1｜EBC Symposium 2016

Brewhouse Challenges caused by Craft Production

Technology at the Highest Level

20.09.2016 2｜EBC Symposium 2016

Definition by: American Craft Brewer (ASBC)

Small Independent Traditional (≤1 Mio hl/a) (≤ 25% owned by industry) (descriptions)

Creative Flexible Individual

-Deeper understanding for the process- 3｜EBC Symposium 2016

Challenge

Craft beer segment = growing Increasing competition Increasing number of and diversity & products

http://www.ucsdbrewingprogram.com

Consumers like to experiment Filling & packaging For long term success, growth and reputation: Outstanding, high quality products are required Whereas industrial sized breweries are specifically designed for the production of certain main brands, craft breweries have to be flexible, in order to create a large variety of beer styles. Therefore the required technology, and hence the usage of the equipment may vary significantly. A deeper understanding for the process is therefore required. Different ingredients High & low gravity 4｜EBC Symposium 2016

Raw materials

Different beer types and brands are brewed with different raw materials. Therefore it is important to adapt the process accordingly to the used ingredients

Water

Water is the main ingredient of !!!

Often the water quality is not adjusted individually in order to meet the demands of the chosen recipe. Each beer style requires a different water. Pale beers are generally brewed with softer water than dark beers.

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Significance of appropriate water quality

EBC Lovibond CU SRM Color Beer type Incredience influence the pH

4-8 2 2 Yellow straw, pale Northern Pilsner, Pale Lager

8-12 5 3-6 Golden, pale, orange Classical Pilsner

12-20 10 10 Amber Pale Ale, Fest beer, Maerzen

20-35 20-25 17 Brown Dark Bock, Dark White beer Mash pH Mash > 60 > 30 > 35 Dark brown, black Stout, Porter, Black beer

Often demineralized water is used or minerals and CaCl2 are added inappropriately. If comparative sour cereals are mashed in (caution also with !!!) with this water, a severe pH-decrease may result. Hence the enzymatic activities are being influenced negatively.

Starch may be not converted. Lautering and filtration problems may occur. The chemical- and physical stability of the product decreases. 6｜EBC Symposium 2016

Mash pH-Value with increasing increments

°F °C Gelatinization

170 Rice, 80 130 Maize Rye, 160 Alpha Milo 70 Amylase 150 Barley, Oat, Beta Amylase 140 60 Wheat 130 Proteolytic 50 120 110 Beta 40 Glucanase 100

4,5 5,0 5,5 pH Desired pH-range 7｜EBC Symposium 2016

Effect Temp. opt. (°C) Temp. inact. (°C) pH opt. (IU)

Dextrinease 55 – 60 60 6,5 – 7,0 β-Amylase 60 – 65 70 5,4 – 5,6 Amylolyse α-Amylase 65 – 75 80 5,6 – 5,8 Maltase 35 – 40 40 6,0 Phosphorolyse Sour Phosphate 50 – 53 60 5,2 Endo-peptidase (-SH) 45 – 50 60 3,9 – 5,5 Proteolyse Carboxy-peptidase 50 70 4,8 – 5,6 Endo-β-1,4-Glucanase 40 – 45 55 4,5 – 4,8 Cytolyse β-Glucan solubilase 62 – 65 70 6,8 Pentosanase 40 – 45 50 5,0 Lipase 35 – 65 6,8 – 7,0 Lipolyse Lipoxigenase 45 – 55 60 6,5 – 7,0 8｜EBC Symposium 2016

Mashing

Often heating rates is often 1°K/min are desired. In order to achieve that, steam with approx. 140 °C is commonly used. Caution: Heating rates will decrease with finer grist.

It is beneficial to have the max. possible heat transfer, so that cooler heating medias can bed used (e.g. hot water -from the energy recovery system-). Steinecker Pillow Plattes and Stirrer technology

Oxygen pickup during in should be avoided Appropriate mashing in potentionally combined with shakers Steinecker Pre-Masher and Shakesbeer

The gelatinization temperature & pH-values of the raw materials It is not mandatory to boil adjuncts at 100 °C have to be considered & controlled. The gelatinization temperature shall be met in order to assure a quick conversion 9｜EBC Symposium 2016

Mash Filtration: Lautertun or Mash-Filter

Wet- and dry mills Limited to hammer mill Throughput decreases with gravities higher than 16-18°P Constant throughput with gravities higher than 16-18°P Restriction to adjunct types Lower restriction on adjunct types Adjunct content max. 40 % Adjunct content more than 40% If many brands are being produced, which are restricted in terms of brand-specific trub- and weak reusage: sometimes higher efforts in logistics 10｜EBC Symposium 2016

Boiling

The evaporation rate of 4% is standard for regular beer types.

The usage of high adjunct ratio may potentially enable lower evaporation amounts, so that the investment of the vapor condenser can be discussed…

CAUTION: The odor emissions increase significantly if no vapor condenser is being used!

Some brands may still require 4% or more evaporation. For those cases, the energy losses are being significantly increased.

The flexibility may decrease dramatically and the financial benefits may only be reasonable in short terms

The energy recovery rate of vapor condensers is very good (up to 95%), so that the regained energy can be reused e.g. for mashing or wort pre-heating. 11｜EBC Symposium 2016

300 Before Boiling 10 Units 250 20 Units 30 Units 40 Units 200 50 Units 60 Units

150 70 Units 80 Units

TBA [IU] TBA 90 Units 100 100 Units 110 Units 50 120 Units 130 Units 140 Units 0 0 10 20 30 40 50 60 70 80 90 100 150 Units

Wort boiling [Minutes] 12｜EBC Symposium 2016

Wort pre-cooling

Wort pre-cooling, to approx. 91°C prior to whirlpooling assures: • That no DMS-P is converted to free DMS, • Less (hop)aroma components are being lost, WP • Late-hopping is hence more efficient, • For breweries located in high altitudes and are applying pressure boiling: An excessive evaporation and potential over foaming in the WP can be avoided • The trub can still be removed conventional

For the connection to the energy recovery system the wort can: • either be cooled by an additional plate cooler (see picture above) • or (Steinecker alternative) be cooled in the wort pre-heater (see picture below) WP

If whole flowered hops are being used for boiling (not recommended) they should always be removed before the whirlpool is entered.

