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IBD General Certificate > Unit 3 - Lesson 1 - Cereal Wort Milling and Mash > Flashcards

Unit 3 - Lesson 1 - Cereal Wort Milling and Mash Flashcards

1
Q

What is good practice for the 1st thing you do checking for grain intake?

A

Make sure the grain batch matches the certification. of analysis

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2
Q

After checking for grain batch matching certification of analysis, what should one do next?

A 
Visual inspection for 
1. Excessive dust
2. Damp grain
3. Foreign object - anything NOT grain
4. Pest free
5. Uniform size kernels
6. No mold growth
7. No strange smells
Need to ID parameters not meeting spec
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3
Q

What happens if kernel size varies?

A

Can affect milling efficiency

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4
Q

What is the issue with broken kernels?

A

Damages starchy endosperm and reduces future extract potential

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5
Q

What is the issues with damp grain?

A

Could indicate mold growth or other microbial growth

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6
Q

Why shouldnt grain be dried with diesel dryers?

A

Can leave a diesel smell

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7
Q

What is the minimum equipment a plant must have to store grain?

A

Dust extraction and magnets

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8
Q

What are the issues with dust?

A
  1. Explosions
  2. Health - uvulitis, conjuctivitis
  3. Long-term
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9
Q

How to manage long term exposure to dust?

A

decrease exposure with good housekeeping
and
PPEs

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10
Q

What are the 5 factors for fire and dust explosions

A
  1. Dust cloud
  2. O2
  3. Fule
  4. Ignition source
  5. Confinement
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11
Q

How to deal with ignition sources?

A

Remove foreign material especially stones which are a potential ignition source
Used de-stoners to remove stones

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12
Q

How are combi-cleaners used?

A
  1. Remove coarse material like broken kernels
  2. Fine dust
  3. Stones - usually larger than grain
  4. Low-density material like loose husks
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13
Q

How are magnets used?

A

permanent or electro- remove any metals which could be an ignition source

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14
Q

How to deal with electrical wires?

A

Make sure they are grounded

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15
Q

How to prevent a dust explosion?

A

Remove one of the following and an explosion should not happen

  1. Dust Cloud
  2. O2
  3. Fuel
  4. Ignition source
  5. Confinement
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16
Q

How to prevent a dust explosion?

A

Remove one of the following and an explosion should not happen

  1. Dust Cloud
  2. O2
  3. Fuel
  4. Ignition source
  5. Confinement
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17
Q

Why do distilleries keep grain stock low?

A

Saves costs and manages cash flow

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18
Q

What are pre-reqs for Grain Silo Storage?

A
  1. Free from leaks
  2. Clean
  3. Self-emptying
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19
Q

How to calc grist weight

A

kg Malt / liters of wort * excess gravity / (3.87 * soluble extract%)

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20
Q

What is the purpose of milling?

A

expose the starch

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21
Q

How do millings work?

A

breaks away the husk from the starchy endosperm, whilst also reducing the particle size of the starchy endosperm.

Basically increases the surface area assisting in conversion process

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22
Q

Types for mills?

A
  1. 2-roller - most basic, not flexible, cheapest
  2. Four-roller Mills
  3. Six-roller Mills
  4. Hammer Mill - not suitable for green malt
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23
Q

Why do mill rollers roll in opposite directions?

A

opposite directions, allowing the flutes (grooves) on the rollers to grip the kernels

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24
Q

Pros/Cons for two-roller mill

A

Pro - cheap
Con - no flexibility, limits different types of grains you can crush like wheat or rye which require more crushed refinement

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25
Q

Pros/Cons of Four-roller Mill

A

1.Suited for well-modified malts since no starchy endosperm

Easily control size, grist composition,

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26
Q

What is the Grist Composition made up of?

A

Grits, Flour and husk

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27
Q

Difference between 4 & 6-roller mill

A

Good for less modified malt

Similar to 4-roller with added pair of rollers and sieves to give more control over particle size

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28
Q

Advantage of a Hammer Mill

A

Good for green malt or other unmalted/undermodified grains

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29
Q

How does a Hammer Mill work?

A
  1. Free swinging metal hammers attached to a rotor?
  2. Hammer crushes grain into smaller pieces
  3. Sieve separates required small from larger pieces
  4. Similar to friabilimeter
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30
Q

Difference between Hammer Mill and Friabilimeter

A

friabilimeter grain is curshed against a sieve

Hammer Mills crush the grain

31
Q

How does a grading sieve work?

A
  1. Typically 5 sieves different hole sizes
  2. Pan and bottom for flour and lid
  3. Auto shaker with a timer
  4. Provides grist analysis breakdown
32
Q

What mills are not suitable for green grains

A

Roller-mills

33
Q

Which mills retain more of the husk intacts?

A

Roller-mills

34
Q

Define wort and draff

A

Wort is the liquid when water is mixed with grist

Draff is the remaining solids

35
Q

What is the purpose of mashing?

A

The purpose of mashing is to extract (dissolve) all the starch from the malt and convert the starch to fermentable sugars.

36
Q

What happens in mashing?

A
  1. Grist is put into mashing vessel (Mash Tun)

2. Temp controlled Water allows the starches to be suspended

37
Q

What are basics that a Mash tun

A 
Optional rakes, blades or a paddle for stirring the mash
A slotted (perforated) base to hold back the solids therefore separating the wort from the spent grain (residual solids)
38
Q

What does high liquor to grist ration indicate?

A

Large amounts of water, produces thinner mash

39
Q

What does a low liquor to grist ration mean?

