Method and system for producing improved fermented beverage concentrates

Abstract

Systems and methods for improved fermented beverage concentrates are described. One embodiment includes a method for producing a fermented beverage concentrate, the method including fermenting a first fermentable aqueous product to produce a base product and performing a nesting process on the base product, the nesting process including a concentration stage in which at least a portion of the base product passes through a separation system and retentate is returned to the base product, a water nest in which water is added to at least a portion of the nested solution and passed through a separation system, and a fermentable aqueous product nest in which a second fermentable aqueous product is added to at least a portion of the nested solution and passed through the separation system to increase the concentration of the nested solution.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS)

[0001] This application incorporates by reference commonly owned and assigned U.S. Patent No. 8,889,201, including, among other things, the description of systems and methods for a nested approach to producing fermented beverage concentrates contained therein.

[0002]

[0002] The present invention relates to systems and methods for the production of fermented beverages. In particular, but not exclusively, the present invention relates to systems and methods for making fermented beverage concentrates. [Background technology]

[0003]

[0003] As used herein, the term "fermented beverage" refers to beverages such as beer, wine, cider, sake, and kombucha, and the ingested product of these beverages is generally understood to be the product obtained after the fermentation process. In this regard, the term "fermented beverage" as used herein does not include distilled spirits (such as vodka, gin, shochu, rum, whiskey, tequila, and brandy), and the solution produced by fermentation is merely an intermediate solution that still requires distillation before it can be considered an ingested product. In fermented beverages, the alcohol content (ABV) of the consumer product is typically limited by the tolerance of yeast. In distilled spirits, the ABV is intentionally increased to create an ingested product with a higher alcohol content. Unlike distilled spirits, where a higher ABV is generally considered a desirable beverage characteristic, for many fermented beverages, it is often desirable to have an ingested product with a lower ABV, such as non-alcoholic beer, non-alcoholic kombucha wine, non-alcoholic kombucha, non-alcoholic sake, and non-alcoholic cider. Note that the term "non-alcoholic" is not limited to beverages that do not contain alcohol. Rather, the term "non-alcoholic" includes beverages with an ABV below a defined threshold. For example, in the United States, the term "non-alcoholic" is often used to describe malt beverages containing up to 0.5% ABV. (See, e.g., 27 CFR § 7.71 ("(e) Non-alcoholic. The term 'non-alcoholic' may be used for malt beverages if the phrase 'Containing less than 0.5 percent (or .5%) of alcohol content' appears in direct juxtaposition with that phrase, in readily legible print, and on a completely contrasting background.").

[0004]

[0004] One of the factors in the production of fermented beverages is the alcohol produced during fermentation. While alcohol is sometimes a desirable by-product of fermentation, it can inhibit or limit the fermentation process. For example, during the production of beer, one of the by-products of fermentation is diacetyl. Diacetyl is often considered an undesirable by-product. While yeast produces diacetyl, it also consumes it later. However, if the alcohol content is too high, it can limit the yeast's ability to remove undesirable by-products such as diacetyl.

[0005] Furthermore, alcohol can limit the ability to produce fermented beverage concentrates. When fermented beverages have a high water content, it may be desirable to produce a fermented beverage concentrate to improve transportability (e.g., to reduce transportation costs and / or make it easier to enjoy these beverages during outdoor activities such as hiking trips or camping). As used herein, the term "fermented beverage concentrate" refers to a solution to which water, alcohol, or other diluents must be added to achieve a desired concentration or specific gravity for consumer consumption. For example, a 2x concentrated fermented beverage concentrate consumer product requires 1 part diluent (e.g., water, alcohol, a combination of water and alcohol, etc.) for every 1 part fermented beverage concentrate to make the consumer product. Similarly, a 3x concentrated fermented beverage concentrate requires 2 parts diluent (e.g., water, alcohol, a combination of water and alcohol, etc.) for every 1 part fermented beverage concentrate to make the consumer product. When referring to a fermented beverage concentrate, the term "concentrated" primarily refers to the specific gravity or concentration of the non-alcoholic ingredients. For example, as apparent from this disclosure, a fermented beverage concentrate may have a low (non-concentrated) alcohol content. Indeed, one of the advantages of the present invention is that it allows for the production of fermented beverage concentrates that are particularly suitable for producing non-alcoholic beverages.

[0006]

[0006] To produce non-alcoholic fermented beverages and / or fermented beverage concentrates, the industry has focused on prior art solutions of breaking down beer, such as removing water before shipping, and then reconstituting it to reach the desired concentration at the destination. For example, several older and more recent disclosures (e.g., WO2016083482A1 to Schutter et al., "Beer or cider concentrate" (Anheuser-Busch Inbev SA), U.S. Patent No. 2016 / 0230133 to Peterson et al., "Alcoholic Beverage Concentrate Process" (Keuring Green Mountain, Inc.), U.S. Patent No. 4,265,920 to Thijssen, "Process for concentration of alcoholic beverages" (Douwe Egberts), and U.S. Patent No. 2008 / 0063749 to Tokuda et al., "Mead making method") focus on breakdown approaches in which the fermented beverage is processed after brewing is complete to break it down into separate components. Using this splitting approach, a fermented beverage (such as beer) can be processed through a separation step to separate it into a permeate stream (comprising essentially water, aromas, and alcohol) and a retentate stream (comprising essentially flavor components, aromas, small amounts of alcohol, and small amounts of water). In certain cases, the permeate stream is then processed so that the alcohol and aromas can be further removed from the permeate and returned to the retentate. Further processing of this permeate stream is typically done using processes such as freeze-concentration or distillation. Many problems exist with the splitting approach. The process requires the fermented beverage to be completely (or nearly completely) brewed prior to concentration, which is therefore an additional step added to the brewing process. This is time-consuming and therefore reduces production capacity. Furthermore, the cost of the additional equipment (e.g., distillation and freeze-concentration equipment) in the splitting approach can be substantial and may require special permits (e.g., distillation permits) depending on the brewing location.Furthermore, degradation techniques also extend potentially damaging processing activities (post-fermentation) that may expose the fragile finished fermented beverage to the effects of oxidation or microbial contamination that can cause spoilage, thus reducing the shelf stability of the finished product.

