Jimma University

JIMMA UNIVERSITY
JIMMA INSTITUTE OF TECHNOLOGY
School of chemical engineering

Internship Report and project for company
Hosting company: harar Brewer S.CO
Duration: from October 1, 2020 to January, 2021
Name id no_
Firesenbet kibru…………………………………………………….ru 4295/09
Date sum.
JIMMA, Ethiopia
AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 1
DECLARATION
I am a 4 th year Chemical engineering student I have undertaken my internship experience in
Harar Brewery Share Company for a period of four month from October 1 - January 30 under the
guidance of Mr. Ermias academic advisors and Mr. Tewlde company advisor. I clarify that my
work is original and compiled according to the internship report writing guideline given by the
department.
NAME OF ADVISOR SIGNATURE DATE
1…………………………………………….. ……………………… ………………

ACKNOWLEDGEMENT
First of all, I would like to thank God for helping me to pass through the internship program
peacefully. Next to this, I would like to thank for the company production manager Mr. Eshetu .
for his great support and helping me to understand the production process well. And also I would
like to thank brew house manager Mr. Tewelde, supervisor Mr. Tewelde and I would like to
thank my advisors Mr. Ermiyas for your help throughout the internship program, and for your
advices in all my activity to upgrade my knowledge. In addition to this I would like to thank all
operators they activated which the sections I worked. Finally I would like to give a great
respecting for my advisor Mr.Ermiyas who indicates me the direction of my project format,
comments and advice throughout my work.

EXECUTIVE SUMMARY
This document contains the internship report that I have performed in Harar brewery Share
Company from October 1-January 30.It includes the background internship hosting company, its
main services and customers, as well as its overall objectives, organization and work flow of
each section, overall internship experience including work tasks, The work flow in the section,
overall benefit gained from the internship and project carried out. I also developed social and
communication skills, how to communicate with different class of employees (an engineer,
operator and technicians) and developed my work with ethics like punctuality, working with
others (team work). And also include the project carried out on the screw conveyor to dosing and
preparation of caustic. After all this topics I included conclusion and recommendation for
improvement of works in the company. Generally I gained a lot from the experience and intend
to use it in the future.

Abbreviation
 HBSC………………………….Harar Brewery Share Company

 TOD…………………………… Tank Out Door
 CCT……………………………Cylndroconical Tank
 BBT…………………………….. Bright Beer Tank
 ATP…………………………….Adenosin Tri Phosphate
 ADP…………………………….Adenosin Di Phosphate
 VDK…………………………… vicinal Diketone
 HACCP……………………….…Hazard analysis and critical control point
 QMS……………………………. Quality management system
 EMS…………………………….. Environmental management system
 EQA…………………………….. Ethiopian quality award
 ISO………….……………………International standard organization
 HRD……………………………. Head of respective department
 PLC………………………………Programming logical system
 NBBT…………………………… New bright beer tanker
 CCT…………………………….. Cellar collectors
 APV…………………………….. alcohol per volume
 HL………………………………..hectoliter
 SQM……………………………..Square kilometer

cHAPTER ONE
introducion
Brewing is fundamentally a natural process. The art and science of brewing lie in converting
natural food material in to a pure beverage. Beer is alcoholic beverage usually made from
malted cereal grain as barley flavored with hops and fermented by yeast. The quality, color
and flavor of the beer depend on the quality, type and quantity of raw material used.
Harar brewery has two main units which are production and the general utility Production
section includes brew house, fermentation and packaging. Brew house is the heart of brewing
which tied with two main consecutive biochemical process stages malting and mashing. In
each stage there are many process stapes milling, mashing, Lautering, boiling, cooling,
fermenting, maturing and filtering. Packaging is the process of packing in suitable way and
supply to the market.
General utility supply all necessary materials for brewing. The unit includes boiler plant,
cooling plant, water treatment plant and waste water treatment plant. Each plant have their
own specific function boiler plant produce steam, cooling plant supply refrigeration for the
factory, water treatment plant supply purified water.
Waste water treatment plant manages the company waste removal system. The company
waste collected, treated and removed by the waste water treatment plant. Harar brewery
follows environmentally friendly way of production the waste water treatment plant is the
major indication of this. In for coming units we will discuss each unit in brief.

1.1. BACKGROUND
Harar brewery Share Company was established in 1984, located at historical town of Harar; at a
distance of 515 km from the capital. The brewery is situated on area of 113,536.48 square
meters. The brewery initial designed capacity was 200,000 hectoliter per annum and it was only
producing Harar lager and draught beer. In the beginning the company has 383 employers. The
brewery was recognized in 1992 as public enterprise by council of Ministers.
The company sells its product locally and overseas. Since 1994 the brewery diversified its
product and put two new brands on the market Hakim stout, alcoholic content 5.5%w/v (dark
beer), Harar sofi alcohol free drink(malt drink). It is one of the breweries in the country involved
in the production of different types of and malt drinks namely: Harar Lager Beer, Harar Sofi and
Lemon Sofi (non-alcoholic) and Hakim Stout (dark beer).
From 1997-2006 the company carried out intensive capacity building. Its major achievements
include replacementof old machineries by new, expansion of the production capacity from
20000hl to 250000hland the company’s water shortage is resolved by constructing its own water
supply system from “Finkile”, located 33km from Harar.
The main ingredients for the production of Harar Lager beer are barely malt, water, hopes and
Brewer’s yeast. Besides the stated production raw materials, Cara malt, Munchinermalt,pilsen
malt, assela malt, Sugar syrup and sugar are used for the production of Harar Sofi (non-alcoholic
malt drink) and Hakim Stout (dark beer). The factory was acquired by Heineken International on
July, 2011 a buyout costing $78 million USD. The factory has about 669 permanent workers
with the composition of professional and semiprofessional (Chemical engineers, Chemists, Food
process Technologists, electricians and electronics experts, micro-biologists and social science
professionals) to nonprofessional ratio about 1:10
The company has installed capacity of 60 million bottles (200,000hectoleter) per year with
annual production about 58million of bottles with 10% additional volume which lift up total
volume about 63 million bottles per annum by upgrading the bottling section capacity. Since
November 2006 the brewery increased its capacity to 90 million bottles (300,000 hectoliters).
Starting from December 2015 the company launched TPM program and inaugurated the new

packaging line that gave the company the capacity of producing 500,000 hectoliters of beer per
annum.
The market share of the brewery is estimated to be about 7%. After privatization the
company has conducted successful optimization program to increase from 300,000 to 400,000
hectoliter per annum.
The management has strong desire and commitment to implement GHP, GMP, HACCP and
ISO 9001:2000 Quality Management System, and Environmental Management System and has
started implementation of the QMS, ISO 9001:2000 & HACCP since December 2004.
To facilitate the implementation process and sustainability of the system, the top and middle
management members have participated in several trainings, seminars and workshops on QMS,
HACCP & EMS. The company revised and integrated the ISO 9001:2000 implementation
practices with HACCP and successfully integrated QMS and HACCP since 2009, ISO 22,000:
2005.
The company has established and implemented documentation and records that could
enhance the implementation of QMS, HACCP and EMS.
The company is certified in quality management system (ISO 9001:2000), HACCP (SANS
10330:20006), environmental management system (ISO14001:2006) and it win first Ethiopia
quality award among manufacturing company in Ethiopian which gives for major achievements
such as effective management performance, policy and strategy Resource management, quality
of production processes and customer oriented activities.

1.2. MISSION AND VISION
1.1.1 Vision
 To be leader in countries beer industries with respect to quality, competitive price,

prospect to high technology and international orients as well as sample for the overall
industrial sector in the country.
 To make Harar beer the central venue for quality beer celebrities.
 To produce consistent beer quality product
1.1.2 Mission
 To contribute for the development of a region by producing and selling customer

proffered quality beer at competition reasonable price and generate a reasonable price.
 To product and seek quality beer at reasonable profit.
1.3. OBJECTIVEOF REPORT

GENERAL OBJECTIVE
 The general objective of the internship is to improve and built up our understanding on
the practical industrial practice.
SPECIFIC OBJECTIVES
The specific objectives of the internship include
 to understand the fundamental processes involved in brewing
 to know the raw materials used and understand the reason why

 to know the equipment’s used and know their function and their working principle
 to reflect the experience and knowledge gained during the internship program
1.4. The main products & Services
The main products of the HararBrewery share company are:
 Harar beer
 Hakim stout beer
 Harar draught beer(locally called draft)
 Harar sofi beer
 And also bukler which is alcohol free but have beer flavor
1.5 The company structure

Managing Director
General Manager
Administration Technical Manager Production Manager Sales and Purchasing

Manager
Sellers
Process Manager
Electrician Mechanics Chemist
Manager Manager Manager
Engineers
Electricians Chemists
Mechanics
Mechanics Welders
Mechanics
Figure 1the company general structure

CHAPTER TWO
2. LITERATURE REVIEW
The process of making beer is known as brewing. A dedicated for the making of beer is called a
brewery, Though beer can be made at home, A beer can made on a domestic scale for non-
commercial reasons is classified as home brewing regardless of where it is made, through most
home brewed is made in the home. Brewing beer is subjected to legislation and taxation in
developed countries, which from the late 19the century, largely restricted brewing to a
commercial operation only.
Today the brewing industry is a global business, consisting of several dominant multinational
companies and many thousands of smaller producers ranging from brew pubs to regional
breweries.
The basic ingredients of beer are pure water, a starch source, such as malted barley, able to be
fermented (converted into alcohol): a brewer’s yeast to process the fermentation; and a flavoring
such as hops.

2.1 RAW MATERIALS
All chemistry and production of beer occur in brew house. The main raw materials for
production of beer are barley, yeast, water and hop.
Hops Yeast
Malt Water
Figure 2 Raw Materials
Malt: It is the main row material for beer prodaction.it is depend on the fact that barley has high
starch and the husk still adheres to the grain even after threshing and processing to malt
consequently it is able to from the work filtration.in next production stages be for use in the
brewery first of all the barley must be convert into malt.
The quality of brewing malt has the following characteristics:
 High water absorption and low water sensitivity,
 Low content of protein,
 High sprouting by the time of malting,
 High enzyme formation,
 High solubility,
HBSC brewery uses barley malt from Assela malt factory and by importing German, Belgium
and cara.
Water: Quantitatively water is the major raw material used in beer production. The main
ingredient in Beer is water and one needs to be very careful about the water, water source that is
being used in producing Beer. It must be pure, with no trace of bacteria. This is very important,

because only then will it allow the other ingredients to release all their flavors. Usually the
mineral present in the water available varies regionally, that is why the taste of beer also used to
vary in olden day as per the regions. However today we can chemically adjust, to produce the
desire flavor/variety of beer. Only a small part of the water required is used directly in the beer
and by far the largest part is needed for cleaning and rising purposes and sometime for the
condensers of cooling equipment. Supply and preparation of the water is particularly important
to the brewer, because the water quality affects the quality of the beer produced.95% of
breweries has their own spring or natural well. HARAR BREWERY also has its own spring
known by the name Sofi Minch.
Hop:-The hop (humuluslupulos) is an aromatic plant that gives for the beer its flavor and
bitterness. It also contributes to the formation of good foam and protects the beer against
contamination by microorganisms. Today, extracts from this plant are used industrially to
preserve its qualities. HARAR BREWERY also uses this type of hop during boiling. Hop
varieties are classified in terms of bitterness and flavor, which vary according to the amount of
resin and essential oils they containHop oils are produced in the Lupulin glands of the flower.
The oils are made of α and β-acids, but α-acids contribute more to the bettering of a beer. These
oils are non-polar, and can only be extracted through a short boiling.
Yeasts: Any of a number of microscopic, one-celled fungi important for their ability to ferment
carbohydrates in various substances is called yeast. Yeast is the most important and mysterious
ingredient which turns wort into beer and produces more of itself. Through anaerobic respiration,
it converts the malt sugar into alcohol, CO2, and other by-products. There are two main types of
yeasts for brewing purposes. These are Saccharomyces uvarum (ale yeast) which prefers warmer
temperatures (20-25°C) and will flocculate on top of the beer, and Saccharomyces cerevisiae
(lager yeast) which prefers cooler temperatures (-5°C) and will precipitate at the bottom of the
beer.IN this case this factory uses lager type of yeast from many type of yeast in the world.
Yeast propagation
In a brewery the quantity of yeast required for fermentation is obtained by propagation of a pure
yeast culture this consist of isolating suitable vigorous yeast cells and multiplying their number.

