Industrial Microbiology

Lecture 2
Alcoholic Beverages
Production of Beers

Prof. M A Malek, PhD

Department of Microbiology, University of
Dhaka
Alcoholic and Non-alcoholic Beverages
Energy
Refreshment
Stimulation
Nourishment
Historical Development of Alcoholic Beverages
7000 B.C. Egyptian civilization & China
4000 B.C. Mesopotamia (grapevines)
3000 B.C. Indian culture (Sura from rice)
1500 B.C. Greek (mead from honey)
800 B.C. India (beer from barley & rice)
65 A.D. Europe (medical purposes)
600 A.D. (Followers of Muhammad, Buddhist &
Hindu Brahmins refrains alcohol drinks
1100 A.D. Distillation started in Italy
1600 A.D. Gin production in England & Scotland
1800 A.D. Modern industrial development in USA
Today Largest industrial
 Standards of Consumption of Alcoholic Beverages

Over Drinking Effects on

Health
• Alcoholism
Addition to alcohol, inability to stop
drinking, and repeated problem that can
be directly attributed to the use of
alcohol.
• Anti-social personality disorder
Production of Materials Required
Beers Cereal grains
Burley grains (Hordeum distichum) contain
little fermentable sugar but contain starch
mainly.
Adjuncts
Ground un-malted cereals (corn or rice) contain
manly starch.
Hops
Aromatic herbs (Humulus lupulus) usually
found in USA for additional flavorings in
modern beer.
Yeast
Suitable yeast strain (Saccharomyces
cerevisiae, S. carlbergensis, S. uvarum).
Water
Good quality mineral water is a paramount
requirement.
Yeast propogator
for preparation of sufficient inoculum
 Flow Diagram for Beer Production

Barley Steeping

Germinating Culms
(green malt) (rootlets) Feed

Kilning at 65-80 C
(malt)
Milling
(grist)
Unmalted cereals
Mashing at 50-80 C
(sweet wort) Spent grains Feed

Hop or hop extract

Hop boiling
(hop wort) Spent hops Fertilizer

Yeast inoculum
Fermentation
(green beer)
BEER
Conditioning To trade
Packaging
(beer)
 Important Steps of Beer Processing

Steeping
The barley grain is moistened to encourage germination, during which
starch and protein hydrolyzing enzymes are active to provide sugar
and amino acids as nutrients for the embryonic plants.

Germinating
Some of the sugars produced by hydrolysis of starch are utilized; much
more enzymes are added on the polysaccharides to produce
glucose or other sugars. After starting germination the rootlets are
separated . It is then dried and grind called green malt.

Kilning
At the appropriate stage of embryonic development, the grain is
heated just sufficient to kill the plant embryo at 65-80 C
(depending on the type of malt required.
• To kill the embryo, but the enzymes are still active
• To permit long time storage (because of drying)
• To improve flavoring
 Important Steps of Beer Processing

Milling
It is necessary to ground the malt to increase the surface area that facilitates
malt extraction.

Mashing
The grounded malt is extracted with hot water (50-80 C) or mashed; often
grounded unmalted cereals is added at this stage. The thermostable
enzyme also actively hydrolyze starch of the adjacent grains to
fermentable sugars during mashing. The sugary extract (sweet wort)
drained from the mash teen is clarified by hask particles functioning as
filter.

Lautering
Lautering is a process in brewing beer in which the mash is separated into
the clear liquid wort and the residual grain. Lautering usually consists of 3
steps: mashout, recirculation, and sparging
 Important Steps of Beer Processing
Hop boiling
The sweet wort is boiled with hops to extract flavors. Hop extract contains –
(i) essential oil (beta-myrcene, beta-farnecene, humulene & beta-
caryophylene, (ii) resins (alpha-acids such as humulone, cohumulone,
adhumulone; beta-aids such as lupulone, colupulone, or adlupulone. The
boiling treatment helps:
• To inactivate enzyme activity of sweet wort
• To sterilize the wort
• To precipitate the undesirable proteins, tannins & phosphates; all these are
filtered of by the bed of hop debris (hop wort).
Composition of hopped wort
Carbohydrates 90-92%
(maltose, mallotriose, glucose, sucrose, fructose &
non-fermentable sugars)
Nitrogenous compounds 3-6%
(amino acids, peptides, proteins & nucleis acids)
Inorganic slats 1.5-2%
(Ca, Na, Zn, K, Mg, Mn, Cu, PO42-, Cl-, SO42-)
Miscellaneous compounds 0.5-1.5%
(vitamins, polyphenols, lipids, hop components, oxygen)
Important Steps of Beer Processing
Fermentation
• The clarified hopped wort is rapidly cooled to 10-15 C & saturated with
oxygen (8-10 mg/L) by exposure to sterile air.
• The wort is then inoculated with brewer’s yeast (initial concentration
10 million cells per ml) from a yeast propogator ( capacity 70-100 kg
per day.
• After 24-48 hr of inoculation clumps of foam (krausen) appear on the
surface due to evolution of CO2; they gradually increase in size until
the surface is covered to a depth of 1 meter (yeast propogation during
lager and ale processes are about 4-5 and 8-10 times of the initial
inoculum).
• As fermentation proceeds, the specific gravity decreases due to
utilization of the raw materials & production of ethanol with other
products.
• The growth of yeast is limited by falling the pH & raising the ethanol.
The condition become anaerobic rapidly due to the consumption of
dissolved oxygen and production of CO2.
Important Steps of Beer Processing
Composition of yeast ferments
Alcohol
ethanol, n-propanol, butanol, amyl alcohol, phenyl ethanol, glycerol.
Acids
acetate, lactate, pyruvate, succinate, caproic acid & caprylic acid.
Esters
Ethyl acetate & other esters of acids and alcohol fermentation products.
Others CO2, acetaldehyde, diacetyl, H2S
Conditioning
• After the end of fermentation, the yeast cells should be settled out in the
non-turbulent condition.

• The finishing process includes clarification, carbonation, and the use of

various additives.

• Further conditions such as clarification by fining agents, filtration,

centrifugation, etc. if required.
Special Traditional Beer Processing

Lager Type Beer

1. Light colored malt preparation (kilned at 65-70 C) is used.
2. Bottom brewer’s yeast (Saccharomyces uvarum or Saccharomyces
carlbergensis) is used.
3. Yeast are settled at the bottom of the fermentor after fermentation
4. Fermentation proceeds at 8-10 C for primary fermentation followed by
prolonged secondary fermentation of up to 3 months at nearly 4 C for
improving flavor and stability of beer.
5. The beer is sweet to taste.
6. The beer can not be preserved for long time.

Ale Type Beer

1. Dark colored malt preparation (kilned at 70-80 C) is used.
2. Top brewer’s yeast (Saccharomyces cerevisiae) is used.
3. Yeast rises to form a thick ‘yeast head’ on the surface of fermentor.
4. Fermentation proceeds at 25-30 C for up to 3 days.
5. The beer is bitter to taste.
6. The beer can be preserved for long time.
Modern Beer Processing
Basic Features
•The cylindroconical fermenter generate a vigorous movement of yeast through the
fermentation wort; rising with CO2 bubbles and sinking by cooling at the wallof the vessel.
•The fermenter is faster, protected from microbial contamination and easily equipped
with automatic cleaning and sterilizing equipment.
•The use of bottom yeast helps to reduce the cost and labor for clarification of the bear.