Akash Cr Brewery Report. A Project Report on “A training study on Beer Manufacturing Process” Submitted to Department of Biotechnology Faculty of Engineering, Management & Life

A Project Report

on

“A training study on Beer Manufacturing Process”

Submitted to

Department of BiotechnologyFaculty of Engineering, Management & Life Sciences

IASE Deemed University, Sardarshahr (Rajasthan) 331401

FOR PARTIAL FULFILLMENT OF FOUR YEARS FULL-TIME DEGREE PROGRAMME OF

BACHELOR OF TECHNOLOGY IN BIOTECHNOLOGY

Submitted byAkash Agrawal

Enrolment no.iase01/07/0043B.Tech (Biotechnology)

Under the supervision ofMr. R. S. Dhalan

Brewery Headmaster Superior Industries, 13/1Main, Mathura road

Faridabad(Haryana)

2007-2011

ACKNOWLEDGEMENTS

I want to thanks all members of Superior Industries to support me to get acquire more knowledge about all matter during training periods.

I feel privileged to express my thanks to Mr. Naresh Agrawal & Mr. Amit Agrawal(CEO), Mr. Rajeev Singh Dhalan(HBM) superior industries for their kind co-operation by time to time & to create family environment in industry.

I express my sincere thanks to Mr. Ashish Singh, Microbiologist of superior industries, for his generous co-operation allowing us to learn in this & blessings.

I would like to thanks Dr. Kamlesh Choure, Head, Department of Biotechnology, IASE Deemed University, to time guidance and moral support.

I express my deep appreciation & thanks to all workers, my friends & colleagues for their co-operation to learn in the industry.

Last but not the least I owe a special debt to my family for the great support in my training without I would have been in vain.

Akash Agrawal

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Topics pages

Acknowledgement 2

Company profile 4

Brewery and their role 5

Yeast and its role in brewing 6

Outline of a brewery 8

Brewing process 11

Introduction of clean in process 26

Quality aspects 29

Conclusion 30

Biblography 31

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Company profile:- Incepted in the year 2000, in Delhi, Superior Industries Ltd was established by a great visionary, Honorable Shri M.M. Agarwal Ji. Today, under the guidance of Chairman Mr. Pradeep Agarwal Ji, who has an experience of 25 years in this industry, we are inspecting tremendous growth within a short period of time, with same dedication and understanding that was developed at the starting.

InfrastructureWe have a state-of-art infrastructure which is spread across Haryana and Uttar Pradesh. This infrastructure is completely equipped with the Latest Technology Automatic Machines that help us to produce unlimited Alcoholic Beverages as per the client’s requirement. In addition, we provide customization to our products and safely pack them in wooden boxes.

TeamWe are backed up a huge team of workers, labors, and quality testers, who work in a most personalized way to produce pure and tasty Alcoholic Beverages. Beside, all of our team members hold a vast experience in their respective fields.

ClienteleThe superior quality Alcoholic Beverages presented by us has gathered huge list of clientele, from different corners of the world. To meet the growing demand for our Alcoholic Beverages, we have established far-reaching distribution network which covers major national and international markets of the world.

Name of Chairman :Mr. Pradeep AgarwalYear of Establishment :2000Nature of Business :Manufacturer, Exporter, Importer &

SupplierNumber of Employees :400Market Covered :Worldwide

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Brewery and its role:-

Brew industries deals with the formation of beer from the of starchy and

sugar containing substance through the fermentation that is called as

Brewing.

Beer Preparation/ Brewing is an art it comprises preparation of extract

from the malted barley or Malt called as wort and then transfer of this wort

to the fermentation for the purpose of fermentation through yeast that

convert the sugar into the alcohol to obtain beer and then filtration /

separation of the yeast and other large particulate carry out to obtain

beer.

Yeast/Saccharomyces Sp. that is basic part of the brewery used in the

fermentation is an Eukaryotic microorganism lie in the kingdom fungi.

Yeasts are chemo organotrophs as they use organic compounds as a

source of energy and do not require sunlight to grow. Carbon is obtained

mostly from hexose sugars such as glucose and fructose, or disaccharides

such as sucrose and maltose. Some species can

metabolize pentose sugars like ribose,[17] alcohols, and organic acids.