They are often removed after fermentation and it can be re used for other brewing purposes. The
propagation of yeast is applied by wort and it takes 20-26 day to sufficiently propagate. The
length of the day to perform fermentation depends on the age of the culture and amount of yeast
added to the fermenter in which it also determines the length of time in each phase of yeast
metabolism
CHAPTER THREE
3. PROCESS DESCRIPTION
There are four main process houses in this factory
1. Brew house
2. Fermentation house
3. Filtration house
4. Filling house
3.1 BREW HOUSE
“The brew house is the heart of the brewery.”
Brew house is a house which consists of a number of unit operation arranged in series that are
responsible for wort production. Hence, the wort produced in brew house passes different stages
beginning from malt milling. In HBSC the mill, grist case, mashing vessels (mashtun), mash
filter (lautertun), wort kettle and whirlpool are contained in brew house.
Beer Production Process
Beer is to all intents and purposes, a beverage made from the fermentation of sugars derived
from malted grain and flavored with hops and it is a controlled process. The main process steps
are:
 Milling
 Mashing

 Lautering
 Boiling
 Sedimentation
 Cooling
 Fermentation
 Maturation
 Filtration
 Packing
3.1.1 Milling
Milling is the process of grinding of malted grain In order for the malt components to be rapidly
extracted and converted by maximizing surface area of contact for enzymaticaction; the malt is
milled to obtain coarse flour called grist. Milling also include the process of breaking down
separating sizing and classifying aggregate material Milling process Keep husk material in-tact
to act as filter bed during wort recovery when grinding Endosperm material into small particles,
grits, which readily hydrate during mashing to reactivate the malt enzymes giving us maximum
extract.
The malt mill uses sets of rollers and screensto separate the husks from the kernel and grind
the kernels in to the grist necessary for mashing. From many types of milling in brewing science
Harar brewery uses dry milling process with 6 roller mills having 3 pairs of count rotating rollers
connected in serious. These pairs of seriously connected rollers are adjusted with different spec
meter (filler gauge) reading for different product of Harar brewery, normal, hakim and Sofi beer.
Filler gauge (spec meter); an instrument used to measure spacing between to materials. In
brewery it is used to measure spacing between 2 rollers of single pair of rollers.
Table 1spacing between rollers
Beer Type Space meter Bottom flour

extracted %
First roller Second roller

Normal 75 55 25-28
Hakim Stout 85 65 28-33
Sofi 85 65 28-33
There are three ways to transport malt in millingsection.
1. Bucket elevator: to transport uncrushed malt vertically upward

2. Screw conveyor: transport grinded malt horizontally
3. Gravity aid of transport: to transport both crushed and uncrushed malt vertically downward
3.1.2 Mashing
In malting process the barley starts to germinate and develops different types of enzymes that
break down starches into simple sugar. Some of these enzymes are alphaamylase, beta amylase,
protease, glucanase and etc. This over all process is creating favourable condition for mashing
process.
Mashing process is the extraction of fermentable sugars from the malted grain. This is simply by
activating the enzymes to form soluble substances for fermentation. Basically it consists of
steeping the malted grist in hot water .This activates naturally occurring enzymes in the malted
grist that convert the grain starches in to sweet sugar(maltose), that yeast can metabolize. This
process occurs in a vessel called a mashtun.
Mashing process is depends on the type of maltwe used .in the current situation Harar brewery
uses barley malt from different type of malt in brewing science. Barley malt is chosen for the
brewing process for enzyme content, yield, disease resistance and malting quality in using barley
maltthere is also adifference in mashing between different types ofbarley malt we use. This is the
core difference of mashing and test of different product of Harar brewery (normal, hakim stout
&sofi).
Table 2Types and amounts of malt added during mashing process in a single batch
Beer AsselaPilson Imported Imported Imported Cara

Munchiner Pilson

Normal beer 1200kg 300kg 1800kg 250kg
Hakim Stout 400kg 1700kg - 1500kg
Sofi 250kg 250kg 1350kg 350kg
During mashing different enzymes are used.
Table 3Enzymes added in the mashtun
Name of Enzyme Purpose Amount

Amyloglucosidase (AMG) Increase the availability of 235 ml
sugar for fermentation
Ultra-flo For fast mash separation by 220 ml
creating lower viscosity
Cemix Starch degradation 235 g
3.1.2.1 Process Steps
1. Hot liquor whose temperature ranging 40 to 55, from the boiler comes through perforated
tube and fill 50% of the mashtun to avoid the sticking of dough on the wall of the tank
during addition of grist.
2. Then the grist and hot liquor comes in to contact on the pre masher above the mash tun
and feed into mashtun simultaneously
3. Continuous stirring with a stirrer located on the middle of mash tun to avoid clumping
4. Heating until the temperature of protease enzyme activated
5. Protein rest: The time taken to degrade malt protein in to soluble protein and free amino
nitrogen (fan) by the enzyme which is called protease. these simpler proteins improve the
growth of yeast
6. Heating until the temperature of beta amylase enzyme activated
7. Scarification rest: the rest taken to breakdown the liquefied starch chains resulting in
successive removal of maltose unit from the non-reducing end in to simple
sugar(maltose)by the enzyme which called beta amylase .the process is isothermal
throughout the time
8. Heating to attain the temperature alpha amylase being active that is why enzymes are
temperature sensitive.

9. Mashing off rest; the time taken for alpha amylaseto break down or liquefy the
gelatinized starch byhydrolysis of the alpha 1, 4 linkages without further heating
10. Mash out
Table 4the temperature and time taken to proceed mashing
Process Parameter Beer type
Normal Hakim Stout Sofi
1 mashing in (min) 15 15 15
mashing in temp(0c) 50 50 40
2 protein rest (min) 0 40 0
protein rest temp(0c) 0 50 0
3 sacchar rest (min) 45 50 10
sacchar rest temp(c) 65 65 52
4 mashing off rest (min) 5 5 5
mashing off rest temp(c) 76 76 76
3.1.3 Lautering
Lautering is method of extraction of the sweet wort from the mash or it is simply the separation
of mash solids from mash liquids. The act of lautering gives the wort neededfor making beer.
In successive process of milling and mashing most of solid particles breaking down in to small
particles and became soluble in water to form sweet wort. These soluble parts are required by the
yeast to convert in to beer. So the resting insoluble part which cannot covert in to beer by
fermentation will be filtered out in lautertun and sell for cattle food. This filtered part is called
spent grains.
Lauterig is carried out in lautertun which is usually cylindrical vessel of large diameter and
comparatively shallow depth with a slotted false bottom 2 cm above the true bottom. False
bottom is slotted stainless steel plate. This plate allows the wortto flow through, but retain the
insoluble particles till exist in the mash. Inside the lautertun there is a raking machine, which can

be raised, lowered and rotated. The raking machine have a radial arms connected with vertical
axis that aligned at the centre of the lautertun to support the blades or rakes. While a brew is
being overflow the radial arms are rotated and the blades slice through and slightly lift the bed.
This assists in preventing compaction, which can result in a slow or stalled run off and also
provides access for the spurge water, thus increasing extract efficiency.
The wort drained of from spent grains withoutaddition of sparging water is called first wort. This
first wort must contain four to six per cent more extract than beer to be produced. For
economical operation the extract retained by spent grains is washed out by hot water. This
process is called sparging. The sparging process is continuous until desired extract concentration
in wort is reached. The last wort washed out from spent grains is called last running. Longer
sparging is uneconomical because evaporating the additional water costs lot during next boiling
process in wort kettle.
For sparging we use hot water because at high temperature the viscosity of fluid decreases so it
makes lautering easier and faster.
In Harar brewery spargings continue until masspercent of solute in first run which is 19% goes to
<1% in last running. The measurement is carried out by saccharometer which used to measure
mass per cent of the solution.
 First Running……68 hl……Extract measurement 14-21 0P
 1stSparging……..114 hl…...Extract measurement 7-14 0P (for normal & high gravity)
 2ndSparging…….165 hl…..Extract measurement 0-7 0P (for normal & high gravity)
 Last Running……226 hl….Extract measurement 0-7 0P (for normal & high gravity)
Figure 3 Lautertun
3.1.4 Boiling
The wort which clarified and diluted during lautering moves from the lautertun to a brew kettle
and is heated to boiling for about one hour. This boiling of wort is carriedout on large, typically
stainless steel vessel called wort kettle. One of the most important parts during boiling is hop
addition. This is done at a time when the wort start to boil. As the wort boils a carefully
measured amount of hop is added based on the specific beer recipe.
There are many reasons to boil the wort
 Boiling inactivates any active enzymes left from the mashing process ensuring the
ferment ability of the wort is set.
 The wort is concentrated through evaporation to a desired specific gravity and

colour develops by caramelization (sugars+amino acids+heat).
 Protein & tannin coagulation which is removed as trub from the base of the vessel after
the whirlpool sequence
 Natural volatile compounds are stripped by vigorous boiling. An example is dimethyl

sulphide (DMS), which has a sweet corn aroma when present at high levels
 Precipitation of calcium phosphate & proteins causing the pH to drop from 5.4 to pH 5.2
 Sanitize the wort (kill bacteria, fungi, and wild yeast)
 Formation of flavour active compounds
3.1.4.1 Process steps
To have effective and low cost boiling Harar brewery use these process steps
 Continuous pumping of the wort from the lautertun to the boiler
 Iodine test if there is a colour change there is a starch in a solution and the mash will back
to the mash tun. If there is no colour change almost all of the starch in the malt has
changed to simple sugar and boiling can start
 Boiling, with internal wort boiler having a bundle of tube wort and steam
circulate and fountain with a venture arrangement in the approach to the fountain,
which helps induces a big rolling boil action in the vessel. The purpose of the fountain is

that a thin film is created with a large surface area, where evaporation can take place.
Another benefit of the fountain is for foam suppression, particularly in the initial raise to
boil phase, before any hopsare added, where the fountain beats down the foam head.
 Hop addition extract type (liquid) 2.5 kg at 87 Pellet type (solid) 7.5 kg 5 minute before
boiling. The hop resins contribute flavour, aroma and bitterness to the brew
 Sugar test by saccharometer, if saccharometer test show 12 mass per cent of sugar the
boiling can stop otherwise the boiling will carry on(for extra evaporation)
Steammash outlet
Figure 4 Wort kettle
3.1.5 Whirlpool
This is a circular vessel where spent hop and the coagulate protein is separated from the wort.
The wort is introduced into the whirl pool tangentially. This accelerates the trub particles toward
the center of the vessel. They form large flocs which then settle down to the center line of the
vessel to form a trub cone. The trub is collected and sent to lautertun.
If not clarified properly the trub will be carried over into the fermentation tank. This can cause
poor yeast performance and slow fermentation. It will also be difficult to filter after fermentation.
The beer therefore may be prone to infection.
3.2 FERMENTATIN HOUSE
3.2.1 Wort Cooling

