Index

Sr. Title Page No.

No.

1 Introduction 1-4

2 What is Beer? 5

3 Beer Consumption in India 6

4 Raw Material’s 7

5 Raw Material for Production of Beer 8-10

6 Processing 11-15

7 Machines 16-17

8 Quality Control Department 18-23

9 Analysis 24-30

10 Water Treatment Plant 31

11 Water Recycling Plant 32

12 Effluent Treatment Plant 33

 INTRODUCTION
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.

United breweries group or UB group, based in Bangalore, is a conglomerate of

different companies with a major focus on the brewery (beer) and alcoholic beverages
industry. The company markets most of its beer under the Kingfisher brand and has also
launched Kingfisher airlines, a domestic airlines service in India.

This man, machines and five raw materials combination along with location
advantage makes kingfisher a cost effective and quality supplier of Beer. Today each one
of the near about more than 32000 beer outlets in India sells one brand or the other from
United Breweries.

The UB group is also into manufacture of fertilizer. The group company

Mangalore chemicals and fertilizers (MCF) has a factory at Panambur in Dakshina
Kannada district of Karnataka. UB Engineering Ltd. is the groups engineering businesses
arm. It undertakes EPC projects, infrastructure, on–site fabrication of structures,
installations, testing and commissioning of Electrical and Mechanical Equipments, piping
etc. for large industrial projects such as Power, Refineries, Steel, Cement, Fertilizers,
Petrochemical and Desalination Projects.

The group entrance to the IT sector had also been marketed by the formation of
UBICS, Inc. the company provides IT consulting, services and professional IT products
to business companies. The group made a first of its kind media alliance for the
promotion of NDTV Good Times, a lifestyle television channel run by NDTV.

United Spirits Ltd. has 144 brands under its Umbrella, including White Mischief
and Valdiwar vodka, the market leading brand in India.

1
HISTORY OF UNITED BREWERIES Ltd.
UB group started in 1935, with Thompsons Leishman, a Scotishman, who
combined five small breweries in South India to form United Breweries. At the age of 22
Vittal Mallya was elected as the company’s first Indian director in 1947.

United Breweries made its initial impact by manufacturing bulk beer for the
British troops, which was transported in huge barrels or “Hogshades”. Kingfisher, the
groups most visible and profitable brand, made a modest entry in the sixties. During the
1950’s and 60’s, the company expanded greatly by acquiring other breweries. In 1988 the
name of the company was changed to UB Ltd. The division today has 11 own and 15
contract manufacturing facilities throughout the country.

UBL is India’s largest beer manufacture with 95% market share. Kingfisher strong
has become the number one brand in strong beer in India, selling over more than 17
million cases. Kingfisher premium beer is currently available in 55 countries outside
India and leads the way amongst Indians beer in the international market. It has been
ranked amongst the top fastest growing brands in UK.

HISTORY OF UBL PONDA, GOA

On 7th of November 1964, “V.M.Salgaonkar Group Of Companies” and F.R.Cruz
group of Companies made a common cause with United Breweries Ltd. to establish a
new firm, Kesarval Beverages Ltd, which would engage in the manufacture of quality of
beverages.

Kesarval beverages Ltd. started its manufacturing activities in August 1965, by

introducing “Light House Whisky” in the local market. The company later added Brandy,
Rum and Gin to the ‘Light House’ range.

In 1970, however, KBL decided to fall in line with the ambitious development
plans of UBL’s then Chairman, Late Shri. Vittal Mallya. The Salgaonkar and Cruz
groups, which were not interested in investing the project, sold their equity share holding
to UBL and KBL become wholly owned subsidiary of United Breweries Ltd.

About 40000 sq. mt. of land were acquired for the construction of two factories a
‘Brewery’ and a ‘Distillery’ at village Bethora in Ponda, Goa where Kesaeval beverages
Ltd., would take shape to manufacture “Indian Made Foreign Liquire”. The two
companies of UB group i.e. UBL and USL were inaugurated in the year 1972.

2
MISSION
We constitute a large, global group based in India. We associate with world
leaders in order to adopt technologies and processes that will enable a leaders in order to
adopt technologies and processes that will enable a leadership in a large spectrum of
activities.

 Focus on assuming leadership in all our target markets.

 Seek to be the most preferred employer wherever it operates.
 The partner of choice for customers, suppliers and other creators of innovative
concepts.
 Continually increase the long–term value of our group for the benefit of our
shareholders.
 Operate as a decentralized organization and allow each business to develop within
its stated value.
 Major contributor to our National Economy and take full advantage of its strong
resource base.

It commits its selves to the on going mission of achieving Scientific Excellance.

UB QUALITY OBJECTIVES
The breweries Division Quality objectives were based on the UB group quality
policy and are as follows:

 India’s foremost producer of quality beer.

 Satisfy and even exceed consumer satisfaction.
 Stay ahead in competition in terms of products and packaging quality.

 Improve economies of production through reduction in process

non–conformities.
 Maintain highest housekeeping, health, safety and environmental standards.

3
ACHIVEMENTS:
 The largest selling beer in India.
 Commands a 34% market share in the country.
 Near about 7 bottles of Kingfisher are sold every second in India.
 Available in 52 countries across the globe.
 The first among Indian brands to launch its own range of designer wear.
 Won the World’s best Lite Lager Award at the Stockholm Beer Festival in 1994.
 Won the World’s best Lite Lager Award at the Stockholm Beer Festival in 1995.
 Won the Gold Medal at the world Beer Championship held in Chicago in 1997.
 Won the first prize for the label work category at the Asian Grand Prix Cyrel
2000 label award.
 First prize in the International Beer awards organized by New Zealand Hop
Marketing Board.
 Won the Bronze award at the ‘Australian International Beer Awards’ in the
“International Packaged Beer Section For The Year 2000”.

