Improving Malt Operations with Marc Marashi of Malt Handling

Written By Chris Overlay

Episode Overview

Join us on this episode of the Get Hoptimized podcast as Marc Marashi, Project Manager at Malt Handling teams up with our host Chris Overlay and together they discuss everything about optimizing malt operations for Craft Brewers and Distillers.

For expert guidance on bringing in fresh malt to spent grain removal, and everything in between, connect with Marc on LinkedIn or visit malthandling.com to discover a system that's tailored for your success.

-Music Credit-

Neon Drive by Punch Deck | www.soundcloud.com/punch-deck 

Music promoted by | www.free-stock-music.com 

Optimizing Your Malt Operations: A Deep Dive with Malt Handling

Are you a craft brewer or distiller looking to boost efficiency and cut costs? The secret might just be in your malt handling systems. In a recent episode of the Get Hoptimized podcast, host Chris sat down with Marc Marashi, Project Manager at Malt Handling, to uncover the critical aspects of designing, installing, and optimizing malt operations.

The Unsung Hero: Why Milling Matters for Efficiency

Marc Marashi's journey into the malt handling industry began over a decade ago, stemming from a realization that most breweries and distilleries lacked truly custom solutions for their grain needs. What started as a niche has grown into a leading force, demonstrating the importance of specialized expertise in this often-overlooked area.

One of the podcast's key takeaways is the profound impact of your milling process on overall efficiency and cost savings. While it might not sound glamorous, upgrading your mill can lead to significant gains. Marc explained that using a high-quality mill, such as a double-pair (four-roll) mill, can drastically improve your yield. Anecdotal evidence suggests brewers have seen their recipes require 10% less grain, leading to a substantial reduction in raw material costs. For a truckload of grain (48,000 lbs), that translates to 4,800 lbs of extra usable product.


Unpacking the Hidden Costs of Pre-Milled Grain

Beyond increased yield, milling your own grain offers other crucial advantages. Marc highlighted the hidden costs of pre-milled grain:

  • Premium Pricing: Suppliers charge more for grain that's already milled. By purchasing whole kernel, you save on this processing fee.

  • Lack of Control: Pre-milled grain offers less control over the grind consistency, which can lead to issues like stuck mashes in your brewing process.

  • Shipping Savings: While not always obvious, increased efficiency can mean fewer truckloads of grain needed over time, saving on significant shipping costs.

Designing Your Ideal Malt System: What to Consider

When it comes to system design and installation, Marc emphasizes that it's ideal for Malt Handling to be involved from the ground floor. While compact solutions are possible (even fitting mills in closets!), optimal design ensures maximum efficiency and functionality.

Key considerations for designing your malt system include:

  • Grain Usage: How much grain do you process? This dictates the need for bulk storage solutions like outdoor silos.

  • User-Friendliness: Do you need a highly automated system for ease of use (e.g., an "IPA button" for auto-batching) or a more manual approach?

  • Budget: This is always a factor, and Malt Handling works with clients to find solutions that fit their financial parameters.

  • Storage Solutions: Options range from indoor bulk bag stands to massive outdoor silos. Marc shared that Malt Handling has installed silos capable of holding up to 120,000 lbs of grain, equivalent to two semi-trucks. These silos are typically filled via pneumatic fill lines, where "blower trucks" pump grain directly into the silo.

Updating vs. New Installation: Making the Right Decision

For those contemplating an upgrade, Marc offered valuable advice on updating current systems versus installing new ones. The primary factor, he suggests, is the return on investment (ROI). Small-scale operations (e.g., a 7.5-barrel brewery) might find a 25-grand mill takes a decade to pay itself back in grain savings.

Marc advises a thorough "number crunching" exercise:

  • Analyze Your Current Product Cost: Understand what you're paying for grain per pound.

  • Factor in Quantity Differences: Larger quantities (e.g., a 48,000 lb semi-load vs. 50 lb bags) significantly reduce your per-pound cost.

  • Estimate Efficiency Gains: While precise figures are hard to guarantee, expect a 2-10% improvement in efficiency from better milling.

This process is akin to evaluating solar panel installation: assess energy usage, upfront costs, and the time it takes to see a positive return.


Handling Spent Grain: A Sustainable Approach

Beyond initial processing, spent grain removal systems are another area where Malt Handling provides expertise. Primarily used as cattle feed due to cows' four stomachs, spent grain needs to be handled effectively to avoid mess and spoilage.

Solutions range from simple trailer setups to dedicated spent grain silos. The latter is ideal for breweries with public-facing areas, preventing the odor and rodent issues associated with open dumpsters. These silos can be on the ground, filled by pumps, or elevated for gravity-fed truck loading.

Safety First: Combustible Grain Dust and Other Hazards

One of the most critical safety aspects in malt handling, often overlooked, is the combustible nature of grain dust. As Marc noted, a cloud of grain dust is essentially a bomb, requiring extreme caution. Explosions in grain silos in rural areas are a grim reminder of this danger.

Malt Handling offers various dust removal systems, from mobile vacuum carts with filters to elaborate integrated systems with explosion panels and venting. These systems are crucial for maintaining a clean and safe environment, particularly in distilleries where explosive vapors can also be present.The Future of Malt Handling and Beyond

While the craft brewing industry navigates current cultural shifts, Marc remains optimistic about the future, citing the cyclical nature of industry booms. Malt Handling is also excited about their partnership with Buer, a company known for producing what Marc calls the "Ferrari of mills," signifying a commitment to high-quality, advanced equipment.

Beyond brewing and distilling, Malt Handling offers solutions for a surprising array of industries, including:

  • Cannabis handling

  • Coffee processing

  • Pet food production

  • Sand storage (for railroad stations and golf courses)When to Contact a Professional: There's No Wrong Time

Marc stressed that contacting a professional like Malt Handling is never too early. They offer free consultations and quotes, with no obligation. Whether you need a simple flex auger or a complex, fully integrated system, their team can guide you through options and help you make informed decisions. It's always better to ask questions first and assess your needs with expert guidance.

READY TO GET HOPTIMIZED?

Are you interested in optimizing your malt operations or learning more about custom grain handling solutions?

Chris Overlay
Next

Effective Retail Displays with Kimberly Ross & BRIAN BECK of Middlestreet Graphics & Display