CN101490237A

CN101490237A - A continuous method of producing a mash extract

Info

Publication number: CN101490237A
Application number: CN200780026504.9A
Authority: CN
Inventors: 亨德里克斯·马儿德
Original assignee: Heineken Supply Chain BV
Current assignee: Heineken Supply Chain BV
Priority date: 2006-05-19
Filing date: 2007-05-14
Publication date: 2009-07-22
Anticipated expiration: 2027-05-14
Also published as: CN101490237B; ZA200809844B

Abstract

The present invention relates to a continuous method of producing a mash extract by decoction mashing, said method comprising: a. mixing a first malt enzyme source with an aqueous liquid to obtain an aqueous malt enzyme suspension; b. separately, mixing a second enzyme source with one or more starch-containing adjuncts to obtain a decoction suspension whilst maintaining temperature conditions that do not cause significant gelatinisation of the starch; c. subjecting the decoction suspension to a first heat treatment at 60-85 C to simultaneously part ially gelat inise and enzymatically degrade the starch; d. subjecting the decoction suspension to a second heat treatment at a higher temperature than the first heat treatment to gelatinise the starch at an increased rate and to a higher extent; e. combining the heated decoction suspension obtained from the second heat treatment with the aqueous malt enzyme suspension from step a. to obtain a mash; f. maintaining the mash at 35-85 C for at least minutes; and g. removing spent grain from the heated mash to produce a mash extract. The present method is very robust and easy to control. Furthermore, the method yields a mash extract of constant quality.

Description

A kind of continuation method of producing the converted mash extract

Technical field

The present invention relates to a kind of continuation method of producing the converted mash extract by decoction mashing.More particularly, the present invention relates to a kind of like this decoction mashing, this method is used the source of one or more starch-containing additive as fermentable sugars.

Background technology

Decoction mashing is to be widely used in one of three kinds of saccharogenic methods producing bottom fermented beer, and other two kinds of methods are single step infusion mashing and infusion mashing progressively.This technology typically needs three kinds of containers: be used to mix the converted mash bucket of converted mash, the converted mash pot that is used to boil (or digestion pot or converted mash digestion pot) and be used for filtering lauter tub (or settling tank).Saccharification begins in the converted mash bucket at low temperatures, and the partially saccharifying wine with dregs is removed simultaneously, and is boiled in the converted mash pot, and is sent back to after a while in the converted mash bucket, and the temperature of whole converted mashs is raise gradually.This technology is repeated two or three times usually, two to six hours consuming time.Can hang down when the temperature of converted mash begins and reach 35 ℃, but more be everlasting 45-50 ℃, and reach 70-78 ℃ at the Mashing process tail end.Then, converted mash is filtered in being called as the independent container of lauter tub, or under specific circumstances, be filtered via the porous of converted mash bucket self bottom.

It is main difference between decoction mashing and the another kind of saccharogenic method that the partially saccharifying wine with dregs is boiled this fact.Owing to boil, the cell walls that contains grain starch is destroyed.This makes the easier arrival starch of enzyme.Therefore, cook the efficient of converted mash usually above other saccharogenic method.Another advantage of decoction mashing is that needing at high temperature, agglomerative grain can be boiled separately in cooking one of step.If use the additive such as corn, rice or naked barley in converted mash, this advantage can be useful.

The decoction mashing that uses in Brewing industry carries out with the batch-wise form.

In DE-A 1 442 292, described a kind of technology that in batches cooks, comprised the following steps:

I. with Fructus Hordei Germinatus and water and the mixing of other compositions, obtain a kind of water-based maltase suspension;

Ii. Fructus Hordei Germinatus, Semen Maydis powder and water are mixed, obtain a kind of suspension that cooks;

Iii. make this cook suspension liquefaction, method is at first 70 ℃ of heating 30 minutes, subsequently 95-100 ℃ of heating 10 minutes;

Iv. make heat cook suspension and mix, obtain converted mash with maltase suspension;

V. converted mash is remained on 70 ℃ and reach 45 minutes; And

Vi. remove spent grains.

The paragraph middle finger goes out in the page 4 bottom: " for avoiding high viscosity occurring in pulp digester, about 10% of Fructus Hordei Germinatus total amount can be added in the Semen Maydis powder ".

It will be favourable cooking saccharification continuously, and it will have several significant advantages, comprise:

Productivity improves and investment reduces: can be for a long time use container at full capacity, this is meaning for equal turnout, required container will be littler than the container in the technology in batches;

Quality is not only stable but also good: easier CONTROL PROCESS, and this is because might make processing parameter adapt to local and instantaneous requirement, and steady-state condition (steady-state-condition) is more highly stable;

The hygienic standard height: continuous processing is to carry out in the system of sealing; More energy-conservation: the energy consumption uniform distribution, do not have main purposes peak;

More laborsaving: the carrying out of continuous processing need personnel still less be paid close attention to;

The number of times that pauses and clear up reduces: the comparable batch process of continuous processing has longer running length.

In U.S. Pat 3,171, a kind of continuation method of producing wort has been described in 746, this method uses a kind of secondary to cook technology, and this technology makes converted mash by Fructus Hordei Germinatus and water in mixing tank-separator, and is separated into thick converted mash and rare converted mash.Thick converted mash is under the certain temperature condition, thereby proteolysis and saccharification will take place, and rare converted mash of rich enzyme is decocted, and subsequently after thick converted mash has been finished proteolysis and saccharification with thick converted mash remix.

The secondary of having described a kind of continuous production wort in DE-A 18 14 377 cooks technology, this technology is by making the mixed converted mash that gets of Fructus Hordei Germinatus and water, and the partially saccharifying wine with dregs is transported in the container, this part converted mash is subjected to thermal treatment in this container, afterwards be not subjected to the heat treated converted mash residuum of this class remix as yet.Then, a part of converted mash is transported in the container once more, and this part converted mash is subjected to thermal treatment in this container, afterwards be not subjected to heat treated converted mash residuum as yet and mix.Converted mash is separated into wort and spent grains subsequently.