4
 What is BEER?
The word BEER stems from the Latin word ‘Biber’ means “to drink”

Beer is an undistilled alcoholic drink.

Beer refers to a beverage which involves in its production of –

1. Extracting malted barley with water, other carbohydrate rich material may
also be employed.
2. Boiling this extract with hops and cooling the extract and fermenting using
yeast.
3. The fermenting beverage is then normally clarified and dispersed in an
effervescent condition.

BEER CONSUMPTION IN INDIA

  The consumption of beer is unevenly spread across the country with a geographic
distribution of North 20%, East 8% , West 26% and South 46%. The fastest
growing markets have been those in the States of Karnataka, Maharashtra, Tamil
Nadu, Andhra Pradesh and Goa.

PRODUCT PROFILE
Sale only in India

Mild Strong
Charger Charger
Kingfisher Gold Kingfisher Strong
Kingfisher Premium Kingfisher Blue
Kingfisher Diet Kingfisher Super Strong
Kingfisher Ultra Kingfisher Red
Kingfisher Draught Kalyani Black Label
Kingfisher Sport London Pilsner
Sandpiper Bullet Super Strong
London Diet Beer Charger Super Strong
London Diet Gold Beer London No.1 Strong
UB Export Mild Beer London Super Strong
UB Ice–Premium Beer Turbo Super Strong
London Pilsner Markopolo Super Strong

EXPORTED OUTSIDE INDIA

MILD
Maharaja
Guru Lager Beer
Flying Horse Royal Beer
Taj Mahal Lager Beer
Golden Glow

RAW MATERIALS
Purchasing of raw materials
 Malt – Punjab, Haryana, Rajasthan
UB groups have their own UB malt division which supplies malt to UB
units in India.
 Maize flakes – Banglore, Karnataka
 Sugar – Maharashtra, Karnataka, Goa.
 Hops – Germany, England
 Cartons – Maharashtra (local suppliers)
 Bottles – New – Pondicherry and Nasik
Old - Margoa
 Crowns – Bangalore
 Labels – Bangalore
 Foil – Bangalore

RAW MATERIALS FOR PRDUCTION OF BEER

 Malt
  Adjuncts
 Water
 Hops
 Yeast
 Miscellaneous ingredients

MALT
 Barley malt is the major raw material used in all breweries because the barley has
husk that act as a good filter media.
 For the production of barley malt, Barley is used. The germinated barley is termed
as Barley.
 For the production of malt, separated malt unit is needed.
 Malting is a controlled germination of barley during which enzymes are formed
and the food reserve are sufficiently modified so they can be further hydrolyzed at
mashing.
 Malting consists of three stages–
 Steeping
 Germination
 Kilning
 In all the above steps, it requires complete complete control of Temprerature,
Humidity and Air flow.

1. Steeping
In this process, the moisture of barley is increased by soaking it in
water for a suitable time and temperature.
2. Germination
During germination, the rootlets are developed and proteins are
converted to simple peptides and amino acid by proteinase enzyme.
ᵅ and ᵝ Amylase, enzymes required for starch conversion are
synthesized.

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3. Kilning
 In this process, the moisture is removed by passing hot air. Kilning
removes moisture content of malt and also any chance of contamination of
microorganisms during the above two processes becomes negligible.

ADJUNCTS
 Adjunct is any carbohydrate source other than malted barley which
contributed sugar to the wort.
 Most commonly used adjunct materials are Maize (Corn) flakes, Rice
flakes, Sugar and/ or Corn Syrup.
 To reduce consumption of malt, adjuncts are used.

WATER
 Maximum content of Beer is water, for about 94–96%.
 The quantity of water influences the properties of Beer (i.e. Flaver, Haze,
Fome, Colour etc.)
 The main difficulty in breweries is to avoid or to deal with contamination in
water.
 For this reason, water required for production of Beer is first treated and
then used. The process is described in the utility part.

HOPS
The Hops are compounds which are aromatic or bitter in nature, are found to
provide the following additional benefits of beer,

 Foam stability is improved.

 The clarity of beer is better.
 There is improvement in flavor stability because of bacteriostatic activity
of activity of the iso–ᵅ acid.
 It enhances the shelf life of beer.

MISCELLANEOUS INGREDIENTS
Miscellaneous ingredients are the ingredients added for following function.

 Zinc Sulphate (Yeast Nutrients)

 Whirlfloc (To remove the proteins in whirlpool)
 Lactic Agid (For maintaining pH)
 Enzymes
 Defoaming agents

MICROORGANISM
Brewing utilize strains of Saccharomyces carlsbergenesis and Saccharomyces
cerevisiae, both bottom and top yeast strains. Beer fermentation employ bottom yeast.

Brewing is different form much other industry fermentation in that the cells for
pitching are often those recovered from a previous fermentation. Fresh yeast inoculums
usually is required only when the vigor of the yeast has begum to decline. Before being
employed as inoculums, the yeast cells from aprevious fermentation are washed (with
phosphoric acid, tartaric acid or ammonium persulphate) by settling, a procedure that
reduces the pH valve and removes considerable bacterial contamination, if present. Thus,
each pound of yeast added to the fermentations at inoculation yields approximately 3 to
4 pounds liquid yeast at harvest, and the excess yeast not required for further use as
inoculums becomes a byproduct of the fermentation.

