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Beer Manufacturing (Kingfisher)
Beer Manufacturing (Kingfisher)
Beer Manufacturing (Kingfisher)
Management
Project Report on
‘Operations Management’
SUBMITTED BY:
Submitted in partial
Mumbai University
CERTIFICATE
Ms Anita S. Phaterpekar
Mr. Ameya Guhagarkar
Ms Anita Anand
Ms Deepa Kodag
Mr. Hitendra Jain
Mr. Omkar Tulaskar
Ms Pallavi Shetty
Mr. Suraj Purohit
Mr. Viral Shah
Signature Signature
Project guide Director
Prof. N.K.Agarwal Dr D.Y.Patil
A Project Report on Operations
Management
DECLARATION
We, the group members of OM project hereby declare that we have visited
United Breweries, Taloja, and the information provided in the report is true to
best of our knowledge.
A Project Report on Operations
Management
ACKNOWLEDGEMENT
We wish to express our deep gratitude towards all the persons who have contributed
towards this project and helped develop ideas and approach in writing this report. We
thank Mr. Ashok Katta, Senior HR Manager, and all officials of United Breweries plant
who guided us in this project.
We would like to thank Prof. Dr. D.Y Patil, the director of Bharti Vidyapeeth’s
Institute of Management Studies and Research, Belapur, Navi Mumbai for his
kind permission to carry on our project work and his co-operation.
Last but not the least we would like to thank all our college friends for their
encouragement and moral support.
A Project Report on Operations
Management
Quality and hygiene are the key elements of the United Breweries'
manufacturing philosophy. To this end, the Central Scientific Laboratory (CSL),
headquartered at Bangalore sets standards for all its breweries. Quality
Management Systems laid out along the lines of ISO 9000 are strictly adhered
to, controlling quality at every stage of production, from raw materials to the end
product. Also, besides controlling the production process, the CSL analyses the
Company's beer taken off market shelves all over the Country, the competition's
beers and beers across the world. These beers are tested as per the standards
laid down by the European Brewery Convention on 40 different parameters. By
these standards, United Breweries' beers don't just equal, but even surpass,
several Dutch and American beers.
In addition, UBL has also entered into mutli-faceted strategic alliance with
Scottish & NewCastle Plc (S&N), an international brewery major, with $6 billion
in revenue and a market capitalization of $5.4 billion. This alliance, apart from
having a joint venture in India, will allow S&N to market it International brands
like Kronenbourg in India, while UBL will utilize S&N's global network to further
globalize its Kingfisher.
A Project Report on Operations
Management
Benefits of MIDC
Water Supply
MIDC has, over the years, created a vast, robust and reliable water supply
system. The system caters to the water needs of the industries within MIDC
industrial areas and also those outside, in the adjoining areas. Not only that, the
system caters to the needs of many large and small local bodies all over the
State which in turn serve their domestic and commercial consumers.
Consumer Base:
Industrial: 26564 MLD
Domestic: 2829 MLD
The above reservation figures indicate the extent to which MIDC has rights to
draw water from rivers, irrigations project and other sources. The reservation
figures indicate that MIDC still has large unutilized rights, which can be used for
future expansion of its water supply systems.
Superior Infrastructure:
The following gives a snapshot of MIDC's water supply infrastructure:
No. Of Schemes 69
No. Of Dams 05
Capacity of pump system 7787 HP
Length of Pipelines 2864 Kms
CHARACTERISTICS
World Health
Organisation-
1971
Highest
Desirable
Maximum
Permissible
Turbidity
5.0
25.00
Nothing
Disagreeable
Color (Pt Scale)
A Project Report on Operations
Management
Capacity Determination
• Solids
Total Assessing existing capacity
• Forecasting future capacity needs
• Identifying alternative ways to modify capacity
• Evaluating financial, economical and technology capacity alternatives
• Selecting a capacity alternative most suited to the strategic mission of
the firm
Iron (Fe)
Production Capacity of UB Ltd. at Taloja
Capacity – Kegs (as per market requirement)
Location
Objective
Manganese
To minimize sum of all costs affected by location, not only presently but in the
long run even
Selection of Region
• Nearness to market
• Availability of Raw Material
• Government Policy , other….
Lay Out
Plant Layout help in determining a floor plan and arranging the desired
machinery and equipment of a plant: It permits
• The quickest flow of materials in processing the product
• From the receipt of the raw materials to the shipment of the
Phenolic substances
finished product
• At the lowest cost and with the least amount of handling
Objectives
Nitrate
A Project Report on Operations
Management
• Materials
• Product
• Workers
Zinc • Machinery
• Type of industry
- Synthetic
• Constituent elements combining to make the final product
e.g. Chemical industry
- Analytical
• Conversion of raw materials into various elements e.g.
Petroleum industry
- Conditioning
• Changing in shape / form or physical properties e.g.
Foundry, metal working industry
- Extractive
• Involving separation of one element from the other e.g.
