II

ACKNOWLEDGEMENT
I want to thank God almighty in a special way for giving me life, strength of mindand body to carry out the
training scheme successfully. Not forgetting my lovingmum who has also been my source of inspiration and
motivation not just duringthe programme but in life generally.I also appreciate the ITF body and those in-
charge of this work experience schemefor giving me the opportunity to learn outside the lecture hall and
have an insighton what working entails, coupled with acquisition of certain industrial skills.I also want to use
this medium to acknowledge the very hardworking andwonderful Head of the Department of Chemical
Engineering, Madonna University Nigeria, Engr. .M. Omotioma for his invaluable and periodic advice, during
thetraining experience

III
ABSTRACT
This report contains information pertaining to the Students Industrial WorkExperience Scheme
(SIWES)/industrial training programme undertaken in a brewing company (Nigerian breweries) that lasted for
a duration of six (6) months.

The Students Industrial Work Experience Scheme (SIWES) is the accepted skilltraining program which forms
part of the approval of minimum academic standardin the various degree programs for all Nigerian
universities. The training wascentered on beer production processes for different brands, done majorly in the
brewing department of the company. Brewing is the production of beer by steepinga starch source
(commonly cereal grains, the most popular of which is barley) inwater and fermenting the resulting sweet
liquid with yeast. For the Brewing ofBeer, four (4) essential raw materials are needed they are: Malt and
Adjuncts, Hopsand Hop Products, Water and Yeast. Steeped grains such as malted barley aremilled to grist,
then the grist is soaked with water and heated at a specifictemperature known as Mashing, the mash is then
filtered to get spent grain andwort, the wort is boiled furthermore and during this process, hops and adjuncts
areadded to the wort. The wort is allowed to cool through the action of a plate heatexchanger and then
allowed to clarify. Yeast introduction known as yeast pitchingcommences on the clarified wort and
fermentation process begins. Afterfermentation must have lasted for about 2-5 days the young beer is then
filteredwith the aid of the Kiehsigur powder after which it is referred to as matured beer.The matured beer is
stored in a Bright beer tank (BBT) which is then sent to bottling hall for packaging. The packaged beer is then
sent to the logisticsdepartment for sales and distribution to vendors.
Iv
TABLE OF CONTENT

Cover PageTitle Page

Dedication…………………………..………………………………............ I

Acknowledgement…………………………………………………...……... II

Abstract……………………………….…………………………………..… III

Table of Contents……………………………….…………………….…….. IV
List of Figure
s………………………………………………………..……… X
ICHAPTER ONEINTRODUCTION
1:0 Background ……………………………………………………………… 1
1:1 Brief history of Nigerian breweries plc. …………………………………. 2

1:2 Kakuri brewery products…………………….…………………………… 4

1:3 The mission of Nigerian brewery
plc…………………………………….. 4

1:4 The vision…………………….…………………….…………………….. 4

1:5 The Kaduna brewery organogram…………………….…………………..

5CHAPTER TWO
2:1 Brief History of Beer…………………….…………………….…….……. 6

2:2 Raw Materials for Beer Production…………………….…………………. 6

2:3 Malt and
Adjuncts…………………….…………………….…………...… 6

V
2:3:1 Malting…………………….…………………….……………………..... 7

2:3:2 Malting Process…………………….…………………….…………….... 8

3:3:3 Degree of modification…………………….…………………….……… 10

2:3:4 Adjuncts…………………….…………………….……………………... 11
2:3:4:1 Categories o
f Adjunct …………………….…………………….……...11

2:4 Hops…………………….…………………….……...……………………. 11

2:5 Water…………………….…………………….……...…………………… 12

2:6 Yeast…………….…………………….……………….…………………... 13
CHAPTER THREE
3:0 Beer Production Process…………….…………………….………………. 14
3:1 Grains for Brewi
ng…………….…………………….…………………….. 14

3:1:1 Silo Activities and Operations…………….……………………………... 16

18
3:1:3 Milling…………….…………………….……………….……………….. 19
3:1:3:1
Milling Equipment…………….…………………….………………….. 19

3:2 Brewing…………….…………………….……………….…………………. 29

3:2:1 Brewing: Mashing…………….…………………….……………….…….. 29

3:2:2 Brewing: Mash Conversion…………….…………………….…………
.. 30

VI

3:2:3 Brewing: Mash Filtration…………….…………………….……………. 35

3:2:4 Brewing: Wort Boiling…………….…………………….………………. 36

3:
2:4:1 Wort Concentration and Standardization…………….………………… 37

3:2:4:2 Sterilization of Wort…………….…………………….………………... 37

3:2:4:3 Termination of Residual Enzyme Activities…………………………… 37

3:2:4:1 Wort Concentration and Standardization…………….………………… 38

3:2:4:2 Ste
rilization of Wort…………….…………………….……………….. 38

3:2:4:3 Termination of Residual Enzyme Activities…………….……………... 38

3:2:4:4 Colour and Flavor Development…………….…………………….….. 38

3:2:4:5 Eradication of Volatiles…………….…………………….……………. 38

3:2:4:6 Formation and Precip
itation of Hot Trubs…………….……………….. 38

3:2:4:7 Addition of Wort Copper Additives…………….……………………... 38

3:2:5 Brewing: Wort Clarification…………….…………………….…………. 39

VII
3:2:6 Brewing: Wort Cooling…………….…………………….…….………… 39

3:2:7 Brewing Wort Aeration…………….…………………….……….……… 40

3:2:7:1 Sterility of Air Used For Wort Aeration…………….……………….…. 41

3:3 Fermentation…………….…………………….……………….…….……… 42

3:3:1 Fermentation Stages……….…………………………….………………… 43

3:3:3 CO2 Purity and CO2 to Engine room……….…………………………….. 43

3:3:4 Dead Cell Purge……….…………………………….…………………….. 44

4:3:5 AE Weighing of the FV……….…………………………….……….……. 44

3:3:6 Daily Temperature Check……….…………………………….…………... 45

3:3:7 Pressure Control……….…………………………….…………………….. 45

3:3:8 Duration of Primary Fermentation……….…………………………….….. 45

3:3:6
Daily Temperature Check……….…………………………….……………46

3:3:7 Pressure Control……….…………………………….…………………….. 46

3:3:8 Duration of Primary Fermentation……….…………………………….….. 46

3:3:9 RuH-
Rest Under Heat (Warm Maturation) ……….……………………… 47

3:3:10 Yeast Harvest……….…………………………….……………………… 47

3:3:11 Deep Cooling……….…………………………….………………………. 47

3:3:12 Cold Purging……….…………………………….……………………...... 47

3:3:13 Phases of Yeast growth during fermentation……….……………………. 47

3:3:9 RuH-
Rest Under Heat (Warm Maturation) ……….……………………… 48

VIII
3:3:10 Yea
st Harvest……….…………………………….……………………… 48

3:3:11 Deep Cooling……….…………………………….……………………… 48

3:3:12 Cold Purging……….…………………………….………………………. 48

3:3:13 Phases of Yeast growth during fermentation……….……………………. 48

3:3:14 Fermentation Card……….…………………………….…………………. 48

3:
4 Beer maturation/storage/lagering……….…………………….…………....... 48

3:5 Beer filtration……….…………………………….…………………………. 48

3:9 Yeast and yeast management in Kaduna brewery…………………………… 51

3:9:1 Yeast Rehydration and Propagation………………………….……………. 51
3:9:1:1 Yeast Rehydra
tion Tank………………………….……………………… 51

3:9:1:2 Preparations for Rehydration………………………….………………… 51

3:9:1:3 Yeast Rehydration………………………….…………………………… 52

3:9:2 Primary Propagation………………………….…………………………… 53

3:9:3 Secondary Propagation………………………….………………………… 53

3:9:4 Ferme
ntation Stage………………………….…………………………..... 53

3:9:5 Yeast Generation and Nomenclature……………………………………... 53

3:9:6 Yeast Pitching………………………….…………………………………. 54

3:9:7 Yeast Storage………………………….…………………………………... 54

3:9:6 Yeast Pitching………………………….………………………………….. 55

3:9:7 Yeast Storage………………………….…………………………………... 55

IX
3:10:1 Depalletiser………………….…………………………………………… 56

3:10:2 Conveyor………………….……………………………………………… 56

3:10:6 Empty Bottle Inspection (Ebi) ………………………………………….... 58

3:10:7 Filler/Crowner……………………………………………………………. 58
3:1
0:8 Full Bottle Inspector (F.B.I) …………………………………………….. 58

3:10:9 Pasteurizer………………………………………………………………... 59

3:10:9:1 Factors Affecting Pasteurization……………………………………….. 59

3:10:10 Labeler…………………………………………………………………... 60

3:10:11 Coding…………………………………………………………………..
. 60
3:10:12 Packer…………………………………………………………………… 60

3:10:13 Full Crate Inspection (F.C.I) …………………………………………… 60

3:10:14 Palletizer………………………………………………………………… 61
3:11:0 Water Quality and Beer…………………………………………………... 61

3:11:1 Water Treatment Plant………………………………………………….. 61

3:11:2 Raw Water Supply……………………………………………………… 63

3:11:3 Pre-
Treatment…………………………………………………………… 63

3:11:4 Lime and Alum Preparation and Dosing………………………………... 63

3:11:5 Sand Filters……………………………………………………………… 63

3:11:6 Noritz Filter and Water Quality…………………………………………...

