Professional Documents
Culture Documents
Brewery in Plant Training Report
Brewery in Plant Training Report
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S.D.M.V.M's COLLEGE OF FOOD TECHNOLOGY,
AURANGABAD.
2017-2018
Submitted by
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PROF. S.R.Patharkar
ACKNOWLEDGEMENT
Food technology is an integrated degree course which aims to provide a right platform in
food technology through theoretical, practical and industrial operations.
We have great pleasure to express our deep sense of gratitudeness and sincere sentiment of
thanks to Principle of our college, Prof. G.R Bhumre Sir , Gahervar S.A, Garude H.S,
Kamble S.B, Choudhary M.M, Ingole S.S, Waghmare U.D,College of food technology and
for this opportunity to undergo inplant training in “UNITED BREWERIES LIMITED
(ELLORA UNIT) , AURANGABAD” for this privilege we would like to thanks Mr. Ravindra
Chavan Sir(Chairman)
We would like to express our sincere gratitude and thanks to Mr.V Srinivas sir A
(Sr.Manager – quality Assurance, United Breweries, Ellora, Aurangabad) for granting us the
permission to undertake in-plant training in this esteemed organization. We also extend our
thanks to Mr. Ravi Chindhe sir (Head of Brewing Department), Mr. Swaroop Banergy sir
(Sr.HR Manager) without whose support, co-operation and guidance this training would not
have been a success. We would also like to give our heartiest thanks to Mr. M. H. Patil (Q. A.
Officer), Mr. Arun Patil (Microbiologist), Mr. Pravin Kathar (Senior Chemist), Mr. Pravin
Ingle (senior Chemist), Mr. Sujit Jadhav (Senior Chemist), for their helpful guide lines and
valuable assistance and top of all for sharing their rich experience with a fresher’s like us.
Last but not the least we would like to say a big thank to all employees & my best
friends Sneha Waghmode at United Breweries, Ltd. For their kind help and endless patience for
making us learn the minutes of brewery under their guidance.
We convey depth of our heartfelt thanks our family, friend who helps us directly or
indirectly and offered their excellent company and affection throughout my stay in this
University.
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We also thanks of their co-operation which we forget to mention by mistake.
CANDIDATE’S DECLARATION
Date: 15/04/2018
Submitted By
CFTGT 14/A/14
.
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Affiliated to Vasantrao Naik Marathwada Krushi Vidhyapeeth, Parbhani
CERTIFICATE
This is to certify that, the In-Plant Training project in “United Breweries
Limited”(Ellora Unit) submitted by Mr. Dhirajsing Shivsing Gour CFTGT 14/A/14
student of B. Tech. (Food Technology) of this College of Food Technology, Aurangabad in
partial fulfillment of the requirement for the Degree of B. Tech. (Food Technology) under my
guidance and supervision is a result of original project work and is of sufficiently high standard
to warrant its presentation to the examination. I also certified that no part of this report has been
submitted by them for the award of Degree or Diploma of any University or Institution.
Dr.B.S.Agarkar
EXTERNAL EXAMINER
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INDEX
SR.NO TITLE PAGE NO
1 Introduction
3
Raw Materials
4 Flow Chart of Beer Manufacturing
6 Fermentation
7 Filtration
8 Bottling
13 Boiler
14 Conclusion
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INTRODUCTION
What Is Beer?
The World BEER stems from the Latin word “Bibber’ means “to drink”
Definition of Beer
The fermenting beverage is than normally clarified and dispersed in an effervescent condition. UB group
started in 1935, with Thompsons Leishman, a Scotishman, who combined five small breweries
in South India ,the oldest being Castle Breweries, which was as old as 1857, two from United
breweries Ltd .This company was brought over by Late Vittal Mallya in 1947
This man machines and five raw materials combination along with location
advantage makes Kingfisher cost effectively and quantity supplier of Beer. Today each one of
the near about the more than 32000 beer outlets in India sells one brand or the other from United
Breweries.
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BREWERY HISTORY & PROFILE
The group has a long history of more than 100 years of operations. The Group
was founded by a Scotsman, Thomas Leishman in 1857 as bulk producer of beer from South
Indian based British breweries. United Breweries Limited (UBL) was founded on March 15,
1915, in Madras by Thomas Leishman, a Scotsman, also its first Managing Director. UBL
manufactured and sold only bulk beer for troops of both the world wars. Vittal Mallya was
closely associated with the growth of the firm in early days and during 1940s it was he who
shaped Indian operations of the firm. Seeing his dynamic leadership and diligence, he was
elected to the Board of Directors of UBL in 1947 at the age of 22 and a year later became its
Chairman.
MISSION
We constitute a large global group in India. We associate with World leader in order to
adopt technologist and processes that will enable a leader in order to adopt technologist and
processes that will enable a leadership in a large spectrum of activities.
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UB QUALITY OBJECTIVES
The breweries division quality objectives were based on the UB group quality, policy and are as
follows
ACHIVEMENTS
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Sr number KPI Status
1 OPINONA 74.90%
2 Water (KL/KL) 3.01%
3 Power (KWH/KL) 85.3%
4 Fuel (MJ/HL) 121.33%
5 Bottle Breakage 0.71%
6 Extract Loss 3.72%
7 Carton Loss 1.60%
9 Beer Loss 4%
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The first and the foremost element that was introduced was Safety. To enter the Brewery,
Safety Shoes are mandatory. Safety briefing of basic Industrial Safety was given at the
entrance gate.
A Safety Manager manages and monitors all the aspects pertaining to safety. He executes
all
his work through:
Safety Cards: These cards/tags are used by everyone to report unsafe acts, unsafe
conditions and near misses.
Work Permit: Any repair, maintenance, fabrication work done in the unit needs a work
permit issued by the Safety Manager. He must show all the PPEs and tools that will ensure
the work is done safely.
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Statutory Requirements: The safety manager also takes care of compliance to pollution
control norms by the govt.
PPE Audits.
RAW MATERIAL
Raw Materials:
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Malt
Hops
Rice Flakes
Broken Rice
Sugar
Water
Additives:
Calcium Chloride
Calcium Sulphate
Lactic Acid
Termamyl
Ultraflow Max
Ceremix
Attenuezyme
Aqungel
Caramel
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Handling of Raw Material:
Materials:
Malt
Malted barley is the main raw material used in the brewing of beer. Malt provides the sugar
that will be fermented into alcohol in the brewing process. Barley is a cereal traditionally grown
in mild maritime climates and for centuries it has been used in the production of beer.
Commonly two species of barley are used for Brewing:
Hordeum vulgare – 6 rowed barley
Hordeum distichon – 2 rowed barley
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Two –row barely has lower enzyme content, less protein, more starch, and a thinner husk than
six row barley. The higher starch content of the two row barley is the principal contributor to
extract.
Two rowed barley varieties produce plumper more symmetrical grains than six rowed and as a
result, six rowed barleys incur greater losses when harvested as smaller grains are screened out.
Over the past thirty years there has been a global move towards growing and malting two rowed
barleys due to their greater yield per hectare.
Malting
Malt is germinated cereal grains which have been dried in a process known as
"malting". The grains are made to germinate by soaking in water, and are then halted from
germinating further by drying with hot air. Malting grains develops the enzymes required to
modify the grain's starches into sugars, including monosaccharaides such as glucose or
fructose, and disaccharides, such as sucrose or maltose. It also develops other enzymes, such
as proteases, which break down the proteins in the grain into forms which can be used by
yeast.
Malting is the process of converting barley into malt, for use in brewing or distilling,
and takes place in a maltings, sometimes called a malt house, or a malting floor. The sprouted
barley is kiln-dried by spreading it on a perforated wooden floor. Smoke, coming from
anroasting fireplace (via smoke channels) is then used to heat the wooden floor and the
sprouted grains. The temperature is usually around 55 °C (131 °F). A typical floor maltings is
a long, single-story building with a floor that slopes slightly from one end of the building to
the other. Floor maltings began to be phased out in the 1940s in favour of "pneumatic plants".
Here, large industrial fans are used to blow air through the germinating grain beds and to pass
hot air through the malt being kilned. Like floor maltings, these pneumatic plants are batch
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processes, but of considerably greater size, typically 100 tons batches compared with 20 tons
batches for a floor malting’s.
The malting process starts with drying the grains to a moisture content below 14%, and
then storing for around six weeks to overcome seed dormancy. When ready, the grain in
immersed or "steeped" in water two or three times over two or three days to allow the grain to
absorb moisture and to start to sprout. When the grain has a moisture content of around 46%,
it is transferred to the malting or germination floor, where it is constantly turned over for
around five days while it is air dried. The grain at this point is called "green malt". The green
malt is then kiln dried to the desired colour and specification. Malts range in colour from very
pale through crystal and amber to chocolate or black malts.
Adjuncts
Barely is the main cereal used for the production of brewer’s malt. However, many unmalted
cereals are used as brewing adjuncts. Adjuncts are regarded, by the uniformed, as a cheap
substitute for malt. The brewing adjuncts contribute mainly carbohydrates to the wort; their
value to the brewer is also related to the flavour and other quality properties which they
contribute to the finished beer. The benefits claimed for solid adjuncts usage are:
1. Reduced starch extracts cost.
2. Improved beer stability and shelf-life especially when maize and rice adjuncts are
used, improved retention properties, especially when barleys or wheat adjuncts are used.
3. To change the character of the beer by altering its colour and flavour.
4. To improve the quality of the beer for example, its fermentability or its haze
potential.
