Mod 3 Raw Materials Flashcards

1
Q

All water used during the production process in the Scotch whisky industry is
derived from

A

Rain or snow

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2
Q

The basic requirements of
water supply are that it is

A

adequate and available

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3
Q

water sources

A
  1. springs
  2. burns/rivers
  3. lochs
  4. wells
  5. boreholes
  6. mains
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4
Q

Water is used in several key phases of the
production process (3)

A
  1. steeping & mashing - ph microbiological purity
  2. cooling - volume temp
  3. dilution - ph,hardness, volume, temp, microbiological content.
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5
Q

why is it good to know the mineral content and ph balance of water when steeping and mashing

A

steeping and mashing are
basically biochemical processes, they can be
affected by the mineral and ion content - and by
the pH - of the water.

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6
Q

Why know hardness level

A

The mashing water used can influence the
fermentation, depending upon the hardness levels
and ions present.

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7
Q

soft water

A

heavier new make

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8
Q

Harder water

A

cleaner/sweeter new make
spirit

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9
Q

Cool Water

A

cool water is required for the
condensers, therefore the quality parameters here
are simply volume and temperature

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10
Q

Dilution

A

For cask filling. Water must pure
in terms of lack of solids and microbiological
content. Quality parameters that can be measured
therefore are pH, hardness, volume used,
temperature and microbiological content.

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11
Q

Once sourced, that water is used at four
key parts of the production process

A

steeping, mashing, cooling & dilution.

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12
Q

Main raw material in the production of single malt

A

Barley

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13
Q

Malting barley moves through 3 key stages in the pre production process

A
  1. growth & harvesting,
  2. variety development
  3. testing
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14
Q

Growth and harvesting

A
  1. malting barleygrown predominately on east side of uk
  2. lower rainfall than the west
    3 . preferable soil
  3. Harvesting takes place in the second half of July
    and August in Southern England and East Anglia
    and can start four to six weeks later in Scotland
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15
Q

Variety development

A

Each barley variety has different characteristics
and morphological features

some features are
1. grain shape
2. rachilla in ventral crease
3. Nerve pigment and colouring

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16
Q

Shape of grain

A

Is it bold, thin, or flat

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17
Q

Rachilla

A

a structure in the ventral crease, can be short or long.

Can have hairs that can be short and wolly or long and straight

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18
Q

what maltsters like in malting barley

A

Cost effective
* Bold grain
* Appropriate nitrogen level
* Good germinative ability
* Varietal purity
* Reliable supply
* Suitable storage

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19
Q

Best malting barley

A

homogenous bulk, with bold and even grains.

Grains of the same size will hydrate and process at
the same rate, leading to more homogenous malt.

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20
Q

Homogeneous Malt

A

Homogeneous simply means of the
same kind or alike. In malting, the
term is often used when describing a
sample of barley at intake.
Numerous samples, for example,
are taken from across the load and
mixed thoroughly to ensure, overall,
the sample is homogenous. Physical
features such as rachilla hairs and
spicules are assessed.

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21
Q

Agriculture and
Horticulture Development Board (AHDB).

A

Testing and breeding system in the UK

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22
Q

produces a recommended lists of barley varieties
and recommends those to use in the various
industries.

A

Agriculture and
Horticulture Development Board (AHDB).

