GRAIN HANDLING, MALTING,

AND MALT ANALYSIS PART 2

BREWING + DISTILLING CENTER, INC.

MALTING LOSSES

There is a substantial loss of weight and mass when barley is

transformed into malt.

100 pounds of barley will become 80 pounds of malt as in this example:

• The original 100 pounds has a moisture content of about 12%,

making the non-water weight 88 lbs.

• Trash plus foreign grains and broken grains account for about

2% of the weight.

• Respiration as the grain germinates accounts for 6%.

• Rootlets, which are removed, account for 4%.

• Final moisture content is about 4%.

Weight as malt = 100 x .88 x .98 x .94 x .96/.96 = 81.1 lbs.

MALT QUALITY AND ANALYSISCertificate of Analysis (COA) serves two purposes:

1. To document production in the Malthouse.

2. To predict the ultimate performance in the brew house.

TERMINOLOGY ON A COA• SRM = Standard Reference Method These two terms

refer to color

• EBC = European Brewing Convention

• MC = Moisture Content

• FG/CG = Fine Grind/Coarse Grind difference

• DP = Diastatic Power

• WK = Windisch-Kolbach

• TN = Total Nitrogen

• SP = Soluble Protein

• SNR = Soluble Nitrogen Ratio

• Mealiness (%)

• Friability

SRM & EBC

FORMULAS

• SRM = (1.3546 x °L) – 0.76 (to convert °Lintner to SRM)

• SRM = EBC x 0.508 (to convert EBC to SRM)

• EBC = SRM x 1.97 (to convert SRM to EBC)

• EBC = (°L x 2.65) – 1.2 (to convert °Lintner to

EBC)

• DP °Lintner = (°WK + 16) / 3.5 (to convert Kolbach

index to °Lintner)

FORMULAS c’d

• °L = (SRM + 0.6) / 1.3546 (to convert SRM to

degrees Lovibond)

• SG = 259 / (259 - °P) -- (to convert degrees Plato to

Specific Gravity)

• °P = (SG – 1) x 250 -- (to convert Specific Gravity to

degrees Plato)

• (DBCG / 1 + MC) – 0.002) x Brewhouse Efficiency

(to give actual brewhouse yield)

FORMULAS c’d

To determine pounds of extract per barrel of wort:

(Weight of a bbl of water + degrees Plato) X the

gravity = lbs. extract per bbl

Example using 12°P wort: (259 lbs. + 12) X .12 = 32.52

lbs extract/bbl

RECIPE DESIGN

Steps to successful recipe design:

1. Choose a beer style.

2. Review style guidelines for the beer you have

chosen.

3. Set target values for original and final gravities,

IBU’s, and color.

4. Identify malt types and determine the quantities to

use.

EXTRACT DETERMINATION STEPS IN WRITING A

RECIPE

1. Decide how strong the wort should be and the final volume.

2. Compute the total extract needed in the wort, using these two values (wort & volume).

3. Adjust the value of potential extract based on brewhouse efficiency.

4. Calculate, sum, and readjust the relative extract contributions of various malts to match the needed potential extract.

For example: We want to make 10 bbls of a 12°P medium colored beer with a full malty flavor---

Malt Grist Fraction

Pale Malt 80%

Munich Malt 12%

Crystal 7.5%

Black .05%

EXTRACT TABLE

By using our formula we find that a 12°P wort contains 32.52 pounds of extract per bbl.

10 bbls X 32.52 = 325.20 pounds of extract needed for the brew

Our brewery has an efficiency of 90%, so 325.20 / .90 = 361.3 pounds of potential extract required in the grist.

Example:

Malt Grist Fraction

Pale Malt 80%

Munich Malt 12%

Crystal 7.5%

Black .05%

The extract and color values for the malts as provided on the COA are:

Malt SRM CGAI Pale Malt 2 80%

Munich malt 10 78%

Crystal 35 72%

Black 500 50%

Example:

Malt Grist Fraction

Pale Malt 80%

Munich Malt 12%

Crystal 7.5%

Black .05%

We can determine the needed extract contribution from each malt by multiplying the grist percentage by the total extract available from the lauter tun (361.3 pounds):

Malt Grist % Extract Contribution

Pale malt 80% 289.0

Munich malt 12% 43.4

Crystal 7.5% 27.1

Black 0.5% 1.81

Total 100% 361.3

To calculate the grist weight needed of each malt we divide the extract contribution by the CGAI value.

