ESTEC Home Brewing Club First Monthly brewing session

ESA UNCLASSIFIED – For Official Use

ESTEC Home Brewing Club First Monthly brewing session

Jean-Francois Dufour

14/11/2013

EHBC First Monthly Meeting | Jean-Francois Dufour | 14/11/2013 | Slide 2


<<For at least 7,000 years, humans have been brewing beer. The act of fermenting sugars derived from grains is so simple that it actually happens on its own in many cases without human intervention. That doesn't mean we don't want to intervene, though. Through the process of refining our methods, we've produced countless varieties of the tasty beverage.Home brewing is a popular hobby, and many engineers partake in it. Of course, any engineer will approach brewing with the goal of improving and automating the process.>> [EETimes, 2013]



The Brewing Process – a quick intro



Agenda

17h00: Breaking the ice & grains (a blond Ale will be brewed today!)17h05: Mash-in 60mins17h10: Start of the meeting

1) Welcome2) Presentation of the Club and its rules3) Election of the committee (feel free to put yourself as a candidate now!)4) The Brewing Process5) Presentation and utilization rules of the equipment6) Any Other Business AoB

18h10: Sparging of the Grains18h25: Start of the Boil (60mins) + 1st hops addition for Bitterness19h15: Second hops addition for Flavor19h23: Third hops addition for Aroma19h25: Cooling of the Wort (unfermented beer is called wort)19h45: Store in fermenter, add yeast20h00: End of meeting / brewing session



Welcome

• Congratulations to everyone• What was the initiative of a few individuals turned out into

an interest pool of 60 people!

• To date, we now have 22 registered members.• If you signed the membership sheet, please do register as

soon as possible! Your contribution is vital for this first year of activity!!

• We need at least 50 members this first year.

• Who am I?



Presentation of the club and its rules

The ESTEC Home Brewing Club was voted by the SSCC assembly (40 people representing each club, each of them with 1 vote) on October 31st.• A great majority voted for the creation of the club, resulting in the creation

of the EHBC.• Note: some restrictions were imposed by the head of establishment

During the first year, the EHBC will rely on the membership fees and on limited financial support from SSCC to procure equipment.



Objectives and implementation

Club ObjectivesThe Club’s goals are, with an engineering perspective,a) to create a community of home brewers (creating team-building, as well as communication and learning environments), b) to educate about brewing techniques (through lectures, experiments, presentations from specialists), c) to promote interactions between home brewers, at ESTEC and also with external entities/clubs, and of course d) to give its members the opportunity to brew their own drinks on-site with colleagues and friends.

To achieve these goals, the Club intends to:a) set up monthly brewing events at ESTEC, sometimes with an invited guest, specialized in brewing. These events are complemented with Lectures, discussions and advices on brewing and the related techniques and equipment.b) set up a small-size home brewery at ESTEC with equipment owned by the club, which facilities will be made available to the club’s members for brewing any day (the EHBC survey shows that the little space in Dutch houses/appartments is why many enthousiast home brewers at ESTEC can difficultly perform this activity at home - 95% of the respondants say that having the facility on-site was a prerequesite).c) share our hard work, passion and curiosity during external events, for example the ESTEC fun day, and to organize visits to famous breweries and to other events.



Conditions imposed by HoE

• Brewing beer is a hobby, even a discipline for many.• It is also a way to produce alcohol which leads to relevant questions,

especially on the worksite.• Therefore, we have been asked the following:

1. No drinking on-site (also valid for tastings)2. Safe utilization of the equipment has to be demonstrated3. No filled beer bottles shall be stored on-site4. No Gaz (propane) to be used inside.

• Note: in time, we intend to request a modification of these conditions. Please just give us a few months to let the idea of having a beer club settle down.



Other Rules directing the EHBC

• A set of rules will be defined, especially for what concerns the utilization of the brewery, the equipment and the ingredients.

• But for the moment, we do not have all the answers yet.…we are working hard to setup

TO BE CONTINUED…



Elections of the Club’s Committee

• In the meantime, we have to setup a proper committee. The Club needs at a minimum a chairman and a treasurer but we have several other opportunities to offer (we actually need your involvement).