63
3:11:7 Softened (Service) Water…………………………………………………
63

X
3:11:8 Product Water………………………………………………….………….
64
3:11:9 Ultra Violet Unit………………………………………………….……….
64CHAPTER FOURCONCLUSION AND RECOMMENDATION4.1
Conclusion………………………………………………….………………...
65
4.2 Recommendations……………………………………………………………
65
Reference………………………………………………….……………………...
67

XI
LIST OF FIGURES
FIG 1 The Kaduna brewery organogram
………………………………………...
5
FIG 2:1 Kilning…………………………………………………………………..
9
FIG 2:2 longitudinal section through a Barley grain…………………………….. 10
FIG 2:3
Structure Of

Acids & Isomerization to Iso-

-
Acids……………………..
….
12
FIG 3:0 Beer Production Process………………………………………………...
13
Fig 3:1 Brewing Operations Process Flow………………………………………. 15

FIG 3:2 Typical Grain Intake Diagram…………………………………………..

17
FIG 3:3 Typical Milling diagram………………………………………………... 20

FIG 3:4 Grain Milling Flow Chart………………………………………………. 21

FIG 3:5 Intake
and milling diagrammatic representation………………………... 21

FIG 3:5:1 Screw Conveyor………………………………………………………. 22

FIG 3:5:2 Chain Conveyor………………………………………………………. 23

FIG 3:5:3 Rotary Drum………………………………………………………….. 23

FIG 3:5:4 Shaker Unit…………………………………………………………… 24

FIG
3:5:5 Blower………………………………………………………………… 24

FIG 3:3:7 Cyclone……………………………………………………………….. 25

FIG 3:5:8 Shaker Unit…………………………………………………………… 26

FIG 3:5:9 De-
Stoner……………………………………………………………... 27

FIG 3:5:10 Dust Aspirator………………………………………………….……. 27

XII
FIG 3:5:11 Hammer M
ill………………………………………………….……. 28

FIG 3:6:0 catalytic cleavage action of ά

-
amylase……………………………… 33

FIG 3:6 Mash filter………………………………………………….…………... 36

FIG 3:7 CO2 Purity Tester………………………………………………….…… 44

FIG 3:8 Brewing process flow…………………………………………….…….. 50

FIG 3:
8 Brewing process flow……….…………………………….……………. 51

FIG 3:9 Depalletiser………………………………………………….………...... 56

FIG 3:10 conveyor………………………………………………….……………. 57

FIG 3:11 unpacker………………………………………………….……………. 57

FIG 3:12 Palletizer………………………………………………….……………. 61

FIG 3:13 San
d filter………………………………………………….…………... 64

FIG 3:14 UV unit………………………………………………….……………... 66

1
CHAPTER ONE
INTRODUCTION
STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)
1:0 INTRODUCTION TO SIWES/ BACKGROUND OF SIWES
The Student Industrial Work Experience Scheme (SIWES) was established as a result of the
realization by the Federal Government in 1971, of the need to introduce a new dimension to the
quality and standard of education obtained in the country to achieve the much-needed
technological advancement and its level of investment in manpower development. The SIWES
is a skill training program designed to prepare and expose students of Nigerian University to the
industrial work situation they are most likely to encounter after graduation.
SIWES was designed to complement classroom teaching and to allow students to familiarize
themselves with the skills needed in the industries after graduation. It is an effort to bridge the
gap existing between the theory and practice of Engineering and Technology, Health Science,
Agriculture, Medical, Management and other professional educational programs in Nigerian
institutions. The scheme is funded by the Federal Government of Nigeria and jointly coordinated
by the National Universities Commission (NUC) and Industrial Training Fund (ITF).
BACKGROUND OF SIWES
Training is a key factor in enhancing the efficiency and expertise of the workforce. The Students
Industrial Work Experience Scheme (SIWES) program students for Labour Markets, and has
become an innovative phenomenon in human resource development and training in Nigeria.
SIWES is a skill development programme designed to prepare students of Universities,
Polytechnics/Monotechnic, and Colleges of Education for the transition from the college
environment to work, (Akerejola, 2008). (Oyedele, 1990) State that work experience is an
educational program that allows students to be part of an actual work situation outside the
classroom.
SIWES is a cooperative industrial internship program that involves institutions of higher
learning, Industries, the federal government of Nigeria, the Industrial Training Fund (ITF),
Nigerian University Commission (NUC) and NBTE in Nigeria. Students that participate in this
work experience program include those studying, science-related courses such as; Engineering,
Vocational, Technological, and related courses in institutions of higher learning, SIWES forms
part of the approved minimum academic standards in the institutions.

Aims and Objectives of SIWES

The objectives of SIWES among others include:

To provide an avenue for students in institutions of higher learning to acquire industrial skills
and experience in their approved course of study.

To prepare students for the industrial works situation that they are likely to meet after graduation.

To expose students to work methods and techniques in handling equipment and machinery not
available in their institutions.

To provide students with an opportunity to apply their knowledge in real work situations thereby
bridging the gap between theories and practices.

To enlist and strengthen employers’ involvement in the entire educational process and prepare
students for employment in Industry and Commerce (Information and Guideline for SIWES,
2002).

Problems Faced During SIWES

Often times, there are some challenges faced by students during SIWES, some are these are;
Inadequate Orientation on how students can go about SIWES in application and others.

Inadequate training and supervision of students at certain industries.

Lack of payment for students and overworking of students in various

roles reduce the quality of SIWES and students readiness to be
proactive and learn effectively.
1:1 BRIEF HISTORY OF NIGERIAN BREWERIES PLC.
Nigeria Breweries is proudly
Nigeria’s pioneer
and largest Brewing firm. Thecompany was incorporated in 1946 and in June 1949, it recorded a landmark
whenthe first bottle of STAR lager beer rolled off the Lagos Brewery bottling lines. Thisfirst brewery in Lagos
has undergone several optimization processes and as at today boasts of one of the most modern brew house
in the country.In 1957, Nigerian Breweries commissioned her second brewery in Aba. The AbaBrewery has
also recently undergone several optimization processes and has beenfitted with best in brewery technology.
1963 witnessed the commissioning of theKaduna Brewery while Ibadan Brewery came on stream in 1982. In
1993, thecompany acquired her fifth brewery in Enugu. A sixth brewery, sited at Ama-eke in9th Mile, Enugu
was commissioned and christened Ama Brewery in October 2003.Ama Brewery is today the biggest and most
modern brewery in Nigeria.Operations in the Old Enugu Brewery were however discontinued in 2004.
Thecompany acquired a malting Plant in Aba in 2008.
In October 2011, Nigeria Breweries bought majority equity interests in SonaSystems Associates Business
Management Limited, (Sona Systems) and Life
Breweries company Limited from Heineken N.V. This followed Heineken’s
acquisition of controlling interests in five breweries in Nigeria from Sona Group in
January 2011. Sona Systems’ two breweries in Ota and Kaduna, and Life Breweries
in Onitsha have now become part of Nigerian Breweries Plc, together with the three brands: Goldberg lager,
Malta Gold and Life Continental lager.In 2014, the company got approval from the Securities and Exchange
Commissionand the respective shareholders of both Nigerian Breweries Plc and ConsolidatedBreweries Plc to
merge the operations of both companies. The merger became finalon December 31, 2014Following the
successful merger, we now have three additional breweries in Ijebu-Ode, Ogun State, Awo-Omamma in Imo
State and Makurdi in Benue State. Themerger also brought an
additional seven brands into the company’s
portfolio.Thus, from that humble beginning in 1946, The Company has now grown into aBrewing Company
with 11 breweries, 2 malting plants and 26 Sales depots fromwhich our high quality products are distributed
to all parts of Nigeria. Nigerian Breweries Plc has a growing export business which covers global sales
andmarketing of our brands and dates back to 1986. NB Plc offers sales, logistics andmarketing support to
make her brands shelf-ready in international markets, includingworld-class outlets such as TESCO and ASDA
Stores in the United Kingdom. Our brands are available in over thirteen countries, across the United
Kingdom, SouthAfrica, Middle-East, West Africa and the United States of America.Kaduna Brewery is located
in Kakuri area of Kaduna South Local Government Area.The Brewery was commissioned in 1963.The company
is made of different departments listed below;
.Human Resources Department
.Administrative Department
.Accounting Department
.Logistic Department
.Engineering Department
.Packaging Department
.Brewing Department
.Technological Department
.Safety Department
.Finance Department
.Quality Assurance department.

