efficient hop flavor€¦ · hop product alpha utilization kettle dose (lb) wort loss (bbl) pellets...

Efficient Hop Flavor

Phillip Chou, Michael Visgil, Virgil McDonald, Christina Schönberger

Phillip ChouDirector of Brewing Solutions

John I. Haas, Inc.

Michael Visgil

Brewing Solutions Specialist

John I. Haas, Inc.

Virgil McDonald

Innovations Brewmaster

John I. Haas, Inc.

Christina Schönberger

Head of Innovation & Education

BarthHaas GMBH & Co. KG

About Us

Take Home Message

Flavor

Why Do We Care About Efficient Hop Flavor?

• Competition: Year to year growth in the number of breweries

• Greater Production Yields: Brew more beer for less money

• Sustainability: Less solid waste generation and disposal,

recyclable packaging

• Reduced Harmful Components like pesticides and herbicides

Hops & Brewing Unit Operations

Efficiency Opportunities?

Kettle Bittering

Kettle Bittering Solutions

Pellets

• Type 90

• Type 45

• Pre-isomerized

CO2 ExtractNext Generation

Products

CO2 Extraction Process

Extraction

Vessel

(filled with

Pellets)

Heat

Exchanger

Pure

Super-

Critical

CO2

CO2 Storage

Vessel

Super-Critical CO2 with Hop Resins

CO2 Pump

Heat Exchanger

evaporates CO2

Separator

EXTRACT

Condensor

liquifies CO2

Gaseous CO2

Liquid CO2

Pressure

Control

Valve

250 bar

⇩70 bar

CO2 Extract Product Features

• Higher concentrations of alpha acids versus pellets

➢ Pellets: 13 - 18% alpha, CO2 Extract: 30 - 55% alpha.

• No vegetative matter.

• Reduction in nitrates & pesticide residues.

Beer Loss

1 kg of Pellets absorbs 10 L of wort/beer

• Process losses due to

absorption by

vegetative matter.

• Can remove by

centrifugation…High

capital cost.

CO2 Extract Yield Increase

No vegetative matter in CO2 Extract, reduces wort loss.

Hop Product Mass to Kettle (g) Avg Yield Loss %

T-90 Pellet 263 13.9

T-45 Pellet 263 10.0

T-35 Powder 263 9.1

CO2 Extract 263 8.1

Visgil, M.; McDonald, V.; Algazzali, V.; Byelashov, A. Supercritical CO2 Hop Extract Improves Brewery Process Yield Over Hop

Pellets. In Proceedings of the 2017 Master Brewers Conference, Atlanta, GA, October 12-14, 2017, Abstract #71.

Brew Volume: 8 gal

Storage & Shelf Life Considerations

1 Box CO2 Extract = 3 Boxes Pellets

Photo Credit: Alec Mull, Founders Brewing

• Can be stored at

ambient temperature.

• 3 year shelf life at

ambient.

Next Generation of Extract-based Hop Products

Flowable Liquid

• Pours from package at ambient temperatures.

Concentrated Alpha Product

• 65% by weight.

• Compare to bittering pellet concentrations of 13-

20% alpha or CO2 extract at ~50-55% alpha.

• No vegetative matter.

• Minimal amounts of beta acids and waxes.

• Up to 98% reduction in nitrates.

Efficiency

• 10-20% (relative) greater alpha acid utilization

relative to pellets during wort boil.

Flowable Hop-based Extract (FHE)

Recyclable

Packaging

Brewing Value

• Reduced Beer Loss

Hop

Product

Alpha

Utilization

Kettle

Dose (lb)

Wort Loss

(bbl)

Pellets 0.25 37.0 1.4^

FHE* 0.30 6.6

100 bbl Brew

50 IBU Target Bitterness

100 bbl Brew

Beer Production Cost: $175/bbl

Beer Loss Reduction Cost Impact: $250

*Flowable Hop Extract-based Product^Wort loss due to hop vegetative matter only. Does

not take into account losses due to other wort solids.

Supply Chain Savings

• Need less kg of FHE* to achieve target IBU’s relative to

pellets.

