Experiment #3

Beer Production
By; Shewarega Habtamu
INTRODUCTION

• Beverage - Flavored solutions of ethanol derived from numerous

substrates.
• Grains- as in beer
• Grapes and other fruits- as in wine
• Any other carbohydrate source: as in distilled sprits
– brandy, whiskey, rum, gin, and vodka…
• Fermentation is carried out by species of
• syccharomyces
• naturally, as in grapes in wine making.
1. Essential ingredients of beer

• Most beer is made from four essential ingredients.

a) Water (around 95%)
b) Malt
c) Hops
d) Yeast
e) Some uses syrup, starch adjuncts (corn, rice…)
• Not only the ingredients differ, but they can also used in
numerous combinations.
a. Water
• More than 90% of beer is water.
• Composition of the water used in beer production have a
significant influence on the quality of the finished product.
– Content of dissolved solids has effect on beer properties, including
flavor.
– The balance of minerals.
• The various water uses in brewery may require different
compositions/treatments appropriate to the requisite
functions.
b. Malt
• the second most important ingredient for beer.
• Malts are made from selected cereal grain, usually barley
(Hordeum vulgare),
• It is then germinated under controlled conditions.
•  soaking in water and is then halted from germinating further by
drying with hot air.
• develops the enzymes (α-amylase, β-amylase, proteases) 
During Germination

• The grain is hydrated, or `steeped', by immersion in water.

– During steeping the water will be changed at least once
• the starchy endosperm, is partly degraded, or modified, and
its physical strength is reduced.
• When germination is sufficiently advanced it is stopped by
kilning.
 C. Hops
• Hop (Humulus lupulus L.) gives beer its typical bitterness and
hop aroma.
• Three groups of substances are especially interesting from the
brewing Technological point of view: hop resins, flavoring
agents, and polyphenols.
• Hop resins Constitute about 10–20% of the hop dry weight.
• it gives their beer its special and predictable character.
D. Yeast
• Most beer is made from one of two different yeast types:
– lager yeast (Saccharomyces uvarum)..(2-13 oC)
• Bottom fermenting
– ale yeast (Saccharomyces cerevisiae)...(16-24 oC)
• Top fermenting
• There are hundreds of strains of these two types of yeast.
• particular strain of yeast will behave somewhat predictably,
producing distinctive characters in beer.
OUTLINE OF THE BREWING STEPS
1. Malting
• converts the raw barley by controlled steeping, germination,
and kilning into a product that is much more friable, with
increased enzyme levels and with altered chemical and
physical properties.
• The grain embryo produces and releases a plant hormone,
gibberellin, which activates the
• aleurone layer of the grain to produce various enzymes.
• These enzymes, together with those already present in the
grain, start to break down the food reserves of the grain.
To stop Germination
• This is achieved by heating (kilning) the grain with hot dry
air. As well as drying the malt to preserve it, kilning also
develops color and flavor.

• The roots are removed mechanically and the malted

Barley/corns are then stored ready for use.
2. Milling and Adjunct Use
• Barley malt can be supplemented with other cereals,
either malted or raw, for specific purposes.
– (barley, oats, maize, rice rye, sorghum, and wheat)
Adjunct for one or a number of the following reasons:

• To produce a more stable beer, as they contain

less protein.
• To produce different flavor.
• To produce a better beer foam due to lower fat
(lipid) levels and different proteins
• To improve the ease of processing in the brew
house.
• To produce beer at lower cost
3. Mashing

• Simply the mixing of warm water with ground malt with a

suitable standing period
• At this time dry malt adjuncts may be added.
– Can decide the type of beer
• Enzymes break down the starch in the grain and convert it
to simple sugars.
• to yield the soluble malt extract, which is called wort.
• Using mash mixer/mash tun
4. Wort Separation
• Once mash conversion is completed and the starch has
been broken down to sugars, the aqueous extract solution
has to be separated from the insoluble malt solids to
produce clear sweet wort.
• The principal objectives are to produce bright wort and to
collect the maximum amount of sugars (extract) from the
residual solid materials.
• Spent grains are removed and sold as cattle feed.
5. Wort Boiling