Described a kind of technology of continuous preparation wort in WO 92/12231, this technology is included in the enzymatic conversion of carrying out Fructus Hordei Germinatus at least one rotating disc contactor continuously.In the example of this patent application, the suspension that cooks that contains corn and Fructus Hordei Germinatus is maintained at 50 ℃ and reaches 5 minutes, in rotating disc contactor, be heated to 95 ℃ and kept 10-15 minute, and mix with Fructus Hordei Germinatus/water, the mixture that obtains subsequently at first is heated to 65 ℃ and kept 30 minutes, is heated to 76 ℃ and kept 5 minutes then.In this technology, the gelling and the enzyme liberating that cook starch contained therein in the suspension are finished by single thermal treatment (promptly keeping 10-15 minute at 95 ℃).As way mentioned above herein, favourable is that decoction mashing is used for by Fructus Hordei Germinatus and starch-containing Additive Production converted mash extract.Therefore, if exist a kind ofly, will be useful applicable to continuous decoction mashing by Fructus Hordei Germinatus and one or more starch-containing Additive Production converted mash extract.

Summary of the invention

The inventor has designed a kind of method by decoction mashing continuous production converted mash extract, this method has the following advantages, be it can be when using a large amount of starch-containing additives, produce high-quality converted mash extract, described starch-containing additive for example can be rice, corn, jowar, barley, wheat and/or naked barley.The characteristics of this continuation method are that it comprises the following steps:

A. the first maltase source is mixed with water, obtain water-based maltase suspension;

B. respectively the second enzyme source is mixed with one or more starch-containing additive, obtain cooking suspension, keep certain temperature condition simultaneously, not cause significant starch gelling;

C. carry out first thermal treatment at 60-85 ℃ to cooking suspension, so that starch part gelling simultaneously and enzymatic degradation;

D. at the higher temperature that is higher than first thermal treatment temp, carry out second thermal treatment, with under higher rate and make the starch gelling to a greater extent to cooking suspension;

E. will cook suspension by the heat that second thermal treatment obtains and mix, obtain converted mash with the water-based maltase suspension that obtains by step a;

F. converted mash is remained on 35-85 ℃ and reach at least 20 minutes; And

G. from hot converted mash, remove spent grains, obtain the converted mash extract.

In this method, the suspension that cooks that contains one or more additive is carried out multistep thermal treatment under the meticulous control.In this multistep heat treatment process, gelling is taken place by boiling in starch-containing additive, can be comprised in the effective hydrolysis of amylase in the water-based maltase suspension subsequently, and heat cooks suspension and mixes with water-based maltase suspension (again).Select certain condition during the first gentle relatively thermal treatment, so that starch gelation rate and starch hydrolysis rate are synchronous, this is meaning the viscosity that cooks suspension and is being maintained at fully low level, so that suspension can be pumped.During much violent second thermal treatment, the rapid gelling of starch, this makes it more be subject to the influence of enzymic hydrolysis, and the starch gelling is initiated when decoction and water-based maltase suspension remix.Before multistep thermal treatment, can be by a certain mode controlled temperature, thereby avoid remarkable gelling, and viscosity is remained on low-level, to guarantee suitable transport condition from mixing vessel to pump.Present method is extremely sane and easily controlled.In addition, can produce stay-in-grade converted mash extract by present method.

Embodiment

Therefore, the present invention relates to a kind of continuation method of producing the converted mash extract by decoction mashing, described method comprises:

A. the first maltase source is mixed with waterborne liquid, obtain water-based maltase suspension;

D. at the higher temperature that is higher than first thermal treatment temp, carry out second thermal treatment, with under higher rate and make the starch gelling to a greater extent to cooking suspension; To cook suspension by the heat that second thermal treatment obtains and mix, obtain converted mash with the water-based maltase suspension that obtains by step a;

E. the temperature of converted mash being remained on 35-85 ℃ reaches to minority minute; And

F. from hot converted mash, remove spent grains, obtain the converted mash extract.

Above-mentioned steps a to g all preferably carries out continuously, as shown in these examples.

Term " additive " but comprise can be used as starch source and is added to any grain or fermented ingredient in the converted mash as used herein.Additive can be handled or handle without Fructus Hordei Germinatus through Fructus Hordei Germinatus, the preferred latter.Additive can be selected pretreated, and these pretreatment modes can be torrification for example, peel off, boil, micronization, baking.Can use rice, corn, jowar, naked barley, oat, wheat, corn, Tapioca Starch, potato, Fructus Hordei Germinatus, barley and combination thereof for this reason.Additive preferably comes from a kind of rice, corn, jowar, barley, naked barley and and cereal of combination of being selected from.The percent by weight of dry matter of starch typically is at least 60% in present method additive therefor, preferably is at least 70%, more preferably is at least 75%.

In the method, Fructus Hordei Germinatus can be suitable as the maltase source.Yet the present invention also comprises the commodity in use zymin, comprises starch degrading enzyme, those enzymes, particularly α-Dian Fenmei, beta-amylase and/or the glucoamylase for example found in Fructus Hordei Germinatus.In addition, use Fructus Hordei Germinatus and commercial enzyme preparation within the scope of the invention, for example the Fructus Hordei Germinatus in water-based maltase suspension preparation and cooking commercial enzyme in the suspension preparation.In the method, preferably use maltase with the Fructus Hordei Germinatus form.

