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(Module 1: Raw Materials)

(Module 2: Processing)

(Module 3: Health, Safety, Environment and Food Safety)

 

 

Module 1 – Raw Materials

Barley:

– Malting barley varieties
– IBD approved list
– Breeding and growing malting barley
– Barley identification, the use of morphological characteristics and electrophoresis
– Null Lox
– Diseases and seasonal factors
– Pre-germination
– Basic knowledge of other cereals
– Basic knowledge of farming practices

Barley purchasing and handling:

– Barley Contracts
– Acceptance/rejection of deliveries
– Intake and sampling procedures
– Due diligence monitoring
– Farm assurance schemes, grain passports, approved use of post-harvest pesticides
– Drying, screening and storage of grain
– Types of stores
– Conveying and handling equipment
– Infestation precautions and treatments
– Temperature control and monitoring of stored grain
– Maintaining quality prior to malting

Principles and interpretation of barley analyses:

– Controls for reducing the impact of dormancy
– Germinative energy and water sensitivity tests
– Water uptake assessments
– Micromalting tests

Barley supply and demand:

– political factors (eg CAP, WTO) affecting world trade in barley
– World grain market drivers – eg biofuels, weather, commodities and geopolitics

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Module 2 – Processing

Steeping:

– Water quality and typical volumes used for processing
– Effects of differing water temperatures
– Use and design of aeration equipment and design used in steeping
– Importance and function of air rest periods
– CO2 extraction, equipment design and typical air volumes used in various designs of steeping vessels
– Achieving appropriate levels of moisture during the steeping process and at cast
– Design of steeping equipment
– Barley washers
– Use of automated recipe based process controls

Additives and processing aids:

– Reasons for the use and application of GA

Germination techniques:

– Different types of vessel design
– Control of moisture in germination
– Control of air temperature and the volumes of air used to maintain control
– Batch size
– Humidity control equipment
– Visual evaluation of germinating grain
– Use of automated recipe-based process controls
– Endosperm modification, enzymes, cell wall modification and proteolysis

Psychrometric charts:

– Interpretation and use in designing malting plant

Kilning procedures:

– Variations for different malt qualities
– Fuels and heating equipment used for kilning
– Kiln design
– Methods in use for reducing energy consumption
– Control of malt analysis
– Malting loss management by variation in processing techniques
– Coloured/roasted and special malts including peating
– Control of flavour compounds in kilning
– Use of automated recipe-based process controls
– Control of NDMA

Types of malting plant:

– Machinery and conveyors
– Air conditioning systems

Malt Despatch:

– Deculming
– Screening
– Weighing
– Sampling
– Grading
– Storage and stock control
– Despatch in bags and bulk
– Conveying equipment to minimise malt breakage
– Malting loss, its source and control

Recommended methods of malt analyses:

– IOB, EBC, ASBC Methodologies
– Specification
– Interpretation
– Quality assurance and quality control
– Use of statistical techniques

Co-products :

– Production and handling
– Analysis

Services:

– Water,
– Electricity all aspects of supply and distribution
– Fuel types, costs pros and cons
– Effluent – types of treatment available, water reuse

Energy conservation:

– Maintenance – computerised maintenance management systems, costs, compliance checks
– Instrumentation automation, PLC controls
– Control systems, closed loop, open loop

Capital and operational costs

Project appraisal:

– Criteria for project approval, payback methods
– Types of project

Distribution

General understanding of the brewing and distilling processes:

– Reasons for specifications of certain malt properties
– Diastatic and non-diastatic malt extracts
– Glycosidic nitrile (GN)
– Predicted spirit yield (PSY)
– The influence of malt quality on brewhouse performance
– Mashing and separation techniques
– Wort quality
– Uses of malt and malt products within the food industry

International malting industry and its markets:

– Industry economics
– Producers and users
– Political factors (eg CAP, WTO) affecting world trade in malt

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Module 3 – Health, Safety, Environment and Food Safety

Hazards and safety in malting:

– Health and safety issues
– Confined spaces
– Dust and explosion risk and DSEAR regulations
– Safe working procedures
– COSHH
– Work permits
– Risk assessments
– Handling and storing chemicals and additives

Accident reporting:

– RIDDOR

Standards and Legislation:

– ISO 9001, ISO 14001, ISO 45001, ISO22000, ISO50001
– FEMAS
– UFAS
– TASCC
– GTAS
– AUKM
– Organic, Kosher and Halal Certification
– HACCP
– TACCP
– The Food Safety Act
– Feed Hygiene Regulations
– Food Hygiene Regulations
– DEFRA Code of Practice for the Control of Salmonella
– Health and Safety Legislation
– IPPC
– EU Food Safety Directives and Legislation
– PUWER
– CDM
– Control of Noise Regulations

Environment:

– Construction of a risk matrix for environment
– Organising mitigation measures
– Environmental impact of different parts of the process
– Waste management

Quality:

– Quality assurance schemes
– Reporting, monitoring and controlling quality
– Impact on business operations and on malt performance in the brewery or distillery
– Analytical parameters
– Typical values
– Action measures when outside pre-defined limits

Food Safety:

– HACCP
– TACCP
– Cleaning and plant hygiene
– Awareness of certification standards
– Legionella
– Pest control

Malting Engineering:

– Fan laws and their interpretation
– Principals of heat transfer – conduction, convection and radiation
– Fluid flow – definition of laminar and turbulent flow, calculations on volume flow, Bernoulli equation
– Valves – types and applications
– Electrical motors
– Pumps – types and applications
– Materials of Construction- Stainless steel types, mild steel use, corrosion, insulation

Energy Efficiency

Waste water:

– Principles of treatment
– The Mogden formula

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