[0007] To address some of the problems of the prior art, one inventive approach is to use a nested fermentation process to produce beverages with higher concentrations. For example, in U.S. Patent No. 8,889,201, the applicant taught an inventive system and method for nested fermentation. In contrast to a disassembly approach, a nested fermentation process is a construction approach in which the finished fermented beverage concentrate is the result of assembling a final level of flavor concentration through one or more additional steps. This is advantageous because it reduces the required residence time of the beverage in the fermentation vessel relative to the amount of serveable product produced, thereby increasing the production capacity of the equipment, an additional asset for the manufacturer. Thus, the fermented beverage concentrate is the result of construction rather than disassembly and reassembly. For example, one benefit of a nested fermentation process is that it allows the fermented beverage concentrate to be completed in the same stable oxidation state or low-solubility oxygen state as a conventional non-concentration approach. The fermented beverage concentrate then deteriorates at the same rate as a conventionally produced fermented beverage. However, as the fermented beverage concentrate is diluted for serving, any off-flavor flavors are also diluted. Thus, the fermented beverage concentrate can exist in its concentrated, undiluted form for a longer period of time than conventional unconcentrated beverages before detrimental effects reach unacceptable flavor threshold levels in the finished consumer beverage. Summary of the Invention

[0008]

[0008] Current devices are functional but not sufficiently precise or satisfactory. Therefore, there is a need for systems and methods to address the shortfalls in the art and to provide other new and innovative features.

[0009]

[0009] Exemplary embodiments of the present invention as shown in the drawings are summarized below. These and other embodiments are described in more detail in the Detailed Description section. However, it will be understood that it is not intended to limit the present invention to the forms set forth in the Summary of the Invention or the Detailed Description. Those skilled in the art will recognize that there are numerous modifications, equivalents, and alternative configurations that fall within the spirit and scope of the present invention as expressed in the claims.

[0010]

[0010] The present invention can provide systems and methods for producing a fermented beverage concentrate. In various exemplary embodiments, the present invention can include a method for producing a fermented beverage concentrate, the method including fermenting a first fermentable aqueous product to produce a base product and performing a nesting process on the base product, the nesting process including a water nest, in which water is added to at least a portion of the base product and passed through a separation system to produce a nested solution, and a fermented aqueous product nest, in which a second fermentable aqueous product is added to at least a portion of the nested solution and passed through a separation system to increase the concentration of the nested solution. In some embodiments, the nesting process can further include a concentration stage, in which at least a portion of the nested solution is passed through a separation system to increase the concentration of the nested solution, and / or a finishing nest, in which fermented components are added to the nested solution without further passing the nested solution through a separation system. Further, in various embodiments, fermenting the first fermentable aqueous product includes using a first yeast and the finishing nest includes using a second yeast, wherein the first yeast and the second yeast are different. In another embodiment, the first and second yeasts can be the same. In other embodiments, the method further includes removing solids from the base product prior to the nesting process. Those skilled in the art will understand that the first and second fermentable aqueous products can comprise the same or different worts.

[0011]

[0011] In an additional exemplary embodiment, the present invention covers a method for producing a fermented beverage concentrate, the method comprising fermenting a first fermentable aqueous product to produce a base product and performing a nesting process on the base product, the nesting process comprising a concentration stage in which at least a portion of the base product is passed through a separation system and the impermeates are returned to the base product to produce a nested solution, a water nest in which water is added to at least a portion of the nested solution and passed through a separation system, and a fermented aqueous product nest in which a second fermentable aqueous product is added to at least a portion of the nested solution and passed through the separation system to increase the concentration of the nested solution.

[0012]

[0012] In an additional exemplary embodiment, the present invention covers a method for producing a fermented beverage concentrate, the method comprising: performing a first fermentation to produce a nested solution; reducing the alcohol content (ABV) of the nested solution, where reducing the ABV comprises combining at least a portion of the nested solution with water to form a first combined solution, passing the first combined solution through a separation system, and returning the retentate to the nested solution; and increasing the concentration of the nested solution, where increasing the concentration comprises combining at least a portion of the nested solution with a fermentable aqueous product to form a second combined solution, passing the second combined solution through a separation system, and returning the retentate to the nested solution. In various embodiments, performing the nesting process may further include passing at least a portion of the nested solution through a separation system and returning the retentate to increase the concentration of the nested solution, and / or adding fermentation components to the nested solution without further passing the nested solution through a separation system. The present invention teaches that, depending on the desired product, the fermented aqueous product may include one of wort, must, sweet tea, or brewer's crystals. In some embodiments, reducing the ABV of the nested solution includes reducing the ABV to 1% or less, 0.75% or less, 0.50% or less, or 0.25% or less. In various embodiments, increasing the concentration of the nested solution includes increasing the concentration of the nested solution to 2.0x, 3.0x, 4.0x, 5.0x, 6.0x, 7.0x, or more than 8.0x the desired concentration of the final consumer product.

[0013]

[0013] In an additional exemplary embodiment, the present invention covers a method for producing a fermented beverage concentrate, the method comprising: performing a first fermentation to produce a base product; concentrating the base product to produce a nested solution, where concentrating comprises passing at least a portion of the base product through a separation system and returning the retentate; reducing the ABV of the nested solution, where reducing the ABV comprises combining at least a portion of the nested solution with water to form a first combined solution, passing the first combined solution through a separation system and returning the retentate to the nested solution; and performing a second fermentation using the nested solution, where performing the second fermentation comprises adding fermentation ingredients to the nested solution.

