EXTRUDED SORGHUM AS A BREWING RAW MATERIAL

Small scale mashes (50 g total grist) with grists containing up to 50% by weight of extruded whole sorghum produced worts of high extract yield and low viscosity. Increasing the proportion of extruded sorghum in the grist resulted in decreasing wort filtration volume, total nitrogen and free amino nitrogen content. The wort filtration behaviour of mashes containing sorghum extruded at 175°C was superior to that of mashes containing sorghum extruded at 165°C or 185°C. The results from such small scale mashing experiments suggested that extruded sorghum compared favourably to extruded barley and extruded wheat as a brewing adjunct. Worts and beers were produced on a pilot brewery scale (100 1) from grists comprising 70% malt + 30% extruded sorghum and 100% malt under isothermal infusion mashing conditions. Mashes containing sorghum extruded at 175°C showed comparable wort filtration behaviour to that of the all malt control mash whereas mashes containing sorghum extruded at 165°C or 185°C showed poor wort filtration behaviour. Worts produced from grists containing extruded sorghum fermented more quickly than the control wort and attained lower values of final gravity. The resulting beers were filtered without difficulty. Beers produced from grists containing extruded sorghum contained lower levels of total nitrogen and free amino nitrogen compared to the control beer consistent with extruded sorghum contributing little or no nitrogenous material to the wort and beer. Beers brewed from grists containing extruded sorghum were of sound flavour and showed reasonable foam stability behaviour.     

THE USE OF EXTRUDED BARLEY,WHEAT AND MAIZE AS ADJUNCTS IN MASHING

The principles of extrusion cooking are summarised. In small scale trials good extracts were obtained from extruded barley when it was mashed with industrial enzymes, using a programmed temperature cycle. Extruded barley, wheat and maize and wheat flour yielded acceptable levels of extract when mashed with lager malt (70%) using a programme with 1 hour rests at 50°C and 65°C. The extracts obtained from these grists were increased above those obtained from grists of lager malt alone and the viscosities of the worts were reduced when the mashes were supplemented by preparations of bacterial enzymes. Enzyme additions also improved extract recoveries from all-malt mashes and reduced the viscosities of the derived worts. Using a temperature programmed mashing cycle and supplementary enzymes beers were prepared from a lager malt grist and grists in which the lager malt was partly replaced, by 30%, with extruded barley or extruded wheat, or extruded maize or wheat flour pellets. In every case wort was recovered relatively easily, the worts fermented normally and the beers were all fully acceptable, although their flavours did differ. However, in contrast to results of preliminary brewing trials, the head retentions of the beers made with adjuncts were unusually low, possibly because of particular enzyme additions.     

Quality characteristics of triticale malts and worts

Worts from triticale malts, in particular well modified malts, separated poorly from mashes. Worts prepared at 70° C had high viscosities (10–27 cSt) indicating that problems would occur during filtration in brewing. The viscosities of triticale worts were higher than those of worts from barley malts. In addition, worts from well modified malts were generally turbid. Proteinaceous material (partly degraded prolamins) was the primary cause of this turbidity. Although the degree of malt modification did influence the rate of wort separation, it had little effect on wort viscosity. High viscosity was caused by pentosans dissolved from the triticale malt during mashing. Oxidative gelation was not observed with these pentosans. Grains and malts were fractionated, and the high molecular weight fractions were analysed for their sugar and acyl components. All were rich in arabinose and xylose. There was a rough inverse correlation between the solubility of the poly saccharide fractions and the levels of substitution with acetyl and feruloyl residues. The poor wort separation from triticale malt grists appeared to be related to the particle size distributions, which were narrow. The sedimentation values of the grist ‘fines’ were high.     

