industrial intern

1. CHAUDHARY GROUP INDUSTRIAL PARK (CGIP)
BREWERY NEPAL
INDUSTRIAL TRAINING AT CG BREWERY NEPAL
Presented By:
Krishna Kumar Gupta
Student of Kathmandu University
Project Supervisor:
Er. Bibek Gupta
Senior Mechanical Engineering at CGBN
TRAINING PRESENTATION
ON

2. PRESENTATION OUTLINE
1. Introduction
2. Beer production and operation
flow chart
3. Priorities for brewing great
Beer
4. Production process and
operation
5. Fermentation and maturation
6. Bottling hall
7. Methodology
9. Maintenance
10. Intern learnings and
involvement outcone
11. Recommendations
12. Conclusion
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3. INTRODUCTION 3
 Beer: A carbonated, fermented alcoholic beverage made from cereal grain, flavored with
hops, and typically contains less than 10% alcohol content.
 CGBN holds 15 percent of total beer market in Nepal .
 Different Recipe produces different kinds of beer.
 Raw material:
Raw material Qualities imparted Availability(Brought from) Price(NRs)
Grains(Barley,
Wheat, Rice, Corn,
Oats, Rye, etc.)
Flavor and Aroma
Color
Fermentable Material
Europe and India 80-270/kg
Hops Bitter and Aromatic Germany 10500/kg
Yeast Alcohol content USA and Europe NA
Water taste Nepal 10/l

4. BEER PRODUCTION AND OPERATION FLOW
CHART 4

5. Priorities for Brewing Great Beer
 Sanitation-
 Fermentation temperature control
 Proper yeast management
 The boil
 The Recipe
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6. PRODUCTION PROCESS AND OPERATION
Production House Utilities Working principle Operation
Store House Silos(100,200, and 400
metric ton)
Cylindrical tank Storage vessel for Malt and
Rice
Bucket Elevator Closed loop chain
drive carrying bucket.
Rice transportation to silo
Pneumatic Conveyor Blowing stream of gas
using blower.
Malt transportation to silo
Screw Conveyor Helicoid flight mounted
on pipe
Grain transport to mill house
Mill House Grain Screener Vibratory motion
Screen
Grain cleaning
Destoner Vibratory motion
Screen
Stone separation from Grain
Roller Mill Rollers driven by
motor(single or double
pass)
Grain milling
Grist Bin Conical vessel fitted
with rotary valve
Storage for milled Grain
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7. 7
Production House Utilities Working Principle Operation
Brew House
Rice Kettle, Mash
Kettle, Wort Kettle
Internal jacketed
cylindrical vessel for
steam passage with
agitator.
Grains cooking/ Wort
boiling
Lautertun cylindrical vessel with
rake arm.
Separation of soluble
extract from wort
Whirlpool Separator cylindrical vessel with a
flat base and 2%
inclination towards the
outlet
Separation of trub from
wort
PHE Series of plates
assembled together
Heat exchange
between wort and RO
chilled water
pppu Uses steam pressure for
condensate pumping
Pumps condensate for
reuse
Unitank A sealed closed vessel
with jacket and RTDs
and pressure gauge.
Gives temporary
environment space for
fermentation
BBT A closed cylindrical
vessel with jacket
Storage for bright beer
and their carbonation

8. FERMENTATION AND MATURATION
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C6H12O6 + yeast → 2 C2H5OH + 2 CO2

9. BOTTLING HALL
 Beer filling and packing process of bottled beer. 9

10. BOTTLE WASHING MACHINE
Basic Principle of Bottle Washing is:
1. The bottle must be cleaned
mechanically.
2. All beer spoilage microorganisms must
be removed and killed.
Zones in washine machine:
1. Pre- heating zone-
2. Caustic Soak-I
3. Caustic Soak-II
4. Hydro Zone
5. Spray Zone
6. Final Rinse
EBI MACHINE
EBI is provided with various cameras, reflective
and proximity sensors.
 Bottle containing foreign bodies – Resend for
washing
 Bottles with defects in the mouth or lower
region – Reject
 Bottles containing residual caustic from the
washer – Resend for washing
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Fig:- EBI machine

11. FILLER (KHS BOTTLE FILLING
MACHINE)
 Fills the beer in the bottle and cap it.
Filling Procedure
 Pressed against the filling element
 Evacuated & counter pressurized once or twice
 Filled
 The filling height in them is corrected
 the pressure is released and sniffing
 the bottles are lowered again & moved away
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Fig:- Filler Bowl with filling valve assembly

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Full bottle inspector (FBI)
 It inspects the under fill, overfill, neck label and body label.
Pasteurization (KHS Pasteurizer Machine)
 The filled Bottles are heated in stage, subjected to the pasteurization temperature for a fixed time,
and then cooled again.
 Heating & cooling of the bottles is performed using various water circulation paths in order to utilize
recovered heat.
 It ensures the destruction of all microorganisms which are detrimental to the beer
 There are 8 chambers within it (i.e. 3 heating zones, 1 superheated zone, 1 pasteurization zone and
3 cooling zones)
 These zones are controlled by their own PID controller