5. To reduce production costs.
Water
Quantitatively water is the predominant brewing raw material with most beers composed of 90-
95% water. Therefore, the condition of this water is of paramount importance to the brewer, as
this will have consequences for the quality of the beer. The importance of water used in the
brewing industry is traditionally so significant (in terms of availability and suitability) that the
location and survival of a brewery has been determined by its water supply. It is easy to ignore
the fact that water has its own unique taste and that this taste differs from geographical area
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where it is present. Let us consider the production of the same beer in different worldwide
locations. If the production conditions are the same, in each brewery, then any differences in
taste may be attributed to the different water source – even if the beers are intended to be the
same. In addition of being a good solvent, water also provides the macro and micro elements that
favour fermentation activities carried out by yeast to a significant extent.
Hops
Hops are the female flowers of Humulus lupulus. Hops, other herbs and spices were probably
first added to finished beer to produce special flavours and cover up “off-flavours” imparted by
microbial contaminants during the earlier days of brewing. Hops are still added to beer during
production. Hop addition is historically recognised to confer bitterness and distinctive aroma or
flavour to the beer, but today hops are recognised as also being able to improve beer stability (in
terms of clarity), head stability, anti-microbial activity and light stability.
In terms of the bitterness of the beer, the hops that are added are key, as its compounds
originating from them that account for the bitter flavour. Hops contain organic compounds called
alpha and beta acids. Most of the bitterness comes from alpha acids, of which there are many,
but five main compounds: humulone, cohumulone, adhumulone, posthumulone and
prehumulone. During the brewing process, they are degraded to form iso-alpha acids; these
compounds are more soluble, and contribute much of the bitterness associated with beer.
Alpha and beta acids have a number of other properties that can be both beneficial and
detrimental to beer brewers. Firstly, both classes of compound have antiseptic properties,
preventing unwanted growth of bacteria and prolonging shelf life, and also enhancing the ability
of the yeast to grow during the fermentation stage. Alpha acids, however, have an unwanted
effect; the iso-alpha acids produced by their degradation can react with light and riboflavin from
the malt to produce unpleasant tasting compounds. Beer in which this occurs is known as
‘lightstruck’, and in order to prevent this from occurring, beer is always stored in opaque
containers or vessels made of dark glass.
Whilst alpha and beta acids provide the bitterness of the beer, essential oils from the hops are
responsible for the bulk of the aroma and flavour. Some of these oils are very volatile,
evaporating easily; for this reason, they are usually obtained by adding hops later in the brewing
stage, or by utilising ‘dry hopping’, a technique which involves soaking hops in the finished beer
for several days or weeks. Some hops are actually specifically grown as ‘finishing hops’ for the
purpose of adding later in the brewing process to produce these essential oils.
Bittering hops (high in Alfa-acids) predominantly provide bitterness although they do confer
aroma. Aroma hops (containing high proportions of essential oils) provide the hoppy aroma, and
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to varying extents bitterness. However, each will impart varying degrees of both bitterness and
aroma.
YEAST:
Yeast is the microorganism that is responsible for fermentation in beer. Yeast metabolizes
the sugars extracted from grains, which produces alcohol and carbon dioxide, and thereby
turns wort into beer. In addition to fermenting the beer, yeast influences the character and
flavor. The dominant types of yeast used to make beer are ale yeast (Saccharomyces
cerevisiae) and lager yeast (Saccharomyces carlsbergenesis); their use distinguishes ale and
lager. Before the role of yeast in fermentation was understood, fermentation involved wild or
airborne yeasts.
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Enzymes:
Additives:
Caramel: Imparts colour to the beer and it is usually added during wort boiling.
Firm aid: Enhances fermentation rate of yeast
Gypsum & Calcium Chloride: It provides macro elements for nutrition of yeast.
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FLOW CHART FOR BEER MANUFACTURING
Cleaning
Sieving
Ambient temp
Conveying & storage of milled malt in grist case
Bottling
Pasteurization
Dispatching
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PROCESS OF BREW HOUSE
MALTING:
There are three stages in the process of converting barley into malt:-
Steeping: Barley is soaked in water to simulate the conditions that start germination or growth.
This is done in a steep tank and usually the tank is aerated to encourage fast moisture uptake by
the barley.
Kilning: During this stage of the malting process, water is removed from the green malt. The
malt then becomes stable and can be stored without deterioration. The malt is also slightly
roasted to give it colour and flavour. The combination of high grain moisture and high
temperature would normally destroy the enzymes developed during germination. Some of the
enzymes, The malt kilning process is manipulated so that the malt is dried at a relatively low
temperature using high flows of air. Then when the malt is dry with a moisture content of around
10%, the kilning temperature is increased so that the malt develops colour and flavour. At the
completion of kilning, the malt’s moisture content will be 4-5%.
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MILLING:
Preparation for milling:
From the silos’ the malt is sent to ASPERATOR, here all the dust particles present in
malt is removed. Then the malt is sent to CLASSIFIER its function is to remove the foreign
materials like threads and plastic pieces. Then the malt passes through the MAGNETIC
SEPERATOR, to remove metals if any. From there with the help BUCKET ELEVATORS
the malt is sent to DESTONER to remove stone particles.
Principles of Milling:
The objective of milling is to break up malt to such an extent that the greatest yield of
extract is produced in the shortest time in the mash filter. With most wort separation systems
it is desirable to keep malt husk as intact as possible, to help for maintain an open filter bed
that favours wort separation. Only comparatively coarse grist’s can be used in mash tuns. If
the grist is too fine (has too high a proportion of small particles) the wort will not separate
from the spent grains. The grist should be uniform in appearance, be free from taints and
insects or other contaminants and should not contain any whole grains or large grain pieces
that indicate that part of the grist has not been effectively milled.
Milling systems may use roller milling, impact milling with disc- or hammer-mills,
and wet milling.
Hammer Mill
A hammer mill may be used if the mash is to be separated in a mash filter.
Here the filter bed is very thin and husk protection is not necessary. A hammer mill
produces a very fine grind.
Hammer mills differ in detail, but the principles of operation are the same. Malt,
sometimes mixed with adjuncts, is fed at a pre-determined rate through a rotary valve or a feed
roll, into the milling chamber, which is strongly ventilated.
The chamber may be mounted vertically or horizontall. The milling chamber contains a
spinning rotor (e.g. turning at 1500rpm) on which are mounted freely swinging pieces of metal,
the beaters or `hammers', which travel at about 100 m/s. The inertia of the rotors is such that
they may take 20±30min.
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Fig: Hammer Mill
The impacts of the hammers on the malt smash it up and this process continues until the
fragments escape through the semicircular screen that makes up part of the wall of the chamber.
Sometimes the inner wall of the chamber also carries short projections against which the moving
malt can impact. The screens may have mesh widths of 0.5, 1.0mm or even 2±4mm. The
powdered grist is carried out of the mill in the airflow, which transports it to the grist case, which
is equipped with explosion vents.
MASHING:
From the grist case the required quantity is sent to the MASH KETTLE for mashing. The
purpose of the mashing was to make the unfermentable sugars to fermentable ones. There is an
agitator inside the mash kettle. It is designed such a way that minimum disruption of the husk will
occur.
Mashing is the process where the crushed malt or grist is mixed with water under specified
conditions so that enzymatic action can take place to convert the starch into fermentable sugars
and in certain cases break down of proteins into more soluble forms also occur.
Beer production starts in the brew house where the malt is processed to release fermentable
sugars.
The production of fermentable sugars from starch is a complex biochemical reaction starting
with ‘gelatinisation’ of the starch by heat. This is where the spiral configuration of the starch
molecule is unwound so the enzymes can attack.
The range of sugars produced during conversion determines the fermentability of the
wort. If the enzyme attack is complete, the wort will be very fermentable. If the enzyme attack is
incomplete, the wort will be only partially fermentable.
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Enzymes are sensitive to the conditions that they work in, they are affected by how much
water is present, temperature and pH or mash acidity. They take time to work, so the length of
time that is allowed for mash conversion will affect the degree of conversion.
There are optimum conditions for mashing and these are illustrated in the table below:-
The process of degradation of starch into sugars is called Saccharification. To know the
degree of Saccharification IODIEN TEST is done.
Iodine Test:
When the mash temp reaches 70 ± 2°C collect the sample from the mash tun to find
whether Saccharification is completed or not. The temperature maintenance was crucial as it
activates the starch degrading enzymes in the malt.
To the sample add iodine solution. If the colour of the solution changes to blue, it
indicates incomplete Saccharification. On the other hand, if the colour of that iodine solution is
not changed, it indicates starch degradation is complete.
Careful control of pH during mashing is essential. Thus, peak enzymatic activity occurs
at the optimum pH for individual enzymes, and the optimum pH is often different for different
enzymes. Thus the mashing pH can affect the relative activities of the various enzymes. There pH
also controls, in part, the amount s of extractives obtained from the malt adjuncts, as well as the
extraction of tannins and bitter resins from the barely husks.
A temperature controlled infusion mash or single decoction mash with an adjunct, should be followed as
specified below.
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The temperature profile to be followed in adjunct kettle:
Adjunct Cooking:
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The adjunct i.e. broken rice is cooked in adjunct kettle.
Broken rice and water are measured and mixed in the adjunct kettle at 650 C. followed by
premashing of hot water and grist or rice. Addition of Termamyl is done. Lactic acid is added to
maintain pH. The temperature profile to be followed is given below:
Wort Separation:
When conversion is complete, the mash will consist of a sugar solution called wort and
the husks of the malted barley. The purpose of wort separation is to remove these husks and
any other particles which are not wanted in the wort. The husks and other particles contain
tannin which is bitter and will make the beer unstable after packaging. They also contain
fatty substances like lipids which will reduce head stability and will also make the beer go
stale.
