MANUFACTURING AND QUALITY ANALYSIS of “BEER”

A Brief History of Beer

4000Bcin the Middle East the super people were fermenting a form of bread make a effect a
divine drink

3000 BC The Babylonians had up to 20 different types of beer. The early beer was cloudy
and unfiltered and was usually drunk through a straw to avoid drinking the solids from the
brew, which could be very bitter.

1550 BC The Egyptians were also keen brewers and beer and malt has been found buried in
the tombs of the Pharaohs to provide sustenance for the afterlife.

100 AD Beer was extensively drunk throughout the Roman Empire. The Romans preferred
wine and introduced grapes into much of the Southern part of the Empire including the South
of England. The local inhabitants tended to drink beer. Beer from this time had to be
consumed fresh, was served cloudy and would have produced little or no foam. To aid its
taste and keeping properties bitter herbs and spices may have been used.

The middle Ages In the Middle Ages the largest brewers were the monasteries. The
refreshing beer made a welcome break in a very austere lifestyle and could still be enjoyed
during times of fasting. Monks soon acquired a taste for ale and records show that in some
monasteries consumption up to five litres a day was allowed.

From 1000 AD most beer was bittered with wild herbs such as bog myrtle (Myrica gale)
often supplemented with lemon balm (Melissa officinal is), borage (Boragio officialis), St
John's wort (Hypericium perforatum) or elderberries (Fructus sambuci nigrae).
The Introduction of Hops Hops are mentioned in records in Germany as early as 822 AD
but their shoots may have been used by asparagus tips. Certainly Hidegarde of Bingen,
writing around 1150 said that hops added to beer 'reduced the putrefaction' caused by
spoilage organisms. The addition of hops slowly spread throughout Europe reaching Britain
by the middle of the 15th century.

The Reinheitsgebot of 1516 The world's first food ingredient regulation is the German
Purity Law or Reinheitsgebot which was first introduced in the Munich area in 1847 and
extended to the whole of Bavaria in 1516. It later included the rest of Germany. The law
stipulated that beer could only be brewed from water, hops and malt -- the use of yeast would
come later, after it had been identified as the organism responsible for fermentation.
The Free Mash Tun Act 1880 Malt was first taxed in Britain in 1660 and the legislation
prohibited the use of other cereals in brewing. This purity act continued until it was repealed
by William Gladstone in 1880 and replaced by a tax on the sugar content of the wort prior to
Fermentation. The repeal followed a bad barley harvest and pressure from the colonial sugar
growers to allow sugar cane to be used in the beer. The new law enabled "the brewer to brew
from what he pleases and have a perfect choice of his materials and methods". The
predominant beers of the day were dark quite sweet and malty - and often served at different
alcoholic strength - strong ale, medium ale and weak ale made from different exracts of the
same brew

BEER is an alcoholic drink which is med from cereals .and it is flavoured with compound
from the cereals, hops (for bitterness) and sugars

Water treatment plant (W.T.P) water is essential in brewing as an ingredient lnd as a process
facilitator. Beer is compound of 90-95 water typically .water impact beer in three awys .water
ions are critical in the mashing process for all grain brewers, where the characters of the
water determines the efficiency and flavour of the extracted word . Water also affects the
perceived bitterness and hop utilization of largest single compound in finished beer

The affect of brewing water on beer can be characterized by six main water ions.

Sodium Carbonate, chloride, sulphate calcium and magnesium

The purpose of water treatment is to

1 softening of water (water hardness)

2 Demineralising of water
The process of removal of harness from water is called softening. Hardening is mainly caused
by the presence of Ca2 and mg2 salts .percentage of water in beer is so high that it is
necessary to use treated water that means demineralised water to improve beer quality ,

The process of water treatment is described by following Sketch.

The water from the activated carbon filter is known as filtered water which is stored and used
in brew house and Packaging.

The water from the softener is called soft water which is stored used in boiler,

Refrigeration washing and filtration .salt is added in water at the time of treatment.

Demineralised water is stored and in sparging. Demineralised water is stored .and used
sparging

Water treatment plant of company

MGF, Gravity filter
Filtration can be compared to a sieve or micro-strainer that traps suspended material between
the grains of filter media. However, since most suspended particles can easily pass through
the spaces between grains of the filter media, straining is the least important process in
filtration. Filtration primarily depends on a combination of complex physical and chemical
mechanisms, the most important being adsorption. Adsorption is the process of particles
sticking onto the surface of the individual filter grains or onto the previously deposited
materials. Forces that attract and hold particles to the grains are the same as those that work
in coagulation and flocculation. In fact, coagulation and flocculation may occur in the filter
bed, especially if coagulation and flocculation before filtration was not properly controlled.
Incomplete coagulation can cause serious problems in filter operation.

Several types of filters are used for water treatment. Early slow sand filters typically have
filter rates of 0.05 gpm/ft2 of surface area and require large filter areas. The top several
inches of the sand has to be removed regularly--usually by hand--due to the mass of growing
material ‘schmutzdecke’ that collects in the filter. Sand removed is usually washed and
returned to the filter. These filters are still in use in some small plants, especially in the
western United States as well as in many developing countries. They may also be used as a
final step in wastewater treatment.
ACF Activated carbon filtration
Homeowners are increasingly concerned about contaminates in their water supply that may
affect health or cause taste and order problems. Sources of these contaminates might include
solvents pesticides ,industrial wastes or contaminates & from leaking underground storage
tanks, contaminates such as benzene, chlorides, and vinyl chloride in dirking water may pose
health risk if they are present in quantities. Above the EPA health Advisory level (HAL)
pesticides such as atrizine, also can pose a health risk if present in quantities above EPA
guidelines. Activated carbon (AC) filtration can effectively reduce some of these organic
chemicals as well as certain harmless test and order producing compound

Some drinking water may be disinfected with chlorine or chloramines. During disinfection
the reaction of chlorine with organic matter can produce compounds such as trihalomethanes
(THMs) as By products. These disinfection by products may increase the risk of certain
cancers. The per billion (PPb) or THM in their treated water AC filtration can be effective in
removing chlorine, chloramines, and some disinfection by products

How Does Activated Carbon Work?

