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Setting up a microbrewery

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A new update to my last presentation on setting up microbreweries in India. send me your valuable comments on neo.brewmaster@gmail.com

also mail me your inquiries to :

neo.brewmaster@gmail.com

APART FROM DISCUSSING THE PRESENTATION ALL OTHER SERVICES ARE CHARGEABLE.
CONSULTATIONS (ONLINE/ONSITE) FOR MICROBREWERY/BREWPUB PROVIDED WITH REGARD TO TECHNICALITIES INVOLVED (NO LEGAL OR EXCISE WILL BE DALT WITH)MAY BE PROVIDED.
TURNKEY PROJECT AND CUSTOMIZATION SERVICES PROVIDED. RAW MATERIAL, EQUIPMENT, SETUP, DESIGN, BREWING AND RECIPES WILL BE IN SCOPE OF SERVICES.

Published in: Business

Setting up a microbrewery

  1. 1. AUTHORED BY:RITWIK BHATTACHARYA, BREWERCONTACT: neo.brewmaster@gmail.com
  2. 2.  INTRODUCTION 3 MASHING & MASH TUN 7 LAUTER TUN 10 WHIRPOOL 11 KETTLE 13 MILL 14 YEAST PITCHING & PROPAGATION 15 CHILLER & COMPRESSOR 16 CIP SYSTEM 17 FILTRATION SYSTEM 18 FERMENTATION & BRIGHT BEER TANKS 20
  3. 3.  DISPENSING SYTEM 23 WATER TREATMENT PLANT 25 EFFLUENT TREATMENT PLANT 26 MISCELLANEOUS & ANCILLARY 27 ABOUT THE AUTHOR 30
  4. 4.  In my previous presentation titled ‘Brewpub and microbrewery in India’ (http://www.slideshare.net/ritwik9/brewpub-amp- microbrewery-in-india) I had dealt with basic setup issues regarding a microbreweries in India, the history, the styles catered to and in lines of conceptualizing a whole project touching briefly points pertaining to license, technology involved and other ancillary. Following it up, I am putting up this presentation to take into consideration more of technology based queries. More often I find microbreweries being setup, with less emphasis on the technology, quality and commissioning and more into price, which is depressing for most brewers
  5. 5.  For a long run, such pre requisites should be of prime concern for a smooth operation, and unperturbed quality of beer. The motto behind this presentation is principally to organize such activities and to get a better understanding about the equipments for the entrepreneur or the investor. The other reason being to culminate the interests of the interests of the investor to get a good profit and the brewer to make a good yield, come in union, by asking these basic questions depending on which the magnitude of the project could be fathomed. I also want to stress that this is not the only methodology to go about the setting up a microbrewery or brewpub, but this is the approach that I personally prefer.
  6. 6.  Capacity of mash tun in HL (Gross and net Diameter of mash tun v/s lauter tun Heating mechanism- electrical element/boiler steam If electrical element: a. number and position of coils b. Provision of circulation across external calandria c. Heating time from ambient to 100 deg C d. Voltage and whether voltage regulation is a possibility.
  7. 7.  If boiler: a. oil fired/propane fired b. Water heating time from ambient to steam c. Autocut off mechanism at specific temperature and pressure d. Water tank holding capacity and max pressure generation e. MS lines whether redox coated & location of boiler. Mash tun to lauter tun pipe diameter, whether decoction a possibility. PLC: Automatic/ Semiautomatic- Step infusion mashing a possibility from 35 deg C. Exhaust line: hood or condensate line from Kettle &/ Mash tun.
  8. 8.  Brewhouse vessel system-2/3/4, whether any extra provision of holding tank with heating system. Type of sensors: RTD/ PT 100 Tank volume properly marked in level gauge in graduation of 50 ltrs. Origin of tanks: Europe/India/China/Others Mechanism of mashing: Single infusion/Multiple infusion/Decoction Tanks surface with copper cladding (electroplated)/ Copper strips/Polished steel-B finish (interior/exterior).
  9. 9.  Steel used: non radioactive with proper certification from 3rd party, Minimum SS 304 for steel sheets and SS310 for valves. Butterfly valves in all tanks except ball valves in boiler and glycol lines for manual operation. Mash tun agitator RPM
  10. 10.  Lauter tun: single sieve/ double sieve. Sieve pore size Provision of underlet water line at start of lautering. Water circulation time, Scraper RPM & Manhole size Ratio of diameter of lauter tun in comparision to mash tun, minimum and max grain bed height recommended. Sparging ball position, and sparging pressure.
  11. 11.  Supernatant tank cone capacity. View glass and level guage to control clarity of liquid, minimum run off volume in ideal case & provision of a flowmeter
