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Alcohol Beer: the CERB Experience

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Alcohol Beer: the CERB Experience Brewing process study for high quality low-alcohol beer: the CERB experience Prof. Giuseppe PERRETTI and Prof. Paolo FANTOZZI Italian Brewing Research Centre, University of Perugia EBC Brewing Science Group 10th Technical Meeting 2014, Wien, 9-11th September The importance of making an improved low- alcohol beer Drink-drive awareness Diet Health Volume sales increasing (Germany, +12 % in 2013) Total volume (Spain, 13% total) Lower tax New market opportunities … GIUSEPPE PERRETTI “Low-alcohol and ”Alcohol-free”. Main production methods Biological: Physical: Cold contact Vacuum rectification (thermal) High gravity brewing Falling film evaporation (thermal) High temperature mashing Dialysis (membrane) Use of special yeasts (NCYs) Reverse osmosis (membrane) … Osmotic distillation (membrane) … Branyik T., 2012 (ICT). A review of methods of low alcohol and alcohol-free beer production. Journal of Food Engineering 108 493-506. GIUSEPPE PERRETTI Biological The state of art: Cold contact process Muller R., 1990 (BRI). Review. The production of low-alcohol and alcohol-free beers by limited fermentations. Ferment 3 (4), 224–230. Perpète P., Collin S., 1999 (UCL). State of the art in low-alcohol beer production. Cerevisia 24, 27–33. It is the only biological method to make alcohol-free beer with less than 0.05 v/v ethanol. Relatively simple to manage. In comparison with other methods of production, the CCP is characterized by one of the lowest aldehyde reduction capacity, worty off-flavor. Long refrigeration needed. GIUSEPPE PERRETTI Biological The state of art: High gravity brewing Muller R., 1990 (BRI). Review. The production of low-alcohol and alcohol-free beers by limited fermentations. Ferment 3 (4), 224–230. Relatively simple to manage. Good stability because of low level of fermentable sugars at the end of process. Good level of esters and higher alcohols. Head retention very low. The foam is poor. More suitable to beers with 2 % v/v ethanol. Beer with 1 % v/v are lack of body and tasteless. GIUSEPPE PERRETTI Biological The state of art: High temperature mashing Muller R., 1990 (BRI). Review. The production of low-alcohol and alcohol-free beers by limited fermentations. Ferment 3 (4), 224–230. Good flavor. No problem to achieve beer with less than 1.2 % v/v ethanol. High pH of beer. Stability problem. Pasteurization needed. Risk of worty off-flavor. GIUSEPPE PERRETTI Biological The state of art: Use of special yeasts (NCYs) Narziss L., Miedaner H., Kern E., Leibhard M., 1992 (TUM). Technology and composition of non- alcoholic beers, Brauwelt International 4:396–410. The process is easy to handle and does not require continuous monitoring of extract reduction. Difficulty in controlling the microbial activity. There is a remaining slight worty off-flavor. Diacetyl level above the taste threshold. Risk of excessive sweetness of beer. High pH. GIUSEPPE PERRETTI Physical The state of art: Vacuum rectification Narziss L., Back W., Stich S., 1993 (TUM). Alcohol removal from beer by countercurrent distillation in combination with rectification (written in German). Brauwelt 133 (38), 1806–1820. Kern M., 1994. Alcohol removal from beer using continuous vacuum refinement. Alimentacion Equipos y Tecnologia 13 (5), 37–41. Zürcher A. (Feldschlösschen Getränke AG), Jakob M., Back W., 2005 (TUM). Improvements in flavor and colloidal stability of alcohol free beers. In: Proceedings of the European Brewing Convention Congress, Prague, Czech Republic. Potential to remove alcohol from beer completely, possibility to commercialize the separated alcohol, thermal stress very low. Elevated running and plant costs, excessive loss of volatile compounds. Taste empty, sour. Carbonation needed. Beer re- dilution after treatment. GIUSEPPE PERRETTI Physical The state of art: Falling film evaporation Zufall C., Wackerbauer K., (VLB) 2000. Process engineering parameters for the dealcoholization of beer by means of falling film evaporation and its influence on beer quality. Monatsschrift fuer Brauwissenschaft 53 (7/8), 124–137. Considered the cheapest thermal process. Easy to clean. Beer has a short product contact time, generally a few seconds. Loss of volatile compounds. Re-dilution with degassed water needed. Re-addition of carbon dioxide required. GIUSEPPE PERRETTI Physical The state of art: Dialysis Donhauser S., Glas K., Mueller O., 1991 (TUM). Behavior of beer components during the manufacture of alcohol-reduced products by dialysis. Brauwelt International 2, 139–144. Zufall C., Wackerbauer K., (VLB). The dealcoholization of beer by dialysis – influencing beer quality by process engineering. Monatsschrift fuer Brauwissenschaft 53 (9/10), 164–179. Low running temperature and