Professional Documents
Culture Documents
Production
David J Maradyn
Staff Scientist – Brewing Customer Solutions
Novozymes North America
Franklinton, NC
2
AGENDA
• About Novozymes
• Basic enzymology
• Bioinnovation replaces
chemical ingredients in
processes and products
• Bioinnovation reduces
the use of raw
materials
• Bioinnovation optimizes
processes to save
energy and water
• Bioinnovation makes
many food products
healthier
.
7
Practical examples of
Bioinnovation across industries
Improve process
efficiency and the
Bioenergy
. of the end
quality
Agriculture
product while
reducing energy
consumption with
enzymatic process
enhancements.
Wastewater BioPharma
Solutions
Textiles Leather
Novozymes R&D
A common STRONG technology platform combined with dedicated
application teams
Diversity Screening
Beverages
Strain development
Detergent
Protein purification
Enzyme kinetics
Structural
characterization Technical
Assay development
Automation
HTS
10
Industrial enzyme
production
C-domain
Calcium
Calcium
A-domain
Active site
Calcium
B-domain Calcium
•H-bonds
•van der Waals interactions
•Salt bridges
•S-S bridges (cys-cys)
•Hydrophobic interaction
Calcium
•Metal ion binding (e.g. Ca2+)
•Ligand (incl. substrate or
substrate analog) binding
Sodium
Slide
No. 15
Binding specificity!
Even when different substrate
molecules are present, only those
that have the specific
complementary shape are able to
bind with the enzyme's active
site.
Active site
18
Enzyme kinetics
Enzyme reaction: E + S ↔ ES ↔ E + P
Kd kcat
Michaelis-Menten equation:
V = Vmax * [S]
Km + [S]
Km is Michaelis-Menten constant
(substrate concentration where the enzyme reaction rate is 50%
of the maximum rate)
1. Enzyme concentration
2. Substrate concentration
3. Temperature
4. pH
5. Inhibition
20
Inhibition
Competitive inhibition:
two similar molecules
fight for the same active
site on the enzyme
Product inhibition:
The reaction products of the
enzyme reaction competes
with the substrate for the
active site
25
Everywhere
Anytime
There is no life without enzymes
27
Novozymes enzymes
Production organisms
Fungi Bacteria
E.g., Aspergillus niger E.g., Bacillus licheniformis
31
Fermentation
Water
Raw materials
Mixing of
nutrient medium
Carbohydrates: Exhaust
Ground grain/corn
Sterilisation
Starch
Glucose
Sugar
Cooling water
Proteins:
Soy bean meal
Gluten
Corn steep liquor
Salts:
Inoculation flask
Phosphates
Sulphates
Ammonium salts
Seed fermenter
Enzyme recovery
Fermenter Pretreatment
Preservatives
Filter aid are added
is added
Liquid
product
Bacterial
Culture filtration
Ultrafiltration
broth
Stabilisation
Liquid
concentrate
Cooling Crystallisation for granulation
A
B
Enzyme crystals for
granulation
Drum filtration Filtration of
Bacterial filtration
enzyme crystals
33
Granulation
Raw materials
Enzyme crystals
or liquid
concentrate from Granulation mixer Processing aids
the recovery plant are added
Fluid-bed dryer
Sifter
Hopper
Coating mixer
Big bag
Sifter
Production equipment
Fermentors
35
Enzyme essentials
Specific – Natural – Not alive
Enzymes used in
Distilling
39
Winemaking process:
Industrial production of an Australian Popular Premium white wine
Clarification
(enzymes)
Extraction
Maceration
(enzymes)
6. Settling tanks
Maturation
7. Fermentation
tanks
43
With bioinnovation…
… wine filtration is problem free, smooth, and
reliable.
With bioinnovation…
… winemakers can offer consumers richer and
fruitier white wine with enhanced aroma.
.
.
Carbohydrases release
color, flavor, and aroma
compounds trapped in
the polysaccharide
matrix.
46
Target customers:
- companies that manufacture juices from fruits
Customer needs:
- produce storage stable juices at maximized juice yield,
and provide maximized value to the consumer.
Markets served:
- fruit crushers, drink formulators and service providers
With bioinnovation…
… specific enzyme preparations increase the
yield of essential oils.
Berries Mash treatment and pectin Maximized juice yield / press capacity + clear and stable
degradation juice
Citrus Clarification Clear and stable juice
Cloudy and peal treatment Achieve a stable cloudy juice
Essential oil extraction Facilitate extraction of oils of the peel
•Faster processes
Attenuation control
(Light beer)
Packaging
Guarantee Process efficiency
55
Fermentation
α-acetolactate
decarboxylase
Filtration
β-glucanase
xylanase
Quality
Attenuation control
amyloglucosidase, pullulanase,
α-amylase
With bioinnovation…
... brewers can produce quality beers from
available raw materials supplied with variations
in quality.