YEAST
 Yeast is unicellular fungi.
 Yeast used in brewing have basic similarities in their properties and therefore can
be classified as one or other of the species of genus Sacchromyces.
 Sacchromyces cerevisiae
 Sacchromyces uvarum
 Most top fermentation yeast belong to Sacchromyces cerevisiae.
 Most bottom fermentation yeast belongs to Sacchromyces uvarum.
 Presence of wild yeast or other non culture yeast causes haze and off flavor,
therefore every measure available must be taken to eliminate such contam ination.

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PROCESSING
MALT SILO
In silo, the unloaded malt from trucks is stored and is taken up through conveyor
when required.

MALT MILL
 In the mill, firstly malt is crushed so as to separate the husk from the kernel
and the endosperm.
 Two to three pairs of roll mills are used.
 Magnetic separator removes any metallic particles.
 Screen analysis of mill is necessary to check the efficiency of milling and
also to check the separation of the husk from the endosperm and kernel.
 In the mill, screening also done.

MASH KETTLE
 Mashing is the process in which malt and adjunct are mixed with water in a
controlled heating process to digest and extract proteins, carbohydrates,
enzymes and phenolic substances to obtain fermentable sugar and nitrogen
compounds for yeast nutrition.
 An agitator is provided for good mixing during temperature rise.
 Firstly milled malt is mixed with water (45ᵒc) and then the same
temperature is maintained for about 30min.
 Then temperature raised up to 72ᵒc and again water is added and when
water reaches at 72ᵒC.

LAUTER TUN
A Lauter tun is the traditional vessel used for the extracted wort.

The false bottom in a lauter tun has thin slits to hold back small solids and allow
liquids to pass through. The solids form a filtration medium and hold back small solids,
allowing the otherwise cloudy mash to run out of the lauter tun as a clear liquid.

The lauter tun has rotating rake arms with a central drive unit. Depending on the
size of the lauter tun, there can be between two to six rake arms.

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Cutting blades hang from these arms. The blade is usually waxy and has a plough–
like foot. Each blade has its own path around the tun and the hole rake assembly can be
raised and lowered. Attached to each of the these arms is flap that can be raised and
lowered for pushing the spent grains out of the tun. The brewer or an automated system
can raised and lowered the rake arms depending on the turbidity (cloudiness) of the run–
off, and the tightness of the grain bed, as measured by the pressure difference between
the top and bottom of the grain bed. There must be a system for introducing sparge water
into the lauter tun. Most system have a ring of spray heads that insure an even and gentle
introduction of the sparger water. The watering system should not beat down on the grain
bed and from channel.

 The mash from mash kettle is transferred to the lauter tun and heating is
done for 2mins.
 In the lauter tun water is used at the same temperature at the mash (76ᴼc).
 Filtration takes place in the lauter tun. Husk is separated which can further
be used as a cattle fodder and the clear fluid is removed as wort 1 and wort
2. Wort 1 is concentrated is dark in colour while wort 2 is light in colour as
it contains water and is less concentrated. Wort 2 is called as sweet wort.

WHIRLPOOL
There is a separate tank for whirlpool. These tanks have a large diameter to
encourage settling, a flat bottom, a tangential inlet near the bottom of the whirlpool, an
outlet on the bottom near the outer edge of the whirlpool.

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

 After boiling in copper tank, the wort is collected in the whirlpool by rapid
whirling due to which protein gets settled down.
 Here the whirlfloc help in coagulation of protein to get settled down.
 Here the temperature is 91 to 100ᴼC.
 Rest of 30mins is given before cooling.
 Here before inoculating or pitching with yeast, the clarified wort is cooled
rapidly to 10 to 15ᴼC to minimize microbial contamination.

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WORT COOLER
 Wort is cooled immediately to 12ᴼC by plate heat exchanger. The dissolved
oxygen level should be sufficient for adequate fermentation rate. The air which is
incorporated should be microbiologically sterile.

UNITANK
The wort is transferred to the UNITANK after cooling.

FERMENTATION TANK
Fermentation as a step in the brewing process starts as soon as yeast is added to
the cooled wort. This is also the point at which the product is first called beer. During this
stage, the sugars from the malt are metabolized into alcohol and carbon dioxide.

Breweries use cylindrical vessels and have a conical bottom and cylindrical top.
The concave’s aperture is typically around 60ᴼ, an angle that will allow the yeast to flow
towards cone’s apex, but is not so steep as to take up too much vertical space at the end
of fermentation, the yeast and other solids that have fallen to the cone’s apex can be
simply flushed out a port at the apex.

The reaction of the fermentation differs according to sugar being used and the
product produced. Below the sugar will be glucose (C6H12O6) the simplest sugar and the
product will be ethanol (2C2H5OH). This is one of the fermentation reaction carried out
by yeast, and is used in beer production.

Chemical equation: C6H12O6→2C2H5OH+2CO2+2ATP

Wort equation:

Sugar (glucose, fructose or sucrose) →Alcohol (ethanol) +Carbondioxide+Energy

FILTRATION
Filtration is done by Kieselghur filter also called as Hyflow super cell. Beer haze
should be constantly monitored during the entire filtration process. The carbonation to
required level takes place after filtration (post filtration).

13

BRIGHT BEER TANK (BBT)

 There should be a minimum 4 hours rest and maximum of 72 hours in BBT prior
and packaging.