Lager yeast can only live and ferment at low temperatures, as a result, the hot wort must be
cooled as quickly as possible to 8 to110c.This is also important since a long period at
intermediate temperatures increase the risk of growth of beer spoilage microorganisms. Because
Wort is free from microorganism on casting(boiling).when beer spoilage microorganisms get in
to beer during the production process and multiply ,they can, as a result of formation of
metabolic products ,make the beer un saleable.
Rapid wort cooling is now days performed exclusively with plate heat exchanger some times in
Harar brewery called by the name plate cooler. In this, the wort is cooled by cold water. And the
heat exchange occurs through thin chrome-nickel steel plates.
A plate heat exchanger consists of a large number of thin metal plates, arranged behind one
another, between which wort and cold water flow alternatively wort flow through channels on
one side and cold water through channels on the other, a basic element (flow path) always
consists of two plates.In the plate heat exchanger the hot wort is cooled by cold water from about
90ºC to 8-11ºC pitching temperature.
 There are different characteristics of plate heat exchanger to acquire good heat exchange
 Very thin metal plates are used
 The plates have a profile which will produce turbulence
 The gap between the plates is very small
 Counter flow of wort and cold water is used
 The direction of the flow is changed frequently
3.2.2 Wort Aeration
Wort aeration is essential for good yeast growth and is the driving force behind many
aspects of yeast metabolism including fermentation. Oxygen is quickly absorbed by yeast and
is used to synthesize unsaturated fatty acids and sterols which form the cell membrane. These
molecules are important for both growth and fermentation and serve as a means of storing
oxygen within the cell. They are also necessary for increasing cell mass (growth), improving the

overall uptake of nutrients, and determining alcohol tolerance. Oxygen also stimulates synthesis
of molecules necessary for yeast to metabolize and take up maltose, the primary sugar in wort.
The wort transfers to fermentation must fulfil the output requirements of oxygen to obtain good
beer quality. Poor wort aeration may result in a poor quality of the final product (taste deviations,
foam stability, haze and SO2 levels).This could also lead to the production of high sulphite
content which can cause allergic reactions.
The pressure difference(increase) when the wort transforms from high velocity to low velocity is
measured by a pressure gauge and also the oxygen content of the aerated wort is measured by
electrochemical sensor(dissolved oxygen mater) at the location where all oxygen is dissolved
1. Pressure on Truncated tube 1.50 k Pascal
2. Pressure on wider tube 2 k Pascal
3. Oxygen content in a wort8-340mg of Oxygen/l
3.2.3 Yeast Propagation

It is important to realize that optimal yeast growth is distinct from fermentation.
Therefore, the conditions and methodologies used for propagating and maintaining yeast need
not be identical to those used for fermenting wort. The purpose of a yeast propagator (starter) is
to produce a sufficient quantity of yeast for subsequent fermentation. Propagation conditions
should be such that a maximal amount of yeast is produced which provides optimal fermentation
performance once pitched. The main criterion for fermentation performance is based on the rate
and extent of fermentation as well as the production of a beer with a balanced sensory profile
with no off-flavour aromas or inappropriate esters. Therefore there is a need of careful process of
propagation to havea best fermented beer.
The yeast propagation process is carried out in yeast propagation tank which can contain
maximumof 25 hl wort. This process is repeated in every 4 weeks to have enough young
generation yeast max less than or equal to 6.In the yeast propagation room there are also two
yeast storage cylindrical tanks which store the harvested yeast after primary fermentation.

The storage capacity of these tanks is about 32 hl and stores the yeast up to generation
five. The first propagated yeast in yeast propagation is called zero generation.
3.2.3.1 Operation Procedure
Procedure for lm07 yeast rehydration and propagation in Harar brewery (copied from the lab
manual)
1. 1 kg dried yeast is added to the Carlsberg flasks and the amount of 2mg/Lzn(5000 mg of
zinc=13.8g znso4.wort for the final propagation volume of 25 hl)the flask is already
filled with 10 L sterile Harar beer wort with a temperature of 15 Celsius .the flask is
aerated in the laboratory with sterile air for approximately 45 minutes (1minute on /10
minute off).the flasks needed to be manually shake every 5 minutes to mix the contents.
2. After the rehydration in the Carlsberg flask, the temperature of the yeast/wort
suspension will be 21 to 220c after empting the flask only limited amount of yeast
should be left behind in the flasks (approx. 100g)
3. The flask is pushed in to the large propagator through the sampling valve .by using
sterile air. The transfer time is approximately 15 minutes. Filling the propagator must be
done aseptically (using 70 v/v% alcohol to sterilize the possible contact areas andclose
to a burner or flame to prevent infection).
4. The first propagation step is done under continuous aeration (appr.50Nl/min) at a

temperature of 110c without stirring. Propagation should be done pressure less
(<5mbar).
5. When the apparent extract is between 5-70p, the 25 hl wort is transferred to a 1000 hl
CCT.
6. Make sure that within max.4h after transfer, 1 normal brew of 200 hl normally aerated
wort of a(normal)pitching temperature 80c is added. this brew should also get zinc for 5
brews(1mg/zn).this means a total of 100 g zinc=(=275 gznso4H2O)added manually in
the whirlpool.
7. The second propagation step is done without aeration (only normal wort aeration) at a
temperature of 110in 1000 hl CCT. When the apparent extract is between 5-70p the CCT
must be topped up with 4 brews of 200hl to the final volume of the CCT 1025hl.
8. Make sure that within max 4h after reaching the AE, the first of 4 brews of 200
hl normally aerated wort of a(normal)pitching temperature 80c is added to the 1000 hl
tank.

9. Fill the tank with normal brew rtm with another 3normaly aerated brews with a pitching
temperature of 80c and follow the normal fermentation process at 160c(harvest in
time ,ruhetc)
10. The production fermentation as indicated in step8-10 is the so called 0-generation

fermentation. The yeast harvested will be reuse and is called first generation yeast
3.2.4 Fermentation
Fermentation is the process in which yeast converts the wort into alcohol and carbon dioxide.
This is where the "real magic" of brewing happens which is the conversion of wortinto beer.
Fermentation can last a few days or a few weeks depending of the strain of yeast and the strength
of the beer. During the process the yeast reproduce and then metabolize the sugars, making C02,
alcohol, and a host of other flavourful and aromatic compounds that add complexity to the beer.
C6H12O6 yeast 2C2H5OH+2CO2
For lager beer which is produce in HARAR BERWERY fermentation is divided into two stapes
primary fermentation and secondary fermentation.
The primary fermentation takes anywhere from a few days to about two weeks, depending on
the yeaststrain and beer style. During this time, the yeast activity is greatest and most of
the wort sugars convert to alcohol and CO2. In Harar brewery primary fermentation lasts 7 to 8
days and temperatures used are between 10 and 160c. During the primary fermentation most
of the flavour compounds are formed. The fermentation is the result of the growth and natural
activity of millions copies of yeast.
The secondary fermentation also known as maturation it can be performed in the same vessel
as the main fermentation or the beer can be transferred into another vessel. The main objective of
the secondary fermentation is to remove diacetyl, which causes an off-flavour in lager beer. After
primary fermentation the settle down yeast removed and the beer is cooled down. In HARAR
BREWERY the temperature is cooled down around00c and maturation lasts about
In HARAR BREWERY there are two types of fermentation tanks new fermentation tanks CCT
and old fermentation tanks. Old fermentation tanks use different tanks forprimary fermentation

and secondary fermentation. For primary fermentation there are 24 upper part cylindrical and
lower part conical tanks which labels as “a1 a2 a3 a4 a5 a6 …d6” and each have the capacity of
200hl. They have jacket in which ice water will circulate to keep the standard temperature and
the temperature will manipulate by using thermostat. They have no any coated insulation for heat
exchange so they use room cooling to keep the temperature low. The room is closed by large
insulation doors.
The secondary fermentation room is known as cellar rooms. Cellar tanks usually are built to
withstand higher pressures. Beer remains under elevated pressures for two reasons to
naturally carbonate the beer and to keep the beer under CO2 pressure, free from the
damaging effects of oxygen. In HARAR BEREWERY there are 42 cellar tanks each have the
capacity of 400hl and arranged horizontally to facilitate settlement as old primary fermentation
tanks they have ice water which circulate under the jacket and use room cooling because they
have no insulation.
New fermentation tanks also known as CCT (cylindrical conical fermentation tanks). These
are modern fermentation tanks which can undergo both primary fermentation and maturation.
They have coated insulation so unlike old fermentation tanks and cellar tanks no need of room
cooling so they are more energy efficient. Instead of ice water they use ethanol circulate under
jacket for cooling. One dis advantage of these tanks is contamination of bottom beer by settled
dead yeast in conical section of pressurized fermentation tanks. In HARARBEREWERY we
have 7 CCT tanks each have capacity of1000hl.
The table below summarized fermentation process staying time for three products of Harar
brewery

Table 5fermentation process staying time
Lager beer Hakim stout Hararsofi
Staying time in 7-8 7-8 2-3

primary ferm/days
Staying time in 10-11 10-11
secondary ferm/days
Temp of primary 15-16 15-16 8 then
immediate
ferm /0c cooling to 0.
Temp of secondary 4-6 4-6
ferm/0c
3.2.4.1 Fermentation Process Steps
1. Prepare solution of sanitized according to each sanitation chemical. Clean using

automatic CIP system.
2. Identify yeast generation and prepare for pitching.
3. Pitch thick yeast in to aerated cold wort based onthickness and viability of yeast. Mix
optimum amount of yeast and aerate the wort during transfer to fermenting or CCT tanks.
Aeration is carried out in all brews and all yeastis added in the first brew.
4. Adjust the temp and measure extract daily to monitor fermentation process. After 24hrs
of wort receiving open the co2 valve to co2 recovery plant until the extract reduced to
40p.
5. Measure the extract and adjust the temp to rackingtemp (3-50c) for small fermenting
tanks.
6. Standard for racking extract is 2-2.50p and racking temp 3-50c for HARAR BEER
fermenting tanks.
7. Clean lines from fermenting tank to storage cellarfor raking and from fermenting tank to
yeast collecting tanks using automatic CIP system.
8. Collecting yeast after less than 24 hours of when the extract reaches 2.50p and rack green
beer from fermenting tanks after cooling down. the Ruh time is 72-96hrs collect yeast at
less than 24 hrs when the extract reaches 2.5 0p and adjust the program to cooling down,
in order to cool the beer after Ruh to -1.50c –(+0.50c) for CCT - After cooling of CCT the

beer is transferred to horizontal SCT. - Clean lines and tanks to make ready for next
operation.
3.3 FILTRATION HOUSE
3.3.1 Beer Filtration

