Beverage manufacturing method

Abstract

A method for producing a combination of beer and a non-fermented beverage from a grain feedstock utilizes by-products from beer production in the production of the non-fermented beverage, thereby improving resource efficiency. The method includes processing the grain feedstock into a mash (301), separating the mash into a fermentable wort and a residue (302), the residue material comprising at least a portion of the residue, processing the residue material into a slurry (303), separating the slurry into liquid and solid components (304), processing the liquid component into a non-fermented beverage (305), processing the fermentable wort into beer (306), outputting the non-fermented beverage (307), and outputting the beer (309).

Description

[Technical field]

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

[0002] Beer production plants come in many forms, from small-scale plants in craft breweries and microbreweries to plants that produce beer on an industrial scale. Beer brewing involves at least three main steps: mashing, lautering, and fermentation. Mashing is the process of mixing crushed grains (usually malt) with water and heating them at a controlled temperature with resting time so that enzymes break down the starch in the grains into sugars such as maltose. The result of mashing is the mash. Lautering is the process of separating the mash into fermentable wort and the retentate. Lautering is done in a lauter tune or mash filter. Fermentation begins when yeast is added to the wort. Only at this stage is it called beer. At this stage, the fermentable sugars in the wort are metabolized to alcohol and carbon dioxide.

[0003] The residue from lautering is a by-product of brewing and is known as draf or brewer's spent grain. It is produced in large quantities in breweries, for example 15 kilograms per 100 liters of beer. The residue is nutritious and contains proteins, fibers and carbohydrates. At the same time, it is rapidly decomposed by microbial activity and can even spoil within a few hours after lautering. Currently, the residue is used as livestock feed or as a raw material for biogas production. It has also been proposed, for example in WO2019 / 023647, to dry and mill the residue into a protein-rich flour. However, in today's breweries, a large amount of residue is discarded. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE PRESENT EMBODIMENT An object of the present invention is to at least partially overcome the above mentioned disadvantages.

[0005] One such objective is to improve resource efficiency in beer production.

[0006] Another objective is to provide a technique for utilizing residues from beer production to produce non-fermented beverages that comply with food safety regulations.

[0007] A further object is to provide a technology that can be easily integrated into existing beer production, allowing for production flexibility.

[0008] One or more of these objects, as well as those that will become apparent from the following description, are at least partly achieved by a method for the combined production of beer and non-fermented beverages from cereal raw materials according to the independent claims, embodiments of which are defined by the dependent claims. [Means for solving the problem]

[0009] One aspect of the invention is a method for producing a combination of beer and a non-fermented beverage from a grain feedstock, the method including the steps of processing the grain feedstock into a mash, separating the mash into a fermentable wort and a residue, the residue material comprising at least a portion of the residue, processing the residue material into a slurry, separating the slurry into a liquid component and a solid component, processing the liquid component into a non-fermented beverage, processing the fermentable wort into beer, outputting the non-fermented beverage, and outputting the beer.

[0010] The first aspect is to produce two types of beverages from a single starting material. The method integrates the production of a non-fermented beverage with the production of beer by utilizing the residue separated from the mash during beer production. The residue is a by-product that beer makers regularly store and then discard, often paying for its disposal. The method consumes at least a portion of the residue within the beer production plant to produce a non-fermented beverage that is in high demand in modern society. The non-fermented beverage is a plant-based beverage that may be produced to fall into the type of beverage known as "plant-based milk". Plant-based milk is a vegan beverage consumed as a plant-based alternative to dairy products, often offering a creamy mouthfeel. Plant-based milk is also known as alternative milk, simulated milk, or vegan milk. The method of the first aspect can produce a non-fermented beverage with a high protein content, making it suitable for vegetarians and those looking for an alternative protein source.

[0011] Embodiments of the first aspect enable further technical advantages, for example in terms of energy efficiency, compliance with food safety regulations, flexibility in production, etc.

[0012] Further objects, aspects, as well as features, embodiments and technical advantages will become apparent from the following detailed description and drawings. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a plan view showing an example of a beer and non-fermented beverage production plant. [Figure 2A] FIG. 2 is an exemplary timing diagram of the procedures in the combined production of beer and non-fermented beverages. [Figure 2B] FIG. 2 is an exemplary timing diagram of the procedures in the combined production of beer and non-fermented beverages. [Diagram 3] This is an example of a method for the combined production of beer and non-fermented beverages. [Figure 4A] 4 is a flowchart of a procedure for producing a non-fermented beverage in the method of FIG. 3 according to the first embodiment. [Figure 4B]FIG. 1 is a plan view showing a production line for a non-fermented beverage according to a first embodiment. [Figure 5A] 4 is a flow chart of a procedure for producing a non-fermented beverage in the method of FIG. 3 according to a second embodiment. [Figure 5B] FIG. 11 is a plan view showing a production line for a non-fermented beverage according to a second embodiment. [Figure 5C] FIG. 5C is a plan view showing an example of a yield improvement station in the manufacturing line of FIG. 5B. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014]

[0023] The embodiments will now be described in more detail with reference to the accompanying drawings, in which some, but not all, embodiments are shown. 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, but rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0015] Well-known functions or structures may not be described in detail for brevity and / or clarity.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.

[0016] Like numbers refer to like elements throughout.

