Malting Process In Brewing Industry

[Jeff]

Malting is the process in which raw barley or another grain is made ready to become the main ingredient in the brewing process. The grain is steeped in water, then rested under precise conditions to encourage germination, and finally dried in a kiln and/or a roaster. See malt. Professionally, the person responsible for this process is known as a maltster. Malting is essentially the first step in beer making; the second is mashing, lautering, and boiling in the brewhouse; the third step is fermentation in the cellar; and the final step is the packaging of the beer in kegs, bottles, or cans.

During germination, the grain enzymes kick their activities into high gear, producing malt sugars, soluble starch, and usable yeast nutrients such as amino acids. See starch, sugar, and yeast nutrients.

Characteristics of malts will differ partly depending on whether the raw grain used was two-row or six-row barley. Six-row barley malt tends to have more polyphenols and more enzymes than does two-row barley malt. This is principally because the kernels of six-row barley are generally smaller than those of two-row barley, giving six-row kernels a greater husk-to-endosperm ratio. See endosperm and husk. Six-row malt, however, tends to work well with raw adjunct grains, because its higher enzymatic power is capable of converting their starches. See adjuncts and diastatic power.

Malting is a process through which different grains, especially barley, are prepared for brewing through a controlled germination process in a humid environment. Many other grains can be used for malting which can include sorghum, wheat, oats, rye, corn among others. Barley is the preferred one as it has a high starch to protein ratio. It also has a clinging husk that produces more yield, better quality and more flavoured beverages like beers.

Germination is the next phase of the malting process, also known as the control phase. The steeped grain is then transferred to the germination room. The grain is kept between 16C and 19C for another 4 to 6 days. The grain is kept well aerated through a flow of humid air and is turned frequently. This avoids the roots growing from matting together. It also clears the carbon dioxide, heat and moisture generated during the process. The germination process is also carried out to speed up the malting process in the brewing industry as the grain enzymes become more active. The resultant activity yields soluble starch, malt sugars and amino acids from usable yeast nutrients.

The next step in the malting process is kilning. Here the grains are dried at the temperature of 80C to 90C for about 2 to 4 hours. The grains get dried down to 3-5% moisture. This process preserves nutrients in the grain by eliminating the embryo. Enzymes continue to work initially in this process but as the temperature rises the enzymes become dormant. The enzymes can again be reactivated later by the hot and humid environment in the mashing vessel.

Different coloured and flavoured malts are produced by variations in air flows and kiln temperature. Small rootlets are removed from the resultant malt and the latter is taken for roasting.

This is the last step of the malting process in the brewing industry. It takes place in the 2 roasting drums for a period of 2 to 3 hours at very high temperatures. A batch of malt may weigh between 2.4 to 3.4 tons. The roasted malt is then placed in a cooler for about 35 to 60 minutes to cool it down. It also fixes the colour and flavours. Further, the malt is examined, stored and dispatched.

Amylases are used for breaking down starch in the malting process. Amylase breakdown starch into smaller molecules of glucose, maltose, and oligosaccharides. Amylase requires a controlled temperature to function. Alpha-amylase requires an optimal pH and temperature of 5.2 and 73.89C to function. On the other hand, beta-amylase require an optimal pH and temperature of 5.5 and 62.78C. Beta amylases are essential for the saccharification process & maltose production and are used commercially in the brewing industry.

Beta Glucanase is an essential enzyme required for the malting process in the brewing industry, especially in the malting and mashing process.

Beta Glucanase hydrolyses B-glucan polymers to release extra sugars and control viscosity. Beta Glucanase is naturally found in barley and is also known as endo-b1, 3-1, 4-glucanases. For manufacturing lighter beers, commercial-grade Beta-Glucanase is used as it clears the beer colour. Between 300 grams to 1 kg of this enzyme is used for a ton of malt. Beta Glucanase works at the optimum temperature of 45C to hydrolyze the cell walls of the grains.

Protease breaks down peptide bonds in proteins. Protease use enhances the beer quality by improving protein solubility that lowers beer viscosity and enhances the flavour. Protease speeds up the yeast growth, mashing process and wort fermenting. Protease occurs naturally in grain kernels, with commercial-grade protease added judicially to the malting process to enhance the beer quality.

Other enzymes are increasingly being used to achieve higher brewing quality. These enzymes maintain and enhance the beer quality and are also used for preserving the beers for a long period. Alpha-acetolactate decarboxylase (ALDC), is an enzyme that reduces the foul smell of diacetyl which is formed during the fermentation phase of beer production. Ficin and papain are chill proof thermostability enzymes that hydrolyze proteins and thus help with the chilling haze.

What is the malting process in the brewing industry? Hope our article answers all your queries regarding this topic. Enzymes are necessary for the malting and brewing industry. Enzymes are biological catalysts that speed up the malting process and enhance the quality of malt beverages. Enzymes have become essential today for different industries like detergents, fabric dying, pulp and paper and especially for the food & beverage industry.

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