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WEYERMANN® Specialty Malts Influence on wort and beer quality
September 2018
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Alirio Caldera
• Weyermann® International Customer Consultant
• MSc. Brewing Science and Beverage Technology
• Chemical Engineer
• Beer Sommelier
Speaker Introduction
Weyermann® - all rights reserved 2
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• Introduction Weyermann® Company
• Weyermann® Specialty Malts Production
• Quality Assurance by Weyermann®
• Development of Color in the Roasting and Brewing Process – A Quality Review
• pH Influence on the Quality of Wort and Beer
• Beer Recipes with Weyermann® Sour Products
• Weyermann® World
Presentation Overview
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Weyermann® - all rights reserved 4
Weyermann® History
1600 1879 1904
The first Weyermann family
members were fishermen and
skippers on the Main/Regnitz
rivers around Bamberg
Johann Baptist Weyermann
started to roast barley under a
tent
Mich. Weyermann® Malthouse:
the first pneumatic Malthouse in
the world
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Weyermann® Family-owned and -operated
• Family Tradition
and Competence
in the 4th Generation!
• Sabine Weyermann and
Thomas Kraus-Weyermann
• Weihenstephan trained
Husband and Wife Team
• The 5th Generation, Franziska
Weyermann, joined the
management team in 2017
Weyermann® - all rights reserved 5
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Weyermann® Malthouse & Head Office Bamberg
Weyermann® - all rights reserved 6
Weyermann® Production Sites
Interesting facts: with more than 300 local breweries, Bamberg has the highest
brewery density in the world with a per capita consumption of approx. 280 L/person
every year
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Weyermann® Malthouse Hassfurt, Grain Elevator Leesau and Malthouse Clingen
Weyermann® - all rights reserved 7
Weyermann® Production Sites
Clingen – 2017Moving Piece Malting
Hassfurt – 2001Base Malts
Leesau – 2005Grain Elevator45.000 Mton
Continuously growing, continuously reinvesting!
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Weyermann® - all rights reserved 8
Weyermann® Regional Grain Supply
Northern Bavaria
Saxony
Thuringia
Bohemia in Czech Republic
Growing Area for Authentic
Bohemian Barley Varieties
Venice - Italy
Terroir Malt Eraclea
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Weyermann® - all rights reserved 9
Weyermann® around the Globe
Weyermann® Malt is the soul of beers in over 135
countries – in all continents!
Weyermann® customer network of round 5.000 brewing and
distilling happy passionates!
Weyermann® offers 85 different
products including liquid extracts!
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Weyermann® - all rights reserved 10
Weyermann® Raw Materials
All raw materials come from local farmers – 85% fixed contracts
2-Row-Barley Wheat Rye Spelt
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Weyermann® - all rights reserved 11
Weyermann® Malts Color Specifications and Products
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• Introduction to the Weyermann® Company
• Weyermann® Specialty Malts Production
• Quality Assurance by Manufacturing Weyermann® Malts
• Development of color in the roasting and brewing process – A Quality Review
• pH influence on the quality of the wort and beer
• Beer recipes with Weyermann® Sour Products
• Weyermann® World
Presentation Overview
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Weyermann® - all rights reserved 13
Weyermann® Specialty Malt Production Process
2
4
5
1
6
3
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Weyermann® - all rights reserved 14
Weyermann® Base Malt Production
Steeping Vessel
60 tons (1 of 4)
One Floor
High Capacity Kiln (1 of 4) Germination Box
120 tons (1 of 8)
Quality aspects:
- Constant steeping temperatures
- Treated spring water (RO-Water)
- Odorless water
Quality aspects:
- Two laboratory analyses per day
- Continuous temperature monitoring
- Thin bed layer
Quality aspects:
- Thin bed layer
- Exact temperature control
- Exact air flow control
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• Complete caramelization
• Typical caramel to bread aroma
• Homogeneity
• Glassy, caramelized texture
• No friability test applicable
• Enhances foam stability
• Improves aroma, body, flavor
Weyermann® - all rights reserved 15
Homogenously manufactured Caramel Malt
➔Weyermann® has developed gentle caramelization processes to assure the best
flavor and color, without overheating the malt → true caramel color and aroma!
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Weyermann® - all rights reserved 16
Weyermann® Caramelization Drum
100°C
80°C
50°C / 122°F
65°C
130°C/266°F
Cara
meliz
ation
70°C/158°F
60°C
50°C
28°C//82°F
40°C
Kiln
Comparasion3
- Cost-cutting budget production
- Temperature difference green malt bed
- Inhomogeneous temperature
- Inhomogeneous saccharification
- Not every kernel reaches the required temperature
- Lack of caramelization
- Inhomogeneous malt
- Lack of caramel flavor
- Lack of typical caramel malt colors
+ State of the Art production process
+ Rapid and evenly temperature change
+ Homogeneous temperature
+ Homogeneous saccharification
+ All kernels reach saccharification temp.
