EA004916B1 - Improvements in and relating to the steeping of barley - Google Patents

Abstract

1. A process of steeping barley for subsequent malting in a steeping system (1) comprising three vertical arranged, one above the other, steeping vessels, namely a highest initial (2), an intermediate (3) and a lowest final (4) steeping vessels each steeping vessel (2,3,4) having cylindrical sides (5), terminating in a conical base (8), a water inlet manifold (11) and outlet manifold (13) in the base (6) and a plurality of sets of circumferentially arranged and spaced-apart aeration rings (7) in the base (6), the initial steeping vessel (2) additionally having in overflow receiving channel (25) around its periphery and a central rousing tube (30) open at both ends, the rousing tube (30) being spaced-apart from and adjacent the base (6) and in communication with a pressurised air inlet pipe (31) for delivering barley up through he rousing tubes for recirculation of the barley and a conical protective cover (32) is mounted above the rousing tube (33) and spaced-apart therefrom, the system further comprising control means comprising data recording and control means and a systems database, the control means being connected to temperature, moisture content and germination capacity monitors for the vessels to control the operating parameters of the process, the process comprising: for each variety of barley being malted prior to acceptance of the variety for steeping, carrying out a micro-malting process on a sample to determine optimum steeping parameters; storing the parameters in the database together with the characteristics of the barley including at least the variety and where grown; and then prior to commencing the steeping, obtaining the parameters stored and setting the steeping parameters having regard to the stored parameters; during the steeping, recording and storing the actual parameters in the database for subsequent use with barley having those characteristics; from time to time carrying out a further micro-malting process on other barley; and then on receiving a batch or barley for steeping, the steps are performed of: (a) delivering water and barley into the initial steeping vessel (2); (b) delivering further water into the initial steeping vessel (2) to cause overflow into the overflow receiving channel (2) while rousing and aerating the barley using the lift tube (30) and aeration rings (7); (c) stopping the rousing, and adding potassium permanganate; (d) transferring the wet barley and water to the intermediate steeping vessel (3); (e) steeping the barley with intermittent aeration by the aeration rings (7) in the intermediate steeping vessel (3); (f) draining the water; (g) allowing the drained barley to rest white extracting CO2 from above the barley and intermittently spraying the barley; (h) filing the intermediate steeping vessel (3) with water; (i) steeping the barley with intermittent aeration using the aeration rings (7); (j) transferring the barley and water to the final steeping vessel (4); (k) steeping the barley with intermittent aeration in the final steeping vessel 4); (l) draining the water; (m) allowing the drained water to rest while extracting CO2 from above the barley and intermittently spraying the barley; (n) filling the final steeping vessel (4) with water; (o) steeping the barley with intermittent aeration in the final steeping vessel (4); and (p) delivering the wet barley onwards for germination; and in which additional: during each resting step (g) and (m), wetting the barley every two hours for between 0.01 and 0.03 hours and checking the temperature of the barley and if the temperature exceeds 25 degree C, the additional steps of filing the steeping vessel (3,4) and draining the steeping vessel (3,4) are performed prior to continuing with the resting step (g) and (m); adding the water at between 11 degree C and 13 degree C for each steeping step (b), (e), (i), (k) and (o); and continuously monitoring the temperature, the moisture content and germination capacity of the barley and when, during the last resting step (g) and (m) in the intermediate steeping vessel (3) and the final steeping vessel (4), the moisture content of the barley is below 32 to 35% and 32% respectively, the appropriate resting step (g), (m) is prolonged with additional wetting until the required moisture content is achieved. 2. A process as claimed in claim 1, in which the characteristics stored additionally comprise one or more of: Batch number; Start date and time; Site number; Vessel group; Steeping method etc. 3. A process as claimed in claim 1 or 2, in which the micro-malting process is carried out on each variety at least ones a year prior to commencing steeping while the barley is in storage. 4. A process as claimed in any preceding claim, in which in the initial steeping vessel (2): step (b) of rousing the barley is carried out for between 0.25 and 0.45 hours; and step (c) of further steeping the barley is carried out for between 1 and 2 hours. 5. A process as claimed in claim 4, in which the times for carrying out steps (b) and (c) are of the order of 0.5 and 1.5 hours respectively. 6. A process as claimed in any preceding claim, in which in the intermediate steeping vessel (3): step (e) of steeping the barley is carried out for between 4 and 8 hours; step (g) of resting the barley is carried out for between 10.5 and 16.5 hours; and step (i) of steeping the barley is carried out for between 2.0 an 5.0 hours. 7. A process as claimed in claim 6, in which the times for carrying out steps (e), (g) and (i) are of the order of 6.0, 13.5 and 3.5 hours respectively. 8. A process as claimed in any preceding claim, in which in the final steeping vessel (4): step (k) of steeping is carried out for between 3.0 and 5.0 hours; step (m) of resting the barley is carried out for between 9.5 and 13.5 hours; and step (o) of steeping is carried out for between 6.0 and 9.5 hours. 9. A process as claimed in claim 8, in which the times for carrying out steps (k), (m) and (o) are of the order of 4.0, 11.5 and 7.5 hours respectively. 10. A process as claimed in any preceding claim, in which the intermittent aeration is carried out for between 20% and 30% of the resting time. 11. A process as claimed in claim 10, in which the time taken to carry out intermittent aeration is of the order of 25% of the resting time. 12. A process as claimed in any preceding claim, in which when, during a resting step (b), (e), (i), (k) and (o), the temperature exceeds 25 degree C and the resting step is within one hour of anticipated termination, the resting step (b), (e), (i), (k) and (o) is terminated. 13. A process as claimed in any preceding claim, in which between 1.5 and 3.5m<3> of water is added per tonne of barley. 14. A process as claimed in any preceding claim, in which the air is supplied at between 775 and 875 millibar. 15. A process as claimed in any preceding claim, in which when carrying out step (b) and causing overflow, the top of the initial steeping vessel is skimmed to remove floating debris.

