This ppt desires the process of making Beer and its fundamentals ....

1. Prepared By
Dept. Of Food
Technology

2. Firstly, I would like to express my deep and sincere regards towards our food
tech department for giving me this great opportunity to widen my horizon of
knowledge.
I would like to thank the Mr. KULVEER AHLAWAT, (H.O.D.FOOD
TECHNOLOGY) for their immense support through the training.
It is not just acknowledgment rather it’s my deepest gratitude towards our
ATPO Mr. VEDPAL YADAV (Lecturer in Food Technology) who made my
training at MOHAN MEAKIN LIMITED, SOLAN BREWERY. DISTT.SOLAN {H.P},
INDIA, 17321
I would also extend my deep gratitude to Mr. BANSI LAL (Lecturer in Food
Technology) & entire food department staff for their constant support,
guidance and help.

3. The history of this company can be traced back to the establishment of
a Brewery at Kasauli by Edward Dyer in 1855. It was the India’s brewing
pioneer who brought to this sun-drenched land of ours the bliss of a real
thirst quencher – the modern beer, to refresh and pep up a people hanging
over in sweltering clime that is so peculiar to this part of the World. He
realized for the first time that there were a few spots on earth where a really
good drink was more welcome.
But, in his flush of enthusiasm he had set before himself such a big
task of quenching the thirst of a nation as obviously could not be expected
to reach fulfillment by his one, howsoever efficiently working brewery at
Kasauli. Consequently, with ardourous zeal he scaled the whole width of
this subcontinent and established breweries and distilleries at Simla,
Solan, Lucknow and Mandalay (Burma).
During the same century, another enterprising man, named H.G.
Meakin, coming from a well known brewing family of Burton-on-Trent
where he was trained, came forward with enviable enthusiasm and founded
Meakin & Co. Ltd. He bought the old Simla and Kasauli Breweries and built
others at Dalhousie, Ranikhet, Chakrarta, Darjeeling and Kirkee.
HISTROY

4. Both these firms E. Dyer & Co., and Meakin & Co. Ltd., continued doing
business separately up till after the second decade of the 20th century.
During the first World War (1914-18), when it was a big job to import beer, the
two firms quenched the hugely increased thirst of India with superb beer at a
rock-bottom price. Vast quantities of Malted Barley were sent to Egypt, to
help keep soldiers’ beer at a reasonable price.
Following these successes, the two firms joined hands and started a new
joint stock venture under the style of Dyer Meakin & Co.Ltd. Brewing was
suspended at the Kasauli Brewery and a latest brewing and bottling plant
was installed at conveniently placed Solan. Extensive malting at Kasauli
were, however, continued in operation. There are few places on earth where
the water is ideally suited to brewing. Solan is one. Those who fancy the hill-
climb would like to see our famous springs high up on Karol Mountain, far
from everything, a lovely lookout, with the source of crystal clear spring
water that drew our pioneer to Solan.

5. With the times, as modern scientific progress made it possible to
augment production several times with the latest machinery, the
unproductive centres were closed down one by one retaining distilleries at
Kasauli and Lucknow and brewery at Solan (Simla Hills) ; all the three
centres enormously expanded to meet any expected demand.
During the World War II, Solan Beer played its valuable part by keeping
the soldiers of the allied nations in perfect pep and cheer. After the War, all
manufacturing plants at Solan, Kasauli and Lucknow were replaced by the
new latest automatic ones.
In 1935 when Burma was dismembered from India the name of the
Company with Indian assets and liabilities was changed to Dyer Meakin
Breweries Ltd., from Dyer Meakin & Co. Ltd., and the assets and liabilities
of Burma Brewery in Burma were separated. Thereafter the Company’s
name was changed from Dyer Meakin Breweries Ltd., to Mohan Meakin
Breweries Ltd., w.e.f. 1.11.1966 and from 24.4.1980 the name was further
changed to Mohan Meakin Ltd., and as such the Company is now known as
Mohan Meakin Limited.