All BBT’s must be checked for flavor, appearance, Co2 and DO contain immediately
after filling for release for bottling.

FEELING
Care should be taken to minimize air content in the bottle. The filler should be
fitted with an effective jetting device. The temperature of the jetting water has to be 80
to82ᴼC. a counter pressure of Co2 and pre–evacuation in accordance with manufactures
instruction should be maintained.

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15
 MACHINE
BOTTLE WASHING
The dirty bottles, which are received from the suppliers, are manually loaded on
the conveyor belt by the loaders which go in the washing machine where the bottles are
washed with caustic. The machine has got capacity to wash 36 bottles at a time. Bottle
washer, which comprises of four compartments.

 Pre–rinse–water is sprayed in the bottles.

 Soak 1 contains caustic and Satol at a temperature at 50 to 55ᴼC.
 Soak 2 contains caustic of 2.5–3% and temperature of 75 to 80ᴼC.
 Final rinse– Then bottles are washed with hot water.

Then there are two sightors who check if the bottles are clean properly and they also
separate chipped bottles from good ones. The capacity of the washer is 28000 bottles per
hour.

FILLER MACHINE

When the bottles enters in the filling machine, the bottles are first vacuumed i.e.
the water, air is removed from the bottle, during this the bottles are subjected to
breakages. The bottles are filled and then crowned. Before going pasteurization the
sighter removes the un–capped, half filled bottles and checks whether there are any
particles in the bottles. The capacity of the filler 63 bottles and cap 15 bottles at a time.
The machine has the capacity to fill 18000 bottles in 1 hour. The machine has the
capacity of filling 1, 50000–1, 95000 bottles per day in each shift. The machine is
adjusted according to size of the bottles i.e. 330ml and 650ml.

PASTEURIZATION
In pasteurization there are 4 zones of temperature 35, 45, 55 and 62ᴼC. the bottles
moves through this zones in increasing order and then the bottles are cooled in the
decreasing order. One batch pasteurization takes one hour to complete. The total capacity
of the pasteurizer is approximately 18000 bottles per hour. After pasteurization the bottle
passes to the final sighter where half–filled and over filled bottles are removed and then
the bottles go for labeling.

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LABELING MACHINE
In the labeling machine the top foil, the front label and the back label are put. On
the label the Manufacturing Date, Batch No and the BBT No are printed. The capacity of
labeling machine is 19,800 bottles per hour.

ROBO PACKER
After labeling the bottles comes to the Robo packer, the machine which packs the
bottles into the cartons. The cases are folded manually and passed to the packer through
the conveyor belt. The capacity of Robo packer is six cases in 9 second.

SEALING MACHINE
After the cases are packed by the packer, they come to the sealing machine. The
cases are sealed with the help of gum. And then the cases are kept in the bond strong
(godown). The capacity of sealer is 1000 cartons per hour.

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 QUALITY CONTROL DEPARTMENT
United Breweries say that quality is an attitude to achieve perfection so make
quality a way of life. The Central Scientific Laboratory (CSL), headqurtered 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 when the product is dispatched. These beer are tested as per the
standards laid down by the European Brewery Convention on 40 different parameters.
By these standards, United Breweries beers do not just equal, but even surpass, several
Dutch and American beers.

The main aim of this department is to control the quality of product from raw
material to finished good. Quality management is the heart of the company emphasizes
on the quality of product.

This unit has a great responsibility of keeping the product safe for the customer on
which the whole company depends upon. If there is no customer satisfaction, the demand
for the product will drop and the company will run into loss. The quality lab checks
each thing, which is used to manufacture beer like bottles, crowns, labels, raw material
etc. The quality department checks the quality in each stage of manufacturing. Besides
checking the bottles in Goa, a sample of about 2 bottles per stage are sent for quality
analysis at Bangalore.

Specification parameters are taste, color, pH, bitterness, lethal pasteurization, haze,
dissolved oxygen, carbon–dioxide, total air and alcohol content. The batch which has not
met the specification is blended with the one which has attained these parameters of
specification. Weekly reports of all the details are sending to the head office in
Bangalore.

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INWARD INSPECTION
Once the raw material is produced they are sent in the quality control department
for assessment. The quality chemist will check whether the raw material is up to
specification standard; and if there are any rejections, rejection notes are send to suppliers
along with defects details. After the inspection, the raw materials are sending for
production.

BARLEY
 Size of malt is tested by using the instruments – Sieve Analyzer
Sieves have many ranges. In this the malt is crushed and tested whether it can be
used for brewing beer. More malt should be in the range of 2.1 than 2.5 i.e. 70%
malt should be range of 2.1
 Kettle test – to check the aroma of the malt and to check off odors.
 Acrospires growth.
 Total corn weight (1000 corn weight)

MAIZE FLAKES
 Size of the flakes.
 Kettle test.
 Moisture.

CARTONS
 Length
 Width
 Height
 Number of flutes
 Board substance
 Outer (VK)
 Corrugated (ARK)
 Inner (SVK)

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NEW GLASS BOTTLES
 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
 Heel height

CROWN
 Internal defect
 Shade variation
 Change in text
 Peeing of lacquer
 Spots and smudges
 Without liner
 Other brand
 CuSO4 test
 Dimension analysis
 Skirt diameter
 Internal diameter
 Weight of liner
 Height
 Weight of crown
 Liner adhesion test

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LABELS
 Wrong labels
 Torn labels
 Legal declaration
 Defect in paper
 Colours missing
 Incorrect or wrong color
 Label sticking together
 Mutually displaced colour
 Colours partially missing
 Colours coming off

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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 process,
this reduce wastage and ensures optimum usage of resources. During their routine round
they also check whether the batch no. is printed properly or not.