Implementation of commercial oat and sorghum flours in brewing

Brewing with commercial flours has the potential to reduce mashing times and improve brewhouse efficiency. At present, however, no studies are available assessing the application of commercial oat and sorghum flours as brewing adjuncts. Therefore, the objectives of this study were to evaluate the quality and processability of mashes/worts produced with 10–90 % oat or sorghum flour as well as to reveal the advantages and limitations of their use as a substitute for barley malt. For these purposes, both flour types were fully analyzed in terms of brewing-relevant characteristics using standard methods, Lab-on-a-Chip capillary electrophoresis, and scanning electron microscopy. Laboratory-scale mashing trials were performed to assess the effect of up to 90 % flour adjunct on mash/wort quality. Equivalent factors were introduced to determine the performance efficiency of different oat/sorghum flour concentrations. Commercial oat flour sourced in Ireland exhibited significantly more protein, β-glucan, and fat, less starch, ash, and polyphenols, as well as a lower starch gelatinization temperature than commercial sorghum flour obtained from the USA. Worts produced with 10–90 % oat or sorghum flour had lighter colors, higher pH values, and lower concentrations of foam-positive proteins as well as free amino nitrogen compared to 100 % barley malt worts. In terms of extract yields, the use of up to 70 % oat flour and 50 % sorghum flour, respectively, has proven economically beneficial. Worts containing up to 70 % oat flour showed a very good or good fermentability, those containing 30–50 % sorghum flour resulted, however, in a lower alcohol production.     

THE PROPERTIES,COMPOSITION AND FERMENTABILITIES OF WORTS MADE FROM 100% RAW SORGHUM AND COMMERCIAL ENZYMES

A mashing regime was developed using 100% raw sorghum which enabled commercially acceptable hot water extracts to be obtained in 85 minutes with minimal use of a heat stable α-amylase and proteolytic enzymes. This gave worts of HWE 295 1°/kg, with FAN levels of about 40 mg/l and ammonium ion concentration of about 60 mg/l. Higher, but commercially unacceptable, levels of proteolytic enzymes gave worts with FAN from 84.5 to 95 (mg/l). Addition of an amyloglucosidase as the commercial preparation Amylo300L, was required to convert the HWE to fermentable extract. The addition of Amylo300L, increased the DP1, DP2 and DP3 carbohydrate fractions of the worts from 22% to more than 90% of the total, compared to about 80% for a wort made from malted barley without the use of enzymes. Two different proteolytic enzymes gave different extracts and FAN contents presumably reflecting either differences in susceptibilities of the sorghum to the two enzymes or the presence of different additional enzyme activities in the different preparations. The level of ammonium ions in malted barley worts was 86 mg/l and up to 88 mg/l in worts produced from sorghum and enzymes. Enzyme addition produced increased levels of ammonia. The content of Group A (the most readily assimilated) amino acids was proportionally higher in sorghum worts compared to malted barley wort. Worts made from raw sorghum and enzymes, containing as little as 40 mg/l FAN, were fully attenuated. The yeast consumed about 35 mg/l FAN and 45 mg/l ammonium ions. Under identical fermentation conditions, the same yeast, fermenting a malted barley wort of comparable extract consumed 104 mg/l FAN and 37 mg/l ammonium ions.     

Alpha Amino Nitrogen and Fusel Alcohols of Sorghum Worts Fermented into Lager Beer

The levels of alpha amino nitrogen (AAN) and fusel alcohols during fermentations of lager worts produced from waxy sorghum grits either inoculated with yeast cultured in wort or yeast-malt media were performed. Worts produced from waxy sorghum grits had comparable AAN to commercial wort. The oxygen concentration in the reactor headspace changed from 20% at the beginning of fermentation to less than 1% after 72 hrs fermentation indicating a gradual change from aerobic to anaerobic conditions. The utilization of AAN for production of propanol, isobutanol and amyl-isoamyl alcohols from waxy sorghum grits was comparable to a control wort. Production of propanol, isobutanol and amyl-isoamyl alcohols followed the same trend over 144 hr fermentation. Isobutanol was produced in the lowest concentration. The initiation of propanol production occurred after 24 and 36 hr fermentation for worts inoculated with yeast cultured in wort and yeast-malt media, respectively. The final concentration of ethanol and fusel alcohols were within the expected range found in commercial beers. Worts produced from barley malt and waxy sorghum grits were an adequate substrate for Saccharomyces cerevisiae, and were comparable to a commercial wort. The utilisation of refined waxy sorghum grits as brewing adjuncts for lager beers was demonstrated.     

