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INTRODUCTION
Malt is a natural food product that results from the
transformation of a cereal grain. Barley is
the grain most used today, but wheat can also be used for making
"white" beers. Malt is the main
ingredient used in brewing beer, along with water, hops, and
yeast. Malts high enzyme content enables
the production of simple sugars and amino acids from the starch
in the proteins. Thus malt is the source
of sugar, which is then transformed into alcohol and carbon
dioxide gas in the beer. It also contributes
color and taste to the beer.
The main use of malt today is in brewing, for making beer. It is
also used in distilling, to make
whisky. It can also be used as a component (as malt extract) in
food manufacture (in making bread,
cereal bars, and energy drinks). Because of the products
energetic and enzymatic potential, other uses
for it are emerging or could be developed. Various species of
barley, both winter and spring barleys, may
be used in malt production. For a given species, different
varieties are used.
The industry nowadays uses a modern technology to keep the best
and high quality of the
products. In each of the process, Instrumentation and Controls
manipulate the overall progression of
the manufacturing to ensure proper amount of mass or volume,
temperature, speed, stress, force,
pressure, flow rate, movement, density and any other common
measurement.
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Brief Discussion of Old Malt Production
Step 1: The earliest known malt house was a simple structure
located at the bottom of a hill
or mountain adjacent to a stream, which could supply low
temperature water by gravity. These houses
had massive stone walls with floors of stone or mortar. Small
windows set in these heavy walls were the
only means of ventilation. Barley would be received into the top
of such a house, and dropped into deep
cisterns for steeping. From there, it would be deposited in a
pile onto the stone floor of the house for
germination.
Step 2: As growth commenced and heat was generated, the malt was
shoveled from this pile
and spread in a thin bed toward the front of the room. Any
necessary further cooling could only be
accomplished during the cool evenings or night hours when
experienced workmen shoveled the first
thin layer of malt forward to another spot on the floor,
throwing it into the air, and allowing it to fall in a
thin shower. The proper moisture was applied by the simple
old-fashioned sprinkling can.
Step 3: The process of shoveling to control temperature
gradually moved the bed from the rear
to the forward end of the floor, and as each successive steep
was deposited onto the floor from the
steeping cistern, it followed its predecessor down the length of
the floor. In this way there were on each
floor, a number of beds of malt in varying stages of
germination. When the malt reached the front of the
floor, its germination was completed, and it was shoveled by
hand through a trap door into wheel
barrows beneath, by means of which it was transported to the
kiln for drying.
Step 4: The kiln, at that time, was simply a room with a tile
floor, under which were crude
furnaces. The ceiling of the room assumed the shape of a high
tapered dome, in which was located a
large duct or chimney to pass off the moist hot air. After the
germinated malt was spread on the floors,
the fires were started, and drying accomplished by simple
heating. The malt was agitated from time to
tie by a shovel. Later the tile floors were perforated, so that
the combustion gases could pass directly
through the grain.
Step 5: All ventilation was by natural draft, and, of course,
was influenced greatly by weather
conditions. The art of malting under those conditions was one of
the highest. The maltster personally
controlled all processes, and through highly developed manual
skill maintained proper conditions. He
alone checked the temperatures, mostly by sense. It was he who
determined when more moisture was
required. In short, it was exclusively his skill and experience
which brought out a finished malt of the
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proper character. Because temperature controls were dependent on
atmospheric conditions, malting at
that time was confined to the cool months, which averaged about
five months per year. During the rest
of the year, the house was completely closed. Naturally, with
this short production season, volume was
very definitely limited.
Brief Discussion of Modern Malt Production
The basic principle of these early malt houses again prevailed
for centuries, but always with the
search for new means of increasing production. It was not until
the advent of steam, and later electrical
power, that any major change occurred in the malting process.
Undoubtedly, someone at some time
drove ventilating bellows by water power in an effort to
continue malting during the warmer weather,
but there is no definite record of such device.
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Step 1: Mixing of Barley and Rye Malt, as the raw materials for
Malt Production, from their
storage down to the soaking vessel.
Malted Barley Rye Malt
Barley and Rye Malt Composition
Rye Malt
Lovibond Flavor Unique Characteristics/Applications
3.7 Rye
DP 105. Another uniquely-Briess specialty malt, Rye Malt
isn't
just for rye beer styles. Although brewing a traditional rye
beer
is exceptionally rewarding, try adding Rye Malt to light-
and
medium-colored and flavored beers for complexity. Or fire up
your new distillery and use it to make a single malt
whiskey.
