Patent Application
20080020090
While the invention is claimed in the concluding portions hereof, preferred embodiments are provided in the accompanying detailed description which may be best understood in conjunction with the accompanying diagrams where like parts in each of the several diagrams are labeled with like numbers, and where:
It has been recently discovered that cereal grains typically used in traditional methods of brewing can be replaced by a natural protein concentrate, along with a source of fermentable sugar such as a corn syrup to produce a wort suitable for use in a brewing process. It is thus an object of the invention to provide a method of brewing that makes use of a natural protein concentrate in place of cereal grains. The natural protein concentrate can be produced by either wet or dry processes known to those skilled in the art. Conveniently, the natural protein concentrate can be derived from a number of sources including peas, rice, soy, potatoes and the like. Other sources of protein will also be readily adaptable for use in the brewing method of the invention, and thus the source of protein is not meant to limit the scope of the invention in any way.
The various benefits and manufacturing advantages of the process of the present invention as well as the finished product of the process of the present invention can be seen by comparing the invention to prior art brewing methods.
The next step 101 in a typical prior art brewing process is the mashing step. The malted grain is crushed, to grist which is mixed with heated water in a vessel producing a mash. During mashing and mixing of the mash, various natural enzymes operate to hydrolyze starch into sugars, as well as to break down other components of the grain such as beta glucans.
Once mashing is completed, the liquid is then separated from the gram m a process step in termed lautering 102. Lautering separates the grain extract from the spent grains. Additional water may also be used to further rinse the grains free of the desired components, in a step and process termed sparging.
The liquid at this stage is termed the wort, and it is the wort that is the main ingredient in the beer fermentation process. Preparation of the wort for fermentation is shown in
Following boiling of the wort, shown at 103, the next step in a typical prior art to fermentation process, such as that demonstrated in
Following the completion of wort preparation, fermentation can finally be commenced. The fermentation stage of the brewing process is shown at Step 105 in
Following fermentation beers are usually stored for periods ranging from 7-21 days. During storage, yeast and other particulates settle out of the beer. The beer is then subsequently filtered and bottled. The storage and final handling steps are shown at 106 and 107. In total, prior art methods of beer production require from 3-4 weeks to complete, and require a number of specialized pieces of equipment, especially for the malting of grain, mixing of the mash, the sparging procedure and for the storage of the product following fermentation. Each step in the brewing process requires time and energy.
The prior art method of
Natural Protein Concentrate:
The core of the present invention is the discovery that the use of a natural protein concentrate obtained from a non-cereal grain source in the preparation of a wort for use in fermentation processes used to produce liquid fermentation products such as beer and the like, results in the ability to remove the malting step from a traditional brewing process which not only reduces substantially the cost and complexity of the brewing process but also the use of this type of a natural protein concentrate to produce a wort for use in fermentation, whereby the fermentation process itself will not be reliant upon the presence of malt in the wort to feed the yeast, can also result in the production of a liquid fermentation product that is either devoid of or very low in gluten.
The general category then of sources of the natural protein concentrate which is used in the production of the wort for use in the remainder of the fermentation process of the present invention is non-cereal grains. It will be understood that the use of a natural protein concentrate from any non-cereal grain in the production of a wort or in any fermentation process outlined in the remainder of this document is contemplated within the scope of the present invention.
Certain non-cereal grains are also either low in or devoid of gluten. The use of a natural protein concentrate obtained from those particular starting materials can result in the end product being either gluten-free or very low in gluten. It will be understood that the ability to produce gluten-free fermented beverage products is a major commercial benefit to the process of the present invention, but even beyond the potential to produce gluten-free products, the general production of fermented beverage products and other liquid fermentation products without the use of malt, regardless of the presence of gluten, represents a significant economic and time efficiency in the production of liquid fermentation products over methods presently used.
The actual method of preparation or recovery of natural protein concentrates from non-cereal grains for use in a fermentation wort will be understood to those skilled in the art of seed processing. The specific method of recovery of the protein concentrate, beyond the requirement that it be a natural nonchemical method, might vary and it will be understood that any method resulting in the production or recovery of a natural protein concentrate from non-cereal grain is contemplated within the scope of the present invention.