The objectives of effective wort separation are the removal of unwanted material
while at the same time extracting all the available wort.
There are many systems to separate the wort from the mash, the most common
being:-
• The mash tun.
• The lauter tun.
• The mash filter.
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The modern thin-bed mash filter (e.g. Meura 2001) has several important
refinements as can be seen in the diagram below:-
Plate
Filter cloth
Membrane
Frame
The Mash frames are fitted with an expandable membrane which is inflated in order to
squeeze the mash beds gently and improve yield (extract). This also gives a much drier
The operating principles of the modern mash filter are explained below:-
The mash filter is gives good quality wort, excellent extract recovery and a fast turn
round time.
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3
Pre 7 8 7 73 16 14 23 20 5
compressi
on
First 16 15 18 76 443 590 87 82 20 12. 4.9
spargung 7
WORT BOILING:
When the wort has been separated from the malt husk, it is boiled. There are
several important reasons for doing this:-
• To sterilise the wort. Malted barley is contaminated with moulds, and bacteria mainly
on its surface. These contaminants are extracted into the wort and need to be destroyed.
• To stabilise the wort. The enzymes that converted the starch into sugar and the protein
into amino acid will continue to work. Boiling stops any enzymic action and fixes the
mixture of sugars that has been created.
• To evaporate away the unpleasant aromas that are associated with the wort. DMS,
the sulphury character found in lagers is generated on the malt kiln and during boiling,
it is also evaporated off in the kettle. Aldehydes, the substances t hat give beer an
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unpleasant straw/grassy aroma are evaporated off.
• To dissolve the Bittering resins from the hops and to stabilise them..
• To denature and coagulate some of the protein derived from the malt.
Protein has the potential to make packaged beer go cloudy as it ages. Its removal it at
this stage will protect the beer’s stability.
• To develop wort colour and flavour through the action of heat on sugars and amino
acids (the chemical reaction between sugars and amino acids is known as the Maillard
Reaction).
• Finally, and most importantly, to increase the strength or concentration of the wort.
Wort concentration is a factor in ensuring that the chemical changes described
above actually occur. It is a l s o i m p o r t a n t i n t h e production of strong beers whose
original gravity is higher than that of the wort coming from the wort separation system.
Kettle additions:
The boiling stage is the correct time to add certain other raw materials and process
aids to the brew:-
• Hops or hop extracts are added because the bitter resins (alpha acids) dissolve better in hot
wort. These alpha acids need to be modified by ‘isomerisation’ reactions which are heat
induced to stabilise the bitterness that is typical of beer flavour.
• Adjuncts like sugar are added here because they need to be dissolved and well
mixed. They also need to be sterilised by the boiling wort.
Wort Clarification:
At the end of the boil, the wort will be bright but there will be large
particles floating in it. These particles or flocs contain:-
• Tannin material from the malt husk and from the hops. Tannin is very
astringent
and would pass this character on to the beer. It will also combine with protein to
cause haze problems.
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• Lipids or fatty material that will destroy the beer’s head stability and will also
make the beer taste stale as it gets older.
It is necessary to remove this ‘trub’ to protect the beer’s quality. There are four main
ways of doing this depending on the type of hops used and the requirement
for absolute wort clarity:-
WHIRLPOOLING:
The wort from the kettle is transferred to the whirlpool at a tangent, and
the whole contents of the tank spin. The solids (proteins and hop debris)
aggregate in the centre and continue to settle down. This increases their mass as
they reach to the bottom of the tank.
The solids are spun to the centre and settle into a “trub cone” whilst the
clarified wort can be drawn off from a number of wort outlets for cooling
Wort Cooling:
The wort coming from the kettle will be at 100°C. After clarification and cooling
of the wort yeast i s a dded. The optimum temperature for the start of fermentation,
depending on the yeast strain, will be between 6°C and 20°C. This is why the wort has to
be cooled down before yeast is pitched in. In the present study wort is cooled to 10 0C before
yeast pitching is done.
Originally wort was cooled in shallow open vessels or vertical open coolers, but
now the plate heat exchanger is used exclusively for wort cooling. This is because:-
• Plate heat exchangers are very efficient and can cool the wort down in a short time.
There is a large plate surface area for wort/coolant and the liquids’ flow across the
surface is very fast.
• Nearly all the heat from the wort can be recovered to generate a hot water
supply for brewing and other production uses.
• They are enclosed and are easy to clean in line. Therefore they keep the wort
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sterile.
The hot wort is cooled in a counter current direction against the brewing liquor.
• In general 400 hl of hot wort at around 98 C will be cooled to say 12 C by
around 410 hl of incoming brewing water at 10 C which in turn will be heated to
around 85 C.
• This makes wort cooling a very efficient process recovering most of the sensible
heat from wort boiling which can be used for brewing. The hot water generated
being used for brewing purposes.
100C
The wort that leaves the cooling system is now ready for the next stage of the brewing
process, that is, fermentation.
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Wort Oxygenation / Aeration:
Yeast needs oxygen to encourage growth and the wort cooling stage is the
ideal time for aeration.
It is usual to inject air or sometimes oxygen into the wort stream and as the
amount of dissolved oxygen in the wort affects yeast growth so much, some form of
control is required to guarantee consistency. The control may be by an air flow meter
backed up by dissolved oxygen (DO) measurement.
Aeration can take place before or after cooling. The advantages and disadvantages
of either choice are listed in the table below:-
It should be noted that different yeasts need different levels of oxygen for
adequate yeast growth. Since yeast growth has a direct effect on the level of higher
alcohols and esters produced during fermentation, then it follows that different beers
will need different levels of dissolved oxygen to provide the correct amount of esters
and alcohols.
In practice, levels of dissolved oxygen are finely tuned by each brewery for each
quality to give fermentations that ferment on profile, give an acceptable flavour
match and minimise excessive yeast growth and losses.
In mash filter, filtration is done by using filter plates which have membrane at one side and cloth
at other side. There are 80 plates for filtration and which hydraulic unit is having pressure 80
bars. Sweet wort is added having gravity 25-26. Water sparging is done three times.
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Compression is done to remove extract. Spent grains are removed and this waste of industry is
used for cattle feed.
Yeast Pitching:
Pitching is the term used for adding yeast to the wort to start the fermentation. The choice
of pitching yeast has a major influence on the performance of the fermentation and its
outcome.
Brewing utilizes strains of Saccharomyces carlsbergensis bottom yeast, and
Saccharomyces cereviceae Top yeast. Yeast strains are specially selected for their fermentation
ability to flocculate at the proper time beat the end of the fermentation. As a result, a separate
industry may select and propagate these strains as well as production of inoculums, although
these functions also can be carried out by the brewery itself.
The yeast is pitched in the wort during transfer of wort from plate heat exchanger to fermentor,
which is carried out in pitching room.
1. Orthophosphoric acid- for acid wash of yeast at a pH between 2.1 to 2.3. This
will inhibit bacterial contamination during fermentation.
2. Zinc Sulphate- For supply of micro element Zinc for yeast enzymatic activities.
3. Biofoam- To generate foam and increase the surface area for better fermentation.
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Brew length in HL X 0.0259 X Required pitching cell count in millions X 104 = HL yeast of
Yeast Solids % X Viability % for pitching
For eg: For pitching yeast which has 95% viability and 60% Solids into a 400 HL fermentor, the
above formula can be applied as follows:
400 X 0.0259 X 18 X 104 = 3.27 HL of Yeast
60 X 95
Brewing is different from much other industrial fermentation in that the cell for pitching are
often those recovered from a previous fermentation. In other words, fresh inoculums is not
necessarily prepared for each fermentation run and, in fact, fresh-yeast inoculums usually is
required only when contamination present a real problem or when the viability of the yeast has
began to decline. Before being employed as inoculums, the yeast cells from a previous
fermentation are washed (with phosphoric acid, tartaric acid, or ammonium per sulphate) by
settling, as procedure that reduces the pH value from 2.1 to 2.3 and removes considerable
bacterial contamination, if present. Thus each pound of yeast added to the fermentation at
inoculation yields approximately 3-4 pounds liquid yeast at harvest, and the excess yeast not
required for further use as inoculums becomes a by – product of the fermentation.
Approximately three – quarters to one pound of yeast are added for each barrel of wort, and
within 24 hrs after pitching, foam begins to appear on the surface of the medium, first along the
wall of the tank and then gradually across the surface. The carbon dioxide evolution then
increases so that the yeast cells become suspended in the medium. Initially the temperature of
the fermentor post pitching is maintained at 12oC to facilitate yeast growth. Thus it should be
noted that the
brewing fermentation is again unusual as regards the of these very low incubation temperature.
By approximately 40-60 hours after pitching, the surface foam layer becomes very thick and can
measure up to almost 12 inches in depth. It is during this time that the most rapid yeast – cell
multiplications occur, and considerable heat, which is associated with this high metabolic
activity, is evolved. This heat evolution causes a temperature rise to approximately 12-15 oc, the
35
peak temperature for this fermentation. This will enhance the activity of enzymes involved in
fermentation that convert all the reducible sugars to alcohol and Co2.The Original gravity of the
wort gradually drops from 15.5 to 2.2 due to conversion to sugars to alcohol by yeast. Diacetyl is
a significant intermediate produced by yeast during fermentation, which is further metabolised to
aldehydes and Co2 at temperature about 15oC.
By approximately the fifth day of fermentation, there is no longer enough carbon dioxide
evolution to support the heavy foam and, therefore, the foam begins to collapse. Also, the
decreased evolution of heat by the cells allows the medium to be cooled by the cooling coils.
