Getting the most out of malt! - Atlantic Grains...

Getting the most out of malt!

Aaron MacLeodMaritime Craft Malt WorkshopNovember 30 2018

Our Mission

▪ Support growth and innovation in craft food and beverage production through quality testing, technical support, & education.

Investment

▪ The Center was awarded a total of $1,125,000 in start-up funding from federal, state, and private sources

▪ Empire State Development

▪ USDA Rural Business Development

▪ Appalachian Regional Commission

▪ George Alden Trust

Grain Quality Testing

Barley Selection Package (Moisture,

Protein, Plump, Kernel Weight,

Germination Energy, RVA, & DON)

$75

Moisture & Protein $15

Starch $25

Germination (4mL, 8mL & Capacity) $20

DON (ELISA) $35

RVA (for pre-harvest germination) $25

Malt Quality Testing

Full Malt Analysis – (Moisture, Assortment,

Friability, Fine Extract, Coarse Extract, F/C

Difference, β-glucan, FAN, soluble protein, S/T, DP,

α-amylase, color, filtration time, clarity)

$150

Basic Malt Analysis – (Moisture, Fine Extract,

β-glucan, FAN, DP, α-amylase, color, filtration time,

clarity)

$75

Enzymes Only (Diastatic Power & α-amylase) $50

Specialty Malt Analysis – (Moisture, Extract,

Color)$25

Safety Testing

DON $35

Aflatoxin $35

Ochratoxin $30

Total Aerobic Count $30

Yeast & Mold Count $30

EColi $30

Nitrosamines (NDMA) $250

Glycosidic Nitrile $225

Beer Quality Testing

Alcohol (ABV) $15

Bitterness (IBU) $20

Free Amino Nitrogen (FAN) $20

Beer QC (ABV, SG, RE, OE, RDF, IBU,

Color, pH)$50

Minerals (Ca, Mg, & Zn) $225

Beer Spoiler Alert™ $75

Micro and Pilot Scale Malting

▪ Micromalting assessment

▪ Variety & Agronomy Trials

▪ Cornell

▪ Penn State

▪ Virginia Tech

▪ UD Davis

▪ Oregon State University

▪ Washington State University

▪ AAFC

Using Third Party Labs

▪ Outsourcing some analysis can fill gaps in your quality assurance program by providing analysis that requires equipment you don’t have or validation that your own analysis makes sense.

▪ Third party analysis can be used for:

▪ Identify high quality raw materials

▪ Feedback for process optimization

▪ Characterizing finished products

▪ Monitoring process variation

▪ Validation of in house test methods

Malting barley quality selection criteria

Characteristic SpecificationProtein content 9–12% dry matter

Plumpness >85% (over 6/64”)

Varietal purity >98%Germination Energy >95%Rapid Visco Analyzer >120 stirring number

DON <1.0ppm

Moisture

▪ Barley moisture < 13.5% to ensure good storability

▪ High moisture encourages microbial growth and germination loss

▪ Exercise caution when drying barley grain as it can destroy germination (max 100°F)

Grain Moisture

0

10

20

30

40

50

60

70

80

90

100

32 41 50 59 68 77 86

Ma

xim

um

Nu

mb

er

of W

ee

ks

Storage Temperature (°F)

10%

12%

14%

16%

18%

Protein

▪ Related to growing environment, agronomic practice, and genetics

▪ High protein limits extract potential

▪ Low protein limits enzymes

Nitrogen Management

Nitrogen

Yie

ld

Gra

in P

rote

in

Protein%

FRI%

EX%

SP%

S/T%

BGppm

DP°L

9.1 95 82.3 4.3 44.6 45 116

9.6 91 81.5 4.3 43.0 78 128

10.5 86 81.1 4.4 42.0 114 132

12.2 76 80.0 4.5 37.1 150 152

13.0 67 79.4 4.6 36.4 270 160

Germination

▪ Will the barley germinate now?- Germinative energy

Vitality versus Vigor

Variety 24h 48 h 72h 3 Day

Endeavor 70 27 1 98

Puffin 9 32 57 98

Germination

▪ Will the barley germinate now?- Germinative energy

▪ Is it dead or just dormant?- Germinative capacity

Dormancy

▪ Dormancy is characterized by the absence of germination in the presence of favorable conditions

▪ Subsides after a period of grain storage

▪ Varies by variety

Germination & Dormancy - 20174

mL

Ge

rmin

ati

on

% (

at

ha

rve

st)

