Continuous Decoction Mashing for High-Gravity Mash Extract
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Solution Overview
Problem
Current decoction mashing methods in the brewing industry are batch-based, limiting productivity, quality control, and energy efficiency, and do not effectively utilize starch-containing adjuncts for high-quality mash extract production.
Innovation Solution
A continuous decoction mashing method involving a multi-step heat treatment process for starch-containing adjuncts, using steam injection to control viscosity and enhance enzymatic degradation, allowing for the production of high-quality mash extract with a significant portion of fermentable sugars from adjuncts like rice, maize, and barley.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-wise decoction mashing is used, then traditional brewing process is maintained, but productivity is limited and energy consumption is high
Solution Approach 1:
The patent converts the traditional batch-wise decoction mashing process into a continuous process where starch-containing adjuncts are continuously fed through the system, subjected to continuous heat treatment and enzymatic degradation, and continuously discharged as mash extract. This eliminates the start-stop nature of batch processing, maintains continuous useful action throughout the system, and directly addresses the productivity limitation and energy inefficiency of batch operations
2Quantity of substance
If starch-containing adjuncts are used in batch decoction, then fermentable sugars are produced, but viscosity increases and process control becomes difficult
Solution Approach 1:
The patent systematically changes temperature parameters through multiple staged heat treatment zones, progressively increasing temperature to optimize starch gelatinization and enzymatic degradation while controlling viscosity. By adjusting temperature as the key parameter through different zones, the process achieves high fermentable sugar production from starch-containing adjuncts while maintaining controllable operating conditions
Solution Approach 2:
The patent replaces mechanical mixing and manual process control with a continuous flow system driven by fluid dynamics and automated temperature control. The continuous conveyor mechanism substitutes for batch-wise manual operations, and the systematic temperature gradient replaces the need for complex mechanical agitation and manual viscosity management
3Manufacturing precision
If multiple heat treatment steps are applied, then starch gelatinisation and enzymatic degradation are enhanced, but process complexity increases
Solution Approach 1:
The patent divides the heat treatment and enzymatic degradation process into multiple sequential zones along the continuous conveyor, with each zone performing a specific function (initial heating, starch gelatinization, enzymatic degradation, final processing). This segmentation allows complex multi-step processing to be distributed along the flow path, achieving high manufacturing precision through specialized zones while maintaining a relatively simple overall continuous system structure
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 achieves high productivity, consistent quality, and reduced energy consumption while maintaining low extract losses, enabling the production of high-gravity mash extracts with improved efficiency and longer operational run lengths.
Implementation Method 1
subjecting the decoction suspension to a first heat treatment of at least 1 minute at 65-82 °C... subjecting the decoction suspension to a second heat treatment for at least 1 minute at 85-120 °C... wherein the first and the second heat treatment comprise steam injection
Implementation Method 2
enzymatically degrade the starch... mixing a first malt enzyme source with water to obtain an aqueous malt enzyme suspension
Implementation Method 3
enzymatically degrade the starch... to obtain a mash extract
Implementation Method 4
subjecting the decoction suspension to a second heat treatment for at least 1 minute at 85-120 °C to gelatinise the starch at an increased rate and to a higher extent
Data Source
AI summary
The present invention relates to a continuous method of producing a mash extract by decoction mashing, said method comprising: a. mixing a first malt enzyme source with an aqueous liquid to obtain an aqueous malt enzyme suspension; b. separately, mixing a second enzyme source with one or more starch-containing adjuncts to obtain a decoction suspension whilst maintaining temperature conditions that do not cause significant gelatinisation of the starch; c. subjecting the decoction suspension to a first heat treatment at 60-85 ºC to simultaneously part ially gelat inise and enzymatically degrade the starch; d. subjecting the decoction suspension to a second heat treatment at a higher temperature than the first heat treatment to gelatinise the starch at an increased rate and to a higher extent; e. combining the heated decoction suspension obtained from the second heat treatment with the aqueous malt enzyme suspension from step a. to obtain a mash; f. maintaining the mash at 35-85 ºC for at least minutes; and g. removing spent grain from the heated mash to produce a mash extract. The present method is very robust and easy to control. Furthermore, the method yields a mash extract of constant quality.