Method for producing beverage

Abstract

The invention provides a method for producing a non-fermented beverage by using brewer's grains (BSG) so as to improve the efficiency of beer production resources. The method comprises: obtaining (203) BSG from a beer production process; mixing (204) the BSG with water to form a slurry; treating (205) the slurry to produce a precursor liquid; and storing (206) the precursor liquid during a storage period of time, followed by use as a base for the production of a non-fermented beverage, where the storage period of time exceeds 2 hours. The method is easily integrated with existing beer production. Dependencies between non-fermented beverage production and beer production are reduced, for example, allowing beer and non-fermented beverages to be produced in different factories.

Description

Technical Field

[0001] The present disclosure relates generally to the field of beverage production, and more particularly to the resource-efficient production of beer and non-fermented beverages. Background Art

[0002] Beer production facilities vary from small craft breweries or microbreweries to industrial-scale beer production facilities. Beer brewing involves at least three main steps: mashing, lautering, and fermentation. Mashing involves mixing ground grain (usually malt) with water and heating it at a controlled temperature, allowing enzymes to break down the starch in the grain into sugars such as maltose. Mashing produces mash. Lautering separates the mash into fermentable wort and retentate. Lautering can be performed in a lauter tun or mash filter. Fermentation begins when yeast is added to the wort. This is when the product is first called beer. During this stage, the fermentable sugars in the wort are metabolized into alcohol and carbon dioxide.

[0003] The retentate produced by filtration is a by-product of brewing, also known as draff spent grain or brewer's spent grain. Breweries produce a large amount of this substance, for example, 15 kg for every 100 liters of beer. The retentate is nutritious and rich in protein, fiber and carbohydrates. At the same time, the retentate is rapidly degraded by microbial activity and may deteriorate within hours of filtration. Currently, the retentate is used as animal feed or raw material for biogas production. For example, in WO2019 / 023647, it is also proposed to dry the retentate and grind it into protein-rich flour. However, today's beer production plants discard a large amount of retentate. Summary of the Invention

[0004] It is an object of the present invention to at least partially overcome one or more limitations of the prior art.

[0005] One of the aims is to increase the resource efficiency of beer production.

[0006] Another object is to provide a technology for producing non-fermented beverages based on beer production retentate that comply with food safety regulations.

[0007] Another object was to provide a technology that is easy to integrate into existing beer production and flexible in production.

[0008] One or more of these objects, as well as other objects that may appear from the description below, are achieved at least in part by a method for producing a precursor liquid for the production of a non-fermented beverage according to the independent claim, embodiments of which are defined by the dependent claims.

[0009] A first aspect of the present disclosure is a method for producing a precursor liquid for producing a non-fermented beverage. The method comprises: obtaining brewer's spent grains (BSG) from a beer production process; mixing the BSG with water to form a slurry; treating the slurry to produce a precursor liquid; and storing the precursor liquid for a storage period for subsequent use as a base for producing a non-fermented beverage, wherein the storage period exceeds 2 hours.

[0010] The method of the first aspect improves the resource efficiency of beer production by using BSG, a by-product of beer production, to produce non-fermented beverages. The method is easy to integrate with existing beer production. By producing and storing the precursor liquid, the production of non-fermented beverages is more independent of beer production. For example, if the precursor liquid is produced in a beer production plant and transported from the beer production plant to another plant for producing non-fermented beverages as part of the storage, beer and non-fermented beverages can be produced in different plants. The precursor liquid can be manufactured using well-defined or standardized components, and the same precursor liquid can subsequently be processed into different non-fermented beverages. It is also conceivable to manufacture precursor liquids with different well-defined components, which can be customized to be used as base materials for producing a corresponding group of non-fermented beverages.

[0011] According to this specification, some combinable embodiments of the first aspect are as follows.

[0012] In some embodiments, the method includes performing a stabilization treatment on at least one of the slurry or the precursor liquid to reduce microbial activity thereof.

[0013] In some embodiments, stabilization comprises at least one of heating, cooling, or changing the pH by acidification or alkalization.

[0014] In some embodiments, the storage time period for intermediate storage of the precursor liquid exceeds 8 hours.

[0015] In some embodiments, the storing of the precursor liquid comprises transporting the precursor liquid from a first factory for producing beer to a second factory for producing a non-fermented beverage.

[0016] In some embodiments, storage of the precursor liquid is performed so as to inactivate microbial activity in the precursor liquid during the storage period.

[0017] In some embodiments, processing of the slurry includes separating the slurry into a liquid component and a solid component, and forming a precursor liquid from the liquid component.

[0018] In some embodiments, the method includes heating the slurry to at least 100°C for a predetermined period of time before separating the slurry into a liquid component and a solid component.

[0019] In some embodiments, the method includes treating the slurry to increase the protein and / or dry matter content of the slurry prior to separating the slurry into a liquid component and a solid component.

[0020] In some embodiments, treating the slurry to increase the protein and / or dry matter content comprises performing an enzymatic treatment on the slurry.

[0021] In some embodiments, performing the enzymatic treatment comprises performing at least one of: a first enzymatic treatment comprising enzymatically breaking down fibers in the pulp; or a second enzymatic treatment comprising enzymatically breaking down proteins in the pulp.

[0022] In some embodiments, performing the enzymatic treatment comprises adding one or more enzymes to the slurry.

[0023] In some embodiments, the one or more enzymes are added in an amount of 0.5% to 3% (by weight) of the slurry.

[0024] In some embodiments, the one or more enzymes include one or more carbohydrases and / or one or more proteases.

[0025] In some embodiments, the method comprises cooling the slurry to a temperature below 70°C prior to performing the enzyme treatment.

[0026] In some embodiments, the method further comprises, after the enzyme treatment, treating the slurry or liquid component to inactivate its enzyme activity.

[0027] In some embodiments, the method further comprises treating the slurry to intermittently increase the pH of the slurry.

[0028] In some embodiments, the slurry is maintained at a temperature of at least 70°C until the slurry separates into a liquid component and a solid component.

[0029] In some embodiments, the mixing of BSG and water is performed at a temperature of at least above 70°C.

[0030] In some embodiments, the enzymatic treatment comprises, in sequence, heating the slurry to a temperature in the range of 40°C-70°C, adding one or more carbohydrases to the slurry, adjusting the pH of the slurry to a range of 7-11, and adding one or more proteases to the slurry, wherein the one or more carbohydrases are reacted with the slurry within a first treatment period in the range of 0.5-12 hours, and the one or more proteases are reacted with the slurry within a second treatment period of no more than 2 hours.

[0031] In some embodiments, the one or more carbohydrases include a combination of cellulase and beta-glucanase.

[0032] In some embodiments, the one or more proteases include an endoprotease.

[0033] In some embodiments, adjusting the pH comprises adding one or more alkaline salts or alkaline solutions to the slurry.

[0034] In some embodiments, forming the precursor liquid includes separating water from the liquid component to produce a concentrated liquid component.

[0035] In some embodiments, separating the water includes evaporating water from the liquid component and producing evaporated water, and the method further includes providing at least a portion of the evaporated water for mixing with the BSG to form a slurry.

[0036] In some embodiments, mixing comprises running a high-shear mixer through the mixture of water and BSG.

[0037] In some embodiments, the high shear mixer is operated on the slurry for less than 60 minutes, and preferably less than 45 minutes or 30 minutes.

[0038] In some embodiments, mixing comprises operating a plurality of mixing devices fluidly connected in series to sequentially process the mixture of water and BSG, wherein the plurality of mixing devices comprises at least one grinder.

[0039] In some embodiments, the plurality of mixing devices includes at least one colloid mill.

[0040] In some embodiments, the plurality of mixing devices includes at least two colloid mills configured to produce different particle sizes.

[0041] In some embodiments, the plurality of mixing devices comprises a disc mill.

[0042] In some embodiments, the D90 particle size of the slurry generated by mixing is less than 1500 μm, preferably less than 1200 μm or 1100 μm.

[0043] In some embodiments, mixing is performed to achieve a total solids content of the slurry of 8% to 12% (by weight).

[0044] Other objects and aspects, as well as features, embodiments and technical advantages, will become apparent from the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is a schematic block diagram of an example system for producing beer and non-fermented beverages.

