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This page features questions submitted to Ask the Maltster and their
answers. We invite you to submit
your own question to the maltster.
Question
Just what is "malt", and
what are the process steps that convert barley
grains to malt?
Posed by James F. Galbraith, Bremerton Washington U. S. of A. on July 13, 2002
Answer
Malt is malted barley.
The malting process consists of three steps.
1. steeping - the raw barley is submerged in a bath of sorts in order to raise the moisture content.
2. germination - the moist barley is placed in a germination bin where it is allowed to germinate for a period of time. the goal is to convert starches into sugars.
3. kilning or roasting - the modified barley is then kilned or roasted depending on the desired finished color. the kilning process dries out the barley and stops and further germination.
the finished product is malted barley.
Question
Curious? How old is the plant? How long have you been Malting at your present location? Are you using Drum-type roasters or state of art new equipment? How many Hectoacres/kilos do you malt a year? I've not used your malt yet, but I'm looking foward to some testing. Thanks In Advance Scott Christoffel Head of Brewing Ops. Left Hand/ Tabernash
Posed by Scott Christoffel, Fort Collins CO USA on May 2, 2002
Answer
As a business unit of Cargill, the Specialty Malt division has the benefit of pulling their malt from several different locations within the Cargill system.
All of our specialty malts are produced at the previous Schreier malt house in Sheboygan, WI which has been in continuos operation since 1865. That facility has a capicity of 120,000 MT. All of the specialty malts are produced in a state of the art circular kiln which was commisioned in 1996.
The majority of our pale malt we pull from our facility in Saskatchewan, Canada, Prairie Malt Limited.
In addition to our self-produced specialty and pale malts, we also import a wide range of world class malts from Dingemans of Belgium, Meussdoerffer of Germany and Pauls from the UK. We also have distribution arrangements with Crisp, Gambrinus and Weyermann.
Please let us know how we may be of additional service to you.
Question
What is a typical percentage of husk to gross weight of malted barley (two-row, pale ale malt)? In other words, if I could remove the husk, what percent of the original weight of my malt would be left?
Posed by Tommy Kilcoyne, Corning NY USA on April 17, 2002
Answer
Husk makes up approximately 5% of the total gross weight.
Question
That a great site.
Can you please tell me where can I purchase the
equipments for malting production in Europe.
Thank you and all the very best.
Posed by GAVIN VYDELINGUM, Krasnodar Krasnodar Russia on November 20, 2000
Answer
Try the Saladin Corporation, phone 612-559-2018 or fax, 612-559-1121.
Question
I am interested in making a gluten free beer.
I would like to experiment with making a beer with 100% corn malt.
Would you give me some general rules for malting corn?
such as:
1. How long should the grain steep?
2. approximately how many day should the germination process take?
3. How long shoud the acrospire be when the malt process is at the right stage?
4. Any other information that you think will be helpful such as the name of a book that will explain the process.
Posed by Willie Clayton, Sumiton Alabama USA on October 30, 2000
Answer
I don't doubt that you will be able to make some kind of alcoholic beverage from corn, but I doubt it will taste much like beer.
Unfortunatley I have absolutely no experience in working with corn in the malting process.
Question
I need information about the company that can provide engineering design+facility+equipment for turn key project of malt production?
I appreciate any information regarding this project.
Sincerely
Peter
Posed by Petr, WDM IA USA on October 2, 2000
Answer
Try Mr. William Kloster at the Kloster Corporation in Minneapolis, MN.
phone: 612-559-2018
fax: 612-559-1121
Question
Hi!I'm a reasercher,I want to explain to me about malt extract productin such as :process,equipments,
packaging,different kind of products and other useful data.
Posed by Mir Nader Ghazali, isfahan isfahan iran on August 1, 2000
Answer
Sorry, I am not at all familiar with the production of malt extract and unfortunately the amount of information on the web is very minimal.
Question
My name is Richard Sieben and my father was the brewer at Sieben's brewery from 1933 until it closed in 1967. I was looking through his brew logs and saw some references made to 'Special K' malt and to 'Fancy Malt'. Do you know what this is and does Briess make an equivalent? The Maltster they used was 'Laddish' and I believe they were in Milwaukee, but I don't think they exist any longer. (Sieben's did floor malt their own until about 1935 I believe.) As you may have guessed, I am trying to recreate the beer so any information you may have would be helpful and appreciated.
