A Project Report

on

A training study on Beer

Manufacturing Process
Submitted to

Department of Biotechnology
Faculty of Engineering, Management & Life Sciences IASE Deemed University, Sardarshahr (Rajasthan) 331401

FOR PARTIAL FULFILLMENT OF FOUR YEARS FULL-TIME DEGREE PROGRAMME OF

BACHELOR OF TECHNOLOGY IN BIOTECHNOLOGY

Submitted by

Akash Agrawal
Enrolment no.iase01/07/0043 B.Tech (Biotechnology) Under the supervision of

Mr. R. S. Dhalan
Brewery Headmaster Superior Industries, 13/1Main, Mathura road Faridabad(Haryana)

2007-2011

ACKNOWLEDGEMENTS

I want to thanks all members of Superior Industries to support me to get acquire more knowledge about all matter during training periods. I feel privileged to express my thanks to Mr. Naresh Agrawal & Mr. Amit Agrawal(CEO), Mr. Rajeev Singh Dhalan(HBM) superior industries for their kind co-operation by time to time & to create family environment in industry. I express my sincere thanks to Mr. Ashish Singh, Microbiologist of superior industries, for his generous co-operation allowing us to learn in this & blessings. I would like to thanks Dr. Kamlesh Choure, Head, Department of Biotechnology, IASE Deemed University, to time guidance and moral support. I express my deep appreciation & thanks to all workers, my friends & colleagues for their co-operation to learn in the industry. Last but not the least I owe a special debt to my family for the great support in my training without I would have been in vain.

Akash Agrawal

Topics Acknowledgement Company 4 Brewery and their role Yeast 6 Outline 8 Brewing process Introduction 26 Quality 29 Conclusion Biblography
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pages 2 profile 5 role a in brewing brewery 11 of clean in process aspects 30 31

and

its of

Company profile:Incepted in the year 2000, in Delhi, Superior Industries Ltd was established by a great visionary, Honorable Shri M.M. Agarwal Ji. Today, under the guidance of Chairman Mr. Pradeep Agarwal Ji, who has an experience of 25 years in this industry, we are inspecting tremendous growth within a short period of time, with same dedication and understanding that was developed at the starting.
Infrastructure

We have a state-of-art infrastructure which is spread across Haryana and Uttar Pradesh. This infrastructure is completely equipped with the Latest Technology Automatic Machines that help us to produce unlimited Alcoholic Beverages as per the clients requirement. In addition, we provide customization to our products and safely pack them in wooden boxes.
Team

We are backed up a huge team of workers, labors, and quality testers, who work in a most personalized way to produce pure and tasty Alcoholic Beverages. Beside, all of our team members hold a vast experience in their respective fields.
Clientele

The superior quality Alcoholic Beverages presented by us has gathered huge list of clientele, from different corners of the world. To meet the growing demand for our Alcoholic Beverages, we have established farreaching distribution network which covers major national and international markets of the world. Name of Chairman Year of Establishment Nature of Business Number of Employees Market Covered :Mr. Pradeep Agarwal :2000 :Manufacturer, Exporter, Importer & Supplier :400 :Worldwide

Brewery and its role:Brew industries deals with the formation of beer from the of starchy and sugar containing substance through the fermentation that is called as Brewing. Beer Preparation/ Brewing is an art it comprises preparation of extract from the malted barley or Malt called as wort and then transfer of this wort to the fermentation for the purpose of fermentation through yeast that convert the sugar into the alcohol beer. Yeast/Saccharomyces Sp. that is basic part of the brewery used in the fermentation is an Eukaryotic microorganism lie in the kingdom fungi. Yeasts are chemo organotrophs as they use organic compounds as a source of energy and do not require sunlight to grow. Carbon is obtained mostly from hexose sugars such as glucose and fructose, or disaccharides such Yeast as sucrose and maltose. like species either require Some oxygen for species and organic can acids. metabolize pentose sugars ribose,[17] alcohols, to obtain beer and then filtration / separation of the yeast and other large particulate carry out to obtain

aerobic cellular

respiration (obligate aerobes), or are anaerobic but also have aerobic methods of energy production (facultative anaerobes). Unlike bacteria, there are no known yeast species that grow only anaerobically (obligate anaerobes).yeast mainly grow by the budding process that in the metabolically active stage. Yeasts grow best in a neutral or slightly acidic pH environment.Today genetically engineered yeast are also available in the market that led to the fermentation of xylose .yeast available in the market both in form of yeast cake or granulated powder in solid state.

