1. PRODUCTION OF BEER BY THE PROCESS OF
FERMENTATION IN BIOREACTOR
CONDUCTED AT
MOHAN MEAKIN LIMITED, MOHAN NAGAR
GHAZIABAD (U.P.)
A MINOR PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF BACHELOR OF TECHNOLOGY IN BIOTECHNOLOGY
PROJECT GUIDE:
Mr. Harish Datta
Production Manager / Coordinator
SUBMITTED BY:
ABHISHEK PATHAK
DEPARTMENT OF BIOTECHNOLOGY
SIR CHHOTU RAM INSTITUTE OF ENGINEERING &
TECHNOLOGY
C.C.S UNIVERSITY (CAMPUS) MEERUT.
2009
1

2. ACKNOWLEDGMENT
Though only my name appears on the cover of this dissertation, many people have
contributed to its production. I owe my gratitude to all those people who have
made this dissertation possible and because of whom my graduate experience has
been one that I will cherish forever.
I would especially like to thank Mr. Harish Datta Production Manager/
Coordinator, for his generous time and commitment throughout my practical
training.
I am extremely grateful for the assistance, generosity, and advice I received from
Dr. H.S Singh Director S.C.R.I.E.T and Dr. Pratibha Malik, (Coordinator)
Department of Bio Technology.
I extend many thanks to my colleagues and friends for being so organized and
helpful. Finally, I'd like to thank my family a constant source of support, for their
encouragement and enthusiasm.
At last I would like to thanks almighty who kept his blessing through out on me to
finish this entire project.
Abhishek Pathak
2

3. CONTENTS
 Introduction of Industry and Practical Training
 Beer and its History
 Beer Brewing Process
 Principle
 Sugar Catabolism In Yeast
 Methodology
 Step 1 Malting Barley
 Step 2 Mashing
 Step 3 Wort Separation
 Step 4 Wort boiling
 Step 5 Wort cooling and aeration
 Step 6 Fermentation
 Step 7 Filtration
 Step 8 Beer carbonation
 Step 9 Bottling
 Result and Discussion
 List of Figures
 Bibliography
3

4. INTRODUCTION ABOUT THE INDUSTRY & PRACTICAL
TRAINING
A saga that began over a century and a half ago, continues on its path of service to the
world with dedication, courage and an unflinching commitment to quality. Over the years
the Company has embraced modernity and adapted to changing times. Yet, its basic
values remain the same--Integrity, Craftsmanship, and Tradition. From old tradition
sprang Mohan Meakin where the sanctity of ancient culture, technological development
and craving for quality are artfully blended into the products.
The origin of Mohan Meakin traces back to Edward Dyer from United Kingdom who set
up the first-ever brewery and made indigenous beer available to the Indians as well as
Britons. He set up more Breweries at Solan, Simla, Murree, Rawalpindi and Mandalay.
Another entrepreneur H G Meakin came to India from Britain and bought the old Simla
and Solan Breweries from Edward Dyer and added more at Ranikhet, Dalhousie,
Chakrata, Darjeeling and Kirkee. A distillery was then set up at Kasauli instead. Another
distillery was set up in the historic city of Lucknow. In addition to meet the increased
demand of Mohan Meakin Products an Industcrial Complex on 150 acres of land was set
up in the year 1960 near Dehli in Ghaziabad Distt. of Uttar Paresh. Mohan Meakin have
established fully equipped labratories at its various manufacturing centres manned by
highly qualified and experienced technical persons to ensure the maintenance of high
standard quality products.During the training period I gone through the various
techniques & procedures which are being used in the production of Beer by fermentation
process by using s. cerevisiae as the microorganism.The main emphasis is focused on the
temperature control, pH maintenance and alcohol concentration (approx. 4.5% in 650ml
of Beer). Which is necessary for maintaining the quality of Beer.
In 1949 Mr. N. N. Mohan took over the management of the Company. Under the
dynamic stewardship of Mr. N. N. Mohan the Company’s assets and profits registered a
manifold increase. To mark the contribution of Mohans the Company’s name was
changed from Dyer Meakin Breweries Limited to Mohan Meakin Breweries Limited in
1967. On passing away of Mr. N. N. Mohan in 1969, his eldest son Col. V.R. Mohan
took over as the Managing Director of the company. He introduced a number of new
products that are brand leader even today. In the Seventies the manufacturing activities
of the company were diversified into other fields under the leadership of Brig. Kapil
Mohan, VSM, who became the Managing Director of the company in 1973.
Subsequently the word Brewery was dropped in 1982 to remove the impression that the
Company is engaged only in beer making.
4

5. PRODUCTS OF MOHAN MEAKIN LTD.
• WHISKY PRODUCTS
SOLAN NO. 1 :
Solan No.1 distilled out of Malt made at Kasauli, Simla Hills, matured in oakwood casks and
diluted to desired strength with Himalayan Water has come to be known as Scotch of India. The
Royal Institute of Public Health & Hygiene, London has certified it as a product of high quality
conforming to international standards.
COLONEL’S SPECIAL :
The heart of this blend is matured in oakwood casks longer than any other Indian Whisky.
• RUM PRODUCTS
OLD MONK RUM
The Country’s most popular rum is Old Monk Rum. A superlative drink whose popularity has
spread in other countries of the world. This legendary drink has been awarded gold medals at
Monde World Selection since 1982 for its quality.
OLD MONK GOLD RESERVE RUM
Old Monk Gold Reserve is an epitome of unflinching dedication to quality. Blended with highly
matured spirits, most of them 12 years old, Old Monk Gold Reserve is becoming popular
amongst younger generation.
• BRANDY PRODUCTS
The graceful way to round off a good meal. The ideal warm-up when chilly winds blow. Mohan
Meakin’s brandies come brimful with delightful promise.
GOLDEN EAGLE DOCTOR’S BRANDY
Wonderfully warming for that rosy glow of contentment.
DOCTOR RESERVE NO.1 BRANDY
It has carved a lace for itself in bars across the country.
TRIPLE CROWN
Smooth and subtle Gently poured when the perfect evening is drawing to a close.
5

6. • GIN PRODUCTS
Smooth and excellent by itself, superb in cocktails. As a long drink Mohan Meakin’s Gins are
well known. Their popularity is every increasing.
BIG BEN DELUXE LONDON DRY GIN
Beautifully dry, flavoured just right with juniper berries. Found frequently in tall frosted
glasses.
• VODKA PRODUCTS
The epicurean’s delight.For the perfect Bloody Mary. A Vodka even Russians will welcome.
KAPALANSKY
For the pleasures of a superbly balanced drink.The connoisseur’s delight.
• BEER PRODUCTS
The rich amber liquid that is so indispensable in India’s long, hot, thirsty summer. Mohan
Meakin has been quenching a nation’s thirst for over a century & quarter now.
GOLDEN EAGLE
The discerning drinker’s beer for millions. Sunday afternoons are incomplete without it. Golden
Eagle, the drinker’s preference has come to be known as the king of beers in India. South after
in International Markets for its taste and quality this beer has won gold Medals at Monde World
Section since 1982.
SOLAN
Made with the clear spring water of the Solan Peaks. Bubbling freshness only this special water
can bring.
GYMKHANA
An old favorites mentioned in the book, The World’s Beers.
ASIA 72
The people’s choice brewed to perfection.
LION
For the lion-hearted also mentioned in the book, The World’s Beers.
OLD MONK
It can wash away the righours of the longest hottest summer with a distinctive taste.
BLACK KNIGHT SUPER STRONG
The thirst quencher that packs quite a punch. The regular drinker’s beer
6

