Abstract
Small brewery operations face increasing pressure to reduce energy consumption while maintaining malt quality, extract recovery, and product consistency. This study examines sustainable malt processing and energy reduction strategies in small brewery systems. Controlled processing scenarios were evaluated across steeping, germination, kilning, milling, and mashing operations, with attention to heat demand, water use, enzyme preservation, extract yield, wort quality, and production stability. The results show that optimized kilning schedules, improved heat recovery, controlled moisture removal, and efficient mash temperature management reduced energy demand without compromising fermentable extract release. Excessive thermal reduction, however, weakened malt drying consistency and affected flavour precursor development. Better process scheduling also reduced idle equipment energy loss and improved operational efficiency. The study demonstrates that sustainability in small breweries depends on integrated control of malting-related energy use, wort production efficiency, and product quality. Overall, practical energy-reduction strategies can support lower operating costs and more sustainable brewing.