4TH PART IN SERIES OF MCROBREWERIES IN INDIA.
KINDLY REFER TO FOLLOWING PRESENTATIONS
FOR MORE DETAILED OVERVIEW:
http://www.slideshare.net/ritwik9/setting-up-a-microbrewery
http://www.slideshare.net/ritwik9/brewpub-amp-microbrewery-
in-india?related=1
http://www.slideshare.net/ritwik9/microbrewery-in-india-
equipments-52424466
 MALT
THEY ARE REGARDED AS THE MAIN SOURCE OF SUGAR WHICH IS
CONSUMED BY YEASTS DURING FERMENTATION TO PRODUCE ALCOHOL
(ETHANOL) AND CARBON-DI-OXIDE (THE HEAD OF BEER). BARLEY
GRAINS ARE THE MOST ABUNDANTLY USED RAW MATERIAL USED FOR
MAKING BEER. MALTING IS A PROCESS THAT TAKES PLACE IN MALTING
INDUSTRY FOR 25 DAYS TO A MONTH, WHERE THE SIMPLE BARLEY GRAIN
DEVELOPS MORE CHARACTERSTIC FLAVOUR, COLOUR AND BETTER
CONVERSION POTENTIAL FOR SUGAR GENERATION. OTHER THAN
BARLEY, WHEAT , RYE AND SOME OTHER GRAINS ARE ALSO USED IN
MALT FROM FOR SPECIAL BER STYLES.
OTHER FORMS OF MALT:
MALT IS ALSO AVAILABLE IN LIQUID FORM CALLED, MALT EXTRACT,
USED BY SOME BREWERS FOR EXTRACT BREWING, HOWEVER ARE
COSTLY AND DIFFICULT TO MAINTAIN. DME (DRY MALT EXTRACT) ARE
UTILIZED BY SOME TYPICAL BREWING EQUIPMENTS AS WELL.
TYPES OF MALTS
1. PALE/BASE MALT
2. SPECIALIZED MALT
3. ROASTED/DARK MALT
4. WHEAT MALT
5. OTHER GRAIN MALTS
BASED ON THEIR SUGAR AND INSTRINSIC ENZYMES, MALTS CAN BE
SUBDIVIDIED INTO 2 VARIETIES:
1. 2 ROW MALT: HIGHER SUGAR POTENTIAL
2. 6 ROW MALT: HIGHER ENZYME POTENTIAL
BASED ON ORIGIN MALT CAN BE OF 2 TYPES:
1. INDIAN MALT: MOSTLY 6 ROW
2. IMPORTED MALT: MOSTLY 2 ROW
THEY ARE GENERALLY AVAILABLE IN FOLLOWING CAPACITY(KG)
1. 50 KG BAGS (INDIAN)
2. 45 KG BAGS (INDIAN)
3. 25 KG BAGS (IMPORTED)
Sl noMalt type
Avg price
india(Rs/kg)
Avg price
imported
(Rs/kg)
12 row 60-70 90-135
26 row 40-50 70-90
3wheat malt 50-70 115-145
4dark malt 110-120 115-190
6roasted malt 140-160 115-200
7speciality malt 110-130 170-195
 HOPS
HOPS ARE DERIVED FROM CONES OF CONIFEROUS TREES. THEY
AREPREDOMINANTLY GROWN IN EUROPE.RESPONSIBLE FOR THE TYPICAL
FLAVOUR OF BEER, OWING TO FOLLOWING TYPES OF HOPS
1. BITTERNESS HOP VARIETIES
2. AROMATIC HOP VARITEIS
THEIR MORE THAN 300 TYPES OF HOPS AND MOSTLY THEY ARE
AVAILALE IN FOLLOWING FORMS:
1. WHOLE HOP CONES
2. DRY PELLETS
3. HOP OILS
4. HOP EXTRACTS
HOP CONES ARE THE NATURAL FORM HOWEVER THEY YEILD LOW
AROMA AND BITTERNESS POTENTIAL AND ARE REQUIRED IN HUGE
QUANTITIES, AT THE SAME TIME BEING IN VEGETATIVE FORM THEY ARE
DIFFICULT TO MAINTAIN, HENCE ARE NOT SO COST EFFECTIVE FOR
RECURRING BEER STYLES.
