Tully Hadley (MBrew)
Dynamic Dry Hopping for Aroma
Utilisation : A New Technique
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 2
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 3
Outline
1. What is the problem we are trying to solve?
2. What tools do we have at our disposal?
3. What research did we do?
4. Lab scale trials
5. Small scale trials
6. Commercial Implementation
7. Learnings
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 4
What is the problem we are trying to solve?
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CUB Dry Hopped Brands
2010 2011 2012 2013 2014 2015 2016 2017
Vo
lum
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Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 5
What is the problem we are trying to solve?
Large scale brewing of dry hopped brands
presents some issues for brewing at scale:
5000hL X 200g/hL = 1000kg of hop pellets
A 5000hL fermenter is 5 stories high!
Existing FV
Increasing Hopping
Rates
Growth of Dry
Hopped Brands
.
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 6
Objectives
Match current brand sensory profiles
No negative impact to beer quality
More efficient slurrying system
Reduced beer loss
Increase utilisation of aroma hops
Sustainable yeast re-pitching strategy for dry hopped beer
Integration with existing assets
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Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 7
What tools do we have at our disposal?
• Partnering with Industry OEMs
• Pilot Research Brewery
• Experimental Brewery
• CUB Hop Volatile analysis techniques
• Trained hop profiling sensory panel
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 8
What was the idea?
• Alfa Laval Rotary Jet technology (Iso-Mix) is used widely in our
company
• Adapt this technology to the Dry Hopping process
• Use the Rotary Jet Mixer to mix beer and hops
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 9
What was the idea?
Increased efficiency of aroma compound extraction
Increased homogeneity
Decreased extraction of unwanted polyphenols (harsh, astringent)
Homogenous feed to centrifuges to overcome overloading issues
Prevent hop particle settling
Reducing dissolved CO2 could aid with flocculation of ale strain yeast
Efficient hydration of all hop particles to prevent flotation
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The idea of keeping hop slurry in solution with fermenting or fermented beer
could have several advantages:
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 10
Dynamic Dry Hopping Design
Hop Slurrying and Transfer Minimise Manual Handling
Ensure System Cleanliness
No oxygen ingress
Process Flexibility
Hop / Yeast Separation Ensure Adequate Separation
Minimise Beer Losses
Maximise Yeast Harvest
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 11
Dynamic Dry Hopping Processes
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Dry Hopping No oxygen ingress
Maximise Extraction Efficiency
Ensure Homogeneity
Process Flexibility – Warm, Cold, During or End of Fermentation
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 12
Lab Trials
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Tim
e (
min
s)
Temperature (deg C)
Hop Pellet Dispersion Time
Deaerated Water (4°C) : low oxy but
long mixing time
Decreasing dispersion time with
increasing temperature
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 13
Lab trials
Increasing extraction
of volatile aromatics
with temperature
But….. i reasi g volatilisation also
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Hop Volatile Extraction
4°C
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60°C
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 14
Pilot plant trials
Iso-Mix technology installed into Unitank (15 hL)
Process variables determined through a series of trial and control brews
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EoF 4 8 16 32 Storage Control
Storage
Linalool
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 15
Pilot plant trials Dynamic Dry Hopping shows extraction occurs very quickly
Volatilisation losses occur over time
Extraction efficiency is higher than conventional dry hopping process
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 16
Pilot plant trials
Isomix S1 Cntr Isomix S1 T1
Floral
Liking
Intensity
Body
Sweet
Bitter
Malty
Estery
Hop Ester
Spicy
Resinous
Sulphury Fruit
Green
Citrus8
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Control Dynamic Dry Hop
Hop Profile
Answers taken Product Preferred
22 Control 10
Dynamic Dry Hop 12
Paired comparison Sensory Testing
No statistically significant difference in
preference for Control or Dynamic Dry
Hopped beer
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 17
Commercial Implementation
• With the technical support of Alfa Laval and Matrix Process Solutions, Iso-Mix
installations were commissioned on 2 x 2200hL vessels at the Abbotsford
Brewery in Melbourne
• CUB built a custom designed hop slurring and transfer system
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 18
Commercial Implementation
Beer is pumped out of the vessel cone
Pumped back to the fermenter
Up into the rotary jet mixer
Hops introduced from slurry system
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 19
Hop/Yeast Separation
0%
20%
40%
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100%
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Cu
mu
lati
ve
Pe
rce
nta
ge
(%
)
Time (min)
Hop Particle and Yeast Settling
Maximum Hops Settling Rate
Average Hops Settling Rate
Minimum Hops Settling Rate
Maximum Yeast settling Rate
Average Yeast Settling Rate
Minimum Yeast Settling Rate
ℎ = 𝑉𝜋 tan2 303
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 20
Commercial Implementation
Calculations showed that hop and yeast particles could be physically separated by
time.
Experimental work showed that hop slurry settled to the bottom of the cone
within 3.5hrs and then yeast would begin to settle.
If too much yeast was able to settle, hop material would become compacted and
block pipework.
You can achieve a clean hop/yeast interface with minimal beer loss and maximise
yeast collection.
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 21
Commercial Implementation
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200 Hop Aroma Analysis
Dynamic Dry Hopping vs Traditional Method
Traditional
Dynamic Dry Hop
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 22
Outcomes
1. Match current brand sensory profiles
2. No negative impact to beer quality
3. More efficient slurrying system
4. Reduced beer loss
5. Increase utilisation of aroma hops
6. Sustainable yeast re-pitching strategy for dry hopped beer
7. Integration with existing assets
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 23
Learnings
Get the hop/yeast interface correct!
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Learnings
• Hop material can partially block Rotating Jet Head gearing – still get liquid flow
through nozzles, but no 360o rotation. Need to carefully control the initial slurry/beer
ratio to ensure no blockage.
• Very suitable for Ale Strains because they wo ’t flo ulate at fermentation
temperature, good separation. Lager strains can flocculate with hops.
• Micro – hops are stable, infections can occur when resins build up on conveying and
transfer equipment. Minimise e ha i al ha dli g of hops, or etter still do ’t use any.
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 25
Learnings
Drawing on the experiences at Abbotsford and other sites, Alfa Laval has developed a
special version of the Iso-Mix technology especially for dry hopping.
The new external drive (motor-driven) Rotary Jet Mixer separates the rotation drive
from the fluid circulation flow, allowing the mixer to handle high concentrations of
particles such as hops without plugging or rotation stoppage issues.
The new technology is presently in testing in several locations in our region and
elsewhere in the world, and will be officially launched by Alfa Laval later this year.
Acknowledgments
• Sam Seward (Engineering)
• Claude Nyaguy & Drew Parker (Research Brewery)
• Mark Goldsmith (Raw Materials Specialist)
• Melinda Christofersen (Analytical Services)
• Alyce Hartvigsen (Alfa Laval)
• Katie Jessup (Engineering)
• Jaideep Chandrasekharan (Chief Brewer)
• James van der Watt and Trevor Cowley(SABM Research Brewery,
Nottingham)
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 26
IBD PPT – Final Slide