Posed by Richard Sieben, Island Lake IL USA on July 10, 2000
Answer
I'm not sure if Briess makes an equivalent to Special K and Fancy Malt because I work for Schreier Malting. Sorry.
Ladish Malting is still very much in business in Jefferson Junction, WI. They may be reached at 920-674-8500. I am certain someone there would be able to tell you exactly what Special K and Fancy Malt were.
Question
What equipment is needed for the malting process? And what equipment do you use ?
Posed by Adrian, Kishinau MD Moldova on July 2, 2000
Answer
Malt is made through three basic steps; 1.steeping, which requires a steep tank
2.germination, which requires a germination bed and a turning device of some sort
3.kilning, which requires a kiln.
Question
Are DWC grains floor-malted? How does the process of floor- (versus pneumatic-) malting show itself in the final product? Thank you.
Posed by Bryan Baird, Numazu Shizuoka Japan on April 8, 2000
Answer
Yes, DeWolf does have floor maltings in Leuven, Belgium. Actually this is the largest floor maltings in the world at 80,000 metric tons capacity.
However, I do not believe that any of their floor malted production is shipped outside of Belgium.
The net result in floor malting is that malt modification (S/T) is typically lower and is more uniform.
Question
dear sir,
in the malting process if barley is heat treated(in order to kill molds) before germination what is the maximum temperaturewhich can be adopted so that the germination process will not be affected
thanks
Posed by bala, fargo north dakota u.s. on February 26, 2000
Answer
I hesitate to give a "temperature" as "heating" depends on time, temperture and air flow used.
A better solution may be to just start with a better grade of barley to avoid potential problems.
Question
dear sir,
does irradiation have any effect in reducing the deoxynivalenol content in the malting process.
thanks
Posed by kottapalli balasubrahmanyam, fargo northdakota u.s. on February 18, 2000
Answer
I have not heard of this being affective in reducing DON after it is formed.
I don't think you would change the chemical structure, destroy it, or make it more benevolent.
Question
To what moisture content do you kiln the greenmalt of wheat? Why do you use this moisture content? I have noticed at malt analysis page, that the greenmalt is dried to 4% H2O. Why this moisture level and is it possible to store wheat malt at higher moisture levels?
Posed by Koen De Bie, Deinze Belgium on February 13, 2000
Answer
We bring the moisture of our wheat down to 4% primariuly from an economic stand point. Our customers would prefer not to pay for excess water content.
If we went much over 5% there would be concern about product stability and storage.
Question
What is an average size of a germinating and kiln compartment?
Posed by Don Moyer, S. Beloit IL US on February 6, 2000
Answer
Our average production piece is 6,000 bushels of barley which results in roughly 7,000 bushels of malt after kilning.
The germination area is roughly 126 feet long and 20 feet wide.
Our circular kiln is roughly 75 feet in diameter.
Question
How to analysis the hetereocyclic compounds in the specialty malts?
Posed by chenzhigui, Beijing China on January 22, 2000
Answer
No, I am not aware of a way to analyze hetereocyclic compounds. Areas of taste and aroma are difficult to measure.
Question
This is a great little service you have here.
I've been a professional brewer for seven years and about two years ago a local farmer approached us about malting his own barley. We loaned him our copy of Malting & Brewing Sciences and he did the rest. Now, two years later, we have his first sample of malt. It is of six-row Robust variety and it sounds like he did everything by the book.
Unfortunately all the trials I've made on the malt come up with zilch. I've done nothing more intricate than single infusion mashing (10 lbs./5 gals.) for times of 1/2 hr./ 1 hr./ 3hrs. and overnight and still come up with gravities no higher than 1.016 and a negative iodine test. The malt has been stored cool and dry and is only about eight months old.
My Questions (if you have the time) are as follows:
1) Can something go horribly awry in the malting process to destroy a malt?
2) Are there any other tests I can preform to determine the conversion ability of the malt?
3) Are there any independent agencies that are available to preform a malt analysis?
Any feedback you may have would be appreciated.
Thank You,
Shawn Duncan
Posed by Shawn Duncan, Bar Harbor Maine USA on November 15, 1999
Answer
It sounds like the barley to malt enzmyes were either destroyed in the malting process or they were never properly developed.
If you are getting a negative iodine reading, I would guess that your "malt" is still barley.
The Siebel Institute, phone 773-279-0966, would be an excellent resource to have your malt tested for alpha and beta levels.