Description

The present invention relates to a method of soaking barley in locking systems for subsequent malting.

Prior art

Known cylinder-shaped and cone-shaped vats, commonly referred to as conical locking vats. Three such vats are placed one above the other, and barley is passed through them successively in the soaking process. Such vats have found successful application in the past only to a certain extent. Unfortunately, in the process of soaking there are problems associated with the part of the grain, which is located in the lower part of the cone forming the base. Due to the absorption of water, metabolic processes continuously increase, hence respiration.

Summary of Invention

The present invention is directed to eliminating the problems inherent in the soaking process, while at the same time providing the possibility of using conical locking vats present in many malting houses.

In accordance with the invention, a method of soaking barley is proposed for subsequent malting in a locking system comprising three locking vats arranged one above the other vertically: an upper primary locking vat, an intermediate locking vat, and a lower final locking vat, each of which has cylindrical walls converting into a conical a base provided with an inlet distributor and an outlet distributor for water, as well as circumferentially spaced aeration rings. The primary lock vat is provided with an overflow receiving chute located around the vat and an open central mixing tube open at both ends, which is installed with a clearance from the base and communicates with the compressed air supply pipe, through which the barley is fed up through the lifting tube to provide its recycling. A conical protective cover is installed above the lifting tube. The system is equipped with appropriate management tools containing data recording and management tools, as well as a system database, and associated with temperature, moisture content and sprouting instrumentation control devices provided for vats in order to control the operating parameters of the method.

The method includes the following operations: micro-creeping a sample of each barley to be salted, before soaking this type of barley, in order to determine the optimal soaking parameters;

storing the specified parameters in a database together with the characteristics of barley, including at least the type of barley and the place of cultivation;

retrieving stored parameters and setting soaking parameters on their basis, carried out prior to the start of soaking;

recording and storing in the database in the process of soaking the current parameters for subsequent use in relation to barley, which has the specified characteristics;

periodic micro-salting of other barley.

According to the proposed method, after receiving a batch of barley for soaking, the following operations are carried out:

(a) loading barley and water into the primary lock vat;

(b) additional water is poured into the primary lock tank to ensure overflow into the overflow receiving trough, mixing and aerating the barley using a lifting pipe for mixing and aeration rings;

(c) stop stirring and add potassium permanganate;

(d) transfer the moistened barley and water to the intermediate lock vat;

(e) barley is soaked in an intermediate locking vat with periodic aeration by means of aeration rings;

(e) drain the water;

(g) provide a resting stage of dried barley with release of carbon dioxide from the barley surface with periodic irrigation of barley;

(h) fill the intermediate lock tank with water;

(i) soaked barley with periodic aeration using aeration rings;

(j) transfer barley and water to the final lock vat;

(k) barley is soaked with periodic aeration in the final lock vat;

(m) drain the water;

(n) ensure the resting stage of dried barley with release of carbon dioxide from the surface of barley during periodic irrigation of barley;

(o) fill the final lock-vat with water;

(n) barley is soaked with periodic aeration in the final locking vat;

(p) Serves wetted barley for germination.

