WOLFGANG KUNZE ie ChNO LOGY BREWING™MALTINGThe Right Address for the Brewing Industry Mb, KHS KHS Maschinen- und Anlagenbau AG Juchostrasse 20 | D-44143 Dortmund Phone: +49 231 569-0 Fax: +49 231 569-1541 E-Mail: info@khs-ag.comBibliographic information published by Die Deutsche Bibliothek Die Deutsche Bibliothek lists this publication jin the Deutsche Nationalbibliografie; detailed bibliographic data is available in the Internet at dnb.ddb.de Wolfgang Kunze Technology Brewing and Malting Translated by Susan Pratt, Berlin 3" completely updated edition, 2004 ISBN 3-921690-49-8 © VLB Berlin, Germany All rights reserved by the Versuchs- und Lehranstalt fiir Brauerei in Berlin (VLB), Seestrasse 13, 13353 Berlin, Germany, www.vlb-berlin.org No part of this book may be repro- duced, by photocopying or in any other way, without express prior permission of the publisher. Re-Design, Typesetting: Grafikdesign Anne Kulessa, Dresden Printing: Westkreuz-Druckerei Ahrens KG Berlin/Bonn Printed in Germany 2004WOLFGANG KUNZE TECHNOLOGY BREWING™MALTING Chapter 11 co-written by Dr H J Manger 3rd INTERNATIONAL EDITION Published byWater, hops, malt... ..and yeast are the only raw materials for beer brewing according to the German purity law of 1516.Preface to the 3rd imernational Edition of wTechnology Brewing and Malting** Every year about 1.5 billion hectolitres of beer are brewed and drunk worldwide. First deserip- tions of beer brewing are nearly 5000 years old. In fact beer is a cultural asset which has found friends all over the world. As a source of vitality and pleasure beer brings people together whilst being good for both spirit and body. Meanwhile medical research has proven without doubt, that moderate beer consumption has a positive impact on human health, All this leads to the obligation for the brewers to make the highest demands on the quality of raw materials, the technical equipment, the pro- cesses and - last but not least - on the qualif ion of the employees. With 1300 breweries and round about 5000 beer brands brewing science and education has always been very distinetive in Germany. Brewing specific research and deve- lopment - among others at the Universities in Berlin and Munich-Weihenstephan - have led to great progress in this field. In addition the German purity law (‘Reinheitsgebor’) with its strict limitation on four natural raw materials for beer brewing (water, hops. malt and yeast) has inspired the creativity of our brewers and e: neers for centuries, A lot of this extensive knowledge is summari- zed in the new edi ion of Technology Brewing and Malting*, Since its first edition in 1961 more than 40,000 copies have been sold. With transla- tions into. Hungarian, Polish, English, Yugoslavian, Chinese and Russian the original German edition has found its way to brewers all over the world, Knowledge is dynamic. It is continuously extended by research and development - also in the brewing and malting industries. As a result, this third international edition of ,:Technology Brewing and Malting* has been completely updated and newly translated, In more than one year of work the author Wolfgang Kunze has considered the latest developments in the field of brewing and malting technology. Current trends such as the filling of beer in PET bottles, mem- brane filtration, new methods of wort production and new applications for process control are des- cribed in detail, With numerous illustrations and his distinctive didactic style the author has succeeded again in explaining complex issues very succinctly and clearly. The new edition proves once again the reputa- tion of Technology Brewing and Malting™ as the worldwide leading standard work for professio- nal brewers and maltsters. an Dr Axel Th Simon President of the VLB BerlinForeword hy the author This book is the completely revised, third English language edition of a German textbook for the training of brewing and maltsters, which has meanwhile also been translated into many languages. The book provides a comprehensive overview of the transformations, the technology and the processes in the production of malt and beer, including all related subjects. Particular value has been placed on the integration of new insights and on putting emphasis on new techno- logy. As in the earlier editions, | have attempted to present the material in an easily understanda- ble form and where possible, have made use of diagrams for the purpose of clarification, The production of beer - albeit with very dis- tinctive regional differences - has increased throughout the world in recent years. Today beer is no longer produced and drunk solely in the classical beer countries, but all over the world. As well as the large brewing companies, which nowadays are increasingly dominating the beer market with large production plants, small bre- wing companies have become firmly established everywhere, which have gained particular signi- ficance with niche products and local lair and thus helped to make the beer landscape more interesting. 6 The book is based on the technology of the production of malt and beer of high quality according to the Reinheitsgebot, but nevertheless takes into account in equal measure that nowa- days throughout the world, adjuncts and com- mercially produced enzymes are used for econo- mic reasons, The increasing variety in the tech- nology of beer production, of whieh it has only been possible here to include the most important aspects, has led to an expansion of the material despite considerable efforts to compress it. In addition to this, the analysis of raw materials, intermediate and final products has been given more attention Chapter [1 on Automation and Plant Plan- ning” has been completely rewritten in co-opera- tion with Dr. Hans MANGER, to whom | am particularly grateful for the many references. I would also like to thank the Management Board of VLB Berlin, my former alma mater, in parti- cular Mr Olaf HENDEL for his successful publishing work with the textbook, as well as Ms Susan PRATT for her conscientious translation of the new English language edition, I am espe- cially grateful to graphic designer Ms Anne KULESSA, who carried out my numerous speci- al requests concerning layout patiently and con- structively thus providing the book with a balan- ced and attractive appearance. I wish the third international edition of the book every success. May it contribute to enab- ling the reader to acquire an even better under. standing of the relationships in the production of malt and beer in order to produce a good beer quality while employing good economic values i} wilContents Beer - the oldest drink for the common man 1 Raw materials 11 Barley 1.1.1 Barley types and varieties ~ Barley types - Barley varieties Barley cultivation Structure of the barley kernel ~ External structure = Internal structure Compositions and Properties ~ Carbohydrates = Nitrogen compounds - Fats 12 113 = Inorganic material ~ Other Substances Barley evaluation = Hand evaluation ~ Physical and chemical examinations - Physiological examinations 1.2 Hops 1.2.1 Growing regions 1.2.2 Harvesting, drying and stabilising hops 1.2.3 Hop cone structure 1.2.4 Composition and properties