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At
SAB Miller India Pvt. Ltd.
M-99, MIDC Area,
Waluj,
Aurangabad, Maharashtra
Guided by:
Mr. Pradeep Digule (QA
Manager)
Mr. Mahadev Shinde
Mr. Yogesh Sonawane
Batch: May-June 2009 Mr. Viresh Rajannavar
Date: Mr. Sudip Ankush
Mr. Prashant Bhalerao
Acknowledgment
I would like to thank Mr. Yogesh Tapkire, HR Executive
of SAB Miller India Pvt Ltd. for permitting me an Inplant training in
such a reputed company. I thank Mr. Pradeep Dighule, QA Manager
for giving me knowledge with regard to Quality Assurance process
and for providing me such a good topic as a project. I extent my
sincere gratitude towards my project guide Mr. Mahadev Shinde for
his excellent guidance and co-operation during the inplant training
and project preparation. I also thank my College Biotechnology Dept.
HOD, Mrs. Yogeshwari Jagat for giving me permission to do Inplant
training and project. And last but not the least I sincerely thank to
each department Manager. Without the generous helpful co-operation
of these people my project wouldn’t have been a success.
ABOUT COMPANY
SAB Miller India Pvt. Ltd is a company engaged in the manufacturing of Beer.
Foster its is one of the branch of SAB Miller India, India’s second largest beer
manufacturer. The company was established in India in September 1995 and started
production activities from 1998. The Foster India Brewery at Aurangabad was
officially opened by Foster’s Brewing Group President and CEO MR. E.T. (TED)
KUNKEL on 10th September 1998. The company is mainly engaged in production of
Beer like Foster’s Lager Beer; Foster’s export premium Lager Beer; Amberro Strong
Beer and Amberro Lager Beer, Hayward 5000 strong beer, and from this year started
Knock out brand.
Now, in April 2009 the brewery’s annual capacity goes up by 20,00,000 cases
to 84,00,000 cases (i.e. from 170,000 to 700,000 cases per month) taking it to the big
league of country’s largest breweries. Like this the increasing capacity helps the
company to meet the demand in and around the country.
Beer produced by the company is rated amongst top ten in the world
breweries, Foster plant at waluj, Aurangabad constitutes various processes for the
manufacturing beer. The company maintains a very high standard of house keeping
and hygiene. The system adapted for material handling as well as process ensure safe
and quality production.
INDEX
Sr. No. Content Page No.
History of brewing 6
1.
Types of beer 7-8
2.
Beer a good source of energy 8
3.
4. Introduction to brewing
Raw material for brewing.
1. Barley 9-14
2. Water
3. Adjuncts
Brew house
Milling
Mashing
Lautering
Adjunct kettle 14-33
5.
Wort kettle
Weak wort kettle
Whirlpool
Wort cooling
Aeration
Yeast
Yeast Reproduction
Stages of Yeast Growth
Yeast handling 34-40
6.
1. Yeast pitching
2. Yeast cropping
3. Yeast Storage
4. Yeast Propogation
Fermentation
1. Collection and processing
2. Attemperation
3. Rousing
7. 4. Monitoring 40-48
5. Cooling
Fermenter
Maturation
Filteration
Filtration Process
8. 49-55
Filtration to bright beer tank
Bright beer tank
Quality
Quality Assurance
Quality Assurance in brewery
10. Raw material Inspection 56-67
Analytical QA
Microbiology QA
Packaging QA
Packaging
Bottle washer
Filler cum crowner
13.
Pasteurizer 74-78
Labeling
Case packer
79
15. Suggestions
16. References 80
HISTORY OF BREWING
Beer is one of the world's oldest beverages, possibly dating back to the early
Neolithic or 9000 BC, and is recorded in the written history of ancient Egypt and
Mesopotamia. The earliest Sumerian writings contain references to a type of beer. A
prayer to the goddess Ninkasi, known as "The Hymn to Ninkasi", serves as both a
prayer as well as a method of remembering the recipe for beer in a culture with few
literate people. As almost any substance containing carbohydrates, mainly sugar or
starch, can naturally undergo fermentation, it is likely that beer-like beverages were
independently invented among various cultures throughout the world. The invention
of bread and beer has been argued to be responsible for humanity's ability to develop
technology and build civilization. The earliest known chemical evidence of beer dates
to circa 3500–3100 BC from the site of Godin Tepe in the Zagros Mountains of
western Iran.
Beer was spread through Europe by Germanic and Celtic tribes as far back as
3000 BC, though it was mainly brewed on a domestic scale. The product that the early
Europeans drank might not be recognised as beer by most people today. The early
European beers might contain alongside the basic starch source: fruits, honey,
numerous types of plants, spices and other substances such as narcotic drugs. What
they did not contain was hops, as that was a later addition—first mentioned in Europe
around 822 by a Carolingian Abbot and again in 1067 by Abbess Hildegard of
Bingen. Beer produced before the Industrial Revolution continued to be made and
sold on a domestic scale, although by the 7th century AD, beer was also being
produced and sold by European monasteries. During the Industrial Revolution, the
production of beer moved from artisanal manufacture to industrial manufacture, and
domestic manufacture ceased to be significant by the end of the 19th century. The
development of hydrometers and thermometers changed brewing by allowing the
brewer more control of the process and greater knowledge of the results.
Today, the brewing industry is a global business, consisting of several
dominant multinational companies and many thousands of smaller producers ranging
from brewpubs to regional breweries. More than 133 billion liters (35 billion gallons)
are sold per year (the equivalent of a cube 510 metres on a side), producing total
global revenues of $294.5 billion (£147.7 billion) in 2006.
TYPES OF BEER
The basics of brewing beer are shared across national and cultural boundaries and are
commonly categorized into two main types — the globally popular pale lagers, and the
regionally distinct ales, which are further categorised into other varieties such as pale ale,
stout and brown ale. The strength of beer is usually around 4% to 6% alcohol by volume
(abv) though may range from less than 1% abv to over 20% abv in rare cases.
1. Pale lager:
Pale lager is a very pale to golden-coloured beer with a well attenuated body and noble
hop bitterness. The resulting pale coloured, lean and stable beers were very successful and
gradually spread around the globe to become the most common form of beer consumed in the
world today, and includes the American beer Budweiser, the world's highest volume selling
beer.
The main elements of the lagering method still used today, and depend on a slow acting
yeast that ferments at a low temperature while being stored. Indeed, the German term 'Lager'
means 'storage'.
2. Ale:
Ale is a type of beer brewed from malted barley using a top-fermenting brewers'
yeast. This yeast ferments the beer quickly, giving it a sweet, full bodied and fruity taste.
Most ales contain hops, which impart a bitter herbal flavour that helps to balance the
sweetness of the malt and preserve the beer. The other major style of beer -- lager -- is
bottom-fermented.
Ales typically take 3 to 4 weeks to make, although some varieties can take as long as 4
months. Lagers take significantly longer to brew than ales and tend to be less sweet.
a. Pale ale:
Pale ale is a term used to describe a variety of beers which use ale yeast and
predominantly pale malts. It is widely considered to be one of the major beer style groups.
All of the major ale-producing countries have a version of Pale Ale: England has Bitter,
Scotland Heavy and IPA, America has American pale ale, France has Bière de Garde,
Germany has Altbier, etc. Pale ales generally over 6% ABV tend to be grouped as Strong
Pale Ales under such names as Scotch Ale, Saison, or American Pale Ale.
b. Stout:
Stout and porter are dark beers, and more specifically ales, made using roasted malt or
barley, hops, water, and ale (top fermenting) yeast. Stouts were traditionally the generic term
for the strongest or stoutest beers, typically 7% or 8%, produced by a brewery.
There are a number of variations including Baltic porter, dry stout, and Imperial stout.
The name Porter was first used in 1721 to describe a dark beer popular with street and river
porters of London that had been made with roasted malts. This same beer later also became
known as stout, though the word stout had been used as early as 1677. The history and
development of stout and porter are intertwined.
c. Brown ale:
Brown ale is a style of beer with a dark amber or brown colour. The term brown beer was
first used by London brewers in the late 1600s to describe their products, such as mild ale.
Though the term had a rather different meaning than it does today. 18th-century Brown Ales
were lightly-hopped and brewed from 100% brown malt.
