all there is to know about breweries and brewing - food technology

1. BREWERIES

2. • Place dedicated to make beer
• Diversity of breweries is based on
-diversity of processes
- degrees of automation
-kinds of beer produced
• Oldest brewery – Weinhnstephan brewery in
Bavaria, Germany.

3. INDUSTRIALIZATION OF
BREWERY
• Can be traced back to almost 5,000 years to
Mesopotamian writings
• Production of beer took place at home-
“women’s work”.
• Monasteries and other Christian institutions
used beer as payment.
• Early breweries were built on multiple stories
• Used large copper vats
• Fermentation and packaging in lined wooden
containers.

4. MAJOR TECHNOLOGICAL
ADVANCES
• The steam engine by James Watt brought
automatic stirring mechanisms and pumps into
the brewery.
• Carl Von Linde is credited with developing the
refrigeration machine .
• The discovery of microbes by Louis Pasteur was
instrumental in controlling the fermentation
process.

5. MODERN BREWERY
• Vessels- stainless steel
• Heating – pressurized steam, direct- fire
systems
• Cooling- jackets
• Samples are pulled out at every step of the
process.

6. BEER
• World’s most widely consumed alcoholic beverage
• Third most popular drink overall after water and tea
• The “code of Hammurabi” included laws regulating beer
and beer products
• “the Hymn to Ninkasi” – a prayer to the Mesopotamian
Goddess of beer
• Today brewing is a global business that includes several
multinational companies
• Strength of beer is usually around 4 to 6% although it
may vary from 0.5 % to 40 %

7. BREWING
• Process of making beer
• Starch source wort beer
• effected by yeast

8. INGREDIENTS
• Water
• Starch source, such as
malted barley
• Brewer’s yeast
• Hops ( for flavoring)
MATLED BARLEY BEFORE
ROASTING

9. Less commonly used starch sources include
• Millet, sorghum and cassava root in Africa
• Potato in Brazil
• Agave in Mexico

10. WATER
• Beer is composed mostly of water
• Different mineral compositions of water- different
types of beer
• Dublin has hard water, well suited to make stout
like Guinness
• Waters of Burton in England contain Gypsum
which benefits making pale ale.

11. STARCH SOURCE
• Fermentable material
• Key source in determining the strength and
flavor of beer
• Malted grain – most common source
GRAIN IS SOAKED IN WATER
DRYING PARTIALLY GERMINATED
GRAIN IN A KILN

12. • Malting grain produces enzymes that
convert starch into fermentable sugars
• Different roasting time and temperature
are used to create different colors of malt
from the same grain
• Darker malts produce darker beers.

13. HOPS
• Flavoring beer
• Flowers from hop vine
are used as flavoring and
preservative agent
• Flowers are called hops
HOP CONE

14. CHARACTERISTICS OF HOPS
• Contributes bitterness to the beer, that balances
the sweetness of malt
• Contribute floral, citrus and herbal aromas and
flavor to the beer
• Have an antibiotic effect- useful in fermentation
process
• Aids in “head” retention
• The acidity of hops is a preservative.

15. YEAST
• Brewer’s yeast- Saccharomyces cerevisea(top
fermentor)
Saccharomyces uvarum( bottom
fermentor)
• Responsible for fermentation in beer
• Metabolize the sugars extracted from grains into
alcohol and CO₂.
• also influence character and flavor of beer

16. BREWING PROCESS
9 steps:
• Malting
• Milling
• Mashing
• Lautering
• Boiling
• Fermenting
• Conditioning
• Filtering
• Filling
ROYAL BREWERY IN
MANCHESTER, UK

18. MASHING
• Combining malted barley
and water and heating in
a “mash tun”
• Allows enzymes in the
malt to convert complex
sugars into maltose
• Usually takes 1 to 2 hours
• The end product of
mashing is called “wort”.

19. • Mashing involves pauses at certain
temperatures
-45˚C –activates various proteases
-62˚C –activates β- glucanase
-73˚C-used to convert starches in the malt to
sugar.

20. LAUTERING
• Separation of wort from the grains
• Carried out in a lauter tun
• Tank with holes at the bottom small enough to
hold back the large bits of hulls.
• Two stages:
1. wort run off
2. sparging

21. BOILING
• Beer wort is boiled with
hops in “copper” or brew
kettles
• Chemical reactions
-releasing of hop flavors
-sterilization of wort
-precipitation of proteins
-stopping enzymatic
reactions
-concentration of wort
BREW KETTLES

22. WHIRLPOOLING
• Tea-leaf paradox
forces denser solids (
coagulated proteins,
vegetable matter from
hops) into a cone in
the centre of the tank.
• There is a separate
tank for whirl pooling

23. WORT COOLING
• After whirl pooling, the wort is brought down to
fermentation temperature before yeast is added
• 20 to 26˚C
• Plate heat exchanger

24. FERMENTATION
• Chemical conversion of
sugars into alcohol
• Wort is cooled and
aerated with sterile air
• Yeast is added to it and
fermentation begins.
• Cyclo-cylindrical vessels
or CCVs are used
• Cone’s aperture is 60˚
• Made of stainless steel

25. • Brewing yeasts may be classified as
- top fermenting ( S. cervisea)
- bottom fermenting (S. uvarum)
• Top fermenting yeasts- form a foam on top of
the wort during fermentation
• Higher alcohol content
• Higher temperature (16 to 24˚C)
• Fruitier and sweeter beers.

26. • Bottom fermenting yeasts
- cool fermented, lager type beers
-ferment more sugars
- dry beer
-grow well at low temperature ( 10 to 18 ˚C)
- Ex. Saccharomyces pastorianus, formerly
known as Saccharomyces carlsbergensis

27. CONDITIONING
• Maturing or aging
• 2 to 4 weeks, several months or years
depending on the type of beer
• Beer is transferred to a second container so that
it is no longer exposed to yeast.

28. Krausening:
• Fermenting wort is added to the finished beer
• The active yeast will restart fermentation
• Introduce fresh CO₂
• Conditioning tanks are sealed so that CO₂ will
dissolve in the beer
• May be used to condition bottle beer

29. Lagering:
• Lagers are aged at near freezing temperatures
for 1 to 6 months
• Serves to reduce sulphur compounds produced
by bottom- fermenters
• Produces a cleaner tasting final product with
fewer esters.

30. FILTRATION
• Stabilizes flavor
• Gives beer its polished shine and brilliance
• Diatomaceous earth powder
• Filtration ratings:
- rough : leaves some cloudiness in the beer
-fine : removes all cloudiness
-sterile : removes microorganisms

31. PACKAGING
• Glass bottles
• Aluminum cans
• Kegs

33. NUTRITIONAL INFORMATION
1 can (350 ml) of beer contains:
• Calories :153
• Fat(g): 0
• Carbohydrates(g): 12.64
• Fibers(g): 0
• Protein(g): 1.64
• Cholesterol(mg): 0

34. HEALTH EFFECTS
• Brewer’s yeast is a rich source of nutrients
• Beer contains significant amount of magnesium,
selenium, phosphorous,potassium, biotin,
chromium and B vitamins
• Low alcohol beer has anti cancer properties
• Non alcoholic beer has cardiovascular benefits.