of the components = Bitter substances oF hop resins = Hop oil - Tannins or polyphenols - Nitrogen compounds 1.2.5 Hop evaluation ~ Hand evaluation of hop cones = Bitter substances content 1.2.6 Hop varieties 1.2.7 Hop products = Hop pellets = Hop extracts 13° Water 13.1 Water cycle 1.3.2. Water use in the brewery 68 1.3.3 13.4 13.6 14 14d 142 143 144 Obtaining water Extracting ground water extracting of surface water ~ Importance of private wa Water treatment supply - Removal of suspended matter = Removal of dissolved materials - Biological specification requirements Brewing water ions ~ Chemically inactive lons = Chemically reactive fons Improvement of the residual alkalinity of water ~ Decarbonation salts removal - Water sterilisation Yeast Structure and compositions of the yeast cell Yeast metabolism - Carbohydrate metabolism = Nitrogen metabolism ~ Metabolism of inorganic substances and growth factors - Energy metabolism of yeast ‘Yeast multiplication and growth Characterisation of brewing yeasts ~ Morphological characteristics ~ Physiological differences Fermentation technological differences Systematic classification Adjunets Maize Rice Barley Sorghum Wheat Sugar Glucose syrup Colouring sugar (also couleur) Malt Production Intake, cleaning, grading and transfer of barley Barley intake 69 69 76 83 83 86 87 87 88 89 SSee ol 92 93 93 93 94 95 95 98 9822 2.2.1 2.2.2 2.2.3 224 25 = Intake of barley from lorries or rail waggons Intake of barley from ships Cleaning and grading the barley - Barley precleaning ~ Magnetic devices = Dry destoners ~ Grain cleaner (trieur) ~ Barley grading ‘Transfer of barley and malt - Mecha = Pneumatic conveyors Equipment of dust removal = Cyclones = Dust filters Drying and storage of barley Barley respiration Barley drying Barley cooling Barley storage = Storage in silos ical conveyors = Storage in bins ~ Pest infestations Barley steeping Processes during steeping = Water uptake = Provision of oxygen = Cleaning Steep vessels Steeping process Barley germination Process occuring during germination = Groth processes = Enzyme formation to storage materials during germination ~ Conclusion about how to perform germination Germination methods - Floor maltings = Pheumatically operated malting systems = Conirol of germination Malt kilning 98 99 lol 103 103 10s 106 108 10 3 116 7 118, 120 120 121 122 123 123 124 124 126 126 126 128, 129 129 134 135 135 135 137 138) 145 145 145 146 158 158 2.6 2.6.1 2.6.2 263 264 27 2.8 2.8.1 2.8.2 ng during kilning, ~ Lowering of the water content - Termination of germination and modification - Formation of colour and flavour ‘compounds (Maillard reactions) ~ Formation of DMS precursor and free DMS during kilning + Effect of kilning temperature and duration - Formation of nitrosamines ~ Enzyme inactivation Kiln structure ~ Heating and forcing of air through the kiln = Older type two-floor kilns - Kilning with tipping floors ~ Kilns with loader and unloader - Vertical kilning Mangement of kilning ~ Production of Pilsner malt = Production of Munie malt ~ Unloading the kiln ~ Control of kilning ‘Treatment of malt after kilning Cooling of the kilned malt Malt cleaning Malt storage Malt polishing ‘Yeald during malting Malt evolution Hand evolution Physical and physiological examinations ~ Screening ~ Thousand corn weight ~ Hectolitre weight ~ Sinker test (floaters) ~ Glassiness ~ Hardness ~ Acrospire length ~ Germinative capacity - Density 160 160 162 162 162 163 166 166 167 168 168 170 172 Il 172 172 172 172 173 173 174 174 174 174 174 174 174 175 175 175 175 175 175 Chemical and physiological methods 176 ~ Water content 17629 2.9.1 2.9.2 2.9.3 2.9.4 2.9.5 2.9.6 2.9.7 2.9.8 2.9.9 2.9.10 2.9.11 2.9.12 9.13 2.9.14 29.15 2.9.16 2.10 3 31 3.1.2 313 3.14 3S = Congress mash ~ Diastatic power examination ~ Malt supply contract Special malts and malt from other cereals Pilsner malt (pale malt) Dark malt (Munic malt) Vienna malt Brumalt/melanoidin malt Caramel malt Acid malt Short grown and chit malts Smoked malt Diastase malt Roasted malt/chocolate Roasted malt beer Wheat malt Malt extract Malt of other bread cereals = Spelt - Emmer Rye - Triticale Sorghum malt Usage of different types of malt for various types of beer Safety precautions in malting Wort production: Malt milling Pretreatment of the malt ~ Removal of dust and stones from the malt = Weighing the malt charge Basic aspects of milling Dry milling ~ Six roller mills ~ Five roller mills ~ Four roller mills = Two roller mills = Rollers of malt mills - Grist case = Hammer mills Wet milling Steep conditioning 176 176 178 179 179 179 180 180 180 182 182 182 182 182 183 183 184, 184 185 185 185 185, 185 186 187 195 196 196 196 197 200 200 201 202 202 203 204 206 207 208 209 3.1.6 3.17 3.2 3.2.1 3.2.2 3.24 3.2.5 3.2.6 33 331 3.3.2 3.3.3 3.34 3.3.5 34 34.1 Fine comminution with water Evaluation of the grist Mashing Transformations during mashing = Purpose of mashing ~ Properties of enzymes = Starch degradation ~ B-glukan degradation = Other degradations and dissolving provesses ~ Composition of the extract - Acidification of mash and wort Mash vessels ~~ Mash vessels ~ Heating through semicircular pipes = Heating by means of a direct steam injection Mashing-in ~ Addition of the brewing water ~ Mashing-in temperature = Mixing of the water and grist Mashing ~ Parameters ti consider when mashing - Infusion mashing ~ Decoction process ~ Special mashing processes Mashing duration Control of mashing Lautering First wort and second wort Last runnings Mash spearation with a lauter tun Masch separation with a mash filter Spent grains ~ Transfer of wet spent grains = Spent grain analysis Wort boiling Wort boiling operations ~ Extraction and transformation ‘of hop components = Formation and precipitation of protein-phenol compounds ~ Evaporation of water - wort sterilisation = Destruction of all enzymes 212 213 214 214 214 215 220 225 230 284 285 2853.4.1 3.4. 35. 37 10 2 3 ~ Thermal stress on the wort ~ Lowering the pH of the wort Formation of reducing substances (reductones) ~ Evaporation of undesirable aroma substances ~ Zink content of the wort Unboiled wort - cast wort Design and heating of the wort kettle Directly heated wort kettles ~ Steam heated wort kettles ~ Wort kettle with low pressure boiling ~ High temperature wort boiling - Energy saving wort boiling systems ~ Modern wort boiling systems - Energy usage during wort boiling - Vapour condensate = Underback (wort buffer vessels) Performing wort boiling ~ Boiling the wort = Hop addition Monitoring the wort Brewhouse yield Calculation of the brewhouse yield ~ Determination of the mass percent ~ Determination of the mass of extract per hl wort ~ Conversion of the volume of the hot casting wort to that of the cold wort = Calculation of the amont of the extract obtained in the brewhouse - Determination of the brewhouse yield Factors affecting the yield Calculation of a brewhouse yield Brewhouse equipment Number and arrangement of vessels Vessel size ‘Vessel material Brewhouse capacity Special type of brewhouses ~ Pub brewery brewhouses = Integral brewhouses ~ Research and trainig brewhouses Casting the wort 287 288 288 289 289 290 204 301 302 306 318 319 319 