According to of the present invention one particularly preferred embodiment, the part of the water-based maltase suspension that makes in step a is used as the second enzyme source among the step b.Again more preferably, the 1-50% (weight percent) of the water-based maltase suspension that makes in step a is used as the second enzyme source among the step b, and the residuum of water-based maltase suspension cooks suspension with the heat that obtains from second thermal treatment and mixes.

The present invention includes a kind of method, wherein water-based maltase suspension is separated into two kinds of maltase suspension with different solids content, for example thick and rare converted mash suspension.Yet the composition of water-based maltase suspension is preferably identical with the composition in the second enzyme source among the step b among the step a.The solids content of the maltase suspension that uses in this technology is typically in the 200-500g/l scope, preferably in the 250-350g/l scope.

When quite most fermentable sugars in the converted mash extract is when being provided by one or more additive, the advantage of present method is the most remarkable.Therefore, in a preferred embodiment, in the converted mash extract at least 5% of fermentable sugars (weight percent), preferably at least from 10% (weight percent) and more preferably 20-90% (weight percent) come from one or more starch-containing additive.

In the method, make and cook suspension, keep certain temperature condition simultaneously, not make the remarkable gelling of starch.More preferably, these temperature condition can not make the starch gelling.Favourable way is to keep the said temperature condition, up to carrying out first thermal treatment.

As mentioned above herein, the condition during first thermal treatment is gentle relatively, guaranteeing that gelation rate is remained on low relatively level, and makes starch that enzyme liberating can take place.During first heating steps, the partial hydrolysis of starch has been offset and has been followed starch agglomerative viscosity to increase usually.Therefore, caning be controlled in the viscosity that observes between first and second heating period increases, so that this viscosity is no more than the level that suspension can not be pumped.Go up to the second heat treated viscosity that cooks suspension and typically be no more than 10Pa.s, preferably be no more than 5Pa.s, more preferably no more than 1Pa.s.Whenever mentioning viscosity in this article, described viscosity is the (caliber of determining by the pressure reduction that records under regulation caliber and flow condition: 25mm; Pipe range: 5m; Flow: 200l/hr presents the performance of Newton type fluid).

During first and second thermal treatments, make the required heating condition of starch gelling depend on the characteristic of starch to a great extent.Some starch such as barley starch begins gelling in low relatively temperature, for example 55-62 ℃.Other starch such as rice starch are much stable when the trend gelling, and not significantly gelling when temperature is lower than 70-80 ℃.Therefore, the heating condition that uses in first and second heating stepses needs and is cooking the starch type that exists in the suspension and match.

In the method, favourable way is that first thermal treatment typically comprises and being heated in the 65-82 ℃ of scope cooking suspension, preferably is heated in the 65-80 ℃ of scope.The first heat treated time length is preferably in 1-30 minute scope, more preferably in 2-15 minute scope.

Known indivedual starch small grain can gelling in a certain temperature range.Raise more starch small grain gellings with temperature.With the further rising of temperature, starch small grain begins degraded, and degradation rate begins to surpass gelation rate when peak viscosity, makes that viscosity begins to descend.In the method, cook suspension and during second thermal treatment, reach its peak viscosity.After second thermal treatment, the viscosity that cooks suspension typically is no more than 30Pa.s, preferably is no more than 10Pa.s, more preferably no more than 1Pa.s.Definite mode of these viscosity is described identical with preamble.

Favourable way is, second thermal treatment that cooks suspension comprises and being heated in the 85-120 ℃ of scope, more preferably is heated in the 100-120 ℃ of scope.The second heat treated time length is preferably in 1-30 minute scope, more preferably in 2-15 minute scope.

According to a particularly preferred embodiment, first and second thermal treatments that cook suspension comprise steam treatment.The advantage of annotating evaporation is can realize being rapidly heated without staining heat exchange surface.In first thermal treatment of present method, preferably do not use the rotating disc contactor of in patent WO 92/12231, describing.Similarly, in second thermal treatment, preferably do not use this device.

According to another preferred embodiment, cook suspension after second thermal treatment and be cooled to 60-100 ℃ before water-based maltase suspension mixes.Before heat cooks suspension and water-based maltase suspension mixes, heat is cooked suspension cooling, can effectively control the temperature of gained converted mash thus.

In the method, by the second enzyme source is mixed with one or more starch-containing additive, make and cook suspension.Favourable way is to sneak into other water in the preparation that cooks suspension.The solids content that cooks suspension is typically in the 200-500g/l scope, preferably in the 220-400g/l scope.According to a particularly preferred embodiment, water-based maltase suspension is maintained in the 250-350g/l scope with the solids content that cooks suspension.

After second thermal treatment, will keep under certain condition by the converted mash that cooks the acquisition of suspension and water-based maltase suspension remix, to help the enzymic hydrolysis of jelling starch.During this section of present method, starch is converted into fermentable sugars in liquefaction and these two stages of saccharification.Liquefaction comprises that starch is degraded to compounding sugar (dextrin) under the effect of for example α-Dian Fenmei.When liquefaction stage was finished, converted mash cannot not become stickingly manyly.Under the effect of the enzyme such as glucoamylase and beta-amylase, compounding sugar is a fermentable sugars by saccharification or Degradation and Transformation.In the method, typically by the temperature with converted mash remain in the 35-85 ℃ of scope, preferably in 40-80 ℃ of scope, realize liquefaction and saccharification.For making starch suitably be converted into fermentable sugars, require usually to stop at least 20 minutes at said temperature.Residence time that these temperature are used preferably in 30-120 minute scope, more preferably in 40-110 minute scope.

At water-based maltase suspension and/or cook in the preparation of suspension, present method can suitably be used tap water or spring.Yet, according to a particularly preferred embodiment, be used for production water-based maltase suspension waterborne liquid (preferably also comprise and cook suspension), be derived from the recirculation washing current that the converted mash extract is produced.Use the advantage of this class recirculation washing current to be, can need not to use under the situation of big water gaging, obtain high extract content.Simultaneously, recirculation make might be when realizing so high extract content, produce hyperbaric converted mash extract.