7. HISTORY OF BEER
ANTIQUITY
Beer has been brewed since time immemorial. It is thought that it was first made in
Palestine around ten thousand years ago, in 8000 BC, by macerating barley bread
in water.
The Sumerians developed no fewer than ten varieties of beer, and the Babylonians
added at least 34 more. Later on, the Egyptians developed what can be called
government breweries, making brewing a state monopoly. These "barley wines"
were used as offerings to the gods. Pharaoh Ramses II, who is referred to as the
"brewing Pharaoh", imposed very strict rules on the making of beer.
Beer made its way to Europe around 5000 - 4800 BC along two routes: the
Danubian route (Eastern Europe) and the Mediterranean route (south of France).
Contrary to what is generally believed, beer was brewed and consumed very early
in Greece and Rome until it was to some extent replaced by wine.
However , while the Romans were more fond of wine, this did not prevent them
from appreciating beer, in particular in the northern regions, where conditions
were better for barley fields than for vineyards. For example, the remains of a
Gallo-Roman villa were found to contain a brewery dating from the 3rd or 4th
century. Among Belgium's ancestors, the Gauls, the brewing of barley beer was a
cottage industry; it was brewed within the family by the women. It were the Gauls
who came up with the idea of replacing recipients made of pottery by wooden
barrels, which, by the way, they invented. They called malt "brace", a word that
has come down to us in the French terms brassin (beer mix), brasseur (brewer),
etc.
After the fall of the Roman Empire, the church took control of the land. The
monks took an interest in this beverage, and eventually it appears that there were
breweries in every abbey in Christendom. And brewing also went on in inns,
castles and homesteads.
7

8. THE MIDDLE AGES
In spite of barbaric invasions, brewing never quite disappeared from our regions.
As early as the 7th and 8th centuries, the first monastic communities consumed
beer, which had by then become a popular beverage. At that time, monks lived just
like everyone else, but of course they were isolated from society. In the region of
the Meuse, the oldest monastery appears to be the Grand-Axe, which is first
mentioned in documents in the year 805.
As we have just seen, the first Belgian abbeys already each had their own brewery.
This was the case for Villers-la-Ville, which has had a community of monks since
1146. The immense abbey they built was inspired by the architecture of the
Cîteaux (the order of the Cistercians). The brewery, in the Romanesque style, was
built in the first half of the 13th century. However, the abbey destroyed waste in
the religious wars of the 16th century and the French Revolution. Also around this
time, the first guilds were set up. The purpose of guilds was to maintain the quality
of products and to ensure respect for traditions.
Breweries then proliferated in the 14th and 15th centuries, as beer became a
popular beverage. Around this time, it was commonly believed that it was better to
drink beer than water, because epidemics like cholera and the plague could be
transmitted by water, while the cause of these diseases was eliminated in the
brewing process.
The Renaissance (around the 16th century) was the golden age of brewing. Their
corporations were very rich. In Brussels, brewers bought the "Arbre d'or", a fine
building that is now the "Maison des Brasseurs" (House of Brewers) on the
Grand'Place. They restored this dwelling and embellished it in the 17th century.
Although it was completely destroyed in the bombarding of Brussels by the
Marshal de Villeroy, it was quickly rebuilt, at great expense, in the 18th century,
when it was adorned with the facade that is still admired to this day by countless
tourists. It was sold off by the French revolutionaries in the 18th century, and then
in 1954 after some radical conversion work it once again became the "Maison des
Brasseurs".
From the 17th century until the Second World War
In the 17th century, many different types of beer began to appear up and down the
country. Each variety was characterized by the specific ingredients used and the
quality of the water. Small breweries flourished at this time, and as in those days
8

9. there were no sophisticated means of preserving the product, each village had its
own brewery.
At the end of the 18th century, a historical event took place that was anything but
beneficial to the tradition of brewing: the French Revolution. In addition to the fact
that it put an end to brewers' guilds, the Revolution led to
the destruction of many monasteries and abbeys, effectively wiping out much of
the brewing industry. However, with the arrival of Napoleon on the scene brewing
took off again thanks to a general economic recovery, although from that time on
brewing would no longer be reserved for monks. It became a fully-fledged
industry in its own right.
At the end of the 19th century, the scientific progress achieved by Louis Pasteur
(1822-1895) in the study of yeast and the preservation of food by "pasteurization"
gave breweries new impetus for some time. And these discoveries not only made it
possible to preserve beer more efficiently, but they also improved the quality of
beer, as the various types of yeast produce different flavors.
By the year 1900, there were 3,223 registered breweries in Belgium, including
Wielemans' Brewery in Forest (Brussels), which was considered to be the biggest
and most modern in Europe. It was also in Brussels (in the brewery called the
Grande Brasserie de Koekelberg, to be precise) that the first bottom-fermenting
beer (Pills) was brewed in 1886.
After the First World War, there was a considerable drop in the number of
breweries. In fact, by 1920 there were only 2,013. The reason was that there was a
dearth of the raw materials and manpower needed for brewing, and the few
breweries that resumed production had to be mechanized. In the 1930s, the
economic crisis made the situation even worse, and the Second World War caused
a further reduction in the number of breweries. As a result, in 1946 Belgium had
only 755.
9

10. TYPES OF BEER
Beer can be divided into, depending on the fermentation method.
Bottom-fermenting beer is the most recent type. The process dates from 1840
and produces a specific type of beer, Pils or lager. This type accounts for 90% of
worldwide beer production. Pils is a light, clear, golden beer. It has a fresh, bitter
and refined hoppy flavour.
Top-fermenting beer is a much older and more traditional variety. This process is
involved in the production of many different types of beer, in particular Amber or
"Special Belgian" beer. Originally, this type of beer had the same density and
alcohol content as Pils. The amber colour is obtained by using coloured or
caramelised malt. The alcohol content is now slightly higher, and this beer is
considered to be typical "sampling" beer.
White beer is non-filtered and cloudy in appearance. In addition to barley malt,
the ingredients include unmalted wheat and sometimes oats. Also, during the
heating process, coriander and orange peel are added to give it its characteristic
refreshing taste.
The Trappist Order is abbey beers. They are marketed under protected copyright
names that belong to the Cistercian Order. This legal protection entails certain
rules. This type of beer must be brewed in a Cistercian abbey under the
supervision of monks belonging to the Trappist Order. There are various types:
blonde, double, dark and triple. Each of the three abbeys has its own recipes.
The other abbey beers are marketed under licenses which are granted to lay
brewers, whose trademark refers to an abbey that may exist or may have
disappeared. There are various types of abbey beer: Lagers, which are
characterized by a mild, slightly malty aroma, a neutral or slightly sweet taste and
an often very bitter after-taste. The double or dark beers, so called because the
brewer uses more malt. Nowadays this type of beer is darker and has a sweetish,
sometimes sugary taste and a bitter after-taste). Finally, triple beers, in which the
brewer uses even more malt and which undergo triple fermentation, the final stage
of fermentation being in the bottle.
Strong blonde beers are often clear. They are generally served with a large head.
They undergo triple fermentation and contain aromatic malts.
10

