CN101490237B - A continuous method of producing a mash extract - Google Patents
A continuous method of producing a mash extract Download PDFInfo
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- CN101490237B CN101490237B CN2007800265049A CN200780026504A CN101490237B CN 101490237 B CN101490237 B CN 101490237B CN 2007800265049 A CN2007800265049 A CN 2007800265049A CN 200780026504 A CN200780026504 A CN 200780026504A CN 101490237 B CN101490237 B CN 101490237B
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- suspension
- starch
- converted mash
- maltase
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12C—BEER; PREPARATION OF BEER BY FERMENTATION; PREPARATION OF MALT FOR MAKING BEER; PREPARATION OF HOPS FOR MAKING BEER
- C12C7/00—Preparation of wort
- C12C7/04—Preparation or treatment of the mash
- C12C7/047—Preparation or treatment of the mash part of the mash being unmalted cereal mash
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12C—BEER; PREPARATION OF BEER BY FERMENTATION; PREPARATION OF MALT FOR MAKING BEER; PREPARATION OF HOPS FOR MAKING BEER
- C12C7/00—Preparation of wort
- C12C7/04—Preparation or treatment of the mash
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12C—BEER; PREPARATION OF BEER BY FERMENTATION; PREPARATION OF MALT FOR MAKING BEER; PREPARATION OF HOPS FOR MAKING BEER
- C12C11/00—Fermentation processes for beer
- C12C11/07—Continuous fermentation
Abstract
The present invention relates to a continuous method of producing a mash extract by decoction mashing, said method comprising: a. mixing a first malt enzyme source with an aqueous liquid to obtain an aqueous malt enzyme suspension; b. separately, mixing a second enzyme source with one or more starch-containing adjuncts to obtain a decoction suspension whilst maintaining temperature conditions that do not cause significant gelatinisation of the starch; c. subjecting the decoction suspension to a first heat treatment at 60-85 C to simultaneously part ially gelat inise and enzymatically degrade the starch; d. subjecting the decoction suspension to a second heat treatment at a higher temperature than the first heat treatment to gelatinise the starch at an increased rate and to a higher extent; e. combining the heated decoction suspension obtained from the second heat treatment with the aqueous malt enzyme suspension from step a. to obtain a mash; f. maintaining the mash at 35-85 C for at least minutes; and g. removing spent grain from the heated mash to produce a mash extract. The present method is very robust and easy to control. Furthermore, the method yields a mash extract of constant quality.
Description
Technical field
The present invention relates to a kind of continuation method of producing the converted mash extract by decoction mashing.More particularly, the present invention relates to a kind of like this decoction mashing, the method is used the source of one or more starch-containing additive as fermentable sugars.
Background technology
Decoction mashing is to be widely used in one of three kinds of saccharogenic methods producing bottom fermented beer, and other two kinds of methods are single step infusion mashing and infusion mashing progressively.This technique typically needs three kinds of containers: be used for mixing the converted mash bucket of converted mash, the lauter tub (or settling tank) that is used for the converted mash pot (or digestion pot or converted mash digestion pot) that boils and is used for filtration.Saccharification starts at low temperatures in the converted mash bucket, the partially saccharifying wine with dregs is removed simultaneously, and is boiled in the converted mash pot, and is sent back to after a while in the converted mash bucket, and the temperature of whole converted mashs is raise gradually.This technique is repeated two or three times usually, two to six hours consuming time.Can hang down and reach 35 ℃ when the temperature of converted mash starts, but the 45-50 ℃ that more is everlasting, and at the Mashing process tail end, reach 70-78 ℃.Then, converted mash is filtered in being called as the independent container of lauter tub, or under specific circumstances, in the porous via converted mash bucket self bottom, be filtered.
It is Main Differences between decoction mashing and another kind of saccharogenic method that the partially saccharifying wine with dregs is boiled this fact.Owing to boiling, the cell walls that contains grain starch is destroyed.This makes enzyme more easily arrive starch.Therefore, cook the efficiency of converted mash usually above other saccharogenic method.Another advantage of decoction mashing is to need the grain of at high temperature gelling to be boiled separately in cooking one of step.If use the additive such as corn, rice or naked barley in converted mash, this advantage can be useful.
The decoction mashing that uses in Brewing industry is to carry out with form in batches.
Described a kind of technique that in batches cooks in DE-A 1 442 292, comprised the following steps:
I., with Fructus Hordei Germinatus and water and the mixing of other compositions, obtain a kind of water-based maltase suspension;
Ii. Fructus Hordei Germinatus, Semen Maydis powder and water are mixed, obtain a kind of suspension that cooks;
Iii. make this cook suspension liquefaction, method is at first 70 ℃ of heating 30 minutes, subsequently 95-100 ℃ of heating 10 minutes;
Iv. make heat cook suspension and mix with maltase suspension, obtain converted mash;
V. converted mash is remained on 70 ℃ and reach 45 minutes; And
Vi. remove spent grains.
The paragraph middle finger goes out in page 4 bottom: " for avoiding high viscosity occurring in pulp digester, Fructus Hordei Germinatus total amount approximately 10% can be added in Semen Maydis powder ".
It will be favourable cooking continuously saccharification, and it will have several significant advantages, comprise:
● productivity improves and investment reduces: can use for a long time container, this is meaning for the turnout that equates at full capacity, and required container will be less than the container in technique in batches;
● quality is not only stable but also good: more easily control technique, this is because likely make processing parameter adapt to local and instantaneous requirement, and steady-state condition (steady-state-condition) is more highly stable;
● hygienic standard is high: continuous processing is to carry out in the system of sealing; More energy-conservation: balanced energy consumption distributes, without main purposes peak;
● more laborsaving: the carrying out of continuous processing need to personnel still less be paid close attention to;
● the number of times minimizing that pauses and clear up: the comparable batch process of continuous processing has longer running length.
In US Patent No. 3,171, a kind of continuation method of producing wort has been described in 746, the method uses a kind of secondary to cook technique, and this technique makes converted mash by Fructus Hordei Germinatus and water in mixing tank-separator, and is separated into thick converted mash and rare converted mash.Thick converted mash is under certain temperature condition, thereby proteolysis and saccharification will occur, and rare converted mash of rich enzyme is decocted, and subsequently after thick converted mash has been completed proteolysis and saccharification with thick converted mash remix.
