Fresh Beer, Fresh Ideas MBAA – New England January 2014
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Transcript of Fresh Beer, Fresh Ideas MBAA – New England January 2014
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123rd MBAA Anniversary Convention
Fresh Beer, Fresh IdeasMBAA – New England
January 2014
Alastair PringlePringle –Scott LLC
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Objective and Outline
• Objective– Identify practical solutions for keeping beer as fresh
as possible.
• Outline– Background – What is freshness? – Reactions in brewhouse, fermentation, & finishing – Practical steps to freshness improvement– Making decisions on freshness
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Background - Factors that Affect Beer Shelf Life • Microbiological spoilage – Bacteria: lactic acid, diacetyl, H2S, etc – Yeast: over-attenuation, over carbonation–
• Physical stability – Chill-haze– Permanent haze
• Flavor stability – Changes in flavor
3This talk will focus on flavor stability
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Background - Why Worry About Flavor Stability?
• Customers want a consistent flavor
• They accept consistent flavor, even if it includes off-flavors– e.g. DMS, oxidation, light-struck
• They reject variable flavors – Beer will not meet their expectations– Do not like surprises
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Freshness in the Marketplace • Wide freshness variation – confuses the customer
• Narrow range – customer gets a consistent product
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Freq
uenc
y
Stale Fresh
Freq
uenc
y
Stale Fresh
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WHAT IS FRESHNESS?
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Freshness• Freshness is how close a
product is to when it was : – Picked from the field – Made in the bakery or brewery
• Implied:– Better taste– Better nutrition – No artificial preservatives
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Changes in Beer • Freshness begins to decline once beer is
packaged• The decline is accelerated by increased
temperature
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0 50 100 150 200 250 3004
4.55
5.56
6.57
7.58
8.59
Days
80oF
70oF
36oF
Less
Fre
sh
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Why Does Beer Lose Freshness?
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Sulfite
Cardboard
Paper
Ester
Bitter
Harsh
Sweet
Staling is the sum of many flavor changes:- no single compound or mechanism is responsible- there is no single solution
Inte
nsity
Time
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Where Should You focus? • Across the entire system
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Brewery Wholesaler Retailer
Brewhouse Fermentation Finishing Packaging
We will first look at the brewing process
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BREWHOUSE
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First, a Word about Carbonyls • A class of compounds that contain a C=O group
C=O
• Include:– long-chain unsaturated aldehydes.• 1969 - trans-2-nonenal was shown to impart a stale,
cardboard, flavor when added to beer.– other volatile carbonyls: • ketones, esters
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A
B
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Brewhouse Chemistry - Mashing and Lautering -
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Unsat. Fatty Acids
Carbonyls
Lipase
Polyphenols
Tannins
O2
Lipoxygenase
Malt polyphenols Malt LipidsMalt Protein
Amino Acids
Protease
Oxygen is important in carbonyl production
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Brewhouse Chemistry- Boiling -
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Polyphenols
Carbonyls
O2
Iso-alpha acids
Extraction
Isomerization
Tannins + Protein
Carbonyl-protein
Wort protein
From Mashing
Maillard Products
Unsat. Fatty Acids
Heat
Amino acids
Hops Sugar
Copper
Vessels & coils
Oxygen and heat drive complex reactions
Malt Tannins
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FERMENTATION
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Fermentation Chemistry
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Carbonyls
Alcohols
Protein– carbonyl
SO2
SO2– carbonyl
Sulfate
H+
Yeast
Ethanol
Sugars
SO2
SO2 is an important anti-oxidant, especially in lagersCarbonyls become bound to protein and SO2
Iron
Yeast
Iron
Uptake
Autolysis
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FINISHING AND PACKAGING
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Finishing and Packaging Chemistry
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Iron
Reactive Oxygen Species O2
- superoxide anion HOO- perhydroxyl radical H2O2 hydrogen peroxide HO. hydroxyl radical
OxygenFilter medium
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Chemistry in the Package- reactions involving oxygen-
Oxygen
Reactive Oxygen Species
Finished Beer
Package
Iron & Copper
Sulfur Dioxide
Iso-alpha acids
Sulfate
Sweet, fruity• e.g. Ethyl
isovalerate
Side chain
Polyphenols Harsh, astringent• tannins
+
Others reactions – oxidation of ethanol and higher alcohols
Ethanol
Diagram courtesy of Grace Darex Packaging Technologies
ingressD.O.
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Chemistry in the Package-reactions independent of oxygen-
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SO2– carbonyl
Protein – carbonyl Carbonyl +
Maillard Products +
Paper, cardboard• e.g. Trans-2-
nonenal Solvent • e.g. furfuryl ethyl
ether
SO2
Other reactions – esterification, etherification, glycoside hydrolysis, & ester hydrolysis
Ethanol
These compounds, which developed in the brewhouse,result in stale flavors in the package
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The Brewing Process - factors that are important for freshness -
• Yeast– SO2
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Brewhouse Fermentation Finishing Packaging
• Oxygen • Metal ions
• Oxygen• Heat
• Oxygen
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PRACTICAL STEPS TO FRESHNESS IMPROVEMENT
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How can Freshness be improved?
