weyermann specialty malts influence on wort and beer...

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WEYERMANN® Specialty Malts Influence on wort and beer quality

September 2018

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Alirio Caldera

• Weyermann® International Customer Consultant

• MSc. Brewing Science and Beverage Technology

• Chemical Engineer

• Beer Sommelier

Speaker Introduction

Weyermann® - all rights reserved 2

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• Introduction Weyermann® Company

• Weyermann® Specialty Malts Production

• Quality Assurance by Weyermann®

• Development of Color in the Roasting and Brewing Process – A Quality Review

• pH Influence on the Quality of Wort and Beer

• Beer Recipes with Weyermann® Sour Products

• Weyermann® World

Presentation Overview

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Weyermann® History

1600 1879 1904

The first Weyermann family

members were fishermen and

skippers on the Main/Regnitz

rivers around Bamberg

Johann Baptist Weyermann

started to roast barley under a

tent

Mich. Weyermann® Malthouse:

the first pneumatic Malthouse in

the world

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Weyermann® Family-owned and -operated

• Family Tradition

and Competence

in the 4th Generation!

• Sabine Weyermann and

Thomas Kraus-Weyermann

• Weihenstephan trained

Husband and Wife Team

• The 5th Generation, Franziska

Weyermann, joined the

management team in 2017


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Weyermann® Malthouse & Head Office Bamberg


Weyermann® Production Sites

Interesting facts: with more than 300 local breweries, Bamberg has the highest

brewery density in the world with a per capita consumption of approx. 280 L/person

every year

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Weyermann® Malthouse Hassfurt, Grain Elevator Leesau and Malthouse Clingen


Weyermann® Production Sites

Clingen – 2017Moving Piece Malting

Hassfurt – 2001Base Malts

Leesau – 2005Grain Elevator45.000 Mton

Continuously growing, continuously reinvesting!

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Weyermann® Regional Grain Supply

Northern Bavaria

Saxony

Thuringia

Bohemia in Czech Republic

Growing Area for Authentic

Bohemian Barley Varieties

Venice - Italy

Terroir Malt Eraclea

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Weyermann® around the Globe

Weyermann® Malt is the soul of beers in over 135

countries – in all continents!

Weyermann® customer network of round 5.000 brewing and

distilling happy passionates!

Weyermann® offers 85 different

products including liquid extracts!

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Weyermann® Raw Materials

All raw materials come from local farmers – 85% fixed contracts

2-Row-Barley Wheat Rye Spelt

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Weyermann® Malts Color Specifications and Products

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• Introduction to the Weyermann® Company


• Quality Assurance by Manufacturing Weyermann® Malts

• Development of color in the roasting and brewing process – A Quality Review

• pH influence on the quality of the wort and beer

• Beer recipes with Weyermann® Sour Products



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Weyermann® Specialty Malt Production Process

2

4

5

1

6

3

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Weyermann® Base Malt Production

Steeping Vessel

60 tons (1 of 4)

One Floor

High Capacity Kiln (1 of 4) Germination Box

120 tons (1 of 8)

Quality aspects:

- Constant steeping temperatures

- Treated spring water (RO-Water)

- Odorless water

Quality aspects:

- Two laboratory analyses per day

- Continuous temperature monitoring

- Thin bed layer

Quality aspects:

- Thin bed layer

- Exact temperature control

- Exact air flow control

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• Complete caramelization

• Typical caramel to bread aroma

• Homogeneity

• Glassy, caramelized texture

• No friability test applicable

• Enhances foam stability

• Improves aroma, body, flavor


Homogenously manufactured Caramel Malt

➔Weyermann® has developed gentle caramelization processes to assure the best

flavor and color, without overheating the malt → true caramel color and aroma!

