Professional Documents
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Final Report1.pdf1
Final Report1.pdf1
Acknowledgment
Initially I would like to thank Addis Ababa Science and Technology University for providing me
with such an opportunity to develop my practical skill. Secondly, I would like to express my
sincere gratitude to BGI Ethiopia for letting to work in this brewery company for my internship
program that has lasted for 4 months. Special thanks go to my company advisor, Mr. Andualem,
and his co-workers for helping and supporting me in every aspect on my stay there. Here after, I
would be thanking our department advisor, Mr. Demelash Tilahun for guiding me on my
internship program including advices and corrections on my project and report.
Abstract
This report contains historical background about B.G.I Ethiopia and also about the raw materials
used for beer production that is barley malt, hops, water and yeast and also the various unit
operations and their operating mechanisms used in this brewery. This report also contains the
challenges that I have faced and how I overcome them. And also what I have gained in terms of
improving my practical skills, what I have gained in terms of upgrading my theoretical
knowledge, what I have gained interims of improving my inter personal communication skills,
and also improving my leader ship skills and so on. And at last it contains my recommendation to
the company that I have seen some problems. On this paper I tried to do my project on how to
decrease the beer loss from the packaging section.
Table of Contents
ACKNOWLEDGMENT...............................................................................................................................II
Abstract........................................................................................................................................................III
1.1. Objectives of the company............................................................................................................2 1.3
Main products and service of the company.........................................................................................3
1.4 Overall organizational structure and work flow...........................Error! Bookmark not defined.
2. Introduction............................................................................................................................................... 3
2.1 Beer......................................................................................................................................................3
Bioglucanase: enzyme required in degradation of β – glucanase inside the malt.....................................5
2.3. Types of Beer......................................................................................................................................5
3. Brewing Process Description.....................................................................................................................5
3.1 Malt Storage.........................................................................................................................................6
3.4. Filtration
section................................................................................................................................12
3.5. Packaging.........................................................................................................................................15
3.5.1. Bottling...................................................................................................................................
... 15
3.5.2. Kegging.............................................................................................................................18
3.6. Utility................................................................................................................................................19
3.7. BGI Ethiopia Quality Management Department..............................................................................24
4. Material and Energy Balance...................................................................................................................25
4.1 Material balance.................................................................................................................................25
4.2Energy Balance...................................................................................................................................28
6. Project………………………………………………………………………………………..33
List of Figures
Figure 3.: Overall Process Flow Diagram.........................................................................6
List of Acronym
9. O
p =Degree Plato
1
1. Background of the Company
The St. George Brewery is the most popular company situated near the Mexico square, Addis
Ababa, and occupies an area of 20,000 sq. Meters of land. The founder of St. George Brewery,
according to some sources, is Mussie Dawit Hale who is a Belgian, other sources say that the
Brewery was owned and operated by a Germen company. In fact, the Brewery was set up by
Mussie Dawit Hale who lately sold it to a Germen company. The Brewery stands right on the
same site it was 80 years ago. During the time of last Emperor, it was known as marshal Smut
Street. It was a fine and a fairly big building and it started off as one of the pioneers in Ethiopia’s
industrial development.
The factory started with machineries that were operated by hand and foot and work was done by
direct human labor. Transporting of raw material to the silo, fermenting of the malt, boiling the
barely, filtering the beer, filling the bottle’s, etc. were all done manually. Basic raw materials like
barely and hops were imported from Europe. The management staff of the factory and the
leading technicians who controlled the brewery’s activities was all foreigners. During its first
years about 200 bottles (half litter size) were produced daily. Some sources say that the brewery
was closed during the five years of Italian occupation.
The company continues its work after the occupation, and according to some reports there arose
problems related to ownership. Eventually, however, an Ethiopian company takeover the brewery
in 1952/3. This Company was said to have been organized as a shareholding entity, the larger
share of which was owned by Emperor Haile Selassie.
Towards the end of the 1950s the annual production of the brewery had reached 50,000
hectoliters.
According to the review made on ‘The Ethiopian trade Journal’ the brewery had 53 silos, which
had the capacity of 100-hectoliters each. There were about 300 employees who worked in two
shifts for 24 hours. Trucks were also introduced that transported beer through the empire. Slowly,
but steadily, St. George Brewery continued to grow in the early years of the 1970’s the brewery
was in good shape in terms of its machineries, physical buildings, vehicles, marketing network,
etc.
On the other hand, the brewery was lacking the finance it needed to introduce new technologies they
come in the 1970s. The name of the brewery was also changed as ‘’Pilsner Brewery’’ and later as
‘’Addis Ababa Brewery’’. Most of all, the workers showed a great commitment and dedication to
keep the brewery and its product popular. The role played by the brewery was significant in
supporting and promoting other social activities include St. George sport club. St. George Breweries
once again privatized. The factory is now owned by BGI, an internationally acclaimed Brewing
Company that operates in many countries. Nowadays St. George Brewery has excellent reputation in
producing quality beer and standardized beer over the other three branches such as, Kombolcha,
Hawassa and the one and the most famous within the country as well as outside the country Bgi
Ethiopia.
From store, the beer is sold to wholesalers and consumers. Trucks transport the distribution of the
product to different regions of the country. The distributions are managed and controlled by the
sales department of the company. Apart from local, the company is also exporting beers to
Djibouti and sometimes to USA and Europe. Different societies are its product user. The sales
representative of the company distributes the product fairly to satisfy its customer. Currently BGI
has so many costumers; its product is not kept in store since the produces are familiar.
Generally main consumer or end users are: wholesalers, consumers in over all the country and
foreign country such as Djibouti, USA and Europe.
