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Malting is the process of steeping, germinating and drying grain to convert it into malt. Germination and sprouting involve a number of enzymes to produce the changes from seed to seedling and the malt producer stops this stage of the process when the required enzymes are optimal. Among other things, the enzymes convert starch to sugars such as maltose, maltotriose and maltodextrines.
The malt is mainly used for brewing or whisky making, but can also be used to make malt vinegar or malt extract. Various grains are used for malting, most often barley, sorghum, wheat or rye.
Several types of equipment can be used to produce the malt. Traditional floor malting germinates the grains in a thin layer on a solid floor, and the grain is manually raked and turned to keep the grains loose and aerated. In a modern malt house the process is more automated, and the grain is germinated on a floor that is slotted to allow air to be forced through the grain bed. Large mechanical turners, e.g., Saladin boxes, keep the much thicker bed loose with higher productivity and better energy efficiency.
The grain is received at the malt house from the farmer. It is taken in from the field and cleaned (dressed), and dried if necessary, to ensure the grain remains in the best condition to produce good malt. It is tested to check for suitability for malting and to prevent dead or unfit grain from entering the process. Typical quality checks include:
Barley received at the malt house with moisture of more than 13% must be dried before it can be safely stored without loss of germinative capacity. The moisture is removed by circulating heated air (up to 50 °C) through the grain and can either be performed using dedicated grain driers or as a batch process using a kiln. High temperatures or over-drying will damage or kill the barley embryos and the grain will not germinate after steeping. The dry barley can safely be stored for up to 18 months without fungal growth or loss of grain vigour.
The aim of barley cleaning is to remove foreign matter (straw, chaff, dust and thin corns) found in the incoming grain, leaving only the grain most likely to produce a good malt. Magnets are used to remove ferrous metals from the grain, in turn reducing the possibility of sparks, which could lead to a dust explosion. Rotating and shaking sieves are used to remove unwanted foreign matter either larger (straw and un-threshed ears) or smaller (sand and thin corns) than the normal barley grain. During the sieving process an aspiration system removes the dust and chaff. De-stoners or shaking screens are used to separate small stones from the barley. The stones, which are denser than the barley, move out the top of the machine and the cleaned barley exits at the bottom. Half corn separators may be used to remove broken kernels. Half kernels need to be removed as only the one half will germinate and produce enzymes. At the end of the cleaning process the grain is weighed to determine the cleaning losses (the difference between the weight of grain received and the weight of the grain after cleaning) and it is transferred to a silo for storage.
The barley must be safely stored to maintain the grain vigour for germination. Storage at a malt house is normally in vertical silos made of steel or concrete for ease of use, but may be in flat stores when large amounts of grain is to be stored. The grain is stored in a manner that protects it from moisture and pests. A typical silo will store between 5,000 and 20,000 tons of clean dry barley ready for malting.
During storage the temperature of the silo is measured and monitored over time as a temperature increase can indicate insect activity. Additional equipment may be used to keep the grain temperature below 18 °C to inhibit insect growth. Silos are normally fitted with a system for rotating grain from one silo to another to break-up hot spots within the grain. A fumigation system can be used to administer a fumigant (normally phosphine) to the silo.
The wet process begins with steeping to get germination started and ends with kilning which removes the moisture and produces a stable final product. [1]
A batch of malt is known as a piece and a piece can be as large as 400 tons. Below a standardised base malt protocol is described:
Steeping is the start of the active malting process. Steep water is added to cover the grain and the grain moisture content increases from around 12% to between 40 and 45%. In a modern pneumatic malt house, the grain is alternatively submerged (wet stand) and then drained (an air rest) for two or three cycles to achieve the target grain moisture content and chit count. The first visible sign of germination is the appearance of rootlets known as "chit"; the proportion of chitted grains indicates the progress of the steeping process.