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23
Q

Testing is done

A

prior to maltsters buying barley

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24
Q

5 test on barley

A
  1. Nitrogen
  2. Moisture
  3. Screenings
  4. Germination
  5. Varietal purity
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25
Reference method for nitrogen
Dumas method
26
Near Infrared (NIR) equipment
equipment that most analysis is carried out on
27
barleyis dried because
a) off the field it is too wet for storage (in England the moisture level is usually between 14-16% whereas in Scotland it can be up to 20%), b) infestation can occur (insects cannot breed in barley if it is less than 15°C and less than 12% moisture c) dry barley can be stored safely for longer (germination potential can be inhibited if stored at higher moistures and temperatures).
28
Insects cannot breed in what temps
(insects cannot breed in barley if it is less than 15°C and less than 12% moisture
29
recognized industry levels for barley temps and moisture during storage are
are less than 12% moisture & 15°C.
30
how is barley dried
tower drier method The drying is controlled by the rate of barley flowing through the drier and the temperature of the air being used. The wetter the barley, the lower the air on temperature is required to be, as wet barley can be damaged by heat
31
how is barely stored
Silos ventilation systems normally suck air rather than blow air. Flat store or ‘big shed’ have a higher capital cost and can result in waste. The air is blown through the bulk via permanent or temporary air ducts.
32
barely is stored
in a silo or flat store
33
steeping
raising the moisture level to such an extent that germination is initiated.
34
barely is dried prior to storage because
because, once off the field, it is usually too wet to store. Drying barley also helps to reduce what is called dormancy in the grain
35
Dormancy
is the natural tendency to inhibit germination, and can vary depending upon variety, growing conditions and harvesting conditions.
36
self-emptying cylindroconical vessel
very water efficient compared to false bottom flat steeps, used for steeping
37
level of hydration in grain dependent on
Water temperature * Grain size * Variety * Viability
38
Water temperature
Higher water temperature results in more rapid water uptake and may be required if the grain is less mature
39
Grain size
Larger grains require more time under water to reach the same moisture level as smaller grains.
40
Viability
The maturity (or viability) of grain also affects water uptake, with the barley taking in water more quickly as it matures.
41
Variety
Different varieties may take in water at different rates, so steeping cycles would be altered Optic typically takes longer to reach the same moisture level than Concerto.
42
Multiple Steeping
The multiple steeping cycle normally takes place over a 48-hour cycle and consists of two or three ‘wet’ periods, with ‘air rests’ in between.
43
What is multiple steeping
The multiple steeping cycle normally takes place over a 48-hour cycle and consists of two or three ‘wet’ periods, with ‘air rests’ in between.
44
Target moisture at the end of steeping
the mid-40s but the actual figure is dependent upon the type of malt being made.
45
higher steep out or cast moisture
result in increased respiration and therefore increased malting loss. It will also result in increased enzyme activity and soluble nitrogen content.
46
Cast moisture
is the moisture level in the grain as it is moved from the steeping stage to the germination stage.
47
Cast moisture
1. the more water, the more active the grain, until you get to the stage where it will drown. 2. The more active the grain, the quicker the breakdown processes inside the grain;
48
Hydrolysis
the technical term for the breakdown of starch into sugars.
49
Germination physical changes
After water intake, the grain has swelled and a small white chit (root cover) can be seen.
50
Chemical Changes
Enzymes, stimulated by the release of hormones, are released into the endosperm degrading the cell walls and protein matrix, thereby making the starch supply available for hydrolysis during the mashing process.
51
Germination
produces the enzymes required for the hydrolysis process. And distillers want the starch and the enzymes
52
Structures in barley grain related to germination
* Micropyle * Embryo * Endosperm * Husk
53
Germination
54
Embryo
the living part of the grain, sometimes called the germ; it is the ‘baby’ plant.
55
Micropyle
the structure at the embryo end of the corn that allows water to flow into the grain (Basically, it is a hole that allows for water to enter.)
56
Husk
the ‘skin’ that surrounds and protects the barley.
57
Endosperm
the food reserve for the embryo. It is a hard structure consisting of starch molecules (long chains of sugar molecules) embedded within a protein matrix all surrounded by cell walls.
58
Endosperm during germination
altered due to the action of enzymes.
59
what does the embryo release at the start of germination
a hormone called Gibberellic Acid, known as GA3.
60
MOdification Front
This initiates the aleurone layer to release the enzymes required to break down the cell walls, protein matrix and starch granules.
61
Modification front breakdown occurs
from the embryo end to the distal end of the grain.
62
Malting Loss
Germination is complete once the endosperm has been made friable. That is, it can be rubbed out; meaning the cell walls and protein matrix have been broken down.
63
starch is also broken down and used for root and shoot growth, this usage is
Malting Loss
64
Controlled Germination
Keeps malting loss at a minimum more malting loss that occurs, the less starch available for distillers to work with
65
Enzyme release timing
1. Cell walls break down first 2. second, protein matrix 3. third, the starch
66
Physical changes during germination
1. the grain has swelled and a small white chit (root cover) can be seen. If the husk is peeled away, the endosperm is still hard but getting rubbery. 2. Rootlets appear - endosperm can be rubbed out once rootlets are at their strongest
