INDUSTRIAL

MICROBIOLOGY
Lecture IX
ALCOHOL-BASED
FERMENTATION INDUSTRIES
PRODUCTION OF BEER

BARLEY
BEERS

BARLEY BEERS

The process of
producing beer is
known as brewing.

RAW
MATERIALS
FOR BREWING

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

adjuncts,

yeasts,

hops, and

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

As a brewing cereal, barley

has the following
advantages:

Its husks are thick, difficult to

crush and adhere to the
kernel. This makes malting

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

As a brewing cereal, barley

has the following
advantages:

The second advantage is that

the thick husk is a protection
against fungal attack during

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

As a brewing cereal, barley

has the following
advantages:
Thirdly, the gelatinization
temperature (i.e., the
temperature at which the
starch is converted into a
water soluble gel) is 52-59C
much lower than the

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

As a brewing cereal, barley

has the following
advantages:

Finally, the barley grain even

before malting contains very
high amounts of betaamylase unlike wheat, rice

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

Hordeum vulgare

six rows of fertile kernel

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

adjuncts,

Adjuncts are starchy materials

Corn grits (defatted and ground), corn syrup,

and rice are most widely used in the United

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

adjuncts,

yeasts,

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

adjuncts,

yeasts,

hops

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

adjuncts,

yeasts,

hops

Hops are the dried coneshaped female flower of hopplant Humulus lupulus
It is a temperate climate
crop and grows wild in
northern parts of Europe,
Asia and North America.

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

adjuncts,

yeasts,

hops, and

The mineral and ionic content

and the pH of the water have
profound effects on the type of
beer produced.
Some ions are undesirable in
brewing water:
nitrates slow down
fermentation, while
iron destroys the colloidal
stability of the beer.

THE RAW MATERIALS USED IN

BREWING ARE:
barley,

malt,

adjuncts,

yeasts,

hops, and

In general calcium ions lead to

a better flavor than
magnesium and sodium ions.

BREWING PROCESS
The processes involved in the conversion of
barley malt to beer may be divided into the
following:
1. Malting
2. Cleaning and milling of the malt
3. Mashing
4. Mash operation
5. Wort boiling treatment
6. Fermentation

BARLEY
AND MALT
PROCESS

HARVESTING

BARLEY MALT - AN OVERVIEW

Most common source
of fermentable sugars
in beer
Grass family Gramineae
Species Hordeolum
vulgare
formed by sprouting
barley kernels to a
desired length, stripping
off the rootlets, and
drying to a specific color

BARLEY MALT
OVEVIEW
Parts of the Kernel
(CONTINUED)
germ (actual

growing part of the

kernel)
Acrospire- above
ground portion
Rootlet - below
ground portion
endosperm (starch
food supply for the
germ)
needs to be converted to
sugar for brewing

husk (cellulose
protective cover)

TYPES OF BARLEY
Two row barley
only two of the six flower rows are
fertile and able to produce kernels

Six row barley

all six rows are fertile and produce
kernels

DIFFERENCES IN BARLEY TYPES

Two Row
bigger kernels, higher
yield per head
lower protein
(nitrogen) content
lower husk contents
(less grainy flavor)
less enzymes

Six Row

more yield per acre

more diastatic power
ie. enzymes (better
when using lots of
adjuncts)
higher husk level
makes for better
lautering filter bed

2-Row

6-Row

PURPOSES FOR MALTING

1. Convert the large chains of insoluble
starch in the endosperm to short chain
water-soluble starches
2. Break down proteins in the barley by
activating Proteolytic (protein breaking)
enzymes
3. Activates the enzymes that will convert
starches to sugars during mashing

MALTING ENZYMES
(CONTINUED)
Cytases (hemicellulases & B-

gluconsases)
Occur during germination, not malting
break down husk cell walls
allow the diastatic enzymes to work
more easily during the malting process

Dextrase
Break the large starch chains at the 1-6
links to make smaller polysaccharide
chains

MALTING ENZYMES
(CONTINUED)

Diastatic enzymes

-amylase
breaks the 1-4 links in the middle of
the -glucans starch to make
smaller starch chains
-amylase
breaks the smaller starch chains
into maltose sugar by breaking 1-4
links near the reducing ends of the
smaller chains

Malting is a 3-step process

1)Steeping

2) Germination

3) Drying

STEEPING
Primary
Immersion
Phase

Drain &
Air Rest
Phase

Spray or
Additional
Immersions

Steep
Out

Objective
is to
obtain
uniform
germinati
on or
chitting

GERMINATION
Germination,
which began
in the steep
tank,
continues in
the
compartment
where the
barley
undergoes
modification.

