2. Contents
• Background: Brewing is complicated
• Background: Flavour is complicated
• Beer design: How the big boys do it
• Beer design: Smaller brewery method
• Summary
• Questions, arguments and fighting in the car park
3. Brewing is easy peasy
• Beer is 4 basic raw materials
• Cooked together in a simple process
• Beer tastes of malt, hops and fruit
• Flavour is controlled through recipe changes
• It’s all down to selecting the right varieties
• None of this is accurate!
4. •• • Adjunct cooking • Cell mass
Adjunct purity temperature•• •Adjunct cooking temperature• temperature
• Adjunct cooking temperature Adjunct cooking temperature •Adjunct cooking temperature
Liquor cooking • Wort DO2cooking temperature Adjunct cooking temperature
Adjunct
•• •
•• •Adjunct level Adjunct level • •Adjunct level state of yeast
Metabolic
• Adjunct salt profile
Adjunct level
Cell mass increase
Liquor level • Adjunct level regime
Wort heating
Adjunct level • Adjunct level
••
• Mash pH 2
Wort DO
Mash pH •• •Mash pHpH• Mash pH
Wort pH
• Mash pH
Mash • •Mash pHpH
Fermentation temperature
• Mash
• Liquor temperature • Run
••
• Run offFAN
Run off profile
Wort profile •• •Run offoff profile off profile • •Degreeoff filtration
• Run off profile
Wort viscosity
Run profile
Fermenter shape
•Run off of profile
Run profile
••
•
• Lautering rateacid oxygen
Liquor dissolved
Wort amino
Lautering rate profile •
•• •Lautering rateLautering rate • •Temperaturerate pressure
• Lautering rate wort
Final gravityrate
Lautering of
Fermenter top
•Lautering rate
Lautering drop
••
•
• Liquorrake spectrum
Wort pH
Lauter sugarangle
Lauter rake angle Wort rake•angle
•• •Lauter silicate level rake angle•Temperature of maturation
• Lauter rake angle
Lauter
Lauter rake angle
Fermenter depth
• •Lauter rake angle
Lauter rake angle
•• • Sparge
•• •Spargepolyphenol level • •Concentration of dry characteris
Wort temperature temperature Sparge temperature
Yeast flocculation
• Sparge temperature
Barley variety
Zinc level
Sparge temperature • Sparge temperature
Sparge temperature •Sparge temperature hops
••
• Spargemodification
Sparge rate
Vitamin level
Malt rate •• •SpargeFAN • Sparge rate • •Sparge rate hops
• Sparge rate
Wort rate
Sparge rate
Yeast head potential
•Type of dry
Sparge rate
••
• Bed height
Wort colour
pH drop
Bed height •• •Bed height • Bed height level •Varietyheight hops
Wort Maillard precursor
• Bed height
Bed height • •Bed height concentration
Yeast cell
Bed of dry
• Malt
••
• Collection rate level
Wort carbonate
Collection rate Wort beta•glucan level rate • •Maturation yeast
•• •Collection rate
• Collection rate
Collection
Collection rate
Yeast growth rate
•Collection rate
Collection rate
••
•
•
Grist composition
Hop type fermentation
Vigour of
Hop type Type of •
•• •Hop typekettleHop type
• Hop type
Hop type • •Diacetyl rest
Fermentation temperature p
•Hop type
Hop type
••
• Special malt •
Hop variety modification •• •Hop variety Hop variety • •Free variety Attemperation rate
• Rousing
Hop variety • Hop variety heater
Type of wort
Hop variety •Hop rise
Hop variety
••
• Hop addition timings
Hop addition roast
Special malt timings
Yeast viability Delta T on•heatingaddition timingsHop addition timings
Hop surface • •Hop addition timings
•• •Hop addition timings
• Hop addition timings
Hop addition timings
Fermenter cleanliness
•Antioxidant use
•• • pH at
Worthop additions hop • •Yeast hop additions
•• •pHpH at hop additions additions pH concentration strains used
Number of yeast
• pH at hop additions
temperature
Yeast variety
pH at hop additions • pH at hop additions
at velocity •pH at at hop additions
•• • • •Maturation vessel size
Cation vitality roast moisture •• •Cation level inCation level in wort Cation level wort
Presence of bacteria
• Cation level in wort
Yeast level in wort
Special malt Cation level wort
• Cation level in of heater
Temperature in wort
wort •Cation level in in wort
••
• Shape of kettle
Shape autolysis
Yeast of kettle
level •• •Shape of of•kettleof heater • •Maturation vessel pressure
• Shape of kettle
Steam pressure
Shape kettle
Shape of kettle Shape of kettle wild yeast
Presence of
• Shape of kettle
•• • Degree
Degreestorage temperature •• •Degree of of reflux of reflux •Maturation of fermeter constru
Material vessle
• •Degree of of refluxmaterial
•
• Degree of reflux time
Yeast of reflux
Special malt roast • Degree of reflux
Evaporation rate
Degree reflux Degree reflux
•• •
Boil vigour Boil temperature•profile treatment profile
•• •Boil temperature profile Wood temperature constructio
Material of kettle
• Boil temperature profile
Yeast storage time
Boil temperature profile Boil temperature profile • •Boil temperature profile
• Boil temperature profile Boil
••
•
• Type ofstorage DO2 system •• •Typedrop in• kettle of system • •Maturation addititvessystem
Grist size profile Type trub removalConcentration of fatty acids
pH of trub removal system system