Main reason for beer filtration is to create a bright beer by the removal of solids.Solids like:
• Yeast
• Proteins
• Suspended particles
Filtration is passing unclarified beer through a porous medium. The solids are retained in or on
the medium and the clarified product stream passes through. Mature beer from the fermentation
tank still contains some yeast and haze particles. Beer has to be clear when packed this is mainly
because
- To prevent further biological change taking place during or after packaging due to yeast
or haze particles.
- The consumer expects clear beer and it is immediately perceived.
Before the filtration process starts the beer needs to be in the right temperature.
3.3.2 Filtration process
During forward filtration the beer is first transferred from the storage vessels through the
unfiltered beer line (UBL) to the unfiltered beer tank (UBT) where beer is supplied to the
membranes via a feed pump. The beer is pumped in a loop to induce high velocities in the fibers.
The filtrate valve then opens and the filtration starts. To prevent solids concentration build up in
the loop the bleed valve is opened and some of the beer in the loop is bled back to the unfiltered
beer tank while the filtered beer goes to the filtered beer tank (FBT). During filtration the amount
of suspended solids increases in the concentrate tank. To reduce the amount of solids in the
system the unfiltered beer tank is normally purged. During filtration pressure climbs slowly with

time as the inevitable membrane fouling takes place. To partially restore the membrane flux a
backwash is done.
3.3.2.1 Chilling
When mature beer is transferred from the fermentation tank its temperature increases, so it is first
cooled by using plate heat exchanger. As the temperature decreases it causes the impurities to
clump together when silica gel is dosed in the next step. To cool the beer alcohol water is used.
This is because the freezing point of the alcohol water is lower so it can better cool the beer.
3.3.2.2 UBT
Once the beer is cooled it transferred to the UBT. But during the transfer process silica gel is
dosed into the beer. The silica gel absorbs the protein and increase in size so during filtration it is
easily filtered out and the impurities wont block the pores. So the haze of the beer is also
adjusted. The UBT serves as a buffer tank till the filtration process starts.
3.3.2.3 BMF
The beer from the UBT is transferred into the membrane filter. The beer enters from the bottom
and as it is being filtered through the membranes the pressure must be lower than the Trans
membrane pressure (TMP). TMP is the pressure between the membranes. The filtered beer is
then transferred to the FBT.
Process Description of BMF
The 2880 membrane fibers are fixed in 12 compartments. The membranes are held together in
the module housing (at the top end and bottom end) by an epoxy material. This epoxy potting
separates the unfiltered side (concentrate) from the filtered side (permeate).
The permeate line connects to the flow control valve which throttles open as the pressure builds
up on the walls of the membrane thereby maintaining constant beer output. Each module is

supplied with a side glass which an operator can use to detect the faulty module in case of a yeast
breakthrough. The compact skid is equipped with a 250 m3/h circulation pump which maintains
velocities of up to 1.5 m/s inside the fibers.
The skids also have a central filtrate pipe which collects all filtrate that is sent to the filtered
buffer tank. The concentrate is collected and continuously re-circulated on the modules by cross
flow circulation flow except for some that is bled back to the unfiltered beer tank.
Cross Flow Microfiltration Technology
Micro filtration membranes are used to remove particles in the range of 0.1 – 10 µm from a
suspension. Cross flow micro filtration is a pressure driven separation process. It involves two
flow paths. The filtrate (free of suspended particles) flows out and perpendicular to the
membrane surface. The concentrated liquid flows in an axial direction to the surface thereby
discouraging the formation of cake by sweeping away the deposits on the surface of the
membrane.
The hollow fiber membranes are made from the Polyethersulfone (PES) material, and are shaped
as straws. The whole surface of the membrane is porous with an average pore size of 0.5 µm.
These fibers are designed for an inside-out operation. The beer flows inside the fiber with the
filtrate (bright beer) leaving the fiber on the outside, all around its circumference, throughout its
length. The concentrate exits on the opposite end of the fiber (inside the straw) and the flow of
the concentrate is set up such that high velocities are induced in the fiber to promote high
turbulence on the inside surface of the fiber thereby discouraging the formation of the cake
Membrane properties
The PES membrane has the following Physical properties:
Description Specifications
Average Pore size 0.5 µm

Fiber Length 0.8 m
Inner fiber diameter 1.5 mm

Filtration area (per module) 9.8 m2
Membranes/module 2880
System Pressure -3.0 bar…..+5.0 bar
Maximum trans membrane pressure 1.2 bar
Membrane fouling
The major obstacle to the technology is membrane fouling, which reduces throughput of the
membrane. There are 3 major mechanisms by which the membrane can foul.
a) Surface Cake
Formation The cross flow velocity helps to minimize the formation of the cake but cannot totally
eliminate it. After a certain period of operation the cake builds up, and to partially remove the
cake on the membrane surface a process of backwashing (see section below) is used.
b) Surface Pore-Blocking
The particles that are bigger than the membrane pore can sit on top of the pores thereby blocking
the beer from passing through. These particles can also be easily removed through backwashing.
c) In Depth Pore Adsorption
The particles smaller than the pore size can get through the membrane surface and adsorb on the
walls of the porous structure. This limits the membrane throughput as it constricts the pores. This
kind of fouling is irreversible and hence cannot be rectified by back flushing. A full membrane
cleaning is required to break down the adsorbed particles and restore the throughput of the
membrane filter.
Layer formation Pore blocking Adsorption

Figure 5 Membrane fouling
Soak Back flush
Figure 6 BMF
During a filtration period the TMP will rise to 1.2bar and a soak back flush must be executed.
The soak back flush is used mainly to rid the membrane of material that is deposited on the
surface and that which may be blocking the pores. Backwashing partially restores the membrane
throughput. The back flush is performed in opposite direction of the filtration; from the outside
of the fiber into the inside. The force of liquid flowing from the outside is used to lift the cake
from the surface thereby cleaning the membrane.
Membrane Cleaning (CIP)

The forward filtration-backwash sequence continues until the pressure build-up on the wall of
the membrane requires full cleaning (see fig 10). Whereas backwashing cannot clean the
membrane pores internally, the full cleaning breaks down the deposits on the pores and fully
restores the membrane throughput. The membrane cleaning is performed from the inside to the
outside of the membrane, similar to filtration. The full cleaning is done in 2 steps with cleaning
agents:
a) Oxidation cleaning
This is done using a 2% caustic solution with 0,5% oxidation agent named Real. The cleaning is
done at 70oC with a temperature increased at around 3oC/min and maintained at 70oC and then
taken down slowly back to 30oC.

The Real cleaning agent is a special beer membrane cleaning agent developed by Pentair. The
agent oxidizes substances that adsorb on the walls of the membranes (mostly smaller molecular
proteins, polyphenols and β-glucans). This cleaning solution eats away the deposits and leaves
the membrane clean and ready for operation again.
b) Acid Rinse
The acid rinse step is applied to de-scale the membranes. Water hardness components such as
carbonates and sulphates can easily deposit on the membrane pores thereby clogging them and
an acid rinse ensures no suchdeposition takes place. The cleaning is done at ambient
temperatures and at pH 1.7.
 Before and after each cleaning step a water rinse is performed to rinse out the surplus
cleaning agents.
 After the CIP protocol the membranes are flushed with DAW and the filtration process
can be started up again.
3.3.2.4 FBT
Filtered beer tank also acts as a buffer tank but for filtered beer, if any interruption happens and
controls any pressure shocks.
3.3.2.5 Security Filter
The filtered beer will then be filtered again in the security filter to catch any substance that might
have escaped from the beer membrane filter or in the case of the BMF failure to catch the
particles.
3.3.2.6 CO2 Dosing
The perfectly filtered beer is supply through carbonization device into six stainless steel which
has the holding capacity are 200hl each of them. If it filled, the beer stored in NBBT, which are
two in number and holding capacity, is 500 hl each and CO2fills at 1.5 bars into NBBT. The
carbonation amount of co2 required in 200 hl of beers
Table 6 the carbonation amount of CO2required in 200hl of beers
Beer Type Amount of co2added in %
1 Normal 58-60
2 Drought 54-55

3 Sofi 60
3.3.2.7 DAW
De-aerated water is water that doesn’t contain oxygen. DAW in HBSC is used for pre and post
run during filtration and beer dilution.
Water is first warmed in a plate heat exchanger. This is done because as temperature increases
solubility decreases and that is needed to help ease in the removal of the oxygen. The warmed
water is then transferred to the de-aeration tank. The water is sprayed from the top so that when
entering the tank the oxygen rises to the top and is released to the atmosphere. As the water
reaches the bottom carbon dioxide is introduced to the water and then transferred to a plate heat
exchanger to be cooled so as to increase the solubility of the carbon dioxide in the water. The
DAW is then stored in DAW tank.
3.3.2.8 Bright Beer Tank
Once the beer is filtered again in the security filter it is transferred to the BBT, which serves as a
storage tank till the beer is needed for packaging. But before entering the BBT it is diluted with
DAW. It is also blended with carbon dioxide to give the beer its characteristics.
The carbonated beer in NBBT again very fine particles settle and the room is cooled at
temperature below 3oc CO2by ice water fan ventilation and ethanol circulating jacket .the use of
ice water fan is to maintain the room cold to avoid heat loss to the surrounding by the external
wall of the jacket. Now the beer is ready for packaging, thus send to the packaging unit for
pasteurization and bottle filling.