Therefore, in of the present invention one particularly advantageous embodiment, the production stage of converted mash extract is as follows:

A. hot converted mash is transported in first separator, converted mash is separated into converted mash extract and spent grains;

B. spent grains is transported in first mixing vessel, and uses water spray to mix;

C. the mixture with spent grains and water spray is transported in second separator, removes spent grains;

D. will be recycled in the production of water-based maltase suspension from the water-based liquid stream of second separator.

Term " separator " comprises applicable to isolate any device of solid from liquid as used herein.Example applicable to the separator of present method comprises: whizzer, decanting vessel, settling vessel, hydrocyclone, sieve, strainer, filter membrane and pressure filter.In the method, can use the combination (for example decanting vessel and sieve) of dissimilar separators certainly.The separator that uses in this technology is preferably selected from whizzer, decanting vessel and sieve, more preferably is selected from decanting vessel and whizzer, most preferably is decanting vessel.

It should be understood that whenever mentioning first separator, second separator, the 3rd separator etc. in fact this class first, second or the 3rd separator can comprise two or more tripping devices, common separate solid of these tripping devices and liquid.These two or more tripping devices can walk abreast and/or the serial operation.For example, favourable way can be to use the separator that is made of a series of sieves, and wherein Shai pore size reduces along downstream direction.Equally, favourable way can be to use a sequence whizzer and/or a decanting vessel, and wherein the centrifugal force that is applied increases along downstream direction.Favourable way also can be, especially when technology is carried out continuously, the some parallel tripping devices of operation.When far below under the full capacity during parallel running, a tripping device breaks down or shuts down the converted mash extraction process is interrupted, and this is meaning this technology and can carry out incessantly for a long time.

When two or more tripping device parallel runnings, the proportion of the converted mash extract that is obtained by separator is meant by the mean specific gravity that constitutes the converted mash extract that two of separator or more tripping devices obtain.When two or more tripping device serials operation, the proportion of the extract that is obtained by separator is meant the proportion of the extract that is obtained by last tripping device.

As separator, the mixing vessel that uses in this technology in fact also can comprise the mixing device of two or more serial or parallel operations.

Use the aforesaid recirculation washing water of this paper can make hyperbaric converted mash extract, for example the proportion of converted mash extract is 15 ° of P or higher.The special embodiment of this of present method can reach very high efficient with regard to power consumption and extract content.In addition, can in the operation of distillery, realize high productivity.

When the proportion of the converted mash extract that is obtained by first separator surpassed 18 ° of P, the advantage of present method was particularly remarkable.The proportion of converted mash extract more preferably surpasses 20 ° of P, more preferably surpasses 25 ° of P again.In a particularly preferred embodiment, the proportion of the converted mash extract that is obtained by first separator surpasses 28 ° of P, most preferably surpasses 30 ° of P.

People are unexpected to be found, although the proportion height of the converted mash extract that obtains by present method, the extract loss that observes in the method typically is lower than 5% (weight percent), preferably be lower than 4% (weight percent), more preferably less than 3% (weight percent), most preferably be lower than 2% (weight percent).The efficient of back preferably realizes by whole wort production technique, comprises that the converted mash separation separates with residue.In the production of converted mash extract, the loss amount of extract can suitably be determined in the following manner, promptly is used for determining the standard method in wort extract concentration, the concentration (density measurement that for example adopts Anton Paar to carry out) of measurement extract in liquid spent grains by use.Because lack free fluid in the dehydration spent grains, described available hot water extracts spent grains easily, subsequently by filtering to isolate useless spent grains.The extract loss can be drawn by the extract level calculation that records in extract, and the water yield of adding is taken into account.

Especially when present method is used three of sequences or more separators, can reduce the loss of extract very effectively to the full extent.Therefore, a preferred embodiment of the present invention relates to the aforesaid a kind of method of this paper, and described method also comprises:

A. will be transported to second mixing vessel by the spent grains that second separator obtains, and use water spray to mix;

B. the mixture with spent grains and water spray is transported in the 3rd separator, removes spent grains; And

C. when ejecting water to first mixing vessel, will carry out recirculation from the water-based liquid stream of the 3rd separator.

The proportion that the water-based liquid that is obtained by second separator flows is typically in 1-10 ° of P scope, preferably in 1-8 ° of P scope.The proportion that the water-based liquid that is obtained by the 3rd separator flows is typically very low, shows that spent grains is useless substantially.From the proportion of the water-based liquid of the 3rd separator stream preferably in 0.1-2 ° of P scope, more preferably in 0.1-1.5 ° of P scope.The proportion that the water-based liquid that is obtained by the second and the 3rd separator flows depends on the concentration of the extract that obtains consumingly in elementary converted mash extract.

For under the situation of extract loss minimum, producing hyperbaric converted mash extract, preferably will be recycled in the saccharification step by whole water-based liquid streams that second separator obtains.In saccharification step, except that water-based liquid stream, also can use the water-based liquid stream (for example from the yeast washing) that produces by the distillery downstream from second separator.In saccharification step, typically constitute at least 80% (weight percent) of used total amount of liquid, preferred at least 90% (weight percent) from the recirculation water-based liquid of second separator stream.Most preferred way is that all saccharification liquid that use in saccharification step are the recirculation water-based liquid stream from second separator.

Can further illustrate the present invention by following example.