[0017] Before describing the embodiments in more detail, some definitions are provided.

[0018] As used herein, "cereals" refers to grains or combinations of grains that are used or useful in the production of beer. Cereals may be used in brewing beer after malting or as a starch additive unmalted. The primary raw material used in beer production is barley, although corn, rice, and wheat are also commonly used. Other examples of grains include barley, sorghum, millet, oats, rye, triticale, fonio, etc. As used herein, the term cereal also includes pseudo-cereals such as buckwheat.

[0019] As used herein, "slurry" refers to a mixture of solids denser than water suspended in a liquid.

[0020] A range from a first value to a second value is intended to include both the first value and the second value.

[0021] FIG. 1 is a schematic block diagram of an integrated beer and non-fermented beverage production plant 1. Non-fermented beverages are produced without fermentation by the addition of yeast or lactic acid bacteria. Typically, non-fermented beverages are so-called ready-to-serve (RTS) type beverages. In some embodiments, non-fermented beverages are produced without the addition of alcohol and are therefore non-alcoholic. In some embodiments, non-fermented beverages are plant-based milks, as defined in the summary section. In the following, non-fermented beverages are abbreviated as NFB.

[0022] The factory 1 includes a beer production line 10 and an NFB production line 20. The production line 20 is configured to produce NFB using a by-product from the production line 10. The by-product is generated as a residue from the filtration process in the line 10. Specifically, the by-product includes all solids separated from the wort by filtration. The residue R1 includes mainly non-starchy parts, such as pericarp and husks, of the grain raw material used as a raw material for beer production by the production line 10. As mentioned in the prior art, the residue R1 may also be referred to as draff or brewer's spent grain (BSG).

[0023] The beer production line 10 is of conventional construction and is configured to process water 100 and raw cereal material 101 into beer 103 by the addition of yeast 102. In the illustrated example, the line 10 comprises a mashing station 11, a filtering station 12, and a fermentation station 103. The mashing station 11 is configured to receive the water 100 and the raw cereal material 101, and optionally one or more further ingredients. The mashing station mixes the water and the raw cereal material to form an enzyme-containing mash. The enzymes may be derived from the raw cereal material or may be added separately from the mash. In the mashing station 11, the enzymes break down starch into a mixture of fermentable sugars, such as glucose, maltose, and maltotriose. The filtering station 12 is configured to separate the mash into a wort containing fermentable sugars and spent grain, i.e., the residue R1 described above. The process of separating the spent grain from the wort is known as "wort separation" and can be accomplished by lautering, where the grain bed itself acts as the filter medium, and / or by using a filter frame.

[0024] Residue R1 contains fiber, which is primarily a non-starch polysaccharide, and significant amounts of protein and lignin, with arabinoxylan (AX) generally being the most abundant component. Thus, R1 is essentially a lignocellulosic material. Typically, about half of R1 on a dry weight basis contains fiber. Up to about 30% of R1 on a dry weight basis may contain proteins, e.g., hordeins, glutelins, globulins, and albumins. Essential amino acids may account for about 30% of the total protein content, with lysine being the most abundant. Cellulose is typically the predominant polysaccharide in R1. Monosaccharides in R1 may include xylose, glucose, arabinose, etc. In addition, R1 may contain various minerals, such as silicon, phosphorus, calcium, and magnesium.

[0025] From the filtering station 12, the wort is transferred to the fermentation station 13 where fermentation is initiated by the addition of yeast 102. In the fermentation station 13, the wort is turned into beer in a process that can take anywhere from one week to several months depending on the type of yeast and the strength of the beer. Not only is ethanol produced, but any particulate matter suspended in the wort will settle during fermentation. Once fermentation is complete, the fermentation station 13 outputs beer 103.

[0026] It should be understood that the production line 10 of Fig. 1 is given merely as a non-limiting example. The stations 11-13 may be configured for additional processing, such as, for example, flavoring the wort, heating the wort, cooling the wort, filtering the beer, maturing the beer, etc., and / or the line 10 may include additional stations for such additional processing. The factory 1 may comprise multiple beer production lines 10, and such production lines 10 may share equipment.

[0027] The NFB production line 20 may be of a similar or different structure to a conventional plant milk production line. Examples of configurations of the production line 20 are shown further below with reference to Figures 4B, 5B and 5C. The line 20 is configured to process water 200 and retentate material R2 into NFB 202, optionally by adding one or more further ingredients 201, for example to achieve a desired flavor and / or mouthfeel. The retentate material 2 comprises at least a portion of the retentate R1 from the beer production line 10, subject to one or more constraints, as will be further described below. The plant 1 may be composed of multiple NFB production lines 20, and such production lines 20 may share equipment.

[0028] As shown in FIG. 1, the plant 1 may comprise a beer packaging station 31 arranged to receive beer 103 from the production line 10 and fill the beer into a first container 110. The first container 110 may be configured for batch distribution (e.g., kegs or kegs) or for direct consumption (e.g., cans or bottles). The plant 1 may further comprise an NFB packaging station 32 arranged to receive NFB 202 from the production line 20 and fill the NFB into a second container 210. The second container 210 may be aseptic or semi-aseptic. The second container 110 may be configured for batch distribution or for direct consumption. In some embodiments, the second container 210 is any type of consumer package, including but not limited to glass or plastic bottles, metal cans, or carton-based packages, which may be sealed for subsequent distribution.

