AU668046B2 - Process for manufacturing fermented beverages - Google Patents

Description

18011 6 8J~ P/00/0011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT *Q~e i a a a a o 1 o a~e i a ocsd i d 0 o ae S aa ir

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ORIGINAL

Name of Applicant: Actual Inventor: Address for service in Australia: MORTON WILLIAM COUTTS Morton William Coutts CARTER SMITH BEADLE 2 Railway Parade Camberwell Victoria 3124 Australia Invention Title: PROCESS FOR MANUFACTURING

BEVERAGES

FERMENTED

The following statement is a full description of this invention, including the best method of performing it known to us a C-LC C_ 9L- -I 4 vw- _dl O BI -2- This invention relates to processes for the manufacture of beer and other alcoholic beverages and related products.

This invention relates to a process for the manufacture of alcoholic beverages and in particular relates to a process where important yeast nutrients contained in the liquid extract obtained from processed germinated grain are retained in the extract solution until it is fermented by brewers yeast to produce alcohol and other substances.

Brewing literature shows that coagulation and adsorption during and after the traditional extract boiling process used in breweries are responsible for the removal from the germinated grain extract of many of the important fermenting yeast nutrients.

With a view to preventing the loss of yeast nutrients resulting from the coagulation of processed germinated grain extract materials during and after the traditional extract boiling I have developed a process which allows the processed 15 germinated grain extract containing the important yeast nutrients to be cooled o 000e directly to a fermenting zone and because there has been no loss of the extract nutrients, brewers yeast will quickly ferment this extract to the higher than normal alcohol content of over 9% alcohol by volume.

In a first aspect the present invention consists in, in a malting and brewing 00 "0 20 process, a method of manufacturing an alcoholic beverage comprising the steps of: holding moisture infused grain until the grain has germinated, then o odisintegrating it and with water in a brewer's mashing equipment making a brewer's mash where all processing temperatures including 0:000 those temperatures used to enhance enzyme activity which will produce extracts of carbohydrates and protein materials in liquid form are all kept below 180'F, (ii) removing the extracts in soluble liquid form from the residue grain and heating the extracts to temperatures below 180F to enhance enzyme activity therein, and then cooling the soluble extracts in liquid form to a temperature of between 50F and 60°F and JRG:D:fISl0.R]3S 12 Fobruy 1996

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~P SL~-L~_ILC- _L~CI -3- (iii) mixing the soluble extracts in liquid form of step (ii) with fermented extract containing 3% or over of alcohol by volume which before fermentation was prepared according to step(s) and (ii) so that the mixture now contains 1.5% or over of alcohol by volume and other products of fermentation, and (iv) fermenting said mixture of (iii) with oxygenated brewers yeast to provide said alcoholic beverage.

Preferably in step (iii) mixing the soluble extract in liquid form with the fermented extract is in a ratio of 1:1 by volume.

Preferably step (ii) involves heating said extracts to a temperature below 180°F and holding it for up to 40 minutes.

Prefe:rably the fermented extract of step (iii) before mixing contains from 3% to 6% of alcohol by volume and the mixture to be fermented containing from to 3% of alcohol by volume.

15 Preferably the fermentation of said mixture commences with an alcohol content of over 3% by volume.

Preferably the alcohol content of the alcoholic beverage is from 6% to 12% °by volume.

Preferably the soluble extract of step is obtained from germinated grain 20 which has been subjected to drying to below 15% moisture using air at a .00 temperature below 180°F to enable the grain to be screened and polished to become 0° what is known as malt and then subjected to processing after disintegration.

o Preferably the processing of the germinated grain in step is performed in vessels with at least a partial vacuum.

Preferably said heating step (ii) is performed in a vessel with at least a partial vacuum.

Preferably said soluble extracts of is extracted by pressing in a manner analogous to grape pressing.

Preferably the fermented extract of step (iii) is a recycle of at least part of an alcoholic beverage prepared by all of steps to (iv).

12 Fcbrury 1996

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I;i- -4- Preferably the method is performed substantially as herein described with reference to any one or more of the accompanying drawings.

