RU2785410C2 - Method for malting with grain soaking, including water circulation stage - Google Patents

Abstract

FIELD: brewing industry.

SUBSTANCE: method for malting with grain soaking includes: provision of the presence of a malting installation containing a certain number of soaking tanks, a supplying device; a device for supply of air and heat; a device for removal of air and heat from an inner space of each of soaking tanks; a device providing water movement, loading to each soaking tank of grain from the same batch, being in the same soaking phase, supply of water to the inner space of the first soaking tank until grain in the first soaking tank is completely immersed in water, while grain in the second soaking tank is not immersed in water; supply of air to the inner space of the first soaking tank, movement of water through an outlet of the first soaking tank to the device providing water movement, while grain remains in the first soaking tank, and water supply from the first soaking tank to the second soaking tank through the device providing water movement until grain in the first soaking tank is not immersed in water anymore.

EFFECT: invention allows for reduction in water consumption, while saving grain quality.

9 cl, 2 dwg, 2 tbl, 3 ex

Description

The invention relates to a method of malting with grain soaking.

Malting consists of three main processes: soaking (soaking in water), germination and drying.

The purpose of the soaking process is to increase the moisture content of the grain, which initiates the activation of enzymes and induces a natural germination process.

Soaking is carried out in two types of key vats: the first type is distinguished by a conical bottom, and the second by a flat one.

The advantage of the first type of key vats is lower water consumption and gravity flow, but their productivity is limited for technical reasons (tank size) and the quality (uniformity of the production process, ventilation efficiency, etc.) cannot be high. The capacity of key vats with a conical bottom does not exceed 70 tons; to obtain large quantities and higher production capacity, groups of locking devices are used.

The capacity of the second type of lock vats is not limited, which is their advantage, due to which better ventilation is possible, and they are sometimes used as tanks for pre-emergence processing of grain. But such vats have the disadvantage that they require more water due to the shape and need an unloader with radial blades for unloading, which is why the filling is higher.

Plants with large production capacities usually use both types of vats.

The purpose of soaking is to increase the moisture content of the grain to initiate germination so that the grain does not "suffocate".

To do this, soaking with air exposure is carried out, that is, the grain is kept in water 1-4 times (usually 2-3 times) with breaks for air exposure. This process usually takes 1-2 days.

When a grain is in water, it is completely immersed in it. At the same time, air is periodically supplied to the water so that the dissolved oxygen necessary for grain respiration is not depleted, and the contents of the vat are mixed. Therefore, it is important to completely immerse the grain in water.

For air aging, the water is removed so that no water remains between the grains; at the bottom of the vat there is a grate that traps grain, but allows water and air to pass through, allowing heat to be removed.

The described two phases of the soaking process - immersion in water and air exposure - are repeated 2-3 times depending on the design of the plant, water temperature, type and variety of cereal, as well as the desired properties of the product.

When grain is immersed in water, its consumption is usually 1-1.3 m ³ per 1 ton of soaked barley, depending on the equipment. The water consumption in a malting plant is determined mainly by the moisture content of the barley grain during soaking compared to the other two industrial processes that require water - germination and grain washing.

In addition, the water used for soaking the grain must be of the proper degree of frequency, namely clean for use in the food industry. When storing water in which grains have been immersed, microorganisms develop in it, making it unsuitable for reuse for soaking grains.

In plants with a discontinuous production line, a batch of grain is often divided into several key vats, in which soaking occurs in parallel. At the end of this steeping, the grains from all the vats are collected in one sprouting container, so that all the grains of a given batch germinate together. In such plants, each key vat is filled with water suitable for use in the food industry, independently of the other vats.

As the cost of water increases and in some areas it is scarce, and for environmental reasons, malt producers have to look for alternative solutions to the problem of water use, striving for sustainable environmentally friendly development.

It is known that the reuse of water used to soak the grain leads to a delay in germination and a decrease in the quality of the malt, since such water contains agents that inhibit germination and other organic compounds that favor the growth of microorganisms during storage of this water, as well as other undesirable substances.

Patent document EP 1 988 150 describes a malting process in which steeping is carried out - at least in part - with the reuse of water. At the same time, at the end of soaking, the used water is taken from one vat containing grains from this batch, treated to remove substances that inhibit germination, and fed back into the same vat, but containing new grains from another batch.

However, in such a process, the used water can be stored for quite a long time before it is used again, and in addition, a bioreactor is needed to remove germination inhibitors and/or microorganisms from this water.

The OPTISTEEP® malting process is known in the art. OPTISTEEP® is a purification system for water treatment used in grain soaking, and involves only a single but prolonged immersion of the grain in water. At the same time, the water into which the grain from a given batch is immersed in one key vat is continuously purified by selective adsorption and filtration and enters the same vat again during the same period of the grain’s stay in water, so that unwanted substances that adversely affect the germination of grains are removed. . OPTISTEEP® has an expensive specific water treatment system. The OPTISTEEP® technology is particularly attractive when the grain is immersed in water only once.

In the more common cases in modern malting plants, where grain steeping alternates between periods of immersion in water and periods of air soaking, it is not possible to reduce water consumption with the OPTISTEEP® system.