319 319 320 323 324 325 329 329 330 330 331 331 331 332 332 333 334 334 334 335 336 38 3.8.1 3.8.2 3.8.3 3.84 3.8.5 39 3.9.1 3.9.2 3.9.3 3.94 3.9.5 3.10 aL 41 Removal of the coarse break (coarse trub) Coolship Settling tank Whirlpool = Operations prineiple of the whirlpool = Whirlpool design = Performing wort classification in a whirlpool Centrifuges - The principle used in centrification = Types of centrifuge = Design and operation of selfcleaning separators ~ Evaluation of hot wort separation Recovery of wort from cloudy wort Cooling and clarifying the wort Procedures during cooling = Wort cooling ~ Formation and optimal removal of cold break ~ Wort aeration ~ Changes in wort concentration Equipment for wort cooling ~ Structure of plate heat exchangers ~ Method of operation of the plate heat exchangers ~ Adyentages of plate heat exchanger Wort aeration ~Method of wort aeration ~ Time of yeast aeration Equipment for cold break removal ~ Kieselgubr or perlite ~ Flotation Wort cooling lines Control and monitoring of wort production process Safety at work during wort production Beer production (Fermentation, maturation and filtration) Changes during fermentation and maturation 336 337 337 337 338 340 341 341 341 343 344 344 345 347 347 347 347 348 348 348 348 350 352 353 353 355 355 355 356 357 359 367 3674.1.2 413 414 41s 4.1.6 42 4.2.1 4.2.2 423 424 43 431 Yeast: the brewer's most important partner Metabolism of yeast - Fermentation of the sugar - Protein metabolism - Fat metabolism = Carbohydrate metabolism ~ Mineral metabolism Formation and removal of fermentation by-products ~ Diacetyl (vicinal dicetones) ~ Aldehydes (carbonyl compounds) - Higher alcohols ~ Esters ~ Sulphur compounds ~ Organic acids ~ Evaluation of the aroma compounds Other reactions and changes = Changes in composition of nitrogen compounds ~ Lowering of the pH value ~ Changes in the redox properties ~ Changes in the beer colour - Precipitation of the bitter substances and polyphenols = CO, content of beer ~ Clarification and colloidal stability of beer Effects of different factors on the yeast Floceulation of the yeast (break formation) Pure yeast culture propagation Basic of yeast propagation Isolation of suitable yeast cells Propagation in the laboratory ‘Yeast propagation in the brewery ~ Yeast propagation plants ~ Assimilation procedure - Single vessel pure yeast culture procedure = Open yeast propagation Conventional fermentation and maturation Fermentation tanks - equipment 367 369 369 372 373 374 374 375 376 376 379 379 380 381 381 382 382 382 383 383 383 384 384 384 386 386 386 387 387 388 389 391 393 393 395 4.3.2 43.3 43.4 4.3.5 43.6 43.7 43.8 43.9 44 44.1 4.4.2 of the fermentation cellar 395 ~ Fermentation tanks 395 ~ Layout of the open fermentation cellar 396 Fermentation cellar yield 398 Management of primary fermentation 399 - Pitching 399 - Fermentation management 402 = Degree of attenuation 403 ~ Beer transfer from the tank 406 Yeast collection in the tank 409 Processes during beer maturation in conventional tanks 409 ~ Saturation of beer with carbon dioxide under pressure 409 - Beer clarification 410 Equipment in conventional lager cellars all ~ Lager cellar installation all ~ Lagering tanks 41 Perfortmance of lagering in conventional tanks 412 ~ Beer transfer 412 ~ Pressure regulation 412 Storage vessel tapping 414 - Establishment of the connection 4l4 - Pressure during tapping and emptying 414 Drawing off from conventional tanks 414 ~ Blending unit 41s ~ Pressure regulator 45 - Recovery of tank bottom beer 415 - Deep cooling of the beer 4s - Fore-run and post-run 416 Fermentation and maturation in cylindroconical vessels (CCVs) 416 Construction and installation of cylindroconical vessels 416 + Design, shape and construction materials of eylindroconical vessels. 416 = Size of COVs 4i7 ~ Location and arragement of the CVs 419 Cylindroconical tank fittings 420 = Control and operating elements and safety fittings a7 ~ Cooling of the CCV 428 ~ Possible methodes for controlling i443 444 445 446 447 448 449 45 45.1 and automatic evoling Manging the fermentation and maturation in CCVs ~ Special points to consider when fermenting and maturing in CCVs ~ Cold fermentation - cold maturation = Cold fermentation with accelereted maturation in a CCV = Warm ferementation without pressure - cold maturation - Pressure fermentation: ~ Cold fermentation - warm maturation - Cold primary fermentation with programmed maturation = Warm primary fermentation with normal or forced maturation Yeast cropping from the CCV - Time of yeast cropping - Methods of collecting yeast ~ Treatment and storage of the yeast crop ~ Monitoring of the yeast crop Beer quality on drawing off Beer recovery from surplus yeast (tank bottom beer) = Yeast pressing ~ Yeast separation ~ Membrane filtration of the yeast - Beer recovery using a sedicanter - Treatment of tank bottom beer Cleaning of the CCV CO, recovery Immobilised yeast Beer filtration Various filtration methods = Separation mechanism - Filters ~ Filter aids Structural forms of filters ~ Mass filter = Powder filters ~ Sheet filters (frame-type filters) ~ Membrane filters ~ Multi Micro-System-Filter ~ Areas of filtration 440 44 Ma 442 442 443 443 443 444 445 446 447 447 447 448 448 449 449 450 450 451 453 454 454 455 457 459 459 473 474 476 476 46 46.1 4.6.2 4.63 4.6.4 47 48 4.8.1 4.8.2 48.3 49 4.9.1 4.9.2 4.9.3 49.4 5. 51 SLI ~ Cross-flow-filtration - Kieselguhr-free beer filtration Beer stabilsation Microbiological stabilisation of beer = Pasteurisation = Flash pasteurisation - Hot filling of beer ~ Pasteurisation in a tunnel pasteuriser - Cold sterile filling of beer Colloidal stabilisation of beer - Nature of colloidal hazes = Improving the colloidal stability - Technological measures for improving colloidal stability = Addition of stabilising agents Filtration plant Flavour stability ~ Ageiong carbonyls - Factors encouraging flavour stability ~ Measures for the avoidance of oxygen addition durin filtration and bottling ~ Measures to prevent negative influence ‘on the flavour stability after bottling Carbonisation of the beer Special methods for beer- production High gravity brewing Ice beer produetion Processes for removing aleohol ~ Membrane separation processes - Heat treatment processes/distillation = Suppression of aleohol formation Accident prevention in the fermentation, maturation and filtration areas Danger of accidents due to fermentation carbon dioxide Work in pressure vessels Working with kieselguhr General advice regarding accident prevention Filling the beer Filling in returnable glass bottles Returnable glass bottles 47 479 487 487 488 488 491 491 491 493 493 494 494 495 501 504 504 505 507 507 509 509 512 513 514 S17 521 523 $24 525 525 532 532 5325.13 5.1.6 SLT 5.18 ~ Advantages and disadvantages of glass bottles - Glass bottle production = Bottle shape = Bottle colour = Surface coating ~ Seuffing - Boitle aflercoating - Plastic coated light glass returnable bottles ~ Procedural steps in the filling of returnable glass bottles, Cleaning of returnable glass bottles ~ Factors which influence bottle washing ~ Bottle washing machines ‘austic solution leaning and maintenance work on the