• To advertise the product by erecting artistic notice boards in towns, at main public station,
using internet, and soon.
• To provide practical education for students, research institutes, technical personnel, etc.
• To allocates a large amount of budget every year for providing refrigerators, modern
washing machines, donating professional.
• To produce beer and draft with quality within country as well as export in Europe.
1.2 Mission and Vision of the company
• Mission: Providing efficient and standardized service towards the first choice of
customers, consumers as well as team members.
• Vision: To be the leading company in image, visibility, product mix and volume
and market share.
• Main Focus: increasing the sales volume of castle and lunching its draft as well as
increasing our visibility and help and high standard quality of service on draft.
2. Introduction
2.1. Beer
Beer is one of the oldest and most widely consumed alcoholic drinks worldwide. Beer is brewed
from cereal grains: most commonly from malted barley although maize (corn), wheat and rice
can also be used. During brewing process, fermentation of starch extract, i.e., fermentable simple
sugar found in the wort produces ethanol and Carbon dioxide in the beer. Most modern beer use
hop, which add bitterness and other flavors. It also acts as a natural preservative and stabilizing
agent. Other flavoring agents such as herbs or fruits may be included or used instead of hops. The
strength of modern beer is usually around 4 to 6 % alcohol by volume. Beer is distributed in
bottles and cans.
• Barley malt
• Water
• Yeast
• Hop
Barley Malt
Malt can be of any type of cereal grain. But barley malt is preferable due to:
Has enough enzyme, Has balanced and enough carbohydrate, Has Minimum amount of protein ,
Little amount of fats/oils which decreases foam formation, has husk which facilitates filtration by
trapping unwanted materials. Have its own preferable color, mouth feel and texture.
Water
Water is needed in every process of production of beer either as steam, boiling or cooling agent
and some portion of the water is used directly in the beer which contains about 95 % of water in
it and sometime for the condensers of cooling equipment.
Yeast
Different types of Beer yeast help to give Beer its various tastes. During beer production the
sugar in the wort is fermented by yeast to alcohol, for productions in BGI yeast fungi known as
lager yeast is used.
Hop
Hops are grown in special growing regions where the necessary growth conditions exist. After
the harvesting of the hops, they are dried and processed to avoid a reduction in their value. The
variety of hops used, will leave its own distinct flavor / aroma. Here there are 3 types of hops
used namely the CO2 Extract, IKE and tetra hops.
Sugar: Is to increase fermentable sugar amount needed in fermentation and also to provide
sweeter test for the beer.
• Ale Beer: are top fermented beers that use yeast named Saccharomyces Cervisiae, and a
relatively higher fermentation temperature with respect to lager and a complex filtration
mechanism is required.
• Lager Beer: are bottom fermented beers that use yeast named Saccharomyces uvarum,
and a cooler fermentation temperature and easier filtration mechanism. They are stored
for some time after fermentation has ended.
• Wheat Beer: is produced from wheat malt by using top fermentation method but is not
advisable due to its high protein content and absence of husk.
Stouts: are dark colored beer brewed from amber malts or over-kilned malts with either
Malt used in this factory is of two types. It is either imported or local. Imported malts come from
three European Countries namely France, Belgium and Netherlands. This imported malt come in
containers thus are immediately transported to silos.
On their way to the silos dusts and any metallic substances are removed by the help of dust
removers and magnets attached on their flow path. And, any foreign materials with larger size are
screened out from the malt. There are 4 silos found in BGI Company in Addis.
However, local Malts are delivered from Assela Malt factory and Gonder Malt factory in bags of
each 50 kilograms, so manual labor is used to transport malts to storage rooms.
When malt is needed in the milling section it is transported in pipes with the help of air pressure.
Local malt is screened, dust and metal removed before passing onto the pipes of malt intake.
The following figure 3.1 will shows the detail description of brew house process.
It is process of size reduction for better extraction by increasing surface area of malt for
enzymatic actions. This factory uses hammer mill which the malts are milled to sizes of less than
2.75mm. B.
Premashing
Mechamasher
is the place
where grist,
process water
temperature of
to be
maintained at
62.4 0 C. this is
done by
varying and
maintaining the
steam and
process water
inlet amounts.
Carbon
dioxide is used
here to transfer
mash to mash
tune by
providing
pressure.
c. Mashing mash tun is the tank where mashing process occurs in. It’s the process of degradation
of larger molecules to smaller ones. It includes breaking of proteins to amino acids,
polysaccharides (starch) to fermentable and non- fermentable sugars, and also breaking of fats to
fatty acids. This all processes occur with the help of enzymes. Barley contains α and β amylases
and proteases which converts starches and proteins, respectively.
Mash tun uses agitator for uniform mixing and is heated to provide favorable temperature for the
enzymes. Proteases work well at 55 0 C, β amylases work well at 64 0 C, and α amylases work
well at 74 0 C. Additives in this stage are CaCl2, HCl, and Bioglucanase.
1. β - glucanase degradation:
The cell wall of barley endosperm consists of a fixed network of proteins, cellulose and
hemicelluloses which are linked together by β - glucanase. The starch reserve is in the endosperm
so the β - glucanase should be degraded first by endo β glucanase.
2. Starch degradation:
The most important component of beer is the alcohol formed during fermentation from sugars. It
is therefore important to degrade the starch to a large extent to fermentable sugar like maltose.
Starch degradation occurs in three stages namely gelatinization, liquefaction and saccharification.
Gelatinization: Each cereal has its own gelatinization temperature. Malt starch will gelatinize at
600 C in the presence of amylase. Simply gelatinization means swelling and bursting of starch
granules in hot aqueous solution. A viscous (sticky) solution is formed and the degree of
viscosity is dependent on the extent of water. At this stage there is no chemical degradation
happening.