[0014]

[0014] In another embodiment, the invention includes a nesting system for producing a fermented beverage concentrate, the system comprising: a nesting tank for holding a nesting solution; an output of the nesting tank connected to an input to a separation system, the separation system comprising a series of filters, at least one filter in the series having increasingly selective filtration relative to the previous filter in the series; and an impermeate output connected to the input to the nesting tank, the impermeate output carrying impermeate from the series of filters. The series of filters may comprise a series of membranes, in one embodiment one or more nanofiltration membranes and one or more reverse osmosis membranes. The separation system may further comprise a permeate output carrying permeate from the series of filters. The permeate is recovered and may optionally be used.

[0015] In yet another embodiment, the present invention includes a method for washing hops used during beer production, the method including producing a beer concentrate, including hops in the beer concentrate, separating the hops from the beer concentrate, washing the hops removed from the beer concentrate, and recovering the liquid used to wash the hops. In some embodiments, the hops are added during the process of producing the beer concentrate, while in other embodiments, the hops are added to the beer concentrate after the beer concentrate has been fully fermented.

[0016]

[0016] As previously stated, the above embodiments and examples are for illustrative purposes only. Numerous other embodiments, examples, and details of the present invention will be readily apparent to those skilled in the art from the following description and claims.

[0017]

[0017] Various objects and advantages of the present invention and a more complete understanding thereof will become apparent and more easily understood by reference to the following detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0018] [Figures 1A-1C] 1A-1C illustrate exemplary systems and methods consistent with embodiments of the present invention, including an exemplary system and process for preparing a base product (FIG. 1A) and an exemplary system and process for nested fermentation (FIGS. 1B-1C). [Figure 2] 1 is an exemplary diagram showing a separation system consistent with an embodiment of the present invention. [Figure 3] FIG. 1 is an exemplary diagram showing a nested system consistent with an embodiment of the present invention. [Figure 4] FIG. 1 illustrates an exemplary system and method for nested fermentation consistent with embodiments of the present invention. [Figure 5A-5B]5A-5B illustrate exemplary systems and methods consistent with embodiments of the present invention, including an exemplary system and process for preparing a base product (FIG. 5A) and an exemplary system and process for nested fermentation (FIG. 5B). [Figure 6] FIG. 1 is an exemplary diagram showing a process for making a beer concentrate consistent with an embodiment of the present invention, with potential outputs for each process step. DETAILED DESCRIPTION OF THE INVENTION

[0019]

[0018] Referring to the drawings, in which identical or similar elements are designated by the same reference numerals throughout the views, and particularly to Figure 1, Figure 1 illustrates a system and method for producing a fermented beverage concentrate. For purposes of explanation, some figures show method steps with corresponding exemplary system diagrams. Those skilled in the art will understand that the method steps are not limited by the system diagrams. For example, some of the illustrated embodiments are shown using multiple different tanks for different process steps. However, those skilled in the art will understand that the same tanks, or no tanks at all, may be used to achieve the same functionality.

[0020]

[0019] Production of Fermented Aqueous Products (FAP) FIG. 1A begins with the preparation of a fermentable aqueous product (FAP), indicated at 1100. Fermented beverages are generally based on an aqueous product containing sugars that are consumed during the fermentation process. For example, in beer production, the FAP is often referred to as "wort," which is an aqueous product containing malt extract (derived from grain mash) and water. In wine production, the FAP is often referred to as "must," which is an aqueous product containing juice (typically from grapes) and pomace (the solid part of the fruit, including skins, seeds, stems, etc.). In kombucha, sweet tea is often used as the FAP. Those skilled in the art will readily understand what the FAPs are in various fermented beverages.

[0021]

[0021] In the present invention, the production 1100 of the FAP can be carried out using conventional methods and known processes. While Figure 1A shows that the FAP is prepared in a FAP tank, those skilled in the art will understand that this is in no way a limitation of the present invention. For example, the production of beer wort, including steps such as mashing, filtering, boiling, separating, and cooling, is well known to those skilled in the art, and method steps and system options for producing wort are well known in the art. Similarly, various options for producing wine must, kombucha sweet tea, etc. are well known to those skilled in the art.

[0022]

[0022] Furthermore, although not required by the present invention, those skilled in the art will recognize (from the description herein) that systems and methods consistent with the present invention may benefit from using FAPs having a higher concentration (or higher specific gravity) than those used in typical or conventional processes. For example, in beer production, if a typical wort can be used to produce N consumable 12-ounce bottles of beer, systems and methods consistent with the present invention may benefit from using concentrated wort that can be used to produce a number of consumable 12-ounce bottles of beer that is a multiple of N, with the multiple typically being in the range of 1.05N to 1.75N. Similarly, in kombucha production, the present invention may use a higher amount of sugar and tea leaves to form a sweet tea FAP.

[0023] Additionally, although not required by the present invention, those skilled in the art will appreciate that one of the benefits of the present invention is that it allows for the use of the same FAP during different fermentation steps (base fermentation 1200, FAP nest 1430, and / or finishing fermentation 1440, as discussed below), or the use of different FAPs during one or more of the different steps, including a "base" FAP used during base fermentation 1200, a "nested" FAP used during the FAP nest process 1430, and a "finishing" FAP used during final fermentation 1440. For many fermented beverages produced according to the present invention, fermentation during nesting 1430 and / or finishing fermentation 1440 significantly influences characteristics such as flavor, aroma, and mouthfeel. Accordingly, brewers may desire to use specific yeasts (which can often be uncommon and expensive) during nesting and / or final fermentation to achieve these desired characteristics (as discussed herein). Similarly, as discussed herein, a brewer may desire to use a more efficient (economical and operational) fermentable product for nesting and / or finishing fermentation 1430 / 1440.