1:2 KAKURI BREWERY PRODUCTS

Below are the list of products currently being produced by Kakuri Brewery:
.Star
.Gulder
.Starlite
.Goldberg
.Life
.33 Export
.Maltina
.Fayrouz (Pear and Pineapple)
.MORE

1:3 THE MISSION OF NIGERIAN BREWERY PLC

"To be the leading beverage company in Nigeria, marketing high quality brands todeliver superior customer
satisfaction in an environmentally friendly way”

1:4 THE VISION

“To be a world class Company”

1:5 THE KADUNA BREWERY ORGANOGRAM

.FIG 1 THE KADUNA BREWERY ORGANOGRAM

Chapter 2

LITERATURE REVIEW2:1 Brief History of Beer

Beer was first brewed about 6000 years ago by the Sumerians. At about 14th-15th century, 275 liters of Beer
was drunk in a year (460 bottles) as time went on beerconsumption increased as people took more beer and
less water .Why? People believed beer protected them from typhoid and cholera. This is not true anyway.
But beer was safer than the water they were drinking. How? Over the years, scientists played important role
to improve the quality of beer. Louis Pasteur that yeast is the microorganism responsible for beer production
in sugar-containingliquids.Dr. Elion (A student of Pasteur) isolated the famous Heineken A yeast for the
production of Heineken beer.
2:2 Raw Materials for Beer Production
For the Brewing of Beer, four (4) essential raw materials are neededThey are:
.Malt and Adjuncts
.Hops and Hop Products
.Water
.Yeast

2:3 Malt and Adjuncts:

Cereal grains serve as source of sugar for brewing.Several cereal grains are usually malted before they are
used for Brewing to produceMalt. Barley is the first cereal grains that was malted. Barley grain, just like
othercereals, contain starch as granules which are embedded in a protein matrix. Thismatrix is surrounded by
cell walls containing a gum called beta glucan. The starchgranules are therefore inaccessible to enzymes for
conversion to sugar during brewing. During the malting process the cell walls and the protein will be
dissolved
by other enzymes which are produced naturally as the seed grows. This exposes thestarch for enzymatic
breakdown during brewing.
2:3:1 Malting
The purpose of Malting is to:
1.Make the starch readily available during the mashing process to be convertedto a range of fermentable and
non-fermentable sugars.
2.Provide a source of amino acids and proteins for the yeast to be able to growhealthily during fermentation.
3.Develop desirable colours and flavors which are not present in barley itself
4.Produce a final product which is stable, capable of storage and transport to the brewery.
5. Produce a food product which is wholesome and meets food quality criteria.
Cereal grains selected for Malting must meet certain specific requirements
.It must be capable of germination, with a minimum 95% of the barley cornsready to grow. Dormant cereal
seeds are not suitable for malting.
.The grains should be of an even size so that they are more likely to growevenly.
.The grains should be of consistent colour. This helps to indicate that there is no damage due to moisture etc.
and also that they are of same variety.
.The grains should be large. Large corns are easier to process when the maltgets to the Brewery.
.The corns must be undamaged, free of split or pre-germinated grains or dust.
.The corn must be free of disease or pests such as beetles or moths.
.They must be free of other cereals
.The grains should be of same variety

2:3:2 Malting Process

There are 3 stages involved in the process of converting cereals (Barley, sorghum)into malt:
.Steeping
.Germination
.Kilning

(A).STEEPING:
The grain is soaked in water to stimulate the conditions that start germination orgrowth. This is carried out in
a steep tank. During steeping, the grain is aerated. (Bydraining and drawing air through the wet grain bed
before resoaking).Why aeration?
.To reduce the number of grains dying off due to drowning.
.To increase the rate of water uptake.The barley is usually steeped and aerated a number of times-at the end
of steepingthe moisture content of the grains should be around 45% depending on the type ofmalt being
produced.
(B).GERMINATION:
At the end of steeping the cereal seed is allowed to grow. During germination, twomajor changes occur:
.Firstly, Hormones stimulate the production of enzymes in the aleurone layer
.Secondly, these enzymes start to act. During malting they will break down thegummy cell walls and break
down the protein matrix inside the starchcontaining cells. This breakdown releases the starch granules
making themaccessible for conversion into sugar. The changes taking place duringgermination are called
‘modification’.The maltster can influence the degree of modification during malting by controlling the
moistureFIG 2:0

Turners are also present in the germination chamber to turn/mix the grains from timeto time to prevent the
growing roots from matting together and creating masses ofgrains impermeable to the air. The time required
for germination is basically around4 days. Germination usually takes place in a chamber or vessel.Air is blown
or drawn through the growing malt for the following reasons:
.To prevent it from suffocating in the CO2
produced
.To control its temperature and moisture content

(C).KILNING
During this stage of the malting process, water is removed from the green malt. Themalt then becomes
stable and can be stored without deterioration. The malt may also be slightly roasted to give it colour and
flavor.
of the enzymes, for examplethose required later in the brewing process for starch and protein conversion
must be preserved. The combination of high grain moisture and high temperature wouldnormally destroy or
denature the enzymes developed during germination.

FIG 2:1

KILNING

3:3:3 DEGREE OF MODIFICATION

This is the extent to which the grains endosperm cell wall, proteins and to a lesserextent the starch granules
are broken down during malting.
The Malting Process produces Malted cereals as explained above. Barley is the firstcereal to be malted. Other
cereal grains such as Sorghum, Wheat can also be malted.Malted Barley is the major raw material for making
beer.
Longitudinal section through a Barley grain
FIG 2:2 Longitudinal section through a Barley grain

2:3:4 Adjuncts
Other sources of starch apart from barley malt are regarded as adjuncts. Theseinclude:
.Malted sorghum
.Raw Sorghum
.Barley
.Rice
.Sucrose (Sugar)
.Wheat etc.

2:3:4:1 Categories of Adjunct

.Malted Cereals: Coloured Malt-Crystal Malt, Carapils and Munich Malt,Amber Malt, Brown Malt, Black Malt
and Chocolate Malt, Malted wheat,Malted Sorghum
.Processed Cereals: Roasted Barley, Torrified wheat, Wheat flour, Maize grits,Maize flakes
Unprocessed Cereals-Rice, oat, wheat, sorghum, Rye, barley
Sugars or Syrups-Sucrose, Glucose, HMS, Lactose, Carame

2:4 Hops
Hops contribute to the flavor and appearance of beer. They provide beer with itscharacteristic bitterness and
aroma. The alpha acids from hops improve foamstability and provide beer with protection against some
spoilage organisms. Hops provide the bitter taste in beer (with alpha acid the principal precursor). The oils
provide aroma. Hops contribute to beer texture (mouthfeel). Hops have bacteriostatic properties which
protects beer against some biological spoilage organisms. Hopsreduce over foaming during wort boiling.
Hops aid in protein coagulation during the boil. Hops are a foam active agent in beer.FIG 2:3
2:6 Yeast
A living micro-organism that converts malt sugars through cell division into alcohol during fermentation.
There are two types of yeast: bottom and top yeast. Beers fermented with bottom yeast are called lager and
those fermented with top yeast ales.