Liquefaction: It is the reduction in the viscosity of the long chain glucose in starch
(Amylase and amylo pectin) or gelatinized starch by α-amylase. The long chain glucose
in starch are very rapidly broken to form smaller chains by α-amylase. The α-amylase is
active at the temperature of 72 – 75 o C and the PH range is 5.6 – 5.8.
3. Protein degradation:
The breakdown of proteins such as albumins, globulins and glutens start during malting and
continues during mashing by proteases which breakdown proteins to peptones to polypeptides
and poly peptidases which breakdown the polypeptides to amino acids. The enzymes proteases
and peptidase are two main enzymes of this group. Protease is responsible for degrading
albumins already dissolved in the wort, along with insoluble globulins, into simpler mediumsized
proteins (peptones and peptides).
Iodine test is done during mashing to identify if starch has degraded to fermentable sugar or not.
If sample from mash tun changes color to blue black, starch is still present so requires additional
time. But when sample changes color of iodine to yellow, it represents all starch has degraded to
simple sugar thus mashing ends here.
E. Mash Filtration
Mash filter is a plate and frame filter which uses membranes. There are 4 stages which are first
sparging, second sparging, third sparging and finally compression. The wort is transferred to
holding vessel and spent grain is discharged to hopper after compression. Then spent grain is
.
F. Wort boiling
0
Wort kettle is a cooking section rising the temperature to 99.9 C. It is a tank where wort is
heated for: Removal / Evaporation of extra water, fully denaturing enzymes Hop isomerization,
Killing micro- organisms Better coloring Additives in this step are hop of two types called IKE
and Extract, caramel, ZnSO4, Sugar, and CaCl2. Overall process takes 1 hour, hop and CaCl2 are
added at the start of the process, sugar in the form of syrup is added at 50 minute of process and
ZnSO4 is added a minute before sugar.
G.Claris aver
Claris saver is a tank with a conical shape at the bottom of it. It is where heavy materials settle
down by the principle of precipitate
A. Wort Cooling and Wort Aeration: Is decreasing temperature of clarified wort (98 0 C) to
10 0 C using plate heat exchanger and dosing of Oxygen to wort required for aerobic respiration
of yeasts in the fermentation process for yeast propagation.
B. Yeaster: Is a tank where yeast propagation and homogenization of powder yeast with wort
occurs in. There are two Yeaster tanks. Yeasts are dosed to the wort going to fermentation
tanks from these tanks on the pipes where aerated, cold wort is passes through.
A. Fermentation is initially maintained at 12.5 0 C. Yeasts work well at this temperature, and when
extract reaches.
Some specified amount, specifically for BGI 8, temperature is rose to 16 0 C. This is to reduce the
VDK amount produced by side reaction during fermentation. After this when VDK is below
0.15, temperature is decreased back to 4 0 C.
And again, at this time limit extract is approximately reached. Limit extract is the maximum
amount of production of ethanol from the extracted sugar using yeast.
E. Maturation: It is stage of taking extra time in fermentation tanks for better coloring of the
beer and removal of yeasts due to precipitation. When TOD tanks reach 4 0 C, yeasts are
removed by the help of conical shaped bottom of TODs. Then after removing yeasts, temperature
is decreased to – 2 0 C. Fermenters use glycol to decrease temperature.
H.G. beer is the beer transferred from the fermentation process to filtration section. It contains
15 % yeast, alcohol and Carbon dioxide. H.G. beer uses Lantern A and B are used as transferring
mechanisms to the filtration process to remove any gap that might be formed in the pipes which
would let air in pipes. Lantern B is used as a reservoir for continuity of fluid transportation.
Is cooling of H.G. Beer from about – 1.5 0 C to – 2 0 C using glycol with a plate heat exchanger.
C.Centrifuge
It is separation of yeasts (heavier substances) from the lighter liquid beer. Centrifuge is a
machine which rotates with a very high speed to separate materials. The centrifuge used here
rotates with 4840 rpm (revolutions per minute). It is re- cooled again to -2 0 C, because it will
gain some amount of heat due to collision between molecules during spinning.
It is the addition and homogenization of silica gel with the H.G. Beer to increase size of
impurities especially proteins found in the beer. This is done to increase shelf life of beer by
further purification.
E. Buffer Tank 1
Is tank used for settling of impurities and stabilization of the beer since it was in high speed
revolution in the centrifuge as well as in the silica gel unit agitation processes. Out flow from this
tank occurs when amount of beer in it has reached 80 % of the full capacity.
Filtration at this stage requires use of filter aid. The filter aid known as clarcel or kieselguhr has 3
types that are speed plus, speed flow and super aid. These are mixed in kieselguhr with the beer.
Then they are passed to plate type filter. Then it is passed into the filtered outlet beer tank or
buffer tank 2.
G. Blending
Based on the alcohol content, amount of water required to produce 4.7 % alcohol in final beer is
known, thus degassed water will be added and blended with the beer.
H. Additives
Filter outlet beer is stored in Buffer tank 2 for laboratory testing and stability. Sample is taken
from this tank and tests like bitterness, color, CO2, Dissolved O2, and alcohol are done. If
bitterness is not in the specified range, hop is added or dosed into it. If color is not in specified
range, caramel is added. In addition to this, KMS (Potassium Meta Bi-Sulfate) is added to beer
which increases the shelf life of the beer and Vitamin C (Ascorbic acid) is added to the Draft
which gives it flavor.