 HOP OILS AND EXTRACTS ARE PRE ISOMERIZED
FORMS AAND REQUIRED IN MUCH LOWER QUANTITY,
HOWEVER PROCUREMENT AND MAINTENANCE OF
NECESSARY TYPES IS DIFFICULT APART FROM BEING
EXPENSIVE. HOP PELLETS ARE THE MOST COST
EFFECTIVE EASILY AVAILABLE HOP FORM THAT IS
EASY TO STORE FOR LONGER DURATIONS, HENCE
BEING USED MOST WIDELY BOTH IN COMMERCIAL
AND MICROBREWERY.
 HOPS ARE GENERALLY NOT GROWN IN INDIA AND
MOSTLY IMPORTED THROUGH IMPORT AGENTS. THEY
ARE GENERALLY AVAILABLE IN 5 KG BAGS.
 HOPS ARE ADDED AT THE END OF BOILING. HOWEVER
DRY HOPPING IS ALSO PRACTICED IN VARIOUS STYLES
OF BEER AFTER MATURATION FOR DISTINCT AROMA
AND BITTERNESS.
Sl no Hops type
Avg
price(Rs/kg)
1 bitter 1450-1800
2 aroma 2150-4500
 YEAST
MICROORGANISMS, MODIFIED OR TRUE FORM RESPONSIBLE FOR FERMENTATION
PROFILES IN BEER. IT USES AVAILABLE FERMENTABLE SUGARS OBTAINED AFTER THE
MASHING OF MALT IN PRESENCE OF INTRINSIC ENZYMES TO CONVERT THEM TO
ALCOHOL AND CARBONDIOXIDE. EACH YEAST HAS ITS OWN CHARACTERESTIC
FACTORS:
1. FLAVOUR IMPARTED TO BEER
2. TYPE OF RAW MATERIAL IT USES
3. VIABILITY
4. PITCHING TEMPERATURE
5. ACIDITY
6. CELL COUNT FOR ACTIVITY
7. PRECIPITATION COEFFICIENT
8. MODE OF ACTION
YEASTS ARE MOSTLY IMPORTED FROM USA AND EUROPE BASED ON THE
TYPICAL STYLE OF BEERTHEY ARE BEING USEDFOR. THERE ARE OVER 100 TYPICAL
POPULAR STYLES OF YEAST AVAILABLE
BASED ON ITS MODE OF ACTION,YEAST CAN BE USED TO MAKE 2 KINDS OF
BEER:
1. LAGER STYLES USED BOTTOM FERMENTING YEAST
2. ALE STYLES USE TOP FERMENTING YEAST
ALSO FOR CIDER, A SPECIALIZED YEAST WHICH RESEMBLES
CHAMPAGNE/WINE YEAST IS USED.
YEAST CAN BE OBTAINED IN 2 FORMS:
1. POWDERED DRY YEAST: AVAILABLE IN 500 GM PACKS
2. LIQUID YEAST: AVAILABLE IN 100 ML VIALS
A YEAST CAN BE REUTLIZED BASED ON ITS QUALITY/VIABILITY AND
CELL COUNT, THIS IS CALLED HARVESTING OF YEAST AND REPITCHING.
IT CAN BE CARREID OUT AS LONG THE ABOVE FACTORS ARE VERIFIED
IN LABORATORY. GENERALLY A YEAST TYPE CAN BE USED FOR
MINIMUM 8 GERNATIONS IF HANDLED PROPERLY.
YEAST STORAGE AND PROPAGATION IS ALSO CARREID TO INCREASE
THE SUBSEQUENT GENERATIONS OF A BACTH OF YEAST MULTIPLE
TIMES AND REQUIRES A SPECIALIZED LABORATORY AND EQUIPMENT.