Production of wort:
At the heart of the modified brewing or fermentation process of the present invention is the production and use of a wort which does not rely on malt and rather in its place replaces the malt in the wort with a natural protein concentrate from a non-cereal grain source. The removal of reliance upon malt as an active ingredient in the wort removes the need for the malting steps from the prior art fermentation methods considered and yields significant process efficiencies. As outlined elsewhere herein, the replacement of the malt in the wort with a natural protein concentrate from a non-cereal grain source, also potentially results in a wort and finished fermentation liquid which is either low in or does not contain gluten, depending upon the source of the natural protein concentrate and any other ingredients added to the wort or to the fermentation process. Minimization or removal of gluten from the finished process is another added, albeit not necessarily linked, commercial benefit of the modified fermentation process of the present invention for use in the production of liquid fermentation products such as beverages and beverage components.
Referring to
In certain cases again dependent in large part upon the desired final profile of the wort being prepared, other ingredients along with the protein concentrate may be added to the water in the preparation of the admixture for use in the production of the wort. For example, one or more fermentable sugars may be added to the admixture, coloring agents, flavoring agents or bittering agents might all be added to the admixture to react with other ingredients in the wort as the admixture is boiled, or simply so that they are all incorporated into the wort when the wort is fermented in a later process step.
Other components may be added to the wort m addition to the natural protein concentrate and fermentable sugars. In one aspect of the invention these would include commonly used flavorings like hop extracts, herbs, brewer's caramel and other additives well known to those skilled in the art. Other embodiments would make use of other additives and flavorings or coloring well known in the art and suitable for preparing alcoholic beverages for consumption. The use of such added materials will thus be chosen based on the desired preferences of the brewer, or of the consumer for which the fermentation product is being prepared.
Following preparation of the protein water and admixture, the next step in the process of production of the wort outlined in
The duration of the boiling step will be determined based on the degree of extraction desired, or the time needed to inactivate enzymes or microorganisms. Typically the boiling stage will take from 5-10 minutes, but it is expected that other boiling times may also be used effectively when practicing the present process. Boiling may be performed in a variety of styles of equipment, including simple kettle, or more modern equipment that includes internal or external calandria, all of which are common to the art of brewing.
Following boiling, the hot wort is allowed to rest, shown at 203. The period of time may vary, but conveniently a time ranging from 0-30 minutes may be used. The resting step allows settling out of solids from the boiled wort (e.g. coagulated protein—often referred to as “trub”, vegetable matter such as hops or herbs). In some embodiments, a separate whirlpool vessel may be used for this stage of the wort production process.
Once the wort has had an opportunity to rest or settle, the impurities or other non-desirable components can be removed from the stratified wort. The wort might also be actively cooled while it is allowed to rest for purification purposes, or it might simply be allowed to passively cool in the environment of the production facility.
As outlined above, the wort produced in accordance with this method might be produced and then stored for subsequent use or for sale to other brewing or fermentation customers. Alternatively, in certain embodiments, the wort may be produced in accordance with this method and may be directly fed on into the remaining steps of the fermentation process of the present invention. The product, a wort for use in fermentation which is prepared using a natural protein concentrate from a non-cereal grain source in place of malt, is understood to be covered within the scope of the claims and specification herein.
Concentrated Wort Product:
In addition to the production of wort in a “ready to use” format for subsequent use, it is also contemplated that within the scope of the present invention is the means and method for the production of a concentrated wort product. Conceptually what is contemplated is the concentration of wort produced in accordance with the wort production method and parameters outlined herein to yield either a dry format or a wet format wort concentrate which in a concentrated form would be more compact or easy to ship, or perhaps more shelfstable, which concentrate could then subsequently be reconstituted by the addition of water into a wort of the appropriate concentration at the time that it was going to be used in a liquid fermentation process.
The admixture would be brought to a boil and held at that temperature for a desired length of time. The boiling process is used to improve extraction of desirable components from the components of the wort, and is also operative to inactivate enzymes and microorganisms that may be present in the wort, and whose presence is undesirable during fermentation and subsequent steps of processing.
