1. GRAIN HANDLING, MALTING, AND MALT ANALYSIS PART 2
Brewing + distilling center, inc.

2. 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.

3. MALT QUALITY AND ANALYSIS
Certificate of Analysis (COA) serves two purposes:
To document production in the Malthouse.
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

4. SRM & EBC
ASBC is the American Society of Brewing Chemists

5. FORMULAS SRM = (1.3546 x °L) – 0.76 (to convert °Lintner to SRM)
SRM = EBC x (to convert EBC to SRM)
EBC = SRM x (to convert SRM to EBC)
EBC = (°L x 2.65) – (to convert °Lintner to EBC)
DP °Lintner = (°WK + 16) / 3.5 (to convert Kolbach
index to °Lintner)

6. FORMULAS c’d
°L = (SRM + 0.6) / (to convert SRM to degrees Lovibond)
SG = 259 / (259 - °P) -- (to convert degrees Plato to Specific Gravity)
°P = (SG – 1) x (to convert Specific Gravity to degrees Plato)
(DBCG / 1 + MC) – 0.002) x Brewhouse Efficiency (to give actual brewhouse yield)

7. 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 = lbs extract/bbl

8. 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.
Mastering the brewing of classic and traditional beer styles is, in my opinion, one of the most important things a brewer can do to advance his standing in and knowledge of the chosen profession of brewing. Once a brewer has mastered the classic styles he has a firm base upon which to experiment.

9. 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 %
Munich Malt %
Crystal %
Black %
This from page 13 of the Malt book.

10. EXTRACT TABLE
To calculate the total extract needed we need to refer to the ASBC extract table which I was unable to access on the internet, not being a member of the ASBC; however, this table that I did find is close. However, you can arrive at the correct pounds of extract per bbl of wort with this formula:
(weight of a bbl of water + degrees Plato) X the gravity = lbs. extract per bbl.
Example for a 12°P wort: (259 lbs. + 12) X .12 = lbs. extract /bbl (which agrees with our chart above).

11. Example:
Malt Grist Fraction
Pale Malt %
Munich Malt %
Crystal %
Black %
By using our formula we find that a 12°P wort contains pounds of extract per bbl. 10 bbls X = pounds of extract needed for the brew Our brewery has an efficiency of 90%, so / .90 = pounds of potential extract required in the grist.

12. Example:
Malt Grist Fraction
Pale Malt %
Munich Malt %
Crystal %
Black %
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 %

13. Example:
Malt Grist Fraction
Pale Malt %
Munich Malt %
Crystal %
Black %
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 %
Munich malt %
Crystal %
Black %
Total %
To calculate the grist weight needed of each malt we divide the extract contribution by the CGAI value.

14. CALCULATING GRIST WEIGHT
Example:
Malt Grist Fraction
Pale Malt %
Munich Malt %
Crystal %
Black %
CALCULATING GRIST WEIGHT
Malt/Grist lbs. Extract Contribution CGAI Pale Malt / % Munich Malt / % 55.6 Crystal / % 37.6 Black / % 3.6 Total ************************************************************* 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.

15. FIGURING SRM (COLOR)
Malt Grist lbs. SRM SRM•lbs. Pale Malt Munich Malt Crystal Black 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

16. BREWING SOFTWARE PROGRAMS
Spreadsheet
Beer Smith
Brewers Friend

17. BEERSMITH
This is part of my recipe for Belgian Dubbel as seen on the BrewSmith screen. As you can see, my starting gravity was just inside the low end of the starting gravity range for the Dubbel style. Bitterness was in the middle of the range. Color was off the scale, so if I was worried about it being to dark I would need to cut back on the darker malts. My ABV was barely inside the range, but we were limited at BBF Brewery to 6% ABV by Tennessee law. We did let it creep up closer to 7% during my 3 years at the brewery because we did not list the alcohol content on the label. Please disregard the double addition of Aromatic Malt, as one should have been deleted.

18. 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. = Brewery efficiency = 85%
Malt Grist Fraction CGAI
Pilsner malt % %
Caramunich III malt % %
Munich malt I % %
Carahell malt % %
Wheat malt % %
Carafa II malt % %

19. Determine pounds of extract per bbl of wort
IN-CLASS PROJECT
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 ) = X .225 = lbs. of extract per bbl

20. Determine pounds of extract needed for the brew
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 lbs extract per bbl = lbs extract needed for the brew

21. Use brewery efficiency to figure potential extract
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 / .85 = 1490 lbs potential extract required in the grist

22. Figuring contribution of each malt 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 X = lbs extract contributed
Caramunich III X = “ “ “
Munich Malt I X = “ “ “
Carahell Malt X = “ “ “
Wheat Malt X = “ “ “
Carafa II Malt X = “ “ “
Total = lbs. total extract

23. Calculating grist weight of each malt
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 / .83 = 1293 lbs. grist Caramunich III / .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

24. MILLING THE MALT MILLS: 2 –Roll mills 6-Roll mills GRIST CASE
This two roll malt mill at Blackberry Farm Brewery is just one example of the two roll mills popular in smaller craftbreweries due to the lower cost of these mills when compared to four row and six roll mills. The crush is not as good as 4 or 6 roller mills but is acceptable to most small breweries.
Grist case holds milled malt until brewer is ready to mash-in.
When I read this line in The Practical Brewer I had to suppress a laugh – “Older mills are principally of a two-roll design. While some of these two-roll mills are still in operation, they have largely been replaced by modern multi-roll mills…”. When someone is planning a small craftbrewery or brewpub they will more than likely balk at spending $10, or more on a two-roll mill and definitely do not have the money for a larger mill in their budget.
GRIST CASE

25. MALT MILL ROLLERS DIAGRAM OF 6 ROLLER MILL
These rolls in a malt mill are definitely from a homebrew size malt mill. Generally the rolls in a professional malt mill will be grooved from end to end but will not have the diamond shaped pattern shown here.
DIAGRAM OF 6 ROLLER MILL

26. WET MILLS WET MILL SIERRA NEVADA, NC
Wet mills function by spraying the malt with a film of water before it enters rollers or by soaking the malt for a short time to achieve a certain moisture level before milling. The damp husk will not shatter as much as it might when milled dry. Ideally the husk will remain intact while the starchy interior will be uniformly crushed.
WET MILL SIERRA NEVADA, NC

27. 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
This is called the ideal because most small breweries are probably never going to realize it unless they have a six roll malt mill, preferably a wet mill. A lot of small breweries have the problem of the rollers eventually becoming farther apart at one end than at the other, which is a difficult adjustment to correct on many small malt mills. This will result in “old maids”, i.e. uncrushed kernels, coming out from one end of the rollers and too much flour coming out from the other end.

28. IDEALLY CRUSHED MALT
This is called the ideal because most small breweries are probably never going to realize it unless they have a six roll malt mill, preferably a wet mill. A lot of small breweries have the problem of the rollers eventually becoming farther apart at one end than at the other, which is a difficult adjustment to correct on many small malt mills. This will result in “old maids”, i.e. uncrushed kernels, coming out from one end of the rollers and too much flour coming out from the other end.

29. PROPER MALT CRUSH
If the gap in the malt mill rollers is properly set the endosperm of the malt will be uniformly crushed and the husk will remain mostly intact. When the husk is shredded it provides more surface area in the mash and releases excess tannins into the wort. This causes astringency in the beer.
I have not mentioned hammer mills here but if any of you go to work in one of the new craftbrewery that use mash filters instead of a lauter tun you will encounter the hammer mill, which completely pulverizes the malt.