BREWING WITH VARIOUS ADJUNCTS

BANGKOK BREWING CONFERENCE 2011

Christoph Kunzmann, CSA Manager cpku@novozymes.com

15th June, 2011

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TOPICS

Motivation of adjunct inclusion Processing of various adjuncts

Corn / corn starch / rice Sorghum Barley

Conclusion

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Corn, rice and barley are the dominating adjuncts the choice of adjunct is driven by various factors

SYRUP Capacity Cost Colour

One ton of maltose syrups provides the same amount of saccharides as 1.15 tons of barley

CORN Cost Taste Availability

Syrups (20%)

Corn and Corn Starch (35%)

Other (10%) BARLEY Cost Local raw material Shortage of malt Taste wise closest to malt Quality

Barley (15%) Rice (20%)

RICE Cost Taste Quality Capacity

Source: Novozymes market intelligence

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Processing of Adjuncts
Cereal Cooking Infusion Mashing Saccharified Adjuncts

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Penetration of adjuncts
Adjuncts are widely used around the world Usage levels vary in the different regions as well as the choice of adjuncts
Penetration of adjuncts As % of beers produced in the region Region Mashed-in barley and wheat Cereal-cooked corn and rice Syrups

Penetration As average % of adjuncts included in the recipe

Central & Western Europe Eastern Europe China South East Asia Latin America North America

10 30 10 5 10 0

5 10 45 25 30 35

0 15 20 10 25 30

5-10 25 45 20 25 25

Source: Novozymes market intelligence

Rice

Corn & corn starch

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Overall, cost is the strongest driver for the use of adjuncts, with corn and barley in particular representing significant cost reduction potentials

Raw material prices (EUR/t) Average 2010

400 350 300 250 200 150 100 50 0
Malt, Europe Barley, malting, Europe Barley, f eed, Europe Corn, Europe Barley, f eed, US Corn, US Corn, Asia Rice, China Sorghum Af rica

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Adjuncts where the starch has a high gelatinization temperature need to be separately cooked and liquefied
The starch gelatinization temperatures of some adjuncts, namely
Corn starch (GT of 6275 oC) Rice starch (6885 oC) Sorghum (7078 oC)

Gelatinization of corn
65 C

... are above the inactivation temperature of the malt beta-amylase and consequently they need to be gelatinized before saccharification
corn or rice is gelatinized and then liquefied by a thermostable alpha-amylase in a cereal cooker 78 C 72 C 65 C 52 C Proteolysis Saccharification Transfer to lauter tun

70 C

110 100 90

85 C

80 70 60 50 40 0 15 30

Min
45 60 75 90

Typical mashing regime for cereal-cooked rice or corn

Starch granules swell Viscosity increases Starch gelatinizes Then the enzyme can act

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Selecting the right amylase for cereal cooking

A thermostable amylase is required
Viscosity, falling ball (sec)

Other important features

Standard amylase (Termamyl) Improved version (Termamyl SC)

Viscosity as a function of pH A broad pH profile is desired Dextrose Equivalents % Standard amylase (Termamyl) Improved version(Termamyl SC)

Comparison of the thermoactivity profile of malt alpha-amylase and a typical industrial liquefaction amylase

DE (%) at 88 oC. High efficiency at temperatures around 90 oC is preferred

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Quick-test for monitoring of liquefaction in practice

optimal enzyme utilization through LDA-Kit.

DE = Ratio of reducing sugars in percent. Calibration of LDA Kit with osmometer (or Fehling titration)

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Adjunct Brewing of the Future

.

(high gelatinizing adjuncts)

Background

Challange
Sugar profile without proper enzymes leads to insufficient saccharide levels.

Energetical improvement and OPEX/CAPEX reduction. Simplification and shortening of mashing. Debottlenecking. Flexible adjunct use in infusion mashing. Sugar profile with experimental enzyme blend.

Temp.

62C 52C
Malt Tgel 62-64C

72C
Adjunct Tgel 70-78C

Time

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resulting attenuation levels (ADF%)

theo. ADF %= fermentables % * 0.9 / 0.81 (0.9 = empiric value sugar extract) (0.81 RDF to ADF)

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Wort/Beer Quality
(rice / corn in infusion mashing)

FAN Levels
Grouping of amino acids (aas) grouped in relation to how well yeast can utilize and absorb the aa:
A: Fast B: Intermediate C: Slow D: None

Rice/Corn as Adjunct FAN Levels

In general acceptable FAN levels for high adjunct inclusions. Can be highered by introducing a 52C mashing step or an additional protease.