11. Seasonal beers are typically brewed in Wallonia, especially in the districts of
Hainaut and Walloon Brabant, and are sparkling and fruity summer beers. They
involve the use of raw hopping and sometimes secondary fermentation in the
bottle.
The regional and special beers are fine examples of the creativity and know-how
of our local brewers. They are all very different. Each variety has its own
characteristic manufacturing process and ingredients (spelt, honey, Liège syrup,
mustard, etc.).
Scotch is a beer of Anglo-Saxon origin which, over the years, has become a
specialty of the Walloon Brabant and Hainaut district. It is characterised by a very
malty and slightly smoky taste. Its sugary taste is due to the addition of candy
sugar.
Spontaneous fermentation, a process that is characteristic of the Brussels region, is
used to produce Lambic. Lambic is a flat beer with no head. It is produced
through spontaneous fermentation of the yeasts found specifically in the valley of
the river Senne. It matures in barrels made of different types of wood and has a
wide range of tastes.
Gueuze is obtained by the fermentation caused by mixing "old" Lambic (that has
not completely fermented) and "young" Lambic. This new fermentation produces a
sparkling, sharp beer, the "champagne of beers".
Fruity beers are basically made by mixing different fruits (cherries for Kriek) and
Lambic. Traditional Kriek is a mixture of 50 kg of cherries and around 250 litres
of Lambic. This mixture matures for 6 months in the barrel and produces a beer
with a fruity but not sugary taste. The industrial process involves fruit juice and
extract. he result is a sweet, fruity beer.
11

12. Fig (1):- Out line diagram for production of beer
12

13. PRINCIPLE
YEAST METABOLISM
Metabolism refers to the biochemical assimilation (in anabolic pathways) and
dissimilation (in catabolic pathways) of nutrient by a cell. Like in other organisms,
in yeast these processes are mediated by enzymatic reactions and regulation of the
underlying pathways have been studied in great detail in yeast. Anabolic pathways
include reductive processes leading to the production of new cellular material,
while catabolic pathways are oxidative processes, which remove electrons from
substrate or intermediate that are used to generate energy. Preferably, these
processes use NADP or NAD, respectively, as co-factors.
Although all yeast are microorganisms that drive their chemical energy in the form
of ATP, from the breakdown of organic compounds, there is metallic in how these
organism generate and consume from these substrates. Knowledge of the
underlying regularity mechanism is not only valuable in the understanding of
general principle of regulation but also of great importance in biotechnology, if
new metabolic capabilities of particular yeast have to be exploited.
It is now well established that the most yeast employ sugars as their main carbon
source, but there are particular yeast which can utilize non-conventional carbon
sources. With regard to nitrogen metabolism, most yeast is capable of assimilating
simple nitrogenous sources to biosynthesize amino acids and proteins. Aspects of
phosphorus and sulphur metabolism as well as aspects of metabolism of other
inorganic compounds have been studied in some detail, predominantly in the yeast,
sacchromyces cerevisiae.
13

14. NUTRIENT FOR GROWTH OF YEAST CELLS (S.
CEREVISIAE)
• Substrate for growth of s.cerevisiae
• Saccharose (>Glucose + Fructose) Invertase
• Maltose (> Glucose)
• Mellblose (> Glucose + Galactose)
• Glucose (>Glycol sis)
• Ethanol (>Acetaldehyde > Acetyl- CoA > Oxaloacetate > Gluconeogenesis)
ADH2
• Lactate (> Pyruavte > Gluconeogenesis)
• Glycerol (> Glycerol -3- phosphate > DAP > Gluconeogenesis)
• Amino acids
• Glutamine
14

15. SUGAR CATABOLISM IN YEAST
Principle pathways:
The major source for energy production in the yeast, saccharomyces cerevisiae, is
glucose and glycol sis is the general pathway for conversion of glucose to
pyruvate, whereby production of energy in the form of ATP is coupled to the
generation of intermediate and reducing power in form of NADH for biosynthetic
pathways.
Two major modes of the use of pyruvate in further energy production can be
distinguished: respiration and fermentation. In the presence of oxygen and absence
of respiration pyruvates enters the mitochondrial matrix where it is oxidative
decarboxylated to Acetyl CoA by the pyruvate dehydrogenase multi enzyme
complex. This reaction links gylcolysis to the citric acid cycle, in which the Acetyl
CoA is completely oxidized to give two molecules of co2 and reductive equivalents
in the form of NADH and FADH2, however, the citric acid cycle is an amphibolic
pathway, since it combines both catabolic ad anabolic functions. The latter results,
for example, from the production of intermediate for the synthesis of amino acids
and nucleotides.
Replenishment of compound necessary to drive the citric acid cycle, such as
oxaloacetate and α-ketoglutarate, are:
(1) The fixation of co2 to pyruvate by the action of the enzymes pyruvate
carboxylase (ATP dependent) and phosphoenolpyruvate carboxykinase,
(2) The glyoxalate cycle (a shortcut across the citric acid cycle ), which is
important when, yeast are grown on two – carbon sources, such as acetate or
ethanol
15

16. Microorganisms
Brewing utilizes strains of saccahromyces carlsbergensis, bottom yeast, and
saccharomyces cervisiae, both bottom and top yeast strains. Top yeast to the
surface during the fermentation while bottom yeast settles to the bottom. Top yeast
are used for the production of ale distillers. Bakers and wine yeast also are top
yeast. However, beer fermentation employs bottom yeasts.
Yeast strains are specially selected for their fermenting ability to flocculate at the
proper time near the end fermentation. Brewery itself can select and propagate
these strains as well as produce the inoculums. Brewing is different from much
other industrial fermentation, in that cell for pitching are often those recovered
from a previous fermentation. Fresh inoculum is not necessarily prepared for each
fermentation run and in fact, fresh yeast inoculum is required only when
contamination presents a real problem or when the vigor, of the yeast has begun to
decline. Before being employed as inoculums, the yeast cells from a previous
fermentation are washed (with phosphoric acid, tartaric acid or ammonium per
sulphate) by setting, process that reduces the pH value to about 2.5 and removes
considerable bacterial contamination.
Thus, each pound of yeast added to the fermentation at inoculation yields
approximately 3 to 4 pounds liquid yeast at harvest, and the excess yeast, which is
not required for further inoculums, becomes a b product of the fermentation.
16