• Maximal freshness can only be achieved by making improvements across the entire production chain– Chain is as good as its weakest link – Do not only focus on one area
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Brewery Wholesaler Retailer
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Brewhouse Freshness Best PracticesMashing
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Bottom entry
Fore masher
Course grind Malt
No scorching or build-up No votex upon emptying
Water Effective mixing that minimizes foam and
creates no vortex
Pump seals maintained to
avoid air pick-up
Minimize exposure to air
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Brewhouse Freshness Best Practices- Lautering -
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Bottom mash entry
Side mash entry
Minimal Foam
Not exposing the
grain bed
or
Minimize exposure to air
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Brewhouse Freshness Best Practices – Boiling -
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Gentle fill minimizing foam
Avoid extended boil time
Efficient heat transfer – minimal scorching
No vortex during emptying Pump seals
maintained to avoid air pick-up
Avoid boil temperatures above 212 F
Minimize air and heat
Vigorous boil
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Brewhouse Freshness Best Practices- Whirlpool-
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Tangential flow
Minimal foam on wort surface
Pump seals maintained to
avoid air pick-up
Gentle wort flow
Avoid excess time
Minimize air and heat exposure
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Fermentation Best Practices • Increase SO2 levels in lagers– SO2 is an antioxidant– below level requiring labeling
• Minimize yeast autolysis – Can release iron into beer.
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Fermentor
Yeast
Maturation
Increase SO2 Reduce autolysis Lower ferm. temp X
Lower aeration rate X
Lower pitch rate X
Increase yeast food X X
Lower maturation temp. X
Reduce maturation time X
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Finishing Best Practices
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De-oxygenate adjustment water
Filter Beer Tank
Water Filter
Gas with CO2
before filling
Use low iron D.E.
Chiller
Buffer
Chill-proofer
Maintain to avoid oxygen
pick up
Seals maintained to avoid air pick-up
De-oxygenate water
Minimize air and iron pickup
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PACKAGING
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Packaging Freshness Best Practices• Minimize oxygen – Finished beer D.O. should be low (50 ppb or less)– Bottles
• Evacuation• CO2 flushing • Proper adjustment of jetters
– Cans • Use CO2 flushing • Bubble breakers • Under-cover gassing with CO2
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Measuring Package Oxygen • Shake-out method – fair – Better than not measuring oxygen – Detects very high levels – Too inaccurate to be used for driving
down oxygen levels • Dissolved oxygen – better – Pierce package and run beer through a DO
meter. – Detects beer DO levels - but not
headspace oxygen• Total package oxygen - best – Oxygen in beer + headspace oxygen – Semi-automatic
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Packaging Materials Best Practices • Many more times the oxygen may
enter the package over its shelf-life as is present immediately after packaging
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Package Type Source of oxygen ingress Improve freshness through:
Glass Bottle • Crown • Barrier crown - better• Absorbing crown – best
Plastic Bottle • Closure
• Bottle
• Barrier crown – better • Absorbing crown – best
• Oxygen barrier – nylon • Absorbing technology – e.g. Co
Can • Minimal ingress
Diagram courtesy of Grace Darex Packaging Technologies
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DISTRIBUTION
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0 50 100 150 200 250 3004
4.55
5.56
6.57
7.58
8.59
Days
Distribution Chain Control- It all about Time and Temperature -
• Higher temperature leads to a rapid loss of freshness – 2 to 4 times more for every 18oF
(10oC)– Beer stored at 80o F for 50 days
will be as fresh as beer stored at 70oF for 100 days
• Draft beer that is kept cold will remain fresher than packaged
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40oF
80oF 70oF
Keeping beer cool and for shorter times means beer is consumed fresher
– local production and distribution helps
Less
Fre
sh
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MAKING FRESHNESS DECISIONS
36Photo courtesy of PureMalt
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Tools to Assess the Process• Process assessment – Visual:
• Vortexing • Excessive foam in brewery vessels• Scorching on heat exchange surfaces
– Measurement • Excessive levels of dissolved oxygen
where you have clear liquid– Lauter– Wort receiver– Kettle knock out
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Freshness Measurement • Focus on a reliable measure related to the consumer
experience. – Sensory is the best measure– Avoid complex chemical analyses– Measurement of radicals is mainly related to SO2 and or iron level
• Develop a Freshness Panel– Train using in-house or outside expertise (FlavorActiv)– Develop a scale: e.g. 1 to 10
• Use the panel to provide feedback on experiments and process improvement efforts– Does a process change improve freshness?– Is the cost worth it?– What is the shelf-life of a beer? 38
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Beer Shelf-Life Determination
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0 50 100 150 200 250 3004
4.55
5.56
6.57
7.58
8.59
Days
70 F
32 F Le
ss F
resh
Shelf-life is the time before the beer tastes unacceptably different from fresh beer
X
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Summary
• Freshness of beer in the marketplace is affected by:– Production methods from the brewhouse to the
finished package– Storage conditions after the beer is packaged
• The freshness of beer that reaches the consumer can be enhanced by systematically improving each link in the chain as much as practically possible
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Brewery Wholesaler Retailer
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The Art of Beer
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Prin
gle-
Scot
t.com
Questions?