ATR-FTIR Spectroscopy for Real-Time Mashing Process Control
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Solution Overview
Problem
The brewing industry lacks effective online monitoring methods for controlling the enzymatic mashing process, particularly in determining the ratio of short-chain and long-chain sugar compounds and protein hydrolysis, leading to suboptimal brew quality due to reliance on recipes and trial-and-error approaches.
Innovation Solution
A method and system utilizing continuous attenuated total reflectance infrared (ATR) spectroscopy to measure IR spectra of sugar mixtures during mashing, allowing real-time determination of sugar molecule types, average chain lengths, protein concentration, and amino acid levels, which are then calculated and fed back to control the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If HPLC or GPC is used to analyze sugar compounds, then measurement precision is improved, but measurement time is too long for online monitoring
Solution Approach 1:
The patent replaces the mechanical HPLC/GPC separation system with an optical ATR-FTIR spectroscopy system. The infrared spectroscopy method provides rapid online monitoring of sugar compounds during mashing without the time-consuming mechanical separation steps, achieving both speed and measurement capability through optical rather than mechanical means.
Solution Approach 2:
The patent introduces an ATR-FTIR spectroscopic analysis system as an intermediary method between traditional offline HPLC/GPC and real-time process control. This intermediary technique provides continuous online data without requiring the lengthy sample preparation and analysis time of conventional methods, enabling timely process adjustments.
2Ease of operation
If traditional recipes and trial-and-error approaches are used for mashing, then ease of operation is maintained, but manufacturing precision of brew quality deteriorates
Solution Approach 1:
The patent implements real-time feedback control by continuously monitoring sugar compound ratios and protein hydrolysis levels during mashing using ATR-FTIR spectroscopy. The system provides immediate feedback on process parameters, enabling operators to adjust conditions to achieve precise target compositions rather than relying on fixed recipes or trial-and-error methods.
Solution Approach 2:
The patent enables dynamic parameter changes during the mashing process based on real-time spectral analysis. By monitoring the progression of starch conversion and protein hydrolysis, the system allows adjustment of temperature, time, and enzyme addition parameters to optimize brew quality for different malt compositions, moving from static recipes to dynamic parameter control.
3Ease of operation
If the ratio of short-chain and long-chain sugars is not controlled, then ease of operation is maintained, but product quality deteriorates due to over-mashing or under-mashing
Solution Approach 1:
The patent uses ATR-FTIR spectroscopy to provide real-time feedback on the ratio of short-chain to long-chain sugars during mashing. This continuous monitoring enables precise control of the sugar composition by detecting changes in the spectral signatures of different sugar types, allowing operators to stop the process at the optimal point rather than relying on fixed time or temperature protocols.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise control of the mashing process, optimizing sugar conversion and protein hydrolysis, thereby improving brew quality by providing real-time data on sugar composition and protein levels, reducing the reliance on trial-and-error methods.
Implementation Method 1
continuously measuring attenuated total reflectance (ATR) IR spectra of the sample mixture with the IR spectrometer in real time at wavelengths between 400-3500 cm−1 during the enzymatic pre-treatment process
Data Source
AI summary
The invention relates to a method for controlling an enzymatic pre-treatment process, e.g. a mashing process. The method allows for accurate determination of specific sugar molecules as well as the average length of the sugar chains in real-time during e.g. a mashing process. Further information on e.g. the concentration of dissolved protein and free amino acids can also be obtained simultaneously. The method comprises the use of an infrared (IR) spectometer for continuously measuring attenuated total reflectance (ATR) IR spectra of samples obtained during pre-treatment of biomass.