The secondary of having described a kind of continuous production wort in DE-A 18 14 377 cooks technique, this technique is by making Fructus Hordei Germinatus mix and make converted mash with water, and the partially saccharifying wine with dregs is transported in a container, this part converted mash is subject to thermal treatment in this container, afterwards with not yet be subject to the heat treated converted mash residuum of this class remix.Then, a part of converted mash is transported in a container again, and this part converted mash is subject to thermal treatment in this container, afterwards with not yet be subject to heat treated converted mash residuum and mix.Converted mash is separated into wort and spent grains subsequently.
Described a kind of technique of continuous production wort in WO 92/12231, this technique is included in the enzymatic conversion of carrying out continuously Fructus Hordei Germinatus at least one rotating disc contactor.In the example of this patent application, the suspension that cooks that contains corn and Fructus Hordei Germinatus is maintained at 50 ℃ and reaches 5 minutes, be heated to 95 ℃ and keep 10-15 minute in rotating disc contactor, and with Fructus Hordei Germinatus/water, mix, at first the mixture that obtains subsequently is heated to 65 ℃ and kept 30 minutes, then is heated to 76 ℃ and kept 5 minutes.In this technique, the gelling and the enzyme liberating that cook starch contained therein in suspension are to complete by single thermal treatment (namely at 95 ℃, keeping 10-15 minute).That decoction mashing is used for by Fructus Hordei Germinatus and starch-containing Additive Production converted mash extract as way mentioned above herein, favourable.Therefore,, if exist a kind ofly applicable to the continuous decoction mashing by Fructus Hordei Germinatus and one or more starch-containing Additive Production converted mash extract, will be useful.
Summary of the invention
The inventor has designed a kind of method of producing continuously the converted mash extract by decoction mashing, the method has the following advantages, be it can be when using a large amount of starch-containing additives, produce high-quality converted mash extract, described starch-containing additive can be for example rice, corn, jowar, barley, wheat and/or naked barley.The characteristics of this continuation method are that it comprises the following steps:
A. the first maltase source is mixed with water, obtain water-based maltase suspension;
B. respectively the starch-containing additive of second enzyme source and one or more is mixed, obtain cooking suspension, keep simultaneously certain temperature condition, not cause significant starch gelling;
C. carry out the first thermal treatment at 60-85 ℃ to cooking suspension, so that starch part gelling simultaneously and enzymatic degradation;
D. at the higher temperature higher than the first thermal treatment temp, to cooking suspension, carry out the second thermal treatment, with under higher rate and make to a greater extent the starch gelling;
E. will be cooked by the heat that the second thermal treatment obtains suspension and mix with the water-based maltase suspension that is obtained by step a, obtain converted mash;
F. converted mash is remained on 35-85 ℃ and reach at least 20 minutes; And
G. remove spent grains from hot converted mash, obtain the converted mash extract.
In this method, the suspension that cooks that contains one or more additive is carried out multistep thermal treatment under meticulous control.In this multistep heat treatment process, gelling is occurred by boiling in starch-containing additive, and the amylase that can be comprised in subsequently in water-based maltase suspension effectively is hydrolyzed, and heat cooks suspension and mixes with water-based maltase suspension (again).Select certain condition at the first relatively gentle during Heat Treatment, so that the starch gelation rate is synchronizeed with Starch Hydrolysis speed, this is meaning the viscosity that cooks suspension and is being maintained at fully low level, so that suspension can be pumped.At much violent the second during Heat Treatment, the rapid gelling of starch, this makes it more be subject to the impact of enzymic hydrolysis, and the starch gelling is initiated when decoction and water-based maltase suspension remix.Before multistep thermal treatment, can control temperature by a certain mode, thereby avoid remarkable gelling, and viscosity is remained on low-level, to guarantee the suitable transport condition from mixing vessel to pump.Present method is extremely sane and easily controlled.In addition, can produce stay-in-grade converted mash extract by present method.
Embodiment
Therefore, the present invention relates to a kind of continuation method of producing the converted mash extract by decoction mashing, described method comprises:
A. the first maltase source is mixed with waterborne liquid, obtain water-based maltase suspension;
B. respectively the starch-containing additive of second enzyme source and one or more is mixed, obtain cooking suspension, keep simultaneously certain temperature condition, not cause significant starch gelling;
C. carry out the first thermal treatment at 60-85 ℃ to cooking suspension, so that starch part gelling simultaneously and enzymatic degradation;
D. at the higher temperature higher than the first thermal treatment temp, to cooking suspension, carry out the second thermal treatment, with under higher rate and make to a greater extent the starch gelling; To be cooked by the heat that the second thermal treatment obtains suspension and mix with the water-based maltase suspension that is obtained by step a, obtain converted mash;
E. the temperature of converted mash being remained on 35-85 ℃ reaches to minority minute; And
F. remove spent grains from hot converted mash, obtain the converted mash extract.
Above-mentioned steps a to g all preferably carries out continuously, as shown in these examples.
Term " additive " but comprise can be used as starch source and is added to any grain or fermented ingredient in converted mash as used herein.Additive can be processed or without Fructus Hordei Germinatus, process through Fructus Hordei Germinatus, the preferred latter.Additive can be selected pretreated, and these pretreatment modes can be for example torrification, peel off, boil, micronization, baking.Can use rice, corn, jowar, naked barley, oat, wheat, corn, Tapioca Starch, potato, Fructus Hordei Germinatus, barley and combination thereof for this reason.Additive preferably comes from a kind of rice, corn, jowar, barley, naked barley and and cereal of combination of being selected from.In present method additive therefor, the percent by weight of dry matter of starch typically is at least 60%, preferably is at least 70%, more preferably is at least 75%.
In the method, Fructus Hordei Germinatus can be suitable as the maltase source.Yet the present invention also comprises the commodity in use zymin, comprises starch degrading enzyme, those enzymes, particularly α-amylase, beta-amylase and/or the glucoamylase for example found in Fructus Hordei Germinatus.In addition, use Fructus Hordei Germinatus and commercial enzyme preparation within the scope of the invention, for example the Fructus Hordei Germinatus in the preparation of water-based maltase suspension and cooking commercial enzyme in the suspension preparation.In the method, preferably with the Fructus Hordei Germinatus form, use maltase.