From seven to nine days, the last phase of the fermentation, the yeast become starved and
flocculate, the “yeast break”. The yeast settle to the bottom, and the medium is further cooled to
below 5oC to fasten settling. At this time, the Diacetyl of the fermentor checked to confirm its
consumption by yeast. Or, Diacetyl left in significant levels in fermentor (>0.07ppm) would
often contribute Buttery flavour which is undesirable in finished beer. Some of the surface scum
may be removed to help improve flavour.
Yeast is collected in storage tanks maintained at temperature 4.5 oC, which can further be used
for next batch of fermentation.
Post separation of yeast from fermenter the temperature of the medium is further cooled to
around -1oC, This facilitates the precipitation of suspended solids, there by clarification of the
beer to promote clarification lager chemicals like Shine aid, KMS, Flocaid are added and beer is
left for 5-7days.This process is called Maturation/Aging.
FILTRATION:
From Fermenter beer is sent to Pre Buffer Tank. In Pre buffer tank the beer is stored in
order to reduce the flow pressure. From this the beer is send to FILTROX1 it is composed of
steel candles. The se candles are deposited with Hyflo Food Grade Powder (Diatomite). This
powder will help in removal of yeast, other suspended particles and dust in the beer. Now the
beer is send to FILTROX2. It is composed of several candles; they will remove the dust and
suspended particles, if any. Now the beer is send to Post Buffer Tank. From there it is send to
Corboblender. The function of Corboblender is that is addition of carbon dioxide and also to
control the foam in the beer. The Corboblender is attached with an equipment called
ANTONPAAR helps in on line monitoring of critical parameters like Co2, Gravity, Alcohol
content, which work with the principal of Henry’s law (with the help of temp and pressure
carbon dioxide can be calculated).
Then the beer is passed CONTROLLING VALVE to reduce pressure. Now it is send to BIGHT
BEER TANK (BBT). For the storage, through PLATE HEAT EXCHANGER to maintain the
temp
36
at -1 0 C. from BBT the beer passed through TRAP FILTER. Where the haze presents in the beer
is removed than the beer is send to BOTTLING and KEG FILLING.
Beer packaged in barrels or kegs is not pasteurized and, hence, has a relatively
short storage life. Beer for bottles and cans, however, often is pasteurized after capping
of the bottles or closing of the cans, although bulk pasteurizes are now employed by
many breweries. The pasteurization of beer, however, affects its flavour and, to correct
this situation, recent innovations now allow the sterilization of beer without the use of
pasteurization so that the keg flavorful is maintained along with good keeping quality.
Carbonation
Carbonation of the beer is accomplished either by injecting of cleaned carbon
dioxide recovered from the evolved fermentation gas, or by the “Krause’ process in which
actively fermenting yeast is added to provide the so-called “natural carbonation”. Addition
of carbon dioxide which is the most common practice, provides a final dissolved carbon
dioxide dissolved oxygen, which is detrimental to the stability of the beer, and helps in
the production and retention of foam and in the preservation of the beer.
The parameter such as D.O, Color, Alcohol content, CO 2, Haze Bitterness, O.G, A.E,
Diacetyl & pH are analyzed from the B.B.T, Beer.
Bottling of Beer:
Once the final quality of the beer has been achieved, it is ready for bottling. The bottling
of beer is one of the most complex aspects of brewery operations and the most labor intensive of
the entire production process.
37
1. Bottle washing
2. Slighter Station 1
3. EBI
4. Bottle filling
5. Bottle crowning
6. Tunnel pasteurization
7. Bottle labelling
8. Case packing
1. Bottle washer: - Empty bottles are unloaded from trucks and the bottles having perfect shape
without any crakes or damage are only used. The bottles are separated manually according to the
brand they belong to. These bottles are then pre-rinsed with normal water to remove any dust or
mud particles from bottles for prolong life of caustic. Now the bottles are sent to washer where
they are washed with hot water of 80oC and caustic. The washer is provided with jetters that
flush the bottles from inside as well as from outside. There are 3 caustic zone in washer.
a) 1st zone- in this zone the caustic level is maintained at min 2.5%.
b) 2nd zone- in this zone the caustic level is maintained at min 2.5%.
c) 3rd zone- in this zone the caustic level is maintained at min 2.0%.
The bottles washed with caustic are germ free and all kind of dirt is removed along with labels
and foils. After treating with caustic, bottles are subjected to wash with soft water to remove
caustic traces. The capacity of washer is 36000bottles/hr and 47 bottles/line can be washed in it.
2. Sighter Station 1:- Sighters are the people who ensure the proper washing of bottles. There are
4 sighter stations after washer. The sighters observe the bottle coming out of the washing and
remove the bottle having:
a. Any damage or crack.
b. Any foreign matter.
38
c. Any dirt.
d. Presence of caustic.
The observation is done with back ground as white screen for better vision of bottle.
4. Filler and Crowner: - Filler is the important part of packaging. The bottles must be filled with
accurate amount and pressure of beer and carbon-di-oxide. Carbon-di-oxide is the best
preservative for beverages. The filler has double evacuation system. Jetter implies the pressure of
0.85bar on bottles to suck out all air from bottle. It this process some bottles may burst because of
being old or losing their strength. The bottles are filled with carbon-di-oxide and sucked out twice.
Now the bottle is filled with beer at the temperature of 0 0C. Again carbon-di-oxide is passed in
bottle at high pressure that helps to throw out other unwanted gases from beer filled bottle. 104
bottles are filled in each single rotation of filler. A fobbing Jetter passes a rapid vapour of hot
water and removes surface oxygen over beer in the bottle, before crowning. The bottles are now
crowned in crowner which can crown 13 bottles per rotation. Thus, it runs 8 times faster than
filler.
1) Pre-evascuation - 400ms
2) Rinsing- 300ms
3) Pre-evascuation- 800ms
4) Blowing out- 70ms
4. Sighter Station 2:- At this sighter station sighters check bottles of following types and
remove them from line. a) Empty bottle b) Low fill c) High fill d) Chipped bottle e) bottle
with dirt e) Bottle with suspended particles in beer f) Other brand embossed bottles g)
Bottles with plastic sachet or any foreign matter in beer h) uncrowned bottles i) Bottles with
label carry over j) bottles with external damage at shoulder or base k) Bottles with defective
crowns (leakage). l) Bottles filled with water or any chemical liquids
39
controlled manner. A typical tunnel pasteurizer has different zones in it as shown below.
Beer bottles are passed through different zones of pasteurizer in the sequential manner. The
temperature starts from 250C in R1H, increases to 350C in R2H followed by 450C in R3H
then to Pasteurization at 620C in P1, P2, P3, and P4. Now it again decreased in R3C to 45 0C,
to 350C in R2C and to 250C in R1C. This whole process takes place in 56.9 minutes.
25.0 35.0 45.0 62.0 62.0 61.9 61.8 45.0 35.0 25.0
BOTTLE BOTTLES
S IN OUT
6. Sighter Station 3:- Sighters perform the same work as they do in sighter station -2 to ensure
quality of the product bottles.
7. Case Packer and Palletizer: case packing is done with the help of packing machineries
which take the bottles from line by creating vacuum between bottle and holder and put into
case. The case is packed with 12 bottles in it.
Wooden or plastic pallets are arranged by palletizer such that each pallet takes up
68 cases. The pallets are then shifted to warehouse by fork lift machine for dispatch after
quality approval.
Caustic analysis
Total Caustic strength:
40
ALUMINATES:
Carbonates
Take 10 ml of sample.
Add one full spoon of barium chloride.
Add 2-3 drops of phenolphthalein indicator. After adding pink color appears.
Titrate against 1N HCL until it becomes milky white.
Mark this titer value as “P3”.
% Aluminate = P2×0.01
% Carbonates = (P3-P1)×0.053
Yeast Propagation
The development of pure yeast strains and their importance in the brewing process has been
going on for over a century and is still an active area of research. In 1883, Emil Christian
Hansen described the first techniques for successfully isolating single yeast cells and
propagating them to a larger scale. This was a landmark finding since up until then all yeasts
were a mixture containing various forms of brewing yeast, wild yeast, bacteria, and
molds. Brewing with these mixtures of micro-organisms was difficult. Beer spoiling was
common and there was wide variability in beer quality. Hansen's techniques changed all that
and were quickly applied to improving large scale beer production; first in the Carlsberg brewery
and a few years later in American breweries. Current propagation techniques remain similar to
those first described by Hansen. Further characterizations of yeast physiology and fermentation
technology, however, have also influenced the current methods used to propagate and maintain
yeast.
41
optimal in the presence of oxygen. In this case, yeast will rapidly grow to high densities and will
convert sugar (glucose) to carbon dioxide and water. Under anaerobic conditions, yeast grows
much more slowly and to lower densities and glucose is incompletely metabolized to ethanol and
carbon dioxide. It is important to realize that optimal yeast growth is distinct from
fermentation. Therefore, the conditions and methodologies used for propagating and
maintaining yeast need not be identical to those used for fermenting wort. The purpose of a
yeast starter is not to produce an enjoyable fermented beverage but rather to produce a sufficient
quantity of yeast for subsequent fermentation. Propagation conditions should be such that a
maximal amount of yeast is produced which provides optimal fermentation performance once
pitched. What do we mean by fermentation performance? The main criteria for fermentation
performance is based on the rate and extent of fermentation as well as the production of a beer
with a balanced sensory profile with no off-flavors/aromas or inappropriate esters. The former
refers primarily to attenuation (technically referred to as the apparent attenuation) and is usually
indicated by the percent reduction in gravity or:
Apparent Attenuation = (O.G. - F.G)
(O.G)
Apparent attenuation between 70-85% is normal for most yeast. Also fermentation should
occur rapidly and be completed within 3-5 days.