[0046] Figure 2An exemplary method for producing beer and non-fermented beverages from cereal materials.

[0047] Figure 3A According to the first example Figure 2 a flow chart of a process for producing a precursor liquid in a method of Figure 3B FIG. 1 is a block diagram of a production line for producing a precursor liquid according to a first example.

[0048] Figure 4A According to the second example Figure 2 A flow chart of a process for producing a precursor liquid in a method of Figure 4B is a block diagram of a production line for producing a precursor liquid according to a second example; and Figure 4C for Figure 4B A plan view of an exemplary yield increasing station in a production line.

[0049] Figure 5A is a flow chart of an example procedure for processing a precursor liquid into a non-fermented beverage; and Figure 5B is used according to Figure 5A Block diagram of an exemplary processing station for producing a non-fermented beverage.

[0050] Figure 6 is a block diagram of an exemplary mixing station in a production line for producing a precursor liquid.

[0051] Figure 7A is a block diagram of an exemplary subsystem for water recovery in a production line for producing a precursor liquid; and Figure 7B yes Figure 7A Flowchart of an exemplary method performed by a subsystem in . DETAILED DESCRIPTION

[0052] The embodiments will be described more fully hereinafter with reference to the accompanying drawings, which show only some, but not all, embodiments. Indeed, the subject matter of this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0053] For the sake of brevity and / or clarity, well-known functions or constructions may not be described in detail. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0054] Like reference numerals refer to like elements throughout.

[0055] Before describing the embodiments in more detail, some definitions will be given.

[0056] As used herein, "grain material" refers to any grain or combination of grains that is used or can be used for beer production. Grains can be used to brew beer after malting or as an unmalted starch adjunct. Barley is the primary raw material for beer production, but corn, rice, and wheat are also commonly used. Examples of other grain materials include sorghum, millet, oats, rye, triticale, and fonio. The term "grain" as used herein also includes pseudocereals such as buckwheat.

[0057] As used herein, "beer" refers to a fermented beverage made from cereal materials. Beer may or may not contain alcohol.

[0058] As used herein, "brewer's spent grain," or BSG, is a byproduct of the brewing industry, also known as spent grains. BSG is obtained as a primarily solid residue during the saccharification process, where starch is converted into sugars during beer production. The composition of BSG can vary depending on the type of grain used, how it was grown, and other factors, but BSG is generally rich in cellulose, hemicellulose, lignin, and protein. BSG is also naturally rich in fiber.

[0059] As used herein, "slurry" refers to a mixture of solids having a density greater than water suspended in a liquid.

[0060] As used herein, "precursor liquid" or PL refers to a liquid suitable for further processing into a non-fermented beverage. A precursor liquid may also be referred to as a "base liquid" or "base liquid." Typically, a precursor liquid lacks one or more properties that make it suitable for human consumption (e.g., in terms of taste and / or mouthfeel).

[0061] As used herein, "non-fermented beverage" or NFB refers to a so-called ready-to-serve (RTS) beverage that is produced without the need for fermentation (whether by the addition of yeast or lactic acid bacteria). Specifically, NFB is a precursor liquid that is further processed to make it easier for humans to drink (e.g., in terms of taste and / or mouthfeel). In some embodiments, no alcohol is added during the production of the non-fermented beverage and, therefore, does not contain alcohol. In some embodiments, the non-fermented beverage is a plant milk. Plant milk is a vegan beverage that is a plant-based alternative to cow's milk and typically has a smooth mouthfeel. Plant milk is also known as alternative milk, pseudo milk, or vegan milk.

[0062] As used herein, a range is defined as extending from a first value to a second value, and is intended to include the first value and the second value.

[0063] As used herein, "total solids" or TS is used in its ordinary sense and is a measure of all suspended, colloidal, and dissolved solids in a sample. The total solids content of a sample is typically determined as the amount of solids remaining after heating the sample to 105°C to constant weight.

[0064] As used herein, a "high-shear mixer" includes a mixing device, such as a rotor, paddle, propeller, blade, turbine, or the like, that has a peripheral speed of at least 10 m / s, at least 15 m / s, or at least 20 m / s. In some implementations, the mixing device may be surrounded by a stator to enhance the high-shear mixing effect. A high-shear mixer is a batch mixer that is mounted within a container and is used to process fluid materials in batches, with the possibility of recirculating the fluid material during the mixing process.

[0065] As used herein, the term "disc mill" is used in its ordinary sense and is also referred to as a friction grinder. A disc mill comprises opposing discs or plates that interact with the material to be ground. During the grinding process, one disc is stationary while the other rotates. In some implementations, the gap between the discs is adjustable. The discs may be grooved, serrated, or spiked. One of the discs may be perforated to facilitate the delivery of pulverized material.

[0066] As used herein, "colloid mill" is used in its ordinary sense and comprises a stationary cone (stator) and a rapidly rotating cone (rotor) which form a gap in which fluid material is ground.

[0067] The present disclosure relates to the production of non-fermented beverages (NFBs) using BSG produced during beer production. The applicant has discovered that effectively separating NFB production from beer production would be highly advantageous. As will be described further below, BSG obtained from beer production is highly susceptible to microbial activity and can significantly degrade within hours of production. One approach to complying with NFB food safety regulations is to integrate beer and NFB production into a single facility, allowing BSG to be used for NFB production before significant degradation occurs. Treatment of BSG to mitigate microbial degradation, such as through heat treatment, could also be considered, thereby extending its useful life. However, BSG is primarily made from soaked grain materials and has a slurry-like consistency. Given its consistency, adequately mitigating microbial degradation throughout the BSG can be difficult and expensive. Furthermore, even if the useful life of BSG is extended, transporting BSG between facilities is equally difficult and costly. One contributing factor to this logistical challenge is that BSG cannot be pumped; handling requires the use of conveyors, carts, wheel loaders, dump trucks, and other equipment. Furthermore, during transportation, BSG is susceptible to contaminants or microbial contamination. Cleaning handling equipment and transport vehicles can also be laborious and costly. The applicants recognized that these issues can be overcome by separating NFB production into two stages: the production of a precursor liquid from BSG and the production of NFB from the precursor liquid. The precursor liquid itself is a liquid and pumpable, making it easy to handle and transport under well-controlled conditions. Any equipment used to handle and transport the precursor liquid is also much easier to clean than with BSG.

[0068] Based on this, the applicants have further recognized that allowing for intermediate storage of the precursor liquid for at least a predetermined minimum period of time, whether produced in the same facility as beer production or in a separate facility, would greatly facilitate NFB production. Intermediate storage can reduce the dependency between NFB production and beer production. In some embodiments, the storage period is set to allow for transport between the aforementioned different facilities. In some embodiments, the storage period is set to facilitate production within a single facility. It is currently believed that the storage period should be at least 2 hours. In some embodiments, the storage period is at least 4, 6, or 8 hours. In preferred embodiments, the storage period exceeds 8 hours. This provides significant flexibility in transportation and / or production. It is currently believed that storage periods exceeding 8 hours require one or more additional measures to maintain the quality of the precursor liquid and ensure that the resulting NFB complies with food and safety regulations. One such measure may involve stabilization during the precursor liquid production process to reduce or terminate microbial activity in the precursor liquid. Another such measure may involve intermediate storage to inactivate or slow microbial activity in the precursor liquid during the storage period, for example by cooling the precursor liquid during the storage period. It will be appreciated that the above measures may be taken to ensure the quality of the precursor liquid even if the storage period is less than 8 hours.

[0069] The content of the precursor liquid can affect the perceived quality of the NFB, such as in terms of taste and mouthfeel, as well as nutritional value. The precursor liquid can be seen to be composed of sugars (monosaccharides and disaccharides), protein, total solids, moisture, and ash. It is currently considered ideal to produce a precursor liquid with the following contents (based on the weight percentage of the precursor liquid): 0.5%-2% sugars, 0.7%-2% protein, 4%-7% total solids, 93%-96% moisture, and 0.1%-0.5% ash. This is the target composition of the precursor liquid in all embodiments and examples disclosed herein. Applicants currently believe that better NFB performance can be achieved by producing a precursor liquid with the following contents: 1.0%-1.1% sugars, 0.9%-1.6% protein, 5% (±0.5%) total solids, 95% (±0.2%) moisture, and 0.3% (±0.05%) ash.

