Beruflich Dokumente
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DESCRIPTION OF BEER
1.1. Definition of Beer
Beer is made by transforming barley to malt and fermentation of malt in some conditions,
then this fermentated juice aramatized with hop and leaved for fermantation. It contains
carbondioxide in form of solution, has a smell and taste of own and it is a soft drink (3-5 % in
volume). Gas bubbles in it is the result of naturally occuring carbondioxide. Alcohol in beer,
is made on its own during fermentation, it is impossible to add alcohol in beer in production
process.
Alcohol degree of beer, decreases or increases according to malt quantity in beer juice. Beer
,its production is goes to B.C. 6000 years is stillone of the most consumed drinks in world.
Raw materials, used in beer production and required amount for 1 litre of beer are showned
on the chart below.
Raw materials
Unit
Barley
Kg.
1,3
Required amount for
production of 1 litre beer
Malt
Gr.
175
Malt Additive
Gr.
30
Hop
Gr.
1,7
Beer Fermentation
Gr.
(Rice)*
Malt additive and amount varies according to beer type and production methods. In
our country, usually rice is used as malt additive.
Mainly known bottom fermentation beer types are; Pilsen, Mnih, Dortmunt, top fermentation
beer types are; Ale, Stant and Porter. In Turkey, bottom fermantation beer types are being
produced.
Its seperated and called as 2-5%,5,7-8%,11-14% and 16% according to its juices
extract amount. This classification is very important for tax in some countries.
As to its variety, generally beers that are used in trade are understood. ( Special beer,
export beer, diet beer etc.)
Its seperated as colour, bitterness of hop and malt taste. For instance; Pilsen beer, Dortmund
beer and Mnih beer etc.
Mnih beer is dark coloured, aromatic, stout and little bitter. Aromatic malt taste is its
characteristic feature.
Pilsen beer is made of 11-12 balling juice. Malt is well dried in the oven and leaved in 80C
for 4-5 hours. Malt is kight coloured and in mashing very soft water is used. Its boiled once
or twice ; fermentated in low tenperature and reposed for 3 months.
Dortmund beer barleys sprout time is longer but parching-drying is same with pilsen. In
other words, totally melt and malt, that has dried like Pilsen, is used. Water, used in mashing,
contains carbonate, sulfate, CaCl2 . balling of juice is 13-14. double boiling is made. Amount
of hop is between Pilsen and Mnih beers.
Mnih beer is made of 11-14 boiling juice. Barleys, that is high in protein, are used. To make
sprout is contunued until complete melt. Amount of carbonate is high in water which was
used for mashing, but other kind of salts are not present. Tripartite method is applied. A little
hop is added. Fermentation is made in low temperature and reposed for 3 months.
Staut : Its dark coloured and contains hop. %10 black malt or parched barley and
sometimes caramel is added to well melt malt. Hop amount is high. (600-700gr/hl)
Berliner Weissbier : It is made of 1/3 or barley wheat malt mix. Juice is not melt for
this type of beer. Balling of juice is 7-8. fermentation is made in 14-20C. These beers
are sore because its leaved for fermentation by mixing lactic asid bacteria to top
fermantation leaven. To repose is done by leaving in bottle for 2-3 weeks in 12-16C.
Bitterbier : It is produced with enfusion method and a lot of hop added. Fermentation
is made in 9-13C, reposing is made in 5-7C for 2-3 months. During reposing, again
30-50 gr hop is added for one hectolitre.
Malzbier : It is dark coloured, contains little hop and it is sweet. After fermantation
sugar is added, reposing is made in bottle or thank. When enough amount of
carbondioxide is present it should be pastorized of filter immediately.
Lambic : It is peculiar to Brussels. 60% malt and uncooked wheat are used. The most
important feature is not adding leaven and spontane fermentation. In spontane
fermentation, termobacteria, wild leavens, lactic acid bacteria and Brettanomyceses
are active.
Export Beers : Because these beers are sent to far and different clima countries,
their stability has to e very good, in other words they have to stay clear for a long
time without sedimentation for production of this beer, barleys, that gives high
enzimatic malt. So, proteins are shattering good while making malt. Malt shoul be
completely melt. Because there are melanoidins that plays as productive colloid,
it is colour is dark. At the end of mashing, PH should be 5,2-5,4 and for this reason
appropriate water mixture is used. In juice, dextrin amount should be high, so
mashing should not be in 62-63C. Hop should be fresh and for good coagulation,
it should put to boiler when juice is just starting to bail. Juice should not e boiled
for a long time.
