2.4.

2.4.1.

Plant operation wort separation

What is mash separation?

During mashing the Amylases, Glucanases and Proteases started work. The breakdown products they produced dissolved into the mashing water. We now have to separate out this liquid, called wort from the spent grains. In Lauter Tuns and British style Mash Tuns we do this by filtering the liquid out from the mash through the remaining solid material. The bottom of the tun may be flat or sloped. It may be constructed with several concentric valleys with intervening ridges. Suspended above the true bottom of the tun is a false bottom of milled, slotted, or welded wedge wire steel plates. These act as a support for the mash. The wort filters through the mash and out through the slots to the true bottom. From there it is sent to the copper.

MASH
Slot Slot

Wort

Wort

Wort

Wort

Slots

Plate

Inside of a Lauter tun showing the Slotted plates.

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You should note that the slots are only to let the wort through. They are NOT the filter. The filter is the entire mass of solids. The husk is the most important part. This keeps the filter bed open. There is a second type of mash separator . This is the Mash Filter. The mash filter is like a large press. The sections are separated by a cloth. The mash and husk are pressed onto these. The wort is pumped through under pressure and is filtered by the solids which are retained by the filter cloths.

Again, note that the cloths are NOT the filter. They only act as a support for the solids which actually do the filtering.

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A modern mash filter: the Meura 2001

2.4.2.

The Theory of wort separation.

Wort is separated from the husk by two physical processes: 2.4.2.1. Leaching

First of all the dissolved solids (sugars, protein etc.) need to be drawn (leached) from the grains. This is dependent on the concentration of dissolved solids already present. If there is a lot dissolved solids(high Gravity) then it is difficult to dissolve more. We keep the concentration low by removing the products of leaching (drawing off wort) and replacing them with fresh water (sparging). Leaching can be maximised by having a finer grind. 2.4.2.2. Filtration

Filtration is the separation of liquids and solids in the mash through a filter bed. The filter bed is made up of the solid material of the mash (husk and other malt debris). This is supported on a metal screen in the case of the Mash and Lauter tuns or a polypropylene filter cloth in the case of the Mash Filter. The large particles form a bridge across the base element of the filter. The bed formed by these particles will in turn hold back smaller particles. This sieving effect removes the majority of the solids present. This allows clarified bright wort to flow in to the kettle. Fine particles clog the filter bed and result in a slow run off, or a set bed. The rate of filtration is maximised by a coarse grind. 2.4.2.3. Efficiency

The efficiency of the mash separation process is measured by: Turn around time The time to process a complete brew. Generally a modern brewhouse (with 7 vessels) would process 8 to 10 brews every 24 hours. Extract Efficiency This is based on a direct comparison of the total extract (gravity x volume) collected in fermentation vessel against the laboratory extract. Generally a modern brew house will recover 98% of laboratory extract.
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 Wort Quality This is more difficult to measure but typical parameters would be: o Wort Haze in E.B.C. - should be < 50 EBC 10 minutes after the start of run off. o Suspended solids - no more than 10 to 15 mls as sediment after 2 hrs in an IMHOFF cone o Dry Solids/ wort residue - Measured using centrifugation and pellet drying or in specialised heated centrifuges or filter paper. Normal values around 250 to 500 p.p.m.

For the technically minded! Filtration is generally defined in terms of Darcys equation: Flow rate u = filter surface area (A) x pressure differential across filter ( P) viscosity ( x resistance to the flow of beer (L ) Therefore using this equation it is possible to predict the conditions for optimum flow: Large surface area the higher the flow The higher the differential pressure the higher the flow The lower the wort viscosity the higher the flow The shallower the filter bed the higher the flow.

Darcys equation describes the conditions for optimum flow not optimum wort quality.

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2.4.3.

Wort separation process

Wort separation follows a similar pattern in all of the separation systems. Firstly the strong (main) wort is separated. Secondly, after all the strong wort has been collected the grain bed is washed with fresh water in a process called sparging. Hot water (at between 76 to 780C) is sprayed over the grains. This passes through the grain bed. It washes out remaining wort until the required wort volume and gravity is collected in the wort kettle. The sparge is then stopped and the additional wort is run to drain or weak wort recovery as required. The sparge system may have significant effects on wort quality. If the pH of the sparge water is too high (pH > 7.2) or the sparge is continued until it reaches a low gravity (around 10 Plato) it may lead to the extraction of unwanted wort compounds. This may give flavour and processing problems in the finished beer. It is also necessary to ensure bright worts are produced. Cloudy worts indicate the extraction of polyphenols and lipids from the malt husk. This can cause harsh flavours. Cloudy worts can be an indication of starch granules being extracted into wort. The extraction of these compounds are greater: with higher wort pH (> 5.5) with higher sparge temperatures (> 780C) with low last running gravity's (< 10 Plato).