17. METHODOLOGY
STEP – 1
MALTING BARLEY
Barley selected for use in the malting industry must meet special quality
specification as mentioned below. Accepted malting barley varieties have to
modify evenly and produce finished malt whose properties lie within the brewer’s
specifications. The malt quality of given barley variety is determined by its genetic
background and the physical conditions during the growth, harvest and storage.
Malting barley has to be tested in micro malting trials, pilot malting and industrial
malting trials; and brewing trials also in pilot and production scale.
The physical conditions of the barley must meet specification concerning:
Factor Range
Germination % Minimum 97% after 3 days
Germination index Minimum 6, 0
Water content 12, 0%; maximum 13, 0%
Protein content > 9, 0% and <11, 5%
Grading Minimum 90% > 2, 5mm
β- glucan content Maximum 4%
Micro-organism Below a set level
Pesticide residues According to national law
Ochratoxin According to national law
Aflatoxin According to national law
Variety purity Minimum 99%
17

18. STORAGE CONDITIONS
Vitality
During prolonged storage, barley grain will slowly loose its vitality, causing a
slower germination and even grain death, and will therefore be of o less value for
the maltster.
The rate at which barley loses its vitality is dependent on the storage conditions.
When stored at very low temperatures and low moisture content, barley may keep
its vitality for centuries, but with increasing temperature and moisture, the
deterioration processes faster and barley can loose its germination ability in a very
short time. Malting barley stored for1 to 1.5 years, should be kept at a moisture
content of below 12% and at temperature below 120 C.
More information about the influence of temperature and moisture on vitality can
be seen in the table below.
Fungal Contamination During storage
Fungi may attack barley with moisture content of above 14% during storage
especially by species aspergillus and penicillium. Most fungi produce secondary
metabolites, some of which cause gushing in beer, where the beer spontaneously
gushes from a bottle on opening. It is therefore, important that malting barley is
stored under conditions, which prevent fungal growth.
18

19. Maximal length of storage for maintaining malting barley quality
under different storage conditions
Temperatur Seed moisture content
e
10% 12% 14% 16% 18%
o
0C 16 years 6 years 2 years 1 years 190 days
2 oC 14 years 5 years 1.8 years 315 days 160 days
4 oC 11 years 4 years 1.5 years 260 days 130 days
6 oC 9 years 3 years 1.3 years 210 days 105 days
8 oC 7.5 years 2.5 years 1 years 170 days 89 days
10 oC 6 years 2 years 300 days 140 days 70 days
12oC 5 years 1.6 years 240 days 110 days 55 days
14 oC 3.8 years 1.3 years 190 days 85 years 45 years
16 oC 3 years 1 years 150 days 50 Days 25 Days
18 oC 2.3Years 290 Days 115 Days 40 Days 25 Days
20 oC 1.8Years 220 Days 90 Days 30 Days 20 Days
22 oC 1.4Years 170 Days 70 Days 25 Days 15 Days
24 oC 1Years 130 Days 55 Days 18 Days 12 Days
26 oC 290 100 Days 40 Days 13 Days 9 Days
Days
28 oC 210 70 Days 30 Days 10 Days 7 Days
Days
30 oC 160Days 55 Days 22 Days 10 Days 5 Days
At the Carlsberg research laboratory loss of seed vigour has been studied
intensively ( EBC 1989 and 1991 .)Barely seeds lose both their ability to germinate
fast as a consequently of storage. The rate at which seed vigour is lost is dependent
on the storage condition . It is our experience that malting barley can be stored
safely for the maximal lengths of time indicate in the table.
19

20. Malting
Barley , which is the fundamental raw material of beer , does not give , just as it , a
fermentable extract by yeast.
By mashing it in hot water we could get a bad use of it. We have a let it go through
a beginning of germination. Enzymes, which attack the grain and dissolved it in
water, are produced during the mashing.
This beginning of germination is called malting. This preliminary step of the
production of an constitutes an industries on its own: the malt house . The
brewere” Grain d’orge ” buys directly the malt in a malt – house .
Malting consist first of a soaking in water during about three days. Then it is
spread inlayer to let it germinate during eight days and finally we stop germination
by the desiccation on a kiln or killing. After this operation, the color of the malt
varies between yellow and brown going through every golden hue. According to
his will of making of lager or brown beer, the brewer chooses one or the other
malt.
Malting Process
In the malt house, barley grain germinate is initiated by the uptake of water in a
steeping vessel (A). The grain imbibes water during controlled cycles of water
spraying or water immersion followed by aeration, until the water content of he
grain reaches 42 to 48 % .water enter enters the grain via the embryo and after
approximatelyt24 hours, hours, the first visible sign of germination is the
appearance of the root, as a white chit. The grain are then transferred to malting
beds where germination is allowed to proceed over a period of around five days
(b). The speed of germination is controlled by temperature and aeration of the malt
bed, while moisture content is maintained by spraying. Further embryo growth,
with the appearance of the root lets and acrospires, can lead to root entangling. The
grain bed is regularly
turned with a rotating screw to prevent grain malting together. Green malt,
produced after 5 days of germination, in kiln dried and partly cooked in a forced
flow of hot air (C). Hydrolysis produced during malting are partly inactivated
during this process. Malt color, enhanced by kilning at higher temperature, may be
desirable for production of darker beer, but it leads to further heat inactivation of
20

21. hydrolysis. The brittle malt rootlets are separated from the malt and utilized in
animal feeds.
STEP – 2
MASHING
The goal of mashing is to obtain from the raw material (water, malt and hop) sweet
and flavored wort, which will then go through alcohol fermentation.
Mashing includes the three following operations:
Malt crushing
Mashing
Wort filtration
During the mashing, the malt that was crushed before is mixed with water. This
mixture of water, crushed malt with other various ingredients is the mash.
The mash is heated at accurate temperature during predetermined laps of time, in
order to have a complete transformation of the starch from the malt and of the
cereals used for sugar:
That is the mashing.
This transformation of starch into sugar by the enzyme was lightly initiated during
malting. It is essential because yeast can not transform directly starch into alcohol.
Starch has to be first transformed into sugar by the enzyme developed during
malting.
Once these transformations into sugar finished, the liquid is filtered to eliminate
the husk oh the malt grain. The product that is then obtained is the wort; it is a
sweet liquid, which already has the colour of beer.
The brewer can, by choosing the temperature level, act on the composition of the
wort. For maltose is fermentescible and for starch gums aren’t he can obtain beer
that is more or less rich in alcohol. The duration of mashing is more or less two
ours. Then the mash is filtered in a filter press. The insoluble materials are the
spent grains (25% of the weight of the malt). The wort is pumped into a brew
kettle heated by vapor coils.
21