Question
In a low tech attempt to "floor malt" a couple of bushels of Stony plain Barley. I noticed after after it was spread for germination, (approx.4 days), a pungent aroma emanating from the malt. The shoots were approx. the full length of the kernels. Is this normal. The smell was sharp almost vinegary.
My farmer friend that gave it to me was familiar with the smell.
Any advice would be appreciated. If nothing else my boss told me I can't do it in the shop if it's going to smell like that.
Regards
Guy dobson
leduc Alberta
Posed by Guy Dobson, leduc alberta Canada on November 8, 1999
Answer
Usually when a vinegary odor is noted, it it associated with too high of grain moistures and a lack of adequate air flow through the grain.
Seeing as you were floor malting, I would suspect your problem was in aeration.
Question
I am going to malt a couple of bushles of malt barley given to me by a farmer friend.
How long should the shoots be allowed to grow before it is kilned off.
I will be brewing pale ales and stouts with it, assuming it works.
regards
Guy Dobson
Posed by Guy Dobson, Edmonton alberta canada on November 4, 1999
Answer
Normally you would want about 10-20% of the acrospires extending just past the end of the kernel.
More importantly is the uniformity of the development as seen by observing all of the acrospires.
Question
In the modification of the malt due to growth or germanation how do the numeric descriptions (1/4-3/4) relate to the sprout on the seed?
Posed by Tony Joska, Bushnell NE USA on March 12, 1999
Answer
The acrospire is visually compared to the length of the kernel. This serves as a physical indication of the progress of germination.
It is not exact, but it gives a good idea of overall modification.
Question
Gambrinus malting has a malt that they refer to as "honey malt" This malt looks like a 20-40 lovibond crystal malt but lacks the sharp "bite" that crystal malts can contribute and gives my beer a very smooth honeylike texture and a hint of a honey like flavor. Is this malt comparable to any of your products and what makes this malt different than the crystal/caramel malts?
Thanks,
Mic Heynekamp
Posed by Michiel Heynekamp, Socorro NM USA on March 3, 1999
Answer
The Gambrinus Honey malt is one of a kind. It also known in Europe as "brumalt."
The closest match that Schreier would have in terms of color would be the DeWolf-Cosyns Aromatic malt.
I believe the primary difference is that the Honey Malt is rich in simple sugars as a result of a germination and kilning cycle that is different than typical crystal/caramel malt production.
Question
Why is 6-row barley used for your Caramel 10,20 and 60 is stead of a 2-row barley like Caramel 30?
Posed by Don Smith, Manville NJ USA on January 15, 1999
Answer
6-Row barley affords us a higher soluble protein content and higher modification percentage than 2-Row. These elements are the precursors for desired color and flavor in our Caramel malts.
From time to time we will run a piece of 2-Row for our Caramel malts assuming the barley specifications are appropriate.
Question
Beta glucans and arabinoxylans can cause the brewer quite a few head aches. I understand Beta glucans pretty well, but these arabinoxylans are worrying me. What is the exact structure of the arabinoxylans, and what enzymes attack the arabinoxylans. Are these enzymes synthesised along with the beta glucanases in the aleurone layer of the barley grain, and what are their thermal stabilities. I think that is enough questions for now. Thanks a lot. Hoo-roo.
Posed by Jeff Goodieson, redan victoria Australia on January 13, 1999
Answer
Thank you for your excellent question!
Perhaps we should change the name of this forum to "Stump The Maltster."
I would refer you to Malting and Brewing Science, Volume 1, Malt and Sweet Wort by Briggs, Hough, Stevens and Young, for an accurate and thorough answer.
Question
Dear Sirs,
I am an engineer and currently looking for a good reference book or manual on malting processes. Could you recommend me one?
Wim Maaskant
Posed by Wim Maaskant, Nijmegen Netherlands on October 19, 1998
Answer
I recommend Malting and Brewing Science, Volume 1, Malt and Sweet Wort by Briggs, Hough, Stevens and Young. You may purchase this book through the Institute for Brewing Studies, ibs@aob.org
Question
Dear Sirs:
I recently posted a question about the difference between crystal and caramel malts. You kindly answered it and gave me a complete explanation about the subject. I now understand the difference.
I still have a question though. What is the difference between the kiln and the roaster. They seem pretty alike to me. What is the difference between the processes that malts undergo in the kiln and the roaster? Besides, what is the malt you call brewers malt?
Thanks again.