[0070] This novel principle for producing beer and NFB will combine Figure 1 For further explanation and examples, Figure 1is a schematic block diagram of a combined beer and NFB production system. The system comprises a first subsystem 1 for producing beer and a second subsystem 1' for producing non-fermented beverage NFB. The first subsystem 1 comprises a beer production line 10 and a precursor liquid PL production line 20. The production line 20 is configured to produce PL using a by-product of the production line 10. The by-product is the retentate R1 resulting from the filtration process in the line 10. Specifically, the retentate R1 comprises all solids separated from the wort by filtration. The retentate R1 primarily comprises the peel and hull fractions and other non-starch fractions of the cereal material used as raw material for beer production in the line 10. The retentate R1 is commonly referred to as brewer's grains, BSG.

[0071] The beer production line 10 adopts a traditional structure and processes water W and grain material GM into beer B by adding yeast Y. In the illustrated example, the line 10 includes a saccharification station 11, a filtering station 12 and a fermentation station 13. The saccharification station 11 is configured to receive water W and grain material GM, and optionally one or more other ingredients. The saccharification station mixes water and grain material to form an enzyme-containing mash. The enzyme can be derived from the grain material or added to the mash separately. In the saccharification station 11, the enzyme breaks down starch into fermentable sugars, such as a mixture of glucose, maltose and maltotriose. The mash produced by the saccharification station 11 is transported to the filtering station 12, which is configured to separate the mash into wort containing fermentable sugars and lees, the above-mentioned retentate R1. The process of separating lees from the wort is called "wort separation" and can be performed by filtration (wherein the grain bed itself acts as a filter medium) and / or using a filter frame.

[0072] The retentate R1 mainly contains fiber (mainly non-starch polysaccharides), as well as a large amount of protein and lignin, of which arabinoxylan (AX) usually constitutes the most abundant component. Therefore, R1 is basically a lignocellulosic material. Typically, about half of R1, based on dry weight, contains fiber. Up to about 30% of R1, based on dry weight, may contain proteins, such as hordeins, glutenins, globulins and albumins. Essential amino acids account for about 30% of the total protein content, of which lysine is the most abundant. Cellulose is usually the most abundant polysaccharide in R1. Monosaccharides in R1 may include xylose, glucose and arabinose. In addition, R1 may contain various minerals, such as silicon, phosphorus, calcium and magnesium.

[0073] From the filtration station 12, the wort is transported to the fermentation station 13, where fermentation begins by adding yeast Y. In the fermentation station 13, the wort is transformed into beer, a process that can take from a week to several months, depending on the type of yeast and the strength of the beer. In addition to producing ethanol, fine particulate matter suspended in the wort also settles during fermentation. After fermentation is complete, beer B is discharged from the fermentation station 13. Figure 1As shown, the subsystem 1 may include a beer packaging station 31 configured to receive beer B from the production line 10 and fill it into a first container 110. The first container 110 may be configured for bulk distribution (e.g., kegs or cans) or for direct drinking (e.g., cans or bottles). Figure 1 Not shown, but subsystem 1 may include dedicated tanks for storing beer ready for packaging.

[0074] It should be understood that Figure 1 The beer production line 10 in FIG. 1 is provided as a non-limiting example only. Stations 11-13 may be configured to perform additional processes, and / or the line 10 may include additional stations for such additional processes, such as wort flavoring, wort heating, wort cooling, beer filtration, beer maturation, etc. The subsystem 1 may include multiple beer production lines 10, and these production lines 10 may share equipment.

[0075] The PL production line 20 is configured to process water W and retentate material R2 into a precursor liquid PL, optionally including the addition of one or more other ingredients I1, such as one or more enzymes, to increase the protein and / or dry matter content of the PL. The retentate material R2 comprises at least a portion of the retentate R1 from the beer production line 10, subject to one or more constraints, as described below. Here, R2 is also BSG. The subsystem 1 may include multiple PL production lines 20, and these production lines 20 may share equipment. Figure 3B 、 Figures 4B-4C 、 Figure 6 and Figure 7A An example configuration of a PL production line 20 is further shown.

[0076] Subsystem 1 also includes a control system 40 configured to generate control signals Ci for equipment within subsystem 1, including equipment in production lines 10 and 20. For example, control system 40 can control various process parameters within the corresponding lines, such as mixing level, residence time, temperature, pressure, ingredient addition, etc. However, at least some of the process steps for producing beer and PL, respectively, can be performed manually and / or controlled by an operator.

[0077] The beer production line 10 produces a large amount of retentate R1. Typically, about 100-130 kg of retentate R1 can be obtained for every 100 kg of cereal material, which is equivalent to about 15-20 kg of retentate per hectoliter of beer. Figure 1In the figure, the properties of R1 are represented by Q1. It should be noted that R1 refers to the retentate directly after production from line 10. The main component of R1 is water, which is primarily present in the R1 stillage. Typically, the relative moisture content of R1 ranges from 60% to 90%, corresponding to a total solids (TS) content of 10% to 40%. In actual production, the relative moisture content of R1 is typically in the range of 70% to 85%, corresponding to a TS content of 15% to 30%. The production temperature of R1 ranges from 55°C to 90°C. This refers to the average temperature of R1, as temperature variations may occur within a batch of retentate produced from line 10. In practice, the temperature of R1 is typically above 65°C or above 70°C, and preferably below 85°C or below 80°C. R1 is rich in polysaccharides and proteins, has a high moisture content, and is heated to a relatively high temperature, making it susceptible to microbial growth and spoilage. Thus, while R1 may be microbiologically stable and within acceptable limits for food use when produced in line 10, the proliferation of microaerophilic and anaerobic bacteria causes the microbial flora in R1 to be susceptible to rapid changes. Because NFB is intended for human consumption, the retentate material, R2, must comply with food safety regulations, including limits on the presence of bacteria and toxins. Figure 1 Subsystem 1 in

[15] facilitates compliance with such regulations because the PL production line 20 is located within the same physical facility as the beer production line 10. Specifically, the time from R1 output from line 10 to R2 input line 20 may be restricted.

[0078] It is important to note that line 10 produces R1 in bulk, while line 20 may or may not consume R2 in bulk. Depending on the production capacity of lines 10 and 20, R2 may contain all or only a portion of R1.

[0079] exist Figure 1In the figure, block 10' represents optional equipment in subsystem 1 for transporting, storing, or processing R1. In some embodiments, block 10' includes a fixed device for transporting at least a portion of R1 from line 10 to line 20. This fixed device may include one or more screw conveyors, pipes, etc. This fixed device may also include a transfer mechanism configured to ensure the required amount of R2 for line 20 by transferring a portion of R1, for example, to a separate storage tank (not shown) or another production line (not shown) for producing PL or other products based on the transferred R1. However, in some embodiments, the transfer of the retentate from line 10 to line 20 can be performed without a fixed device, such as using a wheeled cart or pallet, which may or may not be motorized. In some embodiments, block 10' includes an intermediate storage for storing the retentate. In some embodiments, block 10' includes equipment for stabilizing the retentate by reducing its microbial activity. This stabilization can be achieved by one or more of heating, cooling, drying, or altering the pH of the retentate by acidification or alkalization.

[0080] In some embodiments, this stabilization is omitted. Thus, R2 can be produced without any active processing of R1 to change its properties. As used herein, "active processing" refers to the supply of energy and / or one or more substances. By omitting active processing, the construction and operation of subsystem 1 can be simplified and production costs can be reduced. The lower production costs are not only due to the lower consumption of energy and / or substances, but also to the reduced need for cleaning and maintenance of the stabilization equipment.