Brewing Bitterness Target: 40 IBU

3 kg of FHE = 20 kg of 15% pellets

$136.38

$36.03Yakima, WA to MA

UPS Shipping

Costs

✓ Ambient

Storage

✓ Less Storage

Space

*Flowable Hop Extract-based Product

Aroma & Taste:

Whirlpool & Cold

Side Operations

Comparison of Aroma & Taste Delivery Products

Pellets

• Type 90

• Type 45

Next Generation

Products

✓ Beer absoption by

vegetative matter

✓ Solid waste generation

✓ Supply chain impact

✓ Deliver desired flavor

outcomes

✓ Beer loss reduction

✓ Improved sustainability

✓ Supply chain cost

savings

✓ Easy & safe to use

Hops & Brewing Unit Operations: Whirlpool Hop Additions

Next Generation Whirlpool Hopping

Pourable Liquid Hop Extract Product (LHEP)

• Flows from package at ambient temperatures

Concentrated Flavor Product

• Varietal-specific

• 40 – 55% Alpha Acids

• High Oil Content: 8 – 14% Total Oils

• No vegetative matter

• Up to 98% reduction in nitrates

Application

• Whirlpool addition

Recyclable

Packaging

Liquid Hop Extract Product (LHEP) Features

Bitterness Impact

• 2 – 10% Alpha Acid Utilization

Equivalents

• 1 g/L LHEP replaces 5.8 g/L

(1.5 lb/bbl) pellets

Increased yields by substituting Liquid Hop Extract

Product (LHEP) for pellets.

Hop

Product

Whirlpool

Dose (lb)

Wort Loss

(bbl)

Pellets 150.0 5.8*

LHEP 25.8

100 bbl Brew

Impact on Efficiency

*Wort loss due to hop vegetative matter only. Does

not take into account losses due to other wort solids.

Increased yields by substituting LHEP for pellets.

T-90 Citra®

Pellets (lb)

T-90 Mosaic®

Pellets (lb)

Citra LHEP

(lb)

Mosaic LHEP

(lb)

% Beer

Yield

Pellet Beer

Control18 18 82

LHEP Beer 3.1 3.1 93

• 30 bbl Brews

• 70 IBU Target

• 7% ABV Target

• Beer Cost: $175/bbl

• Value of Beer Gained Due to Increased Yield: $577

Liquid Hop Extract Product (LHEP) Features

Pellets

LHEP

Gas Chromatography-Mass

Spectrometry data indicated

that oil profiles were

comparable for LHEP & pellet

beers

Liquid Hop Extract Product (LHEP) Aroma Analysis

LHEP

Pellets

LHEP

Hops & Brewing Unit Operations: Cold Side Hop Additions

Hopping Trends

Traditional IPA Hazy IPA

50 IBU

1 lb/bbl (0.38 kg/hL) Dry Hopping

30 IBU

5 lb/bbl (1.94 kg/hL) Dry Hopping

Dry Hopping Losses

Hazy IPA

30 IBU

5 lb/bbl (1.94 kg/hL) Dry Hopping

Dry Hopping Beer Loss

T-90

Pellets

226.8 kg 22.7 hL

500 lb 19.3 bbl

117.3 hL (100 bbl) Brew

1 kg of Pellets absorbs 10 L of wort/beer

• Beer Production Cost: $175/bbl

• Production Loss: $3,378

Dry-hopping Considerations

HopGun (BrauKon)

Specialized Equipment Safety Issues

Solid Waste

1 kg of Pellets absorbs 10 L of wort/beer

Solid waste

handling &

cost needs to

be taken into

account

Sustainability

• Reduced solid waste management costs.

Spent

Hops

Transport to Waste

Handling FacilityHolding Tank+ Wort

Waste Water

Treatment Plant

Hop Aroma Chemistry

Design by Victor Algazzali

Graphics from http://www.bojensen.net/index.html

Table adapted from: Eyres, G.; Dufour, J.

J. Chromat. A 1977, 1150, 70.

Hop Oil Isolation & Fractionation

CO2 Extract

Hop Oils Alpha Acids

Beta Acids

Oil

Component

Oil

Component

Oil

Component

Distillation

Separation

• Cold side applications

• Completely soluble in beer

• No vegetative matter

• 2 Year shelf life (refrigerated)

Hop Oil Product

• Imparts a wide variety of aroma

attributes

➢Citrus

➢Floral

➢Spicy

➢Herbal

• Can be varietal-specific

➢Citra

➢Mosaic

➢Cascade

➢Hersbrucker

➢Perle

Sensory Impact of Hop Oil Product Addition

Control Beer

Beer + Hop

Oil Product A

Hop Oil Product A

Control

Beer + Hop Oil Prod B

Sensory Impact of Hop Oil Product Addition

Hop Oil Product B

• Achieving desired aroma, flavor, and bitterness can be

achieved efficiently through the use of advanced hop

products.

• Extract- & essential oil-based products address different

needs in the brewery, provides ease of use, as well as cost

savings.

Summary

• Marshall Ligare

• Victor Algazzali

Acknowledgements