Enzyme Mashing for Adjunct Brewing
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Solution Overview
Problem
The brewing industry faces challenges in reducing costs and increasing production efficiency due to high raw material prices and energy consumption, particularly when using adjuncts with higher gelatinization temperatures, which require additional processing steps and energy inputs.
Innovation Solution
A combination of pullulanase, alpha amylase, and either maltogenic alpha amylase or beta amylase enzymes is used in the mashing process, allowing for a higher percentage of adjuncts to be included in the brewing process without the need for separate cereal cooking, resulting in energy savings and improved saccharification profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If adjuncts with higher gelatinization temperatures (maize, rice) are used to reduce raw material costs, then raw material cost decreases, but additional energy for heating and separate cereal cooking is required
Solution Approach 1:
The patent changes the chemical parameters of the mashing process by introducing specific enzymes (pullulanase, alpha amylase, maltogenic alpha amylase) that enable starch conversion at lower temperatures. This allows adjuncts with high gelatinization temperatures to be processed without separate cooking, resolving the contradiction between using cost-effective adjuncts and avoiding additional energy consumption.
Solution Approach 2:
The patent uses enzymes as intermediaries to facilitate the breakdown of starch in adjuncts. These enzymes act as catalysts that enable the conversion of starch to fermentable sugars without requiring high-temperature cooking, thus allowing cost-effective adjuncts to be used without the associated energy penalty.
2Quantity of substance
If adjuncts are used to replace expensive barley malt, then raw material cost decreases, but production efficiency and saccharification profile are compromised
Solution Approach 1:
The patent uses a composite enzymatic system comprising multiple enzymes (pullulanase, alpha amylase, and maltogenic alpha amylase) working synergistically. This composite approach enables complete saccharification of diverse adjuncts, maintaining production efficiency while allowing high ratios of cost-effective adjuncts to replace expensive barley malt.
Solution Approach 2:
The enzymatic system described in the patent has universal applicability to various types of adjuncts (maize, rice, sorghum, etc.). The combination of enzymes can handle different starch structures and gelatinization temperatures, making the process universally efficient across different adjunct types while maintaining high productivity.
3Quantity of substance
If a higher percentage of adjuncts is included in the grist, then raw material cost decreases, but additional processing steps (separate cereal cooking) are required
Solution Approach 1:
The patent merges the saccharification step with the mashing process by adding enzymes directly to the mash. This eliminates the need for separate cereal cooking equipment and steps, allowing high percentages of adjuncts to be used without increasing process complexity. The enzymatic conversion occurs simultaneously with protein breakdown and starch conversion in the same 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 enzyme combination enables increased energy savings, reduced costs, and improved production efficiency while maintaining beer quality, as it allows for the use of a higher percentage of adjuncts and eliminates the need for separate cereal cooking, thereby optimizing the brewing process.
Implementation Method 1
contacting the grist with i) a pullulanase; ii) an alpha amylase; and iii) a maltogenic alpha amylase and/or a beta amylase to make a wort
Implementation Method 2
Mashing is the process of converting starch in the mash into fermentable and un-fermentable sugars
Data Source
AI summary
A method of mashing comprising providing a grist comprising malt and adjunct; and contacting the grist with a pullulanase; an alpha amylase; and a maltogenic alpha amylase and/or a beta amylase to make a wort. An enzyme composition comprising a pullulanase; an alpha amylase; and a maltogenic alpha amylase and/or a beta amylase and the use of these enzymes in brewing is disclosed.