boitle cleaning machine ~ Cleari and cans Control of the cleaned recyclablke glass bottles Bottle filling Principles of filling - Prineiples of bottle filling machine design away new glass bottles ~ Component elements of the bottle filling machines = Construction and mode oF operation of the bottle filling organs ~ High pressure jetting Closing the bottles “losing, with crown corks ~ Closure with a swing stopper Cleaning the filter and the closer ‘Contro! of the filled and closed bottles - Filling level control - Oxygen in the bottle neck Pasteurising in bottles ~ Principles of pasteurisation in bottles = Important components of the tunnel pasteuriser = PU fase 532 532 532 534 534 535 535 535 558 564 564 567 568 571 587 587 387 593 594 597 597 597 599 599 600 603 5.1.9 Labelling and foiling the bottles ~ Labels and foils ~ Label adhesive = Basic principle of labelling = Design of labelling machines = Head folding with foils Dating the labels Special features when filling into non-returnable glass bottles Clearing of new glass bottles Rinsing Filling into PET bottles PET bottles ~ Structural properties of PET - Barrier properties of PET - Barrier technology ~ Importance of Seavanger Production of PET bottles = Production of the preforms = Stretching and blow-moulding ~ Monitoring of the manufactured PET bottles - Rinsing of new bottles Transportation of the PET bottles Filling of PET bottles Closing of PET bottles - Plastic screw cap closures ~ Aluminium rolled-on closure Labelling of PET bottles Filling of plastic returnable bottles PEN Cleaning of returnable plastic bottles Inspection of foreign substances Filling of cans Cans and can closure Storing, depalletising an removal of empty cans Instection of the empty cans Rinsing of the cans Filling of the cans ~ Mechanical can fillers = Can filler with volumetric filling Closing the eans 604 604 606 607 609 610 610 oll oll oll 612 612 613 613 614 614 615 61s ols 616 6l7 19 619 631 631 634 635 637 637 637 639 641 642 645 647 648 648, 653 653 662 13Cleaning of the can filler and closer Widgets Inspection of the filled cans Pasteurisation of cans Overall labelling of cans Dating of the cans ing of casks, kegs, party casks, and large cans Filling of wooden barrels and casks Kegs and fittings = Material, shape and size of the keg = Keg fittings Cleaning and filling the kegs ~ Cleaning of the keg ~ Fill Keg plants as a whole 5.6.3 5.6.4 5.6.5 5.6.6 5.7 57.1 5.7.2 Filling of large cans ‘Transport and packaging Transport contain Treatment of plastic crates - Elimination of foreign and demaged crates and bottles ~ Washing of the erates = Crate magazine ‘Transport technology Bottle and ean transport Contai sr transport ging technology Packing head and packing tulips ~ Types of packer Palletiser and depalletiser equipment ~ Robot technology ~ Design and funetion of the palletisers and depalletisers ~ Stacking plants for full pack pallets ~ Transport plants for pallets ~ Pallet set positions ~ Infeed and output equipment ~ Pallet magazines ~ Pallet control securing the pallets = Palletising in keg filling 5.8 The filling plant as a whole 5.9 Beer losses 664 664 665 666 666 667 669 669 671 oT 612 674 615 675 677 677 678 679 679 681 681 682 683 683 684 687 688 688 690 696 697 698. 700 700 700 701 701 701 701 702 702 709 5.9.1 61 6.1.2 6.13 6.2 63 6.4. 65 6.6 67 68 WM Td 72 72 721 122 13 Calculation of the amount of sales beer produced Stocktaking and calculation of beer for sale Calculation of the volume loss Calculation of malt usage in kg malt/ hl beer Importance of the loss and possible ways of reducing it Cleaning and Disinfection Materials and their behavior towards cleaning agents Aluminium vessels Vessels ans pipes made of chrome-nickel steel Hoses and seals Cleaning agents Disinfection agents Cleaning and disinfection using a CIP system Cleaning procedure Mechanical cleaning Monitoring of cleaning and disinfection Protection at work when cleaning and disinfection Finished beer Beer composition Components of beer Beer and health ‘Taste and foam Beer flavour Beer foam Beer types and special features Beer produced by top fermentation = Special features of top fermentation, ~ Wheat beers ~ Berliner WeiBe ~ Alibier = Kosch =Ale = Stout ~ Porter 709 710 m1 716 716 716 17 719 720 721 Bee 730 731 732 732 732 735 737 737 740 742 742 743 745 747 748 748 749 749 750132 133 14 TAA 742 143 18 751 75.2 75.3 734 Belgian beer types Bottom fermentation beer types = Pilsner type beer ~ Lager beers / Vollbiere - Export beer - Black beers ~ Festival beers ~ Ice beer = Marzen - Bockbier = Doppelbock ~ Alcohol-free beer - Dietetic beer + Light beer ~ Malt drink (Malzbier) ~ Beer types witha very low proportion = Beer mix drinks Trends regarding the development of beer types not corresponding to the Reinheitsgebot Quality examination Beer tasting Microbiological examination Beer analysis ~ Determination of the original gravity - Distillation analysis = Refraction analysis ~ Analysis machines ~ Measurement of beer colour = Measurement of the pH ~ Measurement of the oxygen content ~ Measurement of the diacetyl content ~ Measurement of foam stability - Determination of the earbon dioxide content = Measurement of bitterness units - Measurement of haze stability - Fikterability of the beer ~ Other measurements Process measurement and analysis technology Temperature meters Flow meters Filling level meters Density meters 750 751 751 752 753 753 753 753 754 754 754 755 755 7156 187 758 758 759 761 761 763 766 767 769 769 770 ™ ™ ™ 772 773 774 774 774 715 775 776 776 776 7 778 75.5 15.6 157 75.8 75.9 7.5.10 TSA 8.1 9.1 92 92.1 9.2.2 Haze meters Oxygen meters pHi value meters Conductivity measurement Limit value probes Pressure measurement Optical measuring technology Small Scale Brewing Pub breweries ~ Brewing plant ~ Fermentation and maturation cellar ~ Dispense equipment - Types of beer - Energy supplies = With regard to legal regulations - Investigate money saving altematives Microbrewers Hobby brewers = Making your own malt - Beer production Waste disposal and the environment Environmental legislation Waste water Waste water costs ~ All oxidisable substances ~ Phosphorous in the form of phosphates = Nitrogen in the form of nitrates = Organic halogen compounds (AOX) Definition of terms used relating to waste water ~ Sedimentable solids: - BODs - COD ~ Waste water load - Resident equivalence value Waste water treatment = Aerobic waste water treatment plants |. Activated sludge basins and troughs 2. Special reactors 3. Reactors containing immobilised biomass. ~ Anaerobic waste water treatment plants 779 779 79 779 780 780 780 786 786 789 790 791 791 792 792 792 792 793 793 795 798 798 799 799 799 799 800 800 801 801 801 302 302 802 802 802 803 803 803 803 15= Amount and composition of brewery waste water 804 - Wi water treatment with mixing and balancing tanks 806 ~ Type A 806 - Type B 806 9.3 Residues and waste material 807 9.3.1 Spent malt and hops 807 Break 808 Surplus yeast 808 934 Kieselguhre slurry 808 9.3.5 Old labels 809 9.3.6 Broken glass 809 9.3.7 Beer cans 809 9.3.8 Minor sources of waste 810 9.4 Emissions 810 9.4.1 Dust and dust emissions 810 9.4.2 Brewhouse emissions 810 9.4.3 