Application of Unconventional Raw Materials, pp.275-278 Volume 105 No.

5, 1999

Application of Unconventional Raw Materials and Procedures

in Wort Production*
By Olgica Grujic

Faculty of Technology, Novi Sad, Yugoslavia

Received 17th July 1998

This paper deals with investigations of wort production by the application of unmalted raw
material - native barley as a partial sttbstitute for malt in grist Tliis adjunct was differently
treated: (1) thermal decomposition, (2) enzymic decomposition by the addition of commercial
enzyme "Termamyl", and (3) hydrothermic decomposition i.e. extruding.
Native barley prepared by these methods was added in proportions up to 70% of the grist,
without the addition of exogenous enzymes. Experiments were carried out on a laboratory scale
by using an infusion mashing procedure for wort production.
The results obtained indicated that the application of native barley as the adjunct, gelatinised
by heat treatment gave good results up to 10% as malt substitute. Larger amounts of barley
gelatinised by heat treatment decreased extract yields.
Malt substitution with pretreatment of barley with enzyme did not produce satisfactory
results. Worts had reduced levels of extract and soluble nitrogen, which were insufficient for the
production of high quality beer.
Application of barley flakes in quantities up to 50% produced wort which had good analytical
quality parameters.

Key Words: Adjuncts, barley, barley flakes, wort quality.

INTRODUCTION available on the domestic market, as well as inadequate

In Yugoslavia, as in most other countries in the world, capacities of brewhouses for summer peaks of beer

beer is brewed with the addition of adjuncts to malt consumption, which resulted in the consumption of
grists. The principal adjunct is maize, or refined maize high proportions of sugar-type adjuncts, mainly sucrose
grits, but, in the last decade, unmalted barley has also at that time. Today, the technical capacities of the
been applied. The quantities or types of adjuncts are not Yugoslav malting industry significantly exceed the
legally restricted, but breweries add up to 40% of maize needs of Yugoslav breweries, even if they produced only
starch or maize grits in the whole grist, normally with all-malt beers. In spite of that, low beer prices, high
commercial enzymes, but in some cases conversion in duties, and the small purchasing power of the
the brewhouse is performed only with enzymes from population, force the breweries to use adjuncts in high
brewer's malt. If used, barley represents some 20-30% of percentages.

the grist, and it is processed with enzymes which have Having that in mind, it was considered as useful to
liquefying (thermostabile a-amylase), saccharifying, examine whether one relatively new product on the
proteolytic and cytolytic (p-glucanase) activities10 7"15. In Yugoslav market, i.e. pregelatinised barley flakes, could
some breweries adjunct addition can be as high as 60%. be used to decrease further the costs of raw materials for
Small quantities of all-malt (specialty) beers are beer production.
produced in several of the 13 active breweries in
Yugoslavia while some minimal quantities of pure-malt EXPERIMENTAL
beers are produced by "butique" breweries.
Materials
The main current reason for the high proportion of The raw materials for mashing experiments were
adjuncts used is that of economics and starchy adjuncts commercial pale malt obtained from a commercial
are normally 2 or more times cheaper than malt. The Yugoslav malting plant; barley flour (fine grind, DLFU)
principal reasons for the use of adjuncts in Yugoslavia obtained from the winter barley Novosadski 183;
20-25 years ago were insufficient quantities of malt gelatinised (extruded) barley flakes, commercial
product of the "Agroseme" Co., Subotica, Yugoslavia;
* Presented at 1st International Conference of the Chemical Societies
of the South-East European Countries "Chemical Sciences and heat-stable a-amylase Termamyl™ 120 L (Novo,
Industry", Halkidiki, Greece, June 1-4, 1998 Copenhagen) and distilled water.
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Journal of The Institute of Brewing 275

 Volume 105, No. 5,1999 Application of Unconventional Raw Materials

Design of experiments TABLE II. Analyses of native barley and of the extruded barley
flakes
Experiments were performed on a laboratory scale,
using grists composed so that 0-70% extract content of NATIVE BARLEY BARLEY FLAKES
malt was replaced by an adjunct, based on the results of
Parameter Value Parameter Value
determination of the extract content for malt by the
Congress method3, extract content of crude barley Moisture content, % 11.2 Moisture content, % 7.9

according to the Graf method" and extract content of Extract, Graf, %DM 79.4 Extract, %DM 82.0

barley flakes according to De-Clerk's method of Ash content, %DM 2.1 Ash content, %DM 1.6

determination of extract of maize flakes4. In this way, Total nitrogen, %DM 1.64 Total nitrogen, %DM 1.80