GERMINATION
Germination,
which began
in the steep
tank,
continues in
the
compartment
where the
barley
undergoes
modification.

MODIFICATION

Sprouting the grains to

correct modification
Acrospire grows from the
germ end of the kernel
toward the opposite end
Length ratio of acrospire to
the kernel determines the
level of modification

MODIFICATION- A DEFINITION
The degree of germination a barley
kernel achieves during the malting
process.
the degree to which the protein/gum
matrix of the starch in the kernel is broken
down
increases the amount of proteins which
will become soluble in water

MODIFICATION (CONTINUED)
Modification is achieved through
the malting process
Varies from under-modified to
highly modified malts

DIFFERENCES
Under-modified
more complete set of
enzymes
more proteins that will
require additional
protease enzymatic
breakdown to avoid the
protein-polyphenol
induced haze (chill
haze)

Highly modified

high level of
IN MODIFICATION
protein
degradation
doesnt require
a long protein
rest
may not
necessarily be
suitable
brewing all
styles of beer

MODIFICATION: EXAMPLE 1
Fully modified - Ratio 1.0
Acrospire as long as the kernel
will have a low protein content
endosperm (starch) almost fully
water soluble

MODIFICATION: EXAMPLE 2
75% Modification
Acrospire is 3/4 the
length of the kernel
more of the endosperm
is retained for
fermentation availability
more protein remains
(adds complexity to the
beer)
the expense is that there
is reduced diastatic
enzyme activity for
mashing

>75%

DEGREES OF MODIFIED MALTS

Continental
50-75% modified
retains more endosperm
for fermentation
creates more protein
complexity but:
at the expense of
reduced enzyme activity

American 6-row

Fully modified
because of higher protein
content, has greater
enzymatic strength than
Continental

DEGREES OF MODIFICATION
(CONT.)
Both Continental and American
malts require a protein rest at
about 122o F to degrade
albuminous proteins
promotes yeast growth
aids in head retention

DEGREES OF MODIFICATION
(CONT.)
Caramel &
Crystal
fully modified
kilned at 50%
moisture (not
bone dry)
This essentially
mashes the
starch directly
inside the kernel

Chocolate & Patent

under modified
(<50%)
do not require protein
rest, as the kilning
process degrades the
starches

KILNING

Objectives of
Kiln Drying
Stop growth and
modification
Preserve enzymatic
activity
Create shelf stability
Create colors and
flavors

KILNING

Degree of modification + kilning = type of malt

KILNING (CONTINUED)
Pale Malts (British & American)
Kilned between 130o and 180o F

Vienna Malt
low kilned at around 145o F

Czech Malts
raised slowly from 120o to 170o F, then roasted at 178o F

KILNING (CONTINUED)
Dortmunder & Munich malts

kilned at low temperature, then raised

before the malt has dried to 195-205o F
(Dortmunder) or 210-244o F (Munich)
Amber malt

well modified, then dried and rapidly heated

to 200o F.
Temp then raised to 280-300o F and held
until desired color is reached

KILNING (CONTINUED)
Crystal & Caramel

fully modified, then kilned at 50% moisture

Temp raised to 150-170o F and held for 1.5 to 2 hours
Essentially mashes the endosperm inside the husk
Heated to final roasting temp, time/temp determines final
Lovibond color index

KILNING (CONTINUED)
Chocolate & Patent Malts

dried to 5% moisture
roasted at 420-450o F for up to two hours
high heat degrades the starch so no protein rest is needed
can also be roasted over beechwood fires (Bamberg style)

KILNING (CONTINUED)
ALL malts
Once the malt is evenly roasted, they are cooled to 100o F
Placed in a rotary bin (or some other method) and rootlets
are removed
Malt needs to rest for at least one month before mashing

Categories of
Specialty Malts
Kiln Produced
Roaster
Produced

Kiln Dried,
Roasted
Malts

Victory
Special Roast
Chocolate
Dark
Chocolate
Black

Roasted
Barley,
Black
Barley

Milling

Weighin
g

MASH TUN

The mash tun is a vessel in which the milled malted barley is mixed with wate
And the enzymes are allowed to degrade the starches and proteins into
Substrates that the yeast can utilize during fermentation

MASH

These photos show the milled

Malted barley being mixed with
Warm water. The enzymes
Convert the starch to maltose and
The proteins to amino acids creating
What is known as sweet wort.