List of proposed candidates for the 2013-2014 year:• Chairman Jean-François Dufour• Treasurer and Procurement Officer _____________• Liaison Officer Martin Kaspers• Events Officer _____________• Engineering Officer Phil Blake

== PROCEED TO VOTE ==



Other roles to play in the Club

• We will create a great community.• But we are still in the development phase and we would enjoy having more

involved members to participate in our Core meetings.• These “Core Meetings” will take place regularly until we have a fully

functioning club • includes the brewery, the scheduling/organizing of events, the

monthly brewing sessions, etc.

We will pass a sheet: please add your name if you have the interest and motivation to be involved in these meetings!



Monthly Brewing Meetings

• The Monthly brewing meetings will have the following structure:• We brew a Club Beer with 1 Braumeister machine• During the Mash, we have discussions, presentations, tutorials,

guests, etc• (maybe we manage to do tastings in the future)

• In parallel, it is possible for a member (and friends) to use the other Braumeister machines to brew his e.g. first beer while everyone is around to support him. We will have 3 parallel chains possible (3 machines).

Craft Brew Board : Every single beer brewed in this facility will have to be written on the Craft Brew Board.

• This will help us track the utilization of equipment, facility, ingredients, fermenters, etc



The Brewing Process – a quick intro

• Types of Brewing Techniques



Ingredients

• There are 3 main ingredients: Malts, Hops and Yeast.• Ingredients will be provided by the Club for the first few months, then we will assess

if this is the best way to proceed.• Is this the best way to go? E.g. is it fair?• Other strategies will be evaluated

• E.g. 5kg of grains cost approximately 6EUR. • We could ask 5EUR per beer brewed to pay for the grains, and

we could include the hops for free.• Yeast is a little more tricky. Suggestion:

• The club could provide dry yeast for free• Liquid yeast costs 12EUR, therefore we have to discuss how to

proceed here (e.g. paid by the member)• We can promote techniques like Yeast Washing (harvesting

yeast from your primary fermenter and make it available for other brewers – storage in our fridge)



Brewing Equipment

• Presentation of Home Brewing Equipment• Presentation of our Brewery Equipment• How to use our equipment

Fermentation Chamber• The temperature-controlled chamber will be designed to host 20 fermenters. • Typical fermentation profiles should try to be as close as possible to:

• 1 week primary, 3 weeks secondary, then bottling. • 2-4 weeks primary, then bottling.• These are guidelines only, but just to avoid situations where a fermenter is

left 2 months and takes the space of others possible brewers. We will start like this and will review the situation after a few months of existence.



Safety

• Don’t hurt yourself• Notify the Committee when you notice safety issues/dangers• Don’t hurt yourself.



Any other Business

• The club is very very young and we did not have time to figure out all the answers and procedures we need.

• Here are some open items• Website Creation• Booking system for equipment/social






Introduction to Alcoholic Beverages

Robert S. WallaceDepartment of Ecology, Evolution, and Organismal BiologyIowa State UniversityAmes, Iowa 50011


Introduction to Alcoholic Beverages:

Beer



What is Beer?

1.A fermented (alcoholic) beverage derived from grains.

2.Flavorings are often added to balance residual sweetness of unfermented sugars and other polysaccharides; bitter flavors used most.

3.The fermentation organism is typically a yeast species within the genus Saccharomyces.

4.Most beers have natural or intentionally added carbonation.



Origins of Beer• Earliest evidence for the deliberate

production of beer dates to at least 5,500 BCE in Sumeria.

• Use of domesticated barley is evident from impressions of grains in vessels

• Original beers were likely spontaneously fermented, and may have been derived by soaking roasted barley cakes in water.

• Beers that had finished fermenting likely had sediment and floating debris; the clear liquid in the middle was drunk through reeds – precursors of our modern ‘straws’.



A Sumerian bas-relief sculpture depicting the drinking beer from amphora-like vessels.







• Selection for attributes of “full” heads that do not shatter, and multiple fruits drove the domestication process

• Different qualities selected for various uses of the grain: e.g. baking versus brewing.