Beer consumed in moderate quantities is a better source of energy and other nutrients
as compared beverages that have large amount of sugars i.e. empty calories.
INTRODUCTION TO BREWING
Beer is the world's oldest and most widely consumed alcoholic beverage and the third
most popular drink overall after water and tea. It is produced by the brewing and fermentation
of starches, mainly derived from cereal grains—the most common of which is malted barley,
although now adjunts are widely used. Most beer is flavoured with hops, which add bitterness
and act as a natural preservative, though other flavourings such as herbs or fruit may
occasionally be included. Beer is an alcoholic beverage produced with the help of yeast by
the fermentation of sugar derived from a cereal starch source. Most of the sugar in brewing
comes from barley, which has to be malted to release the sugars before fermentation can
occur.
1. BARLEY
Barley is the principal source of carbohydrate used in brewing. The energy in barley
is stored as starch in the endosperm. Before it can be used in brewing it is necessary to
activate the natural plant enzymes, to break down the cell structure of the endosperm and to
release the enzymes necessary to convert starch to sugar. Within the cell walls, there are
starch granules embedded in a protein matrix. This breakdown is achieved through the
malting process.
Malted Barley
Malting Process:
The malting process aims to control the natural phenomenon. Malting process includes
three basic steps.
b. Germination
Embryo begins to grow and from rootlets and a small shootlets, which grow under the
husk forming the outer covering of barley corn.
Food reserves for embryo are stored in endosperm cells and have starch, proteins, fats and
inorganic ions. These cells have walls made up of carbohydrates, pentosans and β-glucan.
c. Kilning
Plants are killed and roots and shoots are then removed by rubbing on the screen. Green
malt is dried (to stop enzyme modifying endosperm) to produce kilned malt that is dry
(enough to store for months/years). Compounds contributing to beer flavour, foam and colour
are formed.
Malt provides yeast nutrients and is responsible for flavour, foam and colour of beer.
When malt has been mashed with water, the liquor (wort) that is fermented (to produce beer)
must be separated from insoluble residue (spent grain).
Kilning process also develop colour and flavour compounds.
The aims of kilning are:-
(a) To provide a dry and stable product that can be stored for considerable periods.
(b) To develop characteristic aroma, flavours and colour in the malt.
(c) To facilitate removal of rootlets formed during the germination stage.
(d) To fix the chemical biological changes those have occurred during germination.
(e) To provide a friable product that is easy to mill.
1. WATER
Water comprises over 94% of the content of a regular beer. Water composition
effects beer flavour and determined various different beer styles developed. Water used to
make beer is called liquor.
2. ADUJUNCT
Neverthless malted barley or malted wheat is usually the main, but not the only,
source of the starch or sugar used to make beer. Typically 20-40% of the malt is replaced by
these substances which are known collectively as adjuncts. These includes sugar syrups and
other sources of starch such as unmalted barley, wheat, maize (also known as corn) or rice.
When using adjuncts, because up to 40% of the malted enzymes may be missing, added
enzymes may be needed to help convert the starch to sugar and/or to supplements other
enzymes in the malt which act on other substances such as proteins.
Types of Adjuncts:
1. Solid adjuncts: Starch which has to be converted to fermentable sugars in the brew
house during mashing.
2. Liquid adjuncts: In the form of fermentable sugars, where the conversion from starch
has already been undertaken. Generally added directly to the kettle.
BREW HOUSE
• Before brewing the malt has to be milled which involves splitting the husk and
grinding the endosperm into small grits.
• It is necessary to keep the husk as whole as possible since it will be used to form the
filter bed during run off.
• The endosperm must be broken down to allow the enzymes to attack the starch.
• Malt mill used is 6 roller malt mill.
1. MILLING
Purpose: To expose the starch for its conversion to sugars.
The purpose of milling is to prepare the malt for mashing and starch conversion by
making the centre of the malt corn accessible. Where a wort separation system like a mash
tun or lauter tun is used, milling must crush the starch into fine particles while preserving the
husk so that it can be utilised as an effective filter during separation. Where a mash filter is
used, the preservation of the husk fraction is less important and a mill that crushes the whole
corn into fine particles can be used.
Malt is received from the malt sters and stored (usually in silos on site). Before brewing
the malt has to be milled which involves splitting the husk and grinding the endosperm into
small grits. It is necessary to keep the husk as whole as possible since it will be used to form
the filter bed during run off. The endosperm must be broken down to allow the enzymes to
attack the starch.
Bucket elevator I
(cap: 8 ton/hr)
Enmass conveyor II
(cap: 3 ton/hr)
Bucket elevator II
(cap: 8 ton/hr)
Screener
Magnetic separator
Destoner
Batch Tipper
(1 tip: 50 kg Malt)
Screw conveyor
Malt Mill
(6 Roll dry mill)
Grist Case
(cap: 5 ton)
Mash Tun
(cap: 220 hl)
(1 hl = 100 lit)
Process:
Malt store is used to store the incoming malt, which is formed by processing from
Barley.
Bucket elevator I which is nothing but the small buckets attached to the belt is used to
carry the malt from the godown into the Silo.
Silo is being used for the storage purpose so that controlled conditions are maintained
before mill mailing.
Enmass conveyor I and II is a belt which carry malt just by pushing it in-between the
chain, and Bucket elevator II gives malt to the Screener which screen it.
Then it goes to the Magnetic Separator, where if any ions are present are separated.
Then it gives to the Destoner which separates if any stones are there and then to the
Batch Tipper which measure the malt in Tips (1 tip: 50 kg malt).
Bucket elevator III and Screw conveyor give malt to the Malt Mill, were the malt is
milled and then goes to the Grist case, below which there is the digital weighing
balance which measures the Malt and put it finally into the Mash tun.
Type of Mill:
6 Roll Dry Mill with Screens:
These mills give more effective separation and a more narrow particle size
distribution.
Suitable for less well modified malts.
The screens oscillate at around 400 strokes/minute.
1st sieve directs large particles to second rollers, grits to third and fines direct to grist.
There may be differences in roller speeds between top and bottom with the top rollers
revolving up to twice as fast.
Roller gaps are critical: Generally 1.2 mm top and 0.9 mm bottom.
2. MASHINGS/MASH TUN
Purpose:
To mix the crushed grain evenly with the correct amount of water at the correct
temperature.
To allow other additions such as brewing salts and enzymes to be evenly mixed in.
To allow the enzymic conversion of protein to amino acids and starch into simpler
sugars in the correct amounts to give consistent fermentation and the right %ABV and
Original Gravity.
To extract colour and flavour from any coloured malts and adjuncts used.
Process:
Mashing is the process where the crushed malt or grist is mixed with water under
specified conditions so that enzymic action can take place to convert the starch into
fermentable sugar and also break down proteins into more soluble forms.
At a later stage the fermentable sugars will be separated from the malt husks.
Conversion is the term used to describe a complex biochemical reaction and the
diagrams below illustrate how the enzymes in the malt attack the long chains of sugar
units that make up the starch molecule and convert them into fermentable wort.
The range of sugars produced during conversion determines the fermentability of the
wort. If the enzyme attack is complete, the wort will be very fermentable. If the
enzyme attack is incomplete, the wort will be only partially fermentable. Mostly this
process is carried out for nearly 3 hrs.
Mashing profile:
There are two amylases, the term means starch breaking enzyme. They convert
the starch to a range of sugars. Some are fermentable and others contribute the final gravity,
sweetness and mouth feel of the beer. Proteases will break proteins into amino acids, peptides
and larger molecules. Amino acids allow the yeast to reproduce but provide nutrient for
infecting organisms as well. Larger molecules contribute to beer foam but also beer haze.
Glucanases break down the cell wall. Residual glucans can effect the filterability of beer as
they as gummy, often an addition of beta glucan is made to the mash. Enzymes are sensitive
to the conditions that they work in, they are affected by how much water is present,
temperature and pH or mash acidity. They take time to work, so the length of time that is
allowed for mash conversion will affect the degree of conversion.
Each enzyme is a very specific protein and its performance can be predicted according
to some simple principles:
• There will be an optimum pH and its activity will fall off either side.
• There will be an optimum temperature and its activity will fall off either side.
• Starting with limited substrate the rate of reaction will increase with increased
substrate until the enzyme level is fully occupied and then the rate of conversion will
level off.
• With unlimited substrate the rate of reaction will increase in direct proportion to the
amount of enzyme available.
