Академический Документы
Профессиональный Документы
Культура Документы
ON
MALT SPIRIT PLANT
AT UNITED SPIRITS LTD. UNIT III, NASIK
Submitted by
ACKNOWLEDGEMENT
I take this opportunity to thank United Spirit Limited for
permitting me to do my industrial training at USL, Nasik.
I have to thank Mr. Shasvat Sharma, Unit Head, USL Nasik,
for his kind acceptance to allow me to take training in the
company. I am equally indebted to Mr.Anil Sawai, Head
HR, USL Nasik, who was all through kind in guiding me in
the training process teaching me the nuances of this
challenging profession. I will be failing in my duty if I do
not thank, Mr. Vijay Kumar, GM and Mr. Anoop Saxena,
process Manager of Malt Spirit Plant, USL, Nasik, for his
timely suggestions and help. Finally I have to place on
record my sincere thanks to team USL who have been
very supportive throughout my training. I thank all those
who
were
directly
or
indirectly
programme.
associated
with
this
SR NO.
CHAPTER NAME
TITLE
PAGE NO.
1)
COMPANY PROFILE
2)
3)
RAW MATERIAL
4)
5)
DRY GOODS
MASHING PROCESS
14
20
6)
WORT COLLECTION
WORT RECIEVER
22
7)
WATER SECTION
27
8)
FERMENTATION
28
9)
DISTILLATION
31
10)
CIP SYSTEM
38
11)
MATURATION
39
12)
UTILLITIES
13)
CONCULSION
41
TABLE OF CONTENT
1. COMPANY PROFILE:
United Spirits Limited, is the flagship Spirit Company of the
'UB Group', which has made its presence well known throughout
India and most parts of the world by way of its various Indian Made
Foreign Liquor (IMFL) products such as Whisky, Brandy, Rum, Gin,
Vodka Premixes, etc.,
The Company is headed by its Chairman, Dr. Vijay Mallya & is
having its Registered Office and Head Office at Bangalore.
The total sales of the Company is over 113 million Cases per annum
with 'BAGPIPER WHISKY' No.1 in India selling over 15 Million
cases, 'No.1 McDowells WHISKY', 'No.l McDowell's BRANDY,
NO. 1 McDowells CELEBRATION all sells over 15 million cases.
Four out of above five brands are among 'Top Hundred' selling
brands in the world.
United Spirits Limited has featured for the fifth consecutive year in
the Advertising & Marketing Magazine
Uttar Pradesh, West Bengal, Bihar, Goa, etc. and 'NASIK UNIT' is one
of its most prestigious units which has completed 25 glorious years of
'MANUFACTURING ACTIVITES'.
United Spirits Nasik Unit, earlier known as 'KAY DISTILLERY
INDUSTRY LTD., a part of FORBES CAMPBELL & CO. LTD.
GROUP. It was purchased by The UB Group in March 1990 as
WESTERN INDIA ENTERPRISES LTD. In July 1994 it was renamed
as McDowell & Co. Ltd and in 2006 it was renamed as United Spirits
Limited after amalgamation.
The Unit produces various brands of Black Dog Scotch Whisky and
Whyte & MacKay Scotch Whisky, Brandy, Rum, Gin, Vodka, etc. in
Premium, Semi Premium, Deluxe and Regular Segments.
In the Industrial Relations front too, the unit has established very
cordial and harmonious relations among all the employees where the
workers BELIEVE IN PARTICIPATE MANAGEMENT THROUGH
THEIR OWN UNION. With the atmosphere being favorable and
supportive, the Unit is always on the path of scaling newer heights.
Distillation
Fi
gure : Barley malt
Malt is Germination cereal grains that have been dried in a process known as
"malting". The grains are made to germinate by soaking in water, and are then
halted from germinating. Malted barley is the source of the sugars (principally
maltose) which are fermented into beer. The malting process allows the grain to
partially germinate, making the seed's resources available to the brewer. The
purpose of malting is to create these enzymes, break down the matrix surrounding
the starch granules, prepare the starches for conversion, and then stop this action
until the brewer is ready to utilize the grain. After modification, the grain is dried
and the acrospire and rootlets are knocked off by tumbling. The kiln drying of the
new malt denatures (destroys) a lot of the different enzymes, but several types
remain, including the ones necessary for starch conversion. The amount of
enzymatic starch conversion potential that malt has is referred to as its "diastatic
power". The diastatic power of a particular malt will vary with the type of barley it
is made from. From a brewer's point of view, there are basically two kinds of
malted grain, those that need to be mashed and those that don't. Mashing is the hot
water soaking process that provides the right conditions for the enzymes to convert
the grain starches into fermentable sugars. The basic light colored malts such as
pale ale malt, pilsener malt and malted wheat need to be mashed to convert the
starches into fermentable sugars. These malts make up the bulk of the wort's
fermentable sugars. A simplified diagram of a barley kernel during malting,
showing a progressive picture of how the acrospire (the plant shoot) grows along
one side of the kernel. As it grows, pre-existing enzymes are released and new
enzymes are created in the aleurone layer which "modify" the endosperm (the
protein/carbohydrate matrix starch reserve) for the acrospire's use. Barley malt is
the major source of brewers extract in the India.