If the amount of the above tested parameters is above ranging, the filtered beer will be blended
with another filter outlet with lesser quantity of above parameters.
I. Carbonation
Carbon dioxide is finally dosed, 4.5 for beer and 2 for draft. It is then stored for a short while in
BBT (Bright Beer Tank). And lastly BBT is tested for surety, the tests include: Haziness,
Bitterness, PH, and Color.
3.5. Packaging
3.5.1. Bottling
It is final stage of producing beer to supply for customers. Bottles have a shelf life of 1 year.
A. De-palletizer
Forklifts move stored craters with empty bottles from warehouse to pallets. Then pallets are
transported on to de-palletizer machine. De-palletizer transfers crater from pallets to roller
conveyor by the help of photo electric sensors.
B. Lubricator
Before going to lubricator, it passes direction convertor which arranges the direction of crates.
Then lubricator sprays water onto the crates to moisturize crates and bottles for easier removal of
C.Decamatic: It uses pneumatic system to pull out bottles from the crates to transfer crates to
crate conveyor and bottles to bottle conveyor. It consists of a crate stopper, crate centering and
crate sensor.
D. Crate Conveyor: It transports empty crates to crate washer, which only uses water for cleaning
the crate.
E. Bottle Conveyor
This transfers bottles to in-fit conveyor, which passes bottles into introducer for washing. Here
after, introducer transfers to pusher that pushes bottles to fit into the pocket. Bottles in pocket
have inclined sitting to easily remove wastes by gravitational force. In addition to this pressurized
water is also used.
F. Bottle Washer
i. First and second soaking: This two are together, but initially a chemical named PT
100 is added to easily remove labels strongly attached to the bottles. Labels are moved
out of the washing process using conveyors and a brush removes labels from
conveyor to the garbage. Then soaking of bottles uses caustic soda and steam to wash
bottles.
ii. Third soaking: is washing bottles using lesser amount of caustic soda to remove
leftover dirty or wastes which haven’t been removed in earlier washing stages.
Iii.Fourth soaking: it uses small amount of acid to neutralize soda left in the bottles
and is then finally drained and washed with pure water to finish washing.
G. Bottle size Inspector
It has photoelectric sensor to test if bottle is of right size. Foreign bottles either longer or shorter
are removed with the help of mono-rejecter.
It checks overall cleanliness of the bottle. It has testers for the mouth, bottom, base, and internal
parts to check if any broken area is present and not purely cleaned. It also takes a picture of each
bottle and writes, saves information about the clean and rejected bottles.
I. Filling
Bottle presence sensor initially gives information to the filler. If bottles are present vacuum
pumper starts up. It removes any materials that might have entered bottle from the air when being
transferred from washer to this region. Then passes to Carbon dioxide pumper where CO2 is filled
onto the bottle to remove any moisture or air that can spoil the beer within short period of time. If
pressure in bottles is high during CO2 addition, bottles will explode. Then filler fills bottles with
beer with the help of Umbrella and corks are immediately closed. There are 72 valves for filling
process. Then chrome has hot water and air which is used to take CO2 to the top of the bottle to
maintain amount of CO2 needed, if greater than needed it will be removed.
J. Full Bottle Inspector 1: Full bottle inspector is a sensor to test and rejects with mono-
rejecter.
K. Pasteurizing Section: This is heating of beer to increase the shelf life. It uses hot water
and overall process of pasteurization takes about 40 minutes. If not pasteurized, beer will be
spoiled within 12 hours. Pasteurization has 3 zones; these are:
i. Heating zone: it has internally again 3 zones. The first zone is heating to a temperature
of 38 0 C, then second zone is heating to a temperature of 44 0 C and third zone is
heating to a temperature of 58 0 C.
ii. Pasteurizing zone: It has again 3 zones. First zone heats to a temperature of 63 0 C,
0
then second zone heats to a temperature of 56 C and third zone heats to a
temperature of 63 0 C.
iii. Cooling zone: It has also 3 zones. First zone cools to 58 0 C, then second zone cools to
0 0
44 C and third zone cools to 38 C. Cooling is done to decrease expansion of
molecules caused due to heating of molecules. If not cooled down bottles will explode.
L. Labeling: Its body and neck labels are done here using glue to attach labels to the bottle.
M. Domino: Is attaching expiry date to the bottle using inks sprayed onto the bottles.
N. Full Bottle Inspector 2: It tests proper attachment of labels on the body and neck and if improper,
improper label rejecter rejects bottles. In addition to the above, there is an ultrasonic cork sensor
to test presence of corks. After this, Optical chemical is sprayed on bottles to brighten up the
bottles or to give a shining glow to the bottles.
O. O.Incamatic: It fills crater with full bottles using pneumatic system to pick and put bottles. Bottles are
transferred from full bottle conveyors to craters.
Q. Palletizer: Transports crates from full crate conveyor to pallets to be stored in stocks.
3.5.2 Kegging
It is other form of supplying beer to customers. Draft has a shelf life of 30 days or 1 month. Saint
George draft is pasteurized draft, where pasteurization occurs before packaging. There are two
buffer tanks (BT) used as a storage tank each with capacity of 80 hl. One buffer tank stores beer
sent from BBT and the other stores pasteurized draft ready for filling. The draft or low gravity
Beer (L.G. Beer) stored in BT 1 is passed to and initially heated used a plate heat exchanger with
0
water of temperature 80 C. Then after heating, it is cooled back using cold water with a
temperature of 4 0 C and is stored in BT 2. BT starts process when reaching above 66 hl.
a. De-palletizer: Is transferring Keg from pallets to roller conveyor that transports keg.
d. Washer: Is external washing of the body of the keg using caustic and hot water.