Starch Breakdown:
• Amylose is a straight chain, amylopectin is branched.
• a amylase breaks anywhere but not close to a branch -optimum temperature around
62oC.
• b amylase nibbles from one end but not right up to a branch- optimum temperature
around 66oC.
• Produces mainly maltose:
but some glucose and maltotriose, which are fermentable.
• Longer strings of glucose and branch residues are not fermentable.
• The starch in mashing is broken down by a number of natural malt enzymes into
simple sugars.
• Check for presence of starch after mash stand period with iodine (Iodine Test): Take
sample on a clean grease free slide and add 2-3 drops of iodine if colour changes to
Blue/Black test is positive or if no colour changes then the test is negative.
Protein Breakdown:
As well as carbohydrate (sugars & starch) malt contains proteins and these are
also broken down by its own natural enzyme system, principally during mashing.
Much of the larger protein remains insoluble and is lost with the spent grains.
However some protein is dissolved in the wort and goes on to produce:
• Amino acids for yeast growth
• Foam proteins.
• Haze proteins.
Mash tun
Incoming dry grist will be mixed with hot water by passing down over an
inverted cone. This forms a falling curtain of grist and allows the hot water to spray into it
and mix in quickly and evenly. The mash vessel has a steam jacket to allow step temperature
rises and a final increase to lower wort viscosity at the end of the cycle. There is a stirrer to
transfer heat rapidly and ensure homogeneity of the mash. The mash needs to be transferred
to a lauter tun or mash filter to separate the wort. The brewer can select a temperature profile
to utilise the different enzyme systems – with low temperatures around 50 oC favour cell wall
destruction (protein and beta-glucan reduction) – temperatures around 62oC favouring beta
amylase activity and around 68oC alpha amylase activity. By the time the temperature has
reached 78oC most of the enzyme activity will have ceased.
Objective:
The objective is to produce clear bright worts free from solids, it is also
important not to extract compounds such as polyphenols and lipids from the
husk.
Effective Wort separation Means:
High extract recovery (around 98% to 100%)
Bright worts - free from suspended solids.
Worts free of starch.
Process:
The mash is transferred to the lauter where it is recirculated until the wort is
bright. The strong wort is first run off followed by sparging water and weaker wort. In
Lauter Tun instead of mash floating, it will tend to settle down in a stratified form above the
false bottom, which holds back the solid mash and allows the liquid to strain through. In a
mash or lauter tun it is usually a set of slotted plates. In a mash press it is the filter cloth itself
that forms the screen or sieve. A slight increase in wort viscosity can have a dramatic effect
on run off performance. Most lauter tuns are fully automated and as well as controlling the
wort run off rate, they also measure and control the differential pressure above and below the
lauter plates. When this pressure falls below a set pressure it has reached a "set bed”
condition. Another measurement often used to control run off is haze which measures the
wort turbidity. The contents of the lauter tun are re-circulated to ensure that only wort runs to
the kettle.
To save extract it is tempted to keep collecting last runnings to save that last
drop of sugar. There are penalties downstream as last runnings are high in polyphenols which
need to be removed later at a cost to improve haze performance. There are also lipids which
can lead to flavour problems. These compounds are extracted as the pH rises. Limit to 1004 o
or 1oP even if we are recycling the weak worts for the next mash, the unwanted compounds
may still present.
There is Racking arm which is being used to press the husk bed depending upon
the need of the more filterate and/if there is improper filteration, Swiper is also attached to
the main Racking arm its use is to swipe off the husk/spent grain form the lauter tun from the
sieve in the discharge hole which discharge into the spent grain collector/holder mounted
below the lauter tun. This process is carried out for nearly 3 hrs. Which is then forced to the
spent grain silo and then it is being taken for the cattle as fed or might be for the making of
the various biscuits. This process is being done automatically by using the main frame
computer. The sugar solution (wort) has to be removed from the spent grains. It is filtered
through a bed made up of the the husk from the malt. Wort must be clear and produced with
minimum effluent. Oxygen should be excluded. The solids left behind are called spent grains
and are fed to cattle.
4. ADJUNCT KETTLE
In this kettle sugar are added in specific amount of wort, which is being taken
from the Lauter tun and then transferred this to the Wort kettle. The reason behind this, is to
enhance the percentage of alcohol. Hence, the ratio of sugar addition is depend on the mild or
strong beer. i.e. Strong beer = more sugar and vice versa.
Purpose : To stabilise the wort and to extract and isomerise the bitter compounds from hops.
Process:
After wort separation the clarified wort is boiled.One of the modern generation of
boilers where the wort is heated externally through a shell and tube heater and circulation can
be achieved by pumping. Hops and sugar adjunct (if required) are added at this stage. A
successful boil is being done vigorously. Usually 60 -90 minutes at 100oC.
HOPS:
Disadvantages:
• Bulkier than extracts.
• Losses in wort compared to extract.
• Low utilisation (30 - 40%).
• Increased production/processing costs.
• Possible adverse effects on beer quality and taste.
Hop storage:
During storage compressed intact hop cones deteriorate, mainly by oxidation but
also as a result of other reaction. Even when stored dry, tightly compressed in bales to
prevent access of air and at low temperatures (i.e. 0 to 4 oC) both the α-acid content and the
essential oil content decrease fairly rapidly. When stored at about 20 oC the losses can be
about 50% within a year. In very hot climates the losses are even faster.
Hop pellets:
Hop pellets are produced from pure varieties or specified mixtures by hammer
milling hop cones which have been dried to about 6% moisture to make them more brittle.
The powdered hops are then pressed into pellets by forcing the powder through a plate
containing holes (an extrusion die) and cutting the cylindrical rods of compressed hop
powder into pellets about 10 mm long.
Hop extracts:
Hop extracts can be classified into hop oil emulsions, kettle extracts and
isomerised hop extracts. Because hop oils are volatile in steam and to a large extent removed
in wort boiling, hop oil emulsion are made by steam distilling hops- preferably at reduced
pressure and so at a low temperature. These extracts which are now produced using CO2 as a
solvent have replaced these emulsions.
Control of DMS flavour:
DMS has a sweet corn flavour and is a component of finished lagers. Excess
quantities are undesirable. DMS is formed from the breakdown of DMS precursor (S-methyl
methionine) from malt due to heating. DMS is highly volatile and is rapidly lost during
boiling. It build up during the hot wort stand and this should be kept to a minimum if DMS
control is required.
WORT CLARIFICATION
Purpose – To separate the coagulated protein (trub) and hop debris from the hot wort.
The principal changes during hot wort clarification:
• Coagulation of protein/polyphenol complexes.
• Precipitation and separation of hot break.
• Temperature dependent chemical reactions started in the boil continue during the hot
stand in the wort clarification stage, e.g. colour formation & oxidation.
• Temperature dependent reactions which produce flavour active volatiles (e.g. DMS)
can build up as they can not be removed in a vigorous boil.
7. WHIRLPOOL
Vent
Three levels of
wort outlet Tangential Inlet
Trub Cone
Purpose:
To remove the unwanted protein particles by coagulation.
Process:
• The wort from the kettle is transferred to the whirlpool at a tangent, for the whole
contents of the tank spin.
• The solids are spun to the centre and settle into a “trub cone” whilst the clarified wort
can be drawn off from a number of wort outlets for cooling.
• Whirlpools have come to represent the most usual method of wort clarification. The
wort is injected at a tangent to the vessel and spins so that the solids (proteins and hop
debris or hot breaks) collect in the centre and continue to aggregate. This increases
their mass as they settle to the bottom of the tank. The clarified wort is drawn off from
the side of the vessel, and this process be carried out for nearly ½ hr.
8. WORT COOLING
Purpose: To cool the clarified wort after boiling prior to fermentation.
Cooling Process:
After clarifying the boiled wort it is necessary to cool and aerate it in
preparation for yeast pitching and fermentation. Originally wort was cooled in shallow open
vessels but now the plate heat exchanger (PHE) is used exclusively for wort cooling. For
cooling process the chilled water is mostly being used, from the chilled water tank having
temperature 5-8oC. The hot wort is cooled in a counter current direction against the brewing
liquor. In general 100 hl of hot wort at around 98 oC will be cooled to say 16oC by around 110
hl of incoming brewing water at 10oC which in turn will be heated to around 85 oC. This
makes wort cooling a very efficient process recovering most of the sensible heat from wort
boiling which can be used for brewing. In ale breweries with relatively high pitching
temperatures of above 15°C, cold well or town's supply water is used as the coolant. The hot
water generated being used for brewing purposes. For lager brewing at lower pitching
temperatures, of typically 8-12°C, an additional cooling stage is usually added. The coolant
in this stage is a refrigerant such as brine, ethanol solution, glycol etc.