LIQUID YEAST IS MOSTLY USED IN THIS PROCESS, DRY POWDERED
YEAST CAN ALSO BE FOR DIRECT PITHING.
Sl no Yeast type Avg price(Rs/kg)
1 ale yeast 11000-15000
2 wheat yeast 14000-18000
3 lager yeast 17500-21500
4 cider yeast 8000-10000
 ADJUNCTS (IF REQUIRED)
ACCORDING GERMAN BEER PURITY LAW OF REINHEITSGEBOT,
BEER PRODUCTION SHOULD NOT USE ANY OTHER RAW MATERIAL
OTHER THAN MALT, YEAST, HOPS AND WATER. HOWEVER SOME
BREWERS USE VARIED SUGAR SOURCES FOR FOLLOWING
REASONS:
1. INCREASED SUGAR POTENTIAL OF MASH, THUS YIELDING
HIGHER ALCOHOL
2. CHEAPER SOURCE OF SUGAR AS COMPARED TO MALT
3. MAY BE EASY TO USE AND STORE
4. PROVIDE DIFFERENT TEXTURE AND FLAVOUR PROFILE TO BEER
THEY ARE GENERALLY LOCALLY AVAILABLE (MOSTLY IN 50 KG
BAGS) AND CAN BE PROCURED EASILY. USE OF ADJUNCTS IS
POPULAR IN COMMERCIAL BREWERIES. GENERALLY THEY ARE
EITHER ADDED DURING MASHING OR DURING BOILING,
DEPENDING ON THE NATURE OF ADJUNCTS.
 SOME EXAMPLES FOR THEM ARE AS FOLLOWS:
1. PRE GELATINIZED RICE FLAKES
2. PRE GELATINIZED OAT FLAKES
3. PRE GELATINIZED CORN FLAKES
4. PRE GELATINIZED RYE FLAKES
5. NON GELATINIZED WHEAT/OATS
6. SUGAR
7. MAPLE OR OTHER SUGARY SYRUPS
8. MOLASSES
 GENERALLY THEIR PRICE RANGE VARIES FROM RS 55-90 PER KG.
 THEIR USE SHOULD ALWAYS BE BELOW 50% OF THE TOTAL
MALT QUANTITY.
 SOME EXAMPLES OF STYLES THAT USE TYPICAL ADJUNCTS:
1. STOUT
2. BLONDE ALES
3. LAGERS
 FLAVOURANTS
SOME OTHER MATERIALS MAY BE ADDED TO A BEER FOR TYPICAL
FLAVOUR AND MOUTH FEEL CHARACTERESTICS.
 CLARIFIERS
NATURAL AND ARTIFICIAL CLARIFIERS MAY BE USED IN PROCESSING TO
GET A CLEARER BEER. HOWEVER MOST CRAFT BEERS AVOID USING THEM
EXCEPT FOR A FEW NATURAL ONES ADDED AT THE TIME OF BREWING.
 ANTIOXDANTS
OXYGEN SCAVENGING AGENTS ARE OFTEN USED IN COMMERCIAL BEERS
TO REDUCE CHANCES OF OFF FLAVOURS DUE TO HIGH DISSOLVED
OXYGEN IN BEER. HOWEVER CRAFT BEERS TRY TO AVOID THEM BY
KEEPING A CLOSE VIGIL ON THE PROCESS, THUS AVOID ADDING
CHEMICAL FLAVOURS COMING FROM THE ANTIOXIDANTS.
 COLORS
ADDING ARTIFICIAL AND VEGETATIVE COLORS ARE ALSO
AT USED IN COMMERCIAL BREWING. HOWEVER MOST
CRAFT BREWERS DO NOT ADVICE IT.
