Curso de produção de Cerveja Artesanal dia 02: Fundamentos Práticos

Name: Curso de produção de Cerveja Artesanal dia 02: Fundamentos Práticos
Uploaded: 2020-11-10T01:30:05.000Z
Duration: 3 h 4 min 31 s

Welcome to the Beer Production Course

Introduction to the Course

The second day of the craft beer production course is introduced, organized by the Academic League of Industrial Pharmacy and Technology in collaboration with Professor's Academic Brewery.

A practical class on beer production will be conducted by Professor Rogelho. Participants are encouraged to engage actively.

Participation and Certification

Viewers are reminded to submit their questions via comments or a form linked in the video description for clarification during a live session at 6 PM.

To receive a completion certificate, participants must fill out a form with keywords presented during today’s class and live session.

Understanding the Brewing Process

Key Steps in Beer Production

The brewing process involves several stages: malting, mashing, filtration, boiling, fermentation, and maturation. Each step is crucial for producing quality beer.

Mashing requires heating malt mixed with water at different temperatures to extract sugars necessary for fermentation. This stage is essential for creating wort from malted grains.

Importance of Hygiene

Emphasis on maintaining cleanliness throughout the brewing process due to microbial involvement; proper handwashing techniques are highlighted as critical for preventing contamination.

Equipment sanitation is equally important; all tools used should be cleaned thoroughly before handling ingredients or performing any manipulations during brewing.

Milling Malt: A Critical Step

Techniques for Milling Malt

The first step in preparing malt involves milling it properly to expose its interior enzymes that aid in sugar extraction during mashing. Proper milling ensures effective filtration later on.

Different milling devices can be used; manual grinders are suitable for small batches while adjustable electric mills can handle larger volumes efficiently without compromising grain integrity.

Adjusting Milling Settings

It’s important to adjust milling settings based on desired outcomes; too coarse or too fine can affect both extraction efficiency and subsequent filtration processes negatively. Regular checks ensure optimal results throughout this phase of production.

Calculating Ingredients for Brewing

Ingredient Ratios

For every kilogram of malt used, approximately 5 liters of beer can be produced; this ratio serves as a guideline but may vary depending on specific styles and recipes chosen by brewers.

When scaling up production (e.g., aiming for 20 liters), adjustments need to be made empirically based on experience rather than strict adherence to ratios alone; flexibility is key in achieving desired flavor profiles.

Introduction to Brewing Process

Initial Steps in Brewing

The brewing process begins by reaching a temperature of 63 degrees Celsius, at which point the heat and stirring are turned off.

At 63 degrees, the enzyme beta-amylase becomes active, breaking down the branched structure of starch into simpler sugars.

This enzymatic action requires a 30-minute hold at 63 degrees for effective hydrolysis before increasing the temperature to 68 degrees.

Temperature Control and Enzyme Activity

The initial operation involves mixing malt with water in a ratio of approximately 1:2; for example, using 60 kg of malt with about 120 liters of water.

Maintaining a temperature of 53 degrees Celsius for half an hour optimizes proteolytic enzymes that release essential amino acids from malt proteins.

Raising the temperature to 68 degrees activates alpha-amylase, which further hydrolyzes polysaccharides into fermentable sugars like glucose and maltose.

Filtration and Clarification

Separation Process

After enzymatic reactions, the mixture is filtered to separate liquid wort from solid residues (spent grains).

Hot water is used to rinse spent grains multiple times to maximize sugar extraction efficiency from the mash.

Importance of Sanitation

Proper sanitation during fermentation is crucial to prevent contamination by unwanted bacteria or wild yeast strains that could spoil the beer.

Fermentation Phase

Key Considerations

The wort must be boiled for over an hour while ensuring no additional ingredients other than malt, water, and hops are introduced during this phase.

Boiling causes protein coagulation and helps extract flavors from hops while sterilizing the wort.

Final Preparations

Post-boiling processes involve cooling down the wort carefully before fermentation begins.

Controlled fermentation conditions are established using double-walled vessels to maintain optimal temperatures throughout fermentation.

Conclusion on Brewing Techniques

Starting Fermentation

The next step involves adding previously heated water (around 55–56°C) to initiate critical reactions necessary for successful brewing.

Process of Beer Production: Initial Steps

Suspension Preparation

The suspension will be submitted at approximately 53ºC, the optimal temperature for proteases to act on proteins, generating amino acids essential for fermentation.

