Our country produces dry fermented and unfermented rye malt.
Dry fermented rye malt(red or stewed) is obtained by sprouting rye grain, its fermentation (simmering), drying and grinding. Unfermented malt(light or uncooked) is obtained in the same way, but without the fermentation process.
The process of “fermentation” refers to the process of aging (simmering) sprouted rye grains at high temperatures. Fermented malt, in addition to this operation, is also dried at high temperatures.
At the same time, in rye malt the process of formation of melanoidins proceeds intensively, giving the malt a red (more precisely red-brown) color and a specific taste and aroma. It is for these properties that this type of malt is produced.
Fermented malt has very low enzyme activity - several times less than ordinary rye wallpaper flour, since high temperatures during the simmering and drying stages lead to inactivation of enzymes. Therefore, fermented rye malt should be considered not as an enzyme preparation, but as an additive that improves the color of the crumb of rye bread (the crumb acquires a pleasant brownish-brown color), its taste and aroma. It was already noted in Chapter VIII that a similar effect can be obtained by significantly lengthening the baking of rye bread from wallpaper flour and without the addition of red rye malt.
Fermented (red) rye malt is usually added to the brew used in the preparation of rye custard, Borodino and some other types of bread.
However, the preparation of red rye malt is a labor-intensive, time-consuming process and, even with the most rational technology, is associated with the loss of about 20% of the dry matter of the rye grain.
Dry rye malt, unfermented Unlike fermented grain, it is dried immediately after germination.
Drying is carried out at reduced pressure and temperature, so that α-amylase, iroteolytic and other enzymes, whose activity increases sharply during grain germination, retain this activity after drying. Milled malt after drying has a light color, very close to the color of flour (therefore it is often called white malt), and a sharply increased activity of enzymes, especially α-amylase.
Therefore, this type of malt (pefermeitirovan) is used in baking as an α-amylolytic enzyme preparation (EP) and for saccharification in the preparation of Riga and some other types of bread, as well as as an improver in the processing of wheat flour with reduced sugar and gas-forming ability.
It should be noted that in the practice of the domestic baking industry, white malt with high enzyme activity is used only in a limited number of corresponding types of bread and is provided as a mandatory component of the recipe in a certain dosage, not linked to the properties, and in particular to the sugar- and gas-forming ability of the processed product. flour.
In a number of countries, the addition of white malt with high enzyme activity or malt extract is linked to the level of sugar-forming ability of flour.
When preparing wheat bread from premium and first grade wheat flour, it is advisable to use crushed pefermented malt instead of malt extracts.
The most valuable components of active white malt for baking - its enzymes, sugars and dextrins - are almost completely transferred into an aqueous solution. Therefore, if you prepare an aqueous extract from malt and boil it (at reduced pressure and temperature, so as not to inactivate the enzymes), you will get an extract - a thick syrupy mass containing all the water-soluble parts of the malt. This extract is free from shells and large grain particles, which cause the darker color of the crumb. The use of malt extracts is widespread in a number of countries.
Malt extracts improve gas formation in the dough, since they consist of approximately 60% fermentable sugars and, in addition, contain active amylolytic enzymes, in particular a-amylase. Proteolytic enzymes of malt extracts, as well as protsolysis activators, also play a significant role.
The use of malt extracts with high proteolytic activity and a high content of proteolysis activators when preparing bread from weak flour with weak gluten can lead to a deterioration in the quality of bread and an increase in its spreadability. Therefore, when characterizing the quality of malt extracts, one should be guided by indicators not only of their chemical composition and α-amylolytic activity, but also of proteolytic activity.
The dosage of malt extract, depending on its enzymatic activity and the properties of flour, ranges from 1-3% by weight of flour.
The greatest effect (a significant increase in the volume and porosity of bread, normal coloring of the crust) is achieved by malt extract added to flour with low sugar-forming ability. The use of malt extract extends the period of consumer freshness of bread.
Malt is the name given to cereal grains sprouted under artificial conditions at a certain temperature and humidity. The process of artificially sprouting grain is called malting. The resulting sprouting product is called freshly sprouted malt, which is then dried to produce dry malt.