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Weyermann® Caramelization Drum

100°C

80°C

50°C / 122°F

65°C

130°C/266°F

Cara

meliz

ation

70°C/158°F

60°C

50°C

28°C//82°F

40°C

Kiln

Comparasion3

- Cost-cutting budget production

- Temperature difference green malt bed

- Inhomogeneous temperature

- Inhomogeneous saccharification

- Not every kernel reaches the required temperature

- Lack of caramelization

- Inhomogeneous malt

- Lack of caramel flavor

- Lack of typical caramel malt colors

+ State of the Art production process

+ Rapid and evenly temperature change

+ Homogeneous temperature

+ Homogeneous saccharification

+ All kernels reach saccharification temp.

+ Perfect Caramelization

+ Max. Homogeneity of the malt

+ Typical caramel flavor

+ Typical caramel malt colors

EE

E

70°C

158°F

70°C

158°F

Saccharification

130°C

266°F

130°C

266°F

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Caramel Malt Production


Weyermann® CARA_Products line

Green Malt

(from Germination Box)

Caramelization DrumSaccharification and Caramelization

Color and Caramel Aromas develop

Caramel Malt(Ingredient for Breweries

and Food Industry)

Rootlets

Energy

RecoveryEnergy

Approx. 45% H2O

6 – 8 % H2O

3-4 hours

Moisture

from 70°C to 200 °C

SugarCaramelization

temperature [°C]

Fructose 110

Glucose 160

Sucrose 160

Maltose 180

Starch

Simple sugars

Caramel compounds

a- and b-Amylase

Dheat

~70°C

>70-200°C

Not exogenous enzymatic cocktails!

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Roasted Malt Production


Weyermann® CARAFA®

Kilned Malt

(from Kiln)

Roasting DrumRoasting

Color and Roast Aromas develop

Roasted Malt(Ingredient for Breweries

and Food Industry)

Rootlets

Energy

Recovery

Energy

Approx. 5% H2O

3% H2O

3-4 hours

Moisture

Up to 250 °C

Water dosage

+ Better reaction control

+ Caramel and pleasant

chocolate flavor is

developed

+ The steam formed

removes burnt flavor

+ debitters the malt

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Weyermann® Specialty Malt Production Process

Base Malts

Technical

Malts

Roasted

Malts

Caramel

Malts

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• Development of color in the roasting and brewing process –A Quality Review





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Weyermann® Quality Concept

How do we assure the quality of our malts?

• Local farmers

• Own grain storage capacity to ensure continuously production and availability

• Gentle Moisture adjustment (if >14,5%)

• Temperature monitoring during the storage and aeration if needed (inside the silo)

• Only 2-row Spring Barley bigger than 2,5mm

Raw Material Supply

• The barley is cleaned 4 times before starting the malting process

• After kilning/roasting the product is cleaned 2 times = 6 cleaning steps!

• Production areas dust and grain free

• HAACP

Cleaning concept

• Modern technology available

• Continuous monitoring of every single process step

• Every batch is at least 14 times analyzed in the laboratory

• Traceability back to the farmer who supplied the initial grain → 24 months

Production process

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Weyermann® Quality Concept

How do we assure the quality of our malts?

• 25-kg Bags according to the bulk density of the material → reduced contact with air

• High density polyethylene bag inside → no aroma losses, reduced air exchange

• Exclusive usage of new pallets

• Isolated palletizing → plastic layers at the bottom an top of the bags → no contact with the exterior

Packaging & Palletizing

• Only odorless and new canisters

• Hot filling

• CO2 - Headspace

• 4 separation processes to assure no turbidity (Sinamar)

Sinamar® and Liquid Extracts

•ISO 9001

•FSSC 22000

•Bioland – Biosuisse Organic – USDA Organic

•Demeter

•KIWA BCS Öko-Garantie

•Federation of Synagogues Kosher Certificate

Certifications

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Weyermann® - all rights reserved

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Development of color in the roasting and brewing process – A Quality Review

Photograph: J. Kenji López-Alt

• Color is formed in malt and wort in the same way as in other foodtypes, mainly due to the Maillard Reaction.