  12. 12. WHIRPOOL Whirpool: tank capacity, height of inlet and pressure at inlet, pump HP Depth of sump for discharge of hot break, wort discharge line height from sump. Whether can be used as a HLT, with a heating element.
  13. 13. KETTLE Separate kettle or mash tun to double up as a kettle. Kettle net and gross volume. Max heating temperature and total time required for unit boil volume to reach it. Boiling pressure and whether internal or external calandria system. Agitator speed in RPM, whether chinese hat present.
  14. 14. MILL Number rollers present in mill: 2/3/4/6, whether all rollers are mobile or a few stationary. Mill hopper to roller line provided with magnets to remove metal particles and siphon action to remove dust and broken grains etc lighter than actual malt. Provision of grill over the hopper. Minimum and maximum adjustment possible in roller gaps. Milling motor HP. Type of milling : Dry/Wet Location of mill: overhead mash tun in mezzanine floor with grist case and auger control (ideal)/ Underneath in basement.
  15. 15. YEAST PITCHING & PROPAGATION Capacity in volumes for yeast pitcher. Type of aeration: hot side (candle filtered air)/ cold side (food grade pure oxygen) Max and min aeration pressure. Whether yeast propagator available, yeast propagator capacity, yeast propagator agitator RPM Number of yeast storage tanks and capacity, provision of separate PLC control for pressure temperature and pitching operations. Level gauges for all tanks Yeast pitching pump HP, clear glass for visual adjustment and flow meter to regulate volume of yeast pitched.
  16. 16. CHILLER & COMPRESSOR TR of glycol chiller Type of glycol being used: Ethylene glycol/Propylene glycol, ratio of Water: Glycol used. Compressor capacity based on volume of total capacity of storage (Fermentors + BBTs + Storage tanks-if any), for subsequent gradual temperature drop from 30 to -2 deg C, as per requirement and style of beer. CLT capacity Generator automatic switchover during power failure.
  17. 17. CIP SYSTEM Capacity of caustic and acid tank. CIP pump HP Minimum and maximum caustic and acid percentage recommended Recommended circulation time for unit size for effective CIP. Provision of extra water line addition for rinsing purpose or for dozing sterilization chemical
  18. 18. FILTRATION SYSTEM Type of filter used: sheet and frame plate/ Kiselguhr filter/ Simple candle filter filter. Pore size of filter paper/sieve/ candle. Number of sieves/filter paper/ candles Minimum and maximum flow in Hl/hr demonstrated across a flowmeter and side glass to check visually for clarity.
  19. 19.  Sampling valve in filtration unit to compare samples after and before filtration and check for DO/CO2 etc. Whether provision of alcolyzer, OD (at 90 & 25 Deg), pH attached to filtration unit. Provision for blending with deoxidized water for high gravity brewing. Type of filter aid if at all used eg Hyflow celite 512, 522 etc. Whether the kiselguhr dosing tank has a agitator, provision of using DA water to stop any kind of oxygen uptake.
  20. 20. FERMENTATION & BRIGHT BEER TANKS (BBTs) Number of fermenters and their type: CCT or flat bottom. Number of BBTs Net and Gross capacity of fermenters and BBTs PRV installation connected to pressure sensors with PLC adjustment. Maximum pressure tolerance by tanks. Type of temperature probes and whether connected to PLC. Separate PLC and chiller for cold room area (fermenters & BBts)
  21. 21.  Sampling valve, cone height, cone volume, discharge line diameter and no of legs for ferementers and BBT. Whether fermenters can also double up as Unitanks, with temperature going down to below 0 deg C. Minimum head room requirement for fermenters. Provision of extra pump for yeast and beer transfer and its HP. Provision of CO2 purging apparatus along with Co2 cylinders.
  22. 22. DISPENSING SYSTEM Number and types of beers on tap. Counter pressure by CO2/N2/Mixed in ration for dispensing across kegs Provision of primary an tertiary regulators. Whether to be dispensed across kegerators or directly from storage tanks/BBts. Glycol chilled lines are up to tower or till the tap across chilling blocks. Proper angle of dispensing for: Ales, Stouts and Pilsner/Lager.
  23. 23.  Minimum and max temperature of dispensing. Cleaning and sterilizing procedure of dispensing tower. Kegging apparatus provision along with keg washer.. Capacity of kegs and numbers, minimum and maximum pressure tolerance
  24. 24.  Type of water treatment plant: RO/Activated Carbon and candle filter. Source of water: Underground/Municipality Original and treated water analysis: Mineral content, TDS, pH, Hardness, SPC and Acidity Provision of iron filter. pH of water alkalinity required in brewing water specific to brews. Whether salts will be supplemented for such purpose eg Calcium chloride, gypsum etc Water filtration rate: Litres/hr Type and volume of treated water storage. Calculated volume of brewing water required per brew.