+ Perfect Caramelization
+ Max. Homogeneity of the malt
+ Typical caramel flavor
+ Typical caramel malt colors
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70°C
158°F
70°C
158°F
Saccharification
130°C
266°F
130°C
266°F
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Caramel Malt Production
Weyermann® - all rights reserved 17
Weyermann® CARA_Products line
Green Malt
(from Germination Box)
Caramelization DrumSaccharification and Caramelization
Color and Caramel Aromas develop
Caramel Malt(Ingredient for Breweries
and Food Industry)
Rootlets
Energy
RecoveryEnergy
Approx. 45% H2O
6 – 8 % H2O
3-4 hours
Moisture
from 70°C to 200 °C
SugarCaramelization
temperature [°C]
Fructose 110
Glucose 160
Sucrose 160
Maltose 180
Starch
Simple sugars
Caramel compounds
a- and b-Amylase
Dheat
~70°C
>70-200°C
Not exogenous enzymatic cocktails!
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Roasted Malt Production
Weyermann® - all rights reserved 18
Weyermann® CARAFA®
Kilned Malt
(from Kiln)
Roasting DrumRoasting
Color and Roast Aromas develop
Roasted Malt(Ingredient for Breweries
and Food Industry)
Rootlets
Energy
Recovery
Energy
Approx. 5% H2O
3% H2O
3-4 hours
Moisture
Up to 250 °C
Water dosage
+ Better reaction control
+ Caramel and pleasant
chocolate flavor is
developed
+ The steam formed
removes burnt flavor
+ debitters the malt
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Weyermann® - all rights reserved 19
Weyermann® Specialty Malt Production Process
Base Malts
Technical
Malts
Roasted
Malts
Caramel
Malts
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• Introduction to the Weyermann® Company
• Weyermann® Specialty Malts Production
• Quality Assurance by Manufacturing Weyermann® Malts
• Development of color in the roasting and brewing process –A Quality Review
• pH influence on the quality of the wort and beer
• Beer recipes with Weyermann® Sour Products
• Weyermann® World
Presentation Overview
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Weyermann® - all rights reserved 21
Weyermann® Quality Concept
How do we assure the quality of our malts?
• Local farmers
• Own grain storage capacity to ensure continuously production and availability
• Gentle Moisture adjustment (if >14,5%)
• Temperature monitoring during the storage and aeration if needed (inside the silo)
• Only 2-row Spring Barley bigger than 2,5mm
Raw Material Supply
• The barley is cleaned 4 times before starting the malting process
• After kilning/roasting the product is cleaned 2 times = 6 cleaning steps!
• Production areas dust and grain free
• HAACP
Cleaning concept
• Modern technology available
• Continuous monitoring of every single process step
• Every batch is at least 14 times analyzed in the laboratory
• Traceability back to the farmer who supplied the initial grain → 24 months
Production process
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Weyermann® - all rights reserved 22
Weyermann® Quality Concept
How do we assure the quality of our malts?
• 25-kg Bags according to the bulk density of the material → reduced contact with air
• High density polyethylene bag inside → no aroma losses, reduced air exchange
• Exclusive usage of new pallets
• Isolated palletizing → plastic layers at the bottom an top of the bags → no contact with the exterior
Packaging & Palletizing
• Only odorless and new canisters
• Hot filling
• CO2 - Headspace
• 4 separation processes to assure no turbidity (Sinamar)
Sinamar® and Liquid Extracts
•ISO 9001
•FSSC 22000
•Bioland – Biosuisse Organic – USDA Organic
•Demeter
•KIWA BCS Öko-Garantie
•Federation of Synagogues Kosher Certificate
Certifications
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• Introduction to the Weyermann® Company
• Weyermann® Specialty Malts Production
• Quality Assurance by Manufacturing Weyermann® Malts
• Development of color in the roasting and brewing process – A Quality Review
• pH influence on the quality of the wort and beer
• Beer recipes with Weyermann® Sour Products
• Weyermann® World
Presentation Overview
Weyermann® - all rights reserved
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Development of color in the roasting and brewing process – A Quality Review
Photograph: J. Kenji López-Alt
• Color is formed in malt and wort in the same way as in other foodtypes, mainly due to the Maillard Reaction.