[0081] The second subsystem 1' is configured to produce a non-fermented beverage NFB from the precursor liquid PL produced by the first subsystem 1'. The second subsystem 1' comprises a processing station 60, which is configured to process the PL into NFB by adding one or more ingredients I2. The process of processing the PL into NFB is also referred to herein as the "final formulation". The ingredients I2 may include any one of vegetable oil, flavoring, sweetener, salt, thickener, stabilizer, vitamins or minerals. Figure 1 As shown, the subsystem 1' may also include a NFB packaging station 32, which is configured to receive the NFB from the processing station 60 and fill it into a second container 210. The second container 210 may be sterile or semi-sterile, or not. The second container 210 may be configured for bulk distribution or direct consumption. In some embodiments, the second container 210 is any type of consumer packaging, including but not limited to glass or plastic bottles, metal cans, or paper boxes, which can be sealed for subsequent distribution. Although Figure 1It is not shown in the figure, but the subsystem 1' may include dedicated tanks for storing NFB during the packaging preparation stage.

[0082] although Figure 1 Not shown, but the second subsystem 1' may include a control system, which may be similar to or a portion of the control system 40, and configured to generate control signals for the devices within the subsystem 1', including the processing station 60.

[0083] like Figure 1 As shown, system 1 also includes a reservoir 50 for storing the precursor liquid PL produced by production line 20. Reservoir 50 is configured for intermediate storage of the aforementioned precursor liquid. Reservoir 50 may include one or more containers, vessels, storage tanks, etc., which may be fixed or movable. As described above, intermediate storage may involve transportation from a first factory containing subsystem 1 to a second factory containing subsystem 1'. The first and second factories may be quite far apart, for example, 10-500 km. Transportation can be carried out by cargo transport units, such as road freight vehicles, rail freight cars, freight containers, road tankers, rail wagons, portable tanks, or any other conventional units for transporting liquids. Alternatively, subsystems 1 and 1' may be located within the same factory, with the precursor liquid being pumped into reservoir 50 after production by subsystem 1 and being pumped out of reservoir 50 by subsystem 1' as needed during the production of NFB.

[0084] Figure 2 is a flow chart of an example method 200 for producing beer and NFB. Figure 1 The system in the method 200 is described. In step 201, the cereal material is processed into mash by subsystem 1 (for example in the mashing station 11). In step 202, the mash is separated into fermentable wort and retentate by subsystem 1 (for example in the lautering station 12). Step 202 thus produces R1. In step 203, R2 is obtained by the production line 20. In step 204, R2 is processed into a slurry. As described above, R2 contains at least a portion of R1. In step 205, the slurry is processed into a precursor liquid PL, for example, according to the following reference Figure 3A and Figure 4A In step 206, the precursor liquid is pumped into a reservoir (e.g. Figure 1 The storage device 50) is used for intermediate storage for at least a predetermined minimum period of time. Figure 1 In the example shown in FIG. 2 , steps 204 - 206 are performed by production line 20 .

[0085] As shown in the dashed box, the method 200 may also include at least one stabilization step 207 to reduce microbial activity. The stabilization step 207 may be particularly relevant if R2 is obtained without stabilization of R1. However, experiments have shown that the stabilization step 207 may also be important if the BSG has been stabilized. In one example, Figure 2 As shown, the slurry is stabilized to reduce its microbial activity. In another example, as Figure 2 As shown, the precursor liquid is stabilized to reduce its microbial activity. In another example not shown, stabilization is performed as a part of step 205, for example by treating the liquid component extracted from the slurry (see below). Depending on the specific implementation, stabilization may involve heating, cooling, changing the pH value by acidification or alkalization, or any combination of the above operations. In a preferred embodiment, stabilization is performed by heating (also referred to as heat treatment). Compared with cooling and pH adjustment, heat treatment is more effective in eliminating microorganisms. In addition, compared with pH adjustment, heat treatment has the least effect on the properties of the stabilized material.

[0086] For example, the heat treatment may involve one or more of the following operations: heating to 60°C-70°C for 10-15 seconds (heat treatment), heating to 72°C-110°C for 15-120 seconds (pasteurization), heating to 120°C-130°C for 15-120 seconds (high temperature pasteurization), or heating to 137°C-145°C for 4-16 seconds (ultra-high temperature heat treatment or sterilization). The heat treatment may be adjusted according to the microbial load of R2 and / or the expected time of intermediate storage of the precursor liquid (step 206). The heat treatment may be performed by direct heating (e.g., steam injection) or indirect heating (e.g., in one or more heat exchangers), or a combination of the two.

[0087] like Figure 1-2 As shown by the horizontal dashed line in the middle, the production of NFB is separated from the processing of the retentate material R2 by an intermediate storage of the precursor liquid. Figure 2 In the method 200, the method 200 includes a step 211, which is performed by the subsystem 1' (eg Figure 1 The precursor liquid is processed into NFB at the processing station 60. Step 211 can be performed according to conventional practices, such as those used in traditional plant milk production, to obtain the desired NFB taste and / or mouthfeel. Figure 5A The example of step 211 is further described. In step 212 , the NFB is output and packaged, for example in the packaging station 32 .

[0088] Method 200 further comprises step 221, in which fermentable wort is processed into beer in subsystem 1, for example, in fermentation station 13. Step 221 can be performed according to any conventional procedure and begins with the addition of yeast to the wort. In step 222, the beer is discharged and packaged (for example, in packaging station 31).

[0089] Figure 3A is a flow chart of a first example process 230A for producing a precursor liquid PL, such as Figure 2 The process 230A is a part of the method 200. The process 230A provides a simple and effective technique for producing PL from the retentate material R2. The process 230A can be performed by Figure 1 The production line 20 in FIG. 1 is executed and includes steps 204, 208 and 205 executed in sequence. Figure 3A In the embodiment, step 204 of processing R2 into a slurry includes inputting R2 (step 204A), adding water (step 204B), and mixing R2 and water into the slurry (step 204C). Steps 204A-204C can be performed in a mixing device, such as a storage tank with an integrated or additional mixing device (such as a recirculation system and / or a rotor or impeller). In some embodiments, the mixing device includes a heating device for heating the contents of the storage tank, such as by directly injecting steam or circulating a heating medium in the tank jacket, which is well known in the art. As can be understood from the above, R2 is included in step 201 ( Figure 2 ) is processed into mash in step 204B. The mixing in step 204C cuts these particles into smaller particles, which are suspended in the water added in step 204B. The amount of water added in step 204B depends on the desired TS of the PL and the TS of R2. In a non-limiting example, the TS of the slurry may be in the range of 4%-15% (weight percentage). In a preferred embodiment, the TS of the slurry is in the range of 8%-12% (weight percentage). Within this range, the viscosity of the slurry is low enough to make it easy to pump, and the TS enables subsequent PL to be used to produce NFB with the desired properties. Steps 204A-204C can be performed in a different order. For example, water can be added before R2. In addition, R2 and water can be added in batches, and mixing can be performed for each batch.

[0090] Adding water in step 204B has significant advantages. The slurry becomes pumpable, which facilitates subsequent processing. In addition, the slurry can be heated using one or more heat exchangers and can be pumped into tanks for storage and / or further processing. It has been proposed to extract liquid from BSG by pressing, similar to pressing grapes in wine production. However, because most of the water in BSG is bound, only a small amount of water can be extracted by pressing. Internal tests have shown that from 60 kg of BSG, pressing can extract approximately 30 liters of liquid. In contrast, by generating the slurry according to step 204, the same amount of BSG can produce approximately 900 liters of PL.

[0091] In some embodiments, the temperature of the water added in step 204B is at least above 70° C., and preferably at least above 75° C. or at least 80° C. This will inhibit the growth of microorganisms in the slurry.

[0092] In some embodiments, the mixing in step 204C is performed at a temperature greater than or equal to a minimum temperature, which may be 70°C, preferably 75°C or 80°C. Furthermore, the temperature during the mixing process may be equal to or less than a maximum temperature, which may be 100°C. According to these embodiments, the temperature of the mixture of R2 and water is maintained within the temperature range defined by the minimum and maximum temperatures throughout the mixing step. In addition to inhibiting microbial growth, the elevated temperature also reduces the viscosity of the mixture.

[0093] In some embodiments, as Figure 3A As shown in step 208 of FIG, after mixing, the slurry is maintained within the aforementioned temperature range for a period of time, for example, to ensure the correct yield of protein in the slurry. In a non-limiting example, the holding time may range from 1 to 60 minutes. The longer the holding time, the more important it is to maintain the temperature to counteract microbial activity in the slurry. Step 208 may be performed in the mixing apparatus, in a dedicated storage tank, or during transport in preparation for step 205.

