Tài liệu Danisco Brewing Enzyme Guide pot

Danisco’s brewing enzyme capabilities 5 Challenge: High performance in brewing with local raw materials 11 Challenge: Cost-efficient & consistent adjunct cooking 14 Challenge: Improved

We use ”Imagine with us” to reflect the heart of our food enzyme

business The words invite people to join us on a journey of imagination,

discovery and opportunity in the world of food and beverage enzymes

They describe a hotspot of innovation, staffed by knowledgeable and

imaginative people At the same time, “Imagine with us” communicates

our constant drive to break new ground and make technological

advancements easy to implement for our customers

Imagine with us

Danisco’s brewing enzyme capabilities 5

Challenge: High performance in brewing with local raw materials 11

Challenge: Cost-efficient & consistent adjunct cooking 14

Challenge: Improved mash separation & beer filtration 16

Challenge: Increased fermentability & controlled attenuation 18 Product solution: DIAZYME® X4 & DIAZYME® P10 19

Getting started – what do I need to use brewing enzymes? 22

Safe use of bioproducts in Danisco’s enzyme production 24

Is your mash separation equipment a bottleneck?

Check your

brewhouse performance

If you can answer yes to any of the questions below, the use of our enzymes will benefit your brewhouse:

• Is your brewhouse yield <98%

• Do you experience an inconsistent process time?

• Do you have a hard time getting your adjuncts liquefied?

• Is your mash separation equipment a bottleneck?

• Are you interested in energy savings during your adjunct cooking?

• Do you experience low real degree of fermentation (RDF) or slow fermentation?

• Do you wish to boost your fermentation capacity through very high gravity brewing?

• Do you want to produce low carb beer?

• Do you want to ensure consistent beer filtration?

• Are you interested in using local raw materials?

• Do you want to secure consistent beer quality from inconsistent malt quality?

– depending on lack in raw material

On the following pages you can learn more about how Danisco’s Brewing enzymes can help you overcome

these challenges

Danisco’s brewing

enzyme capabilities

Choose the enzyme provider that knows most

about food and beverages

Every day, somewhere around the world, our enzymes help brewing companies sharpen their competitive edge They enable our customers to keep costs down yet maintain product quality and profitability

We have developed a specialised range of enzymes that maximise brewing efficiency and create stable, high quality beer with great mouthfeel Supported by a unique knowledge base and hands-on industry specialists, these solutions are uniquely able to improve your business by securing:

• Consistently high quality

• Lower raw material costs

• Faster production process

• Lower energy consumption

• More appealing mouthfeel

• Enhanced sustainability

Imagine your business with Danisco’s capabilities

As a leading food ingredients manufacturer, Danisco knows more about food and beverage than any other enzyme provider in the world By talking with us, you will be able to discover, source and apply know-how from the entire food system to the challenges your business faces

We invest heavily in expanding this knowledge and making it accessible for our customers via our global network of research and development centres And we use it to help you identify and profit from new opportunities, too

Danisco has facilities in more than 45 countries For brewing, we have application centres in Brabrand/Denmark and Shanghai/China Our dedicated brewing R&D group is also located in Brabrand and works closely with our grain process-ing and biofuel R&D groups in Leiden/Holland, Palo Alto/US and Shanghai/China We produce enzymes at seven plants around the world

Did you know

All enzymes are proteins

and bio-degradable

Enzymes and brewing

What are enzymes?

Enzymes are proteins present in all living cells, such as plants, animals, human beings and microorganisms They function as catalysts for the thousands of chemical reactions that take place in these cells

As natural substances, enzymes are ideal ingredients for use in the modern food industry By adding modern technology and knowledge to nature’s own material, Danisco is able to mimic and speed up the natural enzymatic proc-ess The result is enzymes as they might appear in natural settings but with an accelerated effect that brings value-adding and previously unattainable functionalities to food products

science/bio-Enzymes are processing aids and not additives Once the enzyme has done its work, it is inactivated, becoming just another protein

How can brewing benefit from enzymes?

