MALTING FACILITY

Abstract

Batch malting installation Batch malting installation, comprising a malting chamber 7 including steeping, germination and kilning components, a tank 2 encompassing the malting chamber 7, the malting chamber 7 including a perforated bottom 6 formed of wire, common side walls with the tank 2 and a top wall provided with a grain feed opening to supply grain onto said perforated bottom 6, the steeping components including a water supply 8, a water heater 12, a water spray bar 15 for spraying the grains supported by said perforated bottom 6, a sensor for measuring the water level in the tank 2, a water recirculation configured to take water from the bottom 4 of the tank 2 and send it to the spray bar 15, and a water drain;the germination components comprising an air conditioner 23 for supplying the malting chamber 7 with air at controlled temperature and humidity and a turner 31 configured to spread the grain in a bed when loading the grain onto said perforated bottom 6, to turn the grain bed during germination, and, furthermore, to assist in the unloading of the malt obtained from the grain, the kilning components comprising a heater to supply hot air under the grain bed.;

Description

Title of the invention: MALTING FACILITY

[0001] The invention relates to malting.

[0002] Malting includes the steps of steeping to provide the grain with the moisture necessary to trigger the germination process, germination and kilning to stop the germination process at a predetermined state.

[0003] During the germination of a cereal, the grain develops enzymes. The cereal used generally includes barley, rye, sorghum, wheat, spelt and buckwheat.

[0004] The germinated cereal is called green malt. The cereal as it comes out of the kiln is called malt. The kilning process, through its temperature and duration, allows for the control of the degree of toasting, and therefore the concentration of certain desired or undesired compounds in the malt.

[0005] The general principles of malting, known for a very long time, are described in the book "Malting and Brewing", by Jean SUNIER, 2nd edition, La Concorde printing house, Lausanne, 1968, or in its more recent re-edition under the new title "The Making of Beer", Alliage publisher, September 26, 2007, ISBN-13 No. 978-2921327602.

[0006] Malting is carried out in factories called malt houses. A typical malt house for brewing malt has a production of 50,000 to 150,000 tonnes per year and is located in a place chosen according to production basins, consumption areas, routes for transporting heavy goods, the price of land, and the supply of low-cost water and energy.

[0007] A small volume market exists for craft breweries and grain alcohol manufacturers, particularly whiskies.

[0008] The Applicant has identified a need for small volumes of single-estate malts of the customer's choice. A large malt house is unsuitable for supplying small volumes of single-estate malts. A small barrel malt house lacks the expertise to produce single-estate malts. A small, conventional malt house with a capacity of 10 to 1000 tonnes per year is very expensive and requires significant handling.

[0009] Application WO2018 193168 addresses the need for a small-scale, industrial-grade automated malt house. However, the market for craft beer and spirits is growing while the market for major beer brands is declining.

[0010] This new malt house concept of the Applicant, adapted to the production slots of 5 to 1000 tonnes of malts per year, perfectly meets current sanitary requirements for an artisanal size.

[0011] The invention improves the situation.

[0012] The batch malting installation includes a malting chamber comprising steeping, germination and kilning components, a tank encompassing the malting chamber, the malting chamber comprising a perforated bottom formed of wire mesh, common side walls with the tank and a top wall provided with a grain feed opening to supply grain onto said perforated bottom, the steeping components comprising a water supply, a water heater, a water spray bar for spraying the grains supported by said perforated bottom, a sensor for measuring the water level in the tank, a water recirculation configured to take water from the bottom of the tank and send it to the spray bar, and a water drain;the germination components including an air conditioner to supply the malting chamber with air at controlled temperature and humidity and a turner configured to spread the grain in a bed when the grain is loaded onto said perforated bottom, to turn the grain bed during germination, and, furthermore, to assist in the unloading of the malt obtained from the grain, the kilning components including a heater to supply hot air under the grain bed.

