IE84831B1 - Improvements in and relating to the steeping of barley - Google Patents

Abstract

ABSTRACT There is illustrated a steeping system (1) comprising three steeping vessels, namely initial (2), intermediate (3) and final (4) steeping vessels. Steeping with rousing through concentric aeration rings (7) and a lift tube (30) is performed in the initial steeping vessel (2) with overflow to thoroughly wash and clean and grain, as well as to provide a certain amount of moisture intake. Various altering steeping and resting operations are performed in each of the vessels, while Continuously monitoring the temperature, the moisture content and the germination capacity of the barley, so as to be able to alter the process, depending on the condition of the barley.

Description

Improvements in and relating to the steeping of barley Introduction The present invention relates to a process of steeping barley for subsequent malting in a steeping system. It is known to provide cylindroconical vessels, commonly called conical steeping vessels, consisting of three conical steep vessels arranged one above the other with the barley passing through them sequentially during steeping.

Such steeping vessels have in the past been only somewhat successful.

Unfortunately, for the portions of the grain which are in the lower part of the cone forming the base, problems can occur during steeping. With the water uptake, the metabolic processes and consequently the respiration are continuously intensified.

The present invention is directed towards overcoming the problems of steeping, while at the same time using conical steep vessels which are available in many a malting house.

Statements of Invention According to the invention, there is provided a process of steeping barley for subsequent malting in a steeping system comprising three vertically arranged, one above the other, steeping vessels, namely a highest initial, an intermediate and a lowest final steeping vessels, each steeping vessel having cylindrical sides, terminating in a conical base, a water inlet manifold and outlet manifold in the base and a plurality of sets of circumferentially arranged and spaced-apart aeration rings in the base, the initial steeping vessel additionally having an overflow receiving channel around its periphery and a central rousing tube open at both ends, the rousing tube being spaced-apart from and adjacent the base and in communication with a pressurised air inlet pipe for delivering barley up through the rousing tube for recirculation of the barley and a conical protective cover is mounted above the rousing tube and spaced-apart therefrom, the system further comprising control means comprising data recording and control means and a systems database, the control means being connected to temperature, moisture content and germination capacity monitors for the vessels to control the operating parameters of the process, the process comprising: for each variety of barley being malted prior to acceptance of the variety for steeping, carrying out a micro-malting process on a sample to determine optimum steeping parameters; storing the parameters in the database together with the characteristics of the barley including at least the variety and where grown; and then prior to commencing the steeping, obtaining the parameters stored and setting the steeping parameters having regard to the stored parameters; during the steeping, recording and storing the actual parameters in the database for subsequent use with barley having those characteristics; from time to time carrying out a further micro-malting process on other barley; then on receiving a batch of barley for steeping, the steps are performed of: (a) delivering water and barley into the initial steeping vessel; (b) delivering further water into the initial steeping vessel to cause overflow into the overflow receiving channel while rousing and aerating the barley using the lift tube and aeration rings; (c) stopping the rousing, and adding potassium permanganate; (d) transferring the wet barley and water to the intermediate steeping vessel; (e) steeping the barley with intermittent aeration by the aeration rings in the intermediate steeping vessel; draining the water; allowing the drained barley to rest while extracting CO; from above the barley and intermittently spraying the barley with water; filling the intermediate steeping vessel with water; steeping the barley with intermittent aeration using the aeration rings; transferring the barley and water to the final steeping vessel; steeping the barley with intermittent aeration in the final steeping vessel; draining the water; allowing the drained barley to rest while extracting CO2 from above the barley and intennittently spraying the barley with water; filling the final steeping vessel with water; steeping the barley with intermittent aeration in the final steeping vessel; delivering the wet barley onwards for germination; and in which additionally: during each resting step (g) and (m), wetting the barley every two hours for between 0.01 and 0.03 hours and checking the temperature of the barley and if the temperature exceeds 25°C, the additional steps of filling the steeping vessel and draining the steeping vessel are performed prior to continuing with the resting step (g) and (m); adding the water at between 11°C and 13°C for each steeping step (b), (9). (i). (K) and (0); and continuously monitoring the temperature, the moisture content and germination capacity of the barley and when, during the last resting step (g) and (m) in the intermediate steeping vessel and the final steeping vessel, the moisture content of the barley is below 32% and 42% respectively, the appropriate resting step (g), (m) is prolonged with additional wetting until the required moisture content is achieved.