[0024] For example, in the production of beer, the base wort, nested wort, and finishing wort can be the same wort or different worts. Depending on the beer being produced, a brewer may desire to use the same wort for base fermentation, nesting, and finishing fermentation, or a particular "base" wort for base fermentation 1200, a particular nested wort for nesting 1430, and / or a particular finishing wort for finishing fermentation 1440. In some cases, the base wort may be selected because it uses less expensive ingredients. In other cases, the base wort may be selected because it uses a malt extract that produces a more stable base for the nesting process 1400. The nested and finishing worts can be the same or different, and may also be a more efficient (economical and operational) product, such as Brewer's Crystals.

[0025]

[0025] Base fermentation

[0026] As shown in Figure 1A, the FAP is used in base fermentation 1200. During base fermentation 1200, the FAP is fermented to produce a base product for nesting process 1400. During the base fermentation process 1200, sugars in the FAP are converted into metabolic by-products such as alcohol and carbon dioxide.

[0026]

[0027] The primary purpose of the base fermentation step 1200 is to produce a base product for the nesting process 1400. As discussed herein, the nesting process 1400, including the FAP and / or finishing nest 1430 / 1440, has a greater impact on characteristics such as taste, aroma, and mouthfeel, so the base fermentation step 1200 may be less concerned with these properties. Similar to the discussion above regarding the FAP, the systems and methods of the present invention may also benefit from using the same or different yeasts for the base fermentation 1200 (base fermentation yeast), nesting 1430 (nested yeast), and finishing fermentation 1440 (finishing fermentation yeast).

[0027]

[0028] Because concerns about properties such as flavor and aroma are reduced during the base fermentation process 1200, systems and methods consistent with the present invention may differ from conventional processes in that they may use a fermented aqueous product with a higher concentration (or specific gravity) and may be performed for a shorter time period. Furthermore, because the overall goal of the present invention is to produce a fermented beverage concentrate, the base fermentation process 1200 preferably produces a base product with a higher density than the desired density of the consumable product. The density of the base product may depend, in part, on the desired density of the final fermented beverage concentrate. For example, if the overall goal is to produce a fermented beverage concentrate with 8 times the density of the consumable product, it may be desirable for the base fermentation process 1200 to produce a base product with approximately 1.5 to 2 times the density of the consumable product. If the overall goal is to produce a fermented beverage concentrate with 6 times the density of the consumable product, it may be desirable for the base fermentation process 1200 to produce a base product with approximately 1.25 to 1.75 times the density of the consumable product. In yet a further embodiment, it may be desirable for the fermentation step 1200 to produce a base product with 1.05 to 3.0 times the density of the consumable product. Base products that are more than three times the density of the consumable product are not excluded from the scope of the present invention.

[0028]

[0029] Using the example of beer production, one of the primary goals of base fermentation 1200 is to convert sugars in the wort to alcohol to form a beer base for nesting process 1400. Given the processing involved during nesting process 1400, one skilled in the art will understand that creating aroma and more complex flavor components in the beer base is not important, and in many cases, aroma and other components are undesirable. Thus, the focus of base fermentation process 1200 is to convert sugars to alcohol and not produce aroma. Base fermentation yeast may be selected to reduce costs, improve efficiency, and / or produce a more stable base beer.

[0029]

[0030] Additionally, as noted above, it may be advantageous to use a higher density or higher gravity base wort (e.g., a wort capable of producing 1.05 to 2.0 times the amount of beer consumed compared to conventional wort) to obtain a beer base that is denser than the beer consumed by consumers. For example, if the overall goal is to produce a beer concentrate that is six times the density of the consumer beer, the brewer would control the base fermentation process 1200 to create a base beer that is 1.25 to 1.75 times the density of the consumer beer. If the overall goal is to produce a beer concentrate that is four times the density of the consumer beer, the brewer would control the base fermentation step 1200 to create a base beer that is 1.1 to 1.6 times the density of the consumer beer.

[0030]

[0031] Removal of solids from the base product

[0032] Prior to nesting process 1400, the base product is preferably processed to remove undesired solids. For example, as shown in FIG. 1A, the base product (with solids) may be passed through a clarification system (such as a centrifuge, filter, or settling tank) to separate the undesired solids from the liquid. The output is a more optimal base product (without solids) in nesting process 1400. In the beer-making example, yeast, trout, and plant matter would be removed. In the wine-making example, undesired solids such as yeast and plant matter would be removed. In the kombucha example, microorganisms (SCOBY) and plant matter would be removed. In the wine example, undesired solids such as fruit solids and yeast solids would be removed. In the sake example, undesired solids such as fruit solids, rice solids, yeast solids, or koji solids would be removed. Those skilled in the art will readily recognize the undesired solids in various fermented beverages and the various options for separating the undesired solids from the liquid.

[0031]

[0033] Nested process and finishing fermentation

[0034] Preferably, after the solids are removed from the base product, the base product is passed to a nesting system where it undergoes a nesting process 1400 .

[0032]

[0035] The nesting process can include four general stages: a "concentration stage" 1410 to increase the concentration of the solution; a "water nest" 1420 to reduce the ABV of the solution; a "FAP nest" 1430 to further increase the concentration and improve finishing characteristics such as flavor, aroma, and mouthfeel; and a "finishing nest" 1440 to condition the solution. For illustrative purposes, these four general stages are shown in FIGS. 1B-1C along with exemplary system diagrams. As described herein, these stages are not strictly linear, nor are they mutually exclusive. For example, the concentration stage 1410 and the water nest 1420 are typically performed before the finishing nest 1440, and one skilled in the art will understand that the concentration stage 1410 and the water nest 1420 can be performed separately, together, and in different orders, overlapping or non-overlapping. Furthermore, all four stages may not be necessary for particular processes and products.