The method also includes the following additional operations:

at each stage of dormancy (g) and (n) moisten barley every 2 hours for from 0.01 to 0.03 hours and control the temperature of the barley, and in case of exceeding the temperature of 25 ° C, perform additional operations of filling the lock tanks with water and draining the water of the indicated 3 lock vans before continuing to ensure the stages of rest (g) and (n);

add water at a temperature between 11 and 13 ° C at each stage of soaking (b), (d), (i), (l) and (p); and carry out current control of temperature, moisture content and barley sprouting indicators, while at the dormancy (g) and (n) barley stages in the intermediate locker vat and final lockbox its moisture is below 32-35% and 42%, respectively, prolonging the corresponding resting stage with additional moistening of barley to achieve the required moisture.

The advantage of using aeration rings is to provide better and more uniform absorption of moisture, as well as to avoid the quality problems inherent in such lock vats. Although aeration rings are well known, their use in combination with a stirring tube installed in the primary lock box is a special advantage. In addition, using the first tank as the primary lock vat, and not just as a flushing tank, leads to a significant improvement in the quality of the malt and an increase in its homogeneity.

However, the main advantage of the present invention relates to more stringent control over the process and setting the proper parameters prior to the start of soaking. The problem is that the implementation of control by service personnel is becoming more and more multilateral and complex task. Often the problem is the availability of competent and experienced personnel. Indeed, for any person who has ever participated in the management of such an installation, it is clear that the main problem is to provide working personnel who exercise proper control over production operations and also use the correct operating parameters.

The present invention eliminates a significant number of such problems by excluding from the staff those who must make decisions. As a result, only those who maintain the installation remain, and not those whose duties include monitoring the process.

In a preferred embodiment of the method, the stored characteristics of barley additionally include one or more characteristics selected from the group including the batch number of the barley, the date and time of the beginning of the process, the number of the bunker, the group of vats, the soaking method, etc.

In the following preferred embodiment, micro-salinization of each barley is carried out at least once a year before soaking, when the barley is in storage.

According to a variant of the proposed method, in the primary lock-up tank at the stage (b), the barley is stirred for 0.25-0.45 hours, and at the stage (c) the barley is additionally soaked for 1-2 hours. In a preferred embodiment, at the stage (b) the barley is stirred for about 0.5 hours, and at the stage (c) the barley is soaked for about 1.5 hours

In the following variant of the method in the intermediate lock-up vat the duration of the stage (d) soaking barley is from 4 to 8 h, the duration of the stage (g) dormancy of barley is from 10.5 to 16.5 h, and the duration of the stage (s) of soaking barley is 2 to 5 hours. The duration of stages (e), (g) and (i) is preferably about 6, 13, 5 and 3.5 hours, respectively.

In yet another embodiment of the method in the final locking vat, the duration of the barley steeping stage (l) is from 3 to 5 hours, the rest period of the barley stage (n) is from 9.5 to 13.5 hours, and the duration of the barley steeping stage (p) is from 6 to 9.5 hours. The duration of the stages (l), (n) and (p) is preferably about 4, 11, 5 and 7.5 hours, respectively.

It was found that periodic aeration should be carried out for a period of time ranging from 20 to 30% of the duration of the rest stage, preferably of the order of 25% of the duration of the rest stage.

In the proposed method, the resting stage of barley is completed when the temperature exceeds 25 ° C, and if before the planned completion of these stages there is time within one hour.

For proper absorption per ton of barley, water is added in an amount from 1.5 to 3.5 m ³ .

Air is preferably supplied at a pressure of from 775 to 875 mbar to ensure sufficient aeration and mixing of barley.

In another embodiment of the method according to the invention, in the implementation of stage (b), ensuring overflow removes floating debris from the top of the primary locking vat.