1. Mashing of malt
Gravity (mild – low)
(Strong – high)
2. Lautering
Initial gravity
Final gravity
3. Wort kettle
Bitterness according to European Brewing convention (EBC)
Colour (strong 7-10)
(mild 5-6)
4. Cold storage tank
pH 4.2-4.4
5. Della Tofolla (filtration)
Dissolved oxygen (if DO is more than beer will be spoiled fast)
Haze
6. Bottling hall
For washing the bottles the concentration of caustic is checked
7. Line inspection
Checking the bottles after bottling
8. Shelf life of beer
Beer is placed in water at a temperature of 60ᴼC. if turbidity occurs within one
week than the beer will remains only for 2 months.
9. Microbiological analysis
Test to check whether the beer is not affected by micro-organisms.
10.Carbondioxide test
To check the amount or concentration of CO2 present in beer.
11.Sensory analysis
Beer of every batch is tested by the chemist and head brewer to check whether it
meets specifications.
22
12.Alcohol content
Mild 4.25-4.4
Strong less than 7
13.Effluent treatment plant
Firstly anaerobic and then aerobic treatment of effluent water. This treated water is
used for gardening.

23
 ANALYSIS
WATER ANALYSIS
 Chloride test
 First take 100 ml of water.
 Add 1 ml of potassium chromate.
 After that titrate with silver nitrate
 End point – colour changes from yellow to red.
 Hardness of water
 First take 100 ml of water.
 Add 1 ml of Ammonium buffer.
 Add 4-5 drops of echrichrome black.
 Titrate with EDTA solution.
 End point – colour changes from violet to blue.
 Alkalanity
 First take 100 ml of water.
 Add 4-5 drops of methyl orange.
 Titrate with Hydrochroric acid.
 End point – colour changes from yellow to pink.

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CAUSTIC ANALYSIS
 Caustic test
 First take 10 ml of sample.
 Add phenolphthalein indicator 2-3 drops.
 Titrate with 2.5 N HCL
 End point – Colour changes from pink to colourless.
 Net caustic
 First take 10 ml of sample.
 Add 1 ml of Barium chloride.
 Add the 2-3 drops of phenolphthalein indicator.
 After that titrate with sulphuric acid.
 Colour changes from pink to colourless (take P1reading)
 After that add 4gm of sodium fluoride.
 Titrate with sulphuric acid (take P2 reading)
 After that take 10 ml sample and add 4-5 drops of methyl orange.
 Then titrate with sulphuric acid (take P3 reading)

Formula

NaOH – (2×P1-1/3×P2-P3) ×0.4

Aluminium – P2×0.09

Carbonate – (P3-P1) ×1.06

CALORIFIC VALUE OF BRIQUETTE

 Calorific value is checked to determine the energy released by coal or

briquette. Coal and briquette are required in the boiler for steam generation.
 Bomb calorimeter is used to calculate the calorific value/.
 Around 0.75-0.85 coal or briquette is weighted and a pallet is made.
 After that it is placed in the bomb and oxygen passed at 30lb.
 When the pressure comes down to 10, bomb is used in calorie meter and the
reading is taken as rise in temperature.
 The reading automatically comes on computer.

25
BEER ANALYSIS
 Specific Gravity of Beer
 Colour
 Haze in Beer
 pH
 Alcohol Content in Beer by Distillation
 Iron
 Diacetyl
 Bitterness
 Determination of total SO2
 Determination of calcium
 Polyphenols
 Free Amino Nitrogen (FAN)

 Specific Gravity of Beer

 Take sample in measuring cylinder.
 After that place hydrometer in measuring cylinder.
 Take reading of hydrometer.
 Colour
 Take sample and place it in the spectrophotometer.
 Haze
 Take sample and place it in the haze meter.

 pH
 Take sample and placed in pH meter.
 Alcohol Content in Beer by Distillation
 First take 100 ml sample.
 Then add 50 ml water.
 Set distillation unit.
 Put ice in it.
 Volumetric flask is used.
 Take the residue unit the flask is cooled.
 After that put it in freezer,

26
 Iron
 First take 4 test tubes.
 Two test tube name as test and another two named as blank.
 First take one test tube of test in that add 25 ml of brew water and in
another test test tube take 25 ml of beer sample. And do same for blank test
tube.
 Add 1 ml of ascorbic acid in each test tube.
 Then add 2ml Ortho-F in test test tube.
 Then add 2ml distilled water in blank test tube.
 Then shake all the test tubes.
 After that all test tubes sample is put into spectrophotometer and take
reading.
 Diacetyle
 First take 100 ml of beer in 500 ml bottom flask.
 Then add disodium hydrogen in flask.
 Take tube and add 2ml of distilled water in a tube and keep for distillation.
 Collect around 18-19ml of sample in a tube and make up its volume up to
20ml.
 Divide the sample into 2 tubes as test and blank.
 In test test tube add 1ml of hydroxylamine hydrochloride and keep both
blank and that sample in oil bath.
 First at 80ᴼc and after that 15mins 100ᴼc.
 Cool tube and add in blank test tube 1ml of hydroxylamine hydrochloride
and all test tube add 1ml disodium hydrogen (PO4)
 Then make up 10ml with distilled water.
 Put sample in spectrophotometer.
 Bitterness
 Configuration only for CST and wort (5ml sample+5ml distilled water)
 BBT are directly.
 1st take 10ml sample.
 Add 1ml of HCl after that add 20ml iso-octane.
 Keep under shaking condition for 15mins.
 After that sample kept sample in spectrophotometer.
 27