Exhaust gas emissions 810 944 Noise emissions sil 9.5 Recycling of PET bottles sil 10 Energy management in the brewery and maltings 812 10.1 Energy requirement and brewing 812 10.2 Boiler plants 813 10.2.1 Fuels 813 10.2.2 Steam 84 Heat of evaporation 84 ~ Wet steam ais - Superheated steam 816 - Hot water 816 Boiler 816 Classification of boilers 816 ‘Types of boiler structure 817 ~ Fire-tube exhaust gas-tube boilers 817 ~ Water-tube boilers 817 - High speed steam producers 817 Three pass boilers 818 Energy recovery and improvement of efficiency 820 ~ Exhaust gas temperature 820 ~ Economiser (Eeo) 820 ~ Superheater 821 16 - Return of condensate 10.2.4 Steam engines 10.2.5 Combined heat and power plants 10.3 Refrigeration plants 10.3.1 Refrigerants and cooling agents ~ Refrigerants - Cooling agents - Operating principle of refrigeration ~ Circulation in the refrigeration plant - Ways of saving energy - Decreasing the difference in pressure between evaporator and condensator - Separating the cooling circulations according to temperature of evaporation - Subeooling the ammonia in the evaporative condenser ~ Attaching a heat pump - Other ways of saving energy 10.3.2 Compression refrigeration plants Operating principle ~ Evaporator - Compressor ~ Condenser or liquiefier - Expansion valve Evaporators = Vertical tube evaporators = Shell and tube evaporators, Compressors - Reciprocating piston compressor - Rolling piston compressors - Rotating piston compressors - Turbocompressors Condensers (liquefiers) ~ Water cooled condensers + Air cooled condensers ~ Evaporative condensers Control valves Ice water storage unit 10.3.3. Absorption cooling machines - Principle of the absorption cooling machine Space and liquid cooling Cooling of conventional fermentation and lager cellars 10.3.4 821 821 821 823 823 823 824 824 825 826 826 827 828 829 829 829 829 829 830 830 830 831 831 832 832 832 833 833 834 834 834 834 834 835 83510.3.5 10.4 10.4.1 10.4.2 10.4.3 10.4.4 10.4.5 10.5 10.5.1 - Stationary cooling, - Air circulation cooling Modern cooling plants Cooling of liquids - Single stage cooling - Two-stage cooling Advice for economic operation of cooling plants - Production of cooling potential - Distribution of cooling Electrical equipment Supply of electrical energy Power factor cos - The economic importance of the power factor, cos - Improving the power factor, cos ‘Transforming the electric current Safety measures Information concerning economic use of electrical energy Pumps, fans and compressors Pumps Centrifugal pumps Radial centrifugal pumps Side channel pumps/star wheel pumps Channel impellers (non-clogging) Mixed flow pumps Serew centrifiigal pumps Positive displacement pumps Displacement pumps with constant delivery Eccentric serew pumps Rotating piston pumps Lobed rotor pumps Gear pumps Intemally toothed pumps Peristaltic (hose) pumps Flexible vane pumps Displacement pumps with pulsating delivery Piston pumps Membrane pumps Selection of pump size - Cavitation Control of the pump rotation speed 838 838 839 839 841 841 842 842 842 843, 843, 843, 845 845 846 847 848 848 849 849 850 851 851 851 852 852 852 853 853 854 854 855 855 856 856 856 856 857 858 10.5.2 10.5.3 iW ud Well W.L.2, LL Wad LLS 1.16 11.2 121 11.22 1123 124 Lubricative ring seal Fans Axial fans or ventilators Radial fans Compressed air plants Compressors Reciprocating piston compressors Scioll compressors, ‘Toothed rotor compressors Screw compressors Turbocompressors Air driers Pressure containers Pressure piping network Air filters Automation and plant planning Indications concerning the use of measurement, control and regulation technology General indications Requirements concerning the ‘measurement uncertainty of the measuring technology used Requirements of the place of installation and cleaning and disinfecting requirements Operational and equipment security requirements Maintenance and upkeep requirements Requirements of automatic controls ~ Requirements concerning visualisa- tion of the procedures = Requirements of the programms ~ General indications Plant planning Iniroduetion Basic aspects of plant planning Different procedures for planning and setting up a plant Important documents and files concerning plant planning General remarks 858 859 859 859 859 861 861 862 863 863 864 865 867 867 867 869 869 869 869 870 872 872 873 874 875 875 876 876 878 879 881 881 17The methodical process ‘The procedure scheme ‘The basic mimic diagram The procedural mimic diagram The pipe and instrument mimie diagram Pipe and assembly plans ‘The procedure description ‘The creation of design documents, - Graphic procedures = Model projection ~ Aids for drawing up planning documents: = Drafts and drawing formats = The duplication of plant documentation 11.2.5 Indications for the drawing up of contracts 11.2.6 Inauguration and performance run 11.2.7 End of the project 11.2.8 Documentation of the project 890 890 890 890 891 892 893 11.3. Plant design and the requirements of the plants 11.3.1 General indications 11.3.2 Preconditions for the automation of modern plants 11.3.3 Requirements of pipe and plant design with respect to contami- nation-free work 11.3.4 Operational safety requirements of the plants Separation of media Securing the plants against unauthorised pressures = Securing the plants against unauthorised overpressure ~ Securing the plant against unauthorised underpressure 11.3.5 Indications for pipe design General indications Pipe connections + Inseparable pipe connections = Separable pipe connections The laying of piping systems and. the construction of pipe holders hermally caused changes in length 18 893 893 894 894 895, 895 897 897 897 898 898 898 898 808, 901 ‘The flow velocity in pipes: pressure losses - Estimation of pressure losses usi a nomogram for liquids Measures against liquid strikes and vibrations ‘Venting the pipes: oxygen removal Creating heat insulations in pipes Shaping of pipe outlets Securing the pipe against frost and blockages Dead spaces in pipes Steam pipes 11.3.6 Indications for the creation of heat and cold insulations neral indications Avoidance of vapour diffusion and condensation 11.3.7 Indications concerning pipe connection, application of fittings and sampling General indications ‘The manual connecting technique Fixed piping Fittings for pipes and equipment parts Sampling fittings Types of fitting designs 11.3.8 Indications concerning the arrangement and operation of CIP stations 11.3.9 Indications for the chemical warehouse 11.3.1 Indications concerning the surface constitution of machines and apparatus List of abbreviations used Conversion of legally defined and commonly used measurement units Index of advertisers Reference to diagrams and documents used Literature references Index of technical terms 905 906 906 907 907 907 908 908 908 909 909 909 909 910 ol 912 913 O17 O18 919 923 926 927 931 939Beer - the oldest drink for the common man The production of beer is tied to three con- secutive biochemical processes: the formation of enzymes in germinating grain, the breakdown of starch to sugar by these enzymes and the resulting fermentation of the sugar to alcohol and CO, These processes and their heady results have been