Formulación de cerveza artesanal tipo "ale" a partir de maíz (zea mays) como alternativa a la producción local de cerveza artesanal y a la importación de maltas

Abstract

In Ecuador, both industrial and craft breweries import malt for brewing their beers, resulting in a significant outflow of foreign currency due to the importation of this raw material. Therefore, the primary objective of this thesis was to formulate a craft corn Ale beer with a partial substitution of corn malt for barley malt. This substitution serves as an alternative to local beer production and malt importation while ensuring sensory acceptability by consumers. For the beer production process, a base formulation was utilized, drawing references from the ingredients typically found in American Brown Ale style beer. This beer style is renowned for its dark appearance derived from dark malts, distinctive hop aroma, and robust body. Mix designs were created using the Design Expert program for each corn variety. The factors considered for the “Chulpi” variety included the percentage of “Chulpi” corn malt (%CM) and Pale Ale barley malt (%BM), while for the “Blanco Blandito” variety, it involved the percentage of “Blanco Blandito” corn malt (%BBM) and Pale Ale barley malt (%BM). The response variable under scrutiny was the overall impression. Statistical tests were conducted at a 95% confidence level using the Minitab® statistical software version 19. Both corn varieties underwent malting using an adapted barley malting process, meticulously controlling parameters such as temperature, time, and humidity (ranging between 38°C-31°C, 3-5 days, and 53% HR). Following this process, germinated corn was obtained, accounting for 93% for the “Chulpi” variety and 85% for the “Blanco Blandito” variety, respectively. Subsequently, the germinated corn underwent a controlled drying process, ensuring optimal conditions of time and temperature (24 hours at 65°C). Proximal analysis of each malted corn variety, encompassing parameters such as moisture, carbohydrates, protein, lipids, fiber, ash, acidity, and pH, revealed a higher concentration of carbohydrates in the “Blanco Blandito” variety. The efficiency of the applied treatments was thoroughly compared, with the TC70 treatment emerging as the most efficient for the “Chulpi” variety (comprising 70% malted corn and 30% barley malt). Meanwhile, for the “Blanco Blandito” variety, the TB70 treatment yielded the best results, albeit with no significant differences compared to the TB80 treatment. Brewing treatments were implemented utilizing a mashing temperature range of 67-70°C. Through sensory analysis, the best formulation was identified as TC70, garnering an average rating of 4.4 for overall impression, indicative of acceptability by the panelists. No significant differences were discerned when compared to treatments TB70, TB80, TC80, TC90, and TB90. Attributes such as color, transparency, liveliness, foam retention, malt aroma, hop aroma, fermentation aroma, corn aroma, alcohol aroma, sweetness, bitterness, saltiness, acidity, corn flavor, alcohol flavor, astringency, effervescence, body, aftertaste, complexity, balance, and overall impression were meticulously evaluated.