 Determination of total SO2

 Take 250ml sample.
 After that add 10ml of concentrated HCl.
 After that add 15ml of water in beaker.
 After that add 0.5 starch iodine indicator and 10 drops of iodine.
 Then titrate against iodine.
 Determination of calcium
 1st take 20ml of sample.
 After that 100ml of distilled water.
 After that add 3ml of sodium hydroxide.
 After that add 0.5 calsine indicator.
 After that titrate with 0.005 N EDTA solution.
 End point – colour changes from green to straw yellow.
 Polyphenols test
 1st take sample and then centrifuge it for 2min.
 After that add 10ml sample in both tubes.
 After that add 8ml of EDTA reagent to sample.
 Then mix it well and add 0.5ml of ammonium reagent then mix it well.
 After that add 0.5ml of ferric reagent then mix it well.
 After that make up the volume with distilled water.
 Free Amino Nitrogen (FAN)
 First of all take 4 tubes 1for glycine solution 2 nd and 3rd for beer sample and
for distlled water.
 Then take 1ml of all solution in the tubes.
 After that make up 100ml with water.
 Then take another 4 tubes and take 2ml from each solution in the tubes.
 After that add 1ml ninhydrin solution in each tube.
 Then keep in water boiler for 16mins.
 After that cool it.
 28

MICROBIOLOGICAL ANALYSIS

 Aerobic bacteria count

The media used for this count is Walerstein Lab Differential Agar (WLD).
Bromocresol green indicator present in WLD medium. Aerobic bacteria
shows green colour colony where as acid producing bacteria shows yellow
colour due to acid production.
 Lactobacillus count
Medium used for this count is Demnn Rogosa Sharpe Agar(MRS). Medium
gives white colour colony
 Coliform count
Medium used for this count is Macconkey’s agar. All the plates should be
incubated at 20ᴼC.

Unpasteurized Beer

 For Unpasteurized beer, membrane filtration is done. Cellulose nitrate filter

is used for this techniques (Pore size of Cellulose Nitrate filter=0.45µm)
 Lactic asid bacteria count is also checked on MRS medium
 Aerobic bacteria count is checked on WLN ( Walerstein Lab Nutrient
Agar ) and WLD.

Pasteurized Beer

 Aerobic count on WLD medium

 Anaerobic count
 Lactic acid bacteria count on MRS media.
 Detection of non Saccharomyces wild yeast on Lysine media. It shows
white colony.
 Saccharomyces wild yeast on YMC (Yeast Malt Agar)
 Membrane filtration is also done for pasteurized beer.
 29

Bright Beer Tank (BBT)

 Aerobic count on media

 Lactic acid bacteria count on MRS media.

Cleaning process Sample (CIP)

 This is the sample obtained after the washing of FV tank, UT tank and CST
tank.

Yeast analysis
 Yeast cell count
 Collect sample and if required dilute it to 10 times using 0.85% normal
saline. Count number of yeast cells using Haemocytometer. Count the yeast
cells in 5 squares.
 The area of each small square is 0.0025 sq. mm., the total area being
0.10mm/0.0001ml/cc.
 Neglect the budding cells smaller than half of the mother cells.
 Count the cells equal or more than half of mother cells as individual cells.
 Count the cell on the upper and lower margined cells.
 Neglect cells on the upper and right margins.
 Report the results as ‘x’ million cells per ml of sample where ‘x’ is the
number of cells counted in 5sq.

 Yeast viability
 Collect the samples and mix with 0.01% methylene blue stain in the equal
volume.
 Count as many as 200 cells in 4-5 sq. of Haemocytometer counting
chamber.
 The cells not retaining the stain rather reducing it are considered as viable
cells.
 30

WATER TREATMENT PLANT

SAND FILTER
TANK
MIDC Water Cl dosing
Valve
Inlet

UV Lamp
BREW ACF-1
HOUSE Tank Overhead tank

Salt
regeneration

ACF-2 Tank Softner Tank

Process Water
Tank
31
 WATER RECYCLING PLANT

BOTTLE BASKET
BOTTLE
WASHER STAINER

MICRON

PLATE HEAT
COOLING EXCHANGER
ACF (Activated
Carbon Filter)

CI2 Dosing
DEGASER R.C.C.
STORAGE CO2 Removal COLLECTION
TANK
lime
WAC (Weak Acid Ferrous
Tank)
Sulphate

ACF (Activated
Carbon Filter) SETTLING TANK

PSF (Pressure Sand HOLDING TANK

Filter)

32
 EFFLUENT TREATMENT PLANT

Raw Equalization
Industrial Raw Equalization
Tank-2 (Mixing)
Effluent Tank-1
pH-6.8-7.2

(Lime, Caustic, PAC,PE)

Supernatant
USAB TANK Buffer Tank Primary
(Methnogen grow pH-7 Clarification pH-
and produce gas 6.5-6
pH7) (COD<400)

(Recirculation)
Gas
Solid
Collection
Tank
Dry out and Decanter

Aerobic Tank Secondary TREATED

(COD-200 ppm) Clarification EFFULENT
(Solid settle)
 RAW MATERIALS FOR PRDUCTION OF BEER
 Malt
 Adjuncts
 Water
 Hops
 Yeast
 Miscellaneous ingredients

converted to simple peptides and amino acid by proteinase enzyme.