• Every time we put a steak on our barbecue and the color of themeat turns from red to cooked, dark, etc., we are promoting thenon-enzymatic browning caused by the Maillard Reaction.
• The Maillard Reaction occurs during thermal processing of foodsuch as roasting meat, coffee, malt and baking bread.
• The substances responsible for this browning of meat andmalt/wort are called melanoidins.
• Melanoidins are brown, high molecular weight polymers that areformed at high temperatures.
• Melanoidins not only lend food and beverages a brown color, butalso affects the taste and smell.
• This sensory effect could be positive if the browning process isdone right, or could be unpleasant to the palate if done wrong.
Source: https://bbqpit.de/beef-jerky/
Weyermann® - all rights reserved
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How is color developed in the roasting and brewing process?
• Maillard Reaction and production of melanoidins
Reducing sugar(sucrose, maltose)
Starch
a-Amylaseb-Amylase
• Sugars and amino acids are the
starting components
→ all of them are built during the
malting process and (mainly) in the
mashing process
• The goal is to build melanoidins and
avoid formation of Strecker aldehydes
and specifically their precursors
(dicarbonyls)
• Strecker aldehydes are strong aroma
active and are related to the beer
aroma staling
• Strecker aldehydes and intermediaries
are formed mainly during wort boiling
Proteinsmalt proteases
Weyermann® - all rights reserved
Maillard
Reaction
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Maillard
Reaction
Weyermann® - all rights reserved 26
Development of color in the roasting and brewing process – A Quality Review
Roasting process
Brewing process
Melanoidins
(red) Color
Caramel
Roast
Chocolate
Strecker
Aldehydes
Stale flavors
Poor flavor stabilitySource: http://www.picklejarstudios.com/potato-beer-
gratin/
antioxidants
Better flavor stability
➔ Let the color of the beer come from the Weyermann® Products and not from overboiling your wort at the
brewhouse or letting it sit too long inside the whirlpool
➔ Avoid any oxygen contact or too strong stirring (vortex formation) during the process → Oxidation of
polyphenols leads to darker colour and unpleasant bitterness in the beer
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Development of color in the roasting and brewing process – A Quality Review
• Factors promoting the color forming substances and avoiding the Strecker aldehydes
Malting process:
• Controlled low temperatures during the first step of kilning
• Homogeneous distribution of the heat during the caramelization or roasting
process
→ roasting drums instead kilns
• Minimal thermal load
→ on-site controlling of the color to finish the roasting when desired color
intensity is achieved
Brewing process:
• No overproduction of amino acids during the mashing process
• No long boiling times
• Usage of sour malt in the malt bill → proteases have mainly basic pH-optima
• Usage of sour extract to lower the wort pH → better break formation, slower
Maillard Reaction kinetics
Weyermann® - all rights reserved
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Weyermann® - all rights reserved 28
Development of color in the roasting and brewing process – A Quality Review
• Weyermann® Melanoidin is a kilned specialty
malt with an intense malt aroma and unique
brewing characteristics.
• It has a high degree of modification of both
proteins and starches, excellent friability, low β-
glucan values, and high acidity.
• These attributes help promote flavor stability,
add body, and produce a smooth mouthfeel.
• Weyermann® Melanoidin malt adds a deep
amber to red-brown color to finished beer.
• The rich malt flavor has notes of honey and
biscuit.
• Melanoidin malt is best used in dark or red-
colored beers such as amber ales, Scottish ales,
Irish red ales, bocks, and Kellerbier.
• Usage rate: up to 20%
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• Introduction to the Weyermann® Company
• Weyermann® Specialty Malts Production
• Quality Assurance by Manufacturing Weyermann® Malts
• Development of color in the roasting and brewing process – A Quality Review
• pH influence on the quality of the wort and beer
• Beer recipes with Weyermann® Sour Products
• Weyermann® World
Presentation Overview
Weyermann® - all rights reserved
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Biological Mash and/or Wort Acidification in the Brewhouse
Weyermann® - all rights reserved 30
• Enhanced enzymatic degradation of materials
• Higher levels of growth-promoting substances
• Suppression of lipoxygenase activity
• Better lautering performance
• Enhanced redox potential, i.e. reduced
susceptibility to oxygen
AND / OR
pH = 5.6 – 5.8 pH = 5.2 – 5.4
Malt
Acidulated malt
Water Sour wort
Mash tun
Mash acidification
• Less color formation
• Enhanced protein coagulation/precipitation
• Improved sensory quality
• Increased chemical-physical stability
• Enhanced microbiological stability
Wort acidification
Wort kettle Whirlpool
pH = 5.3 – 5.7 pH = 5.0 – 5.2
Sour wort Sour wort
or
Hops
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pH-adjustment using Weyermann® Acidulated Malt
Weyermann® - all rights reserved
• Use of Acidulated Malt can lower wort pH
resulting in better mash efficiency,
intensified fermentation, lighter color,
improved flavor stability and enhanced
flavor.