In export beer production, beer should be clear at the end of fermentation. It is
better not to make thrashing beers even malts, because it destroys colloidal
balance. For botting beer without contact with air and for keeping used capsules
cork for a long time, it should be covered with aluminium.
Light Beers : Light beers are high attennuationy and must not include
carbonhydrate that harmful for diabetics more than 0,75 gr/100 ml. The protein
amount is maximum 0,5gr/100ml and alcohol amount 4,3% and also these beers
calory amount is low. To create this, by the beer producing,it must be waited a
long time between 62-64C that maltot oceurs mashing. Apart from that, in
fermantation drastase enzyme preparate or malt extraer or for one hectolitre 500800 gr malt flour is added. Than the remained dextrin shattered and it is prowded
to have fermentation by leavens for this reason, light beers, contains more alcohol
also amount of hop is high.
Alcohol free beers : the beers that contains 0,5-1,5% alcohol are called as less
alcohol beer, the beer that has less alcohol than 0,5% are called as alcohol free
beer.
These beers are being produced in different ways for example. It is marketed by mixing beer
and juice or fermentation of juice is stopped by pastorization or filteration. Also, to have less
alcohol in beer, a mashing process may applied that has little fermentable sugars (malt)in
juice. In some countries, alcohol free beer is being produced by taking alcohol in beer with
vacuum distillation. But the beers that has less alcohol than 1,5% are not prefered much.
11,1%
Starch
63,2%
Oil
2,94%
Cellulose
5,83%
2,93%
The most important material of marley is starch. Because the alcohol in beer occurs by
shattering of starch. While the amount of protein in the barley increases, the sprout of barley
becomes forceful. So, it makes harder to control beer production. The amount of protein in the
particle, starch and extract are converse commensurate.
2 HOP : Hop that being used in beer production is a more years plant from canabinaceae
family. Although, being more wild species of hop in Turkey, the culture races are more
efficient.
The main factors of hop that makes producing beer more valuable are alpha acid, essential oil
and wetness.
The most important section of hop is yellow lupuline. This section includes preservative and
taste giving materials. The composition of yellow lupuline has two sections. These are
essential oils that give to the beer its flavoring and rosins that gives to the beer its bitterness
and preservative. Also, the reason of using hop in beer production is lupuline dust.
The chemical composition of hop is;
Water
12,5%
Ash
7,5 %
Cellulose
13,3%
0,4%
Ether extracts
18,3%
Tanine
3,0%
27,5%
The most important materials in beer production between these are ether oils and rosins.
Especially lupuline dusts include ether oils and rosins.
3 WATER : Water is important in beer production as much as barley and hop. Water is
being used for making barley sprout, preparing mash, feeding to vapor boiler and cleaning.
The water, being used in beer production, is much more than the beer producted. Due to the
fact that 80% percent of beer is water, it is important and it must be qualified as clear drinking
water.
Production Amounts
Anheuse-Busch
Beer Market
Market Size
130
USA
226
Heineken NV
79
China
199
56
Germany
105
Interbrew
48.3
Brasil
82
47.7
Japan
72
3. Description of Process
Beer is a beverage made of malt including alcohol and CO2. As another saying; germinated
grain aromatized with hopfen. This means malt must enters alcohol fermentation. There are
5 sections in beer production:
1. Grinding the malt
2. Mashing and Boiling
3. Fermentation and Maturing
4. Filtration
5. Bottling, barrelling and Pastorisation
3.1 Grinding The Malt
Malt is need to be grinded and mixed with water for mashing for beer production. After
grinding of malt, endosperms must be like flour. On the other hand the shells of malt must
remain in big particles. This can happens if the malt is easily melting and fully dry.
Uncracked shells prevents the materials causes unwanted smells and also they are required in
the straining of mash. In straining process, they are used as filters.
The mill used in grinding of malt is located above the mashing-boiling section. The malt
coming from the silos passes from magnets to be seperated from iron particles within. Then
grinded malt is weighted in automatic scales. Dusts in malt are absorbed while entering the
mill from malt silos.
3.2 Mashing and Boiling
MASHING
The seperation of starch into yeastible sugar particles called as mashing. Grinded malt mixes
with water in mash boiling tank and warmed up to various temperatures.