Corn grist adjunct – application and influence on the brewing process and beer quality

In the brewing industry, barley malt is often partially replaced with adjuncts (unmalted barley, wheat, rice, sorghum and corn in different forms). It is crucial, however, to preserve constant quality in the beer to meet the expectations of consumers. In this work, how the addition of corn grist (10 and 20%) influences the quality of wort and beer was examined. The following parameters were analysed: wort colour, dimethyl sulphide (DMS) and protein content, non‐fermentable extract, extract drop during fermentation, alcohol content and the attenuation level of the beer, together with filtration performance. The samples (all‐malt, and adjunct at 10 and 20% corn grist) were industrial worts and the beers produced in a commercial brewery (3000 hL fermentation tanks). The application of 10 and 20% corn grist had an effect on the wort colour, making it slightly lighter (11.1 and 10.5°EBC, respectively) than the reference barley malt wort (12.2°EBC). The free amino nitrogen level, DMS and non‐fermentable extract were significantly lower in the worts produced with the adjunct; the alcohol content and attenuation levels were higher in the beers produced with adjunct. The use of corn grist, at the level of up to 20% of total load, appears to affect some of the technological aspects of wort and beer production, but it does not significantly influence the final product characteristics. Copyright © 2014 The Institute of Brewing & Distilling     

Influence of malted barley and exogenous enzymes on the glucose/maltose balance of worts with sorghum or barley as an adjunct

The sugar profile of wort from laboratory malted barley, malted sorghum, unmalted barley and unmalted sorghum grains mashed with commercial enzyme preparations were studied. Similar levels of glucose to maltose (1:7) were observed in wort of malted barley and malted sorghum. Mashing barley or sorghum grains with commercial enzymes changed the glucose to maltose ratio in both worts, with a greater change in wort from sorghum grains. Although hydrolysis with commercial enzymes released more glucose from maltose in sorghum wort, the same treatment retained more maltose in barley wort. Adding malted barley to sorghum grains mashed with commercial enzymes restored the glucose to maltose ratio in sorghum mash. Fermentation of wort produced from all barley malt (ABM) mash and commercial enzyme/barley malt/sorghum adjunct (CEBMSA) mash of similar wort gravity was also studied. ABM and CEBMSA worts exhibited similar glucose to maltose ratios and similar amino acid spectra. However, ABM released more individual amino acids and five times more proline than wort from commercial enzyme/barley malt/sorghum adjunct. ABM produced 27% more glucose and 7% more maltose than CEBMSA. After fermentation, ABM mash produced 9.45% ABV whilst commercial enzyme/barley malt/sorghum adjunct mash produced 9.06% ABV. Restoration of the glucose/maltose ratio in the CEBMSA mash produced wort with a sugar balance required for high gravity brewing. © 2020 The Institute of Brewing & Distilling     

Malted and unmalted oats in brewing

Using oats as a raw material in brewing has recently become the focus of increased interest. This is due to research findings that have shown that oats can be consumed safely by coeliac sufferers. It is also a response to consumer demand for products with novel sensory properties. In this study, beer was produced entirely from oat malt, from barley malt and from oat and barley malts mixed with various quantities of unmalted oats. Compared with barley wort, wort made from malted oats provided a lower extract content and had a higher protein content, but a lower free amino nitrogen content (FAN). The oat wort also showed increased viscosity and haze. The addition of unmalted oats during wort production produced significant changes in the physico‐chemical parameters of both oat and barley worts and beers. Unmalted oats caused an increase in wort viscosity and haze, and a reduction in total soluble nitrogen and FAN. Unmalted oats also contributed to lowering the concentration of higher alcohols and esters. Beer made from 100% oat and barley malts exhibited a similar alcohol content. The use of an oat adjunct in both cases resulted in a lower ethanol content. The introduction of enzyme preparations during the production of wort with oat adjunct had many benefits: increased extract content and FAN; a higher volume of wort; and a lower viscosity that led to faster wort filtration. This research suggests that the use of enzymes is necessary to make production using a high proportion of oats in the grist profitable. Copyright © 2014 The Institute of Brewing & Distilling     

Application of Unconventional Raw Materials and Procedures in Wort Production*

This paper deals with investigations of wort production by the application of unmalted raw material — native barley as a partial substitute for malt in grist. This adjunct was differently treated: (1) thermal decomposition, (2) enzymic decomposition by the addition of commercial enzyme “Termamyl”, and (3) hydrothermic decomposition i.e. extruding. Native barley prepared by these methods was added in proportions up to 70% of the grist, without the addition of exogenous enzymes. Experiments were carried out on a laboratory scale by using an infusion mashing procedure for wort production. The results obtained indicated that the application of native barley as the adjunct, gelatinised by heat treatment gave good results up to 10% as malt substitute. Larger amounts of barley gelatinised by heat treatment decreased extract yields. Malt substitution with pretreatment of barley with enzyme did not produce satisfactory results. Worts had reduced levels of extract and soluble nitrogen, which were insufficient for the production of high quality beer. Application of barley flakes in quantities up to 50% produced wort which had good analytical quality parameters.     