GB 2258243 describes a means of reusing water by supplying it from below the surface on which the grain rests to the top of the same vat, which substantially smoothes the temperature profile in the thickness of the grain. If this invention is used to reduce water consumption, then the grain in the key tun will not be completely immersed in the water in the key tun, which will inevitably lead to an uneven flow of water through the grain, and thus to heterogeneity in the quality of the soaked grains, and this is contrary to the purpose of this production process. .

According to European standards, malt producers are required to use only water with a purity grade for use in the food industry when soaking each batch of grain at the beginning of its immersion in water. In other words, it is forbidden to reuse the water used to submerge the grain from this batch to soak the grain from another batch.

The present invention aims to overcome the problems described above.

The inventors of the present invention have found that if, during the steeping during the same phase of contact with water, the grain of one batch is loaded into several vats and the water passes from vat to vat without moving the grains, then the water consumption during soaking with grain immersion in water is reduced. , and the quality of the grain does not suffer. Specifically, according to the present invention, water is not retained in the transition from vat to vat, and in all vats containing grain of a given batch, the grain-water contact phase occurs simultaneously; this means that the water flows from vat to vat and is not reused, contrary to the method proposed in patent document EP 1 988 150.

Thus, the method of malting with grain soaking according to this invention includes the following successive steps.

1) Provision of equipment - malting plant (10, 10’), including at least:

- several locking vats (18, 20, 22), each of which (18, 20, 22) has walls that limit the internal space where the grain is loaded (25); inlet (30) for grain, water and/or air; outlet (32) for grain, water and/or air; grate (28) with holes of such a configuration that water leaves the vats (18, 20, 22) and air circulates, and the grains remain in the internal space (25) of the vats (18, 20, 22);

- if necessary, a device for supplying water to the interior of each of the key vats (18, 20, 22);

- if necessary, a device for removing air and heat from the internal space of each of the key vats;

- if necessary, a device for supplying air to the interior of each of the key vats;

- a water movement device (44) located between at least the first (18) and the second (20) in the sequence of key vats (18, 20, 22), this device fluidly connecting the outlet (32) of the first a tub (18) and an inlet (30) of at least a second key tub (20);

- 2a) filling each of the key vats (18, 20, 22) with grain from the same batch, which is in the same phase of contact with water of the soaking process;

- 2b) supplying water to the interior (25) of the first key vat (18) until the grain in it is immersed in water, while the grain in the interior of the second vat (20) is not immersed in water ;

- 2c) if necessary, the supply of air into the interior (25) of the first key vat (18), and the grain in this vat (18) remains immersed in water for a predetermined period of time;

- 2d) diverting the entry through the water outlet (32) of the first key vat (18) into the water movement device (44), while the grain remains in the first key vat;

- 3) supplying said water from the first key tun (18) to the second key tun (20) through the water movement device (44) until the grain in the first key vat (18) is no longer immersed in water.

Thus, the steeping water from the first key tun is used in the second key tun as well, while the grain in the first key vat remains in contact with the water and continues to be moistened. The result is water savings. During the entire soaking process, the grain does not pass from vat to vat, and during the same phase of grain contact with water in the same steeping vat, it is immersed in water several times. Also, water does not linger between the key vats, so there is no change in the composition of the water due to the development of microorganisms. In addition, the contact time of the water used for soaking with the grain immersed in it is short, so that this water is not burdened with germination inhibitors or other organic compounds released from the grains.

In preferred embodiments of the present invention, the grain steeping malting process also includes the following features, individually or in any combination that is technically feasible:

- the device providing the movement of water contains at least one circulation pump;

- the malting plant also includes a water aeration device connected to a water movement device located between the outlet of the first key vat and the inlet of the second vat;

- the malting process includes step 4, and steps 2b - 3 are repeated;

- step 3 includes the supply of water to the interior of the second key vat until the grain in this second vat is immersed in water, while the grain in the first vat is not immersed in water, and most of this water is water supplied from the first key vat through a device that ensures the movement of water, if necessary with the supply of air into the interior of the second key vat, and the grain in the second key vat remains immersed in water for a predetermined period of time and the water flows out of the second vat through it outlet, and the grain remains in the second key vat.

- water from the last in the sequence of key vats (not the first vat) enters again into the first in the sequence of key vats through a device that ensures the movement of water.

Thus, the water soaking the grain from the first key vat makes a cycle and enters again into the specified first key vat.

This invention limits water consumption by allowing multiple immersions during the grain-water contact phase, whereas in the OPTISTEEP® soaking process, there is only one immersion of the grain in water, corresponding to contact with water without air soaking. The present invention thus makes it possible to save water for soaking grain in existing plants at no significant cost, and expensive water treatment equipment is required to use the OPTISTEEP® technology.

The time interval between two periods of soaking the grain in water in the same key vat is preferably selected so that during this time interval the grain in the given vat remains moist.

Thus, during the entire phase of contact with water, the grain in all key vats remains moist.

The malting plant may also include a device for treating water flowing from the outlet of at least one of the series of key vats.

The grain-soaking malting method of the present invention may also include the step of treating water flowing out of the keypot outlet with a water treatment device.

The water treatment device makes it possible to remove from the water that has passed through the device that provides the movement of water, particles suspended in it or any other undesirable material.

The malting plant may also include faucets/valves that, when open, allow the flow of water and, when closed, stop it; these faucets/valves are located at the outlet of each key vat, and each faucet/valve operates independently.