To produce malt, mainly barley and rye are used. Dry fermented (red) and unfermented (white) rye malt is produced from rye; light and dark barley malt, as well as caramel and roasted, are produced from barley. In baking production, dry fermented (red) and unfermented (light) rye malt is mainly used.
Fermented rye malt is used in baking as a flavoring additive in the production of improved varieties of rye bread. It gives the bread crumb a dark brown color, pleasant taste and aroma.
Unfermented rye malt is used in baking as a preparation containing active enzymes for the preparation of infusions, in the processing of defective flour, and as a recipe component in the production of certain types of bread.
Rye malt is used in the production of kvass concentrate and bread kvass.
Barley malt is the main raw material in the preparation of beer. It is also used for saccharification of starch-containing raw materials in the production of alcohol.
MALT PRODUCTION
The technological scheme for malt production includes several mandatory processes:
Cleaning and sorting of grain.
Grain intended for malt production is cleaned of large impurities, dust and sand, then sorted by grain size to obtain batches with the same uniformity. This ensures uniform soaking and germination of the grains.
Washing and disinfection.
To clean the grain mass from remaining contaminants, defective grains, microorganisms that contaminate the surface of the grains, the grain is washed with water and disinfected before soaking.
Soaking the grain.
To achieve optimal humidity for germination, the grain is soaked.
Grain germination (malting).
The purpose of germinating grain is to activate enzymes in it. Germination occurs at sufficiently high grain humidity, favorable temperature and air access. To obtain unfermented light barley malt, the grain is usually germinated for 7-8 days, light rye - 5-6, red rye - 3-4 days.
Fermentation.
Fermentation (simmering) is a special technological processing of freshly sprouted malt, used ONLY in the production of red rye malt in order to maximize the accumulation of low-molecular-weight products of enzymatic hydrolysis of carbohydrates, proteins and other substances. When malt is dried, melanoidins are formed as a result of the interaction of these products. They determine the brown-red color of fermented rye malt and give it the specific aroma of rye bread. Fermentation duration is 4-5 days.
Drying freshly sprouted malt.
During the drying period, deep biochemical, chemical and physicochemical processes occur in the malt, as a result of which the enzymatic activity, chemical composition, taste, aroma and color of dry malt are finally formed.
Unfermented rye malt (white) is dried for about 18 hours, and fermented (red) - 24 hours. Once the moisture content reaches 8-10%, drying of light malt stops. Red malt is subjected to further drying with an increase in temperature to 70-85°C, while the humidity is reduced to 8%. During this period, a large amount of aromatic and coloring substances are formed.
Separation of sprouts and polishing of malt.
After drying the malt, the sprouts are separated using a sprouting machine, as they have a bitter taste and degrade the quality of the malt. Given the rich chemical composition of sprouts, they are used to produce malt extracts. After removing the germs, the malt is polished on a polishing machine and cleaned of impurities.
Aging dry malt.
Cleaned malt is aged for 4-5 weeks. During the resting period, the quality of the malt improves.
Grinding and storage of malt.
Malt can be produced in the form of grains and ground - in the form of a fine powder. Malt is stored on racks in ventilated, clean, odor-free rooms, not infested with barn pests, at a temperature of -10 to +30°C and a relative air humidity of 75%.
MALT PRODUCTS
Malt preparations are products obtained by concentrating the water-soluble substances of malt or malt sprouts. These products, unlike malt, do not contain grain shells, which lead to a deterioration in the color of the product.
Polymalt extracts.
They are produced from a mixture of corn, oat and wheat malt. They are a thick, medium-viscosity liquid of brown or dark brown color with a sweetish malt taste.
Polymalt extracts are used as food products for therapeutic and prophylactic purposes, as well as raw materials for non-alcoholic production and additives for bakery and dairy products.
Barley malt extract.
It is obtained from light barley malt. Its technology is similar to the technology of polymalt extracts.
A special feature of the technology is that 30% of the malt is replaced with unmalted barley, which is an additional source of vitamins. In addition, for a more complete extraction of extractive substances, it is recommended to use enzyme preparations, as well as liquid brewer’s yeast, administered as a vitamin supplement.
It is advisable to use barley malt extract as an additive in the production of bakery, confectionery, dairy products, as well as in the production of soft drinks.
Malt sprout extract.
Malt sprouts are obtained by separating them from malt during drying and processing.