[0094] In a preferred embodiment, the heating according to steps 204 and 208 can achieve stabilization of the above slurry. Figure 2 Step 207 in the embodiment is implemented by steps 204 and 208 together.

[0095] In a variant not shown, step 204 is performed without heating the slurry and a dedicated stabilization step 207 is performed between steps 204 and 205 to stabilize the slurry, for example by heat treatment. In another variant, the stabilization step can be performed during or after step 205, for example with reference to Figure 2 As stated.

[0096] and Figure 2As shown, method 230A includes step 205 of processing the slurry into a precursor liquid PL. In the example shown, step 205 includes step 205A of separating the slurry into a solid component and a liquid component, and step 205B of obtaining the precursor liquid from the liquid component. The separation in step 205A removes solids larger than a minimum size from the slurry. These solids form a sludge containing husks, fibers and other solid particles. The solid component is usually discarded. In a non-limiting example, the minimum size is in the range of 50-500 μm, for example, about 100 μm. In some embodiments, during step 205A, the temperature is also maintained within the above-mentioned temperature range. Step 205A can be performed in any type of filtering or separation device (e.g., a decanter).

[0097] Step 205B may or may not involve further processing of the liquid component to form a precursor liquid. In a simple embodiment, the precursor liquid is obtained by receiving the liquid component from the filtration / separation device performing step 205A. Alternatively, the liquid component may be processed in step 205B to stop an ongoing hydrolysis process that was previously initiated by adding one or more enzymes to the slurry (see Figure 4A Alternatively or additionally, the liquid component may be concentrated in step 205B to reduce its water content. Figure 4A Step 205B is further explained with an example.

[0098] Figure 3B 2 is a block diagram of an exemplary production line 20 configured for producing a precursor liquid according to one embodiment. Production line 20 includes a mixing station 21 configured to perform step 204. Mixing station 21 may include a mixing device as described above. Mixing station 21 is configured to receive R2 and water W and output slurry S. Stabilization station 22 is configured to perform the same steps as step 207 ( Figure 2 ) corresponding heat treatment and output stabilized slurry SS. The separation station 23 is configured to receive the stabilized slurry SS and is configured to perform step 205A. The separation station 23 may include one or more decanters. Through the separation station 23, the slurry SS is separated into a liquid component LC and a solid component SC. In the illustrated example, the liquid component LC forms the precursor liquid PL and is pumped to the storage 50 for intermediate storage. The solid component SC is discarded. The stabilization station 22 may also be operated or alternatively operated to perform step 208 ( Figure 3A ), the temperature of the slurry is maintained within the above temperature range. Alternatively, station 22 can be omitted and the stabilization step 207 can be performed in the mixing station 21.

[0099] Figure 4Ais a flow chart of a second example process 230B for producing a precursor liquid PL, for example as Figure 2 The process 230B may be performed by Figure 1 The process is performed in accordance with the production line 20 in FIG. 20 and includes steps 204, 207A, 207B, and 205 performed in sequence. Compared to process 230A, process 230B provides a more advanced technique for producing PL from R2, which includes a step specifically for increasing the protein and / or dry matter content of PL by enzyme treatment. Process 230B begins with step 204, where R2 is processed into a slurry. Step 204 can be combined with process 230A ( Figure 3A ). Step 204 is followed by a stabilization treatment, namely steps 207A and 207B. In step 207A, the slurry is subjected to a heat treatment. The purpose of step 207A is to kill bacteria, viruses, and spores that may be present in the slurry. Step 207A is used to prepare the slurry for subsequent enzyme treatment, in which the slurry is kept at a lower temperature for a longer time. Without the heat treatment of step 207A, microorganisms may multiply during the enzyme treatment and destroy the resulting PL. In some embodiments, step 207A is performed under pressurized conditions in a closed heating container, similar to treatment in an autoclave. In step 207B, the slurry is cooled to the operating temperature of the enzyme treatment. Depending on the enzyme used, the operating temperature can be in the range of 40°C to 95°C. In one example, the operating temperature is below 70°C. In some embodiments, step 207A and / or step 207B are omitted.

[0100] In a non-limiting example of step 207A, the slurry is heated by a combination of indirect heating and direct heating. For example, the slurry can be pumped through a heat exchanger (HE) (e.g., a tubular or plate HE) in which the slurry is heated to 60°C to 90°C. The incoming slurry temperature can be in the range of 4°C to 70°C. The slurry is then further heated by injecting steam (e.g., in a dedicated container). As a result, the temperature of the slurry can be raised to 137°C to 145°C. The injected steam has culinary quality. Then, in step 207B, the slurry can be passed through a vacuum chamber to allow the slurry to be evaporated and cooled to 60°C to 90°C. The vacuum level in the vacuum chamber can be adjusted depending on the final temperature to be achieved. The slurry can then be further cooled to approximately 20°C to 30°C in a heat exchanger HX (tubular or plate).

[0101] In another non-limiting example of step 207A, the slurry is heated by indirect heating. For example, the slurry is preheated to 60°C-90°C in the first section of a heat exchanger HX (tubular or plate type), and then further heated to a target temperature of 137°C-145°C in another section of HX. The slurry is kept under pressure to avoid flashing and is held at the target temperature for 4-16 seconds. Then, in step 207B, the slurry can be transferred to another heat exchanger HX (tubular or plate type), cooled to 60°C-90°C in the first section, and then cooled to about 20°C-30°C in the second section.

[0102] Step 205 of treating the slurry into a precursor liquid includes step 205C, i.e. treating the slurry to increase its protein and / or dry matter content. Specifically, step 205C includes performing an enzyme treatment on the slurry. In the context of the present disclosure, enzyme treatment is also referred to as "hydrolysis" or "hydrolysis process". The enzyme treatment includes adding one or more enzymes to the slurry, mixing the corresponding enzymes with the slurry, and allowing it to decompose the components of the slurry within a predetermined treatment time period. It is currently believed that effective enzyme treatment is achieved by adding the corresponding enzyme in an amount of 0.5%-3% (by weight percentage) of the slurry. During the treatment time period, the mixture of slurry and enzyme may or may not be mixed. The control parameters of the enzyme treatment, such as temperature, pH value and treatment time, can be adjusted according to the corresponding enzyme. The applicant has found that it may be advantageous to include at least one of the following: a first enzyme treatment, which includes enzymatic decomposition of fibers in the slurry; or a second enzyme treatment, which includes enzymatic decomposition of proteins in the slurry. The first enzyme treatment may include adding one or more carbohydrate enzymes to the slurry. Examples of suitable carbohydrases include arabinanases, cellulases, beta-glucanases, hemicellulases, or xylanases. The second enzymatic treatment may include the addition of one or more proteases to the slurry. Examples of suitable proteases include endoproteases. The applicants have surprisingly discovered that combining the first and second enzymatic treatments can significantly increase the yield of protein and / or dry matter in PL. The first enzymatic treatment can break down the fibers in the slurry, producing proteins and other compounds, while the second enzymatic treatment can break down the proteins into smaller polypeptides or individual amino acids. Thus, the first enzymatic treatment can increase the yield of the second enzymatic treatment.

[0103] exist Figure 4AIn, step 205C comprises this combined enzyme treatment, and this treatment can be carried out in one or more storage tanks, and these storage tanks may or may not comprise one or more mixing devices.Start the first enzyme treatment 205C1, perform the first treatment time period (" first time period ").Step 205C1 is followed by step 205C2, for adjusting the pH value of the second enzyme treatment. Generally, protease is more effective than carbohydrase at higher pH values. Therefore, step 205C2 can be performed to improve the pH value of the slurry, for example, by adding alkaline salt or alkaline solution to the slurry. The example of alkaline salt includes sodium hydroxide, disodium phosphate, sodium bicarbonate etc. After step 205C2 has adjusted the pH value, start the second enzyme treatment 205C3, perform the second treatment time period (" second time period "). The first enzyme treatment continues in the second time period, so the second time period is shorter than the first time period in nature. According to the specific implementation scheme, after step 205C3, the further pH adjustment in step 205C4 can also be performed, for example, by adding acid or acid salt to reduce the pH value.