e. Piston: It divides keg onto channels. There are 11 channels divided into 2 paths. The first path
g. First Stage (head 1): is internal washing by initially draining any leftover draft in the keg and
sterilizing check is done in here. Then it is washed with mixed water, i.e., acid and water, and
caustic soda and is drained. It is then finally soaked with caustic soda.
i. Second Stage (head 2): washes with caustic A, i.e., mixed caustic and water. Then it is
washed with caustic B, i.e., pure caustic.
ii. Third Stage (head 3): is washing with acid and mixed water.
iii. Fourth Stage (head 4): washing with low flow and mixed water. Then it is drained and
finally steam is filled into it, this is done to kill micro-organisms.
iv. Fifth Stage (head 5): it is stage of cooling down the keg and injecting CO2 into it. And
the mouth is washed with hot water.
v. Sixth Stage (head 6): Filling keg with draft
g.Turner: It turns direction of the mouth of the keg from bottom to top.
Spray alcohol (medical) on the moth and Close mouth with cap.
H. Domino and Label: It’s attaching expiry date to keg And attaching label
to keg.
3.6. Utility
Utilities are not main processes but are supporting units for the process.
Initially, ground water is pumped out from 250 m deep bore hole below the ground. Ground
water might contain ions, minerals, micro-organisms and suspended solid particles which require
further treatment to be used.
Two chemicals NaClO3 and HCl are reacted in a tank to produce ClO2. This ClO2 is used to kill
micro- organisms which are present in the original water. The ground water is mixed with ClO2 in
3 tanks where water is initially stored in and passed to sand filter. The sand filter has 3 layers
namely coarse, medium and fine. These layers are used to filter out suspended solids of different
sizes and also dead micro- organisms.
After passing this step of filtration, the chlorinated (mixed with ClO2) and filtered (sand filtered)
water is passed to and stored in the chlorinated and filtered water tank. Here after, the water is
passed through a 20 µ filter. This is done to trap particles with larger sizes greater than 20 µm
particle diameter. Then the water that has passed through is either transferred to 5 µ filter or
softener.
When passed to softener, Resins are used to remove ions of Calcium (Ca) and Magnesium (Mg)
present in the water. These resins contain Na+ (Sodium ions), but when removing Ca2+ and Mg2+
ions, Na+ ions are lost thus needs to be recovered. Recovery of resins is done by washing softener
with NaCl. Soft water is then directed to blending tank to be mixed with permeate water.
The other path where water from 20 µ filter passes to is 5 µ filter where pretreatment occurs in.
Then after passing through the filter Sodium Meta bi sulfate is added to the water to remove ClO2
by forming NaCl salt. Then Hydrex Is added to the water. Hydrex is used as an antiscaling, i.e.,
to prevent scale formation. If scale is formed in Reverse Osmosis, membrane will be damaged.
And the membrane is very expensive thus pretreatment mechanisms are required to prevent
damaging of membranes.
From Hydrex water is transferred to reverse osmosis section. Water leaving Hydrex contains high
amount of salt content which is removed in reverse osmosis by process of moving ions from high
to low concentration and moving water from low to high concentration.
Water leaving reverse osmosis section is known as permeate water which has a hardness of about
0.25%. This water is used in brewing process as process water either as steam, hot water or cold
water. And blended water contains this permeate water. Blended water is used in utility system as
a heat exchanger for heating or cooling systems and in washing purpose.
After this Carbon filter is used for further purification. It has 4 filters. Permeate water is
transferred to 1 and 2 Carbon filters, which is used to remove any odor causing ions and minerals
like chlorine (Cl). Blended water is transferred to 3 and 4 Carbon filters, which are used to
remove ions.
Gas filter is the last filtration stage where de- chlorination process takes place in. This is done if
incase there is passing of molecules of chlorine in the above stage of carbon filtration. Finally,
water is treated and prepared to be used in the factory for the above different processes.
B. Boiler House
It is where permeated and blended water are boiled in, to produce steam and hot water. Boiling
for steams is at 300 0 C and for hot water is at 120 – 130 0 C. It uses diesel oil for boiling the
water.
C. Carbon Dioxide
Carbon dioxide (CO2) is a byproduct produced in the fermentation process of converting sugar
into alcohol. Though it is a byproduct it is used in the production process and can be sold out thus
carbon dioxide needs to be recovered.
The first step is transferring Carbon dioxide (CO2) from the Fermenters to Foam Separator. In the
separator foam is separated from the carbon dioxide gas. After this, purified Carbon dioxide is
transferred to collector. The collector is also known as a balloon. It is the area where the Carbon
dioxide is collected in.
Then Gas Washer is the place where other gases are separated and removed from Carbon dioxide
by showering the collected Carbon dioxide with water. After this Pure Carbon dioxide is
compressed using the compressor with about 17 bar pressure for further treatment.
It is then passed to Activated Carbon filter/ Drier, where activated carbon filter is used for odor
maintenance and removal and drier is used to remove any moisture and dusts will settle after
burning. After this it is passed to Carbon dioxide Condenser/ Re- boiler. Here Carbon dioxide
(CO2) is changed from its gaseous form into liquid state and CO2 gas will be free. Here NH3 is
used to decrease the temperature or as a cooling agent for Carbon dioxide (CO2). There are two
condensers available in the plant.
Then after this it is passed to Caron dioxide buffer tank as a stabilizing or cooling area. Then it is
passed to evaporator to prepare it in gaseous form to be used in filter blending with beer or
Carbon dioxide storage tanks (cylinders).