Embodiment

Example 1

136kg/hr sledge mill malt meal liquid flows in 701 continuous stirred tank reactors of being batched, and mixes with the 313kg/hr brewing water at 50 ℃.After this, a part that is called as the mixture of ' converted mash ' is transferred (3401/hr) in the vertical cylindrical plug flow reactor.This malt amylase mash stream provides essential enzyme (starch degrading enzyme), to be reduced in the viscosity during the thermal treatment in the reactor.Reactor used type is described in Heineken patent (WO 92/12231) more early.The remainder of converted mash is pumped in 501 continuous stirred tank reactors, in this 59kg/hr Semen Maydis powder liquid stream is batched 140kg/hr water.The temperature of combination liquid stream is 50 ℃, and this is far below the gelation temperature of W-Gum.For make starch gelling and the liquefaction in the corn by the enzyme effect, the suspension of malt mash, Semen Maydis powder and water is made temperature be raised to 78 ℃ by directly steam treatment.Under this temperature, a large amount of starch gellings, but also liquefied by maltase.If there are not these enzymes, starch can form a kind of thick paste at once, and disabling facility.After this heats up for the first time, enzyme is acted in 1 meter long plug flow reactor reach 5 minutes on the starch.Subsequently, carry out another direct steam treatment and handle, make temperature be raised to 100 ℃, starch small grain passes through in this temperature, was similarly stopping 5 minutes and complete gelation in the plug flow reactor.

The liquid stream (cooking liquid stream) that comprises the complete gelation starch small grain also is pumped in the above-mentioned stirring plug flow reactor this moment, and it mixes with malt amylase mash stream at this.Temperature is that 100 ℃ cook liquid stream and temperature is that 50 ℃ malt amylase mash stream mixes, and forms total mellow solution of saccharification and flows, and temperature is 65 ℃.Use heating jacket that saccharification temperature is controlled at 67 ℃.At the top of tower, converted mash is heated cover and is heated to 78 ℃, and whole reactor is insulated, thermosteresis is reduced to minimum.The total residence time of converted mash in tower is 65 minutes, and the converted mash that makes is transported to the converted mash centrifugal station.

By two decanting vessels Fructus Hordei Germinatus shell and other solids are separated from converted mash.These decanting vessels are the Scroll-type settling centrifuge, and clarified liq and multiviscosisty spent grains are by continuous blow-down.The speed of rotation of first decanting vessel is 3500rpm, and differential screw speed is 2rpm.The theoretical utilization ratio of this decanting vessel is 1700m ²

The theoretical utilization ratio of decanting vessel (SIGMA value) is to calculate according to the relation between the following factors: the length of rotatingcylindrical drum (L), universal gravity constant (g), circular frequency (ω), lock ring (dam ring) or the radius (r1) of overflow ring and the radius (r of rotatingcylindrical drum ₂).

Product (converted mash extract) is dumped into next unit operation (boiling), and spent grains is released in the small-sized continuous stirred tank reactor.In the latter, use 80 ℃ of washing water of 5061/hr, the residence time is 13 minutes, and spent grains particulate and water are by uniform mixing.

The liquid phase mixture that makes is separated in second decanting vessel, and the differential screw speed during this second decanting vessel operation is 2rpm, and rotating speed is 4000rpm, and theoretical utilization ratio is 1800m ²The supernatant liquid of clarification back liquid is recycled, and mixes with the outlet liquid stream of saccharification tower, and the gained mixture is as the charging of first decanting vessel.Extract concentration from the product liquid of first decanting vessel stream is 14.8 ° of P.Two decanting vessels all are equipped with centrifugal blower, thereby can be used as the pump in the supernatant liquid outlet.

Separate the product that makes by converted mash and now be called as wort, flow is 1030kg/hr.The hops extract is with continuous online the batching of speed quilt of 140g/hr, and this mixture is heated to 102 ℃ by direct steam treatment.By the positive pressure head of first decanting vessel, wort is pumped in the plug flow reactor.This tower reactor has identical characteristic with the previous saccharification converter of describing.The volume of this reactor is 1m ³, the residence time is 60 minutes.The type reaction that takes place in this reactor is as follows: protein denaturation and cohesion, sterilization, hops isomerization, form color, by its Fructus Hordei Germinatus based precursor (S-methylmethionine) make dimethylsulphide (dimethylsulphide, DMS).

Wort is processed in the sieve plate shape stripping tower that previous Heineken patent (WO 95/26395) is described subsequently.In counter-current operation, use 1.5bar steam, with under 15kg/h flow and atmospheric condition, remove nonconforming flavoursome compound (mainly being DMS) at the stripping tower top.The wort that leaves the stripping tower bottom is transported in the insignificant minibuffer of size, and is delivered directly in discharging at the intermittence type whizzer.The rotating speed of this machine is 7400rpm, and theoretical utilization ratio is 13000m ²

The theoretical utilization ratio of whizzer is according at " Solid-Liquid Separation ", 2nd edition, and 1981, by Ladislav Svarovsky, the method for describing among the Butterworth-Heineman is calculated.This utilization ratio is to calculate according to the relation between the following factors: disk quantity (n), universal gravity constant (g), circular frequency (ω), the angle (α) with disk of vertical feed-pipe, disc assembly internal diameter (r ₁) and disc assembly external diameter (r ₂).

Then, cool off wort in two parallel plate and frame wort coolers, these two water coolers are by two-stage water-ethylene glycol device, drop to 8 ℃ with the temperature of wort from 95-100 ℃.

Cumulative volume is 2.2m ³Cold wort be that the live yeast of 2.5g/l is transported in cylindrical/conical fermentor tank continuously together with concentration.Carry out continuous oxidation by online aeration.Elementary batch fermentation carries out at 10 ℃, and when extract concentration reaches 6.5 ° of P, can make temperature be raised to 13 ℃.After the concentration of dimethylglyoxal dropped to the level of 30ppm, thing was cooled to-1.5 ℃ in the groove after 24 hours.This state of cooling is held and reaches 6 days.

Then, beer is filtered by the limpid beer filter of vertical disc type diatomite.After this filtered, beer was stabilized under the PVPP of dosage usually and essential PVPP filter.At last, beer is packaged in the appropriate containers (vial).

