BAHIR DAR UNIVERSITY

COLLEGE OF SCIENCE
DEPARTMENT OF INDUSTRIAL CHEMISTRY
SUMMER INTERNSHIP PROGRAM REPORT
START DATE OF INTERNSHIP: 17/07/2017/18
END DATE: 01/09/2017/18

PREPARED BY: BIRUK AYELE ID: 0702889

EMAIL : biruke.3@gmail.com

RAYA BREWERY SH.CO.,MAICHEW,ETHIOPIA

PHONE:0347771419, 0911096284
• Raya Brewery has an initial annual total
capacity of 600,000 hectolitres (180million,
33cl bottles of beer per year enough to supply
the population of Ethiopia with 2 bottles each)
current production output stand at 300,000
hectolitres (90 million bottles).
• Raya Brewery has an initial annual total
capacity of 600,000 hectolitres (180million,
33cl bottles of beer per year. enough to supply
the population of Ethiopia with 2 bottles each)
current production output stand at 300,000
hectolitres (90 million bottles).
 Brief history of the company

• Raya Brewery S.C is a new brewery production plant. This

beer factory used sophisticated technologies for the
production of Raya beer and keg (drought) beer.
• Raya Brewery S.C is found in Maichew town, which can be
reached in two ways. The first route is from Addis Ababa
through Dessie, woldya--kobo-Alamata – Mehone – Maichew
road, which is 668km from Addis Ababa.
• The second route is from Addis Ababa through Dessie –
woldya-kobo-Alamata - Korem-Maichew road, which is 622km
from Addis Ababa.
• The company start production of beer in 2007 E.C.
• Beer is an alcoholic beverage made from yeast
fermented malt flavoured with hops. The
production of an alcoholic beverages is as old as
history.
• The earliest record of brewing comes from the
ancient Sumerians over 6000 years ago; a piece of
pottery found there, shows workers either stirring
or skimming a brewing vat.
• Nowadays alcoholic beverage production
represents a significant contribution to the
economies of many countries.
• Malt handling and reception

50% imported
malt, 50% local
Screw conveyor, bucket elevator
malt

Silos

Screw conveyor, bucket elevator

Pure air
Aspiration system

( cyclone )
Husk

Magnetic material  Mgnet

 Destoner Cyclone
Stone Pure air

Dust
  Magnet
Off sized particles,
 Drum sieve
cyclone
Malts, magnetic materials Pure air

Dust

 Magnet
Metallic -  Hammer
plastic mill
materials

Grist

Hopper

Screw conveyor

Pre-masher
 Cont`d

ZnSO4
 Purpose of milling
 To split the husk made up of hemicelluloses,
polyphenol and cellulose
 To expose the inner portion of the kernel
 To prevent excessive dough formation in
mashing.
 To extract more sugar easily.

Darcy low: The fine the malt milled the greater

extraction capability but difficult to filter.
• There are two types of milling

Dry milling : milling in dray state

E.g. hammer milling

Wet milling : milling by soaking with water

 pre- masher
. venture meter measure flow rate
. Pressure gauge convert pressure d/nce to
volume

. Initiate all enzymes

. Activate protinase enzymes
• remember all enzymes are proteins
• Water to grist ratio is 2.3:1 ( thick mash)
 Mash kettle
Major chemistry takes place
• mash go from rests to rest temperature (
infusion mashing)
• Activate enzymes at their optimum temp.
• Starch converts to fermentable sugar

• Protein converts to amino acids( which ppt in

wort pan)
• Protein polyphenol complex formed
• Ca salts added to lower PH reacting with
polypeptides

• The higher temperature also lower pH due to

dissociation reactions
• phosphoric acid added to react with calcium ion
and lower pH because the enzymes have their
optimum pH
• The following table show s the optimum pH and
temp. for some enzymes:
 The starch in the milled barley converts to simple
sugar in three steps.
• Gelatinization: Means the swelling and bursting
of starch granules in a hot aqueous solution.
• Liquefaction: means reduction of viscosity of
gelatinised starch by alpha amylase.
• Saccharification : means alpha amylase
progressively break open the chain of amylase
and amyl pectin to form dextrin's containing 7 -12
glucose residue ,
Iodine test the complete degradation of starch
 Factors affecting mashing process are;
• Temperature
• mashing time
• PH
• Malt types,
• extract composition ,mash concentration, and
size of mashing vessel
• are also another factors.
 IBD lecture. mode 1 (05.08 2005 revised); Wort production

MASH FILTER
• The main objective of mash filtration is
separation of wort from spent grain.
• Though there are many mash separation
system in the world brewing technology, Raya
brewery uses mash filter which has 69 plates
and is Belgium made. The filter consists of
an alternative series of membrane chamber
modules and grid pates made of very poor
heat conductor polypropylene
• The husk ,protein-poly phenol complexes, fats
and other organic compounds removed as
spent grain.
• The spent grain composition is as follows
Spent grain composition Approximate percentage (%)
Protien 28

Nitrogen free extracts 41

Cellulose 17.5

Inorganic material 5.3

Fat 8.2

Kunze W. International brewing technology: ed.1 page250

 BUFFER TANK

Its main objective is wort stabilization and

constant flow regulator. Its size is more
smaller than wort collector tank.
FIRST WORT COLLECTOR
• The wort collector is larger in size than buffer
tank and its function is similar to that of
buffer tank.
 WORT PAN
Main objectives
• wort sterilization
• inactivation of enzymes
• concentration of extract
• volatile removable :
• bitterness development
• acidification of wort
• trup formation
• Colour formation.( milliard reaction )
Millard reaction
 HOP
• Contains alpha and beta acids that cause
bitterness of to beer,
• Alpha acid is 9 times bitter than beta acids
• German is the first worlds largest hop growing
country
• Hop pellet, hop extract and hop cone are the
common form of hop used in brewing.
 HOP ISOMERIZATION
In reaction ring contraction (common in hop
chemistry). Isomerisation, good solubility.
 Calculating a hop grist
In order to calculate the weight of hops required to produce a beer with a
required level of bitterness it is necessary to know:

• Bitterness of beer required in IBU`s

• The % alphaacid in the hop material used.
•% Utilisation of the hop material

It is generally taken that: 1 IBU (International Bitterness Unit) is

equivalent to 1 milligram of isoalpha acid in 1 litre of water or beer It is
important for the Brewer to monitor the % utilisation of the hops added
to the beer, which is calculated:

Hop utilisation % = amount of isoalpha acid in the beer X 100%

Amount of alpha acid added
Example:
Calculate how many Kg of Hops is needed to produce 325 hl of Raya beer
containing 26 IBU`s with Hops with a 40 % alpha
acid content and Hop Utilisation of 45% .
Volume = 325 hl x 100 = 32500 litres

1 IBU = 1 mg iso alpha acid/l: 26 IBU`s = 26 x 1mg iso alpha acid/l = 26 mg

iso alpha acid/l
Since 1 litre of beer of 26 IBU’s contains 26 mg 32500 litre of beer contains 32
500 x 26 = 845000 mg iso alpha acid = 0.845kg iso ALPHA-acid
If hop utilisation is only 45% (i.e. only 45% of the starting a-
acid finishes up as isoa acid in the final beer)
Then we will require to supply 325/45 x 0.845 = 6.1 kg alpha acid is used.
Since the alpha acid content of the 40% we have to add(6.1ₓ325)/40 = 49.5 kg
 WHIRLPOOL (TRUP SEPARATION)
A tangential wort inlet causes whirlpool to
settle the trups from wort
. Trup settling follows stoke”s low. The settling
of trup takes around 30 min. The trup
collected in the trup tank and pure wort (with
15 – 18 0 p) send to room two for cooling in
plate type heat exchanger. Ice water used to
exchange heat and lower the temperature
from 900 c to 80 c. The collected hot trup
recycled back to mash filter after 12 hr if the
brewing is continuous. It discarded if brewing
is continuous.
 BREW HOUSE CALCULATIONS
• Conversion of volume of hot wort to cold
wort volume
• Example; what is the volume of the cold wort
obtained in cooling with plate type heat
exchanger if the cast wort volume is 260 hl?
• Solution; cold wort volume = (260) hl. (0.96) =
249.6 hl
 MASS PERCENT
The mass percent is measure with a specific
gravity hydrometer (sacharometer).
hydrometer is floatable body which operates like
adensi-meter
. The lower the specific gravity of the liquid, the
The a dipper the hydrometer sinks. The
hydrometer first calibrated with sucrose or
other mass known solution.
Example ; hydrometer reading = 11.6%
Correction = +2
Weight percent = 11.8%
The corrected value shows how many kilogram
of extract are present in 100 kg of wort

DETERMINATION OF MASS OF EXTRACT PER

HECTO –LITTER
• Specific gravity = (mass %. 0.004) +1
• Extract content in kg = specific gravity. Extract
%
• But if table is available we only need to focus
measured mass percent value and look
converted mass percent on the table.
• 11.8% mass in Plato table has a converted
percent gram in 100 ml at 200 c of 12.34 %.
So a wort having 11.8 mass percent in
hydrometer means a wort has 12.34 kg extract
in 1 hl wort at 20 0c.
• CALCULATION OF AMOUNT OF EXTRACT IN
BREW HOUSE.
• Extract amount in kg = mass%.A. 0.96. Hot
wort volume
• A = specific gravity at (20/40c), 0.96;
correction factor but
• Aₓ0.96ₓ mass% = constant and called yield
factor It can obtain from the Plato
standardization commission table
• EXAMPLE; 260 hl wort produced from 6000 kg malt
grist in Raya brewery. A sample is taken and cooled to
200 c without evaporation as well as dilution. The
hydrometer measurement result is obtained as 11.8%.
• A, What is the extract amount in kg?
B, what is the brew house yield?
• Solution; a, 11.8% mass in Plato table has a yield factor
of 11.85
Extract amount in Kg = 260 ₓ 11.85 = 3081 kg.

B, YBH = extract mass in kg ₓ 100%

= grist mass( kg)
= 3081ₓ 100% = 51.3% too low !.
6000 kg
• CIP; means cleaning in placeof brewing
equipment.

Pre-rinse water ………→ caustic solution………→

acidic solution
• ……→ brew water
RECOMMENDATION ;
Raya brewery imports 50% of its malt consumption
from Belgium. Why not all from local market? The
climate of Ethiopia is suitable to grow barley, so
why not we export to international market? It is
better to support the farmers that grow barley.
The malting process is better to be here too.
• The ceramic of the floor is being crack down only in three
year service. This is due to week cleaning system and
over chemical load. It is better to discharge waste
elongating a pipe with commercially available pipe to the
drainage.
• There is a leakage in pipe fittings strainers and in pipes
wort pan and mash kettle visualizing glass. Weekly
maintenance should be done to avoid losses and hazards.
• Today, most factory of the world use adjuncants to
decrease the cost for malt. It is better to use un-malted
barley incorporating with malt to be economical.
• In external cleaning, some equipment is going to rest.
Those materials are made from stainless still and are
coated. Care must be taken during cleaning with
caustics and water.
Thank you !!!!