Enzymatic filtration raises the benchmark for
mash separation and beer filtration, providing
Ultraflo® Max process predictability and consistency for
improved quality and cost-efficiency.
57
.
.
Breaking up complex
carbohydrate structures
into smaller, more
soluble oligomers leads
to lower viscosity and
better filterability.
58
With bioinnovation…
... brewers are given great flexibility in their
choice of raw materials for brewing.
.
If no or insufficient malt
. are present,
enzymes
carbohydrases and
proteases will hydrolyze
polysaccharides and
proteins into oligomers
for easy brewing of
quality beer.
60
With bioinnovation…
... there is no risk of diacetyl formation.
. α-acetolactate
Acetolactate
decarboxylase converts
α-acetolactate into Acetolactate
acetoin so that diacetyl decarboxylase
formation can be
avoided.
62
Substrate: starch
Amylose:
•α-1,4 glycosidic bond (~100%)
•10–30% typical composition
Amylopectin:
•α-1,4 glycosidic bond (94–95%)
•α-1,6 glycosidic bond (5–6%)
•70–90% typical composition
65
α-amylase
DP6
DP4
DP3
DP2
66
Thermostable α-amylases
work better at 85–95 ºC
Faster Throughput
More Extract
71
Ultraflo Max
added at start of mashing
72
β-glucanases
Cellobiohydrolase
-1,4-
-1,3
-1,4-
-1,4- -1,4-
β-glucosidase Endoglucanase
Endo-β-1,3(4)-glucanase
(β-glucanase, cellulase)
Glucose
β-glucan
Long molecules of mixed linked
1,3–1,4-glucose
74
Arabinoxylanases
Arabinoxylan
Long molecules of xylose
backbones with arabinose
75
Therefore they:
Make wort and beer filtration processes much more
difficult
May also prevent optimal extraction
76
Improved Attenuation
Control
79
Beer specifications
alcohol content
residual extract
calories
Brewing process
Extract yield
Breaking down more starch more
consistently
81
Amylose
Amylopectin
82
Simple
Long-chain sugars sugars
(dextrins)
First generation
AMG 300L
Glucoamylase activity
Fungyl alpha-amylase activity
Non-GMO derived
Second generation
Attenuzyme
Glucoamylase activity
Fungyl alpha-amylase activity
Derived from GMO
More heat-stable, broader pH-activity range
Third generation
Attenuzyme Flex
Glucoamylase activity
Fungyl alpha-amylase activity
Pullulanase activity
Derived from GMO
Improved attenuation control – Light beer – Brand
87 building
Amyloglucosidase (glucoamylase), pullulanase,
amylase
α-amylase
Pullulanase
Glucoamylase
Fermentation
92
Fermentation
Diacetyl (2,3-butanedione) is arguably the most
important flavor characteristic of beer during
maturation
2,3-Pentanedione acts in a similar way, although
with a much higher taste threshold
These two compounds are considered together and
referred to as vicinal diketones (VDK’s)
The breakdown of these compounds is considered
essential criteria for the state of beer maturation
93
Fermentation
94
Fermentation
VDK reduction is accomplished by
Increasing temperatures at the end of
fermentation
Diacetyl rest
Extending maturation
Depending on adjunct ratio, yeast type, physical
environment
Time and temperature requirements for VDK
reduction are not easily predicted
High barley ratios and use of sugars as adjunct can
lead to increased VDK formation by yeast
95
Fermentation
Alpha-acetolactate decarboxylase enzyme solution
by Novozymes
Maturex® 2000L
Breaks down alpha-acetolactate directly into
acetoin
Avoids the formation of diacetyl
Will not affect any diacetyl already formed
Added to cold wort at the beginning of
fermentation
Prior to pitching of yeast
96
Fermentation
97
Fermentation
Maturex® allows brewers to
Shorten, or even bypass, rate-limiting warm maturation
(diacetyl-rest)
Optimize vessel use
Reduce energy consumption
Maintain high quality index of final beer
Dosages can be adjusted to meet VDK specification at the
same time as final attenuation is achieved
98
Diacetyl
(mg/L)
3.0
2.0
1.0 0 ADU/L
40 ADU/L
0.0 100 ADU/L
200 ADU/L
0 1 2 3 4 5 6 7
Fermentation (days)
99
Fermentation
0.6
Without Maturex ®
0.5
0.4
Diacetyl (ppm)
0.3
With Maturex ®
0.2
0.1
0
0 20 40 60 80 100 120 140 160 180 200
Time (hr)
Fermentation
100
1 Cleaning 1 Cleaning
to Filter to Filter
2 Lagering -1°C Lagering -1°C
Cooling
3
Cooling
3 Lagering 7°C Lagering 7°C
4 5
Tank 5 Tank
