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CCHHEEMMIICCAALL EENNGGIINNEEEERRIINNGG TTRRAANNSSAACCTTIIOONNSS
VOL. 38, 2014
A publication of
The Italian Association
of Chemical Engineering
www.aidic.it/cet
Guest Editors: Enrico Bardone, Marco Bravi, Taj Keshavarz
Copyright © 2014, AIDIC Servizi S.r.l.,
ISBN 978-88-95608-29-7; ISSN 2283-9216
An Economically Viable Way to Produce Beer from the
Maize Malt
Rogério Baillya, Silvério C. Silva Filhoa, Neide M. N. Satob, João B. Severo
Júniorc, Roberto R. Souzac, José C. C. Santanaa*
aIndustrial Engineering Post-Graduation Program, Nine of July University (UNINOVE), Av. Francisco Matarazzo, 612,
Água Branca, Zip Code: 05001-100, São Paulo, Brazil.
bPolitechnical School, University of São Paulo, São Paulo, SP, Brazil.
cDepartment of Chemical Engineering, Federal University of Sergipe, São Cristóvão, SE, Brazil.
jccurvelo@yahoo.com.br
This work was done to dry of maize malt (Zea mays) by a infrared dryer in order to generate a derivative of
high commercial value beer industry, and try to add value to maize culture. Models of drying curves were
used to simulate the drying isotherms at 45, 55 and 65°C. From this maize malt a beer has been obtained
and its sensorial qualities were compared with two commercial beers. The cost of production of the malt
was also being measured to verify the economic feasibility of the process. Results showed that the best
condition to dry the maize malt in a infrared dryer was 55°C for 1.5 h and this process time was about 4-
times minor than drying in a convective dryer. Comparing the sensory quality of maize beer showed that
the beer is as good as the commercial beers. It was found that the production cost of beer reduces by 10%
when changing the barley malt by maize malt.The proposed of applying of infrared drying process to
obtain the maize malt obtain was viable, obtaining therefore a competitive advantage for both the
producer, industrial and consumer, providing an alternative source of income as well as to the beer
industrial for which the innovation of raw materials will determine the adaptability, processing flexibility and
competitiveness in the market.
1. Introduction
The economy of various countries have been busy the maize trade, despite the international crisis, Brazil
is expected to reap a record maize harvest total of 67.8 million tons in 2011/12, compared to a production
of 57.4 million tons in the previous cycle, according to projections released by the National Supply
Company (CONAB), surpassing the volume of soybeans. The competition has influenced the industry to
develop new sources of competitive advantages, requiring a continual process of innovation. This has led
companies to generate and use technologies or tools that will create opportunities for new products,
services and business processes (Simon and Satolo, 2009). Thus, this study aimed to analyze the
insertion of a malt production from maize as a competitive alternative to the beer industry. A new drying
process (infrared drying) has been used to obtain the maize malt and it was used in beer production.
Beer is not a drink distilled, obtained by alcoholic fermentation of must from malted cereal, usually barley
malt. The addition of other raw starch or hop is optional, and in general the alcohol content is low, 3% to
8%, being considered an almost complete food because its membership encompasses compounds such
as proteins, amino acids, carbohydrates (glucose, maltose, dextrin, etc.), various mineral elements
(calcium, phosphorus, sulfur, etc.) alcohol, carbon dioxide and most of the B vitamins. The basic raw
materials for the manufacture of beer are water, hops, malt and yeast. The malt is still the saccharification
agent allowed in brewing, although techniques may be proposals for its replacement by the use of pure
enzymes. In its preparation can be kept active enzyme system, mainly composed of α and β-amylase
(Aquarone at al., 2001).
DOI: 10.3303/CET1438039
Please cite this article as: Bailly R., Silva-Filho S.C.D., Sato N.M.N., Severo Junior J.B., Souza R.R.D., Santana J.C.C., 2014, An
economically viable way to produce beer from the maize malt, Chemical Engineering Transactions, 38, 229-234
DOI: 10.3303/CET1438039
229
However, as barley is little produced in Brazil, the effect of barley malt in beer production cost is high,
since, most of this raw material is imported. Thus, the producing malt from a source which is produced in
Brazil will reduces its costs for breweries. As malt is obtained from either germinated seed, which must be
subsequently dried, so that are reduced the moisture content and maintained its enzymatic activity.
Therefore, a study of the ideal conditions of the drying process should be performed (Benvenga et al.,
2011; Curvelo Santana et al., 2010).