The plates of the heat exchanger are as thin stainless steel as possible (0.5 mm)
to maximise heat transfer. Surface area and turbulence are also increased by embossing or
rippling the plates. It is vital that wort cooling temperature is accurately controlled as this will
affect how the beer ferments, how long it stays in FV and the final flavour of the beer. As the
wort cools even more protein material tends to come out of solution This material is called
'cold break' and should form good flocs that settle quickly leaving bright wort. Altering
copper fining rates and types can alter cold breaks. It is important to measure and check cold
break performance on each brew. The sample should be taken from the cold side of the wort
cooler.
• Cooling is usually done on the cold side, to avoid colour pick up.
• Hot side if aerating will sterilise the air.
• Aeration will add around 8ppm O2.
• Oxygen must be used for higher gravity worts.
• More gas dissolves in colder and lower density liquids.
• Gas must be sterile and dissolve before reaching the fermenter.
Where ever needed Hot water, Cold water, Chilled water are being taken form the this
above stated tanks.
YEAST
Yeast is a single celled fungus and is (or should be) the only living organism
that comes into contact with the beer until it is drunk by the consumer. Yeast acts as a
catalyst in converting sugar to alcohol, but does form not part of the end product (beer),
except in naturally conditioned beers. Yeasts are found everywhere, in the atmosphere and
particularly on the surface of dead and decaying animals and plants. There are a large number
of yeast species which are adapted to a variety of environments. The particular strain which is
mainly used in fermentation is called Saccharomyces cerevisiae, Yeast can be described as a
facultative anaerobe, i.e. it can live either with oxygen when it respires normally producing
carbon dioxide and water. Under aerobic conditions its metabolic pathway produces ethanol
and carbon dioxide. This is known as fermentation. Bud cells are clearly visible on this
electron micrograph Yeast is a single celled micro-organism (fungus). It exists wild in nature
and under oxygen free (anaerobic conditions) it is capable of turning sugars into alcohol &
CO2. Under aerobic conditions yeast is able to respire normally and produces CO 2 & water.
Yeast needs some oxygen for cell wall production. It reproduces by budding. Yeast can be
seen easily under the microscope.
Morphological features:
• Size: 5-8 µm.
• Shape slightly ovule.
• Single cell organism.
• Some appear in chains.
• Cell wall with a bud scar. The cell wall regulates the flow of biochemicals in and out
of the cell.
Yeast Reproduction:
Yeast cells multiply by budding, producing daughter cells. Up to 30 daughter
cells during the cell life time have been described. In a normal fermentation yeast will
reproduce itself between 4 and 6 times. If oxygen is limited it cannot produce sufficient cell
wall material for effective budding. Insufficient yeast growth will produce a defective
fermentation.
Yeast handling:
Yeast is the only living organism which should be found in beer. At the start of
the fermentation it has to be added and mixed with the wort. At the end of fermentation it has
to be separated from wort. Every given number of generations the yeast has to be replaced
with a fresh culture.
• Addition to wort – yeast pitching.
• Separation from wort – yeast cropping.
• Holding between brews – yeast storage.
• Introducing replacement yeast strains – yeast propagation.
• Getting rid of surplus yeast – waste yeast.
1. Yeast pitching:
• Yeast is added to the cool wort along with a small amount of air or oxygen to promote
vigorous growth at the start of fermentation.
• Quantity of yeast addition depends upon the consistency and viability of yeast.
• Yeast is pitched directly in to cool wort.
• Yeast from storage or propagation is pitched, in line into the cool wort, or directly
into the FV.
• This pitched yeast is having “0” cycle/generation, and when this yeast is again used
for the pitching purpose in the other UT will be known as “first” cycle/generation and
so can be used only for “seven” generations. Because if we use it for more than that it
will not produce product as efficiently than when we use in between the given
standard life cycle only.
2. Yeast cropping:
• Yeast is pitched directly in to cool wort.
• At the end of fermentation the FV is cooled to around 5oC- 8oC and the yeast settles
out.
• The first crop of yeast contains trub & dead yeast cells and should go to waste.
• The rest of the crop can be stored for up to 5 days for pitching or sent for
reprocessing.
• 1 crop will pitch 2 to 3 new brews.
3. Yeast Storage:
The yeast for re-pitching should be checked:
• Free from microbial contamination.
• Yeast density – (number of cells per ml).
• Yeast viability – (% live cells).
• Temperature of storage.
4. Yeast Propogation:
Wort collection for propagation: 12 lit of fitered wort is collected before it goes to the UTs.
1ml from slant is inoculated into 15ml wort with yeast food & incubated at 150rpm for
24 hrs at 250C.
2ml from 15 ml stage inoculated into 200 ml wort with yeast food & incubated at 150rpm for
24 hrs at 200C.
The whole culture is transferred into 10 lit wort with yeast food in CV (2 in nos) Incubated at
200C water bath for 24 hrs
Note: Yeast cell count to ensure proper growth and multiplication; Plating to monitor
contamination or variations are done.
All these steps are done in replications.
Stages Yeast count
expected
Note: Yeast Food Preparation
(million/ml)
Stage MassSlant
of 250±50
Volume of water
15 ml 155±20
yeast food (g) to be used (ml)
15ml 0.02200 ml 180±30
20
200ml 0.04 CV 105±30
40
CV 0.2 100
20 lit culture from 2CVs is inoculated into 2 HL wort in YPV and maintained at 160C for 48
hrs
Top up with wort to make 20 HL in YPV and maintained at 160C for 48 hrs.
Crop the yeast after the gravity has reached min possible and this yeast is called “ZERO”
generation yeast
FERMENTATION
Fermentation is the process by which yeast converts the glucose in the wort to
ethyl alcohol and carbon dioxide gas -- giving the beer both its alcohol content and its
carbonation. To begin the fermentation process, the cooled wort is transferred into a
fermentation vessel to which the yeast has been added. If the beer being made is an ale, the
wort will be maintained at a constant temperature of 68 F (20 oC) for about two weeks. If the
beer is a lager, the temperature will be maintained at 48 F (9oC) for about six weeks. Since
fermentation produces a substantial amount of heat, the tanks must be cooled constantly to
maintain the proper temperature.
When the yeast first hits the wort, concentrations of glucose (C 6H12O6) are very
high, so through diffusion, glucose enters the yeast (in fact, it keeps entering the yeast as long
as there is glucose in the solution). As each glucose molecule enters the yeast, it is broken
down in a 10-step process called glycolysis. The product of glycolysis is two three-carbon
sugars, called pyruvates, and some ATP (adenosine triphosphate), which supplies energy to
the yeast and allows it to multiply. The two pyruvates are then converted by the yeast into
carbon dioxide (CO2) and ethanol (CH3CH2OH, which is the alcohol in beer). These cell gain
energy from the break down of the sugar. The by-product, CO 2, bubbles through the liquid
and dissipates into the air. The other by-product alcohol, remains in the liquid which is great
for us but not for the yeast, as the yeast dies when the alcohol exceeds its tolerance level.
The overall reaction is:
C6H12O6 => 2(CH3CH2OH) + 2(CO2)
1. Wort Collection:
2. Attemperation:
Objective:
• To ensure that the fermentation temperature is maintained at the set level which
prevents formation of unwanted flavours.
• To ensure yeast viability.
• To reduce fobbing.
• Control cooling carefully to avoid stopping the fermentation.
• If cooling applied early the yeast will be unable to grow and the fermentation will
stick. If cooling is not put on as the yeast is actively fermenting the fermentation
temperature will rise to an unacceptable level causing damage to the yeast. Crash
cooling during the active stage of yeast growth tends to stop the fermentation.
Attemperation should be carried out gently using feedback control. The process today
is normally controlled automatically by setting the required temperature measuring
the beer temperature with a probe in the vessel and allowing this to control the flow of
coolant to the vessel. But due to the improper working of the probes present (due to
the old age) it is being operated manually, opening a valve depending on a
thermometer reading. Conical vessels which are used have a jacket through which the
coolant circulates..