7
STEEPING:
i)
ii)
iii)
iv)
v)
vi)
vii)
xix) At the end of germination the Acrospore should 3/4 th of length of the
corn.
xx) At the end of the germination period the moisture should be 41 42 %
xxi) The diastatic power of Enzyme development will be maximum.
xxii) Spread out thinly until the rootlets begin to dry and grain now reffered
to as green malt Becomes mealy- Malsters call this modification.
xxiii) And gauge the progress made by biting the grain to taste its sweetness
and rubbing it to assess its texture.
xxiv) If the grain is chalky & smooth it is ready.
xxv) If lumps remain it is under modified, the degree of modification may
make a difference to the overall flavour of the malt alcohol.
xxvi) Formation of hydrolytic enzymes and degradation of grain structure
KILNING/DRYING:
i)
ii)
10
If the peat is used the air temperature must be kept below 60 0C, it
helps to maintain distinct characteristics of Phenolic compounds.
xvi) Lower the temperature higher the level of peatiness communicated to
the malt.
xvii) Dried over fires of coke and peat in the pagoda shaped kilns.
xviii) The kiln between drying the green malt to a suitably low moisture
level for storage.
xix) Finally there may be cooling phase where the temperature is lowered
to about 300 C to prevent further curing of malt.
xx) The whole exercise takes between 20 to 48 hrs, depending upon type
of kilning process is being used, the size of the kiln & amount of malt.
xxi) Curing to give appropriate flavour and retaining sufficient enzyme
activity.
xxii) The kiln temperature is increased slowly over 48 hrs periods to
achieve an even rate of drying and the desired flavour.
xxiii) The latter character is achieved by fuelling the furnace with peat
during the early part of the kilning period when the green malt is
moist and readily absorbs the peat smoke.
xxiv) In mechanical maltings the green malt is dried at a faster rate with a
forced air draught.
xxv) The amount of peat used varies with different maltings.
xxvi) Malted barley used in the mash contains sufficient enzyme activity to
convert all of the starch in the mash into fermentable sugars.
xxvii) Malts used in production of malt whisky have a nitrogen content of
1.8% or higher (Compared with brewers malt barley with N2 c 1.5%).
xxviii)
Peat smoke contains a wide range of compounds.
xxix) The peaty character is imparted to the malt barley largely as a result of
absorption of phenols.
xxx) Malt content 10 ppm phenols.
xxxi) Malt having 12 % moisture is allowed.
xxxii) 1 MT of peat must be used for drying each MT of malted barley.
Six compound namely furfural, 5-methylfurfural, guiacol, phenol, pcresol and 5-xylenol detected in the aqueous fraction on GLC
xxxiii) 3, 5-xylenol is marked by the peaks of m-ethylphenol and pethylphenol, two compounds make an important contribution to peat
aroma & taste.
xv)
11
Measurement
Barley
Malt
Brewers
Distillers
(High Distatic)
Kernal
Plumber
Heavier
32-36
29-32
29-32
Germination
content, %
moisture -
43-46
42-45
71-82
49-60
Final moisture, %
4.0
5.0-7.0
Starch, %
55-60
50-55
50.55
Sugar, %
0.5-1.0
8.0-10.0
8.0-10.0
Total N2, %
1.6-2.3
1.6-2.3
1.6-2.3
Soluble N2, %
10-12
35-45
40-50
10
Distatic power
50-60
100-150
150-200
11
-amylase
Trace
35-40
55-65
12
Proteolytic activity
Trace
15-20
20-25
Barley characteristics:
Selection of barley variety depends on availability and cost
1995 IOB Barley Committee defined:
High priorities:
i) Hot water extract over range of TN( Total Nitrogen)
ii) High fermentability
iii) Low gelatinisation temperature
iv) Rapid, even and complete modification
v) High predicted spirit yield (PSY)
Medium priorities:
i) Low malting loss
ii) Appropriate pentose/pentosan balance
iii) Low mycotoxins
Malt specifications:
Diastatic Power a measure of the starchhydrolysing enzymes in a malt,
principally -amylase and amylase.
For grain distilling need very distilling, high DP malt
Historically, very high DP malt (200oIOB)
imported from Scandinavia where barley varieties and climate made it possible
PSY Predicted Spirit Yield litres of pure
alcohol per tonne of malt. Theoretical maximum about 430 lpa/t
13
Mashing:
Premasher Grist is mixed with hot water to form a homogeneous mixture.
i) The proportion of one part grist and four part of water.
ii) Mash Tun or Lauter Tun The above mixture is heated upto 60 - 650C and
held at that temperature for approximate 1 hour.
iii) The enzymes of malt (particularly the -amylase and -amylase) breakdown
the starch to fermentable sugars.
iv) The liquid extract has Sp. Gravity 1.060 1.070
v) First aftermash has Sp. Gravity 1.030.
14
vi) Second ( Sp. Gravity 1.010 & third aftermash (Sp. Gravity 1.006) is recycle
to mash preparation tank.
vii)
The liquid extract & first aftermash having Sp. Gravity 1.045 1.060
and pH 5.5, Amino nitrogen content of about 150 180 mg/lit.
viii)
The conversion of starch to fermentable sugars is confirmed by Iodine
test 0.05N Iodine = Gives blue colour in presence of starch.
Filtration:
i)
To produce fermentable wort.
ii)
In lauter tun or wash holding tanks.
iii) During fermentation water is added to extracts sugars as much as possible.
iv) The wort sp. Gravity is adjusted to about 1.045 1.060 before fermentation.