Besides its importance in the removal of moisture, which serves to avoid microbial contamination and
increase the shelf life of products, the drying processes are used to improve the taste, enzymes, vitamins
and other functional contents into foods. Due to importance of drying process to industries, several
techniques have been applied to fruits and vegetables, from the simplest ones as solar and sun drying to
the most expensive, like microwave and freeze drying. In order to get dried products with high nutritional
and sensorial attributes, non-conventional drying methods have also been used, like those with modified
atmosphere, microwave, osmotic dehydration, sun/solar, freezer drying, foam mat drying, spray drying and
others (Cui et al., 2008; De Jesus and Maciel Filho, 2011; Fernande and Rodrigues, 2008; Oi et al., 2013;
Santos and Silva, 2008).
De Jesus and Maciel Filho (2011) have been optimized the drying process of amylase by response
surface methodology. In this study a microwave vacuum drying was used to estimate the main effects of
vacuum pressure and power on the enzymatic and water activities. The experimental in star design
revealed that microwave vacuum drying is influenced mainly by power. The dehydrated product showed
high enzymatic activity and low water activity. Benvenga et al. (2011) and Curvelo Santana et al. (2010)
have been used an aired convective dryer to dry the amylases from maize malt, After the execution of the
experiments an optimal condition to obtain the high enzymatic activity has been found at 54°C for 5-6 h of
drying process.
2. Material and Methods
2.1. Maize malt and beer production
Maize seeds were selected, weighted, washed, carried to the moisture absorption from 40 to 45 % and
carried to germination in laboratorial scale. The germination time was between 4 and 5 days. Maize malt
was dried according to drying methodology and after that, it was triturated and stored at 5°C (Biazus et al,
2009). In each drying samples of maize malt the enzymatic activity was determined by Wohlgenuth
method, modified for Sandstedt, Kneen & Blish (SKB), according to Biazus et al. (2009) and protein
content in drying samples of the maize malt was measured by Bradford (1976) modified method. The
maize malt was mixed with maize starch and hydrolyzed for 8 h at 55-60°C, as described by Aquaroni et
al. (2001). When hydrolyzed inorganic nutrients were added, the pH adjusted pasteurized and added to
the Saccharomyces cerevisiae (Fermix ® or Flashman ®) yeast. The fermentation was maintained at a
temperature of about 6 ° C in order to hold greater amount of CO2, and after fermentation, the alcohol
content of the beers was close to 6 ° GL. The sensory analyzes were made comparing appearance, flavor
and aroma of two maize beers with two commercial barley beers according to 1-9 time of a Hedonic scale.
The samples passed through a statistical analysis by Student's t test (Aquaroni et al., 2001).
2.2. Drying process methodology
Infrared dryer with air circulation was utilized in maize malt drying process. Dryer operated in constants
conditions of temperature, air relative moisture (60 ± 2%) and air flux (1 m3/h). Tree drying temperature
were utilized in the assays, 45°C, 55°C e 65°C, according to Curvelo Santana et al. (2010). The
germinated seeds (malt) were placed in watch glass (previously dried and weight measured in drying
temperatures), weight moistures were measured and they were placed to dryer in the assays
temperatures. After each drying hour (12 h in total), drying samples were collected for measuring the
drying weight (Xi) and; the moisture content (Mi) withdrawal from maize malt was obtained by weight
difference (on percent form). The initial moisture content was measured at 103-105°C of drying
temperature, during 40 at 50 hours in convective dryer according to Curvelo Santana et al. (2010). The
malted seeds weights were dimensionless (X) after division for moisture weight of germinated seeds. The
drying isotherms were made in the temperatures studied (Benvenga et al., 2011; Curvelo Santana et al.,
2010).
0X
X
X i=
(1)
−
=
0
0
X
XX
M ii
(2.a) or in percents 100*
0
0
−
=
X
XX
M ii
(2.b)
While: X as the malt weight varying with the drying time (t, min), from an initial, X0, is the initial malt weight
and Xi is the malt weight at time i (i varying from 0 until 12, equivalent to the hours of drying process). For
simulation of the drying process of maize seeds some model have been used, such as it showed in Table
230
1, found in Curvelo Santana et al. (2010). While, consider X as the malt weight varying with the drying time
(t, h) from an initial, X0, until an equilibrium weight, Xe, on a constant rate of moisture withdrawn, K (h-1).
