ALCOHOLIC BEVERAGES

1. ALCOHOLIC BEVERAGES

2. Alcoholic beverages have been known since antiquity. These are judged in terms of flavour and stimulant effect and hardly at all as sources of calories. However, the calorific value of alcohol in 7 Kcal/g and excess of alcohol consumed could add to the total calorie intake of a person.

3. In the case of distilled liquors (whisky, brandy, gin and rum), the calorific value is only due to alcohol and consumption of 10 ml of these, beverages would yield about 230 Kcal of energy and wine contain some nutrients present in the original malted barley and the fruit juice used in their preparation and naturally their energy value would be higher than that of distilled liquors; 350 ml of beer gives about 150 Kcal and 100 ml of wine about 80 Kcal.

4. Alcohol is absorbed without prior digestion but the body has limited capacity to oxidize it. That is the reason why alcoholic beverages are to be sipped instead of gulping them. As a drug the effects of alcohol vary from mild stimulation, when small amounts are consumed, to loss of coordination and even death when large amounts are consumed.

5. There are three main classes of alcoholic beverages-wines, malted beverages (beer) and distilled liquors. • Different starting materials and different methods are used in their manufacture. But there is one common characteristic in all of them, namely, they are made by the process of fermentation. • The essential step in all the fermentation processes is the conversion of glucose into alcohol by yeast. The enzymes present in yeast catalyze the breakdown of glucose. Yeast enzymes C6H1206 -------------------------->2C2H5 OH + 2C02

6. BEER Beer is an alcoholic beverage produced by the saccharification of starch and fermentation of the resulting sugar. The starch and saccharification enzymes are often derived from malted cereal grains, most commonly malted barley and malted wheat. Most beer is also flavoured with hops, which add bitterness and act as a natural preservative, though other flavourings such as herbs or fruit may occasionally be included. The preparation of beer is called brewing. Beer is the world's most widely consumed alcoholic beverage, and is the third-most popular drink overall, after water and tea. It is thought by some to be the oldest fermented beverage.

7. BEER MANUFACTURING 1. MALTING 2. BREWING MALTING is the process of controlled germination followed by controlled drying of barley. Such conditions are provided so that the enzymatic requirements of raw material reaches to its optimumum level. BREWING (production of malt beverages) is the combined process of preparing beverages from grains that have undergone sproughting and fermentation of the sugar solution by yeast where a portion of the carbohydrate is converted to alcohol and CO2.

8. Raw materials use in beer manufacturing : cereal grains like barley, wheat, rice, maize etc. The complex starches and proteins in these grains must be changed to a more readily usable mixture of simple carbohydrates and amino acids. Process involves germination of the barley grains and activation of their enzymes to produce a malt. The malt is then mixed with water and the desired grains(adjuncts), and the mixture is transferred to the mash tun or cask in order to hydrolyze the starch to usable carbohydrates. Once this process is completed ,the mash is heated with hops (dried flowers of the female vine Humuluslupulis which are originally added to the mash to inhibit spoilage micro organisms. The hops also provide flavour and assist in clarification of the wort. In this heating step, hydrolytic enzymes are inactivated and the wort is inoculated with the desired yeast for fermentation.

9. INGREDIENTS OF BEER • Water: portable • Barley & malt:- Malting is basically the initiation of germinating process carrying it to a desired end point and then applying hot air to dry and stabilize the germinated grain so that the enzyme activity that has developed is preserved. Malt is an excellent source of α-amylases. • Adjuncts:- additional source of cheaper carbohydrate to be acted upon by amylase. e.g. corn, corn syrup, corn sugar, rice, sorghum grits, barley, low protein wheat flakes . • Hops: plant material impart bitterness and is a source of tannins, resins & essential oils. • Brewer's Yeast: Saccharomycescerevisae, Saccharomycescarlsbergensis

10. Certain other products are used in the making of beer, in particular spices: coriander, ginger, cloves, sage, fennel, mustard seeds, aniseed, cinnamon, etc.

11. BEER CONSTITUENTS • water: 90% • Alcohol: vary from 4-8%, in general 2.5-5.0% • Carbohydrates (unfermented): 4%, include mono, di or tri polysaccharides • Inorganic compounds: Chlorides, sulfates, bicarbonates of Mg & Ca: 0.8% • N- compounds: 0.3% • Organic acids: 0.2% • CO2: 0.5% • Other compounds: 0.2%.