A critical aspect of this initial process is the amount of water used to create the malt suspension; typically, a ratio of 1 kg of malt requires about 2 liters of water.

Proportions and Equipment

For every kilogram of malt (60 kg in this case), around 120 liters of water is needed for the first process. The density of the suspension should neither be too thick nor too diluted.

In brewing, one kilogram of malt yields approximately five liters of beer; this ratio will be established in later stages. During mashing, an additional liter per kilogram may be added for efficiency.

Brewing Equipment Overview

The equipment consists of three systems: a mash tun that heats the mixture at different temperatures to extract necessary components from the malt effectively.

After saccharification, there’s a step called lautering where the wort is transferred to another vessel for clarification before moving it to boiling stages. This ensures maximum extraction from the grains used.

Extracting Nutrients and Home Brewing Tips

Nutrient Extraction

The spent grains are washed with hot water to maximize nutrient extraction before transferring the wort for fermentation preparation. This step is crucial as it ensures all nutrients are utilized efficiently during brewing.

Home Brewing Setup

To brew beer at home without significant investment, one can use a kitchen stove with at least two pots; volume depends on desired beer quantity while ensuring proper temperature control during mashing processes.

Recommended mashing temperatures range between 53ºC and 75ºC depending on specific requirements; using a pot with a ratio close to 1 kg malt to 2 liters water is suggested for effective results in home brewing setups.

Importance of Temperature Control

Manual Transfer and Agitation

After heating at various temperatures, it's important to manually transfer mixtures into filtration vessels while maintaining agitation throughout heating processes to ensure even temperature distribution and prevent scorching or overheating certain areas within the mash tun.

Consistent Agitation Requirement

Continuous stirring or mechanical agitation is vital whenever heat is applied; this prevents uneven cooking and ensures all parts receive adequate heat treatment during mashing phases which enhances overall quality in final products produced through these methods.

Understanding Malt in Beer Production

Definition and Composition

Many people are unaware that malt refers specifically to cereal grains like barley or wheat that undergo germination processes; understanding what constitutes malt helps clarify its role in beer production beyond just being an ingredient but rather as a fundamental component influencing flavor profiles significantly throughout brewing cycles.

Germination Process

Malted grains such as barley or wheat begin germinating when slightly moistened; enzymes like proteases and amylases develop during this phase which play crucial roles later by breaking down starches into fermentable sugars essential for yeast activity during fermentation stages leading up towards final product creation post-brewing activities undertaken earlier mentioned above!

This structured approach provides clarity on each stage involved in beer production while emphasizing key concepts related directly back towards practical applications whether done commercially or personally within home settings alike!

The Brewing Process: From Ingredients to Beer

Understanding the Initial Steps of Brewing

The brewing process begins with the hydrolysis of carbohydrates, releasing glucose, maltose, and maltotriose. This mixture is then filtered and clarified before fermentation occurs with yeast.

Recent trends in beer production include terms like "double malt" and "formalate," driven by regulations allowing up to 40% of malt content to be replaced with cheaper cereals like corn.

Economic Considerations in Brewing

Substituting traditional malts with less expensive grains helps reduce production costs significantly, as these alternatives are cheaper than malt. For instance, corn contributes starch to the mix.

Large breweries often compensate for reduced malt quality by adding enzymes during brewing, which can mask differences when consumed cold (5-8 degrees Celsius). This marketing strategy promotes drinking beer at low temperatures to enhance consumer experience.

Temperature Control and Hydrolysis Testing

The optimal temperature for enzyme activity during hydrolysis is 68°C; this temperature allows for effective breakdown of starches into fermentable sugars. Monitoring time and intensity through iodine tests is crucial for assessing efficiency.

An iodine test involves mixing a sample from the mash with a 2% iodine solution; a dark color indicates high starch content while lighter colors suggest successful hydrolysis after one hour at 68°C. Subsequent tests help track progress over time.

Progressing Through Hydrolysis

After an hour at 68°C, if the color remains dark, it indicates incomplete hydrolysis; further testing after another half-hour should show significant changes towards lighter shades if enzymatic action has been effective.

Once sufficient hydrolysis is achieved (indicated by lightening color), brewers raise the temperature to 75°C to deactivate enzymes before proceeding to filtration stages in brewing preparation.

Filtration Techniques in Brewing

Following enzyme deactivation, the next step involves transferring the mash into a filtration vessel where liquid separation occurs through recirculation methods aimed at clarifying the wort (the liquid extracted from the mash).