grists were composed of 100-30% of malt together with Protein content, %DM 10.25 Protein content, %DM 11.25

calculated quantities of adjuncts, corresponding to a

TABLE HI. Analyses of worts obtained by replacing of (part of
total equivalent of grists of 50 grams of malt.
the) malt with barley flour gelatinised by heat treatment
Three series of experiments were performed. In the (cooking)
first series, 0-70% malt were replaced with barley flour Parameter Qua ntity <>f mal t repla cedb y,%

as an adjunct. This was gelatinised by cooking for 10 0 10 20 30 40 50 60 70

minutes, following the procedure given for the
Extract, % by weight 8.6 8.6 8.4 8.4 83 82 7.9 7.7
determination of extract of rice- or maize grits, in the Saccharificarion, min. 10-15 10-15 10-15 10-15 15-20 20-25 35-H) noMcdi

Analytica-EBO. This included mashing in the calculated Filtration rate normal

quantities of barley flour with 200 ml of water, heating Wort clarity slightly opalescent opalescent

to 90°C for gelatinisation, cooling to 75°C by addition of Wort colour. EBC 3.0 2.5 10

cold water, addition of 1 g of malt flour, liquefaction for Wort viscosity. 8.6%. mPa*s 1.7 1.7 1.7 1.7 1.8 1.8 10 22

WortpH 5.4 5.4 55 53 5.6 5.6 5.6 5.7

5 minutes, heating to boiling, boiling for 10 minutes,
Wort odor norma
cooling to 45°C and addition of 100 ml of water at 45°C.
Soluble N in wort mg/100ml 81.9 - 79.8 59.3 59.3 60.7 48.0 40.3
The second series of mashings was performed in a Limit attenuation, real, % 63.8 66.4 64.9 64.5 56.8 56.4 49.2 47.3
similar way, except for omitting the 1st gelatinisation at Limit attenuation, apparent, % 789 84.8 80.2 80.1 70.5 69.7 61.4 59.1

90°C and mashing in directly at 75°C the whole quantity

TABLE IV. Analyses of worts obtained by replacing of (part of
of barley flour with the addition of 0.05% (vol./wt) of
the) malt with barley flour liquified by enzyme preparation
Termamyl. In the third series, 0-70% of malt was Termamyl
replaced with the calculated quantities of barley flakes Parameter Qua ntity <>f mal trepla cedb y,%
and mashed-in with 200 ml of water at 45°C.
0 10 20 30 40 50 60 70
Further mashing, after addition of malt in the 1st and Extract. X by weight 8.6 8.4 83 8.2 83 8.1 8.0 7.9

2nd series was performed exactly according the Saccharificarjon. min. 10-15 10-15 10-15 10-15 15-20 20-25 30-35 no wcrfi

Congress mashing procedure in all series, but omitting Filtration rate normal

the additions of 100 ml of water at 70°C for the 1st and Wort clarity slightly opalescent opalescent

Wort colour, EBC 3.0 2.0 2.5

2nd series, and adjusting the weight of the mashes prior
Wort viscosity, 8.6%, mPa.s 17 1.7 1.7 1.7 1.8 1.9 2.1 25
to the filtration to 450 g in all cases.
WortpH 5.4 5.4 55 55 55 S3 55 56

Analyses Wort odour normal

Soluble N in wort, mg/ 100ml 81.9 76.9 69.9 65.7 62.1 60.7 51.5 48.7
All analyses were performed by standard techniques,2-12 Limit attenuation, real, % 63.8 57.8 59.3 59.7 59.7 50.4 52.1 51.6
with the exception that calculations of extract contents Limit attenuation, apparent, % 78.9 71.1 73.3 73.9 73.4 623 64.7 63.8

of the worts employed regression equations proposed

by Rosendal et a/.13. TABLE V. Analyses of worts obtained by replacing of (part of
the) malt with the extruded barley flakes
Parameter Quantity <)f mal t repb cedb y.%
TABLE I. Analyses of malt used for the experiments
0 10 20 30 40 50 60 70

Parameter Value Parameter Value Extract, % by weight 8.6 8.5 8.5 8.5 8.6 8.7 8.5 8.5

Sacehariricjtion, min. 10-15 10-15 10-15 10-15 15-20 20-25 30-35 4045
Hectolitre weight, kg 58.4 Wort viscosity, mPa«s, 8.6% 1.60
Filtration rate normal
Thousand corn weight, gDM 33.5 Wort pH value 53 Wort clarity slightly opalescent °«23 | slightly opalescent
Moisture content, % 5.3 Soluble nitrogen, mg/ 100ml 78.4 Wort colour, EBC 3.0 2.5 2.0