12. Most beers are fermented with bottom yeast or lagar yeast related to Saccharomycescarlsbergensis now Saccharomycesuvarum with lesser O2 requirement, It settle down at the bottom of the fermentation vat. Beer flavour is also influenced by production of small amounts of glycerol and acetic acid. Bottom yeast produce beer with a pH is 4.1 to 4.2 and require 35-50˚ F temperature and 7-10 days of fermentation. • With a top yeast or ale yeast such as Saccharomycescerevisiae, the pH is lowered to produce ales. Groth temperatures ranges between 60-75 ˚ F, with a greater O2 requirement. • Freshly fermented (green beers are aged or lagered and when they are bottled, CO2 is usually added. Beer can be pasteurized at 140oF or higher or sterilized by passage through membrane filters to minimized flavour changes.

13. BARLEY • Not used for direct human consumption. • Rest is used for cattle feeding, because of fibrous nature. • Added in some special foods such as Bournvita, Maltova, Boost etc. as source of sugar & energy. • Mostly used as barley malt for beer production. General requirements: 1. Clean, sound, undamaged grains free from mould are used for beer manufacturing. 2. Moisture content of grains should be <12%. 3. Germination percentage of grains should be >90%. 4. Low protein & high starch content grains are desirable. 5. Husk of grains should be thin as required for proper hydration.

14. beer manufacturing Process • I) MALTING • II) BREWING PROCESS • 1. Milling • 2. Mashing • 3. Lautering • 4. Wort Boiling & Cooling • 5. Cold Wort Aeration & Yeast Pitching • 6. Fermentation • 7. Aging & Finishing • Flavour maturation • Carbonation • Standardization • Chill proofing • Clarification • 8. Packaging • Filling • Pasteurization

15. a)Preliminary Steps • Drying of Barley: reduces moisture content up to 10-14% • Cleaning & Grading • Storage : 3 month storage period is required to break dormancy of grains. b) Steeping of barley • Soaking & hydration for 40-60 hrs. at 10-12oC • Duration depends upon thickness of kernel. • hard core results under steeping • Over steeping results delayed germination, increased microbial growth, undesirable odour. c)Draining and spreading over malting floor • Optimum moisture for growth is 40-45% d) Germination, under controlled conditions • Duration: 4-8 days • Temperature: 12-15oC • Shoot lets length: 1/2 - 2/3 ”

16. Germination of seeds

17. ENZYMES either synthesized or activated during germination. • Cytases • Phosphatases • Phytases • Cellulases • Proteases • Amylases: α – amylase, β – amylase e) Drying / klin drying: Preserves enzymatic activities as they depend on temperature and moisture content.High temperature of drying gives dark colour product - dark beer e) Screening: remove shootlets & rootlets

18. MALTING

19. BREWING MILLING Mixing of Malt Adjuncts Adjuncts: source of cheaper carbohydrate to be acted upon by amylase. e.g. corn, corn syrup, corn sugar, rice, sorghum grits, barley, low protein wheat flakes

20. Malting & Mashing

21. Mashing Process by which malt & malt adjuncts are dissolved, heated & digested. A number of biochemical changes occur in presence of enzymes. Barley has to be cracked open so that water can get inside and activate the enzymes. These enzymes called diastases, become most active around 150-160 degrees F. They convert the starches from the barley into simple sugars. This process is known as mashing. After the solids are strained out the dark, sweet liquid is called "wort." The wort must be boiled for 30-90 minutes depending on the recipe.

22. Mashing Temp 50 - 70C and pH 5.0 – 5. Temp of mashing influences enzymatic activities (specifically α & β amylase) and also control alcohol content. Higher temp- greater α & β amylase activities results more dextrins & low alcohol Low temp- less dextrins & high alcohol When α amylase is fvoured and β amylase is inhibited , dextrins accumulate at the expense of maltose . Therefore, by selecting temp , the ratio of sugars to dextrins is maintained. • results size of starch molecules reduces and causes reduced viscosity • reducing ability increase with increase in functional reducing groups.