Mature beer Silica gel dosed
Plate heat exchanger UBT BMF
DAW&CO2
BBT Security filter FBT
Bright beer Filtered beer Filtered beer
Figure 7 flow diagram of filtration

3.4 FILLING HOUSE
3.4.1 Packaging Unit

In the bottle shop of a brewery returned empty bottles go through Washer in which they receive a
thorough cleaning. After washing, the bottles are passes through EBI(empty bottle
inspection)and passion to the rotary filler. This machine can fill up to 30,000bottles per hour. A
crowning machine, integrated with the filler, places caps on the bottles. The filled bottles may
then pass through a "tunnel pasteurizer" (often able to hold 33,000 bottles) where the temperature
of the beer is raised about 68 °C (for beer) and 74°C (forSofi). For a sufficient length of Time
(43-60minutes) to provide biological stability then cooled to room temperature. Emergingfrom
the pasteurizer, the bottles are inspected, labelled, Placed in boxes, stacked on pallets and
carried by lift truck to the Ware housing areas to await shipment. Packaged beer may be
heatpasteurized or micro-filtered, providing a shelf-life of up to six months when properly
stored. Draught beer, since it is normally sold and consumed within a few weeks, may not go
through this process. The draught Beer is placed in sterilized kegs ready for shipment.
The activity in this section is neither calm nor intermittent unlike other sections of the
technological process. The filling and packaging section is very much alive. The section is where
a relatively large work force is engaged, because of the array of moving machinery that requires
constant follow-up. Since the operations are interdependent and simultaneous. Minor stops in
filling line costs a lot.
3.4.2 Packaging Steps
Bottle washer EBI Bottle Filler

Video Jet Labelle Pasteurizer
Figure8packaging steps
3.4.2.1 Bottle washing

Working Principle of bottle washing machine
The Washer is one of the Machines in the PackagingHall responsible for effective Cleaning and
Sterilization of all the bottles to be used in the packaging line without the threatof contamination
of product. The bottle washer consists of three main parts namely:
 The In feed Mechanism
 The Main Body
 The Discharge Mechanism.
Feed mechanism
The washer in feed mechanism is a sub assembly of the Bottle Washer which is responsible for
reception of bottles from the in feed conveyor, rearranging them into Planes on the Marshalling
Table, lifting and loading the bottles into the bottle pockets where they travel for further
processing inthe washer.
The Main Body
This part of the machine houses the bottle washing unit of the machine. It has the pre-soak and
pre-rinse section, Soda
Soaking, compartment, label extraction unit and post rinse and final rinse section.
Discharge mechanism
The washed, rinsed and cooled bottles are discharged from the washer via the discharge
mechanism to inspection conveyor.
3.4.2.2 Bottle filling
Bottle filling machine working principle
The filler is the central machine of the packaging line responsible for distributing the product
contained in the BBT into smaller containers (bottles) as quickly as possiblewithout any

alteration in the products quality and taste and also hygienically fill the container to the required
level. In achieving this purpose, the filler is equipped with various units and parts which work
together to enable the filler perform optimally.
1. In feed conveyor: Take the inspected bottles into the filler.
2. In feed worm: Spaced the incoming bottles according to pitch.
3. In feed star: Push bottles into bottle plates.
4. Centring bell: Fix position of bottles onbottle plates.
5. Lifting elements: The upward and down wardmovement supported.
6. Transfer star: Takes filled bottles from bottle plates after filling process.
7. Bottle Guide Curve: Guide bottles into transfer star.
3.4.2.2.1 Stages of bottle filling process
VACUUM VALVE: - This is the valve that opens during the start of the filling process to
remove any air or foreign gas inside the bottle before counter pressurizing. The bottle must be
under sealed condition before condition vacuuming.
VENT TUBE:-Air inside bottle is removed through thevent tube by the vacuum pump.Co2 in the
filler bowl passes into the bottle and pressurizes the bottle before filling, through the vent tube.
During filling the counter pressure (CO2 in the bottle goes back to the filler bowl via the vent
tube until filling stops.
GAS VALVE:-This valve has a rubber seal and controls the closing and opening of the vent tube
passage.
SNIFTING VALVE: - This valve opens after filling the product inside the bottle to reduce the
pressure in the bottle to atmospheric pressure. It controls or prevents product foaming after
filling.
BEER VALVE:-This is the opening that allows beverage into the bottle when the pressure in the
bottle is equal to the pressure in the bowl.

NEEDLE VALVE:-This is the spindle or rod that moves up or down to close the gas valve. It is
operated by the Butterfly Lever.
3.4.2.3 Pasteurization
Working principle of pasteurizer
The Pasteurizer is part of the machine on the packaging line responsible for the deactivation of
microbes present in the product in order to increase the shelf life of the product.
The pasteurization happen in three major parts namely:
• The In feed
• The Main Body
• The Discharge
In the feed unit
The In feed unit is responsible for admittingcontainers/product into the pasteurizer for further
processing
Main body
The main body of the pasteurizer is where thepasteurization of the product takes place.
Depending on the design of the pasteurizer, the main body is divided into zones/compartments.
Each zone is designed to hold the product at a particular temperature for a particular period of
time. The zones present in the pasteurizer include in the following table
Table 7the zones present in the pasteurizer
Zones Name of zones Temp (0C)
1 Heating 36
2 Heating 45
3 Heating 56
4 Superheating 68
5 Pasteurization 65
6 Cooling 55

7 Cooling 45
8 Cooling 34
The product is expected to enter the pasteurizer at a temperature of 5oC, but more often the
product would have acquired heat (due to its motion and the ambient Temperature) before
getting to the in feed and thus enter at a much higher temperature, as a result the set
temperature of thezones prior to the pasteurization zone are adjusted to cater for this increased
temperature to prevent thermal shock of the containers as they enter the pasteurizer.
The main body is equipped with several spray tubes which continuously spray heated water from
tanks (attached to each zones) on the container as they pass through each zone of the pasteurizer.
DISCHARGE MECHANISM:-The discharge Unit is responsible for discharging pasteurized

bottles away from thepasteurizer.
3.4.2.4 Labeller
Working principles of labeller
A labeller is one of the machines in the packaging hall that is responsible for attaching labels on
the bottled product. Basically, it is used to stick label(s) firmly and completely straight on bottled
product at a predetermined position on the bottle.
This consists of three main parts:
The in feed unit
The Labelling unit or Aggregates
The bottle transfer or discharge unit
3.4.2.5 Conveyor
THE BOTTLE TRANSFER UNIT:-This Unit holds the bottles in place during labelling and
transfers them to the discharge star wheel and discharge conveyor. It consists:

1. Rotating Bottle Table: It receives the bottles from the in feed star wheel, guides and
transports them throughout the labelling exercise.
2. The Bottle Platforms: These are smaller turntables mounted in a circle round the rotating
bottle table.
3. Centring Head and centring Bell: This is located above each bottle platform. It
holds the bottle firmly on the turntable throughout the labelling process.
4. Folding Brushes: The folding brushes help to properly fold the labels on the bottles.
5. Discharge Star Wheel: Made of Teflon material with grooves. It receives the bottles from
the rotating bottle table and transfers them to the discharge conveyor.
3.4.2.6 The video jet

This is the machine responsible for a direct, non-contact printing of variable data on the bottles.
It is located immediately after the Labeller in the Packaging hall. The production date, best
before date and the batch number are all other information are available on the paper.
Kegging (Drought Beer)

In Harar brewery the kegs, which are made of chrome and nickel steel, are cleaned and sterilized
in to two major categories before filling.
 External washing and
 Internal washing
External washing: is important for removing the expiree date labeled before and also
cleaning the outer surface of the kegges which are highly exposed for (dust, mud, humidity and
other environmental contaminations).

Internal washing: inthis washing category it uses warm water (78-800c), hot water (1300c),
caustic soda (2%), and acid (1.5%) in order to sanitize and clean dirt, undesirable impurities, and
contamination. It uses 6 different stages of cleaning before finally the beer is filled with beer.
 Internal washing stages
 Stage-1: washing with warm water
 Stage-2,3&4: washingwith caustic soda at different temperature
 Stage-5: washing with acids
 Stage-6: Hot water sterilization at 130kpa for 30minutes
In this brewery the production of drought beer, involves double filtration method with the help of
micro membrane filtration instead of pasteurizing the beer for 30 minutes at 740 c.
NB: the micro filtration process could filter
 Fine yeast particle
 Fine protein particle
 Fine hop resins
Finally the micro membrane filtered beer will filled to kegs with the help of fillers and distribute
to consumers.
Table 8 relation b/n beer and drought
BEER DROUGHT
Pasteurized Micro membrane filtration

6 month shelf life 1 month shelf life
Less in nutrients High in nutrients
Bottled Kegging
On QC
Even If the all quality parameters were cheeked before it sends for kegging, the quality of
drought beer is again controlled by taking samples after the beer has been already filtered with
micro membrane filtration.
Quality tastes
 Haziness
 All other parameters using alcholyser

Over All Beer Product Flow Chart
Figure 9 over all beer flow diagram

CHAPTER FOUR
4. QUALITY CONTROL
Producing a quality product consistently is the key to success. Every brewer has the capability
of monitoring process and product to determine the level of consistency and quality. In fact,
basic record keeping is essential to establishing consistency and developing a basic quality
control program. Quality control programs should be run starting from raw materials up to
finished goods. One good definition for a quality beer is simply "a beer that consistently meets
specification"
 Specifications
Setting up specifications is done all the time. Brewers decide on the basic properties of original
gravity, color, and flavor and from this develop a formulation of raw materials and a process to
extract what is wanted from them. Brewers should know how to read and use the specifications
of the raw materials they buy. These specified items, however, become of singular importance
when brewers must make the same beer many times and perhaps over many years, because
specifications are nothing more or less than a list of beer properties that define the product. Beer
specifications and the analysis that go with them are of two general kinds:
 Those that can be perceived by the human senses and
 Those that require instrumental analysis.
 Consistency
The other aspect of the original definition of quality is "consistency". Brewers generally
behave in consistent ways when making beer. For example they repeat quite exactly the weights
of malts and hops used, and the times and temperatures at which they are brewed. Although
temperature can be hit or miss, especially in some infusion systems (for mashing), brewers
should learn how to calculate (predict) mash temperature and manipulate the wort data.
Generally, brewers are well aware of the need for specification and consistency (quality) in
the brew house operations. That might be said with less confidence in cellar (TOD) management,
i.e., in wort aeration, fermentation temperature, and so on. In addition, there is one glaring
shortcoming in many breweries that is worth mentioning: control of the yeast pitching rate.

4.1. Quality control areas in a typical Brewery
In general, for quality control of beer, the quantitative determination of these parameters below
is of high importance.
 Wort Production: extraction, color and PH.
 Pitching: cell count, dead cell and yeast pitching rate
 Fermentation: temperature, pressure, cell count, dead cell, growth rate and PH.
 Maturation: original extract (0Plato), alcohol, apparent extract, bitterness and pH
 Filtration: turbidity (haze), dissolved oxygen, CO2content, original extract and alcohol.
 Packaging: CO2content, total oxygen content and air in head space.
Table 9Quality Control procedures done in the laboratory
Parameters Standards Deviation added
Alcohol 4.85-5.15 +0.08
Co2 0.51-0.57 -
O2 0.2 -
Original gravity 11.45-11.75 +0.16
Apparent extract 1.8-2.4 +0.03
Haziness <1 -
PH 3.85-4.25 +0.03
Colour 7.5-10.2 +1
4.2. Quality Control procedures done in the laboratory

In HBSC to produce a good beer they are a number of parameters must be continually monitored
like;
 Analysis of beer to determine extract and alcohol content, the final attenuation, pH….
 Measurement of bitterness.
 Measurements of dissolved oxygen content in the beer.