3. Rousing:
• Some yeasts have tendency to flocculate early and settle.
• Circulation currents in deep vessels keep yeast in contact with the wort.
• The addition of air during rousing can restart a sluggish fermentation.
Some strains of yeast have a tendency to form clumps of cells (a process referred to as
flocculation) at an early stage of fermentation. In order to keep these yeasts in contact with
the wort it is necessary to rouse the contents of the vessel. This is done by pumping the
fermenting wort from the bottom of the FV and returning to the top of the vessel. The yeast in
conical fermenters is kept in suspension by the convection currents set up within the vessel
due to the cooling jackets and yeast growth. Due to this and the pressure in the vessel which
keeps the head down, yeasts which normally come out of suspension can be used in conical
fermenters. Conical FVs should not be roused as excessive fobbing will occur causing large
losses. Rousing should not be carried out towards the end of fermentation as off-flavours
(aldehydes) will be formed due to oxidation. Rousing is carried out intermittently usually for
10 minutes every hour to reduce fobbing.
4. Monitoring
• To ensure that the yeast is producing alcohol as required.
• To detect any deviations from standard.
• To indicate when the fermentation can be stopped.
• The gravity of the fermenting wort is measured in every 12 hours. This gravity is
measured using a saccharometer or densitometer. This gravity reading is being
compared with standard and so the monitoring is done.
Conditioning:
• It is done by adding biofine: As biofine speed up the yeast sedimentation or settling
by forming aggregates with negatively charged yeast cells and also decreases the
haze. Biofine is extracted from collagen, isolated from swine bladder.
• Profix: It degrades protein particles present as it consist proteases which acts on
proteins.
• L10 Leucolite solution: It is also one of the source of yeast settlement.
The requirements which must be met before fermentation can take place are:
• Quantity and quality of yeast.
• Wort composition.
• Temperature.
• Shape and size of fermenter.
• O2 present.
Fermenter:
Safety:
• During fermentation CO2 gas is given off. The gas is heavier than air and can
accumulate in a fermenting room. It kills by asphyxiation.
• On no account enter a fermenting vessel unless it has been vented and checked.
• CO2 rapidly dissolves in caustic CIP. This could cause a vessel to implode. The
vessel must be purged before CIP. An anti-vacuum device is not sufficient.
• A permit to work must be issued for all maintenance & vessel entry, CIP & plant
under remote control.
• We should return to safe working with gases in the Utilities module.
Maturation:
Objectives of maturation and conditioning:
• To clarify beer, prior to filtration, by removal of insoluble suspended material and
maximise filter run length.
• To produce beer with good colloidal stability, by the removal of haze forming
materials.
• To provide flavour stable beer, and ensure that no undesirable off flavours develop
during and after packaging.
• To make adjustments to critical beer parameters, so that the product is within
specification.
Maturation Process
• Beer is stored cold at -1oC or -2oC for 2 to 3 days.
• CO2 is adjusted for the (i.e. addition) post filtration.
Carbonation
• The amount of dissolved carbon dioxide in the beer is a function of pressure (beer
depth)and temperature.
• At the end of a normal fermentation lager CO2 could be 3.5 to 4 g/hl ( 1.8 to 2.0 vol)
• Additional CO2 is introduced through secondary fermentation or direct addition of
CO2 to the beer after filtration if there is need to do so.
Blending:
Blending is traditional in many breweries but it makes trace ability difficult in
the rare instance of product recall. If consistent processing has been followed, blending is
only necessary in problem instances where beer may be reject for colour or bitterness or be
the first fermentation with a yeast culture where the cell count was inadequate and the
fermentation slow and atypical. Routine blending should not be necessary with consistent raw
materials, consistent brew house, yeast and fermentation control. Effective beer stabilisation
with minimal levels of oxygen.
FILTERATION
Purpose:
To remove solid particles from the beer stream to produce a bright stable beer free of yeast &
(most) bacteria.Primary filtration can remove particles in 1 micron range.Fine or sterile
filtration removes particles above 0.45 micron.
Filtration Process:
Firstly the young beer is collected from the UTs by using the pump at speed 80
hl/hr and temperature is reduced to about-0.12oc by passing it though PHE. Then it is being
transferred to the Buffer tank 1 by CO2 purging depending on the need called primary
purging. Buffer tank 1 is used for maintaining pressure or flow speed (1 kg/cm 2) in between
the inflow and the outflow to the BBT. It is then transferred to the dosing tank in which there
is addition of kieselguhr powder, which consist of Super cell (fine) 2-3 µm and High flow
(course) ˜10 µm. 15 kg each are mixed in dosing tank and allow to flow with young beer
with constant speed of inlet and outlet. And by passing 47 sheet the beer is being filtered.
Sheet bed porosity is maintained by the continual dosing of a filter aid like kieselguhr or
perlite. The bed has to be build up carefully to ensure adequate porosity. The first precoat will
be a coarse powder followed by a second precoat usually the same powder as the bottom
feed. As soon as filtration commences powder is dosed into the beer flow to continue to build
the bed up and keep it porous. The pressure will rise as the filter blinds so it need to increase
the dosing rate if the pressures starts to rise more than normal. Similarly if the pressure build
more slowly, more powder is being used than necessary and the filter run will be shorter than
expected. The filter will need washing off once the void area is full of powder. Yeast and
haze particles will be trapped but most bacteria will pass through. Filter runs can be
prolonged by ensuring the beer is bright to the eye. Beer filtration requires a filter aid such as
kieselguhr to help trap the solids and give depth to the filter bed. Then it is transferred to
Buffer tank 2 having same pressure maintained as that of the Buffer tank1 and if need CO2 is
punched at this stage called secondary purging and then finally goes through PHE to BBT in
the form of bright beer.
• 1st Precoat – coarse.
• 2nd Precoat – Fine.
• Powder filtration will remove yeast but not bacteria.
Beer and powder are dosed into the frame chambers. The precoat has been built
up on a thick paper support pad. This pad may be covered by a disposable paper slip often
known as a nappy liner. This paper makes removal of the cake easier later. The beer is
filtered through the bed and into the support pad. Channels behind the pad in the plate surface
direct the bright beer to the outlet manifold. Since caustic detergents are difficult to rinse out
of the cellulose support pads, the filter must be cleaned with hot water and only deterged
when the pads are about to be changed Powder builds up on cellulose support pads usually
covered with a ‘nappy liner’ to aid manual wash off. Pads should last for 150000BL. Dosing
is controlled in response to pressure build up - 50g/ BL is typical. At 7 bar differential the
chamber bridges and a 3 hour manual wash off ensues. Filter run time depends on filter
surface area.
Keiselghur powder
• Diatomaceous earth or kieselguhr ( DE ) is the skeletal remains of marine or fresh
water diatoms. It builds up a complex three dimensional structure to maintain
permeability and hold the solids. But is a hazardous material to handle. Beware of
taints and iron content.
• Beer filtration requires a filter aid such as kieselguhr to help trap the solids and give
depth to the filter bed. So precoating is done
• 1st Precoat - coarse
• 2nd Precoat - Fine
• Body feed- coarse+fine
• The dust being classified as dangerous as asbestos. Properly aspirated handling
equipment is essential. Filter powders are prone to pick up taints during their
transportation and storage. All new deliveries should be checked suspending powder
in water, the water is tasted for metallic taints and sniffed for other entrained volatiles.
One brewer traced an unwanted orange aroma to a load of powder which travelled
from the US with a hold full of oranges.DE is the skeletal remains of marine or fresh
water diatoms. It builds up a complex three dimensional structure to maintain
permeability and hold the solids.
TOP PRESSURE
LAGGED PIPEWORK
SMOOTH
FILTER TRIM CHILLER PIPE
BENDS
Tanks used is being clean and steriled. It is being checked for smooth internal
surfaces. Any rousers ave supplementary spray balls to clean shadow areas. Tanks is being
counter pressured with inert CO2 or nitrogen. Beer flow to the tanks maintained at the correct
flow rate without having any sharp bends which can promote fobbing. Inlet rate made smooth
to avoid gas break out in the bottom of the tank. High CO2 and DO levels are corrected by
purging with oxygen free nitrogen through a sinter at the base of the vessel. Degassing to
correct dissolved gas levels cause some fobbing in the tank. Fob remain on the vessel walls
during emptying and might dry and cause a haze in the next filling if vessel rinsing is
ineffective. Sometimes dried bits of collapsed fob fall back into the parent beer and cause
similar rejects.