3:0 BEER PRODUCTION PROCESS

Six major steps are involved in Beer Production Process

FIG 3:0 Beer Production ProcessFor the Brewing department, its own leg of Beer Production starts at milling
andstops at Filtration. Milling is, however preceded by grains receipt and storage

14
3:1 GRAINS FOR BREWING
Grains are primary material/substance required for brewing of
beer theadministration and processing of the grains are
been carried out in the SILOdepartment. Below are the
activities and operations carried out in the department
3:1:1 SILO ACTIVITIES AND OPERATIONS
There are Ten Silos in all. Eight (Silo 1-Silo 8) of which has a
capacity of 250tons, while the remaining two Silos (Silo 9 and Silo 10) are of 150 tons.
.The duty of the silo operator are:
Receipt of grains and grits into the designated silos.
Milling of grains / transfer of grits to brew house.
Autonomous Maintenance
Call technicians (mechanical/automation) during breakdowns.
Documentation of the quantity of grains / grits received.
Silo reconciliation when empty.
 Notification of fitter for mechanical and fitting jobs.
Weekly cleaning of dust lines and dust chambers.
 Notification of lab analyst to check the moisture and fats content ofgrains / grits before intake.
 Notification of senior lab analyst to take samples during milling for sieveanalysis.
Daily stock taking.
Documentation of all process carried out.
Operation of panels in the silo.

18
3:1:3 MILLING
This is the process of size reduction of grains, so as to release trapped extracts in thegrain and to increase the
surface area of contact of the grains for mashing. Millingis also necessary so that enzyme can easily reach and
transform the endospermicmaterials in grains
like starch, protein, β
-glucan etc. into soluble constituents.To begin the brewing process, malted barley is run through the mill to
crush the huskof the barley this in turn exposes the fermentable starches within. After being milledthe grain
is referred to as grist. The grist is then fed into the Mash Tun kettle (Tank).Other adjuncts like malted
sorghum, raw sorghum, maize are fed into the MashCopper.
3:1:3:1 Milling Equipment
Storage Silo
Discharge conveyor
Screw conveyor
Bucket elevator
Classifier ( Shaker)
Bar magnet
De- stoner
Weighing scale
Hammer mill
Dust blower
Dust chamber

FIG 3:3 Typical Milling diagram.

FIG 3:4 Grain Milling Flow Chart.

3:2 BREWING itself involves the following processes:

Mashing
Mash conversion
Mash Filtration
Wort boiling
Wort Casting
Wort Clarification
Wort Cooling
Wort Aeration
Wort Pitching
3:2:1 Brewing: Mashing
Mashing a brewing term used to describe when ground malt and solid adjuncts (grist)are mixed with a set
volume of water. A specific temperature is used. Thetemperature is set to get the best action from the
enzymes in the malt.The mash can be slightly thicker or thinner depending recipe. This makes wort.

3:2:2 Brewing: Mash Conversion

The rate and nature of extraction of the soluble materials during mash conversiondepends on:
•Temperature
• pH
•concentration(Mash thickness).
3:2:3 Brewing: Mash Filtration
During Mash Conversion, several products are extracted into the mashing water.Mash Filtration process
separates this liquid, called wort from the Separate grains.Mash
Filtration is achieved in either a lauter tun, a wide vessel with a false
bottom,or a mash filter, a plate- and-frame filter designed for this
kind of separation. Mashfilter is the separation equipment in use in
Nigeria Breweries. A mash filter is a plate-and-frame filter. The
empty frames contain the mash, including the spent grains. The
plates contain a support structure for the filter cloth. The
Mash is pumped againstthe Filter cloth and clear liquid (wort) is
produced.
FIG 3:6 Mash filter

3:2:4 Brewing: Wort Boiling

After mash filtration/wort separation the wort is boiled. Hops and sugar/liquidadjunct (if required) are added
at this stage.

35
Wort boiling is the most energy intensive stage of the brewing process. Not onlydoes the wort have to reach
boiling point, but it is usual to evaporate between 2%and 10% of the kettle contents. A successful boil must
be vigorous.
The wort is boiled for about an hour in a kettle or “copper”. Hops are added during
the boil to provide bitterness and aroma. Boiling also improves the physical (haze)stability of the beer and
kills any micro-organisms which could infect the beer andcause flavor problems
Benefits of Wort Boiling

Inactivation of enzymes
Sterilisation of the wort
Coagulation of proteinaceous material out of the wort
Formation of proteinaceous/polyphenol complexes
Formation of flavour and colour complexes.
Fall in wort pH
Concentration of the wort gravity through evaporation of water.
Removal of volatile compounds from the wort

3:2:7 BREWING WORT AERATION

As soon as the wort leaves the PHE it is aerated. There is a wort aeration panel besidethe PHE that
guarantees a sterile aeration with the aid of pall air filters. Wort isaerated because oxygen is needed for cell
wall formation via synthesis of unsaturatedfatty acids and sterols by yeast cells, prior to fermentation. Wort
is never aerated athigh temperature because, this might result in the formation of irreversible
oxidationcoloured complexes that are detrimental to beer flavor and quality in general.Over aeration of cold
wort can result in over multiplication of yeast cells, which inturn translates to high extract losses. Under
aeration on the other hand, will result tosluggish cell wall formation and ultimately a prolonged
fermentation.The norm for oxygen content in cold wort is (7-9) mg of O2/litre of cold wort at15

BEER FILTRATION
Beer has to be clear when packaged to:
Prevent further biological changes taking place during or after
packaging dueto yeast or haze particlesBeer Filtration is the
operation that gives the beer its clear quality, eliminating thelast
remaining traces of clouding still in suspension. It consists of
pumping the liquidthrough a suitable filter. The filtered bright beer is
then stored in tanks, now readyto be bottled.
Beer Filtration is passing un-clarified beer through a porous medium,
the solids areretained in or on the medium. The clarified product
stream passes through the sizeof the pores and the depth of the filter path determines the size and number
of the particles which are retained.

Summarily, we have the Brewing process flow thus:

 CHAPTER 3
DETAILED INTERN’S ROLE AND DAILY ACTIVITIES
In this section, I’ll discuss the activities I carried out during the period of my industrial
attachment at the Nigerian Brewery Plc Kakuri . During my stay in Nigerian Brewery Company,
I was assigned to the Engineering and Maintenance department. Job duties in the department
includes; Registration and Closing of work permit forms, carrying out preventive and corrective
maintenance of the machines. Installation and repair of damaged parts of the machines. Setting
up, running, and ensuring proper operation of the machine on a daily routine, Troubleshooting
machinery (clearing jams, adjusting machine parts and parameters) to maintain optimum
machine performance. Inputting downtime and other relevant machine performance data into
performance logbook.

HEALTH, SAFETY AND ENVIRONMENT (HSE) INDUCTION

Health, Safety and Environment (HSE) is a set of processes and procedures identifying potential
hazards to a certain environment, developing best practices to reduce or remove those hazards
and then training employees for accident prevention. Safety is an integral part of the business in
Nigerian Brewery (NB). We were taught on the importance of safety in the workplace and also
in the production halls. We were taught what Health (absence of diseases or illness), Safety
(Freedom from unacceptable risk) and Environment is. We were also taught why HSE and the
benefits of HSE, some of these benefits include;

WHY HSE?

To promote physical, mental and social wellbeing of employees.

Protect employees and others affected from risks

Provide adequate welfare facilities

Develop a management system and policies

Create a positive HSE culture in the work place.

PERSONAL PROTECTIVE EQUIPMENT

Personal Protective Equipment refers to all equipment designed to be worn or held by a person at

work to protect him/her against one or more risks. We were introduced to the various types of

PPE and how they are worn and also what they are used for. We were also taught on the role of

employer and employee responsibility in PPE and how it can be used as the last resort to HSE

control. We were also given PPE, some of which includes helmet, safety boots, earmuff,

Reflective Jacket etc.

Figure 2.1 Personal Protective Equipment

Work Permit System

A Permit to Work System or PTW is a standard operational
procedure used by Nigerian Brewery or organizations to issue documented
permission to perform tasks that are considered
hazardous or non-routine. A permit to work form consists
of specific instructions of the nature of the job, the time
and place along with adequate information of critical
safety procedures to follow.

A valid permit to work document, whether paper-

based or digitized should essentially have the
following:
1.Roles and responsibilities for a given task.
2.Clearly define hazards that workers may face
along with the necessary precautionary actions
to take.
3.Precise description of the task along with a
timeline, scope of work and clear instructions
on how to perform the given task.
4. An elaborate set of risk assessment protocols including site
audit check , safety equipment check, safety training of
personnel check, and more such safety checks which varies
according to the type of job.
5. A record to indicate the status of the work permit – be it
closed, cancelled, revoked, re-issued, etc.

