Malt Products Corp. Sees Increased Interest in Malt Extract as Part of Surge in Malt-based Beverages
MPC’s MaltRite™ malted barley extract gaining attention as base for malt-based energy drinks; ethnic beverages; kombucha and specialty teas; and sports recovery drinks.
Saddle Brook, NJ – Malt Products Corporation (MPC), a manufacturer of malted barley extract and other natural, nutritious sweeteners, is seeing an uptick in beverage-related inquiries for its Malt-Rite™ line of malt extract sweeteners, which have become increasingly popular ingredients in a wide variety of malt-based drinks. In addition to the generally heightened interest in plant-based, multi-functional ingredients, malt extract sweeteners also provide sector-specific benefits for a spectrum of beverage-industry items.
For example, nearly a third of consumers have increased their consumption of nutrition or performance beverages, and many are seeking products with ingredients deemed simple, natural or clean. Malt-based beverages offer not only unique flavor profiles and subtle sweetness but – unlike cane sugar, high-fructose corn syrups and artificial sweeteners – contain an abundance of antioxidants (five times the amount of broccoli) as well as essential amino acids, vitamins, minerals and soluble fiber.
In addition, a trend already in full swing in Europe has been coming to America of late: the recognition that malt-based drinks offer superior sports recovery for athletes. Malt-based beverages for sports recovery are, essentially, non-alcoholic beer, which German Olympians are known to prefer. In the US, often unique flavors are added, both for extra sweetness and fruitier notes.
Another trend is the recognition by companies of the growing diversification of the US population. Malt-based beverages are extremely popular in Asia (such as Nestle’s Milo) and South & Central America (Malta). To grow their market share among expanding ethnic populations, US beverage companies are developing similar malt-based beverages that, particularly in these segments, enjoy a strong and positive association with health benefits.
Yet another trend is the popularity of fermented drinks, including kombucha and specialty teas, that reflect growing recognition of the importance of sustaining good gut microbes, known to reduce inflammatory diseases, type two diabetes and obesity. Malt is widely considered a substance that supports these helpful gut microbes.
A “Base for Malt-based” Beverages
Malt Product Corporation’s Malt-Rite™ is a malted barley extract serving as an ideal base for malt-based beverages. Malt extract is made by brewing the whole grain in the same way beer is made but skipping the fermentation step; once varying amounts of water is evaporated, the result is a syrupy liquid or soluble powder. This eliminates the need for a conventional brewing operation.
“For manufacturers, one advantage of using Malt-Rite malt extract is that you are not tied to a contract brewery, since it is already brewed and easily transported because the water has been evaporated,” said Amy Targan, President of Malt Products Corporation. “Since all that is needed is a bottling plant, this makes it far easier for a company to enter the market – a big plus for making niche malt-based drinks.”
While Targan notes that most inquiries from beverage companies have involved liquid malt extracts, soluble powder malt extract also is a viable option. Here, the company’s recently installed $15 million state-of-the-art vacuum belt dryer comes into play; in addition to giving MPC in-house flexibility for batch drying, the new dryer also produces powders far more soluble than traditional spray drying operations. Compared with spray drying, vacuum belt drying also comprises a gentler process that preserves the flavors and nutrients of the whole grain.
A vacuum belt dryer helps a manufacturer take control of the production of its malted barley extracts
Published by ProFood World; authored by Maya Norris.
Malt Products Corporation (MPC) recently invested $15 million in a state-of-the-art vacuum belt dryer to produce its dry malted barley extracts — and the company is already reaping the benefits. The new vacuum belt dryer has delivered efficiency and flexibility to MPC’s production process and improved product quality.
MPC installed the 58-foot-long Bucher Dryband vacuum belt dryer from Bucher Unipektin last year. It was the culmination of MPC’s five-year, $50 million expansion of its Dayton, Ohio, manufacturing facility, expanding to 114,000 sq ft from 60,000 sq ft. The plant produces and distributes a variety of natural sweeteners, including oat extract and agave nectar, for a global market. It manufactures about 100 million lb of liquid sweeteners and 30 million lb of dry extract sweeteners annually.