When the grain is immersed in water (known as a "wet stand"), air is bubbled through the slurry of water and grain periodically. The aim of this aeration [2] is to keep the process aerobic to maximize barley growth. Other advantages of the rousing are to get good mixing, to loosen dirt and to even out hydrostatic pressures at the bottom of the steep vessels. (Air flow rate: 1.5m3/ton per hour) [3]
At the end of the wet stand the water is drained out and this is the start of the "air stand" or "air rest". Fans are run to supply fresh air to replenish oxygen and to remove excess carbon dioxide produced by grain respiration. The temperature of the air supplied is important as the grain should be kept between 10 and 15 °C. The aeration requirements (cubic metres per ton per minute) are higher in the second and third air rests as the grain's metabolic activity is higher. (Air flow rate: 300m3/ton per hour). [3]
At the end of steeping the grain is "cast-out" to germination. Cast-out may be done as a slurry during a wet stand or as moist grain during an air rest.
The aim of germination is to grow the barley grains. This allows the development of malt enzymes, and these enzymes modify the structure of the barley endosperm by breaking down the cell walls and the protein matrix. Germination produces a large amount of heat; if safety precautions are not taken, the malt will burn. [4]
The enzymes produced during germination are needed to break down the starch for the brewer or distiller during the mashing process.
The grain bed is maintained at a constant temperature of between 10 and 16 °C by the constant supply of fresh humidified air. Turners move through the grain bed to keep it loose to allow for sufficient airflow.
Kilning reduces the grain moisture content and stops the germination process. [5] In the first stage, the "free drying stage" the air temperatures are kept cool to dry the grain without causing the enzymes to denature.
As the grain dries it is possible to raise the incoming air temperature for the second stage of forced drying to further dry the grain; the target malt moisture after kilning is around 5% by weight. During forced drying the relative humidity of the air coming from the bed drops, and the maltster is able to use a portion of the warm air as return air.
During the last few hours of kilning the air temperature is raised to above 80 °C (the "curing stage") to break SMM down to DMS to reduce the DMS potential of the malt. DMS is an off flavour that tastes like sweetcorn in the final beer. The high temperatures of kilning also produce the colour in the malt through the Maillard reaction.
Finally the kilned malt is cooled before the kiln is stripped (emptied).
The rootlets of the malt (also known as culms) are removed[ clarification needed ] from the malt soon after transfer from the kiln. The removed culms are sold or processed as animal feed. [6]
The cleaned malt is stored in silos to be blended with similar malt pieces to produce larger homogenous batches of malt.
Finally the malt is cleaned prior to sale using sieves and aspiration to remove the dust, lumps and stones in the malt. Magnets are used to remove any steel that might damage the mill rollers.
Brewing is the production of beer by steeping a starch source in water and fermenting the resulting sweet liquid with yeast. It may be done in a brewery by a commercial brewer, at home by a homebrewer, or communally. Brewing has taken place since around the 6th millennium BC, and archaeological evidence suggests that emerging civilizations, including ancient Egypt, China, and Mesopotamia, brewed beer. Since the nineteenth century the brewing industry has been part of most western economies.
A kiln is a thermally insulated chamber, a type of oven, that produces temperatures sufficient to complete some process, such as hardening, drying, or chemical changes. Kilns have been used for millennia to turn objects made from clay into pottery, tiles and bricks. Various industries use rotary kilns for pyroprocessing and to transform many other materials.
Malt is any cereal grain that has been made to germinate by soaking in water and then stopped from germinating further by drying with hot air, a process known as "malting". Malted grain is used to make beer, whisky, malted milk, malt vinegar, confections such as Maltesers and Whoppers, flavored drinks such as Horlicks, Ovaltine, and Milo, and some baked goods, such as malt loaf, bagels, and Rich Tea biscuits. Malted grain that has been ground into a coarse meal is known as "sweet meal".
Homebrewing is the brewing of beer or other alcoholic beverages on a small scale for personal, non-commercial purposes. Supplies, such as kits and fermentation tanks, can be purchased locally at specialty stores or online. Beer was brewed domestically for thousands of years before its commercial production although its legality has varied according to local regulation. Homebrewing is closely related to the hobby of home distillation, the production of alcoholic spirits for personal consumption, but home distillation is generally more tightly regulated.
Single malt whisky is malt whisky from a single distillery.
Sprouting is the natural process by which seeds or spores germinate and put out shoots, and already established plants produce new leaves or buds, or other structures experience further growth.
A culm is the aerial (above-ground) stem of a grass or sedge. It is derived from Latin culmus, meaning "stalk." It originally referred to the stem of any type of plant.
Smoked beer is a type of beer with a distinctive smoke flavour imparted by using malted barley dried over an open flame.