22. Mashing involves heating the crushed malt and rice flakes mixture in the mash
kettle in order to convert the starches in the malt, and adjuncts if added, into
fermentable and unfermentable sugars.
Mash kettle: 150 HL
Mashing 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 favors one enzyme, which degrade cell walls and
protein are rather heat labile, it is important for their function that mashing begins
at a low temperature. Subsequent mashing at 65oC, 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)- β-glucanase and xylanase for cell
wall degradation, endo-peptidase and carboxypeptidase’s for protein degradation;
and amylase, limit dextrinase and α- glucosidase for starch degradation.
Temperature controlled mashing
Mashing extracts those materials from the malt and malt adjuncts, which can be
solublized under the particular mashing conditions being employed, also allows
the malt amylases and proteases to degrade starch and protein, respectively. A
portion of the starch must be partially degraded to dextrins and the rest totally
degraded to maltose and glucose. In the same manner, the proteins must be
partially degraded to peptones and peptides as well as totally degraded to amino
acids. The degree of enzymatic hydrolysis of these compounds is influenced
strongly by temperature and to some extent, by pH. The temperature program is
yield defined mixtures of particularly and totally degraded enzymatic products.
The temperature optima for the alpha amylase and beta amylases of malt occur
within the range of approximately 55 to 77oC. The beta amylase with a temperature
optimum at 57 to 65oC, cleaves maltose units from the ends of linear glucose
polymers but can degrade only the short side chains not including the branches.
Alpha amylase with a temperature optimum in the range of 70 to 75oC, cleaves
starch at random yielding large fragment dexrtins with or without branching units
so as to make straight chains available for beta amylase activity. Proteolytic
activity of the malt at temperature of approximately 60oC allows the formation of
the higher molecular weight peptones and peptides but at about 50oC the enzymatic
22

23. activity yields a higher proportion of amino acids and low molecular weight
peptides.
The peptones and peptides resulting from the Proteolytic activity of the malt
provider flavour, foam, and foam stabilization. The dextrins being non-
fermentable, provider low alcohol beer and certain flavor characterstics.
Chemical changes at mashing
The mashing process is conducted over a period of time at various temperature in
order to activate the enzymes responsible for the acidulation of the mash
(traditionally for lagers) and the reduction in proteins and carbohydrates. Enzymes
are biological catalyst responsible for initiating specific chemical reactions.
Although there are numerous enzyme present in the mash, each with a specific role
to play, this discussion is limited to the three principal groups and their respective
processes. These enzymes are:
 Phytases (acidifying),
 Proteolytic enzymes (protein-degrading ) and
 Carbohydrase enzymes (starch-degrading).
Starch conversion
By far the most important change brought about in mashing is the conversion of
starch molecules into fermentable sugars and unfermentable dextrins. The
principal enzymes responsible for starch conversion are alpha and beta
amylase. Alpha and beta amylase very rapidly reduces insoluble and soluble
starch by splitting starch molecules into many shorter chins (i.e., partially-
fermentable polysaccharide fractions – dextrins and maltotiose) that can be
attacked by beta amylase. Given a long enough “rest”, the alpha – amylase can
dismantle all the dextrins to maltose, glucose, and small, branched “limit
dextrins”. However, starch conversion is more effective by the faster acting
beta amylase. Beta amylase is more selective than alpha amylase since it breaks
off two sugar at a time from the starch chain. The disaccharide it produces is
maltose, the most common sugar in malt. Together, alpha and beta amylase are
capable of converting only 60 to 80 % of the available starch to fermentable
sugars.
23

24. Factor affecting mashing conditions
Temperature
Temperature influences the amount of extract produced (yield) and the
fermentability of the wort during mashing. In general, the higher the
temperature, the greater the yield but the lower the fermentability of the wort.
At lower temperature less extract is produced, but fermentability is higher.
Only at very high temperature will extract begin to drop off.
Mash times
Mash times another factor influencing yield and the fermentability of the
wort.In general, longer mash times increases the concentration of the extract,
but the rate of increase becomes slower and slower. In general, short mash
times at high mash temperature will produce more dextrinous worts, while
longer mash times at high temperature will produce more dextinous worts,
while longer mash times at higher temperature produce more fermentable
worts.
Mash pH
The optimum pH range for mashing is generally at 5.5 to 5.6 for both amylases.
The “normal” mash pH, however, depends on the type of malts employed, the
pH of the water, the method of mashing. The mash cycle should not be started
until the proper initial mash is approximated (within pH 0.2).
Water ions
The nature of the mashing water has an important influence on mash reactions.
The ions of major importance at mashing are those of calcium and carbonate,
with magnesium and sodium ions playing lesser roles. Calcium lowers the pH
of the mash mainly by its interaction with phosphates and to a lesser degree
with protein from the malt. Carbonate ions operate in the reverse direction.
24

25. STEP - 3
WORT SEPERATION
After mashing, when the starch is broken down, it is necessary to separate the
liquid extract (the wort) from the solids (spent grain particles and adjuncts).
Wort separation is important because the solids contain large amount of protein,
poorly modified starch, fatty material, silicates, and polyphenols (tannins).
Lauter tun
Figure:2
The lauter tun is equipped with a sparing system to wash the extract from the
mash. The top of the tun is usually spherical or conical and fitted with a vent
for relieving the vapor of the hot mash to the atmosphere. The bottom of the tun
25

26. may be flat or sloped, or it may be constructed with several concentric valleys
with intervening ridges. Suspended above the true bottom of the tun is a false
bottom of milled, slotted, or welded wedge wire steel plates that act as the
filtering system. Free surface area ( the area through which the wort can flow)
varies 8 to 15% foe milled bottoms and up
to 25% on welded screen bottoms. The false bottom is not a filter plate but acts
as a support for the grain bed.
Typically, false bottoms in craft brewery lauter tuns do not consist of the pie-
shaped
Sections of the machined plate, but rather of the rectangular wedge sections of
“wedge” – or “v”- wire screen. Their cost is considerable cheaper than
machined bottoms, and the screens perform reasonably well. The lauter tun, is
equipped with rakes to assist mash transfer and for leveling the bed and
facilitating filtration of the, liquid from the mash. Rakes are more important
when the mash is stirred and mixed, such as with temperature controlled
infusion or decoction mashing. Unlike single temperature infusion mashing, the
mash loses its entrained air and sinks onto the false bottom in a dense bed.
Procedure
Lauter tun with a perforated base is used to separate wort from the husk & other
matter. Once the wort stops passing out through the base & a bed of huskis
formed, water is sprayed from the top by a shower at a pressure of 2Kgcm -2 and
water bed is formed which keeps seeping through the husk bed and dissolving
the remaining glucose & maltose with it, if present.
(Total time required: 3.5 hr)
26

27. STEP – 4
WORT BOILING
Following extraction of carbohydrates, proteins, and yeast nutrients in the mash,
the clear wort must be conditioned by boiling the wort in the kettle. The purpose of
wort boiling is to stabilize the wort and extract desirable components from the
hops. The principle biochemical changes that occur during wort boiling are as
follows:
• Sterilization
• Destruction enzyme
• Protein ppt.
• Color development
• Isomerization
• Dissipation of volatile constituents
• Concentration
• Oxidation
27