Effect of Amyloglucosidase on Wort Composition and Fermentable Carbohydrate Depletion in Sorghum Lager Beers

A three‐factorial experiment with a level of confidence of P < 0.05 was performed to study fermentable carbohydrate depletion and ethanol production during 144 h fermentations of lager beers produced with barley malt (BM), sorghum malt (SM), refined maize (MZ) or waxy sorghum (WXSOR) grits treated during mashing with or without amyloglucosidase (AMG). The percentage glucose, maltose and maltotriose, based on total fermentable carbohydrates for the BM wort was 20, 68 and 13% and for the SM wort 35, 48 and 17% respectively. Treatment with AMG increased wort glucose from 9.3 to 24.5 g/L wort and total fermentable sugar equivalents, expressed as g glucose/L, from 59.2 to 72.6 g/L wort. The SM worts had approximately 50% more glucose and 40% less initial maltose content respectively compared to the BM worts. The WXSOR grits produced worts and beers with similar properties to those produced from the MZ adjuncts. AMG addition led to a >2.5 fold increment in wort glucose and 23% in total fermentable carbohydrate content. Linear regression analysis determined that the consumption rate of fermentable carbohydrates during fermentation followed first order reaction kinetics. Depletion times to reach 50% of the initial concentrations of glucose, maltose and maltotriose were 49, 128 and 125 h, respectively, clearly indicating that the fermenting yeast preferred glucose. Maltose and maltotriose depletion times of the AMG treated worts were significantly faster and lower, respectively, when compared with the untreated worts. At the end of the fermentation, the BM beers contained higher ethanol levels (5.1% v/v) than the SM beers (3.9% v/v). For AMG treated beers, no significant differences in ethanol content were observed among samples mashed with BM and beers produced from SM and MZ grits. The results demonstrated that AMG could be used to increase the initial concentration of glucose and total fermentable carbohydrates thus decreasing dextrin levels, especially from sorghum mashes.     

Mashing Studies with Unmalted Sorghum and Malted Barley

The effects on wort quality when mashing with unmalted sorghum (0–100%) and malted barley (100–0%) in combination with industrial enzymes were evaluated. A mashing program with temperature stands at 50°C, 95°C and 60°C was used. Different combinations of commercial enzymes were evaluated. A heat stable α‐amylase was found to be essential for efficient saccharification. The inclusion of a fungal α‐amylase in mashes with a high sorghum content improved filtration rates to that of 100% malted barley mashes. Addition of a bacterial protease increased the amount of nitrogen solubilisation and peptide degradation. An increase of the relative proportion of sorghum in the grist resulted in decreases in wort filtration, colour, viscosity, attenuation limit, free amino nitrogen, high molecular weight nitrogen, and a corresponding increase in pH (p < 0.01). Overall the addition of malted barley in small proportions to unmalted sorghum mashes together with commercial enzymes was found to improve the potential for brewing a high quality lager beer from unmalted sorghum.     

FERMENTATION OF WORTS MADE FROM 100% RAW SORGHUM AND ENZYMES

Worts made from raw sorghum and enzymes were successfully fermented even though the level of FAN present (51 mg/l) is well below that essential for fermentation of wort made from malted barley. Changes in typical fermentation parameters such as specific gravity, pH uptake of free amino nitrogen (FAN) and ammonium ions mirrored the increase in yeast cell concentration. Yeast viability remained high throughout the fermentation. Under identical fermentation conditions, malted barley worts showed typical fermentation profiles. However, malted barley worts with specific gravity maintained by the addition of D-glucose, but in which the FAN was diluted to a level similar to that found in a wort made from sorghum and enzymes, fermented more slowly and failed to attenuate fully. Five consecutive fermentations, using yeast cropped from the preceding to pitch the current fermentation were conducted. The specific gravity profiles were essentially the same in all five fermentations. Final values of pH, yeast in suspension, yeast viability and FAN were also indistinguishable. The yeast crop taken from fermentations of worts made from raw sorghum and enzymes represented a 5-fold increase over the initial pitching rate. When compared to commercial beers, the beers derived from fermentation of worts made from raw sorghum and enzymes contained lower levels of ethyl acetate, and higher levels of both 2- and 3-methyl butanol. In the beers derived from sorghum, isobutanol was always less than 20% of the total higher alcohol concentration.     