Malt sprouts contain proteins, fats, minerals, a complex of various enzymes, as well as vitamins B, PP, E, C.
An aqueous extract is obtained from malt sprouts, into which water-soluble substances are transferred. The extract is evaporated and a malt extract containing 60% dry matter is obtained. The extract can be used in the yeast and baking industries as a component of nutrient media for growing baker's yeast.
EFFECT OF MALT ON THE HUMAN BODY
Regular consumption of rye malt normalizes the acid-base balance in the gastrointestinal tract and improves digestion; prevents the appearance of stones in the gall bladder, bile ducts and liver; actively promotes increased intestinal peristalsis, helping the body timely cleanse itself of accumulated waste and toxins.
The introduction of rye malt into the diet will prevent the occurrence and development of cholelithiasis and will bring tangible benefits for diseases such as dysbiosis, gastritis with low acidity, enterocolitis, duodenitis, chronic constipation resulting from dysbacteriosis or colitis. Regular consumption of products enriched with malt is a good prevention of rectal and colon cancer.
Polyunsaturated fatty acids Omega-3 and Omega-6, which are part of rye malt along with other components, help reduce the level of “bad” cholesterol in the blood and prevent the deposition of atherosclerotic plaques on the walls of blood vessels. Rye malt contains a high content of vitamin E, which normalizes blood pressure and actively prevents blood clots. This vitamin, like other antioxidant vitamins A and C contained in this product, perfectly strengthens and protects the walls of blood vessels and helps reduce capillary permeability. Potassium and magnesium, which rye malt is rich in, are essential for the smooth functioning of the heart muscle. Therefore, rye malt is especially useful to include in the diet of people suffering from atherosclerosis, hypertension, coronary heart disease and other diseases of the cardiovascular system, as well as for the prevention of heart attacks and strokes.
Rye malt– a valuable diabetic product. The substances contained in rye malt slow down the absorption of fats and carbohydrates, helping to stabilize blood sugar levels, and a complex of minerals (manganese, magnesium, zinc, chromium, selenium) play an important role in the process of regulating the production of natural insulin by the pancreas.
Regular consumption of rye malt will prevent many diseases, including tumors, strengthen the immune system and effectively restore the body’s energy tone (especially useful for patients who have suffered serious illnesses, complex operations, as well as for people suffering from exhaustion or in an asthenic state ).
Products enriched with rye malt can be successfully used in the prevention and complex treatment of obesity, anemia (anemia), various inflammatory and tumor processes.
Daily consumption of products enriched with rye malt (salads, yoghurts, cereals or soups, etc.) helps cleanse and rejuvenate the body.
What is malt extract?
Malt extract is a concentrated and/or dried essence from barley malt. Most of the world's malt is used in the food industry, such as in malted milk, breakfast cereals, baking dough additives, and even pet food. There are two main varieties of barley: malt and fodder, and several subvarieties within each. It is believed that barley from which food extracts are made (grades 3 and 4) is worse than malt and pure varieties. Low grade barley grains are usually small, with a high protein content, poorly digestible starch and a thick husk that is not suitable for consumption. Brewing uses the highest quality barley, and in order to brew a good batch of beer, you need to be sure that the extract for it is made from exactly this (beer) barley.
To prepare the extract, barley grains are first soaked and dried to allow the grain to begin to sprout. While the sprout breaks through the grain, enzymes are activated that process the starch necessary to nourish the embryo, and proteins into sugars and amino acids that the sprout will need in the future. It is important for brewers to be able to use these enzymes and starch reserves. As soon as the grain begins to germinate, it is dried in a special oven to stop the process at the most profitable stage for brewers and preserve all the necessary substances. It is this grain at a fixed stage of germination that is called malt. There are many varieties of malt, distinguished by taste, smell and color, and the type of beer depends on their choice. There are lager malts, pale malts, Vienna malts, Munich malts, kilned malts, roasted malts, and even chocolate malts.