7
6
7 1
8
3
1
Fermentation
Dosage
0.75 to 1.50 g/hL
pH dependence
Activity strongly pH dependent
Activity at pH 5.0 3X higher than at pH 4.0
pH should be monitored during fermentation and controlled
if needed
Ensure diacetyl control at lowest treatment cost
102
Fermentation
Benefits
Cost savings
Shorter production cycles
Energy savings through cooler fermentations
Enables increased adjunct ratios for raw material savings
without extending diacetyl rest
Reduced capacity costs for new breweries through
improved utilization
103
Fermentation
Optimum throughput
Meet peak season capacity demands
If capacity not an issue, apply time savings to extend cold
aging period for better cold break formation, and longer
beer filtration cycle
Brand management
Never release beer with detectable levels of diacetyl
Increased flexibility to choose yeast types for maximum
flavor development
Cost Effective Adjunct and
Malt Solutions
105
Introduction
Brewing with increased amount barley is primarily driven by the
lower cost of barley compared with malt
Other drivers includes
Reduction of the CO2 emission
Use of local raw materials
Barley is usually added by mashing-in of a limited percentage of
barley, up to 30%
The Novozymes Ondea® Pro concept enables for brewing of
100% barley (or combinations of barley and adjuncts)
Where the barley wort can be blended with a malt-wort to
produce beer
or be sold as is
Or
Barley and malt can be mixed together (varying ratios) in
the mash-tun to produce a barley/malt wort to produce beer
109
Ondea Brewing
β-glucanase, xylanase, protease, amylase,
pullulanase, lipase
Ondea® Pro
110
66
70
64 68
Maltose > 60 %
62 66
RDF
60 64 Maltotriose < 15 %
58 62
60 Dextrins (DP4+) < 20 %
56
58
54 56
52 54 Low glucose level leafs the opportunity to add
0 1 2 3 syrup and still create a “maltose” profile
kg Ondea Pro
Maltose % RDF% per ton barley
114
13
12
11 Barley wort needs
10 only
9 9 mg FAN/l/Plato
mg FAN/l/Plato
8 to secure a good
7
fermentation
6
5
4
3
2
1 NOTE: pre-inactivation of
the endogenous
0
proteolytic enzymes by a
0 2 3 4 heat treatment at 75°C
Kg Ondea® Pro per ton barley for 30 minutes
Without inactivation With preinactivation of barley enzymes
Barley wort produced with Novozymes Ondea® Pro has
116
FAN level and FAA profile of barley and malt wort in pilot and
industrial scale
FAN / mg/l
60 200
% RDF
40
20 100
0 0
0 24 48 72 96 120 0 24 48 72 96
Fermentation time/hr Fermentation time /hr
100 % barley 100% malt 100% Barley 100% Malt
119
3
mPa*s
2.5
no enzyme
2
2 kg/t Novozymes
Ondea® Pro
1.5
1
50 60 70 80 90 100 % Barley
121
Barley Milling
45% 45%
40%
40%
Percentage of fraction
35%
30%
30%
25%
20%
15%
15% 14% 14%
13%
10% 8%
8%
5% 6%
5%
2%
0%
0 1 2 3 4 5 6
Sieve
Malt Barley
123
The concept has been tested in a number of pilot and production brews globally
The majority of products produced were good-tasting beers – no defects
The resulting sensory profiles have been different reflecting the brewmaster’s
optimization
The barley beer taste can be optimized to resemble taste of a malt based beer
Flavour Characteristics
Beer quality
Ondea® Pro pilsner is similar to all-malt pilsner wrt
Plato, RDF, gravity, alcohol, haze, pH, CO2, foam, etc.
…..and most importantly…TASTE
125
8 % CO2 Barley
REDUCTION AT BREWERY
Brewery
Beer
GO DIRECTLY FROM
BARLEY TO BEER USING
NOVOZYMES ONDEA®
PRO
Conclusions
A enzyme solution – Ondea® Pro - and process have been
developed to enable the brewing of great-tasting beer with up to
100% unmalted barley with existing brewing equipment
Ondea® Pro works in synergy with the endogenous enzymes
from barley
The pullulanase component found in Ondea® Pro is essential for
the attenuation performance, producing a high-maltose wort
The amino acid composition of 100% unmalted barley wort
differs from malt based wort
higher group A and B amino acids and lower proline content
Effective lautering and filtration is ensured through the enzyme
system, milling adjustment and lauter tun management
Flavor of 100% unmalted barley beer is similar to 100% malted
barley beer
130
THANK-YOU
Questions
Answers
CONTACT INFORMATION:
DAVID MARADYN