6-row 2-row







• Palea and lemma remain in cleaned grains.

• These form the ‘husk’ that is desirable in barley to form the filter bed during mashing and sparging.







http://koti.mbnet.fi/pandion/maisemat.htm

http://koti.mbnet.fi/pandion/maisemat.htm



Malting

1.Malting is the process of germinating viable seed to allow the embryo to develop enzymes (amylases, and others) which are capable of breaking-down stored carbohydrates, typically in the form of starch, and then stopping this growth at a specific stage of development through kilning.

2.The process begins by imbibing the seed with water to initiate germination.

3.Germination under aerobic conditions continues until a critical stage of development, when the process is rapidly stopped by heating and drying the germinated seed.

4.Traditional malting techniques included carrying out this process on the floors of special facilities, and processing the germinating grains by hand.

5.Modern techniques involve bulk processing of grains in specialized malthouses, most involving the use of automated troughs or (Saladin) boxes in environmentally controlled conditions.


ESA UNCLASSIFIED – For Official UseFloor Malting - DeWolf-Cosyns Malting, Brussels, Belgium




ESA UNCLASSIFIED – For Official UseAdolph Coors Brewing Company, Golden, Colorado


ESA UNCLASSIFIED – For Official UseCargill Malting, Stevens Junction, Wisconsin



• Following imbibition of the grain in the steeping tanks, the grain is sent through pipes in a grain-water slurry.

• The grains fill a long trough which is kept under cool temperatures and high humidity which favors germination condition.

• A series of automated augers turn the grainbed during the germination process to assure uniformity and maintain aerobic conditions for the sprouting grains.

Malting: Filling the Saladin Box


ESA UNCLASSIFIED – For Official UseSaladin Box - Cargill Malting, Stevens Junction, Wisconsin




ESA UNCLASSIFIED – For Official UseAdolph Coors Brewing Company, Golden, Colorado





Kilning of Malt - I

1.Once the critical stage of germination and embryo growth has been achieved, the process needs to be abruptly stopped.

2.The germinated grain is transferred to a kilning box where hot, dry air is passed through the grain bed, which kills the embryo (without effecting the enzyme characteristics), and dries the malt to an acceptable moisture content.

3.The malt is then cleaned of rootlets and other structures, and prepared for packaging and shipment.

4.Extensive biochemical and physical assays determine the malts brewing (or other) characteristics.

5.Specialized kilning of certain malt products under a range of temperature and moisture conditions, for varying lengths of time, produce ‘specialty’ malts that are widely used in brewing.



Cargill Malting, Stevens Junction, Wisconsin



Kilning of Malt - II

1.Kilning done with wet malt under closed conditions results in “crystal” or “caramel” malt due to thermal saccharification of starches.

2.“Roasting” or dry kilning of malt results in ‘darkening’ or ‘browning’ of the grains due to Maillard reactions:

α-amino acids +sugars

melanoidins(Maillard products)[O2]

heat(colorless or pale)(dark color)



Malt color is determined by kilning – Measured in degrees Lovibond



Melanoidins contribute to beer color…..



Other Grains Used in Brewing

• A variety of grains other than barley are used in the brewing process as adjunct grains. These typically do not have the same enzymatic composition as barley, but do provide alternative sources of fermentable carbohydrates, along with a range of aromatic and other flavor compounds.

• Main Adjunct Grains:Wheat – Triticum aestivumRice – Oryza sativaOats – Avena sativaRye – Secale ceraleCorn – Zea maysSorghum – Sorghum bicolorMillet – Panicum milleaceum









Starch Conversion - Mashing

1.Necessary to activate enzymes produced by grass embryos by re-hydrating crushed grains.

2.Temperature raised to optimum temperature to enable enzymatic breakdown of starch into component sugars.

3.Selection of temperature and duration of mash will determine fermentability of the resulting wort.

4.Mashing also liberates medium molecular weight proteins which contribute to mouthfeel and heading characteristics.