According to of the present invention one particularly preferred embodiment, the part of the water-based maltase suspension that makes in step a is used as the second enzyme source in step b.Again more preferably, the 1-50% (weight percent) of the water-based maltase suspension that makes in step a is used as the second enzyme source in step b, and the residuum of water-based maltase suspension cooks suspension with the heat that obtains from the second thermal treatment and mixes.
The present invention includes a kind of method, wherein water-based maltase suspension is separated into two kinds of maltase suspension with different solids content, for example thick and rare converted mash suspension.Yet in step a, the composition of water-based maltase suspension is preferably identical with the composition in second enzyme source in step b.The solids content of the maltase suspension that uses in this technique is typically in the 200-500g/l scope, preferably in the 250-350g/1 scope.
When quite most fermentable sugars in the converted mash extract is while by one or more additive, being provided, the advantage of present method is the most remarkable.Therefore, in a preferred embodiment, in the converted mash extract at least 5% of fermentable sugars (weight percent), preferably at least from 10% (weight percent) and more preferably 20-90% (weight percent) come from one or more starch-containing additive.
In the method, make and cook suspension, keep simultaneously certain temperature condition, not make the remarkable gelling of starch.More preferably, these temperature condition can not make the starch gelling.Favourable way is to keep the said temperature condition, until carry out the first thermal treatment.
As mentioned above herein, relatively gentle in the condition of the first during Heat Treatment, to guarantee that gelation rate is remained on relatively low level, and make starch that enzyme liberating can occur.During the first heating steps, the viscosity of usually following the starch gelling has been offset in the partial hydrolysis of starch to be increased.Therefore, caning be controlled in the viscosity that observes between the first and second heating period increases, so that this viscosity is no more than the level that suspension can not be pumped.Upper typically be no more than 10Pa.s to the second heat treated viscosity that cooks suspension, preferably be no more than 5Pa.s, more preferably no more than 1Pa.s.Whenever mentioning in this article viscosity, described viscosity is the (caliber: 25mm of determining by the pressure reduction that records under regulation caliber and flow condition; Pipe range: 5m; Flow: 200l/hr, present the performance of Newton type fluid).
, at the first and second during Heat Treatments, make the required heating condition of starch gelling depend on to a great extent the characteristic of starch.Some starch such as barley starch starts gelling in relatively low temperature, for example 55-62 ℃.Other starch such as rice starch are much stable during gelling in trend, and in temperature significantly gelling during lower than 70-80 ℃.Therefore, the heating condition that uses in the first and second heating stepses needs and is cooking the starch type that exists in suspension and match.
In the method, favourable way is that the first thermal treatment typically comprises and being heated in 65-82 ℃ of scope cooking suspension, preferably is heated in 65-80 ℃ of scope.The first heat treated time length is preferably in 1-30 minute scope, more preferably in 2-15 minute scope.
Known indivedual starch small grain can gelling in a certain temperature range.Raise with temperature, more starch small grain gellings.With the further rising of temperature, starch small grain starts degraded, and degradation rate starts to surpass gelation rate when peak viscosity, makes viscosity start to descend.In the method, cook suspension and reach its peak viscosity at the second during Heat Treatment.After the second thermal treatment, the viscosity that cooks suspension typically is no more than 30Pa.s, preferably is no more than 10Pa.s, more preferably no more than 1Pa.s.Definite mode of these viscosity is described identical with preamble.
Favourable way is, the second thermal treatment that cooks suspension comprises and being heated in 85-120 ℃ of scope, more preferably is heated in 100-120 ℃ of scope.The second heat treated time length is preferably in 1-30 minute scope, more preferably in 2-15 minute scope.
According to a particularly preferred embodiment, the first and second thermal treatments that cook suspension comprise steam treatment.The advantage of annotating evaporation is can realize being rapidly heated without staining heat exchange surface.In first thermal treatment of present method, preferably do not use the rotating disc contactor of describing in patent WO 92/12231.Similarly, preferably do not use this device in the second thermal treatment.
According to another preferred embodiment, cook suspension after the second thermal treatment and be cooled to 60-100 ℃ before water-based maltase suspension mixes.Before heat cooks suspension and water-based maltase suspension mixes, that heat is cooked suspension is cooling, can effectively control thus the temperature of gained converted mash.
In the method,, by the starch-containing additive of second enzyme source and one or more is mixed, make and cook suspension.Favourable way is to sneak into other water in the preparation that cooks suspension.Cook the solids content of suspension typically in the 200-500g/l scope, preferably in the 220-400g/l scope.According to a particularly preferred embodiment, water-based maltase suspension is maintained in the 250-350g/l scope with the solids content that cooks suspension.
After the second thermal treatment, will be kept under certain condition by the converted mash that cooks suspension and the acquisition of water-based maltase suspension remix, to be conducive to the enzymic hydrolysis of jelling starch.During this section of present method, starch is converted into fermentable sugars in liquefaction and these two stages of saccharification.Liquefaction comprises that starch is degraded to compounding sugar (dextrin) under the effect of for example α-amylase.When liquefaction stage was completed, converted mash cannot not become stickingly manyly.Under the effect of the enzyme such as glucoamylase and beta-amylase, compounding sugar is fermentable sugars by saccharification or Degradation and Transformation.In the method, typically by the temperature with converted mash remain in 35-85 ℃ of scope, preferably in 40-80 ℃ of scope, realize liquefaction and saccharification., for making starch suitably be converted into fermentable sugars, usually require to stop at least 20 minutes at said temperature.In residence time that these temperature are used preferably in 30-120 minute scope, more preferably in 40-110 minute scope.
At water-based maltase suspension and/or in cooking the preparation of suspension, present method can suitably be used tap water or spring.Yet,, according to a particularly preferred embodiment, for the production of the waterborne liquid (preferably also comprise and cook suspension) of water-based maltase suspension, the recirculation that is derived from the production of converted mash extract, wash current.Use the advantage of these class recirculation washing current to be, can be in the situation that need not to use large water gaging, the high extract content of acquisition.Simultaneously, recirculation makes likely when realizing so high extract content, produces hyperbaric converted mash extract.