Table 1. Drying models used in this work
Equation Model Author
3 X= A exp (-K.t) Brooeker et al. (1974)
4 X = exp (-K.t) Lewis (1921)
5 t = A.lnX + B.[lnX]2 Thompson et al. (1968)
6 X = 1 + A.t + B.t2 Wang e Singh (1978)
2.4. bibliographic
Taking into account that the development of new products from by-products and / or wastes, it is not only
environmental awareness as well as competitive strategy and also in view of that maize possesses
interesting chemical-producing maize malt, carried out a study of the main destinations of this raw material
to include the optimization of drying of malt as part of the maize chain. Therefore, a literature search was
performed, based on the consultation papers selected through a search engine for database SciELO
(Scientific Electronic Library Online) and Scopus-Elsevier, and conference proceedings and libraries
renowned universities. The focus of the research was the interaction between the concepts of
competitiveness, sustainability, supply chain and the use of maize byproducts. Within this context, this
work was divided into five stages. In the first step, it was determined the maize supply chain, identifying
the critical points of this chain. The second determines the concentration of total protein. In the third stage
presents analysis of enzyme activity. In the fourth step is presented obtaining the malt and the fifth stage
the drying of the malt. In this study we propose a methodology for the extraction of malt (Simon and
Satolo, 2009).
3. Results and Discussions
3.1. Maize malt production
Table 2 shows the results of measurements of change in mass of maize malt with the drying time in
dimensionless form. Note that the time to stabilize the mass of malt is approximately 360 min at
temperature of 45 ° C and near 100 min for all other temperatures. The mass of moisture removal (M) at
temperatures of 45 and 65 ° C was close to 40% and at temperatures of 55 °C was around 46% of the
initial mass. Figure 1 shows the drying data of maize seeds drying process. According Biazus et al. (2009)
the β-amylases have the optimum temperature close to 55 °C and the α-amylases, close to 75 °C, and
they are deactivated by thermal denaturation when exposed at temperatures above their optimum
temperature for a long period of drying. Thus, the temperature of 55 ° C was regarded as the optimal for
this drying process because there is lower energy expenditure at this temperature. By the variance
analysis was found that from 90 min drying no significant differences for the experimental points and the
average dry weight was 54.1% of the initial mass, indicating that there was a moisture removal of 46%.
Bevenga et al. (2011) and Santana et al. (2010) also showed that the best temperature for the drying of
malt using convective dryer with air circulation is close to 55 °C. However, the ideal time for drying was
between 5.18 and 6 h (311 and 360 min), since only after these conditions malt was dry, losing up to 43%
moisture. Under these conditions, the enzyme activity of dry malt was 5.26 times higher than the initial
activity of malt, 20 000 times higher than the activity of maize "in nature" and 6-times higher than the
activity of malt barley. So, infrared is the best drying process than other drying processes.
A comparison between the results obtained in this work with those obtained by Bevenga et al. (2011) and
by Santana et al. (2010) showed that it is possible to obtain malt, maize dried by the drying method with
infrared waves, while maintaining the quality obtained in a convective dryer, but with a drying time of 3 to 4
times lower and removing more than 7% moisture drying of the joint. And as drying time, means energy
expenditure and, consequently, spending money, just an economic advantage between drying with respect
to conventional infrared can be observed. According Biazus et al. (2009), the dry malt can be stored for up
to 19 weeks at room temperature so as cooled to 10 °C. Thus, the product can be stored for a long period
without being contaminated by microorganisms and without losing its quality.
Table 3 shows the results of the fit of the models, their parameters of drying kinetics and correlation (R).
According to Barros Neto et al. (2001), the closer to 1.0 is its correlation coefficient (R) will be adjusted
over the model. Thus, according to the data presented in Table 3, it can be considered that the model of
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Thompson et al. (1968) is among the models studied in this work, the most adjusted to the experimental
data for drying of malt by infrared waves, since all the values of R were higher than 0.90.
Table 3. Results on the fit of models
Models Brooeker et al. (1974) Lewis (1921)
T(°C) X = A exp(-Kt) R X = exp (-Kt) R
45 X=0.8613exp(-0.0008)t 0.9003 X=exp(-0.0010)t 0.5520
55 X=0.8330exp(-0.0030)t 0.9061 X=exp(-0.0050)t 0.7540
65 X=0.8299exp(-0.0020)t 0.8856 X=exp(-0.0030)t 0.5740
Models Thompson et al (1968) Wang & Singh (1978)
T(°C) t = A ln X + B [ln X]2 R X = 1 + At + Bt2 R
45 t = 453.1 lnx+3358 (lnx)2 0.9847 X=1-0.0021t+2.10-6t2 0.8973
55 t = -1.244 lnx +360.9 (lnx)2 0.9416 X=1-0.0070t+210-5t2 0.9275
65 t = 186.4 lnx +1134 (lnx)2 0.9622 X=1-0.0050t+1.10-5t2 0.9184
3.2. Maize beer as a factor of competitiveness
Thus, competition is seen as an active process of creating spaces and opportunities through innovation in
a broad sense, not restricted by technological change, but considering innovation as any effort aimed at
the development of new production processes, sources of raw materials, managerial dimensions or field of
activity of the company. In studies on sustainable supply chain was considered not only the product from
initial processing of raw materials to delivery to the customer, but also integrating sustainability issues and
flows that extend beyond the core management of the supply chain and product design, production of by-
products, by-products produced during the use of the product, extending product life, product end of life
and recovery processes at end of life (Simon and Satolo, 2009). The analysis life cycle, according to Dias
(2009), is a tool to study the environmental aspects and impacts associated with a product, process or
service. Such an assessment, in addition to environmental concerns, aims to improve the competitiveness
of products in markets with conceptual concerns of sustainability and reduce production costs, to include
decisions regarding end of life for products. Increasingly valued by consumers, environmental awareness
has become a differentiator, not only the image of the company that adopts, but the real impact that occurs
in the environment.
