XII Международная студенческая научная конференция Студенческий научный форум - 2020

In the framework of the research work “Development of technology and justification of the necessary complex of barley malt production machines in the conditions of the Kostroma region” and expanding professional knowledge, we consider it necessary to study foreign experience in the field of our activity. The production of malt is widely used in world practice and there are numerous descriptions of its technologies and equipment used in the scientific and technical literature. The purpose of the given article we briefly present a part of the material reviewed.

The main disadvantage of the traditional method of producing malt is the long duration of the process, especially at the stage of germination, as well as the insufficient enzymatic activity of the finished malt. In addition, malting barley in Russia often does not meet the requirements of the modernized brewing industry in quality. Currently, a search is underway for new methods of influencing barley grain with the aim of increasing germination, reducing the time of germination of barley, increasing enzymatic activity and improving the quality of the finished malt.

Fabrication of integrated malting unit for production of malts

Malting is a three step process i.e. steeping (grain soaked in water), germination (development of sprout and enhance enzymatic activity) and kilning (drying the grain and stop the enzymatic activity). All these three steps are completed in separate plants. The integrated malting unit would allow to perform all three operations in one device. An integrated malting unit used for small scale production of malt was developed in the department of Post-harvest Process and Food Engineering, G. B. Pant University of Agriculture and Technology, Pantnagar in December 2012. It can reduce the cost of process of malt production. The integrated malting unit can also provide employment for small scale malt producer [1].

Producing Quality Barley for the Malting Industry

In malting barley production, malt quality factors are more important than yield; therefore, these cropping systems are managed more intensely than fields producing feed grade barley. In executing these practices, producers pay special attention to planting times and conditions, nutrient management, growth stages, irrigation and harvest.

Barley production has become increasingly more intensive over the years. Many management decisions regarding the application of fertilizers, pesticides, and growth regulators are dependent on the developmental stage of the crop. To accurately schedule management inputs and employ tactical control measures (i.e. insect or pathogen) it is essential for the producer to know the specific growth stages of the crop. A number of cereal grain staging systems have been employed for describing the developmental stages of barley. Currently, the Zadoks system is the most universally recognized system that is used for describing growth stages of cereal grains.

Irrigation management is one of the most important factors affecting malting barley yield and quality. Growers are encouraged to monitor soil moisture throughout the season to ensure their crop has sufficient water. Monitoring can be conducted using soil moisture sensors, such as neutron probes, time domain reflectometry (TDR), tensiometers, or gypsum blocks. These instruments enable the grower to easily determine the soil moisture in many locations across the field [2].

Modern malt production equipment

We searched for modern equipment for malt production and found several modern companies:

«Yingtai» company:the professional manufacturer of beer barley malting equipment over 30 years of experience
They make several types of equipment:

Malt making technology:

This technology was invented by a German engineer, it consists of cleaning raw material, steep, germination, drying and scale packing, its advantage: germination box is rectangle box, fan provides uniformity air from one end or side so as to achieve humiture control. Material transmission adopts mechanization, drying adopts single layer high efficiency kiln, double layer high efficiency kiln or round kiln. Drying adopts copper stove will be save 50% coal than steam generator. The annual output is less than 5 tons.

Tower type malt processing line

This technology improved some questions, such as technology parameter control, labor strength, high production cost and high efficiency.

The main process: the barley aftercleaning will be transferred to the tower top by bucket elevator, through steeping, germinating, drying according to the technology time, at last it will be drying, grubbing and packing, this kind of malt 

processing line could produce 100,000 tons for one year. Malt index is easy to 

control, high degree of automation, lower production cost, small covered area. But it needs to invest large on building, it also needs high level workers for operation and maintenance. 

Layout tower type malt processing line

Layout tower type malt processing line adopts round germination box technology, let 5 pcs round germination box placed on the same plane.

Adopts transmission equipment under box transferring the barley to drying box, the best advantage is not only achieve all requirement of tower type malt making, but also save lager building cost [3].

Czech company specializing in the production of malt: «Mopos». MOPOS is the original manufacturer of all critical machines for malt producing plant: for soaking barley, sprouting barley, malting and complex malt houses.

The whole production process on the equipment of this company is fully automatic, computer-controlled, a complete visualization of the processes is provided in the room for staff.

Provision for all germinating conditions – may be preset for each box individually as per differing qualities of raw material (barley) [4].

The Bühler Holding AG, based in Uzwil, Switzerland is a technology company clarification needed for plant and equipment and related services for processing foods and manufacturing advanced materials. The organization holds leading market positions worldwide in the fields of technology as well as processes for transforming grain into flour and animal feeds, producing pasta and chocolate.

Bühler's malt production division specializes in designing and launching industrial malts with integrated logistics and automation solutions.

The company produces equipment based on the latest digital technologies, which allow real-time analysis of products, monitoring and control of equipment at a distance and on the move.

Company uses program "PreMa – Silo Bin Monitoring" – which is a smart way of controlling storage condition by getting an immediate visual overview, anywhere at any time. Cloud connectivity enables online access to plant information and storage conditions. Control processes can be optimized using storage condition based alarms and push notifications. The clear structure and intuitive navigation giving a detailed view of the silo bin and help to identify storage problems quickly [5].

Analyzing the state of technological progress in the field of malt production in the world, we can conclude that many countries have gone far ahead in this field, using technological progress and the latest innovative technologies. Some of these technologies could be applied in Russia to implement efficient production of a quality product that meets all the requirements of consumers.

References:

Sanjay Kumar et. al. Int. Journal of Engineering Research and Applications www.ijera.com ISSN: 2248-9622, Vol. 6, Issue 8, (Part - 3) August 2016, pp.33-36

Spring 4-20-2015 Producing Quality Barley for the Malting Industry Haley H. Oser DPH University of Nebraska-Lincoln

[Electronic resource] https://www.alibaba.com/product-detail/Yingtai-Malt-Turning-Machine-for-Beer_1148813673.html

[Electronic resource] https://www.mopos.com/production-programme/malt_plants

[Electronic resource] https://www.buhlergroup.com/content/buhlergroup/global/en/services/Digital-services/Prema-Silo-Monitoring-App.html

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