Therefore, in of the present invention one particularly advantageous embodiment, the production stage of converted mash extract is as follows:
A. hot converted mash is transported in the first separator, converted mash is separated into converted mash extract and spent grains;
B. spent grains is transported in the first mixing vessel, and uses water spray to mix;
C. the mixture of spent grains and water spray is transported in the second separator, removes spent grains;
D. will be recycled in the production of water-based maltase suspension from the aqueous solution stream of the second separator.
Term " separator " comprises applicable to any device of isolating solid from liquid as used herein.Example applicable to the separator of present method comprises: whizzer, decanting vessel, settling vessel, hydrocyclone, sieve, strainer, filter membrane and pressure filter.In the method, certainly can use the combination (for example decanting vessel and sieve) of dissimilar separator.The separator that uses in this technique is preferably selected from whizzer, decanting vessel and sieve, more preferably is selected from decanting vessel and whizzer, most preferably is decanting vessel.
It should be understood that whenever mentioning the first separator, the second separator, the 3rd separator etc., in fact this class first, second or the 3rd separator can comprise two or more tripping devices, the common separate solid of these tripping devices and liquid.These two or more tripping devices can walk abreast and/or the serial operation.For example, favourable way can be to use the separator that consists of a series of sieves, and wherein the pore size of sieve reduces along downstream direction.Equally, favourable way can be to use sequence whizzer and/or a decanting vessel, and the centrifugal force that wherein applies increases along downstream direction.Favourable way can be also, especially when technique is carried out continuously, the some parallel tripping devices of operation.When far below under full capacity during parallel running, a tripping device breaks down or shuts down the converted mash extraction process is interrupted, and this is meaning this technique and can carry out incessantly for a long time.
When two or more tripping device parallel runnings, the proportion of the converted mash extract that is obtained by separator refers to by the mean specific gravity that forms the converted mash extract that two of separator or more tripping devices obtain.When two or more tripping device serials operation, the proportion of the extract that is obtained by separator refers to the proportion of the extract that is obtained by last tripping device.
As separator, the mixing vessel that uses in this technique in fact also can comprise the mixing device of two or more serial or parallel operations.
Use the aforesaid recirculation washing water of this paper can make hyperbaric converted mash extract, for example the proportion of converted mash extract is 15 ° of P or higher.The special embodiment of this of present method can reach very high efficiency with regard to power consumption and extract content.In addition, can realize high productivity in the operation of distillery.
When the proportion of the converted mash extract that is obtained by the first separator surpassed 18 ° of P, the advantage of present method was particularly remarkable.The proportion of converted mash extract more preferably surpasses 20 ° of P, more preferably surpasses again 25 ° of P.In a particularly preferred embodiment, the proportion of the converted mash extract that is obtained by the first separator surpasses 28 ° of P, most preferably surpasses 30 ° of P.
People are unexpected to be found, although the proportion of the converted mash extract that is obtained by present method is high, the extract loss that observes in the method is typically lower than 5% (weight percent), preferably lower than 4% (weight percent), more preferably less than 3% (weight percent), most preferably lower than 2% (weight percent).The efficiency of back preferably realizes by whole wort production technique, comprises that the converted mash separation separates with residue.In the production of converted mash extract, the loss amount of extract can suitably be determined in the following manner, namely by use, is used for determining the standard method in wort extract concentration, the concentration (density measurement that for example adopts Anton Paar to carry out) of measurement extract in liquid spent grains.Owing to lacking free fluid in the dehydration spent grains, described available hot water extracts spent grains easily, subsequently by filtering to isolate useless spent grains.The extract loss can be drawn by the extract level calculation that records in extract, and the water yield of adding is taken into account.
Especially when present method is used three of sequences or more separators, can very effectively reduce to the full extent the loss of extract.Therefore, a preferred embodiment of the present invention relates to a kind of aforesaid method of this paper, and described method also comprises:
A. will be transported to the second mixing vessel by the spent grains that the second separator obtains, and use water spray to mix;
B. the mixture of spent grains and water spray is transported in the 3rd separator, removes spent grains; And
C. when ejecting water to the first mixing vessel, will carry out recirculation from the aqueous solution stream of the 3rd separator.
The proportion that the aqueous solution that is obtained by the second separator flows is typically in 1-10 ° of P scope, preferably in 1-8 ° of P scope.The proportion that the aqueous solution that is obtained by the 3rd separator flows is typically very low, shows that spent grains is useless substantially.From the proportion of the aqueous solution of the 3rd separator stream preferably in 0.1-2 ° of P scope, more preferably in 0.1-1.5 ° of P scope.The proportion that the aqueous solution that is obtained by the second and the 3rd separator flows depends on the concentration of the extract that obtains in elementary converted mash extract consumingly.
, in the situation that the extract loss reduction is produced hyperbaric converted mash extract, preferably will be recycled in saccharification step by whole aqueous solution streams that the second separator obtains.In saccharification step, except the stream of the aqueous solution from the second separator, also can use the aqueous solution stream (for example from the yeast washing) that is produced by the distillery downstream.Typically form at least 80% (weight percent) of total amount of liquid used, preferred at least 90% (weight percent) from the recirculation water-based liquid of the second separator stream in saccharification step.Most preferred way is that all saccharification liquid that use in saccharification step are the recirculation water-based liquid stream from the second separator.
Can further illustrate the present invention by following example.
Embodiment
Example 1
136kg/hr sledge mill malt meal liquid stream is arrived in the 70l continuous stirred tank reactor by dosing, and at 50 ℃, with the 313kg/hr brewing water, mixes.After this, a part that is called as the mixture of ' converted mash ' is transferred (340l/hr) in the vertical cylindrical plug flow reactor.This malt amylase mash stream provides essential enzyme (starch degrading enzyme), to be reduced in the viscosity of during Heat Treatment in reactor.Reactor used type is described in Heineken patent (WO 92/12231) more early.The remainder of converted mash is pumped in the 50l continuous stirred tank reactor, at this 59kg/hr Semen Maydis powder liquid stream, by dosing, is arrived in 140kg/hr water.The temperature of combination liquid stream is 50 ℃, and this is far below the gelation temperature of W-Gum.For make starch gelling and the liquefaction in corn by the enzyme effect, the suspension of malt mash, Semen Maydis powder and water, by directly steam treatment, makes temperature be raised to 78 ℃.At this temperature, the much starch gelling, but also by maltase, liquefied.If there is no these enzymes, starch can form a kind of thick paste at once, and disabling facility.After this heats up for the first time, can make enzyme act on starch and reach 5 minutes in 1 meter long plug flow reactor.Subsequently, carry out another direct steam treatment and process, make temperature be raised to 100 ℃, starch small grain passes through in this temperature, was similarly stopping 5 minutes and complete gelation in plug flow reactor.