Glycol is initially imported at room temperature in tanks. It is a colorless chemical with high
viscosity thus is mixed with water to make it less viscous for easier circulation in pipes. Then
density is tested and when it reaches 1.025 g/ cm 3, it is introduced to Buffer Tank 1 and is cooled
to – 1 0 C using Ammonia. After this once glycol is stored in Buffer Tank 1 it can be reused for
many times, as a cooling agent.
i. Buffer Tank 1: stores glycol at – 1 0 C and is re-cooled for usage in the production
process.
ii. Cooling plants: there are 4 cooling heat exchangers used to decrease temperature of
glycol to – 5 0 C using Ammonia.
0
iii. Buffer Tank 2: stores re-cooled glycol with temperature of – 5 C. It is then
transported to different places from this tank with a pressure of 7 bar.
Glycol is used in different areas at a temperature of – 5 0 C. Some are: BBT, TODs, Ice water
Cooling, Beer transfer lines, Flash Pasteurizer, etc.
E. Air System
Air is needed in pneumatic systems but cannot be directly used from the surrounding thus needs
to be processed.
Air is initially sucked from the surrounding using two sucking units. Then air is compressed
using 7.1 bar pressure to fit in storage tanks. It is then stored in tanks for a short time. It is next
transferred to dryer recovery vessels. Here it is burned to remove dusts and moisture. Then it is
finally transferred to air networking tank. It is stored in here until it is needed in the process. It is
then pumped to all pneumatic systems of the factory from this storage area.
Ammonia (NH3) is the best cooling agent from all forms of chemicals with very low freezing
point. But it is poisonous chemical if in case it meets beverages, so cannot be directly used for
cooling areas in the production. Ammonia is used for cooling glycol and CO2.
Ammonia is initially evaporated when cooling glycol since it receives heat from glycol. Thus, as soon
as it evaporates it goes onto compressor. Here it is compressed to have a high pressure in a vapor
form. Then it is sent onto a condenser to be changed into liquid state. Condenser uses air, fan and
water. Air spins the fan and cools the water then sprays it on the condenser. And internally in the
condenser moisture and droplets of compressed NH3 would form liquid, high pressure NH3. Then it is
transferred to expansion valves which would lower the pressure and give off liquid, low pressure NH3.
Finally, this ammonia is re-used for cooling plants.
Waste water collected in the factory is mainly from Brew house wastes and bottling wastes. Brew
house wastes include all waste waters from brew house, fermentation, filtration, boiler house and
some utilities. They are initially stored in septic tanks. And when volume of waste water in septic
tank reaches 60 – 80 % of its total holding capacity, it is transferred to treatment plant.
When being transferred to the process it is initially screened for removing larger materials which
might block flow of materials. Then it passes through a de-fatter section for removal of oils
which might be present due to leakage from motors. Then it goes into influent pit for checking
the temperature and PH using sensors. After this it passes through a static screen of 1mm by 1mm
size.
Then it goes to Equalization Tank or Buffer Tank. It stays here for 6 hours and based on its PH
additives might be added to neutralize the waste water. If PH is > 7.5, CO2 and sometimes HCl is
Then it is passed to PH correction tank for further correction and evaluation of its PH. PH has a
very high effect on bacteria’s to be used in the next stage. These bacteria’s must be kept under
optimum PH and temperature for longer use in anaerobic reactors. If affected by any means
including fuels from furnace or any other toxic substances, bacteria will be damaged and dead.
Then if PH is between 6 and 7.5, it is passed to UASB (Upper Anaerobic Sludge Broke). Here it
stays for 6 to 8 hours and bacteria produce Biogas named methane gas from byproducts.
After this, treated water is passed to re-aeration section/tank to oxygenate water to be released to
river and also to make it odorless by ventilation. And bio-filter is then used to separate biogas
from water. It gives off 78% biogas at this stage. Then finally biogas is passed to biogas torch to
be burnt into water vapor and carbon dioxide which can be easily released to the atmosphere.
H. CIP
1. Cold CIP
It is used to clean TODs, Bright Beer Tanks, Buffer Tanks, and all other tanks. All chemicals
used here are at room temperature. It uses 4 types of chemicals called caustic soda, ATR acid,
Sept acid and cold water. And cleaning has 3 stages, this are:
i. 1st Cleaning: Wash with caustic soda then rinse with cold water.
ii. 2nd Cleaning: Circulating the tank with ATR acid, to neutralize the tank.
iii. 3rd Cleaning: Circulating tank with septic acid for disinfection / sterilizing tank. And
finally drain.
2. Hot CIP
It is used for cleaning pipes/ tubes. All chemicals used here are at 80 0 C. It uses 3 types
of chemicals named as caustic soda, ATR acid and hot water. And it has 3 cleaning stages,
this are:
i. 1st Cleaning: Wash with caustic soda then drain.
ii. 2nd Cleaning: Circulating the tank with ATR acid, to neutralize the tank. iii.
3rd Cleaning: wash and rise with hot water for cleaning and sterilizing the tank.
Tanks use cold CIP not to heat up tanks and if there is presence of caustic in tanks and hot water
is added to it, it would form a vacuum which might cause tanks to collapse.
The Physic- Chemical Laboratory is the other laboratory where all in process tests are done in.
• Fermentation tests such as apparent extract, yeast population, and VDK (VicynlDiketone)
• Filter outlet tests like bitterness, haziness, color, dissolved oxygen, Carbon Dioxide,
alcohol content, PH, and extract.
• Bright beer tank tests include haziness, bitterness, PH, and Color.
• Water treatment tests like total hardness, phosphate content, sulfite content, alkalinity,
and conductivity.
• Waste water treatment tests like BOD, COD, PH, fat content, etc.