23. During the kilning of malt , activities of the synthesized enzymes are drastically reduced with the exception of α & β amylase. Phosphorylase (in embryo), attacks on 1 – 4 links starch chain is shortend at non-reducing end by one unit (phosphorylated) of glucose . α- (in embryo), attacks on 1 – 4 or 1 – 6 linkage and starch chain is shortend by one units of glucose. α & β - amylases yield a carbohydrate product with a carbon bearing its hyroxyl group at α or β positions respectively. α- amylase is a metallo-enzyme, and is an endo-enzyme β- amylase is a thiol– enzyme, and is an exo-enzyme

24. Activities of α and β- amylases

26. a) ATTACK ON STARCH CHAIN α-amylase acts randomly (except near chain ends and branch points) β- amylase cutts off maltose units from non–reducing ends b) GLUCONOSIDIC LINKS ATTACKED α- amylase:  1-4 linkage β- amylase:  1- 4 linkage c) PRODUCTS OF ATTACK α - amylase: produces mainly dextrins, few sugar β- amylase: produces maltose (mainly), branched dextrins d) PRODUCTION OF REDUCING GROUPS α - amylase: one per attack β- amylase: one per attack e) PRODUCTION OF NON – REDUCING ENDS α - amylase: one per attack β- amylase: one per attack f) GENERAL REQUIREMENTS α - amylase: calcium ions β- amylase: reducing conditions to maintain thiol groups

27. g) INHIBITORS • α - amylase: calcium sequestrants • β- amylase: heavy metals & Na- idoacetate • h)OPTIMUM pH for activities • α- amylase: 5.5 • β- amylase: 5.2 • i) OPTIMUM TEMPERATURE FOR MOST RAPID ACTION • α - amylase: 70OC • β- amylase: 60OC • j) PRESENCE BEFORE GERMINATION • α - amylase: not present in mature barley grains, begins to form during germination. • β- amylase: present in mature barley grains but become active enzyme during germination.

28. LAUTERING It involve process of filtration and separation of sweet wort from spent grains. After mashing, the whole volume is filtered in order to separate the spent grains (which is an excellent animal feed) from the wort itself. This is done by passing water through the mash at the right temperature in a filter press or lautertun, which lasts around 2-3 hours, conducted at a temperature of 75-80 ºC.

29. Boiling the wortand Hopping Hops are added at this stage. • sterlization of wort • extraction of hops • hot break- precipitated flocculent insoluble proteins , polyphenols (tannins) ,hops resin, & metal ions, affect sensory qualities, if not removed. • caramelization of sugars- gives dark beer • reduced conditions- favours yeast growth • isomerization of some compounds- like HUMULONES  ISOHUMULONES  ALLOISOHUMULONES • denaturation of enzymes

30. Boiling, which usually lasts about two hours, serves to concentrate the wort to a desired specific gravity, to sterilize it and to obtain the desired extract from the hops. The hop resins contribute flavour, aroma and bitterness to the brew. Once the hops have flavoured the brew, they are removed. When applicable, highly-fermentable syrup may be added to the kettle. Undesirable protein substances that have survived the journey from the mash mixer are coagulated, leaving the wort clear.

31. Hops

33. Hop Separation and Cooling Hot trub/Hot break- Insoluble flocculants material formed during kettle boil. Cold trub/Cold break- Material soluble at high temperature but precipitates on cooling

34. After the beer has taken on the flavour of the hops, the wort then proceeds to the "hot wort tank". It is then cooled, usually in a simple-looking apparatus called a "plate cooler". After boiling, it is necessary to separate the precipitated protein and the insoluble hop components from the hot wort. Separation may be carried out in a decanter using gravity or with centripetal force in a "whirlpool". Before the hopped wort goes into the fermentation tanks, it is cooled to a temperature of around 9 ºC and aired in sterile conditions. The wort is cooled, so the yeasts to be added next don't die.

35. COLD WORT AERATION AND YEAST PITCHING Yeast growth and fermentation rate depend on the initial presence of some dissolved oxygen. since dissolved oxygen is expelled from wort during kettle boil, it must be replaced and this is done by saturating to 100% . It is equivalent to oxygen saturation at about 20%. At this initial conc. of O2, achieved fermentation rate is at its max level. Therefore acts as growth factor, not involve in respiration. Pitching- Inoculation of cooled wort with yeast culture.