10
Purpose of Mashing
To make the enzymes influence the extract materials in malt and splitted them into low
molecules to pass into must, so that the best extract from malt can be gained.
Mashing Methods
The mixture formed of malt and water is called the mash. There are two types of mashing;
1. Decoction
2. Infusion
Infusion Method
The main principle of this method is rising the temperature of mash slowly to 75-78C. No
boiling happens in this method. So the enzymes do not get damages. In brewering mashing is
made with good soluble malt. Besides this another method called Double Mashing can be
used. A lot of diastase is required to sugarize the additive starch. For this reason infusion
method is important.
11
100C
90
80
70
60
50
40
30
1
(hour)
Infusion Diagram
Double Mashing Method
Malt starch is an expensive ingredient. To reduce the cost of beer, the starches of rice and
corn are used. But the starch must be pasted, else amilase cant influence the starch. To
prevent this, the additives must be boiled before addition. During the boiling, both rice and
corn particles must be in small pieces. During this operation starch becomes sticky and then
can be added to grinded malt.
This method is prefered in bright colored beer production. In fact double mashing is a type of
infusion method.
Straining of the Mash
The seperation of extract gained in mashing and strainig of must have to be complete and
done in a short time. This operation is done in two stages;
1. First must is strained
12
2. Remaining crashed seeds are washed in hot water at 80C, then sent to straining tank
to be strained.
3.3 Straining Tank
This tank is used for straining of mash. It looks like mashing tank. The shells in mash settle
on the perforated base and form a filtering layer. After the main must flows, the remained
extracts on the filter are gained with hot water. Straining tanks are cylindrical in shape and
have perforated bases. The holes are like long cracks. The equipment is made of stainless
steel. There is a plate layer 1 cm below the base. Strained must passes from the perforated
base and accumulate here. Then must is sent to boiling tank. To prevent themust to become
cooler straining tank is built double sided.
Crashed Seeds
After the straining lots of crashed seeds remain. 110 kg grained malt leaves 110-120 kg
crashed seeds including %80 water. Wet crashed seeds can be fermentated to sugar up to
%0.5. Crashed seeds are transfered to their tanks via air flow.
3.4 Boiling
The must gained from straining tank is sent to must boiling tank. The boiling of must is the
turning point in the production. Practically, all the malt must and hopfen are boiled 1-2hours
together. Nothing can be added meanwhile.
Some or all of the hopfen can be exchanged with hopfen extract. If the hopfen is seperated
from the extract and independently isomerizeda it can be more efficient. Previously
isomerized hopfen will be added to beer after fermentation.
Many complex reactions occurs during te boiling process. By the heating of the must all
enzymes like amilase, whick stabilized the carbohydrate composition, become ineffective. At
boiling temperature the must is purified from germs. During the boiling, proteins collapse and
some of them react each other with the help of some simple nitrogen mixtures and
13
14
15
When the must is cooled to required temperature, it is mixed with yeast and sent to floatation
pools. Thereare two types of fermentation;
1. Top Fermentation
2. Bottom Fermentation
Bottom Fermentation
There are three stages in this fermentation;
1. Floatation
2. Major Fermentation
3. Maturing of second Fermentation
3.6 Floatation
The must coming from cooling, is fermented before transfering to floatation pools. How must
is fermented is explained below;
Before dosing the yeast an air flow is given from the bottom to obtain homogenization. At the
moment of must entering the tank dosing starts and finishes just before the flowing stops.
Entering the floatation pool fermented, the must is matured there for 6 days. At this time
period must is warmed up to 8-9C, so the yeasts increase. After the finish of floatation,
fermented must is pumped to fermentation tanks.
Purpose of Floatation
1. To sediment the dead yeasts
2. To float the unwanted materials gained from hopfens
16
to base and the young beer gets brighter. The bitter and dark layer in the surface of the beer is
cleaned and then beer is pumped to maturing tanks. The main event in the major fermentation
is the ethyl alcohol fermentation.
3.8 Chemical Mechanism of Ethyl Alcohol Fermentation
Lavosier found that the products of fermentation are CO2 and alcohol in 1789. In 1815 GayLussac formulized this;
C6H12O6 2C2H5OH + 2CO2
Glucose
Ethanol
2 mols of ethyl alcohol and 2 mols of CO2 are produced from 1 mol glucose. Also many by
products are produced too.