67
Rootlets
68
Endosperm
the cell walls, protein matrix and starch granules
69
Germination Vessels Features
* Mechanism to load and empty the vessel * False bottom to allow air flow * Fan for blowing humid air through the bed * Mechanism to turn the grain
70
What has improved the control of germination
Drum maltings Cool air can be blown through the perforated deck into the grain bed thus removing heat and carbon dioxide. The bed is turned automatically by rotating the drum.
71
Second main stage process of malting
Germination
72
What is germination
the modification of the endosperm and uses enzymes.
73
What is measured during germination
1. growth 2. temperature 3. moisture
74
Kilning
heat the germinated barley to dry it and, crucially, to stop germination. The moisture in the grain is reduced to 4-5% prior to further use in the distillery.
75
at what stage can flavor and color be added
Kilning
76
What does kilning do
It reduces some undesirable flavours in the malt and stabilises the enzymes, so that they can be utilised later during mashing.
77
What percentage does kilning reduce the moisture in the grain to
4- 5%
78
two important parameters of kilning
1. air on - temp entering the grain bed 2. air off - temp leaving the grain bed
79
Why are there lower air temperatures used at the start?
To protect the enzyme systems in the green malt. As the grain is dried, the air on temperature can be increased, as the enzyme systems are stabilised.
80
Free drying
also known as pre break
81
air off increases in temp when?
as the kiln time progresses and as the grain dries, the air off has less moisture and therefore increases in temperature. This stage is known as forced drying (or post-break).
82
Parameters monitored during kilning
1. Air Air on and air off temperatures. 2. Humidity Humidity for air off (although this is not very common). 3. Moisture The moisture of the malt These parameters are determined at the end of the kilning process.
83
is endosperm softer during kilning?
Yes
84
What develops flavour and color
maillard reactions and NDMA formation
85
NDMA formation
formed when nitrous oxides react with nitrogen compounds in the presence of heat) could have occurred unless care is taken.
85
Maillard reactions
formed from amino acids and sugars in the presence of heat chemical reactions that take place in heat, producing flavour and colour compounds. They take place in the kiln when temperatures reach above 160°C. Amino acids (from the protein matrix breakdown) react with the sugars (from the starch breakdown) to produce colour and flavour.
86
What is NDMA
a carcinogenic compound that can be formed in kilning under certain circumstances. NDMA formation is a bad thing in malt as this compound has been found to be a carcinogen and therefore has legislative limits for spirit in some countries. NDMA can travel through the process into the spirit, so the malt and the new make spirit are routinely analysed for NDMA as a due diligence test. Modern practices however reduce the formation of this compound in the malt.
87
What is Peat
is an additive and is used to add flavour to the malt during the kilning process. It is partially decomposed plant material, produced in a wet environment in the absence of oxygen. Peat can be dug up and dried, thus becoming a fuel that can be burned.
88
How is peat described (2 ways)
* Medicinal (TCP, germoline, hospitals) * Smoky (smoked meat, burnt wood, bonfire)
89
What differentiates peat
Different areas in Scotland produce peat with different active compounds, dependent upon plant species and environmental conditions
90
How much original phenolic compound ends up in the new make
about 1/3rd. Can be altered in the still run. it is all about the spirit to feints cut in the spirit still (
91
When are phenols collected
in the later part of the heart or spirit cut
92
Phenols
1. heavier more medicinal phenols come off later in the run vs lighter smoke and bonfire earlier 2. later you cut from spirit to feints, the heavier the new make 3. Lagavulin and Caol Ila use the same malt so have the same phenol range entering the stills, but Caol Ila cuts off spirit earlier so has less medicinal phenols in their spirit than Lagavulin
93
the same malt produces an entirely different spirit due to the spirit-to-feints cut point.
True
94
The longer the spirit run, the more phenols in the spirit; this also results in a lower alcohol strength in the final spirit collected.
True
95
too long of a spirit run can result in feinty characteristics
True
96
How long storage for kilned malt
3 weeks
97
why 3 weeks
allows for homogenization of the analysis and allows the malt to ‘settle’.
98
fiery Stills
A fiery still is when it is very hard to control the level of frothing inside the still at the start of distillation, and can sometimes lead to carryover where froth and solids go through the condenser into the safe. This will cause quality issues in the spirit. You normally get fiery stills if the malt processed has not been rested for at least three weeks after kilning.
99
Deculmed Malt
Rootlets removed, done prior to dispatch
100
Third main stage of malting process
Kilning
101
Important parameters of kilning
air on and air off
102
A flavor and coloring added during kilning
peating
103
what adds medicinal and smoky flavours
Peat
104
Steeps today
cylindroconical vessels that load via gravity into a germination vessel. They use compressed air for rousing
105
Drum maltings greatly improved the control of germination
True
106
Kilning systems have improved cost effectiveness
True
107
Steeps use compressed air to rouse the grain and fans to remove CO2 and heat.
True
108
Germination vessels all have false bottoms for air flow and a means to mix up the grain
True
109
Kilns are now designed to improve efficiency such as the use of waste heat
True
110
what system makes use of a small foot print
tower malting system
111
what happens before milling
1. malt passes through a destoner 2. a magnet is used to remove ferrous material
112
MIlling process