Yeast species either require oxygen for aerobic cellular

respiration (obligate aerobes), or are anaerobic but also have aerobic

methods of energy production (facultative anaerobes). Unlike bacteria,

there are no known yeast species that grow only anaerobically (obligate

anaerobes).yeast mainly grow by the budding process that in the

metabolically active stage. Yeasts grow best in a neutral or slightly acidic

pH environment.Today genetically engineered yeast are also available in

the market that led to the fermentation of xylose .yeast available in the

market both in form of yeast cake or granulated powder in solid state.

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Brewing Yeast

In brewery yeast are of two types one is Ales while the other one is Lager.

Ale yeast :-

These are those that carry out fermentation on the surface rather then the

bottom they are show optimum fermentation at the temperature 15-20 ºC

they produce foam at the surface of the beer they are pale to opaque

black in colour. Ale yeast can prepare beer in three weeks and can be

collected from the primary fermentors and can stored in refrigerator.

Lager yeast :-

Lager yeast tends to collect at the bottom of the fermenter and is

often referred to as bottom-fermenting yeast. Lager is fermented

at much lower temperatures, around 10 °C (50 °F), compared to

typical ale fermentation temperatures of 18 °C (64 °F). It is then

stored for 30 days or longer close to freezing point. During

storage, the beer mellows and flavours become

smoother. Sulfur components developed during fermentation

dissipate

Wort consist of a good amount of sugars for the fermentation to form

alcohol .Alcohol formation by the yeast is an metabolic process yeast is an

facultative anaerobe and in the absence of oxygen it after the glycolysis it

convert the pyruvate so obtain by the degradation of glucose in the

alcohol as shown this alcohol concentration decides the quality of beer too

and that’s depend on the fermentation time as more fermentation can

lead to the formation of some off flavor substance in the beer that that

may degrade the quality of the beer these substance may include the

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formation of aldehydes ,ketones and other product that form due to over

fermentation.

7

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General Outline Of a Brewery:-

A brew industry in general can be categorised in the two section that

is:-

1). Hot section :-The section theoretically called Hot as here the brew

prepares at the high temperature it comprises various components of

brewing i.e. Mashing , Lautring , Wort boiling and trub sepration at all

this stages operates at high temperature.the high temperature

required here for the digestion of starch by the enzyme i.e. also called

as saccharification .Due to saccharification sugars are available for

the fermentation purpose. Also at the high Temperture the mash or

wort become decontaiminated .

2). Cold Section :- The section holds all other operations of brewing at

lower temperature this includes the fermentation of wort and filtration

of prepared beer. Temperature of the cold section lies in the range of

9-0º C or below it too depend on the type of process stage that is

going to be employed in the process step. The temperature control

unit uses glycol for that purpose glycol has the temperature of -4ºC

and that holds the temperature unit of the system

9

10

Belt

Metallic Particles and Damaged Grains

Stones/Particulates

Rice Flakes

Gryst

Gryst

Water(55º c)

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Mini HopperCollection Hopper

Milling section flow chart

Vibrational screener

Magnetic Drums

Destoner

Weighing Unit

MillGryst Collection Tank

Rice flakes collection Tank

For premash

Cylo

Brewing

In the brewing wort is prepared from the brew that is the mixture of

various components treated at a certain temperature with starch digestion

enzyme to obtain fermentable sugar in the wort these components and

their temperature treatment vary they are brand specific. The brewing

process depends on the various parameters like saccharification pH and

specific gravity that vary from brand to brand .

A typical brewing process for the superior 50000 are as follows:-

After the gryst collected in the gryst collector then initiation of the process

starts through the mashing .

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Mashtank

In Mashing the ingredients /raw material treated with the enzymes at the

higher temperature for the saccharification i.e. conversion of starch into

the fermentable sugar. Mashing operates in the mash tun .

Technical design of mash tun comprises a dome shape steel tank that has

internal attached steam coils for the regulation of the temperature .The

flow of the steam in the coil decide the temperature of the mash tun.

At the Initiation of the mashing gryst and rice flakes allow to move in the

pre mash where they are allow to mix with the hot water from where it is

transfer to the mash tun.

The temperature of water is 52.c that is obtained by the premixing of the

hot water (88ºC) and cold water (9ºC) about 265 HL of water added at the

flow rate 750HL/hrs to the gryst and after mixing the mixture transfer to

the mash tun.

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In the mash tun there is already present the foundation water of about 50

Hl that purpose of which to prevents the back jump of the liquid mixture

that may set along with the upper walls of the mash tun .