Brief Description of the Drawings

The invention is more clear from the further description of the preferred embodiments, which is solely an example of the invention, with reference to the accompanying drawings, in which FIG. 1 shows schematically a cross section of a locking system according to the invention;

in fig. 2 shows in more detail on an enlarged scale one of the lock vats of FIG. one;

in fig. 3 shows on an enlarged scale one of the two remaining lock tanks of FIG. one.

Information confirming the possibility of carrying out the invention

The drawings show a locking system, generally designated by the numeral 1, containing three locking vats: a primary locking vat 2, an intermediate locking vat 3, and a final locking vat 4. Each of the vats 24 has cylindrical walls 5 passing into a conical base 6. Around each conical The bases 6 have three aeration rings 7, each of which is connected to a compressed air supply line 8 connected to a compressor (not shown). Aeration rings 7 have spaced air holes (not shown). The lower part of each lock vat is provided with a perforated conical section 10, which is connected on one side to a freshwater distributor 11 connected to a pipeline 12 for supplying water, and on the other side to another distributor 13, which in turn is connected to a drain pipe 14. The feed screw conveyor 15, driven by the engine 16, loads grain into the inlet hopper 17 located above the primary lock vat 2. This primary tank is equipped with an overflow chute 25 passing along its periphery and communicating with ascending pipe 14. The implementation of the above message is not shown in the drawings. Inside the primary lock vat 2, a lifting pipe 30 is installed, under which is located a pipe 31 for supplying compressed air. On top of the lifting pipe 30 closes the conical protective cover 32, located with a gap from this pipe. From the primary lock vat 2 departs the discharge pipe 33 with the exhaust valve 34, leading to the intermediate lock vat 3, from which departs another discharge pipe 33 with the exhaust valve 34, leading to the final lock vat 4. From this final tank also departs the discharge pipe 33, equipped with an exhaust valve 34, through which a moistened barley is fed to the output screw conveyor, driven by the engine, which is fed further into the rostrum.

The intermediate lock vat 3 and the final lock vat 4 have an identical construction, therefore in FIG. 3, on an enlarged scale, only one such vat 3 is shown. The locking vats 3 and 4 lack lifting pipes and overflow receiving channels.

The described system is equipped with appropriate controls, such as a conventional computer (not shown), which contain, along with computing tools, data recording and management tools, as well as a system database. These controls are associated with temperature, moisture content and germination indicators instrumentation. These devices are provided for each vat. For example, a germination indicator monitor includes means for sampling from a vat. In this way, the controls regulate the operating parameters of the vats.

In the process, the barley is loaded via a screw conveyor 15 into the primary lock vat 2, into which water is also supplied through the pipeline 12, as a rule, simultaneously with the loading of the barley. Initially, water is introduced into the lock tank 2 in an amount sufficient to cover the barley, while compressed air is fed through the aeration rings 7 and up through the lifting pipe 30 through the pipe 31 to mix the barley. The compressed air supplied upward through the pipe 30 causes the barley and water to rise through this pipe, which then get into the protective cover 32, as shown in FIG. 1. This cover 32 contributes to the distribution of moistened barley through the primary locking tank 2 without loss of water and barley, which may occur due to splash. Then an additional amount of water is introduced into the primary lock-up tank 2 until the moment when water begins to overflow with dirt, husks, chaff, etc. in the form of a suspension in an overflow receiving chute 25. In this chute, any debris floating on the surface of the water is removed, and the mixing of barley is continued by supplying air through the lifting pipe 30 and aeration rings 7. The duration of this mixing is from 0.25 to 0.45 h, preferably 0.5 h. Then potassium permanganate is added to the water, usually at the rate of 0.024 kg per ton of barley, and the barley and water are left alone. After a proper soaking time, ranging from 1 to 2 hours, usually about 1.5 hours, the moistened barley is overloaded into the intermediate lock vat. Usually, after adding potassium permanganate, sufficient water is added to the primary lock vat for overflow.

In the intermediate lock tank, the moistened barley is stirred for 4-8 hours using aeration rings 7. Then water is drained from this tank and the barley is dried for approximately 0.5 hours. After that, the barley is left at rest for 10.5-16 , 5 hours, preferably 13.5 hours, which is accompanied by a constant release of carbon dioxide. The surface of the moistened barley is watered for approximately 2 minutes every 2 hours.