[0104] After extensive experimentation, the applicant has identified various enzyme treatment operating settings that can achieve desirable properties for PL, such as its protein and / or dry matter content. One operating setting is to add a combination of at least one cellulase and at least one β-glucanase in step 205C1. The experiments have used cellulase enzymes provided by Novozymes. and β-glucanase XL. Another operation setting is to add at least one endoprotease in step 205C3. The experiment has used the endoprotease provided by Novozymes and Execute. Another operation setting is to ensure that the temperature of the slurry is in the range of 30°C to 80°C when the enzyme treatment starts in step 205C. Experiments have shown that during the enzyme treatment, the performance is improved when the slurry temperature is maintained in the range of 40°C to 70°C, and the performance is better when the slurry temperature is maintained in the range of 50°C to 60°C. The currently preferred slurry temperature during the enzyme treatment is 55°C (±2°C). Another operation setting is to set the first time period to be in the range of 0.5h to 24h. Experiments have shown that the performance is improved when the first time period is set to be in the range of 0.5h to 24h, and the performance is better when the first time period is set to be in the range of 1h to 4h. The currently preferred first time period is 2h (±0.5h). Another operation setting is to adjust the pH value of the slurry to the range of 6-12 through step 205C2. Experiments have shown that the performance is improved when the adjusted pH value is in the range of 7-11, and the performance is better when the adjusted pH value is in the range of 8-10. A currently preferred adjusted pH value is 8 (±0.2). Another operating setting is to use a second time period of less than or equal to 3 hours. If the second time period is too long, the protease may produce bitter peptides, thereby reducing the effectiveness of the precursor liquid. Experiments have shown that when the second time period is less than or equal to 2 hours, performance is improved, and when the second time period is less than or equal to 1 hour, performance is even better. A currently preferred second time period is 45 minutes (±5 minutes).

[0105] Table 1 shows the effectiveness of the enzyme treatment, which compares the properties of the precursor liquid obtained from three different treatment experiments: no enzyme treatment, a first enzyme treatment (using only endoprotease), and a combination of the first and second enzyme treatments (cellulase, β-glucanase, and endoprotease). The properties of the slurry were the same at the beginning of all experiments, except that the pH was set according to Table 1. The use of enzyme treatment can increase the content of both TS and protein in the slurry. In addition, the protein content in the slurry was further significantly increased by using a combination of carbohydrase and protease. Although not shown in Table 1, the second enzyme treatment (one or more carbohydrases, no protease) was also found to increase the content of both TS and protein in the slurry compared to the process without enzyme treatment.

[0106] Table 1 Enzyme treatment pH TS (%) protein(%) none 6 4 0.3 Protease 7.9 5 0.6 Carbohydrate enzymes + proteases 7.6 5 0.85

[0107] Back to Figure 4A , step 205C is followed by step 205A, which separates the liquid component from the slurry. Step 205A can be combined with procedure 230A ( Figure 3A) are the same. Step 205A is followed by step 205B, which obtains a precursor liquid from the liquid component. As shown, step 205B may include step 205B1 to inactivate the enzyme added to the slurry in step 205C. Step 205B1 is performed to define a first and a second time period, i.e., to terminate the activity of the corresponding enzyme. Step 205B1 can be performed by heating the liquid component and keeping the heated liquid component for a predetermined time period (e.g., in the range of 10-600 seconds). For example, step 205B1 can include heating the liquid component to at least 80°C or at least 85°C, but not more than about 115°C. Heating can be performed in one or more heat exchangers. Alternatively or additionally, step 205B1 can include cooling the liquid component to inactivate the enzyme. For example, step 205B1 can include cooling the liquid component to below 10°C, and preferably below 5°C, but above 0°C, for example, in the range of 3°C to 5°C. Cooling can be performed in one or more heat exchangers. In one variation, step 205B1 is performed before step 205A, so that this step operates on the slurry rather than the liquid component. In some embodiments, step 205B1 is omitted.

[0108] exist Figure 4A In the embodiment of the present invention, after the deactivation step 205B1 (if performed), a concentration process of the liquid component is performed in step 205B2. The concentration process removes water from the liquid component, thereby increasing its concentration. The concentration process is particularly advantageous when the precursor liquid needs to be transported between factories because it reduces the volume and weight of the transported precursor liquid, thereby reducing the environmental impact of transportation. The concentration process can be performed by any technique for removing water from the liquid, including but not limited to evaporation and filtration.

[0109] Figure 4B is a block diagram of an example production line 20 according to one embodiment. The production line 20 includes a mixing station 21, which can be connected to Figure 3B The same as in. The mixing station 21 is configured to receive R2 and water W, and output a slurry S. The stabilization station 22 is configured to perform a heat treatment corresponding to steps 207A-207B, and output a stabilized slurry SS. In one variation, station 22 can be omitted, and the heat treatment can be performed in the mixing station 21. The hydrolysis station 24 is configured to receive the stabilized slurry SS. The hydrolysis station 24 is configured to start the enzymatic treatment of step 205C by adding one or more enzymes [E]. In some embodiments, the hydrolysis station 24 can be configured to perform steps 205C1-205C4 as described above. The hydrolysis station 24 may include one or more storage tanks, which may or may not include one or more mixing devices. The hydrolysis station 24 outputs a hydrolyzed slurry HS, i.e., a hydrolyzed slurry. The separation station 23 is configured to receive the hydrolyzed slurry HS, and is configured to perform step 205A. The separation station 23 can be connected to Figure 3BThe same as in. Through the separation station 23, the slurry HS is separated into a liquid component LC and a solid component SC. The deactivation station 25 is configured to receive the liquid component LC from the separation station 23 and is configured to treat the liquid component LC according to step 205B1 to inactivate its enzyme activity. The deactivation station 25 outputs the hydrolyzed liquid component HLC. The concentration station 26 is configured to receive the HLC from the deactivation station 25 and is configured to remove water from the HLC according to step 205B2 to obtain the precursor liquid PL. The concentration process obtains the extracted water EW, which is removed from the HLC. In some embodiments, as Figure 4B As shown, the concentration station 26 is fluidly connected to supply all or part of the EW to the mixing station 21 for producing the slurry S. This water recycling reduces the water consumption of the production line 20. Figures 7A-7B Give an example of water recycling.

[0110] exist Figure 4B In the example of FIG, the first and second time periods of the enzyme treatment include: the residence time of the corresponding enzyme in the slurry in the hydrolysis station 24, the time of pumping the slurry from the hydrolysis station 24 to the separation station 23, the time of producing the liquid component from the slurry, and the time of pumping the liquid component to the inactivation station 25. It is understood by those skilled in the art that the production line 20 can be designed to achieve the fluid passing through Figure 4B The transmission of stations 24, 23 and 25 in the embodiment of the present invention is consistent and meets the operating settings of the first and second time periods. This can be achieved by batch processing or continuous processing in the corresponding stations.

[0111] Figure 4B This is given as an example only. In an alternative, the pH adjustment in step 205B4 is performed by the deactivation station 25. In another alternative, the deactivation station 25 is arranged between the hydrolysis station 24 and the separation station 23. This arrangement of the deactivation station 25 makes it easier to control the first and second time periods. However, if the deactivation station 25 is arranged downstream of the separation station 23 (e.g. Figure 4B If the inactivation step 25 is used as shown in FIG2 , the complexity can be reduced because the volume of fluid to be inactivated is reduced. In addition, the viscosity of the liquid component LC is significantly lower than that of the slurry, which increases the heat exchangers available for inactivation by heating or cooling. In some installations, the inactivation station 25 or the concentration station 26, or both, can be omitted.