The invention also consists in an alcoholic beverage when produced by a process of the present invention.

Preferably the alcohol content is above 6% to 12% by volume.

Various known extraction methods used in the brewing industry which produce yeast fermentable extracts containing important yeast nutrients are described as Figure 1 to 6A and 6B hereafter.

One such extraction process for obtaining a liquid extract from a germinated grain (such as barley) comprises the steps of: germinating the grain or corn (eg. barley) in moisture and growing the same in air until the enzyme mechanism has been developed by the embryo; heating the resulting product to an elevated temperature to enable the enzymes developed there within to convert the convertible material within the content of the germinated grain or corn; and thereafter separating, as a liquid or in a liquid medium, the convertible extract from the inner contents of the grain.

Preferably, the extract is in a liquid form and is either cunveyed to S, 0: fermentation or to cold storage until required.

1 1 20 Preferably, said elevated temperature is about 150 0

F.

Preferably, after said separation stage, ie. of the husks or skins, the embryo i and other unfermentable material from the liquid extract but prior to feeding into a V I" fermentation zone, there is a dwell time at said elevated temperature in order to ensure a conversion of any residual convertible material and to destroy any unwanted organisms.

Preferably, said separation from the extract is by a pressing process, eg. such as a continuous grape press with a sparge.

Preferably, said dwell time is up to about 40 minutes at a temperature of about 150 0

F.

Preferably, said grain is of barley but any other grain can be used.

i SC C *1 0 C. CC Another extraction process for obtaining a liquid extract from a germinated grain which has been subjected to a kilning process (preferably a known process) to become what is known as malt, is subjecting the malt to moisture, heating the resultin 3duct in stages (or at least incrementally increasing) to elevated temperatures to enable the enzymes developed within the corns to produce a yeast nutrient substance or substances within the malted corn, thereafter separating the yeast nutrient substance and fermentable substances in a liquid medium from the inner contents of the grain..

Preferably the final stage of the elevated temperatures is about 150F.

Preferably after said separation stage, ie. of the husks and/or skins, the embryo and other unfermentable material from the extract there is a dwell time at said final elevated temperature in order to ensure enzyme conversion of any residual nutrient and fermentable material(s) and to destroy unwanted organisms before being cooled to a fermentation zone.

Preferably, said separation stage is by a pressing process, eg. such as a known continuous grape press with a sparge.

Preferably said dwell time is up to about 40 minutes at a temperature of about 150 0

F.

Preferably said grain is of barley but other grain can be used.

Yet another extraction process for obtaining a liquid extract from a germinated grain which has been subjected to a kilning process (preferably a known process) to become what is known as malt, is subjecting the malt after disintegration to moisture heating the resulting product in stages (or at least incrementally increasing) to elevated temperatures to enable the enzymes developed within the corn contents to produce a yeast nutrient and fermentable substance or substances, and thereafter extracting the yeast nutrient and fermentable substance or substances in a liquid medium.

Preferably the heating is in vessels with at least a partial vacuum.

Preferably the moistening step is in a vessel with at least a partial vacuum.

Preferably said extraction is from a vessel in which heating took place.

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The invention consists in the foregoing of which the following gives examples.

Preferred forms are shown in the following drawings in which: Figure 1 shows a diagrammatic view of the first stages of one form of the invention; Figure 2 shows a diagrammatic view of the final stages of one form of the invention; Figure 3 shows a diagrammatic view of another form of the invention; Figure 4 shows equipment and a process for heating kilned malt or germinated barley with heated water; Figure 5 shows a most preferred process; and Figures 6A and 6B show another preferred process e.g. where malt and/or germinated grain is at least partially disintegrated to assist moisture uptake and with some recycling yeast fermentable and nutrient extracts are made available for fermentation.

The coagulation and adsorption during and after wort boiling are responsible for the loss of many important fermenting yeast nutrients.

With a view to preventing the loss of yeast nutrients resulting from the coagulation of wort materials during and after the traditional wort boiling process, 20 I have developed a process to retain these nutrients by fermenting the extract directly from the mashing process unit and not boil the extract at all.