[0029] Although not shown in FIG. 1, the factory 1 may also be provided with dedicated storage tanks for storing beer and / or NFB being prepared for packaging.

[0030] The factory 1 of Fig. 1 comprises a control system 40 configured to generate control signals Ci for equipment in the factory 1, including equipment in the production lines 10, 20. For example, the control system 40 may control various process parameters in each line, such as the degree of mixing, residence time, temperature, pressure, ingredient addition, etc. However, at least some of the processing steps for producing beer and NFB, respectively, may be performed and / or controlled manually by an operator.

[0031] The beer production line 10 produces a large amount of residue R1. Typically, 100 kg of grain raw material gives about 100-130 kg of residue R1, which corresponds to about 15-20 kg of residue per hectoliter of beer. The properties of R1 are represented by Q1 in FIG. 1. It should be noted that R1 refers to the residue immediately after it is produced on the line 10. The main component of R1 is water, which is mainly contained in the spent grain in R1. Generally, the relative moisture content in R1 ranges from 60% to 90%, corresponding to a total solids (TS) in the range of 10% to 40%. In practice, the relative moisture content of R1 is often in the range of 70% to 85%, with a TS in the range of 15% to 30%. R1 is produced at a temperature in the range of 55 ° C to 90 ° C. This refers to the average temperature of R1, taking into account that there may be temperature fluctuations within the batch of residue produced by the line 10. In practice, the temperature of R1 is typically 65°C or higher or 70°C or higher, and preferably 85°C or lower or 80°C or lower. The rich polysaccharide and protein content of R1, its high moisture content, and its temperature make it susceptible to microbial growth and spoilage. Thus, even if R1 is microbiologically stable and within the food acceptable range when produced in line 10, the microflora in R1 is susceptible to rapid change due to the growth of microaerophilic and anaerobic bacteria. Because NFB is intended for human consumption, it is essential that the residue material R2 meets food safety regulations, including restrictions on the presence of bacteria and toxins. The factory 1 of FIG. 1 facilitates compliance with such regulations because the NFB production line 20 is located in the same physical facility as the beer production line 10. Specifically, the time between the output of R1 from line 10 and the input of R2 to line 20 may be limited.

[0032] Note that line 10 produces residue in batches, while line 20 may or may not consume R2 in batches. Depending on the respective capacities of lines 10, 20, R2 may contain all or only a portion of R1.

[0033] In FIG. 1, block 30 represents any installation in plant 2 for transferring, storing, or processing R1. In some embodiments, block 30 comprises fixed installations for transferring at least a portion of R1 from line 10 to line 20. Such fixed installations may include one or more screw conveyors, piping, one or more pumps, etc. The fixed installation may also include a diversion mechanism, which is configured to ensure that the required amount of R2 is received at line 20, for example by diverting a portion of R1 to a separate storage (not shown) or to another production line (not shown) for producing NFB or another product based on the thus diverted R1. However, in some embodiments, the transfer of the residue from line 10 to line 20 may be performed without fixed installations, for example by motorized or non-motorized wheeled carts or trays. In some embodiments, block 30 comprises an intermediate reservoir for storing the residue. In some embodiments, block 30 comprises a device for stabilizing the residue by reducing its microbiological activity. Such stabilization may be achieved by one or more of heating the residue, cooling the residue, drying the residue, or altering the pH of the residue by acidification or alkalinization.

[0034] In some embodiments, such stabilization is omitted. Thus, R2 is produced without active treatment of R1 to modify its properties. As used herein, "active treatment" refers to the supply of energy and / or one or more substances. The omission of active treatment simplifies the construction and operation of factory 1, and keeps production costs low. The lower production costs are due to the lower consumption of energy and / or substances, as well as the reduced need for cleaning and maintenance of the stabilization equipment.

[0035] FIG. 3 is a flow chart of an example of a method 300 for the combined production of beer and NFB. The method 300 is described by way of example with reference to the factory 1 of FIG. 1. In step 301, the cereal raw material is processed into a mash, for example in the mashing station 11. In step 302, the mash is separated into a fermentable wort and a residue, for example in the filtering station 12. By means of step 302, R1 is produced. In step 303, the residue material R2 is processed into a slurry. As mentioned above, R2 comprises at least a part of R1. It should be noted that step 303 forms the starting point of the procedure for producing NFB. In step 304, the slurry is separated into a liquid component and a solid component. The solid component is a sludge and may be discarded. In step 305, the liquid component is processed into NFB, for example according to the procedure described below with reference to FIGS. 4A and 5A. Steps 303 to 305 may be performed by the production line 20 of FIG. 1. In step 306, the fermentable wort is processed into beer, for example at fermentation station 13. Step 306 can be performed according to any conventional procedure and begins with the addition of yeast to the wort. In step 307, the NFB is output from production line 20. In optional step 308, the NFB is packaged, for example at second packaging station 32. In step 309, the beer is output from production line 10. In optional step 310, the beer is packaged, for example at first packaging station 31. The exemplary method 300, by involving combined production of beer and NFB, facilitates compliance with food safety regulations by allowing control of the properties of R2.