[0112] Figure 4C is a block diagram of an exemplary hydrolysis station 24, which may be included in Figure 4BIn the production line 20, a first substation 241 is configured to receive stabilized slurry SS and is configured to perform a first enzymatic treatment according to step 205C1 by adding one or more first enzymes E1. A second substation 242 is configured to receive the slurry from substation 241 and is configured to adjust the pH according to step 205C2, for example, by adding one or more alkaline salts or alkaline solutions A1. A third substation 243 is configured to receive the slurry from substation 242 and is configured to perform a second enzymatic treatment according to step 205C3 by adding one or more second enzymes E2. A fourth substation 243 is configured to receive the slurry from substation 243 and is configured to adjust the pH according to step 205C4, for example, by adding one or more acids or acid salts A2. It should be noted that separation into substations 241-244 is optional. It is contemplated that two or more of steps 205C1-205C4 can be performed by the same device by sequentially adding components E1, A1, E2, and A2.

[0113] Figure 5A is a flow chart that can be used as Figure 2 The method 200 shown is part of step 211, in which the precursor liquid is processed into the NFB ("final formulation"). In step 501, vegetable oil is added to the precursor liquid. The addition of the vegetable oil will at least partially shape the consistency of the NFB, for example, to achieve a desired mouthfeel. The amount of vegetable oil used depends on the formulation but can range from 0.1% to 5% by volume of the NFB. In step 502, the vegetable oil is mixed with the liquid component so that it is evenly dispersed in the liquid component, similar to a homogenization process. Step 502 can be performed in a tank equipped with a mixing device (e.g., a high shear mixer). In step 503, one or more other ingredients are added and mixed with the precursor liquid to form the NFB. These other ingredients can include one or more flavorings, sweeteners, salts, thickeners, stabilizers, vitamins, or minerals. Alternatively, one or more ingredients can be mixed with the precursor liquid before step 501 or step 502. The process may also include an optional step 504 of pasteurizing or sterilizing the NFB, intended to eliminate or at least reduce microorganisms in the NFB prior to storage or packaging. Step 504 can be performed in a conventional heater configured for UHT treatment, ultra-pasteurization, or pasteurization. For example, the NFB can be heated to a temperature in the range of 135°C to 150°C for a duration of 4 to 30 seconds.

[0114] Figure 5B is a block diagram of an example processing station 60 for processing PL into NFB according to one embodiment. The recipe substation 61 is configured to process the PL into NFB from the storage 50 ( Figure 1 ) receives the precursor liquid PL. For example, Figure 5AIn steps 501-503 of the process, the formulation station 61 can be configured to mix one or more ingredients I2 with PL. The formulation station 61 can include any number and type of conventional mixing equipment used for the final formulation. The stabilization station 62 is configured to receive the NFB from the formulation station 61 and stabilize it by sterilization or pasteurization. The NFB is then output from the stabilization station 62.

[0115] Back to Figure 1 The applicant has conducted extensive testing of different types of existing mixing equipment to find a scalable and efficient process that can achieve a suitable precursor liquid composition, with reference to the mixing station 21 in Figure 3 and the slurry generation step 203 in Figure 3. It is currently believed that it is beneficial to produce a slurry with a D90 particle size of less than about 1500 μm, preferably less than about 1200 μm or about 1100 μm, for the composition of the precursor liquid. Such a particle size is conducive to achieving the desired sugar, protein and TS content in the resulting precursor liquid. Tests have shown that a particle size of about 1400 μm (D90) can be obtained using a high shear mixer (HSM) running for 60 minutes (with or without recirculation turned on). More detailed tests show that the decrease in particle size tends to level off with longer HSM operating times, as shown in Table 2.

[0116] Table 2 Time (min) D90(μm) 15 1690 30 1520 45 1430 60 1400

[0117] As a result, the HSM run time can be shortened to approximately 30 minutes, or even less, without significantly increasing particle size. This reduces overall processing time and energy consumption. For example, an acceptable particle size can be achieved when the HSM is run for 45 minutes.

[0118] Tests also showed that a particle size of 1100-1200 μm could be achieved using a colloid mill when the gap size was in the range of 0.15-0.45 mm.

[0119] In order to obtain smaller particle sizes it has been found to be beneficial to operate a plurality of mixing devices in series on a mixture of water and BSG.Preferably the mixing devices are arranged in such a way that the particle size of their respective output fluids is reduced. Figure 6is a block diagram of an example mixing station 21 comprising three mixing devices 21A, 21B, and 21C in series, which sequentially process incoming retentate material R2 and water W. The number of mixing devices may also be two or more. The first mixing device 21A receives R2 and W and processes them into an output fluid, which is received and processed by the second mixing device 21B, and so on. The last mixing device in the series (here device 21C) outputs a slurry S. In some embodiments, at least one of the mixing devices in the series is a grinder, preferably a colloid mill. In some embodiments, the series mixing device comprises two colloid mills, one of which produces a smaller particle size than the other. In some embodiments, the series mixing device comprises a disc mill. It has been found that it is beneficial to arrange the disc mill upstream of the colloid mill to operate as a pre-grinder. Alternatively or additionally, the series mixing device may comprise an HSM. It has been found that it is also beneficial to arrange the HSM upstream of the colloid mill to operate as a pre-grinder.

[0120] Figure 7A is used to connect the enrichment station 26 fluid to Figure 4B A block diagram of an exemplary arrangement of the mixing station 21 in the production line 20 is shown. Hereinafter, it is assumed that the concentration station 26 comprises an evaporator configured to receive and evaporate at least a portion of the liquid component HLC, thereby generating evaporated water EW and a concentrated portion, which forms the precursor liquid PL. The evaporated water EW may contain other volatile substances or molecules, but typically the EW is composed of more than 97% water or more than 99% water. The amount of water evaporated from the HLC may be in the range of 90%-95% (by weight), or even higher, so that a large amount of water can be recycled back to the mixing station 21 and reused in the preparation of the slurry S. In addition, the EW may leave the evaporator at a higher temperature (e.g., in the range of 70°C-80°C or higher), and this heated water can be used to provide heat for the preparation of the slurry S, thereby significantly saving energy.

[0121] In order to return and reuse the EW, a return path (e.g., a suitable return line 80) is fluidly connected to the output of the evaporator for conveying the EW to the mixing station 21. The return line 80 may include any number of additional processing equipment, such as flow control equipment, instruments, branching devices, etc. In addition, the return line 80 may convey the EW in vapor or liquid form. In some embodiments, a condenser may be provided at the EW outlet of the evaporator.

[0122] like Figure 7AAs shown, the EW can be returned to the mixing station 21 in a variety of ways. For example, as shown, after leaving the concentration station 26, the EW can be returned directly to the input of the mixing station 21 via a branched fluid return line 80A, without further processing by other components of the apparatus. To ensure an appropriate mass balance of the EW in the slurry S, the apparatus may also include at least one flow meter 81, such as a mass flow meter or a volume flow meter, disposed between stations 26 and 21. Furthermore, to control the heat content of the slurry S, the apparatus may also include at least one temperature sensor 87 located upstream of the mixing station 21 to measure the heat content of the recirculated water fed into the mixing station 21.

[0123] In some cases, the EW may contain unwanted flavors, volatiles, or other impurities. In this case, the EW can be filtered using a suitable filter 83 to remove these impurities. Filter 83 can include a reverse osmosis (RO) filter, which provides excellent filtration. A pre-filter (e.g., a 25-micron needle filter bag) can also be used before RO filtration to extend the life of the RO filter. Because some types of filters may degrade at high temperatures (e.g., EW temperature), the apparatus can also include a cooler 82 upstream of filter 83. Cooler 82 can include a suitable heat exchanger configured to reduce the temperature of the EW to a desired temperature, for example, to approximately 50°C or lower, before filtration. To conserve the heat energy extracted from the EW for reuse, a heat transfer line 80B can be thermally coupled to cooler 82 and configured to transfer at least a portion of the extracted heat energy back to the recirculating water before entering the mixing station 21. In other cases, if it is desired that flavors, volatiles, impurities, or other molecules from the EW be included in the slurry S, the apparatus can include a bypass line 80C that bypasses filter 83.

[0124] The apparatus may be provided with a buffer tank 84 for receiving EW from the filter 83 or through the bypass line 80C to help separate the input / output capacity of the apparatus. The buffer tank 84 may also be configured to receive water W and mix it with the EW to form a water mixture, which is then supplied to the mixing station 21. The water W added to the tank 84 may at least partially compensate for the total amount of water required to generate the slurry S.