 Determination of the colloidal stability of beer by a forcing test.
 Measurement of vicinal Diketones,(VDK)
 Measurement of co2content, total hardness of water,
Generally other very important parameters in wort and beer quality such as:-
Original gravity, Extract apparent, degree of fermentation and Alcoholic Content.
CHAPTER FIVE
5. General utilities
As mentioned in the introduction section the general requirements and supplies of beer
processing is provided from the general utility section. This general utility section is partly
divided in to four parts namely;
1. Cooling plant
2. Water treatment plant
3. Boiler plant
4. Waste water treatment plant
5. Air compressor
6. Carbon dioxide plant
5.1 Cooling plant

The term refrigeration may be defined as the process of removing heat from a substance under
controlled conditions. It also includes the process of reducing heat & maintaining the
temperature of a body below the general temperature of its surroundings.
5.1.1 Refrigerator & Refrigerant
A refrigerator is a reversed heat engine or a heat pump which takes out heat from a cold
body & delivers it to a hot body. The refrigerant is a heat carrying media which during the cycle
in a refrigeration system it absorbs heat from a low temperature system & delivers it to a higher
temperature system. In case of this brewery refrigerant fluid is Ammonium (NH3).

Desired properties for refrigerants are nearly the same as for any other thermal-energy transport
fluid:-
 Large thermal capacity (to minimise flow rate)

 Wide temperature margin (to avoid decomposition or freezing).
 High thermal conductivity (to lower residence time).
 Low viscosity (to lower pumping needs).
 Compatibility with piping materials and joints.
 Safe (non-flammable, non-toxic).
 Adequate economic and environmental constrains.
5.1.2 Ethanol-water cooling
Initially, the heat gained ethanol-water mixture from CCT, Cellar and BBT tanker is
pumped to chiller and ammonia pumped from ammonia storage tanker to chiller. The mixture
and ammonia in chiller (plate heat exchanger) takes heat exchanging process, the hot mixture
receives cold from ammonia and gives heat to ammonia in order to boil it. Then ammonia vapor
flow to ammonium separator tanker to separate moisture from ammonium vapor. Then the pure
vapor of ammonia goes to compressor (11bar & 1400c) in order to compress vapor into
compressed vapor. Then the compressed ammonium vapor goes to condenser in order to
condense or to be changed into liquid ammonia. Then liquid ammonium goes to throttling valve
or pressure reducer valve in order to reduce pressure (2bar at 1400c). Then the pressure reduced
liquid ammonia goes to evaporator in order to boil and cooling process of mixture working in
cooling plant by reputing this process again and again. The mixture ethanol and water cooled to
-20c and goes to CCT, BBT and cellar. When the mixture of ethanol and water is backing into
cooling plant after cooling the systems it attain temperature of 70c.
5.1.3 Ice water cooling
The second coolant in the cooling plant is water. Initially treated water from water treatment
plant pumped to plate heat exchanger and simultaneously ammonia pumped to heat exchanger.
The heat exchanging process takes place and water changed into ice water of temperature -10c.
The vaporized ammonia goes to ammonia separator in order to separate vapor from liquid occur
in ammonia. Then pure ammonia vapor goes to compressor in order to change ammonia vapor
into compressed ammonia vapor. Then the compressed ammonia vapor goes to condenser at the
same pressure in order to change compress ammonia vapor into ammonia liquid.
Then ammonia liquid goes to pressure reducer valve in order to reduce pressure at the same
temperature. Then pressure reduced liquid goes to evaporator in order to boil into vapor form.
Cooling process of mixture is working in cooling plant by reputing this process again and again.
The cooled ice at 20c water goes to old fermentation, wort cooling plate type heat exchanger and
pasteurizer.
Figure 10 Flow process of cooling
5.1.4 COMPRESSORS
Different types of compressors are used according to refrigeration capacity (size). For <10
kW refrigeration reciprocating (piston-type) used with pressure-ratios in the range 2.6.For
medium-size and large refrigerators (from 10 kW to 1 MW of refrigeration) screw compressors
are used, with pressure ratios in the range 8.20.working nowadays with R134a or R600a.
Centrifugal compressors are only used in very large refrigeration systems (>0.5 MW of

refrigeration). In case of HARAR brewery Share Company, cooling plant work with screw type
and piston type compressor.
Piston type compressor
In a hermetically sealed reciprocating compressor, all components (electrical windings, stator,

rotor, crank-shaft, compressor chamber, and exhaust duct) are exposed to both lubricant oil and
low-pressure cold gas from the ammonia separator. The stator coil is cooled by oil at the bottom
whereas the rotor coil is cooled by the refrigerant vapours before been compressed. Notice that
electrical dissipation adds to the cooling load, decreasing energy efficiency.
Screw type compressor
The screw compressor is a positive displacement rotary machine, consisting of a pair of

matching screws (helical lobed rotors of several shape) rotating within a tight casing (i.e. with a
very small clearance).
5.1.5 Condenser
Condensers are phase-change heat exchangers. The typical condenser in case of this brewery
is the plate type and shell tube type.
5.1.6 Pressure reducer valve
The throttling device has two purposes; the basic one is producing a flow restriction to
maintain the pressure difference between condenser and vaporiser that is the origin of cooling,
and the second one is to control the flow-rate. This can be achieved by means of a thermostatic
expansion valve (TEV) that adjusts the pressure drop.
5.1.7 Vaporizer
Vaporisers (also named evaporators) and condensers are phase-change heat exchangers. The
typical vaporiser in case of this brewery is the recirculation type to avoid having dry sections (i.e.
vapour without liquid).

5.2 Water treatment plant (WTP)
Currently the water treatment plant of the factory working on purifying the public water of
Finkile, which is located 33 km away from the factory. As much as it is taken from the streams it
may contains mud, sands, Ca, mg, k and etc. the existence of these hardness making compounds
have a harmful effect on flavor and quality of beer therefore this is the reason why we need to
purify the public water before using.
The effect of ions on brewing
The effect Sodium ion on brewing: sodium ions present in all beers. Excessive levels are
undesirable as it can impart sour or salty flavors at high concentration. The effect of Calcium ion
on brewing the existence of calcium ion on brewing water stabilize the enzyme alpha amylase
during mashing and by interacting with phosphate, peptide and proteins in the mash and wort
kettle, the pH value of the mash and wort are usefully reduced.
However the concentration of calcium ions should not greatly exceed 100mg/l in the mashing
water as no great advantage is gained from higher doses and there is a risk that too much
phosphate may be removed from the wort, and the yeast may then have an inadequate supply.
The effect of Magnesium ion on brewing: In some respect the effect of this magnesium ions
resemble with those of the effect of calcium ions. But the effect on pH from interaction of
phosphate is less than comparing to calcium ions because the salts are more soluble. While high
concentration of magnesium ions can impart or give a sour or bitter flavor for the beer.
The effect of trace element on brewing
Metals such as Iron, Manganese, Copper and Zinc may be found in small quantities in water
and are all utilized by yeast. Higher levels can cause colloidal hazes and metallic off flavors,
particularly with higher levels of Iron. High levels of heavy metals can be toxic to the yeast.
5.2.1 Process steps of water treatment
5.2.1.1Primary storage:-this is a tank where the water from the hakim gara and Finkile stored in.
During this storage time there is a pre settling of mud and sediments and also the addition of the

sodium hypo chloride is carried out. Sodium hypo chloride is added to kill bacteria still exist in
the primary storage tank.
5.2.1.2 Gravel bed filtration:-At this stage the raw water from the storage tank go through the
gravel filled tank .concurrently with the flow of water, the gravel bed retain the mud and
coagulates contained in the water.
Figure 11 gravel bed
5.2.1.3Cation exchange:-after gravel bed filtration the water deliver to cat ion exchanger by
motor suction. cat ion exchange is the chemical filtration process that used to remove the
hardness from water .in this stage the water hardness making compounds for example sodium,
magnesium, iron chemically purified by redox reaction. To undergo this operation we use ion
exchange resin. Ion exchange resins are used to replace the magnesium and calcium ions found
in hard water with sodium ions. When the resin is fresh, it contains sodium ions at its active
sites .when in contact with a solution containing magnesium and calcium ions(but a low
concentration of sodium ions).the magnesium and calcium ions preferentially migrate out of
solution to the active sites on the resin, being replaced in solution by sodium ions. This process
reaches equilibrium with much lower concentration of magnesium and calcium ions in solution

than was started with. There are two cat ion exchangers those uses both resin and gravel
simultaneously.
The resin can be recharged by washing it with a solution containing a high concentration of
sodium ions (it has a large amount of NaCl dissolved in it).the calcium and magnesium ions
migrate of the resin, being replaced by sodium ions from the solution until a new equilibrium is
reached. The salt is used to recharge cation exchange resin which itself is used to soften the
water.
5.2.1.4Anion exchange:-The anion exchange unit is similar to the cation exchange unit.
The difference is that the resin beads are saturated with negatively charged ions that replace the
contaminants. Chloride ion is used in these treatment systems. The most common application for
anion exchange units is the removal of nitrate, arsenic and bicarbonate. There are two anion
exchangers those uses both gravel and resin simultaneously.
The recharging process of the resin is performed by hydrochloric acid solution by washing it
with. During regeneration of resin the ion exchange occur between the resin and hydrochloric
acid solution, the nitrates and other anions from the resin surface leave away the resin and
reacted with hydrogen contained in the hydrochloric acid solution concurrently the chlorine ion
from the solution is trapped by resin.
5.2.1.5 Carbon dioxide trickling:-this is a stage where carbon dioxide removal is occurred. In this
stage the water from the anion exchanger come in to the carbon dioxide tackler and delivered in
to the tank by the pipe above the tank down ward when the co2 inject upward from the bottom of
the tank during this process co2 contained in the water removed by bubbling with the injected air.
The oxygen injected in to the tank is sucks from the environment.
5.2.1.6 Caustic dosing:-The water after passing the co2 trickling the water goes to the caustic
dosing unit. In the caustic dosing unit the continuous dosing of caustic soda undergoing to
neutralize the acidity of water and maintain the PH value ranging from 6.5 to 7.5.

5.2.1.7 De-chlorination:-As much as the water passes in successive dosing of sodium hypo
chloride the water contain large amount of chlorine that must be removed therefore the water is
de-chlorinated in the de-chlorination tank. This tank has activated carbon, sand and filter to
eliminate the chlorine contained in the water. The activated carbon is used to trap the chlorine
ions.
The water used for beer processing is passing through this overall process but that of the
service water is passing only the first three steps until the cation exchange.
Cation exchanger CO2

P-4
V-1
Primary CO2
storage trickler
P-3
Physical filter E-2
P-1
Anion exchanger Air
blower
Service water
storage
Air from
atmosphere
Lime
P-21
saturation
tank
Lime
mixing
Brew water E-11
vessel
storage P-15
De-chlorine filtrate
Figure 12 flow process of water treatment plant
5.3 Boiler plant

Boiling is production of hot water and stem which used in the factory. Hot water uses in
various places in the factory for example in mashing, Lautering and in wort cooling as heat
exchanging. Steam mainly used for heat exchanging, for pasteurization and cleaning.
Boilers are horizontal well insulated devises which used to heat water to steam. Boilers fulfill
the factory steam requirements. Boilers produce steam that flows through pipes from higher
pressure to lower pressure. Boilers are classified into two different types based on the flow in the
tube and shell as Fire tube and Water tube boilers.
Water tube boilers are boilers in which water flows in the inside of the tubes and the hot
gases from combustion flow around the outside of the tubes (shell).Fire tubeboilers are boilers in
which water flows in the outside (shell) of the tubes and the hot gases from combustion flow
inside of the tubes.
In Harar brewery boiler plant there are two fire tube boilers and one pre heater. The two
boilers work in shift. Fire tube boilers consist of a series of straight tubes that are housed inside a
water-filled outer shell. The tubes are arranged so that hot combustion gases flow through the
tubes. As hot gases flow through the tubes, they heat the water that surrounds the tubes. The
water is confined by the outer shell of the boiler. To avoid the need for a thick outer shell, fire
tube boilers are used for lower-pressure applications. The fire tube boiler built for medium and
high output steam temperature and operating pressure of up to 18 bars.
There are two types of fire tube boilers three way and two way boilers. in the two way
boiler fire collide with the wall and return one time while in the three way boiler the fire collide
and return two times. The two ways boiler made in Italia which have 150 fire tubes and capacity
of producing maximum about 6000kg stem per hour. While the three way boiler made in
Germany and has capacity of producing the 7000kg of steam per hour.

