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WORT PRODUCTIONBREWING + DISTILLING CENTER, INC.
Wort Production
WORT• Solution of fermentable sugars
• Glucose
• Maltose
• Maltotriose
• Produced by MASHING
• Solution that YEAST is added for FERMENTATION
Wort Production
Begin with PROPER MILLING of malted barley
Wort Production
Begin with PROPER MILLING:
• Separate the outer husk material from the grain
with minimal damage, while crushing the
endosperm to small, but uniform, particle size.
• Maximize surface area of the endsoperm for
greatest amount of starch conversion, while leaving larger undamaged pieces of husk.
Wort Production
Begin with PROPER MILLING:
• Larger pieces of grain husk contribute to:
• Proper grain bed structure
• Better lautering porosity
• Smaller, damaged pieces of husk can release
elevated levels of polyphenols, such as tannins, that can add astringency to the finished product.
*Review any milling topics as needed
Wort Production
Malting enzymatic reactions continue during
MASHING
MASHING:
• The ‘cooking’ of grist to enzymatically convert
unfermentable starch/sugars to fermentable
simple sugars
• Increased temperature and water hastens
enzymatic activity
Mashing
Mashing is the process of turning the complex
carbohydrate—starch—of the malted barley, into
simple sugars—glucose, maltose, and maltotriose—
that yeast can eat (to produce ethanol and carbon dioxide
through fermentation).
Malted barley + hot water + enzymes simple sugars(glucose, maltose, maltotriose)(Starches)
Mashing
simple sugars/carbohydrate
*enzymes
*ENZYMES: Alpha Amylase + Beta Amylase
STARCH: complex sugar/carbohydrate
Alpha amylase
Beta amylase
Mashing
Mashing ENZYMES (naturally occurring in barley seed):
Alpha amylase: chops starch molecules in the
middle of the starch molecule (initially forming DEXTRINS)
Works best at:
150oF – 167oF
pH of 5.6 – 5.8
Dextrins- sugars larger
than 3 glucose
molecules
Mashing ENZYMES
Mashing ENZYMES
Beta amylase: chops single glucose molecules from
the ends of starch and shorter sugar molecules
Works best at:
145oF – 150oF
pH of 5.4-5.6
Mashing
Alpha and beta-amylase activity in MASHING :
Undigestible starch is converted into “chewable”
simple sugars yeast can eat so they can ferment and
produce ethanol and CO2
There are 3 steps of Mashing:
1. Gelatinization
2. Liquification
3. Saccharization
Mashing STEPS
Step 1: GELATINIZATION
▪ Separation of the large, long, flat starch
molecules from each other
▪ To start increasing the surface area for the
amylase enzymes to start working
▪ The hot water (about 150 F) breaks down the
bonds between the starch molecules to separate
them.
Mashing STEPS
Step 1: GELATINIZATION
stacked starch
molecules
separated starch
molecules
hot water
Mashing STEPSStep 2: LIQUIFICATION
▪The amylase enzymes begin chopping the
starch molecule into smaller dextrin molecules.
▪T up to 167 F.
Mashing STEPS
Step 3: SACCHARIZATION
▪The beta-amylase finishes chopping the sugar
molecules into single glucose molecules.
▪Temperature down to 150 F. pH = 5.2-5.4.
Mashing STEPS
Step 3: SACCHARIZATION
maltotriose maltose dextrin
Mashing
Maintaining correct temperatures and pH is vital
Incorrect temps and pH:
1. Incomplete mashing
▪ not enough simple
sugars produced for yeast
to eat
▪ less ethanol produced
▪ wasted money
2. Off-flavors
Mashing
Maintaining correct temperatures and pH is vital
Tending to Your Mash
⚫ Take all precautions to help maintain rest temperature
⚫ Regular mixing of mash
⚫Helps enzymatic activity
⚫Avoid temperature gradients
⚫ Confirm mash temperatures
⚫ Check mash depth
⚫ Use Iodine test to confirm completion of starch conversion
Mashing
Mashing
The result of mashing: WORT (The simple sugar
solution)
• The wort is now separated from the grain and hull and
other solid particles (spent grain)
• The wort is boiled to sterilize it to get rid of any bacterial
or wild yeasts that can contaminate beer
• Hops is added during the wort boil (as discussed)
Different Mashing Schedules
⚫ Single Step Infusion⚫Primarily British and American brewing
⚫ Multi-Step Infusion⚫Primarily Continental European Brewing
⚫ Decoction Mash
⚫ Step by Steam
Mashing
pH and Your Mash
⚫ Enzymatic activity is dependent on proper pH⚫Mash pH ranges...