[0013] Malt production in a malting chamber, where steeping, germination, and kilning are carried out, avoids disrupting the enzymatic processes of the process diagram, which are typically performed during transfer stages. According to the invention, these enzymatic processes are carried out within the malting chamber itself. Considerable time is saved by eliminating the transfers: steeping to germination, germination to kiln. This also saves on the space and energy consumption of the corresponding conveyors, as well as the labor required for their cleaning and sanitation. The kilning stage, at approximately 85°C and potentially up to 120°C, reduces bacterial growth and toxin concentration within the process unit, thus meeting the quality requirements of organic production.

[0014] Furthermore, the installation can be designed to road transport dimensions so that it can be moved from one site to another, thus avoiding the transport of grain from the production site to the malt house and then from the malt house to the brewery. The installation can be placed next to a brewery and supply, in a production run of a few weeks, a sufficient quantity of malt for the brewery's longer-term consumption. The installation is also suitable for strategically unstable regions because it can be moved quickly.

[0015] In one embodiment, the installation includes a device for evacuating by-products falling through the openings in the perforated bottom, by flushing.

[0016] In one embodiment, the installation includes a device for removing by-products falling through the openings in the perforated bottom by means of mechanized sweeping. Manual sweeping is avoided. Downtime is reduced.

[0017] In one embodiment, the tank is watertight to be able to contain water and thermally insulated.

[0018] In one embodiment, the water recycling system includes a filter for filtering the water. The water can be recycled.

[0019] In one embodiment, the water recycling includes an oxygenator to increase the dissolved oxygen level in the recycled water.

[0020] In one embodiment, the turner comprises an upper carriage mounted to roll on an upward-facing rail and a lower carriage mounted to roll on a downward-facing rail. The turner is capable of pushing the grain towards either end.

[0021] In one embodiment, said rails are formed by opposite surfaces of a beam arranged in the malting chamber above and at a distance from the openwork bottom.

[0022] In one embodiment, the installation includes a passive heat exchanger to recover heat from the outgoing air, recover water by condensation from the outgoing air, and supply heat to the incoming air.

[0023] In one embodiment, the malting chamber has a rectangular parallelepiped shape.

[0024] In one embodiment, the water inlets have water pipes arranged above the tank and extending into downpipes on the sides and inside the tank. Water stagnation is avoided.

[0025] In one embodiment, the water supply, water heating, water spray bar, water recycling, water drainage, air conditioner, and air heater are located at the end of the tank. The installation has a width compatible with the road transport width of 2.50 m or the container width of 2.43 m.

[0026] In one embodiment, the sensor for measuring the water level in the tank is disposed in an air supply duct. The sensor is protected.

[0027] In one embodiment, the installation is equipped with remote control.

[0028] In one embodiment, the installation includes unloading devices including hinged traps, a turner and a collector.

[0029] In one embodiment, a set of batch malting installations is provided. The installations are provided with air and water connections between them.

[0030] The invention also relates to a single-chamber batch malting process implementing an installation such as the above.

[0031] The operating conditions are strict. Temperatures, exposure times and food hygiene must be respected, otherwise the malt will be degraded and used for animal feed.

[0032] The natural germination process of a cereal is used to enable it to develop certain enzymes (notably amylase and protease). The cereals generally used include barley, rye, wheat, sorghum, teff, buckwheat, and spelt.

[0033] Other features and advantages of the invention will become apparent from an examination of the detailed description below, and the accompanying drawings, in which, taking as an example the model of approximately 600 tonnes of malts per year:

[0034] [Fig-1] is, in top view, a layout diagram for an embodiment of a malt house.

[0035] [Fig.2] is, in side view, a layout diagram for an embodiment of a malt house.

[0036] [Fig.3] is, in cross-section, an implementation diagram for a method of setting up a malt house.

[0037] [Fig.4] is, in side view, a layout diagram for an embodiment of a malt house.

[0038] [Fig.5] is, in perspective view, an implementation diagram for a mode of rea setting up a malt house.

[0039] [Fig.6] is, in longitudinal section, an implantation diagram for a mode of rea Installation of a malt house.

[0040] [Fig.7] is, in perspective view from another angle, an installation diagram for a method of constructing a malt house.

[0041] [Fig.8] is a detail view of [Fig.6].

[0042] The accompanying drawings may not only serve to complete the invention, but also contribute to its definition, if necessary.

