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O-31. From barley to the glass—Create your own beer

Presenter: Johannes Preiss, Kaspar Schulz, Bamberg, Germany
Coauthors: Jörg Binkert, Johannes Lauer, and Dietram Haertl, Kaspar Schulz, Bamberg, Germany

Until the middle of the last century the malthouse was an integral part of many breweries. Thus, brewers were able to control all technical and technological operations. Nevertheless, at least in Germany, the professional title is still “brewer and maltster.” As a result of this capability brewers could directly affect the characteristics and quality of their malts, which led to an unlimited variety of types and flavors. Currently, the trend toward individualization of beers is experiencing a strong revival, but at the moment, brewers are depending on the raw materials offered by the markets, with all that implies. The history of the 336 year old company Kaspar Schulz contains chapters where malting technology played a big role. Already at the beginning of the last century machinery for malthouses was produced in Bamberg. This technology should be recovered and adapted to the current needs of brewers and maltsters. For this purpose a compact malting plant was developed by Kaspar Schulz. The system includes the needed ventilation technology and fits into an area of just 20 m2 for an output of 2 tons/week. The largest drum is designed for a maximum output of 25 tons/ week. The process steps steeping, germination, and kiln-drying are automatically operated in a drum system and a consigned steep. Careful conveying and gentle agitation are realized by the slow rotation of the drum in combination with an integrated screw conveyor. Modern manufacturing technologies guarantee an optimized hygienic design of the plant. Besides compact construction, the modularity of the system offers many advantages. Thus, the system can be easily expanded, e.g., by a further drum for germination and kiln-drying. This additional drum may use the existing steep, the burner and glass tube heat exchanger of the ventilation system, as well as the handling and processing equipment for grain and malt. All process steps are fully automated and customizable. It’s possible to produce all common types of malt. In combination with the handling and processing equipment for grain and malt, the brewer can independently create his own product from corn stalk to the glass. The prototype of this system was successfully tested at the beginning of this year at Kaspar Schulz in Bamberg. The results of this research project, as well as the easy use of this system, will be presented in this work.

Johannes Preiss’ career in brewing began in Weihenstephan, Germany, where he studied at the Technische Universität München. Johannes graduated with a degree in brewing and beverage technology. He started working in 2008 at Krones AG, Germany, as a project manager in the Research & Development Department. The main focus of his work was brewhouse and cleaning technology, as well as energy optimization. His main topics were lautering technology and integration of solar heat into breweries. As a result of his work, Johannes published several patents and scientific papers. Since the end of 2012 he has been working as the technical director for Kaspar Schulz, Bamberg, Germany. Besides his profession, Johannes is a talented musician. In 2009 he received the cultural award from the City of Nuremberg, Germany.

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