Why Permit to Work?

A permit to work system provides an easy way for Nigerian Brewery or
organizations to keep a constant eye on work-flows using
a well-documented system to streamline operations and
control safety outcomes.
Without a work permit, you unintentionally put yourself
and those around you in danger. For example: Imagine
being stuck or asphyxiated in a confined space with no
one knowing you’re actually there or operating machinery
without enough practice or training.

More Safety
Safety permits ensure that personnel are well-
equipped with the right PPE equipment, trained with
adequate safe-working procedures and instructed on
specific threats and vulnerabilities before they embark
on their duty.

More Accountability
Through work permits, employees and contractors are
authorized to complete a given task. Therefore, any
incident or near miss after receiving a written permit
puts the onus and responsibility solely on the
company.
Better Analysis
A recorded compilation of data will give a deeper
understanding to regulate incidents, taking into
account the human error probability and investing in
better safety equipment or new operational
procedures.

Types of Work Permits

There are seven main types of work permits: Hot Work
Permits, Cold Work Permits, Confined Spaces Work
Permits, Chemical Work Permits,
Height Work Permit, and Excavation Permit.
Each work permit is categorized depending on the nature of the job
and the hazard involved in it.

Height Work Permit

Authorization to work on elevated spaces
(2m from the ground) be it ladders,
scaffolds, Mobile Elevated Work Platforms
(MEWP) and other spaces that are off the
ground.

Hot Work Permit

Authorization to perform tasks in
conditions that produce sparks, flames or
any other source of ignition. Examples of
Hot Work Permit include welding,
soldering, flammable gases and other heat
inducing operations.

Electrical Isolation Permit

Authorization to work in high voltage zones
that are prone to uncontrolled dispersion of
electricity. Common electrical isolation
work is to manage and maintain Lock-out
systems and site maintenance by electrical
engineers.

Confined Spaces Work Permit

Authorization to perform tasks in a narrow
space which is prone to hazards like
asphyxiation, a substance that has the
ability to engulf, toxic atmosphere, etc.
Confined spaces refer to vents, shafts,
sewages, tanks and much more.

Excavation Permit
Authorization for personnel to mine or dig
land in order to build infrastructure, extract
resources or unearth hidden artifacts. The
risk involved in excavation includes falling,
being trapped, explosions, airborne
contaminants, etc.

Cold Work Permit

Authorization to operate machinery or other
functions that do not generate any form of
heat in the manufacturing process.
Mechanically induced bending, shearing,
squeezing and drawing are some examples
of Cold Work Permit .

Chemical Work Permit

Authorization to work with harmful
chemical substances or in a chemically
induced atmosphere that is either toxic or
corrosive by nature. Chemical engineers
that mostly work in chemical plants and
labs.

PTW Checklists
A Permit to Work checklist is a comprehensive
documentation of everything associated with the work
permit to be issued. The checklist template has to cover
all the aspects of a work permit including the work related
details, safety checks to be followed, worker profiles,
emergency protocols, authorizations, duration of work etc.

Content of Work permit Form

1. Complete Credentials & Authorizations.
Names, designations, and signatures from the
originator, permit user, issuing authority, site
checker and other designated authorities.

Permit Title and Reference Number :

To give a clear identification to the permit to
work form to ensure that permits can be easily
stored and retrieved.

Job Location and Timing

Names, designations, and signatures from the
originator, permit user, issuing authority, site
checker and other designated authorities.

Plant Identification
This will help in pinpointing the exact location of
the plant where the task is to be performed.
 Description of work
A complete summary of the task to be
performed with procedures to follow, the scope
of work and limitations.

Hazard Identification

A complete summary of hazards that you may

face during the job from residual, ergonomic,
physical, radiation and much more.

Precautionary Steps
Safety measures to take to avoid any hazardous
circumstances that may arise during the job.

PPE (Personal Protective Equipment)

A list of the Safety gear needed while performing
the assigned task. Safety equipment includes
gloves, respiratory mask, safety helmets,
footwear, harness and much more depending on
the job.

Permit Sign Off

The final part of the permit to work system

where you will have to mention if the work
assigned is completed or incomplete.

MAINTENANCE ON MACHINERIES USED IN THE PACKAGING HALL

In the next few pages of this section I’ll briefly explain the various maintenance I did on each
machine and Administrative work.
Preventative Maintenance
This is done every Wednesday of the week through a process called CLIT.
C – Cleaning

L – Lubrication

I – Inspection

T – Tightening

All engineers check each machines every Wednesday to be sure this process is done for each
machine by the operators and we also assist them.
Corrective Maintenance
This is done whenever there is a mechanical or Electrical breakdown during production hours.
We the engineers try as much as possible to reduce the downtime during such breakdown.

3:10:0 PRODUCT PACKAGING

The bottling hall popularly called packaging department, performs the operation of reducing large volume of
the product to a smaller volumes (bottle). The department also provides some useful information such as, the
best before date, the ingredients used, the brand name etc, to the consumer, by labeling the bottles.The
reduction of large volume into smaller volume is achieved by the use of machines. The machines are listed
below:
 De-palletizer
Unpacker
Bottle Washer
Crate Washer
Empty Bottle Inspector (E.B.I.)
Filler/Crowner
Pasteurizer
Labeller
Full Bottle Inspector (F.B.I.)
Packer
Palletizer

3:10:1 DEPALLETISER
Depalletising is the removal of crates from the pallets and putting the crates on thecrate conveyors. The
crates are stacked in five layers and two patterns. Using the breadth of the crate, the pattern for a layer is
four vertical crates, then three horizontalcrates, and a repetition in that order. For the next layer, the pattern
will be reversedstarting with three horizontal crates.The first step in depalletising is using forklift to put the
pallet in the palletconveyor, which transports the pallet to the depalletiser. The bottling hall has
fourindependently operating depalletisers. The depalletiser removes (picks) the crateslayer by layer and puts
the crates on the crate conveyor. The empty pallets will betransported on a carriage (pallet conveyor) on rails
to a pallet-checking zone. The pallet inspection is performed by a group of rollers that exerts pressure on the
pallet.Depending on the response gotten, the bad ones will be rejected and stacked by the pallet turner to be
evacuated by forklift. Meanwhile, the empty good pallets will bestacked by the pallet turner and transported
on a pallet conveyor to the palletizinggroup of four palletisers.
3:9 depalletiser

3:10:2 CONVEYOR
The conveyor conveys bottles or crates as the case might be from one machine toanother. The conveyors are
chains that links up to all machines for without them,there shall be no transfer of bottle or crate.

FIG 3:10 conveyor

3:10:3 UNPACKER
The crates are transported to the unpacker on a crate conveyor. The function of theunpacker is to remove
used empty bottles from the crate.

3:11 unpacker

3:10:4 CRATE WASHER

The empty crates will be transported on a crate conveyor to the crate washer. Thecrate washer washes the
crates. It has two regions; the soda bath unit, and the risenunit. For the crates to be washed, the crates first
enter the soda bath unit, then intothe risen unit and come
out cleaned. The crate washer has a crate turner that
turnsthe crate for proper washing
.
3:10:5 BOTTLE WASHER

The used empty bottles will be transported on a bottle

conveyor to the bottlewasher. The bottle washer washes
the bottles. It has three regions; caustic soda unit(which is at a temperature range of 70 – 80° C), the scraper
unit (where the alreadysoaked labels will be scraped off the bottle and then be removed by the label
press),and the risen unit (where the bottles will be risen first with warm water and then withcold water).
3:10:6 EMPTY BOTTLE INSPECTION (EBI)
The washed bottles will be transported on a bottle conveyor to the empty bottleinspection unit en route to
the EBI unit, the glide- liner makes the bottles to be in astraight line. The unit has four cameras and a reject
system. The first inspection isthe side- wall 1 inspection, in
which 270°side wall of the bottle will be inspected.The second
inspection is the neck finish inspection, in which the unit checks
forcracked mouth (neck) and rusted mouth. The next
inspection is the base inspection,in which the base of the bottle is
checked to see if it contains some dirt. Then comesthe residual
liquid inspection, through which to check for any liquid soda residualinside the bottle. The last inspection is
the side-wall 2 inspection in which theremaining 9°side wall of the bottle will be inspected. To enable the unit
do that,the bottle will be turned by the help of a belt for the unit to inspect the remaining 90° side wall of the
bottle. At the in feed of the EBI unit there is a foreign bottledetection/rejection system, which checks the
colour and height of the bottles.
3:10:7 FILLER/CROWNER

The inspected bottles will be transported on a bottle conveyor to the filler/crownerto be filled with the
product (beer), and corked. The filler/crowner is a singlemachine that has 96 filling valves and 18 crowning
heads. The filler/crowner hasthree facilities for its smooth operation. These are the in-feed worm-like
wheelwhich spaces the bottles in the appropriate proportions, the in- feed star wheel, whichis at the center,
and then the discharge star wheel. Next to the filler is a hopper forthe crown corks, and an automatic crown
cork system/conveyor (magnetic type).