Figure represents the possible inclusion of maize malt in beer chain, which is obtained from a product
(fresh maize) come from the retailer and going directly to the industrialization and being marketed mainly
for brewing industry thus the main consumer in this chain. From the farm, from where you get the seed
maize, past the warehouses, where the quality control of the maize is done, until the industrial brewers.
The good quality control of seeds in warehouses will lead to a good quality malt that will be obtained in the
malting and thus, if you get a good quality beer.
Beer is the result of the combination of basically four raw materials: water, barley malt, yeast and hops.
Another component is the packaging, in particular, the high share in the total cost of the product. Another
raw material added in substitution for malt are non-malted cereals (adjuncts) such as broken rice, maize
grits and syrup, invert sugar maize, better known by the name of high-maltose. The use of the latter is
growing considerably the production of factories. The proportion of adjuncts beer, however, most
breweries, does not exceed 35%.
232
Table 4 is shown a survey of the production cost of beer, Brazil. It is noted that overhead costs represent
more than 70% of beer production costs. On individual costs, the barley malt represents approximately
15% of beer production costs (Setti, 2013). The barley price exported to Brazil is approximately US$ 240
per ton of seeds, which the maize price commercialized in Brazil is US$ 180 per ton of seeds, which will
have a reduction of 25% in cost with raw material for the beer production (AGROLINK, 2013; WORLD
BANK, 2013). According to Curvelo Santana et al. (2010), the amylases from maize malt were 6-times
more active than the barley malt and therefore can be reduced in 6-times the amount of malt to be used in
beer production and thus, the raw material cost is reduced by 87% and more than 10% of total costs.
These arguments make maize a raw material of high competitive degree for Brazilian brewing industry.
Figure 3 shows the variation of sensory results attributed by consumers for appearance, flavor and aroma
of two maize beers (this work) and two barley beers marketed in Brazil.
Figure 2. Supply chain malt barley for obtaining
beer
Table 4. Composition of beer costs using barley
and maize malt
Item Barley malt Maize malt
Variable Costs 27.5 17.8
Barley Malt 14.8 3.40
High-Maltose 3.30 3.74
Hand Labor 3.70 4.20
Utilities 3.20 3.63
Breaking 0.70 0.79
Other 1.80 2.04
Overhead Costs 72.5 82.2
Sales 18.4 20.9
Administrative 13.9 15.8
Depreciation 11.0 12.5
Other 29.2 33.1
Figure 3. Sensorial evaluation of beers by the hedonic scale.
Sensory analysis showed that beer obtained by S. cerevisiae yeast from Flashman ® was the best in all
sensory qualities. However, even maize beer (S. cerevisiae yeast Fermix®) that had bad results presented
with sensory values equal to one of the marketed. The physico-chemical analyzes show that the beers are
within the standards set for beers with the already produced industrially. Thus, it proved that is possible to
produce beer from malted maize, looking to add economic value to a cereal as consolidated in the regional
economy and high availability.
233
4. Conclusions
It is possible concluded that the best condition to dry the maize malt in a infrared dryer was 55°C for 1.5 h
and this process time was about 4-times minor than drying in a convective dryer. Comparing the sensory
quality of maize beer showed that the beer is as good as the commercial beers. It was found that the
production cost of beer reduces by 10% when changing the barley malt by maize malt.The proposed of
applying of infrared drying process to obtain the maize malt obtain was viable, obtaining therefore a
competitive advantage for both the producer, industrial and consumer, providing an alternative source of
income as well as to the beer industrial for which the innovation of raw materials will determine the
adaptability, processing flexibility and competitiveness in the market.
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