Dean Swift’s Ale – Food Processing Assignment

Objectives Dean Swift’s Ale Introduction Beer has been one of the favorite drinks of many nations of the world since ancient times. For beer production with the rapid popularity of the VIII-IX centuries, hops were introduced in Europe for beer production which lead improved quality and properties of beer. As the recipe for the brewed beer improved, it improved and changed at production technologies, processes, conditions. Beer production has risen sharply. Beer is made from water, barley malt and hops with the addition of yeast. The taste of beer formed by fermentation aldehydes, higher alcohols, diacetyl, sulfur compounds, etc. These compounds give beer high levels of spice and aroma at high concentration that then affects the quality of the beer. In order to obtain a consumer-acceptable taste and smell for the beer it is needed to optimize the conditions of east growth. It is necessary to control the parameters to have the right pH, low temperature, yeast to get enough nitrogen. To avoid by-products, it is necessary to maintain the concentrations of CO2, oxygen, biomass, substrate, alcohol in the solutions, so the parameters must be stable. Beer production is one of the oldest known biotechnologies, the essence of which does not change until now days. Currently, this technology is more advanced, because timely control of all processes is ensured, which is important to maintain product stability and high quality. Malt is used in beer production. The grains are immersed in water to activate them metabolism and activated enzymes. The process of malting creates enzymes that lowers the starch and proteins in the process of malting and mashing, and because of this the beer is clearer, has better head retention and body. The grains then germinate, breaking down during this process cell walls and proteins, and the mechanical properties of grains change, they become easier to shred. Activated alpha amylases hydrolyze starch. At the end of the germination phase, they are weaned seedlings (the latter give the malt bitterness) and grains are heat-treated. During this process moisture evaporates and enzymes are activated, grain color and taste change. Malt can be light, and dark depends on what beer is planned to be produced. After a few weeks the malt is malam, the purpose of this process is to obtain more easily extractable particles. Ground malt treated with hot water to pasteurize the starch granules and increase the alpha hydrolysisamylase efficacy. The resulting liquid (wort) is filtered and the resulting sweet liquid is boiled. Hops are added during the cooking process, they not only act as antiseptics, but at the same time provide beer the desired bitterness and a characteristic aroma acceptable to the consumer. The cooled wort is mixed with yeast and left to ferment for several days. During this process, the saccharides are converted to ethanol and carbon dioxide, sensory properties are formed. The yeast is then removed, the beer stabilized, clarified and bottled. The malt in the beer provides, colour, flavour, maltose (fermentable sugars got from malted grain, these sugars are converted into carbon dioxide and alcohol), proteins – helps to form and hold the foam. Dextrins give that mouth feel feeling in the beer. The hops gives beer, flavour, bitterness, aroma and stability. By stability it’s meant that the hops provide shelf life, by the beta acids in it that prevents bacterial contamination. An average person consumes around 73 litres (Statistica.com,2021) Claims. They also state that there’s 2273 breweries currently operating in the UK. Drinking higher amounts of beer can cause side effects such as confusion, loss of coordination, iregular hearbeats, and others. The longer-term side effects can lead to alcohol dependance, memory loss, liver failure and other health problems. Cirrhosis can also be developed if consuming 6 or more cans of beer daily, for a longer period of time. (Schott, 2021) Materials and Methods Clean and sanitise buckets, mash tuns, stirrers, tabletops and other utensils before and after production Process Flow Diagram for single temperature infusion mash wort production: Weigh out malts, speciality grains and brewing salts into a bucket and mix, record grist temperature (see recipe) Heat 11.5 L of water to 770C i.e strike heat Pre-heat mash tun with 1.5 Litres of 770C water for 5 mins and drain Run Mash Liquor Volume (as per recipe) of 770C liquor into mash tun with grain/brewing salts, stabilize temp at mash target temperature of 65.50C, add hot/cold water as necessary Record mash pH and temperature, place lid on mash tun and leave for 90 mins, complete Iodine test on sample wort Record mash pH and temperature at end of mash. Repeat Iodine test on wort post mash run off “sweet wort” slowly into collection vessel, grain acting as filter bed, first turbid run off should be added back to mash tun. Ensure Sparge Liquor available for sparging at 77 oC Sparging- add water to top of grain bed slowly to wash residual sugars from mash bed Check taste and S.G. Check last wort runnings SG at 1010 Record volume of wort produced pre-boil and record S.G., pour wort into boiler, switch on boiler as soon as elements covered. Record time at which rolling boil begins, this will continue for 70 mins. A number of additions are made at the following times: At start of rolling boil – bittering hops, 55 mins – flavour hops and irish moss, 65 mins aroma hops Switch of boiler and allow trub to settle. Run off wort to container and record volume and S.G. at 21 oC. Calculate cold liquor addition to achieve desired Original Gravity Make up yeast starter - take 11g of yeast add to 100ml water at 32 oC (previously boiled) allow to rehydrate for 20 mins and then add to wort. Ensure starter temperature within 5 oC of wort when pitching to avoid cold shock. Cool wort to 20 oC, aerate and then pitch yeast. Record the volume of beer wort produced. Place lid on fermenter, add fermentation lock and label, and allow to ferment until SG reaches at least 1011. This will probably take 3 - 4 days for ale yeast or 7 - 14 