The boiled wort would be allowed to rest or would otherwise be purified, shown at Step 303. Purification of the wort, in any number of more or less elaborate means from something as simple as allowing the boiled wort to rest and lower temperature to other types of filtration or stratification of the boiled wort, are all contemplated within the scope of Step 303 as shown.
The final step in the production of the concentrated wort product as outlined in the method of
The concentration step might itself comprise any type of a step or steps which could be used to create a concentrated wort in either a wet or dry format as otherwise outlined herein, Overall the idea of concentration of the wort is to yield a product which is either less voluminous or otherwise more shelf stable or desirable from a storage, sale or transportation perspective, which could be reconstituted by the addition of water at the appropriate time to yield a wort of the proper concentration by the addition of water. For example, the concentration Step 304 might comprise spray drying the wort to result in a spray dried concentrate which could be reconstituted by the addition or blending of the concentrate with water, or a wet concentrate could be created by removing a percentage of the water from the wort to result in a concentrate which could be brought back to the appropriate concentration for use by the reintroduction of a certain percentage or amount of water into the concentrated wort for blending, to result in the wort of a pre-identified desired concentration for use in the remainder of the fermentation process. The completion of the concentrated wort product in accordance with the method of the present invention is shown at Step 305 of this Figure.
Fermentation Using Natural Protein Concentrate:
In order to commence the fermentation, the wort is brought to an appropriate fermentation starting temperature in a fermentation vessel of some kind. Placement of the wort at this initial temperature in a fermentation vessel is demonstrated at Step 401 of the Figure. Fermentation of the wort is initiated by the addition of live yeast cells, shown at 402. The particular strain of yeast added will depend on the style of fermentation product desired, and will be known to one skilled in the art of brewing. In traditional brewing methods, yeast is added a concentration of 1.25 million cells per mL per degree Plato. The Plato system is a measure of the sugar content in a wort commonly used by brewers, with 1° Plato equal to 0.004 difference in specific gravity and corresponding to a sucrose concentration of 1%. Using prior art methods of preparing fermented alcohol bases similar to that produced by the method of the present invention, a yeast pitching rate is typically ten-fold or more, or in the range of 20-30 million cells per mL per degree Plato is required.
It has been discovered that using the brewing process of the present invention the amount of yeast need to initiate fermentation may be significantly reduced from similar types of fermentations. For example, in the present process, yeast may be added at of 1.25 million cells per mL per degree Plato and still result in the efficient fermentation of the wort.
Following the addition of the yeast, the fermentation of the wort within the fermentation vessel is shown at Step 403. In traditional brewing methods varying the temperature of fermentation will vary the properties of the resultant fermentation product. For example, in the production of lager beers, it is common to ferment a temperature of 12-15° C. for 7-10 days, while for producing ale a temperature of about 20° C. for 4-7 days is typical. The present method is well-adapted for use at varying temperature and times in order to vary the nature of the resulting fermentation product. The precise time and temperature of fermentation will depend on the particular taste and character desired in the fermentation product. For example, shorter fermentation will result in a product with residual sugar and thus an apparent sweetness. In contrast, allowing fermentation to proceed to completion will result in a fermentation product with higher alcohol content, and a “drier” taste. In the present case, fermentation is allowed to proceed for the desired time, and at a desired temperature, both of which will be readily determined by the skilled brewer.
Following the completion of fermentation, the contents of the fermentation vessel can be purified, shown at 404, to remove spent yeast and the like from the completed fermented liquid. The contents of the fermentation vessel at the completion of the fermentation Step 403 is the liquid fermentation product, which following the purification shown at 404 would be ready for use. Shown as an additional final step in the embodiment of the fermentation method of
If desired, carbon dioxide can be injected at the bottling or packaging stage to enhance the carbonation of the product. In another aspect of the invention, the fermentation product may be filtered and then used in blending with other components to produce various alcoholic beverages. In yet another aspect it is anticipated that an unfiltered fermentation product might also be useful, and in those cases the fermentation product obtained by the present method could be used immediately.