Factors influencing yeast growth
Several factors influence both yeast growth (and fermentation) and therefore should be
considered when propagating and maintaining, and yeast. The most important are oxygen, pH,
temperature, and wort composition.
Oxygen. As mentioned above oxygen or aeration is essential for good yeast growth and is the
driving force behind many aspects of yeast metabolism including fermentation. Oxygen is
quickly absorbed by yeast and is used to synthesize unsaturated fatty acids and sterols which
form the cell membrane. These molecules are important for both growth and fermentation and
serve as a means of storing oxygen within the cell. They are also necessary for increasing cell
mass (growth), improving the overall uptake of nutrients, and determining alcohol
tolerance. Oxygen also stimulates synthesis of molecules necessary for yeast to metabolize and
take up maltose, the primary sugar in wort.
Well since oxygen directly correlates with rapid growth and increase in yeast mass (cell
number), aeration during yeast propagation should increase the overall number of yeast cells. In
other words, your starters need to be well-aerated.
In terms of fermentation, aeration is also important but only in the early stages (first 6-24
hours). Aeration in later stages can oxidize beer constituents and lead to the development of off-
flavors. Since aeration sets the stage for maltose fermentation and alcohol tolerance.
The levels of oxygen necessary for optimal fermentation vary depending on the yeast
strain. Ale strains usually need between 8-12 part per million (ppm) while lager strains
require slightly higher amounts (10-15 ppm).
42
temperature for propagating brewing yeasts. At this temperature rapid growth and
fermentation occurs without any adverse affects on subsequent fermentation performance.
Lagers, however, should be pitched at lower temperatures (60 °F or lower). In this case it
may be necessary to acclimate the starters to a lower temperature to prevent cold shocking
them. This can be done by slowly lowering the temperature of the starter the day before. Yeast
growth and fermentations are energy generating processes and therefore generate heat. The
temperature within the fermenter can be as much as 8 °F higher than outside of the fermenter
during the first few days of fermentation. So beers that are fermenting in refrigerators set at 65
°F are most likely fermenting at about 72 °F.
Wort or media composition. Wort (or media) composition also determines yeast growth and
fermentation performance and is important in maintaining and storing viable, stable yeast. In
terms of fermentation, standard brewing wort contains most of the ingredients necessary for
fermentation. Problems arise only if the nitrogen composition is low. This occurs only if a
cheap or poor quality malt extract is used or if there are a large amount of adjuncts added.
Some experiments indicate that the addition of certain yeast nutrients can increase the rate of
yeast growth but not the overall concentration or yield of yeast. Thus the addition of yeast
nutrient to starters can help accelerate their growth.
Zinc also supposedly improves yeast growth and fermentation and is added to the propagation
tanks in some British breweries. 0.5 ppm zinc is optimal.
pH. The last factor to affect yeast growth is pH (a measure of acidity). Yeast grow well at
acidic pH. They grow best between pH 4 to pH 6. Normal wort is acidic with a pH near
5.2. During growth and fermentation the pH drops to about 4.1-4.2 and in some cases even
lower. The further acidification of the wort helps to prevent bacterial infection. (Most bacteria
cannot tolerate acid pH). Yeast can survive at very low pH, as low as 2.0. This is the basis of
acid washing where the bacterial load of a yeast slurry is reduced prior to repitching by lowering
the pH to 2.2. Most bacteria will be destroyed at this pH while a good percentage of the yeast
will survive.
Yeast is the unicellular fungi which give the best conversion rate of sugars to alcohol. Yeast has
the special character that it is facultative and can live as haploid when starved, as well as diploid
when there is a plenty of nutrition. Thus, it divides rapidly and delivers the sufficient quantity of
invertase and zymase that convert sugars into alcohol and carbon dioxide in anaerobic
conditions. Thus, even at low concentrations the yeast is efficient in carrying out fermentation.
Yeast Propagation refers to culture the yeast in wort itself from small quantity to Hectoliters to
maintain the viability of Yeast and Yeast solids in UniTanks. Culturing of yeast in wort make
yeast’s progeny to become habitual of the conditions of wort
43
6. Culture purity testing by inoculation of sample from slant, on WLD,YMCA, MRS and Lysine
media.
7. Incubation of inoculated flask at 20-25°c for two days.
44
SATGE 6 – Unitank inoculation
1. CIP of 311 and ensuring micro clearance of CIP sample.
2. 100 HL Wort collection into 311 and addition of 44.1 gm of Zinc sulphate.
3. Transfer of yeast from YPV III (30 HL) to 311.
4. Aeration of culture at 311 by passing oxygen through pre-sterilized 0.2 µ filters.
5. Viability, cell count of inoculum and gravity monitoring after every 12hrs to ensure active
growth of yeast.
6. Culture purity testing by inoculation of sample from YPV II, on WLD, YMCA, MRS and
Lysine media.
7. After cell count in UT 311 reaches 60 millions/ml, Top up the UT 311 with 260 HL of wort
(with 114.4 gm of Zinc sulphate in it) to get final volume of 400 HL.
Aseptic transfer of yeast inoculum was done for scale up of culture up to fermentor stage. For
every stage of yeast propagation Cell count, Viability and Gravity were monitored.
1. Cell Count:-
Cell count was done on Heamocytometer for estimation of approximate no. of cells in tank.
Procedure:
Sample was collected in a screw-cap tube and mixed well on vortex.
9 ml of saline solution was taken in a test tube and 1ml of sample was added in it.
The diluted sample was mixed well for 10 to 15 sec on vortex.
A cover slip was put on Haemocytometer and carefully the diluted sample was applied between
the cover slip and Haemocytometer through the Grove.
The preparation was observed under microscope using 40X lens.
Cells visible in four corner squares and one centre square (out of 25 squares) were counted
In each square, cells present on left and bottom lines were only counted. Each budding cells with
daughter cell with at least of half of the mother cell size were counted as two.
Calculations-
Total cell count = Total no of cells in 5 squares X 5 X dilution factor X 104.
2. Viability:-
Viability of Cells was measure to know the active stage of yeast growth in propagation stages.
Procedure-
1 ml of the sample diluted in saline solution was taken in micro pipette and added to 1 ml of 0.01
% Methylene Blue solution and mixed well on vortex.
Dead cells uptake the Methylene Blue and get stained with blue colour.
Cells were observed under microscope with 40X lens.
Observation of at least 200 or more total cells was done for accurate study of viability.
Calculations-
Viability = No. of viable cells X100
No. of Viable cells + No. of Dead cells.
45
3. Gravity Measurement: After yeast culture was transferred to Yeast propagation vessels, gravity
was monitored at interval of every 12 hours to ensure proper growth rate.
Procedure:
Sample from propagator was collected and thoroughly agitated for mixing and degassing.
Pycnometer was filled with sample and thermometer was inserted without any air bubbles.
Sample weight at 200C was taken and compared with reference table for specific gravity.
Calculation:
Specific gravity (g/cc) = (Weight of pycnometer with extract – Weight of empty pycnometer)
(Weight of pycnometer with water – Weight of empty pycnometer)
INWARD INSPECTION
Once the raw materials are produced they are sent in the quality control department for
assessment. The quality chemist will check whether the raw material is up to specification and if
there any rejection notes are sent to supplier along with defect details. After the inspection the
raw materials are sending to production.
BARLEY
Appearance:
Malt Should be golden brown in colour without any spot and free from foreign matter like straw,
stones and broken grains.
Adjuncts like broken rice /rice flakes should be clear from dust and whitish in colour.
Kettle test
46
Moisture content
Apparatus:
1. Buhler universal laboratory disc mill set to a gap of 0.2 mm to give fine grind/ grinder.
2. Moisture Analyzer
High moisture will lead to microbial growth and also increases its weight in spite of less content of
original material.
Procedure:
5grams of grinded malt or broken rice sample was taken in moisture analyzer
Temperature of moisture analyzer was set at 105 oC
The instrument was left undisturbed, until the moisture content was displayed on the screen.
Apparatus:
Analytical balance
Procedure:
Calculation:
47
1000 corn weight on dry weight basis = W x 1000(100-M)
N x 100
Where,
Sieve analysis:
Apparatus:
Specification:
48
Broken Rice
Principle
A test portion of the broken rice is added to a solution containing two pH specific indicators. The colour
change of the solution is a measure of the formation of fatty acids by oxidation during storage, and is
therefore a measure of the freshness of the rice.
Reagents
1. Solution A: Dissolve 0.1 g (± 0.005 g) Methyl Red and 0.3 g (± 0.005 g) Bromothymol Blue in about
150 ml of analytical pure ethanol in a 200 ml glass-stoppered volumetric flask, and make up to the mark
with distilled water.
Ensure that the test samples are fully representative of the lots from which they are drawn. Therefore, mix
carefully before sampling.
Procedure
49
Stage of oxidation:
Expression of results
Note the colour of the solution and report the freshness (i.e. fresh, old or very old).
Notes
Unbroken rice samples may also be tested by this method. However, in the experience the colour change
(from green to yellow) is not observed within the first year. In view of the long storage period required,
this test is not normally recommended for unbroken rice.
Appearance:
Observe against white background and report as white, cream, amber, brown, buff, gray etc. Observe for
intensity and uniformity.
Specification:
Procedure:
Calculation:
50
PH of 10 % Sugar solution
Procedure:
Sufficient volume of 10% sugar solution was taken in a glass beaker which is enough to dip the
tip of electrode. PH reading was noted when it attained constant value.
