Peeled Chit Malt Composition for Lower Transport and Storage Volume
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Solution Overview
Problem
Existing malt production processes are inefficient in terms of productivity, energy consumption, and transportation/storage requirements due to the high husk content of traditional malt, which affects the production and handling of malt-based beverages like beer and whisky.
Innovation Solution
A novel malt production process involving a shortened germination period and a peeling step after kilning to produce peeled chit malt with low alpha-amylase activity, low husk content, and high extract content, characterized by specific moisture, lignin, and ash content ratios, which allows for reduced transportation and storage volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional malt production process is used with full germination period, then high alpha-amylase activity is achieved, but productivity is low and transportation/storage volume is large
Solution Approach 1:
The invention extracts and removes the husk from the malt grain through a peeling step, separating the valuable inner components (endosperm with enzymes and extract) from the bulky outer husk. This extraction principle directly reduces transportation and storage volume while maintaining the functional enzyme activity needed for brewing, resolving the contradiction between productivity and volume.
Solution Approach 2:
The invention applies a preliminary peeling action before the full germination process is completed, creating chit malt with reduced husk content. This preliminary processing allows the malt to achieve sufficient enzyme activity for brewing while minimizing the volume that needs to be transported and stored, thereby improving productivity without sacrificing functional performance.
2Volume of moving object
If husk is removed from malt, then transportation and storage volume is reduced, but alpha-amylase activity may be affected
Solution Approach 1:
The invention applies local quality by selectively removing only the husk (outer layer) while preserving the inner endosperm and germ components that contain the alpha-amylase enzymes. The peeling process is localized to specific grain layers, ensuring that enzyme activity is maintained in the retained portions while reducing overall volume, thus resolving the contradiction between volume reduction and enzyme stability.
Solution Approach 2:
Through the peeling step, the invention extracts and removes specifically the husk material that contributes to volume but not to enzyme activity. This selective extraction preserves the functional integrity of the malt by retaining the enzyme-containing components while eliminating the bulky outer layers, thereby maintaining reliability while reducing volume.
3Productivity
If shortened germination period is used, then productivity is improved, but alpha-amylase activity is reduced
Solution Approach 1:
The invention changes the parameter of germination duration from the traditional full period to a shortened period (chit malt process), and compensates for the resulting enzyme activity reduction through the peeling step and optimized malt composition. This parameter change allows faster production while maintaining sufficient enzyme activity for brewing applications, resolving the contradiction between productivity and enzyme reliability.
Solution Approach 2:
The invention applies preliminary peeling action to create chit malt with reduced husk content before or during the shortened germination process. This preliminary processing optimizes the grain structure to achieve sufficient enzyme development in a shorter time frame, thereby improving productivity while maintaining the necessary enzyme activity levels for brewing through optimized process parameters.
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 peeled chit malt reduces transportation and storage needs, enhances brewhouse efficiency, and maintains beverage quality by combining with ordinary malt, thus improving productivity and reducing environmental impact.
Implementation Method 1
mashing the mixture to convert starch into fermentable sugars
Implementation Method 2
Peeling is a mechanical treatment that is used to remove tissue, e.g. husk and/or bran, from grains by mechanical abrasive action
Implementation Method 3
Kilning reduces the grain moisture content of the green malt and stops the germination process
Implementation Method 4
During sprouting, malt enzymes are activated and these enzymes start modifying the structure of the barley endosperm by breaking down the cell walls and the protein matrix
Implementation Method 5
Steeping is the start of the malting process and comprises the addition of steep water to cover the grain to increase the moisture content of the grain
Data Source
AI summary
The invention relates to a peeled chit malt, said malt having the following combination of features: • a moisture content of less than 15 wt.%; • an alpha-amylase activity of less than 58 Dextrinizing Units (DU) per gram of dry matter; • an extract content of solid adjuncts (CE) of at least 79% by weight of dry matter; and • a Klason lignin content (CL) of less than 1.8% by weight of dry matter; and • an ash content (CA) of less than 2.2 % by weight of dry matter; wherein 25 ≤ CE/(CL*CA) ≤ 160. The malt of the present invention can be produced by a malting process that differs from the process that is used to produce ordinary malt in that it employs a shortened germination period of 12 to 72 hours and further in that it employs a peeling step after kilning.