Introduction
Maltina is a natural malt drink
which is produced by mashing of grains to get sugar that is blended together
with other essential ingredients which provides taste, colour, flavour,
multivitamins and minerals. It is enriched with Vit A, B, B2, B3, B5 B6, c and
calcium which makes it to be positioned as the drink that delivers superior
‘Nourishment for life’-Nourishment for an active, vibrant life and for all.
Malti na is beneficiary to human in many ways such as; it provides extra
Nourishment to build,
protect and rehabilitate the body system. It gives firm
support to the bones and teeth and makes them strong due to the presence of
calcium. It is good for patients because it gives them strength and
rehabilitates the body system.
RAW MATERIALS
USED FOR PRODUCTION OF MALTINA
Malt
Adjunct {malted
sorghum, raw sorghum and maize grist}
Hops
Water
ADDITIVES
Amylex
Calcium chloride
{cacl}
Maltina complex( vitamin A, B complex and C)
Caramelized
dextrose maltase {CDM}
Lactic acid
Malt: This is barley
that has been germinated and dried. The germination process creates a number of
enzymes, notably α-amylase and β-amylase, which will be used during mashing to
convert starch in the grains into sugar. It is the main raw material used for
production of beer and non-alcoholic malted drinks. Its use depends on the fact
that barley has high starch content and the husk still adheres to grain even
after threshing and processing to grains.
Adjuncts {raw sorghum,
malted sorghum, maize grist}: These are additional source of starch used to
partially replace/supplement malt. These adjuncts are used for some reasons
which includes; To reduce raw material cost, contribute their own colour and
flavours to the beverage etc
Hops: It gives beer
its bitter taste and has an effect on the aroma of the beverage
Water:
Quantitatively, the most important material is water. It makes up 95% of the
beverage.
Lactic acid and
calcium chloride
are added during mashing to regulate PH.
Amylex: This is an
enzyme added during mashing to help convert the starches to sugar.
Caramelized dextrose
maltose {CDM}: This is a caramelized sugar, it gives the dark
colour to the beverage.
Process flow
chart for maltina
Grains
intake/pre-treatment
Storage
Treatment
Milling
Weighing
Mashing
Mash filtration
Wort boiling
Whirpool rest
Wort cooling
Filtration
Carbonation
BBT storage
Packaging
Grains Intake
/Pre –Treatment
There are two seperate intake
pits; one for the intake of malt while the other is for adjunct (raw/malted
sorghum and maize grist.)
The grains are discharged into
the intake pit, which has a chain and a screw conveyor connected to its base,
these conveyors transport the grains horizontally through a magnet (removes
metallic objects from the grains). It is then conveyed to a drum sieve for
bigger object to be removed. From the drum sieve, the grains move downward to
the screen sieve shaker for object smaller than the size of the grains to be
removed. These grains are then discharged into the bucket elevator which
transport the grains vertically and empties into a chain conveyor at the top,
which then transfers the grains to
designated silo.
Storage
The per-treated grains are then
sent to their different silos for storage until the need arises for its usage.
During storage, the grains in the silos are checked for infestation with insect
and rise in temperature which is not expected to exceed 35°C otherwise the
moisture content of the grains will rise beyond normal due to rise in
temperature and condensation
Treatment
When the grains are needed for
production, it will be discharged from the bottom of the silo to the bucket
elevator which conveys it upward to combi cleaner (destoner). This machine
removes stones of different sizes from the grains.
Milling
From the destoner, it goes directly into the
hammer mill where the beaters in the mill crush the grains to smaller sizes
The discharge opening of the mill
is covered with a perforated metal screen of
2.5 mm which retains coarse materials for further
grinding while allowing the
properly sized materials to pass
through
Weighing
From the hammer mill, the
resulting grist will be conveyed via a
screw conveyor to the weighing bin,
which weighs the quantity of the raw
materials needed
The quantity of the raw material
required for one brew of maltina includes;
|
malt
|
Sorghum malt
|
Raw sorghum
|
maize grist
|
|
6 tons
|
2.4tons
|
6 tons
|
2 tons
|
Mashing
The weighed grist is transported via a pneumatic conveyor (air blower ) into
a mashing Vessel where it is mixed with water the malt is mashed into the mash
tun while the adjunct is mashed into the mash copper and is allowed to under go protein rest, gelatinization rest, and liquefaction
rest before it is transferred into the
mash tun to mix with the malt and under go saccharification rest
together.