[0036] Returning to Figure 1, the characteristics of R2 are designated Q2. Note that R2 refers to the residual material as it is fed into line 20, i.e., when the NFB manufacturing procedure begins with step 303. Applicants have identified constraints on Q2 that they believe provide distinct technical advantages. These constraints are presented below in terms of combinable embodiments.

[0037] In some embodiments, the characteristic Q2 of R2 is approximately the same as the characteristic Q1 of R1. In this context, approximately the same means that the differences in each characteristic are less than ±10%, preferably less than ±5%. This means that R1 does not undergo active processing to generate R2, and the time from the output of R1 to the input of R2 is limited.

[0038] In some embodiments, R2 has about the same relative moisture content as R1, for example within about ±10%, meaning that R1 is not subjected to aggressive drying to produce R2.

[0039] In some embodiments, R2 has a relative moisture content in the range of 60% to 90%, preferably in the range of 70% to 85%, again meaning that R1 is not subjected to active drying to produce R2.

[0040] In some embodiments, R2 has a temperature in the range of 40°C to 99°C, preferably 50°C or more or 55°C or more, and preferably 85°C or less or 80°C or less. It is understood that even in the absence of active cooling, the temperature of the residue will decrease over time. By limiting the temperature to 40°C or more, preferably 50°C or more or 55°C or more, the growth of harmful bacteria in R2 is prevented or at least mitigated. By limiting the temperature to 99°C or less, preferably 85°C or less or 80°C or less, the energy consumption for active heating of the reprocessing liquid is reduced or avoided.

[0041] In some embodiments, R2 has a temperature equal to or less than the temperature of R1, meaning that R1 is not actively heated to produce R2.

[0042] 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 is not actively heated or cooled to produce R2.

[0043] In some embodiments, the pH of R2 is equal to or lower than the pH of R1. This allows for active acidification of the residue for stabilization. However, even in the absence of active acidification, the pH may be lower in R2 than in R1 as a result of natural processes in the residue.

[0044] In some embodiments, the pH of R2 ranges from 5 to 7. Such a pH range is currently believed to be suitable for the production of NFB in line 20.

[0045] In some embodiments, the pH difference between R2 and R1 is less than 1, preferably less than 0.6, 0.4 or 0.2, meaning that R1 does not undergo aggressive acidification or alkalization to produce R2.

[0046] FIG. 2A is a timing diagram of a beer production procedure P1 and a NFB production procedure P2 according to the method 300 of FIG. 3. In the factory 1 of FIG. 1, P1 can be performed by the line 10 and P2 by the line 20. Procedure P1 is divided into a first sub-procedure P1a and a second sub-procedure P1b. The first sub-procedure P1a ends when R1 is output. The second sub-procedure P1b starts when P1a ends and ends when the beer is output (see step 309 of FIG. 3). P1b substantially corresponds to step 305 of processing the wort into beer. The duration of P1a is denoted as ΔP1a and the duration of P1b is denoted as ΔP1b. Beer production is a slow process and ΔP1b is rather long, usually taking at least 4 days. P1b is not uncommon in the range of 4 to 14 days, but may be longer, for example more than a month. 2A, the duration of P2 is denoted as ΔP2. P2 starts when the processing of R2 starts (step 303) and ends when the NFB is output (step 307).

[0047] In some embodiments, the method 300 may apply a predefined maximum time to the period between the generation of R1 in step 302 and the start of the processing of R2 in step 303. Thus, according to such an embodiment, the method 300 is required to start the processing of R2, which includes at least a portion of R1, no later than a maximum time after R1 is generated. In FIG. 2A, the maximum time is designated Δmax and extends from the end of P1a. The maximum time can be established to ensure that the quality of R2 is sufficient to result in a NFB that meets food safety requirements. In some embodiments, Δmax is equal to or less than 8 hours. Such a Δmax is currently believed to remove the need to stabilize the residue by aggressive processing. However, it is also conceivable that the method 300 applies a more restrictive Δmax. For example, Δmax can be equal to or less than 6 hours, 4 hours, or 2 hours.

[0048] In the example of FIG. 2A, the method 300 is configured with ΔP2 being shorter than Δmax. Having P2 equal to or shorter than Δmax provides flexibility in production. For example, as shown by the dashed arrow in FIG. 2A, the same batch of residue material R2 can be used as a feedstock in procedures P2 executed in sequence to produce NFB. This can be an important advantage, at least in large-scale beer production, in terms of the large amount of residue produced for one batch of beer, since it increases the amount of residue material that one and the same production line 20 can input from the beer production line 10 without violating the constraint Δmax. Although not shown in FIG. 2A, it should be understood that two or more procedures P2 can be executed in parallel to input the residue material R2 generated by the sub-procedure P1a.

[0049] In some embodiments, as shown for example in FIG. 2A, the method 300 is configured such that ΔP2 is shorter, preferably much shorter, than ΔPb1. This corresponds to the NFB being output (step 307) before the processing of the wort into beer is completed. Such an embodiment provides flexibility in production, for example by allowing one and the same production line 20 to receive residue material R2 from two or more beer production lines 10. FIG. 2B is a timing diagram of two procedures P1 for beer production, which are performed in an overlapping manner by two different production lines 10. As indicated by the dashed arrows, the residue material R2 from the two procedures P1 can be used as a raw material for a successive procedure P2 for the production of NFB, which can be performed by one and the same production line 20. With appropriate timing between procedures P1, one and the same production line 20 can process residue material R2 from multiple beer production lines 10 without violating the constraint Δmax.