I have developed an oxygen free mash extraction unit which produces extracts that normal brewers yeast can quickly ferment to a concentration of over 6% alcohol by volume.

The extract which contains all available lipids and other yeast nutrients free from oxidation is cooled directly from the mashing unit th a fermenting vessel where it is mixed with an equal amount of fermented extract containing over 6% alcohol by volume.

After normal aeration and yeast addition the mixture begins fermentation with a pH where it is safe from wort bacteria and with an alcohol content of over 3% which prevents unwanted fermentation flavours being produced.

'iT r' c* Ja~~~pa ~L ba~rC~- This method of extract production and fermentation makes it possible to do without the wort boiling process now used in breweries.

In a first form of the invention, the process proceeds substantially under the force of gravity. Of course, other forms are envisaged wherein the process proceeds by means of pumping or other mechanical movement means. As shown in Figure 1, screened viable barley is stored in a storage tank or vessel 1. The barley is then moved into tank 2 and water is added. In other forms of the invention, the barley is simply added straight into the tank 2. The barley is allowed to steep in the water as in known processes.

The steeped barley is then moved into the drum 3. This drum is preferably heated for four days to encourage embryo growth to maximise enzyme production.

After the barley growth, the barley is moved from drum 3 into tank 4. The temperature of the barley is raised to approximately 150F which prevents further activity by the embryo. At this stage the process is held until there is complete i 15 conversion of the wanted proteins and carbohydrates. The converted liquid barley *exits the tank 4 at point As shown in Figure 2 the barley, which exits the part of the process shown in Figure 1 at point enters the part of the process shown in Figure 2 at the point marked also. The converted barley passes into an auger, for example, a grape press at point The grape press 5 compresses the converted 20 barley and the husks of the barley exit at point 6. The liquid portion of the barley content exits at point 7 and passes into tank 8. The barley extracting tank 8 is maintained at about 150F and this temperature is held for up to about 40 minutes.

If required, isomerized hop extract is added to the liquid barley extract at point for anti-bacterial purpose before the fermentation occurs. The liquid barley extract exits the tank 8 at point 9 at which stage it is taken to storage and settling which preferably takes place at 32 0 F/or to a fermentation zone where it is fermented.

Another form of the invention is as shown in Figure 3. This extract preparation equipment comprises a tank 20 to which barley is admitted from barley storage. Water is added at 21 and passes into the continuous auger 22. The first 0 stage of the auger consists of a steeping and growth section which allows the barley to be steeped in the water and embryo growth to occur. This section is labelled 23 on the Figure 3. The steeped barley then passes into the heating and saccharification section. This is labelled 24 on the diagram. The final section of the auger is the section labelled 25 which is the continuous grape press and sparge. The husks and skin and other unwanted materials are exited from the auger at the point labelled 26. The extract passes out of the auger at the point labelled 27 where it is, if desired, mixed with an isomerised hop extract. It then passes into a tank 29 at a point 28. The extract is preferably held at 150'F for forty minutes. The extract exits at the point labelled 30 and is cooled to 50°F at which point 3 1 it passes into a fermentation plant of the type which are well known in the art or it is taken to a cold storage where it can be stored at preferab!y 32°F until required.

It is obvious to those skilled in the art that the form of the invention as shown in Figure 3 can easily be incorporated into a continuous fermentation plant where the steady state content of alcohol concentrations could be greater than 9% by volume which enables a sterile environment to be maintained.

Figure 4 shows equipment for heating kiln malt or germinated barley with heated water showing: i) the addition of measured quantities cf brew water to give final specific gravity required for the extract; ~ii) heat circulating liquor to give the temperature required for maximum activity of the various enzymes as required; iii) circulating liquor at between pH 5.2 and pH 5.6 is expected to minimise extraction from the grain skins.

A preferred malt produced process also within accordance with the present Sinvention is as previously set forth, ie. obtaining a liquor extract from a germinated grain which has been subjected to a known kilning process to become malt then subjecting the malt to moisture heating the resulting product in stages to elevated temperatures to enable the enzymes to develop within the corns to produce a yeast fermentable extract and nutrient substance or substances within the malted corn, and thereafter separating the yeast fermentable extract in a liquid medium from the inner Scontents of the grain, preferably using a grape type press to achieve the rupturing.