Metal from iron ore
Arsenic
Each of above further classified into
Intermittent industries
Continuous industries
• Location
• Managerial policies
Hexavalent Chromium
Cellular Manufacturing (CM) or Group Technology (GT)
layout
• A form of production that has been developed recently
• In GT,the products or components being manufactured are placed
in families or groups and separate manufacturing cells are used
for manufacturing these groups
– GT enables production of a wide variety of parts in small
batches to achieve economies of line-flow production
without
– Transportation costs reduced as parts do not have to
moved in large batches
– Reduction in w-i-p inventory, and the manufacturing cycle-
time or through-put time
– Most common application in automobile spare parts
manufacturing
Functional Groups
Since its a Mfg unit, only functional group present there is Production
Department. This department comprises of
• 25 Managers
• 35 Technical Staff,
• 70 Workers
Material Management
• Obtaining the best possible raw material at the least possible price
This is the component where raw malt is stored. It comprises of two tanks with
a capacity of 200 metric tones each. Daily consumption of barley malt is 20
metric tones. Every 10 ten days the new stock is added to the silo. Barley can
be stored for about 6 months without being spoilt. In silo the malt is aerated
with dry air throughout.
Malt:
UBL obtains malt required in the mfg in Patiala and it purchases Rice Flakes
from Delhi
Hops- The most important ingredient. Imported from Germany because the
climatic conditions are favourable for plantation of Hops and adds to the bitter
taste and the aroma of the beer. The Hops reported from Germany is of the
best quality.
1. Pellets
2. Oil &
3. Liquids
Brew House
After the barley is separated and cleaned it is then sent to the brew house
department. In the brew house the following processes take place
1. Mash Kettle
2. Lauter Tun
3. Wort Kettle
4. Whirlpool &
5. PHE (Plate Heat Exchanger)
6. Yeast Room
7. Fermentation Tank
8. Lagering Process
9. Filtration Process
Mash Kettle
Here the barley malt is mixed with rice flakes and water and boiled for one hour
(till certain specifications based on transparency of Wort). The temperature is
maintained at 102 deg C. There are two separate Mash Kettle each of capacity
of 25000 litres.
Lauter Tun
Wort (mother liquor) is pumped into lauter tun and water is added to form a
proper mixture. It is then mixed for one hour using blades at 1000 C. And it is
allowed to settle and form a filter bed made of husk and undissolved flakes.
Then the filterate is pumped to wort kettle.
Wort Kettle
Sugar and Hops is added manually at this stage. Then the wort is mixed to
dissolve sugar and hops for one hour and at the end of process the
temperature comes to 90 deg C.
Whirlpool
The wort is vortexed which enables and undissolved particles to settle at the
bottom. The temperature reduces to 65-70 deg C.
Fermentation
the final mixture is moved to fermentor where it is mixed or pitched with Yeast
which will convert the mixture of malt and hops into Beer. The Yeast converts
ingredient Sugar and Proteins into Alcohol. The temperature maintain at 4 to 6
deg. C. till the fermentation the desired concentration of alcohol is reached.
CIP: Cleaning In Process, fermentors are cleaned using automated CIP.
Laggering
After fermentation the temperature of beer is lowered to 0 deg. C and let it
matured for a period of one week and then transferred to packaging unit.
Fermentation and Laggering is carried out in same fermentor.
Packaging
A Project Report on Operations
Management
1. Keg
2. Cans
3. Bottles
Keg – Keg is a barrel like container which is used to store unpasturized beer. It
is available in varying capacities of 10, 20, 30 and 50 litres. Unpasturized beer
has a very short shelf life of approximately 5-6 days. The beer is produced in
the morning and dispatched in the evening. It has only produced in the required
quantities and not in excess. This beer is supplied to pubs, bars and five star
hotels.
Cans – The cans are imported from Thailand, UAE and Singapore. UB now
procures its cans from a local unit Raxem Industries which is located in Taloja
itself. This helps UB to reduce its overhead costs involved in the manufacturing
of beer. Each can has a capacity of 330ml.
Quality Management
Quality and hygiene are the key elements of the UB groups’ manufacturing
philosophy. To this end the Central Scientific Laboratory(CSL) headquartered at
Bangalore sets standards for all its breweries.Quality Management Systems
laid out along the lines of ISO 9000 are strictly adhered to, controlling quality at
every stage of production.
Quality of the beer is checked electronically at the end of each process and the
quality of the final packaged product is manually checked.
Environmental Management
1. Provisions for Pollution Control
• ETP (Effluent Treatment Plant) – The waste water released after
the manufacturing process is treated at the ETP which is located
within the plant. The treatment process takes 6-7 days on an
average and the treated water is utilized for cleaning purposes.
• Recycled Bottles – Kingfisher contributes to the environment by
using recycled bottles.
• ISO 9001:2000
A Project Report on Operations
Management