1. Hammer Mill
A single brew takes an average of 7200 Kg malt where about 2700 Kg is of imported malt and
4500 Kg is of local malts. Here losses are very small thus are negligible.
7200kg7200kg
HAMMER MILL
2.mecha-masher
Solution
V1 = 155 hl
= 15,500 Kg + 7,200 Kg m3 =
22,700 Kg
3. Mash Tun
Mash
Solution
=
Mash from pre-masher (m3) + CaCl2 (m4) + HCl (m5) + Bioglucanase (m6) = mash to mash filter
(m7)
m3 = 22,700 Kg m4 = 7 Kg m5 = 3 Kg m6 = 2 Kg m7 = m3 + m4 + m5 + m6 = 22,700 Kg + 7 Kg +
3 Kg + 2 Kg
m7= 22,712 Kg
4. Mash Filter
MASH FILTER
Sparging Water
Spent grain
Solution
Wort from mash tun. (m7) + Sparging water (m8) = Filtered wort (m9) + Spent Grain
(m10)
m7 = 22,712 Kg
V8 = 152 hl
4.2.Energy Balance
1. Hammer Mill
Analysis
Wi = 12.74
m = 7200 Kg
DP = 2.75mm, since >80 % of product passes through this sieve DF = 3mm, since >80 %
of feed passes through this sieve size.
E = 742.5 KW
Thus 742.5 KW of energy is consumed in crushing malt needed for a single brew.
dissolved in water resulting in a liquid known as wort. In B.G.I the yeast is originally propagated
from a single cells structure and recovered after fermentation. Generally, there are also two types
of yeast in brewing that is top and bottom type but in B.G.I Company it used the bottom type one
due to which does not usually for spore. This is well adapted slow fermentation at low
temperature and settles to the bottom of the tank at the end of fermentation. Finally, filtration
commenced, this process is a separation process in which the yeast cells and other turbidity
causing still presents in the beer are removed from the beer. At the same time substance is which
would, during the next weeks or months; they precipitate and make the beer turbid. Once the
desired quality of the beer is attained in the bright beer tank, the beer will finally ready to be
filled in the bottle or keg.
5.2. RECOMMENDATION
Malt storage
In B.G.I, the silo is made from stainless steel container and they are planted out in the open field
and there is no mechanism of controlling parameters such as temperature and humidity. If these
parameters increase in the storage it will cause physical and chemical changes in the endosperm
of the malt and this make it difficult for fermentation and other process. In order to fix this
problem, the malt must be stored in dry and cold environment. I want to recommend that some
controlling device fitted in the silo to monitor and stated parameters and there by adjusting the
environment of the malt storage for getting a massive amount of yield.
Energy recovery
In the wort kettle, there is a large amount of water vapor evaporated and it enters the surrounding.
However, this water vapor is steam which is produced on boiling. Now a day, the wort produces
0.8 hl of hot water at 80oC. More over the evaporated water mass contains a great deal of energy.
In my recommendation the company has two options, and this helps saving a high amount of heat
energy from the vapor. These are, - I. Vapor compression II. Vapor condensation Filtration
house
The beers that passes through the filter sheet, the sheet should be clean frequently if not there
might pass unclear beer so that it wills decrease the beer quality.
In order to recover the rejected beer first we have to open and drain it on an equipment for further
processing. Opening of the bottle will expose the beer to atmospheric condition which increases
the dissolved oxygen (DO) amount above the standard. In addition to, opening makes the beer
contaminate with microorganisms. Under the presence of dissolved oxygen metabolism of
microorganisms will be favored and decrees the shelf life of the beer. Therefore, decreasing DO
amount and complete deactivation of microorganisms (sterilization) are critical issues in beer
recovery.
6.4. Objective
6.4.1. General objective
The general objective of this project is to develop the system which can be used to recover the
rejected beer at FBI1 and FBI2 from bottle packaging.
6.5.2. Limitation
As the project needs modern and sophisticated equipment’s to be done it was not possible to
conduct practically with prototype and the general problem will be solved if the inadequate
a) dry heat sterilization - Dry heat sterilization (killing or removal of all microorganisms,
including bacterial spores) technique requires longer exposure time (1.5 to 3 hours)
and higher temperatures
b) Moist heat sterilization- Moist heat sterilization describes sterilization techniques that
use hot air that is heavily laden with water vapor and where this moisture plays the
most important role in the sterilization. Heating an article is one of the earliest forms
of sterilization practiced. The various procedures used to perform moist heat
sterilization
c) Sterilization by radiation- In physics, radiation is the emission or transmission of
energy in the form of waves or particles through space or through a material medium.
This includes: electromagnetic radiation, such as radio waves, microwaves, infrared,
visible light, ultraviolet, x-rays, and gamma radiation (γ) particle radiation, such as
alpha radiation.
Chemical sterilization- The active agent of the gas sterilization process can be ethylene oxide or
another highly volatile substance. The highly flammable and potentially explosive nature of such
agents is a disadvantage unless they are mixed with suitable inert gases to reduce their highly
toxic properties and the possibility of toxic residues remaining in treated materials. The whole
process is difficult to control and should only be considered if no other sterilization procedure
can be used. It must only be carried out under the supervision of highly skilled staff.
• Many objects cannot withstand the very high temperatures required for dry heat
sterilization (ex: some plastics would melt)
Not all objects can withstand the temperatures of dry heat sterilization
• No degradation of media during sterilization, thus it can be used for thermally labile
media
6.7. Methodology
6.7.1. Data collection
The necessary data have been collected by interviewing skilled employer, by making laboratory
analysis at the factory and using different websites. Microbiologists provided laboratorial
analysis for the determination of microbial contamination. The result obtained showed that the
beer contain microorganism of mold and bacteria and it contains some oxygen more than the
standard value. Therefore, highly sensitive risk is due to microorganism but not oxygen and it is
recommended to focus on the sterilization of microorganism.
content is determined, proportionality with high gravity beer is made to achieve the standard (the
oxygen content which should be present in beer i.e. ≤ 0.15ppb).