The faucets/valves allow the vat to be filled with the desired amount of water from the water supply device or from the water movement device and, if required, create the possibility of bypassing the main water flow path.

Below for a better understanding of the present invention is a description of the examples and with the help of drawings.

Brief description of the drawings

In FIG. 1 is a schematic representation of a malt plant according to one exemplary embodiment of the present invention.

In FIG. 2 is a schematic representation of a malting plant according to another exemplary embodiment of the present invention.

Implementation of the invention

One embodiment of a malting plant according to the present invention is illustrated in FIG.

The malting plant 10 includes at least a plurality of malting vats 12 into which the grain is loaded and a device 14 supplying water for soaking the grain.

The terms "key vat" and "vat" are used interchangeably herein.

According to the present invention, the term "grain"/"grains" includes fruits of the "grain" type of cereal plants, as a result of which malt is obtained as a result of germination; in particular, malt is made from wheat, barley, sorghum, or oats.

In the present description, the expressions "upstream" and "downstream" refer to the direction of water movement, which in Fig.1 is depicted by arrows.

In the installation shown in figures 1 and 2, three key tubs (18, 20, 22) are used. Alternatively, the malting plant of this invention may include another number of vats, such as two or at least four.

Depicted in figure 1 key vats 18, 20, 22 further to distinguish between them. the first vat 18, the second vat 20 and the third vat 22 are called; these names are used only for clarity of presentation.

Each of the vats 18, 20, 22 has a body 24. Typically, the body 24 is axially symmetrical. The housing 24 is in the form of a cylinder with a conical or flat bottom.

In the case when the bottom of the key tun is flat, it is equipped with an unloader with radial blades for grain evacuation.

Alternatively, the malting plant 10 includes only taper-bottomed vats.

The malting plant 10 may include only flat-bottomed vats.

Alternatively, the malt plant 10 may include both conical outer and flat-bottomed vats.

In the lock vats 18, 20, 22, the housing 24 defines the boundaries of the internal space containing the grain (25); hereinafter it is called the inner space 25.

The capacity of the interior of the vats 18, 20, 22 is generally not more than 70 tons, not more than 100 tons, not more than 600 tons. Preferably, the interior 25 of the vats 18, 20, 22 is not more than 100 tons.

In the lock vats 18, 20, 22, the top 26 is open, and at the bottom 27 there is a bottom.

Key vats 18, 20, 22 are equipped with a grate 28 with holes. The grate 28 is typically located in the interior 25 of the key vat near its bottom 27. The grate openings may be oval, round, rectangular, or any other suitable shape.

The diameter of the grating openings is usually smaller than the size of the grain, so that water leaves the key vat and air can circulate, and the grain remains in the interior 25 of the key vat.

For example, if the holes are oblong, then their length is 10-20 mm, width 1-2 mm, usually 1.8 mm.

This feature also allows for air holding in the same key tun as contacting the grain with water.

The lock vats 18, 20, 22 each have at least one grain inlet, at least one water inlet, and/or at least one air inlet.

In one of the embodiments of the present invention (see figure 1) these inlets for grain and for air is one inlet 30.

Or different inlets are used for grain and air.

The lock vats 18, 20, 22 each have at least one grain outlet, at least one water outlet, and/or at least one air outlet.

In one of the embodiments of the present invention (see figure 1) the specified inlet for grain and for air is one inlet 32.

Or, for grain, for water and for air, there are different outlets.

Each of the vats 18, 20, 22 has at least one grain outlet, at least one water outlet, and/or at least one air outlet.

In one embodiment of the present invention (see FIG. 1), said grain, water and/or air outlets are one outlet 32, or grain, water and air are different outlets.

However, the number of inlet and outlet openings in the key vats is not limited in any way.

In the example illustrated in FIG. 1, the lock vats 18, 20, 22 have a water inlet at the upper end of the vat and a water outlet at its lower end. In the lock vats 18, 20, 22, the grain inlet is located at the upper end of the vat, and the grain outlet is located at its lower end. As a rule, air is supplied to the key vats with a flat bottom from below. In key vats with a conical bottom, air can be supplied at different levels.

However, the location of the inlet and outlet openings is not limited in any way.

For example, lock vats 18, 20, 22 may have a water inlet or an air inlet.

The pots 18, 20, 22 are typically made of stainless steel or coated steel or concrete or any other suitable material.

The grain soaking water supply device 14 includes a tank 34 containing water 40 used to soak the grain.

Potable water is usually used for soaking grains to meet malt quality requirements. The water supply device typically includes a conduit 36 which supplies potable water from the tank 34 to the water inlet 30 in the lock vats 18, 20, 22.

Alternatively, the water supply device 14 includes a conduit for at least one key vat.

The malting plant 10 may include an air supply device (not shown) to aerate the grain.

The device supplying air for aerating grain usually includes an air compressor. The air supply device according to the invention generally has two modes of operation, an operating mode and a rest mode, which can be changed as desired during the process.

The malting plant 10 may also include a device for evacuating exhaust air and removing heat from the key vats (not shown).

Exhaust air in this context refers to the air evacuated from the key vats, which contains carbon dioxide and other gaseous substances emitted by the grains.

A device for evacuating exhaust air and removing heat from the interior of the key vat is connected to the air outlet for each of the vats 18, 20, 22.