pressure. No thermal and mechanical stress, no worthy off-flavor. A selective removal of ethanol cannot still be achieved. Excessive loss of volatile compounds. Carbonation is necessary at the end of dealcoholization. High plant costs. GIUSEPPE PERRETTI Physical The state of art: Reverse osmosis Kavanagh T. (Foster’s), Clarke B.J., Miles M., Nicholson B. 1991. Volatile flavor compounds in low alcohol beers. Tech. Q. Master Brew. Assoc. Am. 1991, 28, 111−118. Pilipovik M.V., Riverol C., 2005 (University of Trinidad and Tobago). Assessing dealcoholization systems based on reverse osmosis. Journal of Food Engineering, 69 (4), 437-441. Starting from beers with normal composition, beers with alcohol contents very low (< 0.05 % vol.) can be obtained. Elevated running costs (energy). Carbonation is necessary ended the dealcoholization. Excessive loss of volatile compounds. It is not economically feasible to large-scale. GIUSEPPE PERRETTI Physical The state of art: Osmotic distillation, evaporative pertraction Diban N., Arruti A., Barceló A., Puxeu M., Urtiaga A., Ortiz I., 2013 (University of Cantabria). Membrane dealcoholization of different wine varieties reducing aroma losses. Modeling and experimental validation, Innovative Food Science and Emerging Technologies, 20, 259-268. Low running temperature and pressure. Low energy consumption. No thermal and mechanical stress. Easy to manage. Low aroma losses. It is necessary carbonation. Excessive loss of volatile compounds. Membrane life-time. Membrane replacement costs. GIUSEPPE PERRETTI the CERB experience I experimental section: II experimental section: Biological process Physical process Screening of a new strain of NCYs Beer dealcoholization using for low-alcohol beer production osmotic distillation GIUSEPPE PERRETTI Italian Brewing Research Center GIUSEPPE PERRETTI Interdisciplinary work on NCYs Department of Agricultural, Food and Environmental Italian Brewing Research Center Industrial Yeasts Collection GIUSEPPE PERRETTI Interdisciplinary work on OD Department of Agricultural, Food and Environmental Sciences Scale-Up University of Salerno, Italy GIUSEPPE PERRETTI NCYs: the literature There are few detailed studies on the behavior of those yeasts. 1. Huige, N.J., Leidig, A.R. and Sanchez, G.W. Process for preparing a nonalcoholic (less to 0.5 volume percent alcohol) malt beverage. Patent, 1990. 2. Narziss, H. Miedaner, E. Kern and M. Leibhard. Technology and composition of non-alcoholic beers. 1992. 3. Mohammadi A., Razavi S.H., Mousavi S.M., Rezaei K. A comparison between sugar consumption and ethanol production in wort by immobilized Saccharomyces cerevisiae, Saccharomyces ludwigii and Saccharomyces rouxii on brewer’s spent grain. University oh Tehran, 2011. Zygosaccharomyces rouxii Saccharomycodes ludwigii GIUSEPPE PERRETTI Use of non-conventional yeasts (NCYs) S. ludwigii is unable to use maltose, while Z. rouxii is able to partially use maltose. Boundy-Mills K., Stratford M., Miller M. W. (2011) The yeasts: a taxonomic study, fifth edition, (Kurtzman C. P., Fell J. W., Boekhout T. eds.), vol. 1, cap. 62, Elsevier. FERMENTABLE S. ludwigii Z. rouxii SUGARS Glucose + + Galactose - - Sucrose + v Maltose - +/w Lactose - - Raffinose + - Trehalose - w/- Melibiose - - GIUSEPPE PERRETTI Use of non-conventional yeasts (NCYs) 11 strains were selected from DBVPG (International Industrial Yeast Collection – 4,000str, 500 Spp.) STRAINS SPECIES Isolation source Isolation area DBVPG 4084 Dates Iraq DBVPG 6187 Grape must Italy DBVPG 6424 Z. rouxii Honey The Netherlands DBVPG 6463 Pickle USA DBVPG 6921 Honey Canada DBVPG 3010 Grape must Italy DBVPG 3304 N.A. Italy DBVPG 3398 Tea beer N.A. S. ludwigii DBVPG 3931 Grape must Italy DBVPG 4116 Grape must Slovenia DBVPG 6721 N.A. N.A. GIUSEPPE PERRETTI Use of non-conventional yeasts (NCYs) The wort used to run micro-fermentation trials was produced by a specific mashing program with the CERB pilot plant. GIUSEPPE PERRETTI Specific mashing program C) ° Temperature ( Temperature Time (min) High temperature mashing method GIUSEPPE PERRETTI Specific mashing program Specific Target wort Parameters EBC method wort (12 °P)* ANALYTICA EBC 8.3 Original Gravity (wt%) 12.01 ± 0.10 12.25 ± 0.10 / 2004 ANALYTICA EBC pH 5.57 ± 0.08 5.49 ± 0.08 8.17 / 1999 ANALYTICA EBC 8.5 Colour (EBC units) 7.20 ± 0.8 9.40 ± 2.1 / 2000 > Dextrins ANALYTICA EBC 8.4 Viscosity (mPa*s) 1.82 ± 0.08 1.67 ± 0.04 / 2004 Turbidity (EBC units) IP/01/2007 67.60 ± 2.50 69.60 ± 1.50 ANALYTICA EBC Total Nitrogen (mg/L) 1090 ± 68.00 847 ± 58 8.9.1 / 2000 ANALYTICA EBC FAN (mg/L) 217.00 ± 7.00 161.00 ± 17 8.10 / 2002 ANALYTICA EBC Fermentability (%) 8.6.1 / 2004 65 ± 2 83 ± 2 ANALYTICA EBC β-glucan (mg/L) 231.00 ± 42.00 167.00 ÷ 39.00 4.16.3 / 2005 * Mashing: 52 °C for 10 min., 65 °C for 45 min., 72°C for 20 min., 76°C for 10 min. GIUSEPPE
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