Unmalted Cereal Brewing Process Enzyme Optimization
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Solution Overview
Problem
Current brewing processes using unmalted cereals face challenges such as low fermentability, high viscosity, and turbidity issues, which are not fully addressed by existing enzyme blends, especially when attempting to substitute a significant portion or all of malted cereals with unmalted cereals, leading to increased mashing time and economic inefficiencies.
Innovation Solution
A process involving a specific combination of exogenous enzymes, including α-amylase, pullulanase, proteolytic, and β-glucanase activities, along with thermal activation of endogenous enzymes, is used to produce a wort from a grist comprising up to 100% unmalted cereals, optimizing β-amylase activity and reducing lipoxygenase activity, to achieve filterability and amino acid composition comparable to malted cereal worts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If unmalted cereals are used to substitute malted cereals, then production costs are reduced, but fermentability decreases and viscosity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the enzyme composition and dosage specifically for unmalted cereal substrates. The enzyme blend contains adjusted ratios of amylases, proteases, and beta-glucanases to compensate for the absence of malt enzymes, thereby achieving effective saccharification and maintaining fermentability while using unmalted cereals
Solution Approach 2:
Exogenous enzymes serve as intermediaries to bridge the functional gap created by substituting unmalted cereals for malted cereals. The added enzymes perform the saccharification and protein degradation functions that would normally be provided by endogenous malt enzymes, enabling the brewing process to proceed effectively with unmalted substrates
2Loss of energy
If unmalted cereals are used to substitute malted cereals, then production costs are reduced, but mash viscosity increases and filterability worsens
Solution Approach 1:
The patent applies parameter changes by including specific dosages of beta-glucanase and protease enzymes in the blend. These enzymes modify the physical parameters of the mash by degrading beta-glucans and proteins that contribute to viscosity, thereby improving lautering and filterability while maintaining cost benefits from unmalted cereal usage
Solution Approach 2:
Beta-glucanase and protease enzymes act as intermediaries to reduce mash viscosity. These enzymes specifically target and degrade the polysaccharides and proteins that cause high viscosity in unmalted cereal mashes, enabling smooth lautering and filtration processes
3Productivity
If exogenous enzymes are added to compensate for lacking malt enzymes, then saccharification is improved, but mashing time increases and economic efficiency decreases
Solution Approach 1:
The patent merges multiple enzyme activities into a single optimized blend formulation. The combination of amylases, proteases, beta-glucanases, and other enzymes works synergistically to perform multiple functions simultaneously (starch degradation, protein breakdown, viscosity reduction), thereby achieving complete saccharification faster than individual enzymes could achieve alone
Solution Approach 2:
The patent optimizes the dosage parameters of each enzyme in the blend to achieve maximum saccharification efficiency within reduced time frames. The specific enzyme dosages are calibrated to work together synergistically, preventing the need for prolonged mashing while ensuring complete starch conversion
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 process enables the production of a wort with high fermentable sugars, optimal amino acid composition, and improved filterability, reducing mashing time and maintaining the sugar profile of malted cereal worts, while allowing for the use of up to 100% unmalted cereals, thus addressing economic and quality challenges.
Implementation Method 1
contacting the mash with exogenous enzymes comprising: i. an α-amylase activity, ii. a pullulanase activity, iii. a proteolytic activity, and iv. a β-glucanase activity
Implementation Method 2
obtaining a mash by mashing a grist, of which at least 70 wt % is unmalted cereal(s) comprising β-amylase activity and of which less than 30 wt % is malted cereal(s), at a temperature at which exogenous (added) enzymes and the endogenous β-amylase are active
Data Source
AI summary
The invention relates to a process for the production of wort, comprising the enzymatic treatment of grist in up to 100% unmalted (grain) form, for further processing into high quality beverage products. By the addition of a combination of exogenous enzymes (α-amylase, isoamylase/pullulanase, FAN generating activity (proteases) and beta-glucanase activity) to the mash and by the simultaneously thermal activation of the maltose-generating endogenous β-amylase, it is possible to obtain a wort based on up to even 100% barley. The invention further relates to a process for the production of a high quality beer or beer product and to the high quality beer produced according to the process.