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2.4.4.

The Lauter Tun 2.4.4.1. What does it consist of?

2.4.4.1.1.

Construction

It is usually built of stainless steel or copper. It is insulated to prevent heat loss of the mash. There is a vent to discharge vapour. It has a false bottom.

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Milled slots
Wear line

2.4.4.1.2.

Plates

The false bottom is built up of interlocking plates. These may have either milled slots or they may be built up of wedge wire. The advantage of wedge wire over cut slots is that wear on the wire does not produce an " opening" of the gap.

G a p in c r e a s e s w it h w e a r

Wedge wire slots

Wear line

No gap change with wear

The plates are made in sections so that they can be lifted. This enables them to be thoroughly cleaned if required.

2.4.4.1.3.

Sparge

It has a sparging system. This is used to spray water over the mash to wash out the worts. 2.4.4.1.4. Rakes It has a raking system. These are knives which can cut the bed. This, when used properly, helps the filtration process.

There is a CIP system installed. There are spray balls or jets which clean the internal surface and under the plates. Raking can be continuous or using a number of discrete steps. The sparge can be added continuously or as a batch addition.

2.4.4.1.5.

Cleaning
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The vessel is normally thoroughly cleaned and descaled once a week with Caustic 2.4.4.1.6. Draw off

All Lauter tuns are fitted with a draw off device. This enables the operator to balance run off to the differential pressure of the bed over the plates. Too much differential pressure will pull the bed onto the plates. This will cause a set mash. Modern Lauter Tuns are computer controlled. 2.4.4.1.7. Mash inlet

There is an inlet for the mash. This is normally through the bottom. This cuts down on oxidation during the transfer from the mash tun. 2.4.4.2. Operation

The mash is transferred from the Mash tun into the Lauter Tun. The filter bed in the lauter tun is shallow and has a large surface area. A fine grind increases the resistance to flow and this is compensated for by the use of rakes. These open the bed to allow faster filtration. The rakes must operate in such a way that sparge is not channelled and the filter bed is not totally disrupted. A slight increase in wort viscosity can have a dramatic effect on run off performance. Most lauter tuns are fully automated. The wort run off rate is controlled. Also the differential pressure above and below the lauter plates is measured and controlled. When this pressure falls below a set pressure it has reached a "set bed condition. The run off is stopped and the rakes are lowered to the bottom of the bed and used to break up the bed for 5 to 10 minutes before normal filtration is resumed. The typical run off sequences and control are shown below. Another measurement often used to control run off is haze. The wort turbidity is measured. The contents of the lauter tun are re-circulated to ensure that only bright (haze less than 5 to 12 EBC) wort runs to the kettle. A typical lauter tun cycle to collect 1000 hl is described below.

Event Underletting This covers the false bottom. It stops the mash settling into the slots and blocking them. Filling The mash is pumped from the mashing vessel. Re-circulation Wort is recirculated until it is bright. First worts The strong worts are run off Second worts Weaker worts are run off. Sparge water starts to wash out the wort. Last worts

Duration 3 minutes

Volume HI 23

11 minutes

4 minutes 41 minutes 74 minutes

20 200 475

10 minutes

141
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The last weak runnings are collected Weak worts Weak worts are sent to drain. They may be collected and used for mashing the next brew. This saves extract. However they must be kept hot and therefore sterile. Drain down The remaining liquid goes to drain. Grain removal Spent grains are removed Under plate flush The space under the plates is cleaned. This removes any bits of grain which may have got through the slots. If it was left it would get infected very quickly. Total

16 minutes

179

8 minutes 25 minutes 5 minutes

93

197 minutes

1000

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2.4.5.

Mash Filter 2.4.5.1. What does it consist of?

It consists of alternating plates. Mash is pumped into one plate. This is hollow:

Hollow plate

Perforated support plate

Perforated support pla Wort outlet port

The cloths are put over the adjoining plate, which has a perforated centre area. The cloth holds the mash. The wort travels through the cloth. It goes through the perforated plate and into its hollow inside. It then feeds out through exit ports. Cloths are normally polypropylene which is easily washed.

The plates are held together by a hydraulic press.