[0043] Reference is made to the works "Malterie et brasserie" and / or "La Fabrication de la bière", already cited, to acquire, if necessary, an overview of malting facilities.

[0044] The conventional malting process comprises at least the following steps: a) Steeping the grains. This can be done in various types of steeping tanks, b) Germination, which takes place in germination chambers. After this step, the cereal grain is called green malt, c) Kilning, which is drying on a rack by passing hot air through a bed of grains. After this step, the barley is called malt, d) Degermination, which consists of removing the rootlets from the barley.

[0045] We will now give some typical general indications of these different stages. The cereal grains are first carefully cleaned. The main purpose of soaking is to bring the grain to a moisture content close to 50%, typically between 40 and 45%. It is also beneficial to provide oxygen, so that germination is just beginning or about to begin upon completion of soaking.

[0046] Alternating or discontinuous quenching is used, with alternating periods during which the grain is underwater, and others (of approximately half duration) where the grain is exposed.

[0047] The water temperature is typically 12 to 15°C, or even 20°C with alternating cold water. The maximum is around 25°C, above which the grain risks dying. Biological additives may be used to prevent fermentation and the growth of microorganisms during soaking.

[0048] Germination is achieved by placing a bed of soaked grains on a fine grid, through which an airflow passes under controlled temperature, pressure and humidity.

[0049] Kilning takes place on a rack through which hot air passes, also under controlled temperature, pressure, and humidity, on which the grains are placed. The aim is to dry them to stop germination, while preserving as much as possible the desired properties of the malt. The residence time of the grains is also controlled.

[0050] As its name indicates, known turning is carried out on a circular platform. According to the invention, turning is carried out on a rectangular platform.

[0051] In [Fig. 1], a malt house 1 is connected upstream to a grain storage facility and downstream to a malt storage facility. The malt house 1 can be the size of a road container 12 m long, 2.4 m wide, and 2.6 m high. Upon unloading the container, the malt house is connected to an electrical power supply, a water supply, and a wastewater outlet. Grain is fed in via collectors fixed to the top of the malt house. A malt outlet is provided for connection to a conveyor, for example, a screw conveyor.

[0052] The malt house 1 comprises a rectangular vat 2 open at the top and a vat lid 3 disposed on the vat 2. The vat 2 comprises a vat bottom 4 and side walls 5. The vat bottom 4 is V-shaped or W-shaped to form at least one low drain point at each longitudinal end. Longitudinally, the bottom 4 is shaped like a circumflex accent with two symmetrical sides forming a high point in the middle of its length. The vat 2 is intended to collect liquids. The malt house 1 comprises a perforated bottom 6 disposed in the vat 2. A malting chamber 7 is defined by the perforated bottom 6, the lid 3, and the side walls 5 of the vat 2. The malting chamber 7 is intended to hold grain during the malting process. The side walls 5 are thermally insulated. The perforated bottom 6 is positioned above the bottom 4 of tank 2. The perforated bottom 6 has a flat upper surface.The openwork base 6 can be made of metal wire. The openwork base 6 may have longitudinal openings.

[0053] The malt house 1 comprises steeping units, germination units and kilning units, arranged near the malting chamber 7 or in the malting chamber 7.

[0054] The steeping components include a water supply 8. The water supply 8 is located outside the tank 2 and is connected to a water network and / or a water reservoir. The water supply 8 supplies the downstream components described below. The presence of a water reservoir near the malt house is preferred to allow for rapid filling of the tank and to ensure uniform steeping time for the grains in a grain bed. The water supply 8 includes a valve 10 controlled by a control unit 11 shown in [Fig. 2]. The control unit 11 is housed in an electrical cabinet. The control unit 11 is equipped with a graphical interface.

[0055] The soaking elements comprise a hot water inlet 12 and a cold water inlet 13. The hot water inlet 12 is intended to supply water at a high temperature, for example, 50 to 70°C. The hot water is then mixed with cold water from the cold water inlet 13 or from the water recirculation system to obtain a water temperature suitable for soaking. Soaking causes the grains to become moist, which is a condition for initiating germination. A mixing valve 14 is supplied by the hot water inlet 12 and the cold water inlet 13. The mixing valve 14 is controlled by the control unit 11.

