Bad Weather Doesn’t Have to Mean Bad Business: Let Enzymes Help

Brewing with Enzymes by NOVOZYMES

North America
Alex Merz [email protected]
Europe
Brewing Engineer [email protected]
NOVOZYMES EU
Novozymes A/S is the largest global biotechnology
company, headquartered in Bagsværd, Denmark.

• Our focus is research & development and production of

industrial enzymes, microorganisms, and
biopharmaceutical ingredients.
Agenda

• Enzymes
• 101 Make it smaller all 5
will fit
• In brewing
• Assisting with low
quality barley/malt
• Lowering high
energy costs
Enzyme 101

Active proteins
In all living organisms
• Plant
• Animal
• Microorganisms-fungal,
bacterial

Specific
Works under mild conditions
Can replace/reduce chemicals
 pH effect
Enzymes need specific conditions to
perform 100

Activity peak

Activity (%)
Relative
80
Universal factors Situational factors

60
5.2 5.6 pH
pH Temperature Solids level Oxygen
Temperature effect
Enzyme
Time Stabilizers Inhibitors 100
dosage
Water Activity peak

Activity (%)
quality

Relative
80

60 55 oC 75 oC Temperature
~10.000 BC
~2.000 BC
1425 AD
1516 AD
~1900 AD

Enzymes in brewing: expressed during malting

needed for degradation of starch and other high
molecular components
 Enzymes expressed during barley malting
Topt [°C] pHopt Substrate Product
α-Amylase 65 – 75 5.6 – 5.8 High- and low molecular α-glucans Oligosaccharides

β-Amylase 60 – 65 5.4 – 5.6 α-glucans Maltose

Limit dextrinase 55 - 60 5.1 Limit dextrins Dextrins Process
…
limitations
Topt [°C] pHopt Substrate Product
Endopeptidase 45 – 50 3.9 – 5.5 Proteins Peptides, free AS
Carboxypeptidase 50 4.8 – 5.6 Proteins, Peptides Free AS
Aminopeptidase 45 7.0 – 7.2 Proteins, Peptides Free AS
Dipeptidase 45 8.8 Dipeptides Free AS

Topt [°C] pHopt Substrate Product

β-Glucan Solubilase 62 – 65 6.8 Matrix bound β-Glucan Soluable high molecular
β-Glucan
Endo-1,3- β-Glucanase <60 4.6 Soluable high molecular Low molecular
β-Glucan β-Glucan
Endo-1,4- β-Glucanase 40 – 45 4.5 – 4.8 Soluable high molecular Low molecular
β-Glucan β-Glucan
…
Goal of mashing
Solubilize key malt/adjunct constituents
(sugars, starch, amino acids, peptides,
protein)
Hydrolyze high molecular components into
fermentable molecules (starch, sugars;
protein, peptides amino acids)
• Malt delivers both the substrate (i.e. starch,
protein) and the enzymes (catalyst) transforming
it into components fermentable by brewing yeast
• Applying the right biochemical and physical
conditions (pH, temperature, water: grist ratio,
content of ions etc.) in order to maximally utilize
the malt-enzyme potential and substrate
availability (i.e. solubilizing, gelatinization)
Mashing with exogenous enzymes

Process efficiency
• Improved planning reliability
• Reduced losses
• Increased flexibility on raw material (type,
quality)
Space to innovate
• Use of untraditional raw materials
• Enhance/reduce concentration of present beer
components
Improve sustainability
• Reduced water, energy consumption and CO2
emission
• Usage of locally grown raw material
 Enzymes Enyzmes
High
Most brewing gelatinizing Malt
Barley
enzymes are added adjunct
Wheat
into
MASH VESSEL/
CEREAL COOKER
at the beginning of
the process.