The advantage of this is that by the use of the aeration rings, it is possible to obtain much better and more even uptake of moisture and to avoid the quality problems heretofore experienced in such steeping vessels. While such aeration rings are well known, their use in combination with the rousing tube in the initial steeping vessel is particularly advantageous. Further, the use of the first steep tank as an initial steeping vessel, rather than just simply a washing vessel, has led to a greatly improved malt quality and malt homogeneity.

The main advantage of the present invention, however, relates to the tighter control of the process and the setting of suitable parameters, prior to commencing steeping.

The problem is that it is becoming more and more complex and complicated for the operative to control. Further, availability of competent and skilled operatives is often a problem. Indeed, as everybody is aware, who has ever operated such a plant, the difficulty in getting the operatives to control the operation correctly and use the correct operating parameters is a major problem.

The present invention obviates a considerable amount of these problems by removing most of the decision making from the operative who then becomes more a minder of the plant, rather than an actual controller of it.

Ideally, the characteristics stored additionally comprise one or more of: Batch number; Start date and time; Silo number; Vessel group Steeping method Ideally, the micro—malting process is carried out on each variety at least once a year prior to commencing steeping while the barley is in storage.

In one process according to the invention, in relation to the initial steeping vessel: step (b) of rousing the barley is carried out for between 0.25 and 0.45 hours.

In one process according to the invention, in the intermediate steeping vessel: step (e) of steeping the barley is carried out for between 4 and 8 hours; step (g) of resting the barley is carried out for between 10.5 and 16.5 hours; step (i) of steeping the barley is carried out for between 2.0 an 5.0 hours.

Ideally, the times for carrying out steps (e), (g) and (i) are of the order of 6.0, 13.5 and 3.5 hours respectively.

In one process according to the invention, in the final steeping vessel: step (k) of steeping is carried out for between 3.0 and 5.0 hours; step (m) of resting the barley is carried out for between 9.5 and 13.5 hours; step (0) of steeping is carried out for between 6.0 and 9.5 hours, which times for carrying out steps (k), (m) and (0) are ideally of the order of 4.0, 11.5 and 7.5 hours respectively.

It will be found, in accordance with the invention, that ideally the intermittent aeration is carried out for between 20% and 30% of the steeping time and is preferably of the order of 25% of the steeping time. in the process according to the invention, when during a resting step (g) and (m), the temperature exceeds 25°C and the resting step is within one hour of anticipated termination, the resting step (g) and (m) is terminated.

For suitable uptake of water, generally between 1.5 and 3.5m3 of water is added per tonne of barley.

Preferably, air is supplied at between 775 and 875 millibar which ensures sufficient aeration and agitation of the barley.

In one process according to the invention, when carrying out step (b) and causing overflow, the top of the initial steeping vessel is skimmed to remove floating debris.

Detailed Description of the Invention The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which:- Fig. 1 is a partially diagrammatic. part sectional view of a steeping system according to the invention, Fig. 2 is a detailed enlarged view of one of the steeping vessels of Fig. 1, and Fig. 3 is an enlarged view of one of the other two steeping vessels of Fig. 1.

Referring to the drawings, there is provided a steeping system, indicated generally by the reference numeral 1, which in turn comprises three steeping vessels, namely an initial steeping vessel 2, an intermediate steeping vessel 3 and a final steeping vessel . Each steeping vessel 2, 3 and 4 has cylindrical sides 5 terminating in a conical base 6. Mounted around each conical base 6 are three aeration rings 7, each connected to a pressurised air supply line 8, connected to a compressor, not shown.