Jorge Blasig
Posed by Jorge Blasig, Montevdeo Uruguay on August 14, 1998
Answer
Malting consist of three steps.
In the first step, called steeping, cleaned, graded barley is immersed in water until the proper moisture content is reached.
In the second step, called germination, the steeped barley is grown under controlled conditions.
In the third step, called kilning, the germinated barley is dried in a flow of hot air and growth is stopped.
At Schreier, the kilning process is done in long, narrow "boxes."
If the maltster has a roaster in his malt house, than the kilning process is accomplished in the roaster. Roasters look like large cylindrical drums.
Brewers malt is a generic term for any base malt such as 2-Row Pale, 6-Row Pale, Pilsen, or Wheat.
Roasting is accomplished in large cylindrical drums. Roasting should be considered a "further processing" function.
Question
Dear Sir:
I read several posts asking about the difference between crystal and caramel malt. The difference comes from the process to prepare these two kinds of malts. I want to know exactly what is the difference between kilning and roasting. Caramel is prepared by kilning green malt, right? And crystal is prepared by roasting dried malt, right? But what is kilning exactly? Besides, what is the temperature used for kilning caramel malt? It depends on the color of the malt you want, but which is the starting temperature?
Thanks.
Jorge Blasig
Posed by Jorge Blasig, Montevideo Uruguay on August 7, 1998
Answer
There are three main types of specialty malts: color malts (Schreier identifies these as caramel malts), caramel malts (also known as crystal malts), and roasted malts.
Color malts, which have darker wort colors and more intense flavors than brewer's malt, can be be produced in a standard malt kiln, with no roasting.
Caramel malts, which are produced by drying green malt in roasters at temperatures that cause saccharification, essentially have the kilning step replaced by roasting.
Roasted malts, the very dark malts, are finished malts which are further processed in roasters after kilning.
There is frequently some confusion over the words used for the first two groups, color and caramel, which are lighter specialty malts. What European brewers usually call color malts are frequently called caramel or hi-dried malts in the United States. The term "caramel" in Europe is generally reserved for malts that have undergone saccharification during their manufacture. In the United States, these malts frequently go by the name "crystal."
The group known as color malts include a wide variety of products, such as Pale Ale, Munich, Aromatic, Hi Dried, and Vienna. These malts are produced in the same kiln in which brewers malt would be produced, but by using higher temperatures in the cycle, at earlier times, to develop more flavor and color.
The higher the temperature to which malt is subjected during kilning while it is still relatively high in moisture, the more color and flavor will be developed.
In producing color malts, brewer's malt will be kilned in a cycle that begins at about 63 degrees Centigrade for much of the cycle, until the malt is at approximately 10% moisture. Then it will be raised to 71 degrees for two to three hours, followed by three more hours at 85 degrees Centigrade.
In producing Caramel (Crystal) malt, the green malt is sent directly to the roaster rather than the kiln. Low heat is applied during the first part of the cycle to dry off the surface of the grain. Then the grain is subjected to higher temperatures to maximize the activity of the enzymes in the kernel.
After saccarification, the malt is dried to 5 or 6% moisture with higher temperatures. The temperatures may be anywhere from 80 degrees C to 145 degrees C. Colors and flavors are developed during this phase in a way similar to the color malts.
Roasted malts are produced by taking finished malts and further processing them in a roaster. In the roaster the product is subjected to very high temperatures, gradually increasing through the process, as high as 220 to 230 degrees Centigrade. The higher the temperatures, or the longer that the product is exposed to high temperatures, the darker or more carbonized the malt will be.
Question
Can you explain the difference between a crystal malt and a caramel malt. I know from experience that crystal malts are harder (like glass inside), and caramel malts are softer. Is this difference caused by special or different production methods?
Posed by Stephen Cavan, Saskatoon SK Canada on June 20, 1998
Answer
Color/Caramel or Hi-Dried malts are produced in a standard malt kiln, with no roasting.
Caramel/Crystal malts, which are produced by drying green malt in roasters at temperatures that cause saccharification, essentially have the kilning step replaced by roasting.
Question
What´s the process of making a caramel malt.
Posed by Gustavo González, Mexico City Distrito federal Mexico on June 3, 1998
Answer
Caramel malts are produced in the kiln, much like brewers malt, but at higher temperatures in the malting cycle, at earlier times, to develop more flavor and color.
The higher the temperature to which malt is subjected during kilning while it is still relatively high in moisture, the more color and flavor will be developed.
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