Mash tun has the working capacity of about 398 HL while its gross

capacity is about 448 HL .mixture of water and gryst takes about 30

minutes to enter into the mash tun after enter into the mash tun some

additives also added manually that includes enzymes for the starch

digestion a variety of enzyme used for the starch digestion during the

mashing this includes :-

β-Gluconase – That digest proteins

Promalt – it include the blend of α amylase and β- amylase that

responsible for the starch digestion

During the mashing pH of the mixture should be maintained at the range

of 5.2±1 for this phosphoric acid will be added. Gypsum also added here

with the view to adjust pH as the phosphate addition have certain limit.

Temperature is the very important parameter along with the PH as both

decide the rate of reaction of enzyme .the temperature variation along

with time vary for brand to brand . In case of Haywards 5000 the Mixture

of gryst and water rest for 5 min initially at 45 ºC then it raises for about 7

minute with the rate of 1ºC per minute and set up to 52 ºC then rest for 15

minute now again temperature rises for about 12 minute and then brew

rest at this temperature i.e. 64 ºC for another 15 minute then it raises for

about 8 minute and raises upto 72 here it rest at this temperature the

saccharification test take place for 35 minutes then within 5 minute

temperature raise upto 77 ºC

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The temperature profile affect the enzyme action and their rate of reaction

at 64 ºC the enzyme works with the optimum rate and then for its

deactivation the temperature finally sets to the 77ºC.

After the Mashing the whole brew transfer to the lauter tun this takes

about 15 minutes to transfer the wort to the lauter tun .In the mash tun

then water flushes with for about 30 seconds that is also transfer to the

mash tun after that the rinsing of the the mash tun occurs for about 60

seconds and the water is then allow to drain.

Lauter Tun

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A

lauter tun is the traditional vessel used for separation of the

extracted wort. While the basic principle of its operation has remained the

same since its first use, technological advances have led to better

designed lauter tuns capable of quicker and more complete extraction of

the sugars from the grain.

The false bottom in a lauter tun has thin (0.7 to 1.1 mm) slits to hold back

the solids and allow liquids to pass through. The solids, not the false

bottom, form a filtration medium and hold back small solids, allowing the

otherwise cloudy mash to run out of the lauter tun as a clear liquid. The

false bottom of a lauter tun is today made of wedge wire, which can

provide a free-flow surface of up to 12% of the bottom of the tun.

The run off tubes should be evenly distributed across the bottom, with one

tube servicing about 1 m² of area. Typically these tubes have a wide,

shallow cone around them to prevent drastic forces from compacting the

grain directly above the outlet. In the past the run-off tubes flowed

through swan-neck valves into a wort collection grant. While visually

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stunning, this system led to a lot of oxygen uptake. Such a system has

mostly been replaced either by a central wort-collection vessel or the

arrangement of outlet ports into concentric zones, with each zone having

a ring-shaped collection pipe. Brewhouses in plain public view, particularly

those in brewpubs, often maintain the swan-neck valves and grant for

their visual effect.

A quality lauter tun has rotating rake arms with a central drive unit.

Depending on the size of the lauter tun, there can be between two and six

rake arms. Cutting blades hang from these arms. The blade is usually

wavy and has a plough-like foot. Each blade has its own path around the

tun and the whole rake assembly can be raised and lowered. Attached to

each of these arms is a flap which can be raised and lowered for pushing

the spent grains out of the tun. The brewer, or better yet an automated

system, can raise and lower the rake arms depending on the turbidity

(cloudiness) of the run-off, and the tightness of the grain bed, as

measured by the pressure difference between the top and bottom of the

grain bed.

There must be a system for introducing sparge water into the lauter tun.

Most systems have a ring of spray heads that insure an even and gentle

introduction of the sparge water. The watering system should not beat

down on the grain bed and form a channel.

Large breweries have self-closing inlets on the bottom of the tun through

which the mash is transferred to the lauter tun, and one outlet, also on the

bottom of the tun, into which the spent grains fall after lautering is

complete. Craft breweries often have many ways on the side of the mash

tun for spent grain removal, which then must be helped along to a large

extent by the brewer.

Some small breweries use a combination mash/lauter tun, in which the

rake system cannot be implemented because the mixing mechanism for

mashing is of higher importance. The stirring blades can be used as an

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ersatz rake, but typically they cannot be moved up and down, and would

disturb the bed too much were they used deep in the grain bed.