Blending
Beer presented for packaging must be in specification for all analysed
parameters. Any blending at bright beer stage must ensure that the mix is consistent over the
entire batch. Need as complex plant as beer dilution with no pressure surging or ingress of
air. Probably better to blend ex maturation tank if there is a risk of inadequate mixing to
packaging. It is possible that some packages will be out of specification and require
expensive decanting. Beer must be 100% right in bright beer tank during committing to
expensive packaging and expensive packaging materials.
Safety:
• Nose masks: During the addition of Kiesulghur due to its amorphous nature it forms
mist and as it is carcinogenic, during addition is it must to wear nose mask.
• Safety shooes / Gum boots: At the filtration is in the filter room, it is must to wear
safety shoos / Gum boots.
• Pressure relief valves: During the filtration, filter pressure increase to avoid the
increase of overpressure, safety valves required.
• Emergency lamp: As the filter unit is in the filter room during the power failure
emergency lamp is required.
Cold section:
Cold Water Tank: Capacity 37 hl
Sanitiser Tank (Divosin active): Capacity 18 hl
Cold Caustic Tank: Capacity 18 hl
QUALITY
The concept of quality relates to a contract, specifying the supply of a product by one
party (the supplier) to a second party (the customer).
Total Quality control is a technique is used to detect and correct errors before they result in a
defective product or service.
It means meeting the customers requirements for a product or service. The general goal is to
meet on time with no error and defects.
Quality Assurance
In general, Quality Assurance is nothing but the identification of problems through quality
(QI) and elimination of problems through QP and QC, to detect the problems early enough to
prevent their consequences. And the new process is to implement through QLP.
In brief, Quality Control involves the identification of process problems and defective
products. Whereas Quality Assurance involves PROBLEM SOLVING in addition to Quality
Control.
1. Bottle inspection:
Bottle colour, Shape, Diameter, Height all as per the standard.
2. Crown inspection:
Crown colour, Shape, Seal shell, Linear, Linear contamination, Linear adhesion, Text,
Damage or Scratches, Mix Description, Weight, Body diameter all as per the standard.
3. Label inspection:
Label colour, Shape, Text, Types such as the front label, back label, neck label, Size all
as per the standard.
4. Carton inspection:
On delivery, following inspections are done:
Each carton to be clearly marked with the manufacturing factory identification, Date of
manufacture,
Batch no.
They are not excepted if:
• It is not legibly marked as above.
• The manufacturer's seal is not intact.
• The lot is damaged.
• The lot is soiled (for example, water or oil stained), or has an appearance which
suggests contamination.
• The lot has a foreign odour.
• If it consists of different batch numbers.
The preliminary acceptance test which are followed during acceptance of the cartons. The lot
is deemed to be accepted if:
a. The moisture content of the carton should not exceed as per standard.
b. Dimension The dimension of the carton as specified in the standards all conformed to
the internal dimensions as +3mm.
c. Visual Inspection of carton - The carton are conform to the shade card which is
being attached to the specification sheet and compared.
d. Bursting Strength The cartons are being checked for the bursting strength and to
ensure it conforms to the specification prior to acceptance.
5. Malt inspection:
Taste: Should be free from any abnormal taste
Odour: Should be free from any abnormal odour.
Appearance: Foreign materials should be present.
Moisture: 5 gm malt is weighed and inspection is done by using the moisture analyzer should
be in standard 0-11.
7. Sugar inspection:
Taste: Should be free from any abnormal taste.
Odour: Should be free from any abnormal odour.
Appearance: Should be free from Foreign materials
Colour: <0.30 EBC.
Analytical QA:
There are various test performed in this Quality section. Of the various test performed here
are some of the test which are being performed.
• Beer colour intensity on a sample free of turbidity and having the spectral
characteristics of an average beer, is 10 times the absorbance of the beer measured in
a half inch cell with monochromatic light of wavelength 430 nm.
• Turbidity exhibits equal spectral characteristics on the absorbance of monochromatic
light with a wavelength 430 nm and the maximum absorbance is best established at
wavelength 700 nm
pH value
0 7 14
pH c ondition a cid ne utra l alka line
• When solutions contain hydrogen ions [H+], a voltage develops which is directly
proportional to the [H+] concentration and thus, the pH can be measured
electrometrically.
• In the pH meter the voltage across the electrode bridge is balanced with standard
buffer solution or solutions (in a two-buffer calibration) of known pH (voltage) at
20°C.
• The bitterness in beer arises from a group of compounds which are extracted from
hops during wort boiling. These compounds are isomerised under the wort pH and
boiling conditions. The term “Bitterness Units” is used to describe the concentration
of these compounds.
• The method depends upon suppressing the ionisation of these compounds by the
addition of strong hydrochloric acid in order to ensure their total extraction into iso-
octane during shaking. The aqueous and solvent fractions are separated by
centrifugation. The concentration of bittering compounds in the iso-octane is
determined spectrophotometrically by measuring the absorbance of ultra violet (UV)
light at a wavelength of 275 nm.
4. DETERMINATION OF ALPHA-GLUCAN
• The limit to which a sample is fermented by brewer’s yeast under ideal conditions,
that is, at an elevated temperature and with agitation, is termed the limit of attenuation
or the limit to which it can be fermented.
• The relative density (RD) of the extract is determined and from this RD value the LE
percent Plato (%P) is determined from the Plato tables.
Note: Where the mass of both is determined in the same volumetric container.
• Relative density is thus a measure of concentration due to the presence of solutes in
the liquid.
• Relative density is used to measure and control extract. Yield is determined by the
amount of extract obtained from the malt and adjuncts used.
• Relative density determination using a densitometer is based on the principle of an
oscillating U-tube. The oscillating frequency of two standards (pure water and air) is
required for the calibration of the densitometer. The oscillating frequency of the U-
tube is altered by the density of sample (in the U-tube). This sample frequency is
internally micro computed and displayed as its relative density.
Note: Densitometer RD’s are only valid on homogenous solutions free from entrained
particles and gas bubbles.
7. DETERMINATION OF CHILL HAZE BY HAFFMAN VOS 4000 HAZE
METER
8. DO- ORBISHERE
Microbiological QA:
Yeast Handling
Packaging QA
1. Bottle Washer
• Caustic zone 1strenght- (1.25-3.2%)
• Caustic zone 2strenght- (1.25-3.2%)
• Caustic zone 1 temp- (>800C)
• Caustic zone 2 temp- (>800C)
• Label carryover: Number of bottle carried with labels are counted.
• Methylene blue: Put few drops of methylene blue in the washed bottle, if blue colour
appears then mould or fungi may be present and if no colour appears then test is
negative.
• Caustic carry over: Put few drops of 1% Phenolphthalein indicator in the washed
bottle, if colour appears means caustic is carried over or if no colour appears test is
negative and caustic carry over is nil.
• This method details the procedures used for measuring total oxygen (headspace and
dissolved) and the carbon dioxide content in packaged product by means of the
Orbisphere Analyser
• Once the package has been pierced, the system goes through the headspace and
Liquid measurement and computes the final data.
Principle:
O2 sensor - It has Silver Anode and Gold cathode dipped in electrolytic solution. The electric
current proportional to O2 gas which is proportional to the partial pressure of gas in beer and
out side atmosphere.
CO2 sensor – Thermal conductivity of a gas is the amount of heat transferred by the 1g of gas
present between 2 plates of 1cm2 area and 1 cm apart and 1oC difference between plates. Each
gas has different thermal conductivity. Orbhishere has a specific TC chip which is covered by
membrane for protection. When gaseous CO2 enters and comes in contact with chip the
thermal conductivity changes and corresponding voltage change is measured.
The method is suitable for use with both bottles and cans, with particular application to ex
filler samples
1. Sampling Tube insertion device and handles.
2. Sampling tube adjustable lower stop.
3. Analyser manifold.
4. Two step device (left side) to analyse cans, with release spacer.
5. Piercing Knife, metal or plastic type.
6. Package positioning system (cans, glass, PET bottles)
7. Piercer lever, to lower or raise the piercing knife.
8. Adjustable pressure regulator set at 2 bar (Festo) for purge / forcing gas (behind panel)
9. Flow meter to regulate product flow past the sensors.
10.Pressure gauge for TC sensor purge gas regulated pressure.