• Wort boiling is the process unique to beer production. Wort

for boiling is collected after the separation process.
– Concentrates the liquid
– Sterilizes it
– Inactivate enzymes
– Extracts the hops soluble precipitates protein and caramalizes
sugar.
– Coagulation of excess proteins and tannins to form solid particles
(trub) that can be removed later. This is important for beer
stability and foam
– Color and flavor formation
6. Hop addition

• Hops can be added all at once or can be divided over up to

four additions. For the production of beer with low bitterness
and a more subtle hop aroma, hops are usually added all at
once at kettle fill up, or up to 20 min after the start of boiling.
• Contributes –flavor, aroma and bitterness
• Hops can be added in different forms
(i) whole hops
(ii) hop pellets or powders
(iii) hop extract.
7. Trub removal

• The coagulated material formed during the boil does need

to be removed .
• Hot break is the name for the particles present in the hot
boiled wort, and they are quite large, 20 to 80 µm.
• A much finer particle (cold break, 2 µm) appears when wort
is cooled below 60°C.
– coating of the yeast to inhibit efficient fermentation.
8. Wort Cooling/Aeration
• To the temperature desirable for fermentation
• This process will be either two-stage or single-stage.
• The temperature for fermentation is typically 8 to 13°C for
lager and 14 to 17°C for ale.
• Aeration- for the yeast to complete fermentation
consistently.
• The air/oxygen will dissolve to varying degrees depending
particularly on the method of injection/dispersion into the
wort. More finely dispersed bubbles dissolve more
efficiently.
9. Yeast Handling

• The inoculum has to satisfy the following conditions to be

used for fermentation.
it should be active and healthy in order to minimize the lag
phase .
should be available in large volume
 should have suitable formology
should be free from contamination
should retain its product forming capacity.
 10. Yeast Pitching
• Contamination of pitching yeast with either bacteria or
wild yeast must be minimized, as these contaminants will
cause undesirable flavors in the beer.
• Consistent fermentations require consistent pitching
rates.
– An alternative is to mix wort and yeast in a starting tank prior to
transfer to the fermentor.
– Another advantage is that holding pitched wort in a starting tank
for up to 24 h before transfer to the fermentor allows some
undesirable solids to be removed by settling or floatation.
 11. Fermentation

• There are two main classifications of

fermentations, ale and lager,
A) Ale fermentation: ale uses a Saccharomyces
cerevisiae, top-cropping yeast at a temperature of
14°C to 17°C. The fermentation is fast and
exothermic, so cooling is applied to maintain a
constant temperature.
• The yeast is cropped early from the vessel to
prevent off-flavors from yeast autolysis and also to
provide healthy, vital yeast for subsequent
fermentations.
B)Lager fermentation: Lager ferments at a lower
temperature, typically 8°C to 13°C, and uses bottom-
cropping Saccharomyces uvarum yeast.

• The traditional lagering process involved a primary

fermentation using flocculent yeast, which was
followed by a secondary fermentation using
nonflocculent yeast at a lower temperature, say 8°C
(warm storage), followed by cold storage at less than
0°C to stabilize the beer.
• excess CO2 from the fermentation is vented off from the
vessel, either to the atmosphere or collected for use
later in the packaging process. A level of CO2 remains in
the beer to give it bubble in a beer.
• Toward the end of fermentation, as the sugars are
depleted, the yeast begins to flocculate. A good
separation of the yeast by flocculation is important in
obtaining a clean, good-tasting beer
12. Yeast Removal

• More powdery strains are best removed by

centrifugation or filtration, while highly flocculent
strains are more efficiently separated by
sedimentation
• Part of left over yeast can be recycled 5- 100 times
before viability and contamination becomes a
problem.
13. Aging
• Aging refers to flavor maturation.
• During the next 2-6 weeks @a temperature close to zero
the precipitation of yeast and other undesirable products.
• Caramel may be added-to control colour
• Isomerize hop extracts- to control bitterness.
14. Clarification
• Removes any remaining yeast and suspended
particles forms during cold storage or aging.

• Filtration will produce a bright, sparkling beer that

will remain clear throughout its shelf life, provided
that the stabilization has been correctly applied.
15. Packaging

• The packaging of beer can be conveniently divided into

two categories:
– Large pack that includes kegs, casks, and demountable bulk
tanks
– Small pack that covers cans and bottles.
• 16. Warehousing and Distribution