Mashing
Processes
The adjunct is mixed with ambient
water at about 32°c and hot water of about 85oc into the mash copper to achieve a pre mash
water of 50oc. After mashing-in into the mash copper, the
temperature is maintained at 50oc and left for 50mins protein rest
{breaking down of protein to amino-acids} at this point, Amylex is added. Here
the PH is checked and the norm should be b/w 5.2-5.6. Correction is made by
adding either lactic acid or calcium chloride. The mash is then heated up to 75oc
at 1oc rise per min. At about 73oc, mashing-in of malt
into the mash tun{MT} is done. Before the malt grist start droping into the
mash tun, lactic acid is added also PH is checked and correction {5.2-5.6} is
done where necessary. Protein rest is imposed into the mash tun at this point
too. At 75oc in the mash copper {MC}, the mash is allowed to rest
{gelatinization} for 40 Mins so as to expose the starch by liberating them from
the confines of the protein already broken down, After which it is heated to 93oc.
At 93oc, a rest (Liquefaction) for 10 mins is imposed; this makes
the starch soft and more exposed and ready for sugar conversion.
The mash then is transferred into
the mash tun. Initially, the transfer is done directly and when the temperature
in the mash tun is 60oc. the transfer is done via a cooler so as to
bring the mash temperature to 66oc. Before entering the mash tun, PH
test is carried out to confirm it is between 5.5-5.7 otherwise, correction too
is made. At the end of transfer, the mash is allowed to rest {saccharification}
for about 15 mins. At this point, starch is being converted into sugar and a
mash sample is taken for sacharification test.
Mash Filtration
After mashing, the mash is pumped to a
mash filter where the resulting liquid is strained from the grains. sparge
water is used to rinse the mash filter. The filtrate {wort} is sent to the wort
copper for boiling while the spent grains are sent to the spent grain silo.
Wort Boiling
At this point, the liquid
{filtrate} is called wort. The wort is transferred into the wort copper for
boiling. During boiling, hops, sugar, caramelized dextrose maltase {CDM},
calcium chloride {CalCl}, maltina complex is added. Wort boiling processes
serves as to;
i. sterilize
the wort {some bacteria and moulds that could have survived the
brewing process so far are killed}
ii terminate enzymatic processes
iii coagulate proteins
iv volatilize off flavours
v
Isomerize hop resins {extract the
bittering substance from hops} hops gives the bettering taste to the beverages.
Whirlpool Rest
After wort
boiling, the wort will be send to a whirlpool vessel for the coagulated
proteins (trub) and other heavy materials to be separated from the wort. The
hot Wort is pumped in at an angle tangential to the whirlpool vessel. This
produces a force of in-flow that causes the trub particles to accelerate
towards the centre of the vessel. They form large flocs, which then settle down
at the center bottom line of the vessel to form a trub cone. The clarified wort
is run off from above the trub cone through senses of run off points on the
whirlpool vessel.
Wort Cooling
The clarified wort which leaves
the whirlpool around 85oC has to be cooled down to 0°C before
carbonation. This is achieved by passing counter flows of cold water against
wort on either sides of the plate heat exchanger. The process of heat transfer
i.e heat loss by the wort and the heat gained by the water tends to bring the temperature down.
Filtration
The unclearified malted drink is
transferred to the KG filter for it to
be filtered. As it is moving to the KG filter, it will pass through a cooler
which tends to maintain the temperature at
00C from the cooler to
a stabilizer (BK 75). Here, the protein
component of the beverages is coagulated to form bigger particles. It is at this
stage that certain corrections
like colour dosing, hops dosing
are made. It moves to the KG
filter, this KG filter contains different candle size that
are coated with filter powders (Keiselgur) to entrap the coagulated protein particles while it moves
through a pipe to the carbon
blender for carbonation.
Carbonation
It moves from the KG filter to
carbon blender for addition of carbon (iv) oxide. O2 gives the soft
drink an appetizing taste (mouth feel)
and also increases the shelf life of the beverage. At this stage,
dilution of the original gravity (OG) is
carried out and it is done with deaerated water (DAW)
BBT Storage
The carbonated drink is send to
the BBT for storage until when the need arises it will be send to packaging
department for it to be bottled.
Packaging
When
the drinks are needed for bottling, it
will be sent from the bright beverage tank (BBT) to the bottling hall.
Here the bottles are washed and
inspected before they are conveyed to the filler/crowner to be filled with the
beverage. From the filler/crowner, the bottle is conveyed to the full bottle
inspector (FBI) that inspects and removes under filled bottles, improper corked
bottles from the line. The bottles move on the conveyor to the pasteurizer
where the microorganisms are rendered inactive. From the pasteurizer, it goes
to the labeling machine where the maltina bottle is labelled then to the coding
machine that prints the production date, expiring date and batch no on the
labeled product. The labeled bottles moves on the conveyor to the packer where
they are packed into crates. From there to the full crate inspector (FCI) which
inspects and removes any crate that contains improper crating. From the (FCI),
the crate is conveyed to the palletizer where it is palletized after which it
is transported to the full bottle store where it is stored before its
distribution