Brew House Section flow chart procedure:
BARELY MALT SILO
CLASSIFIER
DESTONER
MALT MILL
GRIST CASE
LAUTER TUN
15
BM
A
1
M
BM
M
D
DESTONER
B
M
D
CLASSIFIER
I
C
M
MALT MILL
M
M
2
12345678-
GRIST
1
CASE
-2
COLLECTION
COLLECTION
COLLECTION
HOT
MOTOR PUMP
M
WATER
LAUTER TUN
16
The malt that is used in The Malt Spirit Plant is malted barley bought
from Haryana and Punjab. It is unloaded in a Malt Silo which has a
capacity of 750 MT. Except the conveyor below the silo all the
conveyors are automatic and controlled from the control room. It has
to be manually operated from the control panel near the silo. The malt
is first sent to the classifier through bucket elevators where the ropes
and any large impurities are separated from the malt. Then it is sent
through a destoner where the stones in the malt if any are removed. It
is sent through a pair of magnets which traps the iron particles and dirt
in the malt before sending it to the Mill. In the mill, it is crushed
between four rollers. The gap between the 1 s t two rollers is 1.2 inches
and the next two is 0.7 inches. A sample of this milled malt is
collected and its sieve analysis is carried out. Its ratio of Large:
Moderate: Fine malt is approximately about 70:20:10. This is called as
Grist Ratio. The malt from the mill is then sent to the Grist Case
through bucket elevators. A fixed amount of malt is required for
preparing a brew. It is about 8000kg of malted barley.
Brewing Section:
Mashing is the first step of brewing where the malt is mixed with hot
water at a temperature of 65C. 320Hl (Hecto-liter) of water and weak
wort obtained from the previous brewing process is added to the
Lauter Tun for mashing. 20Hl of that volume is sent in to the lauter
tun through the underlet. During this process, 1600ml of Amylo
enzyme is added to the mash. Amylo breaks up the starch into simple
sugars like glucose and maltose which are easily used up by the yeast
17
19
5. LAUTER TUN:
1.
MASHING PROCESS :
Malt Charge: 107 * 75 kgs bags = 8000 Kgs in Grist Case .
Grinding time: 2 hrs - Grinding time is dependent on the malt mill & cleaning
equipments capacity, however milling time should not exceed brewing time
Grist Ratio: 20:70:10 (Mesh size BSS-10 BSS-85)
Initial water in LAUTER TUN adding under let 20 HL then 320 HL (32000 Lit
Weak wort of previous batch & Hot water) with Malt Grist Case is 8000 Kg
homogenously mixing and Grist water ratio: 1:4
20
22
LAUTERING PROCESSES :
The grist is fed into the Lauter Tun for mashing, with the help of a motor and hot
water from hot water tank. The entire grist from grist case, i.e. 8 Ton, is emptied
into the lauter tun. The grist is mixed with 32,000 liters (320 HL) of water at 65C
and stirred with the help of racking arm, for 27 minutes. This process is called
mashing. The temperature of water is maintained by the mixer, by mixing water
from hot water tank and cold water tank. During mashing, the starch gets
dissolved into the water and percolates through the layer of husk formed during
mashing and further seeps through flush plate into the Intermediate Wort
Collection Tank, having a capacity of 30,000 liters (30 HL). After mashing, the
lauter tun is given rest and recirculation is done for 30 minutes. During
recirculation, the wort collected, is pumped back into the lauter tun and collected
again to have uniform gravity.
Now, after recirculation the first wort collection starts and it lasts for about 65
minutes. As the wort collection starts, the wort collected in intermediate-wortcollection tank starts flowing into wort receiver tank, having a capacity of
100,000 liters (100 HL). The wort collection in these 65 minutes is about 220 HL
in volume. So wort is collected and simultaneously sent to process ahead for
further processing. The collected wort has gravity about 1072 to 1074 and its
temperature is around 65-67C.
After first wort collection, first sparging is done. During first sparging, 180 HL
of hot water at 85C is sprinkled over the mash in about 22-24 minutes.
Then the mash is left still for 20 minutes, so that remaining starch could also
dissolve in water. After this, second wort collection is done for about 45-50
minutes. The volume collected this time is about 200 HL and has gravity lying
23
between 1038 and 1042. The temperature of wort collected second time is higher
than that collected before i.e. 81-83C.
Second wort collection being done, second sparging begins in lauter tun. It goes
on for about 30 minutes and it consumes about 220 HL of water, at 95C. The
mash is allowed to rest for 10 minutes and then weak wort collection begins. In
about 30 minutes of collection time over 220 HL of weak wort is collected. After
the collection, the lauter tun is given a rest for 5 minutes. The weak wort is
collected in Weak wort tank & is used in mashing of next batch.
When all wort has be extracted out of the mashed grist only spent grain remains in
the lauter tun. So the process of empting the lauter tun begins with spent grain
discharge. Within 15 minutes, the entire spent grain is removed from the lauter
tun into the dump tank. This is done by rotating the racking arm at lower height in
the lauter tun. But before the lauter tun is ready.
MASHING EFFICIENCY:
Note:
* 100
THEROTICAL YIELD
PR. YIELD =VOL.OF FERMENTED WASH * ALCHOL IN WASH *100.
THEROTICAL YIELD = (WORT VOLUME * Brix *0.644) / 100.
DISTILLATION EFFICIENCY (DE ) % :
DE % = PRACTICAL YIELD
* 100
THEROTICAL YIELD
PRACTICAL YIELD: FMS PRODUCED( BL) *STRENGTH OF FMS IN %V/V
100
THERO. YIELD: VOL.OF WASH CHARGE D * ALCOHOL IN % IN WASH
100
OVERALL EFFICIECY %: (ME/100*FE/100* DE/100 )* 100
25
FOR EXAMPLE:
26
7. WATER SECTION:
HOT WATER
TANK 500HL
AAA
98C
TANK
WEAK WATER
AMBIENT WATER
TANK 500HL
TANK 500HL
75C
PHE
P-pump
The water section consists of three tanks: Ambient Water Tank, Hot
Water Tank and Weak Wort Tank. Hot water tank is used for collection
of hot water that utilizes for sparing to Lauter Tun. Hot water tank
capacity as 500HL which is collected from Wort PHE through Hot
water line and other from a Fermenter PHE Hot water receiver line.