3:10:8 FULL BOTTLE INSPECTOR (F.B.I)

After filling and crowning, the crowned product will be transported on bottleconveyor to the checkmate unit
for inspection. This unit performs the followinginspections; filling height (level), crown cork, leakage
inspections. Any product thatdoes not meet the requirements of the unit will be rejected by separating it
from therest. This is done by the reject system of the unit. A proximity switch monitors thespeed of the
product during these inspections.

3:10:9 PASTEURISER

Consequent to the inspections, the product will be transported on a bottle conveyorto the tunnel pasteurizer.
Pasteurization is processes that improves shelf life of thetreated products by kilning or inactivating the micro-
organism that could developsubsequently. The basic principle of the process is to preserve the products for a
period of time. The function of the pasteurizer are:
To inactivate the residual yeast that is present in the products.
To destroy the microbial life that picked up during processes.
To increase the shelf life of the products.
To impact pasteurization taste on the products.
The pasteurizer removes any remaining microbe that could not be removed during brewing. The pasteurizer
has a continuous running wire mesh conveyor belt madeof stainless steel. It also has an automatic dosing
device for additives, and causticdosing unit for cleaning purposes. The pasteurizer has a cooling system. The
systemworks in a way that the incoming products will first meet a cold region, and as these products move
through the pasteurizer a steady increasing temperature will meetthem until the highest set temperature of
the pasteurizer is reached. At this point, the products are at the middle of the pasteurizer. Then as the
products leave from themiddle to the outside of the pasteurizer, the temperature decreases until at
thedischarge end of the pasteurizer, which is cold region. So the product (beer) comesout of the pasteurizer
been chilled.

3:10:9:1 FACTORS AFFECTING PASTEURIZATION

1. TEMPERATURE: - This refers to actual pasteurization temperature attained bythe product itself within the
bottle. The lower the temperature, the lower theeffectiveness of the pasteurization and vice versa. The
optimum temperature forlager and Maltina are 62°C and 65°C respectively.2. TIME: - This refers to the time
for which the product is held at the pasteurizationtemperature to attain complete pasteurization. If the time
is too short, it will result tounder pasteurization and if the time is too long, over pasteurization will be the
result.Therefore, the optimum time is eight (8) minutes.
3. MIROBIAL LOAD/RESISTANCE: - It is expected that the higher the micro-organism, the less the effectiveness
of the pasteurization. For the pasteurization to be effective on the product, the pasteurizer machine is
divided into 8 zones:
Zone 1 – heating, spraying with water of zone 8
Zone 2 - heating, spraying with water of zone 7
Zone 3 - heating, spraying with water of zone 6
Zone 4 – super heating zone 5
Zone 5– pasteurizing zone 4
Zone 6 – cooling, spraying with water of zone 3
Zone 7 – cooling, spraying with water of zone 2
Zone 8 – cooling, spraying with water of zone 1

3:10:10 LABELER

The already pasteurized product will be transported on bottle conveyor to thelabeler. The labeler beautifies
the bottled product by putting on it body label andneck label. The labeler has automatic magazine in-feed
devices for the labels, a glue pump, a steel glue roll and a sectionalized glue scraper.
3:10:11 CODING

After beautification, the decorated bottled product will be transported on bottleconveyor to the laser jet unit
for coding. The coding is done on the body label by theuse of laser beam which heats up part of the label that
it touches. The codingincludes; the date of production, the expiration date, and the brewery location.

3:10:12 PACKER
From the coding unit, the product moves on bottle conveyor to the packer. The packer then puts the bottled
product into already washed crates that had beentransported to the packer on crate conveyor

3:10:13 FULL CRATE INSPECTION (F.C.I)

The full crate inspection unit follows the packer. This inspects the already loadedcrates in order to verify if
the crate is actually having the required number of bottlesand
with the required conditions. The unit makes use of
photocells to perform this function. The unit has reject system
that removes the crates that did not meet therequired conditions
from the rest.

3:10:14 PALLETISER
After inspection, the crates move on crate conveyor to
the palletizer. Before eachcrate gets to the palletizer, there is a
crate turner which arranges the crates into theaforementioned pattern for putting onto the pallet. When the
palletizer has put on 5layers of crates on the pallet, the loaded pallet will automatically move out for thenext
empty pallet to come in. The loaded pallet moves on a carriage on rails to the pallet turner, which keeps the
pallet in position for it to be evacuated by the forkliftinto the full (drinks) store.
 3:12 Palletizer

3:11:0 WATER QUALITY AND BEER.

Water is an important raw material for brewing and accounts for more than 90% ofthe weight of the brewing
products (lagers, ale and malt drinks). Though watereconomy is highly encouraged.There are different
sources where the brewery can get its water, from surface watersource as obtained in Kaduna brewery.

BLOWER MACHINE MAINTENANCE

Changing the kick belt at the bottom of the blower machine
First we need to release the tension from the belt tensioning system. This often involves
loosening or removing tensioning bolts or mechanisms.
Carefully slide the old belt off the pulleys and rollers. Keep track of the belt's path and how it is
threaded through the machine, as you'll need this information when installing the new belt.
While the old belt is removed, take the opportunity to inspect the pulleys and rollers for any
signs of wear or damage. Replace any components that show excessive wear.
Carefully thread the new belt onto the pulleys and rollers, following the same path as the old
belt. Refer to the machine's manual or documentation for the correct belt routing.
Restore tension to the belt using the machine's tensioning system. Ensure that the belt is properly
tensioned to prevent slipping or excessive wear.

Figure 2.2 Belt, Rollers and Tensioner

Servicing of shaking mold base due to deformed bottle

Carefully inspect the shaking base mold for any signs of wear, damage, or debris buildup. Clean
the components as needed. Use compressed air or suitable cleaning tools to remove dust and
debris.
Check if the shaking base mold requires lubrication on moving parts or sliding surfaces. Refer to
the machine's manual or manufacturer's recommendations for the appropriate lubricant.
Examine the alignment of the shaking base mold to ensure it is correctly positioned and aligned
with the other components of the machine. Misalignment can lead to operational issues.
 If the shaking base mold uses bearings or bushings, inspect these components for wear or
damage. Replace any worn-out bearings or bushings with new ones as necessary.
Check all fasteners, bolts, and nuts securing the shaking base mold assembly. Ensure they are
properly tightened. If any are loose or damaged, replace or tighten them as needed.
If the shaking base mold uses springs for its operation, check the tension of these springs. Adjust
or replace them if they are weak or damaged.

Figure 2.3 Mold Base

Straightening of bent transfer fingers

Inspect the transfer fingers carefully to identify the extent of the bending or damage. Determine
if a finger can be straightened or if it needs to be replaced.
Open the access panels or doors that provide access to the transfer finger assembly. The location
of these access points may vary depending on the machine's design.
Identify the specific bent transfer finger that needs straightening and isolate it from the others.
You may need to disconnect or remove any components that obstruct access to the affected
finger.
Provide adequate support to the transfer finger to prevent further damage during the
straightening process. You may use blocks of wood or other suitable materials to support it.
Carefully use appropriate tools, such as pliers or vise grips, to gently bend the transfer finger
back into its correct alignment.
Ensure that the straightening process is gradual and controlled to avoid over-bending or causing
stress fractures in the finger.
 After straightening, visually inspect the transfer finger to confirm that it is properly aligned and
straight. Ensure that there are no kinks or deformities.
Figure 2.4 Transfer Finger

