tully hadley (mbrew)

Tully Hadley (MBrew)

Dynamic Dry Hopping for Aroma

Utilisation : A New Technique

Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 2


Outline

1. What is the problem we are trying to solve?

2. What tools do we have at our disposal?

3. What research did we do?

4. Lab scale trials

5. Small scale trials

6. Commercial Implementation

7. Learnings


What is the problem we are trying to solve?

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CUB Dry Hopped Brands

2010 2011 2012 2013 2014 2015 2016 2017

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What is the problem we are trying to solve?

Large scale brewing of dry hopped brands

presents some issues for brewing at scale:

5000hL X 200g/hL = 1000kg of hop pellets

A 5000hL fermenter is 5 stories high!

Existing FV

Increasing Hopping

Rates

Growth of Dry

Hopped Brands

.


Objectives

Match current brand sensory profiles

No negative impact to beer quality

More efficient slurrying system

Reduced beer loss

Increase utilisation of aroma hops

Sustainable yeast re-pitching strategy for dry hopped beer

Integration with existing assets

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What tools do we have at our disposal?

• Partnering with Industry OEMs

• Pilot Research Brewery

• Experimental Brewery

• CUB Hop Volatile analysis techniques

• Trained hop profiling sensory panel


What was the idea?

• Alfa Laval Rotary Jet technology (Iso-Mix) is used widely in our

company

• Adapt this technology to the Dry Hopping process

• Use the Rotary Jet Mixer to mix beer and hops


What was the idea?

Increased efficiency of aroma compound extraction

Increased homogeneity

Decreased extraction of unwanted polyphenols (harsh, astringent)

Homogenous feed to centrifuges to overcome overloading issues

Prevent hop particle settling

Reducing dissolved CO2 could aid with flocculation of ale strain yeast

Efficient hydration of all hop particles to prevent flotation

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The idea of keeping hop slurry in solution with fermenting or fermented beer

could have several advantages:


Dynamic Dry Hopping Design

Hop Slurrying and Transfer Minimise Manual Handling

Ensure System Cleanliness

No oxygen ingress

Process Flexibility

Hop / Yeast Separation Ensure Adequate Separation

Minimise Beer Losses

Maximise Yeast Harvest


Dynamic Dry Hopping Processes

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Dry Hopping No oxygen ingress

Maximise Extraction Efficiency

Ensure Homogeneity

Process Flexibility – Warm, Cold, During or End of Fermentation


Lab Trials

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Tim

e (

min

s)

Temperature (deg C)

Hop Pellet Dispersion Time

Deaerated Water (4°C) : low oxy but

long mixing time

Decreasing dispersion time with

increasing temperature


Lab trials

Increasing extraction

of volatile aromatics

with temperature

But….. i reasi g volatilisation also

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Hop Volatile Extraction

4°C

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40°C

60°C


Pilot plant trials

Iso-Mix technology installed into Unitank (15 hL)

Process variables determined through a series of trial and control brews

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EoF 4 8 16 32 Storage Control

Storage

Linalool


Pilot plant trials Dynamic Dry Hopping shows extraction occurs very quickly

Volatilisation losses occur over time

Extraction efficiency is higher than conventional dry hopping process


Pilot plant trials

Isomix S1 Cntr Isomix S1 T1

Floral

Liking

Intensity

Body

Sweet

Bitter

Malty

Estery

Hop Ester

Spicy

Resinous

Sulphury Fruit

Green

Citrus8

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Control Dynamic Dry Hop

Hop Profile

Answers taken Product Preferred

22 Control 10

Dynamic Dry Hop 12

Paired comparison Sensory Testing

No statistically significant difference in

preference for Control or Dynamic Dry

Hopped beer


Commercial Implementation

• With the technical support of Alfa Laval and Matrix Process Solutions, Iso-Mix

installations were commissioned on 2 x 2200hL vessels at the Abbotsford

Brewery in Melbourne

• CUB built a custom designed hop slurring and transfer system



Beer is pumped out of the vessel cone

Pumped back to the fermenter

Up into the rotary jet mixer

Hops introduced from slurry system


Hop/Yeast Separation

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Cu

mu

lati

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Pe

rce

nta

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(%

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Time (min)

Hop Particle and Yeast Settling

Maximum Hops Settling Rate

Average Hops Settling Rate

Minimum Hops Settling Rate

Maximum Yeast settling Rate

Average Yeast Settling Rate

Minimum Yeast Settling Rate

ℎ = 𝑉𝜋 tan2 303



Calculations showed that hop and yeast particles could be physically separated by

time.

Experimental work showed that hop slurry settled to the bottom of the cone

within 3.5hrs and then yeast would begin to settle.

If too much yeast was able to settle, hop material would become compacted and

block pipework.

You can achieve a clean hop/yeast interface with minimal beer loss and maximise

yeast collection.



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200 Hop Aroma Analysis

Dynamic Dry Hopping vs Traditional Method

Traditional

Dynamic Dry Hop


Outcomes

1. Match current brand sensory profiles

2. No negative impact to beer quality

3. More efficient slurrying system

4. Reduced beer loss

5. Increase utilisation of aroma hops

6. Sustainable yeast re-pitching strategy for dry hopped beer

7. Integration with existing assets


Learnings

Get the hop/yeast interface correct!


Learnings

• Hop material can partially block Rotating Jet Head gearing – still get liquid flow

through nozzles, but no 360o rotation. Need to carefully control the initial slurry/beer

ratio to ensure no blockage.

• Very suitable for Ale Strains because they wo ’t flo ulate at fermentation

temperature, good separation. Lager strains can flocculate with hops.

• Micro – hops are stable, infections can occur when resins build up on conveying and

transfer equipment. Minimise e ha i al ha dli g of hops, or etter still do ’t use any.


Learnings

Drawing on the experiences at Abbotsford and other sites, Alfa Laval has developed a

special version of the Iso-Mix technology especially for dry hopping.

The new external drive (motor-driven) Rotary Jet Mixer separates the rotation drive

from the fluid circulation flow, allowing the mixer to handle high concentrations of

particles such as hops without plugging or rotation stoppage issues.

The new technology is presently in testing in several locations in our region and

elsewhere in the world, and will be officially launched by Alfa Laval later this year.

Acknowledgments

• Sam Seward (Engineering)

• Claude Nyaguy & Drew Parker (Research Brewery)

• Mark Goldsmith (Raw Materials Specialist)

• Melinda Christofersen (Analytical Services)

• Alyce Hartvigsen (Alfa Laval)

• Katie Jessup (Engineering)

• Jaideep Chandrasekharan (Chief Brewer)

• James van der Watt and Trevor Cowley(SABM Research Brewery,

Nottingham)


IBD PPT – Final Slide

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