MPC uses its new vacuum belt dryer to create dry malted barley extracts. After it converts malted barley into syrup, the liquid is transferred to the vacuum belt dryer. Swiveling nozzles uniformly distribute the liquid onto the belts that convey the liquid through six chambers or zones with heating and cooling plates. The liquid enters the first four zones, where the product is heated, before the last two zones cool down the liquid — a process that pulls the moisture out of the product. The vacuum system quickly removes the evaporated moisture. The resulting dried product, known as a cake, is then taken to a mill for grinding. After the product is ground, the malted barley extract is inspected by metal detectors and packaged.
Using the vacuum belt dryer has allowed MPC to optimize and streamline the production process for its malted barley extract by cutting ties with spray drying tollers. Previously, the company used toll spray drying services out of state to process its syrup into malted barley extract. The burdensome procedure required a lot of advance planning for MPC, which had to schedule and reserve the vendors’ spray dryers and services at least three months in advance. And even then, the spray drying vendors sometimes couldn’t meet MPC’s deadlines if they fell behind schedule with another customer. In addition, when MPC received unexpected orders for malted barley extracts, the tollers often didn’t have the capacity to accommodate MPC’s last-minute requests.
“We were at their mercy,” says Jim Hochberg, vice president of Malt Products Corporation. “Anytime you outsource something, you are going to end up waiting an indiscriminate amount of time to get your product back depending on how busy the service provider is at that moment.
“The reason why Malt Products decided to get a dryer was [to] have more control of the process and be much more fluid,” he says. “Now that we have the process in-house, it’s much more efficient time-wise, and it gives us more flexibility.”
On its own terms
MPC can now produce malted barley extract much more efficiently and cost effectively with the vacuum belt dryer at the plant. Because it no longer has to wait three or more months for tolling services, MPC can produce dry malted barley extract at any time and at its own pace. In addition, it can fulfill unanticipated orders easily, especially because changeover time is minimal.
“With the toll process drying, when we send a load of product out, we can’t change it midrun,” says Troy Smedley, maintenance superintendent. “So if we get a bunch of orders for a dark malt versus our lighter malt products, now we can stop production, make the dark malt out of our light malt products and switch right into dark malt and start producing it in a day or two.”
In addition, MPC has significantly reduced its transportation costs by using its in-house vacuum belt dryer. The company previously drove eight to 10 trucks to deliver its malted barley syrup to various out-of-state toll dryers, costing MPC between $15,000 and $30,000 that month, depending on how far the trucks traveled.
The vacuum belt dryer also produces a better product than a spray dryer, according to MPC. Because the vacuum belt dryer operates by reducing the pressure in its chambers, moisture is evaporated from the product at far lower temperatures than spray drying. This eliminates oxidation and prevents damage to critical functionalities of the original syrup, including antioxidants, essential amino acids, minerals and vitamins. This gentle process also helps retain flavor, aroma and color of the malted barley extract. And it better controls the maillard reaction for a more consistent final product color.
“Any time you expose something to higher heat, you are changing it. You’re altering it,” Hochberg says. “We’re able to retain the integrity of the flavor and characteristics of the liquid as it changes into the powder by drying under vacuum at lower temperatures.”
At IFT 2019, Malt Products Corp. to Showcase Portfolio of Nutrient-Rich Malted Barley Extract Sweeteners
In addition to its MaltRite™ natural sweeteners, company also will feature OatRite™ line of extracts in response to growth in oat-based ingredients.
Saddle Brook, NJ – Malt Products Corporation (MPC), a manufacturer of malted barley extract and other natural, nutritious sweeteners, will feature a variety of products from its MaltRite™ portfolio of malted barley extracts at the Institute of Food Technology (IFT) Annual Meeting & Food Expo, June 2-5 in New Orleans. Amid increasing demand for non-GMO, plant-based, and nutrient-rich ingredients, the company’s spectrum of liquid (LME) and dry (DME) malt extracts will be on display at Booth 4852.