Brewing Yeast

In brewery yeast are of two types one is Ales while the other one is Lager.

Ale yeast :These are those that carry out fermentation on the surface rather then the bottom they are show optimum fermentation at the temperature 15-20 C they produce foam at the surface of the beer they are pale to opaque black in colour. Ale yeast can prepare beer in three weeks and can be collected from the primary fermentors and can stored in refrigerator.

Lager yeast :Lager yeast tends to collect at the bottom of the fermenter and is often referred to as bottom-fermenting yeast. Lager is fermented at much lower temperatures, around 10 C (50 F), compared to typical ale fermentation temperatures of 18 C (64 F). It is then stored for 30 days or longer close to freezing point. During storage, dissipate Wort consist of a good amount of sugars for the fermentation to form alcohol .Alcohol formation by the yeast is an metabolic process yeast is an facultative anaerobe and in the absence of oxygen it after the glycolysis it convert the pyruvate so obtain by the degradation of glucose in the alcohol as shown this alcohol concentration decides the quality of beer too and thats depend on the fermentation time as more fermentation can lead to the formation of some off flavor substance in the beer that that the beer mellows and flavours during become smoother. Sulfur components developed fermentation

may degrade the quality of the beer these substance may include the formation of aldehydes ,ketones and other product that form due to over fermentation.

General Outline Of a Brewery:A brew industry in general can be categorised in the two section that is:1). Hot section :-The section theoretically called Hot as here the brew prepares at the high temperature it comprises various components of brewing i.e. Mashing , Lautring , Wort boiling and trub sepration at all this stages operates at high temperature.the high temperature required here for the digestion of starch by the enzyme i.e. also called as saccharification .Due to saccharification sugars are available for the fermentation purpose. Also at the high Temperture the mash or wort become decontaiminated .

2).

Cold Section :- The section holds all other operations of brewing at lower temperature this includes the fermentation of wort and filtration of prepared beer. Temperature of the cold section lies in the range of 9-0 C or below it too depend on the type of process stage that is going to be employed in the process step. The temperature control unit uses glycol for that purpose glycol has the temperature of -4 C and that holds the temperature unit of the system

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Milling section flow chart Belt Collection Mini Hopper Conveyer Bucket Hopper Conveyer Vibrational screener

Magnetic Drums

Destoner

Rice Tank

flakes

collection

Weighing Unit

Gryst Collection Tank

Mill

For premash 11

Cylo

Metallic Particles and Damaged Grains

Stones/Particulates

Rice Flakes

Gryst

Gryst Water (55c)

Brewing

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In the brewing wort is prepared from the brew that is the mixture of various components treated at a certain temperature with starch digestion enzyme to obtain fermentable sugar in the wort these components and their temperature treatment vary they are brand specific. The brewing process depends on the various parameters like saccharification pH and specific gravity that vary from brand to brand . A typical brewing process for the superior 50000 are as follows:After the gryst collected in the gryst collector then initiation of the process starts through the mashing .

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Mashtank

In Mashing the ingredients /raw material treated with the enzymes at the higher temperature for the saccharification i.e. conversion of starch into the fermentable sugar. Mashing operates in the mash tun . Technical design of mash tun comprises a dome shape steel tank that has internal attached steam coils for the regulation of the temperature .The flow of the steam in the coil decide the temperature of the mash tun.

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At the Initiation of the mashing gryst and rice flakes allow to move in the pre mash where they are allow to mix with the hot water from where it is transfer to the mash tun. The temperature of water is 52.c that is obtained by the premixing of the hot water (88C) and cold water (9C) about 265 HL of water added at the flow rate 750HL/hrs to the gryst and after mixing the mixture transfer to the mash tun.