Ideally, the final stage of the elevated temperatures is about 150'F and that there is r -9a dwell time of the order of 40 minutes at that period in order to ensure enzyme conversion of any residual material(s) and to destroy unwanted organisms before being cooled to a fermentation zone and fermenting the said extract.

Figure 5 shows a most preferred embodiment in which: 32 is germinated grain or disintegrated kilned malt where all processing temperatures are below 180°F; 33 is a combined steam condenser and vacuum pump; 34 is a grain shredder; is a tubular heat exchanger to heat the contents of the vessel in stages to a maximum of 150°F; 36 is a grain slurry pump to circulate the vessel contents as shown in Figure 37 is a centrifugal pump; 38 is a combined press and filter (eg. MEURA 2001); with Pore size to allow free passage of Lipids through the filter when separating the liquid extract from the unfermentable material.

S- 39 is a heated dwell vessel to a maximum of 150°F; S- 40 is a heat exchanger; S- 41 is a to fermenter at about 54°F to be fermented as described for Figure 20 6 or cold storage at 32 0

F;

42 is acid addition to reduce pH to about 5.4.

When processing germinated grain directly from an adjacent germinating f zone where the moisture content of the corns is about 35% moisture the grain shredder 34 should be used as soon as the final saccharification temperature of 150°F has been reached.

The vacuum pump should be used to reduce the air in the vessel as soon as the grain and water begins entering the vessel. Preferably the vacuum should be increased so that the contents of the vessel begin to "boil" about 20 minutes after the final saccharification temperature of 150°F has been reached and continued until the required specific gravity of the extract has been attained. The liquid content in the vessel should be maintained so that it covers the grain contents until that time when the "boiling" and the extract concentration process commences.

When using enough brew water to keep the mash pumpable it will be found that the obtainable fermentable extract concentration is not enough (or not always enough) for the yeast fermentation to produce the concentration of alcohol required.

In this situation approved processed soluble carbohydrate concentrates such as crystallized cane sugars and/or other approved soluble yeast fermentable concentrates should be added to vessel 39 shown at Figure This addition should be made during the extract dwell time of 40 minutes at 150°F until the required concentration of fermentable extract is obtained in vessel 39. Known mixing means should be provided to vessel 39 to ensure a homogenous condition of the extract contents before being pumped to the heat exchanger 40 for cooling and to fermentation at 41.

15 The present invention provides not only improved processes for malt and/or germinated barley extract production as shown in Figure 5 but also the products of any such procedure as well as any by-products.

Figures 6A and 6B show a variation of the foregoing procedures.

If germinated grain which has been dried to below 15% moisture is used to 20 assist moisture take-up it should be screened and polished and disintegrated.

The disintegrator 34 shown in Figure 5 could be located at the vessel So IA point of entry 2A.

When the required concentration of fermentable extract must be obtained from the germinated grain mash only, a feed back method using residual extract from the previous mash is used to mix. with the new incoming disintegrated grain to make the next mash. This residual extract recycle method is shown at Figure 6A and is described as follows.

Germinated grain with over 30% moisture and/or germinated grain which has been dried to below 15% moisture and has been screened, polished and t P disintegrated by known means is added to vessel 1A at tube entry 2A. To prevent U dust forming in vessel 1A the grain can be made wet by adjusting valve 3A.

11 The residual liquid extract from the previous mash which has been held in vessel 7A is cooled by adding cold brew water through valve 9A and the residual extract is then transferred back to vessel 1A by way of pump 6A and valve 5A and 8A during the time the grain is entering vessel 1A through tube 2A.

The contents of vessel 7A can be made homogenous by opening valve 16A before the transfer.

The temperature of the contents of vessel 7A is controlled so that when !mixed with the grain in vessel 1A the temperature of the mixture will be about 124°F. As soon as the grain entry is completed close valve Remove as much air as possible from vessel 1A by opening valve 4A and starting the condenser vacuum pump 14A. The circulating circuit is put into operation by opening valves 10A and 1 A and starting pump 12A.