The device for evacuation of exhaust air and heat removal provides better grain aeration and optimal temperature in the key vat. This device can be any device commonly used to remove air and heat in the malting industry.

The malting plant 10 of this invention may also include any other equipment commonly used in malting plants.

Preferably, the malting plant 10 of the present invention also includes a conduit 42 for draining used effluent water to the outside, which is located downstream of the water outlet 32 of the key vats 18, 20, 22 (arrow A in FIG. 1).

The malting plant 10 of the present invention also includes a water movement device 44 fluidly connected to all of the key vats 18, 20, 22.

Said water coming out of the outlets of the locking vats is hereinafter referred to as the water used for soaking the grain.

In the example illustrated in FIG. 1, the water movement device 44 typically includes a first conduit 46, 46' which supplies water used to soak the grain 41 from the first key vat 18 to the second key vat 20. The first conduit 46 , 46' is typically located below (downstream 46') the water outlet 32 of the first key vat 18 and above (upstream 46) the water inlet 30 of the second key vat 20.

The device 44, providing movement of water, typically includes a second conduit 48, 48', supplying water used to soak the grain, 41 from the second key tun 20 to the third key vat 22. The second conduit 48, 48' is usually located below (along flow 48') water outlet 32 of the second key vat 20 and above (downstream 48) the water inlet 30 of the third key vat 22.

The device 44, providing movement of water, typically includes a third conduit 50, 50', supplying water used to soak the grain, 41 from the third key vat 22 to the first key vat 18. The third conduit 50, 50' is usually located below (along flow 50') water outlet 32 of the third key vat 22 and above (downstream 50) water inlet 30 of the first key vat 18.

Of course, with a different number of key vats, the device that ensures the movement of water contains additional pipelines connecting the corresponding key vats.

In another embodiment of the present invention, in which the number of cauldrons is an even number, the water movement apparatus includes conduits connecting the water inlets and outlets of the cauldrons in pairs.

As a rule, in the device that provides the movement of water, there is at least one circulation pump 52. The circulation pump 52 ensures the flow of water from the outlets 32 of the lock vats 18, 20, 22 to the inlets 30 of the vats 18, 20, 22. As is known, the circulation pump can be with a cylinder - such a pump does not empty. The pump cylinder 52 is not designed to hold water during the operation of the malting plant 10.

Conduits 46, 48, 50 are typically at least partially fluidly connected to a water supply device 14 and to a conduit 42 for draining waste water to the outside.

Typically, the device 44, which provides movement of water, includes at least one valve/faucet 82, located downstream of the outlet 32 of the key vats 18, 20, 22 on the pipelines 46', 48', 50', so that when it was necessary to bypass the device 44, which provides the movement of water.

The water movement device 44 may also include at least one faucet/valve 76 located upstream (downstream) of the water inlet 30 of the key vats 18, 20, 22.

Preferably, in the malting plant 10 according to the present invention, there is no storage facility for steeping water between two malting vats. The water movement device of the present invention is suitable for circulating water between key vats containing grains of the same batch in the same phase of the soaking process, but not for circulating water between grains from different batches.

In each of the lock vats 18, 20, 22, at least one faucet/valve 54 is located at the water outlet 32.

In the example illustrated in FIG. 1, in each of the key vats 18, 20, 22, one valve/faucet 56 is also located at the water inlet 30 so that it is possible to select which vat to fill with water from the water movement device 44 or from a water supply device 14.

In the present description, the faucets/valves 54, 56 operate in two modes: "open" when water flows through a given faucet/valve, and "closed" when no water passes through it.

Preferably, each of the taps/valves 54, 56, 76, 82 operates independently. Preferably, the operation of the faucets/valves 54, 56 is also automated.

A faucet/valve 60 is typically positioned upstream (downstream) of conduit 42 to vent waste water to the outside.

In the example illustrated in FIG. 2, the three vats 18, 20, 22 of the malting plant 10' are arranged vertically one below the other.

A faucet/valve 54 is located at the outlet 32 of each of the lock vats 18, 20, 22. Thus, water can flow from vat to vat by gravity through the water movement device 44. The water supply device 14 can be connected in fluid medium with each of the key vats 18, 20, 22 separately. Alternatively, the water supply device 14 is fluidly connected to at least one of the tubs 18, 20, 22.

The circulation pump 52 ensures the flow of water from the lower key vat 22 to the upper vat 18.

In one specific embodiment of the present invention, the malting plant 10 includes a device 70 for treating the steeping water 41 that flows from the outlet 32 of at least one of the vats 18, 20, 22 before entering the next key vat. The soaking water treatment device 70 41 serves to retain material suspended in the water.

For example, the water treatment device 70 includes a filtration system, such as a filter membrane in a transverse water circulation line, or an ultrafiltration membrane, or a drum screen, or a sand filter, or a cartridge filter. Alternatively, the water treatment device 70 includes some other suitable water treatment device.

In this particular embodiment of the present invention, the water treatment device 70 typically includes at least one faucet/valve located upstream (downstream) of the water treatment device 70 and at least one faucet/valve located below (downstream). flow) of the water treatment device 70 so that the water treatment device 70 can be bypassed if desired.

