1. Bob Hansen Briess Malt & Ingredients Co. Chilton, Wisconsin USA 2006 CBC Balancing Water in the Brewhouse

2. Brewing is a process of balancing additions of water and several soluble and insoluble components to finish with a product with exact concentrations of each component. Introduction to Materials (Mass) Balance

3. Better Control of Process Energy Efficiency Water Conservation Waste Water Reduction Optimization of Throughput Yield Maximization Quality Improvement Rewards of a Balanced Process

4. Hops Grain Inputs Water Soluble Components Insolubles Water Soluble Components Insolubles Water Wort Water Soluble Components Spent Material Waste Water Water Soluble Components Insolubles Water Soluble Components Water (Steam) Outputs Brewing Process Mass Balance

5. Hops Grain Inputs Water Soluble Components Insolubles Water Soluble Components Insolubles Water Wort Water Soluble Components Spent Material Waste Water Water Soluble Components Insolubles Water Soluble Components Water (Steam) Outputs = = Water Soluble Components Insolubles Water Soluble Components Insolubles Brewing Process Mass Balance

6. Basic Equations and Terminology Specific Gravity Weight of Water Weight of Wort = ________

7. Degrees Plato Weight of Wort Weight of Wort Solids = ________ X 100 Basic Equations and Terminology

8. Concentration (Plato) and Relative Density (S.G.) are Related Degrees Plato - 1 ) X 1000 /4 1 + (Plato X 4 / 1000) = Specific Gravity ( = 1 + (10 X 4 / 1000) 1.040 0.040 ) X 1000 /410

9. Basic Equations and Terminology Specific Gravity Weight of Water Weight of Wort = ________ X Weight of Water = 8.34 lbs / Gal Weight of Water = 1 kg / liter

10. Basic Equations and Terminology Degrees Plato Weight of Wort Weight of Wort Solids = ________ X 100 _______________________

11. Basic Equations and Terminology Liquor / Grist Ratio Weight of Grain Weight of Liquor (water) = ________

12. Grain (500 lbs) Inputs Water (0.05 x 500 lbs = 25 lbs) Soluble Components (0.75 x 500 lbs = 375 lbs) Insolubles (0.20 x 500 lbs = 100 lbs) Water (1500 lbs) Outputs Mashing Mass Balance Mash (2000lbs) Water ( 25lbs + 1500 lbs = 1525 lbs) Soluble Components (375 lbs) Insolubles (100 lbs) This is a 3.0 L/G ratio 1500 Lbs / 8.34 Lbs/Gal = 180 Gal or 5.8 Brls

13. Mash Vessel Material Balance

15. Thicker Mashes have lower pH (0.1 or more) Thicker Mashes Stabilize Enzymes –Can Increase Soluble Nitrogen +10-20% –Increase Alpha Amylase Survival Time +20% Thicker Mashes Reduce Enzyme Mobility –Thicker Mashes Produce More Dextrinous Worts –Fermentability Can be Reduced 5% Water Balance Sets Maximum Extract Possible In The Brewery –Total Extract (Wort Solids) –Sets Maximum Wort Strength Effects of Water Balance in the Mash

17. Inputs Underplate/Chase (200 lbs) Outputs Lautering Mass Balance This is a 3.0 L/G ratio Mash (2000lbs) Water (1525 lbs) Soluble Components (375 lbs) Insolubles (100 lbs) Sparge Water (1500 lbs) Wort (2985 lbs) Water (2637 lbs) Soluble Components (348 lbs) Insolubles (98 lbs) Water (400 lbs) Soluble Components (17 lbs) Water (188 lbs) Soluble Components (10 lbs) Insolubles (2 lbs) Spent Grain (515 lbs) Drain Water (200 lbs) 23.5 gal x 1.020 x 8.34 lbs/gal 5.0 P x 200 lbs 348 / 2985 = 11.7 % (Plato)

18. Lautertun Material Balance 348 / 375 = 93 % Brewhouse Efficiency 500 lbs x 95 % Solids = 475 lbs S.G = 1.047 x 8.34 lbs/ gal = 8.73 lbs/ gal = Weight of Wort2985 lbs / (8.73 lbs / gal) = 342 gal = 11.0 Barrels

19. Balance will Determine Yield –Improper balance or timing leads to loss in grains or drain water –Yield losses lead to increased waste water costs Balance will Determine Preboil Wort Strength and Volume –Poor balance leads to oversparging and overdilution Balance can effect product quality –Oversparging leads to increased color, pH and Tannin extraction Balance effects runoff speed and throughput –Improper balance leads to difficult or lengthy lautercycles Effects of Lautertun Water Balance

20. Gallons Plato

23. 93% Yield, 15.7 P 87% Yield, 14.3 P

24. Water Balance Affects Runoff Max Flow Viscosity Various Factors = _______________ XBed Depth Viscosity Increases Directly with Plato

25. Inputs Outputs Kettle / Whirlpool Mass Balance Wort (2782 lbs) Water (2436 lbs) Soluble Components (346 lbs) Wort (2985lbs) Water (2637 lbs) Soluble Components (348 lbs) Insolubles (3.4 lbs) Water (0.4 lbs) Hops (4 lbs) Insolubles (4 lbs) Water (16 lbs) Spent Hops (20 lbs) Soluble Components (1.7 lbs) Water (6.8 lbs) Trub (8.5 lbs) Steam (Water) (264 lbs) Soluble Components (0.2 lbs) Water (83 lbs)

27. Water Balance Cannot be Separated from the 5 “-ations of Brewing –Sterilization –Isomerization –Concentration (Evaporation) –Carmelization (Color and Flavor Development) –Volitilization Excessive Concentration is Innefficient and Can Lower Quality Concentration increases Exponentially with Water Removal Effects of Kettle Water Balance

28. Concentration at Constant Boiling

29. Boiling to Gravity

30. HG Beer Balance

31. High Gravity Balance

32. Summary Questions?

33. Thank You Bob Hansen Briess Malt & Ingredients Co. Chilton, Wisconsin USA 2006 CBC