known to man for thousands of years, although he did not at first realise the connection between them and how to exploit this. Our knowledge of man’s deliberate attempt at beer production fades into the dim and distant past, The time, though, is, Fig. 0.1 Beer production in ancient Egypt probably linked to the settling of the hunter- gatherers, and the beginning of grain cultivation, The oldest mention of beer is in Mesopota- mian cuneiform writing, from the year 2800 BC, which describes the distribution of the daily ration of beer and bread to the workforce, The production and dispensing of beer was regulated closely in the collection of laws of the Babyloni- an king Hammurabi (1728 — 1686 BC). This re- cord shows that there must also have been irre- gularities. In ancient Egypt, too, beer flourished widely, as can be seen from numerous illustr tions and findings (Fig. 0.1). It was noticed very early that beer was free from dangerous germs and that water, too, which was fiequently available in a less than perfect condition, could be purified by the fermentation process and the natural acids thereby produced For many centuries, therefore, beer - and in some areas wine - and not water, was the natural eve- ryday thirst-quencher, both for the ruler and the common man. In Europe beer was a well loved drink of the Germanic tribes, and of the Scythians and the Celts. It was brewed as daily household nourish- ment by the women, since baking and brewing were women’s work in all primitive cultures. The change to a brewing industry” occurred in the breweries of Christian religious foundations (monasteries and nunneries) where beer was pro- duced not only for their own consumption but was also supplied to others for a payment Simultaneously it changed to being men’s work (Fig. 0.2), as it has remained until today, The use of hops as the sole flavouring ingre- dient began in the 14th century. Previously a mixture of various flavouring plants was used, which was referred to in German as ,Grut” (gruit in English).Beer brewer, 1397 In Germany in the Middle Ages there was a considerable difference between the conditions for beer brewing in the North and in the South. In the North brewing was a civie right and occurred the large brewing towns such as Bremen, Hamburg or Einbeck. In Southern Germany, the transformation from home brewing to industrial brewing gradually took place in the 14th century. In the towns and cities in particular, official in- fluence began to take hold of the development of the brewing industry, which was illustrated by the fact that the right to brew was granted as a prince’s privilege. This is particularly important, because beer production in the early Middle Ages in the Southern region became a very widespread industry (Fig 0.3). In the 15th century the commercial position of the brewer became established, but it was restric- 20 ted in the South in particular by a large number of regulations [5]. Both the organisation of the trade and also the production of the product, from purchase of raw materi ture of the final product an to municipal laws, These laws also included re- gulations about the price of yeast and quality of the yeast, which primarily looked after the inter- ests of the bakers, who obtained their yeast fom the brewers, At that time, and for a long time afterwards, the brewing trade had the monopoly on yeast production Meanwhile shortages of raw materials, as a result of poor harvests and other circumstances, led to the use of raw materials other than those previously customarily employed. Thus hops were often replaced by other flavouring plants. Is to the manuf its sale, were subject Dev Bierbreutwer, “Auf Gerfken fied ich gutes Bier Fig. 0.3 Beer production in early Middle Agesderlidyen/das fiican allenchalbia in vnfern Getta A tace= ten/onnd auf dem Sannde/3G Fainem Piersmecer fiucths dann allain Berften/hopffen/ynd waffergenomen vind _ geprandyt (Olle werden, Welbee aber dife vninfece oxdnung, Fig. 0.4 Excerpt from the Reinheitsgebot of 23. April 1516 (sthat from now on, in all towns and markets and in the country, no other ingredient thean barley, hops and water shall be used in the production of beer”) Cereals for bread making or cheaper oats were also used in the grist for brewing, There was even a health risk from some of the hop replace- ments. To prevent any such deplorable state of affairs in future, official laws laid down that only mall, hops and water were to be used for the pro- duction of beer. The first documentary reference is found in Article 12 of the , Statuta tha- of the Thuringian town of Weissensee, laid down in 1434. In Munich, too, the same form of documentary reference to the production of beer was made in 1447. On the 23, April 1516, the Bavarian purity law was signed by the jointly ruling Dukes Wilhelm IV and Ludwig X at the ,Landstindetag™ in Ingolstadt (Fig. 0.4) and thereby acquired legal force. Since 1906 this purity law, in which it was established that beer could he produced only from barley, hops and water, has enjoyed unrestricted legal force throughout Germany for bottom fer~ mented beer. The law was enacted in order to pro- Vide the burghers with a sufficient amount of pro- ducts at a fair price. For these reasons the town councils regulated, in the interest of consumer protection, the manufacture of the product and established the price in relation to the product qua- lity. The purity law can therefore also be described as the first consumer protection law in the world. The Thirty Years war set the development of beer production back a long way, and at the same time, the arrival of newer drinks such as tea and coffee, led to a considerable reduction in beer output for a long time. Later the dark, bottom fer- mented lager beer began to spread through all Germany and Bohemia under the name ,Bava- rian beer*, In order to maintain the advance of this transportable Bavarian beer, the first Bava- rian Beer Brewery was founded outside Bavaria around 1830. With the development in 1765 by James Wait of a practical, usable steam engine, the foundation stone for the introduction of new technology was laid. In 1784 the first steam engines were in use in England and they were already widespread there by 1800, However, there was still a considerable delay before Gabriel Sedlmayr in 1846, after a trip to England, installed the first steam engine, with a | horse power rating, in his Spaten brewery in Munich, Fig. 0.5 Carl von Linde (1842 - 1934) The introduction of such new technology, the invention (1871) and installation (1876) of a re- frigeration machine by Carl von Linde (Fig. 0.5), as well as the development of the transportsystem through the construction of the railway network,led in the subsequent decades to building and expansion of larger breweries in all developed countries, [t was not by chance that the first freight to be transported on the German railways con: ted of two barrels of beer. Above all, though, the invention of the reftige- ration machine meant that man was no longer dependent on the seasons and the storage of natu- ral ice in cold winters. The Frenchman Louis Pasteur (Fig. 0.6) was the real founder of modem microbiology. He