MALTING

Malting is the controlled, limited germination of cereal grains (usually

barley) which are then dried to give a friable, easily processed source of
fermentable sugars and other yeast nutrients.
The process begins when the grain is hydrated thus triggering
germination.
Hormones, including gibberellic acid (GA3) are produced by the embryo
stimulating the secretion of hydrolytic enzymes (notably amylases,
glucanases, pentosanases and proteases) by the scutellum and aleurone
layer.
These migrate to the starchy endosperm causing the progressive
breakdown with time of its structural components along the barley
kernel from the proximal (embryo) end to the distal end.
Malting industry: current practice conventionally, malting is divided into
three stages; steeping, germination and kilning. In current practice this
division has become increasingly blurred and may now be regarded as
an outmoded, if still convenient, classification. There is also rather more
to commercial malt production.

Current practice in malting

Grain selection, delivery, drying, cleaning and storage

 Steeping

Germination

Kilning and roasting

Dressing

Blending

Storage
 Dispatch
Pre-treatment of grain
Grain is delivered to malting in bulk, either direct from the farm or via
grain merchants. It is tested before acceptance (primarily for purity,
viability, nitrogen and moisture content) and passed to the undried
(green) barley store. Drying of the grain to 12% w/w moisture or less is
carried out as soon as practicable after delivery.
Cleaning of the grain to remove impurities such as stones, earth, dust,
nails as well as broken grains, husks, etc. is usually performed after
drying.
Required grain characteristics for malting Characteristic Benefit to the
maltster Varietal purity (ca. 99% of correct single Ease and uniformity
of malting variety) Sound grain (corns substantially undamaged, Avoids
problems in malting and with minimal fungal contamination, absence
maximizes yield of pre-germination, free from contaminants such as
insects, stones, etc.)
Steeping
Steeping involves increasing the moisture content of the grain to around
42–48% w/w.
This is usually achieved by immersing the grain in water but, in some
systems, involves spraying water over it. Before the grain is steeped, it is
tested to ensure that it has matured sufficiently during storage for
dormancy to have declined so that ready germination can occur.
During steeping the grain swells by about 25% and softens as cell
metabolism recommences. Water uptake is initially rapid and then
gradually plateaus out.
The rate of hydration is dependent upon variety, grain sample, corn size,
nitrogen content, temperature and other factors.
As the immersion period progresses, the steep water becomes
discolored due to the presence of dissolved materials and microbes from
the outer layers of the grain and is accordingly changed at least once.
A temperature of around 16ºC is commonly used for steeping as a
compromise between the physiological optimum and the need to hydrate
the grain quickly. It is common practice for air to be blown through the
immersed grain19 and for ‘air rests’ to be incorporated into the steeping
program.
This latter procedure, which involves draining off the water and leaving
the grain exposed to air for a period of 8–24 hours before re-immersion,
was initially advocated at the turn of the 19th century as a means of
speeding up malting but was little utilized at the time as such measures
were regarded with suspicion.
When the grain has reached the required moisture content, the water is
drained off for a final time. In most malting plants the grain is then
transferred (cast) to the germination vessel but in some designs, steeping
and germination are carried out in the same vessel.

Germination
Although malting is frequently spoken of by maltsters as a natural
process, it hardly qualifies for that description.
Successful germination to the maltster involves the controlled digestion
of the endosperm with the minimal growth of new tissue.
Such a transformation is only possible with human intervention. Various
additives have been used in malting, either on experimental or
production scale, in order to influence grain metabolism for the benefit
of the maltster.
In modern practice, probably only gibberellic acid (GA3) remains
relatively widely used. This hormone is usually applied as a sprayed
solution (ca. 0.1–0.25 mg GA3/kg barley) to supplement the natural
level in the grain.
Within that concentration range, good quality malts may be produced in
a shorter time, with smaller malting losses, as modification is enhanced
to a greater relative extent than is growth.
The treatment is particularly useful with otherwise unpromising raw
material. Potassium bromate, when applied to germinating barley, has
the effect of reducing respiration, rootlet growth and levels of soluble
nitrogen.
Over the years, better control of the process coupled with the wish to
accelerate production have led to the use of higher temperatures (16–
20ºC) which, together with the use of gibberellic acid, allows
germination to be complete in 3–5 days.
In Cereal biotechnology commercial malting, temperatures are altered
depending upon the type of malt required and also with the aim of
regulating malt composition and adjusting for variations in raw material.
Kilning
Kilning involves the drying of germinated grain in a forced flow of hot
air.
Choice of conditions will depend upon the type of malt being produced.
For most malt, the aim is to reduce moisture to below 5% allowing
storage for extended periods.
It is usual to start kilning with air at a temperature of 50–60ºC as it
enters the grain bed. Water is then removed at an approximately linear
rate until about half of the initial moisture remains.
The airflow will then be reduced and the temperature raised to facilitate
further drying.
When the moisture has fallen to 5–8% the curing stage is reached with
further reductions in airflow and increases in temperature.
Curing conditions largely determine the extent of color and flavor
development and enzyme survival.
With some lager malts, curing temperature may be as low as 65ºC,
whilst for some darker malt temperatures above 100ºC are used. Some
special malt is finished in roasting drums.
Modern kilns employ indirect firing in which passage of fuel
combustion products through the grain bed is avoided.
Furnace gases are used to heat radiators, which, in turn, heat the air for
kilning.
Dressing, blending, storage and dispatch
After kilning, the malt is dressed by a process of agitation, sieving and
aspiration which removes the brittle rootlets, dust and broken corns.
Freshly dressed malt is mixed with a bulk of malt which shows similar
analysis. Further blending may be carried out to ensure uniformity of
supply.
Malt is usually stored in bulk in water- and air-tight bins or silos.
It is usual practice to store malt for at least three weeks before it is
considered suitable for brewing.
Malt is dispatched to customers, usually in bulk, after a final cleaning
and analytical check.