Preferably, the malting plant 10 includes a water aeration device 90 that is connected to a water movement device 44 connected to the outlet 32 of the first key vat 18 and to the inlet 30 of the second key vat 20.

Preferably, the water aeration device 90 is located downstream (downstream) of the water treatment device 70. Thus, the water is saturated with air after the purification treatment.

The water aeration device 90 ensures that the water used to soak the grain 41 is oxygenated while the water is circulating.

For example, the device 90 for aerating water used for soaking grain is a suction system based on the Venturi effect (Venturi tube) connected upstream of the water circulation line 46, 48, 50.

We now turn to the description of the method of malting with grain soaking according to this invention.

Typically, the grain steeping malting process includes the two main operations of immersing the grain in water and air holding, as described above, each of these operations being carried out one or more times in each key vat.

In the context of this invention, we will consider in detail only the phase of contacting the grain with water.

At the beginning of the soaking process of the grain according to this invention, grain is loaded into the key vats 18, 20, 22. In this case, a certain amount of grain is placed in the interior of each of the vats 18, 20, 22. Preferably, said grain is taken from the same batch. A batch of grain in this document refers to one production batch of grain; this grain is subject to the same phase of contact with water in several vats in parallel.

Accordingly, one batch of malt is obtained from the same batch of grain.

Next, at least one key vat 18 is filled with a certain amount of water, sufficient for the grain in this vat to be completely immersed in water, while the grain in the interior of the second key vat 20 is not immersed in water.

This process is preferably carried out so that in each vat containing grain from a given batch, the duration of each period of immersion of grain in water is sufficient, that is, that between two successive periods of immersion in water, the grain does not have time to dry.

In figures 1 and 2, the flow of water is shown by arrows.

The water-contact phase of grain soaking is described below in detail for a single key vat 18. It is understood that the grain-water contact phase occurs in the same way in all key vats.

The amounts of grain and water loaded into the first key tun 18 are selected according to the type of vat used so that all steeped grains are submerged in water, which ensures the same wetting of the grains and prevents uneven flow of water through the grain mass.

Those skilled in the art will understand that the amount of water is taken depending on the properties of the grain (mainly the weight and shape of the grains matter) and on the shape of the vat.

As a rule, from 1 to 2 cubic meters of water is used per 1 ton of grain. Preferably, the amount of water used for filling the grain is 1-1.3 m ³ /t. Usually, in the case of a flat-bottomed key vat, 1 m ³ /t is taken in addition to the volume of water that is enclosed between the grate and the bottom of the vat.

During contact of the grain with water, the key vat 18 is usually supplied with air from the air supply device through the air inlet into the interior 25 of this vat.

As a rule, when water 40 is supplied to the key vat 18, to ensure its desired temperature, heating and cooling devices operate, the operation of which is determined by a temperature controller. The temperature of the water 40 supplied to the vat is preferably 12°C to 20°C.

The grain in the key vat 18 is completely immersed in water for a prescribed period of time. For example, typically the period of immersion of grain in water is from 15 to 60 minutes.

At the end of this prescribed period of time, the water in which the grain was immersed 41 from the interior 25 of the first key vat 18 leaves through the water outlet 32 of the first key vat 18, while the grain remains in this vat.

Water from the first key vat 18 passes into the second vat 20 with the help of a device that provides water movement 44, and the grain retained by the grate with holes 28 remains in the interior of the first key vat 18.

After all the water from the first key vat 18 has gone and the grain is sufficiently drained, air and heat are removed through the air outlet 32.

In the circulation step, the water 41 used to soak the grain in the first key vat 18 flows through the water movement device 44 into the second key vat 20 until the grain in the first key vat 18 remains out of the water. Typically, the water used to soak the grain 41 is supplied through the first circulation line 46. In the example illustrated in FIG. at the water inlet 30 of the second key vat 20 are open. Faucet/valve 82 located below (downstream) the outlets 32 of the tanks 18, 20, 22 on the circulation line 46', 48', 50', and the faucet/valve 76 located above (downstream) the water inlets 30 key vats 18, 20, 22, open. In this example, the taps/valves located at the water inlet 30 of the first key vat 18, at the water outlet 32 of the second key vat 20, and at the water inlet 30 and water outlet 32 of the third key vat 22 are closed.

The amount of water in the second key tub 20, which is taken from the water tank 34 at the expense of water 40, is selected so that in this tub all the soaked grain is completely immersed in water to evenly moisten it.

At the end of the water overflow step, the water outlet faucet/valve 56 at the water inlet 30 of the second key vat 20 is closed.

The time interval between the start of the stage of water flowing from the first key vat 18 to the second key vat 20 and the end of this stage is usually from 15 to 60 minutes, depending on the capacity of these vats and the specifics of the device that provides water movement.

Then the grain is immersed in water in the second key tub 20 for the prescribed time.

During this stage, the grain in the first key vat 18 is not immersed in water, but remains wet.

Thus, in both locking vats - 18 and 20 - the same phase of grain soaking - contact with water - takes place.

At the end of the prescribed period of time, the above process is repeated for the second and third vats (20 and 22) and then for the third and first (22 and 18). And then first - the first (18) and the second (20), the second (20) and the third (22), the third (22) and the first (18) and so on with the prescribed duration. The vat from which water flows back into the first lock vat 18 is called the last.