[0050] Also, note that in the embodiment shown in Figures 2A-2B, it is possible to perform and complete the packaging of the NFB (step 308) before packaging the beer (step 310). This may allow for optimization of packaging resources, for example, by using at least partially the same equipment for packaging both the NFB and the beer. In the example of Figure 1, the first and second packaging stations 31, 32 may share equipment or be performed by the same physical station. To the extent that the same equipment / station is used, the embodiment of Figures 2A-2B may provide time to clean the equipment / station before switching from the NFB to the beer. Packaging the NFB before the beer may reduce staffing needs in the plant by reducing the need for parallel packaging of the beer and the NFB. In some embodiments, the packaging of the NFB occurs 1-1000 hours before the packaging of the beer, typically at least 24-48 hours before the packaging of the beer.

[0051] FIG. 4A is a flow chart of a first exemplary procedure 320A for producing NFB, for example as part of the method 300 of FIG. 3. Procedure 320A provides a simple yet effective technique for producing a non-fermented beverage NFB from a residue material R2. Procedure 320A may be performed by the production line 20 of FIG. 1 and includes steps 303, 303′, 304, 305, which are performed in sequence. Procedure 320A may correspond to procedure P2 of FIG. 2A-2B. In FIG. 4A, step 303 of processing R2 into a slurry includes charging R2 (step 303A), adding water (step 303B), and mixing R2 and water into a slurry (step 303C). Steps 303A-303C may be performed in a mixing arrangement, for example a tank with a recirculation system and / or an integrated or attached mixing device, such as a rotor or impeller. In some embodiments, the mixing arrangement includes a heating device for heating the contents of the tank, for example by direct injection of steam or by circulating a heating medium in a jacket on the tank as known in the art. As will be appreciated from the above, R2 includes particles that are generated when the grain feedstock is processed into a mash in step 301 (FIG. 3). The mixing in step 303C breaks these particles into smaller particles that are suspended in the water added in step 303B. The amount of water added in step 303B depends on the desired TS of the NFB as well as the TS of R2. In a non-limiting example, the TS of the NFB ranges from 6% to 15%, preferably 5% to 12%. Steps 303A to 303C can be performed in a different order. For example, water may be added before R2. Additionally, R2 and water may be added in batches and mixing may be performed batch by batch.

[0052] It should be noted that, by definition, the processing of R2 is initiated by the addition of water to R2, and therefore the processing of R2 into NFB begins as soon as water is added to at least a portion of R1, thereby forming R2.

[0053] In some embodiments, the water added in step 303B has a temperature of at least 70° C. or greater, preferably at least 75° C. or greater or at least 80° C. This mitigates microbial growth in the slurry.

[0054] In some embodiments, the mixing in step 303C is performed at a temperature equal to or greater than a minimum temperature, which may be 70° C., preferably 75° C. or 80° C. Furthermore, the temperature during mixing may be equal to or less than a maximum temperature, which may be 100° C. According to these embodiments, the temperature in the mixture of R2 and water is thus maintained in the temperature range defined by the minimum and maximum temperatures throughout the mixing step. Besides mitigating microbial growth, the increase in temperature reduces the viscosity of the mixture.

[0055] In some embodiments, as shown in step 303' of FIG. 4A, the slurry is maintained at the above temperature ranges for a holding time after mixing, for example to ensure the correct yield of protein in the slurry. In a non-limiting example, the holding time can be in the range of 1-60 minutes. The longer the holding time, the more important it is to maintain the temperature to combat microbial activity in the slurry. Step 303' may be performed at the mixing location, in a dedicated holding tank, or during transport in preparation for step 304.

[0056] Step 304 of separating the slurry into solid and liquid components can be performed in any type of filtering or separation arrangement, such as a decanter. The separation in step 304 removes solids from the slurry that are larger than a minimum size. Such solids form a sludge consisting of husk, fibers, and other solid particles. The solid component is typically discarded. In a non-limiting example, the minimum size is in the range of 50-500 μm, such as about 100 μm. In some embodiments, the temperature is maintained in the above-mentioned temperature range during step 304.

[0057] The step 305 of processing the liquid ingredients into NFB is also known as the final formulation. Step 305 includes adding one or more ingredients to the liquid ingredients and optionally mixing with the liquid ingredients. Such ingredients may include any of vegetable oils, flavors, sweeteners, salts, thickeners, stabilizers, vitamins, or minerals. In some embodiments, step 305 includes collecting the liquid ingredients produced in step 304 in one or more storage tanks, and the blending of the ingredients is performed using recirculation mixing in the storage tanks. Alternatively, batch mixing may be used. In some embodiments, the temperature is maintained in the above temperature ranges during step 305.