Dormancy Break

Germination

▪ Will the barley germinate now?- Germinative energy

▪ Is it dead or just dormant?- Germinative capacity

▪ Special care required for steeping?- Water sensitivity

Water Sensitivity

▪ the failure of seed to germinate in excess moisture

▪ Special case of dormancy, but may not improve on storage

▪ Steeping process parameters must be adjusted to overcome water sensitivity

▪ Shorter wet immersions

▪ Longer air rests

Water Sensitivity - 20178

mL

Ge

rmin

ati

on

%

Water Sensivity

Day 1 Day 2 Day 3 Total

4 mL 47 51 2 100

8 mL 95 3 0 98

4 mL 33 91 3 97

8 mL 31 22 8 61

Barley A

Barley B

Multi Step Immersion Steeping

Germination

▪ Will the barley germinate now?- Germinative energy

▪ Is it dead or just dormant?- Germinative capacity

▪ Special care required for steeping?- Water sensitivity

▪ Long term storability of the barley?- sprouting/pre-germination

Pre-Harvest Sprouting

▪ Caused by excessive moisture prior to harvest

▪ Can be visually detected at only at severe levels

▪ Pre-germination (early signs) can not be visually seen, but can be measured using Falling Number or Rapid Visco Anaysis(RVA)

Risk of loss of germination on storage

▪ RVA > 120

▪ Barley is sound, high probability that germination will be retained on long term storage

▪ 50 < RVA < 120

▪ Barley is moderately pre-germinated, medium risk of germination loss on storage. Risk can be reduced if storage conditions are cool and dry

▪ RVA < 50

▪ Barley is severely pre-germinated, should be malted as soon as possible.

Germination Loss

Storage Time

Ger

min

atio

n E

ner

gy

sound

moderatelypre-germinated

Severelypre-germinated

Germination loss during storage

At Harvest July/Aug December

Moisture%

GerminationEnergy %

RVAGermination

Energy %

Scala 13.2 99 65 93

Synergy 13.3 98 75 98

Synergy 14.1 97 55 91

Scala 15.3 97 50 73

Conlon 15.3 94 30 73

Newdale 16.1 98 20 48

Fusarium & DON

▪ Mycotoxin produced by fusarium mold

▪ Can survive the brewing process

▪ Fusarium is implicated in gushing and PYF

▪ Maltsters reject >1.0 ppm

Fusarium and malting

▪ Highly infected barley can produce additional DON during malting

▪ Fusarium growth and DON production more likely after harvest then after long term storage

▪ Fusarium viability declines during storage

▪ The mold produces enzymes which cause damage to the protein structures

▪ Excessive soluble protein, FAN

▪ Elevated wort color

Solutions - Grower

▪ Variety choice

▪ Look for varieties with resistance

▪ Rotation

▪ Do not follow corn or small grains

▪ Fungicide & Timing

▪ Tillage

Solutions - Maltster

▪ Screen barley and malt for DON

▪ Have a “do not accept level” for incoming barley

▪ Cleaning

▪ DON is difficult to clean out of barley

▪ Small reductions in damaged kernels might be possible

▪ Storage

▪ Fusarium losses viability and is less likely to grow

Solutions - Maltster

▪ Malting Practice

▪ Increased overflow in steep may help to rinse surface contamination

▪ Chemical Control (e.g. bleach, ozone)

▪ Research is inconclusive on safety or effectiveness

▪ Microbiological Control

▪ Adjusting steep water pH (alkaline or acidify)

▪ Protective cultures (lactic acid bacteria or geotricum yeast)

Best practices to maintain high quality

▪ Harvest malting barley in a timely manner, ideally in good conditions when both grain and straw are mature.

▪ Dry grain gently (<100°F) to < 13.5% moisture

▪ Obtain an accurate/representative sample for testing

▪ Handle harvested grain gently to avoid breakage and hull abrasion

Keys to success

▪ Know your market

▪ Discuss variety choice, quality specifications, & price with maltster in advance

▪ Plan for alternative markets if quality isn’t met

▪ Know your product

▪ Send a representative sample for testing

▪ Monitor quality during storage

▪ Keep a representative sample

What Is Quality?

▪ Fitness for use

▪ functional characteristics

▪ Meets customer expectations

▪ Free from defects

▪ Preforms well in the brewery

▪ Safe

▪ Brand Values

▪ the art of malting

▪ Distinctive, innovative, local, sustainable, flavorful

Understanding Malt Analysis

▪ What do we use it for?

▪ Process quality control

▪ Comparing different malts

▪ Predicting brewingperformance

▪ specifications

What do brewers need?

▪ High BrewhouseYield

▪ high extract

Endosperm Modification

▪ Barley genetics

▪ Kernel hydration

▪ Germination moisture/temperature/time

Ease of modification

Bet

a-G

luca

n(m

g/L

)

What do brewers need?

