Dmitry Nekrasov’s Philosophy — on the Past, Present and Future of Ukrainian Brewing IndustryA meeting with Dmitry Nekrasov always turns into a training course: “Introduction to brewing business“. We are talking to a clever “playing trainer“ a person that can be called a godfather of the Ukrainian craft. He has a dozen of successful projects to his name. Dmitry told us about craft beer in Ukraine, on market cycles, on specifity of operating in retail and HoReCa, on union of Ukrainian brewers and certainly, how a brewery of his own, First Dnipro Brewery is doing.
The market of import beer in Russia: review and databasesThe market of import beer is rapidly growing and changing. But while in the past years it was growing due to brands variety, in 2019 major and affordable brands from TOP-10 were developing actively. It seems that the fact of a brand origin from far abroad counties, even if it is not well known but has moderate price and good distribution provides for million liters of sales in the territory of Russia. Among distributors AB InBev Efes was far behind, yet the role of Baltika and suppliers of the second row got more important. The boom of German brands was followed by stagnation of import from other traditional regions (and Belarus) instead the supplies from Mexico, Lithuania and Asian countries grew considerably.
Russia: Positions of Brewing CompaniesThe review contains an analysis of interim performance of brewers in the first half of 2019. There are rather dynamic changes behind a modest industry growth. Baltika is again experiencing a stage of volumes and market share slid due to competition with AB InBev Efes. Because of the price competition and presence expansion in the modern trade company #2. has come close to the leading position. At the same time sales of Heineken Russia have continued growing which makes the premium part of the portfolio heavier. The market premiumization trend had been also confirmed by import brands. MBC and Zavod Trekhsosenskiy have been the most successful among federal market players. The market share of independent regional brewers and Ochakovo have continued falling as they are being squeezed out by the market leaders at their competitive fields.
Ukrainian beer market 2019: companies and brandsIn 2019 beer production and market have been still fluctuating about zero point. However, the past season was successful for brewers judging by the sales profitability. The price mix has improved due to rapid general market premiumization, as well as its particular aspect, the growth of import beer sales. By the season end AB InBev Efes improved its positions considerably. It turned out that consumers had not forgot Efes brands that had to leave the market, but started to recover rapidly. Against the stagnating market that meant sales decline of other companies, in the first place Carlsberg Group that most of all beneficiated from Efes exiting the market. PPB turned out to be stable to branding activity of its competitor and Obolon kept the same volumes and at the moment it is the absolute leader of the economy segment. The share growth of independent producers took place thanks to leading craft breweries, that so far do not have a big market weight, but they are rapidly gaining it.
Brewing industry in Kazakhstan 2019During the first half of 2019, the majority of Kazakh brewers made their contribution into positive dynamics. Yet it was companies of the lower division, not the two transnational leaders that raised their production and sales. The shares of draft beer and aluminum can which is rapidly squeezing glass bottle out of the market, have been growing. The price segmentation has remained stable despite the substantial rise of retail prices and fluctuations of brand market shares, while the borders between segments have become blurred. The main events in the industry have been: the announced revision of the beer excise policy, launch of BeerKhan brand in the strong beer segment, and most important – purchasing assets of Shymkentbeer by Arasan.
The trend of complication of Russian beer market is going on and in several directions at the same time. The range has got wider, the import and small segments are growing, namely craft beer, alcohol-free beer and special flavor beer. At the same time, all ex-mega brands and light lagers by Russian brewers are experiencing a decline of their shares. AB InBev Efes, Heineken, MBC and Pivzavod Trekhsosenskiy have exceeded the market, Carlsberg was developing slower than the market and Ochakovo as well as some other mid-sized breweries have been cutting down their volumes. To a big extent brewers’ performance was connected to their ability to reach agreement with networks, sacrifice their margin and enter new markets. Craft brewers are facing a serious danger of producers’ registration introduction – de facto licensing. ...