In the mash tun there is already present the foundation water of about 50 Hl that purpose of which to prevents the back jump of the liquid mixture that may set along with the upper walls of the mash tun . Mash tun has the working capacity of about 398 HL while its gross capacity is about 448 HL .mixture of water and gryst takes about 30 minutes to enter into the mash tun after enter into the mash tun some additives also added manually that includes enzymes for the starch digestion a variety of enzyme used for the starch digestion during the mashing this includes :-Gluconase That digest proteins Promalt it include the blend of amylase and - amylase that responsible for the starch digestion During the mashing pH of the mixture should be maintained at the range of 5.21 for this phosphoric acid will be added. Gypsum also added here with the view to adjust pH as the phosphate addition have certain limit. Temperature is the very important parameter along with the PH as both decide the rate of reaction of enzyme .the temperature variation along with time vary for brand to brand . In case of Haywards 5000 the Mixture of gryst and water rest for 5 min initially at 45 C then it raises for about 7

15

minute with the rate of 1C per minute and set up to 52 C then rest for 15 minute now again temperature rises for about 12 minute and then brew rest at this temperature i.e. 64 C for another 15 minute then it raises for about 8 minute and raises upto 72 here it rest at this temperature the saccharification test take place temperature raise upto 77 C The temperature profile affect the enzyme action and their rate of reaction at 64 C the enzyme works with the optimum rate and then for its deactivation the temperature finally sets to the 77C. After the Mashing the whole brew transfer to the lauter tun this takes about 15 minutes to transfer the wort to the lauter tun .In the mash tun then water flushes with for about 30 seconds that is also transfer to the mash tun after that the rinsing of the the mash tun occurs for about 60 seconds and the water is then allow to drain. for 35 minutes then within 5 minute

Lauter Tun

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A lauter tun is the traditional vessel used for separation of the extracted wort. While the basic principle of its operation has remained the same since its first use, technological advances have led to better designed lauter tuns capable of quicker and more complete extraction of the sugars from the grain. The false bottom in a lauter tun has thin (0.7 to 1.1 mm) slits to hold back the solids and allow liquids to pass through. The solids, not the false bottom, form a filtration medium and hold back small solids, allowing the otherwise cloudy mash to run out of the lauter tun as a clear liquid. The false bottom of a lauter tun is today made of wedge wire, which can provide a free-flow surface of up to 12% of the bottom of the tun. The run off tubes should be evenly distributed across the bottom, with one tube servicing about 1 m of area. Typically these tubes have a wide, shallow cone around them to prevent drastic forces from compacting the grain directly above the outlet. In the past the run-off tubes flowed through swan-neck valves into a wort collection grant. While visually

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stunning, this system led to a lot of oxygen uptake. Such a system has mostly been replaced either by a central wort-collection vessel or the arrangement of outlet ports into concentric zones, with each zone having a ring-shaped collection pipe. Brewhouses in plain public view, particularly those in brewpubs, often maintain the swan-neck valves and grant for their visual effect. A quality lauter tun has rotating rake arms with a central drive unit. Depending on the size of the lauter tun, there can be between two and six rake arms. Cutting blades hang from these arms. The blade is usually wavy and has a plough-like foot. Each blade has its own path around the tun and the whole rake assembly can be raised and lowered. Attached to each of these arms is a flap which can be raised and lowered for pushing the spent grains out of the tun. The brewer, or better yet an automated system, can raise and lower the rake arms depending on the turbidity (cloudiness) of the run-off, and the tightness of the grain bed, as measured by the pressure difference between the top and bottom of the grain bed. There must be a system for introducing sparge water into the lauter tun. Most systems have a ring of spray heads that insure an even and gentle introduction of the sparge water. The watering system should not beat down on the grain bed and form a channel. Large breweries have self-closing inlets on the bottom of the tun through which the mash is transferred to the lauter tun, and one outlet, also on the bottom of the tun, into which the spent grains fall after lautering is complete. Craft breweries often have many ways on the side of the mash tun for spent grain removal, which then must be helped along to a large extent by the brewer. Some small breweries use a combination mash/lauter tun, in which the rake system cannot be implemented because the mixing mechanism for mashing is of higher importance. The stirring blades can be used as an

18

ersatz rake, but typically they cannot be moved up and down, and would disturb the bed too much were they used deep in the grain bed.

As stated that Mash takes about 15 minute to transfer to the lauter tun here it recirculate so as for good filtration and formation of bed .Raking arms serves to move so that efficient filtration carry out and wort is thus obtained while the husk remains behind .after collection of the First wort the sparging is carry out in the tank with about 105 HL of water to obtained remain extract in the husk the sparging continues till the specific gravity remains above 1.5 P after that the spent grain that remains in the tank removed through the lower way that can be used as the fodder for the animals. After that the wort is then transfer to the wort kettle for the boiling so as to remove any micro and to removes off flavors also hops are added in the wort kettle so as to provide bitterness to the sweet wort that imparts taste to the beer.