28. Figure: 3
KETLE
Operating the kettle
Traditionally , the kettle times lasted between 90 and 120 min., wit a minimum of
10 % evaporation per hour. However, today kettle times for an all – grain beer last
from 60 to 90 min with 8 to 10 % evaporation ate. In order save time, most
brewers begin applying heat as soon as the wort covers the kettle to minimize
charring (or scoring ), and to prevent damsge to the kettle. Some systems may be
require that the kettle be more than halfway full before applying heat. Care must
be taken when using direct gas fire since the first running are easily caramelized .
if system jackes are used, heating may be started as soon as several inches of wort
are in the kettle by shutting off the side jacket.
Hops and Hop Products
Substances that are important in beer
Bitter substance 19.0 %
Oils 0.5 %
Polyphcnols 4.0 %
Protein 20.0 %
Minerals 8.0 %
28

29. A good beer need a good aroma acceptable plate and a deal of that in beer is
provide by hops . It has been said: “ Malt is the soul of beer and yeast gives it life
but the kiss of the hop is the consummation of that life .” the lupulin glands of the
female flower cones f the hop plant provide the different biter substances, which
are the basis for beer bettering . Hop cones or hop extract are added during the
wort boiling where the largely insoluble
α -acids (humulones) from the hops are isomerized to the more soluble Iso - α –
acids, the main bettering substances found in the beer. Hopes also contain β –acids
(Iupulones), which are claimed to add bitterness to bee, especially after oxidation.
Analysis of the hop acids in hop products is important for quality control. The
analysis is performed by HPLC ( high pressure liquid chromatography ) using a
reverse phase C18 column especially developed for this purpose, and elution with
acidic , aqueous methanol.
Hoes are added to he boiler tank as the boiling is started. Hopes are the agent ,
which impart flavour ( bitterness ) to the beer.
Two types of Hopes are used:
 Pellets
 Slimy extract
Sugar is added at the start of the boiling to have the require amount of the
fermentable sugar in the wort to obtain a desired concentration of alcohol in the
bee finally obtain.
After boiling the wort in transferred to the whirlpool for the susended hops
particles, sugar impurities etc. to settle down.
Wort boiling system
Traditionally , wort was boiled in direct – fired kettles, often made of copper.
Since the heat , source is localized at the bottom of the kettle, these vessels are not
efficient in transferring heat into the wort , can scorch the wort, and are restrict by
the volume of wort, that can be boiled at anyone time.
“ The advent of steam coils and internal heating system allowed for more efficient
heat transfer and larger kettle for boiling larger volume of wort . the disadvantage
29

30. with steam coils are that they are difficult to clean , prone to corrosion , and
limited the circulation of wort. ”
However , internal cookers offers several advantages , A circulation pump ( and its
additional energy consumption) is not necessary since natural convection of the
wort takes place in the kettle. The degree of efficiency of an internal cooker is
significantly higher than that of an external cooker even without considering the
forced circulation of the latter. This is because of the internal cooker is always
completely surrounded by the wort. Wort is subject to less thermal stress . the
boiling temp. of the wort using an internal boiler is approximately 1010C. using an
external boiler; outlet temp. of the wort is approximately 106 to 1070 C, such high
wort temp. in external boiler are to a pseudopressure cooking effect, which man
brewmasters is approximately four times the no. of forced circulation of wort in an
external boiler.
STEP – 5
WORT COOLING AND AERATION
After boiling and clarification , the wort is cooled in preparation for the addition of
yeast and subsequent fermentation. Te principle changes that occur during wort
cooling are follows:
• Cooling the wort to yeast pitching temp.
• The formation and separation of break and
• Oxygenation of the wort to support yeast growth.
Wort cooling systems
After boiling and clarification , the wort leaving the whirlpool has to be cooled
in preparation for the addition of yeast and subsequent fermentation. Wort is
usually cooled though plate heat exchanges.
Heat exchangers are of two types:
1. Single – stage ( Chilled water only ) or
2. Multi - stages ( amient water , glycol).
30

31. Wort enters the heat exchanger at approximately 96 to 990 C and exists one –
stage cooling .
The firs stage utilizes water to remove the bulk of the heat, cooling the
incoming water to within 30 C of fermentation temp.
In the second stage , the wort is cooled to the fermentation temp. by a
secondary refrigerant , e.g.; glycol. Some craft brewers , in an attempt to reduce
capital expenditure, ill use the same glycol system that provides the cooling for
the fermentation. Most small brewers would prefer two – stages cooling but use
one – stages cooling to save money .Alternatively ,the cooling operation can be
achieved in a single stages using a glycol – jacked cold water to approximately
30 C below that of the required wort temp. In both systems, the heat from the
wort is transferred to the water. That water cant hen be used other purposes ,
but mainly as a source of warm brewing water.
Aeration and chilled water
Aeration of the chilled wort is needed in order to provide the yeast with
sufficient oxygen for growth during fermentation . The amount of oxygen
required depends on yeast strain, wort temp. wort gravity, amount of tub in the
wort, and a no. of other factors. Foe e.g.; wort at high temp. and high specific
specific gravity has greater oxygen require than wort at lower temp. and
specific gravities. Wort low in trub generally has high oxygen requirement
,while wort with high trub levels have lower oxygen requirements.
The oxygen requirements for individuals for brewing strains can range from 3
to 30 mg,O2 / l but usually it I in the range of 7 to 18 mg O2 / l . Yeast strains
with low O2 requirements can be aerated using sterile air since it contains
approximately 8 mg O2/l, while strains with high O2 requirements must be
aerated with pure gaseous O2.
STEP – 6
FERMENTATION
31

32. figure: 4
Wort is cooled and added with yeast, which transforms the fermentation sugar
dissolved in water into alcohol and carbon dioxide. After about eight days, this
fermentation is finished.
We distinguish two main types: the bottom fermenting beers, fermented at a law
temp. (12 to 150 C) with yeast that settle at the bottom of the ale and the top –
fermenting beers, fermented at 20 – 250 C with yeast that rise to the top of the beer
after the fermentation.
Bottom yeast gives a smother, less flavoured and almost neutral taste that makes
the taste of the flavour and of the hop stronger. It is the yeast used foe classical
beers.
Top yeast is energetic yeast that reproduce a lot and that only works well with a
temp. higher than 200 C. It produce more ethereal and flavoured beers that seem to
be light and easily digestible , even when their density . It is the ideal yeast for
specially for specialty beers.
After fermentation is complete, the beer is set in the fermenter for several weeks at
00 C. The goal of this is to refine the taste, clarify partly the beer and o saturate it
with CO2 . Top beers only undergo a shot cooling.
During the primary fermentation (H), the fermentable sugars, mainly maltose and
glucose are converted to ethanol and CO2 . This action is performed by the brewing
yeast , which during the brewing process also procedure many of the characteristic
aroma compound found in beer. At the end of the primary fermentation , the yeast
cells flocculate and sediment at the bottomof the fermentor and can be cropped and
used for a new fermentation. Not all yeast cells sediment, some will remain sin
suspension , and these cells are responsible for maturation of the beer . During this
32