 ENZYMES
TO INCREASE SUGAR EXTRACT WHICH FURTHER
FERMENTS TO PRODUCE HIGHER ALCOHOL IN BEER,
COMMERCIAL LAGERS OWING TO HIGH PRODUCTION
VOLUME UTILIZE ARTIFICAL ENZYME MIXTURES. BUT IN
MICROBREWERIES, ALCOHOL CONTENT OF THE BEER IS
MOSTLY BELOW 5% ABV, AND INCREASED ALCOHOL LEADS
TO ADDITIONAL EXCISE DUTY. THUS MOSTLY ARE NOT
USED. ALSO SINCE MOST OF THIS ARTIFICAL ADDITIVES
WHICH ARE OF ORGANIC NATURE MAY USE GLYCEROL AS A
PRESERVATIVE MAY IMPART A TYPICAL OFF FLAVOUR IN
COMMERCIAL LAGERS, WHICH IS WHY THEY ARE
PREDOMINANTLY AVOIDED BY CRAFT BREWERS
 FINING AGENTS
SEAWEED BASED AND OTHER NATURAL FINING AGENTS ARE COMMONLY USED
DURING BOILING PROCESS OR AFTERWARDS TO OBTAIN CLEARER WORT AND
FINAL PRODUCT.
 YEAST PRECURSORS
ORGANIC AND CHEMICAL YEAST PRECURSORS ARE AT TIMES ADDED DURING
PITCHING FOR SWIFT TRANSITION OF YEAST FROM CULTURE TO WORT SUGAR
CLIMATE AND ACLAMATIZE FOR LOWER LAG PHASE DURATION.
 DRY HOPPING
A COMMON PRACTICE OF ADDING HOPS AFTER OR DURING MATURATION OF BEER
FOR ADDITIONAL AROMA OR BITTERNESS. MOSTLY PRACTICED IN DOUBLE AND
TRIPLE IPA.
 SALTS
VARIOUS SALTS MAY BE ADDED TO MODIFY THE CHEMICAL
STRUCTURE OF THE WATER FOR PREPARATION OF SPECIFIC BEER
STYLES.
 SPICES
SOME SPECIFIC BEER STYLES REQUIRE SPICE ADDITIONS IN
ADDITION TO AROMATIC SPICE NOTES AQUIRED FROM HOPS.
 ORGANIC FLAVOURANTS
FRUITS AND OTHER ADDTIVES TO ENHANCE SUGAR AS WELL
ADDING CHARATERSTIC FLAVOUR TO THE BEER MAY BE ADDED
DURING PROCESS OR AFTER MATURATION FOR SPECIFIC BEER
STYLES.
HONEY,ORGANIC SYRUPS AND LACTOSE POWDER MAY ALSO BE
USED FOR SPECIFIC STYLES OF BEER.
 INVERT SUGAR
SOME HOME BREWERS WHO BOTTLE THEIR CRAFT BEER ADD INVERT
SUGAR/CORN SUGAR TO BEER BEFORE CAPING IT. THIS LEADS TO
SECONDARY FERMENTATION AND PRODUCES EXCESS CARBONATION IN
BEER.
 GASES
CARBON DI OXIDE IS A BY PRODUCT OF FERMENTATION AND RESPONSIBLE
FOR THE HEAD/FROTH IN BEER. IT IS ADDED TO BEER EXTRINSICALLY
FRO VARIOUS REASONS:
1. MAINTAIN BODY OF BEER OVER A PERIOD OF TIME
2. USED AS COUNTER PRESURE FOR DISPENSING BEER
OXYGEN IS INTIALLY REQUIRED BY YEAST IN GROWTH AND INCREASE ITS
POPULATION TO CATER THE AVAILABLE SUGAR IN THE WORT PRESENT.
DURING PITCHING AND TRANSFER OF WORT TO FERMENTERS, OXYGEN
IS MIXED ALONG WITH THEM TO FACILITATE THE MENTIONED IN
APPROPRIATE QUANTITY. HOWEVER APART FROM THIS PROCESS, USE
OF OXYGEN IS TOXIC TO BEER QUALITY.
 GLYCOL
USED TO LOWER THE FREEZING POINT OF WATER. IT USED AS A
CHILLING MEDIUM, MIXED IN APPROPRIATE QUANTITIES WITH
WATER AND CIRCULATED THROUGH CHILLING LINES FOR
REGULATING TEMPERATURE IN TANKS (FERMENTERS, BBT’S AND
PHE). CHILLING IS FACILITATED BY VARIOUS GRADES OF
REFRIGERANT GASES ACROSS RUN BY A COMPRESSOR OF
APPROPRIATE TR.