Ambient Water Tank is the tank which gets it water from the WTP. Its
water is used for all general purposes like cleaning and washing of
laboratory equipments. It is used in hot water make up through CIP
PHE and Hot Water PHE. The level of the Ambient water tank is
always maintained at a higher level. The temperature of the hot water
in the Hot Water Tank is maintained by hot water circulation through
the hot water PHE. Similarly the temperature make up can be also
done for the Weak Wort Tank.
27
8. FERMENTION:
vessel and add dry Yeast 8 Kg with supply air to bub vessel. The yeast
cells in the wort utilize the glucose in the wort and convert it into
ethanol at 21C. The fermentation process time minimum 45Hrs,
typically for 50 to 72hrs. The initial sp. gravity of the wort in the
fermenter is 1.050 and the finial fermentation process ceases when the
sp. gravity falls to 1.000. The sp. gravity and pH of the sample from
the fermenter is estimated every 4hr. the pH of the sample should be
around 5.5. During fermentation, CO 2 gas is released from the
fermenter through an outlet at the top of the fermenter. When the
fermentation process ceases, the evolution of CO 2 gas also stops and
the fermented wash is sent to the Still House Section for Distillation.
28
BUB
VES
SEL
FERMENTATION SECTION:
F
V
1
F
V
2
F
V
3
F
V
4
F
V
5
F
V
6
F
V
1
1
F
V
1
2
F
V
1
3
F
V
1
4
F
V
7
F
V
8
C I P S UP P LY
W O RT
WAS H
CIP RETRUN
F
V
9
F
V
1
0
F
V
1
5
29
F
V
1
6
BUB VEESEL:
Add 8 kgs of dry yeast after collecting 20HL (2,000 Lit) wort at 24 to 26 C
collected in bub vessel aerate with supply air for aeration and transferred to
fermenter after 2 Hrs.
Maximum wort transfer time to fermenter: 180 Min (Wort from the Buffer tank
should be transferred to fermenter before start of next brew)
Fermenter Setup volume: 41000 Lit (410HL) 250 Lit (For 8 MT of Malt)
Set up temp: 20 2C
Setup Gravity: 1.050 2
Final wash gravity: 1.000 1
Alcohol content in wash: 6% 0.25(v/v)
PH: Initial 4.5 to 5 & Final - 3.5 to 3.75
Maxi fermentation temp: 30 2 C
Fermentation time: 48 to 60 Hrs.
30
9. DISTILLATION:
STILL HOUSE SECTION:
Wash Distillation
Spirit Distillation
Maturation
Blending and Packaging
31
Purifier:
32
Role of copper:
Copper important role in determining spirit character..
Formation of desirable congeners.
Removal of undesirable congeners.
Particularly removal of sulphur containing Compounds.
influenced by still and condenser surfaces.
- Copper is the material of choice for pot still fabrication, because of the ease with
which it can be worked and its chemical benefits.
Copper removal:
Cu content in pot ale (30 50 mg/l) and spent lees more in spent lees
Cu Level in Spirit is low (0.5 3.0 mg/l)
Anaerobic and aerobic treatment of spentlees and other effluents concentrates the
Cu in the sludge (50 100 mg/l)
When land sprayed, Cu can build up in the soil or run off into water courses.
Conventional effluent treatment:
Conventional effluent treatment will concentrate the Cu in the sludge
Treated effluent may still be too high in Cu for water course discharge eg
Glenfiddich wetlandsproject absorbed into willow trees
Sludge will have high Cu level (50 100 mg/l)
Therefore sludge disposal may be an issue may need to incinerate or bury,
rather than land spraying.
Other treatments:
Lime treatment of spent lees before conventional effluent treatment
Ion exchange + acid addition + electrolysis of eluate.
A) Wash distillation:
The wash (typically 89% (v/v) ethanol) is used to charge the still to about two
thirds capacity; wash is usually at least 48 hours old
Boiling starts at about 92C and excessive frothing must be avoided to prevent
foul distillation
Wash preheating may be used to avoid fouling of heat transfer surfaces in the
still
33
Low wines are collected, initially at about 50% (v/v) ethanol, falling to 1%, and
giving a final ethanol content of about 20 to 23% ABV
Residual pot ale contains about 0.1% (v/v) ethanol.
Collection of the wash distillate:
Shell and tube condenser typically consists of bundles of copper tubes that carry
cooling water. This has largely replaced the traditional worm design.
Worm Tubs...
B) Spirit Distillation
Charge contains 2530% (v/v) ethanol and consists of low wines with foreshots
and feints from previous distillations.
Foreshots contain oily and waxy products from the previous distillation (detected
with the demisting test)
First cut typically taken at 7075% (v/v) ethanol
Middle cut is collected as newmake spirit
Second cut typically at 6264% (v/v) ethanol, can be as low as 57% (v/v)
Foreshots and remaining feints are combined with low wines for further
distillation
Important considerations in spirit distillation:
Foreshots and feints can be collected in a separate receiver (FR) and low wine
collected in a separate receiver then combined low wines and feints in a
common charge spirit distillation pot s.
In balanced operation, the charge to the spirit still has a constant composition
and ethanol content .In unbalanced operation, the charge varies in volume,
composition and ethanol content. The resulting spirit will vary from distillation
distillation and batches are combined before filling into casks.
