Tower Type Malt Production Line

Batch feeding 150 tons malt production line

Tile type: similar to Saladin process, each layer of germination box,  drying box plane layout, with 6 round germination box, 2 circular  drying box.

 This process is characterized by: the whole tower-style  malt-making process, reducing construction investment.

Flat bottom Steeping tanks

Turning loading unloading machine

Malt Production Line

Production process flow

1.1 Malt manufacturing process

There are three main steps in malt manufacturing: wheat soaking, germination and drying. The process is as follows:

1.1.1 leaching of wheat

The process of making the malt absorb the amount of water needed for germination is called maceration of barley, or dipping. The macerated barley is called macerated barley.

Dipping the barley is to give it the water it needs to germinate, and to give it enough oxygen to start germinating. At the same time can also be washed wheat grains, remove floating wheat, remove wheat bark harmful to beer substances.

Dip wheat water is best to use medium hardness of drinking water, do not exist harmful to health organic matter, should be free of floating. When the content of nitrite in water reaches a certain amount, it can inhibit germination. Too much iron and manganese in water will make the surface of malt gray. Alkaline water will improve the permeability of the shell, increase the iron content of the water, limit sedimentation, and even affect the color.

1.1.2 germination

The process by which macerated barley germinates under ideally controlled conditions to produce fresh malt suitable for beer brewing is called germination. Then it is sent to the roasting system to make beer malt. Therefore, germination is a physiological and biochemical process.

The purpose of barley germination: activating the original enzyme; Making new enzymes; Material transformation.

1.1.3 dry

Undried malt IS called green malt. Green malt contains high water content and cannot be stored or enter the saccharification process. It must be dried. The moisture content of malt can be reduced to less than 5% by drying, which is good for storage. Termination of chemical - biological changes, fixed material composition; The green taste of green malt was removed, and the special color, aroma and taste of malt were produced. Easy to remove wheat root.

1.1.4 grubbing

The root bud is of no significance to beer brewing and affects the quality of beer. The roots and buds have strong hygroscopicity, which can quickly absorb water from the environment, so that the water content of dried malt can be increased again. The root bud contains undesirable bitter taste, which affects the taste of beer. The root bud can increase the color of beer. So the roots and buds should be removed after the malt is dried.

Description of brewing process:

Add 52kg process water to the gelatinizing pot and heat to 45℃; The crushed raw material was added to the gelatinizing pot, and the α-amylase was fully acted at the temperature of 70℃ for 20min. Then, the starch was fully gelatinized at 100℃ to improve the leaching rate, and the heat needed for heating up the mixed mash was provided for 40min.

Add 96kg process water into the saccharifying pot and heat it to 37℃; The raw material has been crushed into the sugar pot, at the temperature of 50℃ under the condition of carboxypeptidase full action, the formation of low molecular nitrogen containing substances; Then, the mash of the gelatinized pot was added to the saccharifying pot and kept at 65℃ for 30min, so that β-amylase could fully degrade the starch. Then the starch was kept at 72 ° c for 40min to allow α-amylase to fully decompose the starch, and then the temperature was raised to 78 ° c.

After removing the wheat grains in the filter tank, the mash is poured into the boiling pot and heated to boil. The boiling point of the mash is 105℃, and the concentration of wort can be properly controlled between 0.12 and 0.13 by boiling. It can destroy the activity of enzyme and terminate the biochemical reaction. Denature and solidify proteins; Make the effective ingredient in hop fully dissolve out.

The solidified proteins of the boiling process are precipitated and removed in a rotary sink; Then pour into a fermenter to ferment.

1.2.1 Raw material crushing

Comminution is a pure mechanical processing process. Through comminution, the specific surface area of raw materials can be increased, so that the contact area between the inclusions and the medium water and the biocatalysts enzymes can be increased, and the dissolution and decomposition of material inclusions can be accelerated.

There are three kinds of malt grinding methods, namely, dry grinding, humidifying grinding and wet grinding. Dry crushing is a traditional and has been continued to the present crushing method, and humidified crushing and wet crushing is used by more and more manufacturers.

1.2.2 saccharification

Glycation is the process by which malt inclusions continue to dissolve and decompose under the action of enzymes. After THE MALT and excipients ARE MIXED with WATER, THEY ARE KEPT AT DIFFERENT TEMPERATURE periods for a certain period of time, so that the enzymes in the malt can fully act on the corresponding substrates under the most suitable conditions, so that they can be decomposed and dissolved in water. The mixed liquid after the raw materials and auxiliary materials are mixed with water is called "mash" (liquid), the mash after saccharification is called "mash", and the dry matter (solute) dissolved in water is called "extract". The extract consists of two parts: fermentable and non-fermentable material. The glycation process should leach out as much as possible the malt dry matter and decompose moderately under the action of enzymes.

1.2.3 Wort filtration

After the saccharification, the mash must be separated from the solid and liquid as soon as possible, that is, filtered, so as to obtain clear wort. The solid part is called "wheat grains", which is one of the main by-products of the brewery; The liquid part is wort, which is the substrate for brewer's yeast fermentation. The filtration of saccharomatous mash takes barley husk as the natural filter layer and adopts gravity filter or pressure filter to separate wort. The wort separation process consists of two steps: the first step is to separate the wort in the mash, which is called "prime wort" or "first wort", and this process is called "prime wort filtration"; The second step is to wash out the wort remaining in the wheat grains with hot water. The washed wort is called "washed wort" or "second wort". This process is called "washed wort".

The objective is to remove the sediment between the sieve plate and the bottom of the tank after standing. (The turbid wort at the beginning of reflux is composed of water, wort and mass at the bottom of the sieve.) This is done by turning on and off the wort valve or pump, which creates a vortex in the wort area and together brings out the sediment from the bottom of the tank. In THE PROCESS OF PRE-FILTRATION (pre-spray), the valve should not be opened too large, so as not to generate too much suction, so that the bad layer suction.

1.2.4 Wort boiling

1.2.4.1 The effect of changes in wort during boiling

1. Evaporate excess water

2. Destroy enzyme activity, terminate biochemical changes, and fix wort composition.

3. Sterilization of wort

4. Extract the active ingredients in hops

5. Denature and solidify proteins

1.2.5 Wort cooling, coagulation separation and oxygenation

The boiled wort is cooled to fermentation temperature, during which the coagulated material is separated and sterile air is passed through to provide oxygen for yeast growth and reproduction. Coagulate is formed in the boiling process of wort due to the denaturation and solidification of proteins and the continuous oxidation and polymerization of polyphenols. According to the temperature of precipitation, it can be divided into hot coagulate and cold coagulate.