WORT KETTLE:
Wort tun is a dome shaped stainless steel tank having an oulet for the exhaustion of gases . It has capacity of 772 HL while its working volume becomes 579 HL .After lautering for about 2 hours the wort transfer to the wort tun. State-of-the-art breweries today use many interesting boiling methods, all of which achieve a more intense boiling and a more complete realisation of the goals of boiling.

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Wort Kettle

Many breweries have a boiling unit outside of the kettle, sometimes called a calandria, through which wort is pumped. The unit is usually a tall, thin cylinder, with many tubes upwards through it. These tubes provide an enormous surface area on which vapor bubbles can nucleate, and thus provides for excellent volitization. The total volume of wort is circulated seven to twelve times an hour through this external boiler, ensuring that the wort is evenly boiled by the end of the boil. The wort is then boiled in the kettle at atmospheric pressure, and through careful control the inlets and outlets on the external boiler, an overpressure can be achieved in the external boiler, raising the boiling point by a few Celsius degrees. Upon return to the boil kettle, a vigorous vaporization occurs. The higher temperature due to increased vaporization can reduce boil times up to 30%. External boilers were originally designed to improve performance of

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kettles which did not provide adequate boiling effect, but have since been adopted by the industry as a sole means of boiling wort. Modern brew houses can also be equipped with internal calandria, which requires no pump. It works on basically the same principle as external units, but relies on convection to move wort through the boiler. This can prevent over boiling, as a deflector above the boiler reduces foaming, and also reduces evaporation. Internal calandria are generally difficult to clean. Technically wort kettle having no steam coil then the boiling takes place through the pre boiler .When the wort kettle filled to the 350HL after that pre boiling starts by circulation of wort through the preboiler at 100C.

During the boiling hops will be added to the kettle hops provides alpha acids to the beer that is IAA acids this provide beer bitterness that can be maintained on the scale of the International Bitterness Unit .Hops may be added in two forms may be either in the pellet form or in the form of Hop Extract and the quantity to which they are added vary from brand to brand. Boiling will be done for the the standard time 75 minute that may

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be up to 90 minute. Wort boiling necessary for the removal off the off flavors from the wort and it also maintain the specific gravity of the wort that is in the range of 11-12 P. After boiling the wort is then transfer to the whirlpool kettle.

Whirl Pool

At the end of the boil, the wort is set into a whirlpool. This transfer of wort takes about 15 minutes The so-called teacup effect forces the denser solids (coagulated proteins, vegetable matter from hops) into a cone in the center of the whirlpool tank. In most large breweries, there is a separate tank for whirlpooling. These tanks have a large diameter to encourage settling, a flat bottom, a tangential inlet near the bottom of the whirlpool, and an outlet on the bottom near the outer edge of the whirlpool. A whirlpool should have no internal protrusions that might slow down the rotation of the liquid. The bottom of the whirlpool is often slightly sloped towards the outlet. Newer whirlpools often have "Denk rings" suspended in the middle of the whirlpool. These rings are aligned horizontally and have about 75% of the diameter of the whirlpool. The Denk rings prevent the formation of

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secondary eddies in the whirlpool, encouraging the formation of a cohesive trub cone in the middle of the whirlpool. Smaller breweries often use the brew kettle as a whirlpool. In the United Kingdom, it is common practice to use a device known as a hop back to clear the green wort (green wort is wort to which yeast has not yet been added). This device has the same effect as, but operates in a completely different manner than, a whirlpool. The two devices are often confused but are in function, quite different. While a whirlpool functions through the use of centrifugal forces, a hop back uses a layer of fresh hop flowers in a confined space to act as a filter bed to remove trub (pronounced tr-oo-b, tr-uh-b in the UK). Furthermore, while a whirlpool is only useful for the removal of pelleted hops (as flowers don't tend to separate as easily), hop backs are generally used only for the removal of whole flower hops (as the particles left by pellets tend to make it through the hop back.).As the wort transfer to the whirlpool tank and after whirl pooling effect the trub and denser particle get settled the wort rest time in the whirlpool for about 25 minutes at during that instance the temperature drops from 100 C to 97C then this wort is then sent for the wort cooling.