The brewing process is dependent on enzymes The enzymes from malt (malted barley) catalyse the hydrolysis of the endosperm cell walls, starch, proteins and lipids during mashing Yeast itself may be considered a complex package of enzymes that catalyse the reactions necessary for converting fermentable sugars into alcohol

Support & control of inconsistent raw material quality

Malted barley is the traditional source of enzymes for brewing However, brewers are often faced with malts of ent quality This can pose challenges such as reduced extract yield, poor mash separation, slow or incomplete fermenta-tion, difficult beer filtration and inferior beer in terms of taste and stability

inconsist-To resolve this situation and achieve consistent, efficient brewhouse performance, exogenous enzymes can be used to supplement the malt enzymes and, in some cases, provide additional activities not inherently present in the malt In addi-tion, these enzymes enable efficient utilisation of a wide range of adjuncts, such as unmalted barley, corn, wheat, sorghum and rice, and can be used to produce beers with specific attributes, such as highly attenuated or low carb beers

Danisco offers a portfolio of innovative enzymes that allow brewers worldwide to develop and maintain cost-effective, consistent processes and high product quality with varying local raw materials

Use our brewing solutions to optimise:

• stabilisation and production of speciality beers

What is the origin of enzymes used for brewing?

Our enzymes for brewing applications are of microbial origin, produced by fungi or bacteria The main reason for using enzymes of microbial origin is their ability to enable commercial production of safe, high quality products

What influences enzyme activity?

• Temperature: Each enzyme has an optimum temperature that gives the highest number of enzyme/substrate tions The optimum temperature varies according to the process conditions, including substrate concentration, pH and the presence/absence of various salts

The brewing process

& possible challenges

Steps in the brewing process include malting, milling, mashing, mash separation, boiling, fermentation, conditioning, filtration and filling The diagram below gives an overview of the process and where enzymes can be added

Malting

Malting prepares cereals for brewing by activating the endogenous enzymes

Malt contains all the enzymes necessary to hydrolyse starch into fermentable sugars, but:

• the malt debranching enzyme is very heat labile and is inactivated in mashing at the temperatures required to gelatinise the starch

• α(1→6) bonds and some adjacent α(1→4) bonds are not hydrolysed, which means the maximum fermentability in normal beers is typically <70 % RDF

Mashing & mash separation

Starch is converted into fermentable sugar Having breaks at different temperatures the different malt enzymes can be more or less effective in the modification of the substrate Protein and non-starch polysaccharides are partly modified.Prior to mash separation, the temperature of the mash is raised to 74-80°C (165-176°F) to inactivate the malt enzyme.The mash is separated into wort and spent grains First, the wort is separated from the mash and sparging water is used

to recover additional soluble extract

Brewhouse performance may be adversely affected by:

• the presence of high molecular weight non-starch polysaccharides, which have a negative effect on mash wort separation

• small starch granules that may not be gelatinised at normal mashing saccharification temperatures, resulting in lower extract yield and potentially starch-positive extract

Wort boiling & cooling

The wort is transferred into a large tank - a “copper” or kettle where it is boiled with hops Many chemical reactions take place during wort boiling, which also serves to inactivate the enzymes Afterwards, the trub (precipitated sediments) are normally removed in a whirlpool

The wort is then cooled using a heat exchanger, yeast is pitched, and everything is transferred to the fermenter

Beer is normally pasteurised before or after filling

Did you know Enzymes are nature’s own catalysts speeding up processes without being consumed in the process.

Profit from the

power of enzymes

We have developed a specialised range of enzymes to maximise brewery efficiency and create stable beer without promising on flavour and clarity Supplementing the enzymes naturally present in malt, they increase extract volume and relieve processing bottlenecks during mash separation and beer filtration, maximising separation and optimising through-put At the same time, the increased conversion of starch into fermentable carbohydrate enhances the malt extract and the quality of the finished beer

com-Consumer demand for greater choice and quality has sent brewers worldwide on a never-ending quest to create ciality beers and develop new styles with exclusive flavour characteristics Their mission has inspired the growing use of cereals other than malt, including corn, rice, wheat and unmalted barley, which contain less enzymes of their own and may require cooking before addition to the mash The addition of our enzymes ensures efficient starch extraction, wort viscos-ity reduction and a sufficient level of free amino nitrogen - all in support of fermentation

spe-High performance in brewing

with local raw materials

Locally grown raw materials, such as rice, corn and sorghum, are clearly an economical and climate-friendly choice, cially in tropical and sub-tropical regions

espe-Malt has a high natural content of enzymes and is capable of breaking down starch unaided, making sugars available for conversion into alcohol Rice, corn and other starch-rich adjuncts, on the other hand, do not contain the necessary amount of enzymes for brewing In situations when the malt is of poor quality or the recipe is based on more than 30% alternative cereals, additional enzymes are required to ensure maximum raw material yield, eliminate filtration bottlenecks and secure the uniform, high quality of the final beer