Changing of brake pads

Before removing the old brake pads, it may be necessary to release tension or pressure on the
braking system to prevent accidents. This can usually be done by loosening or disengaging a
tensioning mechanism.
Carefully remove the old brake pads. This may involve unscrewing bolts or pins that hold the
pads in place.
Take note of the orientation of the brake pads and how they are installed to ensure proper
placement of the new ones.
Thoroughly clean the area where the brake pads were installed. Remove any dust, debris, or
residue to ensure proper contact with the new pads.
Carefully position the new brake pads in the same orientation as the old ones. Ensure they are
securely seated in the brake assembly.
Fasten the bolts or pins to secure the new brake pads in place. Follow the manufacturer's
specifications for torque values.
Depending on the braking system, you may need to make adjustments or align the new brake
pads to ensure they engage with the appropriate components correctly.
 Before closing the access panels or doors, manually test the braking system to ensure that it
engages and releases properly.
Figure 2.5 Blower Brake System

Replacement of safety pins

Carefully remove the old safety pin from its designated slot or hole. This may involve pulling,
unscrewing, or unfastening the pin, depending on the type of safety pin used.
Examine both the old safety pin and the slot or hole it was removed from. Ensure there is no
damage or wear that could affect the effectiveness of the new safety pin.
Ensure that the replacement safety pin is of the correct size, type, and material to match the old
pin. It should have the same locking mechanism, such as a spring-loaded latch or retaining ring.
Insert the new safety pin into the designated slot or hole, making sure it secures the component
or mechanism as intended.
Figure 2.6 Safety Pin and Roller

Replacement of blower nozzles

Carefully remove the old blow nozzle from its mounting or attachment points. This may involve
unscrewing bolts or fasteners that secure it in place.
Ensure you have a firm grip on the old nozzle to prevent it from falling or causing any damage
during removal.
Examine the area where the old blow nozzle was installed. Ensure it is clean and free from debris
or obstructions that could affect the installation of the new nozzle.
 Ensure that the replacement blow nozzle is of the correct type, size, and design to match the
machine's specifications.
Carefully position the new blow nozzle in the mounting area, aligning it with the attachment
Secure the Nozzle
Fasten the new blow nozzle in place using the appropriate bolts, fasteners, or attachment
mechanisms. Follow the manufacturer's specifications for torque values.
Ensure that all fasteners are properly tightened to prevent any movement or vibration during
machine operation.
Figure 2.7 Blower Nozzle

Replacement of bent consoles

Figure 2.8 Mold station Console

Replacement of collapsed bearings and bent shaft (Pin Assembly)

Carefully remove the old pin assembly shaft from its mounting or attachment points. This may
involve unscrewing bolts, fasteners, or other mechanisms holding it in place.
Be cautious to avoid damaging adjacent components or the machine frame during removal.
 Examine the area where the old pin assembly shaft was installed. Ensure it is clean and free from
debris or obstructions that could affect the installation of the new shaft.
Ensure that the replacement pin assembly shaft is the correct size, type, and design to match the
machine's specifications.
Carefully position the new pin assembly shaft in the mounting area, aligning it with the
attachment points. Ensure it is securely seated.
Fasten the new pin assembly shaft in place using the appropriate bolts, fasteners, or attachment
mechanism
Figure 2.9 Mold shell and Shaft

FILLER MACHINE MAINTENANCE

Servicing of filling organs/valves
Isolate the filling organs from the rest of the machine by shutting off relevant valves and
disconnecting any necessary connections to ensure safety during the service
Release any pressure within the filling organs or connected lines to prevent accidental spraying
or spills of product.
Open any drain valves or release mechanisms to remove residual liquid from the system.
Carefully disassemble the filling organs, starting with the removal of valves, nozzles, or other
components that require servicing.
Follow the manufacturer's guidelines for disassembly and take note of the arrangement of parts
for reassembly.
Thoroughly clean all components using suitable cleaning agents and methods. Ensure that there
is no residue or buildup that could affect the filling process.
Pay particular attention to ensuring cleanliness of seals, and contact surfaces.
Inspect all components for signs of wear, damage, or corrosion. Replace any worn-out or
damaged parts with new ones as necessary.
Check for proper alignment and functionality of valves and nozzles.
 If applicable, lubricate moving parts according to the manufacturer's recommendations.
Perform any routine maintenance tasks specified in the machine's manual.
Reassemble the filling organs, ensuring that all parts are properly aligned and tightened
according to manufacturer specifications.
Figure 2.10 Filling Organ/Valve

Servicing of Air manifold at the upper column

The air manifold is responsible for distributing compressed air to various pneumatic components and
actuators within the machine. Here are the general steps to service the air manifold;
•Ensure the machine is disconnected from the power source and depressurized. Lock out and tag out
the machine according to safety procedures.
•Inspect the air manifold for any signs of damage, leaks, or loose connections. Look for worn or
deteriorated components.
•Remove protective covers or panels to access the air manifold.
•Replace any damaged or worn components, such as seals, gaskets, or valves, with new ones.
•Ensure that replacement parts are of the correct specifications and compatible with the machine.
•If the air manifold includes moving parts that require lubrication, apply the recommended lubricant to
ensure smooth operation.
•Carefully reassemble the air manifold and associated components, making sure that all connections
are secure and properly tightened.
 Figure 2.11 Air manifold at the upper column

Servicing Of the Beverage Manifold At The Lower Column

The beverage manifold is responsible for the accurate distribution of beverages to the Filling
valves. Here are the general steps to service the beverage manifold:
•Disconnect the machine from the power source and depressurize it completely. Lock out and tag
out the machine following safety procedures.
•Locate the beverage manifold on the Sidel filler machine. It is typically a complex system of
pipes and valves responsible for the distribution of beverages to the filling valves.
•Inspect the beverage manifold for any signs of wear, damage, or corrosion. Look for loose
connections or damaged components
•Thoroughly clean and sanitize all components of the beverage manifold. Use appropriate
cleaning agents and sanitizers as per hygiene standards for the beverage industry.
•Examine all seals, gaskets, and O-rings within the beverage manifold. Replace any worn or
damaged seals to prevent leaks.
•Reconnect the beverage lines and pressurize the manifold with a non-beverage fluid (e.g., water)
for a pressure test.
•Check for leaks and perform a leak detection test to ensure there are no issues with the beverage
lines or connections. Repair any leaks as needed
Figure 2.12 Beverage Manifold at the lower column

Replaced bent Grippers/holders

 Figure 2.13 Bottle Gripper
LABELLER MACHINE MAINTENANCE
Changed the carousel belt and bearing

Figure 2.17 Labeller Carousel Bearing

Changed the Circlip at the cardan shaft

Figure 2.18 Cardan Shaft

PALLETIZER MACHINE MAINTENANCE

Replacement of product table motor shaft
Figure 2.19 Compactor arm
Changing of linear bearing in the palletizer compactor arm
Figure 2.20 Linear Bearing

Adding Loctite to cylinder bolt

Figure 2.21 Pressure Cylinder and Loctite

Changing of a belt in the palletizer

Figure 2.22 Palletizer Wear Strip

R
 CHAPTER 3
ADMINISTRATIVE RESPONSIBILITIES
Here are some administrative responsibilities is carried out as a SIWES Student in NB Company:
Comprehensive Documentation: I diligently maintained meticulous records of all maintenance
activities throughout my internship. This included thorough documentation of equipment
inspections, repairs, and the execution of preventive maintenance schedules. Accurate record-
keeping served as a vital resource for tracking equipment history and ensuring compliance with
maintenance standards.
Data Entry Expertise: I proficiently entered data associated with maintenance tasks into the
computerized maintenance management system (CMMS) and maintained databases. This
included updates to maintenance logs, equipment statuses, and work order progress, contributing
to efficient data management using Microsoft excel.
Insightful Reports for the Overhauling of Line 3: I prepared insightful reports that
encapsulated overhauling activities, performance metrics, and equipment reliability. These
reports were instrumental in informing decision-making processes and identifying areas for
process improvement.
Effective Communication: I served as a valuable link between the maintenance department and
other crucial departments, such as production and procurement. My role involved transparently
communicating maintenance schedules, equipment availability, and any potential operational
impacts.
Tools and Equipment Management: I was responsible for overseeing records of tools and
equipment used in maintenance activities. This encompassed maintaining maintenance and
calibration schedules for tools, ensuring their reliability.
Meeting Coordination: I took charge of scheduling and coordinating maintenance team
meetings, safety meetings, and training sessions, ensuring that essential gatherings ran smoothly.
My commitment to these administrative responsibilities was driven by a passion for maintaining
an organized and efficient maintenance department. It was a privilege to contribute to effective
communication, compliance with regulations, and the overall reliability of equipment and
machinery in the packaging Hall.
ANANLYSIS AND DESCRIPTION OF TOOLS AND EQUIPMENT
During the practical training received at Nigerian Brewery Kakuri, I made use of a lot of
tools to carry out different jobs. In this session, I will describe some of the tools and
equipment used.
Table 1. Tools and Equipment used in the Plant

EQUIPMENT DIAGRAM USES

Spanner is a metal tool

whose end fits round a nut to
provide grip and mechanical
SPANNER advantage in applying torque
to turn the bolts. Spanners are
in different dimensions and
also fixed or adjustable.