The production of malt extract in a plant is akin to the first stage of brewing from whole barley grains. Malted barley is ground and soaked in hot water to renew and accelerate the formation of enzymes that convert the grain's starchy reserves into fermentable sugars. As a result, a solution of sugars is formed, which is called wort. It is this that the brewer first boils, then mixes with hops and adds yeast for fermentation. To make a concentrated extract from the wort instead of continuing to cook, it is placed in an evaporator where it thickens. In other words, malt extract is simply concentrated wort, so if you buy it and dilute it at home, you get regular industrial wort. Depending on what type of beer you want to make, you can take extract from one or more varieties.
The wort is boiled for two reasons: to destroy the heat-stable proteins that otherwise make the beer cloudy and spoil the taste and aroma of the beer, and to isomerize the alpha acids in the hops to impart bitterness to the beer.
Rice. 18. Malt extract plant (photo courtesy of Briess Malt & Ingredients Company)
This is done both at home and in industrial breweries, although factories do not always immediately add hops to the extract. If hops are added later, then the extract is boiled only to destroy the proteins, and then when adding hops to the wort you need to boil it additionally at home. After boiling at the factory, the wort is placed in vacuum chambers for dehydration so that the extract can be stored longer without preservatives. In these chambers, the solution is evaporated under pressure, which prevents the sugar from caramelizing, since the temperature does not reach 100°C, and preserves the taste and smell of the extract. To make an extract with the addition of hops, it can be added both when the grains are first brewed, and already in the finished extract in the form of hop iso-alpha acids. So, you can see that extract for home brewing is quite difficult to prepare.
It is sold both in liquid (syrup) and powder form. Syrups have about 20% water content, so 4 kg
dry malt extract approximately corresponds to 5 kg of liquid. To produce a dry extract, the liquid extract is heated and sprayed in a high, hot chamber. Small droplets dry quickly and settle on the walls of the chamber. Typically, dry extracts do not contain hops and are generally similar to syrup.
To improve flour with low sugar-forming and gas-forming ability, you can use malt and various preparations from it - malt flour, malt extract and malt extracts. In our bakery industry, the use of red malt for rye custard bread and white malt for Riga bread is widespread.
When baking wheat bread from premium and first grade flour, neither white malt nor flour from it are added, since their addition would cause a noticeable darkening of the bread crumb. Therefore, so-called malt extracts are used for wheat bread.
Malt extracts
The most valuable components of active white malt for baking, its enzymes, sugars and dextrins, are almost completely transferred into an aqueous solution. Therefore, if you prepare an aqueous extract from malt and boil it (at reduced pressure and low temperature, so as not to destroy the enzymes), you will get an extract - a thick syrupy mass containing all the water-soluble parts of malt, including its enzymes, sugars and dextrins. This extract is free from shells and large grain particles, which cause the darker color of the crumb. The use of malt extracts is widespread in a number of countries.
The composition of various malt extracts, according to the Central Laboratory of the Leningrad Baking Trust, is given in the table.
Malt extracts improve gas formation in dough, since approximately half of them consist of fermentable sugars and, in addition, contain active amylolytic enzymes, in particular α=amylase. A significant role is played by the proteolytic enzymes of malt extracts, as well as the content of proteolysis activators in them, noted by Tulchinsky.
The use of malt extracts with high proteolytic activity and a high content of proteolysis activators when preparing bread from weak flour with weak gluten can lead to a deterioration in the quality of bread and an increase in its spreadability. Therefore, when characterizing the quality of malt extracts, one should be guided by indicators not only of their chemical composition, but also of their enzymatic activity.
When establishing the production of baking malt extracts in Russia, it is necessary to establish standards of requirements for their amylolytic and proteolytic activity. In order to inactivate the proteolysis activators contained in malt extracts, it is advisable to produce malt extracts with appropriate additions of potassium bromate.
The content of large amounts of maltose and significant amounts of dextrins in malt extract can have a somewhat improving effect on the physical properties of dough and gluten. This phenomenon was stated by Tulchinsky and Falunina, who, as mentioned above, gave an explanation for this phenomenon.
The dosage of malt extract, depending on its enzymatic activity and the properties of the flour, ranges from 1-3% of the weight of the flour. The Leningrad Central Laboratory recommends adding malt extract not to the dough, but to the dough.
The greatest effect (increase in bread volume by up to 50%, normal coloring of the crust) is obtained by malt extract when applied to flour with low sugar-forming ability. The use of malt extract somewhat slows down the staling of bread.
