MAlting Process

Malted barley, or malt, is the primary ingredient used in the production of beer, providing complex carbohydrates and sugars necessary for fermentation and contributing flavors and colors that are uniquely characteristic of beer. Those same benefits are equally effective in producing yeast-fermented dough systems, baked goods, bars, cereal, granola, prepared foods, snack foods, and other finished food products. And because malt is made from whole grain and minimally processed, it is an all-natural ingredient that helps achieve product claims like natural, healthy, Kosher, and non-GMO. Making malt requires only a cereal grain, usually barley, water, and a three-step process: steeping, germinating, and kilning.

STEEPING

Steeping starts with raw barley that has been sorted and cleaned, then transferred into steep tanks and submerged with water. For the next 40-48 hours, the raw barley goes through waterings and air rest. The absorbed water activates existing enzymes and stimulates the embryo to develop new enzymes.

Steeping is complete when the barley has reached a sufficient moisture level to allow the uniform breakdown of the starches and proteins. One visual indicator that the maltster uses to determine the completion of steeping is to count the percentage of kernels that show "chit."

GERMINATION

In "steep out," the chitted barley is transferred from the steep tank to the germination vessel. Germination, which began in the steep tank, continues in the vessel where the barley kernel undergoes modification. Modification refers to the breakdown of the protein and carbohydrates and the resulting opening up of the seeds' starch reserves. Good conversion requires the barley to remain in the vessel for 4-5 days. Germination is controlled by drawing temperature-adjusted, humidified air through the bed. Turners keep the bed from compacting and rootlets growing together or felting.

KILNING

Germination is halted by kilning. If germination continued, the kernel would continue to grow, and the growing plant would use all of the starch reserves needed by the brewer. Base or standard malts are kiln-dried. Typically with a finishing heat of 180-190° F for 2-4 hours, a flavor develops, ranging from very light malty to subtle malty. Specialty malts are dried in a kiln at higher temperatures for more extended periods, roasted, or both. Varying the moisture level and time and temperature of drying develops each specialty malt's flavor and color characteristics.