Wort viscosity, 8.6%, ml'a<s 1.7 1.7 1.8 1.8 2.0 2.0 2.2 2.4
Extract, fine grind, %DM 78.2 Total nitrogen, %DM 1.88
WortpH 5.4 55 5.4 5.4 5.4 5.4 5.3 5.3
Extract, coarse grind, %DM 77.1 Protein content, %DM 11.8
Wort odour normal
Extract difference, %DM 1.1 Kolbach index, % 37.0
Soluble N in wort, mg/ 100ml 81.9 91.8 88.2 81.9 635 64.2 515 41.7
Sjccharificjtion time, min. 10-15 Hartong number 3.9 Limit attenuation, real % 638 62.0 613 61.1 59.0 58.9 55.9 549

Colour of the wort, EBC 3.0 • Hartong 20cC% 21.0 limit attenuation, apparent, % 78.9 77.2 75.9 75.4 73.0 72.7 69.3 67.9

Wort odor normal • Hartong 45"C,% 34.5

RESULTS AND DISCUSSION
Wort clarity clear • Hartong 65"C, % 98.6
Table I shows the analyses of malt. Table II shows the
Rate of filtration, minutes 59 • Hartong 80°C % 93.9
analyses of native barley and extruded barley flakes

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276 Journal of The Institute of Brewing

Application of Unconventional Raw Materials
while Table III shows the analyses of worts obtained by
replacing part of the malt with barley flour gelatinised
by heat treatment (cooking). Table IV shows analyses of
worts obtained by replacing part of the malt with barley
FIG. 1. Extract contents of worts.
FIG. 2. Viscosities of worts
flour liquefied by enzyme preparation Termamyl. Table
V shows analyses of worts obtained by replacing part of
the malt with extruded barley flakes. Figure 1 shows
extract contents of worts as functions of their adjuncts
levels and of their preparation procedures. Figure 2
FIG. 3. Soluble nitrogen in worts
FIG. 4. Apparent attenuation of worts
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Journal of The Institute of Brewing
Volume 105 No. 5,1999
shows wort viscosities as functions of adjuncts levels
and of their preparation procedures. Figure 3 shows soluble
nitrogen contents in worts as functions of adjuncts levels
and of their preparation procedures. Figure 4 shows
apparent attenuation degrees of worts as functions of
adjuncts levels and of their preparation procedures.
According to these data, malt used for the experiments
(Table I) showed average quality parameters, with
relatively low extract contents and slightly elevated
viscosity. The extract content of barley flakes was
significantly higher than that of native barley flour
(Table II) resulting in the fact that, for the same
substitution rate, the quantities of the flakes were lower
than those of the barley flours (for example, at 10%
substitution, grists were composed of 45 grams of malt
and 5.2 g of barley flour, but only 4.8 g of the flakes).
Considering the results of the worts (Tables III-V, Figs
1-4), it may be concluded that, by applying infusion or
Congress mashing conditions levels of barley adjuncts
were limited to about 30 to 40% irrespective of their type
or pretreatment. At the higher levels, saccharification
rates showed a tendency to be lower, and at 70%
substitution saccharification of the mashes were not
completed after 60 minutes at 70°C.
Comparison of the results obtained with barley flakes
with those obtained with native barley, irrespective of
pretreatment, showed that application of the extruded
barley flakes had several advantages including better
extract yields, which were at expected levels, whereas
extract yields for barley flours showed a tendency to be
lower; higher nitrogen contents in the worts; a tendency
of obtaining worts with higher acidities (lower pH
values); similar or better attenuation.
Barley pretreatment by cooking, with or without
external addition of enzymes for liquefaction showed a
better performance with respect to wort viscosities than
those obtained with pregelatinised barley flakes. At first
sight this seemed to contradict earlier findings of, for
example, Beubler el a/.5, who had showed that the use of
30% barley flour in the grist caused an increase in
viscosity of 10% wort from 1.83 at 2.235 mPa-s, or by
almost 0.4 mPa-s. Further, the finding that wort
viscosities were lower in the present experiments when
barley pretreatment was by heat (cooking) alone than in
corresponding experiments where liquefying enzyme
was used (Tables III and IV; Fig. 2) was also confusing.
These anomalous findings could be explained by
previous studies that suggest that p-glucan and related
viscosity-increasing substances are intimately bounded
with protein and starch, and that they could be
hydrolyzed by the p-glycolytic enzymes only after their
liberation from these materials, for example by
cooking8101305.
In these laboratory experiments, mashes were cooled
down to 45°C, i.e. to a temperature which was low
enough for expression of the activities of cytolytic
Copyright - Journal of the Institute of Brewing
277
Volume 105, No. 5,1999 Application of Unconventional Raw Materials