Example 2

120kg/hr sledge mill malt meal liquid flows in the 70l continuous stirred tank reactor of being batched, and mixes with the 240kg/hr brewing water 50 ℃ of temperature.After this, a part that is called as the mixture of ' converted mash ' is transported in the example 1 described vertical cylindrical plug flow reactor.

Flow is that additive 100kg/hr, that exist with rice powder form, that handled without Fructus Hordei Germinatus is batched in the 50l continuous stirred tank reactor, and wherein adding has the 210kg/hr current.Heat-resisting starch degrading enzyme is batched, to be reduced in the viscosity in the postheat treatment.The temperature of the mixture that makes is 50 ℃, far below the gelation temperature of rice starch.For make starch gelling and the liquefaction in the rice by the enzyme effect, the suspension of rice powder, enzyme and water is made temperature be raised to 78 ℃ by directly steam treatment.Under this temperature, a large amount of starch gellings, but also liquefied by amylolytic enzyme.If there are not these enzymes, starch can form a kind of thick paste at once, and disabling facility.After this heats up for the first time, enzyme is acted in 1 meter long plug flow reactor reach 5 minutes on the starch.Subsequently, carry out another direct steam treatment and handle, make temperature be raised to 100 ℃, starch small grain passes through in this temperature, was similarly stopping 5 minutes and complete gelation in the plug flow reactor.For when mixing, obtaining suitable saccharification temperature (in this example being 67 ℃), cook liquid stream and in shell and tube heat exchanger, be cooled to proper temperature with malt mash.

This cold liquid stream also is pumped in the above-mentioned stirring plug flow reactor, and it mixes with malt amylase mash stream at this.Use heating jacket that saccharification temperature is controlled at 67 ℃.At the top of tower, converted mash is heated cover and is heated to 78 ℃, and whole reactor is insulated, thermosteresis is reduced to minimum.The total residence time of converted mash in tower is 60 minutes, and the converted mash that makes is transported to the converted mash centrifugal station.

By two decanting vessels Fructus Hordei Germinatus shell and other solids are separated from converted mash.These decanting vessels are the Scroll-type settling centrifuge, and clarified liq and multiviscosisty spent grains are by continuous blow-down.The speed of rotation of first decanting vessel is 3500rpm, and differential screw speed is 3rpm.The theoretical utilization ratio of this decanting vessel is 1700m ²Product (converted mash extract) is dumped into next unit operation (boiling) by first decanting vessel, and spent grains is released in the small-sized continuous stirred tank reactor.In the latter, use 80 ℃ of washing water of 510l/hr, the residence time is 13 minutes, and spent grains particulate and water are by uniform mixing.

The liquid phase mixture that makes is separated in second decanting vessel, and the differential screw speed during this second decanting vessel operation is 3rpm, and rotating speed is 4000rpm, and theoretical utilization ratio is 1800m ²The supernatant liquid of clarification back liquid is recycled, and before entering first decanting vessel, mix with converted mash from the saccharification tower.Extract concentration from the product liquid of first decanting vessel stream is 16.4 ° of P.Two decanting vessels all are equipped with centrifugal blower, thereby can be used as the pump in the supernatant liquid outlet.

Separate the product that obtains by converted mash and be called as wort, the hops extract is with continuous online the batching of speed quilt of 120g/hr, and this mixture is heated to 102 ℃ by direct steam treatment.By the positive pressure head of first decanting vessel, wort is pumped in the plug flow reactor.This tower reactor has identical characteristic with the previous saccharification converter of describing.The volume of this reactor is 1m ³, and the residence time be 60 minutes.The type reaction that takes place in this reactor is as follows: protein denaturation and cohesion, sterilization, hops isomerization, form color, by its Fructus Hordei Germinatus based precursor (S-methylmethionine) make dimethylsulphide (dimethylsulphide, DMS).

Wort is processed in the sieve plate shape stripping tower that previous Heineken patent (WO 95/26395) is described subsequently.In counter-current operation, use the steam of 1.5bar, with under 15kg/h flow and atmospheric condition, remove unwelcome flavoursome compound (mainly being DMS) at the stripping tower top.The wort that leaves the stripping tower bottom is transported in the insignificant minibuffer of size, and is delivered directly in discharging at the intermittence type whizzer.The rotating speed of this machine is 7400rpm, and theoretical utilization ratio is 13000m ²To the analysis revealed of wort, final dilution limit is 82-83%.

Example 3

By the mixture that uses malt meal and the Semen Maydis powder of handling without Fructus Hordei Germinatus to constitute, making flow at wort production technique tail end is 4.5m ³The mashing water stream of/hr, extract concentration is 18 ° of P.This wort is fermented and slaking in the successive fermenter, and is being stabilized in the storage tank subsequently in batches, and separated and be filtered on limpid beer filter in whizzer.Detailed description to making method sees below.

At this technology head end, 1620l/hr brewing water (47 ℃) mixes continuously with the 720kg/hr malt meal.This malt meal is to be made by the hammer mill that is equipped with the 2.5mm sieve aperture.It is in 801 the continuous stirred tank reactor that two liquid stream is transported to working volume at 45 ℃.The part of the malt amylase mash stream that makes is introduced to follow-up plug flow saccharification tower, and this saccharification tower is similar with description in example 1.Other parts (250l/hr) of malt amylase mash stream are transported in the parallel technology, and this technology can allow the finally additive of beer product of the Semen Maydis powder conduct will be not handled with Fructus Hordei Germinatus.