33. process the off – flavour , diacetyl is degraded to below the taste tharshould. The
fermentation characteristics of brewer’s yeast are strain – dependent , and are
genetically inheritated. Much of the genetics of sacchromycse yeast has been
elucidated , and the knowledge gained , forms the basis for breeding of brewing
yeast. Thus , new t5ypes of beer with altered aromas can be produced with yeast
strains selected through breeding.
COLD STORAGE
The completed fermentation medium is transfer to storage tanks and held at
approximately 0 – 30 C for a peroid of time. During this “cold storage maturation ”
coagulated nitrogenous substances, resins, insoluble phosphates , and yeast cells
sediments from the beer. In addition, esters are formed, and the beer matures so
that it looses its harshness .
During this maturation process , “ chill proofing ” is commonly practiced to help
prevent turbidity development on letter exposure of finished beer to cold . much of
turbidity can be attributed to unstable protein in the beer, and chill proofing can
mean merely the removal by ppt. or adsorption of these unstable residual proteins
or partial protein hydrolysate products.
Chill proffering ,is practicd by emplying proteolytic enzymes to reduce the mol.
Size of the residual protein and protein hydrolysate produc, so as to insure their
solubility even at cold temp.
Antioxidants are also added during cold storage during maturation to prevent later
oxidative changes in the beer, which affects flavor . Sulfur dioxide ( sulfites ) and
ascorbic acid are commonly used to accomplish this end.
STEP-7
FILTRATION
Extended lagering periods and the addition of flocculation adds both greatly
reduce yeast and haze loadings. Centrifuges are mainly used in the preliminary
reduction of suspended particles , primarily in yeast before sending to the
conditioning tanks. Although these method are very effective in prefiltering the
beer, a final filtration is needed to removed residual yeast , other turbidity –
33

34. causing materials, and micro-organisms in order to achieve colloidal and
microbiological stability.
If there is a significant quantity of suspended material to be removed , powder
filters using diatomacesous earth or perlite must be emploed. Although powder
filter can produced beer of acceptable brilliance after a single filtration, a to stage
filtation process is needd to a final polish. Polish filtration may employ a sheet
filter , used as an intermediate step in handling heavier loads , followed by
acartridge filter.
TYPES OF FILTERS USED FOR FILTRATIONS OF BEER
SCHENK FILTER
Yeast , protein and carbohydrates particles must be removed from the beer to
achieve the necessary clarity . As the first step in filtration , powder filters are
used for removing these suspended particles , the help of high flow super cell
powder makes the powder filter . The powder is injected at the point where the
beer stream , together with yeast and other suspended solids, forms and
incompressible mass referred to as the “ filter – cake”. The porous bed creats a
surface that traps suspended solids , removing them from beer . Not all of the
particles will be trapped at the surface, some especially the finer material, will pass
into the filter cake and be trapped – a process referred to as “ depth filtration ”.
These beds retain up to 99% of the culture and suspended particles . Depth
filtration is not as effective as surface filtration, but is still a significant mechanism
of filtration by filtar aids. Powder filtration is generally regarded s providing the
most economical forms of filtration. The cost of filter aids is quite low , and long
filtration cycles at high flow rates are possible.
The haziness of the beer is seen under a yellow lamp , and until the haziness
disappears, the beer is continuously recycled and refiltered through these powder
beds in the schenk filter.
34

35. For 110 HL of beer , approximately 13 KG of powder is used .
Types ( qualities ) of powder is used
 White powder
 Yellow powder
Yellow powder is of higher quality and higher efficiency than the white powder
but is costlier and has a short self life compared to the white powder.
To counter the deficiencies of yellow powder and to be cost effective , a
combination of both powders is used to make filter beds .
PATE AND FRAME FILTER
The plate and frame filter has been the work house in breweries around the
world for many decades for filtering beer. It is robust and reliable , consistently
filtering beer to the specified . Standards plate and frame filter consists of a
series of chamber enclosed within a metal frame . Between adjacent frames is a
double sided porous filter plate covered by either a fine mesh or a sheet. The
filter sheet acts as a trap for the filter aid, which other wise might bleed through
, their by assuring excellent a clarity . Filter sheet are generally made with
cellulose fiber, diatomaceous earth , perlite, and a resin for bonding to give dry
and wet strength . Some are available only with filtration fiber. The average
pour size of filter sheet is between 4 – 20 microns , therefore plate and frame
filter are readily precoated and less susceptible to malfunction . each plate
alternates with a frame with the entire system held together by a screw or
hydraulic clamp mechanism. This type of filter is very similar in appearance to
the sheet filter, except it has sludge frames. The inlet pressure of the beer into
these type of filter is approximately 0.7 – 0.8 bar .
This step is good enough to retain the remaining 1% of the culture / suspended
particles so that the beer is completely free of any particles.
STEP - 8
35

36. BEER CARBONATION
Secondary fermentation in carbonating Beer
The traditional method involves carbonating the beer during secondary
fermentation at low temp. and under counter pressure. The beer transferred to the
conditions tank should have at least 0.5 to 1.00 C of fermentable extract and be
placed under pressure from 12 to 15 PSI in conditioning tanks. Munroe reports that
if the pressure is to high during sec. fermentation yeast growth may be affected
and change the flavor characteristics of the beer. While in the tank , the remaining
extract ferments and creates sufficient carbon dioxide to saturated the beer to
equilibrium.
Mechanical Beer Carbonation
Mechanical carbonation is accomplished either by in line or in tank techniques.
Carbon dioxide may be purchased from supplies of industrial gases. Alternatively ,
CO2 may be recovered from fermentation vessels and then purified, liquefied ,and
stored until needed for carbonation . However, this collection system can be too
expensive for most craft brewers. In general, the viability of collection CO2
depends on an alternatively cost of purched CO2, is availability, and the quantity
used in the brewery. Some brewers report that use of mechanical carbonation
actually has a greater influence on reducing acetaldehyde levels than does
kraeusening the beer.
PRINCIPLES OF BEER CARBONATION
The time required to reach a desired CO2 concentration depends on a no. of
physical factor. Temp. and pressure play an imp. Role in determining the
equilibrium concentration of CO2 in solution . At equilibrium the same amount of
CO2 is diffusing out of the beer as is being dissolved back into solution .
increasing the pressure leads to a linear increase in the weight of CO2 dissolving
in the beer of water. Decreasing the temp. gives a non- linear increasing CO2
solubility in beer. Consequently, the equilibrium concentration can not be attended
without either increasing the pressure or decreasing the temp. Thus , the closer the
carbonating temp. is to 00C , and the higher the pressure , the greater the CO2
absorption .
Approximately two cylinder of CO2 gas are added to every storage tank of beer of
approximately vol. of 120 HL .
36

37. STEP – 9
BOTTLING
Figure: 5
Before the bottling or the kegging, the beer is filtered to eliminate yeast and the
suspension materials. There after, it is pasteurized (flash pasteurization or tunnel
pasteurization for the bottles and flash pasteurization for the kegs).
37