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Wort Cooling

After the whirlpool, the wort must be brought down to fermentation temperatures (20-26Celsius) before yeast is added. In modern breweries this is achieved through a plate heat exchanger. A plate heat exchanger has many ridged plates, which form two separate paths. The wort is pumped into the heat exchanger, and goes through every other gap between the plates. The cooling medium, usually water, goes through the other gaps. The ridges in the plates ensure turbulent flow. A good heat exchanger can drop 95 C wort to 20 C while warming the cooling medium from about 10 C to 80 C. The last few plates often use a cooling medium which can be cooled to below the freezing point, which allows a finer control over the wort-out temperature, and also enables cooling to around 10 C. After cooling, oxygen is often dissolved into the wort to revitalize the yeast and aid its reproduction. While boiling, it is useful to recover some of the energy used to boil the wort. On its way out of the brewery, the steam created during the boil is passed over a coil through which unheated water flows. By adjusting the

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rate of flow, the output temperature of the water can be controlled. This is also often done using a plate heat exchanger. The water is then stored for later use in the next mash, in equipment cleaning, or wherever necessary. Another common method of energy recovery takes place during the wort cooling. When cold water is used to cool the wort in a heat exchanger, the water is significantly warmed. In an efficient brewery, cold water is passed through the heat exchanger at a rate set to maximize the water's temperature upon exiting. This now-hot water is then stored in a hot water tank.

YEAST ADDITION:
Through the Plate heat exchanger the temperature of the wort down from 97C to 9C. .now this cold wort allow to pass through the yeast room where yeast pitches into the wort .The yeast pitching rate is usually 1.1 Kg/Hl however this rate depends on the consistency and yeast viability .At the same time of pitching the yeast the sterile air also added to the wort as the yeast requires aeration for the growth and initially after added to the fermentation first of all yeast allow to grow and as the air supply ceased then the fermentation begin

FERMENTATION:
Wort and pitched yeast moves to the fermentation vessel(FV)/Unitank(UT)/Combi tank. After the wort is cooled and aerated usually with sterile air yeast is added to it, and it begins to ferment. It is during this stage that sugars won from the malt are metabolized into alcohol and carbon dioxide, and the product can be called beer for the first time. Fermentation happens in tanks which come in all sorts of forms, from enormous cylindro-conical vessels, through open stone vessels, to wooden vats. Most breweries today use cylindro-conical vessels, or CCVs, which have a conical bottom and a cylindrical top. The cone's aperture is typically around 60, an angle that will allow the yeast to flow towards the cones apex, but is not so steep as to take up too much vertical space. CCVs can handle both fermenting and conditioning in the same tank. At the end of

25

fermentation, the yeast and other solids which have fallen to the cones apex can be simply flushed out a port at the apex. In the fermentation vessel the wort transfer at the temperature of 9.5 C .after the initial 4 hours of fermentation trub are allow to drain from the tank. Again after 24 hours trub allow to drain from the tank. During fermentation the yeast converts the glucose ,sucrose and other available sugars into the beer .The yeast are also categories on the basis of mode of their action that is:After about two days the temperature of the vessel rises to 15-16 it is due to the heat generated during division of yeast in the tank that generate metabolic heat. As the conversion of sugars into alcohol the temperature of the beer becomes lower that led to the settling of yeast at the bottom of the tank and also due to lowering of temperature the particles like proteins has tendency to get settled at the bottom of the tank that led to the reduction of the hazy ness in the beer. After 4-5 Days when gravity of the beer so formed drops below 1.8 Original Extract find out this is the difference between the present gravity and least Extract when LE<4.4 at that instant yeast scrapping /Cropping is then done in which yeast are collected from the fermentors from the bottom .Mature yeast are some time allow to drain or may be recollected for further use this is called as cropping. After scrapping Beer in fermentors are allow to go under a stage of diacetyl rest for the period of about 24 hours .Due to diacetyl rest off flavours are removed from the Beer . After Diacetyl Rest fermentors are set to full cooling aur chill back during first 24 hours of which temperature falls back from 16 C to 4C then after this phase the fermentation set into the lagring stage in which tank temperature sets below 4C .lagring time depends on the total process time . This is also called the conditioning of beer it not only promote the settling of the yeast but also led to the settling of solid particles like protein hence remove hazyness. Unpleasant flavors such as phenolic compounds become insoluble in the cold beer, and the beer's flavor becomes