Sensory Analyses:

50% of maize/rice inclusion results in a comparable amino acid profile of the FAN as a 100% WM malt.

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SORGHUM Brewing
Processed malted and un-malted Processable in any ratio up to rd 70% in LT Processable in any ratio up to 100% in MF
Several proteases Xylanases Glucanases Alpha-Amylases

Processable with combination of Cerezyme Sorghum and Fungamyl BrewQ

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SORGHUM brewing

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Two strategies for brewing with barley

Mix & mash
The standard solution for barley brewing Malt and barley are mixed and mashed together Other adjuncts can be added as cooked adjunct or syrup Typically the barley inclusion is 1535% The requirement of the enzyme system increases as the barley inclusion increases

Brew & blend

Separate mashing and fermentation of malt and 85100% barley Blending to the target barley:malt ratio Other adjuncts can be added in any of the mashings A flexible solution where the malt- and barleybased brews can be optimized separately Can also be applied for a 100% barley beer This solution was enabled by the Novozymes Ondea Pro technology launched in 2010

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The Novozymes Ondea Pro enzymatic solution for brewing with up to 100% unmalted barley
Attenuation is ensured through a synergistic action between
Endogenous barley beta-amylase Exogenous added pullulanase and alpha-amylase

Mashing profile
Temperature

7882 C / 10 min 64 C / 4575 min 54 C / 30 min Time

The fermentable amino acids are provided by a synergistic action between

Endogenous exopeptidases An added protease

Good lautering with a clear wort is provided by a combination of welladjusted mills and
A filtration enzyme system including both beta-glucanase and xylanase components A lipase to ensure wort clarity

The synergies between the enzymes are ensured by

A three-temperature step-infusion mashing profile pH 5.65.8

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The Novozymes Ondea Pro brewing concept allows the strict malting barley specifications to be broadened
The barley must be food grade according to local regulations It is not necessary to use spring barley matching malting specifications Parameters especially necessary for a successful malting process (e.g., germination energy, water sensitivity, relationship between cytolytic and proteolytic degradation) are less important The barley performance can be checked using a barley quality test, which is a modified Congress mash with enzymes, measuring turbidity, throughput, FAN, sugar profile (HPLC), viscosity, and pH The barleys endogenous enzymes (exopeptidases and beta-amylase) must be active. So far only one barley sample has shown insufficient activity

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100% barley wort can be processed with the same or lower viscosity than for malt wort
The viscosity-reducing component The viscosity reduction is ensured by the choice of the right xylanase and beta-glucanase
Wort viscosity as a function of barley inclusion (%)
3.5 3 no enzyme 2 kg/t Ondea Pro
Total 0.2 0.8

Barley specification test

Viscosity in mPas (12% oP base)

N= 36 18 18 Average 1.52 1.50 1.55 Adjust: N =1 Min 1.42 Max 1.82 Spec. 1.60

mPa*s

2.5 2 1.5 1 50 60 70 80

% Barley
90 100

Only one sample was out of specification Viscosity is usually not a limiting factor in the selection of grain

The wort viscosity in lab-scale mashing trials was measured at different barley inclusion levels with and without the addition of Novozymes Ondea Pro

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The turbidity-reducing component ensures low turbidity and facilitates lautering

The turbidity-reducing component Barley specification test
Wort turbidity N= Total 0.2 0.8 36 18 18 Average 33 24 41 Min 2 Max 222 Spec 80 NTU/ 20 EBC Adjust N=3

The lipase used reduces the turbidity

of the wort to regular standards The free fatty acids in the mash are at the same level as for malt with an expected similar amount of lipid oxidation products
Turbidity after lautering
160 140 120 100 80 60 40 20 0

Almost all critical samples are obtained when analyzing coarse grist High turbidity can be solved by the addition of 515% malt or by a higher enzyme dose

NTU

Barley

Barley with lipase

Lipase added to laboratory mashing. The turbidity was measured during filtration/lautering

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Synergy with barley peptidases provides good yeast performance

Novozymes Ondea Pros proteolytic component works in synergy with the endogenous enzymes of barley This is demonstrated by a comparison between the effect of Ondea Pro on barley with and without inactivation of the endogenous enzymes
13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 2

mg FAN/l/Plato

Barley wort needs only 9 mg FAN/L/Plato to ensure good fermentation

kg Ondea Pro per ton of barley With preinactivation of barley enzymes

Without inactivation

The inactivation of the endogenous enzymes was done by a heat treatment at 75 C for 30 min The mashes were carried out at 50 C