de- monstrated that fermentation processes are_attri- butable to the activity of microorganisms and for- mulated the expression La fermentation est la vie sans oxygéne" (fermentation is life without oxy gen), His insights on fermentation and the essenti- al requirements to make beer stable (1860) are still valid today. Fig. 0.6 Louis Pasteur (1822 - 1895) ‘The work of Emil Christian Hansen (Fig.0.7), who developed the method for single yeast propa- gation in the Carlsberg Laboratory in Copenhagen in 1883, was improved by Pati! Lindner in 1893 using his drop culture method", thereby laying the foundations for biologically flawless work. As a result of this, it became increasingly possible to make use of pure yeast strains and to reduce the influence of contaminants, This was the basis for the triumph of light coloured beers, which gradu- ally displaced the customary dark Bavarian beer. Thus in 1842 in the Municipal brewhouse in Pilsen, which later became the Pilsner Urquell brewery, the original of the Pilsner type of beer Fig. 0.7 Emil Christian Hansen (1842 - 1909) was developed. The Pilsner type beers spread eve- rywhere throughout Europe and Pilsner is still the type of beer most drunk in Germany. In 1875, fol- lowing a trip to Europe, Adolphus Busch introdu- ced the similar beer ,Budweiser* onto the American market from his brewery (Anheuser - Busch), which in the meantime has become the most popular beer type globally. Furthermore, wlager* beers were developed in all countries and these now account for the majority of beer brands, Asa result of this development, in the middle of the last century a large number of industrially ope- rated breweries were founded in Europe and America and existing older breweries were mo- demised. It should nevertheless not be forgotten that during this period, manual labour still accoun- ted for a lange share of the work (Fig. 0.8). Many of the breweries founded at that time exist today as giant producers with their own range of products. Breweries founded in this intensive phase between 1847 and 1875 include, for example: 1843. the Schultheiss Brauerei AG in Berlin, which before WWI was the largest lager producing brewery in Europe with an annual output of 1.7m hl 1847 the Carlsberg breweries in Copenhagen, DK, founded by J.C. Jacobsen 1855. the Patzenhofer Brauerei in Berlin, which merged with Schultheiss in 1920 1863 the Heineken Brewery, Amsterdam, NL, founded by Gerard A. HeinekenFig. 0.8 100 Years ago: View inside a cask rinsing department, the building where the barrels were cleaned. There was an enormous amount of work invilved in cleaning the returned empty wooden barrels used for beer transport 1868. the Dortmunder Aktien Brauerei 1870. the Binding Brauerei in Frankfurt/Main 1872. the Radeberger Export Beer brewery 1872 the Vereinsbrauerei der Berliner Gastwirte 7u Rixdorf, which since 1910 has been the Berliner Kindl Brauerei AG, Berlin-Neukélin 1872 the Léwenbriiu AG, Munich 1873 the Kaiserbrauerei Beck &Co, now Brauerei Beck & Co, Bremen 1873. the Dortmunder Union Brauerei During this time, already existing breweries were also growing considerably. The Bass Bre- wery in Burton-on-Trent, GB 1876, for example, Was producing 2.5m hl of beer annually and was classified as the largest brewery in the world at this time, but was soon overtaken by Arthur Guinness & Son Co. Ltd. in Dublin. In the USA, the development of the breweries s closely linked with the settlement of the coun- try by the European immigrants, Thus, the first breweries appeared on the east coast of the coun- try and then upriver, following the founding of large cities and the expansion of the railway net- work. Within a few years, the following brewe- ries were founded: 1849. the Joseph Schlitz Brewing Co. in Milwaukee, Wisconsin 1850 the Plank Road Brewery, which in 1855 23became the Miller Brewing Co. in Milwaukee, Wisconsin the Stroh Brewery Co Michigan the Anheuser brewery, since 1875 Anheuser - Busch, St. Louis, Missouri 1858 the Gund and F man brewery, later the Heileman Brewing Co. in La Crosse 1850 Detroit, 1851 1861 the Pabst Brewing Co. in Milwaukee, Wisconsin 1873 the Adolphus Coors Brewing Co. in Golden, Colorado In the second half of the 19th century, howe- ver, the breakthrough in other countries and con- tinents into the industrial era, also occurred in the brewing trade. This was marked by the founding of many new breweries, for example in Japan 1869 the Spring Valley Brewery, since 1907 the Kirin Brewery Co. Ltd. 1876 the Hokkaido Kaitakushi Brewery, later the Asahi Brewery Ltd, and the Sapporo Ltd. Brewery In Australia, the following brewery was foun- ded: 1862 the Cooper’s Brewery in Adelaide. ‘As a result of this development, the science of beer brewing became known and could be taught, In several countries where beer was bre- wed, research laboratories and institutes were created which in due course developed into tea- ching institutes and organisations; for example: © the Weihenstephan Brauereihochschule (University faculty) near Munich (1865), today Chair for Brewing Technology at the Centre for Scientific Research Weihenste- phan and the Faculty for Nutrition, Land Use and the Environment of the TU (Technical University) Munich, © the Dr. Siebel Analytical Laboratory in Chicago (1868), today the Siebel- Institute of Technology © the Versuchs- und Lehranstalt flir Brauerei in Berlin (Brewing Research and Teaching Institute - the VLB) (1883) ‘© the Brewing School in Gent (1885) 24 © the Institute of Brewing (IOB) in London (1886) © the Doemens-Lehranstalten in Grifeling near Munich (1895) and others. At the same time a number of specialised jour- nals were founded, by means of which scientific knowledge, and also other interesting informa- tion on the topic of beer, could be distributed, These include, for example: © Allgemeine Brauer- und Hopfenzeitun; today ,,Brauwelt* in Nuremberg (1861) © Brewer's Journal” in London (1864) © ..The American Brewers Gazette" in New York (1871) © Brewers Guardian (1871) «The Western Brewer" in Chicago (1876) © ,Wochenschrift ftir Brauerei in Berlin (1883), today ,.Brauerei-Forum* © ,,Tageszeitung flr Brauerei* in Berlin (1903) and many others. Expert analysts formed commissions to make the analysis values of different countries conver- tible using standard analysis methods; for exam- ple: © die Mitteleuropdische Brautechnische Analysenkommission™ (MEBAK) © the European Brewing Convention (EBC) ‘© the American Society of Brewing Chemists (ASBC) and others. ‘At the same time, powerful brewing associa- tions and brewers’ organisations developed in almost all countries; for example, in Germany ‘© Deutsche Brauer-Bund e.V. (DBB), founded in 1871 in Dresden © Deutscher Braumeister- und Malzmeister- Bund e.V. (DBMB), founded in 1893 in Leipzig ® , Bundesverband mittelstindischer Privat- brauereien e.V." (Association of Small and Medium Sized Private Breweries) © Deutscher Mailzerbund (Association of German Maltsters)and in America: Master Brewer's Association of the Americas (MBAA) and many others. Naturally, the Bavarian Reinheitsgebot was the prevailing law initially in many countries, but American brewers already knew in the 1860s and 70s the