The aeration rings 7 have spaced-apart air outlets, not shown. The bottom of each steeping vessel 2, 3 and 4 has a perforated conical portion 10, one side of which is connected to a fresh water manifold 11 connected to a water supply pipe 12 and the other side of the perforated conical portion 10 is connected to a further manifold 13 in turn connected to a wastewater pipe 14. An infeed screw conveyor 15, driven by a motor 16, feeds an inlet hopper 17 above the initial steeping vessel 2. The initial steeping vessel 2 has mounted around the periphery thereof, an overflow receiving channel 25 connected to the wastewater recovery pipe 14, the connection to which is not illustrated. Mounted within the initial steeping vessel 2 is a lift tube 30, beneath which is mounted a pressurised air supply pipe 31. Above the lift tube 30, a conical protective cover 32 is mounted spaced-apart therefrom. The initial steeping tank 2 has a discharge outlet pipe 33 mounting an outlet valve 34 which feeds the intermediate steeping vessel 3. The intermediate steeping vessel 3 has a further discharge pipe 33 and valve 34 feeding the final steeping vessel 4 which again has a discharge pipe 33 mounting a discharge outlet valve 34 for delivery to an outlet screw conveyor operated by a motor for delivery of the wet barley to a germination box or bed.

The intermediate steeping vessel 3 and the final steeping vessel 4 are identical in construction and thus only the enlarged intermediate steeping vessel 3 is shown in Fig. 3. The steeping vessels 3 and 4 do not have a lift tube or an overflow receiving channel.

A suitable control means, such as a standard computer (not shown), is provided for the system and will comprise, as well as suitable computing means, data recording and control means and a systems database. This control means is connected to temperature, moisture content and germination capacity monitors. These are provided for each of the vessels. For example, the germination capacity monitor will include some means of obtaining samples from the vessel. The control means will therefore control the operating parameters of the vessels.

In operation, barley is fed through the screw conveyor 15 into the initial steeping vessel 2. Water is also delivered through the supply pipe 12 into the steeping vessel, generally simultaneously with the barley. Sufficient water is initially introduced into the initial steeping vessel 2 to cover the barley while delivering pressurised air through the aeration rings 7 and the air supply pipe 31 up the lift tube 30 to rouse the barley. The delivery of pressurised air up the lift tube 30 causes barley and water to be delivered up the lift tube 30 to impinge initially against the protective cover 32, as illustrated in Fig. 1. This cover 32 assists in distributing the wet barley across the initial steeping vessel 2 without loss of water and barley due to splashing. Then, more water is introduced into the initial steeping vessel 2, until water with dirt, husks, chaff, etc., in suspension, starts to overflow into the overflow receiving channel 25.

Any debris floating on the top of the water is skimmed into the overflow receiving channel 25 and rousing continues by delivering air through the lift tube 30 and the aeration rings 7. This rousing of the barley continues for between 0.25 and 0.45 hours and ideally is for 0.5 hours. After that, the potassium permanganate is added to the water, usually at the rate of 0.024Kg per tonne of barley. The water and barley is left to rest. After a suitable time, of between 1 and 2 hours and of the order generally of 1.5 hours, the wet barley is then transferred to the intermediate steeping vessel. Generally, after the potassium permanganate has been added, sufficient water is introduced into the initial steeping vessel to cause overflow. in the intermediate steeping vessel, the wet barley is roused for between 4 and 6 hours. This is carried out with intermittent rousing by means of the aeration rings 7.

After that, the water is drained from the intermediate tank 2. Then, the barley is drained and this takes approximately 0.5 hours. Then, the barley is left to rest for between 10.5 and 16.5 hours and preferably for 13.5 hours with constant CO2 extraction. The surface of the wet barley is sprayed for approximately two minutes every two hours.

After that, approximately 0.5 hours is spent filling the intermediate steeping vessel 3 with water. Then, the barley and water is retained within the intermediate steeping vessel 3 with intermittent aeration by rousing through the aeration rings 7. The intermittent aeration. namely the rousing, is carried out for between 20% and 30% of the steeping time and generally every quarter of an hour per hour. This steeping with rousing is carried out for between 3 and 5 hours and preferably 4 hours.