FLAVOR & COLOR CONTRIBUTIONS
Malt Style: Rye Malt
Flavor: Spicy Rye
Color: Golden leaning toward orange hues
CHARACTERISTICS / APPLICATIONS
An often overlooked malt, Rye Malt has a unique spicy rye flavor
for the production of great rye beer.
In addition, Rye Malt can help build flavor and develop
complexity in many beer styles, all the way from
medium flavored lagers to dark ales.
We recommend you start light. Use in 5% increments until your
desired flavor is achieved.
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Rye Malt is fully modified. It performs well in a single
temperature infusion mash if used at less than
20% of total grist.
Hulless and with a high beta glucan content, Rye Malt can result
in a sticky mash and slow lautering.
We recommend adding rice hulls when usage levels approach 20%
and supplementing with a
betaglucanase enzyme above 35% for manageable lautering.
1-3% Adds dryness and a touch of spicy rye flavor and interest
to many beer styles, from medium
flavored lagers to dark ales
5% Rye Pale Ales, Wheat and Smoked Beers
10-35% Roggenbier (German Rye Beer), American Rye Beer
NOTE: Grains are pre-crushed in 1 lb. Bags
Malted Barley
Malted barley is the source of the sugars (principally maltose)
which are fermented into beer.
The grain partially germinates, releasing enzymes in the
aleurone layer (outermost layer of the
endosperm). New enzymes are created that break down the
endosperm's protein/carbohydrate matrix
into smaller carbohydrates, amino acids and lipids, and open up
the seed's starch reserves. The
endosperm is composed of large and small starch granules that
are packed in a protein matrix. The cell
walls within the matrix holding the starch granules are
primarily composed of beta-glucans (a type of
cellulose), some pentosans (gummy polysaccharide) and some
protein. The degree to which the
enzymes unpack the starch granules (i.e. breakdown the
endosperm) for use by the growing plant (or
brewers) is referred to as the "modification." It refers to all
of the polymer-degrading processes that
occur during malting.
Barley is the worlds most nutritional crop and is recommended
for beer brewing. This is
because barley contains many elements that are rich sources of
health and energy for brewing yeast.
The composition of barley, including the percentage of minerals,
gives a general idea about its uses in
brewing industry. Barley contains about
Starch 62 66 % Sugars 1 2 %
-glucan 3 5 % Other hemicelluloses (pentosans) 4 7 %
Cellulose 4-5 % Lipids 2 3 %
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Protein 8 13 % Amino acids and peptides 0.5 %
Nucleic acids 0.2 0.3 Minerals 2 %
Other substances 5-6 %
Step 2: Soaking process of Malted Barley and Rye Malt into the
soaking vessel with the addition
of water as the cleaning agent.
The process of malt production starts with dipping the grain in
stainless steel tubs. The grain is
washed and soaked at the same time the soaking may last up to
two days. The soaking process gives
the grain required amount of moisture and increases their
vitality.
Step 3: Germination process of the soaked ingredient with a
defined level of temperature.
After soaking, the grain is transferred to the germination
chamber by hydrotransport.
In the germination chamber, air of necessary humidity and
temperature is blown through the
grain mass. During the process of germination, the goal is to
accumulate as much ferments as possible in
the grains.
Step 4: Roasting/Drying Process of the germinated ingredients
from the previous process.
After germination, the grain is moved to the dryer/roaster.
The drying/roasting process is carried out, using warm air and
applying specific modes of
temperature. Drying/roasting alters not only the moisture
content, but also flavour, odour and aroma.
Step 5: Grounding and Cleaning Process of the roasted
grains.
Dried grain (green malt) is transferred to the sprout breaking
mechanism, where the sprouts are
removed, as they impart an unpleasant taste to beer.
The dried grain is cooled, weighed and transferred to elevator
bins. After a period of ripening,
they become an ingredient for making good beer light malt.
Step 6: Pumping process of the malt into the large storage silos
for storage and preparation for
delivery.
Step 7: Extraction of Beer from the storage tanks for the
delivery and distribution to clients.
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The Instrumentation and Control used for:
Mixing of the raw materials:
MicroTREK - (Guided Microwave) : LEVEL TRANSMITTERS
THERMOPOINT TM - (Multipoint temperature transmitter) :
TEMPERATURE METERS
NIVOROTA-(Rotary Paddle): Level Switches
Soaking process for the mixed barley and rye.
EchoTREK for liquids - (Ultrasonic Compact) : LEVEL
TRANSMITTERS
NIVOSWITCH for liquids - (Vibrating Fork) : LEVEL SWITCHES
NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL
TRANSMITTERS
Germination process.