• Usage rate: 1-5%
• Usage rate: up to 10% (for sour beers)
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• Raw materials used for sour wort production
• Sour wort fermentation
• Concentration of produced sour wort
Weyermann® - all rights reserved 32
pH-adjustment using Weyermann® Sour Wort
conform to the
German Purity Law
Weyermann® / Doehler Sour Wort -
Specification
Parameter Unit Value
Lactic acid g/L 52 – 58
pH - 2.9 – 3.2
Density g/cm³ 1.271 – 1.311
Brix °Bx 58.0 – 63.0
Shelf-life (unopened package): 360 days – Storage at 20°C
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State-of-the-Art Fermentation Technology and Aseptic Filling
Weyermann® - all rights reserved 33
Under CO2 atmosphere,
the sugar in the wort is
converted into lactic acid
by a pure culture of lactic
acid bacteria, namely
L. amylolyticus.
Malt is produced from
barley through steeping,
germination and kilning in
order to completely break
down cell walls, partially
break down proteins and
generate enzymes.
Malting Fermentation FillingWort preparation
Using a classical infusion
mashing process, the valuable
substances of malt grist are
brought into solution. The final
mash is filtered resulting in the
so-called wort.
With the help of
an aseptic filling
machine, the sour
wort is filled in
optimal packages (Bag-in-Box 20 kg).
Activities DöhlerGroup
LAB Fermentation
Products
WortMalt Weyermann® / Doehler Sour Wort
LAB
Steeping
Germination
Kilning
Grain
Water
Air
AirAir
Boiling Separation
Wasser Wasser
Milling
Mashing Lautering
Concentration
The sour wort is
concentrated by
performing a gentle
vacuum
evaporation
(water).
Evaporation
Filling
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Brew 1: Mash acidification using
sour malt (Reference)
Brew 2: Mash acidification using
sour malt, wort acidification using
Weyermann®/Doehler Sour Wort (boiling)
Brew 3: Mash and wort acidification
using Weyermann®/Doehler Sour Wort
Weyermann® - all rights reserved 34
Practical test of the Sour Wort in a Medium-Sized Brewery
Unit Brew 1 Brew 2 Brew 3
Grist load
Pilsner malt kg 2,850 2,850 3,000
Sour malt kg 150 150 0
Percentage % 5 5 0
Cast-out wort
Extract % 12.0 11.9 12.1
Volume hL 199 199 198
Weyermann® /
Doehler Sour Wort
Addition to mash kg 0 0 51.5
Mash pH - 5.35 5.36 5.35
Addition to wort kg 0 57.6 62.2
Cast-out wort pH - 5.32 5.02 4.98
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0
50
100
150
200
250
300
Heatindicators
Oxygenindicators
Agingcomponents
Heatindicators
Oxygenindicators
Agingcomponents
Brew 1 Brew 2 Brew 3
Weyermann® - all rights reserved 35
Results | Aging Indicators in Fresh/Forced-Aged Beer
Fresh beer
Brew 3 lowest
concentration of aging
indicators
Forced-aged beer
Reduction of aging indicator levels
by using Weyermann®/Doehler
Sour Wort in mash and/or wort
Su
m [μg/L
]
Conclusion:
Application of Weyermann®/Doehler
Sour Wort in mash and/or wort
significantly increases the flavor
stability of beer
Brew 1: Mash acidification using sour malt (Reference)
Brew 2: Mash acidification using sour malt, wort acidification using
Weyermann®/Doehler Sour Wort (boiling)
Brew 3: Mash and wort acidification using Weyermann®/Doehler Sour Wort
Fresh beer Forced-aged beer
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• Standardized and cost-effective quality product:
• Production of Weyermann®/Döhler Sour Wort
using state-of-the-art fermentation technology
• No cost-intensive installations; no time-consuming
handling of lactic acid bacteria cultures in the brewery, etc.