Enyzmes
Enzymes assisting with low quality barley/malt

-5%* vs. 2017, leading to higher protein content

Throughput Beer Haze Material Costs

The weather impact on brewing& impact
on raw material quality

Barley High Protein contents Malt

Harder to malt Less extract / ton of grist

Increased extract losses Potential filtration issues
Haze and turbidity risk
Cont’
High Protein contents
Impact: Filtration / Haze Issues due
to poor breakdown of proteins
Malt

Solution:
Integrate additional protein rest. Allow
time for endogenous proteases to act.
Intensified
Protein Rest Optimise with FAN® Boost Pro to maintain
(50-52°C) capacity and prevent gel formation.
FAN® Boost Pro Optimising the Ultraflo® or Ceremix®
Ultraflo® Max applications will aid in improving filtration
by reducing other carbohydrates.
Cont’
More Extract = Less starch
Impact: lower yields due to less
starch content per kernel

Solution:
Optimise Ceremix Flex to ensure
effective, maximum degradation of
starch in the mash-tun.
If Termamyl (Ceremix Flex) only
added to Cereal Cooker review
Ceremix Flex whether necessary to add into the
Ultraflo Max mash-tun (-> transfer-temperature).
(Addition of Ultraflo Max has shown
an overall increase in extract yield
due to lower viscosity)
Cont’ Small Kernels
Impact: Increased gelatinization temperature
due to higher amount of amylopectin (α-1,6
linkages). This can be above deactivation
temperature of the endogenous β-amylase
Adjust saccharification lowering the RDF
temperature
Solution
Adjust saccharification rest to higher
Attenuzyme® Pro gelatinisation temperature.
Support endogenous β-amylase with more
heat robust Attenuzyme Pro.
Pullulanase in Attenuzyme Pro will
breakdown the alpha 1-6 linkage
additionally increasing the RDF and yields.

Topt [°C] pHopt Substrate Product

α-Amylase 65 – 75 5.6 – 5.8 High- and low molecular α- Oligosaccharides
glucans
β-Amylase 60 – 65 5.4 – 5.6 α-glucans Maltose
Cont’
Small Kernels
Impact: Increased gelatinization temperature due
to higher amount of amylopectin (α-1,6 linkages).
Adjust saccharification This can be above deactivation temperature of
temperature
the endogenous β-amylase lowering the RDF

Attenuzyme Pro Solution:

Adjust saccharification rest to higher
gelatinisation temperature.
Support endogenous β-amylase with
α-amylase
more heat robust Attenuzyme Pro.
Pullulanase in Attenuzyme Pro will
breakdown the alpha 1-6 linkage
additionally increasing the RDF and
Pullulanase
yields.
Glucoamylase

Starch or dextrin Glucose Maltose

Summary: Enzymes assisting with low quality barley/malt

High Protein Content Less starch Small kernels (grain size)

Impact: Filtration / Haze Issues due to Impact: lower yields due to less starch Impact: Increased gelatinization
poor breakdown of proteins content per kernel temperature due to higher amount of
amylopectin (α-1,6 linkages). This can be
above deactivation temperature of the
endogenous β-amylase lowering the RDF.

Solution Solution Solution

Integrate additional protein rest. Allow time for Optimize Ceremix® Flex to ensure effective, Adjust saccharification rest to higher
endogenous proteases to act. maximum degradation of starch in the mash-tun. gelatinisation temperature.

Optimise with FAN® Boost Pro to maintain If Ceremix® Flex only added to Cereal Cooker Support endogenous β-amylase with more heat
capacity and prevent gel formation. * review whether necessary to add into the mash- robust Attenuzyme® Pro.
tun (-> transfer-temperature).
Optimising the Ultraflo® Max or Ceremi® Pullulanase in Attenuzyme® Pro will
Flex applications will aid in improving filtration (Addition of Ultraflo® Max has shown an breakdown the alpha 1-6 linkage additionally
by reducing other carbohydrates. overall increase in extract yield due to lower increasing the RDF and yields.
viscosity)
 Enzymes lowering high energy costs
Brewing enzymes in a market with elevated prices and uncertainty

Global Malting Barley Prices (USD/mt)

Global malting barley prices has been trending upwards for

some time and world barley stocks are at the lowest level in
almost 40 years.