As soon as the residual extract in vessel 7A has been returned to vessel 1A and the required amount of grain has been added by way of tube 2A control the steam valve 15A to heat the mash passing through the shell and tube mash heater i j 13A. The temperature of the mash should not be above 145°F at outlet of the mash heater 13A.

Within 15 minutes the mash contents of vessel 1A should have reached a i jtemperature of 144°F and at this point the steam control valve 15A is closed.

i 20 After 20 minutes rest, steam control valve 15A is opened to heat the circulating mash to 151°F at the outlet of the mash heater and continued until the I total contents of vessel 1A has reached 150°F when the steam control valve 15A is Si turned off.

Valve 4A and vacuum pump and condenser 14A are now controlled to maintain a vacuum in vessel 1A necessary to cause the extract to "boil" at 150 0 F and the shell and tube steam heater 13A will be adjusted to maintain the extract at 150 0

F.

The "boiling" process will result in the steam condensing on the floating grain and so causing dilution of any adhering extract which will drain down to the main volume of liquid extract and so increasing the buoyancy of the floating grain.

111~ ~II*LZ~C~f? rrsm~ 12- The circulation and "boiling" at 150F process should be continued for minutes when the enzymic activity will be completed and any sedimented material will have been returned from the cone to the spent grain floating on the concentrated extract.

At this point v' Ives 17A and 19A and pump 18A is controlled to transfer all the available liquid extract in vessel 1A through the strainer plates in the cone of vessel 1A to the dwell vessel 39A.

Dr.ng the dwell time of about 30 minutes the extract is held at 150 0 F by the steam heated jacket on the cone of vessel 39A and the extract will simmer at 150°F under vacuum by opening valve 36A and controlling vacuum pump 14A. This will remove any entrained air and will prevent hot oxidation of some of the extract material occurring.

As soon as the available liquid extract in vessel 1A has been transferred to vessel 39A the valves 17A and 19A are closed and pump 18A is stopped.

An amount of brew water at 160F is added to vessel 7A through valve 9A and pumped by way of valve 5A, pump 6A and valve 8A to vessel 1A until the required liquid level in vessel 1A is reached. Valves 10A and 11A and pump 12A will continue to circulate the mash until the contents of vessel 1A are a homogeneous mixture. The shell and tube steam heater 13A will keep the circulating mixture at 160 0

F.

A controlled flow of the mixed mash from vessel 1A is now run to the continuous grape type press 21A by way of valve 22A. The residual liquid extract pressings are pumped to vessel 7A by way of pump 23A and valve 24A. A further dilution of the residual extract can be made with 160 0 F brew water by way of valve 25A at the press sparge point if desired. The spent grains will exit from the continuous press at point 26A.

When the residual extract pressings of the contents of vessel 1A has been completed, the temperature of the residual extract in vessel 7A is raised to 160°F by the steam heated jacket around the cone of vessel 7A. The valve 27A and the Scondenser vacuum pump 14A is preferably operated to bring the residual extract to a gentle "boil" to remove any entrained air picked up during the pressing and

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TnTo i _II 13 transfer operation. Circulation of the heating residual extract is maintained by pump 6A through valves 5A and 16A.

After 15 minutes, to stop the residual extract circulation, the pump 6A is stopped and valves 5A and 16A are closed and the steam is turned off the heating jacket. The vacuum pump 14A is stopped and valve 27A is closed. Valve 28A is opened to allow a top pressure of CO, on the top of the residual extract which is now held in vessel 7A in a sterile condition until required to repeat the cycle and make the next mash in vessel 1A. The temperature of the held residual extract in vessel 7A may now be increased if required.

Returning to the dwell time vessel 39A containing the concentrated extract from vessel 1A. After the 30 minutes dwell time any sediment in the cone is returned to vessel 1A by way of valves 29A and 31A and pump 30A. Valve 31A is then closed and valve 32A is opened. This allows the concentrated extract in vessel 39A to pass through the heat exchanger 33A where it is cooled to about 54°F and from there to the fermenting vessel 34A where it is mixed with an equal volume of fermented extract which before ferm-nentation was prepared in the same way as the unfermented extract. The mixture now contains an alcohol content of over 3% by volume and a pH value where it is safe from wort bacteria and because of these conditions the mixture then ferments free from unwanted fermentation flavours.