[0033]

[0036] Concentration stage

[0037] The nesting process 1400 generally begins with a base product, preferably separated from undesired solids. For ease of explanation, once this base product begins undergoing the nesting process, the solution will be referred to as a nested solution. In the concentration stage 1410, the base product (now the nested solution) passes through a separation system 2000 to remove alcohol and water, both to reduce the alcohol content (ABV) and to increase the concentration of the nested solution. In FIGS. 1A and 1B, the base product is shown passing through a nesting tank before proceeding to the separation system. However, one skilled in the art will understand that the base product can be passed directly to the separation system without first passing through the nesting tank. Alternatively, a portion of the base product passes directly to the separation system and a portion to the nesting tank. Furthermore, one skilled in the art will understand that several alternative holding tanks can be used between the clarification step 1300 and the nesting process 1400.

[0034]

[0038] A separation system is a system comprising one or more filters and / or one or more membranes that aid in separating a nested solution into a permeate (comprising essentially water and alcohol) and a retentate (comprising essentially flavor components, aroma, minor alcohol, and minor water). In certain embodiments, a separation system may comprise a series of filters and / or membranes. A series of filters and / or membranes may be used to reduce the osmotic pressure across each filter / membrane while still effectively separating certain portions of the solution (water and alcohol) and retaining other portions (comprising flavor components, aroma, minor alcohol, and minor water). In the example of FIG. 2, separation system 2000 comprises a cascade filter 2100 comprising a series of membranes (2110, 2120, 2130, 2140) of increasing separation capacity. A series of increasingly selective filtration membranes (also referred to as a cascade filter) reduces the osmotic pressure threshold across each subsequent membrane, including reverse osmosis membranes, helping the system operate more efficiently. Some separation systems may require fewer stages, while others may require more stages. Those skilled in the art will understand how to design a separation system in accordance with the present invention. In one example of beer production, separation system 2000 may use first, second, and third membranes 2110 / 2120 / 2130 comprising nanofiltration membranes to substantially remove larger molecular weight compounds, and a final reverse osmosis membrane 2140 to polish the final permeate by rejecting smaller molecular weight compounds. In another embodiment, first, second, and third membranes 2110 / 2120 / 2130 may provide the same level of filtration or may provide increasingly more selective filtration. While nanofiltration membranes are a preferred embodiment, ultrafiltration membranes may also be used as one, more, or all of the filters in the cascade filter. In another example of beer production, separation system 2000 may use two filtration membranes: first 2110 and second 2120 nanofiltration membranes, and a final reverse osmosis membrane 2140.The retentate from each cascade filter stage (2110, 2120, 2130, etc.) is preferably combined and passes through retentate output 2300, while the final permeate (consisting essentially of water and alcohol) exits permeate output 2400. In other embodiments, the retentate from each filter stage can be fed to a separate retentate output or can be cycled internally through a separation system. Ultimately, however, the purpose of the separation system is to separate the retentate and permeate and use the retentate for nested fermentation. Those skilled in the art will recognize from this disclosure that other variations are possible.

[0035]

[0039] FIG. 3 provides a schematic diagram of one embodiment of a nesting system 3000 consistent with embodiments of the present invention. As shown in the figure, nesting system 3000 includes a nesting tank 3100 and a separation system 2000. As shown in FIGS. 2 and 3 and discussed herein, separation system 2000 may have one or more inputs 2200 for nesting solution, water, FAP, and / or other ingredients. In a preferred embodiment, ingredients such as base product, nesting / finishing FAP, nesting / finishing yeast, and water are added to the nesting tank, after which the mixed nesting solution is removed from nesting tank 3100 and passed to separation system 2000. Additionally, it is advantageous to design nesting system 3000 to minimize larger ingredients being passed from nesting tank 3100 to separation system 2000.

[0036]

[0040] Although shown as a tank, the nested tank 3100 need not be a separate chamber. For example, in one embodiment, the nested tank 3100 may include a pathway (e.g., a tube or pipe) between the non-permeate output 2300 and the input 2200. If the pathway (e.g., a tube or pipe) can contain a sufficient volume of material, it will function as a "nested tank" 3100 despite the fact that it is not a separate physical tank-like chamber. As discussed herein, tank-like chambers are preferred for the nested tank 3100 to make it easier to combine materials. Furthermore, the present invention is not limited to using multiple tanks, pathways (e.g., tube or pipe pathways) as the nested tank 3100.

[0037]

[0041] During the concentration step 1410, as the retentate is returned to the nesting solution, the overall concentrate of the nesting solution will increase. Depending on the desired level of concentration, only a portion of the nesting solution may need to be passed to the separation system, or the nesting solution (including any retentate that is returned to the nesting solution) may need to be cycled through the separation system once (or more than once) to reach the desired level of concentration. When referring to the concentration of the nesting solution, those skilled in the art are generally referring to the concentration of the nesting solution in the nesting tank at any given time period.

[0038]

[0042] Water Nest

[0043] In the present invention, it may be preferable to further reduce the alcohol content (ABV) of the nested solution before adding additional fermentation components. Because many separation systems operate in equilibrium, it may be desirable to implement a water nest 1420, in which water is added to the nested solution circulated through the separation system 2000. By adding water to the nested solution, it is possible to reduce the ABV of the system for a given concentration level.

[0039]

[0044] Notably, the order of concentration step 1410 and waternest 1420 does not matter. In fact, concentration step 1410 may precede waternest 1420, may follow waternest 1420, or may be performed simultaneously with waternest 1420. For example, waternest 1420 and concentration step 1410 may be performed simultaneously by adding less water than necessary to maintain a constant concentration, while still serving to reduce the overall ABV of the nested solution. In this way, the concentration may increase more slowly than if no water had been added, and the ABV may fall more slowly than if no water had been added, allowing the nested solution to reach the desired concentration and ABV at approximately the same time.