Procedure:
Calculation:
Extract%= P X BX 500
Where,
CARTON
51
Length
Width
Height
Number of flutes
Outer (VK)
Corrugated (ARK)
Inner (SVK)
GSM,
Bursting Factor
Moisture
CARTON BROWN
DUPLEX
TYPE KRAFT
BOARD 3 ply 3PLY
NO. OF
50-56/30cm 50-56/30cm
FLUTES
BOARD
Min 380 GSM Min 435 GSM
SUBSTAN
(+ 5%) (±5%)
CE
COBB
NMT 155g/smm NMT 155g/smm
VALUE
CUTTING
& SATISFACTOR SATISFACTOR
CREASIN Y Y
G
52
Y Y
Bottle height
Bottle weight
Bottle Diameter (Shoulder)
Bottle diameter (Label space)
Bottle diameter (Bottom)
Brimful capacity
Fill point
Volume at fill point
Neck diameter
Internal neck diameter
Body label panel height
Height of embossing
CROWN
Internal defect
Shade variation
Change in text
Peeing of lacquer
53
Spot and smudges
Without liner
Other Brand
CuSO4 test
Dimension analysis
1. Skirt diameter
2. Internal diameter
3. Weight of liner
4. Height
5. Weight of Crown
6. Liner adhesion test
Sl. Specification
No. Description s
1 Dimensions
Height 5.78-6.18 mm
Weight Of The
3 Crown 2.25-2.40 g
Shall Pass
4 Liner Adhesion Test Test
Shall Pass
5 Lacquer Quality Test
Shall Pass
6 Taste Testing Test
Shall Pass
7 Pressure Retention Test
54
Test
Shall Pass
9 Visual Defects Test
LABELS
Wrong labels
Torn labels
Legal declaration
Defect in paper
Color missing
Incorrect or wrong color
Labels sticking together
Mutually displaced color
Colors Partially missing
Color coming off
Description Specification
Dimensions
Back Label 50 x 65 mm
Grammage 75 ± 3 g / Sq m
Border
Front label : A uniform border of 2.0mm± 0.25 mm &
Neck label : A uniform border of 2.0 mm ±0.25 mm
55
IN PROCESS INSPECTION
The store department passes these raw materials to the production department as per the
necessity. Here again the raw materials are inspected while they are in the process, these reduce
wastage and ensure optimum usage of resources. During their routine round they also check
whether the batch no is printed properly or not.
Mashing of malt.
Gravity (Mild – Low and Strong – High)
Lautering. (Initial gravity or Final gravity)
Wort kettle. (Bitterness according to European Brewing Convection ), Color
Cold storage tank
Della Tofolla Filtration. (Dissolve oxygen if DO is more than beer will be spoiled fast) ,
Haze
Bottling hall
For washing the bottles the concentration of caustic is checked.
Line inspection
Checking the bottles after bottling
Shelf life of beer
Beer is placed in water at a temperature of 600C if turbidity occurs within one week than
the beer will remains only for two month
Microbiological Analysis
Test to check whether the beer is not affected by micro-organism.
Carbon dioxide test
To check the amount or concentration of CO2 present in beer.
Sensory Analysis – Beer of every batch is tested by the chemist and head brewer
Alcohol content and Effluent treatment plant.
56
CHEMICAL ANALYSIS
Water analysis
1 Appearance:
The appearance of the water should be clear, colourless, sparkling and free from any suspended solids. Any
abnormality observed should be mentioned properly.
2. Odour:
The odour should be reported as odourless, abnormal or nothing abnormal.
3. Taste:
Taste of water should be normal. It should not give any unnecessary taste that might have been incorporated into it
from other sources. Any such abnormality should be reported.
57
CHEMICAL TESTS
1. pH
Apparatus:
pH meter
Thermometer
Magnetic stirrer
Reagents:
Buffer solution (pH - 7, 4 & 9) which are used for calibration of the pH meter.
Procedure:
Take sufficient volume (50 ml) of water sample in a glass beaker which is enough to dip the tip of
electrode. Note the pH reading when it has attained constant value at 25°C
2. Chlorides
Principle:
Argent metric titration: The sample is titrated against standard silver nitrate solution (AgNO 3) using
potassium chromate as indicator. Silver chloride is precipitated before red silver chromate is formed.
Apparatus:
Procedure:
58
Take 100 ml of water in conical flask (Adjust the pH between 7-10 with sulphuric acid or sodium
hydroxide)
Add 1 ml of 5% potassium chromate
Titrate with 0.0141 N silver nitrate (Va)
End point is appearance of pinkish yellow colour
Establish reagent blank value by titration (Vb)
Calculation:
Vol. of sample
3. Total Hardness
Hardness in water is defined as presence of multivalent cation like carbonates and bicarbonates
Apparatus:
Flasks
Pipettes
Burette 50ml
Principle:
This is complex metric titration of Ca2+ and Mg2+ using eriochrome black T (EBT) indicator. When EBT
is added to a solution containing Ca2+ and Mg2+ ions at pH 10 a wine red complex is formed. This solution
is titrated with standard solution of disodium salt of EDTA, which extracts Ca 2+ and Mg2+ ions from the
dye complex and the dye is changed to its original blue colour.
Reagents:
59
Procedure:
Calculation:
Apparatus:
Procedure:
Take 100 ml of water sample (preferably a sample volume which will give 100-200mg of residue)
in a dried, pre- weighed evaporating dish
Filter through Whatman filter paper No. 542
Keep it for drying in a oven initially 98°C for evaporation to prevent boiling and splattering
Dry at 103°C-105°C for 1-2 hours; dry to a constant mass.
Cool in desiccator
Note the final weight
Calculation:
60
TDS (mg/L) = (B-A) X1000
Volume of sample in ml
Where,
5. Total acidity
Apparatus:
pH meter
Burette 50ml
Magnetic stirrer
Reagents:
0.02 N NaOH
0.02 N potassium hydrogen phthalate
Phenolphthalein indicator
Procedure:
Calculation:
61
Volume of sample in ml
6. Total alkalinity
Apparatus:
pH meter
Burette 50ml
Magnetic stirrer
Reagents:
0.02 N H2SO4
Methyl orange indicator
Phenolphthalein indicator
Procedure:
Calculation:
WORT ANALYSIS
Specific Gravity
62
Procedure:
The sample was collected and cooled to around 150C so that the temperature of sample does
not go beyond 200C at the time of weighing
The pycnometer was filled with sample, and its outside was dried by rubbing with a clean
cloth
As the temperature of the sample reached 20 0C weight of the pycnometer with sample was
noted.
Calculation:
Specific gravity (g/cc) = (Weight of pycnometer with extract – Weight of empty pycnometer)
(Weight of pycnometer with water – Weight of empty pycnometer)
The obtained value was compared with reference table and specific gravity was determined.
Colour
Procedure:
The sample was degassed and filtered, and the filtrate was taken.
Absorbance of filtrate was noted at 430 nm in spectrophotometer, using water as blank.
Calculation:
Reagents Preparation:
CMC-EDTA: Slowly add 10 g of sodium carboxymethyl cellulose and 2 g of disodium
EDTA to 500 ml water with continuous stirring. Dissolve the solid material by
homogenization and make the volume up to 1 liter. If required centrifuge the solution.
Ferric reagent: Dissolve 3.5 g green ammonium iron citrate in 100 ml water. The
solution must be completely clear. Prepare freshly each week and store in the dark.
Ammonium reagent: Dilute 100 ml of concentrated Ammonia to 300 ml with water.
Procedure:
10 ml of malt extract was taken in 25 ml of volumetric flask
8 ml of CMC-EDTA solution was added.
Volumetric flask was stoppered and mixed thoroughly
0.5 ml of green ferric ammonium citrate solution was added.
0.5 ml of ammonia water was added.
The final volume was made up to 25 ml
In case of blank green ferric ammonium citrate was not added
The preparation was mixed and kept for 10 minutes at room temperature
The absorbance was recorded at 600 nm.
63
Calculations:
Total polyphenols in ppm = Absorbance at 600nm x 820 x Dilution factor (if required)
Procedure:
1 ml of wort sample was diluted to 100 ml with distilled water in a volumetric flask
2 ml of wort ( sample) was taken in 2test tubes (For duplicates)
1 ml of ninhydrin was added to each test tube
The test tubes were Stoppard and placed in boiling water bath for 16 minutes
The test tubes were cooled to room temperature by placing in ice bath for 20 minutes
5 ml of KIO3 solution was added to each test tube and mixed thoroughly
Reagents are added to 2 ml of water instead of wort and used as blank
Reagents are added to 2 ml of glycine instead of wort and use as standard
The absorbance was recorded at 570 nm.
Calculations:
FAN (ppm) = A1 x 2 x d
A2
Where,
A1 = Absorbance of test solution at 570 nm.
A2 = Mean absorbance of standard solution at 570 nm.
d = Dilution factor
64
Scope
The determination of the residue in wort using a gravimetric method.
FIELD OF APPLICATION
The method can be applied to all worts.
The gravimetric method is the reference method and the centrifugal method is given as
an alternative.
PRINCIPLE
A known quantity of wort, which should be representative for the entire brew, is filtered through
2
Previously weighed filters. The filters with the residue is rinsed, dried and weighed. The residue
content of the sample is calculated from the weight increased after drying.
REAGENTS
Desiccant of self-indicating silica gel or other effective drying substance.
APPARATUS
Desiccator, containing a thick, perforated plate of metal or porcelain.
Oven, set at 105.0 °C ± 0.5 °C.