The liquid stream (cooking liquid stream) that comprises the complete gelation starch small grain also is pumped in above-mentioned stirring plug flow reactor this moment, and it mixes with malt amylase mash stream at this.Temperature is that the malt amylase mash stream that liquid stream and temperature are 50 ℃ that cooks of 100 ℃ mixes, and forms total mellow solution of saccharification and flows, and temperature is 65 ℃.Use heating jacket that saccharification temperature is controlled at 67 ℃.At the top of tower, converted mash is heated cover and is heated to 78 ℃, and whole reactor is insulated, thermosteresis is reduced to minimum.The total residence time of converted mash in tower is 65 minutes, and the converted mash that makes is transported to the converted mash centrifugal station.
By two decanting vessels, Fructus Hordei Germinatus shell and other solids are separated from converted mash.These decanting vessels are the Scroll-type settling centrifuge, and clarified liq and multiviscosisty spent grains are by continuous blow-down.The speed of rotation of the first decanting vessel is 3500rpm, and differential screw speed is 2rpm.The theoretical utilization ratio of this decanting vessel is 1700m
2.
The theoretical utilization ratio of decanting vessel (SIGMA value) is to calculate according to the relation between following factors: the length of rotatingcylindrical drum (L), universal gravity constant (g), circular frequency (ω), lock ring (dam ring) or the radius (r1) of overflow ring and the radius (r of rotatingcylindrical drum
2).
Product (converted mash extract) is dumped into next unit operation (boiling), and spent grains is released in small-sized continuous stirred tank reactor.In the latter, use 80 ℃ of washing water of 506l/hr, the residence time is 13 minutes, and spent grains particulate and water are evenly mixed.
The liquid phase mixture that makes is separated in the second decanting vessel, and the differential screw speed during this second decanting vessel operation is 2rpm, and rotating speed is 4000rpm, and theoretical utilization ratio is 1800m
2.After clarification, the supernatant liquid of liquid is recycled, and with the oral fluid stream that goes out of saccharification tower, mixes, and the gained mixture is as the charging of the first decanting vessel.Extract concentration from the product liquid of the first decanting vessel stream is 14.8 ° of P.Two decanting vessels all are equipped with centrifugal blower, thereby can be used as the pump in the supernatant liquid outlet.
Separate by converted mash the product that makes and now be called as wort, flow is 1030kg/hr.The hops extract is with the continuously online dosing of speed quilt of 140g/hr, and this mixture is heated to 102 ℃ by direct steam treatment.By the positive pressure head of the first decanting vessel, wort is pumped in plug flow reactor.This tower reactor has identical characteristic with the previous saccharification converter of describing.The volume of this reactor is 1m
3, the residence time is 60 minutes.The type reaction that occurs in this reactor is as follows: protein denaturation and cohesion, sterilization, hops isomerization, form color, by its Fructus Hordei Germinatus based precursor (S-methylmethionine), make dimethylsulphide (dimethylsulphide, DMS).
Wort is processed in the sieve plate shape stripping tower that previous Heineken patent (WO 95/26395) is described subsequently.Use 1.5bar steam in counter-current operation, with under 15kg/h flow and atmospheric condition, remove the nonconforming flavoursome compound (being mainly DMS) at the stripping tower top.The wort that leaves the stripping tower bottom is transported in the insignificant minibuffer of size, and is delivered directly in discharging at intermittence type whizzer.The rotating speed of this machine is 7400rpm, and theoretical utilization ratio is 13000m
2.
The theoretical utilization ratio of whizzer is according at " Solid-Liquid Separation ", 2nd edition, and 1981, by Ladislav Svarovsky, the method for describing in Butterworth-Heineman is calculated.This utilization ratio is to calculate according to the relation between following factors: disk quantity (n), universal gravity constant (g), circular frequency (ω), the angle (α) with disk of vertical feed-pipe, disc assembly internal diameter (r
1) and disc assembly external diameter (r
2).
Then, cooling wort in two parallel plate and frame wort coolers, these two water coolers are by two-stage water-ethylene glycol device, drop to 8 ℃ with the temperature of wort from 95-100 ℃.
Cumulative volume is 2.2m
3Cold wort be that the live yeast of 2.5g/l is transported in cylindrical/conical fermentor tank continuously together with concentration.Carry out continuous oxidation by online aeration.Elementary batch fermentation carries out at 10 ℃, and when extract concentration reaches 6.5 ° of P, can make temperature be raised to 13 ℃.After the concentration of dimethylglyoxal dropped to the level of 30ppm, in groove, thing was cooled to-1.5 ℃ after 24 hours.This state of cooling is held to reach 6 days.
Then, beer is filtered by the limpid beer filter of vertical disc type diatomite.After this filtered, beer was stablized under the PVPP of dosage usually and essential PVPP filter.Finally, beer is packaged in appropriate containers (vial).
Example 2
120kg/hr sledge mill malt meal liquid stream is arrived in the 70l continuous stirred tank reactor by dosing, and 50 ℃ of temperature, with the 240kg/hr brewing water, mixes.After this, a part that is called as the mixture of ' converted mash ' is transported in the described vertical cylindrical plug flow reactor of example 1.