Bread made with malt extract contains more soluble carbohydrates and has a finer porosity and is therefore easier to digest by the human body.
Owners of patent RU 2464304:
The invention relates to a technology for producing malt extracts and can be used in food and baking production. The mash is prepared from malt that has been crushed and extruded at a temperature of 120-240°C. Enzyme preparations with cellulolytic action in the amount of 0.2-0.3 ml/kg of malt dry matter and amylolytic action in the amount of 0.3-0.5 ml/kg of dry matter starch are added to the mash to break down non-starch polysaccharides and hydrolyze the starch contained in the malt . Hydrolysis is carried out at a temperature of 55-60°C for 5-12 hours. The mash is separated into wort and sediment, the wort is concentrated to obtain a malt extract containing 72-76% dry matter. The invention provides an increase in the color of malt extracts and the yield of malt dry substances by 1.5-2%. 2 salary f-ly, 2 ill., 2 pr.
The invention relates to a technology for producing malt extracts and can be used in the food industry and bakery production.
There is a known method for the production of malt extracts from grain raw materials, which involves crushing the malt, preparing the mash, hydrolyzing the mash, separating it, evaporating the wort and bottling the finished product.
About half of the amount of water required for the mash at a temperature of 35-37°C is taken into the mash apparatus and all the crushed malt is poured in with the mixer running continuously, then the rest of the water at a temperature of 35-37°C is added with the mixer running continuously.
The mash hydraulic module should be 1:4-1:6. For enzymatic hydrolysis of malt, the mash is kept at the following temperatures: 40-42°C - 40-45 minutes; 50-52°C - 15-20 min; 63-65°C - 30-40 minutes; 71-72°C - until complete saccharification. The sugared mash is divided into liquid and solid fractions: wort and sediment.
To separate the wort, a filter press or centrifuge is used, then the wort is concentrated in evaporators to a dry matter content of 72-76% (V.S. Ivanova, A.V. Danilevskaya and others. Technology for the production of polymalt extract. Food industry, publishing house Texnika K No. 2, 1984. P. 42).
The disadvantage of this method is that there are not enough coloring substances in malt extracts, which not only intensify the fermentation of the dough, but also give a dark color to the crumb. In addition, grain starch-containing raw materials and products of its processing contain a large amount of non-starch polysaccharides (cellulose, hemicellulose, gum and pectin substances), forming viscous, difficult-to-separate solutions.
The technical result consists in increasing the color of malt extracts due to extrusion processing and increasing the yield of malt dry substances by hydrolysis of non-starch saccharides using enzyme preparations with cellulolytic action.
The technical result is achieved by adding enzyme preparations of cellulolytic and amylolytic action to the prepared mash from extruded malt, respectively, in an amount of 0.2-0.3 ml/kg DM malt and 0.3-0.5 ml/kg DM starch and The mash is hydrolyzed at a temperature of 55-60°C for 5-12 hours.
The proposed method is illustrated by drawings, in which:
Fig.1 is a technological diagram of a known method for producing malt extract;
Fig.2 - technological diagram of the proposed method for producing malt extract.
The method is carried out as follows. Malt is used as the starting raw material, which, after crushing, is subjected to extrusion processing at a temperature of 120-240°C and a mash is prepared (hydromodulus 1:4-1:6), enzyme preparations of cellulolytic and amylolytic action are added, respectively, in an amount of 0.2-0. 3 ml/kg DM malt and 0.3-0.5 ml/kg DM starch and hydrolyze the mash at a temperature of 55-60°C for 5-12 hours, then the mash is separated into liquid and solid fractions (wort and sediment ), the resulting malt wort is concentrated under vacuum to a dry matter content of 72-76% at a temperature of 60-70 0 C and a pressure of not less than 0.079 MPa.