The process of removing contaminants is through catalytic reduction or adsorption.

Adsorption is a process of negatively charged contaminant ions being attracted to the
positively charged activated carbon. Residual disinfectants such as chlorine and chloramines
are removed by catalytic reduction, and organic compounds are removed by adsorption.
Hydrogen sulphide also can be reduced by catalytic reduction. Acidity and the temperature of
the water can be important because greater acidity and lower water temperatures tend to
improve the performance of activated charcoal.

Activated Carbon Filtration Removes contamination compound

Removes organics that can affect taste, odour and colour

Reduces chlorine, trihalomethanes (THM), pesticides, industrial solvents

(Halogenated hydrocarbons), polychlorinated biphenyls (PCBs), polycyclic
Aromatic hydrocarbons (PAHs), radon gases (unknown levels)

Does not remove or reduce microbes, sodium, nitrates, fluoride,

And hardness
Water Softener
The presence of calcium (Ca) and Magnesium (Mg) in water result in water being
considered had calcium and magnesium ions in water

An ions is an atom or molecule that has a positive or negative electrical charge calcium and
magnesium ions are release into water as it dissolves rocks and minerals. These mineral ions
in the water can cause scale buildup in plumbing fixtures and appliances and affect their
performance. In thehot water heater, heat removes some calcium carbonate and magnesium
carbonate from the water, reslting in scale buldup which can then slow the heating process
and increase energy usage cleaning agents used wth hard water are not able to completely
remove dirt and grime. Clothese may. Become dingy and gray with tme and feal heash or
scratchy. Glassware may becomes spotted as it dries.

Films may be left on shower door or curtains wall and tubes and hair washed inhard water
may look dull and feel clean. Hard water is considered a nuisance problem, but removing
hardness ions isn’t. Necessary for health reason.

Treatment principle
Household water softeners are ions exchange devices ion exchange involves removing the
hardness ions calcium and magnesium and replacing them with non-adness ions typical
sodilem supplied by dissolved sodium chloride, salt, or brine

The softener contains a micro porous exchange resin, usually sulfonatad poly- styrene beads.
Thatare super saturated wit sodium to cover thebead surfaces. As water passes through this
resin bed calcium and magnesium ions attach to the resin beads and the loosely held sodium
is released from the resin into the water the softening process is illustrated in after softening a
large quantity of hard water the beads becomes satured with calcium and magnesium ions.

When this occurs, the exchanges resign must be regenerated recharged. To regenerate, the
ions exchange resin is flueded with a alt brine solution are exchanged with the calciu
magnesium ions on the resnand excess. Calcium and magnesium is flushed out with west
water

Demineralised
Demineralization is the process of removing mineral salts from water by using the ion
exchange process.

Demineralized water also known as Deionized water, water that has had its mineral ions
removed. Mineral ions such as cations of sodium, calcium, iron, copper, etc and anions such
as chloride, sulphate, nitrate, etc are common ions present in water. Deionization is a physical
process which uses specially-manufactured ion exchange resins which provides ion exchange
site for the replacement of the mineral salts in water with water forming H+ and OH- ions.
Because the majority of water impurities are dissolved salts, deionization produces a high
purity water that is generally similar to distilled water, and this process is quick and without
scale build-up.

De-mineralization technology is the proven process for treatment of water. A DM Water

System produces mineral free water by operating on the principles of ion exchange,
Degasification, and polishing. Demineralized Water System finds wide application in the
field of steam, power, process, and cooling

Principle:
Raw water is passed via two small polystyrene bead filled (ion exchange resins) beds. While
the cations get exchanged with hydrogen ions in first bed, the anions are exchanged with
hydroxyl ions, in the second one.

Ion Exchange Resins:

There are two basic types of resin - cation-exchange and anion-exchange resins. Cation
exchange resins will release Hydrogen (H+) ions or other positively charged ions in exchange
for impurity cations present in the water. Anion exchange resins will release hydroxyl (OH-)
ions or other negatively charged ions in exchange for impurity anions present in the water.

Figure showing: - W T P Department

 Flow chart:-

NaOCl Raw water tank MGF ACF Softener

Mixed bed Degasser Demineralised
Malt Handling ;- malt is germinated cereals grains that have been dried in a process known
as malting .the grains are made to germinate by soaking in water ,and are that halted from
germinating further by drying with hot air .Malting grains develops the monosaccharide
glucose, the disaccharide maltose , the Trisaccharide Maltoriose, and high sugars called
Maltodextrines. It also develops orther enzymes, such as proteases, which break down the
proteins in the grains into forms can be used by yeast .Malt also contains small amount of
other sugars, such as sucrose and fructose, which are not products of starch modification but
weae already in the grain .

Malting server the purpose of covering insoluble starch to soluble starch reducing complex
protein, generating nutrient fro yeast development and the development of enzymes

The three main steps of the malting process are steeping, germination, and kilning

Barley Steeping:-steeping is to hydrate the endosperm mass and to allow uniform growth
during germination. Steeping begins by mixing the barley kernels with water to raise the
moisture level and activate the metabolic processes of the dormant kernels. The water is
drained and moist grains are turned several Time during steeping to increase oxygen uptake
by the respiring barley.

Barely Germination:-in the germination step the wet barley is germinated by maintaining it
at a suitable temperature and humidity level until adequate modification has been achieved

Malt kilning:-kilning is the final step to dry the the green malt in the kiln at different
temperature. Over a 24 to 48 hour period the green malt ‘is dried carefully, to halt
germination, and to reduce the moisture content from 43%to the required 4.5%. It is vital to
preserve the enzyme, released contend through germination, which enable the final
conversion of starch, fermentable sugar, to be completed during mashing

Malt handling operation:-Malts are purchased in that weigh 50 to 55 K g

Silos:-the malt is conveyed to silos storage. Silos are constructed of galvanized steel, which
offers a higher level of protections from moisture. The capacity of silos is 80,000Kg .after
silos the malt is fed to hopper where it is cleaned and crushed. It includes 3 stages
1. Screener (for removes dust particles)
2. Magnetic separator (which removes ions and other magnetic substances)
3. Destoner (which removes stones from the malt)

Fug:-

Malt supply is getting from malt companies. Each malt packaging contain 70 Kg.
There is seprate room for storage of malt consignments. Malt feeding is done
mannuly.