Recently, malted barley extract has become an increasingly attractive option for food & beverage manufacturers when compared with standard sugars or artificial substitutes. Malted barley extract offers distinct flavor profiles and various health-related benefits pertaining to probiotics, plant-derived proteins and sports recovery. MPC’s MaltRite™ portfolio comprises multi-functional ingredients that act as natural humectants (moisture absorber), and enhance browning (maillard reaction), fermentation, body and viscosity.
With a nod to the “good for you” ingredient trend, malted barley extract’s natural origins make it particularly “pantry-friendly.” Key benefits include:
- Rich with antioxidants: More than five times the antioxidant power of fresh broccoli.
- Athletic recovery: Athletes are relying on malt extract-based beverages to replenish and recover.
- Gut health: Preferred base for fermented beverages and foods, by optimizing the good bacteria and minimizing bad bacteria.
- Not an empty sugar: Contains proteins, essential amino acids, vitamins and minerals. It is mostly maltose, the energy sugar, and contains no fructose, the toxic sugar.
At IFT Expo, MPC also will showcase its OatRite™ portfolio of extracts. Blending oats and malt barley, the extracts provide excellent binding properties with mild sweetness and a pleasant oat taste and aroma. Naturally high in protein, minerals and antioxidants, the non-GMO, label-friendly OatRite™ extracts offer benefits including browning, crystal control for frozen products, improved texture, extended shelf life and easy fermentability. These characteristics make them ideally suited for cereal and granola, non-dairy beverages, breakfast bars, pancakes, cookies and a wide variety of baked goods.
MPC offers a full line of natural sweeteners serving a broad range of industries, including bakery, confectionary, beverages, snack foods and cereals, pet food, animal nutrition, and pharmaceutical. In addition to its MaltRite™ and OatRite™ lines, the company also supplies a broad spectrum of healthy, natural sweeteners including molasses, rice syrup, tapioca syrup, agave and honey.
The company comes into the IFT Expo having recently completed a five-year, $50 million investment, capped off by the completion of a $15 million state-of-the-art vacuum belt dryer. Infrastructure upgrades also included a Meura mash-filter, an expanded laboratory, and elevated R&D and customer application capabilities.
“With a continued focus on natural ingredients, major food and beverage companies are rediscovering ancient ingredients such as malted barley and oats,” said Amy Targan, President of MPC. “Essentially, the old is becoming the new again. As one of the country’s most prominent suppliers, we look forward to showcasing our full selection at IFT Expo.”
Company’s MaltRite™ line meets demand for natural ingredients; molasses-based products provide powerful antioxidants.
Saddle Brook, NJ – Malt Products Corporation (MPC), a manufacturer of malted barley extract and other natural, nutritious sweeteners, will feature a variety of products from its MaltRite™ portfolio of malted barley extracts at Petfood Forum, April 29–May 1 in Kansas City. As the demand for non-GMO, plant-based, and nutrient-rich ingredients in pet food increases, MPC will showcase its liquid (LME) and dry (DME) malt extracts and molasses products at Booth #440.
For pet food applications, notable benefits of malt extract include:
- Minerals,including calcium, copper, magnesium, manganese, potassium, selenium and zinc. Copper and selenium in particular are integral as antioxidant enzyme co-factors, which help shorten recovery in sporting and working dogs.
- B Vitamins, including niacin, riboflavin, pantothenic acid, thiamin, nicotinic acid, biotin, folic acid and Vitamin B6 (pyridoxine). Vitamins are primary cofactors for healthy metabolisms, and formulating with vitamin-containing ingredients helps aid energy production and utilization in animals.
- Protein and amino acids: Malt extract contains ~6% protein and free amino acids, nutritional components required for building and maintaining muscle tissue.
- Palatability: Malt contains compounds that help improve the overall flavor profile of pet foods while masking bitter tastes.
Rich with antioxidants
Grain extracts such as malt extract, and other plant-derived ingredients including molasses, possess free phenolic compounds providing protective benefits against reactive oxygen species (ROS), or free radicals. For example, malt extract contains more than five times the antioxidant power of fresh broccoli, while molasses has been shown to prevent DNA oxidation, protect oxidatively stressed HepG2 cells in humans as effectively as α-tocopherol.