Malt in an amount of 1 kg is crushed and then extruded at a temperature of 180°C for 20 s, crushed in a laboratory mill and the mash is prepared by adding 4 liters of water (hydraulic ratio 1:4), the enzyme preparation Viskoferm is added - a balanced mixture of β-glucanase , xylase, cellulase and α-amylase (Novozymes) at the rate of 0.2 ml/kg DM of malt. Next, amylolytic enzyme preparations are added to the mash: fungal alpha-amylase Fungamyl (Aspergillus oryzae strain) with an activity of 5300 units. AC/ml in an amount of 0.3 ml/kg dry matter starch and glucoamylase AMG (strain Aspergillus niger) with an activity of 3000 units of GlS/ml in an amount of 0.12 ml per 1 kg dry matter starch, hydrolysis is carried out for 12 hours at a temperature of 58- 60°C, then the product is subjected to centrifugation with separation into liquid (wort) and solid (sediment) fractions. The resulting wort with a dry matter content of 18% is concentrated to 76.2% dry matter in a laboratory unit under vacuum at a steam pressure of 0.079 MPa and a temperature of 70°C.
Malt extract has the following physical and chemical properties:
Carbohydrate composition, % dry matter:
1 kg of malt is crushed and then extruded at a temperature of 230°C for 20 s, crushed in a laboratory mill and the mash is prepared by adding 4 liters of water (hydraulic ratio 1:4), the cellulolytic enzyme preparation Viskoferm (Novozymes) is added in an amount of 0 .2 ml/kg DM malt. Next, the complex enzyme preparation Spezyme DBA (Novozymes) is added to the mash - a mixture of barley β-amylase with an activity of 1370 DU/g and mushroom α-amylase with an activity of 450 DU/g in an amount of 0.5 ml/kg of dry starch. Hydrolysis is carried out for 12 hours at a temperature of 58-60°C. Next, the product is subjected to centrifugation with separation into liquid (wort) and solid (sediment) fractions. The resulting wort is concentrated in a laboratory unit under vacuum to 75.8% dry matter at a temperature of 70°C and a steam pressure of 0.079 MPa.
The product has the following physical and chemical characteristics:
Carbohydrate composition, % DM
Thus, the claimed method makes it possible to obtain malt extracts with a darker color of 6000-8000 units. EMU, due to extrusion processing of malt, increases the yield of malt dry matter by hydrolysis of non-starch polysaccharides using cellulolytic enzyme preparations by 1.5-2%.
1. A method for producing malt extract, which involves crushing malt, preparing the mash, hydrolyzing the mash, separating the mash into wort and sediment, thickening the wort to produce a malt extract containing 72-76% of dry substances, characterized in that the prepared mash is made from crushed and During the extrusion processing of malt, enzyme preparations of cellulitic and amylolytic action are introduced, respectively, in the amount of 0.2-0.3 ml/kg of dry matter malt, amylolytic action in the amount of 0.3-0.5 ml/kg of dry matter starch, and hydrolysis of the mash is carried out at a temperature of 55- 60°C for 5-12 hours.
2. The method according to claim 1, characterized in that the cellulolytic drug Viskoferm is used during hydrolysis.
3. The method according to claim 1, characterized in that when hydrolyzing the mash, amylolytic preparations AMG and Fungamyl or Spezyme DBA are used.
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The invention relates to the food industry, namely to the production of polymalt extracts (concentrates), and can be used in the production of food products in the non-alcoholic and confectionery industries.
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// 2492701The invention relates to the food industry, in particular to the production of a functional food product based on freshly prepared grain. The method for producing a functional food product includes washing the seeds with water, treating the seeds with a disinfectant, incubating moistened seeds until they germinate, and fermenting the grain in fermenter chambers. In this case, the incubation of seeds is carried out by moistening to a humidity of 60-65% at a temperature of 12-24°C until they germinate until sprouts are obtained that are 1.5-2 times the length of the grain. Polydimethyldiallylammonium sucrose chloride is used as a disinfectant at the rate of 10 ml of a 25% solution in 500 ml of water per 1 kg of grain at a temperature of 16-24°C. The device for implementing the claimed method is characterized by the presence of containers stacked on top of each other. The bottom of each container is perforated, and the size of the holes is chosen in such a way as to prevent the passage of seeds through them. At the bottom of each container there is a mesh with cells with a mesh size that prevents the passage of seeds through them. The invention makes it possible to shorten the technological cycle and at the same time obtain a high-quality functional food product, free from damage by pathogenic microorganisms, as well as mold and fungi, while maintaining the integrity of freshly sprouted grain. 2 n. and 5 salary f-ly, 2 ill., 1 pr.
The invention relates to the technology for producing malt extracts and can be used in food and baking production
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