Continuous Mash Extract Production with Recirculated Sparging Water
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Solution Overview
Problem
Existing beer brewing methods struggle to produce high gravity mash extracts efficiently without using adjuncts or evaporation, leading to suboptimal energy consumption and extraction yields.
Innovation Solution
A continuous method involving heat-treated mash separation into fermentable mash extract and spent grain, followed by recirculating an aqueous stream to enhance extraction efficiency, using multiple separators and mixing vessels to achieve high gravity mash extracts without adjuncts or evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional brewing methods are used to produce high gravity mash extract, then evaporation or adjuncts must be employed, but this leads to high energy consumption
Solution Approach 1:
The patent employs a continuous counter-current extraction process where spent grain from one stage continuously feeds into the next extraction stage, maintaining uninterrupted useful action. This continuous operation eliminates the need for batch evaporation processes, achieving high gravity extracts (20-30°P) through sustained extraction rather than energy-intensive evaporation
Solution Approach 2:
The process changes the extraction parameters by using multiple sequential extraction stages with progressively diluted wash waters. Instead of evaporating water to concentrate extract, the system adjusts extraction parameters (number of stages, wash water flow rates, grain-to-water ratios) to achieve high gravity extracts through enhanced mass transfer efficiency
2Quantity of substance
If conventional brewing methods are used to produce high gravity mash extract, then evaporation or adjuncts must be employed, but this reduces extraction yield efficiency
Solution Approach 1:
The extraction process is segmented into multiple sequential stages, with each stage performing a specific extraction function. The spent grain progresses through Stage 1 (high gravity extract), Stage 2 (medium gravity extract), and Stage 3 (low gravity extract), with each segment contributing to the overall extraction yield. This segmentation achieves superior productivity by maximizing extract recovery at each stage rather than relying on single-stage evaporation
Solution Approach 2:
The continuous counter-current flow ensures that spent grain is continuously exposed to fresh wash water in each extraction stage, maintaining maximum extraction efficiency throughout the process. This continuous action prevents extraction stagnation and achieves higher overall yields compared to batch methods
3Productivity
If a single separator is used for solid-liquid separation, then the process is simpler, but extraction efficiency and productivity are reduced
Solution Approach 1:
The separation function is segmented across three distinct separators, with each separator handling a specific extraction stage. This segmentation allows each separator to be optimized for its specific function (separating different gravity extracts), achieving superior extraction efficiency despite increased device complexity
Solution Approach 2:
While there are multiple separators, each serves a universal solid-liquid separation function. The system achieves multi-functionality by using the same type of separator (decant器) for different extraction stages, standardizing the separation process while maintaining high productivity through parallel operation
4Use of energy by moving object
If recirculation of aqueous stream is not implemented, then the process is simpler, but extraction efficiency and energy efficiency are reduced
Solution Approach 1:
The recirculation system implements feedback by returning aqueous streams from later extraction stages back to earlier stages. This feedback loop allows the system to continuously optimize extraction efficiency, with the recirculated water carrying dissolved substances back for further extraction, thereby improving energy efficiency without requiring additional energy input
Solution Approach 2:
Instead of discarding the aqueous streams from later extraction stages, the system recovers and recirculates them back to earlier stages. This recovery process extracts additional valuable substances from the recirculated water, improving overall energy efficiency and extraction yield while the recirculation infrastructure adds manageable 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
This method achieves high productivity and energy efficiency with minimal extract loss, producing mash extracts with gravities exceeding 20 °P, typically above 25 °P, while maintaining low energy consumption and extract loss rates.
Implementation Method 1
transferred a heat-treated mash into a first separator for separation into a stream of fermentable mash extract and spent grain
Implementation Method 2
transferred the spent grain into a mixing vessel and mixing it with sparging water
Implementation Method 3
transferred the mixture of spent grain and sparging water into a second separator to remove spent grain
Data Source
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AI summary
One aspect of the present invention relates to a method of producing a mash extract, said method comprising: a. mashing particulate, starch-containing and optionally malted raw materials with a recirculated aqueous stream; b. heat ing the mash and enzymatically hydrolysing the starch; c. transferring the heat-treated mash into a first separator for separation into mash extract and spent grain; d. transferring the spent grain into a first mixing vessel and mixing it with sparging water; e. transferring the mixture of spent grain and sparging water into a second separator to remove spent grain; f. recirculat ing an aqueous stream from the second separator to the mashing step, wherein the gravity of the fermentable mash extract obtained from the first separator is maintained at above 15 ºP. The present method offers the advantage that it is highly efficient in terms of energy consumption and extraction yields. Furthermore, the present method achieves extremely high productivity in the operation of the brewhouse. The invention also provides an apparatus for carrying out the aforementioned method.