• High microbiological stability and long shelf-life
of the Sour Wort due to aseptic filling
• Easy handling and dosage due to optimal, recloseable packaging type
• Low dosage quantities: Only 15% of the amount of traditionally
used sour wort required
• Application according to the German Purity Law
for naturally reducing the pH of mash and wort
• Significant improvement of flavor stability and „drinkability“ of beer
Weyermann® - all rights reserved 36
Our new Product – an efficient & flexible alternative or addition to Sour Malt or Self-Production
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• Introduction to the Weyermann® Company
• Weyermann® Specialty Malts Production
• Quality Assurance by Manufacturing Weyermann® Malts
• Development of color in the roasting and brewing process – A Quality Review
• pH influence on the quality of the wort and beer
• Beer recipes with Weyermann® Sour Products
• Weyermann® World
Presentation Overview
Weyermann® - all rights reserved
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Weyermann® Specialty Malts produces 85 different products, among them:
• Base Malts Pilsner, Pale Ale, Vienna, Munich, Wheat
• Premium Base Malts Terroir, Heirloom, Traditional Floor-Malting
• Technical Malts Carapils®, Carahell®, Acidulated, Melanoidin…
• Smoked Malts Beech Smoked Barley, Oak Smoked Wheat
• Belgian Style Malts Abbey Malt®, Special W®, Carabelge®
• Caramel Malts Carared®, Caraamber®, Caramunich®…
• Chocolate Roasted Malts Carafa®, Carafa® Special…
Weyermann® - all rights reserved 38
Weyermann® Specialty Malt Varieties
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Weyermann® Bohemian Pilsner
92%
5%
2%
1%
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Weyermann® - all rights reserved 40
Floor-Malted Bohemian Malt
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• Original gravity: 11.8 °P (1.0480)
• Alcohol by volume: 4.7 % CO2-Content: 4.5 – 5.5 g/l
• Mash (Infusion): Mash in at 50°C and rest for 10 min,
heat up to 63°C and rest for 45 min, heat up to 68°C
and rest for 5 min, heat up to 72°C and rest for 20 min,
Mash out at 78°C
• Hops: 35 BU (Saazer Aroma Hop)
• Yeast recommendation: Fermentis® Saflager W34/70
Weyermann® - all rights reserved 41
Weyermann® Bohemian Pilsner
Exclusive use of Saazer hops in this bright golden Pilsner achieves a light fruity and floral aroma, reminiscent
of citrus fruits, as well as giving a distinctive bitterness on the palate. Alongside its refreshing carbonation this
beer is presented with a fine malty body utilizing the finest Weyermann® Bohemian Floor Malt.
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Weyermann® - all rights reserved 42
Imperial Stout with Weyermann® Malt
77%
10%
6%
5%
2%
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• Original gravity: 1.0777 (18.8°P)
• Alcohol by volume: 8.0% CO2-Content: 4.5 – 5.5 g/l
• Mash (Infusion): Mash in 55°C (131°F), 60 min 63°C (145°F),
20 min by 72°C (162°F), Transfer by 78°C (172°F)
• Hops: 38 BU (Green Bullet), 10 BU (Williamette)
• Yeast recommendation: Fermentis® Safbrew T-58
Weyermann® - all rights reserved 43
Imperial Stout with Weyermann® Malt
The Imperial Stout is crowned with a foam that makes every cappuccino look flat in comparison. It is noble and piercingly
black, just like Ivory. The fine aroma of licorice is underlined by the warming notes of the alcohol. Beginning with the unique
taste of exquisite bitter chocolate and the finest coco notes and then moving into to the distinctive and mouth filling roast
flavor. Perfect dose of bitterness as ideal balance to malt sweetness.
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Weyermann® - all rights reserved 44
IPA with Weyermann® Malt
89%
10%
1%
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Barley Wine with Weyermann® Malt
83%
10%
5%
2%
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• Pilsner
• Lager
• Wheat
• Ales
• IPA`s
• Strong
Weyermann® - all rights reserved 46
Beer Styles made with Weyermann® Specialty Malts
• Porter
• Stout
• Smoked Beer
• Sour
• Belgian Beers
• Barrel-aged Beers
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Weyermann® Specialty Malts
Weyermann® - all rights reserved 47
The presence of beauty in your beers
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• Introduction to the Weyermann® Company
• Weyermann® Specialty Malts Production
• Quality Assurance by Manufacturing Weyermann® Malts
• Development of color in the roasting and brewing process – A Quality Review
• pH influence on the quality of the wort and beer
• Beer recipes with Weyermann® Sour Products
• Weyermann® World
Presentation Overview
Weyermann® - all rights reserved
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Weyermann® - all rights reserved 49
Weyermann® Spirits
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Weyermann® Visitors Center Bamberg
Weyermann® - all rights reserved 50
Feel Invited!
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Weyermann® - all rights reserved 51
Alirio Caldera
International Customer Consultant
e-mail: [email protected]
Whatsapp: +49-162-2082153
Thank you very muchfor your attention!: weyermannspecialtymalts
@weyermann_specialty_malts