Example:

Malt Grist Fraction

Pale Malt 80%

Munich Malt 12%

Crystal 7.5%

Black .05%

CALCULATING

GRIST WEIGHT

Malt/Grist lbs. Extract Contribution CGAI

Pale Malt / 289.0 80%

361.3

Munich Malt / 43.4 78%

55.6

Crystal / 27.1 72%

37.6

Black / 1.81 50%

3.6

Total

458.1

*************************************************************

We now have a rough grist bill for our brew and can next check the

calculated wort color by multiplying the color contribution of each

malt by the total weight used.

Example:

Malt Grist Fraction

Pale Malt 80%

Munich Malt 12%

Crystal 7.5%

Black .05%

FIGURING SRM (COLOR)

Malt Grist lbs. SRM SRM•lbs.

Pale Malt 361.3 2 723

Munich Malt 55.6 10 556

Crystal 37.6 35 1316

Black 3.6 500 1800

Total 4395

The total is then divided by the total number of gallons to determine

the wort color:

4395 SRM•lbs. / 310 gallons = 14 SRM

BREWING SOFTWARE PROGRAMS

• Spreadsheet

• Beer Smith

• Brewers Friend

BEERSMITH

IN-CLASS PROJECT

We want to brew a high gravity Winterfest Ale.

We need to calculate a grain bill using the following

information and the formulas we have discussed:

20 bbl quantity. S.G. = 1.090. Brewery efficiency = 85%

Malt Grist Fraction CGAI

Pilsner malt 72% 83%

Caramunich III malt 15% 79.5%

Munich malt I 6% 82.5%

Carahell malt 3% 83%

Wheat malt 3% 86%

Carafa II malt 1% 69%

Determine pounds of extract per bbl of wort

First, we need to convert specific gravity to

degrees Plato:

°P = (SG -1) X 250 = (1.090 – 1) X250 = 22.5 degrees

Plato

Using the weight of water per bbl and the degrees

Plato we get:

(259 lbs. + 22.5) = 281.5 X .225 = 63.34 lbs. of extract

per bbl

IN-CLASS PROJECT

Determine pounds of extract needed for the brew

# of bbls X lbs. of extract per bbl = pounds of

extract needed for the brew

20 bbls X 63.34 lbs extract per bbl = 1266.8 lbs

extract needed for the brew

IN-CLASS PROJECT

Use brewery efficiency to figure potential extract

Our brewery has an efficiency of 85%

Lbs. extract needed for brew / brewery efficiency =

lbs. of potential extract required in the grist

1266.8 / .85 = 1490 lbs potential extract required in the

grist

IN-CLASS PROJECT

Figuring contribution of each malt in the grist

Multiply grist percentage of each malt X total extract

available = extract contribution of each malt.

Malt Grist Fraction Total Extract Available

Pilsner Malt .72 X 1490 = 1072.8 lbs extract contributed

Caramunich III .15 X 1490 = 223.5 “ “ “

Munich Malt I .06 X 1490 = 89.4 “ “ “

Carahell Malt .03 X 1490 = 44.7 “ “ “

Wheat Malt .03 X 1490 = 44.7 “ “ “

Carafa II Malt .01 X 1490 = 14.9 “ “ “

Total = 1490 lbs. total extract

IN-CLASS PROJECT

Calculating grist weight of each malt

Now that we know the extract contribution of each malt we need to calculate the weight of each malt using the CGAI. This is done by dividing the lbs. extract by the CGAI:

Malt

Pilsner 1072.8 / .83 = 1293 lbs. grist

Caramunich III 223.5 / .795 = 281 lbs. grist

Munich 89.4 / .825 = 108 lbs. grist

Carahell 44.7 / .83 = 54 lbs. grist

Wheat malt 44.7 / .86 = 52 lbs. grist

Carafa II 14.9 / .69 = 22 lbs. grist

Total = 1810 lbs. grist

IN-CLASS PROJECT

MILLING THE MALT

MILLS:

• 2 –Roll mills

• 6-Roll mills

GRIST CASE

MALT MILL ROLLERS

DIAGRAM OF 6 ROLLER MILL

WET MILLS

WET MILL SIERRA NEVADA, NC

IDEALLY CRUSHED MALT

Ideally crushed malt:

1. No uncrushed kernels

2. Majority of the husks split end to end with no

endosperm particles adhering

3. Endosperm reduced to a uniform small

particle size

4. Minimum of flour

IDEALLY CRUSHED MALT

PROPER MALT CRUSH