Analytical balance, accurate to 0.001 g.
Measuring cylinders, 500 ml.
Suction Erlenmeyer flasks, 1 litre, fitted with a set of conical rubber rings.
Vacuum aspirator, water jet suction pump to give less than 20 mbar vacuum or vacuum
pump.
Büchner funnels, porcelain type, 125 mm filter diameter.
Filter paper circles, Schleicher & Schuell No 5891 (black ribbon), 125 mm diameter.
Water bath, set at 20 °C ± 1.0 °C.
Preparation of samples:
Samples should be shaken just before pouring the sampling onto the filter because solids
can sediment in the sample container.
Samples have to be brought to room temperature by immersion the sample container into
a 20 °C water bath for 30 minutes.
Procedure:
Dry the required number of filter paper circles (2 for each determination) at 105 °C for 6
hours. Allow to cool in a desiccator to room temperature (generally between 30 and 45
minutes), and determine the dry weight of each filter to the nearest 0.001 g; state this
figure on the filter.
65
After the sample has been well mixed by manually shaking, 500 ml of it are measured
into a measuring cylinder.
Connect a suction Erlenmeyer flask with the vacuum aspirator and place a Büchner
funnel into the suction Erlenmeyer flask (use the conical rubber rings).
Place 2 dried and pre-weighed filter paper circles into the Büchner funnel and fix the
filters (by suction) with a little bit of distilled water at 20 °C.
Filter 500 ml of wort through the Büchner funnel. Stop suction when the residue appears
dry. Rinse the residue on the filters three times with approximately 20 ml of distilled
water at 20 °C. Finally, take the filters from the funnel and fold together.
Dry the filters at 105 °C for 24 hours, allow to cool in a desiccator to room temperature
(generally between 30 and 45 minutes), and weigh to the nearest 0.001 g.
Expression of results
Calculation:
Calculate the residue per litre of wort by adding up of the results of two 500 ml
determinations.
Express the residue in mg/litre to the nearest 10 mg.
Principle:
The TBI provides an indication of the quantities of substances present in 100 ml of wort or malt
extract which give rise to a yellow coloration using acetic acid thiobarbituric acid. The
thiobarbituric acid number is obtained by multiplying the adjusted absorption value with a factor
10 and a dilution factor, and, if necessary, standardizing the result to a 12 % m/m (= 12 °Plato)
product.
Reagents:
1. Acetic acid 90 % solution
Dilute 225 g 100 % Acetic acid with distilled water to 250 g.
66
Dissolve 0.288 g thiobarbituric acid (M = 144.15 g/mol) in a 100 ml volumetric flask with 90 %
acetic acid solution by warming in the water bath at 70 °C. After cooling down to 20 °C, make
up to the mark with 90 % acetic acid solution .The solution should be made fresh every day.
3. Kieselguhr, if necessary
Apparatus:
1 Spectrophotometer, to determine absorbance at 448 nm (accuracy at least ± 0.5 nm; this can
be checked using a holmium oxide filter)
2. Cuvettes, glass or polystyrene, optical path length 10 mm3. Water bath, set at 70 °C (± 1 °C)
4. Brown reagent bottles: 20 or 25 ml
5. Orbital shaker, the same shaking device as described in the determination of the apparent
attenuation limit
Preparation of samples:
Samples must be bright. If a sample is not bright it must be clarified with kieselguhr.
The dilution needs to be chosen as such that the final absorbance after reaction with
thiobarbituric acid is
in the range of 0.1 to 0.5.
Under normal circumstances the following dilutions are applicable:
- Congress wort (from pale and dark malt): 5-fold dilution with distilled water
- Production wort: 20-fold dilution with distilled water.
Expression of results
Calculation
Thiobarbituric acid Index (TBI) in the test sample by using the following formula:
TBI = 10 · F · (ER – Ew)
Where:
TBI = Thiobarbituric Acid Index (dimensionless)
F = dilution factor
ER = absorbance at 448 nm of the test sample
EW = absorbance at 448 nm of the blank sample.
10 = conversion factor
Standardize, if necessary, to 12 % m/m (= 12 °Plato) wort by multiplying the TBI value found
with the ratio
of [12 %m/m] / [extract value of the initial wort in %m/m].
8.1.2 Express and report the TBI value rounded off to the nearest whole number.
8.2 Precision
This has not yet been established.
CAUSTIC ANALYSIS
67
Caustic test
Caustic test:-
Titration by 3N HCL
Titration
Titration
68
QUALITY CONTROL
- It is the most important section as the quality of the final product that is ready for sale
needs to be checked very keenly
1. Air test
2. Alcohol test, Original gravity, Present Gravity and Haze
3. Bitterness test
4. Calcium test
5. Color test
6. CO2 purity test
7. DO test
8. Diacetyl test
9. Iron test
10. Invertase test
11. Polyphenol test
12. SO2 test
13. Yeast Analysis
BEER ANALYSIS
Alcohol in Beer:
Procedure:
100 ml of decarbonized beer at 20o C was taken in 500ml round bottom flask.
The volumetric flask was rinsed with distilled water not more than 50 ml &added this
rinsed water to distillation flask.
The distillation apparatus was assembled and 100 ml volumetric flask was used to
receive the distillate.
The distillate was collected about 96-97 ml and made up to 100ml with distilled water,
mixed thoroughly & the Specific Gravity was measured at 200 c.
69
Calculations:
Specific gravity (g/cc) = (Weight of Pycnometer with extract – Weight of empty Pycnometer)
(Weight of Pycnometer with water – Weight of empty Pycnometer)
Reference table was used to note down the alcohol content as w/v and v/v.
Apparent extract:
Procedure:
The specific gravity of de-carbonated beer was measured at 20°C.
Calculation: Specific gravity of de-carbonated beer = W 1-W2 / W3-W2 Where, W1 = Weight
of Pycnometer with de-alcoholised beer.
W2 = Weight of empty Pycnometer.
W3 = Weight of Pycnometer with water.
The value of apparent extract in °P, i.e. grams of extract in 100 grams of de-carbonated beer was
recorded by using standard table.
Real extract:
Procedure:
The residue from the distillation flask after alcohol distillation was transferred
quantitatively to 100ml volumetric flask with the aid of hot water, cooled and made the
volume up to 100ml with distilled water at 20°C.
Specific gravity of the solution is measured at 20°C and by using Pycnometer.
Calculation:
Sp.gr. of de-alcoholised beer = W1-W2
W3-W2
Where,
W1 = Weight of Pycnometer with de-alcoholised beer.
W2 = Weight of empty Pycnometer
W3 = Weight of Pycnometer with water.
The value of real extract in grams of extract in 100 grams of de-alcoholised beer ( oP) was
recorded by using the standard table.
70
Beer bitterness:
Principle:
The bitter substances are extracted from acidified Beer with iso-octane. After Shaking the
absorbance of the iso octane layer is measure at 275 nm against a reference of pure iso-octane.
Reagents:
Iso-octane(2,2,4 trimethyl pentane): the absorbance of this solution must be 0.01 when
measured at 275nm in a 1cm cuvette against a reference of distilled water
Hydrochloric Acid (HCl): 6M
Procedure:
10ml of de-carbonated beer was taken in a 50ml conical flask
.1ml of
3N hydrochloric acid (HCl) and 20ml iso-octane were added
The conical flask was closed tightly with stopper.
The flask was shaken for 20minute at 20°C at 300rpm, on a wrist action shaker.
The absorbance of iso-octane layer was measured at 275 nm using pure iso-octane as
blank
Calculation:
Foam Stability:
Apparatus:
Travelling microscope
Stop watch
Procedure
The beer at 5-7oC was poured in a clean dry glass from a height so that it generates a
foam of about 1½ to 2 inch
The glass with beer was placed on travelling microscopic platform
71
The eye piece was adjusted so that the foam is in view and started the stop watch.
Stopped stop watch after foam settle down.
The time was recorded in seconds i.e. foam stability
Haze in Beer:
Apparatus:
Haffmans Laboratory Haze meter-VOS Rota 90
Procedure:
Fresh beer sample was poured in haze cuvette and it was cooled to 0°C (for 0°C
Haze)
The cooled beer cuvette was kept in haze meter and the reading was recorded which
appears on display of Haze meter
Apparatus:
Haffmans In pack CO2 & Air Meter
Procedure:
The instrument was adjusted at right height of the bottle or can
The bottle was Pierced, While piercing the needle valve should be closed
The value was recorded which appear on the gauge.
The instrument was shaked for awhile with pierced bottle or can till the gauge value does
not increase any more.
Slowly the needle valve was opened, the bottle was removed and the sample temperature
is recorded.
72
By using this temperature and pressure values the CO2 content was noted by means of
standard table.
Procedure:
30% caustic lye was taken in measuring burette (with the help of levelling vessel in case
of Haffmans in pack Air meter. This vessel should be at higher position, about 8cm than
measuring burette. There should not be any air in between the stopper of Haffmans In
pack Air Meter
The instrument was adjusted at right height of the bottle or can
Pierced the bottle. While piercing the needle valve should be closed
After piercing, the needle valve was opened slowly a bit and let the head space gas
bubble through the caustic lye in the measuring burette.
Then the needle valve was closed immediately when no more gas escapes from the bottle
or can
The instrument was shaked along with the pierced bottle or can again and opened the
needle valve slowly. Repeated this till no gas escapes from the bottle or can.
The levelling vessel was moved so that the liquid levels from the levelling vessel and the
measuring burette are on the same height.
Recorded the level of lower meniscus.
Precautions:
The sample should be shaken before handling.
If a bottle has a neck foil, it has to be removed.