  25. 25.  Type of ETP: Aerobic/Anaerobic Components of ETP and area covered Analysis of untreated water: TDS, pH, COD, BOD, Dissolved and particulate matter in compliance with local PCB. Whether yeast is drained, propagated for subsequent generations and then drained, Dried into yeast cakes in yeast driers ( if so capacity of yeast driers), mixed with spent grain and sold as feed ( ratio of spent grain : yeast). Method of handling spent grain: Discharged into ETP or Sold to cattle farmers as feed (recommended) Handling of highly organic solid wastage from ETP.
  26. 26. ANCILLARY & MISCLLENEOUS Spare valves, dispensing taps, Kegs (Plastic/Steel, 25/30/50 liters) extra hoses, valve fittings, clamps, gaskets, Extra pump for tank to tank transfer, Filter papers, candle filters and any other ancillary stock. Raw material inventory & Specification sheets: Base malts, Specialty malts, Adjuncts (ambient storage at around 20 deg C, RH below 10 %) Additives (E.g Enzymes, etc if any), Hops, Yeast (both require cold storage below 4 deg C), Chemical storage (Hazardous/ Non Hazardous).
  27. 27.  Provision of laboratory: Attached to microbrewery, small and secluded / separate more sophisticated with larger array of tests. Basic laboratory requirements: Compound microscope (100 X, oil immersion illuminated), slides, cover slips, basic analytical reagents, dyes and chemicals, Haemocytometer, Ph meter, Hydrometer (0-10, 10-20, 2 each), Thermometers, Bunsen burner and Standard glassware.
  28. 28.  Organized brew charts, Daily production capacity, Fermentation charts, BBT data, Excise flowmeter data, licenses, Inventory data, Analysis sheets, etc maintained in soft copy in a work station. Staff: Brewmaster, Assistant Brewmaster, Operators and supporting staff. Carbon dioxide and Oxygen cylinders, sterilizing chemicals, Caustic flakes and acids for CIP maintained along with inventory. Cleaning equipments, Plumbing fitting, electrical fittings and literature related to machinery and servicemen along with AMC details and electrical and machine drawings. Whether in future, plan of expansion includes bottling and kegging lines and space allocation for the mentioned.
  29. 29.  The author has been involved the brewing industry since last 5 years, involving him self in brewing & process operations, Quality control and assurance, Bottling & manufacturing and other parameters like product excellance and beer tasting. Working and brewing with global MNCs like SAB Miller(Haywards/Knockout), United Breweries(Kingfisher/Kalyani), Heineken, Carlsberg (Carlsberg/Tuborg/Palone), he has gathered substantial experience. However, Ritwik being a passionate brewer from his core, always loved to experience microbrewing and fortunately the first exposure he got was in Indias first Microbrewery in Pune. A bachelors degree holder in Microbiology from University of Calcutta and MSc in Food technology, he later pursued his career in Wine industry for brief time. He has also acquired a Post Grad Diploma in food safety, and has extensive laboratory experience in all distilled and un-distilled alcoholic beverages i.e Spirits (whiskey, gin, rum, vodka etc), Wine ( Red/White/Rose) and Beer ( Lager/Ale
  30. 30.  Indias only J J Morrsion scholarship holder from only certified brewers and distillers global certification council, Institute of Brewing & Distilling, London, he is still pursuing his Diploma in Brewing An avid reader about new technological developments in the brewing industry globally, he has published a few presentations and papers on his research and findings in cider and beer industry in journals and over the net. His earnest wish is to have more entrepreneurs to venture in the industry of Craft Brewing, and he has always shared information free of cost over large number of platforms to prevent circulation of wrong and disfigured information in the market. We hope getting through with this presentation was helpful to you. Do send your comments and suggestions in the email provided in the 1st Slide. KINDLY DON’T ASK FOR A COPY OF THIS PRESENTATION AS IT SOLELY IN DISCREATION OF THE AUTHOR, HOWEVER YOU ARE FREE TO TAKE DOWN POINTERS AS AND WHEN YOU LIKE. ANY OF THE PICURES POSTED IN THE PRESENTATION ARE MERELY SUGGESTIVE IN NATURE. I AM NOT PROMOTING ANY BRAND OR MAKE THROUGH THEM *****************HAPPY BREWING*****************

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