Introduction: Brewing enzymes in a market with elevated prices and

Increasing energy prices impacts the entire value
uncertainty
chain: maltsters, breweries, packaging, logistics.
Crude Oil and US Natural Gas price

Enzymes can create even more value for the breweries:

- In a market with elevated raw material price market and
uncertainty around availability and quality
- In a market with rising utility prices

Sources: RMI Analytics

Save time and energy with
Ceremix® Flex
Process high gelatinizing raw materials in an
infusion process

Cereal Cooker Mash Tun

Ceremix® Flex
Enables processing of high
gelatinizing raw material in an
infusion process avoiding the
boiling step

Ceremix® Flex
Simplify your mashing process
From step mashing to iso-thermal mashing?

Today’s Mashing Regime

Ultraflo® Prime
Ceremix® Flex Simplified mashing:
Mash-in at higher temperature
Isothermal mashing:
Above gelatinization temperature
Enables high-temperature
mashing
Ultraflo® Prime

Ultraflo® Prime
Simplify your mashing process Fresh water consumption*
Studies confirms the benefits of
high temperature mashing 2,0 -11%
1,57 1,51 1,45 1,39
1,5

[hl/hl]
1,0

0,5

0,0%
A simplified mashing regime can have a 45 °C 51 °C 58 °C 65 °C
significantly positive impact on the energy
balance and water consumption. Fresh water consumption at different mashing-in temperatures

Higher temperature = less fresh cold water Thermal energy (steam) consumption*
consumption, less steam heating, and less surplus
hot water consumption.*
40 -18%
31,23 29,58
30 27,63 25,70

[MJ/hl]
20
Brewers now have greater flexibility when 10
choosing the mashing-in temperature.
0%
45 °C 51 °C 58 °C 65 °C

Thermal energy consumption at different mashing-in temperatures

,

Sources: *Brauwelt International 4-2014 / 20.08.2014 / Topics: Filling, Water / Author: Jaap Risselada
Simplify your mashing process Water usage*
Case study: Faster Beer filtration can reduce -9%
water and energy usage by nearly 10% 100%
100%
91,1%

Relative usage
0%
Superior beer filtration performance with as As-Is 12% Faster Filtration

much as 12% higher throughput.

Relative water usage with and without improved beer filtration

Faster filtration at same Kieselguhr consumption = Energy usage*

more volume per cycle
-9%
= improved water and energy usage. 100%
100% 91,4%

Relative usage
Water usage and energy consumption in the beer
filtration step is reduced as much as 9% by faster
filtration.* 0%
As-Is 12% Faster Filtration

Relative energy usage with and without improved beer filtration

,

* Based on internal Novozymes data

Avoid energy intense malting
with Ondea® Pro
Lower the energy requirements of the brewing
process by increasing the amount of barley in your
beers

Ondea® Pro
Enables brewing with barley Malthouse Brewery
and thereby avoiding the
malting process
Ondea® Pro
Barley Continued beer
Malting Milling Mashing
production production
Summary: Enzymes lowering
high energy costs
Brewing enzymes in a market with elevated prices
and uncertainty
Cereal Cooker Mash Tun

Ceremix® Flex
Enables processing of high gelatinizing raw
material in an infusion process avoiding the
boiling step

Today’s Mashing Tomorrow’s

Ultraflo® Prime
Regime Mashing Regime
Enables high-temperature mashing

Ondea® Pro
Enables brewing with barley and thereby
avoiding the malting process

Malthouse Brewery
Bad Weather Doesn’t Have to Mean Bad Business: Let Enzymes Help

Brewing with Enzymes by NOVOZYMES

North America
Alex Merz [email protected]
Europe
Brewing Engineer [email protected]
NOVOZYMES EU