13. Labeler (KHS Labeling Machine)
 Labeling on neck and body of the beer bottle
 Components
 Label supply
 Adhesive roller
 Adhesive or removal segment
 Gripper cylinder
 Bottle Label
Packaging (KHS Innopack Packing Machine)
 A continuous working of Crank Gear link mechanism type drive controlled by frequency drive main
motor
 It has hydraulic arm having 36 suction nozzles that uses pneumatic valve system
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14. MAINTENANCE
 Any correction or prevention of loss due of utility fault or breakdown.
 Types of Maintenance:
 Pre-planned maintenance
 Planned maintenance
 Shutdown maintenance
 Breakdown maintenance
 Emergency maintenance
1. Some Maintenance activities carried out in CGBN are:
 Checking oil level of the all pumps, gear boxes and operating machines within plant and filling if it is
less than required.
 Changing compressor oil at a certain interval as a scheduled maintenance.
 Checking leakages in pipes, pumps and rectifying.
 Greasing in the required machine in required amount.
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15.  Diagnosing the motor, VFD, sensors, actuators, control valves, steam traps, RTDs, pressure gauge
and electrical components that are showing incorrect value.
 Overhauling the complex machine structures like heat exchanger, compressor, Air dryer unit, KHS
machine, or any mechanical or electrical equipment to correct the fault found during work as a
preventive maintenance.
 Diagnosing and rectifying control systems(software/ Hardware) within the plant in case of shutdown
maintenance.
 Diagnosing the mixture of water and propylene glycol (a cooling agent) and correcting the proportion
through glycol/water feeding as per requirement in terms of corrective maintenance.
 Ammonia charging in refrigeration plant as per requirement on the basis of level of ammonia
inspection in Receiver.
 Cleaning of the pumps, motors and all the other controlling equipment’s.
 Rinsing and cleaning all the filling and packing House machines of plant by complete evacuation of
product at the day of shutdown as shutdown maintenance.
 Replacing drive drum, slate chain, guide, motor gearbox assembly of Conveyor system as
breakdown maintenance.
 Changing the faulty parts of forklift whenever it is necessary and overhauling it on annual basis.
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16. Maintenance of Glycol Pump (Centrifugal pump)
 The conditions of failure includes mainly of two types i.e. Head loss and component failure.
 Failure: Leakage, Loss of flushing, vibration, High level Noise
 Failure cause: Seal damage, Bearing failure, Shaft damage, Impeller damage
 Corection measure: Replacement of damaged part/ corrective machining or welding of damaged part
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Fig: Centrifugal Pump and its Seal components

17. Maintenance of Forklift
Failures Detected:
 Lift cylinder Seal failure(O Ring)
 Corrected using replacing the seals of lift cylinder (o-ring)
 Transmission oil Charging pump Seal and backward direction loss failure
This seal failure caused the leakage of transmission oil out of vehicle causing oil leakage
 Corrected by replacing the seal at the faulty position and cleaning the hydraulic direction control system
deeply and changing transmission fluid.
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Fig: Transmission oil gear pump assembly with oil seal
Fig: Seal Kit for Forklift Lift cylinder

18.  Total productive maintenance
 It is a company-wide equipment maintenance system involving all employeesand the building custodians.
It includes:
 Maintenance prevention(PM)
 Maintainability improvement(MI)
 Good-old fashioned PM, a maintenance plan for equipment entire life span.
TPM-combines concepts of:
 Continual Improvement,
 Total quality,
 Employee involvement.
 Use of computerized technology-enabling operators to calibrate selected instrumentation.
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19. INTERN LEARNINGS AND INVOLVEMENT OUTCONE
Objective of Intern
 To observe and understand detail process with deep knowledge regarding operating parameters and
mechanisms of Brewery plant.
 To observe and understand different kinds of utilities and Equipment used in plant.
 To observe and involve in all kinds of maintenance carried out in the plant during intern period.
 To complete different kind of assignments assigned by supervisor interms of calculation, diagram,
modeling or any other.
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20. Gained Skills
Maintenance Skill
 Replacement
 Daily -Inspection
 Lubrication
 Repair
 Machine maintenance
Interpersonal Skill
 Problem solving
 Motivation
 Negotiation and conflict control-to reach an
agreement
 Politeness
 Being openness
 Self –confidence
 Honesty
 Personal right and obligation
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21. RECOMMENDATIONS
 Requirement for Safety engineer
 The alternative scope of Brewery waste
The spent grains can be burned as an alternative fuel to fire a steam boiler .
 Use of a new engineering way for the Maintenance planning
I. Condition monitoring.
Example: A pump vibration, temperature monitoring concluding need for maintenance.
II. FMEA(Failure mode and effect analysis)
It considers all single component failures in turn and identifies the range of their effects on the system.
III. FTA(Fault tree analysis)
It identifies combinations of conditions and component failures which will lead to a single defined
adverse effect.
IV. KAIZEN Sheet
It represents the simple fault report including photo of before and after diagnosis .
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22. 22
Fig: FMEA of Bearing of centrifugal pump Fig: FTA of Motor overheating

23. 23
Fig: KAIZEN sheet of motor gear box assembly design modification in conveyor system

24.  Avoiding mixing of the low and high concentration waste water(raw water from filler and caustic water
from washing) for treatment inorder to reduce ETP load.
 The visual symbols to be represented at the place of components with the best possible data range.
 Installation of sedimentation tank that can be used for the caustic recovery of a bottle washer.
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Fig: Visual management application in industries

25. CONCLUSION
 A great practical experience with ways of work and machineries faults and diagnosis.
 A perfect location for the scope of my theories i.e. fluid mechanics, heat and mass transfer, materials,
process design, process control, power, machine design, statics, engineering economics, pollution
control, optimization, etc
 A skill development in terms of maintenance, management and interpersonal for being prepared to take
challenges ahead.
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26. THANK YOU !!
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