β-Glucanase-Assisted Malting to Shorten Steeping and Germination
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Solution Overview
Problem
The malting process is time-consuming and requires significant capital investment in new vats and tanks, limiting production efficiency and increasing costs.
Innovation Solution
A method involving the use of β-glucanase and Gibberellic acid in the steeping and germination stages, along with controlled temperature and humidity, to accelerate the malting process, reducing steeping and germination times while maintaining quality and reducing DON contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional steeping and germination processes are used, then malt quality is maintained, but malting time is extended to several days and capital investment in new vats and tanks is required
Solution Approach 1:
β-glucanase is added during the steeping phase to pre-digest β-glucan in the grain before germination begins. This preliminary enzymatic action weakens the cell walls and facilitates faster water absorption and enzyme penetration during subsequent germination, thereby reducing the overall malting time without compromising malt quality
Solution Approach 2:
The patent modifies the chemical composition parameters of the steeping water by adding β-glucanase enzyme and controlling its concentration (25-100 ppm). This parameter change accelerates the breakdown of β-glucan, which is a key factor in reducing steeping and germination times while maintaining proper malt development
2Productivity
If steeping time is reduced to increase production, then productivity improves, but water absorption and enzyme penetration may be insufficient
Solution Approach 1:
β-glucanase is applied during steeping to pre-soften the grain structure by breaking down β-glucan. This preliminary action creates more favorable conditions for rapid and efficient water absorption during the shortened steeping period, ensuring that even with reduced time, adequate hydration and enzyme penetration are achieved
Solution Approach 2:
β-glucanase acts as an intermediary substance that facilitates the interaction between water and grain. By breaking down β-glucan barriers, it mediates faster and more efficient water absorption and enzyme penetration, allowing reduced steeping time while maintaining reliability of the process
3Productivity
If conventional malting processes are used without additional enzymes, then process simplicity is maintained, but production capacity is limited and requires large capital expenditures
Solution Approach 1:
The patent changes the chemical parameter of the steeping water by adding β-glucanase at controlled concentrations (25-100 ppm). This relatively simple parameter change produces significant acceleration in malting speed, increasing productivity without requiring complex equipment modifications or large capital investments
Solution Approach 2:
The β-glucanase enzyme performs the function of pre-digesting β-glucan during steeping, which would otherwise require extended germination time. This self-service enzymatic action during steeping reduces the burden on subsequent germination and kilning stages, allowing faster overall processing with minimal additional complexity
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
The method significantly reduces malting time, increases production capacity, and minimizes DON contamination, achieving comparable malt quality with reduced energy consumption and equipment needs.
Implementation Method 1
a grain is steeped in water including β-glucanase to produce chitted malt
Implementation Method 2
an aqueous mixture including β-glucanase and Gibberellic acid is applied to the chitted malt
Implementation Method 3
The initial modification expedites movement of water into the grain by increasing the rate at which micropyles of the grain open
Implementation Method 4
The green malt is then kilned to reduce the moisture content to produce a batch of malt
Data Source
AI summary
Embodiments of the disclosure relate to a method of accelerating a malting process. In the method, a grain is steeped in water including β-glucanase to produce chitted malt. The chitted malt is germinated to produce green malt, and during germinating, an aqueous mixture including β-glucanase and Gibberellic acid is applied to the chitted malt. The green malt is then kilned to reduce the moisture content to produce a batch of malt. Advantageously, the finished batch of malt exhibits lower levels of deoxynivalenol contamination than conventional malts.