Malt milling:-in order for that mat components to be rapidly extracted and
converted, the malt is milled to obtaind flour.
Figure.

Ingredients:-
Broken rice:- the c-kernel of rice can become cracked in the field, during the drying
process, or during the milling process. Are usually caused by moisture migrating too
quickly within the kernel (drying too fast, or moisture being added back to aday
kernel). Often these crecks cause the kernels to break during milling and so broken
rice is generated. The percentage of broken kernels (relative to total milled rice)
generated during milling usually ranges from 12% to 24% in the U.S. Most broken are
removed during the milling process to less then 4% in order to give the consumer high
quality rice. Broken rice tend to get mushy during cooking and makes a poor quality
table rice There are different sizes of broken kernels. With long grain rice in the south
broken are after separated into different sizes. From largest to small they kernel are
called second, screening, and brewers. In California, where the kernel is smaller to
begin with, the brokers kernels are only separated into second heads and brewers.

Sugar: - there are three different from of sugar : Glucose, Fructose, and Sucrose.
Glucose comes from breaking down starches into sugar by use of an enzyme called
amylase. Fructose is natural forming sugar in most fruits, like grapes. Sucrose usually
comes from evaporating the sugary sap found in plants like sugar cane beets.
The source of sugar that most beer and ale brewers are familiar with come some type
of grain, usually barley. The Process of forming this sugar Come from taking the
malted grain and steeping in hot water during the “mashing” process. The enzymes
that are in the mashing bath convert the starches in the grain into sugar required for
fermenting.

Another source of sugar comes from fruits used in brewing. Grapes are normally the
first fruit that come to mind since it s the primary component of wine.
The mashing and pressing of the grapes releases the sugar rice juices,which then
proceeds to get fermented to create wine.

Flow chart:-

Silo

Screener
Mailt feeding Buhler

Magnetic
Screener
Grist case

Destoner

Brewing:-

A. Adjunct cooking:- adjuncts can be broadly classified according to the physical

from in which they are used into solid and liquid syrups.

SOLID ADJUNCTS are either starchy adjuncts which need to be converted to

simpler sugar, or solid sugar adjuncts produced which can be added after conversion.
Solid starchy adjunct are normally production from cereals and are used in the from of
flakes, grain, flour or purified starch and must be added before the mash tun to
convert the starch into simple sugar which the standard mashing temperatures must be
cooking to gelatinise the starch before adding to the mash.

Solid sugar adjuncts include granulated sugar and glucose chips.

Liquid adjuncts are either sucrose syrups from a syrups from a grain (maize, rice or
wheat),are added directly to the wort kettle and there for can be used to reduce
loading on the mash lauter tun and effectively increase the brew house capacity

Liquid adjunct may also be added post fermentation as priming’s sugar to give
sweetness to the beer for secondary fermentation as in cask or bottle conditioning.

Adjuncts are unmalted grain such as rice. Adjuncts are used mainly because they
provide extract at a lower cost than is available from malted barley or modify the
flavour of the beer.

Adjuncts are often used fore their flavouring contribution. Rice has a very natural
aroma and teste. Semi- refined sugar add flavour. Adjuncts also alter the
carbohydrate and nitrogen ratio of the wort, there by affecting fromatin of by
product, such as esters and higher alcohol

B.-Mashing: - mashing involves mixing milled malt called grain and adjunct in the
slurry from with water. 25% malt , 15% sugar crystals and rest 60% water us added to
mark the total volume to 250HL in the mashing kettle.
It involves cooking at a 90° C to 100° C.
The flour from the cereals (malt) is mixed with water and subjected to certain
processes to obtain awort of a suitable composition for the kind of beer being
produced (varying time, temperature and PH). There condition encourages the
development of complex starch molecules and proteins in other ones means of
enzymes formed during production of the malt.

Figure:-
C. Lautering:- lauteringis aprocess in brewing beer in which the mash is separated
into the clear liquid wort and the residual grain. Lautering usually consists of 3 steps.
Mashout, recirulation, and sparing. (After mashing, the which is excellent animal
feed)from the wort itself. This is done by passing water through the mash at the right
temperature in a lautertur, which lasts around 2-3hours, conducted at a temperature of
75-82°C,
C. Wort Boiling:- After wort separation, the lear wort is conditioned by boiling in the oat
kette. Bittering hops are added during boiling to maximize isomerisation of their alpha – acid
content and to drive undesirable flavour compound. The purpose of wort boiling is to steblize
the wort extrat the desirable component from the hops. The purpose of boiling is to:

1. Transform and make soluble the bitter substances in the hops:

2. Establish the final concentration of wort.

3. Provoke the precipitation of protein of high molecular weight:

4. Esteblish the final concentration of wort

Figure:-

d. Whirl pooling: - at the end of the boil. Wort is set a whirlpool. It forces the densor solids
coagulated proteins and hops in to a cone in the center of the whirlpool tank. There tanks
have a large diameter to encourage settling. A flat bottom , a tangential inlet near the bottom
of the whirlpools, and an outlet on the bottom near the outer edge of the whirlpool. It has a
total volume of 290 HL . After boiling, it is necessary to separate the precipitated protein and
the insoluble hop components from the hot wort. Separation is carried out in “whirlpool”
with the application of centripetal force. ZnSo4 & fungamyl is added to the

Whirlpool -ZnSo4 acts as a coenzyme where as fungamyl is added as a yeast food.