As stated that Mash takes about 15 minute to transfer to the lauter tun

here it recirculate so as for good filtration and formation of bed .Raking

arms serves to move so that efficient filtration carry out and wort is thus

obtained while the husk remains behind .after collection of the First wort

the sparging is carry out in the tank with about 105 HL of water to

obtained remain extract in the husk the sparging continues till the specific

gravity remains above 1.5 P after that the spent grain that remains in the

tank removed through the lower way that can be used as the fodder for

the animals.

After that the wort is then transfer to the wort kettle for the boiling so as

to remove any micro and to removes off flavors also hops are added in the

wort kettle so as to provide bitterness to the sweet wort that imparts taste

to the beer.

WORT KETTLE:

Wort tun is a dome shaped stainless steel tank having an oulet for the

exhaustion of gases . It has capacity of 772 HL while its working volume

becomes 579 HL .After lautering for about 2 hours the wort transfer to the

wort tun. State-of-the-art breweries today use many interesting boiling

methods, all of which achieve a more intense boiling and a more complete

realisation of the goals of boiling.

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Wort Kettle

Many breweries have a boiling unit outside of the kettle, sometimes called

a calandria, through which wort is pumped. The unit is usually a tall, thin

cylinder, with many tubes upwards through it. These tubes provide an

enormous surface area on which vapor bubbles can nucleate, and thus

provides for excellent volitization. The total volume of wort is circulated

seven to twelve times an hour through this external boiler, ensuring that

the wort is evenly boiled by the end of the boil. The wort is then boiled in

the kettle at atmospheric pressure, and through careful control the inlets

and outlets on the external boiler, an overpressure can be achieved in the

external boiler, raising the boiling point by a few Celsius degrees. Upon

return to the boil kettle, a vigorous vaporization occurs. The higher

temperature due to increased vaporization can reduce boil times up to

30%. External boilers were originally designed to improve performance of

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kettles which did not provide adequate boiling effect, but have since been

adopted by the industry as a sole means of boiling wort.

Modern brew houses can also be equipped with internal calandria, which

requires no pump. It works on basically the same principle as external

units, but relies on convection to move wort through the boiler. This can

prevent over boiling, as a deflector above the boiler reduces foaming, and

also reduces evaporation. Internal calandria are generally difficult to clean.

Technically wort kettle having no steam coil then the boiling takes place

through the pre boiler .When the wort kettle filled to the 350HL after that

pre boiling starts by circulation of wort through the preboiler at 100ºC.

During the boiling hops will be added to the kettle hops provides alpha

acids to the beer that is IAA acids this provide beer bitterness that can be

maintained on the scale of the International Bitterness Unit .Hops may be

added in two forms may be either in the pellet form or in the form of Hop

Extract and the quantity to which they are added vary from brand to

brand. Boiling will be done for the the standard time 75 minute that may

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be up to 90 minute. Wort boiling necessary for the removal off the off

flavors from the wort and it also maintain the specific gravity of the wort

that is in the range of 11-12 P. After boiling the wort is then transfer to the

whirlpool kettle.

Whirl Pool

At the end of the boil, the wort is set into a whirlpool. This transfer of wort

takes about 15 minutes The so-called teacup effect forces the denser

solids (coagulated proteins, vegetable matter from hops) into a cone in the

center of the whirlpool tank.

In most large breweries, there is a separate tank for whirlpooling. These

tanks have a large diameter to encourage settling, a flat bottom, a

tangential inlet near the bottom of the whirlpool, and an outlet on the

bottom near the outer edge of the whirlpool. A whirlpool should have no

internal protrusions that might slow down the rotation of the liquid. The

bottom of the whirlpool is often slightly sloped towards the outlet. Newer

whirlpools often have "Denk rings" suspended in the middle of the

whirlpool. These rings are aligned horizontally and have about 75% of the

diameter of the whirlpool. The Denk rings prevent the formation of

21

secondary eddies in the whirlpool, encouraging the formation of a

cohesive trub cone in the middle of the whirlpool. Smaller breweries often

use the brew kettle as a whirlpool. In the United Kingdom, it is common

practice to use a device known as a hop back to clear the green wort

(green wort is wort to which yeast has not yet been added). This device

has the same effect as, but operates in a completely different manner

than, a whirlpool. The two devices are often confused but are in function,

quite different. While a whirlpool functions through the use of centrifugal

forces, a hop back uses a layer of fresh hop flowers in a confined space to

act as a filter bed to remove trub (pronounced tr-oo-b, tr-uh-b in the UK).