ESA UNCLASSIFIED – For Official UseTeak Mash Tuns – Shepherd-Neame Brewery, Faversham, Kent, England


ESA UNCLASSIFIED – For Official UseTeak Mash Tun – Shepherd-Neame Brewery, Faversham, Kent, England


ESA UNCLASSIFIED – For Official UseMash Tun No. 1 – Fuller, Smith & Turner Brewery, Chiswick, London, England



Carbohydrate Components of Malt

• Poly 1,4 glucose, amylose (starch)- straight chains- simple, easily-digested by amylases

• Beta-glucans- have both 1,4 and 1,3 bonds- partially digestible with amylases

• Amylopectins - branched starch molecules - branching with 1,6 bonds typical - partially fermentable



Mashing – Amylase Activity

…G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G

…G-G G-G-G-G-G-G G-G G-G-G-G G-G-G-G G-G-G-G-G G-G

…G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G

…G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G-G G-G

…G-G-G-G-G-G-G-G-G-G-G-G-G-G-G G-G G-G G-G G-G G-G

Alpha Amylase (to = 158º F; 70º C)

Beta Amylase (to = 140º F; 60º C)



Sweet Wort and Boiling

1.Following mashing of the grain, the solubilized sugars and oligosaccharides in solution are run off the grain bed to a boiling vessel (the “kettle”).

2.The “spent” grain bed is washed with hot (170º F 77º C) water in a process known as sparging to dissolve residual sugars.

3.At this point, the sugar solution is termed ‘sweet wort’ which is then boiled for an hour or more.

4.During the boiling process, hops are added and a variety of chemical processes occur which result in the liquid becoming bitter; thus it is now termed ‘bitter wort’.



Hops – Humulus lupulus(Family Cannabaceae)1.Hops are dioecious vining perennials, having extensive

stem structures:a. Aboveground stems (bines) and leaves dying at the end of

the growing season in most areas.b. Belowground stems (rhizomes) and roots overwintering.

Rhizomes serve as primary means for vegetative (clonal) propagation of female plants for commercial production.

2.Desired product is the dried inflorescences (“strobiles” or “cones”) of the female plant which have lupulin glands on the bracts and bracteoles which subtend the minute flowers.

3.Male hop plants are used primarily for breeding purposes’ in some cases male hops are planted to assist in improving yield (e.g. British varieties).

4.Female inflorescences (“burs”) continue development even if flowers are not pollinated (wind).



Cannabaceae:

The Hemp/Hop

Family• Related to the Elm (Ulmaceae),

Mulberry (Moraceae) and Stinging Nettle (Urticaceae) families.

• Wind-pollinated.• Family with 2 genera:

Cannabis – 1 (2) species. C. sativa [hemp; marijuana]Humulus – 2 (3) species H. japonicus – Japanese hop H. lupulus – brewing hop


ESA UNCLASSIFIED – For Official UseCannabis sativa L. Hemp cultivar (male)



Humulus lupulus Brewing hop – (female)


ESA UNCLASSIFIED – For Official UseYakima Valley, Washington


ESA UNCLASSIFIED – For Official UseYakima Valley, Washington



• Desired product is the dried dried inflorescences (“strobiles” or “cones”) of the female plant which have lupulin glands on the bracts and bracteoles which subtend the minute flowers.

• Male hop plants are used primarily for breeding purposes’ in some cases male hops are planted to assist in improving yield (e.g. British varieties).

• Female inflorescences (“burs”) continue development even if flowers are not pollinated (wind).

Female inflorescences

of Hops (“Cones”)



Female hop Inflorescences: “Bur stage”• Female inflorescences have

all pistillate flowers with stigmas extending beyond bracts and bracteoles. This is considered the “bur stage”

• Stigmas are receptive to windborne pollen at this stage.

• Female inflorescences (“burs”) continue development even if flowers are not pollinated (wind).



Mature FemaleHop inflorescence

• Composed of bracts and bracteoles that completely cover the minute pistillate flowers.

• Compound inflorescences (groups of individual cones) arise from axillary branches.

• Hops are ready to harvest when the bracts and bracteoles become papery and somewhat dry. Lupulin production will have achieved its maximum at this stage.