6. Year 1949 saw a dynamic transformation in the fortunes of the
Company, with late Padamshree N.N. Mohan at the helm of affairs. With his
far-sightedness he set up big industrial hub near Ghaziabad (U.P.) known as
Mohan Nagar by establishing there various manufacturing Units namely
Brewery, Distillery, Malt Houses, Glass, Ice, Break-fast Food, Fruit Products
and Juices, Malt Extract factories, Cold Storage and Mohan Engineering
Works etc. and there has been no looking back since then.
The Company’s remarkable performance is not limited to liquor, its
business interests are manifold. Turning foresight into reality is the Fruit
juices, Breakfast Foods, Mineral Water and Glass Factory – a strategic
diversification to further re-inforce its business interests.
Mohan Meakin Limited also exports its beer, rum, whisky, brandy, and
gin products to the United States, the United Arab Emirates,
Singapore, Qatar, Germany, Australia, Estonia, Malaysia, China,
Japan, Italy, the Netherlands, Canada, Hong Kong, and Korea.

7. What is Beer?
Beer is generally defined as an alcoholic beverage made by
fermentation of farinaceous extract that is obtained from a starchy raw
material that is barley in the form of malt. Although it is possible to
replace some part of barley in the from of other starchy materials
(eg.Corn, wheat, oak, potatoes) It is usually the main constituent of
brewing materials.
Beer is the world's oldest, possibly dating back to 6000 BC, and most
widely consumed alcoholic beverage and the third most popular drink
after water and tea.
Brewing was one of the earliest processes undertaken as commercial
scale and became one of the first processes that developed from an art
into a technology.

8. What’s in a Beer?
• BARLEY – the body & soul of beer
• YEAST – the life of beer
• HOPS – the spice of beer
• WATER – the integrity & purity of beer
• ADJUNCTS – Additive grains like rice or corn,
fruit or spices

9. Barley – “Body & Soul”
Barley malt gives beer:
• NATURAL enzymes to covert starch to sugar
needed for fermentation
• MALTY sweet flavor
• COLOR
• FOAMY head
Two row & six row barley malt are used in the
brewing process.
Variety of barley malts helps determine the
color, texture and flavor of beer.

10. Yeast is the catalyst of change:
• one cell micro-organism
• produces carbon dioxide and alcohol
Two types of yeast are used to produce beer:
• ALE – top fermenting
• LAGER – bottom fermenting
There are literally thousands of brewers yeast
that create a variety beer styles.
Yeast – “Life of Beer”

11. Water – “Integrity & Purity”
Water’s role in beer:
• water makes up 92% of beer
• through filtration or boiling; impurities, aromas &
flavor differences can be mitigated
Water styles can effect flavor:
• hard water – helps add crisp cleaness
• soft water – adds smoothness

12. Adjuncts – “The Wild Card”
Adjuncts add to beer:
• adjuncts are added to change the flavor,
character or profile of beer.
• used to supplement main starch source to
provide better foam retention, color or aroma
Adjuncts fall into two categories:
• Grains:
• corn, rice, wheat, oats or rye
• Specialty Ingredients:
• sweets – honey or maple
• fruits – raspberry, cherry or cranberry
• spices – cinnamon, coriander or clove

13. BEER
Ale( top-fermented) Lager(Bottom fermented)
Pale
Middle/Brown
Stout(Porter) Pale Dark
Pilsner
Dortmunder
Munchener
Bock
Ale

14. PRODUCTION OF BEER

16. Brewing
The process of making beer is known as brewing. The purpose of
brewing is to convert the starch source into a sugary liquid called
wort and to convert the wort into the alcoholic beverage known as
beer in a fermentation process effected by yeast.
Barley selected for use in the malting industry
must meet special quality specifications. Accepted
malting barley varieties have to modify evenly
and produce a finished malt whose properties lie
within the brewer's specifications. The malt
quality of a given barley variety is determined by
its genetic background and the physical
conditions during growth, harvest and storage.
Malting barley

17. The mature barley grain comprises the embryo and the
endosperm, which provides a store of carbohydrates
(mainly starch) and protein to support the initial growth of
the germinating embryo. The endosperm comprises the
starchy endosperm, which is a non-living storage tissue,
surrounded by a living non-starch cell layer called
aleurone. The grain is protected by an outer husk.

18. Vitality
When stored at very low temperatures and low moisture content,
barley may keep its vitality for centuries
should be kept at a moisture content of below 12 % and at
temperatures below 12 °C.
Fungal contamination during storage
Barley with a moisture content of above 14 % may be attacked by
fungi during storage especially by species Aspergillus , Fusarium,
and Penicillium. Secondary metabolites of these fungi cause
gushing.