Cook continuously in the technology at this, not the Semen Maydis powder of handling with Fructus Hordei Germinatus, be transferred (350kg/hr) in continuous stirred tank reactor together with the brewing water of 52 ℃ (790kg/hr) stream and above-mentioned malt mash stream.The temperature of the liquid that obtains in this 120l container stream combination is 50 ℃, and this temperature is enough low, increases with the excessive gelling of avoiding W-Gum and relevant viscosity.Mixture is pumped in first storage column by direct steam treatment point.Steam treatment is raised to 75-78 ℃ with the temperature that will cook liquid stream, and makes the gelling of part W-Gum.Yet owing to there is a part of wort converted mash, the amylase that is made by Fructus Hordei Germinatus can make the polymerization starch bacterial strain decompose, and its viscosity is reduced.Stop at assigned temperature and can make viscosity drop to a level in 15 minutes, can make temperature be raised to 100 ℃ and can not cause unacceptable high viscosity again in this levels of viscosity.Stopped 5 minutes by another direct steam treatment and in simple plug flow reactor, carry out this second step.The gelling mixture that obtains is cooled to 90 ℃, and is transported to subsequently in the saccharification tower, and mixes with separated malt amylase mash stream at this.Make the mixed solution stream with certain temperature thus, this temperature is optimum for amylase activity and Fructus Hordei Germinatus and corn to the conversion fully of sugar.

The cylindrical plugs flow reactor that is used for Mashing process is described in previous Heineken patent (WO92/12231).At the certain height place of top of tower, by direct steam treatment heating converted mash.Select temperature, so that Fructus Hordei Germinatus starch is fit to product needed to the conversion of fermentable sugars.There is saccharification rest in this temperature profile in the time of 66 ℃, have saccharification when departing from 76 ℃.The residence time of converted mash is 80 minutes, and the converted mash that makes is transported to the converted mash centrifugal station.

The converted mash centrifugal station is made of two Scroll-type settling centrifuges that are commonly called decanting vessel, and clarified liq and multiviscosisty spent grains are by continuous blow-down.Rotating speed during the operation of first decanting vessel is 3650rpm, and differential screw speed is 10rpm, and theoretical utilization ratio is 6200m ²Product (converted mash extract) is dumped into next unit operation (boiling) by first decanting vessel, and spent grains is released in the small-sized continuous stirred tank reactor.In the latter, use 72 ℃ of washing water of 1150l/hr, the residence time is 2 minutes, obtains uniform suspension thus.The liquid phase mixture that makes is separated in second decanting vessel, and the rotating speed during this second decanting vessel operation is 4000rpm, and differential screw speed is 20rpm, and theoretical utilization ratio is 2600m ²The supernatant liquid of clarification back liquid is recycled, and mixes with outlet liquid stream from the saccharification tower.This makes the extract concentration in the first decanting vessel charging drop to about 17 ° of P.The spent grains that is made by second decanting vessel is dumped in the silo.Two decanting vessels all are equipped with centrifugal blower, thereby can be used as the pump in the supernatant liquid outlet.

Separate the product that makes by converted mash and now be called as wort, and flow is 4.5m ³/ hr.The hops extract is batched by online with the speed of 32g/hr, and this mixture is heated to 105 ℃ by direct steam treatment.By the positive pressure head of first decanting vessel, wort is pumped in the plug flow reactor.This tower reactor has identical characteristic with the previous saccharification converter of describing, but height increases in proportion with the increase of flow in this part technology.Therefore the residence time is 67 minutes.The type reaction that takes place in this reactor is as follows: protein denaturation and cohesion, sterilization, hops isomerization, form color, by its Fructus Hordei Germinatus based precursor (S-methylmethionine) make dimethylsulphide (dimethylsulphide, DMS).

Wort is processed in the sieve plate shape stripping tower that previous Heineken patent (WO 95/26395) is described subsequently.In counter-current operation, use the steam of 1.5bar, with under 100kg/hr flow and atmospheric condition, remove unwelcome flavoursome compound (mainly being DMS).The wort that leaves the stripping tower bottom is transported in the insignificant minibuffer of size, and is delivered directly in discharging at the intermittence type whizzer.The rotating speed of this machine is 7400 rev/mins, and the SIGMA value is 70000m ²

By two parallel plate and frame wort coolers cooling worts, these two water coolers are by two-stage water-ethylene glycol device, drop to 4 ℃ with the temperature of wort from 95-100 ℃.

Cooled wort is transported in first agitated fermentation vessel, and its clean working volume is 14m ³The inflation recycle stream that this container is made by the process downstream end by continuous interpolation, operate under 10 ℃ and the aerobic condition, this inflation recycle stream comprises the multiviscosisty yeast, and the multiviscosisty yeast is the main component beyond dewatering.The proportion of material is 13 ° of P in this container.The fermentation required yeasts is that the form with above-mentioned recycle stream is added.

The fermented liquid that is made by first fermenting container is transported to second container.The working volume of this container is 160m ³, and be maintained at 13 ℃ by the cold mode of wall.The initial specific gravity of material is 7 ° of P in this container, and yeast concn is the wet yeast/l of 80g.The effluent liquid stream of this container is divided into two liquid streams: a part (2.5m ³/ hr) mix with another liquid stream that makes at the technology tail end, and be recycled to first fermenting container, and another part (5.3m ³/ hr) be transported in the 3rd fermenting container.

The working volume of the 3rd container is 140m ³, and the initial specific gravity of its content is 3.5 ° of P.It is 7m that the product of this container is transported to working volume ³The yeast settling vessel in.This yeast settling vessel is separated zymic major portion (90-95%) from green beer.Compacting zymic yeast concn in yeast settling vessel bottom is the wet yeast/l of 200g.The part of this liquid stream is recycled to the zymotechnique head end, and another part is transported to useless residue yeast hiding-place.Can control that part of yeast that is transported to the residuum place according to the quantity of leaving yeast settling vessel top and the yeast quantity of in fermenting container, growing.Be transported to continuously in batches in the ripening tank or in the continuous ripening container from the green beer at yeast settling vessel top.