[0040]

[0045] One aspect of the present invention is to control the ABV so that the ABV remains sufficiently low while the concentration of the nested solution increases. In particular, the ABV is controlled to ensure that any components that are insoluble in alcohol (such as many proteins and carbohydrates) do not go out of solution / suspension. In the example of beer brewing, certain beers (such as stouts, wits, porters, and ales) may have higher amounts of proteins and carbohydrates. If the concentration increases before the alcohol content is sufficiently reduced, the nested solution may experience shear thickening in the separation system. By reducing the ABV while the concentration increases, this shear thickening effect can be reduced or prevented.

[0041]

[0046] Although not required by the present invention, it is preferred that both the concentration and ABV of the nested solution at the end of the optional concentration stage 1410 and water nest 1420 be lower than the desired final fermented beverage concentration, since in the next stage of the nesting process additional fermented ingredients are added which increase both the overall concentration of the nested solution and the alcoholic strength of the nested solution.

[0042]

[0047] FAP nest and finishing nest

[0048] To further increase the concentration of the nested solution, the present invention uses nested fermentation, where additional fermentation components, including nested FAPs and nested yeast, are added to the nested solution, as shown in FAP nest 1430 and finishing nest 1440. Although the concentration of the nested solution is increased, the ABV of the nested solution is reduced, allowing for nested fermentation within the concentrated solution.

[0043]

[0049] The FAP nest 1430 and finishing nest 1440 can increase the density of the nested solution while also adding desirable ingredient-based finishing properties that contribute to taste, aroma, and mouthfeel.

[0044]

[0050] The FAP nest 1430 and the finishing nest 1440 can be performed as separate steps or as part of the same step. The FAP nest 1430 generally refers to the period during which the nesting solution continues to circulate through the separation system as and / or after the nesting components are added. Similarly, the finishing nest 1440 refers to the period during which any retentate from the separation system is returned to the nesting solution to support subsequent fermentation and / or the addition of a final component. Fermentation during the finishing nest 1440 can be desirable because it helps consume certain undesirable residual components, such as oxygen, and also continues to enhance desirable properties, such as flavor, aroma, and mouthfeel.

[0045]

[0051] As discussed herein, the implementation of the FAP nest 1430 is not essential or required. Indeed, one of ordinary skill in the art having the benefit of this disclosure will understand that it is not necessary to continue circulating the nesting solution through a separation system as or after the nesting components are added.

[0046]

[0052] The FAP nest 1430 and / or finishing nest 1440 should be controlled to achieve a final alcohol content (ABV) and final concentration by adding the appropriate amount of nesting components (e.g., nesting FAP and / or finishing FAP) to achieve the final ABV and final concentration.

[0047]

[0053] Additional modifications and variations

[0054] Those skilled in the art, having the benefit of this disclosure, will recognize numerous modifications that may be made consistent with the present invention. Further details regarding certain of the modifications mentioned above are provided below.

[0048]

[0055] Alternative (specialty) yeast strains in final fermentation

[0056] As previously mentioned, the flavor and aroma profiles associated with volatile compounds produced during fermentation are less important in the first fermentation. This means that beverage producers can preferentially select yeast strains for the first fermentation based on performance characteristics (e.g., attenuation, alcohol tolerance, economy, availability) rather than yeasts required to impart specific characteristics. While the flavor and aroma provided by the yeast may be less important in the first fermentation, they are often more important in the final characteristics of the finished fermented beverage. If the finished fermented beverage requires a specific yeast strain to match a particular style, that yeast strain should be used in the final fermentation. For example, if the final finished beverage is a Belgian-style ale, an appropriate Belgian-style yeast strain should be used to produce and yield the appropriate flavor and aroma qualities associated with Belgian-style ales. The volume of the final fermentation is typically smaller compared to the initial fermentation, which often means that a smaller total amount of yeast is required in the final fermentation because the total amount of sugar to be metabolized in the final fermentation is often lower. Thus, brewers can utilize economically advantageous and readily accessible yeast for early fermentations where derived yeast flavor and aroma are less important, and can utilize reduced amounts of specialty yeast in final fermentations to achieve a specialty yeast profile for the finished beverage, resulting in economic savings and supply chain efficiencies for brewers who must manage yeast viability and availability.

[0049]

[0057] Alternative fermentable products for additional nested fermentations

[0058] It is common for additional processing time, energy, and resources to be required in both FAP production and the additional time of processing through the separation system in the FAP nest 1430 and / or finishing nest 1440. Therefore, it would be advantageous to support additional fermentations and reap the benefits of those additional fermentations (as previously described herein) without investing additional preparation and production time, ingredients, and resources into building and running the FAP.

[0050]

[0059] One solution is to construct a base FAP for base fermentation 1200 such that the base product embodies the appropriate desired profile to become the finished beverage, and then use the more efficient (either operationally and / or economically) fermentable product to support the FAP nest 1430 and / or finishing nest 1440 for all subsequent nested fermentations.

[0051]

[0060] One example of an alternative fermentable product is brewer's crystals. Brewer's crystals can be used to brew beer, kombucha, and other beverages to reduce costs and / or increase efficiency. In a preferred embodiment, brewer's crystals can be homogeneously dissolved in an appropriate amount of water (to create an aqueous version), allowing for easy blending of the liquid into the nested tank. Brewer's crystals can also be added directly to the nested tank. While not in "aqueous" form, those skilled in the art will understand that brewer's crystals are added directly to the nested tank to accommodate the FAP as described herein. The amount of brewer's crystals to use will be well understood by those skilled in the art. The amount of brewer's crystals used will be the amount necessary to achieve the desired sugar concentration in the FAP to achieve the desired finished ABV of the finished fermented beer.

[0052]

[0061] Brewer's crystals are a blend of common and readily fermentable sugars known to brewers, although other sources of fermentable sugars can be used. For example, in winemaking, the alternative FAP can consist of concentrated grape juice or alternative sugars. In the example of kombucha production, the alternative FAP can consist of in-solution or out-of-solution fermentable sugars. Additionally, multiple sources of readily fermentable sugars can be blended or mixed together. Some examples of other sources of fermentable sugars include dry malt extract, liquid malt extract, and refined or natural sugars. Thus, this concentrated sugar addition can be added directly to the concentrated nested product to support subsequent nested fermentation without undergoing the wort nesting stage of the process.