36. Fermentation (1) Alcoholic Fermentation (Alcoholic Beverages, Bakery) Yeast enzymes C6H1206 -------------------------------->2C2H5 OH (ETOH) + 2C02 (2) Acidic Fermentation-Lactic Fermentation (Fermented Milk Products)- (a)Homofermentation Lactos--------------LAB)--------------LA ( major quantity ) (b) Heterofermentation Lactose-------------(LAB)-------------LA + ETOH + CO2 (1 : 1 : 1)

38. Lagar fermentation • Bottom fermentation • Saccharomycescerevisiaevarcarlsbergensis/Saccharomycesuvarum • Fermentation temperature: 6°—10°c (6°c in Europe, 10°c America) • Duration: 7-12 days • PH of beer 4.1 - 4.2 • Pediococci may grow B. Ale fermentation • Top fermentation • Saccharomycescerevisiae –ellipsoidus • Fermentation temperature: 15°c-16°c or 20° c • Duration 5-7 days • pH of beer 3.8 • Lactobacilli may grow

39. Aging and finishing Low temperature storage for 30-35 days results: H2S content decreases Diacetyl content decrease Acetaldehyde content decrease Many more interaction between compounds takes place. Flavor maturation: Young or green beer is stored or lagared in vats at about 0°c for several weeks to several months, during this period precipitation of yeast, protein, resins, and other undesirable substances take place and beer become clear and mellowed or matured. Ester and other compounds are produced to add to the taste and aroma, and the body change from harsh to smooth.

40. Carbonation: CO2 is incorporated @0.4 to 0.52 % Traditional method: by means of gas, collected during fermentation. Mechanical process: by mechanical means. Standardization:Blending process, to obtain desired level of alcohol in beer. Chill proofing & stabilization: Done to remove proteins, which tend to precipitate at lower temperature 0-3 oC and cause cloudiness /haze. It is done by using: • 1. Clays and silica hydrogel • 2. Polyphenol absorbent such as polyvinyl polypyrolidne (PVPP) • 3. Gallotennin (tannic acid) • 4. Enzymes- like pepsin As a general rule beer is chilled at 0oC at the end of this treatment.

41. Clarification It is done to remove insoluble materials by • 1. Centrifugation • 2. Fining- collagen is used • 3. Diatomaceous earth • 4. Filtration Packaging operations Filling: bottles, cans or barrels Pasteurization: done by filtration through membrane or other material to remove yeast cells or Heating for 6-15 PU ( heating for 1 min at 60 oC = 1 PU

42. Types of beer DRAFT BEER:fresh unpastuerized beer kept cool until served. LA GER BEER:Lagern (German word i.e. to store) • Obtained by bottom fermentation. • High in ethyl alcohol-3.93%. • Low proportion of hops. ALE BEER • Produced by top fermentation. • Pale in color. • High in ETOH 4.75%. • Contains more hops. • Tart in taste. PORTER BEER • Dark ale but more sweet. • Brewed from dark or black malt to produce wort of high extract. • Flavor of hops is less distinct than that of normal ale.

43. Defects in beer 1. Diacetyl content: >0.2 ppm gives unpleasant taste. 2. Metallic taste: >0.1ppm Fe, >0.2 ppm Cu, >2 ppm Al Precipitation of Al – haze formation 3. Light struck beer: Exposure to sunlight develops unpleasant taste. 4. Oxidized beer: due to oxidation of polyphenolic compounds. 5. Medicinal odour: due to formation of ortho-dichlorophenol compounds, even 6 ppb amount can develop unpleasant taste. 6.Grainy harsh/astringent taste: because of incomplete fermentation of grains.

44. 7. Turbidity Biggest problem caused by unstable proteins, protein tannin complex, resin or microbial activities. a) Gluten/ Albumin Turbidity Occurs at low temperature. Due to high protein content barley / barley malt. Disappear on warming. b) Oxidative Turbidity/ Haze O2 stimulate formation of protein tannin complex. CO2 minimize or eliminates turbidity. C) Starch Turbidity Caused by Incomplete conversion of starch. d) Yeast Turbidity Due to Incomplete clarification. e) Resin Turbidity Due to presence of insoluble resin , not removed as hot/ cold trub. f) Microbial Turbidity Due to microbial contamination.

45. Some proteolytic enzymes are added after fermentation during chill proofing to eliminate the problem of haze. • Microorganism associated with haze formation • Gram +Ve bacteria • Lactobacillus delbruekii • Pediococcuscerevisiae • Micrococcus varians • Gram -Ve bacteria • Acetobactorsuboxygens • Gluconobactersuboxygens • Yeast • Candida utilis (fat producer) • Pichiamembranefeciancs • Bretanomycesbruxellansi • Hansenualaanomla

46. 8. Faulty beer- due to a) low grade raw material in mash b) poor quality hops c) contact of beer with Fe of the can

47. References: http://www.thefreedictionary.com/beer http://en.wikipedia.org/wiki/Beer Acknowledgement : Ret. Prof. B.K. Mital FST, GBPUA&T, Pantnagar N. ShakuntalaManny & M. Shadaksharaswamy