Bract

Rachis (“strig”)

Bracteole





Hop Flowers• Female flowers are found in

the axils of each bract.• The ovaries are covered with

lupulin glands.• If flowers are pollinated, the

fruit that develops will be thin-walled and will surround a single seed.

• Unpollinated flowers will not develop fully, and the entire inflorescence may lack any fertile seed.









Hop Picking: Traditional Methods

• All picking was done by hand.• Extremely labor intensive.• Often carried out by migrant

or other seasonal workers.

• Paid for amount harvested.



Hop Harvest: High Trellis System



Harvested Not Harvested

Grandview, Washington





• Mature hop inflorescences (“cones”) are plucked from hop bines using wire “fingers” which are run against suspended bines.

• Cones are moved on to further cleaning operations.

• Leaf and stem material is then chopped-up, and sent to waste piles; this material is then spread on fields as ‘green manure”.

Mechanical Hop Picking





Traditional Methods: ‘Oast House’ – England – Typically coal fired.Hop Kiln – United States – Typically wood fired.

Both relied on convection and slatted floors.Fire risk was always high in these systems.Hops baled using ‘pocket’ technique, or screw type press.

Modern methods:Forced hot air, perforated floor system, over moveable cloth mesh.Careful monitoring of temperature and blower volume possible.Dried at ca. 150°-155° F for 8 to 12+ hours with forced hot air.Cooled without adding heat for ca. 1 hour at ambient temperature.

• Hops are considered ‘dry’ when the strig (rachis) becomes less pliable, and nearly snaps when bent, usually around 9% MC.

Experienced ‘hop dryer’ responsible for monitoring progress of drying operation.

Kilning





Hop Kiln:Slotted metal floor and net-like cloth covering.

• Allows for high volume of hot air to be blown underneath kiln to pass through the bed of drying hops.

• Cloth used to moved dried hops off of kiln and onto ‘baling floor’ following a period of cooling and conditioning.







• Forced hot air (approx. 150O to 155OF is pushed through bed of wet hops for 8 to 12 hours.

• Water removed rapidly; hop cones become “papery” and somewhat brittle.

• Upon cooling hops recover some moisture, and are allowed to cool for a period of time.

• The hops are then “dropped” off of the kiln, and prepared for baling.

Kilning Hops: Rapid and careful drying





Kilned hops allowed to cool; in some cases hops take up atmospheric moisture during cooling which makes them less brittle.

Hops from various parts of the kiln bed are mixed to assure uniform

overall moisture content.

Dried, cooled hops are then transferred to baling area.

Automated machines weigh 200 pound portions of dried hops which pass into a hydraulic press apparatus; bales are then compressed between pieces of burlap.

Burlap pieces are sewn shut, and the bale labeled, weighed, checked for moisture content and prepared for transport and cold storage.

Baling







• Compressed hops are then sewn into a bag made from burlap, a natural plant fiber made from jute (Corchorus capsularis; Tiliaceae).

• Once sewn shut, the weight is checked and the bales are set out to check moisture content.

• Physical quality of the hops is then assessed using a ‘hop tryer’ and a moisture meter.

• Once checked, the hop bales are then moved to cold storage.

Completion of Hops Baling: Burlap Cloth




ESA UNCLASSIFIED – For Official UseHopunion, Yakima, Washington







Kettle Reactions - BoilingBoiling accomplishes several positive processes for the wort prior to fermentation:• Sterilizes wort so that only desired fermentation

organism accomplishes the conversion of wort to beer.

• Coagulates protein which is removed from later stages; also may complex and remove solubilized tannins.

• Volatilizes undesirable compounds, e.g. dimethylsulfides (DMS) which would contribute negatively to aroma profile.

• Isomerizes hop-derived alpha acids to increase solubility, and contribute to bitterness flavor profile.



Kettle Reactions - Boiling• Female flowers are found in the axils of each bract.• The ovaries are covered with lupulin glands.• If flowers are pollinated, the fruit that develops will be

thin-walled and will surround a single seed.• Unpollinated flowers will not develop fully, and the

entire inflorescence may lack any fertile seed.

