble high molecular β-glucane < 4 4,5 Cellobiose, Laminaribiose Soluble high molecular β- Glucane Low molecular β- Glucane; Cellbiose; Laminaribiose Glucose ß-Glucan solubilised at higher temperature remain undegradated due to temperature sensibility of ß-glucanases
6 Background: 5 ß-glucanase activity and its impact on the brewing process Filterability Vmax[ml] 4 3 2 y = 81,388x -,357 r =.841*** 1-5 15 35 55 75 95 ß-Glucan-Gel-Content[ppm] 6 Filterability Vmax [ml] 5 4 3 2 y = 1E+7x -1,953 r =.222 1 29 32 35 38 41 44 47 5 ß-Glucan Content [ppm]
Beta glucan digesting enzymes in Hordeum vulgare Endo-ß-(1,3)(1,4)-Glucanase Isoenzyme I Glb 1 (MW 28 kda, IP 8,5) Isoenzyme II Glb 2 (MW 33 kda, IP >1, more thermostabil) Endo-ß-(1,3)-Glucanase 7 Isoenzymes (G 1 G 7) Endo-ß-(1,4)-Glucanase Exo-ß-(1,3)-Glucanase ß-Glucosidase (?)
Variation of the beta glucanase activity after a treatment of the malt extract with increasing temperatures (relative 1 = 3 C treatment)
Cultivation of exotic barley genotypes in small scale field trials ca. 8. genotypes genetic libraries in Germany, Japan, USA provenances from different continents The 26th Nordic Meeting on Brewing Technology
Grain ears of exotic barley genotypes The 26th Nordic Meeting on Brewing Technology
Remaining activity of beta glucanase of exotic genotypes after a treatment of the malt extract at 6 C (in comparison with 3 C) Grinding Extraction (extraction buffer-puffer / room temperature) Centrifugation (3 g / 1 min) Heat Treatment of the Extract (temperature gradient / thermo-cycler / 1 min) Enzyme assay (enzyme substrate / 3 C / 2 min) Centrifugation (3 g / 1 min) Measuring The 26th Nordic Meeting on Brewing Technology
Remaining beta glucanase activity of various exotic barley genotypes after a heat treatment of the malt extracts 246 62 431 632 185 188 77 16 28 161 The 26th Nordic Meeting on Brewing Technology
Digestion of added barley beta glucan in an isothermal mash at 65 C (duration of the mashing 1 h) The 26th Nordic Meeting on Brewing Technology
Fusarium contamination of selected barley and malt samples (green house trials with artificial infection 21/211 & exotic genotypes) Fusarium ssp. (ng DNA) M. Sporotrich. poae cerealis avenaceum graminearum acuminatum langsethiae tricinctum culmorum nivale F. avenaceum 211 G 2,1 2,1,7 1,1 F. culmorum 211 G 1,2 85,4 F. graminearum 211 G,5,5 4,5 196 F. sporotrichoides. 21 G 3,5,6 1, 2,3 F. langsethiae 21 G,8 11,4 2,4 2,2,1 F. culmorum 21 G,7 1,4,7,1 1,1 36,7 F. culmorum 21 M,1,3 76,5 Argent. Scarlett 211 G,5 VLB 8 8995 M,4,1,3,6,6 VLB 8 2676 M,,2,1 1,1 Artificial Infection The 26th Nordic Meeting on Brewing Technology
Beta glucanase activity (units) of various exotic genotypes after a heat treatment (6 C / 1min) of barley and malt extracts The 26th Nordic Meeting on Brewing Technology
Beta glucanase activity (units) of Fusarium infected malts after a heat treatment (6 C / 1min) of malt extracts The 26th Nordic Meeting on Brewing Technology
Comparative sequencing of the Glb2-Gene of endo-ß-(1,3)(1,4)-glucanase (isoenzyme 2) The 26th Nordic Meeting on Brewing Technology
Comparative sequencing of the Glb2-Gene of endo-ß-(1,3)(1,4)-glucanase (isoenzyme 2) continuation The 26th Nordic Meeting on Brewing Technology
Perspectives Raw material supply to be in allignment with strategic aims of the industry Flexibility needs across the supply chain with define future success. Within demonstrated VLB research: Propagation of exotic genotypes in different environments identification & quantification of the fungal infestation thermostability of the beta glucanase Sequencing of the Glb 2 gene and other glucanase genes Specific activity of the different barley glucanases The 26th Nordic Meeting on Brewing Technology
Thank you for your attention Dr. Roland Folz, Prof. Dr. Frank Rath folz@vlb-berlin.org The 26th Nordic Meeting on Brewing Technology