Steinecker approach for discharging and transportation of whole flowered hops: Screw press

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Whirlpool

At a filling-height to diameter ratio of 2,5:1 to 3,0:1 the whirlpool capacity is approx.: Pellets Type 90: 2,5 kg/m2 Ground-surface Pellets Type 45: 3,0 kg/m2 Ground-surface

(depending on gravity, raw material types, hop-characteristics)

The separation capacity decreases if vessels are smaller in diameter

The filling speed should be 3,5-4,5 m/s, tangential (total transfer time: approx. 10 min) The hot trub amount is approx. 1-1,5% of common cold More hops in brew house: Different technologies!!! 14｜EBC Symposium 2016

Whirlpool

Design Parameter Raw material + Hop-porducts + Extract + Diameter/Hight = max. load

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Trub separation for high hop loads: Sedimentation tank

Conical Whirlpool design

Design has features tailored for every recipe requirement including:

Tangential inlet for hydro cyclone effect

Bottom outlet in cone for trub removal

Multiple drawoff outlets

Turbidity measurement for efficient trub removal and low losses

Well approved technology, for hop loads > 3 kg/m2

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Brewery Development

Craft beer brewers Micro Cube One2brew Hops 5, 10, 25 hl/batch 300.000 hl/a Aroma 2/3 vessel brewhouse Pre-mounted Ingredients Craft/Pub/Pilot Quick, fast & easy installation

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Steinecker industrial technology brought to craft breweries 18｜EBC Symposium 2016

The right system for everyone

Plant capacity and sales beer volume Steinecker plant concepts 3.888.000 MicroCube 1.944.000

10 000 000 CombiCube 972.000

One2Brew 226.800 1 000 000 170.000 Steinecker technology 113.400 27.000 100 000 8.600

4.300 Applications 10 000 sales hlin Annual beervolume Small and pilot lines Craft brewing 1 000 5 10 25 50 Quick reference 75 100 300 Large breweries 600 1200

Brew volume in hl 19｜EBC Symposium 2016

A detailed look at the MicroCube 20｜EBC Symposium 2016

The MicroCube concept

MicroCube is a brewing system consisting of brew house and fermenting cellar and it is suitable for 5, 10, 25 hl cold wort volume per brew.

Supply for water, heat and coolant are included in the concept.

The electronically supported manual operating concept enables utmost flexibility and easy handling at the same time.

Pre-mounted modules are installed in very short time and started up.

The compact design allows for an arrangement on very small space. 21｜EBC Symposium 2016

Layout example

All packages have container dimensions. Coolant supply Diameter of the vessels: High-speed steam max. 1,200 mm generator Valve and pump module: L x W x H = 1,000 x 1,000 x 2,150 mm Complete scope of supply: Clycol water Warm water tank 3-4 items 40' container tank

Fermentation tanks Required surface area: Operator panel Whirlpool wort kettle 14,400 mm x 6,000 mm We recommend to separate the brewhouse Mash lauter tun and the yeast cellar through different

rooms Grist mill Other layout concepts can be designed individually 22｜EBC Symposium 2016 Dry hopping: Not an easy task…

Picture from presentation by: Matt Brynildson, Firestone Walker Brewing Company

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Picture from presentation by: Matt Brynildson, Firestone Walker Brewing Company 24｜EBC Symposium 2016

Dry hopping

There are numerous possibilities of how to achieve the desired hop flavor in the beer. Multiple solutions are available, but only a view allow satisfying results…

General Statements The yeast should be removed before dry hopping The desired contact time depends mainly on: • Fermentate (alcohol & pH) • Processing temperature • Contact surface & homogenization degree • Type of hops • Dilution ratio (hops to fermentate)

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Dry hopping

Value Hops are very valuable, and hence considered to be the most expensive ingredient. The yields (dry hopping: mainly aroma staining) should therefore be as high as possible. Physical aspects The volume of the hops may significantly increase when soaked with fluid (up to 6 x). Flowered hops tend to float first, whereas pellets sink before fragments begin to float. Different types and products contain different amounts of soluble ingredients. High cellulose contents thereby lead to greater losses… Separation The cropping of hop-products out of the beer is very difficult. If the slurry is harvested to early out of the tanks, the beer losses are significantly; whereas a delayed harvest often leads to discharging problems, due to a high density and a compact hop mass. 26｜EBC Symposium 2016

Dry hopping

1. Insert hops into dosing unit

2. Close vessel

2

3. Flush with CO2 & pressurize tank CO 4. Insert largerd beer (ratio hops to beer: approx. 1:15) 5. Homogenize and solve the hops 6. Transfer of the hop slurry into tank 7. Internal tank circulation & homogenization 8. If needed: Repetition

9. Cleaning of dosing unit

10. Cropping of hop sediment (2-6h after circulation) 2 CO Konrad Müller-Auffermann Head of Breweries Product Development

Phone: +49 (0) 8161 953 307 Fax: +49 (0) 9401 709 42 307 Mobile: +49 (0) 151 11 40 18 94

E-mail: [email protected]