Blake Layfield’s research hub isn’t the typical microbiology lab full of petri dishes and lab coats. His lab, full of 80-gallon tanks, cultures the focus of his research, a microbe called Saccharomyces cerevisiae –also known as brewer’s yeast.
Layfield’s passion is beer, and with the guidance of John Sheppard in the Food, Bioprocessing and Nutrition Sciences Department, he’s working towards a doctorate in fermentation science. Specializing in yeast culture and the particular byproduct of its metabolism-beer- Layfield and Sheppard are looking to improve brewing techniques and fermentation of beer.
The ancient practice of fermentation is now a field heavy in microbiology and biochemistry. Though studying beer may seem like an extracurricular for many students, Layfield’s serious approach to his research reflects his conviction that brewing is as much of a science as it is a diversion.
What’s his particular interest? Keeping the yeast cells happy.
Layfield’s research focuses on yeast aging and how to maintain healthy cultures of yeast. The better the yeast, the better the beer. The importance of maintaining a healthy batch of yeast, according to Layfield, keeps beer batches consistent.
The byproducts are an assortment of six beers, each developed by John Sheppard’s research team. Sheppard, a professor of bioprocessing, and graduate students Layfield and Lucas Vann, run and maintain the brewing facility on the ground floor of Schaub Hall.
“Making these beers is developing us as brewing scientists,” Layfield said. “Not only do we need to know what we’re doing from a chemistry and microbiological perspective, but we need to be product developers in order to be true food scientists. We need to know how to make these and consistently produce them.”
That consistency is achieved through precision and patience.
“You’d never chug a beer after realizing how much work is put into just making it,” Layfield said.
First, there’s the recipe. According to difference styles, the recipes change, but there are four basic ingredients: water, malted grain, hops and yeast. Layfield mapped out the course of beer production, and once grains are milled, they are added to hot water in a mash ton, where they steep at particular temperatures to activate the amylase, or starch converting enzymes, that are naturally found in the grains.
During this process, the starches and complex sugars in the grains are broken down into smaller glucose monomers and simpler sugars, which yeast can readily metabolize into ethanol-making beer. Hops are adding during the boil portion, which flavors the beer with the characteristic flavors of pine, citrus and fruity aromas. The boil also sterilizes the beer.
Once the hot liquid, called wort, is quickly cooled in a glycol bath, Layfield inoculates the batch with the yeast. And just like a microbiology experiment, he has to be careful not to contaminate the batch with other microbes.
This process is the simplified version that all breweries use. There is plenty of skill and science involved, but Layfield incorporates a high-tech approach to maintenance.
“For us, we have access to high performance liquid chromatography, so we can get an exact measurement of alcohol we have, how many grams per liter of sugars that we have,” Layfield said. “Through this, we can monitor the fermentation process.”
Additionally, the brew lab is looking at a new system using near infrared technology for modeling not only ethanol and consumption of carbohydrates, but also yeast viability and yeast concentration, according to Layfield.
“This will give us real time assays of what’s going on in our batch,” Layfield said. “You can work quickly to save your batch if something is going wrong. In my research, I’m looking at yeast aging, and we’re also looking to reduce this variability in fermentation. In total, it’s about maintaining a yeast management strategy and making a better brew.”
Though the lab pours its product down the drain, they have a few beers on tap, not to drink, but to see how they handle storage.
However, the department may be looking into a way to avoid throwing the beer away.
But that’s in the distant future.
“To make it perfectly clear, we cannot sell beer,” Chris Daubert, interim head of the Food, Bioprocessing and Nutrition Science Department, said. “However, if we find ourselves with the approval of the University in a position where we could distribute products of our research programs, then those dollars would go back into the education for all the students and to the research to benefit the science of fermentation.”
The hypothetical system would be homologous to Howling Cow ice cream, but as Daubert reiterated, no plans have been discussed.
“We have to be very careful that we’re positioning ourselves to benefit the students, because that’s our product,” Daubert said. “The selling of the products from this department is just the means for us to have students learning how to manufacture these things, and, if their dollars are revenue generated, all of that revenue goes back into educating the next generation of students, so we’re essentially lessening our dependence on the state. It’s all about educating students.”
Daubert said the fermentation science field will be one of interest for the department, especially with developments in the North Carolina craft brewing scene.
“If you learn how to do it better here at N.C. State and you take that knowledge and work for a microbrew, we’re impacting economic development and jobs in the state,” Daubert said. “Have you heard about Sierra Nevada?”
Sierra Nevada, what Layfield called a holy force in the craft-brewing world, has plans to open a plant in Asheville, North Carolina. Bill Manley, director of communication and product development, said the state and Asheville naturally fall into what the company wants in a brewing environment.
“Asheville has a burgeoning and exciting craft brewing scene, and people accept it and expect it in drinking establishments there,” Manley said. “We wanted a place similar to the culture and feel to Chico, California. We’re not that far along yet. Right now, the place we’re looking is mostly forested. We have a lot of work to do before we get staffing and all that. That’s further down the line, and there will be a few people moving from Chico to North Carolina, but we are looking to employ North Carolinians.”
Daubert sees his department as a prime support for this upcoming industry and sees the University’s role as a land-grant school to fuel this.
“That’s just one example. North Carolina is just becoming a central point, especially in the southeast, for craft beer…and with the Sierra Nevada announcement, it’s an industry we feel we’re well positioned to serve,” Daubert said.
For Layfield, looking for an industry job once he finishes his doctorate—that may be something to drink a beer to. In the meantime, he’ll keep up the research he loves.
“I started homebrewing, and when Dr. John Sheppard came here from McGill University and started a brewing lab, I wanted a job and he offered me a position,” Layfield said. “It was dumb luck and I got into it. It’s been great.”