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A modern mash filter: the Meura 2001

Mash in

Filter plates

Wort out

The mash filter is flushed, then preheated with hot water. The mash is then pumped into the filter through the top channel, completely filling the filter frames. The entire transfer to the mash filter is completed in 20 to 30 minutes If the filter is underfilled, the efficiency of the extraction process suffers significantly. The sparge water will flow through the empty portion of the chamber. Overfilling, on the other hand, results in excessive density. This badly affects filtration efficiency. When the filter is full, the wort collection system is opened. The wort is drawn horizontally through the filter cloths. To achieve satisfactory clarity, the wort is normally recirculated through the filter. Sparging is started after the first wort is partially drained but before the filter cake becomes dry. Sparge water between 75 and 78C is pumped into the filter from the bottom and lasts from 90 to 140 minutes. Just as with the lauter tun, the mash filter pressure differential is critical. After the last wort, the filter is opened automatically, plate-by-plate, and spent grains fall into a trough with a screw conveyor. The latest Mash filters like the Meura 2001 (picture above), incorporate a flexible membrane around the mash in the hollow plate. Air can be applied to this membrane to squeeze the mash.
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Filling The mash is pumped at low pressure from the mash conversion vessel

Duration

5 minutes

Pressure

0.7 bar

Volume run off

nil

Filtration The solids in the mash form a cake on the surface of the filter cloths. Clear wort is run off to the kettle.

Duration

30 minutes

Pressure

0.7 bar

Volume run off

175 hl

Pre compression

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As the wort runs off, gentle air compression is applied to the membrane to push the strong worts through the bed.

Duration

5 minutes

Pressure

0.9 bar

Volume run off

10 hl

Sparging When most of the strong worts has been squeezed from the grain, the membrane pressure is gradually released allowing the sparge water to flow in through the mash inlet and flush the bed. Duration 35 minutes

Pressure

0.7 bar

Volume run off

175 hl

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Final compression When all the sparge has supplied the membrane is compressed at high pressure and the grains squeezed dry

Duration

10 minutes

Pressure

1 to 1.5 bar

Volume run off

20 hl

Cake discharge Once all the extract has been squeezed from the grain, the pressure is released, the filter is opened and the spent grains fall into the grain hopper.

Duration

10 minutes

Pressure

nil

Volume run off

nil

Summary of typical mash filter cycle described above: Event Filling Filtration Pre compression Sparging Final Compression Cake discharge Duration mins 5 30 5 35 10 10 Volume HI 0 175 10 175 20 0 Pressure bar 0.7 0.7 0.9 0.7 1 to 1.5 0
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Mash filter run off programme.

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2.4.6.

The Isothermal Mash Tun 2.4.6.1. What does it consist of?

It is a combined conversion and wort separation vessel. It has also been discussed in the mashing section. Its physical construction is similar to a Lauter tun. Older mash tuns will probably not have vents or CIP. All cleaning and grain discharge will be by hand. Isothermal Mash tuns require the coarsest grind. It has no rakes to clear the bed. It has the smallest filter surface area with the deepest bed of the three systems. The combination of these factors gives the mash tun the slowest filtration and poorer extract recovery, but they can also produce the brightest worts. This performance is due to the combined effects of the grind and the bed depth. The poorer extract efficiency results from a coarse grind. This is partially offset by the use of a low rate of mashing water (2:1) and larger sparge volumes. This improves the leaching effect. The flow rate of wort from a mash tun is usually manually controlled by the setting of run off taps. These are adjusted to prevent pulling the bed down on to the plates. The mash in a mash tun floats on the wort, at least during the strong wort recovery. During the initial run off flow rate is low to allow for the high viscosity of the wort. It also prevents the floating bed of mash being drawn down on to the false bottom of the vessel. The flow rate can be increased during sparging starts as the wort viscosity drops. Mashing in is via a Steels masher. This is a rotating screw into which the grist drops. Water at the correct temperature is run into the screw at the same time. The screw mashes the grist which falls into the Mash Tun.

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Typical Mash tun cycle Event Mashing in Mash conversion stand Run off Drain down , Spent grains removal Total turn around time Duration 20 minutes 75 minutes 185 - 330 minutes 20 minutes 300-440 minutes

Excluding the time taken for the mash conversion, the mash tun is the slowest wort separating system. Mash tuns are well suited to their traditional use in producing wort from well modified malt. They are the cheapest system in terms of capital outlay and are the simplest to operate with little or no automation. Mash tuns can only use a single temperature for mash conversion. Poor quality malts or malts requiring a protein or glucanase stand cannot be handled. Mash tuns are also less well suited to modern large batch production. High brewhouse utilisation and extract is not possible.

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2.4.7.

Spent Grains 2.4.7.1. What are spent grains?