The enyzm, generating alcohol from sugar is zymase. It is a copmplex one originated from a
mixture of enzymes. They generate the alcohol in continious reacitons following each other.
According to the theory of Meyerhor et al., alcohol fermentation occurs in 12 stages; 6
carboned hexoz is divided into 3 carboned trioses, glycerin aldehyte and dioxiacheten. These
trioses tranformed into pyruvic acid. 2carboned acet aldehyte and 1 carbone CO2 is generated
from pyruvis acid. Acet aldehyte produce alcohol by gaining H.
Enzymes used in ethyl alcohol fermentation;
1. Hexocinase
2. Oxoisomerase
3. Phosphohexocinase
4. Aldolase
18
5. Phosphotrioisomerase
6. Phosphatedehidrase
7. Phosphoglicerineacidcinase
8. Phosphogliceremutase
9. Enolase
10. Pyruvatecinase
11. Carboxilase
Maturing
After the major fermentation young beer still contains fermetable extracts. This is %1-2 in
volume. To ferment the remained sugar young beer is sent to maturing tanks. Bottom
fermentation beers stays in maturing 3 weeks at 0-2C. this time can be changed according to
season and sales.
At the end maturing, tanks can be mixed with each other to obtain the wanted gas, color and
extract values, then sent to filtering. Before the filtering the beer cooled to -1C with the
gluchol at -2C.
Introduction to Filtration
To obtain the required brightness, beer must be filtered at least one time. Various types of
straining methods can be applicated. These are; Kieselguhr filters, Sheet filters and Pulp
filters.
Filtration Theory
19
At the end of maturing some amount of sediment collapses to bottom. This causes turbidity in
beer. To prevent this event beer must be filtered. After the filtration;
1. Beer must be sterile and clean as availible.
2. Losses of CO2 must be prevented.
3. The contact of beer with air must be prevented.
4. No infections can be occured.
To get the best result from filtration beer must be cooled as much as possible. The more the
beer cold the more the cold sediment arise. Good filtration means, preventing the warming up
of beer itself and seperating the sediments.
3.9 Introduction to Bottling
The bottles come to Bottle Washing Machine by conveyors.
Washing
The bottles are located the hives in the machine. The washing operation takes 20-30 minutes.
In this operation bottles are washed internally and externally. The washing operation stages;
a) Upside and down the bottles to discharge the remainings
b) Approximately 20 minutes, washing with %1 caustic solution at 90C.
c) Spraying caustic solution into bottles
d) Spraying hot water to external sides to remove the stickers
e) Spraying cold water to inside of bottles and then bottles leave the machine clean, dry
and empty.
20
Washed bottles are controlled by Empty Bottle Control equipment. If the bottle is not clean
as wanted it is sent to washing again.
Filling
The bottles are filled with the ventilles of the filling machine. In this operation;
a) The air inside is sucked with vacuum
b) CO2 at 1.5 bar pressure is given to the bottle
c) While CO2 is releasing beer is filled to the bottles
d) A tiny layer of water is charged to the bottle to make the beer foamed.
e) Taps are pressed to bottles by capsulling pistons and bottles leave the bottle filling
machine
Pasteurising
After the filling the bottles are sent to tunnel pasteur. In here the temperature of beer is risen.
Holding the beer at this temeperature for while then temperature is decreased. This cycle sets
beers biological stability.
Passing of bottles from hot to cold areas is the principle of Pasteur. Water is sprayed to
passing bottles. The temperature of sprayed water can be adjusted to wanted beer temperature
in bottles. The wanted temperature is obtained at preheat andsuper heating areas.
Tunnel Pasteurising
After the bottles are filled and tapped, they enter the tunnel pasteur. The bottles are transfered
in conveyors during this operation. During the operation water is sprayed over the bottles. The
pasteur temperature of beer is gained by adjusting the tenperature of spraying water. The
21
pasteur temperature is usually 63C. Beer stays 20 minutes at this temperature. Then cold
water is sprayed over and leave the system.
The water used in pasteur is very important. It must be clean and have a pH degree of 8. Else
pasteur doesnt works.
22
23
4. Capacity Choose
The annual beer production of Turkey is 8 millions hl. EFES PLSEN provides the %75 or 6
millions of this production.