[0125] Because the water W added to storage tank 84 may be lower than the temperature required to prepare slurry S, a heater 85 may be provided downstream of buffer tank 84 to heat the water mixture before it is added to mixing station 21. Heater 85 may heat the water mixture to a temperature in the range of 55°C to 85°C. As described above, heat from cooler 82 (if used) may be added to the water mixture to reduce the external energy required by heater 85 to heat the water mixture to the desired temperature. In one variation, the heat generated by cooler 82 may be used to heat the slurry in mixing station 21.

[0126] A flow meter 86 may be located between the buffer storage tank 84 and the mixing station 21 to determine the mass balance of the water mixture added to the mixing station 21 for preparing the slurry S. The flow meter 86 may be used in conjunction with a suitable flow control device (e.g., a valve) or a suitable control circuit (e.g., an electronic controller) to determine and meter the desired amount of water mixture arriving at the mixing station 21. The flow meter 86 may also be used in conjunction with the flow meter 81 between the thickening station 26 and the buffer storage tank 84 to determine the amount of water W to be added to the storage tank 84. In addition, a temperature sensor 87 may be used to control the amount of water W in the water mixture and / or control the heater 85 to achieve a desired temperature of the water mixture.

[0127] Figure 7A The apparatus shown can be operated as a continuous loop process, where HLC in concentrating station 26 continuously produces water EW, which is returned to mixing station 21 to produce slurry S. Slurry S will therefore contain at least some water from the EW. After downstream processing, HLC is produced, which is then processed again in concentrating station 26 to produce EW. This process may last for hours or days, depending on the need to clean the machine, replenish raw materials, and so on. Although shown as a continuous process, the apparatus can also be used as a semi-continuous or batch process while still achieving the water-saving advantages. For example, after evaporation, the EW can be stored in a separate container and then used to produce slurry S.

[0128] Figure 7B This is a flowchart of an example program that can be used as a basis for Figure 4A The procedure shown can be used to perform the concentration process in step 205B2. Figure 7A In step 701, the concentrated extracted water EW is conditioned by one or more of cooling, filtering and heating and then stored in a buffer tank. In step 702, the temperature and / or amount of the EW is controlled before or during step 703. In step 703, the EW is supplied to form Figure 4A At least a portion of the water added in step 204B.

[0129] Back to Figure 1 The properties of the retentate material R2 are represented by Q2. The applicant has identified constraints on Q2 that are believed to provide unique technical advantages. These constraints will be presented below in the form of combinable embodiments.

[0130] In some embodiments, property Q2 of R2 is substantially the same as property Q1 of R1. In this context, "substantially the same" means that the difference in each property is less than ±10%, preferably less than ±5%. This means that R1 does not need to be actively processed to generate R2, and the time from the output of R1 to the input of R2 is finite.

[0131] In some embodiments, the relative moisture content of R2 is approximately the same as that of R1, for example within a range of about ±10%. This means that R1 does not need to be actively dried to produce R2.

[0132] In some embodiments, the relative moisture content of R2 is in the range of 60% to 90%, preferably in the range of 70% to 85%. Again, this means that R1 does not need to be actively dried to generate R2.

[0133] In some embodiments, the temperature of R2 is in the range of 40°C to 99°C, preferably above 50°C or above 55°C, and preferably below 85°C or below 80°C. It will be appreciated that even without active cooling, the temperature of the retentate will decrease over time. By limiting the temperature to above 40°C, preferably above 50°C or above 55°C, the growth of harmful bacteria in R2 can be prevented or at least mitigated. By limiting the temperature to below 99°C, preferably below 85°C or below 80°C, the energy consumption of active heating of the retentate can be reduced or even eliminated.

[0134] In some embodiments, the temperature of R2 is equal to or lower than the temperature of R1. This means that R1 does not need to be actively heated to generate R2.

[0135] In some embodiments, the temperature difference between R2 and R1 is less than 15° C., preferably less than 10° C. or less than 5° C. This means that R1 does not need to be actively heated or cooled to generate R2.

[0136] In some embodiments, the pH of R2 is equal to or less than the pH of R1. This allows for active acidification of the retentate to achieve a stable state. However, even in the absence of active acidification, the pH of R2 may be lower than the pH of R1 due to natural processes in the retentate.

[0137] In some embodiments, the pH of R2 is in the range of 5 to 7. Such a pH range is currently believed to be suitable for the production of the precursor liquid in line 20.

[0138] In some embodiments, the pH difference between R2 and R1 is less than 1, preferably less than 0.6, 0.4 or 0.2. This means that R1 does not need to be actively acidified or alkaline to generate R2.

[0139] While the subject matter of the present disclosure has been described in connection with what are presently considered to be the most practical embodiments, it should be understood that the subject matter of the present disclosure is not limited to the disclosed embodiments, but is intended to cover various modifications and equivalent arrangements within the spirit and scope of the appended claims. Furthermore, while operations are depicted in a particular order in the drawings, this does not necessarily require that the operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed to achieve the desired results.

Claims

1. A method for producing a precursor liquid for producing a non-fermented beverage, comprising: (203) Brewer's spent grains (BSG) are obtained from the beer production process; Mixing the BSG with water (204) to form a slurry; processing (205) the slurry to generate the precursor liquid; as well as The precursor liquid is stored (206) during a storage period for subsequent use as a base for producing the non-fermented beverage, wherein the storage period exceeds 2 hours.

2. The method according to claim 1, further comprising: At least one of the slurry or the precursor liquid is subjected (207) to a stabilization treatment to reduce microbial activity thereof.

3. The method of claim 2, wherein the stabilization treatment comprises at least one of heating, cooling, or changing the pH value by acidification or alkalization.

4. The method according to any one of the preceding claims, wherein the storage period exceeds 8 hours.

5. The method according to any of the preceding claims, wherein the storing (206) comprises transferring the precursor liquid from a first factory (1) for producing the beer to a second factory (1') for producing the non-fermented beverage.

6. The method according to any of the preceding claims, wherein said processing (205) said slurry comprises separating (205A) said slurry into a liquid component and a solid component, and forming (205B) said precursor liquid from said liquid component.

7. The method of claim 6, wherein said forming (205B) said precursor liquid comprises separating water (205B2) from said liquid component to produce a concentrated liquid component.

8. The method of claim 7, wherein the separating water (205B2) comprises evaporating water from the liquid component and producing evaporated water, the method further comprising supplying (703) at least a portion of the evaporated water to mix with the BSG to form the slurry.

9. A method according to any one of the preceding claims, wherein The storing (206) is performed to inactivate microbial activity in the precursor liquid during the storage period.

10. A method according to any one of the preceding claims, wherein The treating (205) the slurry includes performing (205C) an enzymatic treatment on the slurry by adding (205C1, 205C2) one or more enzymes to the slurry, and treating (205B1) the slurry or the liquid component to inactivate enzyme activity.

11. The method of claim 10, wherein the enzymatic treatment comprises, in sequence: heating (205C1) the slurry to a temperature in the range of 40°C-70°C, adding (205C1) one or more carbohydrases to the slurry, adjusting (205C2) the pH of the slurry to a range of 7-11, and adding (205C3) one or more proteases to the slurry, wherein the one or more carbohydrases are reacted with the slurry within a first treatment period in the range of 0.5-12 hours, and the one or more proteases are reacted with the slurry within a second treatment period of no more than 2 hours.

12. The method according to any one of the preceding claims, wherein the mixing (204) comprises running a high shear mixer (21A, 21B, 21C) on the mixture of the water and the BSG.

13. The method according to any one of the preceding claims, wherein the mixing (204) comprises operating a plurality of mixing devices (21A, 21B, 21C) connected in fluid series to sequentially process the mixture of the water and the BSG, wherein the plurality of mixing devices (21A, 21B, 21C) comprises at least one grinder.

14. The method according to any one of the preceding claims, wherein the slurry produced by the mixing (204) has a D90 particle size of less than 1500 μm, preferably less than 1200 μm or 1100 μm.

15. The method according to any one of the preceding claims, wherein the mixing (204) is performed so as to achieve a total solids content of the slurry in the range of 8% to 12% by weight.

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