Analysis of newmake malt spirit:
Ethanol (% (v/v))
63.5 Ethyl lactate
4.7 Acetaldehyde
3.2
Ethyl octanoate
1.6 Ethyl acetate
23.7
Furfural
3.3
Diethyl acetal
1.7 Ethyl decanoate
5.7
Methano
l 5.1
Phenylethyl acetate 5.7 Propanol
40.8
Ethyl laurate
2.1
iso-Butanol
79.8 Phenylethanol
3.8
Amyl alcohol
47.7
Ethyl myristate
0.6 Ethyl palmitate
2.7
Ethyl palmitoleate 1.5
iso-Amyl alcohol 142.5 ( Units, except for ethanol, are ppm)
Byproducts of malt distillation:
Pot ale: biological oxygen demand is very high (BOD:25,00035,000 ppm)
combined with spent grains and dried to give dark grains
sprayed on farmland
treated in an effluent plant to reduce BOD
discharged to sea
Spent lees: BOD is quite low (BOD:1,0002,000 ppm)
treated in an effluent plant
discharged to sea.
35
37
10.
CIP SYSTEM:
38
11.
MATURATION HALL:
39
Scope:
Mechanisms of maturation
Oak wood extracts
Changes of components in unaged spirits
Changes in ligninrelated compounds
Changes in the physical properties of spirits
Impact of filling strength
Cask size.
Mechanisms of maturation:
Direct extraction of wood components
Decomposition of macromolecules in the wood and
their extraction into spirit
Reaction of wood components with new make spirit
Reactions involving only extracted wood components
Reactions involving only spirit components
Evaporation of low boiling componens
Formation of ethanolwater clusters
Oak wood extracts:
A wide range of sugars and glycerol are extracted from wood into maturing spirit
Arabinose, xylose and glucose are extracted more rapidly initially, whilst fructose
and glycerol are extracted more rapidly later on during maturation
Changes in physical properties
during maturation:
When ethanol and water are mixed together, the properties of one influence the
other
The structure of water is highly complex, involving a substantial degree of loose
connections, or bonds, between adjacent molecules
These connections make water much less volatile than would be expected for
such a small molecule.
Critically, nature favours such bonds as they reduce the energy in a body of
water.
There has been substantial progress in understanding the changes in the analytical
composition of maturing spirit
Additionally, there have been some clear observation on subtle but important
changes to the physical properties of spirit as it matures
The changes in compositional and physical characteristics will affect the sensory
characteristics of the final spirit
Blending complicates this relationship further.
40
12.
UTILLITIES:
41
Consumption by
Malt Spirit Plant
Unit-I (Bottling
3.
Section)
Cooling Towers (Soft
70,000-80,000
4.
5.
6.
Water)
Boiler (Soft Water)
Unit-II
Canteen, Toilets and
70,000-80,000
50,000-60,000
Variable
Others
* t h e s e a re a p p r o xi ma t e v a l u e s
If the river water has a good flow rate it is sent in to the Lamella
Classifier through dozing pumps which adds hypo-chloride to the
water. In this, the mud settles down. It is separated and removed from
the bottom of the lamella classifier. The water then is sent in to the
Collection Tank (CT) and if it doesnt have a good flow rate then it is
directly collected in the CT via a bye-pass connection. The water from
the ETP and bottling section of Unit-I is sent through the zigzag
(snake) settler then collected in the CT. Water from the CT is then
passed through a sand filter twice. Sand filter consists of layers of
sand and pebbles which traps in the dirt from the water. In short, it
reduces the turbidity of the water. The sand filter is cleaned as and
when required by back-washing wherein water is pumped in through
the sand filter in reverse direction at high pressure to remove all the
dirt from it. The outlet water from the sand filter is sent in to a Carbon
filter. It consists of activated carbon which entraps the organic
materials if any from the water thus losing its bad odor and the water
42
now becomes odorless. The carbon filter is also cleaned by backwashing. The water after this treatment is mostly used in the plant. But
for the boiler and cooling towers this treated water is sent through a
Softener where the hardness of the water is removed. The Mg and Ca
salts are removed from the water by NaCl in the Softener. The Na
replaces the Mg and Ca from their salts thus making it soft and making
it useful for the boiler and cooling towers. The soft water when passed
through the RO (Reverse Osmosis) filter makes it drinkable; this water
can be used in the Malt Spirit Plant as well. But recently, the RO filter
is not used as the membranes in RO filter are damaged and the water is
not been purified efficiently.
STORA
GE
FOR DOMESTIC
CONSUMPTION
IN PLANT
TANK
CARBON
FILTER
CARBON FILTER
TO UNIT
SAND FILTER
SOFTEN
ER
CATION
RAW WATER
43
TO BOILER
CANDLE
LAMELLA
CLARIFIER
STORAGE
WATER TREATMENT
PLANT
LAYOUT
UNITED
SPIRITS LIMITED,
RAW
WATER FROMCHLORINE
KADWA
FILTER
ALUMTANK
ADDITION
PART
NASIK1
RIVER
DOSING
TO UNIT
1
EXCHANGE
R CARBO
DM
WATER
NANION
MBR
TO STILLHOUSE
DEGASE
STORAGE
FILTER TANK
2.