[0056] The water outside the malt house is heated by electricity, solar energy and / or combustion.

[0057] The steeping elements include a water spray bar 15 for spraying the grains supported by said perforated bottom 6, see [Fig. 6]. The spray bar 15 is located in the malting chamber 7. The spray bar 15 is positioned under the cover 3 at a distance above the perforated bottom 6 so as to be above the grain bed supported by the perforated bottom 6 during operation. The spray bar 15 includes at least one longitudinal channel 16 and spray nozzles 17 supplied with water by the channel. The spray nozzles 17 are directed downwards to create a jet of droplets reaching the upper surface of the grain bed. The channel 16 is supplied with water by the water supply 8 or by the water heater 12, as required. Optionally, pipe 16 is supplied by a source of disinfectant for cleaning and disinfecting the empty grain tank 2.The activation of the disinfectant product source is controlled by the control unit 11.

[0058] The soaking devices include at least one sensor 18 for measuring the water level in the tank 2. The sensor 18 may be disposed in an air duct. The sensor 18 is connected to the control unit 11 to provide information on the water level in the tank 2. Here, two sensors 18 are installed at a respective low and high level. The high level corresponds to the soaking of the grain bed during the Soaking. The low level corresponds to the dewatering of the grain bed, possibly with spraying, during soaking.

[0059] The soaking devices include a water recirculation system configured to draw water from the bottom 4 of the tank 2 and send it to the spray boom 15. The water recirculation system includes a pipe 19 disposed between the bottom 4 of the tank 2 and the spray boom 15, a pump 20 mounted on the pipe, and a self-cleaning filter. The pipe 19 can be disposed of at a distance from the lowest point of the bottom 4 of the tank 2 to allow any debris to remain in the lower part of the tank 2. The pump 20 is controlled by the control unit 11. The water recirculation system reduces water consumption. The water recirculation system sprays water onto the grain bed, the water level of which is below the perforated bottom 6. The water spray allows the grain to be moistened and to breathe. During a complete soaking with immersion, a larger quantity of water is admitted into tank 2 and the grain bed is flooded.Pump 20 can then deliver water into a pipe 28 opening into tank 2 under the perforated bottom 6. Pump 20 can provide a sufficient flow rate so that the water level in tank 2 rises between the bottom and top of the grain bed in less than ten minutes.

[0060] The soaking devices include a water drain. The water drain includes a valve 22 fluidly connected to a low point at the bottom 4 of the tank 2. Here, four valves 22 are provided, connected to the four low points to prevent water stagnation. The valve 22 is controlled by the control unit 11. Downstream, the water drain can be connected to a water treatment device to separate the different materials, recycle the water, and recover the solid materials for further processing. The dewatering of the grain bed is achieved by opening the water drain.

[0061] The germination components include an air conditioner 23 for supplying the malting chamber 7 with air at controlled temperature and humidity. The air conditioner 23 is connected to an outside air intake 24, an inside air intake connected to the malting chamber 7, an air injector in the tank 2 below the malting chamber 7, and an air outlet to the outside. An outside air exchanger can be mounted between the air intake and the air conditioner 23. The inside air intake is connected to the malting chamber 7 via the cover 3. Thus, air circulates through the air conditioner 23 in an upward direction over the grain bed. The air conditioner 23 includes a fan 26, an external air-to-air heat exchanger, an external air-to-water heat exchanger, and an external reversible heat pump.

[0062] The air-to-air heat exchanger recovers heat from the exhaust air and potentially water, and heats the incoming air, for example at the beginning of kilning when the grain is still moist. The air-to-air heat exchanger can be passive with reverse flow. The air-to-water heat exchanger is capable of recovering heat is recovered from the outgoing water. The air-to-water heat exchanger is capable of recovering heat from the outgoing air and heating water, for example, at the end of kilning. A thermally insulated water tank can be provided for storing the recovered heat energy. The heat pump is configured to recover heat from the outgoing fluids – water / air – and to heat the incoming fluids – water / air. A saturator is also provided to ensure that the air introduced into the malting chamber 7 is saturated with moisture, preventing the grain from drying out during germination or during substages of grain removal during steeping.

