074: Potential Causes for Loss of Extract in a Brewery

Summary

This episode of the Master Brewers Podcast discusses how a group of brewers solved a drop in extract recovery after changing malt suppliers. Simon Nielsen from Central Waters Brewing Company shares how they approached identifying and addressing the issue, starting by checking internal processes like mill operations and temperature calibration. The episode emphasizes the importance of relationship-building with malt suppliers and understanding barley varieties. Additionally, it highlights the benefits of the Master Brewers technical courses for networking and in-depth learning for professionals in the brewing industry.

Takeaways

• 🎙️ The Master Brewers podcast is a resource by the Master Brewers Association of the Americas, focusing on brewing science, technology, and operations.
• 💡 The podcast emphasizes that issues in brewing, such as extract drops, should first be examined internally before blaming external factors like malt suppliers.
• 🔍 Brewers must systematically check various factors, such as mash temperature, milling, and flow meters, when investigating brewing issues.
• 🛠️ Teams should conduct a sieve analysis and inspect milling equipment to ensure proper crush and no wear on the rollers.
• 🚛 Malt delivery and storage conditions, including truck cleanliness and moisture control, are critical factors to investigate before blaming maltsters.
• 🤝 Building relationships with maltsters and suppliers is essential for maintaining consistent product quality and resolving brewing issues.
• 🔄 Malt blending by maltsters, where they mix different barley varieties, can cause inconsistencies in brewing, even if the certificates of analysis appear identical.
• 🌾 Barley variety and where it is grown can significantly impact brewing performance, making communication with both farmers and maltsters important.
• 📚 The Master Brewers course encourages real-world problem-solving and interactive group work, which provides practical insights for brewers of all experience levels.
• 💬 Networking and building relationships with other brewers is highlighted as an invaluable part of learning through courses and industry events.

Q & A

What is the main purpose of the Master Brewers podcast?

The Master Brewers podcast provides interviews with industry experts in brewing science, technology, and operations. It is produced by the Master Brewers Association of the Americas, a nonprofit dedicated to improving brewing products and processes since 1887.

What problem did Simon Nielsen’s group address in the brewing course?

Simon Nielsen’s group was tasked with solving the issue of a significant drop in recovered extract in the brewhouse after switching malt suppliers, despite the new malt having similar analyses and barley varieties.

What was the group's initial approach to solving the extract drop issue?

The group started by identifying potential internal issues in the brewery, such as checking mash and lauter tun temperatures, calibration of thermometers, and verifying that their equipment (mixers, rakes) was functioning properly to avoid missing extract.

Why is it important to check internal processes before blaming external factors, according to the podcast?

Brewers often joke about blaming the maltster first, but the right approach is to ensure everything within the brewery is functioning correctly before looking at external factors, such as the malt supplier.

What role does the milling process play in the extract loss, and how did the group address it?

The milling process is critical in ensuring proper malt crush. The group conducted sieve analyses to check for proper milling, inspected mill rollers for excessive wear, and checked that no damage occurred during the conveyance from the mill to the grist case.

What additional external factors did the group consider after ruling out internal problems?

After ruling out internal issues, the group looked at external factors such as the condition of malt during transportation, the cleanliness of delivery trucks, and the potential for malt getting wet or moldy during transport or storage.

Why is it important to check how malt is delivered and transported?

Improper transportation conditions, such as dirty or wet delivery trucks, can lead to mold or other damage to the malt, affecting the brewing process. Truck PSI during malt delivery can also impact malt quality by crushing it during unloading.

How does communication with maltsters and farmers help avoid brewing issues?

Building strong relationships with maltsters and farmers allows brewers to better understand their processes, including how barley varieties are blended. This helps ensure consistency in malt quality and improves troubleshooting when issues arise.

What did Simon Nielsen learn about malt blending during the course?

Simon learned that maltsters often blend batches of malt to meet specifications, such as beta-glucan levels. Blending can result in varying brewhouse performance if barley varieties or quality fluctuate across batches.

What advice does the podcast offer for brewers experiencing similar extract drop issues?

The podcast advises brewers to systematically check all internal processes, then look at external factors such as transportation and storage, and finally communicate with their maltster to understand potential issues with malt blending or barley variety.