[0053]

[0062] Washing spent dried hops

[0063] It is commonly understood by brewers that adding hops to either fully fermented or still-fermenting beer can impart highly desirable flavor and aroma qualities to the finished beer. Prior to final packaging, dry (vegetable) hops must be removed. This removal is typically accomplished by decanting the supernatant liquid from the settled vegetable hops, centrifugation, filtration, or a combination of these techniques. Regardless of which technique is used, when discarding the spent hops, the brewer also loses the beer infused with those hops. This results in a loss of production and a negative economic impact on the brewer. Therefore, it is desirable to reduce the beer loss caused by discarding the beer-infused hops after dry hopping. This associated impact is amplified in the case of dry hopping of concentrated beer, such as beer produced by nested fermentation, because the loss of hop-infused beer ultimately results in more finished product. Therefore, it would be advantageous for traditional brewers, and particularly brewers producing concentrated beers, to find a solution to reduce beer loss via dry hopping.

[0054]

[0064] The dynamics of managing concentrated beer offer a novel solution to this problem. In concentrated beer, spent hops can be washed one or more times with water, which is then blended into the finished beer prior to packaging. Concentrated beer already requires an additional water step to "dilute" the beer to a normal, consumable concentration level. By first using this water to "wash" the hops, brewers can recover a significant amount of spent hop-soaked beer that would otherwise be lost.

[0055]

[0065] While this solution is particularly suitable for concentrated beer because concentrated beer requires a final water addition prior to packaging, traditional brewers can also take advantage of this solution by brewing beer as a "high gravity beer," in which the beer is brewed to a higher concentration than the final concentration of the beer that will be packaged. The water used for the dilution required to make this adjustment to the final beer concentration can first be used to wash the spent dried hops, recovering a significant amount of beer that would otherwise be lost.

[0056]

[0066] Illustrated Embodiments

[0067] Without limiting the invention, the following discussion provides illustrative embodiments consistent with the description set forth herein.

[0057]

[0068] 4 illustrates an embodiment in which the base product output of the clarification process 1300 (after optionally being combined with water) is passed directly to the separation system 2000. Thus, the retentate that initially enters the nesting tank 3100 has already been through some amount of the water nest 1420 and concentration stage 1410. Once the nested solution (in this case, the retentate from the separation system 2000) enters the nesting tank 3100, it is combined with the nested FAP and / or nested yeast to enable nested fermentation. The nested solution is then returned to the separation system 2000 (with or without added water) until the desired concentration and ABV is reached. Those skilled in the art will appreciate that in this embodiment (as well as other embodiments), the base product (optionally combined with water) continues to be input into the separation system 2000, while the nested solution from the nesting tank (nested solution including the retentate from the separation system) can also be input into the separation system 2000 at the same time.

[0058]

[0069] Turning now to Figures 5A and 5B, these figures illustrate yet another embodiment consistent with the present invention and the preceding description. In this embodiment, preparation of the base product (without solids) follows the same general steps as previously described in Figure 1. However, this embodiment only shows two stages of the nesting process 1400 in Figure 5B: the water nest 1420 and the FAP nest 1430 / 1440. In this embodiment, water is added directly to the nesting tank 3100 before or while the nested solution is passed to the separation system 2000. Therefore, there is no separate concentration stage. By controlling the amount, rate, and time duration of water added to the system, one skilled in the art will be able to precisely control the concentration and ABV within the nested solution at all times. In this embodiment, the FAP nest 1430 is used to perform nested fermentation and control the concentration, ABV, and other characteristics (flavor, taste, mouthfeel, etc.) of the nested solution. Although not directly shown, this embodiment provides the possibility that at some point the retentate can be sent from this system to a separation tank for polishing fermentation 1440. Or alternatively, the nested solution in the nested tank can be passed to a separation tank / chamber for polishing fermentation, or to multiple separation tanks / chambers for polishing fermentation. This may have operational or logistical benefits and is well within the scope of the present invention.

[0059]

[0070] Turning now to Figure 6, for illustrative purposes only and without intending to limit the present invention, an example of the "output" of each process step for an exemplary beer brewing embodiment is provided. The term "output" is used broadly because, as is evident from the disclosure herein, there is no formal "output" for many of the process steps described herein. The purpose of providing this example is to teach how the various process steps can be controlled to obtain a final high gravity beer that is approximately six times more concentrated than the consumer product (e.g., a 12 ounce concentrate can be mixed with carbonated water to produce 6-12 ounces of beer for consumption).

[0060]

[0071] In the exemplary embodiment of FIG. 6 , wort is used to produce high-gravity beer during base fermentation 1200. After solids are removed (1300), nested fermentation is performed using nesting process 1400. A concentration stage 1410 can be used to substantially increase concentration (or gravity) without substantially increasing (and possibly decreasing) ABV. A water nest 1420 is then used to reduce ABV. A FAP nest 1430 can provide a small, almost immediate increase in concentration (or gravity), without necessarily resulting in a large subsequent increase. While ABV does not increase immediately during FAP nest 1430, an increase of approximately 2% can be expected after the FAP nest is complete due to available sugars. And finally, during finishing nest 1440, all fermented ingredients are processed to finish the beer and achieve the desired characteristics discussed above.

[0061]

[0072] In this embodiment, the concentrate has an ABV of 2.5%, which when diluted to a drinkable beer corresponds to an ABV of less than 0.5%. Again, the concentrate and ABV after each stage are not limiting; instead, this is provided solely to assist one of ordinary skill in the art with the benefit of this disclosure.

[0062]

[0073] Those skilled in the art will readily appreciate that numerous modifications and substitutions may be made in the invention, its use, and its configuration to obtain substantially the same results as those achieved by the embodiments described in the appendix.