• Every time we put a steak on our barbecue and the color of themeat turns from red to cooked, dark, etc., we are promoting thenon-enzymatic browning caused by the Maillard Reaction.

• The Maillard Reaction occurs during thermal processing of foodsuch as roasting meat, coffee, malt and baking bread.

• The substances responsible for this browning of meat andmalt/wort are called melanoidins.

• Melanoidins are brown, high molecular weight polymers that areformed at high temperatures.

• Melanoidins not only lend food and beverages a brown color, butalso affects the taste and smell.

• This sensory effect could be positive if the browning process isdone right, or could be unpleasant to the palate if done wrong.

Source: https://bbqpit.de/beef-jerky/


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How is color developed in the roasting and brewing process?

• Maillard Reaction and production of melanoidins

Reducing sugar(sucrose, maltose)

Starch

a-Amylaseb-Amylase

• Sugars and amino acids are the

starting components

→ all of them are built during the

malting process and (mainly) in the

mashing process

• The goal is to build melanoidins and

avoid formation of Strecker aldehydes

and specifically their precursors

(dicarbonyls)

• Strecker aldehydes are strong aroma

active and are related to the beer

aroma staling

• Strecker aldehydes and intermediaries

are formed mainly during wort boiling

Proteinsmalt proteases


Maillard

Reaction

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Maillard

Reaction



Roasting process

Brewing process

Melanoidins

(red) Color

Caramel

Roast

Chocolate

Strecker

Aldehydes

Stale flavors

Poor flavor stabilitySource: http://www.picklejarstudios.com/potato-beer-

gratin/

antioxidants

Better flavor stability

➔ Let the color of the beer come from the Weyermann® Products and not from overboiling your wort at the

brewhouse or letting it sit too long inside the whirlpool

➔ Avoid any oxygen contact or too strong stirring (vortex formation) during the process → Oxidation of

polyphenols leads to darker colour and unpleasant bitterness in the beer

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• Factors promoting the color forming substances and avoiding the Strecker aldehydes

Malting process:

• Controlled low temperatures during the first step of kilning

• Homogeneous distribution of the heat during the caramelization or roasting

process

→ roasting drums instead kilns

• Minimal thermal load

→ on-site controlling of the color to finish the roasting when desired color

intensity is achieved

Brewing process:

• No overproduction of amino acids during the mashing process

• No long boiling times

• Usage of sour malt in the malt bill → proteases have mainly basic pH-optima

• Usage of sour extract to lower the wort pH → better break formation, slower

Maillard Reaction kinetics


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• Weyermann® Melanoidin is a kilned specialty

malt with an intense malt aroma and unique

brewing characteristics.

• It has a high degree of modification of both

proteins and starches, excellent friability, low β-

glucan values, and high acidity.

• These attributes help promote flavor stability,

add body, and produce a smooth mouthfeel.

• Weyermann® Melanoidin malt adds a deep

amber to red-brown color to finished beer.

• The rich malt flavor has notes of honey and

biscuit.

• Melanoidin malt is best used in dark or red-

colored beers such as amber ales, Scottish ales,

Irish red ales, bocks, and Kellerbier.

• Usage rate: up to 20%

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Biological Mash and/or Wort Acidification in the Brewhouse


• Enhanced enzymatic degradation of materials

• Higher levels of growth-promoting substances

• Suppression of lipoxygenase activity

• Better lautering performance

• Enhanced redox potential, i.e. reduced

susceptibility to oxygen

AND / OR

pH = 5.6 – 5.8 pH = 5.2 – 5.4

Malt

Acidulated malt

Water Sour wort

Mash tun

Mash acidification

• Less color formation

• Enhanced protein coagulation/precipitation

• Improved sensory quality

• Increased chemical-physical stability

• Enhanced microbiological stability

Wort acidification

Wort kettle Whirlpool

pH = 5.3 – 5.7 pH = 5.0 – 5.2

Sour wort Sour wort

or

Hops

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pH-adjustment using Weyermann® Acidulated Malt


• Use of Acidulated Malt can lower wort pH

resulting in better mash efficiency,

intensified fermentation, lighter color,

improved flavor stability and enhanced

flavor.