Figure 13 Two way boiler
There are two storage feed thanks the one tank hold water form water treatment plant while
the other from the collection of condensate water from steam lines in the factory. The water from
condensate tank is already heated water so it doesn’t enter the pre heater while the water from
water treatment plant enters the pre heater.
The pre heater is just like shell and tube heat exchanger use steam water to heat water from
room temperature to 760c. This water will send to boiler to produce steam. The pre heater and the
boiler are interdependent the pre heater consume steam from the boiler and the boiler consume
hot water from pre heater.
The boiler has four raw materials hot water, furnace oil, atmospheric air and Acetylene gas.
The water must treat and heats before it enter the boiler. The water heats because to reduce the
large amount of energy uses in the boiler and to reduce the residence time of water in the boiler
so it make the boiler to produce large amount of steam in time. If the water is not hot it will take
more time to super-heated and it will take large amount of furnace oil to produce the desirable
steam temperature. Because of the above reasons the water is heated in pre heater by steam
which is cheaper than furnace oil.

The water must be treated because for brewing soft and pure water is used there forbefore it
inter the boiler plant the water is treated in the water treatment plant and pass all tastes.
Oil furnace is the source of energy and the combustion of this fuel produce heat. The factory
use Arabian oil furnace. Atmospheric air supply oxygen necessary for combustion reaction.
Acetylene uses for ignition of fire in the boiler.
The burner mixes the fuel and oxygen together and, with the assistance of an ignition
device, provides a platform for combustion. This combustion takes place in the combustion
chamber, and the heat that it generates is transferred to the water through the heat exchanger.
Controls regulate the ignition, burner firing rate, fuel supply, air supply, exhaust draft, water
temperature, steam pressure, and boiler pressure.
5.3.1 Operating procedure
1. Storage:- the water from water treatment section delivered to storage tank
2. Pre heating: - the stored water in the storage tank will send to pre heater and heated
from room temperature to 760c by circulating steam tubes.
3. Super heating: - first atmospheric air will inter in to the igniter from the blower by
counter flow with the furnace oil. Then the acetylene valve will open and simultaneously
the electrode ignites the fire by making a friction. During this moment the photo sensor
detect the light and start to jet the furnace oil automatically by using rotary cup. The
rotary cup is the rotary device that injects the furnace oil in the chamber the amount and
the strength of the fire also maintained using this rotary cap by controlling the flow rate
of furnace oil. In this factory average of 5.6 l/min oil inject into the chamber. There is
furnace oil return line if more oil is injected in the boiler. The super heating operation is
carry out by using shell and tube arrangement by setting the water in the shell side and
the fire in the tube side. The heat exchange is occurred between two sides by conduction
and convection.
4. Exit:-at this stage the exhaust gas is run in to the exhaust stack. The exhaust stack is the
piping that conveys the hot combustion gasses away from the boiler to the outside.

Concurrently the super-heated water from the chamber will exit by a pipe called steam
exit.
5.4Waste water treatment plant (WWTP)

Wastewater is a mixture of water with all sorts of inorganic (sand, clay, salts, etc.) and organic
(proteins, sugars, oils and fats, etc.) compounds. Some of these compounds appear in dissolved
and other in suspended form.
All industrial operations produce some wastewater which must be returned to the environment
and this returned wastewater may have an adverse effect on human being, materials, plants and
as well as on animals. Therefore, before it reaches and gets damage we have to treat the
wastewater until it becomes harmless.
Hara brewery has new waste water treatment plant which completed on December 2013 and
costs around 9 million$.
Definition of sludge: - Sludge is a mixture of water with different groups of bacteria and (in)
organic matter. In an anaerobic-aerobic process configuration, three kinds of bacteria will be
present:
 Anaerobic bacteria that live without oxygen. it is favorable that they are
organized in granules;
 Anoxic bacteria: Can survive under anoxic conditions, where only bound oxygen
(like present as nitrites/NO2-, nitrates/NO3-, sulphates/SO42-, etc.) is present.
They are able to consume bound oxygen instead of free oxygen (= O2) for their
metabolism;
 Aerobic bacteria need oxygen for their own metabolism and to biodegrade the
substrate. For most of the aerobic process configurations, it is important that they
are organized in flocks.
5.4.1 Major parameters in wastewater treatment plant
Temperature and pH are the major parameters that manipulate in waste water treatment plant.

1. PH value: pH is the degree of acidity of the (waste)water or sludge. This value determines
whether a watery solution (wastewater, sludge, effluent, etc.) is acidic, neutral or basic. PH
regularly checks if it is obey the standards. PH check in two ways one by taking sample to the
laboratory and the other is by using PH sensor meters which are connected automatically to the
computer system.
2. Temperature:-Waste water temperature has a major influence on biodegradation rates in the

balancing tank. The higher the temperature the faster the biodegradation process will occur. The
anaerobic biodegradation process occurs under mesophilic temperature conditions: 22 – 40 °C
with an optimum around 37 °C. The higher the temperature, the faster the biodegradation
reactions (plus 10°C the reaction velocity doubles) and the better and more stable the process is
functioning. When the temperature rises above 40 °C, the anaerobic, mesophilic bacteria are not
functioning anymore and will die. The methanogens is a very strong temperature depending
reaction with an optimum around 37°C.
The unit operations found in the wastewater treatment plant and their functions
5.4.2The unit operations in the wastewater treatment plant
1. Pre-treatment
2. Equalization
3. Calamity tank
4. Aerobic treatment and effluent channel
5. Sludge treatment
6. Chemicals
5.4.2.1 Pre-treatment: As we indicted above industrial wastewater contains a vast array of

pollutants in soluble, colloidal and particulate forms, both organic and inorganic. Therefore, pre-
treatment of individual stream should be considered whenever these streams might have an
adverse effect on the total treatment system. The pre-treatment system has different

compartments. The first compartment is screens used for separate more coarse compounds like
paper, rags, branches and plastic can be retained by a construction with openings of uniform size.
In the Harar brewery waste water treatment plant the screen opening is around 20mm. Sand or
grit is a hard inorganic silica-compound that can cause erosion of pumps, pipes and valves.
Moreover, it is not biodegradable and thus will increase the fraction non-active suspended
material in the aeration tank, which will increase in their turn supplementary cost of energy. The
best way to remove the grit is by gravitational sedimentation. It is however important that only
the grit will settle, and not the organic compounds, because of odor problems afterwards.
Therefore, beside accurate design, the settled grit will be washed afterwards. The second
compartment used for separate grease and oil. Grease and oil tend to form insoluble layers with
water as a result of their hydrophobic characteristics. And this grease and oil separate from the
water easily by gravity. After pretreatment as much as grease oil and large materials are removed
and the waste water inter influent pit. The task of influent pit is to determine the waste water to
inter equalization tank or calamity tank. Inflate pate has automatic PH and temperature detector
with pneumatic valve. If temperature is between 25-400c and PH 4-12 the waste water will enter
equalization tank otherwise it will inter in to calamity tank.
5.4.2.2 Influent pit:-The influent pit will collect all pre-settled waste water from the brewery
after it pass the sand and fat trap. The influent pump pit transfers the incoming wastewater to
equalization tank or calamity tanks. The influent pit contain PH and temperature sensor.
4.4.2.3Calamity tank:-The purpose of the calamity tank is to slowly feed the calamities back into
the influent pit to reduce the negative effect of the calamities of the brewery on the WWTP. If to
match acidic or basic waste come from the factory it will inter calamity thank and it will
neutralized by its opposite and will send to equalization thank this means calamity tank will
balance the wastewater coming from brewery before going to the equalization tank.
5.4.2.4Equalization:-In order to retained large solid the waste water passes through manual static
screen. In this company static screen retain particle larger than 1mm size and regularly clear by
the operator. Then the waste enter equalization tank will balance the incoming wastewater
coming from the production before the biological treatment. The equalization tank homogenized
continuously by means of agitator to maintain a homogenous content in the equalization tank at
all times and to make sure that the added chemicals are properly mixed. Equalization thank has
capacity of 840m3 and it is equipped with temperature sensor, ph sensor level sensor to monitor.
Level sensor used to fixed level and take the necessary measures to avert over flowing, dry
running of mixer and pumps.
5.4.2.5Aerobic treatment and effluent channel (Lucas):-Aerobic treatment has two major
functions: mixing and oxygen transfer. These systems have five phases: regeneration,
accumulation, rinsing, discharging and sedimentation. Lucas is the where the biological waste
water treatment plant. It is here all the magic happen with the help of microorganism. The whole
operation is automated and will be controlled from special software called SACAD with special
feature called Lucas matrix.
Since bacteria’s metabolized the substrate aerobically they need sufficient oxygen therefore their
oxygen demand will be satisfied with the help of two surface aerators. In Lucas tank after
feeding and aeration a quite zone will settle we call it sedimentation phase during the following
phases the floating decanter in Lucas tank will collect the treated waste water and aerobic sludge.
After the sedimentation phase expire the decanter will rinse first the sludge mixture because we
are going to have two region of clean effluent and sludge mixture in the decanter after rinsing
with the help of rinsing valve for 5 minute we will discharge the effluent with the help the
effluent valve which is controlled by the Lucas matrix .

Table 10 phases of Lucas
Phase no Phases time taken Activities
1 Regeneration 180min There is feeding, aeration and mixing.
2 Accumulation 120min There is no feeding but mixing and aeration

will takes place.
3 Sedimentation 20min  Motor stop and valve is closed.

 Sludge valve open and the sludge
Sludge harvesting 40min
goes to belt in tank.
4 Rinse time 5min Rinsing valve open and clean the
discharging pipe.
5 Discharging 115min Clean water out from aerobic treatment tank

using decanter.
5.4.2.6Sludge treatment:-In the sludge treatment there is aerobic sludge storage tank that will
receive excess sludge from the Lucas during the sedimentation effluent discharge phase. The
aerobic sludge tank functions as buffer to be able to operate the sludge belt press as constant and
as optimal as possible.
The belt press filter utilizes a continuous cloth- filter belt. Waste activated sludge is spread over
the filter medium, and water is removed initially by gravity. The sludge cake is removed at the
end of the filter press by a knife, blade, with the sludge dropping by gravity to a conveyer belt.
5.4.2.7 Chemicals:-Acidic or basic wastewater must be neutralized prior to discharge. If an

industry produces both acidic and basic wastes, these wastes may be mixed together at the proper
rates to obtain neutral pH level. In our plant we use as a base sodium hydroxides and as an acid
sulfuric acid and as well as ferric chloride for settling the sludge in the ground.