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smoother. During this time pressure is maintained on the tanks to prevent the beer from going flat. At the lagring stage just before the 24 hrs before the filteration lucilyte added in the tank the purpose of which to settle yeast and heavy particles .The commonly used lucilyte is silicon dioxide that posses both negative and positive charge i.e. Amphoteric and responsible for the settling of yeast and other heavy particles like trub. After the draining of the lucilyte the prepared beer sent for the filteration. At Rochees Filtration will be done by candle filter have assembly of around 304 candles each candle possese pore that is when integrated with the diatom like kishelghur bring about a quality filtration of the beer .

FILTRATION:
Filtering the beer stabilizes the flavor, and gives beer its polished shine and brilliance. Not all beer is filtered. When tax determination is required by local laws, it is typically done at this stage in a calibrated tank. Filters come in many types. Many use pre-made filtration media such as sheets or candles, while others use a fine powder made of, for example, diatomaceous earth, also called kieselguhr, which is introduced into the beer and recirculated past screens to form a filtration bed. In the candle filter there are three grades of kiselghur powder or celite these are:Celite powder 577 that is very fine in quality. Celite powder 512 has fineness less then celite 577 Celite powder High flow that is coarse in nature.

Applying kiselghur to the filter known as the dosing that is done by mixing kiselghur to the de-areated water in the quantity of about 90 gm/Hl .however depend on the haze appear in the beer quantity of the kiselghur can be changed .In this application coarse high flow apply first as it prevents the chocking of the candles within the filter that gives the good quality of the filtration.

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Filter like candle filter much better then some other technical filter like bed filter as it provides more surface are as compared to the bed filter also candle filter can handle the viscous effect that reduces fluid resistance and hence it will led to the effective filtration as compared to any other filter . In operational mechanism the beer is applied from the bottom of the filter which contains kiselghur this beer then move from lower to upper part of the tank and then through the candles which are present here and the coated with kiselghur beer filters and then move to the upper part due to vaccum pressure from where it is then collected and transfer for the storage. After filteration beer is then transfer to the bright beer tank at temperature below 0.c where it is then collected beer should be satisfied with the certain parameters while packaging CO2 should be 2.7-2.9%v/v De Oxygenated water<50ppb While haze within the beer should be having certain parameters at various angles :H90-<.7 H25<0.4 After the filteration it should be necessary that it should be pack within 4 hrs otherwise there will be creation of the off flavour.

Bottling Section

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Within 4 hours of the filteration it should be necessary that the beer go for the packaging in the bottling plant.It is Allow to go for the packing from the BBT to the botteling. Beer bottles come in various sizes, shapes and colours. Dark glass prevents light from spoiling the beer. However, lighter coloured bottles are often used for marketing reasons. Bottling lines are production lines that fill beer into bottles on a large scale. This typically involves drawing beer from a holding tank and filling it into bottles in a filling machine (filler), which are then capped, labeled and packed into cases or cartons. Many smaller breweries send their bulk beer to large facilities forcontract bottling - though some will bottle by hand.

The first step in bottling beer is depalletising, where the empty bottles are removed from the original pallet packaging delivered from the manufacturer, so that individual bottles may be handled. The bottles may

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then be rinsed with filtered water or air, and may have carbon dioxide injected into them in attempt to reduce the level of oxygen within the bottle. The bottle then enters a "filler" which fills the bottle with beer and may also inject a small amount of inert gas (CO2 or nitrogen) on top of the beer to disperse oxygen, as O2 can ruin the quality of the product by oxidation. Next the bottle enters a labelling machine ("labeller") where a label is applied. The product is then packed into boxes and warehoused, ready for sale.

Clean in place (CIP):

As Like after every prepration it is necessary to clean utensils at the home in the same way after some processes that it is necessary to clean the process equipments but they are of large capacity so they are clean on the place where they are placed hence this type of clean procedure called as Clean in Place. CIP done in two ways: 1) Acidic CIP 2) Caustic CIP On the basis of temperature at which CIP done there are two modes of CIP:a). Hot CIP b). Cold CIP

CIP of various Equipments/Devices that are use in the process are as follows:

Milling portion: In the milling portion the CIP done with the Hot Air as their
in no provision for the use of liquid fluid either in the process or in the CIP.