Brewing Beer with Sorghum

Research reports on extracts, proteins, total nitrogen and free amino nitrogen content of sorghum malt and worts obtained from mashes indicate that sorghum is potentially an alternative substrate for conventional beer brewing in the tropics. Remarkable variations in biochemical characteristics among different sorghum cultivars affect their optimal malting conditions. Factors such as temperature and time of steeping and germinating of grains with their intrinsic enzymic activities, and kilning temperature determine the quality of malt. Further works on mashing, viscosity and fermentability of worts as well as the character of the resulting beers, such as alcoholic content, colour, taste and specific gravity tend to confirm the status of sorghum as a credible substitute for barley in beer brewing. This review reports on progress made in the use of sorghum for brewing beer.     

Application of Biological Acidification to Improve the Quality and Processability of Wort Produced from 50% Raw Barley

In this study four strains of lactic acid bacteria (LAB) were chosen to bioacidify a mash containing 50% barley and 50% malt. The strains were isolated from malted and unmalted barley and assayed for extracellular enzymatic activities (proteases, amylases, β‐glucanases). The biologically acidified mash was compared to a chemically acidified mash, 100% malt mash un‐acidified and 50% malt and 50% barley mash unacidified. Characteristics such as pH, extract, colour, viscosity, total soluble nitrogen (TSN), free amino nitrogen (FAN), apparent fermentability, β‐glucan and lautering performance of the resultant worts were determined. A model lautering system replicating one used in a brewery was designed and built in University College Cork (UCC) to measure the lautering performance of the bioacidified mashes. The new system was compared to the filtration method used in EBC method 4.5.1. Overall the addition of LAB to bioacidify a mash of 50% barley and 50% malt resulted in faster filtration times, which correlated with decreased β‐glucan levels. Proteolytic LAB had a positive influence on the quality of wort and resulted in increased FAN levels. Lighter colour worts were observed along with increased extract levels.     

Pilot Scale Production of a Lager Beer from a Grist Containing 50% Unmalted Sorghum

Pilot scale (1000 L) brews were carried out with a grist comprising of unmalted sorghum (50% of total wet weight of grain) (South African variety) and malted barley (50% of total wet weight of grain) grist using a mashing program with rests at 50°C, 95°C and 60°C. Mashes were supplemented with a high heat stable bacterial α‐amylase, a bacterial neutral protease and a fungal α‐amylase. A control brew containing 100% malted barley was also carried out. Saccharification difficulties were encountered during mashing, and extraction of the grist was lower for the sorghum mashes. The sorghum mashes showed comparable lautering behaviour to that of the control mash. At mashing off the sorghum worts were starch positive. Apparent degree of fermentation of the sorghum gyles were less than the control gyles. Green beer filtration proved unproblematic. The sorghum beers compared quite closely with the control beer with regard to colour, pH and colloidal stability. Foam stability deficiencies were apparent with the sorghum beer. However, the fermentability of the sorghum worts were lower. Hence the sorghum beers were lower in total alcohol. Sensory analysis indicated that no significant differences existed between the sorghum beer and both the control beer and a commercial malted barley beer with regard to aroma, mouth‐feel, after‐taste and clarity. However, the sorghum beer was found to be significantly different to both of the other beers with regard to colour, initial taste and foam stability.     