It is specifically contemplated that the method of
One major benefit of the fermentation process of the present invention is that in the production of the liquid fermentation product of the present invention, as compared to traditionally brewed beer or the like which is produced in accordance with the prior art method along the lines shown in
Following the reconstitution of the concentrated wort product, the reconstituted wort could be used, shown at 503 onwards, in the standard steps of the fermentation process previously described with respect to the method of
Oxygen Injection:
Referring then to the first couple of steps of the embodiment of
Resting the boiled wort accomplishes a couple of objectives, the first of which is to allow to cool to the appropriate fermentation temperature, but also potentially to allow for the stratification of the wort in its boiled form so that the impurities can in some fashion be removed therefrom. Resting and purification of the boiled wort is shown at 603.
Following boiling, and prior to the addition of the yeast, the wort is cooled in order to bring the temperature of the mixture to a temperature suitable for fermentation. Cooling times will vary depending on the volume of the batch, and the specific method of cooling used, neither of which are limiting to the operation of the present method. For example, in one aspect of the invention the wort is cooled to a temperature in the range of 8-10° C. over a period of 60 min. In other embodiments, the final temperature and cooling rate may be chosen based on the yeast strain used in fermentation, the style of fermentation product to be produced, as well as factors that will be readily known and considered by a skilled brewer. Once the wort is cooled or otherwise brought to the appropriate fermentation starting conditions in terms of temperature and the like, fermentation can be commenced within the fermentation vessel by the seeding of yeast into the wort. The addition of the yeast to the wort is shown at Step 605. The following conduct of the fermentation is shown at Step 606 in the Figure.
In order to enhance the onset of fermentation and stimulate proliferation of the yeast, it is often desirable to dissolve additional oxygen into the wort. Commonly, oxygen at 16-20 parts per million is injected to accomplish this purpose. Referring to
In other prior art fermentation processes, other nutrients might often also be added at this stage of the fermentation. For example, it is common in traditional fermenting methods to add compounds such as di-ammonium phosphate or urea, which are effective as yeast nutrients, in order to improve the rate of growth of the yeast culture during fermentation. It has been discovered that the use of the natural protein concentrate in the present brewing method obviates the need for these artificial additives. Thus, an additional advantage is provided in reducing the handling and materials required in the course of brewing when using the present method.
The fermentation process might automatically stop upon exhaustion of the yeast within the wort, or alternatively those skilled in the art will also be aware of different methods by which the fermentation could physically be arrested or stopped if it was desired to do so. The physical stopping of fermentation within the fermentation vessel is an optional step which could be included within the method of the present invention.
Upon reaching the completion of the fermentation process, which will likely be determined based upon testing or any number of parameters by the operator of the process, the contents of the fermentation vessel can be purified as shown at 607 to yield a purified liquid fermentation product. Also shown in the Figure at 608 is the packaging of that finished liquid fermentation product, and as outlined elsewhere herein and previously discussed, that packaging might comprise the preparation of retail packaging of the product if it were ready at that point for retail packaging for consumption as a beverage, or alternatively the packaging Step 608 might also comprise the packaging of the liquid fermentation product of the process of the present invention for subsequent use in the production of blended alcoholic beverages and the like. Optionally in the place of the packaging Step 608, and as outlined with respect to the other Figures and embodiments shown herein, additional beverage blending or completion steps might also be added following the completion of the fermentation and it will be understood that any type of a process resulting in the packaging or blending of the finished liquid beverage product based upon the product of the fermentation process of the present invention is contemplated within the scope hereof
Finishing Various Beverage Products:
The fermentation product resulting from the present invention is suitable for consumption as “beer” after the addition of hop extracts for bittering and aroma, as well as coloring. Alternatively, the fermentation product may be used as a neutral base in the production of other alcoholic beverages. For example, it may be desirable to add other flavorings, coloring or other suitable additive or to blend the fermentation product with products derived from other processes to produce unique flavors and styles that are desirable to consumers.
A number of types of finishing steps could be conducted upon the liquid fermentation product of the method of the present invention to yield final beverages or beverage components with different qualities. For example beyond basic purification steps, the liquid fermentation product of the present invention might be carbonated, distilled or otherwise treated to yield beverage components or beverages with varying profiles as desired by the user of the process.
As outlined elsewhere herein, it is contemplated that in particular circumstances the liquid fermentation product of the fermentation method of the present invention would effectively be a finished beverage product at the completion of fermentation and purification. There are other circumstances however within which the liquid fermentation product of the fermentation method of the present invention might require the incorporation or addition of various flavorings, following completion of the fermentation steps, to yield a completed beverage product.