The time interval between two periods of immersion of grain in water in the same key vat is selected so that during this interval the grain in the indicated vat remains wet.

Grain moisture can be determined by any method known to those skilled in the art, such as visually by looking at the appearance of the grain.

Thus, during the soaking phase, the grain remains wet during the entire phase of contact with water, which includes several successive immersions. The definition of "wet" in this document means that the grains have a film of water, forming at least a meniscus between them.

The method of soaking grain according to the present invention preferably also includes the step of treating the water with the water treatment device 70. than it is fed into the next key tun, it passes through the water treatment device 70. Thus, the material suspended in it or any other undesirable substances is removed from the water used for soaking the grain 41, which increases the efficiency of the phase of contacting the grain with water of the soaking process grains.

Upon completion of the grain-water contact phase of the grain soaking process, the water 41 used in the locking vats 18, 20, 22 is removed from the malting plant.

Then the air supply is stopped.

Preferably, air and heat are removed from each vat 18, 20, 22 through the air outlet 32. The grain enters the air holding phase, as described above, without moving from vat to vat and before a new phase of contact with water, if any, occurs. .

From each key vat 18, 20, 22, a batch of grain that has undergone the described soaking process is discharged through the grain outlet 32 and then enters the germination step.

In another embodiment of the present invention, the malt plant 10 is similar to that illustrated in FIG. 1, but includes at least four key vats, at least two first and at least two second. The number of vats is preferably expressed as an even number. In this embodiment of the present invention, the phase of contacting the grain with water is simultaneously carried out in at least two first key vats for a prescribed period of time. At the end of this period of time, the water into which the grain was immersed is evacuated from the first vats and fed into the second locking vats through a device that ensures the movement of water.

Thanks to the features described above, the water consumption for soaking is reduced. Moreover, this reduction in water consumption is possible without disturbing or slowing down the germination process of the grain, without introducing pollutants and without degrading the quality of the beer produced using the resulting malt.

This invention can be carried out in various ways, without being limited to the embodiments described above.

EXAMPLES

Materials and methods

Experience 1

Four vats A1, A2, B1, B2 were taken and arranged as in the example illustrated in FIG. 1.

These vats were loaded with 99,932 kg of grain, in this case barley variety Nectaria, which was distributed equally among the vats, i.e. came out about 25 tons of grain in each vat. The maximum capacity of one vat is 30 tons.

Pot A1 was supplied with drinking water until the grain was completely submerged. The temperature of the water entering vat PA1 was typically 19°C.

We started the experience.

The grain in the A1 key vat was immersed in water for 10 minutes.

The water containing the grain in vat A1 was then transferred to vat A2 by means of a water movement device. Water entered the lock vat A2 until the grain in this vat was completely immersed in it. The water crossing lasted approximately 15 minutes.

The grain in the A2 key vat was immersed in water for 10 minutes.

The water containing the grain in vat A2 was then transferred to vat B1 by means of a water movement device. Water entered the key vat B1 until the grain in this vat was completely immersed in it. The water crossing lasted approximately 15 minutes.

The grain in the key vat B1 was immersed in water for 10 minutes.

The water containing the grain in vat B1 was then transferred to vat B2 by means of a water movement device. Water entered the key vat B2 until the grain in this vat was completely immersed in it. The water crossing lasted approximately 15 minutes.

The grain in the key vat B2 was immersed in water for 10 minutes.

The water that contained the grain in vat B2 was then transferred to vat A1 by means of a water movement device. Approximately 1 hour and 40 minutes have passed since the beginning of the experiment. Water entered the lock vat A1 until the grain in this vat was completely immersed in it. The water crossing lasted approximately 15 minutes.

The grain in the A1 key vat was immersed in water for 10 minutes.

The described process continued, and in each vat the grain was immersed in water four times.

During the complete immersion of the grain in water, air and heat were removed from each vat continuously for 10 minutes to 1 hour.

After 6 hours and 40 minutes, the water used to soak the grain was removed from vat B2.

The air holding phase began.

To control the moisture and quality of barley grains, 10 hours after the start of the experiment, grain samples BS1 and BS2 were taken from vats A1 and B2, which were also used to judge whether there was a difference in grain properties between the first and last key vats.

Experience 2

Four vats A1, A2, B1, B2 were taken and arranged as in the example illustrated in FIG. 1.

These vats were loaded with 99,932 kg of grain, in this case barley variety Nectaria, which was distributed equally among the vats, i.e. came out about 25 tons of grain in each vat. The maximum capacity of one vat is 30 tons.

Drinking water was supplied to vats A1 and A2 until the grain was completely submerged. The temperature of the water entering vats A1 and A2 was typically 19°C.

We started the experience.

The grain in the vats A1 and A2 was immersed in water for 20 minutes.

The water containing the grain was then transferred from vats A1 and A2 to vats B1 and B2 by means of a water movement device. Water entered vats B1 and B2 until the grain in these vats was completely immersed in it. The water crossing lasted approximately 20 minutes.

The grain in the key vats B1 and B2 was immersed in water for 20 minutes.

The water containing the grain was then transferred from vats B1 and B2 to vats A1 and A2 by means of a water movement device.

Approximately 1 hour and 20 minutes have passed since the beginning of the experiment. Water entered vats A1 and A2 until the grain was completely immersed in it. The water crossing lasted approximately 20 minutes.