[0058] FIG. 4B is a block diagram of an exemplary production line 20 configured to perform step 320A of FIG. 4A. The production line 20 comprises a mixing station 21 configured to perform step 303. The mixing station 21 may comprise a mixing arrangement as described herein above. The mixing station is arranged to receive R2 and water 200 and to output slurry 200A. The separation station 22 is arranged to receive the slurry 200A and configured to perform step 304. The separation station 22 may comprise one or more decanters. The separation station 22 separates the slurry 200A into a liquid component 200B and a solid component 203. As described above, the step 303' of maintaining the slurry at a temperature within the above temperature range may be performed in the station 21 and / or in the piping for the transfer of the slurry 200A from the station 21 to the station 22. The formulation station 23 is arranged to receive the liquid component 200B and configured to perform step 305. The formulation station 23 is configured to combine the above components 201 into a liquid component 200B to produce a NFB 202 that is output from the formulation station 23.

[0059] FIG. 5A is a flow chart of a second exemplary procedure 320B for producing NFB, for example as part of the method 300 of FIG. 3. Procedure 320B may be performed by the production line 20 of FIG. 1 and includes steps 303, 501, 502, 503, 304, 305, 505, performed in sequence. Procedure 320B may correspond to procedure P2 of FIGS. 2A-2B. Compared to procedure 320A, procedure 320B provides a more advanced technique for producing NFB from R2 by including a dedicated step for increasing the protein and / or dry matter content in NFB by enzyme treatment. Procedure 302B starts with step 303 of processing R2 into a slurry. Step 303 may be the same as procedure 320A (FIG. 4A). Step 303 is followed by step 501 of subjecting the slurry to a preliminary heat treatment. In some embodiments, step 501 involves heating the slurry to a temperature of at least 100° C. for a predetermined time, for example, a temperature in the range of 110° C. to 130° C. In a non-limiting example, the predetermined time is in the range of 2 to 30 minutes, for example, at least 15 minutes. The purpose of step 501 is to kill bacteria, viruses, and possibly spores that may be present in the slurry. Step 501 is performed to hold the slurry at a low temperature for an extended period of time in preparation for subsequent enzymatic treatment. Without the heat treatment of step 501, microorganisms may grow during enzymatic treatment and spoil the resulting NFB. In some embodiments, step 501 is performed in a closed heated vessel under pressurized conditions, similar to treatment in an autoclave. Step 501 is followed by step 502, where the slurry is cooled to an operating temperature for enzymatic treatment. Depending on the enzyme used, the operating temperature may range from 40° C. to 95° C. In one example, the operating temperature is 70° C. or lower. In some embodiments, step 501 and / or step 502 are omitted.

[0060] In step 503, the slurry is treated to increase the protein and / or dry matter content by enzymatic treatment. The enzymatic treatment involves adding one or more enzymes to the slurry, mixing the respective enzymes with the slurry, and allowing the respective enzymes to degrade components of the slurry for a predefined treatment time. The mixture of slurry and enzymes may or may not be mixed during the treatment time. The control parameters of the enzymatic treatment, such as temperature, pH, treatment time, etc., are adapted to the respective enzymes. The applicant has found that it may be advantageous to include at least one of a first enzymatic treatment (step 503A) involving enzymatic degradation of fibers in the slurry, or a second enzymatic treatment (step 503C) involving enzymatic degradation of proteins in the slurry. The first enzymatic treatment may include adding one or more carbohydrases to the slurry. Examples of suitable carbohydrate degrading enzymes include arabanases, cellulases, β-glucanases, hemicellulases, and xylanases. In a non-limiting example, the first enzyme treatment may be carried out at a pH in the range of 3.5-6.0 and a temperature in the range of 40-70°C. The second enzyme treatment includes adding one or more proteases to the slurry. Examples of suitable proteases include endoproteases. In a non-limiting example, the second enzyme treatment may be carried out at a pH in the range of 6-10 and a temperature in the range of 45-65°C. The applicant has surprisingly found that the combination of the first and second enzyme treatments has the ability to significantly increase the yield of protein and / or dry matter in the NFB. The first enzyme treatment has the ability to break down the fibers in the slurry, resulting in proteins and other compounds, and the second enzyme treatment has the ability to break down the proteins into smaller polypeptides or single amino acids. The first enzyme treatment can improve the yield of the second enzyme treatment.

[0061] In FIG. 5A, step 503 includes such a multiple enzyme treatment and may be carried out in one or more tanks, which may or may not include one or more mixing devices. The first enzyme treatment 503A is carried out for a first treatment time, for example in the range of 1-6 hours. Step 503A is followed by step 503B of adjusting the pH for the second enzyme treatment. As mentioned above, proteases may work better at higher pH than carbohydrases. Thus, step 503B may be carried out to increase the pH of the slurry, for example by adding alkali or lye to the slurry. Once the pH is adjusted by step 503B, the second enzyme treatment 503C is carried out for a second treatment time, for example in the range of 1-6 hours. It is understood that the first enzyme treatment may be continued for the second treatment time. In some embodiments, step 503C may be followed by a further pH adjustment in step 503D, for example by adding an acid or an acid salt to lower the pH.

[0062] Step 503 is followed by step 304 of separating the liquid component from the slurry. Step 304 may be similar to procedure 320A (FIG. 4A). After step 304, the liquid component is treated in step 504 to inactivate the enzymes added to the slurry in step 503. Step 504 may be performed in any conventional manner, for example by heating the liquid component and holding the heated liquid component for a predetermined time, for example in the range of 10 to 600 seconds. For example, step 504 may include heating the liquid component to at least 80° C. or at least 85° C. Alternatively or additionally, step 504 may include changing the pH of the liquid component. In a variant, step 504 is performed before step 304 and thus operates on the slurry instead of the liquid component. In some embodiments, step 504 is omitted.