38. Once the final quality of the beer has been achievd , it is ready for bottling. The
bottling of beer is one of the most complex aspects of brewery operations and the
most labor intensive of the entire production process.
The bottling of beer can be divided into the following steps:
 Bottle – feeding,
 Bottle rinsing,
 Bottle filling,
 Tunnel pasteurization,
 Bottle labeling and ,
 Case packing
Beer Bottle Feeding
The first in bottling beings with loading the empty bottles on the unscrambling
table. In craft breweries, loading with prepacked bottles is usually done
manually at a rate of 80 100 bottles per minute ( bpm). The table funnels the
wide mass of bottles into a single stream. Several types of mechanism prevent
the bottles from bridging as they are funneled to a single line. These include
mechanical joggers, reverting chains, and good inherting design.
Beer Bottle Rinsing
These are three types of bottles rinsers – twist, gripper, and rotary. Most craft
breweries use twist rinsers, which are design to invert the bottles before
spraying. After being rinsed , the bottles are allowed to drain before swung
back up into the upright position and delivered to the bottle filler. Each bottle
size and shape requires a different “twister”, but the cost of twist rinse is quit
low. Gripper style rinser are a more compact alternative to twist rinser and can
handle various bottle size and shape without parts having to be changed. Rotary
rinser, are compact as well, and are known for their smooth bottle handling.
However, rotary rinser, are the most expensive option for rinsing. A rotary
rinser can also be incorporated into a filler as part of a “monobloc”
arrangement. Monobloc machine also combine a crowner are better than
38

39. separate units, since the bottle must be capped as soon as possible after filling
to exclude air.
Before rising the bottles are washed with caustic soda, thus removing dust ,
labers etc. at 600 C for 30 min.
Beer Bottle Filling
Filling Process
The bottle goes into the machine, the gas is filled into the bottle s& a vacuum is
created, the bottle is lifted a bit ,the beer is filled into the bottle & the pressure
is released. The filled bottle is then passed on for the crowning of the filled
bottles.
Crowning
After filling, the bottles are capped as soon as possible y the crowner. The caps
have a sprayed on, hot – passed PVC based sealing insert or a cold pressed
sealing insert not containing PVC. The caps are conveyed to the crown hopper
means of a magnetic belt or a pneumatic crown feed, or they can be dumped
manually directly into the crown hopper. Whatever method is used, the crown
hopper should be kept only half full of caps. This is to lessen the possibility of
crowns becoming packed and not feeding into the chute fast enough. In
addition , then the caps become packed , the possibility of scratching the cap
finish increases.
After crowning the bottles are screened for the presence for the presence of any
sort of suspended articles or the haze in the beer in front of a a white lamp. If
any such suspended particles are detected , the bottles are returned and not sent
for labeling.
TUNNEL PASTEURIZAION USED IN THE BOTTING BEER
An alternative to flash pasteurization &sterile filtration is tunnel pasteurization.
Tunnel pasteurization is employed after bottles have been filled & sealed. The
39

40. bottles are loaded at one end of the pasteurizer &passed under sprays of the
water as they move along the conveyor. The sprays are so arranged that the
bottles be subjected to increasingly hot water, until the pasteurization
temperature (usually 60oC) is reached by beer in the bottles. The bottles are
then gradually cooled with water until they are discharged from the end of the
pasteurizer. Temperature changes have to be made in the prevent he bottles
from breaking. Heating and cooling of the bottles is preformed using various
water circulation, paths in order to utilize recovered heat. In this way, heat
usage by the tunnel pasteurizer can be reduced t a minimum, Passage through
the tunnel pasteurizer takes about an hour. Bottle breakage is usually no more
than 0.1 to 0.2 percent in the tunnel pasteurizer. If greater, it is usually due
either to poorly made bottles or he lack of head space.
Bottle Labeling
An in line labeler is a type of machine for which the bottle travels in a straight
forward motion , and the label or labels are applied while the bottle is moving
along the bottle conveyor. One such type of in line labeler is the tandem labeler
that is typically used in multiple or “ in tandem ”, with each machine typically
capable of running 60 to 80 bpm. Maintenance of the labelers is fairly demanding;
and even though parts are fairly inexpensive , they may be difficult to obtain.
tandem labels cannot do front and back labels at the same time, and does not
bound labels with a full width of glue, but rather with only two vertical strips one
at each side of the label. The label. The labels may ape puckered due to moisture
condensation or may be crooked or have corner flagged (edge lifted). These
limitations have increasingly contributed to the obsolescence of tandem labelers;
nonetheless, their low cost and simplicity assure their continued use, particular by
craft brewers.
Case packing Beer Bottles
Case packing is done manually or br case packers. Two people standing at a
discharge table can pack up to 100 bpm. For rates above 10 bpm , an automatic
case packers is requied has a linea collection table on which the bottles are
automatically placed inranks that mach the packing pattern in the case. A conveyer
40

41. supplies the the packer with the shiping cases, and from the packer the conveyor
caries the filled cases to the palletizing.
41

42. RESULT AND DISCUSSION
Beer ranges from less than 3% alcohol by volume (above) to almost 30% above.
The alcohol content of beer varies by local practice or beer style. The pale lagers
that most consumers are familiar with fall in the range of 4–6%, with a typical
above of 5%. The customary strength of British ales is quite low, with many
session beers being around 4% above. Some beers, such as tafelbier (table beer)
are of such low alcohol content (1%~4%) that they are served instead of soft
drinks in some schools. In the United States beer with an alcohol content over a
certain level (? 5%) can not be called beer for marketing purposes. The term 'malt
liquor' is often used instead. Many imported 'beers', such as Singa Beer from
Thailand, can not be labeled as beer in America due to its high percentage of
alcohol by volume.
The alcohol in beer comes primarily from the metabolism of sugars that are
produced during fermentation. The quantity of fermentable sugars in the wort and
the variety of yeast used to ferment the wort are the primary factors that determine
the amount of alcohol in the final beer. Additional fermentable sugars are
sometimes added to increase alcohol content, and enzymes are often added to the
wort for certain styles of beer (primarily "light" beers) to convert more complex
carbohydrates (starches) to fermentable sugars. Alcohol is a waste product of yeast
metabolism and is toxic to the yeast; typical brewing yeast cannot survive at
alcohol concentrations above 12% by volume. Low temperatures and too little
fermentation time decreases the effectiveness of yeasts, and consequently
decreases the alcohol content
42

43. LIST OF FIGURE
1. FIGURE-1: OUTLINE DIAGRAM FOR PRODUCTION OF BEER
2. FIGURE-2: LAUTER TUN
3. FIGURE-3: BOILING TANK
4. FIGURE-4: FERMENTER IN BREWERY
5. FIGURE-5: BOTTLING SECTION
43

44. BIBLIOGRAPHY
1. http://en.wikipedia.org/wiki/History_of_beer
2. http://www.opt.be/contenus/history_of_beer/en/2100.html
3. http://www.brasserie-graindorge.com/history-beer.php
4. http://www.opt.be/contenus/beer_types/en/2180.html
5. http://www.opt.be/contenus/how_beer_is_made/en/2140.html
6. http://www.brasserie-graindorge.com/mashing.php
7. http://running_on_alcohol.tripod.com/id20.html
BOOKS
• How to Drink Beer and Save the World,
Christopher Mark O’Brien
• Beer, Its History and Its Economic Value as a National Beverage
By Frederick William Salem
44