Waste water from factory
Sand & fat trap with Pretreatment and

Coarse screen neutralisation
Container
Influent pump pit Calamity tank 1/2/3
Staticscreen
Container
Acid
Equalisation tank
Caustic
Acid Aerobictreatment
Caustic
LUCAS
FeCl3
Effluent pit & channel

Final effluent
A.191.040.201
Sludge treatment
Sludgestorage tank
A.193.050.102
Active carbon filter
Polymer
Belt press
A.193.050.301
Containers
Figure 14 block diagram of WWTP

5.4.3 Sampling:-Sampling and performing analyses is a very important within the frame work of
WWTP process follow-up .analyses results are so to speak.representative sampling should be
taken on regular time intervals (recommended: 24 hour). In case the treatment process consists
out of several treatment steps it is strongly recommended to take effluent samples of each
independent treatment steps. In this way it is possible to check the efficiency of each separate
treatment step and recognize problems in certain treatment step in an early.
Sampling of following streams is obligatory:
 Influent (raw waste water )
 Effluent of each independent treatment steps
 Final effluent (point of discharge)
 Sludge.
Influent:-Influent quality, together with influent flow, determines the loads of total suspended
solid
Effluent:-Final effluent quality is the ultimate test for a WWTP. if all parameters meet the
required effluent limit ,process operation of the WWTP goes on in a good way.
Sludge:-Well settling sludge is very important to insure a quick and complete separation
between effluent and biomass in a convention WWTP (sedimentation and effluent discharge),
obviously, settling capacity of sludge has a major influence on effluent quality.
Generalized sampling
1. PH

Inlet equalization effluent Lucas
8.69 7.49 8.22 9.40
2. Chemical oxygen demand (COD)
Inlet =105mg/l
Equalization=162mg/l
Effluent=110mg/l
3. Total suspended solid (TSS)
100inlet=0.5586-0.5340=246mg/l
30equalization= 0.5434 -0.5336=326.6mg/l
100effluent=0.5289-0.5267=22mg/l
30lucas=0.6648-0.5323=4.4mg/l
100beltout=0.5592-0.5284=308mg/l
30beltin =0.6930-0.5350=0.54mg/l
4. Ammonia(NH3) nitrogen(N) phosphorus(P)
Inlet=3mg/l 27.5mg/l 13.7mg/l
Equalization=2mg/l 26.1mg/l 14.8mg/l

Effluent=1mg/l 1.4mg/l 0mg/l
5.5 Air compressor
Air compressor are used in this industry to supply process requirement such as fermentation for
aerating the yeast, wort cooling, bottling room and to operate pneumatic tools and equipment
specially used for to open or close pneumatic valves. Compressed air systems consist of
following major components: Intake air filters, inter-stage coolers, after coolers, air dryers, and
moisture drain traps, receivers, piping network, filters, regulators and lubricators.
5.5.1 Process description
Atmospheric air enters in to intake air filters to prevent dusts from entering to compressors.
Dusts may causes sticking valves; scoured cylinders and excessive wear etc. once the
atmospheric air passes this intake air filter it directly goes to inter stage cooler to reduce the
temperature of the air before it enters the next stage to reduce the work of compression and
increase efficiency. They are normally water cooled. Once the temperature of the air reduces, the
air goes to after cooler to remove the moisture in the air by reducing the temperature in a water-
cooled heat exchanger. The remaining traces of moisture after after cooler are removed using air
dryers, as air for instrument and pneumatic equipment has to be relatively free of any moisture.
The moisture is removed by using adsorbents like silica gel and moisture drain traps are used for
removal of moisture in the compressed air. Finally air receivers are provided as storage and
smoothening pulsating air output reducing pressure variations from the compressor.
5.6 CARBON DIOXIDE PLANT
To increase the shelf life the beer must be carbonated in order for creating unfavourable
condition for micro-organisms growth and protect the beer against oxidation. Due to this reason
the Harar brewery S.C carbonate the manufactured beer twice before packaging after filtration
and during packaging. The main task of carbon dioxide recovery plant is purifying the CO2
which is generated in the fermentation process. The processed carbon dioxide from this

source is above the factory demand and use for sell. The fermentation product of carbon
dioxide is harvested by the top pipe of carbon dioxide and run to the carbon dioxide recovery
plant after the end of primary fermentation. During the fermentation process the beer is
counter pressurized by sterilized atmospheric air and the carbon dioxide cannot bubble out
therefore the carbon dioxide harvesting is carry out after the counter pressure is removed.
5.6.1Process steps
1. Foam trapping; as it is extracted from the beer the carbon dioxide may contain slight
amount of visible gas impurities like foam. The delivered carbon dioxide from the
fermentation goes through the foam trapper and liberated from these visible gas
impurities.
2. Water scrubbing; in this section the carbon dioxide pass the foam trapping process is
showered by down falling water in water scrubber unit during this counter flow of water
and carbon dioxide water soluble gases are removed.
3. Compressor unit; in this unit two step compression is occur which is followed by
inter and after cooling and dehumidification. Due to this subsequent cooling and
compression humidification will occur which removed by dehumidifier.
4. Carbon filter; the main task of carbon filter is removing odour forming products to make
the gas odour free.
5. Stripping and condensing; Purified CO2 enters the re-boiler for the stripping column in
which it is pre-cooled before liquefaction in the CO2 condenser at temperature down to -
25°C. Here the CO2 is condensed to the reflux tank and inert gas is separated and
discharged to the surroundings. Liquid CO2 is pumped to the top of the stripping column,
where further reduction of oxygen and inert gas is obtained. From the bottom of the
column liquid CO2 is partly pumped to the storage tank and partly circulated through
the re-boiler which heats the column and herby ensure continuous evaporation. For
the simplest plant setup the CO2 is finally led through a steam heated evaporator before

entering the production site, which means that the cooling potential is not utilized due to
time constraints.
6. compression and purification; CO2 is produced during fermentation of the beer and
with a small overpressure it reaches the recovery plant first arriving in the foam trap
which discards possible visible gas impurities such as foam generated during
fermentation. Water soluble impurities (mainly alcohol) are removed in the water
scrubber and the CO2 is lead to the balloon as a buffer supplying the following two-step-
compressors containing inter and after cooler and dehumidifier. Here the CO2 has reached
a relatively high pressure close to 15bar. After the compression odours are removed in
the carbon filters followed by drying the CO2 in the dehydrator.
7. Cooling and dehumidification; an ammonia cycle supplies the CO2 condenser and
dehumidifier with cooling at two different stages, which are separated in an economizer.
Heat removal from the ammonia condenser is done by a water cycle assisted with a
cooling tower that furthermore supplies the inter cooler and after cooler with cooling.
Conclusion
As it is known, the main goal of internship program is to integrate the theoretically acquired
concepts with a tangible practical demonstration. As such, technology students are more
effective in achieving the intended learning competency as they have developed their practical
knowledge in addition to what they have known theoretically. Beside enabling students to be
self-confident. General speaking during the internship program a lots of knowledge and skills
have been gained. This program helps students to develop practical knowledge that can be
applied in the real world, how to solve the problems related to any professional areas, how to
meet challenges. That probably encounters the intern in the future. Moreover, as it is explained
above, the internship program has its own advantage on work ethics and other crosscutting
issues. The overall internship program is very interesting for as. We have got so many things
including the program including practical and theoretical knowledge. In spite of the fact that
there were some challenges that personally encounter during our programmed in the

organization, we are happy and effective because we have gained basic skills both in practical
and theoretical aspects.

Recommendation
During this internship period we are appreciate so many working styles of the company the
company has much developed technological things uses specially filler & labeler machine work
with a high speed within a short period of time .This company has a great effort for fast and huge
production . However due to some small problem the production rate was decreased.
Strength:-Since the company has good outlooks, attitudes are respect for inters, the intern
suggest that the company must keep up it deems necessary for the interns. The company has
enough equipment. It lays a critical role to contribute community.
Weakness:-The company does not have the library or stored data and unable to give as full
information and we are not able move or visit the all parts of the company we simple stay one
place and we right this project using our knowledge, internet and the operator experience. The
company has to use different methods to develop / expand library for the future and arrange this
kinds of problem. Technician does not have manuals or modules. The company has to prepare
enough manual handouts and give to out to technician for the future and the company must put
the copy of the manual in the library, so that technician can use whenever necessary.

Reference
 Operators
 Internet
 Deferent books
 our advisor
 Heineken manual

Appendix
 activated sludge:-mixture of water with different bacteria

 haze:-a complex of protein and polyphenol
 influent:- raw waste water
 effluent:-treated water
 Sacad:- software used to control waste water treatment plant
 Trub;- combination of hop vegetal matter and coagulant proteins
 Ethanol-water:- mixture of water and ethanol
 Calamities:- waste water contain acid or base
 Wort- the extraction of aqueous solution
 Saccharomyces uvarum- ale yeast
 Saccharomyces cerevisiable- lager yeast
 Mecha masher- per masher
 Decontation- density difference
 Sparged- remove

ACRONYMS


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JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

School of chemical engineering

Hosting company: harar Brewer S.CO

Duration: from October 1, 2020 to January, 2021

Firesenbet kibru…………………………………………………….ru 4295/09

NAME OF ADVISOR SIGNATURE DATE

1…………………………………………….. ……………………… ………………

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 2

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 3

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 4

 HBSC………………………….Harar Brewery Share Company

 QMS……………………………. Quality management system

 EMS…………………………….. Environmental management system

 EQA…………………………….. Ethiopian quality award

 ISO………….……………………International standard organization

 HRD……………………………. Head of respective department

 PLC………………………………Programming logical system

 NBBT…………………………… New bright beer tanker

 CCT…………………………….. Cellar collectors

 APV…………………………….. alcohol per volume

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 5

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 6

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 7

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 8

 To be leader in countries beer industries with respect to quality, competitive price,

 To produce consistent beer quality product

 To contribute for the development of a region by producing and selling customer

 To product and seek quality beer at reasonable profit.

1.3. OBJECTIVEOF REPORT

The specific objectives of the internship include

 to understand the fundamental processes involved in brewing

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 9

1.4. The main products & Services

The main products of the HararBrewery share company are:

 Hakim stout beer

 Harar draught beer(locally called draft)

 Harar sofi beer

1.5 The company structure

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 10

Administration Technical Manager Production Manager Sales and Purchasing

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 11

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 12

Figure 2 Raw Materials

The quality of brewing malt has the following characteristics:

 High water absorption and low water sensitivity,

 Low content of protein,

 High sprouting by the time of malting,

 High enzyme formation,

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 14

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 15

3.1 BREW HOUSE

“The brew house is the heart of the brewery.”

Beer Production Process

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 16

Table 1spacing between rollers

Beer Type Space meter Bottom flour

AASTU/CHEMICAL &MATERIAL ENGINEERING/2008E.C Page 17

There are three ways to transport malt in millingsection.