• Usage rate: 1-5%

• Usage rate: up to 10% (for sour beers)

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• Raw materials used for sour wort production

• Sour wort fermentation

• Concentration of produced sour wort


pH-adjustment using Weyermann® Sour Wort

conform to the

German Purity Law

Weyermann® / Doehler Sour Wort -

Specification

Parameter Unit Value

Lactic acid g/L 52 – 58

pH - 2.9 – 3.2

Density g/cm³ 1.271 – 1.311

Brix °Bx 58.0 – 63.0

Shelf-life (unopened package): 360 days – Storage at 20°C

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State-of-the-Art Fermentation Technology and Aseptic Filling


Under CO2 atmosphere,

the sugar in the wort is

converted into lactic acid

by a pure culture of lactic

acid bacteria, namely

L. amylolyticus.

Malt is produced from

barley through steeping,

germination and kilning in

order to completely break

down cell walls, partially

break down proteins and

generate enzymes.

Malting Fermentation FillingWort preparation

Using a classical infusion

mashing process, the valuable

substances of malt grist are

brought into solution. The final

mash is filtered resulting in the

so-called wort.

With the help of

an aseptic filling

machine, the sour

wort is filled in

optimal packages (Bag-in-Box 20 kg).

Activities DöhlerGroup

LAB Fermentation

Products

WortMalt Weyermann® / Doehler Sour Wort

LAB

Steeping

Germination

Kilning

Grain

Water

Air

AirAir

Boiling Separation

Wasser Wasser

Milling

Mashing Lautering

Concentration

The sour wort is

concentrated by

performing a gentle

vacuum

evaporation

(water).

Evaporation

Filling

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Brew 1: Mash acidification using

sour malt (Reference)

Brew 2: Mash acidification using

sour malt, wort acidification using

Weyermann®/Doehler Sour Wort (boiling)

Brew 3: Mash and wort acidification

using Weyermann®/Doehler Sour Wort


Practical test of the Sour Wort in a Medium-Sized Brewery

Unit Brew 1 Brew 2 Brew 3

Grist load

Pilsner malt kg 2,850 2,850 3,000

Sour malt kg 150 150 0

Percentage % 5 5 0

Cast-out wort

Extract % 12.0 11.9 12.1

Volume hL 199 199 198

Weyermann® /

Doehler Sour Wort

Addition to mash kg 0 0 51.5

Mash pH - 5.35 5.36 5.35

Addition to wort kg 0 57.6 62.2

Cast-out wort pH - 5.32 5.02 4.98

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0

50

100

150

200

250

300

Heatindicators

Oxygenindicators

Agingcomponents

Heatindicators

Oxygenindicators

Agingcomponents

Brew 1 Brew 2 Brew 3


Results | Aging Indicators in Fresh/Forced-Aged Beer

Fresh beer

Brew 3 lowest

concentration of aging

indicators

Forced-aged beer

Reduction of aging indicator levels

by using Weyermann®/Doehler

Sour Wort in mash and/or wort

Su

m [μg/L

]

Conclusion:

Application of Weyermann®/Doehler

Sour Wort in mash and/or wort

significantly increases the flavor

stability of beer

Brew 1: Mash acidification using sour malt (Reference)

Brew 2: Mash acidification using sour malt, wort acidification using

Weyermann®/Doehler Sour Wort (boiling)

Brew 3: Mash and wort acidification using Weyermann®/Doehler Sour Wort

Fresh beer Forced-aged beer

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• Standardized and cost-effective quality product:

• Production of Weyermann®/Döhler Sour Wort

using state-of-the-art fermentation technology

• No cost-intensive installations; no time-consuming

handling of lactic acid bacteria cultures in the brewery, etc.