Figure:-

e. Wortcooling: - After the whirlpool, the wor be brought down to fermentation

temperatures (2-26 Celsius) before yeas is added. In modern breweries this is achieved
through plates, heat exchanger. A plate heat exchanger has many ridged plaates, which from
two separate paths. The wort is pumped into the heat exchange, and goes through every
orther gap between the plates. Tha cooling medium, usually water, goes through the other
gape. The ridges in the plates ensure turbulent flow. A good heat exchange can drop 95° C
wort to20° C while warming the cooling medium from about 10 C to 80 C. the last few plants
often a cooling medium which can be cooled to below the freezing point, which allows a
finer control over the wort-out temperature, and also enables cooling to around 10° C. After
cooling, oxygen is often dissolved into the wort to revitalize the yeast and aid ist
reproduction. Use

While boiling, it is useful to recover some of the energy to boil the wort. On its way out of
the brewery, the steam created during the boil is passed over a coil through which unheated
water flows. By adjusting the rate of flow, the output temperature of the water can be
controlled. This is also often done using a plate heat exchange. The water can be controlled.
This is also often done using a plate heat exchange. The water is then stored for later use in
the next mash, in equipment cleaning, or wherever necessary.

Anther commen method of energy recovery takes during the wort cooling.

When cold water is used to cool the wort in a heat exchanger, the water is significantly
warmed. In an efficient brewery,cold water is passed through the heat exchanger at a rat set to
maximize the temperatures of water upon exiting. This now hot water is then stored in a hot
water tank.

6. Yeast is the most impotent ingredient in brewing beer responsible for metabolic processes
that product ethanol. Carbon dioxide and a range of metabolic by product that contribute to
the flavour of Beer. There are two types of beer yeast. Ale yeast (the” top fermenting”) type
(Saccharomyces cerevisiae) and lager yeast (the “bottom – fermenting”type, saccharomyces
pastorianus, referred as saccharomyces carlsbergenesis or saccharmmyces uvarum). top
fermenting yeast produce beer that are more estery, and sometime malty , where as bottom –
fermenting yeast product give beer a characteristics sulphurous aroma.

Ale (top fermenting yeast)- Ale yeasts ferment at warmer temperature as high as a 24° c .
pure ale yeast from foam on the surface of fermenting beer , because of this they are often
refferd to as top- fermenting yeasts. Ales are generally ready to drink within three week after
the beginning of fermenting

Lager (bottom- fermenting Yeast )- lager yeasts tends to collect at bottom of the fermentor
and is often refferedb to as bottom fermenting yeasts. Lager is fermented at much lower
temperatures around 10° c comprared to typical ale fermenting temperatures of 18° c
A Yeast Quality parameter:- Yeast are unicellular micro-organisms which can obtain the
energy they need in the presence of oxygen

(aerobic) by respiration and in the absence of oxygen

(Anaerobic) by fermentation .

During beer production the sugar in the wort is

Fermented by the yeast into alcohol. For this purpose

Yeast fungi of the species saccharomyces cereviae are

used selected strain of this yeast are systematilly

isolated and grown as pure culture brewers, yeast

Because yeast does not only product alcohol during

Fermentation but range of other flavour materials, its

Metabolism has a great influence on the taste and

Character of the beer. Knowledgfe of the stuctures and

Composition of yeast, their metabolism and their

Growth is impotent in producing high quality beer. Yeast cell contain about 75% water. The
composition

Of yeast dry matter consist predominantly of protein. And carbohydrate:

Protein 45- 60%

Carbohydrate 25- 35%

Fat 4- 7%

Inorganic 6- 9%

In addition yeast has a high vitamin and enzyme

Content, the main vitamins in yeast are B1 and B6

b. yeast pitching:- while transferring chilled and aerated wort in fermenting vessel (unitank) it
is needed to pitch yeast to metabolize bwort ( fermentable sugars.)

Figure;-

Fermentation: -
Fermentation is the term used by microbiologists to describe any process for the
Production of a product by means of the mass culture of a microorganism.

At this point in the brewing process the purpose of each preceding process has been to set up
nutrients for the yeast.

Fermentation is where yeast is added to the wort, converting the wort into alcoholic
The cooled wort is delivered from the brew house to the fermentation ceiiar where it is stored
in the starting tanks. Yeast slurry

Is added (pitched) into the starting tanks, initiating the primary fermentation process. The
temperature in the starting tank

Must be strictly controlled to maximize the fermentation Process. Excessive heat (greater
than 14 c) can allow unwanted

By-products to be formed,impacting the final taste and quality of the beer.

During the primary fermentation process, sterile air or oxygen is injected into the bottom of
the tank to support the living

Yeast and ensure that all sugars are consumed by the yeast and converted to alcohol. The
primary fermentation process, takes

Between 3 to 5 day to complete. During this process, a considerable amount of carbon

dioxide is generated which can be

Captured ford downstream caronization of the finished beer, for purging oxygen from
storage tanks or sold to other users of co2

At the conclusion of the primary fermentation, larer beer are cooled to around 1 c and
transferred to lag erring tanks for the

Secondary Fermentation.- This also known as the as the aging process. The lagering tanks are
sealed and the fermentation process Continues for7 to 24 days. During this time, most of the
yeast will settle to the bottom of the tank.

How yeast make Alcohols and carbon dioxide: - when the yeast first hits the wort,
concentration of glucose (C6 H12 O6) are very high, so through diffusion. Glucose enters the
yeast (in fact, it keeps entering the yeast as long as there s glucose in the solution).As each
glucose molecule enters the yeast. It is broken down in a 10- steps process called
GLYCOYSIS. The product of glycolysis is two three- carbon sugar, called pyruvate and
some ATP, which supplies energy to the yeast and allows in multiply. The two pyruvates are
then converted by the yeast into carbon dioxide (CO2) and ethanol (CH3 CH2 OH) which is
the alcohol in beer. The overall reaction is:

C6 H12 O6 yeast 2(CH3 CH2-OH) + 2(CO2)