A

Less water in the mash so thicker mash

40
Q

What is the ideal water to grist ration?

A

2.5 - 3.5L of water per 1kg of dry Grist

41
Q

Why is it important to have ideal liquor to grist ratio?

A

Preserving the malt enzymes

42
Q

What can be a problem for High Liquor to grist ratios?

A

High heat can denature enzymes making the inactive and cause thicker malt

43
Q

What is the benefit of a low Liquor to Grist ratio?

A

Heats more evenly and better protects enzymes

44
Q

Why is mixing the mash important?

A

Ensures starchy endosperm grist is in contact with water

45
Q

Why is hydration important in mash?

A

Dry grits of starch are not yet fully accessible for breakdown by α- and β-amylase

46
Q

What are the steps in starch breakdown of mash?

A
  1. Gelatinization - heating water and malt to right temp for grains
  2. Liquefraction - water seeps deep into structure unwinding starch (or complete hydration)
  3. Saccharification - α- and β-amylase breakdown the chains, unbinding sugar molecules
47
Q

2 types of starch chains in the structure and % of each

A

Amylose - 25%

Amlopectin - 75%

48
Q

What is the challenge with amylose and amylopectin in starch granules?

A

Closed compact structures

α-amylase enzyme can breakdown but slowly

49
Q

Gelatinization

A

This is a vital stage in mashing. The term refers to the process by which the tightly bound starch molecules unwind due to the action of heat and water. Gelatinisation allows them to dissolve. Enzymatic activity then breaks them down.

50
Q

Describe Gelatinization process

A

When heat and water are added, the starches start to unwind and water gets deep into the structure
then the α- and β-amylase enzymes get to work to breakdown into sugars

51
Q

ideal pH, temp & deactive Temp range for α-amylase & β-Amylase

A

α-amylas: 5.6 - 5.8 pH / 70 - 75° C / 75 - 80° C

β-Amylase: - 5.4 -5.5ph / 63 - 65° C / 68-70° C

52
Q

Optimal time for wort the ensure complete starch conversion for each enzyme in “sweet temp” zone?

A

30 min the wort concentrations will plateau while sugars broken down to more fermentable sugars

53
Q

What are the 2 additional enzymes for barely required

A

Maltase (g-glucosidase)

Limi Dextrinase

54
Q

What are some parameters for enzyme performance?

A
  1. Temp - enzymes have optimal range
  2. Time - not more extraction but fermentable sugars
  3. pH - enzymes have optimal range
  4. Liquor to grist ration - thicker mash protects enzymes when heated
55
Q

What is the best temperature for enzyme optimization?

A

Between 62 - 64° C
Optimizes α-amylase & β-amylase
AND does not destroy limit-dexitrinase at 65° C

56
Q

What are the two additional enzymes found in malted barely?

A

limit dextrinase and α-glucosidase (maltase)

57
Q

What does limit dectrinase do?

A

Known as Secondary Conversion - breaking down of the remaining starches residulas

  1. Added extraction by breaking down longer chained Dextrin (9 glucose units) at the “branch points”
  2. NOT ACTIVE at 1st run Wash pH
  3. So “Washback” is added to drop pH to 4.5 pH
  4. It is heat sensitive so could be destroyed in 1st phase of. mash
58
Q

What is the challenge with grains such as maize, sorghum or rice?

A

Gelatinization temps are higher than enzymes can tolerate 70-80* C

59
Q

What is the problem with Maize β-amylase?

A

Optimal gelztinization is 50-50° C which is well below β-amylase optimal temperature range

60
Q

What is the solution for the gelatinization for rica, sorghum and maize?

A

Grain Cooking - for those starches that have not gone through a malting process

61
Q

Why is an agitator used in the Cooking Process?

A

Ensure even cooking

62
Q

What is the range for cooking capacity?

A

2-40 tons

63
Q

What is common heat source for cooking rice, sorghum or maize?

A

Steam - creating a pressure cooker

64
Q

What are the 3 factors for effective cooking process?

A
  1. Pressure 140° C & 4 bar steam
  2. Duration about an hour
  3. Water/Grist Ratio
65
Q

What is backset?

A

The thin watery liquid that remains after distillation; it also includes unfermented solids.

66
Q

Why add backset to unmalted grains?

A

Backset is acidic; adding it to the grain cooker with the mash promotes the breakdown of the grains in the cooker. 5.4 - 5.6 pH

67
Q

What is the cooking process?

A

Batch Process

68
Q

What is continuous cooking under pressure?

A

A process where the mash is pumped through a cooker, exposing the mash to temperatures of 170-177˚C and 7 – 9 barg for two to six minutes

69
Q

What is the last step in Continuous cooking under pressure?

A

Cooling to 63° C

70
Q

Key to Continuous Cooking Under Pressure?

A

Maintain steady state

71
Q

Factors to consider for Continuous Cooking under pressure

A
  1. Fine ground grain (use hammer mill)
  2. Small quantities of malted barely to reduce viscosity
  3. Control of residence time
  4. High pressure/temps
72
Q

4 Main types of Exogenous Enzymes

A

α-Amylases - liquefraction like barley malt amylases
Amyloglucosidases - converts starch to sugar quickly
Proteases - breaks protein matrix around starch
Pullulanases - debranching used with other enzymes

73
Q

What are Exogenous enzymes made from?

A

Bacteria and fungi

74
Q

Why are exogenous enzymes effective?

A

They are from different sources and behave slightly different
Can operate at higher temps up to 90° C

IBD General Certificate (52 decks)

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