BREWING WITH
VARIOUS ADJUNCTS
BANGKOK BREWING CONFERENCE 2011
Christoph Kunzmann, CSA Manager
[email protected]
15th June, 2011
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TOPICS
 Motivation of adjunct inclusion
 Processing of various adjuncts
 Corn / corn starch / rice
 Sorghum
 Barley
 Conclusion
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Corn, rice and barley are the dominating adjuncts
the choice of adjunct is driven by various factors
SYRUP
Capacity
Cost
Colour
CORN
 Cost
 Taste
 Availability
One ton of maltose
syrups provides the
same amount of
saccharides as 1.15
tons of barley
Syrups (20%)
Corn and Corn
Starch (35%)
Other (10%)
BARLEY
Cost
Local raw
material
Shortage of malt
Taste wise closest
to malt
Quality
Barley (15%)
Rice (20%)
Source: Novozymes’ market intelligence
RICE
Cost
Taste
Quality
Capacity
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Processing of Adjuncts
Cereal Cooking
Infusion Mashing
Saccharified
Adjuncts
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Penetration of adjuncts
 Adjuncts are widely used around the world
 Usage levels vary in the different regions as well as the choice of adjuncts
Penetration of adjuncts As % of beers produced in the region
Penetration
As average % of
adjuncts included in
the recipe
Mashed-in
barley and wheat
Cereal-cooked
corn and rice
Syrups
Central & Western
Europe
10
5
0
5-10
Eastern Europe
30
10
15
25
China
10
45
20
45
5
25
10
20
Latin America
10
30
25
25
North America
0
35
30
25
Region
South East Asia
Source: Novozymes’ market intelligence
Rice
Corn &
corn starch
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Overall, cost is the strongest driver for the use of
adjuncts, with corn and barley in particular
representing significant cost reduction potentials
Raw material prices (EUR/t)
Average 2010
400
350
300
250
200
150
100
50
0
Malt,
Europe
Barley,
malting,
Europe
Barley,
f eed,
Europe
Corn,
Europe
Barley,
f eed, US
Corn, US
Corn, Asia Rice, China
Sorghum
Af rica
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Adjuncts where the starch has a high gelatinization
temperature need to be separately cooked and liquefied
 The starch gelatinization temperatures of some
adjuncts, namely
Gelatinization of corn
65 °C
 Corn starch (GT of 62–75 oC)
 Rice starch (68–85 oC)
 Sorghum (70–78 oC)
 ... are above the inactivation temperature of the malt
beta-amylase and consequently they need to be
gelatinized before saccharification
corn or rice is gelatinized and
then liquefied by a
thermostable alpha-amylase in a
cereal cooker
110
100
90
°C
70 °C
85 °C
78 °C
72 °C
80
Transfer to
lauter tun
65 °C
70
52 °C
60
50
Saccharification
Proteolysis
Min
40
0
15
30
45
60
75
Typical mashing regime for cereal-cooked rice or corn
90




Starch granules swell
Viscosity increases
Starch gelatinizes
Then the enzyme can act
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Selecting the right amylase for
cereal cooking
Other important features
Viscosity, falling ball (sec)
A thermostable amylase is required
Standard amylase (Termamyl®)
Improved version (Termamyl SC)
Comparison of the thermoactivity profile of malt
alpha-amylase and a typical industrial liquefaction
amylase
Dextrose Equivalents %
Viscosity as a function of pH
A broad pH profile is desired
Standard amylase (Termamyl)
Improved version(Termamyl SC)
DE (%) at 88 oC. High efficiency at temperatures
around 90 oC is preferred
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Quick-test for monitoring of
liquefaction in practice
› optimal enzyme utilization through LDA-Kit.
 DE = Ratio of reducing sugars in percent.
 Calibration of LDA – Kit with osmometer (or Fehling titration)
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Adjunct Brewing of the Future
Background
.
(high gelatinizing adjuncts)
Challange
 Sugar profile without proper enzymes leads to
insufficient saccharide levels.
Energetical improvement and OPEX/CAPEX reduction.
Simplification and shortening of mashing.
Debottlenecking.
Flexible adjunct use in infusion mashing.
 Sugar profile with experimental enzyme blend.
Temp.




62°C
52°C
Malt
Tgel 62-64°C
72°C
Adjunct
Tgel 70-78°C
Time
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→ resulting attenuation levels (ADF%)
theo. ADF %= fermentables % * 0.9 / 0.81
(0.9 = empiric value sugar → extract)
(0.81 RDF to ADF)
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Wort/Beer Quality
(rice / corn in infusion mashing)
FAN Levels
Rice/Corn as Adjunct – FAN Levels
Grouping of amino acids (aa’s) grouped in
relation to how well yeast can utilize and absorb
the aa:
In general acceptable FAN levels for high adjunct
inclusions. Can be highered by introducing a
52°C mashing step or an additional protease.