19. 1. rapid and uniform germination,
2. the synthesis of hydrolytic enzymes in the scutellum and aleurone
tissues surrounding the endosperm and
3. finally the degradation of endosperm cell walls, described as
modification. (Gibberellin, which regulates these physiological
events, is a plant hormone produced by the germinating embryo.)
Hydrolase Action and Modification

20. Malting In the malt house, barley grain germination
is initiated by
1. the uptake of water in a steeping vessel
(A). The grain imbibes water during
controlled cycles of water spraying or
water immersion
2. followed by aeration, until the water
content of the grain reaches 42 to 48%.
3. The grains are then transferred to
malting beds where germination is
allowed to proceed over a period of
around 5 days (B).
4. Green malt, produced after five days of
germination, is kiln dried and partly
cooked in a forced flow of hot air (C).
Hydrolases produced during malting are
partially inactivated during this process.

21. Mashings are normally performed at pH 5.5 at which most malt-derived enzymes
exhibit high activity.Conditions include a controlled stepwise increase in
temperature that preferentially favours one enzyme over the other, eventually
degrading cells walls, proteins and starch. Since the enzymes which degrade cell
walls and proteins are rather heat labile, it is important for their function that
mashing begins at a low temperature. Subsequent mashing at 65°C, or higher, is
particularly geared to control conversion of gelatinized starch into fermentable
sugars using malt-derived starch degrading enzymes.
Principal mashing enzymes include (1-3,1-4)-ß-glucanase and xylanase for cell
wall degradation, endo-peptidase and carboxypeptidase for protein degradation;
and amylases, limit dextrinase and a-glucosidase for starch degradation.
Mashing Mashings

23.  The brew kettle, a huge cauldron holding
from 70 to 1,000 hectoliters and made of
shiny copper or stainless steel, is
probably the most striking sight in a
brewery. It is fitted with coils or a jacketed
bottom for steam heating and is designed
to boil the wort under carefully-controlled
conditions. Boiling, which usually lasts
about two hours, serves to concentrate
the wort to a desired specific gravity, to
sterilize it and to obtain the desired
extract from the hops. The hop resins
contribute flavor, aroma and bitterness to
the brew. Once the hops have flavored the
brew, they are removed. When applicable,
highly-fermentable syrup may be added to
the kettle. Undesirable protein substances
that have survived the journey from the
mash mixer are coagulated, leaving the
wort clear.
Boiling and Hopping

24. At the end of the boil, the wort is sent into a
whirlpool. The so-called teacup effect
forces the more dense solids (coagulated
proteins, vegetable matter from hops) into a
cone in the centre of the whirlpool tank.
In most large breweries, these 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.
Whirlpool

25. After the whirlpool, the wort must be brought down to
fermentation temperatures 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 950C. 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 11 0C. After cooling, oxygen
is often dissolved into the wort to revitalize the yeast
and aid its reproduction
Wort cooling

26. The traditional quantitative description of the brewery
fermentation has been the anaerobic process of yeast
converting glucose to ethanol and carbon dioxide. Despite its
complexity fermentation is largely dependent upon three
basic parameters, namely the wort composition (nutrient for
the yeast), the yeast, and the processing conditions
Fermentation:
Quality Control during fermentation
During fermentation strict quality control should be enforced to
assure that the progress of fermentation proceeds normally;
that the yeast is healthy and free from contamination; and that it
behaves as expected both in suspension and flocculation.
Physical and chemical method may include checking
parameters such as time, temperature, ph, extract and alcohol
contents, flavor analysis, and yeast cell concentrations.

27. Basic functions of fermenter or Bioreactor:
The main function of a fermenter is to provide a controlled environment for the growth
of a microorganism or a defined mixture of microorganism to obtain a desired product.
The vessel should be capable of being operated aseptically for a number of days and
should be reliable for long term operation. The inadequate aeration and agitation
should be provided to meet the metabolic requirements of the microorganism.
Criteria used for the selection of microorganism for fermentation:
The strain should be genetically stable.
The strain should readily produce many vegetative cells, spores or other structure.
The strain should grow vigorously and rapidly after inoculation in the vessel.
The strain should be pure culture and free from other microorganism including
bacteriophage.
Fermentation consists of four phases:
Lag phase: Fermentation remains in this phase for the initial 10-12 hours. During this
period yeast gets acclimatized to its new environment.
Log phase: This phase starts after 12 hours of fermentation. In this phase vigorous
fermentation starts.
Peak fermentation: This phase comes around 45-48 hours after pitching of yeast.
Fermentation is at its peak during this phase.
End fermentation: This phase comes after 120 hours of fermentation.

