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unit 5 lesson 2 Flashcards

1
Q
A
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2
Q

What are the key objectives of malt intake, handling, and storage?

A
  • Malt received is as specified and will perform well
  • Malt is not damaged and its quality is not diminished
  • Extract loss is minimised
  • Food safety hazards are identified and removed
  • Foreign material is removed
  • Safety of staff and integrity of buildings and equipment are protected
  • Costs and use of energy and resources are minimised

These objectives apply to operations of all sizes and complexities.

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3
Q

What activities are involved in malt intake?

A

Malt intake spans from the lorry arriving at the brewery to the unloading of the grain, which can vary from removing a sack from a pallet to unloading a ship with conveyors and elevators.

The level of inspection and evaluation of malt at arrival varies greatly.

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4
Q

What factors increase the risk of malt condition deterioration during transport?

A
  • Length of time in supply chain
  • Moisture absorption
  • Foreign bodies introduction
  • Infestation with mould, insects, or vermin
  • Exposure to extremes of temperature

The longer malt is in transport, the greater the risk of these issues.

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5
Q

What specifications must trucks transporting malt meet?

A
  • Cleanable
  • Cleaned before filling
  • Inspected before filling
  • Dedicated to transport of food materials
  • Designed to prevent water and pest ingress

These specifications help prevent contamination.

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6
Q

What documents accompany large loads of malt?

A

A bill of lading accompanies large loads, while small consignments arrive with delivery notes.

This documentation helps keep track of the malt quantities.

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7
Q

What is a certificate of analysis (CoA)?

A

A CoA is produced using results from tests undertaken by the malt supplier and accompanies the malt load.

It is used by breweries to adjust recipes and processing.

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8
Q

What are intake tests designed to prevent?

A

Intake tests help ensure that the brewery unloads what has been ordered, not just what has arrived.

Unloading contaminated or infested malt can be very costly.

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9
Q

What are the three ways samples are analysed during malt intake?

A
  • Physical and organoleptic analysis
  • Rapid testing
  • Laboratory testing

Each method serves different purposes in quality assurance.

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10
Q

What does physical and organoleptic analysis check for in malt?

A
  • Homogeneity
  • Varietal purity
  • Damage
  • Modification
  • Infestation
  • Moisture
  • Foreign material
  • Colour

These checks help reject flawed malt.

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11
Q

What does the rapid analytical method of NIR spectroscopy measure?

A

NIR spectroscopy measures the moisture and nitrogen (protein) levels of grain based on their optical properties in the near-infrared spectrum.

It is a quick method commonly used in breweries.

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12
Q

True or False: The dielectric moisture meter is commonly used for determining moisture content in breweries today.

A

False

Most breweries prefer NIR for measuring moisture content.

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13
Q

What is the purpose of the plansifter in malt analysis?

A

To measure grain sizes in a sample and assess milling effectiveness.

It uses a stack of containers with screens of decreasing hole size.

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14
Q

What happens if any results from rapid analysis are out of specification?

A

The load might be resampled for lab analysis or sent back to the suppliers.

Quick analyses are conducted before unloading due to time constraints.

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15
Q

What is the outcome of the malt handling process?

A
  • Free from foreign material
  • Correct size profile for milling
  • Correct moisture level for storage or milling
  • Free from infestation with mould and pests

This ensures quality malt is prepared for brewing.

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16
Q

What components are typically found in a malt handling and storage system?

A
  • Intake pit or hopper
  • Magnets
  • Bucket elevators
  • Conveying systems
  • Dust aspiration system
  • Silos
  • Destoner
  • Malt screening
  • Malt weighers
  • Manual dust cleaning systems

Not all systems will have all components, and their arrangement may vary.

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17
Q

What is the purpose of a pit or hopper in bulk deliveries?

A

To prevent water entry and secure against pest ingress when not in use

It allows the malt to slide towards a conveyor or elevator.

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18
Q

What role does an inline magnet play in malt handling?

A

It catches any ferrous metal present in the grains

Ferrous material can damage equipment and affect beer flavor.

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19
Q

What is the function of screening equipment in malt processing?

A

Separates foreign material based on size

It removes material larger or smaller than the required malt kernel size.

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20
Q

What does a dust aspiration system do in malt handling?

A

Continuously removes dust and maintains negative pressure

Prevents dust from leaking into the brewery.

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21
Q

What is the maximum height of bucket elevators?

A

100 m

They can move grain at speeds of up to 2.8 m/s.

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22
Q

Fill in the blank: In bucket elevators, the malt must be ______ into the base to prevent choking.

A

metered gently

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23
Q

What is a key advantage of chain and flight conveyors?

A

They can move grain as one bulk with minimal internal movement

This reduces the risk of damage to the grains.

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24
Q

What is the maximum incline for screw conveyors?