Subsequently, the wet barley and water is transferred to the final steeping vessel.

The barley and water are allowed to steep in the final steeping vessel for between 3 and 5 hours and preferably 4 hours. During that time, it is subjected to intermittent rousing, using aeration rings 7 only, for generally 15 minutes per hour. Then, the final steeping vessel is drained and this generally takes about 0.5 hours.

Subsequently, the wet barley is allowed to rest for between 9.5 and 13.5 hours, again with constant CO2 extraction and spraying the surface approximately two minutes, every two hours. After that, the barley is again filled with water and this takes approximately 0.5 hours. Then, the barley and water is steeped and roused for between 6 and 9.5 hours, and preferably 7.5 hours, every 15 minutes or so. Finally, the barley is transferred to a germination box.

During each resting step, while the barley is wetted every two hours for between 0.1 and 0.3 hours, the temperature is also checked and if the temperature exceeds 25°C, then the barley is again covered with water and drained almost immediately so as to cool the barley. However, in circumstances where the resting step is less than one hour from completion, very often, the resting step is simply terminated and the next steeping step carried out.

Ideally, water for steeping is added at between 11°C and 13°C for each steeping step.

It is also part of the process to monitor the temperature, the moisture content and the germination capacity of the barley as it progresses through the steeping cycle.

Indeed, what is generally checked is these parameters in the last resting step in both the intermediate steeping vessel and the final steeping vessel because essentially it is during this resting that the barley absorbs the water. However, in both of these resting steps, the moisture content of the barley is checked and if it is, for example, in the intermediate vessel a moisture content somewhat of the order of 32 to 35%, then additional changes to the steeping process would be carried out. Similarly, if, in the final steeping vessel, the moisture content has not achieved somewhat of the order of % additional steeping and even additional resting is carried out.

Throughout the operation, the temperature of the barley is checked and efforts are made to make sure that at no stage does the temperature of the barley exceed 25°C.

Generally, somewhat of the order of approximately 1.5 to 3.5m3 of water is added per tonne of barley. The air is supplied at a relatively low pressure, somewhat of the order of approximately 775 to 875 millibar.

While in the embodiment described above, an infeed screw conveyor 15 has been shown as feeding the inlet hopper, in many instances, a storage bunker is mounted directly above the infeed hopper and then gravity feed can take place.

In the specification the terms "comprise, comprises, comprised and comprising" or any variation thereof and the terms "include, includes, included and including" or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation and vice versa.

The invention is not limited to the embodiment hereinbefore described, but may be varied in both construction and detail within the scope of the appended claims.

Claims (1)