ᵅ and ᵝ Amylase, enzymes required for starch conversion are
synthesize.

ADJUNCTS
 Adjunct is any carbohydrate source other than malted barley which
contributed sugar to the wort.
 Most commonly used adjunct materials are Maize (Corn) flakes, Rice
flakes, Sugar and/ or Corn Syrup.
 To reduce consumption of malt, adjuncts are used.

WATER
 Maximum content of Beer is water, for about 94–96%.
 The quantity of water influences the properties of Beer (i.e. Flaver, Haze,
Fome, Colour etc.)
 The main difficulty in breweries is to avoid or to deal with contamination in
water.
 For this reason, water required for production of Beer is first treated and
then used. The process is described in the utility part.
HOPS
The Hops are compounds which are aromatic or bitter in nature, are found to
provide the following additional benefits of beer,

 Foam stability is improved.

 The clarity of beer is better.
 There is improvement in flavor stability because of bacteriostatic activity
of activity of the iso–ᵅ acid.

MISCELLANEOUS INGREDIENTS.
 Zinc Sulphate (Yeast Nutrients)
 Whirlfloc (To remove the proteins in whirlpool)
 Lactic Agid (For maintaining pH)
 Enzymes
 Defoaming agent (Biofoam)
 PROCESSING
MALT SILO
In silo, the unloaded malt from trucks is stored and is taken up through conveyor
when required.

MALT MILL
 In the mill, firstly malt is crushed so as to separate the husk.
 Two pairs of roll mills are used.
 In the mill, screening also done.

MASH KETTLE
 Mashing is the process in which malt and adjunct are mixed with water in a
controlled heating process to digest and extract proteins, carbohydrates,
enzymes and phenolic substances to obtain fermentable sugar and nitrogen
compounds for yeast nutrition.
 An agitator is provided for good mixing during temperature rise.
 Firstly milled malt is mixed with water (45ᵒc) and then temperature
increases gradually, step by step.
 At each stage rise & rest are present. Temperature increase in 20 min &
rest for 12 min
 At 52ᵒc
 Then temperature raised up to 72ᵒc and again water is added and when
water reaches at 72ᵒC.

LAUTER TUN
A Lauter tun is the traditional vessel used for the extracted wort.

The false bottom in a lauter tun has thin slits to hold back small solids and allow
liquids to pass through. The solids form a filtration medium and hold back small solids,
allowing the otherwise cloudy mash to run out of the lauter tun as a clear liquid.
 The lauter tun has rotating rake arms with a central drive unit. Depending on the
size of the lauter tun, there can be between two to six rake arms.

Cutting blades hang from these arms. The blade is usually waxy and has a plough–
like foot. Each blade has its own path around the tun and the hole rake assembly can be
raised and lowered. Attached to each of the these arms is flap that can be raised and
lowered for pushing the spent grains out of the tun. The brewer or an automated system
can raised and lowered the rake arms depending on the turbidity (cloudiness) of the run–
off, and the tightness of the grain bed, as measured by the pressure difference between
the top and bottom of the grain bed. There must be a system for introducing sparge water
into the lauter tun. Most system have a ring of spray heads that insure an even and gentle
introduction of the sparger water. The watering system should not beat down on the grain
bed and from channel.

 The mash from mash kettle is transferred to the lauter tun and heating is
done for 2mins.
 In the lauter tun water is used at the same temperature at the mash (76ᴼc).
 Filtration takes place in the lauter tun. Husk is separated which can further
be used as a cattle fodder and the clear fluid is removed as wort 1 and wort
2. Wort 1 is concentrated is dark in colour while wort 2 is light in colour as
it contains water and is less concentrated. Wort 2 is called as sweet wort.

WHIRLPOOL
 There is a separate tank for whirlpool. These tanks have a large diameter to
encourage settling, a flat bottom, a tangential inlet near the bottom of the whirlpool, an
outlet on the bottom near the outer edge of the whirlpool.

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

 After boiling in copper tank, the wort is collected in the whirlpool by rapid
whirling due to which protein gets settled down.
 Here the whirlfloc help in coagulation of protein to get settled down.
 Here the temperature is 91 to 100ᴼC.
 Rest of 30mins is given before cooling.
 Here before inoculating or pitching with yeast, the clarified wort is cooled
rapidly to 10 to 15ᴼC to minimize microbial contamination.

WORT COOLER
Wort is cooled immediately to 12ᴼC by plate heat exchanger. The dissolved
oxygen level should be sufficient for adequate fermentation rate. The air which is
incorporated should be microbiologically sterile.

UNITANK
The wort is transferred to the UNITANK after cooling.

FERMENTATION TANK
Fermentation as a step in the brewing process starts as soon as yeast is added to
the cooled wort. This is also the point at which the product is first called beer. During this
stage, the sugars from the malt are metabolized into alcohol and carbon dioxide.

Breweries use cylindrical vessels and have a conical bottom and cylindrical top.
The concave’s aperture is typically around 60ᴼ, an angle that will allow the yeast to flow
towards cone’s apex, but is not so steep as to take up too much vertical space at the end
of fermentation, the yeast and other solids that have fallen to the cone’s apex can be
simply flushed out a port at the apex.
 The reaction of the fermentation differs according to sugar being used and the
product produced. Below the sugar will be glucose (C6H12O6) the simplest sugar and the
product will be ethanol (2C2H5OH). This is one of the fermentation reaction carried out
by yeast, and is used in beer production.