LAUTERING (FILTERING)
The sweet wort
Is separted from
The spent barley
By a filtration step
Known as
Lautering. The
Barley husks serve
As the primary
Filtering material.
Here, the remaining
Spent grains are
Being removed from
The sweet wort
With this screen.

MASH TUN WITH USED MASH

These are the spent malt that acted as a filtering bed for the sweet wort.

USED MASH HEADING

TOWARDS FEEDLOT

SWEET WORT

KETTLE
Sweet Wort
Bring to boil
Add hops
Extract flavors (bitter
acids) and aromatic
compounds

Sterilizes hopped wort

FERMENTATION TANKS

After the yeast is added to the hopped wort, fermentation of the maltose to
Ethanol occurs in these tanks.

ADDING YEAST TO THE

FERMENTER

BLOW-OFF HOSES ON FERMENTATION TANKS

Fermentation produces both ethanol and carbon dioxide. The carbon

Dioxide is allowed to vent out through these blow-off hoses whose ends
Are immersed in a tank of water, producing an air-lock and preventing
Oxygen from entering the fermentation tanks.

Environmentall
y
controlled
packaging
process

Bulk
Loading/
Unloading

TYPES OF
BARLEY
BEERS

TYPES OF BARLEY BEERS

Barley beers can be divided into two broad

groups:

Top-fermented beers
Bottom fermented beers.

This distinction is based on whether the

yeast remains at the top of brew(topfermented beers) or sediments to the

BOTTOM-FERMENTED BEERS
Bottom-fermented
beers are also known
as lager beers
because they were
stored or lagered
(from German lagern
= to store) in cold
cellars after
fermentation for
clarification and
maturation.

BOTTOM-FERMENTED BEERS

Yeasts used in bottomfermented beers are

strains of
Saccharomyces uvarum

(A) PILSENER BEER

This is a pale beer with a
medium hop taste. Its
alcohol content is 3.0- 3.8%
by weight.

Classically it is lagered for

two to three months, but
modern breweries have
substantially reduced the
lagering time, which has
been cut down to about two

(A) PILSENER BEER

The water for Pilsener brew is
soft, containing comparatively
little calcium and magnesium
ions.

(B)DORTMUND BEER
This is a pale beer, but it
contains less hops (and
therefore is less bitter) than
Pilsener.

However it has more body

(i.e., it is thicker) and
aroma.

The alcohol content is also

3.0-3.8%, and is classically

(B)DORTMUND BEER
The brewing water is hard,
containing large amounts of
carbonates, sulphates and
chlorides.

(C) MUNICH
This is a dark, aromatic and
full-bodied beer with a
slightly sweet taste, because
it is only slightly hopped.

The alcohol content could be

quite high, varying from 2 to
5% alcohol.

The brewing water is high in

carbonates but low in other

(D) WEISS
Weiss beer of Germany made
from wheat and steam beer
of California, USA are both
bottom fermented beers
which are characterized by
being highly effervescent.

TOP-FERMENTED BEERS
Top fermented beers are
brewed with strains of
Saccharomyces
cerevisiae.

(A) ALE
Whereas lager beer can be
said to be of German or
continental European origin,
ale (Pale ale) is Englands own
beer. Unless the term lager is
specifically used, beer always
used to refer to ale in England

(A) ALE
Lager is now becoming known
in the UK especially since the
UK joined European Economic
Community. English ale is a
pale, highly hopped beer with
an alcohol content of 4.0 to
5.0% (w/v) and sometimes as
high as 8.0%

(A) ALE
Hops are added during and sometimes after
fermentation.

It is therefore very bitter and has a sharp acid

taste and an aroma of wine because of its high
ester content.

(A) ALE
Mild ale is sweeter
because it is less
strongly hopped than the
standard Pale ale.

In Burton-on-Trent where
the best ales are made,
the water is rich in
gypsum (calcium
sulfate).

(B) PORTER
This is a dark-brown, heavy
bodied, strongly foaming
beer produced from dark
malts.

It contains less hops than

ale and consequently is
sweeter. It has an alcohol
content of about 5.0%.

(C) STOUT
Stout is a very dark heavily
bodied and highly hopped
beer with a strong malt aroma.

It is produced from dark or

caramelized malt; sometimes
caramel may be added.

(C) STOUT
It has a comparatively high
alcohol content, 5.0-6.5%
(w/v) and is classically stored
for up to six months,
fermentation sometimes
proceeding in the bottle.

Some stouts are sweet, being

less hopped than usual.