1. CLAIMS A process of steeping barley for subsequent malting in a steeping system (1) comprising three vertically arranged, one above the other, steeping vessels, namely a highest initial (2), an intermediate (3) and a lowest final (4) steeping vessels, each steeping vessel (2, 3, 4) having cylindrical sides (5), terminating in a conical base (6), a water inlet manifold (11) and outlet manifold (13) in the base (6) and a plurality of sets of circumferentially arranged and spaced-apart aeration rings (7) in the base (6), the initial steeping vessel (2) additionally having an overflow receiving channel (25) around its periphery and a central rousing tube (30) open at both ends, the rousing tube (30) being spaced-apart from and adjacent the base (6) and in communication with a pressurised air inlet pipe (31) for delivering barley up through the rousing tube for recirculation of the barley and a conical protective cover (32) is mounted above the rousing tube (30) and spaced-apart therefrom, the system further comprising control means comprising data recording and control means and a systems database, the control means being connected to temperature, moisture content and germination capacity monitors for the vessels to control the operating parameters of the process, the process comprising: for each variety of barley being malted prior to acceptance of the variety for steeping, carrying out a micro-malting process on a sample to determine optimum steeping parameters; storing the parameters in the database together with the characteristics of the barley including at least the variety and where grown; and then prior to commencing the steeping, obtaining the parameters stored and setting the steeping parameters having regard to the stored parameters; during the steeping, recording and storing the actual parameters in the database for subsequent use with barley having those characteristics; from time to time carrying out a further micro-malting process on other barley: . 12 - and then on receiving a batch of barley for steeping, the steps are performed of: (a) delivering water and barley into the initial steeping vessel (2); (b) delivering further water into the initial steeping vessel (2) to cause overflow into the overflow receiving channel (2) while rousing and aerating the barley using the lift tube (30) and aeration rings (7); (c) stopping the rousing, and adding potassium permanganate; (d) transferring the wet barley and water to the intermediate steeping vessel (3); (e) steeping the barley with intermittent aeration by the aeration rings (7) in the intermediate steeping vessel (3); (f) draining the water; (g) allowing the drained barley to rest while extracting CO2 from above the barley and intermittently spraying the barley with water; (h) filling the intermediate steeping vessel (3) with water; (i) steeping the barley with intermittent aeration using the aeration rings (7); (j) transferring the barley and water to the final steeping vessel (4); (k) steeping the barley with intermittent aeration in the final steeping vessel (4); (I) draining the water; allowing the drained barley to rest while extracting CO2 from above the barley and intermittently spraying the barley with water; filling the final steeping vessel (4) with water; steeping the barley with intermittent aeration in the final steeping vessel (4); and delivering the wet barley onwards for germination; and in which additionally: during each resting step (g) and (m), wetting the barley every two hours for between 0.01 and 0.03 hours and checking the temperature of the barley and if the temperature exceeds 25°C, the additional steps of filling the steeping vessel (3, 4) and draining the steeping vessel (3, 4) are performed prior to continuing with the resting step (9) and (m); adding the water at between 11°C and 13°C for each steeping step (b), (e). (i). (K) and (0); and continuously monitoring the temperature, the moisture content and germination capacity of the barley and when, during the last resting step (g) and (m) in the intermediate steeping vessel (3) and the final steeping vessel (4), the moisture content of the barley is below 32% and 42% respectively, the appropriate resting step (g), (m) is prolonged with additional wetting until the required moisture content is achieved. A process as claimed in claim 1, in which the characteristics stored additionally comprise one or more of: Batch number; Start date and time; Silo number ; Vessel group Steeping method . A process as claimed in claim 1 or 2, in which the micro-malting process is carried out on each variety at least once a year prior to commencing steeping while the barley is in storage. . A process as claimed in any preceding claim, in which in the initial steeping vessel (2) step (b) of rousing the barley is carried out for between 0.25 and 0.45 hours. A process as claimed in any preceding claim, in which in the intermediate steeping vessel (3): step (e) of steeping the barley is carried out for between 4 and 8 hours; step (g) of resting the barley is carried out for between 10.5 and 16.5 hours; and step (i) of steeping the barley is carried out for between 2.0 an 5.0 hours. A process as claimed in claim 5, in which the times for carrying out steps (e), (g) and (i) are of the order of 6.0, 13.5 and 3.5 hours respectively. A process as claimed in any preceding claim, in which in the final steeping vessel (4): step (k) of steeping is carried out for between 3.0 and 5.0 hours; step (m) of resting the barley is carried out for between 9.5 and 13.5 hours; and 20 10. 11. 12. 13. step (0) of steeping is carried out for between 6.0 and 9.5 hours. A process as claimed in claim 7, in which the times for carrying out steps (k), (m) and (o) are of the order of 4.0, 11.5 and 7.5 hours respectively. A process as claimed in any preceding claim, in which the intermittent aeration is carried out for between 20% and 30% of the steeping time. A process as claimed in claim 9, in which the time taken to carry out intermittent aeration is of the order of 25% of the steeping time. A process as claimed in any preceding claim, in which when, during a resting step (g) and (m) the temperature exceeds 25°C and the resting step is within one hour of anticipated termination, the resting step (g) and (m) is terminated. A process as claimed in any preceding claim, in which the air is supplied at between 775 and 875 millibar. A process as claimed in any preceding claim, in which when carrying out step (b) and causing overflow, the top of the initial steeping vessel is skimmed to remove floating debris.