Furthermore, while a whirlpool is only useful for the removal of pelleted

hops (as flowers don't tend to separate as easily), hop backs are generally

used only for the removal of whole flower hops (as the particles left by

pellets tend to make it through the hop back.).As the wort transfer to the

whirlpool tank and after whirl pooling effect the trub and denser particle

get settled the wort rest time in the whirlpool for about 25 minutes at

during that instance the temperature drops from 100ºC to 97ºC then this

wort is then sent for the wort cooling.

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Wort Cooling

After the whirlpool, the wort must be brought down to fermentation

temperatures (20-26°Celsius) before yeast is added. In modern breweries

this is achieved through a plate heat exchanger. A plate heat exchanger

has many ridged plates, which form two separate paths. The wort is

pumped into the heat exchanger, and goes through every other gap

between the plates. The cooling medium, usually water, goes through the

other gaps. The ridges in the plates ensure turbulent flow. A good heat

exchanger can drop 95 °C wort to 20 °C while warming the cooling

medium from about 10 °C to 80 °C. The last few plates often use 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 its reproduction.

While boiling, it is useful to recover some of the energy used 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

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rate of flow, the output temperature of the water can be controlled. This is

also often done using a plate heat exchanger. The water is then stored for

later use in the next mash, in equipment cleaning, or wherever necessary.

Another common method of energy recovery takes place 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 rate set to maximize the water's

temperature upon exiting. This now-hot water is then stored in a hot water

tank.

YEAST ADDITION:

Through the Plate heat exchanger the temperature of the wort down from

97ºC to 9ºC. .now this cold wort allow to pass through the yeast room

where yeast pitches into the wort .The yeast pitching rate is usually 1.1

Kg/Hl however this rate depends on the consistency and yeast viability .At

the same time of pitching the yeast the sterile air also added to the wort

as the yeast requires aeration for the growth and initially after added to

the fermentation first of all yeast allow to grow and as the air supply

ceased then the fermentation begin

FERMENTATION:

Wort and pitched yeast moves to the fermentation

vessel(FV)/Unitank(UT)/Combi tank. After the wort is cooled and aerated —

usually with sterile air — yeast is added to it, and it begins to ferment. It is

during this stage that sugars won from the malt are metabolized into

alcohol and carbon dioxide, and the product can be called beer for the first

time. Fermentation happens in tanks which come in all sorts of forms, from

enormous cylindro-conical vessels, through open stone vessels, to wooden

vats.

Most breweries today use cylindro-conical vessels, or CCVs, which have a

conical bottom and a cylindrical top. The cone's aperture is typically

around 60°, an angle that will allow the yeast to flow towards the cones

apex, but is not so steep as to take up too much vertical space. CCVs can

handle both fermenting and conditioning in the same tank. At the end of

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fermentation, the yeast and other solids which have fallen to the cones

apex can be simply flushed out a port at the apex.

In the fermentation vessel the wort transfer at the temperature of

9.5ºC .after the initial 4 hours of fermentation trub are allow to drain from

the tank. Again after 24 hours trub allow to drain from the tank.

During fermentation the yeast converts the glucose ,sucrose and other

available sugars into the beer .The yeast are also categories on the basis

of mode of their action that is:-

After about two days the temperature of the vessel rises to 15-16º it is due

to the heat generated during division of yeast in the tank that generate

metabolic heat.

As the conversion of sugars into alcohol the temperature of the beer

becomes lower that led to the settling of yeast at the bottom of the tank

and also due to lowering of temperature the particles like proteins has

tendency to get settled at the bottom of the tank that led to the reduction

of the hazy ness in the beer.

After 4-5 Days when gravity of the beer so formed drops below 1.8

Original Extract find out this is the difference between the present gravity

and least Extract when LE<4.4 at that instant yeast scrapping /Cropping is

then done in which yeast are collected from the fermentors from the

bottom .Mature yeast are some time allow to drain or may be recollected

for further use this is called as cropping.

After scrapping Beer in fermentors are allow to go under a stage of

diacetyl rest for the period of about 24 hours .Due to diacetyl rest off

flavours are removed from the Beer .

After Diacetyl Rest fermentors are set to full cooling aur chill back during

first 24 hours of which temperature falls back from 16ºC to 4ºC then after

this phase the fermentation set into the lagring stage in which tank

temperature sets below 4ºC .lagring time depends on the total process

time .