 EQUIPMENT MAINTENANCE
1. SOLUTIONS TO CLEAN SS/COPPER TANK BODY
2. GREASE AND OIL FOR MOVING PARTS IN MOTORS, VALVES ETC
FOR ROUTINE MAINTENANCE ACTIVITIES.
 CAUSTIC SODA
USED IN SPECIFIC QUANTITIES FOR HOT AND COLD CIP OF SPECIFIC CIP PROCEDURES FOR SPECIFIC
DURATION. CAUTION HAS TO BE MAINTAINED.
 ACID
ALSO USED AFTER CASUTIC CIP TO NEUTRALIZE ITS EFFECTS AND FACILITATE MORE EFFECTIVE CIP
PROCESS. WEAKER ACIDS ARE RECOMMENDED TO BE USED IN SPECIFIC QUANTITIES FOR SPCIFIC
DURATION. ONLY COLD ACID CLEANING IS RECOMMENDED, CAUTION HAS TO BE MAINTAINED.
 COMMERCIAL CLEANING AGENTS
COMMERCIAL ALKALINE OR ACIDIC CONCOCTIONS ARE USED AS A FINAL STEP OF CLEANING AND
DEODORIZATION.
HOT AND COLD WATER FLUSHING IS A PRIMARY STEP FOR ALL CIP PROCESS BEFORE AND AFTER
EVERY CIP PROCESS
SL
NO
BEER TYPE COST PER LTR
1 STANDARD BEER 98
2 PREMIUM BEERS 113
3 SEASONAL/EXOTIC BEERS 150
4 CIDERS 135
SALIENT FEATURES
 PRICES STATED BELOW ARE CLACULATED FOR 1 LTR PILOT PLANT SIZES.
 15%-20% REDUCTION IN PRICE IS CUSTOMARY FOR LARGER BATCHES.
 YEAST HARVESTING AND REUSE REDUCES MAY REDUCE COST BY
ADDITIONAL 30% BASED ON QUALITY OF ACTIVE GENERATIONS.
 OTHER COST EFFECTIVE METHODS USED IN PROCESS ARE ALSO
COMMON.
 PRICES INCLUDE ONLY RAW MATERIAL COST.
 WITH INCREASE IN GRADE MORE SPECIALIZED RAW MATERIALS
IMPORTED/INDIAN WILL BE UTILIZED.
 NO SUBSTANDARD RAW MATERAILS ARE TAKEN INTO CONTEXT, MUST BE
VERIFIED BY HEAD BREWER/CONSULTANT
 UTILITY COST
THIS ADDS 10%-15% OF EXSITING PRODUCTION COST. EXPENSES ARE
RELATED TO FOLLOWING FACTORS:
1. ELETRICITY: CHARGED ON UNITS (KWH). COMMERCIAL LINE
2. FUEL FOR BOILER: IF APPLICABLE
3. ANNUAL MAINTENANCE CONTRACT:
MECHANICAL/ELECTRICAL/PLUMBING/CIVIL (MINUS SPARES)
4. REFRIGERANT: TOPUP IF AND WHEN REQUIRED
5. WATER TREATMENT PLANT (WTP): RO/CANDLE FILTER COMMISSIOING
DEPENDING ON QUALITY OF SOURCE WATER. REGULAR MAINTENANCE
AND CLEANING CHEMICALS INCLUDED
6. EFFLUENT TREATMENT PLANT (ETP/STP): DEPENDING ON SCALE OF
OPERATIONS. MAINTENANCE, REGULAR MONITORING AND CLEANING
COSTS INCLUDED
 INVENTORY MANAGEMENT
PROPER VENTILLATION AND AIR CONDITIOING FOR STORING RAW
MATERAILS. PALLETS AND WEIGHING BALANCE ETC ARE ALSO INCLUDED.