[0063] The germination components include a turner 31 configured to spread the grain into a bed when the grain is loaded onto said perforated bottom 6, to turn the grain bed during germination, and, furthermore, to assist in the discharge of the malt obtained from the grain.The turner 31 comprises an upper carriage 32 and a lower carriage 33 within the malting chamber 7. The upper carriage 32 and the lower carriage 33 are positioned above the maximum level of the grain bed and below the cover 3. The upper carriage 32 is mounted to roll on an upward-facing rail 34. The lower carriage 33 is mounted to roll on a downward-facing rail 35. Said rails 34 and 35 are formed by opposing surfaces of a beam located in the malting chamber 7 above and at a distance from the perforated bottom 6. The beam may be adjacent to an upper edge of the vessel 2. The beam is longitudinal. The beam may be made of a profile. The upper carriage 32 and the lower carriage 33 are rigidly assembled. The upper carriage 32 and the lower carriage 33 form a rigid subassembly.The turner 31 may include a first upper carriage 32 and a first lower carriage 33 at a first end of the beam and a second upper carriage 32 and a second lower carriage 33 at a second end of the beam in the direction of the width of the malting chamber 7.

[0064] The turning device 31 comprises a plurality of motorized screws 36 supported by the beam. The screws 36 are vertical and directed downwards from the beam. The screws 36 extend close to each other with some clearance. Mechanical interference is avoided. Each screw 36 is driven by an electric motor, optionally with a gearbox. The motors are arranged above the beam. The beam may be traversed by shafts between the motor and the corresponding screw 36. The screws 36 extend vertically between the perforated base 6 and the beam.

[0065] The turner 31 is movable in translation along the rail(s) from one longitudinal end to the other longitudinal end of the malting chamber 7. The turner 31 includes support wheels resting on the rail(s). The wheels support the beam by means of brackets. The turner 31 includes a motor for said translation, the motor driving at least one of the wheels. The motor may be a stepper motor and connected directly to at least one wheel. The wheel is driven by a reduction gear. The translation of the turner 31 and the rotation of the screws 36 are coordinated to turn the grain, leaving it generally in place according to a first coordination, and to push the grain in front of the turner 31 according to a second coordination to aid unloading. Here, coordination refers to a set of parameters: the linear speed of the turner 31, and the speed and direction of rotation of each screw 36.

[0066] The spray boom 15 is mounted on the turner 31. The spray boom 15 is thus mobile above the perforated bottom 6 designed to receive the grain bed. The spray boom 15 may include a section at one longitudinal end of the turner 31 and a section at the opposite longitudinal end of the turner 31 to moisten the entire grain bed. Spraying by the spray boom 15 is carried out simultaneously with turning by the turner 31, resulting in homogeneous humidification. For this purpose, the spray boom 15 is supplied by a flexible hose mounted on a reel 27. The reel 27 is installed at one longitudinal end of the tank 2 outside the malting chamber 7 so that the hose moves with the turner 31.

[0067] The kilning equipment includes a heater to supply hot air under the grain bed. The heater may include a heat pump and a solar thermal unit or a burner. At the beginning of the kilning stage, a significant energy input is required to dry the grain and bring it to an inactivation temperature. In addition to the thermal energy from the air-to-air heat exchanger, the air-to-water heat exchanger, and the heater, an energy input may be provided by a nearby equivalent installation with excess thermal energy, for example, at the end of the kilning stage, etc.