This is also called the conditioning of beer it not only promote the settling

of the yeast but also led to the settling of solid particles like protein hence

remove hazyness. Unpleasant flavors such as phenolic compounds

become insoluble in the cold beer, and the beer's flavor becomes

25

smoother. During this time pressure is maintained on the tanks to prevent

the beer from going flat.

At the lagring stage just before the 24 hrs before the filteration lucilyte

added in the tank the purpose of which to settle yeast and heavy

particles .The commonly used lucilyte is silicon dioxide that posses both

negative and positive charge i.e. Amphoteric and responsible for the

settling of yeast and other heavy particles like trub.

After the draining of the lucilyte the prepared beer sent for the filteration.

At Rochees Filtration will be done by candle filter have assembly of around

304 candles each candle possese pore that is when integrated with the

diatom like kishelghur bring about a quality filtration of the beer .

FILTRATION:

Filtering the beer stabilizes the flavor, and gives beer its polished shine

and brilliance. Not all beer is filtered. When tax determination is required

by local laws, it is typically done at this stage in a calibrated tank. Filters

come in many types. Many use pre-made filtration media such as sheets

or candles, while others use a fine powder made of, for

example, diatomaceous earth, also called kieselguhr, which is introduced

into the beer and recirculated past screens to form a filtration bed.

In the candle filter there are three grades of kiselghur powder or celite

these are:-

Celite powder 577 that is very fine in quality.

Celite powder 512 has fineness less then celite 577

Celite powder High flow that is coarse in nature.

Applying kiselghur to the filter known as the dosing that is done by mixing

kiselghur to the de-areated water in the quantity of about 90

gm/Hl .however depend on the haze appear in the beer quantity of the

kiselghur can be changed .In this application coarse high flow apply first as

it prevents the chocking of the candles within the filter that gives the good

quality of the filtration.

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Filter like candle filter much better then some other technical filter like

bed filter as it provides more surface are as compared to the bed filter

also candle filter can handle the viscous effect that reduces fluid

resistance and hence it will led to the effective filtration as compared to

any other filter .

In operational mechanism the beer is applied from the bottom of the filter

which contains kiselghur this beer then move from lower to upper part of

the tank and then through the candles which are present here and the

coated with kiselghur beer filters and then move to the upper part due to

vaccum pressure from where it is then collected and transfer for the

storage.

After filteration beer is then transfer to the bright beer tank at

temperature below 0.c where it is then collected beer should be satisfied

with the certain parameters while packaging

CO2 should be 2.7-2.9%v/v

De Oxygenated water<50ppb

While haze within the beer should be having certain parameters at various

angles :-

H90-<.7

H25<0.4

After the filteration it should be necessary that it should be pack within 4

hrs otherwise there will be creation of the off flavour.

Bottling Section

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Within 4 hours of the filteration it should be necessary that the beer go for

the packaging in the bottling plant.It is Allow to go for the packing from

the BBT to the botteling. Beer bottles come in various sizes, shapes and

colours. Dark glass prevents light from spoiling the beer. However, lighter

coloured bottles are often used for marketing reasons.

Bottling lines are production lines that fill beer into bottles on a large

scale.

This typically involves drawing beer from a holding tank and filling it into

bottles in a filling machine (filler), which are then capped, labeled and

packed into cases or cartons. Many smaller breweries send their bulk beer

to large facilities forcontract bottling - though some will bottle by hand.

The first step in bottling beer is depalletising, where the empty bottles are

removed from the original pallet packaging delivered from the

manufacturer, so that individual bottles may be handled. The bottles may

28

then be rinsed with filtered water or air, and may have carbon

dioxide injected into them in attempt to reduce the level of oxygen within

the bottle. The bottle then enters a "filler" which fills the bottle with beer

and may also inject a small amount of inert gas (CO2 or nitrogen) on top of

the beer to disperse oxygen, as O2 can ruin the quality of the product

by oxidation.

Next the bottle enters a labelling machine ("labeller") where a label is

applied. The product is then packed into boxes and warehoused, ready for

sale.

Clean in place (CIP):

As Like after every prepration it is necessary to clean utensils at the home

in the same way after some processes that it is necessary to clean the

process equipments but they are of large capacity so they are clean on

the place where they are placed hence this type of clean procedure called

as Clean in Place.