THERMOCONT TT - (Temperature transmitter) : TEMPERATURE
METERS
NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL
TRANSMITTERS
Roasting process.
NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL
TRANSMITTERS
THERMOCONT TT - (Temperature transmitter) : TEMPERATURE
METERS
Storing the malt product into vessels before to distribute to
its customer and buyers.
NIVOPRESS D - (Hydrostatic level / pressure) : LEVEL
TRANSMITTERS
MicroTREK - (Guided Microwave) : LEVEL TRANSMITTERS
NIVOROTA - (Rotary Paddle) : LEVEL SWITCHES
NIVOCONT R - (Vibrating Rod) : LEVEL SWITCHES
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Tables References
MicroTREK - (Guided Microwave) : LEVEL TRANSMITTERS
FEATURES
APPLICATIONS
SPECIFICATIONS
Two-wire TDR Technology Digital communication High accuracy: 5
mm High pressure range High temperature range Extremely low dead
band Large Dot-Matrix graphic display Local programming feature
Text-based menu system Plastic coated stainless steel probes (PFA,
FEP, PP), Aluminium and plastic housing Wide range of probes
Explosion-proof models
Level, volume measurement Liquids, powders and granular mediums
with Er>1.4 Medium with turbulent surface, dense dust, vapour or
pressurized gas layers above the product surface For all tank
shapes, for narrow vessels Heavy industrial applications
Power supply: 18-35 V DC Accuracy: 5 mm Medium temperature:
-30...+ 200 C Pressure: max. 40 bar Measuring range: up to 24 m
Output: 4-20mA, loop powered Communication: HART Process
connection: 1'' 1 1/2'' or flanges Ingress Protection:IP 65 ATEX
approval: II 1 G Ex ia IIC T6...T3 II 1 G Ex ia IIB T6...T3 II 1D
iaD A20/A21 IP65 T100C
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THERMOPOINT TM - (Multipoint
temperature transmitter) :
TEMPERATURE METERS
FEATURES
APPLICATIONS
SPECIFICATIONS
2-wire multipont temperature Transmitter Max. 30m probe length
Max. 15 sensors Max 35kN tensile force Digitally addressed sensors
HART communication Ex ia or Dust Ex protection APPLICATIONS
For normal and hazardous materials Temperature measurement of
liquids ,or powdered, granular or free flowing solids Grain
industry Feed industry Food industry
Power supply: 12-36 V DC Measuring range: For liquids:
-40C.+125C For solids: -10C.+85C Accuracy: -10C...+85C: 0,5C
-40C...-10C and +85C...125C: 2C Max. tensile force: 35kN Probe
length: 5-30m Output: HART Protection: IP67 Approval: ATEX Ex II 1
G Ex ia IIB T6..T4 ATEX Ex II 1 D Ex iaD A20/A21 T85C IP67 ATEX Ex
II 1 D Ex ta/tb IIIC T85C Da IP67
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NIVOROTA - (Rotary Paddle) : LEVEL SWITCHES
FEATURES
APPLICATIONS
SPECIFICATIONS
Two-wire TDR Technology Digital communication High accuracy: 5
mm High pressure range High temperature range Extremely low dead
band Large Dot-Matrix graphic display Local programming feature
Text-based menu system Plastic coated stainless steel probes (PFA,
FEP, PP), Aluminium and plastic housing Wide range of probes
Explosion-proof models
Level, volume measurement Liquids, powders and granular mediums
with Er>1.4 Medium with turbulent surface, dense dust, vapour or
pressurized gas layers above the product surface For all tank
shapes, for narrow vessels Heavy industrial applications
Power supply: 230/120/24 V AC, 24 V DC Temperature: - 30C to
200C Pressure: max. 3 bar Output: SPDT Relay 250V AC, 15A Process
connection: mouniting plate, or BSPT 1'' / 11/2'' Ingress
protection: IP67 Ex marking: ATEX II 1/2 D Ex tb IIIC T__C IP67
Da/Db
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EchoTREK for liquids - (Ultrasonic Compact) : LEVEL
TRANSMITTERS
FEATURES
APPLICATIONS
SPECIFICATIONS
2- or 4-wire compact transmitters Non-contact level metering
Narrow 5 beam angle Fully temperature compensated Excellent signal
processing via QUEST+ software PP, PVDF, PTFE, stainless steel or
foam faced Transducers Optional field indicator and plug-in
programmer /display Optional switching relay Built-in DataLogger
Plastic or aluminium housing * HART + * PROFIBUS PA + Secondary