Locking lever for the package positioning system height adjustment
3. Pasteurizer
4. Labeling
• Body Label Height.
• Back Lab1el Height.
• Missing Label.
• Up side Down Label.
• Foil /Neck label Height.
• Foil / Neck Label Center.
• Glue Streak on Bottle.
• Loose label.
5. Carton
• Label Damage.
• Carton damage.
• Missing / broken bottles
• Carton seal / tape.
By placing the bottle in ice so that to check the stickiness of the labels in the chilling
condition.
Safety:
• Safety must be given the first order preference.
• QA staff must be thoroughly knowledged about the personal health and safety
precautions to be taken in Lab and shop floor.
• The responsibility of teaching and monitoring the safety practices in all other sections
of brewery lies with QA.
• Fire Exit paths must be marked very clearly.
• Safety showers and eye washes must be in place and in proper working condition
• Extra caution must be taken while handling caustic, hazardous chemicals and
infectious Microbes
TASTING
1. Beer Flavour Profile: Each brand of beer should have a known level of taste like
sweetness, bitterness, sourness and flavours (colour is also assessed), which is
described in the brand profile. Which is assessed and a rating is given.
• Basic tasting: To educate in Identifying the basic off flavours in beer by doping each
at a time in beer.
• TVS tasting: To validate the tasters by assessing their ability to identify the off flavors
doped.
• SV tasting: TO identify the off flavours in SV beer before it is being filtered.
• BBT tasting: Before releasing for filling.
• Packed product tasting: To identify the off flavours in packed product.
• Brand identification tasting: To make the panel familiar with the desired brand
profile.
• Shelf life tasting: To assess the quality of beer after storing it for 4, 8 and 12 weeks.
• Taint netting: To identify the taint if present in water, raw material, kieselghur, BBT
beer, Air and CO2
• Trade tasting or Trade Quality Assessment (TQA): To assess the product at outlets.
To Provide an Ongoing Divisional Measure of the Fitness for Sale of our Product as
Delivered to our Customers and Consumers”
Taste score (Hub Tasting):
• It is done monthly to assess the taste and a score is given.
• Only Advanced Tasters are involved.
• The scores of samples coming from different breweries are compared.
• The best scored samples are sent to South Africa for global tasting.
GTS (Global Tasting System):
• The purpose is to get accurate calculated taste score which can be globally accepted.
It is carried out in South Africa.
• Three essential things required are;
• Brand Profile
• Algorithm
• Advanced tasters
3. Flavour wheel
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UTILITY
1. WATER TREATMENT PLANT
Purpose: Raw water (From MIDC) is treated to produce Soft water, Demineralised (DM)
water which is the one only used for the all the process which are carried out in the company.
Process:
• This process began when in coming raw water coming is taken in the raw water
storage tank (cap:1000 m3).
• It is then passed to the Fire storage tank (cap: 200 m3) so called because used in the
water treatment process (WTP) as well as used during fire is catched anywhere.
• Then is being transferred to the another raw water storage tank (cap: 700 m3).
• Then via pumps, it is transferred to the Multi Grade Filters (MGF) where stones in
varying size are placed and by which the water is being passed though in which the
big particles are entrapped. If improper filtration is occurring it is given back wash
with water and again the process is carried out .
• It then comes in Activated Carbon Filters (ACF-1) were coal is present in this filter
through which water is filtered out and chlorine is removed. This one is also given
back wash when inproper filteration occurs.
• For this it may be transferred to make the Soft water or DM water.
• Soft water is made by passing the ACF-1 to the softner. So, that it will make the
water softer by using salt resins and made upto 30 ppm.
• For DM water, it is transferred to the cation exchanger through the ACF. Where the
cation resins are present which remove cations, if the quantity needed in not given out
then it is washed with water and acidified by using HCL upto 2 pH.
• Then it is transferred though Degassor where water is blowed from bottom of the tank
and all the gases are removed out form the water by releasing from the upside.
• Anion exchanger is used to remove anion present in the water. And if the flow of the
water is not up to the limit then it is basified by adding NaOH (upto 200 gm per 1000
lt).
• Finally, water goes through the ACF-2 by which if any particulates are present is
being removed out. And this DM water is given to the process in which minerals are
removed and pH is maintained.
2.COOLING TOWER:
Purpose: This cooing tower is being mounted for the process of water cooling program.
Process:
This is done so as follows:
• The cooling tower consist of water inlet on top side via which the water comes to the
tower and a big sieve is mounted on top of the tower.
• Through which the water flows on to the cooling fan and by this fan the water is cool
down to the temperature rather than then the present temperature less the 5oC.
• And, for the bottom side the cooled water goes to the Air compressor, Ammonia
compressor, and CO2 compressor.
• This cycle continues and the water is being cooled down.
3.REFRIGERATION:
Purpose: Refrigeration is the process of making chilled brine. Brine is nothing but the
mixture of propylene glycol and water. It is being one of the most useful one for the
temperature control during fermentation.
Process:
• High molecular weigh compound of ammonia is compressed and is being passed to
the condenser due to which there is increase in the pressure and temperature.
• Water form the cooling tower comes to the condenser at 24oC and act on the 80oC
which is present in the shell and tube type condenser. Shell consists of ammonia and
tube water.
• In condenser ammonia vapours are converted to the liquid due to the use of the
chilled water from the cooling tower acting on the hot ammonia and goes to the
receiver.
• Then it goes to the chiller were the brine is chilled during this the liquid ammonia is
converted to the vapour form. And in this way the process continues for the chilling of
brine.
• Then this brine is stored in to the storage tank having internal partition consisting
Cold well (cap: 16 m3) and Hot well (cap: 16 m3). In this cold well the brine is stored
at -6oC.
• And this brine is ready to control the temperature during the fermentation by
decreasing when it exceeds the limit.
6.BIOLER HOUSE:
Purpose: To provide steam for the various process.
Process:
• There are two boiler of IAEC having cap. 8 ton/hr and other is of SHELL MAX
THRUMX having cap. 6 ton/hr.
• Furnace oil is being used of boiling purpose because it is the cheaper one as well as it
catches fire well and for long time period.
• Furnace oil is firstly stored in storage tank (cap: 36 kl) and the transferred to day tank
(cap: 2300 ltr.) and via the pipe it is taken in the ignition box.
• Ignition point is 100-110oC and the heating surface area is of 195 cm2/inch and it is
carried out by electrical heators.
• Boiler consist of an inlet for the water to come and also the outlet from which the
steam goes. And water level is maintained at the given set point.
PACKAGING
Purpose: This is the section or department were the beer formed by the collaborative work
done by the above discussed departments is packed, to be marketed with to in a collaborative
manner.
1. Bottle washer:
Purpose: To wash bottles, so that a proper sterilized bottles are marketed.
Process:
• A particular machine of KHS and model name is INNDCLEAN DMT-27/95-S11N-
232-4.5 and have a capacity of 18000 BPH (Bottles Per Hour), a single end machine.
• It consist of 27 pockets (row) and 385 columns are mounted on the chain and the
process continues as the chain rotates and the washed bottles are dispatched on back
side and again the chain comes and the new bottles are add, that means 10,395 bottles
are washed at a time with a speed of 250 bottle per min.
There are seven zone in the machine:
i. Pre-rinse: 2 spray at top with pressure limit 1.2 bar, time.
ii. Caustic soak1: 2 spray at top and 2 at bottom with pump pressure 1.5 bar limit,
and the caustic strength minimum 2%, temperature range 80-90oC with time
5.1 min.
iii. Caustic soak2: 2 spray at top and 2 at bottom with pump pressure 1.3 bar limit,
and the caustic strength minimum 2%, temperature range 80-90oC with time
9.9 min.
iv. Hydrozone: 1 spray at top with pressure limit 1.2 bar.
v. Pre-final rinse: 2 spray at top with pressure limit 1.2 bar.
vi. Final rinse: 3 spray at top with pressure limit 1.2.
vii. Soft water rinse: 3 spray at top with 2 rotating and a is stabilized one and
pressure limit 1.2 bar. The soft water used maintained at 2.7 pressure.