DEVELOPMENT OF A MASHING PROFILE FOR THE USE OF MICROBIAL ENZYMES IN BREWING WITH RAW SORGHUM (80%) AND MALTED BARLEY OR SORGHUM MALT (20%)

Different time and temperature programmes were used to evaluate the production of hot water extract (HWE) and free amino nitrogen (FAN) from mashes containing raw sorghum and either malted sorghum or malted barley in the presence of microbial enzymes. Two malted varieties of sorghum (SK 5912 and Zaria) were used. The former gave higher HWE but lower FAN than the latter. Sorghum malts were unable to provide enzyme activity for starch extraction and exogenous enzymes were always needed. Seventeen commercially available enzyme preparations were assessed. A double-mash process was developed. Inclusion of calcium ions (200 ppm) was beneficial but adjustment of mash pH had little effect. Raw sorghum was gelatinised at 100°C for 30–40 min in the presence of a heat-stable α-amylase followed by mixing with a malt mash (started at B0°C) to give a temperature of 65°C with a total mash time of 167 min (127 min from mixing the mashes). The inclusion of a single commercial enzyme preparation (containing both proteolytic and amylolytic activities) was sufficient to achieve satisfactory HWE and FAN. Addition of different activities or combinations of activities gave no significant advantages. To obtain levels of FAN of 100–140 mg/l however excessive amounts of enzymes were required.     

MICROBIAL ENZYMES AND THEIR EFFECTS ON EXTRACT RECOVERIES FROM UNMALTED ADJUNCTS

Radial diffusion tests were used to detect β-glucan-, starch-, protein-, pentosan- and triglyceride-degrading enzyme activities in a variety of commercial enzyme preparations. Some implications of the presence of unexpected enzymes in particular preparations are discussed. A series of laboratory mashes were made with grists of milled barley, extruded barley, and extruded wheat, using various enzyme additions and temperature-time programmes. In addition a limited number of experiments were made with pale ale barley malt, and wheat flour pellets. Extract yields varied from acceptable to outstandingly good. The most intensive mashing system, with enzyme supplementation, increased the extract yield of an all-malt mash by 3·9% relative to the control mashing programme. Some worts were evaluated for Total Soluble Nitrogen (T.S.N.), Free Amino Nitrogen (F.A.N.) and viscosity. Slow wort-filtration rates occurred in some mashes although the viscosities of the worts from these mashes were low. This problem did not occur in any of the samples intensively mashed over a 5 h period. The results apparently exclude the possibility that a simple, reliable technique for estimating the extract yields of adjuncts could be devised, using these enzyme preparations.     

THE VISCOSITY OF WORTS IN RELATION TO THEIR CONTENT OF β-GLUCAN

A procedure is given for assessing that proportion of wort viscosity which is attributable to β-glucan. Worts obtained from unkilned samples of malt which have been processed for 54 or 72 h show enhanced viscosity. This is principally due to β-glucan although the contribution of other constituents, absent from the wort of fully modified malt, is of significance. Barley variety is shown to have a pronounced effect on wort viscosity. Insoluble β-glucan is brought into solution in mashes at 65° C. The β-glucan isolated from malt which has been inactivated using aqueous ethanol prior to extraction at 65° C, is of higher specific viscosity than that isolated from control worts prepared at the same temperature. The introduction of a rest by mashing initially at 40° C results in the production of wort of lower viscosity, a decrease in the β-glucan content of the wort and a reduction in the specific viscosity of the β-glucan. There is no apparent relationship between the endo-β-glucanase content of the malts and either the viscosity of derived worts or the degree of breakdown of β-glucan which occurred during malting and mashing. Abrasion of barley, which is a factor assisting the distribution of enzymes during malting, acts to reduce wort viscosity.     

INHIBITOR OF FLUORESCENCE REACTIONS BETWEEN CALCOFLUOR AND β-(1,3)(1,4)-D-GLUCAN IN BEER AND WORT

An inhibitor of calcofluor fluorescence reaction in beer and wort was shown by analyzing beers and worts containing no β-glucan. The inhibitory activity was enhanced against the fluorescence reaction which is intensified by linkage of calcofluor with β-glucan compared to the fluorescence of calcofluor itself. The investigation indicated that the inhibitor was derived from malt and is produced during the germination process. The inhibitory activity in beer and wort changed with the degree of malt modification and the ratio of malt in the grist. Japanese beers had a wide range of inhibitory activities against the calcofluor fluorescence, lowering the apparent β-glucan contents by 12 to 20%. The inhibitor in beer and wort appeared to be an acidic compound with a molecular weight of less than 1000 daltons.