 LABORATORY
BASIC LABORATORY APPARATUS, REAGENTS, CHEMICALS ETC. SEPARATE
ROOM AND WITH AIR CONDITIOING AND ADEQUATE PLUMBING.
 STATIONARY & MISCLENIOUS
COMPUTER & BASIC STATIONARY AS PER REQUIREMENT
 EXCISE, LICENSES, DUTIES AND LEGAL
CAN BE ANNUAL AS WELL AS DUTY PAID PER MONTH OR AS AND WHEN
REQUIRED. TO BE CONFIRMED BY LOCAL EXCISE AND LEGAL
AUTHORITIES.
 FOLLOWING ARE THE TECHNICAL STAFF REQUIREMENTS
FOR MAINTAINING A BREWERY:
1. HEAD BREWER/BREWMASTER-1
2. ASSISTANT BREWER-1
3. TRAINEE BREWER-1
4. HOUSEKEEPING-2
 COST INCURRED FOR HIRING AND MAINTAINING STAFF
WILL BE IN RANGE OF RS 1.7 LAC- 4 LACS PER MONTH.
 FOR HEAD BREWER/ BREWMASTER, BREWERS WITH MORE
THAN 3 YEARS EXPEREINCE IN CRAFT BREWING AND
COMMERCIAL BREWING KNOWLEDGE ARE
RECOMMENDED.
 ADDITONAL CERTIFICATE FROM INSTITUTE OF BREWING
AND DISTILLING, LONDON (IBD) WHICH IS THE ONLY
GLOBALLY ACEPTED COUNCIL WITH VALID ACCREDITION
TO CERTIFY BREWERS SHOULD BE GIVEN MORE
PREFERENCE.
 REMUNERATION ARE NOT SPECIFIC TO PLANT CAPACITY
OR BATCH SIZE, WILL REMAIN SAME FOR BATCHES
RANGING FROM 2.5 HL SYSTEM TO 10 HL SYSTEMS.
 ADDITIONAL PERKS MAY BE APPLICABLE
 FOREIGN BREWERS FOR SHORT PERIODS AVAILABLE FOR
PACKAGE OF ABOVE RS 3 LACS PER MONTH.
 COST INCURRED TO PRODUCTION WILL BE INCREASED BY
25%-30% BASED ON BATCH SIZE AND NUMBER OF BREWS
PER MONTH.
 FINAL COST OF PRODUCTION OF BREWS ARE RANGE FROM:
1. STANDARD BEERS: RS 110/LTR
2. PREMIUM BEERS: RS 130 /LTR
3. SEASONAL/EXOTIC BEER: RS 160 /LTR
4. CIDERS: RS 155 /LTR
 PRICES STATED INCLUDE MAXIMUM PRICES USING BEST
GRADE OF RAW MATERIALS, HOWEVER NONE OF THEM
INCLUDE 100% IMPORTED RAW MATERIALS.
 PRICES ARE STATED CONSIDERING SMALLER BATCH
SYSTEMS (3 HL). PRODUCTION COST WILL DECREASE
ONCE THE BATCH SIZES AND STORAGE CAPACITY OF
PLANT IS INCREASED.
 PRICES NON EXCLUSIVE OF LEGAL AND EXCISE
CHARGES/DUTIES (LEVIED BY STATE).
 PRICES DO NOT INCLUDE PLANT DEPRECIATION COST,
RENT/LOCATION CHARGES AND ANY OTHER
VERTICAL THAT HAS NOT BEEN DISCUSSED
PREVIOUSLY IN THIS REPORT.
 YEAST HARVESTING AND REUSE NOT INCLUDED IN
THE PRICING. THUS PRICES ARE SUBJECT TO GET
LOWER BY 20% MINIMUM.
• THE 3 FACTORS THAT PLAY VITAL ROLE IN EVERY
PERSPECTIVE OF YOUR CRAFT BREWERY:
• 1. EQUIPMENT
• 2. RAW MATERIALS
• 3. BREWER
WE WILL BE DISCUSSING THE 3 RD FACTOR VERY SOON.