[0063]

[0074] In conclusion, the present invention provides, among other things, a system and method for producing an improved fermented beverage concentrate. Those skilled in the art will readily appreciate that numerous modifications and substitutions may be made in the invention, its use, and its configuration to achieve substantially the same results as those achieved by the embodiments described herein. Accordingly, it is not intended that the invention be limited to the exemplary forms disclosed. Many modifications, variations, and alternative constructions are within the scope and spirit of the disclosed invention as expressed in the claims.

Claims

1. 1. A method for producing a fermented beverage concentrate, comprising: fermenting the first fermentable aqueous product to produce a base product; performing a nesting process on the base product; the nesting process comprising: a water nest, in which water is added to at least a portion of the base product and passed through a separation system to produce a nested solution; a fermented aqueous product nest in which a second fermented aqueous product is added to at least a portion of the nested solution and passed through the separation system to increase the concentration of the nested solution; A method comprising:

2. 10. The method of claim 1, wherein performing the nesting process further comprises a finishing nest in which fermentation components are added to the nested solution without further passing the nested solution through the separation system.

3. fermenting the first fermentable aqueous product includes using a first yeast; the finishing nest comprises using a second yeast; The method of claim 2 , wherein the first yeast and the second yeast are different.

4. 10. The method of claim 1, wherein performing the nesting process further comprises a concentration step in which at least a portion of the nested solution is passed through the separation system to increase the concentration of the nested solution.

5. 10. The method of claim 1, further comprising removing solids from the base product prior to the nesting process.

6. the first fermented aqueous product comprises a first wort; 10. The method of claim 1, wherein the second fermented aqueous product comprises a second wort that is different from the first wort.

7. 10. The method of claim 1, wherein the base product has a density that is 1.25 to 1.75 times the desired density of the final consumer product.

8. The method of claim 2 , wherein the fermentation ingredients include a fermented aqueous product and yeast.

9. the first fermented aqueous product comprises the first wort; 10. The method of claim 1, wherein the second fermented aqueous product comprises brewer's crystals.

10. 1. A method for producing a fermented beverage concentrate, comprising: fermenting the first fermentable aqueous product to produce a base product; performing a nesting process on the base product; the nesting process comprising: a concentration step in which at least a portion of the base product is passed through a separation system and the retentate is returned to the base product to produce a nested solution; a water nest, in which water is added to at least a portion of the nesting solution and passed through the separation system; a fermented aqueous product nest in which a second fermented aqueous product is added to at least a portion of the nested solution and passed through the separation system to increase the concentration of the nested solution; A method comprising:

11. 1. A method for producing a fermented beverage concentrate, comprising: conducting a first fermentation to produce a nested solution; reducing the alcohol content (ABV) of the nested solution, wherein reducing the ABV comprises combining at least a portion of the nested solution with water to form a first combined solution, passing the first combined solution through a separation system, and returning the retentate to the nested solution; increasing the concentration of the nested solution, wherein increasing the concentration comprises combining at least a portion of the nested solution with a fermented aqueous product to form a second combined solution, passing the second combined solution through the separation system, and returning the retentate to the nested solution; A method comprising:

12. 12. The method of claim 11, wherein performing the nesting process further comprises adding fermentation components to the nesting solution without further passing the nesting solution through the separation system.

13. 12. The method of claim 11, wherein performing the nesting process further comprises passing at least a portion of the nested solution through a separation system and returning the retentate to increase the concentration of the nested solution.

14. 12. The method of claim 11, wherein the fermented aqueous product comprises one of wort, must, sweet tea, or brewer's crystals.

15. 12. The method of claim 11, wherein reducing the ABV of the nested solution comprises reducing the ABV to 1% or less.

16. 12. The method of claim 11, wherein reducing the ABV of the nested solution comprises reducing the ABV to 0.5% or less.

17. 12. The method of claim 11, wherein increasing the concentration of the nested solution comprises increasing the concentration of the nested solution to a concentration greater than 5.0 times the desired concentration of the final consumer product.

18. The method of claim 12 , wherein the fermentation ingredients include a fermented aqueous product and yeast.

19. 1. A method for producing a fermented beverage concentrate, comprising: conducting a first fermentation to produce a base product; concentrating the base product to produce a nested solution, the concentrating comprising passing at least a portion of the base product through a separation system and returning the retentate; reducing the alcohol content (ABV) of the nested solution, wherein reducing the ABV comprises combining at least a portion of the nested solution with water to form a first combined solution, passing the first combined solution through a separation system, and returning the retentate to the nested solution; performing a second fermentation using the nested solution, wherein performing the second fermentation comprises adding fermentation ingredients to the nested solution; A method comprising:

20. 1. A nested system for producing a fermented beverage concentrate, comprising: a nesting tank for holding a nesting solution; an output of the nested tank connected to an input to a separation system; The separation system comprises: a series of filters, at least one filter in the series having increasingly selective filtration compared to a previous filter in the series; an impermeate output connected to the input to the nested tank, the impermeate output carrying the impermeate from the series of filters; A nested system having:

21. 21. The nested system of claim 20, wherein the series of filters comprises a series of membranes.

22. 21. The nested system of claim 20, wherein the series of filters comprises a first nanofiltration membrane, a second nanofiltration membrane, and a reverse osmosis membrane.

23. 21. The nested system of claim 20, wherein the separation system comprises a permeate output that carries permeate from the series of filters.

24. 1. A method for washing hops used in beer production, comprising: Producing a beer concentrate, including hops in said beer concentrate; separating the hops from the beer concentrate; washing the hops removed from the beer concentrate; and recovering the liquid used to wash the hops; A method comprising:

25. 25. The method of claim 24, wherein the hops are added during the process of producing the beer concentrate.

26. 25. The method of claim 24, wherein the hops are added to the beer concentrate after the beer concentrate has been fully fermented.

Images