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Barley wort produced with Novozymes Ondea Pro has a significantly higher amount of fast-absorption amino acids
The amino acids are often divided into 4 groups according to their absorption by the yeast cell The amino acid profile of 100% barley wort differs from that of malt wort The barley wort contains relatively more of the easy-toferment amino acids and relatively less of the harder-toferment amino acids, especially proline
Relative amino acid composition of malt and barley wort according to amino acid fermentability groups
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Malt wort Barley wort

D C B A

Average of 10 barley samples with the malt from the corresponding barley

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100% barley wort shows comparable fermentation performance with less FAN
The FAN recommendations for malt brews are 10-18 mg/l/Plato The FAN from 100% barley wort is lower; 9-14 mg/l/Plato The barley worts have good fermentability This leads to less unfermented FAN at the end of the fermentation

Lab fermentation of 12 oP malt wort and barley wort (made with Ondea Pro). Fermentation temperature 12 C, Yeast strain W34/70

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The pullulanase ensures around 70% RDF with a high maltose sugar profile
The starch is degraded by a synergistic action between the added pullulanase and alpha-amylase and the beta-amylase from the barley The selected pullulanase is especially essential for the attenuation performance
Maltose and RDF as a function of enzyme dose
70 68 66 64 62 60 58 56 54 52 76 74 72 70 68 66 64 62 60 58 56 54

0
Maltose %

1
RDF%

kgOndea Pro perton of barley

Unique pullulanase added

Starch

Fermentable sugars
Glucose

Results from lab-scale mashing trials Sugar profile Experience from successful pilot and plant trials Glucose and fructose Maltose Maltotriose Dextrins (DP4+) 510% 4560% < 15% < 22%

Maltose

Alphaamylase added

Barley betaamylase

RDF

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The gelatinization temperature influences the starch degradation and the level of dextrins
Correlating attenuation
Dextrins (DP4) as function of the gelatinization temperature of grains

Barley specification test

Dextrins (DP4+) as % of total sugar profile N= Total 0.2 0.8 56 18 18 Average 21.3 Min 14.8 Max 29.7 Spec 22 Adjust N=7

The final attenuation can be adjusted via the dosage and the duration of the 64 C rest
Linear Fit

Correlation between the dextrins and the gelatinization temperature measured by RVA

High gelatinization temperatures reduce the amount of fermentable sugars and are hard to adjust

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Barley Quality Test

barley specification
Parameter Extract Dextrins (DP4+) Gelatinization temperature Viscosity FAN Total protein pH Turbidity Filtration performance NTU ml after 10 min Unit P % C mPas mg/L/P % Standard 1415 < 22 < 64.5 < 1,560 >9 1013 5.75.9 < 80 > 50 < 27 < 67 < 1,600 79 < 10 >6 > 80 < 50 > 27 > 67 > 1,600 <7 Adjust Reject

Sample database

Congress mash with a dose of 2 kg/t Novozymes Ondea Pro on define mash profile
Fine grist for mash filter application (0.2 mm) Coarse grist for lauter tun application (0.8 mm)

Worldwide we tested more than 100 barley samples and conducted over 50 pilot and industrial trials As the database for the barley quality test we used 18 dedicated barley samples

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Market response to beer from Ondea brewing

Breweries impressed by variety and taste High scores in testing Consumers like taste No beer defects Excellent foam Good shelf life

Confirming..
Brewmasters can make desired beer type and quality New beer claims are possible

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Conclusion
Adjuncts are widely used, with corn, rice, and barley being the global dominant adjunct. Sorghum is broadly used in Africa. The penetration of adjuncts is mainly driven by cost and availability, but quality parameters also play a role. The adjunct penetration is being facilitated by the development of enzyme technology. Corn and rice are currently cooked and liquefied with thermostable amylases as these starches have high gelatinization temperatures. Future developments are expected to enable mashing-in of corn and rice after infusion mashing steps. Ondea Pro technology enables brewing with up to 100% barley; this technology is based on a synergy between the endogenous enzymes of barley and a complex enzyme mixture. The innovative effort of enzyme suppliers is likely to continue, facilitating brewing with the inclusion of different adjuncts for cost savings as well as product development utilizing the different quality attributes of the adjuncts.

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