▪ High BrewhouseYield

▪ high extract

▪ Efficient conversion

▪ Adequate alpha amylase

α-amylase

▪ Important enzyme for rapid degradation of starch during mashing

▪ Is produced during malting process

▪ Promotes fast “wort conversion”

▪ Influenced by variety and malting conditions

▪ Specifications:

▪ Moderate: 40 - 55 D.U.

▪ High: 55 - 70 D.U.

▪ Very High: >70 D.U (distillers)

Action of α-amylase

Steep 1 2 3 4 5

a-A

myla

se A

ctivity

What do brewers need?

▪ High BrewhouseYield

▪ high extract

▪ Efficient conversion

▪ Adequate alpha amylase

▪ Good wort separation

▪ low β-glucan, good hull retention

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

0 100 200 300 400 500 600

beta-glucan (mg/L)

wo

rt v

isco

sity

(cP

)

What do brewers need?

▪ High BrewhouseYield

▪ high extract

▪ Efficient conversion

▪ Adequate alpha amylase

▪ Good wort separation

▪ low β-glucan, good hull retention

▪ Fermentability

▪ adequate DP, adequate FAN

Diastatic Power

▪ Represents total activity of starch degrading enzymes

▪ Primarily related to β-amylase activity which produces fermentable sugars

▪ Influenced by variety and protein content

▪ Specification ranges:

▪ High > 150 °L

▪ Moderate 100-150°L

▪ Low < 100°L

Action of β-amylase

Impact of mash temps on enzymes

110 120 130 140 150 160

Malt Sensory – ASBC Hot Steep

Developing flavor in pale malt

▪ Use higher protein barley

▪ Promote modification

▪ Higher steep out moisture

▪ Extend germination time

▪ Higher cure temp (195 vs 185°F)

▪ Raise temperature (130 - 150°F) at higher moisture

▪ Increasing color will reduce DP

Nitrosamines

▪ NDMA in barley malt at levels greater than 10 ppb is considered avoidable contamination under section 406 of the Federal Food, Drug, and Cosmetic Act.

▪ The action level of 10 ppb NDMA in barley malt applies to all barley malt produced after October 1, 1980

▪ Actionable if a composite of 10 subsamples of finished product barley malt contains greater than 10 ppb NDMA

▪ Action levels represent limits at or above which FDA can take legal action to remove products from the market.

Nitrosamines

▪ Risk Factors

▪ Direct fire kilning

▪ Industrial emissions

▪ Mitigation

▪ Indirect fire kilns

▪ Low NOx burners

▪ Burn sulfer in the kiln

Glycosidic Nitrile

▪ Risk Factors

▪ Barley genetics

▪ All malt spirit production

▪ Copper in descending vapor phase

▪ Mitigation

▪ Non-GN producing or Low GN varieties

▪ Malting conditions (low temp, low moisture, short germination)

Malt Quality

Characteristic

Adjunct

Brewing

All Malt

Brewing

Total protein (%) >11.5% <11.5%

Soluble/Total protein (%.) 40-47% 38-45%

Extract (%) >80.0% >81.0%

Diastatic power (oL) >150 100 -120

Free Amino Nitrogen 180 - 220 120 - 180

Spring 2-Row Spring 6-Row Winter 2-Row

Protein, % 11.8 12.7 9.5

Extract, % 80.0 79.0 82.0

β-glucan, % 120 260 70

FAN, mg/L 200 230 150

Diastatic Power, °L 130 140 110

CrispMarrisOtter

SimpsonsGoldenPromise

WeyermanPaleAle

Rahr2-Row

Moisture, % 3.1 4.4 4.8 4.8

Extract, % 81.8 81.2 81.0 81.8

Protein, % 9.4 9.6 11.0 11.6

Friability, % 94.3 94.5 87.2 85.6

Color, °L 4.3 3.2 3.95 2.2

Kolbach, S/T % 47.1 46.7 39.5 43.0

FAN 154 192 148 187

β-glucan. % 212 64 114 118

Diastatic Power, °L 75 100 105 140

α-amylase, DU 40.0 53.2 59.5 63.0

Beyond the numbers…

Growth in Craft Beer Market Share

Source: Brewer’s Association

Projected malt usage

Source: Brewer’s Association

North American Craft Maltsters Guild

▪ Craft Malt is made using a majority (greater than 50% by weight) of locally grown grains

▪ Craft Malthouse producing minimum 5 metric tons & maximum 10,000 metric tons product/year

▪ Ownership by non-craft malt company does not exceed 24%

Find a craft malthouse near you!

February 2-3 . 2019

Bozeman, Montana

www.craftmalting.com

▪ “If you want something different, then it isn’t going to be the same”

-Jason Sahler, Strong Rope Brewery