A: Fast
B: Intermediate
C: Slow
D: None
Sensory Analyses:
50% of maize/rice inclusion results in a comparable
amino acid profile of the FAN as a 100% WM malt.
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SORGHUM Brewing
 Processed malted and
un-malted
 Processable in any ratio up to
rd 70% in LT
 Processable in any ratio up to
100% in MF
 Several proteases
 Xylanases
 Glucanases
 Alpha-Amylases
 Processable with combination
of Cerezyme® Sorghum and
Fungamyl® BrewQ
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SORGHUM brewing
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Two strategies for brewing with barley
Mix & mash
 The standard solution for barley brewing
 Malt and barley are mixed and mashed together
 Other adjuncts can be added as cooked adjunct
or syrup
 Typically the barley inclusion is 15–35%
 The requirement of the enzyme system increases
as the barley inclusion increases
Brew & blend
 Separate mashing and fermentation of malt and
85–100% barley
 Blending to the target barley:malt ratio
 Other adjuncts can be added in any of the
mashings
 A flexible solution where the malt- and barleybased brews can be optimized separately
 Can also be applied for a 100% barley beer
 This solution was enabled by the Novozymes
Ondea® Pro technology launched in 2010
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The Novozymes Ondea® Pro enzymatic solution
for brewing with up to 100% unmalted barley
 Attenuation is ensured through a
synergistic action between
 Endogenous barley beta-amylase
Mashing profile
Temperature
 Exogenous added pullulanase and
alpha-amylase
 The fermentable amino acids are
provided by a synergistic action
between
 Endogenous exopeptidases
78–82 °C / 10 min
64 °C / 45–75 min
54 °C / 30 min
Time
 An added protease
 Good lautering with a clear wort is
provided by a combination of welladjusted mills and
 A filtration enzyme system including
both beta-glucanase and xylanase
components
 A lipase to ensure wort clarity
 The synergies between the
enzymes are ensured by
 A three-temperature step-infusion
mashing profile
 pH 5.6–5.8
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The Novozymes Ondea® Pro brewing concept
allows the strict malting barley specifications to
be broadened
 The barley must be food grade
 The barley performance can be
according to local regulations
checked using a barley quality test,
 It is not necessary to use spring
which is a modified Congress mash
barley matching malting specifications
 Parameters especially necessary for a
successful malting process (e.g.,
germination energy, water sensitivity,
with enzymes, measuring turbidity,
throughput, FAN, sugar profile
(HPLC), viscosity, and pH
 The barley’s endogenous enzymes
relationship between cytolytic and
(exopeptidases and beta-amylase)
proteolytic degradation) are less
must be active. So far only one
important
barley sample has shown
insufficient activity
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100% barley wort can be processed with
the same or lower viscosity than for malt wort
The viscosity-reducing component
Barley specification test
The viscosity reduction is ensured by
the choice of the right xylanase and
beta-glucanase
Viscosity in mPas (12% oP base)
Wort viscosity as a function of
barley inclusion (%)
3.5
no enzyme
2 kg/t Ondea® Pro
mPa*s
3
N=
Average
Min
Max
Spec.
Total
36
1.52
1.42
1.82
1.60
0.2
18
1.50
0.8
18
1.55
Adjust:
N =1
2.5
2
1.5
% Barley
1
50
60
70
80
90
100
The wort viscosity in lab-scale mashing trials was
measured at different barley inclusion levels with
and without the addition of Novozymes Ondea® Pro
 Only one sample was out of
specification
 Viscosity is usually not a limiting
factor in the selection of grain
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The turbidity-reducing component ensures
low turbidity and facilitates lautering
The turbidity-reducing
component
Barley specification test
 The lipase used reduces the turbidity
Wort turbidity
of the wort to regular standards

The free fatty acids in the mash are
at the same level as for malt with an
expected similar amount of lipid
oxidation products
NTU
Turbidity after lautering
160
140
120
100
80
60
40
20
0
N=
Average
Min
Max
Spec
Total
36
33
2
222
80 NTU/
20 EBC
0.2
18
24
0.8
18
41
Adjust
N=3
 Almost all critical samples are
obtained when analyzing coarse grist
Barley
Barley with lipase
Lipase added to laboratory mashing. The turbidity
was measured during filtration/lautering
 High turbidity can be solved by the
addition of 5–15% malt or by a
higher enzyme dose
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Synergy with barley peptidases
provides good yeast performance
mg FAN/l/Plato
 Novozymes Ondea® Pro’s proteolytic component works in synergy with the
endogenous enzymes of barley
 This is demonstrated by a comparison between the effect of Ondea Pro on barley with
and without inactivation of the endogenous enzymes
13
12
11
10
9
8
7
6
5
4
3
2
1
0
Barley wort needs
only 9 mg FAN/L/Plato
to ensure good
fermentation
0
Without inactivation
2
3
4
kg Ondea® Pro per ton of barley
With preinactivation of barley enzymes
The inactivation of the endogenous enzymes was done by a heat treatment at 75 °C for 30 min
The mashes were carried out at 50 °C
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Barley wort produced with Novozymes Ondea® Pro has a
significantly higher amount of fast-absorption amino acids
 The amino acids are often
divided into 4 groups according
to their absorption by the yeast
cell
 The amino acid profile of 100%
barley wort differs from that of
malt wort
 The barley wort contains
relatively more of the easy-toferment amino acids and
relatively less of the harder-toferment amino acids, especially
proline
Relative amino acid composition of malt and barley
wort according to amino acid fermentability groups
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
D
C
B
A
Malt wort
Barley wort
Average of 10 barley samples with the malt from the corresponding barley
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100% barley wort shows comparable
fermentation performance with less FAN