BOILER SECTION :
The boiler forms the core of the Steam system of the plant. The boiler
generates steam for usage in the Malt Spirit Plant. The major
proportion of the steam supplied by the boiler is used for the purpose
of heating in the Distillation Section of the Malt Plant. Rest of the
steam is required for heating of water through Plate-type Heat
44
The soft water to be converted into steam is stored in a tank at the top
of the boiler. The water still has a hardness of 5ppm hence a chemical
called sludge-conditioner is added to the water in this tank so that the
dissolved solids of the water does not get deposited on the walls of the
Steam Drum after formation of steam from it. The Steam Drum is the
place where the actual steam is formed from water. Water is also filled
in tubes and is circulated around the furnace of which steam is formed
and is sent back to the Steam Drum. The steam to fuel ratio is about 35 for this boiler i.e. 3-5 kg of steam can be produced by burning 1kg
of fuel in this boiler. The produced steam is supplied through insulated
pipes to the malt plant. It is insulated with thick layers of glass wool
still 2% of steam is lost in the process. The steam is produced with a
pressure of about 15.5 kg/cm 2 (maximum up to 17 kg/cm 2 ). In the malt
plant, the pressure is reduced to about 3 kg/cm 2 and then it is used.
Some amount of condensate is produced while supplying the steam to
the plant; it is removed by means of steam trap at specific intervals.
After the usage of steam, the condensate is collected and sent back to
the boiler. It forms about 50% of the total water used in the boiler and
thus water is made up for generation of the required amount of steam.
EFFLUENT TREATMENT PLANT:
TSS
3.2 to 3.8
50000 to 70000
mg/L
15000 to 20000
mg/L
Flow
150 m3
COD
Spent lees
pH
CO
D
TSS
Flo
w
4 to 5
5000 to 10000 mg/L
-150 m3
ETP treats the water in two stages. The working of the stages of ETP
can be explained with the help of following flow diagram:
Stage - I:
Settlin
Settlin
47
nake Settler
g Tank
I
g Tank
II
UASB
Lamella
Filter
Buffer Tank
Degasser
Cl. II
SDB
Chlorine
Contact
Tank
Bioreactor
Tank II
Cl. I
Bioreactor
Tank I
Mixing Tank
Sand
Filter
POND
The potale and spent lees is released to the snake (zigzag) settler of
the ETP where the heavy particles settle down and it is collected
Settling Tank I. It is called the Neutralization tank because here lime
(Ca (OH) 2 ) solution is added to the effluent which neutralizes the acid
content of the effluent. Then from the Settling Tank II it is sent to the
Lamella filter from where the sludge that settles down is collected in
SDB (Sludge Drank Bed). The effluent from the top is sent to the
buffer tank where the pH is brought to 6.5-7.5 by addition of buffer
solution. From the buffer tank it is pumped to the UASB (Underflow
Aerobic Sludge Blanketing) tank. Here it is aerated with oxygen in an
enclosed tank and methane gas is released in this tank which is burnt
to form a flare. The effluent through the Mixing tank is sent to
48
SPENT
LEES
BIOREACTO
R1 1
MIXING
TANK
CIP
SD
&FLOOR
B
LAMELL
RECYCLIN
SETTLIN
CLEANING
SETTLI
BUFFER
TANK
AFILTER
UASB
GTANK2
SNAKE
DEGAS G
NG
EFFLUENT
TREATMENT
SPENT
PLANT,
GUARD
POND
MGF
49
CLAFIFIER
1
SAN
BIOREACTOR
D CLARIFIER
IRRIGATIO
CCT
CCT
PERMEATE
BASKE
2
REJECT
WATER
MBBR
SDBCLARIFIE
AGFBOTTLING/W
T TANK FOR
GARDENIN
MIXING
UTILIZATION
ULTRAFILTRATI
IN
13.CONCLUSION:
This training program has opened new vistas of wisdom as to how a
production company functions coordinating the various arms of the
administration.
50
51
52
Wort
Malted Barley
Wash
Distillation
Milling
FMS
Mashing
53
Fermentation
MAINTENANCE:
Maintenance is one of the most crucial departments of the company. A
good bunch of Mechanical and Electrical engineers comprises this
department. They have knowledge of every machinery and system in
the plant. For any breakdown or improper functioning of any system in
the plant, the maintenance department is approached which solves the
issue and brings back the system to normal functioning to the earliest.
There are four important functional components which comes under
maintenance
Machine parts
Power
Water
Air
daily
readings
are
recorded
to
keep
control
on
over-
55
1. ACCOUNTS:
Accounts department mainly deals with the money matters. It deals
with transactions done and payments that has to be made. SAP (Simple
Application Program) plays a very crucial role in maintaining the
accounts of the unit. SAP is intranet software which has different
modules in it of which one is accounting. Accounting gives a platform
to all the departments of the company to update the expenses incurred
in their department and the capital that is required for further dues. It
reduces a lot of paper work and book-keeping as everything becomes
online. Accounts manager analyzes the data in SAP with the actual
data and makes the changes that is required if any. The company
appoints an auditor to do the audit of the company it is called as
internal audit. And the Government of India appoints an auditor to do
the audit of the company after the internal audit; it is called as the
external audit. Audit of the company is done in order to find any cases
56
57
UTILITIES:
1.1
WTP is the most crucial utility of the plant as it is the only soft water
source for the plant without any impurity. WTP is a 24-hr working
58
utility and it provides the major chunk of its treated water to the Malt
Spirit Plant, Bottling section of Unit-I, Boiler, DMW plant, Cooling
Towers and Unit-II. Boiler, Cooling Towers and the DMW plant is
supplied with Soft water whereas others are supplied with primarily
treated water. The major source of water for the WTP is from a nearby
river called Kadhva River and a stream of that river. It supplies about
1.4L - 1.6L liters of water to the WTP. The ETP (Effluent Treatment
Plant) from where the treated water can be further treated in order to
make it useful for production. It supplies about 2L liters of water to
the WTP. Bore well is another major water source which supplies
about 2L liters of water to the WTP. The Bottling Section of Unit-I
also supplies about 1L-2L liters of water to the WTP for treatment. In
case of water shortage, the company supplies water to the WTP from
external sources like water tankers. The WTP treats about 6.5L - 7L
liters of water a day which is sufficient for the smooth functioning of
the entire plant.