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Brew House portion: The CIP of the Mash Tun, Lautring Tank, Wort Kettle
and Whirlpool Done with the Hot caustic .The hot caustic comprises 2% (1.822%) of NaOH that becomes so effective in damaging the microbes if any persist in the tank. Each of this tank have separate attachments for the CIP from the CIP tanks and then after CIP the water is then drain out .During the Hot CIP the hot caustic apply for about 30 minutes and then flush with the RO water. CIP tanks comprises various tanks that built specially for the CIP purpose these are the Hot water tank, cold water tank and Caustic tank .The Caustic Hold in the tank Should satisfy some parameters like having their caustic concentration should be 2% also their carbonate and Aluminate level should be >0.7.After Brew House all the process equipments are go for the cold caustic these includes PHE(Plate Heat Exchanger), Uni tank and Filter also lines for the transfer of the beer. In these area the application of cold caustic posses same effect as the hot caustic in their mode of sterilization and there also can be hot caustic CIP but we prefer Cold Caustic here because as we go for Hot caustic it may take time to get back its temperature normal hence create loss of time while for good industries time is money hence it indirectly loss of money. In standard practice we go for one acidic CIP after every 10 Caustic CIP it is because though the caustic CIP is much more effective in its sterilization effect but to reduce the chances of the growth of the Basophilic microbes it is generally a acidic CIP needed. In the Bright Beer Tank we generally prefer Acidic CIP or Cold Acidic CIP as BBT holds beer that posses alcohol which is itself very effective disinfectant hence there is lesser chances of the growth of microbes in the tank also in its supply line to reduce any risk of the presence of base resistance bacteria we go for the cold acidic CIP.

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Brewing Process Flow Chart Wort Kettle

Water and Gryst

Lauter Tun Mash Tun

Mash (77c) Wort

Wort(97C)

Spent Grain Plate Heat Exchanger

Wort(9C)

Yeast Room
Yeast(1.1Kg/Hl)

Utility
SterileAir

Combi Tank /Fermentation Vessel/Unitank

Beer (0c)

Candle Filter

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Ready To sell Bright Beer Tank

Pasteurization
Filtered Beer

Quality Aspects of Brewery:

Bottling

Quality matters in all the industries it is one of the important aspects that affects the demand of the product in the market also it decide the standard of the production house. Superior industries ltd. adopt the updated approaches method to check the quality of the process and to maintain it to .Here Through this report I would like to focuss on the some techniques adopted in Brewery to check out the presence of any contamination in the Brewing process also in the packed product However quality not only works for checking of the contamination but also it focus on development of the techniques to give out the better quality of the product .Hence applicable and research fields in the quality department of the Brewery like superior industries makes it to maintain their dominancy in the market and to win complete customer satisfaction .

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Quality control

has various parameters upon which the quality of a

standard beer and its raw material decided it also involves microbial parameters that check the efficiency of yeast doing fermentation and also the viability of the yeast these parameters also also involve in the checking for the contamination of microbes in the beer and water sample while the chemical parameters check the chemical nature of the beer that includes the pH, Least Extract in the beer and its real extract ,It also check out some other properties of the beer like bitterness unit that is due to the isomerisation of alpha acids whose concentration then find out using the standard parameters for the beer. some other criteria that when satisfies give the assurance of the quality process.

Conclusion
In the end ,I would say that summer training at superior industries ltd.was a wonderful task. The training gave me a lot of practical exposure in the field that was entirely new to us .

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The concept of beer manufacturing could be successfully learnt an d applied in the plight of the effort and guidance of the experienced trainers at the industry.

From the training I learnt how a product can be manufactured by giving low capital input ,less labor and effort, by employing skillful people and above all using better manufacturing techniques. So, the beer produced will meet the degree of excellence value demanded by our customers.

Thus to conclude ,I would say that the training was very fascinating and enjoyable.

Bibliography 35

 Source from internet: important websites visited are

www.google.com www.wikipedia.com www.britannica.com www.yeastferment.com

Information based on personnel discussion at superior industries Ltd.
A)

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