Calcium:
Reagents:
5N NaOH solution.
Calcein Indicator OR P&R reagent
EDTA solution: 1.8612 EDTA dissolve in 500 ml distilled water for 0.01 M. Take 50 ml
of 0.01M solution and dilute to 100 ml with distil water i.e. 0.005M.
73
Procedure:
20ml of degassed sample was taken in a 250ml conical flask and 100ml of distilled water
was added.
3ml of 5N NaOH, 0.5ml Calcein indicator were added and mixed thoroughly
The sample is titrated with EDTA solution till colour changes from yellow green to
orange brown under black back ground.
Calculation:
Ca (in ppm) = ml EDTA used X 20
Iron
Reagents:
2.5% Ascorbic acid (fresh)
0.3% Orthophenanthralone (colour reagent)
Procedure:
25 ml of sample (degassed) was taken in duplicates, and marked as sample and blank.
2 ml of Orthophenanthralone was added to the sample and 2 ml distilled water to the
blank.
1ml of 2.5% Ascorbic acid was added to the tubes
The tubes are heated at 60oC for 15min and then cooled to room temperature
The absorbance was recorded at 505nm.
Calculation:
Iron = F (As – Ab)
Where
F = 7.12
As = Absorbance of Sample
Ab = Absorbance of Blank
Diacetyl in Beer:
Reagents:
8.5% dehydrogenate PO4
8 % hydroxyl ammonium hydrochloride
Procedure:
100ml of un degassed beer sample was taken in 500ml round bottom flask.
3.5 ml 8.5 % disodium hydrogen PO4 was added.
74
Distillation was started and tip of the delivery tube was kept in 2ml distilled water.
Distillate was collected up to 18-19 ml and made up to 20 ml with distilled water.
This 20 ml of distillate was distributed to two test tubes as 10 ml and labelled as blank
and sample.
1 ml of 8 % hydroxyl ammonium hydrochloride was added to the test tube marked as
sample.
The test tubes were heated to 80◦C for 15min and the solution is concentrated to 4-5ml.
Test tubes were cooled and 1 ml of 8 % hydroxyl ammonium hydrochloride was added to
the test tubes marked as blank.
1ml of 8.5%Na2HPO4was added to both tubes.
Made up the volume to 10 ml by distilled water.
The absorbance was recorded at 230mm on spectrophotometer
Calculation:
Diacetyl = Absorbance X Regression factor
Regression factor = 0.3
Precautions:
The sample should be shaken before handling.
If a bottle has a neck foil, it has to be removed.
SO2 In Beer:
Reagents:
0.025 N iodine
starch indicator
Conc. HCl
Procedure:
250 ml of undegassed beer was taken in 500ml round bottom flask, 10 ml. of conc. HCl
was added to it.
Distillation apparatus was arranged and the tip of the receiver was dipped in beaker
contains 15 ml. of distilled water
Few drops of starch was added in beaker as indicator and few drops of 0.025 N iodine
solution was also added
The sample was allowed to rapid boil
As distillation proceeds keep adding 0.002N Iodine solution to sample till colour persists
for 1 min.
Calculations:
75
SO2 in beer = Burette Reading X 2.56
content as w/v and v/v.
Procedure:
Observe NaOH level on the scale of CO2 tester i.e. purity of CO2.
Note:
CO2 purity should be 99.99%
1. Invertase Test
Reagent:
20% sucrose solution
Fehling’s solutionA&B
Procedure:
Test Blank
76
Cool Cool
Note:
Put these two samples undisturbed for 2hrs at R.T. If blur color turns to red then the
pasteurization is not effective and requires further pasteurization. If color color is not changed
then pasteurization iseffective.
2. Polyphenol test
Reagent:
i. CMC-EDTA 1%
ii. Ferric reagent (3.2gm 16%)
iii. Ammonia (1:3)
I. CMC / EDTA – 10gms of sodium CMC + 1000ml distilled water
+ 2grms of EDTA
II. Ferric reagent- Dissolve 3.5 gms Ammonium iron citrate in 100ml distilled water.
-Store in dark
77
Required concentration-5.6gm/I Fe 3+
Flow Chart =
Add 0.5 ml ammonia reagent in both the samples (Test & Blank Sample).
Mix well
Blank make upto 25ml with distilled water used for adjusting zero on spectrophotometer
Principle- The vicinal diketones are distilled from the beer. The distillate is mixed with
solution of o-phenylene diamine to form derivatives of quinoxaline.
After acidification, the amount of reaction products is measured spectrophotometrically.
The concentration of vicinal diketones is calculated with the help of fixed factor.
78
Reagents:-
HCL:-395 grams conc. HCL IN 400ml distilled water. Cool and shake.
O phenylenediamine solution :-250mg in 25ml 4ml/lit HCL keep solution in dark
place.
-Silicon antifoam.
Apparatus:-
Distillation Unit.
Measuring Cylinder -25, 25<100ml.
Volumetric Flasks- 100 < 1000ml.
Spectrophotometer, Cuvette, Centrifuge.
Pipette-0.5, 2 < 10ml.
Test tubes.
Distillation
15-20ml distillate collected. measuring cylinder with 2ml distilled water in about 10min.
79
CIP Regime:
The below given points are common for all the CIP regimes:-
Caustic CIP
1. ACID CIP (THREE CYCLES)
80
Sl. CIP Step Concentration Temperature( Minimum Time Remarks
No. (%) °C) (min)
81
1 Pre Rinse Reclaim Water Ambient 5 Drain water after
or fresh rinsing
Brewing water
Followed by sanitation
Divosan Active
Reagents:
8% H2SO4
1 N Potassium Permanganate
KI solution
0.1 N Sodium Thiosulphate solution
Method of Analysis:
Take 50 ml. of the user solution of Divosan Active in a 250 ml conical flask.
Add 10 ml of 8% H2SO4 into flask.
Add 1N Potassium Permanganate till colour turns pink.
Add 10 ml KI solution, colour will turn yellow.
82
Titrate above with 0.1 N Sodium Thiosulphate solution till colour changes from yellow to
colorless.
burette reading∗38
% User Concentration of Divosan Active=
500
Plant Standards:
83
Capacity of RO: 50 KL/Hr
pH = 9
Equipment Details: -
Water Source:-
MIDC Water.
Tanker Water ( High TDS)
ETP RO Water.
The Key increasing water Efficiency is high output and judicial used of ETP RO Water.
Treatment Process:
MGF: It is a filter that separates undissolved particles from the Water
ACF: It is a Filter made of Activated Carbon that separates Organic Matter and Chlorine from
the Water.
UF: It is a Filter with a very fine filter capacity. It separates micro sized particles from the
Water.
RO: It is a filter that works with the Principle of Reverse Osmosis. 6 Bar of pressure is applied.
Permeate Pressure 1.5 Bar.
Softener: Softener is used to prepare Soft Water. Soft Water does not go through UF and RO.
MIDC water supply
84
MGF = 50 KL / Hr
ACF = 50 KL /Hr
UF = 50 KL/Hr
RO = 50 Kl/Hr
RO tank = 400 KL
85
Effluent shows typical agro based effluent characteristics such as high biological
oxygen demand load, high chemical oxygen demand load, total dissolved solids , low pH
effluent , dark black or brown color and strong odor.
Buffer Tank
(Buffer maintained)
Tube settler
(Settled sludge is removed)
Clarifier 1
Clarifier 2
Aeration 1
Aeration 2
Flash Mixer
86
(Dosing of Alum and Poly to separate suspended particles)
MGF
MGF
UF Tank
UF
RO
RO Reject RO Permeate
(Settles sludge of tube settler, AHR, Buffer tank and clarifier are collected)
Sludge Dewatering
87
Water equalization Dried sludge
Plant Standards:
88
Cooling Tower is fed with ETP RO Water.
Float Sensors at all Surge Drums
Compressor Load can be controlled though VFD and number of cylinders operating in the
condenser
A PHE in Ammonia discharge line heats boiler feed water.
Steam and Water Control in VAM
Self-cooled KCX series of Ammonia Compressor, which uses suction Ammonia to cool
itself.
BOILER
Plant Standards:
12 Tonnes/Hr Steam Production
Steam Pressure = 16.5 Bar
Steam Temperature = 210 C
Operations:
1. Maintaining feed water quality and temperature (above 95 C) is very critical
2. Using the drum level control effectively
3. Ensure all the air dampers are fully open( closed only during maintenance)
4. Monitor the stack temp
5. Maintaining fuel property is important.( GCV, Moisture, fuel size)
6. Cleaning the fuel path often, will ensures smooth running of fuel flow.
7. Use alarm system to check normal operation of grate system.
8. FD air dampers, ID fan speed and stack O2 readings are very good indicators of smooth
operation.
9. Ensure all ZSS are in use, all the time for Ash and fuel conveying equipments( Belt,
RALV)
10. Ensure cooling water availability all the time.
89
11. Avoid sudden dumping of ash.
12. Use the alarm facility.(Level-1,2,3,4,5,6,7)
Safety:
Drum level- boiler low level and extra low level through mobery. Boiler extra extra low
level though PLC. Alarm level L2
If O2 level goes below 5%, then fuel feed will stop. Will start again at 6,5%. This is to avoid
CO build up in furnace
BY PRODUCTS
CO2
Spent malt
Yeast
90
CONCLUSION
91
I am very lucky to have In-plant Training in such established plant. This
training has definitely increased my interest in pursuing career in Beverage
industry. Once again Thank you for an excellent Four months.
UBL ELLORA has bright future. My best wishes are with UBL ELLORA
Quality Control Team.
May the,
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