enzymes from the malt, which are active between 35 and
45°C. Normally, for technical reasons this is not possible
in industrial practice, and temperatures after mixing the
•adjunct mash with the malt mash are considerably
higher (50-55, or even 60-63°C). The activities of malt P-
glucanases are limited and heat stable cytolytic enzymes
from microbial sources have to be used.
5. Beubler, A., Demwolf, M. and Nielbuck, C: 2. Int.
Symp. Gaerungsind., Leipzig 1968, Bd. 1/1,175.
6. Briggs, D. E., Wadeson, A., Statham, R. and Taylor,
J. F., Journal of the Institute of Brewing, 1986, 92, 468.
7. Delcour, A. J., Methilde, M.E.R., Van Craenenbroeck
and Moerman, E., Journal of the Institute of Brexoing,
1989, 95, 271.

This applies to the mashes where barley flakes were 8. Erdal, K. and Gjersten, P., Proceedings of the European

used as an adjunct in these experiments. However, it is Breioery Convention Congress, Madrid, 1967,295.
important to point out that, with the barley flakes and 9. Fors, S. M. and Nordlov, H., Journal of the Institute of
malt as grist ingredients, the temperature of mashing in Brewing, 1987, 93, 496.

can be lower than with other barley adjuncts. This 10. Gacesa, S., "Dried Green Malt as a mean for

suggests that if green malt or malt dried at low Saccharification of the Increased Barley amounts in Beer

temperatures, with considerably higher cytolytic Production", Ph.D. Thesis, Faculty of Technology,
activities, is to be used as saccharifying agent, by Novi Sad 1973, (in Serbian).

mashing at, for example, 40-45°C, up to 70% of 11. Krajovan, V., Gacesa, S. and Ivkov-Grujiae, O.,

pregelatinised barley flakes as an adjunct should not "Handbook for Malt and Beer Analyses", Faculty of
cause any problems of P-glucan or starch conversion10. Technology, Novi Sad 1972, (in Serbian).
12. BRAUTECHNISCHE ANALYSENMETHODEN, -
CONCLUSIONS MEBAK, Band I, Selbstverlag der MEBAK, Freising-
1. The use of barley flour gelatinised by heat (cooking) Weihenstephan, 1979.
as adjunct was satisfactory only in the case of replacing 13. Rosendal, I. and Schmidt, F.. Monatsschrift fiir
of 10 per cents of malt in the grist. Increased quantities Brauwissenschaft, 1987, 40, 334.
of this adjunct caused lower extract yields, longer 14. Scott, R. W., Journal of the Institute of Braving, 1972,
saccharification times, increase of wort pH values, and 78,179.
reduced contents of soluble nitrogen in worts, resulting 15. Schuster, K., Weinfurtner, L., Narziss, L., "Die
in the production of low-quality beers with strange Technologie der Wiirzebereitung", 6. Aufl., Ferdinand
sensory qualities. Enke Verlag, Stuttgart 1985.

2. Application of enzymatically liquefied barley was

not satisfactory, because extract contents of the worts
obtained were low, saccharification times were
prolonged, pH values were too high, soluble nitrogen
contents were too low, as well as the apparent
attenuation of the worts.
3. Worts obtained from grists with extruded barley
flakes (hydrothermically modified barley flour) in the
quantities of up to 50% in the whole grist, were
characterised by good analytical parameters, with the
exception of the viscosity of wort, which must be
4 / j
corrected by addition of cytolytic enzymes.

4. Based on the savings of time and energy necessary

for preparation of adjuncts, and further possibilities for
application of flexible schemes of brewhouse processes, ' 1T ■
\\ \\
it could be concluded that extruding of barley could be
judged as the best process for barley pretreatment for
brewer's wort production.
< i I
' • \
REFERENCES i ; i

1. Albini, P.A., Briggs, D.E. and Wadeson, A., Journal of

li,1'
the Institute of Brewing, 1987, 93, 97. \\-

2. ANALYTICA EBC, 3. Ausgabe, Schweizer Brauerei-

Rundschau, Zurich, Schweiz, 1983.
3. ANALYTICA EBC, 3. Ausgabe, Schweizer Brauerei-
Rundschau, Zurich, Schweiz, 1983, D25-D28. -.. ■ / r
4. ANALYTICA EBC, 3. Ausgabe, Schweizer Brauerei-
Rundschau, Zurich, Schweiz, 1983, D43 (Dec. 1980)

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