Effective clarification requires careful monitoring of liquid circulation until visual clarity is achieved; this process typically takes around 30 minutes under standard conditions during brewing operations.

Process of Clarifying and Washing Bagasse

Initial Steps in Clarification

The process begins with using a liquid to wash the bagasse, which helps clarify the method of fermentation. The duration for this step is crucial as it determines when the juice will be clarified.

Transferring and Extracting Juice

Once the juice is clarified, it is transferred by gravity into another container, ensuring that all solids are left behind.

Importance of Washing Bagasse

It’s essential to wash the bagasse to remove excess nutrients that could affect future processes. This prevents any undesirable residue from remaining.

Hot Water Application

Hot water at 63 degrees Celsius is used to wash the bagasse thoroughly. The goal is to cover the surface adequately for effective washing.

Monitoring Sugar Content

Before proceeding with further steps, it's important to measure sugar content using a specific device. A reading of 24 centimeters indicates good extraction levels.

Washing Process and Residue Management

Continuous Washing Until Desired Levels Achieved

The washing operation continues until sodium levels reach an acceptable threshold. Proper disposal of residues is necessary to avoid unpleasant odors or contamination.

Best Practices for Residue Disposal

Residues can be repurposed for animal feed or other uses, minimizing waste and promoting sustainability in production practices.

Finalizing Brewing Process

Adding Ingredients for Fermentation

After managing residues, a specific amount of hops (40 grams without lupulin) is added while stirring gently to ensure even distribution before fermentation begins.

Aroma Addition Techniques

During aroma addition, approximately three times more aromatic hops than regular hops are used. This enhances flavor profiles significantly during brewing.

Final Steps in Brewing

After adding ingredients, they are allowed to sit at temperature for additional time (15 minutes), allowing flavors to meld before concluding this phase of brewing.

Process of Fermentation in Brewing

Initial Steps in the Brewing Process

The process begins with increasing agitation speed for 10 minutes to enhance movement without disturbing the sediment.

After agitation, a specific sequence is followed: heating and then cooling the mixture before fermentation.

Post-agitation, a waiting period of 15 minutes allows natural sedimentation of materials before transferring to fermentation.

Temperature Control During Fermentation

The mixture's temperature must be carefully controlled; it should be around 18 to 20 degrees Celsius when transferred to the fermentation vessel.

A cooling system using plate coolers is employed to lower the temperature from approximately 94 degrees Celsius effectively.

Importance of Quality Ingredients

High-quality ingredients are crucial for successful fermentation; maintaining a stable environment for yeast activity is essential.

Practical methods exist for home brewers to manage temperatures and ensure proper fermentation conditions.

Types of Yeast Used in Brewing

Two primary types of yeast are discussed: lager and ale yeasts, each with distinct characteristics affecting flavor and fermentation processes.

Lager Yeast Characteristics

Lager yeasts ferment at lower temperatures (9–13 degrees Celsius), producing less fruity aromas and having a unique flocculation behavior that leads them to settle at the bottom during fermentation.

Ale Yeast Characteristics

Ale yeasts operate at higher temperatures (18–23 degrees Celsius), resulting in more pronounced fruity flavors due to their higher alcohol production and delayed flocculation until later stages.

Cerveja do Tipo Piúce: Processo de Fermentação

Introdução à Levedura e Fermentação

O processo envolve a produção de uma cerveja do tipo piúce, utilizando uma levedura específica derivada da cachaça, que é eficaz em baixas temperaturas e tem boa capacidade de sedimentação.

A transferência do mosto para o fermentador deve ser feita com cuidado, garantindo a higienização adequada do equipamento com água e produtos sanitizantes.

Transferência e Preparação

Para a fermentação, utiliza-se uma suspensão densa de levedura na proporção de 1% do volume total a ser fermentado; por exemplo, 500 ml para 50 litros.

É importante seguir as instruções das leveduras utilizadas (milfilizadas ou líquidas), que indicam as quantidades necessárias baseadas no volume da produção.

Ambiente de Fermentação

O ambiente ideal para a fermentação deve manter uma temperatura constante entre 16 e 18 graus Celsius; um ar condicionado pode ajudar nesse controle.

Um orifício na parte superior do fermentador é necessário para instalar um airlock, que permite a saída dos gases sem permitir a entrada de contaminantes.

Monitoramento da Fermentação

Durante os primeiros dias, o consumo de açúcar deve ser monitorado diariamente; isso ajuda a determinar quando encerrar o processo de fermentação.