• High microbiological stability and long shelf-life

of the Sour Wort due to aseptic filling

• Easy handling and dosage due to optimal, recloseable packaging type

• Low dosage quantities: Only 15% of the amount of traditionally

used sour wort required

• Application according to the German Purity Law

for naturally reducing the pH of mash and wort

• Significant improvement of flavor stability and „drinkability“ of beer


Our new Product – an efficient & flexible alternative or addition to Sour Malt or Self-Production

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Weyermann® Specialty Malts produces 85 different products, among them:

• Base Malts Pilsner, Pale Ale, Vienna, Munich, Wheat

• Premium Base Malts Terroir, Heirloom, Traditional Floor-Malting

• Technical Malts Carapils®, Carahell®, Acidulated, Melanoidin…

• Smoked Malts Beech Smoked Barley, Oak Smoked Wheat

• Belgian Style Malts Abbey Malt®, Special W®, Carabelge®

• Caramel Malts Carared®, Caraamber®, Caramunich®…

• Chocolate Roasted Malts Carafa®, Carafa® Special…


Weyermann® Specialty Malt Varieties

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Weyermann® Bohemian Pilsner

92%

5%

2%

1%

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Floor-Malted Bohemian Malt

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• Original gravity: 11.8 °P (1.0480)

• Alcohol by volume: 4.7 % CO2-Content: 4.5 – 5.5 g/l

• Mash (Infusion): Mash in at 50°C and rest for 10 min,

heat up to 63°C and rest for 45 min, heat up to 68°C

and rest for 5 min, heat up to 72°C and rest for 20 min,

Mash out at 78°C

• Hops: 35 BU (Saazer Aroma Hop)

• Yeast recommendation: Fermentis® Saflager W34/70


Weyermann® Bohemian Pilsner

Exclusive use of Saazer hops in this bright golden Pilsner achieves a light fruity and floral aroma, reminiscent

of citrus fruits, as well as giving a distinctive bitterness on the palate. Alongside its refreshing carbonation this

beer is presented with a fine malty body utilizing the finest Weyermann® Bohemian Floor Malt.

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Imperial Stout with Weyermann® Malt

77%

10%

6%

5%

2%

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• Original gravity: 1.0777 (18.8°P)

• Alcohol by volume: 8.0% CO2-Content: 4.5 – 5.5 g/l

• Mash (Infusion): Mash in 55°C (131°F), 60 min 63°C (145°F),

20 min by 72°C (162°F), Transfer by 78°C (172°F)

• Hops: 38 BU (Green Bullet), 10 BU (Williamette)

• Yeast recommendation: Fermentis® Safbrew T-58


Imperial Stout with Weyermann® Malt

The Imperial Stout is crowned with a foam that makes every cappuccino look flat in comparison. It is noble and piercingly

black, just like Ivory. The fine aroma of licorice is underlined by the warming notes of the alcohol. Beginning with the unique

taste of exquisite bitter chocolate and the finest coco notes and then moving into to the distinctive and mouth filling roast

flavor. Perfect dose of bitterness as ideal balance to malt sweetness.

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IPA with Weyermann® Malt

89%

10%

1%

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Barley Wine with Weyermann® Malt

83%

10%

5%

2%

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• Pilsner

• Lager

• Wheat

• Ales

• IPA`s

• Strong


Beer Styles made with Weyermann® Specialty Malts

• Porter

• Stout

• Smoked Beer

• Sour

• Belgian Beers

• Barrel-aged Beers

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Weyermann® Specialty Malts


The presence of beauty in your beers

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Weyermann® Spirits

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Weyermann® Visitors Center Bamberg


Feel Invited!

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Alirio Caldera

International Customer Consultant

e-mail: [email protected]

Whatsapp: +49-162-2082153

Thank you very muchfor your attention!: weyermannspecialtymalts

@weyermann_specialty_malts

weyermann specialty malts influence on wort and beer...

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