Design and Production of Maize Beer

Submit Manuscript | http://medcraveonline.com the import costs, we want to produce a local beer that may have the similar characteristics like beer barley beer from another cereal, maize. Unlike barley, maize grows very well in all tropical countries of Africa. Qualitatively, the chemical and biochemical components are almost the same as well as in both barley and maize. There are several types of strains of microorganisms used for the production of beer, such as lactic bacteria and yeast. But we have used a yeast strain: Saccharomyces cerevisiae which we can find easily and cheaply. The manufacturing processes of our maize beer essentially involve treatment of grains, malting or germination, mashing or extraction with water, filtration and fermentation.


Comparison of barley and maize
Barley beer is a widely consumed alcoholic beverage throughout the world and global production figures have shown an increasing trend during the last decade. In Africa, the alcoholic beverages such as liqueurs, wine and especially barley beer are much consumed both during moments of joy (festivals, weddings, success in examinations or competitions, winning football matches etc.) and moments of sadness (funerals , job losses, poverty, etc.). The sale of beer is a significant source of revenue for the owners of the maquis, restaurants, etc. It is therefore a creative activity of jobs. But unfortunately, barley beer is imported. To lessen the import costs, we want to produce a local beer that may have the similar characteristics as beer barley beer from another cereal, maize. This can also allow us to diversify the raw material of beer in temperate countries in order to promote cooperation between Russia and African tropical countries for example. Unlike barley, maize grows very well in all tropical countries of Africa. The Table  1 below shows the comparative chemical composition of barley and maize [1][2][3][4][5][6][7][8][9][10][11][12][13].
Qualitatively, the chemical and biochemical components are almost the same as well as in both barley and maize. Corn beer in the Andes has pre-Incan origins. There is archeological evidence that elite women were responsible for brewing in the Wari culture (600 to 1000 AD). In 1796 John Boston created a corn beer, the first fermented alcohol beverage made at Sydney, Australia. Traditionally, barley was the main grain used in brewing beer. However, many brewers use other grains along with barley. Most of the beer sold in the world is made with rice or corn making up a healthy portion of the grain bill. For just one Peruvian sol (around 30 cents), you can get drunk in Peru's Sacred Valley. Concealed amid the areas monstrous mountains, a series of domestic speakeasies serve an ancient Andean drink known as chicha de jora, a fermented corn beer dating back to the ancient Incan Empire. Still widely consumed in the Andean highlands, locals homebrew the concoction through a series of methodical steps involving the germination of jora (a type of yellow corn), a crop revered for its life-sustaining attributes.

Health benefits of barley beer
According to many research works related to health benefits of beer, such as "Bio-medicine" for example, barley beer would have many health benefits if it is consumed in moderate amounts. Some of these interesting health benefits would include the following: a. Anti-cancer properties: Hops used in beer, through its flavonoid compound called Xanthohumol, would play a major role in the chemoprevention of cancer, including prostate cancer. f. Anti-aging properties: Beer would increase the potency and impact of vitamin E, which is a major antioxidant in the body. It would be an important part of the maintenance of healthy skin, while also slowing down the aging process.

g. Gallstones:
Regular consumption of moderate amounts of beer would affect the cholesterol levels and decreases bile concentration, leading to a reduced risk of developing gallstones.
h. Prevention of dementia and coronary disease: Beer consumption also would boost the level of "good cholesterol" by 10-20%, thus reducing the risk of dementia and cardiovascular diseases.
i. Aids digestive system: Beer would possess a number of digestive properties, which would include the stimulation of gastrin, gastric acid, cholecystokinin and pancreatic enzymes.
j. Kidney sones and osteoporosis: Potassium, sodium and magnesium would be present in and would be important in reducing risk of kidney stones. The silicon would be also present in beer and would be readily absorbed by the body, further explaining the protective effect of beer against osteoporosis.
k. Stress buster: Beer would reduce stress, and facilitates sleep. So would do other alcohols.
l. Diuretic: Beer would act as a diuretic and significantly would increase urination. This facilitates the increased removal of toxins and waste materials from the body.