A

12°

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25
True or False: Pneumatic conveying systems are less expensive to install than screw conveyors.
False
26
What is the maximum capacity of a chain and flight conveyor?
300 t/hr
27
What are the two modes of pneumatic grain transport?
Vacuum System and Blow Line ## Footnote Each mode has distinct characteristics for grain collection and deposition.
28
Fill in the blank: A screw conveyor is also known as a ______ conveyor.
worm
29
What is a disadvantage of pneumatic conveying systems?
Can cause damage to grain due to collisions with surfaces ## Footnote Especially in lean phase where high speeds are possible.
30
What maintenance is essential for screw conveyors?
Regular greasing of bearings
31
List three key features of bucket elevators.
* Must be gently filled to prevent choking * Fully enclosed for dust control * Regular cleaning required to remove old grains
32
What is the function of a jam switch in a chain and flight conveyor?
To stop the conveyor if the malt is backed up
33
What is the maximum capacity of screw conveyors?
100 t/h
34
What type of conveyor is used for gentle grain handling and can be cleaned in place?
Pipe, chain, and disc conveyors
35
What is a critical feature of chain and flight conveyors regarding dust?
Fully enclosed, preventing dust release to the atmosphere
36
Fill in the blank: The dust collected from the aspiration system can be ______.
combined with spent grains, sent for anaerobic digestion, or disposed of
37
What is a significant challenge of using pneumatic conveying?
High energy use and maintenance costs
38
What is the maximum incline for chain and flight conveyors?
20°
39
What must be fitted to the bottom pulley of bucket elevators to ensure safety?
A rotation/speed sensor
40
What are the two main types of magnets used in malt processing?
Fixed and dynamic magnets
41
How often must fixed magnets in conveyor systems be inspected and cleaned?
Frequently
42
What is a plate magnet also known as?
Hump magnet
43
What happens when the magnet is pulled away from the plate in a plate magnet system?
The ferrous material is removed
44
What is a grate magnet?
A magnet with rods fitted inside metal tubes over which malt flows
45
Describe how a dynamic drum magnet operates.
Grain flows over a revolving cylinder, half of which is magnetised
46
What types of metals do magnets attract?
Metals containing iron
47
What is the primary material used for constructing storage silos?
Galvanised steel
48
What is the angle of repose for malt typically around?
30°
49
What is funnel flow in silo design?
When the silo empties from the middle, leaving malt at the sides
50
What is the required cone angle for malt silos to achieve mass flow?
Around 60°
51
What is bridging in the context of silos?
When grain stops flowing and forms a bridge over the outlet
52
What is the oldest method of determining silo contents?
Measuring the height of the grain with a plumb line
53
What is the bulk density of malted barley?
Around 0.5 t/m³
54
How does radar level detection measure grain volume in a silo?
By sending out a radio signal and measuring reflected waves
55
What is the most accurate method of measuring silo contents?
Using load cells to measure the mass of the silo
56
What does FIFO stand for in stock management?
First in, first out
57
What four conditions must be controlled during malt storage?
* Moisture * Temperature * Mould * Pests
58
What is the best temperature for grain storage?
Below 15°C
59
What is phosphine used for?
To fumigate malt for pest control
60
What are the risks associated with using phosphine gas?
* Toxicity * Corrosion of certain metals * Spontaneous ignition
61
What is a destoner used for?
To remove stones and nonferrous metals from grain
62
How does a destoner operate?
Air blows up through a moving deck, separating heavier materials
63
What does screening in malt processing remove?
* Larger items * Smaller items * Broken grains * Foreign material
64
What are the two methods of inline batch weighing?
* Tip-scale method * Gravity drop method
65
What is the typical dust generation from malt handling?
0.4-1.4 kg of dust per 100 kg of malt
66
What happens when the weight of the grain in the hopper exceeds the counterweight?
The hopper tips over, releasing the grain into the second hopper.
67
How much dust is produced during malt handling?
Around 0.4-1.4 kg of dust per 100 kg of malt.
68
What are the dangers associated with dust in grain handling?
Dust can harm lungs and cause catastrophic explosions.
69
What happened in 2011 related to grain handling dust?
A grain elevator in Kansas exploded, killing six people.
70
How can sparks and ignition be prevented in grain handling systems?
Using grain cleaners, spark arrestors, and ensuring equipment is electrically earthed.
71
What is the purpose of dust aspiration systems in grain handling?
To keep the level of dust to a minimum by removing it as it is produced.
72
What is a cyclone in the context of dust removal?
A device that spins dusty air to separate dust particles from the air.
73
What maintenance is essential for aspiration systems?
Proper maintenance and regular inspections.
74
What is the risk associated with accumulations of dust?
They provide fuel for secondary explosions.
75
What is the purpose of explosion relieving vents in grain handling systems?
To take the energy out of an explosion before it spreads.
76
What are the three approaches to manage the risk of dust explosions?
1. Prevent sparks and ignition 2. Control the dust 3. Limit the explosion
77
What does the ATEX directive cover?
Explosive atmospheres and equipment allowed in those areas.
78
How are areas at risk of explosions categorized in the ATEX directive?
Zone 20, Zone 21, Zone 22.
79
What is Zone 20 in the ATEX classification?
A place where an explosive atmosphere is present continuously or frequently.
80
What type of equipment is required for Zone 21?
Category 2 equipment.
81
What health risks are associated with dust exposure?
Asthma, farmer's lung, alveolitis, and contact dermatitis.
82
What is the most effective control against dust exposure?
Keeping people out of the malt handling area.
83
What type of bags are most specialty malts delivered in?
One or half tonne bulk bags or 25 kg bags.
84
Why must specialty malts be handled differently than base malts?
They are used in smaller quantities and are often very brittle.
85
What is the storage recommendation for bulk bags and sacks?
Stored on pallets away from the wall to reduce rodent infestation.
86
What is the issue with black malt and roasted barley in milling?
They are brittle and unsuitable for hammer milling.
87
Fill in the blank: Dust is a respiratory ______ that can trigger asthma attacks.
sensitiser

IBD (15 decks)

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