After wort separation is complete the waste material left behind is called spent grains. Spent grains are drained down and normally sold as cattle feed. The removal of the grains depends on the systems: 2.4.7.2. Mash Tun

Thrown out by hand, or removed by a mechanical arm. The arm rotates over the false bottom of the tun and pushes the grains towards outlet ports. 2.4.7.3. Lauter Tun

Normally mechanical. Done by turning the rakes so that they come flat on against the grain bed. The space under the plates is normally rinsed prior to spent grain removal. The spent grain flaps are opened in the base of the lauter tun ( they are set in and pass through the false bottom). The rakes are rotated and slowly drop into the grain bed where each revolution forces a quantity of grain down the chute. When the rakes reach the false bottom a special wiper-shoe (usually a rubber flap) wipes the last bits of spent grain from the surface. The spent grain falls into a holding bin below the lauter tun. It is normally blown with compressed air through a screw conveyor and valve to a holding bin. Steam can be used but can give rise to excessive moisture 2.4.7.4. Mash Filter

The filter is opened up and the grains fall out, occasionally with sticky grains the cloths may require scraping. The installation should receive a full hot CIP at least once per week. 2.4.7.5. Grain disposal

The discharged grains are usually conveyed either by a screw conveyor or using compressed air to a storage silo, where they can be loaded into local transport for removal. The % solids of the grains is between 19 and 36% depending on wort extraction system and drainage. If the grains cannot be taken away wet then it is necessary to dry them. After draining down, the grains may be passed through a decanter centrifuge to remove excess moisture before being dried in a drum oven. The spent grains are valuable sources of protein and carbohydrate and are normally sold as animal feed. If you sell spent grains it is probable that the purchaser will accept spent hop residues mixed in. Whirlpool trub and tank bottoms can enhance the protein content of the spent grain. However do not add yeast to the mixture without prior consultation with the purchaser as cattle in particular cannot tolerate high levels of yeast.

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2.4.7.6.

Q.C.

Analysis of the spent grain can provide valuable information about the brewhouse process. Visual examination should show no whole corns and the husks should be essentially unbroken. Laboratory analysis can also indicate retained extract, which may be improved by refining lautering techniques. 2.4.8. Requirements & Quality of mash separation

1. The following table summarises the different requirements of each system.

Mash Tun Milling system Grist type Mashing and separating vessels Mash water to grist ratio l/kg Sparge water l/kg Total water to grist l/kg Filtration area m2/tonne Grain bed depth mm Bed loading kg/m2 Filtration rate Brews process per day Space for 1000 hl brew length 4 roller dry Coarse One vessel 2 to 2.5 4.5 7 2.5 1,000 400 1 litre/sq m /min 6 250 sq m

Lauter Tun 6 roller or wet mills Medium/fine Two vessels 3 to 3.5 3.8 6.8 4.5 500 200 0.6 litre/sq m /min 8 to 10 180 sq m

Mash Filter hammer mills very fine Two vessels 2.9 2.4 5.3 35 50 28 20 litre/sq m /min 12 50 sq m

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2. The following table summarises the different quality results of each system.

Parameter

Mash Tun

Lauter Tun traditional >20 15 22.5 16 23 >10 180 97

Lauter Tun modern >10 5-8 24 17.5 18 <12 195 98

Modern Mash Filter >20 <5 25 19 17 <5 195 101

Initial wort haze (EBC) Average wort haze (EBC) First wort gravity Kettle gravity Total lipid ( ppm) Solids Imhoff cone (ml/litre) Polyphenol (ppm) Extract efficiency. (% Lab) Spent grains (% solids)

10 4 20 15 2 <8 165 97

19

21

24

36

3. Summary of the process differences between a mash filter and lauter tun. Property Extract efficiency Turn around Mash Filter Circa 102 % Circa 2 hours 12 brews/day Flexibility Operation Full charge + 5 % - 10% No underlet Easier run off Size (10 tonnes) Maintenance Spent grains Small 3 x 12 m Low - few moving parts Dry moisture < 65 % 8 m diameter Higher more moving parts Wet moisture > 78 % Lauter Tun Circa 97.5 % Circa 3 - 4 hours 8 - 10 brews/day Full charge 35 % More problems with run off

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2.4.9.

Brewhouse extract efficiency 2.4.9.1. Calculation of brewhouse extract efficiency

The Brewer is anxious to recover as much of the sugar (extract) from the brewing materials (goods) as possible. The yield or extract efficiency is calculated by comparing the extract recovered in the wort compared with the laboratory extract of the same brewing material. Extract recovered in the wort is expressed as the Original Gravity multiplied by the volume collected in litres. Laboratory extract is based on a laboratory mash of the materials as a 10% solution (see analytical methods). The extract recovered is measured in the fermentation vessel as: 500 hl of wort collected at an original gravity of 12 0 Plato This is equivalent to = 500 x 100 x12 = 600000 0 Plato Grist supplied: Standard malt charge = 6505 Coloured malt charge = 459 Sugar = 703 Extract supplied using EBC methods: Standard malt charge = 6505 Coloured malt charge = 459 Sugar = 703 Total extract supplied Extract yield 2. = (610981.2 600000)/610981.2) x 100 kg kg kg kg x kg x kg x 80% 66.7% 85.3% 80% 66.7% 85.3% = = = = = 520400 30615.3 59965.9 6109810 Plato 98.2%

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