Experiment was conducted on the beer to be recovered to analyze the contamination amount
during opening and pouring of it to the sieve. Microbiologists in the laboratory identified that the
contaminant found in the beer is mostly yeast growth due to the dissolution of oxygen and other
contaminants are more or less noneffective. So, as the dissolution time increases the higher will
be yeast growth.
The wasted beer is 3456L daily. So, the blending ratio of recovered beer to the main stream can
be calculated. The smallest fermentation tanks, (TOD) have a capacity to hold 3 brews, (means
900hl) but, the recovered beer has a volume of 34.56hl. Therefore, the blending flow ration
should be 34.56hl/900hl=0.0384, this is the maximum blending ratio. Therefore, the amount of
dissolved oxygen is almost normal. Even if the wasted beer contains high level, the blending
makes it to be in the interval due to small ratio.
6.8. Process description of beer recovery and Flow sheet for beer recovery
system
a. Flow sheet for beer recovery system
The design is made as shown in the figure 6.2 below. It is extended from packaging section to
filtration section. First, there should be two sieves for screening solid material if the beer contains
and number of pumps are installed along the line where necessary to pump the beer and other
utilities. Two tanks (tank1 and tank2) which are holding vessels are installed, one next to the
sieves and the other near to micro filter and they should contain their own CIP line, CO2 line and
glycol line like BBT. Then text to tank1, uv-light, plate and frame heat exchanger and micro filter
are designed to sterilize, to cool and to filter respectively. Manual valves, at the bottom of tank1
and tank2, are fitted to manipulate the flow and blending valve at the end is installed to inject the
beer properly into the main stream at filtration section. An actuator, before the blending valve, is
situated to regulate the flow. Small sized pipes are also connected from line to line to transfer the
beer and other utilities as needed.
The beer which is removed from FBI1 and FBI2 by the sensor due to under fill and overfill is
received by the receiver and then unpacked (when packed) and poured to recovery tank manually.
Here the beer is kept for some time until the required amount for pumping is reached. Then it is
pumped in the line which is extended from this tank to filtration room. On the way of transferring
it, sterilizer and micro filter (membrane filter) are installed. So, the beer is sterilized using uv-
light sterilizer which is a strong sterilizer of microbes. Then it is cooled to a required temperature
as it was heated during pasteurization and filtered using membrane filter to remove microbes like
bacteria and yeast which will be developed during contamination and killed during sterilization.
After this process, the beer is stored in tank2 and sample is taken to check for its oxygen content
to make it proportional for blending with high gravity beer. Then it is properly injected using the
actuator and blending valve.
6.9 Discussion
In the introduction the background is discussed regarding to the project mainly to ensure its
applicability as preliminary. Other contemporary works as supportive are tried to be included.
Figures and flow sheet are used as illustrative. Generally this project can be profitable if it is
subdued in the way it is designed to be done and actuated in plantation. Designing layout, method
of the project proposal, and som laboratory aspects have been incorporated to complete the
general aspects of the project. Moreover literature review, statements and scopes of the project, to
help it induced, have been explained. So, as it is a profitable one.
In brew house the raw materal (malt) is weighted, crushed, mashed with hot water, boiled, mixed
with other additives, filtered or separated from spents, chilled with ice or cold water to (9-10)0C
and then becomes wort which is ready to be fermented. In fermentation, first it is pitched with
yeast, and then is transferred to fermentation tanks where the simple sugar is converted or
fermented to alcohol, CO2 and energy with the help of yeasts. After the stayment of the day to
(14-15)days, it is sent to filtartion room being separated from yeasts as much as possible. Here in
the room it is filtered from different micro-organisms, dead yeasts, other suspesions etc. this is
done by using differenr flocculants, palte and frame filter and centrifuge. Another thing which is
performed in the room is also the dilution or blending of high gravity beer with deaerated water,
colorization of beer and CO2 blending. Then it is pumped to packaging from its storage. Here in
the packaging bottle and keg are unpacke, washed, inspected, filled with beer, inspected again,
packed again and then be ready for sale to customers.
7.2. Recommendation
In the internship stayment at BGI, St. George beer company, a list of problem was observed
which are needed to be solved for the reduction of expenditure in terms of material and
It is well known that the company imports malt from western countries and it costs a lot
for the long journey transportation. It is recommended that the company have to make
integration with ministry of agriculture to cultivate the known species of barely that uses
for brewing.
The wort kettle high amount of energy is needed to attain the temperature 90 0C. In order
to minimize the energy consumption at this unit there should be pre heat exchanger
which will increase the temperature of the wort. So that the hot wort from heat exchanger
will attain the maximum temperature.
REFERENCE
1. Wolfgang Kunze, Technology of brewing and malting fifth Edition.(the report written from) 2.
Brewing Science and practice Dennis E. Briggs Edited Chris A. Bolton, Peter A. Brookes and
Roger Stevens.
3. Fermentation and Biochemical Engineering Handbook Principles, Process Design
4. The Operation Manuals of the different Departments of the Factory Web sites.
5. Brewing Science and practice Edited by Dennis E. Briggs, Chris A. Boulton, Peter A. Brookes
and Roger Stevens.
Technology Brewing and Malting International Edition by KUNZE, W. (1996