 Maltose Maltotriose

Sucrose Glucose

Phasphoglocokinase
ATP phasphoglucomutas

AD Glucose 6-phosphate

ATP Hexose diphosphate

ADP

Fructose Fructose 6-phosphate

ATP ADP Fructose diphosphate aldolase

Fructose 1,6-diphosphate

Fructose diphosphate aldolase

NAD+ + PO43 - Glyceraldehyde 3-phosphate

NADH + H+ Glyceraldehyde phosphate dehydrogenate

1,3-Diphosphoglycerate

ADP 3-Phosphoglycerate kinase

ATP 3-Phosphoglycerate

Phosphoglycerate phosphomutase

2-Phosphoglycerate

Phosphopyruvate enolase

Phosphoenolpyruvate

ADP Pyruvate kinase

ATP Pyruvate

H3C C CO
O O

Pyruvate decarboxylase

NADH + H+ Acetaldehyde + CO2 H3C CH

NAD+ O
 Alcohol dehydrogenate

Ethanol
CH3CH2OH

The fermenter is sealed off from the air while fermentable is still happening and when the
specific gravity has reached a predetermined level, the carbon dioxide vent tube is capped.
Along narrow vent carbon dioxide pipe is attached to the feamentor to allow the escaps of
carbon dioxide from the fermentor. Since there is a constarnt out flow of CO2 through the
pipe, ouyside air is prevented from the entering the fermentor, which reduces the threat of
contamination by stray yeasts. Now the vessel is sealed, so as fermentation continues,
pressure builds as Co2 continues to be produced. This is how the beer gets most of its
carbonation and the rest is added manually later in bright beer tank.

When fermentation has finished, the beer is cooled to about O C. this helps the remaining
yeast settle to the bottom of the fermentor, along with other undesirable protein this come out
of slotions at this lower temperature.

When most of the solids have settle to the bottom, the beer is slowly pumped from the
fermentor and filterd to remove any remaining solids.

Figure
Maturation: - traditionally, maturation involves secondary fermentation of the remaining
fermentable extract at a reduced rte controlled by low temperatures and a low ayeast count in
the green beer. The phase after fermentation , is the period in which the beer is allowed to rest
at suitable temperature in order for the undesrale volatile components which migh affect the
finalk bouquet of the beer to undesirable volatile components which might affect the finalk
bouquet ofthe beer to released desired temperature is -1 c

Filtration: - filtration the beer stabilized the flavour and give beer its polished shine and
brilliance. Once the beer is matured then its needed clarification and the process of filtration
gives beer its clear limpid quality, eliminating the last reaming traces of clouding still in
suspension. It consists of pumping the liquid through a suitable filter. The filtered beer is then
stored in tanks called bright beer tank (BBT)

Filtration give a glass of beer that we could read a newspaper through, which, no noticeable
cloudiness. Sterile filtration is fine enough theta almost all micro organisms in the beer are
removed during the filtration process. In this brewery there are 4 tanks for the filtration
purposes. These tanks are pre Buffer tank, filtrox, and cartridge filter & post buffer tank.

Beer from the unit tanks are fed in to the pre – buffer tank. Calite & Hyflu hich comes in
power from , are dissolved in a solvent (water) in a separate vessel.

The dissolved powder then goes to the filtrox filter to from a bed over the candeled. The
beer from the per buffer tank are passed to filtrox tank. The filtrox tank consist of 114
candles, on these candles the filtrate froms a layer. The beer passes through the candled
having 1 to 0.1 m and thenb passes to the cartidage filter. In this filter some powder dissolved
with the beer is filterd out. The beer is then transfer to post buffer tank. This tank has a
capacity of 25 HL. From the post buffer tank the beer is passed to the heat exchanger, which
maintains temperature of O c to 1 c. Now the beer is ready to be bottled (green beer) and
stored in the bright beer tank. During filtration it is necessary that the air sould not come in
contact with beer.
Carbonation:- There are two ways to carbonate beer. Natural carbonation involves
transferring the beer to it final container – bottles, casks, or sugar. There is eough yeast that
remains suspended in the beer that this little bit of sugar will be fermented. This will not
significantly contribute to the alcoholic content of the beer but in the sealed container the
second by product of fermentation, CO2, has no place to go and so is absorbed by the beer.
This method of carbonation beer is popular among home brewers that typically don’t have
the equipment to force carbonate their beer. It is also the correct way to carbonate certain
styles of beer such as hefe- wizen.

Bright beer tank:- bight beer tank is a tank where storage of beer is done and they ready
to be packaged after checking its PH, BU,% of CO2 and colour. There are 4 BBT tanks in
brewery. This is the tank from where beer is ready to be bottled beer is ready to be bottled.
Bottles cleaning: - Old empty bottles are subject to feed in an auto washing machine
operated at many stages, at temperature ranges with the help of 3% caustic conc. & hpt water.
Meanwhile all the microbial agent are vanished out and bottles are ready tofilled with beer.

Figure
H ACCP
The World Health Organisation (WHO) Codex Alimentarius Commission developed
the seven HACCP principles. The HACCP system is the standard used throughout the EU
Food Industry and is recognised by several legislative bodies.

To identify hazards that can occur at any stage in the production of the food, to determine
their severity, to put in place control measures with limits outside which the process should
not be operated, to monitor these control points and identify corrective action to be taken
when limits are exceeded.

Stages of HACCP implementation

The HACCP Principles are implemented in a series of stages outlined in the diagram
below.
CCP critical control point
A point, step, or procedure in a food process at which control can be applied and, as a result,
a food safety hazard can be prevented, Eliminated, or reduced to acceptable levels

Critical limit.The maximum or minimum values to which a physical, biological, or chemical

hazard must be controlled at a critical control point to prevent, eliminate, or reduce to an acce
ptable level the occurrence of the identified food safety hazard.

Food safety Hazard. Any biological, chemical, or physical property that May cause a food to
be unsafe for human consumption

1. EBI empty bottle inspection, KBI, Kirin Bottle Inspector,

2. RLD Residential liquid detector
3. BFAFS beer filling Auto flash system
In this instrument used infra ray

1. EBI, KBI, Kirin Bottle Inspection,

One machine is sufficient for the visual inspection of empty bottles. By using
the bottle spin method the high accuracy whole surface bottle inspection is
possible.