Maize Beer Production Procedures
The main source maize beer is starch and its production includes the following steps: a. Treatment of maize grains: The aim of this stage is to have safety grains. Therefore, detoxification of grain before malting may not be practical unless further growth of the mold is also prevented. Physical, biological, chemical and biological methods are used for inhibiting mold growth in grain.

b. Germination or malting:
Grain is soaked in water. Water is absorbed by the grain. There are hydration of grain embryo and stimulation of grain for start of germination. Activities of embryo are awakened, and enzymes will be distributed evenly throughout the kernel. Grain is placed in shallow vessels. Water is removed. Aleurone layer is stimulated to produce enzymes. Enzymes act to degrade cell wall structures. Enzymes are stimulated from the aleurone layer and there is hydrolysis of proteins, carbohydrates, hemicellulose and lipids in maize grain. The temperature of the malt is raised from 15 to 85°C in a controlled manner (temperature, airflow, time). Germination process is halted at desired malt quality, green brown malt is converted to stable, storable product, colour and flavor are developed, enzymes are stabilized and preserved and unwanted flavours are removed. e. Fermentation: Wort solution then cooled to yeast pitching temperature (21-25°C). Temperature is reduced to allow for yeast addition, Yeast is added to sterile cooled wort (cold temperatures encourage precipitation of proteins and beer clarification). Wort components of sugars and proteins are utilized by yeast to form alcohol, CO 2 and flavor components according to the following chemical reaction:

c. Extraction with water or
As objective and results: alcohol level is established, flavor profile of beer is established and carbonation level is established. At the end of fermentation, yeast flocculates and can be easily separated. Cold maturation temperatures will influence beer clarity f. Second Filtration: After the completion of fermentation, the beer is filtered in order to remove the yeast and all the other solid derivatives. In this process, auxiliary materials of natural origin are used. After filtration, the clear product is driven to bottling.

Materials
The Table 2 shows the Reagents, materials and equipment in maize beer production. Figure 1 shows the data for the production of maize beer. 6
PH: 2.8 to 3.2 Calculation: How many Maize do I need to produce 1000 kg of beer 5% alcohol?

Receipts
The yield is 95%.
The quantity of sugar is 1074.32 x 95%=1020.60 kg. The content of alcohol is about 5%. So the quantity of alcohol is 1020.60 x 5%=51.03kg.The quantity of lost is 1074.32-1020.60=365.53 kg. Step 6: Second filtration The yield is 98%.
The quantity of maize is 1020.60x98%=1000kg. The content of alcohol is about 5%. So the quantity of alcohol is 1000x5%=50kg. The quantity of precipitate is 1020.60-1000=20.60kg

Mass of final product: 1000kg
Water: 89-95%:890-950g Practical case for production of 10-15kg beer Treatment of maize grains: 6 kg of maize have been treated and used as raw material.

Germination or malting:
a. Soaking: 6 kg of treated maize and 9 kg (9 liters) of drinking water have been mixed in a basin 24h/30°C. b. Germination: 5 kg of water have been removed in a bucket from the soaking. The germination took place on plastic sheet at 30°C/72h. The maize was recovered with non toxic vegetable leaves (cleaned before in a bleached solution) in order to retain moisture. The cereals were humidified twice per day. Fermentable sugars resulting from starch hydrolysis can be tested by Trommer's reaction with the formation of Cu 2 О precipitation of red-brown colour.
Procedure: 1 g of dried germinated maize can be poured into a test-tube, 6 drops of 10 % NaOH solution were added and drop by drop, 5 drops of 2 % CuSO 4 solution until non-vanishing Cu(ОН) 2 blue coloration. After heating the content of the testtube, changing of color can be observed. After heating the blue coloration, if the formation of Cu 2 О precipitation of red-brown color is observed, we are presence of fermentable sugars.
Extraction with water or mashing a. Drying: The product could be dried at 100°C/4h to 5h through an oven or in the sun. But, it was dried 3 days in the sun through large white sheets of paper. Fortunately we were in summer.

b. Grinding or pounding:
The dried maize has been pounded through a mill. The weight was 6 kg of malted maize. c. Extraction: 6 kg of malted maize and 1kg of rice husks have been added to hot water. 30 liters of hot water have been used. First, 15 liters of hot water have been used for the first mashing: 72°C/90 minutes. Second, 10 liters of the same water have been added for the second mashing: 78°C /60 minutes. During the extraction, we were often stirring the mixture. During the filtration, we had added the other 5 liters, liter by liter. We had obtained about 20 liters of wort with 10°Brix. If the wort is very starchy after Iodine test, we have to add 1 kg of barley malt.

d. Boiling:
The boiling has been done at 100°C/90 minutes. About 25 kg hops have been added after 45 minutes of boiling. We had 15°Brix.