• All the above process is completed on 45 min, and the main zones are of caustic for
which need 15 min and the remaining for the other zones.
• Steam is used of this process, and this is the best machine being used because in this
there is low water loss as the water is taken in from the soft water rinse zone to the
pre-rinse zone and then drain out.
• Caustic strength is checked by quality assurance department and if there is a decrease
in strength from that of standard then caustic bags are added in the dosing tank and
pumped to the caustic zones.
• Brite washer is in use for the bottle shining process so that it look good.
• In this process old bottle as well as the new bottles are being washed and also the
labels are removed off.
• There are few test being performed by the quality assurance department: 1. Caustic
strength check. 2. Caustic carryover 3. Methylene blue test 4.Label carryover. \
• Always the speed of this is maintained +10 than that of the packer cum crowner.
2. Filler cum crowner:
Purpose: To fill and crown the bottle in proper and appropriate manner.
Process:
• A machine is used for this purpose of KRONES, model VK2V 40/KK 10-94 LM with
10,700 rpm.
• It consist of 10 infeed start wheel, 40 beer filling wheel, 20 bowl out or discharge start
wheel after filling and so the crowner crimping head wheel, 10 machine outlet wheel.
3. Pasteurizer:
Purpose: For the sterilization of the packed beer and increase the shelf life.
Process:
• It was impossible to prevent microorganisms getting into beer before the
pasteurization process was invented by a Frenchman called Pasteur in 1870.
• Pasteurization is the process of the heating the beer at the particular temperature for
particular time because if the time exceed at 63oC it may cause change in the flavor
and also lead to increase in haze and slight change in colour.
• So, now a day flash pasteurization is used and beer is heated in a heat exchanger then
held at the distinct temperatures for a particular time period.
• Pasteurizer used is of ELGI, model is Tunnel type, and capacity 14000 BPH.
• As at 63oC microbes are killed so it is maintained at for 1 min by passing it through
the conveyor by transaction (pipe heat exchanger) and increasing the temperature
slowly from 35 oC, 45 oC, 55 oC, 63 oC, 55 oC, 45 oC, 35 oC, and finally at 20oC
for 1hr.
• The pasteurizer in use for 12000 bottles at a time and steam is taken for the boiler
house.
• 1.3% Divergard B400 gel is use as oxidization solution and 2% Divergard 810 is use
for to resist rusting and crossing side inhibitor and water consumption during the
balance condition is 2.5 m3/hr.
• And after Pasteurization bottle via conveyor goes to the labeler.
4. Labeling:
Purpose: To label the bottle at particular position and sight.
Process:
• The model machine in use is of KOSME, model STAR 16T S2 E2 +FOIL and
capacity 14000 BPH.
• Amca adhesive is in use for the labeling purpose and via the pump by using ball it is
pumped during the labeling program.
• Front label magazine and nick label magazines are placed on the sight of the labeling,
for both process is same. The label stick to the holder which is being glued by the
scrapper and holder blade and then it is placed on another holder by gripper. And it is
placed in the position of the labeling to the bottle and finally stick to the bottle and by
the sponge it is completely fixed to the bottle.
• The angle and the rotation of the first roller and the collector should be the same and
if there is any slight change occurs may lead to improper labeling.
• The bottle comes in by the conveyor and then to the main camp were the labels are
sticks to the bottle.
• By the use of the Sensor machine in which the Batch number, Date are preloaded in
the memory and when the bottle comes, as the back label appears in front of the
printer by sensors it print.
• And, then finally via the conveyor the bottles goes to the case packer.
5. Case packer:
Purpose: To pack the bottles in the case box.
Process:
• The machine used is of FIBRE KING QUALITY, case packer, model COP/HM
PACKER AND SEALER, Sr. no. 972811, capacity 960 CPH (Case Per Hour).
• Bottles by the conveyor comes to the packer, 3 lines are formed by the conveyor and
after 4 rows i.e. a matrix is formed.
• After the formation of the matrix a pusher cylinder is opened and it holds 12 bottles in
matrix, then the bottle push cylinder operator puts manually the cartons by stopping
the box push cylinder as by placing hand in front of the sensor.
• As the cartons are placed the box push cylinder pushes box till it rest and then it
comes back. Then box is discharged to the dispenser unit were the top and bottom
tapping is being done and so the bottles are now fully packed.
• Batch number, manufacturing data are printed on the case box by the sensor machine
as that done during labeling.
• Finally, bottles are collected and placed on to the pellet, on which 76 boxes are placed
at a time by the operators.
• And now stored in the BSR (Bottle Store Room), and then dispatched in the market
under the presence of the Government of India, Excise officer.
SUGGESTIONS
• Put a meter at a point of addition of oxygen, so that we can know the amount of the
oxygen and or is provided.
• Also put a meter at a point of addition of CO2 , so that we can know the amount of
the CO2 and or is provided.
• Remove the yeast separately in a big tank and dry it so that can be used as feed or use
as it in active state and try to put in market as it would a commercial benefit and also
reduces the effluent load.
• Allow the BBT to stand for at least 4 hrs after filtration and carbonation for better
stabilization of beer.
• Do conditioning at proper time and at proper amount.
• Focus on maintaining the correct concentration of caustic during CIP.
• Reduce the raw material and beer loss.
• During yeast drain there should be meter fitted on the drain point. So that we will be
able to know the amount of yeast is drained and a pre initialization of the point (i.e.
How much yeast is to be drained) by microbial analysis to be done, as this would a
measure implement and would decrease the beer loss.
• In the water treatment plant there should be a provision of Mixed bed exchanger as
there is presence of the anion and cation exchanger there might be formation of the
mix ion so if mixed bed exchanger is present may produce the DM water as per
standard.
REFERENCES
This project report is mostly produce on the knowledge and the information given by
all the company Executive, Operators. Some of the books and website used for making
this project are as follows:
http://en.wikipedia.org/wiki/Beer, http://www.physorg.com/news79728415.htm,
Principal of Fermentation technology by P. F. STANBURY, A. WHITAKKER and
S.J.HALL, Bioprocess engineering: basic concept by Michael L. Shuler., Industrial
microbiology by Casida.,Bioprocess engineering by Bally and Ollies,
en.wikipedia.org/wiki/Barley,www.maltcompany.com/,amwayz.com/beer-
brewing/default.htm,www.experiencefestival.com/a/Adjunct_beer/id/1903359,www.le-
brewery.com/productionofbeer.htm,www.britannica.com/EBchecked/topic-
en.wikipedia.org/wiki/Lauter_tun,www.beer-
brewing.com/beer-,www.thebrewkettle.com,
recipes.howstuffworks.com/beer3.htm,www.freepatentsonline.com/4836097.html,
www.jmb.or.kr/home/journal/include/downloadPdf.asp?articleuid,www.iso-
mix.com/media/publications/De-aeration_water_beer.pdf,en.wikipedia.org/wiki/Yeast,
www.findarestaurant.ie/menu.asp?menu=249&parent=250&item=5112,www.le-
brewery.com/productionofbeer,eng.baltika.ru/s/41,en.wikipedia.org/wiki/Yeast,
www.intota.com/expert-consultant.asp?bioID=604216&perID=716098,
eng.baltika.ru/s/41, www.westfalia-separator.com/applications-
processes,www.filterstore.com/beer.asp,
www.pall.com/FoodandBev_Beer.asp,www.articlesbase.com/food-and-beverage-
articles/how-to-produce-the-best-tasting-beer-righ, www.kp.pl/en/psi
THANK YOU
I wish to express my grateful thanks to each and individual who have given me
the knowledge during the inplant training period from QA department Mr. Mahadev Shinde,
Mr. Yogesh Sonawane, Mr. Viresh Rajannavar, Mr. Sudip Ankush, Mr. Prashant Bhalerao,
from Brew house Miss. Shweta Jethani. Mr. Prakash Desi, from Fermentation section Mr.
Pushpraj Patekar, from Filteration section Mr. Sushil Gumte, from Boiler house and Water
treatment plant Mr. Kachru Karbhar, from Refrigeration, Air and Co 2 plant Mr. Om Hazare
and Mr. Aftab Shaikh, from Bottle washer Mr. Ganesh Lale, from Production department Mr.
from Effluent Treatment Plant Mr. Zahid Pathan. Once again thank to each for supporting me
and giving such a needful knowledge and boasting my moral.