1. The first set of fluted rollers are used to open up the grain, breaking off the husk. 2. Subsequent sets of rollers grind up the endosperm. 3. Beaters in between the sets of rollers remove husk, fine grit and flour; meaning only the larger grits pass through the bottom rollers.
113
What is Grist
malt is ground into grist Grist is made up of approximately 10% flour, 70% grits and 20% husk.
114
Grist analysis
1. needed for spirit yield 2. impacts sucess of the mashing operation
115
at a large efficient distillery 1 tonne malt
produces 415 to 420 litres of spirit
116
smaller distilleries produce from 1 tonne malt
400 litres
117
Yeast
a single-celled organism which feeds on sugar, producing alcohol, carbon dioxide and heat in return.
118
Yeast used for distilling
Saccharomyces cerevisiae It typically has a 10 micron cell diameter and 1,000,000,000 cells per gram.
119
Yeast cell division
yeast propagates by budding daughter cell to mother cell
120
Anaerobic respiration
In the absence of oxygen, yeast metabolises sugar to give ethanol.
121
What can affect yeast
1. infection 2. alcohol 3. sugar
122
yeast strain can change the flavor profile in the wash
true
123
what is pitching rate
the amount of yeast used can also affect the congener profile by altering the rate of fermentation
124
why is wort clarity iimportant in terms of spirit character
a cloudy wort has the potential to give rise to a nutty spirit, a clear wort more likely to give a fruity or sweet spirit
125
Yeast
one of the three raw materials permitted for single malt Scotch whisky
126
Yeast is a single cell organism which can metabolise sugar into ethanol
True
127
Mashing
he process of adding hot water to the grist
128
Mashing process is filtration
1. the solids form a filter bed, 2. the liquid is filtered through this bed 3. drains out the bottom of the mashtun.
129
Purpose of mashing
breakdown the starch in the grain and turn it into fermentable sugars.
130
wort
a sugary liquid, drained into the washback where fermentation occurs.
131
spout temperature is vital
it is at this point where most of the enzymatic activity occurs.
132
Optimal mashtun temperature
63.5C this temp balances the gelatinizatio of the starch with the enzyme activity
133
Gelatinisation
simply means getting the starch to become soluble in water. When the starch swells and is hydrated, it can be dissolved in water which allows the enzymes access to do their work. Would happen faster at +63.5 but would be denatured
134
Enzymes at the spout
1. α-amylase 2. β-amylase
135
α-amylase
reacts at random along the chain of the starch molecules breaking the α-(1,4) bonds, thus chopping up the starch. This activity reduces once you get above 67°C.
136
β-amylase
more selective, releasing maltose molecules from the nonreducing end of the starch. This enzyme is far less stable with heat, with all activity ceasing after a time at or above 65°C.
137
secondary conversion
remove the wort and cool it quickly so that the enzyme activity can be continued in the washback; This is vital
138
limit dextrinase
Another enzyme breaks down the branches in the starch molecules, acting upon α-(1,6) bonds, producing more straight chain dextrins.
139
where does limit dextrinase happen
does happen in the mashtun but more predominantly in the washback as part of secondary conversion.
140
normal operation in distilleries now means that all further waters are added in one continual sparge
True
141
Subsequent ‘waters’ are added at a higher temperature to allow for full gelatinisation of the starch. Higher temperatures can only be used as adequate levels of enzymes have been removed into the washback with the cooled wort, thus allowing for the breakdown of the gelatinised starch in the next stage of the process.
True
142
Why is wort cooled between16 -20C?
1. To preserve the enzymes to ensure secondary conversion 2. To protect the yeast that will be added to the washback
143
4 types of Mashtuns from older to newer
1. traditional 2. semi lauter 3. full lauter 4. filter
144
What do mashtuns have in common 1
1. Mixing grist -this must be done in such a way as to fully hydrate the grist thus leading to maximum starch gelatinisation and commencing the hydrolysis of the starch molecule
145
Mashtun common 2
2. Additional water - Additional water must be able to be added into the tun and the resultant liquid (wort) must be able to be removed or pumped. The wort must be cooled after draining through the slotted floor and false bottom in the tun.
146
Mashtun commonalities 3
3. Stirring or slicing - Each type also needs a mechanism for stirring or slicing through the bed, to allow for increased drainage.
147
mashtun commonalities 4
4. Draff removal Each type of mashtun must have a system designed to remove the left over draff. can be simple but now usually automated
148
149
in-place cleaning
New progression in mashtun design an automated system cleans in the tun and under the floor, normally with hot caustic; thus removing the need for operator entry.
150
other developments in mashtun technology
1. Temperature probes are now much more accurate and reliable, thus leading to improved efficiency and constancy. 2. Automation, along with computer control, has improved levels of consistency and further reduced operator requirements. 3. Development in pumping control has removed the requirement for an underback and many sites now pump directly to the washbacks.
151
traditional mashtuns are associate dwith
1. distilleries with visitor centers, ie springbank 2. a cloudy wort due to the continual break up of the bed by the rakes or paddle
152
semi-lauter
have to stop pumping while extra water is added. referring to mashtun operation - the arms and knives are at a fixed height.
153
full lauter
water can be added as wort is removed, referring to arms in mashtun operation - the arms and knives can be raised and lowered.
154
What is a mashtun made out of
cast iron or stainless steel
155
The bottom is effectively a sieve which allows the sugary liquid – wort – to drain through to the underback (if there is one) and then onto the washback where fermentation occurs
True