Commercial brewing alpha-amylases have several advantages over natural malt enzymes One is their high heat stability, which speeds up starch liquefaction and, consequently, gives increased productivity Due to their high efficiency, brew-ing α-amylases can be added at relatively low dosages, which means more non-malt cereals can be processed in a single batch At the same time, there is no risk of residual starch being carried over from the cereal cooker to the mash vessel The α-amylases significantly reduce viscosity – the first requirement for a smooth filtration process without bottlenecks Further viscosity reduction is achieved using complexes of β-glucanase and xylanase These complexes have a number of functionalities In addition to offsetting variations in raw material quality, they optimise wort separation and enhance filtration

Consistent mashing

To secure cost-efficient beer production, good brewhouse performance is essential Performance can be adversely affected by a series of factors These include high molecular weight non-starch polysaccharides, which hamper mash separation, small starch granules that may not gelatinise at normal mashing saccharification temperatures, and incomplete proteolysis, possibly resulting in low α-amino nitrogen – a problem during fermentation

Time and temperature are critical to all steps Insufficient time or an excessively high temperature during proteolysis will lead to incomplete breakdown of the proteins and the β-glucan matrix surrounding the starch granules, reducing the amount of starch available for conversion and resulting in low extract yield If the temperature is too low at the finishing stage, ungelatinised residual starch may be carried through to the kettle If the temperature is too high, the α-amylase will

be denaturated and, although the residual starch may be gelatinised, it will not have been converted into sugar

The presence of unconverted starch carried through from the mash results in low yields and the potential for starch haze

in the finished beer This can be avoided by the addition of a more heat stable α-amylase to the mash

Additional proteolytic activity may be required when brewing with certain adjuncts or inconsistent quality malts to mise the rate of fermentation and attenuation

accom-Alphalase® AP3

kg/MT barley

Viscosity (12 ˚Plato)mPa.s

β-glucanmg/l

Filtration (volume/30 min.)

ml

Extract

˚Plato

FANppm

Table 2: Effect of Alphalase® AP3 with 30% barley inclusion

Product Enzyme Functionality/benefit Dosage in the mash, kg/MT of grist

Bacillus licheniformis

Provides heat stable performance in the mash and cereal cooker; secures efficient starch liquefaction

0.01-0.05

neutral protease

Bacillus subtilis, Bacillus amyloliquifaciens

Gives efficient starch faction in mash, improves extract yields, enables high adjunct inclusion; increases soluble protein and free amino amino nitrogen (FAN)

lique-0.2-1Table 1: Danisco’s first choice AMYLEX® and Alphalase® products for mash addition

Cost-efficient & consistent adjunct cooking

Cereals such as corn and rice are common brewing adjuncts The starch gelatinisation temperatures required by these cereals are higher than those used for saccharification in mashing

To ensure complete gelatinisation and liquefaction of the adjunct starch, it is necessary to cook the adjunct before adding

to the mash Liquefaction of the adjunct is traditionally carried out by adding some malt to the adjunct cooker The cereal adjunct is often mashed in with the enzyme at a relatively low initial temperature of 45–55°C The cooker is then heated

to >90°C for 15–20 minutes to complete the gelatinisation and liquefaction process The cooked adjunct is added to the mash vessel to raise the combined temperature of the mash to typically 62–65°C

The malt α-amylase is not sufficiently heat stable to liquefy the starch at the higher temperatures used in the adjunct cooker A more efficient method is to use a heat-stable α-amylase, such as AMYLEX® 4T or AMYLEX® 3T This gives the following benefits:

• Up to 50-minute reduction in process time for cereal cooking

• Up to 25% less energy consumption during adjunct cooking

• Reduced raw material costs in cereal brewing

• Increased extract yields

• Higher adjunct inclusions in the cereal cooker

• Higher solids content (up to 32% due to lower water to grist ratio) than with traditional brewing

• Significantly reduced viscosity and fouling during cereal cooker operations

accom-Product Enzyme/strain Functionality/benefit Dosage in the cereal cooker kg/MT adjunct

AMYLEX® 4T Heat stable α-amylase

Bacillus licheniformis (GMM

organism)

Provides heat stable performance in the mash and cereal cooker; secures efficient starch liquefaction

or cereal cooker, secures efficient starch liquefaction when no special request for high solids in the adjunct cooker

0.40 - 0.80

AMYLEX® BT2 Heat stable α-amylase

Geobacillus mophilus (traditional non-

stearother-GMM)

Provides heat-stable performance in the mash

or cereal cooker, secures efficient starch liquefaction

0.40 - 0.80Table 3: Danisco’s first choice AMYLEX® products for cereal/adjunct cooking