Objective

The objective was to optimize the brewing process by replacing the existing enzyme and process-aid system with an alternative enzyme solution, with a focus on reducing enzyme and additive costs, shortening Total Processing Time (TPT), improving wort filtration efficiency, maintaining required wort quality and production parameters, ensuring consistent fermentation performance, and eliminating unnecessary process inputs wherever possible.

Plant Profile

  • Industry: Malt & Brewery
  • Location: Madhya Pradesh, India
  • Application: Beer Brewing
  • Raw Materials: Malt, Broken Rice & Sugar
  • Production Scale: 330 HL final wort volume per brew

Process Challenges

The brewing process was evaluated to improve brewhouse efficiency, processing time and process economics, while maintaining consistent wort and fermentation performance.

  • High enzyme and process-aid consumption — creating a need for dosage optimization and lower process-input requirements
  • Extended wort filtration time — requiring improved liquefaction, viscosity management and wort clarification
  • Longer Total Processing Time (TPT) — creating a need for faster yeast settling and more efficient maturation
  • Dependence on lactic acid during mashing — creating an opportunity to optimize mashing and eliminate additional acid input
  • Need to maintain process and beer quality — ensuring wort gravity, volume, fermentation performance, filtration and beer clarity remained within required specifications

Catalyst Solution

  • Natunase TAA 4S — Enhances adjunct liquefaction and starch breakdown for improved mash efficiency
  • Natunase BG Prime — Breaks down β-glucans and other non-starch polysaccharides to reduce viscosity and improve filtration.
  • Natufloc Plus — Improves wort clarification and trub separation for smoother downstream processing
  • Natupap NP — Breaks down proteins to support filtration efficiency and reduce chill-haze formation
  • Natufine Plus — Accelerates yeast settling and supports reduced maturation and overall processing time
  • Natufoam SP — Supports foam stability and retention in the finished beer
  • Natunox — Supports efficient wort processing and fermentation performance through improved process conditions

Critical Quality Parameters Maintained

  • Final Wort Gravity — remained within the required specification
  • Final Wort Volume — remained consistent with the target production volume
  • Mash Filtration — continued to operate smoothly without deviation
  • Fermentation Time — remained consistent with the established process cycle
  • Standard AE Achievement — remained within the required fermentation endpoint

Performance Highlights

Parameter Control Trial Improvement Units Remarks
Total Enzyme & Additive Dosage 10.17 6.99 ↓ 3.18 kg/brew Lower process-input consumption
Lactic Acid Usage 2.00 0 ↓ 2.00 kg/brew Mashing operated successfully without lactic acid
Average Wort Filtration Time 115 99 ↓ 16 min Faster Wort Filtration Processing
Total Processing Time (TPT) 19 13 ↓ 6 days Shorter production cycle
Beer Haze @ 25° 0.30 0.26 ↓ 0.04 EBC Improved beer clarity
Beer Haze @ 90° 0.96 0.49 ↓ 0.47 EBC Significant improvement in haze performance

Conclusion

  • Stable brewing performance: Critical parameters including wort gravity, wort volume, mash filtration, fermentation time and standard AE achievement remained within the required specifications
  • Significant process improvement: The Catalysts solution substantially reduced enzyme/additive consumption, wort filtration time and TPT, eliminated lactic acid usage, and improved beer clarity—driving greater process efficiency and operating economics