Consumption by
Malt Spirit Plant
Unit-I (Bottling
3.
Section)
Cooling Towers (Soft
70,000-80,000
59
4.
5.
6.
Water)
Boiler (Soft Water)
Unit-II
Canteen, Toilets and
70,000-80,000
50,000-60,000
Variable
Others
* t h e s e a re a p p r o xi ma t e v a l u e s
If the river water has a good flow rate it is sent in to the Lamella
Classifier through dozing pumps which adds hypo-chloride to the
water. In this, the mud settles down. It is separated and removed from
the bottom of the lamella classifier. The water then is sent in to the
Collection Tank (CT) and if it doesnt have a good flow rate then it is
directly collected in the CT via a bye-pass connection. The water from
the ETP and bottling section of Unit-I is sent through the zigzag
(snake) settler then collected in the CT. Water from the CT is then
passed through a sand filter twice. Sand filter consists of layers of
sand and pebbles which traps in the dirt from the water. In short, it
reduces the turbidity of the water. The sand filter is cleaned as and
when required by back-washing wherein water is pumped in through
the sand filter in reverse direction at high pressure to remove all the
dirt from it. The outlet water from the sand filter is sent in to a Carbon
filter. It consists of activated carbon which entraps the organic
materials if any from the water thus losing its bad odor and the water
now becomes odorless. The carbon filter is also cleaned by backwashing. The water after this treatment is mostly used in the plant. But
for the boiler and cooling towers this treated water is sent through a
Softener where the hardness of the water is removed. The Mg and Ca
salts are removed from the water by NaCl in the Softener. The Na
replaces the Mg and Ca from their salts thus making it soft and making
60
it useful for the boiler and cooling towers. The soft water when passed
through the RO (Reverse Osmosis) filter makes it drinkable; this water
can be used in the Malt Spirit Plant as well. But recently, the RO filter
is not used as the membranes in RO filter are damaged and the water is
not been purified efficiently.
9.2
BOILER:
The boiler forms the core of the Steam system of the plant. The boiler
generates steam for usage in the Malt Spirit Plant. The major
proportion of the steam supplied by the boiler is used for the purpose
of heating in the Distillation Section of the Malt Plant. Rest of the
steam is required for heating of water through Plate-type Heat
Exchangers (PHE). Some of the steam is also required for sterilization
of fermenters before initiation every batch of fermentation.
61
There are three boilers in the plant. The capacity of the boiler is
measured in TPH (tones per hour) the capacity of these three boilers is
4TPH, 10TPH and 20TPH. The 4TPH and 10TPH boilers are shut down
for time being and only the 20TPH boiler is functioning. It is a firetube boiler and can produce about 20 tonnes of steam per hour. It runs
24-hrs a day. It is a multi-fuel boiler with less carbon foot-print.
The boiler gets about 80,000 liters of soft water every day from the
WTP to meet the requirement of steam in the Malt plant. The Malt
plant requires about 250 tonnes of steam per day. Coal is used as the
chief fuel for the boiler. Bagasse and Briquettes are also used as a fuel
for the boiler. Bagasse is the left-over of sugar industries whereas
Briquette is agro-waste from the nearby fields. It consists of left-over
part of maize and jowar plants which are mixed with a small amount of
water and pressed in the form of cakes. The fuel is fed to the mill from
separate feed points which is milled and brought into a desired
proportion for combustion. The fuel then with the help of bucket
elevators and conveyor belts is lifted up and fed to the furnace
intermittently. The proportion of the fuel to be fed to the furnace is not
fixed and is added in order to maintain the temperature of the furnace.
The temperature of the furnace at the bottom where the actual
combustion takes place is about 1300C and at the top is about 600650C. For combustion to take place inside the furnace, air is blown
into the furnace from the bottom through two Air compressor pumps.
The soft water to be converted into steam is stored in a tank at the top
of the boiler. The water still has a hardness of 5ppm hence a chemical
called sludge-conditioner is added to the water in this tank so that the
62
dissolved solids of the water does not get deposited on the walls of the
Steam Drum after formation of steam from it. The Steam Drum is the
place where the actual steam is formed from water. Water is also filled
in tubes and is circulated around the furnace of which steam is formed
and is sent back to the Steam Drum. The steam to fuel ratio is about 35 for this boiler i.e. 3-5 kg of steam can be produced by burning 1kg
of fuel in this boiler. The produced steam is supplied through insulated
pipes to the malt plant. It is insulated with thick layers of glass wool
still 2% of steam is lost in the process. The steam is produced with a
pressure of about 15.5 kg/cm 2 (maximum up to 17 kg/cm 2 ). In the malt
plant, the pressure is reduced to about 3 kg/cm 2 and then it is used.
Some amount of condensate is produced while supplying the steam to
the plant; it is removed by means of steam trap at specific intervals.
After the usage of steam, the condensate is collected and sent back to
the boiler. It forms about 50% of the total water used in the boiler and
thus water is made up for generation of the required amount of steam.
9.3
DMW plant:
63
TSS
3.2 to 3.8
50000 to 70000
mg/L
15000 to 20000
mg/L
Flow
150 m3
COD
Spent lees
pH
CO
D
TSS
Flo
w
4 to 5
5000 to 10000 mg/L
-150 m3
ETP treats the water in two stages. The working of the stages of ETP
can be explained with the help of following flow diagram:
9.4.1.