Malt extract also has been shown to significantly increase the gastrointestinal tolerance of probiotics, positively impacting gut microbiota and digestive health in animals. There is increased awareness that compounds from plants, also called dietary phytochemicals, play a role in the prevention of chronic disease.
Like malt extract, molasses also contains significant amounts of calcium, potassium and Vitamin B6. Molasses also has healthy amounts of blood-building iron.
“Petfood Forum is an ideal platform for MPC to demonstrate the numerous benefits of malt extract and molasses in pet nutrition applications,” said Amy Targan, President of MPC. “As people turn a more watchful eye to what they are feeding their pets, malt extract and molasses provide natural, nutrient-rich alternatives to conventional pet food ingredients.”
Part of $50 million investment, state-of-the-art belt dryer offers benefits over spray drying, including moisture evaporation at lower temps
Saddle Brook, NJ – Malt Products Corporation (MPC), a manufacturer of malted barley extract and other natural, nutritious sweeteners, has invested over $15 million in a new state-of-the-art drying plant, incorporating a vacuum belt dryer designed and built by drying technology expert Bucher Unipektin. The 58-foot-long machine has completed installation and validation, and is currently operating at the company’s Dayton, OH manufacturing facility.
MPC chose the vacuum belt dryer over a spray dryer because of its superior ability to produce free-flowing particulates of viscous sugar syrups, as well as retain flavor, aroma and color. Since vacuum belt drying operates by reducing the pressure in its chamber, moisture is evaporated from the product at far lower temperatures. This eliminates oxidation and prevents damage to critical functionalities of the original syrup.
Important to the drying of malted barley extract, vacuum belt drying utilizes a gentler process that protects unique-to-product characteristics not found in other sweeteners, including antioxidants, essential amino acids, minerals and vitamins. Vacuum belt drying also helps avoid burnt notes or other off-flavors and aromas typical with spray drying, and better controls the maillard reaction for a more consistent final product color.
Vacuum belt drying produces a powder that is highly soluble in cold liquids, making it preferable for malt beverages. The enhanced technology will allow MPC to manufacture products such as honey, agave and molasses that are difficult or impossible to dry on a spray dryer without additives.
The initiative also has an eye toward eco-consciousness: vacuum belt dryers use less energy and water than spray dryers, reducing environmental impact and aligning with MPC’s broader commitment to sustainability.
The new dryer is part of a five-year, $50 million investment by MPC, beginning with the 2015 expansion of its state-of-the-art brew house and addition of a Meura mash-filter, expanded laboratory, research and development and customer application capabilities. These investments are in response to increasing demand for non-GMO and natural, nutritious ingredients.
There has been a growing and renewed interest in MPC’s malted barley extract because of its unique flavor profile and recognition of its health-related benefits in the field of probiotics, plant-derived proteins, sports recovery and antioxidants. MPC’s malted barley extract is a multi-functional ingredient that acts as a natural humectant (moisture absorber), and enhances browning, fermentation, body and viscosity.
Malt Products Corporation also supplies a broad spectrum of healthy, natural sweeteners including molasses, oat extract, rice syrup, tapioca syrup, agave and honey.
“The new drying plant will continue our commitment to supply natural sweeteners which are minimally processed and environmentally sustainable”, said Amy Targan, President of MPC.
Malt Products Corporation (MPC), which manufactures malted barley extract and sweeteners, has seen increasing demand for non-GMO and natural, nutritious ingredients.
In response to this, the company has invested over $15m ($16.96m) in a drying plant, with a vacuum belt dryer designed and built by drying technology expert Bucher Unipektin.
MPC has grown from a regional supplier of malts to an international company offering a full line of natural sweeteners for the bakery. snack foods. cereals. confectionary and beverage industries.
The dryer is the culmination of a five-year, $50m ($56.56m) investment beginning in 2015 with the expansion of its brew house, Meura mash-filter, expanded laboratory, R&D and customer application capabilities.
“The drying plant will continue our commitment to supply natural sweeteners. which are minimally processed and environmentally sustainable,” said Amy Targan, president, MPC.