Após oito dias, se o teor de sólidos estiver estabilizado em torno de seis graus Brix, indica que a levedura não está mais consumindo açúcares.

Conclusão da Fermentação e Início da Maturação

Com base nos dados coletados sobre o consumo dos açúcares, decide-se interromper a fermentação e iniciar o processo de maturação em temperaturas mais baixas (5 a 6 graus Celsius).

Para garantir um bom resultado na produção caseira da cerveja, é essencial ter um espaço controlado com ar condicionado durante a fermentação e um refrigerador adequado para maturar.

Fermentation and Maturation Process in Beer Brewing

Temperature Drop and Its Effects

The temperature will drop to 500 degrees, leading to three key outcomes: fermentation interruption, sedimentation of yeast and fermentation byproducts, and potential metabolism of certain compounds like diacetyl (buttery aroma) and acetaldehyde (headache-causing) during maturation.

Aroma Management During Maturation

The beer will lack buttery aroma and minimize headache effects due to the type of yeast used. Brewer's yeasts are typically selected to avoid these defects post-fermentation. Now, preparation for the maturation vessel is essential.

Hygiene Practices for Equipment Preparation

When preparing the fermentation vessel, hygiene is crucial. Use aluminum foil and a 70% alcohol solution to sanitize effectively before sealing the container to prevent contamination.

Cooling Down for Maturation

Transfer the fermentation vessel into a refrigerator where the temperature will be lowered to approximately 5.3°C for one week, ceasing fermentative activity while allowing suspended yeast to settle at the bottom.

Metabolism of Off-Flavors During Maturation

As temperatures decrease during maturation, off-flavors such as diacetyl and acetaldehyde are metabolized by yeast depending on their capacity, improving overall beer quality before bottling begins.

Bottling Process in Beer Production

Preparing for Bottling

The final stage involves transferring matured beer into bottles without carbonation equipment; instead, sugar is added prior to transfer for natural carbonation through yeast activity in the bottle.

Sugar Addition for Carbonation

A small amount of sugar (50 grams in 200 ml water) is added per approximately 20 liters of beer before bottling; this ensures controlled CO2 production without risking bottle explosions from excessive pressure buildup due to over-carbonation.

Importance of Sanitation Before Transfer

Prior sanitation of all equipment is critical; use a peracetic acid solution after thorough washing with soap to prevent contamination during transfer from fermentation vessel to bottling container.

Careful Handling During Transfer

While transferring beer from one container to another, maintain cleanliness by sanitizing hoses and surfaces involved in the process; have cleaning materials ready nearby for any spills or contamination risks during this delicate operation.

Final Steps Before Sealing Bottles

Ensure that proper amounts of sugar are added based on volume; too much can lead to dangerous pressure levels inside sealed bottles which may cause them to explode if not managed carefully throughout this process.

Process of Beer Bottling and Fermentation

Preparing for Bottling

The speaker discusses the importance of preventing contamination during the bottling process, emphasizing quick actions to mitigate risks.

Sugar is added carefully to the beer before mixing, highlighting the need for homogeneity in preparation as they fill the container.

Equipment and Hygiene

The speaker prepares a vessel for bottling, mentioning that a sugar solution with a concentration of 3 grams per liter has been added to the matured beer.

A recommendation is made to use a heat source (like a stove) while bottling alone to minimize contamination risks.

Cleaning Procedures

Emphasis on cleanliness: bottles and caps must be thoroughly cleaned with water and then sanitized using a 7.03% acetic acid solution.

After washing, bottles should be inverted to drain excess sanitizer, ensuring minimal foam production when filling.

Filling and Sealing Bottles

The importance of maintaining cleanliness during bottling is reiterated; having a flame nearby helps reduce contamination risk.

The speaker demonstrates sealing bottles with caps sanitized in acetic acid, using a manual capper for closure.

Monitoring Fermentation

A special bottle equipped with an accessory (manometer) will be used to monitor CO2 production during fermentation.

It’s noted that pressure should reach around 2 to 2.5 atmospheres within three to four days; this indicates proper fermentation conditions.

Timeline for Beer Production

The entire beer production process takes approximately 15 to 20 days: one day for carbonation preparation, one week for fermentation, and another week for maturation.

Environmental factors such as temperature can affect fermentation time; warmer climates may speed up processes while colder ones may slow them down.

Engagement and Q&A Session Announcement

Viewers are encouraged to submit questions via comments or forms ahead of a live Q&A session scheduled later in the day.