We are willing to establish a factory to be able to produce annually 1200000 hl of malt beer
according to the marketing location and natural underground waters capacity. According to
this quantity our montly production is 100000 hl.
However we have to rearrange our production according to some conditions. For example we
take a break to production in Ramazan Fests. In these times our factory stops for planned
yearly upkeeping. In statistics of beer sales it seems that the major proportion of the sales are
made in May-December 6 months period. This is approximately 800.000 hl of our production.
So we have to produce 800.000 hl of beer in 6 months in a year. The beer production
capacities during the most of the sales are made;
800.000 hl
hl
= 130.000
6 months
month
130.000 hl
hl
= 5000
26 days
day
According to these values we need 3 pieces of 1500hl and 1 piece of 500 hl capacity pulling
tanks for daily 5000 hl production.
Filters loose 8 hours of time during the fill-up and excretion, so they are working;
5000 hl
hl
= 350
flux.
16 hours
h
The mass balance calculation is built up in the basis of boiling tank capacity. If we go rewind
the process from the end, the producti losses are; %0.2 in fermentation and %0.4 in filtration.
So for monthly 130.000 hl/month production;
24
130.000
hl
1
1
hl
= 138.000
month 0.96 0.98
month
The fermentation tank is designed to be filled with %75 liquid and %25 foam. This process is
done twice in month so;
138.000
hl
30days 69.000hl
=
month 15days 15 days
138.000
hl
kg-malt
tons
15
= 2.070.000 kg-malt = 2.070
month
hl
month
2070
tons
month
malt
1
= 80 tons
month
26 days
day
One month is taken as 26 days because of the weekends. So if we want to use 80 tonsmalt/day we need to choose the capacity of boling tank 10.000lt to make 8 times boiling a
day.
25
5. Flow Diagrams
5.1. Block Flow Diagram
Malt
Malt Mill
Bottling
Malt
Boiler
Straining
Tank
Water
Water
Filtering
Fermentati
on Tank
Boiling
Tank
Water
Plate
Cooler
Beer
Malt-10.000 kg Mill Grinded Malt +380 hl water Malt Mashing Tank Main Mash
In mashing tank 3.8 hl water is added per 100 kg malt. So;
26
10.000 kg malt
3.8 hl
= 380 hl water.
100 kg
Input :
Malt = 10.000 kg
Water = 380 hl = 38.000 hl = 38.000 kg
Input = Output 10.000 + 38.000 = 48.000 kg = Main Mash
Basis: A Boiling Process
System: Straining Tank
Water used in straininng tank can be assumed to be 1/1 proportion to water used in mashing
tank. Mash required for one boiling can be strained in 3 hours.
Input:
27
10.000
80
= 8000 kg = 80 hl
100
100g
= 75000 g = 75 kg
1hl
Output:
28
In this tank the mixture is warmed up to 80C from 35C. So the mashing occurs in 2 hours
50 minutes. The required heat and steam:
Q = m.c.T
m = Total Mash
Cp of Malt = 1
kcal
kg.C
kcal
h
29
Q = 2.160.000
60 min
) + 50 min = 170 minutes.
1 hour
kcal
60 min 1 mashing
kcal
762.350
heat is required.
mashing 1 hour 170 min
h
P = 3 At
y = 1 H = 2676.1
kJ
kg
x = 1 h = 419.04
kJ
kg
kJ 1 kcal
kcal
.
540
kg
kg 4.18 kj
(762.350
Q = m.H
m=
Must is boiled from 65C to 100C. This process occurs in 2.5 hours. Boiling occurs in two
parts:
a) Heating
b) Vaporizing
30
a)Heating:
Takes 1 hour to complete:
t2 = 100C
t1=65C t = 35C
QI = m.Cp.t = 75.000 1
kcal
kcal
35C = 2.625.000
kg.C
h
Q
=
Used Steam; mI =
H
kcal
)
h 4860 kg-steam
kcal
h
540
kg
(2.625.000
b)Vaporizing:
Takes 1.5 hours to complete. The amount of steam given to the system is equal to the amount
of steam lost in boiling of the must. Because the energy of steam given to system is equal to
the loss of vapor during the boiling. So steam loss calculated previous mass balance;
Basis : A Boiling Process
msteam = 7575
kg
vaporizing
QB = m B H B = 7575 kg 540
kcal
kcal
= 4.090.500
.