The method shown in
To demonstrate some of the finished liquid fermentation products including the incorporation of flavors which are contemplated to be within the scope of the present invention, it is necessary to consider that the basic liquid fermentation product of the process of the present invention would effectively comprise a fermented alcoholic beverage base to which various flavorings could be added to yield different types of products. For example different types of flavoring compounds could be added to yield a finished beverage or finished liquid fermentation product that had the taste or flavor profile of beer—the flavoring added to be beverage base might in fact be beer or other flavoring compounds used to flavor beers. By the addition of one or more fruit flavorings, fruit type alcoholic cooler beverages could be yielded. It will be understood that the production of any number of different types of flavored liquid fermentation products are beverages by the addition of one or more flavorings to the basic liquid fermentation product of the method of the present invention are all contemplated to be within the scope hereof.
Blended Beverage Product:
Shown in the figure at 801 is the use of the liquid fermentation product of the fermentation method of the present invention as the starting ingredient or as one of the blending components in a blended beverage. The liquid fermentation product, shown at 801, would be blended with another beverage, shown at blending Step 802, to yield a blended beverage, shown at 803. As outlined elsewhere above, it is specifically contemplated that one particular type of a blended beverage which could be produced in accordance with the method of the present invention would be to produce a blended beer which would be a quantity of beer or blended with a quantity of the liquid fermentation product of the present invention which it is felt would yield a significant economic advantage in the production of beer with no significant change in the final flavor profile of the finished product. It will be understood however that any number of different blended beverages in which it was desired to provide some degree of a fermented alcoholic base such as the liquid fermentation product of the present invention could be conceived by one skilled in the art of the production or design of beverage products and that all such products resulting from the blending of the liquid fermentation product of the present invention with other beverage components are contemplated within the scope of the present invention.
Gluten Free Product:
Another object of the invention is to provide a simplified method of brewing a gluten-free fermentation product. In traditional brewing methods, the use of cereals like wheat, rye, oats or triticale results in the inclusion of the protein complex gluten in the wort, and thus in the fermentation product. In those who are genetically predisposed to gluten intolerance, otherwise known as celiac disease, the presence of gluten in foodstuffs or beverages can have significant physiological effects. In those sufferers, ingestion of gluten causes an autoimmune reaction, leading to impaired absorption of nutrients, and in some gastrointestinal discomfort. Persons with celiac disease are advised to avoid gluten containing products in order to avoid the significant health risks that attend this syndrome. However, this also means avoiding consumption of many products which are desirable, one of which is fermentation products such as beer.
Various methods of producing gluten-free beers have been disclosed in the patent literature. Typically though, they involve adaptations of traditional brewing methods to grains that lack gluten. For example, it is possible to use millet, buckwheat, rice, amaranth or quinoa to produce a malted product that is adaptable to traditional brewing processes. Alternatively, chemical and enzymatic treatment of non-gluten containing grains or potatoes has also been successful in producing extracts that can be included in wort suitable for fermentation. However, each of these prior art methods require additional steps, handling or materials in order to produce a gluten-free fermentation product. Thus, they add to the cost and complexity of the brewing process.
In contrast, in the present invention the source of the natural protein concentrate may be conveniently chosen from a non-gluten containing source. For example, peas, soy, rice and potatoes are all sources of natural protein that are adaptable to the present brewing process. Likewise, fermentable sugars derived from corn will also lack gluten, and certified gluten-free hops are available commercially. Other common additives like brewer's caramel used for coloring can also be obtained gluten-free and used in the present brewing process.
When these components are combined and brewed using the method of the present invention, it is thus possible to produce a gluten-free fermentation product. This gluten-free fermentation product is useful in the production of a gluten-free beer, or in blending with other gluten-free flavorings or additives produce a gluten-free alcoholic beverage.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous changes and modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable changes or modifications in structure or operation which may be resorted to are intended to fall within the scope of the claimed invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2552693 | Jul 2006 | CA | national |
| 2583817 | Jul 2007 | CA | national |