[0068] The germination components include a by-product discharge device that removes by-products falling through the openings in the perforated bottom 6, by means of a flush. To this end, the bottom 4 of the tank 2 is inclined, specifically with two opposing slopes and a central high point in the longitudinal direction. At least two collectors 40 are arranged at each end of the bottom 4 of the tank 2. Here, two collectors are arranged at each end of the bottom 4 of the tank 2, in the direction of the width of the tank 2. The collector 40 has a hopper shape converging downwards. At the lower end of the collector 40, two channels are provided that can be closed by valves. A first large-diameter channel 41 extends longitudinally under the tank 2. The first channel 41 is intended for transporting the malt after kilning. The first channel 41 is connected to the lower end of the collector 40 by a first controlled valve 42.The first controlled valve 42 is, here, arranged directly below the lower end of the manifold 40. The first channel 41 connects the downstream of each first controlled valve 42 at each end of the tank 2. The first channel 41 is slightly inclined with respect to . horizontally. In one mode, the first channel 41 is common to both pairs of collectors 40. Here, the first two channels 41 are arranged in parallel and are joined by a V-shaped fitting.

[0069] Each first channel 41 is equipped with a screw conveyor leading to one end of the first channel located beyond the first controlled valves 42. The screw conveyor, or the entire first channel-screw conveyor assembly, is rotatable under the action of an electric motor mounted at one end. Each first channel 41 leads to a malt conveyor 43, for example, a screw conveyor, for the discharge of the malt and the loading of a truck. The V-shaped fitting opens into the conveyor 43.

[0070] A second small-diameter channel 45 extends longitudinally beneath the tank 2. This second channel 45 is for draining the water used during soaking and germination. The second channel 45 is connected to the lower end of the funnel by a second controlled valve 46. The first controlled valve 42 and the second controlled valve 46 have substantially perpendicular axes. The second controlled valve 46 is located directly beneath the lower end of the manifold 40.

[0071] The second channel 45 connects the downstream side of each second controlled valve 46 at each end of the tank 2. These second controlled valves 46 can be operated synchronously. The second channel 45 includes a main section slightly inclined with respect to the horizontal. Here, the second channel 45 is common to both pairs of manifolds. The second channel 45 is equipped with a pump 47 downstream of the controlled valves. The pump 47 is used to discharge the water. The discharged water can pass through a water-to-water heat exchanger, a filter to retain suspended solids, and the water can be recycled.

[0072] The discharge device also includes a pusher 48 or brush disposed in contact with the bottom 4 of the tank 2. The pusher 48 is longitudinally movable in translation while being supported by the bottom 4 of the tank 2. In [Fig. 6], the pusher 48 and the return 31 are in the central position or rest position. The pusher 48, being at the point on the bottom 4, allows the water to flow over the bottom 4 towards the lowest end points.

[0073] The pusher 48 is driven in a movement opposite to the movement of the turner 31. When the turner 31 is to the right, the pusher 48 is to the left, and vice versa. This allows waste to fall through the perforated bottom 6 during a movement of the turner 31 while remaining away from the turner 31 except at the midpoint. Waste removal via the pusher 48 is facilitated. Manual cleaning, which requires opening sealed hatches at the bottom of the tank, is significantly reduced. Unproductive time between batches of grain is also reduced. The pusher 48 provides mechanized sweeping.

[0074] In the embodiment shown, the pusher 48 is driven by a cable 49 connected to the turner 31 in a loop. Return pulleys 39 guide the cable 49. The cable 49 extends between the bottom 4 and the perforated bottom 6. The cable 49 goes up to the ends of the malting chamber 7 and joins the turner 31. Thus, the movement of the turner 31 and the movement of the pusher 48 are opposite.

[0075] The water during soaking becomes depleted of oxygen. An oxygenation ramp 30 can be provided to increase the oxygen level in the filtered water by bubbling compressed air into the water in the tank during soaking. A compressed air inlet 29 is located near a ventilation air inlet downstream of a secondary line 63. The compressed air inlet 29 is located under the perforated bottom 6. The oxygenation ramp 30 is located under the perforated bottom 6. The compressed air inlet 29 supplies compressed air to the oxygenation ramp 30. The oxygenation ramp 30 supplies nozzles 37. Bubbling compressed air into the soaking water maintains a sufficient oxygen level to prevent grain asphyxiation. An external source of compressed air is used.

[0076] During soaking, the water temperature is generally maintained at around 16°C. The water temperature is monitored by at least one temperature sensor 38. The temperature sensor 38 is installed in the tank 2 under the perforated bottom 6. The temperature sensor 38 is connected to the control unit 11. The temperature sensor 38 is also used to monitor the ambient temperature during germination and kilning. In this case, two temperature sensors 38 are provided.