For the batch process mode, the working volume of ripening tank equates with the cumulative volume of the fermenting wort that made in 24 hours.Can by from pipeline to the heat exchange of ripening tank, with and/or natural heat of fermentation exploitation, temperature is raised to 15 ℃.This temperature helps the conversion of acetylactis (a kind of metabolism tunning) to dimethylglyoxal.Because yeast is in this state, yeast can absorb dimethylglyoxal, and it is converted into acetoin or follow-up metabolite.So, can eliminate the disadvantageous effect of dimethylglyoxal in beer, and the level of residue dimethylglyoxal is confirmed as typically＜20ppb.After dimethylglyoxal had dropped to acceptable level, beer was cooled to-1.5 ℃, and is stored several days.After this period, beer is through diatomite filtration, and 80-100g/l diatomite is used as main body charging (bodyfeed).Before filtration, beer is 70 by theoretical utilization ratio, 000m ²The centrifugation of disc type separator, to remove whole suspended solidss, efficient is 95-98%.The typical filtration is at 4-5.5hl/m ²Under/hr the flow and down operation of 6000-8000hl.After this filtered, beer was stabilized under the PVPP of dosage usually and essential PVPP filter.At last, beer is packaged in the appropriate containers (bottle, keg, jar).

When using the successive curing process, green beer is transported to 520m continuously by the spray ball ³The top of container, this spray ball is with the whole surf zone of beer dispense at groove.In this embodiment, beer is heated to 15 ℃ by shell and tube heat exchanger from 13 ℃.This will speed up the conversion of the above-mentioned α-acetylactis that forms to dimethylglyoxal during primary fermentation.Yeast will settle down in beer, and will carry out above-mentioned dimethylglyoxal and the conversion of other adjacent diketone to acetoin and follow-up metabolite.In this embodiment, the residence time of beer is 100 hours, and the residue dimethylglyoxal level be 7.3 ± 2.3ppb (95%CI, n=6).Yeast is deposited in the conical lower section of ripening tank, and is removed, and is used as static beer.Slaking beer is removed directly over sedimentation yeast cone, and to temperature is-1.5 ℃ the groove of refrigeration in batches conveying by the Continuous Heat Transfer device.

The refrigeration groove was filled in one day, and beer is stored in-1.5 ℃ and reaches at least 2 days subsequently.Behind this storage period, the precipitation yeast is washed from the bottom of groove and removes, and residue beer is separated on aforesaid disc centrifuge.After this processing, beer is filtered by kieselguhr filter immediately, and exemplary traffic is 4-5.5hl/m ²/ hr, filtration yield are 6000-8000hl.

Beer handle by PVPP be stabilized after, be packaged in the wrapping material of requirement (bottle, jar, keg).

Claims

1. continuation method of producing the converted mash extract by decoction mashing, described method comprises:

C. carry out first thermal treatment at 60-85 ℃ to cooking suspension, so that part gelling simultaneously of described starch and enzymatic degradation;

D. at the higher temperature that is higher than described first thermal treatment temp, the described suspension that cooks is carried out second thermal treatment, with under higher rate and make described starch gelling to a greater extent;

E. will cook suspension by the described heat that described second thermal treatment obtains and mix, obtain converted mash with the described water-based maltase suspension that obtains by step a;

F. described converted mash is remained on 35-85 ℃ and reach at least 20 minutes; And

G. from described hot converted mash, remove spent grains, obtain the converted mash extract.

2. method according to claim 1 is characterized in that: the part of the described water-based maltase suspension that makes in step a is used as the described second enzyme source among the step b.

3. method according to claim 2, it is characterized in that: the 1-50% (weight percent) of the described water-based maltase suspension that makes in step a is used as the described second enzyme source among the step b, and the described residuum of described water-based maltase suspension cooks suspension with the described heat that obtains from described second thermal treatment and mixes.

4. according to any one the described method in the aforementioned claim, it is characterized in that: at least 5% (weight percent) that is included in the described fermentable sugars in the described converted mash extract comes from described one or more starch-containing additive.

5. according to any one the described method in the aforementioned claim, it is characterized in that: the composition of the maltase of water-based described in step a suspension is identical with the composition in the second enzyme source described in the step b.

6. according to any one the described method in the aforementioned claim, it is characterized in that: described starch-containing source of additive is in a kind of cereal that is selected from rice, corn, jowar, naked barley, oat, wheat, Tapioca Starch, potato, Fructus Hordei Germinatus, barley and combination thereof.

7. according to any one the described method in the aforementioned claim, it is characterized in that: the pretreatment mode of described starch-containing additive comprises torrification, peels off, boils, micronization or baking.

8. according to any one the described method in the aforementioned claim, it is characterized in that: the described viscosity that cooks suspension is no more than 10Pa.s until second thermal treatment, preferably is no more than 5Pa.s, more preferably no more than 1Pa.s.

9. according to any one the described method in the aforementioned claim, it is characterized in that: described described first thermal treatment and described second thermal treatment that cooks suspension comprises steam treatment.

10. according to any one the described method in the aforementioned claim, it is characterized in that: described cook suspension after described second thermal treatment and be cooled to 60-100 ℃ before described water-based maltase suspension mixes.

11. any one the described method according in the aforementioned claim is characterized in that:, make the described suspension that cooks by the described second enzyme source and one or more starch-containing additive and other water are mixed.

12. any one the described method according in the aforementioned claim is characterized in that: described maltase suspension and the described solids content that cooks suspension are maintained in the 200-500g/l scope.

13. any one the described method according in the aforementioned claim is characterized in that: being used to produce described water-based maltase suspension and the described described water that cooks suspension is to wash current from the recirculation of described converted mash extract Production Flow Chart.