Patent EA-004916-B1 (EA)
Title: Improvements in and relating to the steeping of barley
Inventor: NALLEN PETER
IPC: C12C1/02
Filed: 2004-03-10
Abstract: 1. A process of steeping barley for subsequent malting in a steeping system (1) comprising three vertical arranged, one above the other, steeping vessels, namely a highest initial (2), an intermediate (3) and a lowest final (4) steeping vessels each steeping vessel (2,3,4) having cylindrical sides (5), terminating in a conical base (8), a water inlet manifold (11) and outlet manifold (13) in the base (6) and a plurality of sets of circumferentially arranged and spaced-apart aeration rings (7) in the base (6), the initial steeping vessel (2) additionally having in overflow receiving channel (25) around its periphery and a central rousing tube (30) open at both ends, the rousing tube (30) being spaced-apart from and adjacent the base (6) and in communication with a pressurised air inlet pipe (31) for delivering barley up through he rousing tubes for recirculation of the barley and a conical protective cover (32) is mounted above the rousing tube (33) and spaced-apart therefrom, the system further comprising control means comprising data recording and control means and a systems database, the control means being connected to temperature, moisture content and germination capacity monitors for the vessels to control the operating parameters of the process, the process comprising: for each variety of barley being malted prior to acceptance of the variety for steeping, carrying out a micro-malting process on a sample to determine optimum steeping parameters; storing the parameters in the database together with the characteristics of the barley including at least the variety and where grown; and then prior to commencing the steeping, obtaining the parameters stored and setting the steeping parameters having regard to the stored parameters; during the steeping, recording and storing the actual parameters in the database for subsequent use with barley having those characteristics; from time to time carrying out a further micro-malting process on other barley; and then on receiving a batch or barley for steeping, the steps are performed of: (a) delivering water and barley into the initial steeping vessel (2); (b) delivering further water into the initial steeping vessel (2) to cause overflow into the overflow receiving channel (2) while rousing and aerating the barley using the lift tube (30) and aeration rings (7); (c) stopping the rousing, and adding potassium permanganate; (d) transferring the wet barley and water to the intermediate steeping vessel (3); (e) steeping the barley with intermittent aeration by the aeration rings (7) in the intermediate steeping vessel (3); (f) draining the water; (g) allowing the drained barley to rest white extracting CO2 from above the barley and intermittently spraying the barley; (h) filing the intermediate steeping vessel (3) with water; (i) steeping the barley with intermittent aeration using the aeration rings (7); (j) transferring the barley and water to the final steeping vessel (4); (k) steeping the barley with intermittent aeration in the final steeping vessel 4); (l) draining the water; (m) allowing the drained water to rest while extracting CO2 from above the barley and intermittently spraying the barley; (n) filling the final steeping vessel (4) with water; (o) steeping the barley with intermittent aeration in the final steeping vessel (4); and (p) delivering the wet barley onwards for germination; and in which additional: during each resting step (g) and (m), wetting the barley every two hours for between 0.01 and 0.03 hours and checking the temperature of the barley and if the temperature exceeds 25 degree C, the additional steps of filing the steeping vessel (3,4) and draining the steeping vessel (3,4) are performed prior to continuing with the resting step (g) and (m); adding the water at between 11 degree C and 13 degree C for each steeping step (b), (e), (i), (k) and (o); and continuously monitoring the temperature, the moisture content and germination capacity of the barley and when, during the last resting step (g) and (m) in the intermediate steeping vessel (3) and the final steeping vessel (4), the moisture content of the barley is below 32 to 35% and 32% respectively, the appropriate resting step (g), (m) is prolonged with additional wetting until the required moisture content is achieved. 2. A process as claimed in claim 1, in which the characteristics stored additionally comprise one or more of: Batch number; Start date and time; Site number; Vessel group; Steeping method etc. 3. A process as claimed in claim 1 or 2, in which the micro-malting process is carried out on each variety at least ones a year prior to commencing steeping while the barley is in storage. 4. A process as claimed in any preceding claim, in which in the initial steeping vessel (2): step (b) of rousing the barley is carried out for between 0.25 and 0.45 hours; and step (c) of further steeping the barley is carried out for between 1 and 2 hours. 5. A process as claimed in claim 4, in which the times for carrying out steps (b) and (c) are of the order of 0.5 and 1.5 hours respectively. 6. A process as claimed in any preceding claim, in which in the intermediate steeping vessel (3): step (e) of steeping the barley is carried out for between 4 and 8 hours; step (g) of resting the barley is carried out for between 10.5 and 16.5 hours; and step (i) of steeping the barley is carried out for between 2.0 an 5.0 hours. 7. A process as claimed in claim 6, in which the times for carrying out steps (e), (g) and (i) are of the order of 6.0, 13.5 and 3.5 hours respectively. 8. A process as claimed in any preceding claim, in which in the final steeping vessel (4): step (k) of steeping is carried out for between 3.0 and 5.0 hours; step (m) of resting the barley is carried out for between 9.5 and 13.5 hours; and step (o) of steeping is carried out for between 6.0 and 9.5 hours. 9. A process as claimed in claim 8, in which the times for carrying out steps (k), (m) and (o) are of the order of 4.0, 11.5 and 7.5 hours respectively. 10. A process as claimed in any preceding claim, in which the intermittent aeration is carried out for between 20% and 30% of the resting time. 11. A process as claimed in claim 10, in which the time taken to carry out intermittent aeration is of the order of 25% of the resting time. 12. A process as claimed in any preceding claim, in which when, during a resting step (b), (e), (i), (k) and (o), the temperature exceeds 25 degree C and the resting step is within one hour of anticipated termination, the resting step (b), (e), (i), (k) and (o) is terminated. 13. A process as claimed in any preceding claim, in which between 1.5 and 3.5m<3> of water is added per tonne of barley. 14. A process as claimed in any preceding claim, in which the air is supplied at between 775 and 875 millibar. 15. A process as claimed in any preceding claim, in which when carrying out step (b) and causing overflow, the top of the initial steeping vessel is skimmed to remove floating debris.