The grain in vats A1 and A2 was immersed in water for 20 minutes.

The described process continued, and in each vat the grain was immersed in water five times.

After 6 hours 20 minutes after the start of the experiment, the water used to soak the grain was removed from the vats B1 and B2.

Then began the phase of air exposure lasting 12 hours, after which was carried out for the second time the phase of contacting the grain with water for 6 hours. This second phase of grain-water contact was standard.

During the air holding phase, air was purged from each vat in periods of 10 minutes continuously, alternating periods of venting with 20-minute breaks.

To control the moisture and quality of barley grains, 10 hours after the start of the experiment, grain samples BS3 and BS4 were taken from vats A1 and B2, which were also used to judge whether there was a difference in grain properties between the first and last key vats.

Control

With the same barley, standard batches of grain were obtained with the following soaking regimen: 8.5 hours of contact with water - 12 hours of air exposure - 6 hours of contact with water; the water temperature was the same as in the experiments described above.

The malt obtained in the two experiments described above was analyzed for moisture; also determined the water consumption during the experiment and the yield of malt (see table 1) in comparison with malt obtained from standard batches of the same variety of barley.

results

Grain moisture content 10 hours after the start of the experiment

Grain moisture content was determined by infrared drying, typically at 105°C, until the change in grain weight ceased.

BS1 32.2% (1st experience)

BS2 31.8% (1st experience)

BS3 34.2% (2nd experience)

BS4 33.2% (2nd experience)

These differences in grain moisture content are insignificant. Thus, the proposed system, in which four key vats are arranged sequentially one by one or in pairs, allows for uniform (without difference between vats) soaking of grain.

Humidity of the resulting malt

Malt moisture content was determined according to the European Brewing Convention (EBU; Malt section 4.2) by taking samples from the entire batch.

First experience - 4.38%

Second experience - 4.44%

Control - 4.77% and 4.67%

Water consumption

The volume of water was calculated according to the readings of the flow water meter.

In the malting plant used, the grain from the steeping tank is transferred to the germinating tank in a wet state, so that the water consumption is greater than for the actual steeping.

The first experience - 252 m ³ , i.e. 2.52 m ³ per 1 ton of grain

The second experience 270 m ³ ie. 2.70 m ³ /t

Control 335 m ³ and 384 m ³ , i.e. 3.35 m ³ /t and 3.8 m ³ /t, depending on the location of the container for germinating grain relative to the place of soaking (transfer of wet grain).

Malt output

Yield = weight of malt obtained (kg) / weight of soaked barley (kg)

First experience - 85.8%

Second experience - 84.8%

Control - 85.8% and 86.1%

Malt quality

Standard analyzes were carried out according to the European Brewing Convention (EBC; Malt section 4.2) on the malt samples obtained in the first and second experiments, in comparison with control samples. The results are presented in Table 1. These data show no significant difference between the samples taken.

The malt was also checked for hashing by the internal method: 100 g of malt was extracted into 350 ml of distilled water for 1 min using a blender at high speed; centrifuged at 5000 g for 10 min, the supernatant was boiled until its volume reached 200 ml; cooled at room temperature; filtered through a paper filter; 50 ml of the filtrate was added to the contents of a 330 ml bottle of Heineken beer, from which 50 ml had previously been poured. The bottle was then hermetically sealed and pasteurized at 60°C. After cooling, the bottle was weighed and then shaken at a frequency of 60 times per minute in a horizontal position for 3 days at a temperature of 20°C. The bottle was left motionless for 10 minutes, then shaken by hand in a vertical position 3 times for 10 seconds, left motionless for 30 seconds, after which it was opened; if at the same time the beer gushed and part of it poured out of the bottle, then at the end of the hashing it was weighed. The malt was considered non-hashing if the weight loss was less than 50 g. This hashing test was done with three bottles, repeated twice.

The results of testing the malt on the hashing effect are presented in table 2; they are negative.

Fermentation and production of beer

The beer was brewed in a 40 liter microbrewery according to International Organization for Standardization guidelines (ISO/MPFE/002). From each variant of the malt obtained in the experiments described above, and from the control was prepared wort with a sugar content of 12.5 g per 100 g (12.5°Plato). These malt variants were fermented in three stages: 20 min at 50°C, 15 min at 64°C and 20 min at 74°C. The wort was cooled and dry yeast S23 (Saflager) was added to it in an amount of 1.5 g/l. Fermentation took place for 9 days at a temperature of 12°C. The beer was kept for 5 days at a temperature of -1°C, after which it was passed through a filter and sealed in bottles; then analyzed.

Checking the quality of beer.

The quality of the beer was rated by a panel of experts on a scale from 1 (unfit for drinking) to 9 (excellent). Grades over 5 were considered acceptable.

The results of this test are shown in Table 2. The beers produced using this invention scored acceptable, with no significant difference between the products obtained in the experiments described above and the control beer.

Thus, the installation according to the invention makes it possible to reduce the water consumption during grain soaking without affecting its quality.