Brown rice (malt) syrup, also known as rice syrup or rice malt, is a sweetener which is rich in compounds categorized as sugars and is derived by steeping cooked rice starch with saccharifying enzymes to break down the starches, followed by straining off the liquid and reducing it by evaporative heating until the desired consistency is reached. The enzymes used in the saccharification step are supplied by an addition of sprouted barley grains to the rice starch or by adding bacterial- or fungal-derived purified enzyme isolates.
Acoustic cleaning is a maintenance method used in material-handling and storage systems that handle bulk granular or particulate materials, such as grain elevators, to remove the buildup of material on surfaces. An acoustic cleaning apparatus, usually built into the material-handling equipment, works by generating powerful sound waves which shake particulates loose from surfaces, reducing the need for manual cleaning.
Wood drying reduces the moisture content of wood before its use. When the drying is done in a kiln, the product is known as kiln-dried timber or lumber, whereas air drying is the more traditional method.
Mash ingredients, mash bill, mashbill, or grain bill are the materials that brewers use to produce the wort that they then ferment into alcohol. Mashing is the act of creating and extracting fermentable and non-fermentable sugars and flavor components from grain by steeping it in hot water, and then letting it rest at specific temperature ranges to activate naturally occurring enzymes in the grain that convert starches to sugars. The sugars separate from the mash ingredients, and then yeast in the brewing process converts them to alcohol and other fermentation products.
Wort is the liquid extracted from the mashing process during the brewing of beer or whisky. Wort contains the sugars, the most important being maltose and maltotriose, that will be fermented by the brewing yeast to produce alcohol. Wort also contains crucial amino acids to provide nitrogen to the yeast as well as more complex proteins contributing to beer head retention and flavour.
Grain bins are bulk storage structures for dry wheat, soybean, maize, oats, barley and more. Grain bins are cylinders made of corrugated sheets or sheet metal with a coned metal roof that has vents. The floors of grain bins have aeration systems to keep good air flow through the commodities and keep it at a good temperature and humidity level to prevent spoilage. At the top of each grain bin there are tubed conveyors to transport the grain. The grain bin sits on top of a strong concrete base to help the structure withstand high winds and the massive weight from the grain.
A malt house, malt barn, or maltings, is a building where cereal grain is converted into malt by soaking it in water, allowing it to sprout and then drying it to stop further growth. The malt is used in brewing beer, whisky and in certain foods. The traditional malt house was largely phased out during the twentieth century in favour of more mechanised production. Many malt houses have been converted to other uses, such as Snape Maltings, England, which is now a concert hall.
A Saladin box is an instrument used for malting barley. It consists of a large rectangular container about 50 meters in length, and a set of vertical screws attached to a crossbar. The crossbar moves horizontally across the length of the container while the motion of the screws raises the barley from the bottom to the top. Combined with mechanical air flow across the barley for cooling, this allows for beds of barley between 60 cm (24 in) and 80 cm (31 in) deep to be turned over two or three times a day. The screws are moved and turned by a system of pulleys and belts.
Grain drying is the process of drying grain to prevent spoilage during storage. Artificial grain drying uses fuel or electricity powered processes supplementary to natural ones, including swathing/windrowing for air and sun drying, or stooking before threshing.
Toowoomba Maltings is a heritage-listed malthouse at 11 Mort Street, Newtown, Toowoomba, Toowoomba Region, Queensland, Australia. It was built from 1899 to 1907. It is also known as Black Gully Malthouse, Darling Downs Malting Company Ltd, Paterson Redwood and Co, Queensland Brewery Co, Carlton Maltings, Northern Australia Brewers Ltd, Queensland Malting Company Ltd, Redwood's Maltings, State Wheat Board, and William Jones and Son (Maltsters) Ltd. It was added to the Queensland Heritage Register on 21 January 1998.
Grain storage on a subsistence farm is primarily based on minimizing grain loss. In modern agricultural practices there are methods of managing under 1% grain loss, but small subsistence farms can see 20% - 100% of grain loss. This causes starvation and an unstable food supply. Grain loss can be caused by mold growth, bugs, birds, or any other contamination.
Corn wet-milling is a process of breaking corn kernels into their component parts: corn oil, protein, corn starch, and fiber. It uses water and a series of steps to separate the parts to be used for various products.