Then the intermediate lock tank 4 is filled with water for approximately 0.5 hours. Barley and water are kept in the intermediate lock tank 3 with air supplied through aeration rings 7 while stirring. Periodic aeration, in other words, stirring, is carried out for 2030% of the rest time, usually for a quarter of an hour every hour. This soaking with stirring is carried out for 3-5 hours, preferably 4 hours. Subsequently, moistened

The barley and water are reloaded into the final lock tank and left at rest for 3 to 5 hours, preferably for 4 hours. At this time, the barley is periodically stirred using only aeration rings 7, usually for 15 minutes every hour. Next, drain the water from the final lock of the vat for about 0.5 hours.

Then the moistened barley is left alone for 9.5-13.5 hours, also with a constant release of carbon dioxide and irrigation of the barley surface for about 2 minutes every 2 hours. Subsequently, the barley is again filled with water for about 0.5 hours. The barley is soaked from 6 to 9.5 hours, preferably 7.5 hours, with stirring every 15 minutes or so. At the final stage, the barley is sent to the malt house.

At each stage of dormancy, the barley is moistened every 2 hours for 0.1–0.3 hours and the temperature of the barley is monitored, and if the temperature exceeds 25 ° C, the barley is again filled with water and dried almost immediately to cool. However, in the case when less than 1 hour remains until the completion of the resting stage, this stage is often completed and the next soaking step is carried out.

Ideally, at each stage of soaking, soaking water is added at a temperature of 11-13 ° C.

An integral part of the method is the current control of temperature, moisture content and barley germination rates as it passes through the soaking cycle. Usually, these parameters are measured at the last stage of rest, both in the intermediate and in the final lock-in tank, because barley absorbs water, essentially, while in a state of rest. The moisture content is measured at both the mentioned stages of rest, and, if, for example, in the intermediate tank the moisture content in the grain is below about 32-35%, additional changes are made to the soaking process. Similarly, if, for example, in the final vat the moisture content did not reach about 42%, additional soaking is carried out and even provides an additional state of rest.

In the process, the temperature of the barley is measured and efforts are made to ensure that at no stage does the temperature of the barley exceed 25 ° C. Usually about 1.5-3.5 m ^{3 of} water are added per ton of barley. Air is supplied at a relatively low pressure, usually of the order of 775-875 mbar.

Despite the fact that in the described embodiment, a feed screw conveyor 15 is provided for filling the inlet hopper, in many cases a storage bin is installed directly above the inlet hopper, and the barley is fed by gravity.

In the present description, the terms “contain, are contained and contained”, as well as any variations thereof, and the concepts “include, include, included and including” as well as any variations thereof, are completely interchangeable and should be interpreted in the broadest sense of these words.

The invention is not limited to the embodiment described above and can be modified both in a constructive and in a detailed plan within the scope of a formula.

Claims (15)