CIP done in two ways:

1) Acidic CIP

2) Caustic CIP

On the basis of temperature at which CIP done there are two modes of

CIP:-

a). Hot CIP

b). Cold CIP

CIP of various Equipments/Devices that are use in the process are as

follows:

Milling portion : In the milling portion the CIP done with the Hot Air as their

in no provision for the use of liquid fluid either in the process or in the CIP.

29

Brew House portion: The CIP of the Mash Tun, Lautring Tank, Wort Kettle

and Whirlpool Done with the Hot caustic .The hot caustic comprises 2%

(1.822%) of NaOH that becomes so effective in damaging the microbes if

any persist in the tank.

Each of this tank have separate attachments for the CIP from the CIP tanks

and then after CIP the water is then drain out .During the Hot CIP the hot

caustic apply for about 30 minutes and then flush with the RO water.

CIP tanks comprises various tanks that built specially for the CIP purpose

these are the Hot water tank, cold water tank and Caustic tank .The

Caustic Hold in the tank Should satisfy some parameters like having their

caustic concentration should be 2% also their carbonate and Aluminate

level should be >0.7.After Brew House all the process equipments are go

for the cold caustic these includes PHE(Plate Heat Exchanger), Uni tank

and Filter also lines for the transfer of the beer.

In these area the application of cold caustic posses same effect as the hot

caustic in their mode of sterilization and there also can be hot caustic CIP

but we prefer Cold Caustic here because as we go for Hot caustic it may

take time to get back its temperature normal hence create loss of time

while for good industries time is money hence it indirectly loss of money.

In standard practice we go for one acidic CIP after every 10 Caustic CIP it

is because though the caustic CIP is much more effective in its sterilization

effect but to reduce the chances of the growth of the Basophilic microbes

it is generally a acidic CIP needed.

In the Bright Beer Tank we generally prefer Acidic CIP or Cold Acidic CIP as

BBT holds beer that posses alcohol which is itself very effective

disinfectant hence there is lesser chances of the growth of microbes in the

tank also in its supply line to reduce any risk of the presence of base

resistance bacteria we go for the cold acidic CIP.

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Water and GrystMash (77ºc)Wort

Wort(97ºC)

Plate Heat ExchangerWort(9ºC)

Beer (0ºc)

Filtered Beer

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Wort Kettle

Brewing Process Flow Chart

Lauter TunMash Tun

Spent Grain

Yeast Room

Utility

Combi Tank /Fermentation Vessel/Unitank

Candle Filter

Bright Beer Tank

Pasteurization

Ready To sell

Quality Aspects of Brewery:

Quality matters in all the industries it is one of the

important aspects that affects the demand of the product in the market

also it decide the standard of the production house. Superior industries ltd.

adopt the updated approaches method to check the quality of the process

and to maintain it to .Here Through this report I would like to focuss on the

some techniques adopted in Brewery to check out the presence of any

contamination in the Brewing process also in the packed product However

quality not only works for checking of the contamination but also it focus

on development of the techniques to give out the better quality of the

product .Hence applicable and research fields in the quality department of

the Brewery like superior industries makes it to maintain their dominancy

in the market and to win complete customer satisfaction .

Quality control has various parameters upon which the quality of a

standard beer and its raw material decided it also involves microbial

parameters that check the efficiency of yeast doing fermentation and also

the viability of the yeast these parameters also also involve in the

checking for the contamination of microbes in the beer and water sample

while the chemical parameters check the chemical nature of the beer that

includes the pH, Least Extract in the beer and its real extract ,It also check

out some other properties of the beer like bitterness unit that is due to the

isomerisation of alpha acids whose concentration then find out using the

standard parameters for the beer. some other criteria that when satisfies

give the assurance of the quality process.

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Bottling

Conclusion

In the end ,I would say that summer training at superior

industries ltd.was a wonderful task. The training gave me a

lot of practical exposure in the field that was entirely new to

us .

The concept of beer manufacturing could be successfully

learnt an d applied in the plight of the effort and guidance

of the experienced trainers at the industry.

From the training I learnt how a product can be

manufactured by giving low capital input ,less labor and

effort, by employing skillful people and above all using

better manufacturing techniques. So, the beer produced will

meet the degree of excellence value demanded by our

customers.

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Thus to conclude ,I would say that the training was very

fascinating and enjoyable.

Bibliography

Source from internet: important websites visited are

www.google.com

www.wikipedia.com

www.britannica.com

www.yeastferment.com

Information based on personnel discussion at superior

industries Ltd.

A)

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