Stage - I:
65
Snake Settler
Settlin
g Tank
I
Settlin
g Tank
II
UASB
Lamella
Filter
Buffer Tank
Degasser
Cl. II
SDB
Chlorine
Contact
Tank
Bioreactor
Tank II
Cl. I
Bioreactor
Tank I
Mixing Tank
Sand
Filter
POND
The potale and spent lees is released to the snake (zigzag) settler of
the ETP where the heavy particles settle down and it is collected
Settling Tank I. It is called the Neutralization tank because here lime
(Ca (OH) 2 ) solution is added to the effluent which neutralizes the acid
content of the effluent. Then from the Settling Tank II it is sent to the
Lamella filter from where the sludge that settles down is collected in
SDB (Sludge Drank Bed). The effluent from the top is sent to the
buffer tank where the pH is brought to 6.5-7.5 by addition of buffer
66
POND
Moving Bed
Bio-film
Reactor
Cl. III
67
AGS
Settling
Tank
SDB
Utilization
in Process
Permitted
Water Tank
Ultra- Filtration
BF &
MGF
Rejec
t
Tank
Irrigation
In stage II, first the treated effluent is collected in a pond. Other waste
water which also has to be treated like sewage water is added to this
pond. This treated effluent from the pond is added to MBBR (Moving
Bed Bio-film Reactor) which is similar to the Bioreactor Tank but is
more efficient in degrading the organic wastes from the effluent. It is
passed through Clarifier III then into the AGS (Accelerated Gravity
Settler) where the degraded contents settles down and is separated.
The sludge is sent to the SDB from the bottom. This treated effluent is
then sent to another CCT and then it is passed through a MGF (Multigrade filter) and BF (bag filter) which filters and removes all the
solids from the effluent making it suitable for Ultra-filtration (UF).
This treated effluent when passed through the UF membranes becomes
suitable for utilization in different purposes other than drinking. The
pore size of the UF membranes is less than 10microns. The rejected
68
69
Malt Silo
Bu cket
Elevator
Screener
Destoner
Bu cket Elevator
Grist Case
Malt Mill
The malt that is used in The Malt Spirit Plant is malted barley bought
from Haryana and Punjab. It is unloaded in a Malt Silo which has a
capacity of 750 MT. Except the conveyor below the silo all the
conveyors are automatic and controlled from the control room. It has
to be manually operated from the control panel near the silo. The malt
is first sent to the classifier through bucket elevators where the ropes
and any large impurities are separated from the malt. Then it is sent
through a destoner where the stones in the malt if any are removed. It
is sent through a pair of magnets which traps the iron particles and dirt
in the malt before sending it to the Mill. In the mill, it is crushed
between four rollers. The gap between the 1 s t two rollers is 1.2 inches
70
and the next two is 0.7 inches. A sample of this milled malt is
collected and its sieve analysis is carried out. Its ratio of Large:
Moderate: Fine malt is approximately about 70:20:10. This is called as
Grist Ratio. The malt from the mill is then sent to the Grist Case
through bucket elevators. A fixed amount of malt is required for
preparing a brew. It is about 8000kg of malted barley.
71
is a CIP inlet and CIP return line for all the fermenters through which
the caustic and hot water is sent in the fermenter and drained off the
fermenters. Steam is also introduced in the fermenter for an hour or so
for its sterilization. The Wort Cooling PHE is also cleaned periodically
by Back CIP where in the Caustic and hot water is sent in through the
PHE in the reverse direction and the casting is cleaned. The cleaning
is mostly done when the flow through the system decreases. It also
consists of a Caustic lye tank through which the Caustic Tank is
refilled. The hot water for the CIP is produced from the CIP PHE using
ambient water and steam.
The Still House Section consists mainly of a Wash Still and a Spirit
Still and collection tanks for collection of different products that are
formed in distillation. There are two wash stills and two spirit stills in
a single phase and there are two such phases in the section. The still
pots are made up of Copper so that it can be easily heated and it has a
conical top to concentrate the flow of gas from the pot. The fermented
wash after fermentation is sent in to the Wash still first of the Still
House Section for distillation. They are charged in equal amounts in
two wash stills i.e. 205Hl in each Wash Still. Steam is supplied to the
still at 10psi till the temperature of the still reaches up to 92C. At this
temperature, the steam supply is cut and then it is slowly supplied to
the still so that the wash does not flow over the conical section of the
pot. After a period of steam supply, at about 100C we get a
condensate from the pot. The condensate is formed by cooling the gas
that comes out of the pot with water from the cooling tower. This
condensate is termed as Low Wine which is about 28proof. From
410Hl of wash about 15,000Bl (Bulk liter) of low wine is produced.
The collection of low wine takes place for about 4hours and its alcohol
content is measured every hour. It is collected in Low wines Tank. The
collection of low wines is stopped at about 2UP (Under-proof). And
the remnant of the pot is collected as potale in the potale tank and is
sent in to the ETP for treatment and disposal.
The low wines along with the Feints generated from the distillation of
last brew are charged into two Spirit Stills in equal amount. About
9000Bl of Feints is generated from every brew bringing the total to
24,000Bl of that 12,000Bl is loaded in each of the Spirit Still. Then
75
76
10.
EHS:
77
11.
CONCLUSION:
79
Mashing efficiency :
1 TRS in Malt found around 77% when HWE is 76%
2 Degree Brix of Wort is directly related to dissolved percent sugar in wort
i.e., 12 degree brix is equal to 12% dissolved sugar.
MASHING EFFICIENCY
% ME
FERMENTATION EFFICIENCY
(Practical Yield/Theoretical Yield) X
%FE
=
100
Distillation Efficiency
%DE
80
Overall Efficiency
%OE
81