Malting Process Water Circulation System for Grain Steeping

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Solution Overview

Problem

Current malting processes face challenges in reducing water consumption during the steeping phase without compromising grain quality, particularly in large-scale operations where recycling steep water can lead to delayed germination and malt quality deterioration due to microbial growth and the presence of germination inhibitors.

Innovation Solution

Implementing a system where water circulates between multiple steeping tanks within the same batch, without storing water between tanks, allowing continuous use of steeping water while maintaining grain immersion, thus reducing water consumption and preventing microbial contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If steeping water is recycled to subsequent steeps, then water consumption is reduced, but germination is delayed and malt quality deteriorates due to presence of germination inhibitors and microbial growth

Engineering Contradiction:

Improvewater consumptionVSAvoidgermination quality

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The patent divides the steeping process into multiple sequential tanks (first steeping tank, second steeping tank, third steeping tank) where water flows through each tank in sequence. Each tank performs a specific steeping function with controlled water residence time, preventing water recycling while maintaining continuous water usage efficiency. This segmentation allows water to be used multiple times across different tanks without compromising quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements continuous water circulation through the steeping tanks with controlled flow rates and residence times. Water continuously flows from one tank to the next, maintaining constant moisture levels in the grain throughout the steeping process without interruption or recycling, thus preserving germination quality while reducing overall water consumption.

Inventive Principle:

Principle #20Continuity of useful action

2Loss of substance

If water is stored for recycling between steeping steps, then water consumption is reduced, but microbial load increases making water unsuitable for reuse

Engineering Contradiction:

Improvewater consumptionVSAvoidmicrobial contamination

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes steeping water from each tank immediately after use and transfers it to the next tank in the sequence. By continuously moving water through the system without storage, the patent prevents microbial proliferation that would occur in stored water, while still achieving water reuse across multiple tanks.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses the sequential tank system as an intermediary mechanism to transfer water between steeping stages. The tanks act as intermediaries that allow water to be reused without direct recycling, maintaining water quality by preventing prolonged storage and microbial growth through continuous flow.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If multiple steeping tanks are used in parallel for large batch sizes, then production capacity increases, but water consumption increases proportionally

Engineering Contradiction:

Improveproduction capacityVSAvoidwater consumption

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent merges multiple steeping tanks into a sequential water circulation system where water flows through each tank in sequence. This combining approach allows parallel processing of large batch sizes across multiple tanks while sharing water resources efficiently, reducing total water consumption compared to independent parallel tanks that would each require full water volumes.

Inventive Principle:

Principle #5Merging (Combining)

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 effectively reduces water usage during wet steeping phases while maintaining grain quality and preventing the accumulation of germination inhibitors, thereby enhancing the sustainability of malting processes without the need for expensive water treatment systems.

Implementation Method 1

The water circulation device is arranged between a first steeping tank and a second steeping tank... fluidly connecting the outlet of the first steeping tank and the inlet of the second steeping tank

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

water circulates between multiple steeping tanks within the same batch, without storing water between tanks

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 3

preventing the accumulation of germination inhibitors... continuously use of steeping water while maintaining grain immersion

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentUS11459532B2Malting process for steeping grain comprising a water circulation step

Publication Date: 2022.10.04 MALTERIES SOUFFLET

AI summary

The present invention concerns malting process for steeping grain comprising the provision of at least a first steeping tank having an inlet and an outlet, a second steeping tank having an inlet and an outlet, and a water circulation device fluidly connecting the outlet of the first steeping tank and the inlet of the second steeping tank for circulating steeping water from the first steeping tank in the second steeping tank.