Table 1. Malt quality

Humidity (%) Extractivity
(%) Difference extract
goods (%) Pause for osahari
vaniya
(min) Color
EBC General
protein
(%) Soluble Protein (%) Hartong number (%) First experience 4.4 80.7 1.7 10--15 4.3 10.4 4.3 34.9 Second experience 4.3 80.2 1.5 10--15 four 10.8 4.2 33.4 The same barley as in the experiments - previous batches 4.8 80.7 1.7 10--15 four 10.6 4.3 33.5 4.7 80.4 1.1 10--15 3.9 10.7 4.4 36.5

Table 1 continued

Standard analyzes Elm
bone (min ^-1 ) pH Rykh
lost
(%) Full-
tew not changed
grain (%) Partially
don't change
nenoe
grain (%) DON
µg/kg (billion ⁻¹ ) NIV
µg/kg (billion ⁻¹ ) OTA
µg/kg (billion ⁻¹ ) T2-HT2
µg/kg (billion ⁻¹ ) pDMS
(mg/kg) First experience 1.61 6.15 85 1.6 3.2 ND ND ND ND 3.6 Second experience 1.61 6.18 83.6 one 3 ND ND ND ND 3.7 The same barley as in the experiments - previous batches 1.58 6.17 84.8 0.5 2.2 ND ND ND ND 2.8 1.59 6.19 86.6 one 2.7

Table 1 continued

Other Options Received malt Wort Damaged
grain (%) impurities
(%) free amine
nitrogen Weight
(kg) Exit
(R2)% Wort filtration
(min) Beer outlet
(%) First experience 0.9 1.3 154 85774 0.858 88 66.8 Second experience 1.3 1.9 151 84729 0.848 92 66.1 The same barley as in the experiments - previous batches 1.7 1.7 154 85777 0.858 100 62.9 1.8 1.5 154 86045 0.861

Table 2. Beer quality

Content of extractive substances (°Plato) Alcohol
(%) Color
(EBC) Stability
foam
(With) Diacetyl (mg/l) Taste
(conditional scale) Gashing effect (g) First experience 4.64 4.64 7.5 243 0.37 6.11 0 - 0 Second experience 5.02 4.61 6.6 248 0.42 5.78 0 - 6.4 The same barley as in the experiments - previous batches 4.76 4.61 7.8 247 0.35 5.89

ND - not defined; DON - deoxynivalenol (vomitoxin); NIV - nivalenol; OTA, ochratoxin A; T2-HT2 - mycotoxins T2 and HT2; pDMS - polydimethylsiloxane.

Claims (23)

1. The method of malting with grain soaking, characterized in that it includes the following successive steps: 1) providing a malting plant containing at least - a number of lock vats, each of which has walls that limit the internal space containing the grain; inlet for grain, water and/or air; outlet for grain, water and/or air; a grate with holes, the shape of which allows water to be evacuated from the key tun, allows air to circulate and retains grain in the interior of the key tun, - a device for supplying water to the interior of each of the key vats; - a device for supplying air and heat into the interior of each of the lock vats; - a device for removing air and heat from the internal space of each of the key vats; - a device that ensures the movement of water, including at least one circulation pump and located between at least the first key vat from among several key vats and the second key vat from among several key vats, and the device that provides water movement connects in a fluid medium, the outlet of the first key tun with the inlet of at least the second key tun; 2a) loading into each key vat grain from the same lot, which is in the same soaking phase, namely in the phase of contact with water; 2b) supplying water to the interior of the first key vat until the grain in the first key vat is completely immersed in water, while the grain in the second vat is not immersed in water; 2c) supplying air to the interior of the first key vat, wherein the grain in the first key vat remains immersed in water for a period of time long enough that between two successive periods of immersion in water, the grain does not have time to dry out and remains moist; 2d) moving water through the outlet of the first key vat into the water moving device while the grain remains in the first key vat, and 3) the flow of water from the first key tun into the second key tun through a device that provides movement of water until the grain in the first key tun is no longer immersed in water. 2. The method of claim 1, wherein the malting plant further comprises a water aeration device connected to a water movement device that fluidly connects the outlet of the first key vat to the inlet of the second key vat. 3. The method of claim 1, further comprising step 4, where steps 2b through 3 are repeated. 4. The method according to claim 1, wherein step 3 includes the following steps: 3a) supplying water to the interior of the second key vat until the grain in the key vat is completely immersed in water, while the grain in the interior of the first key vat is not immersed in water, the main part of said water coming from the key vat. vat through a device that provides the movement of water; 3b) if necessary, supplying air to the interior of the second key vat, wherein the grain in the second key vat remains immersed in water for a predetermined period of time, and 3c) evacuation of water through the outlet of the second key tun while the grain remains in this key tun. 5. The method of claim. 1, further comprising the step, in which the water from the last key tun of the plurality of key tuns, different from the first key tun, again enters the first key vat of the plurality of key tuns through the water movement device . 6. The method according to claim 1, wherein the period of time between two periods of immersion of the grain in water in the same key tun is chosen so that the grains in said key tun remain wet during this period of time. 7. The method of claim. 1, in which the malting plant further comprises a device for treating water coming from the outlet of at least one key vat from among several key vats. 8. The method of claim. 1, further comprising the step of treating water coming from the outlet of the key vat with a water treatment device. 9. The method according to claim 1, in which the malting plant further comprises taps / valves operating in two modes - in the "open" position, in which water flows, and in the "closed" position, in which the flow of water stops, and these taps / valves are located at the outlet of each of the key vats, and each faucet / valve operates independently.

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