Due to the constant improvements in high speed stable-handling and image

processing techniques, KBI, Kirin Bottle Inspector is favored in the bottle
making industry.

In addition, due to shift to cans and PET bottles, it is necessary to have greater
diverse handling of odd-shaped bottles. By using a direction-control device
handling of odd-shaped bottles in high speed has been possible.

Features
Uniform inspection over the entire circumference of the bottle using bottle spin
method
Sidewall Scars and Laps and Mouth Top Inspections are available as standard
Mouth Side Inspection is available as an option, possible to add Mold Number
Reader

Easy setting by using Windows-based Human-Machine Interface (HMI)

Extensive statistical data management

Wide selection of small, medium and large models depending on your needs of
inspection speed and installation space

Depending on the model maximum of 720 bottle per minute (BPM) high speed
inspection

Inspection Elements
·Sidewall: Foreign Matters

·Bottom Canter: Foreign Matters

Sidewall: Scars, Laps, Bubbles

·Mouth Top: Chips, Cracks, Dents, Bubbles, Line Overs

2. RLD Residential liquid detector

Residual liquid detecter (RLD) provides a simplistic constant monitoring of the

singel file bottle flow leading to the filler to detect the presence of any residual
coustic / liquor /lye that mayu have been carring over from he bottle waher

The RLD system has been conceived and designed with safety in mind and will
as standerd provide an automatic line control stop in the event of caustic being
detected within a passing bottle

Liquid detection is performed using a base mounted custan designed and built.
.capacitive a array wich is apprpximately 8 time more sentive to coustic then it
is to water thus, moisture carry over from washing can be tuned out whilst
harmful caustic carry over can be avoited .

The system s detection technique will generally also, by default identify porous
debris in bittl that holds liquor and plugged bottle

In common with mapex inspection system the RLD is modular whichmeans it

can supplied as a stand alone opration unit or as part of a inspection control
network system

In eigher configuration the inspection module will e castom built to suit the site
requirements related to specific bottle configuration
Figure :EBI

Beer Filling:- the filling unit or filler bowl is cleaned and sanitized before bottling. To
prepare for filling, the beer lines, hoses and filler bare cooled down using cold water. The
water is later blown out before beer is introduced in to the filler bowl from the bright beer
tank. Beer from BBT is released to filler machine and operated filled under CO2 counter
pressure followed by fobbing device and atvarious mode at. First bottle are vacuumed and
after that beer is finally crowing is done.
Figure:-

Pasteurization:- pasteurization is a process of heating beer, and many other consumable

products, to a temperature that will kill any living microbes without changing the chemistry
or flavor. It is used by some brewers to sterilize and stabilize their product. When
pasteurization was first introduced to the brewing industry in the late 19th century, it was
revolutionary. Beer has a tendency to spoil back than when refrigeration was uncommon and
the chances of infection in packaged beer was greater.

Biological stabilization- is done under this process and operated at various temperature
ranges is pasteurizer to increase the life of beer. It s one hour continuous operation and
resulting temperature range at 60-62* C

Figure:-
Labelling:- Rotator labellers are machines for which the bottles must be transferred from
the bottle conveyor in to the labeller. These are equipped to apply front, back neck labels and
aluminium foil over the neck. The black label includes the following things- batch No- _ date
of manufacture _ price, this is computerized. The neck of the beer bottle is wrapped with
Aluminium foil

Figure:-

Case Packing:- After Labeling the bottles are ready to be marketed , so now it should be
sealed in a cartoon.
Case Sealing:- once the case is packed , it is sealed . Case sealing is done manually. After
case sealing a hall mark of the company is put on the top of the cartoon.

Finished Good:- packed finished good are stored in Bihar Govt.Bond House under the
supreme custody of posted govt. excise officer. These finished goods are sell out whit
adhering the Bihar government excise policy

CPI [cleaning in place] Room:- cleaning systems were developed as a means of

reducing the amount oflabour neede for cleaning and sanitizing operation. One of the main
advantages of CIP system is that they can be circulate and allow the reuse of chemicals and
rinse water , there by reducing comsumption by as much as 50% CIP systems largely remove
human constant and cleaning and sanitizing agent, thus reducing the risk of harmful
exposure. Also assure a more consissitent cleaning by removing some of the common sources
of human error in cleaning.

The different tanks in CIP room are - Hot caustic tank

Cold Caustic tank

Caustic recovery Tank

Acid Recovery Tank

Cleaning and sanitation are an integral part brewery and should be taken in to consideration
at every of the beer brewing process. Cleaning proceeds sanitation and prepares the way for
sanitation treatment by removing organic , inorganic residues and micro organism after
cleaning and prevents microbial growth on the brewery equipment .

Nearly all brewery equipment tanks, fermented, brew kettle, and lauter tunes contain product
reside that must be removed between batches or at routine intervals in continuous operation.

CIP single- use Type – in the single – use method, the cleaning solution is prepared and
recirclated through the system and discharged at the completion of cleaning cycles.
Recovery- Type- in the recovery type the solution is recovered at the completions of the
cleaning cycles.
There are two types of CIP :- Hot CIP and Cold CIP. CIP of tank is done by flushing of water
of with 2% caustic so9lution. Cold CIP is done for uni tanks (fermetor) and Bright Beer
Tanks. Hot CIP is done for different tanks of brew house. SU 500 causes cleaning and
shining of brew vessels Disinfectant and Divosan are also used.

Figure

ETP Effluent treatment plant (waste water treatment)

Collection trunk Screen Chamber Equalization tank Tube

Stealer

ACF Filter SBR UASB Rector Buffer tank

Sand filter
Screen Chamber; (Solids removal)
Screening is typically a first step to remove glass, labels, and bottle caps, floating plastic
items and spent grains.

Equalization tank (pH Neutralization)

Adjusting the pH in a waste stream can be one of the most difficult processes in wastewater
treatment. Good pH neutralization and adjustment includes proper mixing, tank
configuration, and instrument control.
Brewery wastewater can contain slugs of materials that can be very low in pH or very high,
depending upon the timing of acid or caustic usage. Over a longer period of time, brewery pH
may be closer to neutral.