“Copper” CW 2 – Fuller, Smith & Turner Brewery, Chiswick, London, England



Isomerization of Humulone

HOHO

R

OOH

α-acids – (humulones)

iso-α-acids (*both cis- and trans- forms)

H

OHOHO

R

OO

**

“Bittering Components”

Isomerization

occurs during the

boiling process





Brewing Microbiology

1.Primary fermentation organisms are yeasts of genus Saccharomyces:

S. cerevisiae – ale strains; wine strains, baking strains

S. delbrückii – weizen beer strainsS. carlsbergensis (syn. S. uvarum) – lager strains

2.Highly diverse range of yeasts and bacteria reported from spontaneous lambic beer fermentations:

Yeasts: Brettanomyces, Kloeckera, Saccharomyces; Bacteria: Citrobacter, Enterobacter, Hafnia, Klebsiella, Pediococcus.

3.Certain beer styles include fermentation with anaerobic lactic fermentative organisms: e.g. Lactobacillus

4.Contaminant organisms (e.g. Pediococcus) found almost ubiquitously in brewery settings; constant screening to avoid spoilage.



Anaerobic Fermentation:Sugars to CO2 and Ethanol

CC

C

CC

OH

H

H

HH

CH2OH

HOOH

OH

OH

pyruvicacid

glucose H3C-C-C-OH

O O

carbondioxide O=C=O

H3C-CH=Oacetaldehyde

H3C-CH2-OHethanol

+

2X





Workhorses of Brewing Fermentation:

Yeasts.• Yeasts are unicellular

ascomycete fungi with no (or sporadic) sexual stages.

• Reproduction occurs primarily through asexual ‘budding’ or clonal growth through simple mitotic cell division.

• Capable of aerobic and anaerobic metabolism.



Traditional Fermentation:Open System

• Open top fermenters protected by a blanket of carbon dioxide during fermentation.

• Typical of ale fermentations which are “top fermenting”.

• Sanitation is a primary concern; contamination risk is high.

• Modern systems utilize closed fermentation.



Modern Fermentation – Closed systems

Redhook Brewery, Woodinville, Washington





Conditioning

• Beer requires a period of post-fermentation conditioning.

• Flavors “mature” through this conditioning period.

• If conditioning is done “cold”, it is referred to as ‘lagering’.

• Carbonation usually also associated with the conditioning process.



Packaging: Bottling• Often done at high rates.• Beer condition improved if air is

excluded.• Must proceed in a sanitary and

efficient manner.• Also must avoid high temperatures.

Shepherd-Neame Brewery, Faversham, Kent, England



Packaging: Kegging• Traditional kegs made

from wood.• Modern kegs are

stainless steel, typically 15.5 US gallons.

• Maintained in cold condition, or beer is flash pasteurized.

• Dispensed with carbon dioxide system.

Stoudt Brewery, Adamstown, Pennsylvania



Beechwood Aging at Anheuser-Busch





“Evolution” of Beer Styles1

1Adapted from M. Jackson, 1988

Witbier

Weizen

Berliner Weisse

Belgian Lambics

Stout

Porter

Brown Ale

India Pale Ale

Barley Wine

Altbier

Belgian Ale

Trappist Ale

Cream Ale

Pale Ale - ESB

S. delbruckii

S. cerevisiae

S. carlsbergensis

pure strain

lactic fermentation

spontaneous fermentation

wheat beers

roasted barleydark malt

Ales

+ corn

pale malt

increasing hops & gravity

Lagers

“bottom-fermenting”

“top-fermenting”

PilsenerDortmunder ExportViennaMärzen/OktoberfestMunichBock

Belgium/NL

Germany

UK

US

+ hops

+ malt

+ malt & sugar



Beer Summary1.Beer is among the oldest beverages made

by humans, and has persisted through thousands of years of human development.

2.Both barley and hops require extensive post-harvest processing before the plant material becomes suitable for use in the brewing industry.

3.Beer is a multi-faceted beverage with a rich, intimate history involving plant domestication, selection, and breeding.

4.Beer is one of the “universal” beverages found in most societies around the world.



Documents

ESTEC Home Brewing Club First Monthly brewing session