Type of trub removal system • Type of of trub removal system •Type of of trub removal system
Yeast trub removal Type trub removal Type trub removal
••
•
• Gristlevels of time
CO moisture level
Hop residence time hot break • time
Hop2residenceyeast storage •• •Hop residenceHop residence • •Maturation additive polyphenol
time Concentration of
• Hop residence time in kettle •Hop residence time concentrat
formation
Hop residence time Hop residence time
•• • Transfer from • •Transfer time and of size
•• •Transfer time and rate time and•Maturationtime and silicates
Transfer timetemperature • Transfer time and rate from rate from additive from
Concentration rate
• Transfer time and yeastfrom
Conversion and rate from
Ethanol levels in rate storage Wort colour and rate from
Transfer time Transfer rate from
kettle on mash yeast • kettlepH drop
Boil kettle •Filtration delta P
Use of amylolytic enzymes
• kettle
• kettle stress on
Shear kettle
kettle kettle
•• • 2+Design of calandria Use of proteolytic enzymes
Design of calandria of wort •• •Designof Mgcalandria •Design of calandria
• •Stabilisation calandria
•
• Osmotic potential
Design viscosity
Mash of calandria • Design of of in wort
Level of calandria
Design calandria Design of regime
• •2+ in wort of calandria rate of calandria
Flow rate
•• •Flow rateCa of calandria
Level of of conversion • •Stabilisation of calandria
• Oil leve lof hops
Recirc through hops • Degree rate calandria
Flow of malt Flow rate time
Flow
5. Flavour is Complicated
• Flavour = aroma + taste
• Taste not just bitter, sweet, salt, umami, and
sour, these are just like the primary colours
• Taste is sensed by taste buds or gustatory
calyculi on tongue, roof of mouth, inside of
cheeks and throat
• Tastes can be hedonically enhancing or
suppressive
7. Aroma
• Involves only volatile compounds
• Is sensed by receptors olfactory mucosa
• No “primary colours” of aroma – much more
complex than taste
• Aromas can be
additive, antagonistic, synergistic, hedonically
enhancing or suppressive
• How an aroma is perceived also depends on its
concentration (diacetyl)
• Aroma can influence taste and taste can influence
aroma (ethyl-maltol)
9. Where it gets complicated
• Receptors in your olfactory mucosa and gustatory
calyculi are stimulated by chemicals in the beer
• They send an electronic message to the brain for
processing
• The brain gives you an appraisal of what it might be
• Every step in this process is subject to genetic variation
and inaccuracy
• Beer flavour is conferred by 1000s of chemicals all
interacting
• Despite the 1000s of aroma compounds evolution is
quite conservative (α-pinene)
10. Beer Design Stages
Concept
Definition
Specification
Recipe
Pilot brew
Full scale brew
Market
11. Big Boys’ Design
1. Market research
2. Focus group
3. Fuzzy front end
4. Attribute specification
5. Pilots
6. Focus groups
7. Full scale brew
12. Labatt Ice
• 1992 in shrinking market
innovation needed
• Idea generation developed beer
names
• Focus groups used to select best
and define attributes
• “Ice Brewing Technology™”
developed to attain attributes
• Beer launched an became
world’s biggest selling Ice beer
and gained 10% market share in
Canada
13. Smaller Brewery Process
“We come up with ideas for new beers after a few jars in
Cask, Pimlico”
• The brew is often the first step in the process
• Concept developed by brewer
• Focus group of one or two
• Pilot brew may be sold
• Whether it is brewed again depends on sales
• Brewer’s palate and understanding of the
market’s palate needs to be excellent
• Product is personal to brewer
14. Chalky’s Bite
• Rick likes Sharp’s beers
• Rick wanted to market a beer (£Kerching!)
• Rick’s team asks Stuart to brew a beer with
wild fennel
• Stuart re-educates Rick’s team
• Pilot beers produced
• Definitive pilot selected
• Commercial scale beer brewed
15. Fennel
• Shares many essential oil components with hops
such linalol and terpenes
• Has non-sugar sweetness from estragole
• Has mint like character from fenchone
• Aniseed aroma from anisole, another hop
component
• Dried fruit have very high concentrations of these
compounds
• Every variety and type of fennel has a different
essential oil composition
16. Designing the beer around fennel
• Selection of right base beer
• Consistent supply of fennel
• Controlling the dominance of fennel notes
• Timing the point of addition
• Beer sculpted from original beer through
iterative brews with small changes
• Compromise on taste between design team
17. From pilot brew to full regular brand
• Upscale calculations
• Split brews
• Specify, specify, specify
• Change to maintain
18. Summary
• Brewing and flavour are highly complex and
interesting
• The process of beer design shows as much variation
as breweries themselves
• Novel ingredients constitute a unique challenge to
the brewer
• Flavour is sculpted through an iterative process
• The beauty of the sculpture is in the eye of the
consumer