This known mixing process is used by both continuous fermentation and the doubling system of batch fermentation where the extract to be fermented has been subjected to the traditional boiling process thereby restricting alcohol products.

Figure 6B is similar to the arrangements shown in Figure 6A but shows the use of a combined press and filter as described in Figure 5 at item 38.

S i 25 It will be noted that the vessels and equipment for processing the fermentable i .textract have been designed to be cleaned automatically by known clean in place a systems.

The processing controls can also be operated automatically by a known system of series connected contacts on the processing controls which make up closed electrical loops. These loops are activated when the operator selects the desired loop by turning a rotary selector switch.

4 RAie IRG:LD:1S58O.RES 12 Fcbruay 1996 r o 14- These systems do not require specialist operators.

If it is not desired to construct a vertical cone vessel strong enough to stand i the inside vacuum necessary to cause the contents to boil at 150F provision has i been made for the injection of CO 2 into the circulating mash loop to give the shredded grain buoyancy aid and the vacuum pump is used only for displaced air removal to prevent oxidation.

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Claims (9)

1. 2. A method of claim 1 wherein step (ii) involves heating said extracts to a temperature below 180F and holding it for up to 40 minutes.
2. 3. A method of claim 1 or claim 2 wherein the fermented extract of step (iii) contains from 3% to 6% of alcohol by volume and the mixture to be fermented containing from 1.5% to 3% of alcohol by volume.
3. 4. A method of claim 1 or 2 wherein the fermentation of said mixture commences with an alcohol content of over 3% by volume. A method of any one of the preceding claims wherein the alcohol content of the alcoholic beverage is from 6% to 12% by volume. JRO:LD:#1S .riS 12 February 1996 'T -16-
4. 6. A method as claimed in any one of the preceding claims wherein the soluble extract of step is obtained from germinated grain which has been subjected to drying to below 15% moisture using air at a temperature below 180°F to enable the grain to be screened and polished to become what is known as malt and then subjected to processing after disintegration.
5. 7. A method as claimed in claim 6 wherein the processing of the malt after disintegration is in a vessel with at least a partial vacuum.
6. 8. A method of any one of the preceding claims wherein the processing of the germinated grain in step is performed in a vessel with at least a partial vacuum.
7. 9. A method as claimed in any of the preceding claims wherein said heating step (ii) is performed in a vessel with at least a partial vacuum. A method of any one of claims 1 to 9 wherein said soluble extracts of is extracted by pressing in a manner analogous to grape pressing.
8. 11. A method of any one of the preceding claims wherein said fermented extract of step (iii) is a recycle of at least part of an alcoholic beverage prepared by all of steps to (iv).
9. 12. A method as claimed in one of the preceding claims when performed substantially as hereinbefore described with reference to any one or more of the accompanying drawings. 20 13. An alcoholic beverage when produced using a process of any one of claims 1 to 12. SI DATED: 12 February 1996 CARTER SMITH BEADLE Patent Attorneys for the Applicant: WILLIAM MORTON COUTTS ,i .RES 12 Fcbmay 1996 i"i-irspmrclr-- I ABSTRACT A method of manufacturing an alcoholic beverage having a high alcohol content using an unboiled liquid extract of soluble yeast nutrients from processed moisture infused germinated grain but still involving heating to enhance enzyme activity therein but to a temperature below that where coagulates are formed which would cause yeast nutrient material to be entrapped in coagulate such as that which would be produced were the liquid extract to be boiled at atmospheric pressure and thereafter fermentirg the cooled liquid extract with oxygenated brewers yeast in a 10 zone having an alcohol content of over 3% by volume and other products of fermentation to provide said alcoholic beverage. Preferably the commencement of fermentation alcohol content and other products of fermentation result from a partial recycle from a preceding fermentation. it.' itt' 'ItI I,, 9I t t I 4 t I It ItI I j