[0063] Final blending step 305 may be similar to procedure 320A (FIG. 4A). In the illustrated example, procedure 305 includes step 305A of adding vegetable oil to the liquid ingredients. The addition of vegetable oil at least partially forms the consistency of the NFB, e.g., to achieve a desired mouthfeel. The amount of vegetable oil varies depending on the recipe, but may range from 0.1-5% by volume of the NFB. Step 305 further includes step 305B of mixing vegetable oil with the liquid ingredients to uniformly distribute the vegetable oil throughout the liquid ingredients, similar to homogenization. Step 305B may be performed in a tank equipped with a mixing device, such as a high shear mixer. Step 305 further includes step 305C of adding one or more additional ingredients, e.g., as listed above, and mixing the ingredients with the liquid ingredients to form the NFB. It is understood that one or more ingredients may alternatively be mixed with the liquid ingredients before step 305A or step 305B. Step 305 shown in FIG. 5A may also be performed in procedure 320A (FIG. 4A).

[0064] Procedure 302B further includes step 505 of pasteurizing or sterilizing the NFB produced by step 305 to eliminate or at least reduce microorganisms in the NFB prior to storage or packaging. Step 305 can be performed according to any conventional procedure. Step 305 can be performed in a conventional heater that may be configured for UHT processing, ultra pasteurization, or pasteurization. For example, the NFB is heated at a temperature in the range of 135° C. to 150° C. for a time in the range of 4 to 30 seconds. Step 505 can also be performed in procedure 320A (FIG. 4A). In some embodiments, step 505 is omitted.

[0065] It should be noted that procedure 320B is provided by way of example only, and in a more general example, procedure 320B may include enzymatically treating the slurry after producing the slurry in step 303, treating the slurry or liquid ingredients to inactivate enzyme activity, mixing vegetable oil into the liquid ingredients to uniformly distribute the vegetable oil throughout the liquid ingredients, and pasteurizing or sterilizing the non-fermented beverage produced from the liquid ingredients.

[0066] FIG. 5B is a block diagram of an exemplary production line 20 configured to perform procedure 320B of FIG. 5A. The production line 20 comprises a mixing station 21, which may be the same as FIG. 4B. The mixing station 21 is configured to perform step 303 and, if performed, optional steps 501-502. A retention enhancement station 24 is arranged to receive the slurry 200A from the mixing station 21. The retention enhancement station 24 is configured to perform step 503 using one or more enzymes 204. The retention enhancement station 24 may consist of one or more tanks, which may or may not include one or more mixing devices. A separation station 22 is arranged to receive the resulting enzyme-treated slurry 200A' from the yield enhancement station 24. The separation station 22 may be the same as FIG. 4B. An inactivation station 25 is arranged to receive the liquid component 200B from the separation station 22 and is configured to process the liquid component 200B to inactivate the enzyme activity according to step 504. The formulation station 23 is arranged to receive the liquid component 200B from the inactivation station 25. The formulation station 23 is configured to perform step 305, mixing the liquid component 200B with one or more components 201. The blending station 23 may be the same as in FIG. 4B. Alternatively, the inactivation station 25 is arranged intermediate the yield enhancement station 24 and the separation station 22. The stabilization station 26 is arranged to receive the NFB from the formulation station 23 and configured to perform step 505, stabilizing the NFB by sterilization or pasteurization. The NFB 202 is then output from the stabilization station 26.

[0067] FIG. 5C is a block diagram of an exemplary yield enhancement station 24 that may be included in the manufacturing line 20 of FIG. 5B. The first substation 241 is arranged to receive the slurry 200A and is configured to perform a first enzyme treatment according to step 503A by the addition of one or more first enzymes 204A. The second substation 242 is arranged to receive the slurry from substation 241 and is configured to adjust the pH according to step 503B, for example, by the addition of an alkali or lye 204B. The third substation 243 is arranged to receive the slurry from substation 242 and is configured to perform a second enzyme treatment according to step 503C by the addition of one or more second enzymes 204C. The fourth substation 243 is arranged to receive the slurry from substation 243 and is configured to adjust the pH according to step 503D, for example, by the addition of an acid or acid salt 204D. It should be noted that the separation into substations 241-244 is optional. It is contemplated that two or more of steps 503A-503D may be performed by the same apparatus through sequential addition of components 204A-204D.

[0068] Following the examples provided herein, several embodiments of methods for producing combined beer and NFB are described below.

[0069] In some embodiments, the method includes heating the slurry to a temperature of at least 100° C. for a period of time prior to separating the slurry into liquid and solid components.

[0070] In some embodiments, the method includes treating the slurry to increase the protein and / or dry matter content in the slurry prior to separating the slurry into liquid and solid components.