economic advantage of using maize meal orice grits as additives. As a result of the refining of the techniques and technology for the proces- sing of raw grain, a new type of beer was produced which has meanwhile gained global importance. In the USA beer production suffered a severe blow through the prohibition of alcohol, introdu- ced in 1919, At that time, the breweries could only stay in existence by producing so-called near beer". As a result of the Prohibition, which was not revoked until 1933, criminal activity and the smuggling of alcoholic drinks had become much more widespread and so the result of the Prohibition was very negative. In Scandinavian countries, too, at this time there were substantial limitations on the production and sale of aleohol- containing beverages, and this still exists in some countries. Fig. 0.9 Wooden tanks and barrels long characterised the face of the brewery When considering the development of brewe- ries in Germany in the second half of the 19th century, one should not overlook the fact that there were still 13,561 breweries in operation here in 1873, of which 10,171 were after all bre- wing top fermenting beer. Added to this were 36,297 households where tax free drinks were being brewed for home use only [2]. By 1891 the number of operating breweries had fallen to 7,785, mainly because of the foun- ding of large brewing public limited companies and cooperatives. Many craft breweries from this time are nevertheless still in existence today. The large difference in size and hence better financi- al resources means there is a far greater opportu- nity for introducing new technology in larger breweries. In particular, the introduction of coal heated steam boilers for in-house energy supply to the brew kettle in the brewhouse, the employ- ment of the brewery’s own steam engine to drive the cooling machine compressors and the pro- duction of their own electricity by large brewe- ries can be financially supported by the econo- mic advantages of operating on a large scale. Small craft breweries could not afford the ex- pensive equipment and retained their traditional equipment and processes - many even until now. ‘The traditional material for brewing equip- ment, wood, disappeared only slowly to be repla- ced by iron, initially coated with piteh. Wooden vats were replaced by open fermenters and the wooden barrels, stacked in many layers, were replaced by tanks. For various reasons, however, this process did not occur in many breweries until the final decade of the last millennium, In addition to iron, aluminium later became impor- tant in breweries, especially for fermenters and lagering vessels. The main changes were, howe- ver, in the material and the heating of the bre wing equipment. Here the cast iron open pots, which were commonplace at the beginning of the 19th century, were replaced by copper as the material from which vessels were made. The shiny beaten vessels with their beautiful copper covers and steam vents, initially heated using 25Fig, 0.10 Copper brewing vessels were the pride of the master brewer coal or gas, and for the last ninety years increa- singly with steam, were the pride of the master brewer (Fig, 0.10), Even today, a copper cover can be found covering a modem stainless steel vessel beneath it. However, since the existence of stainless steel alloys and the tools to work with this difficult material, their triumphal advance can no longer be stopped. The wooden transpor- tation barrel, which had survived for centuries has now been replaced by stainless steel kegs. Since the introduction of stainless steel, an ever increasing number of automated cleaning systems are being used by breweries. As a result of this and also the increasing mechanisation and automation of the production process hard manual labour has been considerably redu ced, This trend also applies to the brewi equipment (Fig. 0.11), particularly as the techni | advantages far outweigh the continuing use of the beaten copper pots which are no longer econom| In the production of malt and beer only the basic bio-chemical processes have remained the same over the centuries © germination of barley in the malt house to produce enzymes, © mashing in the brewhouse to allow them to act and form fermentable sugar, and finally, © the fermentation of sugar to alcohol and ear- bon dioxide Ss Fig. 0.11 Stainless steel brewing vessels are today’s state of the art technology 26Fig, 0.12 A malt house today 150 years ago it was still customary for a bre- wery to produce its own malt requirements. For this purpose almost every brewery had its own small malt house in which the malt that was used for brewing in carly summer was produced in the winter. This was done by the same workforce, which naturally gave rise to the profession of “Brewer and Maltster” which still exists in Ger- many, However, at the same time commercial maltings were being formed, some of them spe- cial malt producers, which were separate from breweries, for example: 1823 Bairds' Malt Ltd., Witham, Essex, GB 1864. the Friedrich Weissheimer Malzfabrik, Andernach, D. 1868 Pauls Malt Ltd., Ipswich, Suffolk, GB 1879 the Michael Weyermann Malzfabrik, Bamberg, D. Of course at this time and until the middle of the 20th century, malt production was still very labour intensive and characterised by heavy manual work in the huge floor maltings. Turning in the kiln was also sometimes performed manu- ally. The path to the moder pneumatic malting systems brought with it enormous savings in energy and workforce requirements. Nowadays the computer rules in the maltings which are lar- gely free of people. Today malting mainly takes place in large companies, the majority of which are made up of small companies which have merged. Of these, the largest produce over Im tons of malt annual- ly, as is the case with the American company Con Agra / Tiger - Oats Malt (1996) and the Cargill Inc. (1978), or also the French group Soufflet (1952) and Groupe Malteurop (1984) (brackets refer to year of founding). But also other companies, like the American Lasaffre- ADM (1998) or Rahr Malting (1847), the English Greencore group (1991) or the Friedrich Weissheimer Malzfabrik (1864) have an annual production of over 500,000 tons of malt, All companies nowadays have subsidiaries in other countries to enable them to produce more econo- mically on the spot (Fig. 0.12). Together these large companies produce around 7m tons of malt and thereby provide almost half of the estimated 15.4.m tons required for the global supply of beer in 2002/3 [238]. There have also been, however, revolutionary changes in other areas of brewing in the last 150 years, The greatest changes after the introduction of refrigeration resulted from the invention of beer filtration by Lorenz Enzinger (1879). Since then it has been possible, first by means of a fil- ter mass, later by use of kieselguhr and other media, to filter beer so that it is quite clear. By use of suitable stabilising measures it is possible to make beer stable for a very long time and the- refore to produce it independently of when it will be consumed. As a result of the development of beer bottles and cans and due to the massive 7