Technical and analytical facts of the new brewhouse of Schlossbrauerei Reckendorf: Experience is the most challenging test
Milling plays a minor role
Already presented at the BrauBeviale 2016, the mash filtration system NESSIE by Ziemann represents the core component of every OMNIUM brewhouse (Fig. 1). This novel lautering process takes place in the transition from the mash tun to the wort kettle and consists of filtration and simultaneous extraction in counter flow allowing the surrounding processes to adapt simultaneously, which in turn reduces brewing time significantly.
Currently, a NESSIE system with four rotating filter modules, each with a diameter of one meter, is used in Reckendorf. NESSIE can process very high wort concentrations of up to 32° Plato, as well as various starch sources resulting in high yields. Thereby, the influence of the grist composition is insignificant to this form of lautering work. Schlossbrauerei Reckendorf was therefore able to continue to operate its existing mill. By means of a switch in the pipe, the grist is transferred to the new mash tun kettle, equipped with an agitator COLIBRI by Ziemann, which can easily process highly concentrated mashes.
Wort boiling and hop isomerization as separate processes
In Reckendorf, about 60 percent of the lautering volume flows directly into the wort kettle, where it is processed to an unhopped boiled wort. In order to have the maximum flexibility in terms of the brew sizes, the wort kettle was equipped with an external boiler. Brews ranging from a total cast-out wort volume of 30 to 95 hl can be produced without compromising quality.
The remaining 40 percent of the lautering volume is fed to a second boiling vessel, the system for separate hop isomerization JANUS by Ziemann. Because the hopped wort is not boiled, but just kept hot; the evaporation is in the range of one percent.
Only the NESSIE wort fraction, whose extract content has dropped to about 2° Plato, is specifically used for hop isomerization. Compared to the boiled wort, this fraction has a slightly higher pH value, known to be advantageous for the alpha acids isomerization process. This wort fraction also contains important minerals such as magnesium, but less protein, which in turn reduces the amount of trub formed. The measured hop yield is higher due to these factors. The produced hop extraction wort can be dosed subsequently into the wort kettle, whirlpool or to the wort upstream from the plate heat exchanger. It can even be added as highly efficient and sterile hopping in the fermentation and storage cellar. This verifies JANUS’ high technological freedom.
Post saccharification with intrinsic malt alpha amylases
The two wort fractions, unhopped wort and hop extraction wort, are brought together in the existing whirlpool of the Schlossbrauerei to be completely saccharified by means of ALADIN by Ziemann. ALADIN is essentially an insulated vessel. About one percent of the lautered wort from the first NESSIE wheel is transferred to this vessel at the very beginning of the filtration process and stored temporarily at about 72 to 75° C. After the wort boiling process in the wort kettle and subsequent cooling to about 80 to 85° C, ALADIN wort with active amylases from the malt is added just upstream the whirlpool. This wort completely saccharifies the dextrins, which are released during the wort boiling by the degradation of the lautered starch particles. The amylases are subsequently inactivated in the whirlpool after saccharification due to the high wort temperature of 80 to 85° C. The final wort is transferred to the fermentation cellar after the hot trub separation. It is worth stating, that the high contents in yeast vital substances in OMNIUM wort, such as zinc or fatty acids, have a continuous and positive effect on the fermentation process.
34 percent shorter brewing times
In early April 2018, the first brew in the new brewhouse in Reckendorf was produced. Instead of the original two brews per day, each with 105 hl cast-out wort, the OMNIUM brewhouse is able to produce three brews per day with 70 hl each, filling the 210 hl fermentation tanks. Wort from both brewhouses (conventional with lauter tun and OMNIUM) was compared and analyzed from the technological and process point of view in order to evaluate the OMNIUM process.