kg
vaporizing
QB = 4.090.500
(Energy in 1 hour)
vap 90min 1hour
h
mB =
Q
=
H
kcal
)
h = 5050 kg-steam
kcal
h
540
kg
(2.727.000
kg-steam
.
h
kcal
h
kcal
h
kg-steam
h
(mmax)steam =
100
kcal
6.793.720
90
h
Qmax
6.793.720
kg-steam
= 12.580
=
540
h
H
PLATE COOLERS
Must enters the cooler at 100C and leaves at 9C. Cooling water enters at 2C and leaves at
85C. Basically cooling time is assumed to be 1 hour.
32
must = 105
kg
lt
Cpwater = 1
kcal
kg.K
Cpextract = 0.38
kcal
kg.K
kcal
kg.K
kcal
h
mwater = Q must
0.96
0.96
= 5.965.903
= 69.000 kg water is required.
Cp water T
1 (85-2)
2. FERMENTATION
33
Fermentation process takes 6 days and 2 days for cooling also 7 days for maturing, totally
takes 15 days to complete.
Sugar percentages in the tank:
0th day %12.5
Cooling starts
hl
(10.9 - 6.15)
kcal
135kcal/1kg-sugar = 1.923.750
)
1tank
100
day
heat exit.
34
hl
(6.15 - 3.70)
kcal
135kcal/1kg-sugar = 992.250
)
day
1tank
100
heat exit.
hl
(3.70 - 2.60)
kcal
135kcal/1kg-sugar = 445.500
)
heat
day
1tank
100
exit.
hl
(2.60 - 2.20)
kcal
135kcal/1kg-sugar = 162.000
)
heat
day
1tank
100
exit.
hl
(2.20 - 2.10)
kcal
135kcal/1kg-sugar = 40.500
)
1tank
100
day
heat exit.
QTotal = 3.564.000
kcal
day
T1 = 12C
Cp = 1
hl
lt
kcal
100
1 (12-(-1)) = 3.900.000
1tank
1hl
day
kcal
kg.C
Q = 3.900.000
kcal
kcal
= 1.950.000
2days
day
35
kcal
hl
kcal
hl
kcal
hl
5000
hl
hl
0.60 = 3000
day
day
Qw = 9500
kcal
hl
1day
kcal
3000
= 1.187.500
hl
day 24 hours
h
Qp = 9000
kcal
hl
1day
kcal
3000
= 1.125.000
hl
day 24 hours
h
For bottling;
QTotal = Qw + Qp = 2.312.000
kcal
h
36
hl
. %60 of this production
day
m=
QTotal
2.312.500
kg-steam
= 4282
=
540
h
H
5000
hl
hl
0.40 = 2000
day
day
kcal
hl
Qw = 5600
kcal
hl
1day
kcal
2000
= 466.600
hl
day 24 hours
h
m=
Qw
kg-steam
= 466.600/540 = 864
H
h
The boiler has two inlets. These are water and malt. Approximately every 100kg-malt
requires 3.8hl water add-on. Also 100kg malt has a 0.7hl volume. For these reasons we
assume the boiling process in a basis of 10.000kg malt;
10.000 kg-malt
0.7hl
= 70 hl volume
100 kg-malt
37
10.000 kg-malt
3.8 hl-water
= 380 hl waters volume
100 kg-malt
QM = 762.350
kcal
h
U = 1950
kJ
h.C
762.350
kcal 4.18 kJ
Fermentation Tank:
Fermentation occurs in the boiler in a 15 days period. This means two fermentation can be
made in a month time. According to our monthly production capacity;
138.000
hl
30 days 69.000hl
=
is the total capacity of a fermentation process. For the
month 15 days 15 days
38
69.000
= 23 tanks are required.
3000
The %25 part of the tank is seperated for foams;
3000
= 4000 hl one of 25 tanks.
0.75
4000hl volumed tank is made of stainless steel. We are designing a tank with a diameter of
6m and 18m height.