[0071] In some embodiments, treating the slurry to increase the protein and / or dry matter content comprises performing an enzymatic treatment of the slurry. In some embodiments, performing an enzymatic treatment may comprise performing at least one of a first enzymatic treatment comprising enzymatic degradation of fibers in the slurry, or a second enzymatic treatment comprising enzymatic degradation of proteins in the slurry. In some embodiments, performing an enzymatic treatment comprises adding one or more enzymes to the slurry. In some embodiments, the one or more enzymes comprise one or more carbohydrases and / or one or more proteases. In some embodiments, the method comprises cooling the slurry to a temperature of less than 70° C. prior to performing the enzymatic treatment.

[0072] In some embodiments, the method further comprises treating the slurry or liquid component following the enzyme treatment to inactivate enzyme activity.

[0073] In some embodiments, the method further comprises treating the slurry to intermittently increase the pH of the slurry.

[0074] In some embodiments, the slurry is maintained at a temperature of at least 70° C. until the slurry separates into liquid and solid components.

[0075] In some embodiments, the mixing of the retentate material with water is carried out at a temperature of at least 70° C. or greater.

[0076] In some embodiments, processing the liquid ingredients into a non-fermented beverage comprises adding a vegetable oil to the liquid ingredients, hi some embodiments, processing the liquid ingredients into a non-fermented beverage further comprises mixing the vegetable oil with the liquid ingredients to uniformly distribute the vegetable oil throughout the liquid ingredients.

[0077] In some embodiments, the method further includes packaging the non-fermented beverage in a first container for distribution and packaging the beer in a second container for distribution, where the packaging of the non-fermented beverage occurs prior to the packaging of the beer.

[0078] In some embodiments, the method further comprises pasteurizing or sterilizing the non-fermented beverage.

[0079] The disclosure also describes a factory comprising a first production line configured to process a grain feedstock into a mash, separate the mash into a fermentable wort and a residue, process the fermentable wort into beer, and output the beer; a second production line configured to process a residue material including at least a portion of the residue into a slurry, separate the slurry into a liquid component and a solid component, process the liquid component into a non-fermented beverage, and output the non-fermented beverage; and a transport arrangement configured to transport the residue material from the first production line to the second production line.

[0080] While the subject matter of the present disclosure has been described in connection with embodiments presently considered to be most practical, it should be understood that the subject matter of the present disclosure is not intended to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the description and scope of the appended claims. Furthermore, although operations are depicted in the figures in a particular order, this should not be construed as requiring such operations to be performed in the particular order shown, or sequentially, or that all of the illustrated operations be performed in order to achieve desirable results.

Claims

1. A method for producing a combination of beer and a non-fermented beverage from a cereal raw material, comprising: processing the cereal raw material into a mash (301); separating the mash into fermentable wort and a residue (R1) (302); a residue material (R2) comprising at least a part of the residue (R1), processing the residue material (R2) into a slurry (303); separating the slurry into a liquid component and a solid component (304); processing the liquid component into a non-fermented beverage (305); processing the fermentable wort into beer (306); outputting the non-fermented beverage (307); outputting the beer (309); A method.

2. The method according to claim 1, wherein the processing (303) of the residue material is initiated by adding water (303B) to the residue material (R2). The method according to claim 1.

3. The method according to claim 2, wherein the processing (303) of the residue material comprises mixing (303C) the residue material (R2) with water. The method according to claim 2.

4. The method according to claim 1, wherein the processing (303) of the residue material is initiated within a predefined maximum time (Δmax) from the separation (302) of the mash. The method according to claim 1.

5. The method according to claim 4, wherein the predefined maximum time (Δmax) is less than 8, 6, 4 or 2 hours. The method according to claim 4.

6. The method according to claim 4, wherein the time (ΔP2) from the start of the processing (303) of the residue material to the output (307) of the non-fermented beverage is equal to or less than a predefined maximum time (Δmax). The method according to claim 4.

7. The method according to claim 1, wherein the residue material (R2) is obtained without any active treatment for the modification of at least a part of the residue (R1). The method according to claim 1.

8. The method according to claim 1, wherein a non-fermented beverage is output (307) before the processing (306) of the fermentable wort is completed. The method according to claim 1.

9. The method according to claim 1, wherein the residue (R1) generated by separating (302) the mash and the residue material (R2) have substantially the same relative moisture content. The method according to claim 1.

10. The method according to claim 1, wherein the residue material (R2) has a relative moisture content in the range of 60% to 90%. The method according to claim 1.

11. The method according to claim 1, wherein when the residue (R1) is generated by separating (302) the mash, the residue (R1) has a temperature in the range of 55°C to 90°C. The method according to claim 1.

12. When the processing (303) of the residue material is started, the residue material (R2) has a temperature in the range of 40°C to 99°C. The method according to claim 1.

13. When the processing (303) of the residue material is started, the residue material (R2) has a temperature equal to or lower than the temperature of the residue (R1) when the mash is produced by the separation (302). The method according to claim 1.

14. The temperature difference between the residue material (R2) and the residue (R1) is less than 15°C, or less than 10°C, or less than 5°C. The method according to claim 1.

15. Perform enzymatic treatment of the slurry (503A, 503C). Treat the slurry or liquid component (504) to inactivate the enzymatic activity. When processing the liquid component into a non-fermented beverage (305). Mix vegetable oil with the liquid component (305B) to uniformly disperse the vegetable oil in the liquid component. Sterilize or pasteurize the non-fermented beverage at a low temperature (505). The method according to claim 1, further comprising.

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