The mashing time in the OMNIUM system was 35 minutes shorter with 105 minutes duration compared to the 140 minutes mashing time on the lauter tun brewhouse. The lautering time with the NESSIE system was 50 minutes compared to the lauter tun with an occupancy time of 165 minutes. The lauter tun brewhouse in the Schlossbrauerei Reckendorf needs for wort production in total eight hours from the mashing-in up to the end of the wort cooling. With the new brewhouse concept, the entire process is reduced to 5.25 hours, which corresponds to savings of 165 minutes or 34 percent (Fig. 2).
50 percent less tanning agents
The tanning agent content in the kettle-full wort is significantly lower in OMNIUM compared to the lauter tun brewhouse. Polyphenols, anthocyanogens and tanning agents are in average 50 percent below the reference values (Fig. 3). This is mainly due to the very short residence time (three to five minutes) of a mash particle in the NESSIE system. In contrast, in the lauter tun brewhouse, tanning agents, husk bitter substances, dyes and silicates are progressively washed out of the husks. This is not the case for the NESSIE system, which has a short residence time, and is evident by the lighter wort color measured from kettle-full worts. The prevailing steam atmosphere in the NESSIE wheels, which prevents oxidation, enhances this effect.
13 percent higher hop yield
The bitter units of the cold wort were adjusted to 24 BE in the OMNIUM as well as for the lauter tun brews. However, these bitter units were achieved in the lauter tun brewhouse with an alpha acid dosing of 57.1 mg/l but only with 50.0 mg/l alpha acids in the OMNIUM brewhouse. This results in a hop yield, all the way to the cold wort, of 42 percent in the old brewhouse and 48 percent in the OMNIUM brewhouse. In total, 7.1 mg/l less alpha acids can be dosed to achieve the same bitter units, which corresponds to 13 percent savings and an extremely attractive economic aspect.
More than one percent higher malt yield
Also in terms of the malt, the yield is more than one percent higher with NESSIE. This is noticeable in the low remaining extract in the spent grains, which is well below the standard values of MEBAK (Fig. 4). The highly efficient washing in the NESSIE generates strikingly low photometric iodine values (0.06) in the spent grains. This means that the NESSIE separation technology also washes out the starch grits, which normally remain in spent grains.
The photometric iodine value of 1.53 in the kettle-full wort is therefore correspondingly high. By dosing the wort from ALADIN, the iodine value of the cold wort is again very low with a value of 0.18. By means of ALADIN’s post saccharification, fermentable sugar is produced, which contributes to the increased yield. In addition, with these low iodine values filtration problems, associated with insufficient saccharification, starch haze or loss of taste are excluded.
30 percent faster fermentation
With the “less sharp” NESSIE separation technology, higher amounts of other technologically important malt ingredients are transferred to the pitching wort, and are not remaining in the spent grains (Fig. 5). The achieved zinc content of 0.38 mg/l in the NESSIE system clearly exceeds, for example, the values of the old brewhouse (0.05 mg/l) and the technologically desired minimum concentration of 0.15 mg/l. The same applies to the long-chain, saturated and unsaturated fatty acids with 1.6 mg/100 ml compared to 0.02 mg/100 ml and the associated increased yeast metabolism.
Due to these positive effects, the Schlossbrauerei was able to reduce massively the wort aeration, among other things, in order to keep the yeast growth within the desired limits. Now only one of three brews in one fermentation tank is aerated for ten minutes to achieve an oxygen content of one ppm. Overall, the Schlossbrauerei Reckendorf achieved a time saving of 30 percent with OMNIUM worts under the same fermentation conditions resulting in an increase in cellar capacities (Fig. 6).
120.000 hl brewing line on 69 m2
Finally yet importantly, the OMNIUM system offers not only the above-mentioned technological aspects but also advantages in terms of the building construction. The OMNIUM brewhouse in Reckendorf has a brewing line with an annual capacity of 120,000 hl and has been built on a net area of only 69 m2 (Fig. 7). For the Schlossbrauerei this was a further positive point in favor of OMNIUM: it was the only way to install the brewhouse in a very compact new building designed for the confined space conditions in Reckendorf.
16 Мар. 2019