Calculation of the heat transfer area for fermentation process in the fermentation tank:
The energy exchange in the fermentation process is:
QTotal = 3.564.000 kcal/day
In fermentation process, in the cooling we are always using the same heating pocket so we are
taking the daily maximum heat transfer value. This amount of heat is for 2 days time:
2 days Q = 1.923.750
335.053
day 1 kcal 1 kcal
h
Q = U.A.Tlog U = 460
T1 = T2 = 12C
Tlog =
kJ
h
t1 = -4C
t2 = 0C
335.053
kJ
kg
= 460
A 14 A=50 m2
h
h
39
Calculation of the heat transfer area in the fermentation tank for the maturing process:
Before we calculated the amount of energy exchange in maturing process;
Q = 1950000
kcal
kcal
kj
1day
kJ
= 1950000
4.18
= 339625
day
day
1 kcal
24 hours
h
Tlog =
T2 = -1C
t1 = -4C
t2 = 0C
T1 T2 (12 (+3))
=
6.5
T1
12
ln(
)
ln
4
T2
As told above we are designing a set of tanks willing to make 8 times boiling a day in which
each of them has the capacity of 10.000hl and the total for 80tons of malt. These tanksa are
again made of stainless steel. Our tanksa are 6m in diameter and 3.6 m in height. Boiling
process happens in outer boilers so we are using pipe type heat exchangers.
We took the basis 1 hout for boiling;
Looking to the amount of the energy in the heating section of the boiling process:
QI = 2625000
kcal
h
40
Straining Tank:
In this tank water is sprayed from perforated trays. To obtain this 200kg-malt is strained in a
standart 1m2 staining area. For our capacity of 10.000kg-malt;
10.000kg-malt
1m 2
= 50m 2 area is needed.
200kg-malt
This 50m2 area is designed to be 8m in diameter and 25m in circumference. Again this tank is
made of stainless steel.
According to literature for the straining flippers, 6 armed 8.1 rpm system is enough for our
process. Straining tank is shaped cyclindrical like mashing tank is. This tank is 8m in
diameter, 1.8 m in height and has a capacity of 900hl. Orifices in the tank are thin and
splitted.
These straining tanks must have the capacity to strain the required malt in 3 hours period.
Plate Cooler:
We are planning to cool the must in 100C to 2C in plate coolers. The heat transfer area of
our cooler according to previous mass and energy balances is calculated as;
Tlog =
(100 85) (9 2)
10.50
15
ln
7
kcal
m 2 .hC
41
Beer is being filtered to obtain the required clearness. There are many types of filtering;
Kieselguhr Filter, Horizontal Filter, Vertical Fitler and Plate Surrounding Filter. We prefer to
use Kieselguhr Filter and PVPP(PoliVinilPoliPolidan). PVPP is made of plastic and polimer
inert material.
Pumps:
We are using 4 HP powered 4 pumps to meet the water need in our plant. These pumps have
total 40 tons water/h pumping capacity. Our plant needs 350 hl water/ hour.
Bottling Machine:
Our beer production capacity is 5000 hl/day. %60 of this amount is for bottling and the rest is
for barreling.
42
to export our production our factory must be nearby the export centers such as airports and
seaports. By the way we must pay attention to the land prices, construction expenses.
In conclusion we decided to establish our factory in Lleburgaz according to all factors told
above.
Another factor is the structure of the soil in factory land. The land structure have to be enable
to allow locating pipes underground to pump the products to the tanks.
The lay out of the plant can be arranged according to process flow. We are establishing the
equipments according to their location in the process. So we dont have to pay extra money
for pumping anf piping.
The main production plan of beer;
Malt Boiling Fermentation Maturing Filtration Bottling.
Our plant lay-out is in appendix.
