Screw Extractor Countercurrent Flow for Hop Bitter Substance Yield
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Solution Overview
Problem
The low yield of bitter substances in beer production using pre-isomerized hop products is due to insufficient extraction of iso-α-acids, which are not adequately dissolved in the wort, leading to reduced utilization and increased raw material costs.
Innovation Solution
A method involving a screw extractor with countercurrent flow of wort and hop product to specifically extract isomerized bitter substances from pre-isomerized hop products, ensuring maximum concentration gradient and efficient transfer into the wort, potentially using the entire wort as an extraction agent, and optimizing extraction processes such as emulsification and temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-isomerized hop products are added directly to the wort, then the bitter substances can be introduced into the wort, but the extraction efficiency is insufficient and the yield of bitter substances remains low (around 40-50%)
Solution Approach 1:
The patent divides the wort into two streams: a main wort flow that bypasses the extraction device, and a partial wort flow that is directed through the extraction device where it contacts the hop product. This segmentation allows efficient extraction of bitter substances from the hop product using a portion of the wort, while the extracted bitter substances are then reintroduced to the main wort flow, thereby increasing overall extraction efficiency and bitter substance yield.
Solution Approach 2:
The patent extracts bitter substances from the hop product using a partial wort flow in a dedicated extraction device. This extraction process separates the bitter substances from the hop product matrix, allowing them to be concentrated and then reintroduced to the main wort flow, thereby increasing the overall yield of bitter substances in the beer.
2Productivity
If conventional hop products with unisomerized bitter substances are used, then the raw material cost can be reduced, but the bitter substances precipitate during fermentation due to temperature drop and pH increase, leading to low yield
Solution Approach 1:
The patent performs isomerization of the bitter substances before they are introduced into the fermentation process. By using pre-isomerized hop products or isomerizing the bitter substances beforehand, the patent ensures that the bitter substances remain soluble during fermentation, preventing precipitation and maintaining stable composition throughout the brewing process.
3Quantity of substance
If hop products are added during wort boiling, then the bitter substances can be extracted, but the extraction efficiency is limited and raw material costs increase
Solution Approach 1:
The patent changes the parameters of the extraction process by using a partial wort flow at controlled temperature and flow rate through the extraction device. This optimization of extraction parameters increases the efficiency of bitter substance extraction from the hop product, allowing for lower hop product dosage while achieving the same or higher bitter substance concentration in the final beer, thereby reducing raw material costs.
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
Significantly increases the yield of bitter substances, reducing the need for pre-isomerized hop products and saving raw material costs while maintaining beer quality and character, with the potential for higher concentrations of unisomerized bitter substances in beers.
Implementation Method 1
A method involving a screw extractor with countercurrent flow of wort and hop product to specifically extract isomerized bitter substances from pre-isomerized hop products
Implementation Method 2
specifically extract isomerized bitter substances from pre-isomerized hop products, ensuring maximum concentration gradient and efficient transfer into the wort
Implementation Method 3
the polarity of the bitter substances increases greatly after isomerization. While almost all dissolved non-isomerized bitter substances are inevitably excreted again in the course of fermentation due to the lower temperatures and the drop in pH - the maximum solubility of these substances falls below 1 to 2 mg/l under fermentation conditions (miscibility gap) - isomerised bitter substances can also remain in solution with a concentration of up to 2000 mg/l due to their increased polarity under these conditions
Data Source
Figure 1
AI summary
The method for the preparation of beer, comprises subjecting a wort, which is obtained from a mash, to a temperature treatment, separating the hot break from the treated wort, obtaining beer from the wort by fermentation after the hot break separation, and extracting the bitterns before the temperature treatment of the wort and after the hot break separation of the wort. During the brewing process, the bitterns are targetedly extracted from hops product using an extraction agent. The extraction step is carried out in the form of an extrusion process and flow process. The method for the preparation of beer, comprises subjecting a wort, which is obtained from a mash, to a temperature treatment, separating the hot break from the treated wort, obtaining beer from the wort by fermentation after the hot break separation, and extracting the bitterns before the temperature treatment of the wort and after the hot break separation of the wort. During the brewing process, the bitterns are targetedly extracted from hops product using an extraction agent. The extraction step is carried out in the form of an extrusion process and flow process, and is a high-pressure extraction. The extraction agent is homogeneously mixed with the hops product and is a wort partial flow obtained from the last drops of the wort before the temperature treatment. The hops product is pressed out for extensive defluidization, and is crushed before the extraction process. The hops product, in which the bitterns are partially present in their isomerized form, is added to the extraction agent and correlates the requirements of the German purity law. An independent claim is included for a device for the preparation of beer.