Barley Products

We are engaged in processing and supplying of barley malt, which cater to the requirements of breweries, distilleries, malted milk food manufacturers, confectioners and pharmaceutical. The three stages of processing Barley Malt are:

Steeping

The process goes as below:

The barley is separated from the foreign material. Once it is separated, it is graded to specific size.

The barley is then shifted to steel tanks, which are provided with outlet pipes and water inlets to carry out vigorous aeration and mixing of the barley or water mixture with the aid of compressed air.

Once barley reaches water content of 43-56%, steeping is stopped

Germination:

• After Steeping get over, the steeped barley is shifted to germinating floors or room to allow germination.

• The entire germination period takes 4-7 days depending upon the type of barley.

• During the germination process, many enzymatic systems such as oxidative and reductive systems get activated and involved with the respiration phase.

• The activate B-amylase or proteolytic enzymes release act on the proteins present, to make them soluble.

• However, about 40% of the total protein is made soluble in water.

• Optimum germination activates a balanced enzyme system and hydrolyzes the starches present.

Kilning

• The Kilning or drying process done at appropriate time and at optimum degree of starch modification, stops the germination.

• The heat catalyses additional reaction, which results in color and flavor development.

• The germinated malt or green malt is hastily and cautiously dried.

• When drying period is over the sprouts and other extraneous materials are removed.

Malt Extract is the hot water extract of malted barley. The extraction method does not involve the use of any chemicals; only the hot water and physical separation processes using residual grain as a natural filter are involved. The resulting wort is carefully evaporated to 80% solids to be naturally preserving and to protect the valuable flavours and nutrients produced. The resulting yellow brown viscous liquid has a pleasant characteristic odor and a mild sweet malty flavour. It consist of a mixture of sugars resulting from the action off the naturally occurring enzymes (mainly alpha and beta amylases) presented in the malted barley on the starch components of the grain.

Uses of Malt Extract:

• Malt extracts are used as food ingredients for one or more of their wide range of attributes.
• Malt Extract may be used for flavour and flavour enhancement;
• Malt Extract is a source of nutrients;
• Malt Extract is a source of fermentable sugars;
• Malt Extract is a natural colour or for colour enhancement through browning;
• Malt Extract is a texture modifier
• Malt Extract is used as sweeteners

Also Malt Extract finds application in wide range of health foods i.e. tonic food beverages like bounvita, horlicks, maltova, viva, nutramul and milo. Breads and crackers, baby foods, biscuit and confectionary and pharmaceuticals (cough syrups), ice creams, brown breads

Apart from all this Malt Extract is also used in manufacturing non alcoholic beer, nutritional health drinks.

Our standard packaging for liquid malt extracts are:

• 25-kg Steel Pails
• 25-kg Plastic Pails
• 300 kg Plastic Drums
• Road Tankers
• Flexi Tanks
• Any Packaging, as per customer's specifications

The liquid Malt Extract is spread over various trays to form a batch. It is placed in a vacuum oven where it is dried into a solid brittle cake. The Malt Extract cake is then granulated through a mill to produce a free flowing Malt Extract Powder. This process is carried out to produce special types of malt extract powder.

Dried Malt Extract Powder offers many benefits and have the following characteristics:

• non-diastatic  
• coarse powder
• easily soluble 
• additional flavour derived from 'cooking' process
• inclusion of other ingredients like milk powder, fat, sugar, where ever possible

General Specification of Malt Extract Powder:

Physical Data

1. Appearance : A light brown powder

2. Odour : A sweet agreeable and characteristic

3. pH : 5 to 6

4. Solubility : Readily dissolves in warm water, aqueous solution

is not clear

5. Loss on drying : Not more than 4 %

Chemical Data

1. Proteins content : Not less than 4 %

2. Maltose content : Not less than 60 %

Microbiological Data

1. Total Plate count/gm : Not more than 10000

2. E.Coli/10 gm : Absent

3. Salmonella/10 gm : Absent

Malt flours are produced by milling grains of malted cereals. . There are different types of mills - roller mills and pin mills for example - each producing different grades of flours. We produce both light and dark flours. Light coloured malt flours offer varying degrees of alpha amylase, protein and malt flavour.The dark flours are produced from malt which has been roasted after the malting process.Dark malt flours are principally used for flavour, texture improvement and appearance enhancement in all areas of the food industry In addition, we are also able to develop specific products to meet individual customer specifications and requirements.

Malt Flours are packed in paper/HDPE sacks of 25kg.They are light in colour and have a low flavour level. When added to bread dough the natural enzymes in the malt flour break down starch to produce maltose and other sugars which act as yeast foods, enhancing yeast performance during fermentation.

Light barley malt flour has high diastatic activity and is excellent at improving bread.


When used in white Breads

It enhances the fermentation and yeast performance. It improves the softness and increases volume of bread. It also gives a malty flavor to the bread without affecting the crumb flavour and colour. Generally it is used at low levels of up to 1% of flour weight.
When used in Brown Breads - It provides a sticky crumb to the loaf. It is used alone or in a combination of up to 5% of flour weight depending on the desired level of stickiness.

Dark malts have a deserved reputation for their quality and variety. Bakers and food manufacturers have traditionally used a 'dark malt flour' to enhance flavour and colour in their products. Nutritionally, dark malt flours have high carbohydrate levels with significant levels of protein and fiber and low levels of fat.

When used in Brown Breads and Brown Rolls

It gives a cake or brioche like crumb to the bread. It also provides a malty flavor to the bread depending on the kind of flour and amount of flour being used. The use of malt extract at a very low level also helps in flavor development. It's most important advantage is that it provides a brown color to the bread and no additional artificial flavour and colour are required. Generally its usage is around 5% of the flour weight.

When used in White Breads

It should be initially used at 3% of flour weight to get a creamy yellow color of the bread. The usage also depends on the individual flavour and colour of the bread required.