lightning protection Explosion-proof models
Almost any liquids
Level, volume and open channel flow measurement
Reliable measurement in challenging applications such as
vapour/fume, stirrer, foam with liquids
Power supply: - 2-wire: 12.5-36V DC - 4-wire: 24 V AC/DC; 230 V
AC 11.4-40V DC / 11.4-28V AC Ambient temperature: -30 C to +70 C
Medium temperature: -30 C to +100 C Pressure: 0.3 - 3 bar Measuring
range: -0.2 to 25 m for liquids Outputs: 4-20 mA, relay, HART,
PROFIBUS PA Protection: IP 67 Approvals: ATEX II 1 G EEx ia IIB
T6
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NIVOSWITCH for liquids - (Vibrating
Fork) : LEVEL SWITCHES
FEATURES
APPLICATIONS
SPECIFICATIONS
No moving parts Self-cleaning for most media High immunity
against vibrations Stainless steel and coated (PFA) probes Solid
rod extension up to 3 m Various output configurations Selectable
density High or low fail-safe mode Plastic, aluminium or stainless
steel housing Explosion-proof models
Most liquids with min. 0.7 kg/dm3 density and max. 10,000 mm2/s
viscosity Corrosive, thick, turbulent, flowing liquids
Power supply: 20-255V AC, 20-60V DC Ambient temperature: -40 C
to +70 C Medium temperature: -40 C to +130 C Medium pressure: max.
40 bar Process connection: 1'', 11/2'' or flanges or hygienic
fittings Output: 1 or 2 SPDT relays, 2-wire AC or DC, transistor
(PNP, NPN) Ingress protection: IP 65/68, IP 67 Ex marking: -ATEX II
1 G Ex ia IIC T4...T6 Ga -ATEX II 1 G Ex ia IIB T4...T6 Ga
Approvals: -Germanischer Lloyd (GL) only for Compact type (RF-400)
instruments
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NIVOPRESS D - (Hydrostatic level /
pressure) : LEVEL TRANSMITTERS
FEATURES
APPLICATIONS
SPECIFICATIONS
Two-wire compact transmitter Stainless steel diaphragm Measuring
range: 0.1-400 bar, -1 bar Scalable analogue output Programmable
damping Level and pressure management Secondary lightning
protection High overload capability High accuracy
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THERMOCONT TT - (Temperature transmitter) :
TEMPERATURE METERS
FEATURES
APPLICATIONS
SPECIFICATIONS
2-wire compact temperature indicator, Transmitter Integral Pt
100 probe Plug-in type indicator and programming unit Measurement
range: -50 C .. +600 C Resolution: 0.1 C up to 200 C HART
communication Probe length upto 3 m Aluminium or plastic housing
Fully programmable Heavy duty field mountable housing
Explosion-proof models
Normal and explosive mediums Temperature indication and
transmission Signal transmission to large distances
Power supply: 10...36 V DC Ambient temperature: -20 C .. +88 C
Medium temperature: -50 C .. +600 C Pressure: max. 25 bar Output:
4...20 mA, HART Process connection: M20x1.5, 1/2'', flange
Protection: IP 65 ATEX II 2 G EEx d IIB T6-T1 II 2(1) G EEx d ia
IIB T6-T1 II 1/2 G EEx d ia IIB T6-T1 II 2(1) G EEx ia IIC T6-T1 II
1/2 G EEx ia IIC T6-T1
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NIVOCONT R - (Vibrating Rod) : LEVEL SWITCHES
FEATURES
APPLICATIONS
SPECIFICATIONS
No moving parts Self-cleaning for most media Stainless steel
vibrating section Solid rod or flexible cable extension up to 20 m
Plastic or aluminium housing Selectable density High or low
fail-safe mode Selectable switching delay Dust-Ex models
Almost any granular material and powder with min. 0.05 kg/dm3
bulk density Grain, flour, plastic granules, cement, fly ash
Power supply: 20255 V AC/DC Ambient temperature: -30 C to +50 C
Medium temperature: -30 C to +160 C Pressure: max. 25 bar Process
connection: 11/2'' Output: relay (SPDT) or electronic switch (SPST)
Protection:IP65, IP 67 (housing) Ex marking: ATEX 1/2 D tD A20/21
IP67 T*
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References:
http://oregonstate.edu/instruct/css/330/five/BarleyOverview.htm
http://www.brewps.com/rye-malt-1-pound.html
http://www.probrewer.com/library/malt/the-maltingprocess/
http://www.maltosa.lt/en/production_of_malt,step.2
http://nivelco.com/egyeb/swf/malata_eng.html