First filtration
The wort added with hops had been filtered, and we had obtained about 14 liters of product. Fermentation a. Cooling: The filtered hopped wort has been cooled between 20 and 25°C through heat exchanger.

b. Fermentation:
The fermentation has been done with 11grams of yeast about 24°C. Before, the tank of fermentation has been rinsed with a paracetic acid solution 1%. We had 15°Brix (density: 1.06). After one week, we had 11°Brix (density: 1.045).
We have filtered this fermentation pouring the supernatant through a siphon in a tank beforehand cleaned with a paracetic acid solution (50 ml in about two liters of water).
After Four weeks, we had 8°Brix (density: 1.035). The beverage was filtered in a tank previously washed with H 2 O 2 solution 1%for 24 hours and rinsed with the solution of paracetic acid solution.
The tank was tightly closed, then the CO 2 to saturation, was injected at 1.7 bars.
-The tank was then kept at 4°C for one week.

Quality control
Physical and chemical analysis: Apart from the quality criteria for ashes, and total sugars, our beer meets the physico-chemical criteria of quality (Table 3). Traditional beer usually uses several ingredients and different types of grains and hops. So the quality of ash rise could be improved with time and practice. The quantity of protein is very near to the criteria and good in mashing wort, 0.48%. In any case, too much protein makes the beer cloudy. As for the amount of total sugars, it is high because maize malt does not have all the enzymes alpha and beta amylases in full. There are only beta amylases. However, even if it does not meet the standards, it is not bad sanitary to have a relatively high rate of carbohydrates. Careful analysis could be made to identify exactly all the sugars present.
Table3: Physical and chemical analysis of maize beer.

Tests Criteria Results
Water The sensory analysis was carried out on a population of 15 people about transparency, color, flavor, taste and foam. They all appreciated our corn beer, except for the criterion of the foam which was not very strong at the opening. The results are mentioned in the above Table 4. With the mark of 21/25, our maize beer was good. All the 15 people appreciated our corn beer. However, they found that the foam which was not very strong at the opening. The results are mentioned in the table above. Two of them even ordered a dozen bottles of 2 liters of our beer. Unfortunately, the quantity was insufficient during the festival. The quality control about the sensory analysis, meets the criteria. However, much remains to be done to perfect our product. That is why we want to compare the chemical characteristics with those of traditional beer, to check whether it is close to international standards and whether it can have the same therapeutic qualities as traditional beer.

Microbiological analysis
The microbiological analysis was not carried out for the following reasons. All arrangements (food hygiene, boiling, adding CO 2 in final product, etc.) have been made to avoid contamination of the product by the application of the HACCP system. So, all dangers of physical, chemical and biological origin have been minimized to the maximum. At all stages of production from raw materials until the final product, we have endeavored to apply and respect the rules of personal hygiene, clothing, environment, premises, equipment, etc.
On the other hand, if the microbiological analysis should be done, we should research the following germs: Lactobacillus, Pediococcus, Acetobacter, Zymomonas mobilis, etc. [14][15][16][17][18][19][20][21][22][23][24]. Which are not dangerous but contaminate the beer and can affect its taste and smell. But fortunately all necessary measures have been taken. Moreover, the pH, which is 4.7, is not conducive to the development of certain pathogenic microorganisms such as Enterobacteria.
There are also yeasts which are defenders of our beer against other possible microorganisms of contamination. Finally, there is bitterness (10.8 IBUs) which prevents dangerous microorganisms from developing there. However, microbiological analysis could have been carried out as a precautionary measure and verified the effectiveness of the prevention measures. We wanted to spare our department from expenses. Food hygiene is also economy.

Conclusion
Throughout sub-Saharan Africa, maize is the grain of choice to produce traditional cloudy and opaque (maize) beers. The key ingredient of these beers is maize malt, which provides hydrolytic enzymes (especially amylases to ferment sugars into ethanol and carbon dioxide), starch (the source of fermentable sugars), yeast nutrients and beer flavour and colour substances.
The design and production of maize beer can be beneficial for everyone in tropical African countries, for the following reasons: a. The main raw material is on site and cheaper, otherwise farmers will be encouraged to produce more in the fight against poverty.
b. Maize beer can be produced by craftsmen.
c. It may have to increase economic activities and employment creation, etc. It is possible to do the comparison of the all physical and chemical characteristics between barley beer and maize beer in order to check the components which are responsible for health benefits in maize beer like barley beer.
The problem of lack of β-amylase in maize can be solved by importing barley malt from temperate countries in reduced amount (10% in the manufacture of beer maize) or associating maize with other cereals. Our work can be improved in order to preserve the shelf life, organoleptic and chemical qualities of our maize beer and also to avoid chemical, physical and microbial contamination. A whole special attention must be made to all unit operations such as germination, drying, mashing, boiling, fermentation, etc. so that our production process could exceeds African borders. By the way, we have to conduct a study about further research of maize beer and barley beer comparison and what would be the mixing percentage of both for healthy person and what preservatives are required.