The FAN recommendations for malt brews are 10-18 mg/l/Plato
The FAN from 100% barley wort is lower; 9-14 mg/l/Plato
The barley worts have good fermentability
This leads to less unfermented FAN at the end of the fermentation
Lab fermentation of 12 oP malt wort and barley wort (made with Ondea® Pro).
Fermentation temperature 12 °C, Yeast strain W34/70
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The pullulanase ensures around 70% RDF
with a high maltose sugar profile
76
74
72
70
68
66
64
62
60
58
56
54
70
68
66
64
62
 The selected pullulanase is especially
essential for the attenuation
performance
60
58
56
54
52
0
1
Maltose %
Unique pullulanase
added
Starch
Maltose
Alphaamylase
added
Barley
betaamylase
RDF%
3
kg Ondea® Pro
per ton of barley
Results from lab-scale mashing trials
Fermentable
sugars
Glucose
2
RDF
 The starch is degraded by a
synergistic action between the added
pullulanase and alpha-amylase and
the beta-amylase from the barley
Maltose and RDF
as a function of enzyme dose
Sugar profile
Experience from successful pilot and plant trials
Glucose and fructose
Maltose
5–10%
45–60%
Maltotriose
< 15%
Dextrins (DP4+)
< 22%
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The gelatinization temperature influences the
starch degradation and the level of dextrins
Correlating attenuation
Barley specification test
Dextrins (DP4) as function of the
gelatinization temperature of grains
Dextrins (DP4+) as % of total sugar profile
N=
Average
Min
Max
Spec
Total
56
21.3
14.8
29.7
22
0.2
18
0.8
18
Adjust
N=7
 The final attenuation can be adjusted
via the dosage and the duration of
the 64 °C rest
Linear Fit
Correlation between the dextrins and the gelatinization
temperature measured by RVA
 High gelatinization temperatures
reduce the amount of fermentable
sugars and are hard to adjust
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Barley Quality Test
barley specification
Parameter
Unit
Standard
Extract
°P
14–15
Dextrins
(DP4+)
%
Gelatinization
temperature
Viscosity
FAN
Total protein
Adjust
Reject
< 22
< 27
> 27
°C
< 64.5
< 67
> 67
mPas
< 1,560
< 1,600
> 1,600
mg/L/°P
>9
7–9
<7
%
10–13
< 10
5.7–5.9
>6
NTU
< 80
> 80
ml after
10 min
> 50
< 50
pH
Turbidity
Filtration
performance
Congress mash with a dose of 2 kg/t
Novozymes Ondea® Pro on define
mash profile
 Fine grist for mash filter application
(0.2 mm)
 Coarse grist for lauter tun application
(0.8 mm)
Sample database
Worldwide we tested more than 100
barley samples and conducted over 50
pilot and industrial trials
As the database for the barley quality
test we used 18 dedicated barley
samples
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Market response to beer from Ondea brewing
 Breweries impressed by variety
and taste
 High scores in testing
 Consumers like taste
 No beer defects
 Excellent foam
 Good shelf life
Confirming..
 Brewmasters can make desired
beer type and quality
 New beer claims are possible
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Conclusion
 Adjuncts are widely used, with corn, rice, and barley being the global dominant
adjunct. Sorghum is broadly used in Africa.
 The penetration of adjuncts is mainly driven by cost and availability, but quality
parameters also play a role.
 The adjunct penetration is being facilitated by the development of enzyme
technology.
 Corn and rice are currently cooked and liquefied with thermostable amylases as
these starches have high gelatinization temperatures. Future developments are
expected to enable mashing-in of corn and rice after infusion mashing steps.
 Ondea Pro technology enables brewing with up to 100% barley; this technology
is based on a synergy between the endogenous enzymes of barley and a
complex enzyme mixture.
 The innovative effort of enzyme suppliers is likely to continue, facilitating
brewing with the inclusion of different adjuncts for cost savings as well as
product development utilizing the different quality attributes of the adjuncts.
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