9. Economical Analysis
Total Instrument Costs
Instruments
Quantity
Price
Total
Mashing Tank
120.000$
120.000$
Straining Tank
30.650$
30.650$
Boiling Tank
147.750$
295.500$
Plate Cooler
150.110$
150.110$
Fermentation Tank
23
192.690$
4.431.870$
Filter
304.000$
304.000$
Pumps
350$
1400$
43
Bottling Machine
900.000$
TOTAL
900.000$
6.233.530$
Cost
Instrument Cost
Instruments
100
6.233.530$
Building Instruments
47
2.929.759$
Instruments and
18
1.122.035$
Piping
66
4.114.129$
Electric System
11
685.688$
Buildings
18
1.122.035$
Enlarging
10
623.353$
Service Processes
70
4.363.471$
Land
374.011$
Direct Expenses
346
21.568.013$
Engineering and
33
2.057.064$
Construction Expenses
41
2.555.747$
Indirect Expenses
74
4.612.812$
Total Expenses
420
26.180.826$
Contractor Expenses
21
1.309.041$
Unexpected
42
2.618.082$
Fixed Capital
483
30.107.949$
Managing Capital
86
5.360.835$
Control
Control
44
TOTAL CAPITAL
569
35.468.735$
Cost(kg/$)
Proportion of
Net Mass(kg)
Cost($)
mass(%)
Malt
0.25
20,5
24.600.000
6.150.000
Hopfen
1.5
0,17
204.000
204.000
45
Production Costs
Proportion of Total
Cost ($)
Cost(%)
Raw Materials
20
6.354.000$
Labor
20
6.354.000$
Control Labor
1.588.500$
1.588.500$
Laboratory
10
3.177.000$
TOTAL
60
19.062.000$
Proportion of Total
Cost ($)
Fixed Expenses
Cost(%)
Corrosion
953.100$
Tax
953.100$
Insurance
1.270.800$
TOTAL
10
3.177.000$
Proportion of Total
Cost ($)
Company Expenses
Cost(%)
Company Expenses
1.588.500$
46
General Expenses
Proportion of Total
Cost ($)
Cost(%)
Management Expenses
1.588.500$
Transportation
15
4.765.500$
R&D
1.588.500$
TOTAL
25
7.942.500$
GENERAL TOTAL
100
31.770.000$
Salary Distrubition
Total Labor Cost is 6.354.000 $
Position
Person
Salary ($/month)
Cost ($/month)
General Director
7000
7000 $
Chemical
4200
37800 $
4900
24500 $
4200
21000 $
Chemist
2100
16800 $
Workers
200
1400
280.000 $
Security
20
1400
28.000 $
Drivers
20
1400
28.000 $
Managing Officials
30
2800
84.000 $
Engineering
Mechanical
Engineering
Electrical
Engineering
TOTAL(Monthly)
527.100 $/month
TOTAL(Annual)
6.354.000 $/year
47
Recovery
In one year period company will gain 120.000.000 x 0.413 = 49.560.000 $
Net Profit = 49.560.000 (120.000.000 x 0.265) = 17.760.000 $
As the capital estimation is calculated = 35.468.735 / 17.760.000 2 years
48
40.000.000
20.000.000
0
-20.000.000
10
-40.000.000
Year
49
15
10. Conclusion
Beer production of Turkey is sufficient for its own needs. %75 of beer sales are made by
EFES PLSEN. Our project is planned to produce %15 need of countrys beer poverty. In
consideration with the potential working power and qualified persons, there will be any
problems on operating this plant. However, most of the equipments, have to be used in beer
production, must be imported from foreign countries, especially from Germany. This causes
the establishing expenses to be increased. With hardworking and enough R&D studies on this
subject can solve the expensive imported instruments costs problem. Beside this the whole
raw materials used in beer production can be gained from our countrys own agriculturel
production. So there is no shortage of raw materials indeed. According to economical
analyses, our factorys payback time is approximately 2 years. This result is satisfactory and
the investment seems feasible.
50
11.Appendix
Tables of Beer Productions and Consumptions
Tables of Malt Production
Factory Lay-out Plan
Fermentation of Etyhl Alcohol
Process Flow Diagram
Change of Parameters During Fermentation
Pictures of Equipments
51
Mashing
+
Malt
Boilers
Fermentation
Tanks
Maturing
Tanks
Bottling
+
Bottle Washibg
Filtering
Security
Warehouse
Firehouse
Manageme
nt Building
Work
shop
Dining
Hall
+
Lockers
Lab
Day
P(BAR)
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
10
0,4
11
0,4
12
0,4
13
0,4
14
0,4
15
0,4
Day
Ph
4,58
4,33
4,23
4,19
4,22
4,22
4,22
4,22
4,22
10
4,22
11
4,22
12
4,22
13
4,22
14
4,22
15
4,22
53
Day
T(C)
12
12
12
12
12
-1
-1
-1
10
-1
11
-1
12
-1
13
-1
14
-1
15
-1
Day
Extract(%)
12,5
10,9
6,15
3,7
2,6
2,2
2,1
2,1
2,1
2,1
10
2,1
11
2,1
12
2,1
13
2,1
14
2,1
15
2,1
54
55
56
12. Preferences
ZEN, Il, (1988), ODT Intership Report
57