⚫ 5.0-5.2 for best hop character, and optimize hot break
⚫ 5.2-5.6 for greatest extract yield
⚫ 5.3-5.4 for obtaining most fermentable wort
⚫ 5.3-5.6 for fastest conversion
⚫ Stop collecting wort when run-off pH is 5.8-6.0
Mashing
If Your Mash pH is Too High:
⚫ Increase in dextrin production
⚫ Higher extraction of polyphenols (e.g. Tannins)
⚫ Colloidal instability
⚫ Slow run-off
⚫ Turbid run-off
Mashing
Vorlauf
⚫ Also known as recirculation⚫Helps separate sugars from grain
⚫Clarifies wort from gain particles
⚫Stabilized grain bed for proper wort run-off
⚫ Watch your speed
Mashing
Vorlauf - precautions
Mashing
⚫ Make sure vorlauf discharge is not oxygenating
the wort
⚫ Running too fast can compact the grain bed, leading to a stuck mash.
⚫ A stuck mash can also develop in the initial milling
and mashing steps.
Lautering
Collecting your wort run-off- Do not run too fast, especially in the beginning
- Avoid oxidation of wort
- Avoid loss of extract efficiency
Things to check while lautering- Gravity of Sweet wort
- pH of sweet wort
- pH towards end of lauter
- Gravity of wort's last runnings
Sparging
Adding additional hot liquor water to mash to extract as
much brewing sugar as possible
Copper Full and Time to Boil
⚫ Copper full is the final amount of wort you wish to
collect before boil. Determined by recipe
⚫ Ideally, heating the wort should be occurring while lautering.
⚫ Once a boil is achieved, it is a good time to check the “pre-boil” gravity of the wort.
Proper Boiling
A proper boil should be as vigorous as possible without
boiling over.-Controlling your heat source
-Manipulating venting areas
*During the boil, there should, at least, be a small surface
area of exposed boiling wort
Boil Activites/Functions
⚫ Drives off unwanted flavor volatiles (e.g. DMS)
⚫ Lowers pH through precipitation of Calcium
Phosphate
⚫ Denatures malt enzymes
⚫ Sterilizes the wort
Boil Activites/Functions
⚫ Denatures and coagulates proteins
⚫ Concentrates wort gravity
⚫ Increases wort color, and flavor characteristics
through caramelization, formation of melanoids, and
oxidation of tannins
⚫ Changes hops alpha acids to iso-alpha acids
End of Boil
End of boil volume/also known as Copper Cast-Check wort volume
-Check wort gravity
-Determine if dilution is needed:
If so...
Current Volume x Current Specific Gravity/Specific Gravity
Desired = Diluted Volume
*Once calculations are complete, proceed with whirlpool.
Wort Cooling Wort cooling is achieved by passing hot wort through a
heat exchanger, while counter flowing a cold liquid through the heat exchanger's alternating plates.
-Ground Water
-Cold Liquor Water
-Glycol
Oxygenation
O2 is added to the cooled wort
-In line during cast out,
-Or to the wort in the fermenter
O2 is necessary to stimulate YEAST TO REPRODUCE (will be covered in detail in
FERMENTATION CHEMISTRY)
*Pure oxygen should not come into direct contact with yeast
Pitch that yeast baby!
Introduce the yeast into the fermenter with the cooled, oxygenated wort
-Directly through an opening in the fermenter
-Inline from a propagator
-Inline from another fermenter
-Injecter from a “yeast brink”