28. When the sugar in the fermenting beer has been almost
completely digested, the fermentation slows down and the yeast
starts to the bottom of the tank. At this stage, the beer is cooled
to around freezing, which encourages settling of the yeast, and
causes proteins to coagulate become insoluble in the cold beer,
and the beer’s flavor becomes smoother. During this time
pressure is maintained on the tanks to prevent the beer from
going flat.
If the fermentation tanks have cooling jackets on them,as
opposed to the whole fermentation cellar being cooled,
conditioning can take place in the same tank as
fermentation.Otherwise separate thank (in a separate cellar )
must be emploed
Conditioning

29. A centrifuge is basically a rotating container
which separates the solid from the liquid using
centrifugal force 5000 to 8000 times greater than
the acceleration due to gravity. The magnitude of
the centrifugal force is proportional to the square
of the number of revolutions per minute
multiplied by the effective radius.
Centrifuges used for beer clarification are
normally the disk self-opening type. Disk
separation is about 0.5 mm, which means that the
settling distance is less than 1.0 mm compared to
the setting distance of several meter in a tank.
Beer enters the top of the centrifuge and is
distributed between each disk. Clarified beer
work towards the center and is discharge by
means of centripetal pump.
Centrifugation

30. Gravity sedimentation, fining and centrifugation clarify beer
to a certain degree but do not give the brilliance required in
the market place. It is normal to filter beer at least one time at
the end of storage process prior to packaging to obtain
brilliant clarity. Filtration is needed for various reason, they
are:
(1)To remove residual yeast and other turbidity causing
material and microorganism in order to achieve colloidal and
microbiological stability.
(2)Lager period and addition of flocculation aids both greatly
reduced yeast and haze loadings
Filtering the beer stabilizes the flavor, and gives beer its
polished shine and brilliance.
Filtration

31. The next process which takes place after filtration is
carbonation. CO2 not only contributes to perceived fullness or
body and enhances foaming potentials, it also acts as a flavor
enhances and plays an important role in extending the self life
of product. The level of carbon dioxide in beer after normal,
non-pressurised fermentation is 1.2 to 1.7 volumes of CO2
volume of beer. Common practice is to raise this to 2.5 to 2.8 v/v
prior to packaging. The final level is lower than in soft drinks,
which are about 3.5 v/v, but sufficient to properly enhance the
flavor and drink ability of beer.
Beer Carbonation

32. In the BBT the beer is than stored thus beer is called draught
because this is unpasteurized beer. The temp profile is 0 to 2 C.
In the BBT CO2 is applied here for the following importance:
To prevent contamination
To protect from oxidation
Increase the shelf life of beer
CO2 enhances its taste and refreshment value
Beer bottling tanks:

33. Health Benefits of Beer:-
•Up to two beers a day for men (women should only have one),
will help to reduce your risk of having strokes, and heart disease.
Light drinking appears to reduce the risk by as much as 20%
according to research in United States.
•Beer can help to increase the level of HDL (beneficial
cholesterol) in the body and decrease the likelihood of blood
clots.
•A couple of beers can raise the level of anti-oxidants in the blood
stream. This enables the cells to carry more oxygen around the
body. More oxygen helps better muscle activity among other
things.
•Beer contains vitamin B6 which is needed to make
hemoglobin,the red coloring in blood. This carries oxygen around
the body. It also helps maintain correct blood sugar levels.
•It is fat free, aids restful sleep and promotes relaxation.

34. •Beer contain vitamins B and B2 (as well as B6) and essential
minerals like calcium, potassium, and phosphorus.
•Dark beer is better for you than light.It contains more flavanoids
which are natural oxidants that help to protect the body from
disease.
•For post menopausal women, beer may be a beneficial addition to
the diet. Some hop flavanoids have properties like estrogen and
research suggests that this property may make it possible to
produce a natural form of HRT to replace the current one.
•Beer can help to reduce blood pressure and levels of insulin in the
blood.
•Beer drinking can also reduce the incidence of kidney stones. This
may be due to the water, the hops, or the alcohol, but, whatever the
reason, it seems to help.

35. Thank You