[0077] The lid 3 of tank 2 is made of several identical domed sections mounted in succession. Each domed section has four edges and four inclined faces. Each domed section includes a top opening 50 that can be closed by a controlled valve. Each domed section converges upwards.

[0078] One of the top openings 50 is dedicated to the exhaust of air during kilning. This air, at a high temperature, is intended to pass through a heat exchanger and / or a heat pump. The other top opening 50 is dedicated to the exhaust of air during germination. This air, at a temperature close to ambient temperature, can either be released into the atmosphere, sent to a heat exchanger and / or a heat pump (which also recovers condensation water), or recycled for ventilation of the malting chamber during germination via an upper duct (not shown). The top openings 50 are arranged laterally at one end of the malting chamber 7, opposite the air inlets. The air inlets in the vessel are lateral and located under the perforated bottom 6.

[0079] Several openings 51 are provided in the lid 3. The openings 51 are aligned and laterally centered. The openings 51 are regularly spaced. The openings 51 serve to feed grain by a conveyor, for example a screw conveyor or a The grain is then spread by the turner 31. During loading, the openings 51 can be active simultaneously for rapid loading. After loading, the openings 51 are closed by shutters.

[0080] The malting chamber 7 has an air outlet 60 located near the cover 3. The air outlet 60 is provided at one of its longitudinal ends. The air outlet 60 is located in an upper area in which the trolleys move, above the maximum level of a grain bed. The air outlet 60 has a convergent section. The air outlet 60 is connected to the fan 26 of the air conditioner 23 by a supply line. The fan 26 is installed beyond the malting chamber 7 at the same longitudinal end as the air outlet 60. Downstream of the fan 26, a main line 61 and an air distributor 62 supplying secondary lines 63 are mounted.

[0081] In the embodiment shown, the main duct 61 is bent between a vertical portion near the fan 26 and a horizontal portion near the top of the tank 2. The air distributor 62 divides the airflow driven by the fan 26 into a plurality of substantially equal flows. The secondary ducts 63 comprise a horizontal portion downstream of the air distributor, the lengths of the horizontal portions differing from one secondary duct to another, then a vertical portion, the lengths of the vertical portions being equal, and then a bend forming an inlet 64 into the malting chamber 7. Said inlet 64 is provided under the grid. Air is blown under the grain bed and tends to lift it, which reduces the risk of compaction in the event of rootlet growth during germination. The blown air is discharged through one of the top openings 50 depending on the stage, germination or kilning.The horizontal sections are positioned at approximately the same height as the screw motors. This prevents water in tank 2 from rising into the horizontal sections.

[0082] At the end of the kilning process, the malted grain, now with the desired moisture content, is ready. The heating and ventilation are switched off. Discharge mechanisms are activated. These discharge mechanisms include a hinged gate 65 at each longitudinal end of the malting chamber 7. Each hinged gate 65 is rotatably mounted about an axis 66. The axis 66 is transverse. The axis 66 is located at a distance from the longitudinal end of the malting chamber 7. The axis 66 is mounted under the perforated bottom. In a grain retention position, the hinged gate 65 is aligned with the perforated bottom 6. The hinged gate 65 may be perforated like the perforated bottom 6. In a discharge position, the hinged gate 65 is oriented downwards. The malt falls from the malting chamber 7 towards the hopper of the collector 40. The malt is picked up downstream by the conveyor 43.The turner 31 is set in alternating motion from one end to the other of the malting chamber 7, tilting traps 65. In the unloading position, the pusher 48 pushes the malt towards the ends of the malting chamber 7, causing it to fall into the hopper of the collector 40. The pusher 48 moves in the opposite direction to the turner 31, preventing malt from remaining on a portion of the bottom 4 near the hopper of the collector 40. Unloading is carried out without water circulation. The hinged gates 65 are closed in the grain retention position.

[0083] The unloading devices include the tilting gates 65, the turner 31 and the collector 40. The turner 31 is active during loading and unloading, during soaking, germination and kilning.