Flow is that additive 100kg/hr, that exist with rice powder form, that processed without Fructus Hordei Germinatus is arrived in the 50l continuous stirred tank reactor by dosing, wherein adds the 210kg/hr current are arranged.Heat-resisting starch degrading enzyme is by dosing, to be reduced in the viscosity in postheat treatment.The temperature of the mixture that makes is 50 ℃, far below the gelation temperature of rice starch.For make starch gelling and the liquefaction in rice by the enzyme effect, the suspension of rice powder, enzyme and water, by directly steam treatment, makes temperature be raised to 78 ℃.At this temperature, the much starch gelling, but also by the Starch Hydrolysis enzyme liquefaction.If there is no these enzymes, starch can form a kind of thick paste at once, and disabling facility.After this heats up for the first time, can make enzyme act on starch and reach 5 minutes in 1 meter long plug flow reactor.Subsequently, carry out another direct steam treatment and process, make temperature be raised to 100 ℃, starch small grain passes through in this temperature, was similarly stopping 5 minutes and complete gelation in plug flow reactor., for obtain suitable saccharification temperature (in this example being 67 ℃) when with malt mash, mixing, cook liquid stream and be cooled to proper temperature in shell and tube heat exchanger.
This cold liquid stream also is pumped in above-mentioned stirring plug flow reactor, and it mixes with malt amylase mash stream at this.Use heating jacket that saccharification temperature is controlled at 67 ℃.At the top of tower, converted mash is heated cover and is heated to 78 ℃, and whole reactor is insulated, thermosteresis is reduced to minimum.The total residence time of converted mash in tower is 60 minutes, and the converted mash that makes is transported to the converted mash centrifugal station.
By two decanting vessels, Fructus Hordei Germinatus shell and other solids are separated from converted mash.These decanting vessels are the Scroll-type settling centrifuge, and clarified liq and multiviscosisty spent grains are by continuous blow-down.The speed of rotation of the first decanting vessel is 3500rpm, and differential screw speed is 3rpm.The theoretical utilization ratio of this decanting vessel is 1700m
2.Product (converted mash extract) is dumped into next unit operation (boiling) by the first decanting vessel, and spent grains is released in small-sized continuous stirred tank reactor.In the latter, use 80 ℃ of washing water of 510l/hr, the residence time is 13 minutes, and spent grains particulate and water are evenly mixed.
The liquid phase mixture that makes is separated in the second decanting vessel, and the differential screw speed during this second decanting vessel operation is 3rpm, and rotating speed is 4000rpm, and theoretical utilization ratio is 1800m
2.After clarification, the supernatant liquid of liquid is recycled, and before entering the first decanting vessel, with the converted mash from the saccharification tower, mix.Extract concentration from the product liquid of the first decanting vessel stream is 16.4 ° of P.Two decanting vessels all are equipped with centrifugal blower, thereby can be used as the pump in the supernatant liquid outlet.
Separate by converted mash the product that obtains and be called as wort, the hops extract is with the continuously online dosing of speed quilt of 120g/hr, and this mixture is heated to 102 ℃ by direct steam treatment.By the positive pressure head of the first decanting vessel, wort is pumped in plug flow reactor.This tower reactor has identical characteristic with the previous saccharification converter of describing.The volume of this reactor is 1m
3, and the residence time be 60 minutes.The type reaction that occurs in this reactor is as follows: protein denaturation and cohesion, sterilization, hops isomerization, form color, by its Fructus Hordei Germinatus based precursor (S-methylmethionine), make dimethylsulphide (dimethylsulphide, DMS).
Wort is processed in the sieve plate shape stripping tower that previous Heineken patent (WO 95/26395) is described subsequently.Use the steam of 1.5bar in counter-current operation, with under 15kg/h flow and atmospheric condition, remove the unwelcome flavoursome compound (being mainly DMS) at the stripping tower top.The wort that leaves the stripping tower bottom is transported in the insignificant minibuffer of size, and is delivered directly in discharging at intermittence type whizzer.The rotating speed of this machine is 7400rpm, and theoretical utilization ratio is 13000m
2.To the analysis showed that of wort, final dilution limit is 82-83%.
Then, cooling wort in two parallel plate and frame wort coolers, these two water coolers are by two-stage water-ethylene glycol device, drop to 8 ℃ with the temperature of wort from 95-100 ℃.
Cumulative volume is 2.2m
3Cold wort be that the live yeast of 2.5g/l is transported in cylindrical/conical fermentor tank continuously together with concentration.Carry out continuous oxidation by online aeration.Elementary batch fermentation carries out at 10 ℃, and when extract concentration reaches 6.5 ° of P, can make temperature be raised to 13 ℃.After the concentration of dimethylglyoxal dropped to the level of 30ppm, in groove, thing was cooled to-1.5 ℃ after 24 hours.This state of cooling is held to reach 6 days.
Then, beer is filtered by the limpid beer filter of vertical disc type diatomite.After this filtered, beer was stablized under the PVPP of dosage usually and essential PVPP filter.Finally, beer is packaged in appropriate containers (vial).
Example 3
By the mixture that uses malt meal and the Semen Maydis powder of processing without Fructus Hordei Germinatus to form, making flow at wort production technique tail end is 4.5m
3The mashing water stream of/hr, extract concentration is 18 ° of P.This wort is fermented and slaking in continuous fermenter, and is being stablized in storage tank subsequently in batches, and separated and be filtered on limpid beer filter in whizzer.Detailed description to making method sees below.
At this technique head end, 1620l/hr brewing water (47 ℃) mixes continuously with the 720kg/hr malt meal.This malt meal is to be made by the hammer mill that is equipped with the 2.5mm sieve aperture.Two liquid streams are transported in the continuous stirred tank reactor that working volume is 80l at 45 ℃.The part of the malt amylase mash stream that makes is introduced to follow-up plug flow saccharification tower, and this saccharification tower is similar with description in example 1.Other parts (250l/hr) of malt amylase mash stream are transported in a parallel technique, and this technique can allow the finally additive of beer product of the Semen Maydis powder conduct of will be not processing with Fructus Hordei Germinatus.