days for lager yeast Siphon into conditioning tank and leave for 2 weeks at 10 oC Prime with sugar and bottle. Condition bottles at 210C for 2 - 4 weeks or until beer is suitably carbonated. Inspect clarity, flavour, aroma and body. Record Product SG and calculate % ABV (L.Beattie,2021) Materials Required pH indicator paper Iodine indicator and white tile Hydrometer and measuring cylinder Thermometer with probe VWP sanitizer and PBW flash cooler cleaner Hot liquor tank Mash tun Graduated Beaker Weighing Balance Basins Boiling Kettle Flash Cooler (Heat Exchanger) Tubing 30 L Fermenter Bubble lock and plastic bung Stirring Paddle conical flask Grain bucket Raw materials including brewing grains, hops, liquor salts, water (liquor), irish moss and yeast as per “ Dean Swift’s Ale” recipe provided. Results and Discussions Beer Costing Information Ingredients Price per Price per brew Pale malt (4 EBC) 3420 g £1.31/kg £4.48 Crystal Malt (120 EBC) 220 g £1.50/kg £0.33 Calcium Sulphate (gypsum) 1.5 g £6.50/kg £0.01 Magnesium Sulphate (Epsom salts) 1.0 g £6.50/kg >£0.01 Calcium Chloride 1.0 g £6.50/kg >£0.01 Total Liquor (L) 27 L £0.01/10L £0.03 Mash Liquor (L) 9 L (part of the total Liqour) Challenger Hops 6.8% A.A. (90 mins) 25 g bittering £41/kg £1.06 Williamette Hops (1 min) 14 g aroma £41/kg £0.57 Yeast N/A £2.50/brew £2.50 500 ml bottles N/A £0.30/bottle £8.40 WWP sanitizer N/A £0.50/brew £0.50 Electricity N/A £2.00/brew £2.00 Irish moss/Protafloc N/A £0.40/brew £0.40 Beer duty 28 £0.40/bottle £11.20 Total £31.50 Price per bottle: £ £1.125 = £1.13 Sugar Extract Pale ale malt – 3.42kg x 305 = 1043.1L0 of soluble sugars if 100% efficient Chrystal Malt – 0.22kg x 260 = 57.2 L0 of soluble sugars if 100% efficient Total = 1100.3 L0 of soluble sugars if 100% efficient Iodine Test Iodine test was done on wort sample taken. At the start of the mash the sample was black, and at the end of the mash the sample was turned to yellow/ orange colour. The reason behind this is that the starch conversion occurs in the malt. The goal was to have 100% mash conversion. By mashing, all available starch should be converted to sugar by enzymes. The result outcome (orange colour) was acceptable, as there was no indications of any black, meaning the mash conversion was successful. If there would’ve been traces of blackness more mashing would be required, but not at this occasion. Mash pH The biggest factors that affect mash pH are water and malt. The mash pH is different from the water pH. This is because the malts are acidic, and will lower the pH when it’s added to the water. The results for the mash pH was 5.2. The acceptable and ideal mash pH range between 5.2 and 5.5. The obtained results are acceptable and within the limits. The high pH levels will allow better enzyme activity during the mashing. Lower pH also helps with east health in the fermentation process and inhibits bacterial growth. (Importance of Mash pH | Brew, 2021) Temperature in the mashing process is very important as it determines how much sugar is going to be in the wort. Because the temperatures controls the enzyme activity during the process of mash. They help to transform complex sugars into more simpler sugars. The goal temperature to be achieved was 65.50 C. Mash Temperature achieved was 630 C. This could’ve happed if the strike water wasn’t hot enough. Once the starch is converted into sugars, it is easier for the yeast to consume it. Lower temperature result in affecting beta amylase. Beta-amylase produces maltose. Simple sugars fermented more easily but, the beer ending up having higher alcohol content than usually but less body and mouth feel. The sugars end up being less fermented. “Alpha-amylase breaks down large, complex, insoluble starch molecules into smaller, soluble molecules for the beta-amylase. It is stable in hot, watery mashes and will convert starch to soluble sugars in a temperature range from 63°C to 70°C.” (Association, Brew and Brew, 2021) First wort running from mash tun S.G 1.090 Final wort running from mash tun S.G 1.020 The target specific gravity was 1.010. From the results obtain, it is clear that some sugar was left behind. It would be recommended to continue sparging until all sugar is cleared. The volume of wort in boiler prior to boil was 18.0L S.G of wort in boiler prior to boil was 1.041 Sugar gotten out of the mash tun – 18 x 41 = 738 per L0 Mash Extract efficiency Pale malt - 3.42kg x 305 (hot water extract) = 1043.1 Chrystal Malt – 0.22kg x 260(hot water extract) = 57.2 100% amount of sugar potentially extractable from the product. 1100 divided by 1043 x 100 = 94% Mash extract – 94% Yield Calculation There was only 28 x 500ml bottles produced as 2L of the beer was lost due to cold break in fermenter upon transfering to conditioning tank. 28x500ml = 14L % Yield = Batch Size Produced Litres x 100 Target Batch Size Litres % Yield = 14L x 100 19L % Yield = 73.68% %Yield = 73.7% The target yield was 19 litres % Alcohol by Volume (A.B.V.) Final Gravity: 1008 Original Gravity: 1043 Original Gravity - Final Gravity x F Factor * = % ABV %ABV = 1043-1008 x 0.129 = 4.515 %ABV =4.5% No Liquor back volume was required. Recommendations The temperature drop for the mash in the process, was not helpful, and would be recommended to measure temperatures more often, and stick to the recommended temperatures to avoid any disfunctions and changes in the beer. It would also be recommended to look into the profitability of the product. The specific gravy has also shown that there was sugar left behind, so it is recommended to continue sparging process until there’s no sugars left behind. The yield results were quite low, and the process would need to be improved to avoid any losses of the finished product, and to increase profits. References: Beattie,L 2021, Practical Brewing Session, lecture notes, CAFRE College, Loughry Campus, delivered 24 March 2021. Association, E., Brew, H. and Brew, H., 2021. Enzymes in Beer: What’s Happening In the Mash | American Homebrewers Association. [online] American Homebrewers Association. Available at:

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