[0084] After unloading, cleaning can be carried out, for example rinsing the malting chamber 7. Then a new batch of grain can be brought into the malting chamber 7 for steeping.

[0085] Advantageously, several malting plants are arranged in parallel with staggered processing phases. This staggered timing allows for better energy recovery and water recycling without the need for additional storage capacity. The external air-to-air heat exchanger, the external air-to-water heat exchanger, and / or the external reversible heat pump can be shared by several neighboring malting plants.

[0086] In general, the surfaces in contact with the cereal are of food grade.

[0087] Thus, a compact malting process comprises:

[0088] The cereal is soaked in a malting chamber 7.

[0089] The moist cereal germinates in the malting chamber 7, the germinating cereal resting on a grid with elongated openings, with ventilation from below, passing through the grid and the germinating cereal.

[0090] In the past, grain was transported between steeping and germination, and then between germination and kilning. Here, the grain remains in the same single malting chamber. The temperature and humidity conditions for each stage of malting are provided to the grain in situ. The savings in energy consumed by transport, space occupied by conveyors, and time required to transport an entire batch of grain are considerable. When transporting a batch of grain within the malt house, two chambers are immobilized: the upstream and downstream chambers. The steeping, germination, and kilning components are considered functional. Some of their components, particularly hydraulic and pneumatic ones, are common.

Claims

Claims

1. Batch malting plant, comprising a malting chamber (7) including soaking, germination and kilning members, a tank (2) enclosing the malting chamber (7), the tank (2) being sealed to be capable of containing water, the malting chamber (7) comprising a perforated bottom (6) formed of metal wire, side walls common with the tank (2) and an upper wall provided with a grain feed opening for supplying grain onto said perforated bottom (6), the soaking members comprising a water supply (8), a water heater (12), a water spray bar (15) for watering the grains supported by said perforated bottom (6), a sensor for measuring the water level in the tank (2), a water recycle configured to take water from the bottom 4 of the tank (2) and send it to the spray bar (15), and a water drainage;the germination members comprising an air conditioner (23) for supplying the malting chamber (7) with air at controlled temperature and humidity and a turner (31) configured to spread the grain in a bed when loading the grain onto said perforated bottom (6), to turn the grain bed during germination, and, further, to assist in the unloading of the malt obtained from the grain, the kilning members comprising a heater for supplying hot air under the grain bed, and a member for discharging by-products falling through the holes in the perforated bottom (6).;

2. Installation according to claim 1, comprising a in which the member for evacuating by-products falling through the days of the perforated bottom (6), by comprises a flush and / or by a mechanized sweep.

3. Installation according to claim 1 or 2, in which the tank (2) is sealed to be capable of containing water and thermally insulated.

4. An installation according to one of the preceding claims, in which the water recycling comprises a filter for filtering the water and an oxygenator for increasing the level of dissolved oxygen in the recycled water.

5. Installation according to one of the preceding claims, in which the turner (31) comprises an upper carriage (32) mounted to roll on a rail directed upwards and a lower carriage (33) mounted to roll on a rail directed downwards, said rails being formed by opposite surfaces of a beam arranged in the malting chamber (7) above and at a distance from the perforated bottom (6).

6. Installation according to one of the preceding claims, comprising a passive heat exchanger for recovering heat from the outgoing air, recovering water by condensation of the outgoing air, and supplying heat to the incoming air.

7. Installation according to one of the preceding claims, in which the malting chamber (7) has the shape of a rectangular parallelepiped and the water inlets have water pipes arranged above the tank (2) and extending by descents on the sides and inside the tank (2); and the water supply (8), the water heating (12), the water spray bar (15), the water recycling, the water evacuation, the air conditioner (23), and the air heating are arranged at the end of the tank (2), the sensor for measuring the water level in the tank (2) being arranged in an air inlet pipe and the installation is equipped with remote control.

8. Installation according to one of the preceding claims, comprising unloading members comprising tilting hatches (65), a returner (31) and a collector (40).

9. Set of installations according to one of the preceding claims, provided with air and water connections between said installations.

10. Single-chamber batch malting process, implementing an installation according to one of the preceding claims.

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