Copper Tube Mash Heating for Flavor Control
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Solution Overview
Problem
Existing methods for producing saccharified mash in beer-taste beverages face challenges in achieving consistent flavor extraction, as high-temperature treatments can lead to undesirable 'burnt' flavors and require inefficient facility operations, and traditional copper kettles are complex to maintain.
Innovation Solution
A method involving a copper tube for heating a portion of the mash, which is then returned and mixed with the remainder, using a stainless steel tank with an external copper circulation pipe to control the heating process, enhancing flavor components like 'body' and 'aroma' while minimizing 'burnt' tastes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high-temperature treatment (122°C or higher) is applied to extract flavor components, then richness in taste and aroma is enhanced, but burnt-like flavors are formed and facility efficiency decreases
Solution Approach 1:
The patent applies local quality by using a copper tube specifically for heating the mash, rather than heating the entire kettle uniformly. The copper tube provides localized high-temperature treatment to extract flavor components while the rest of the mash remains at lower temperatures, preventing burnt flavor formation throughout the entire batch.
Solution Approach 2:
The heating process is segmented into two distinct zones: a copper tube where high-temperature heating occurs for flavor extraction, and the main kettle body where the mash remains at lower temperatures. This segmentation allows simultaneous achievement of flavor concentration and burnt flavor prevention.
2Quantity of substance
If high-temperature treatment is applied to enhance aroma and taste, then flavor richness is improved, but facility operation efficiency deteriorates
Solution Approach 1:
The facility is segmented into a standard stainless steel kettle for bulk mash processing and a separate copper tube for targeted high-temperature treatment. This allows the majority of the mash to be processed efficiently at lower temperatures while only a portion receives intensive heating for flavor enhancement, improving overall facility efficiency.
Solution Approach 2:
The patent changes the temperature parameter locally within the copper tube to achieve high-temperature flavor extraction, while maintaining lower temperatures in the main kettle. This parameter differentiation optimizes both flavor production and energy efficiency.
3Quantity of substance
If traditional copper kettle is used for heating, then flavor extraction is improved, but maintenance complexity increases
Solution Approach 1:
The system is segmented into a stainless steel main kettle for easy maintenance and a copper tube insert for flavor extraction. The copper tube can be removed and replaced independently, allowing the beneficial copper heating properties to be retained while simplifying overall system maintenance through the use of durable stainless steel for the main vessel.
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
This approach allows precise control over flavor generation, resulting in a saccharified mash that produces beer-taste beverages with improved 'body', 'aroma', and taste, while avoiding 'burnt' flavors, and simplifies facility maintenance by using stainless steel equipment.
Implementation Method 1
heating the drawn-out mash to be saccharified in a copper tube
Implementation Method 2
returning the part and mixing with the remainder part
Implementation Method 3
mixing with the remainder part
Data Source
Figure 1
Figure 2
AI summary
A method for producing a saccharified mash comprising drawing out a part of a mash to be saccharified into a tank, heating the part, and returning the part and mixing with the remainder part, characterized in that the method comprises heating the drawn-out mash to be saccharified in a copper tube. A beer using a saccharified mash obtained by the production method of the present invention allows to control the generation of factors that would be regarded as negative in sensory aspect such as "burnt taste," and shows overall excellent flavor such as being excellent in body, aroma and taste, so that a new taste can be provided as a luxurious product.