In this continuous boiling goes out technique, the Semen Maydis powder of with Fructus Hordei Germinatus, not processing, together with the brewing water of 52 ℃ (790kg/hr) stream and above-mentioned malt mash stream, be transferred (350kg/hr) in continuous stirred tank reactor.The temperature of the liquid that obtains in this 120l container stream combination is 50 ℃, and this temperature is enough low, with the excessive gelling of avoiding W-Gum and relevant viscosity, increases.Mixture is pumped in the first storage column by direct steam treatment point.Steam treatment, be raised to 75-78 ℃ with the temperature that will cook liquid stream, and make the gelling of part W-Gum.Yet owing to there being a part of wort converted mash, the amylase that is made by Fructus Hordei Germinatus can make the polymerization starch bacterial strain decompose, and makes its reduced viscosity.Stop and can make viscosity drop to a level in 15 minutes at assigned temperature, in this levels of viscosity, can make again temperature be raised to 100 ℃ and can not cause unacceptable high viscosity.Stopped 5 minutes by another direct steam treatment and in simple plug flow reactor, carry out this second step.The gelling mixture that obtains is cooled to 90 ℃, and is transported to subsequently in the saccharification tower, and at this, with separated malt amylase mash stream, mixes.Make thus the mixed solution stream with certain temperature, this temperature is optimum for amylase activity and Fructus Hordei Germinatus and corn to the conversion fully of sugar.
The cylindrical plugs flow reactor that is used for Mashing process is described in previous Heineken patent (WO92/12231).At the certain height place of top of tower, by direct steam treatment heating converted mash.Select temperature, so that Fructus Hordei Germinatus starch is to the suitable product needed of the conversion of fermentable sugars.There is saccharification rest in this temperature profile in the time of 66 ℃, have saccharification when departing from 76 ℃.The residence time of converted mash is 80 minutes, and the converted mash that makes is transported to the converted mash centrifugal station.
The converted mash centrifugal station consists of two Scroll-type settling centrifuges that are commonly called decanting vessel, and clarified liq and multiviscosisty spent grains are by continuous blow-down.Rotating speed during the first decanting vessel operation is 3650rpm, and differential screw speed is 10rpm, and theoretical utilization ratio is 6200m
2.Product (converted mash extract) is dumped into next unit operation (boiling) by the first decanting vessel, and spent grains is released in small-sized continuous stirred tank reactor.In the latter, use 72 ℃ of washing water of 1150l/hr, the residence time is 2 minutes, obtains thus uniform suspension.The liquid phase mixture that makes is separated in the second decanting vessel, and the rotating speed during this second decanting vessel operation is 4000rpm, and differential screw speed is 20rpm, and theoretical utilization ratio is 2600m
2.After clarification, the supernatant liquid of liquid is recycled, and with the oral fluid stream that goes out from the saccharification tower, mixes.This makes the extract concentration in the first decanting vessel charging drop to approximately 17 ° of P.The spent grains that is made by the second decanting vessel is dumped in silo.Two decanting vessels all are equipped with centrifugal blower, thereby can be used as the pump in the supernatant liquid outlet.
Separate by converted mash the product that makes and now be called as wort, and flow is 4.5m
3/ hr.The hops extract is with the online dosing of speed quilt of 32g/hr, and this mixture is heated to 105 ℃ by direct steam treatment.By the positive pressure head of the first decanting vessel, wort is pumped in plug flow reactor.This tower reactor has identical characteristic with the previous saccharification converter of describing, but height increases in proportion with the increase of flow in this part technique.Therefore the residence time is 67 minutes.The type reaction that occurs in this reactor is as follows: protein denaturation and cohesion, sterilization, hops isomerization, form color, by its Fructus Hordei Germinatus based precursor (S-methylmethionine), make dimethylsulphide (dimethylsulphide, DMS).
Wort is processed in the sieve plate shape stripping tower that previous Heineken patent (WO 95/26395) is described subsequently.Use the steam of 1.5bar in counter-current operation, with under 100kg/hr flow and atmospheric condition, remove unwelcome flavoursome compound (being mainly DMS).The wort that leaves the stripping tower bottom is transported in the insignificant minibuffer of size, and is delivered directly in discharging at intermittence type whizzer.The rotating speed of this machine is 7400 rev/mins, and the SIGMA value is 70000m
2.
By two parallel cooling worts of plate and frame wort cooler, these two water coolers are by two-stage water-ethylene glycol device, drop to 4 ℃ with the temperature of wort from 95-100 ℃.
Cooled wort is transported in the first agitated fermentation vessel, and its clean working volume is 14m
3.The inflation recycle stream that this container is made by the process downstream end by continuous adding, operate under 10 ℃ and aerobic condition, this inflation recycle stream comprises the multiviscosisty yeast, and the multiviscosisty yeast is the main component beyond dewatering.The proportion of material is 13 ° of P in this container.The fermentation required yeasts is that the form with above-mentioned recycle stream is added.
The fermented liquid that is made by the first fermenting container is transported to second container.The working volume of this container is 160m
3, and by the cold mode of wall, be maintained at 13 ℃.The initial specific gravity of material is 7 ° of P in this container, and yeast concn is the wet yeast/l of 80g.The effluent liquid stream of this container is divided into two liquid streams: a part (2.5m
3/ hr) with another liquid stream that makes at the technique tail end, mix, and be recycled to the first fermenting container, and another part (5.3m
3/ hr) be transported in the 3rd fermenting container.
The working volume of the 3rd container is 140m
3, and the initial specific gravity of its content is 3.5 ° of P.It is 7m that the product of this container is transported to working volume
3The yeast settling vessel in.This yeast settling vessel is separated the major portion of yeast (90-95%) from green beer.The yeast concn of the compacting yeast bottom the yeast settling vessel is the wet yeast/l of 200g.The part of this liquid stream is recycled to the zymotechnique head end, and another part is transported to useless surplus yeast hiding-place.Can, according to the quantity of leaving yeast settling vessel top and the yeast quantity of growing in fermenting container, control part and be transported to the yeast at residuum place.Be transported to continuously in batches in ripening tank or in the continuous ripening container from the green beer at yeast settling vessel top.