FILTRATION
Filtration is done by Kieselghur filter also called as Hyflow super cell. Beer haze
should be constantly monitored during the entire filtration process. Rock salts
(diautomiser) are use for better filtration. White powder particle size is more than pink

Powder. These powders are circulates with water, before circulation of beer. These
powders settle on filtrate media & filtration takes place. There are 100 plates in first
filter. Then it pass from micro filter.

After filteration beer goes for blanding (bright beer +deaerated water).

BRIGHT BEER TANK (BBT)

There should be a minimum 4 hours rest and maximum of 72 hours in BBT prior
and packaging.

All BBT’s must be checked for flavor, appearance, Co2 and DO contain immediately
after filling for release for bottling.

FEELING
Care should be taken to minimize air content in the bottle. The filler should be
fitted with an effective jetting device. The temperature of the jetting water has to be 80
to82ᴼC. a counter pressure of Co2 and pre–evacuation in accordance with manufactures
instruction should be maintain.
 ANALYSIS
WATER ANALYSIS
 Chloride test
 First take 100 ml of water.
 Add 1 ml of potassium chromate.
 After that titrate with silver nitrate
 End point – colour changes from yellow to red.
 Hardness of water
 First take 100 ml of water.
 Add 1 ml of Ammonium buffer.
 Add 4-5 drops of echrichrome black.
 Titrate with EDTA solution.
 End point – colour changes from violet to blue.
 Alkalanity
 First take 100 ml of water.
 Add 4-5 drops of methyl orange.
 Titrate with Hydrochroric acid.
 End point – colour changes from yellow to pink.

CAUSTIC ANALYSIS
 Caustic test
 First take 10 ml of sample.
 Add phenolphthalein indicator 2-3 drops.
 Titrate with 2.5 N HCL
 End point – Colour changes from pink to colourless.
 Net caustic
 First take 10 ml of sample.
  Add 1 ml of Barium chloride.
 Add the 2-3 drops of phenolphthalein indicator.
 After that titrate with sulphuric acid.
 Colour changes from pink to colourless (take P1reading)
 After that add 4gm of sodium fluoride.
 Titrate with sulphuric acid (take P2 reading)
 After that take 10 ml sample and add 4-5 drops of methyl orange.
 Then titrate with sulphuric acid (take P3 reading)

Formula

NaOH – (2×P1-1/3×P2-P3) ×0.4

Aluminium – P2×0.09

Carbonate – (P3-P1) ×1.06

CALORIFIC VALUE OF BRIQUETTE

 Calorific value is checked to determine the energy released by coal or

briquette. Coal and briquette are required in the boiler for steam generation.
 Bomb calorimeter is used to calculate the calorific value/.
 Around 0.75-0.85 coal or briquette is weighted and a pallet is made.
 After that it is placed in the bomb and oxygen passed at 30lb.
 When the pressure comes down to 10, bomb is used in calorie meter and the
reading is taken as rise in temperature.
 The reading automatically comes on computer.

BEER ANALYSIS
 Specific Gravity of Beer
 Colour
 Haze in Beer
 pH
 Alcohol Content in Beer by Distillation
 Iron
 Diacetyl
 Bitterness
 Determination of total SO2
 Determination of calcium

 Specific Gravity of Beer
 Take sample in measuring cylinder.
 After that place hydrometer in measuring cylinder.
 Take reading of hydrometer.
 Colour
 Take sample and place it in the spectrophotometer.
 Haze
 Take sample and place it in the haze meter.

 pH
 Take sample and placed in pH meter.
 Alcohol Content in Beer by Distillation
 First take 100 ml sample.
 Then add 50 ml water.
 Set distillation unit.
 Put ice in it.
 Volumetric flask is used.
 Take the residue unit the flask is cooled.
 After that put it in freezer,

 Iron
 First take 4 test tubes.
 Two test tube name as test and another two named as blank.
 First take one test tube of test in that add 25 ml of brew water and in
another test test tube take 25 ml of beer sample. And do same for blank test
tube.
 Add 1 ml of ascorbic acid in each test tube.
 Then add 2ml Ortho-F in test test tube.
 Then add 2ml distilled water in blank test tube.
 Then shake all the test tubes.
  After that all test tubes sample is put into spectrophotometer and take
reading.
 Diacetyle
 First take 100 ml of beer in 500 ml bottom flask.
 Then add disodium hydrogen in flask.
 Take tube and add 2ml of distilled water in a tube and keep for distillation.
 Collect around 18-19ml of sample in a tube and make up its volume up to
20ml.
 Divide the sample into 2 tubes as test and blank.
 In test test tube add 1ml of hydroxylamine hydrochloride and keep both
blank and that sample in oil bath.
 First at 80ᴼc and after that 15mins 100ᴼc.
 Cool tube and add in blank test tube 1ml of hydroxylamine hydrochloride
and all test tube add 1ml disodium hydrogen (PO4)
 Then make up 10ml with distilled water.
 Put sample in spectrophotometer.
 Bitterness
 Configuration only for CST and wort (5ml sample+5ml distilled water)
 BBT are directly.
 1st take 10ml sample.
 Add 1ml of HCl after that add 20ml iso-octane.
 Keep under shaking condition for 15mins.
 After that sample kept sample in spectrophotometer.

 Determination of calcium
 1st take 20ml of sample.
 After that 100ml of distilled water.
 After that add 3ml of sodium hydroxide.
 After that add 0.5 calsine indicator.
 After that titrate with 0.005 N EDTA solution.
 End point – colour changes from green to straw yellow.
33