MPC chose the vacuum belt dryer over a spray dryer because of its ability to produce free-flowing particulates of viscous sugar syrups, as well as retain flavor, aroma and color.
The 58-foot-long machine has completed installation and validation. and is installed at the company’s Dayton. Ohio. US. manufacturing facility.
Essential amino acids
Vacuum belt dryers operate by reducing the pressure in the chamber and moisture is evaporated from the product at lower temperatures. This eliminates oxidation and prevents damage to the syrup.
Important to the drying of malted barley extract vacuum belt drying uses a gentler process that protects unique-to-product characteristics not found in other sweeteners, including antioxidants, essential amino acids, minerals and vitamins.
Vacuum belt drying also helps avoid burnt notes or other off-flavors and aromas typical with spray drying, and better controls the maillard reaction for a more consistent final product color.
Vacuum belt drying produces a powder that is highly soluble in cold liquids, making it preferable for malt beverages.
The enhanced technology will allow MPC to manufacture products such as honey, agave and molasses that are difficult or impossible to dry on a spray dryer without additives.
Targan noted there has been a growing and renewed interest in MPC’s malted barley extract because of its unique flavor profile and recognition of its health-related benefits in the field of probiotics, plant-derived proteins, sports recovery and antioxidants.
MPC’s malted barley extract is a multi-functional ingredient that acts as a natural humectant (moisture absorber), and enhances browning. fermentation, body and viscosity.
Malt historically has been an attractive ingredient in pet food and animal feed for its whole grain derived nutritional contributions. Some of the more common associations with malt include:
Minerals: including calcium, copper, magnesium, manganese, potassium, selenium and zinc. Copper and seleni-um are integral as antioxidant enzyme co-factors which help shorten recovery in sporting and working dogs.
From malt extract, B Vitamins: (niacin, riboflavin, pantothenic acid, thiamin, nicotinic acid, Vitamin B6 (pyridoxine), biotin, and folic acid). Vitamins are primary cofactors in metabolism and formulating with vita-min containing ingredients helps aid energy production and utilization in animals that consume them.
Protein and amino acids: malt extract contains ~6% protein and free amino acids which are nutritional compo-nents required for building and maintaining muscle tissue. Physical exertion increases the need to rebuild and reinforce muscle fibers, and the presence of protein and amino acid helps in this regard.
Pallatability: Malt contains compounds that help improve the overall flavor profile of petoods and that can mask bitter tastes.
With clean labels being all the rage among consumers these days, various retailers are rethinking their prepared foods ingredients list, and how best to tailor it for mass appeal. When it comes to using sweeteners for those that are made in-house, malt and molasses not only fit the bill for a clean label, but have significant nutritional benefits that can enable your product to boast an even healthier lifestyle than its branded and shipped counterparts.
“Malt used to be thought of only for its nutritional value, in products such as Ovaltine and Carnation Instant Milk,” says Jim Kappas, vice president of sales and marketing for Malt Products Corp. “Over the years, corn and cane sugar have been substituted because they are less expensive, so many Americans only think of malted milk shakes and malted milk ball candy as areas where malt can be used. Our main message is to consider adding malt for its nutritional value. On a gram-per-gram basis, malt has five times more antioxidant power than broccoli. It is also well established to help athletes recover after endurance exercise.”
Recently, Malt Products Corporation, located in the USA, entrusted Meura with the order for a new brewhouse of their new malt extract plant, the Malt Company of Ohio. Malt Products Corporation is a world leader in the field of malt extract production and has grown from a regional supplier of malts in 1957 to an international company at present.
“Because malt extract is derived from whole grains, I like to call it a ‘nutritious sugar,’ ” said Jim Kappas, vice president, sales and marketing, Malt Products Corp. He compared its potential appeal to the whole grains message that has recently transformed the baking industry. Although used by bakers since ancient times, recent years have seen malt taken out of formulations for cost reduction purposes.
But as a source of fermentable carbohydrates and natural enzymes and colorants, it can restore artisan quality to foods, reduce oven times and enhance the chew and crust qualities of hearth breads. The nutritional benefits count as an extra.