Pliers are versatile hand tools

used for gripping, bending,
PLIERS
cutting, and holding various
materials.

Screwdrivers are hand tools

used for turning or driving
screws into surfaces, typically
with a rotating motion.
SCREW
They are crucial for securing
DRIVERS
components and ensuring the
proper functioning of bottling
equipment by tightening or
loosening screws and fasteners.
 EQUIPMENT DIAGRAM USES

An Allen key, also known as a

hex key or hex wrench, is a tool
with a hexagonal-shaped tip
used for turning screws, bolts,
or fasteners with hexagonal
ALLEN KEY
sockets. They allow for precise
and secure tightening or
loosening of fasteners and are
essential for equipment
maintenance and setup tasks.
Circlip pliers, also known as
snap ring pliers, are specialized
hand tools used to install or
remove circlips or snap rings. In
a bottling plant, these pliers can
be useful for tasks such as
assembling or disassembling
CIRCLIP PLIER
components that use circlips,
such as shafts, bearings, and
pulleys. Circlip pliers help
secure or release these retaining
rings, ensuring the proper
function and maintenance of
equipment.

The Pipe wrench is used to

PIPE WRENCH tighten, hold bigger nuts and
bolts.
 EQUIPMENT DIAGRAM USES

A file tool is a hand tool with a

rough or abrasive surface used
FILE for shaping, smoothing, and
removing material from various
work pieces.
A filler gauge, also known as a
feeler gauge, is a precision
measurement tool used to
measure the gap or clearance
between two components. In a
FILLER GAUGE bottling plant or any industrial
setting, a filler gauge is often
used for tasks like checking the
clearance between moving
parts, verifying tolerances, or
ensuring proper alignment.

Ratchets are used to tighten or

loosen nuts or bolts located in
RACHET AND positions difficult to access
SOCKET using spanners. Sockets are
used with ratchet for this
purpose.
EQUIPMENT DIAGRAM USES

A C-spanner, also known as a

C-wrench or hook spanner, is a
specialized hand tool with a
C-SPANNER hook or C-shaped end designed
to engage with slots, notches, or
holes on certain types of
fasteners.

A spirit level, also known as a

bubble level or a leveler, is a
tool used for checking the
horizontal or vertical alignment
SPIRIT LEVEL
of surfaces. It typically consists
of a rectangular or tubular body
filled with liquid and an air
bubble.
A grinding machine is a power
tool used for smoothing,
cutting, shaping, or removing
material from a workpiece
through abrasive grinding
GRINDER AND
wheels or discs.
DISC
A grinding disc, often attached
to the grinding machine, is a
replaceable abrasive tool that
performs the actual grinding
operation.
 EQUIPMENT DIAGRAM USES

Gripping pliers, also known as

locking pliers or Vise-Grip
pliers, are versatile hand tools
used for securely gripping,
clamping, or holding objects in
GRIP LOCKING place.
PLIER Their adjustable, locking
mechanism makes them
invaluable for providing a
strong and stable grip on
objects, aiding in a wide range
of applications.

A hacksaw is a hand tool used

for cutting various materials,
HACK SAW
primarily metal, plastic, and
wood.

DISCUSSION, ANALYSIS AND EVALUATION

Experience gained during my SIWES at Nigerian Brewery PLC
My time as SIWES Student at Nigerian Brewery PLC has offered me many relevant experience
useful in the working place as Engineer in the Nigerian Brewery Company. This experience
gathered were as a result of some of the day-to-day activities at NB, working with my
supervisors and other staffs, communication with my fellow SIWES Students, learning from
contractors and others. The experience includes;
•Equipment Maintenance: I learnt how to perform routine maintenance tasks on bottling equipment,
including cleaning, lubricating, and inspecting machinery to ensure it operates smoothly.
•Troubleshooting: I gained experience in diagnosing and troubleshooting mechanical issues, such as
 identifying and addressing equipment breakdowns or malfunctions.
•Repair Work: I assisted in conducting repairs on machines and mechanical systems, learning to use
hand tools and power tools for maintenance and fixes.
•Machine Calibration: I participated in the calibration of machines and equipment to ensure accuracy in
production processes.
•Preventive Maintenance: I also gained experience in developing and implementing preventive
maintenance schedules and procedures to minimize downtime and extend equipment lifespan.
•Safety Protocols: I learnt about safety protocols and adhering to them, including lockout/tag out
procedures and safety guidelines, to ensure a safe working environment.
•Equipment Overhauling: I was involved in the overhauling project of the equipment on production
line 11, including replacement, retrofitting or improving existing machinery for enhanced
performance and efficiency.
•Documentation: Gained experience in maintaining accurate records of maintenance activities,
equipment inspections, and repairs.
•Collaboration: Worked collaboratively with maintenance teams and engineers to address mechanical
issues and optimize equipment performance.
•Hands-On Training: Gained hands-on experience with a wide range of mechanical systems, including
conveyors, filling machines, labeling machines, and packaging equipment.
•Communication Skills: Developing effective communication skills by interacting with team members
and conveying technical information.
•Problem Solving: Enhancing problem-solving skills through practical applications in resolving
mechanical challenges.
•Professional Development: Learning about the specific requirements and best practices in the bottling
industry and how they relate to mechanical engineering principles.

CHAPTER FOUR: CONCLUSION AND RECOMMENDATION

4.1 CONCLUSION
The Six Months attachment with Kakuri brewery was indeed a thrilling experiencefor me as a Chemical
Engineering Student. This is because it has helped meappreciate the level of responsibility of my discipline
and boosted my level of theknowledge of the science of brewing. A lot of planning and co-ordination is put in
place by the Engineering and brew-house management to achieve set objectives.From the training, it can be
appropriately established that the Students IndustrialWork Experience Scheme (SIWES) has achieved the
objective for which it wasestablished. The work experience not only exposed me to the practical
applicationsof the knowledge obtained in the classroom but also conditions facing real workingenvironment,
work ethics as well as how to adjust, cooperate with colleagues andteam members as regards real life
experiences, and also to appreciate the field ofEngineering better.
4.2 RECOMMENDATIONS
Having undergone the Students Industrial Work Experience Scheme (SIWES), Istrongly recommend the
following
1.A comprehensive and detailed directory of employers who accept students forSIWES is urgently required to
facilitate placement of students in industry.
2.In order to guarantee quality assurance of the scheme, there is a need forthorough supervision of SIWES
participants by institutions and the ITF.
3.Due to the scarcity of places of industrial attachment, students should beencouraged to undergo SIWES in
small- and medium-scale industries wherethey can contribute to improving the production processes and
also gain aninsight into entrepreneurship.
4.The ITF should revisit, redesign and fine-tune the website (SIWES data.org)created to facilitate online
payment of student allowances in order to removethe bottlenecks associated with its usage.
5.The stipulation that employers should accept students for SIWES should bestrengthened with stiffer
penalties put in place for defaulters

REFERENCES
Brewing Department, Nigeria Breweries Plc, Kakuri, Kaduna
Brewing Department Presentation, pptx
Beer Filtration Learning Manual.doc
Nigerian Breweries Plc LM Water Plant Structure. doc
Packaging department, Nigerian Breweries Plc, Kakuri, Kaduna
Maintenance workshop, Nigerian breweries plc, Kakuri, Kaduna
Water Treatment Plant and Waste Water Treatment Plant, Kakuri, Kaduna
Https://en.wikipedia.org/wiki/Nigerian_Breweries
Uvah, I. I. (2004). The Place and Relevance of SIWES in the Curricula ofScience, Engineering and Technology
(SET) Programmes. Workshop on the
Students’ Industrial Work -Experience Scheme, University of Lagos, Akoka,Lagos
Federal Military Government (1990). Industrial Training Fund (Amendment)Decree, 1990. Ministry of
Information, Abuja
ITF (1973). Policy Document No 1. Industrial Training Fund, Jos, Nigeria