Biological Treatment
After the brewery wastewater has undergone physical and chemical treatment, it can be
biologically treated. Biological treatment of wastewater can be either aerobic (with
air/oxygen supply) or anaerobic (without oxygen). Generally, municipalities have relied upon
aerobic systems for the treatment of brewery wastewater. Recently, anaerobic systems have
become a more attractive option since biogas can be generated for energy use.

Anaerobic treatment UASB Reactor

Anaerobic wastewater treatment is the biological treatment of wastewater without the use of
air or elemental oxygen. Anaerobic treatment is characterized by biological conversion of
organic compounds by anaerobic microorganisms into biogas. Biogas is mainly methane (55-
75 vole %) and carbon dioxide (25-40 vole %) with traces of hydrogen sulphide.
80+% COD reduction

Anaerobic Treatment in the Brewing Industry

 Requires small amounts of chemicals
 Produces low amounts of sludge
 Generally soluble organics and medium to high strength
 Suited for brewery wastewater

SBR (Aerobic biological treatment)

Aerobic biological treatment is performed in the presence of oxygen by aerobic
microorganisms (principally bacteria) that metabolize the organic matter in the wastewater,
thereby producing more microorganisms and inorganic end products

Aerobic treatment utilizes biological treatment processes, in which microorganisms convert

non-settleable solids to settleable solids. Sedimentation typically follows, allowing the settle
able solids to settle out.
99+% BOD reductions
Waste water Analysis: - a. process:- Brewery waste mainly consist of two streams:
residual substances from production. Yeast, fermentable sugar or kiesselguhr, fro example,
can be recycled as valuable substances into the production process once solid and liquid
components have been separated. This reduces costs and boosts the yield.

The second main stream of brewery waste water comes from the cleaning of fermentation
and storage tanks as well as vat and bottle rinsing. Decanters have proved to be extremely
efficient for removing these residues and cleaning agents thereby making a specific
contribution to environmental protection and to reducing disposal costs.

Among The chemical treatment methods, PH adjustment and flocculation is some of the
most commonly used at breweries in removing toxic materials and colloidal impurities?

PH Adjustment

The acidity or alkalinity of waste water affects both waste water treatment And the
Environment. Low PH indicates increasing acidity while a high PH indicates increasing
alkalinity (A PH of 7 is neutral). The PH of waste water needs to remain between 6 and thus
inactivating waste water treatment processes.
Water Analysis:-There are four test which is done in water test:-

A. Hardness

B. Chloride

C. Alkalinity

D. PH

A. Hardness:- 50m of H2O was taken and 1 Total hardness indicator Tabled was
added to it. After that 0.5 ml of Ammonia buffer was added. And had titrate with EDTA
solution of N/50.Till the colour of water had not changed to purple colour.

Calculation: - burette reading * 20 = Total hardness

B. Chloride:- 50ml of H2O was taken & 1ml of K2Cr2 O7 of 5% was added in water.
After that solution was titrated with AgNo3 of .1 Normal.

Calculation: - VA –VB *35.5*N*1000/ volume of sample

Where VA= Burette reading

VB= chloride content distilled water

N= Normality

C. Standard of Alkalinity
IS: 105000 (1991) = 200 mg IL (maximum), beyond this limit taste becomes unpleasant. 600
mg IL (permissible in the absence of alternate source)
Alkalinity: - 50 ml of H20 was taken &3,4 drops of Methyl orange was added in water.
After. That solution was titrated with.05 NH2S04

Calculation: - Breading* Normality *61*100/ volume of sample.

Caustic Analysis: - There are two types of caustic:- hot caustic and cold caustic.
25.ml caustic solution (any hot and cold) was taken & 50.ml of water was added to it. And
then three drops as phenolphthalein of 1% as added. And then solution was titrated with HCL
of O.5N.

Beer quality analysis

Bitterness measurement:- the term Bu is being used to communicate the bitterness
level. This is simply a measurement of the amount of alpha acid Dissolved in a litter of beer.
10.mg of alpha acid dissolved in 1 litter of beer would be 10BU; 40mg of alpha acid in
solution would be 40BU

Bitterness in beer comes a compound in HOPS called “Alpha Acid” Different varieties of
hops have different ranges of Alpha with some varieties being very high (usually used for
flavor and aroma)

Procedure:-

Bitterness measurement of BBT

10ml of beer was taken & to it 0.5 of 6NHCL was added to it. To the above solution 20ml of
Iso-octane was added. Then the above solution was allowed for proper mixing fro 15minutes
at 210 R.P.M

Observation:- Then O.D of the above solution was measured in an UV-VIS

spectrophotometer at 275 nm.
Bitterness measurement of Unit tank:-
Lager beer was taken & centrifuged at 2200 RPM for 15 minutes to allow the yeasts to settle
down which otherwise mislead to result.

10ml of the supernatant was taken to it 0.5 ml of 6NHCL is added. 20ml of Iso-octane is
added to it then the above solution was allowed for 15 minutes shaking at 210RPM

Observation:- Then O.D of the above solution was taken at 275 nm in U.V,VIS
spectrophotometer.

Calculation:- BU= (O.D at 275nm)* 50

Normal range

Wort= 16.5 BU

BBT Beer=13.0to 15.0BU

Matured beer=10to15BU

Colour Measurement: - The beer form the BBT consists yeast which makes difficult in
measurement of colour of beer. So the beer is centrifuged at 2200RPM for 5 minutes to allow
all the yeast to settle down. 10ml of the supernatant of the beer was taken 0.1 drop of
Ocatanal was added (for de foaming) Then 0.5 of 6N HCL (for stopping further isomerisation
of B acid to A acid) was added. 20ml of isooctane was added to the above solution (to extract
a acids from the beer).

Few glass beads are added to above solution & it was air tight properly. The tube was
tightened in a container & allowed for 15 minutes. Shaking in Reciprocating shaker. This will
allow for proper mixing.