CLAIM 1. The method of soaking barley for subsequent malting in the locking system (1), containing three locking vats placed one above the other vertically: the upper primary locking vat (2), the intermediate locking vat (3) and the lower final locking vat (4), each of which has cylindrical walls (5), passing into a conical base (6), equipped with an inlet distributor (11) and an outlet distributor (13) for water, as well as spaced around a circumference of aeration rings (7), with the primary locking h n (2) is equipped with an overflow receiving chute (25) located around the tank and open at both ends of the central lifting tube (30) for mixing, which is installed with a gap from the base (6) and is in communication with the pipe (31) for feeding compressed air, by means of which the barley is fed upward through the lifting pipe (30) to ensure its recirculation, with a conical protective cover (32) installed over the lifting pipe (30) with a gap, and the system is equipped with control means containing data recording and control tools, and also with a system database and associated with instrumentation devices of temperature, moisture content and sprouting indicators provided for vats to control the operating parameters of the method, including microslining of the sample of each barley to be salted before commencing soaking of the barley to determine the optimal soaking parameters; storing the specified parameters in a database together with the characteristics of barley, including at least the type of barley and the place of cultivation; retrieving stored parameters and setting soaking parameters on their basis, carried out prior to the start of soaking; recording and storing in the database in the process of soaking the current parameters for subsequent use in relation to barley, which has the specified characteristics; periodic micro-curing of other barley, and after receiving a batch of barley for soaking, the following operations are carried out: (a) loading barley and water into the primary lock vat (2); (b) additional water is poured into the primary lock vat (2) to ensure overflow into the overflow receiving chute, mixing and aerating the barley using a riser pipe (30) and aeration rings (7); (c) stop stirring and add potassium permanganate; (d) transfer the moistened barley and water to the intermediate lock vat (3); (e) barley is soaked in an intermediate locking vat (3) with periodic aeration with aeration rings (7); (e) drain the water; (g) provide a resting stage of dried barley with release of carbon dioxide from the barley surface with periodic irrigation of barley; (h) fill the intermediate lock vat (3) with water; (i) soaked barley with periodic aeration by means of aeration rings (7); (j) transfer barley and water to the final lock vat (4); (l) barley is soaked with periodic aeration in the final locking vat (4); (m) drain the water; (n) ensure the resting stage of dried barley with release of carbon dioxide from the surface of barley during periodic irrigation of barley; (o) fill the final lock vat (4) with water; (n) barley is soaked with periodic aeration in the final locking vat (4); (p) serves moistened barley for germination, and the method includes additional operations: at each stage of dormancy (g) and (n) moisten barley every 2 hours for from 0.01 to 0.03 hours and control the temperature of the barley, and in case of exceeding the temperature of 25 ° C, perform additional operations of filling the lock vats (3, 4 a) water and drainage of water from the above lock tanks until the maintenance of the rest stages (g) and (n) is continued; add water at a temperature between 11 and 13 ° C at each stage of soaking (b), (d), (i), (l) and (p); and carry out current control of temperature, moisture content and barley sprouting indicators, while, at the resting stages (g) and (n) barley, in the intermediate locker tank (3) and final lockbox (4) its humidity is below 32-35% and 42%, respectively, prolong the appropriate dormancy with additional barley wetting until the desired moisture is reached. 2. The method according to claim 1, wherein the stored characteristics of barley additionally include one or more characteristics selected from the group consisting of the batch number of the barley, the date and time of the process, the bunker number, the group of vats, the soaking method, etc. 3. The method according to claim 1 or 2, characterized in that they carry out microslining of each type of barley at least once a year before soaking, when the barley is in storage. 4. The method according to one of the preceding paragraphs, characterized in that in the primary locking vat (2) at stage (b) the barley is stirred for 0.25-0.45 hours, and at stage (c) the barley is additionally soaked for 1 -2 hours 5. The method according to claim 4, characterized in that in stage (b) the barley is stirred for about 0.5 hours, and in stage (c) the barley is soaked for about 1.5 hours. 6. The method according to one of the preceding paragraphs, characterized in that in the intermediate locking vat (3) the duration of the stage (d) soaking barley is 4 to 8 hours, the duration of the stage (g) the rest of the barley is from 10.5 to 16.5 h, and the duration of the stage (s) soaking barley is from 2 to 5 h. 7. The method according to claim 6, characterized in that the duration of the stages (d), (g) and (i) is about 6, 13, 5 and 3.5 hours, respectively. 8. The method according to one of the preceding paragraphs, characterized in that in the final locking vat (4) the duration of the stage (l) soaking barley is from 3 to 5 hours, the duration of the stage (n) rest of the barley is from 9.5 to 13.5 h, and the duration of the stage (p) soaking barley is from 6 to 9.5 hours 9. The method according to claim 8, characterized in that the duration of the stages (l), (n) and (p) is about 4, 11, 5 and 7.5 hours, respectively. 10. The method according to one of the preceding paragraphs, characterized in that the periodic aeration is carried out for a period of time, comprising from 20 to 30% of the duration of the quiescent stage. 11. The method according to claim 10, characterized in that the periodic aeration is carried out for a period of time, amounting to about 25% of the duration of the resting stage. 12. The method according to one of the preceding paragraphs, characterized in that the resting stage of barley is completed if the temperature exceeds 25 ° C and if until the planned completion of these stages there is time within 1 hour. 13. The method according to one of the preceding paragraphs, characterized in that from 1.5 to 3.5 m ^{3 of} water is added to a ton of barley. At stage (b), floating debris is removed from the upper part of the primary lock box to ensure overflow. 14. The method according to one of the preceding paragraphs, characterized in that the air is supplied under a pressure of from 775 to 875 mbar. 15. The method according to one of the preceding paragraphs, characterized in that when