For the batch process mode, the working volume of ripening tank equates with the cumulative volume of the fermenting wort that made in 24 hours.Can by the heat exchange to ripening tank and/or natural heat of fermentation exploitation from pipeline, temperature be raised to 15 ℃.This temperature is conducive to the conversion of acetylactis (a kind of metabolism tunning) to dimethylglyoxal.Because yeast is in this state, yeast can absorb dimethylglyoxal, and it is converted into acetoin or follow-up metabolite.So, can eliminate the disadvantageous effect of dimethylglyoxal in beer, and the level of residue dimethylglyoxal is confirmed as typically＜20ppb.After dimethylglyoxal had dropped to acceptable level, beer was cooled to-1.5 ℃, and is stored several days.After this period, beer is through diatomite filtration, and 80-100g/l diatomite is used as main body charging (bodyfeed).Before filtration, beer is 70,000m by theoretical utilization ratio
2The disc separator centrifugation, to remove whole suspended solidss, efficiency is 95-98%.The typical filtration is at 4-5.5hl/m
2Under/hr flow and move under 6000-8000hl.After this filtered, beer was stablized under the PVPP of dosage usually and essential PVPP filter.Finally, beer is packaged in appropriate containers (bottle, keg, jar).
When using continuous curing process, green beer is transported to 520m continuously by the spray ball
3The top of container, this spray ball is with the whole surf zone of beer dispense at groove.In this embodiment, beer is heated to 15 ℃ by shell and tube heat exchanger from 13 ℃.This will speed up the conversion of the above-mentioned α-acetylactis that forms during primary fermentation to dimethylglyoxal.Yeast will settle down in beer, and will carry out above-mentioned dimethylglyoxal and the conversion of other adjacent diketone to acetoin and follow-up metabolite.In this embodiment, the residence time of beer is 100 hours, and the level of residue dimethylglyoxal is 7.3 ± 2.3ppb (95%CI, n=6).Yeast is deposited in the conical lower section of ripening tank, and is removed, and is used as static beer.Slaking beer is removed directly over sedimentation yeast cone, and by the groove of refrigeration in batches that the Continuous Heat Transfer device is-1.5 ℃ to temperature, carries.
The refrigeration groove was filled in one day, and beer is stored in-1.5 ℃ and reaches at least 2 days subsequently.After this storage period, the precipitation yeast is washed and removes from the bottom of groove, and residue beer is separated on disc centrifuge as above.After this processing, beer is filtered by kieselguhr filter immediately, and exemplary traffic is 4-5.5hl/m
2/ hr, filtration yield are 6000-8000hl.
Beer is being processed by PVPP by after stable, is packaged in the wrapping material of requirement (bottle, jar, keg).
Claims (11)
1. continuation method of producing the converted mash extract by decoction mashing, described method comprises following step of all carrying out in a continuous manner:
A. the first maltase source is mixed with waterborne liquid, obtain water-based maltase suspension;
B. respectively the starch-containing additive of second enzyme source and one or more is mixed, obtain cooking suspension, keep simultaneously certain temperature condition, not cause significant starch gelling;
C. carry out the first thermal treatment at 65-85 ℃ to cooking suspension, so that the part gelling simultaneously of described starch and enzymatic degradation;
D. at 85-120 ℃, the described suspension that cooks is carried out the second thermal treatment, with under higher rate and make to a greater extent described starch gelling;
E. will be cooked by the described heat that described the second thermal treatment obtains suspension and mix with the described water-based maltase suspension that is obtained by step a, obtain converted mash;
F. described converted mash is remained on 35-85 ℃ and reach at least 20 minutes; And
G. remove spent grains from described hot converted mash, obtain the converted mash extract;
Wherein said described the first thermal treatment and described the second thermal treatment that cooks suspension comprises steam treatment, and the wherein said viscosity that cooks suspension is until all be no more than 1Pa.s after the second thermal treatment.
2. method according to claim 1, it is characterized in that: the part of the described water-based maltase suspension that makes in step a is used as the described second enzyme source in step b.
3. method according to claim 2, it is characterized in that: the 1-50% weight percent of the described water-based maltase suspension that makes in step a is used as the described second enzyme source in step b, and the residuum of described water-based maltase suspension cooks suspension with the described heat that obtains from described the second thermal treatment and mixes.
4., according to any one the described method in aforementioned claim, it is characterized in that: at least 5% weight percent that is included in the fermentable sugars in described converted mash extract comes from described one or more starch-containing additive.
5., according to any one the described method in aforementioned claim, it is characterized in that: the composition of the maltase of water-based described in step a suspension is identical with the composition in second enzyme source described in step b.
6., according to any one the described method in aforementioned claim, it is characterized in that: described starch-containing source of additive is in a kind of cereal that is selected from rice, corn, jowar, naked barley, oat, wheat, Tapioca Starch, potato, Fructus Hordei Germinatus, barley and combination thereof.
7., according to any one the described method in aforementioned claim, it is characterized in that: the pretreatment mode of described starch-containing additive comprises torrification, peels off, boils, micronization or baking.
8., according to any one the described method in aforementioned claim, it is characterized in that: described cook suspension after described the second thermal treatment and be cooled to 60-100 ℃ before described water-based maltase suspension mixes.
9., according to any one the described method in aforementioned claim, it is characterized in that:, by described second enzyme source and one or more starch-containing additive and other water are mixed, make the described suspension that cooks.
10., according to any one the described method in aforementioned claim, it is characterized in that: described maltase suspension and the described solids content that cooks suspension are maintained in the 200-500g/l scope.
11. any one the described method according in aforementioned claim is characterized in that: for the production of described water-based maltase suspension and the described described water that cooks suspension, be to wash current from the recirculation of described converted mash extract Production Flow Chart.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP06114264 | 2006-05-19 | ||
| EP06114264.2 | 2006-05-19 | ||
| EP06114242 | 2006-05-19 | ||
| EP06114242.8 | 2006-05-19 | ||
| PCT/NL2007/050207 WO2007136252A1 (en) | 2006-05-19 | 2007-05-14 | A continuous method of producing a mash extract |
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| CN101490237A CN101490237A (en) | 2009-07-22 |
| CN101490237B true CN101490237B (en) | 2013-11-13 |
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| CN2007800265049A Expired - Fee Related CN101490237B (en) | 2006-05-19 | 2007-05-14 | A continuous method of producing a mash extract |
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Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE1442292A1 (en) * | 1965-04-07 | 1968-11-21 | Pfizer & Co C | Process for the production of wort |
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Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE1442292A1 (en) * | 1965-04-07 | 1968-11-21 | Pfizer & Co C | Process for the production of wort |
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