Observation:-
Optical Density of the above solution was taken in UV-VIS spectrophotometer at 430nm
&700nm
Colour measurement for BBT beer:-
10ml of the beer was taken. Then 0.5 of 6NHCL (for stopping further isomerisation of b-
acids to a-acids was added 20ml of iso octane was added to the above solution (to extract a
acids from the beer).

Few glass beads are added to the above solution & it was air tight properly. Then the tube
was tightened in container & allowed for 15minute. Shaking in reciprocating shaker. This
will allow for proper mixing of the solution.

Observation:- optical density of the above solution was taken in UV _VIS spectrophotometer
at 430nm &700

Calculation:- colour range = (O.D at 430nm-O.D at 700nm)*25EBC

Normal Range:-

For Wort=12to15EBC

For BBT Beer=7.0to9.1EBC

For mature Beer=7.0to10.0EBC

Yeast Viability Test:-

Methylene blue dye will diffuse in to the yeast cells. If the cells are living they will pump the
blue dye out if they are dead they will remain blue.

Equipments and Materials:-

1. Yeast samples
2. Microscopes
 3. microscopes slides and coverslips
4. dropper
5. 0.1% methylene blue solution
6. 50cm3 beaker
7. Stirring

Procedure:-
1. A drop of the diluted yeasts was placed on to the microscopes slides,

A drop of methylene blue dye was added and left for 5 minutes for getting properly stained.

2. The yeast was covered with cover slip & the slide was placed one the stage of microscope
and focused.

3. All the blue cells and clear cell was counted.

4. The results was recorded.

5. The percentage of viable cells was calculated

MALT ANALYSIS
Procedure
 First of all weight 50g (fine& coarse) of malt.
 After that taken d/w in two flask.
 The first is placed in water bath and gives temp 45 C
 When temp reached up to 45 C then add (coarse fine) in a stainless steal like beker for
20 min. and agitate it
 Then increases temperature up to 63 C for 30 min & also agitate it.
 After that again increases temperature up to 32 C for 30min.
 And here scarification taste occurs i.e iodine test.
 At last increase temperature up to 36 C for 10min.
 And also agitate it with the help of glass rod.
 Then cool down temperature i.e 60
 MALT

COARSE FINE

50M 50GM

Placed on water bath

Placed 2 conical flask with d/w

Give temperature 45 C & placed it in to stainless steel beaker

Added coarse coarse & find malt in separate beaker (30min)

Agitate it

Increases temperature up to 63 C of water bath

Agitate it

Increases temperature up to 72 C for 30 min

Iodine tests
 Increases temperature up to 76 c for 10min

Decreases temperature slowly 60 C -45 C-30 C

Specific Gravity (OG&PG) Measurement:-

Introduction;- The term specific gravity refers to the density of any liquid. By convention,
pure water is assigned an SG or specific gravity of1.00 at 15.5 C and is used as standard. The
1.00 refers to the fact that the density of H2O is 1 Kg per liter. So, if a liter of beer has an SG
of 1.05 it will have a mass of 1.05 Kg.

When used in brewing, specific gravity is broker down under further in to the starting or
original gravity (OG). Which is measure of SG before fermentation.

The Number helps to measure How much sugar is dissolved in the wort which is malty liquid
that is fermented in order to make beer.

The density is the made of sugar dissolved in the water, which will get converted to ethanol-
beer alcohol content, by fermentation

Measurement are made of specific gravity after fermentation as wall where the number is
called the final, terminal or post gravity (PG). The difference between the final number and
the initial number provides a simplified for estimation the amount of alcohol produced
during fermentation. Fermentation converts maltose in to ethanol and carbon dioxide, with
most of CO2 bubbling away during the process. Since theethanol is less dense than the sugary
water wort the post gravity is less than the original gravity. Pure ethanol has an SG of 0.79
Kg/L. One side effect of this is that sweeter beers will have a lower OG. Since the yeast does
not completely convert all malt sugar available in that case.

Hydrometer is a device for measuring the density of a liquid>A hydrometer will float higher
in amore dense liquid that in a less dense one brewing hydrometer are usually calibrated to
pure water at 20 C specific gravity is a ratio of the liquid S density compared to the density of
water. Giving water .a specific gravity of1. Wirt is a sugar solution and is more dense than
water. Reading taken after fermentation will give a lower reading since sugars have been
converted to alcohol.
Procedure:- The sample was place in the jar after defoaming. The hydrometer was lowered in
to jar. It was spinned to remove clinging bubbles. The hydrometer must be floating straight
and not touching the sides. When the hydrometer is steady, scale at the lowest level of the
liquid is noted. The temperature of the steady, te scale at the lowest level of the liquid is
noted. Tha temperature of the liquid was reas and adjusted to 20 C by sparging water on the
side walls of the jar.

Normal Rage

Wort = OG = 14.375 to 14.623 degree plato

BBT Beer =PG = 1.75 to 2.25 degree plato

Matured Beer = OG = 14.0 to 15.0 degree plato

PG = 1.75 to 2.25 degree plato

PH Measurement:-
PH of the wort & BBT Beer is tankan with the help of meter

Normal Range

Wort =3.0 to 4.1 Mature Beer = 4.0 to 4.4

Figure PH meter

Method of counting the yeast population

 1. Dilution:- The conent of beaker ( from uni tanks) are thoroughly mixed – using stirring
rod or pipette. Using plastic bulb pipette, some yeast suspensions is removed from te beaker.
1 ml of this yeast suspension is added to a measuring cylinder.10% acetic acid is added
slowly as a diluting agent till seen fro clarity and mixing by inverting. This will dilute the
yeast suspensions by x time, where x is total volume of acetic acid end beer.

2. Using the counter chamber:- Using a different pipette, transfer 2-3 drops of the diluted
suspense’s to the centre of slide ( Haemocytometer slide ) and carefully lower on the special
coner slip. Mop up any excess the counting chamber was placed on the microscope and
examine carefully on low power focus carefully, then moved to higher power. Yeast cll are
round or oval dots.

Calculations:- the yeast populations density is given by the following:

Number of cell per ml= average count per square

*1,000,000*100

Normal arrange:- 10 million yeast.