 THE AUTHOR HAS EXTENSIVE EXPEREINCE CLOSE TO 8 YEARS IN
VARIOUS COMMERCIAL AND MICROBREWERIES ACROSS INDIA. AN
AVID CONTRIBUTOR TO THE MICROBREWERY SCENE IN INDIA
SINCE ITS INCEPTION IN 2007. HE HAS HNADLED DIFFERENT
TECHNICAL ROLES WITH REGARD TO BREWING, EQUIPMENT
DESIGN, MODIFICATION,
CEHMICAL/BIOCHEMICAL/BIOCHEMICAL/SENSORY ANALYSIS OF
BEER AND RAW MATERIALS, MANUFACTURING AND BOTTLING,
RECIPE DEVELOPMENT, R&D, PRODUCT EXCELLANCE SERVICES,
COST SHEET ESTIMATIONS, PROJECT SETUP, FINANCIAL AND
MARKETING FORECASTING, INVENTORY MANAGEMENT, VENDOR
DEVELOPMENT, ETP, WTP ETC
 FOR FURTHER QUERIES, CONSULTATION OR QUOTES FEEL FREE
TO SEND US AN ENQUIRY TO :
brewindo@gmail.com
ALSO CHECK OUT FACEBOOK PAGE(LIKE AND SHARE, FOR MORE
INFOS)
https://www.facebook.com/microbreweryindia?ref=bookmarks

Microbrewery in india- raw materials

  • 1.
    4TH PART INSERIES OF MCROBREWERIES IN INDIA. KINDLY REFER TO FOLLOWING PRESENTATIONS FOR MORE DETAILED OVERVIEW: http://www.slideshare.net/ritwik9/setting-up-a-microbrewery http://www.slideshare.net/ritwik9/brewpub-amp-microbrewery- in-india?related=1 http://www.slideshare.net/ritwik9/microbrewery-in-india- equipments-52424466
  • 2.
     MALT THEY AREREGARDED AS THE MAIN SOURCE OF SUGAR WHICH IS CONSUMED BY YEASTS DURING FERMENTATION TO PRODUCE ALCOHOL (ETHANOL) AND CARBON-DI-OXIDE (THE HEAD OF BEER). BARLEY GRAINS ARE THE MOST ABUNDANTLY USED RAW MATERIAL USED FOR MAKING BEER. MALTING IS A PROCESS THAT TAKES PLACE IN MALTING INDUSTRY FOR 25 DAYS TO A MONTH, WHERE THE SIMPLE BARLEY GRAIN DEVELOPS MORE CHARACTERSTIC FLAVOUR, COLOUR AND BETTER CONVERSION POTENTIAL FOR SUGAR GENERATION. OTHER THAN BARLEY, WHEAT , RYE AND SOME OTHER GRAINS ARE ALSO USED IN MALT FROM FOR SPECIAL BER STYLES. OTHER FORMS OF MALT: MALT IS ALSO AVAILABLE IN LIQUID FORM CALLED, MALT EXTRACT, USED BY SOME BREWERS FOR EXTRACT BREWING, HOWEVER ARE COSTLY AND DIFFICULT TO MAINTAIN. DME (DRY MALT EXTRACT) ARE UTILIZED BY SOME TYPICAL BREWING EQUIPMENTS AS WELL.
  • 3.
    TYPES OF MALTS 1.PALE/BASE MALT 2. SPECIALIZED MALT 3. ROASTED/DARK MALT 4. WHEAT MALT 5. OTHER GRAIN MALTS BASED ON THEIR SUGAR AND INSTRINSIC ENZYMES, MALTS CAN BE SUBDIVIDIED INTO 2 VARIETIES: 1. 2 ROW MALT: HIGHER SUGAR POTENTIAL 2. 6 ROW MALT: HIGHER ENZYME POTENTIAL BASED ON ORIGIN MALT CAN BE OF 2 TYPES: 1. INDIAN MALT: MOSTLY 6 ROW 2. IMPORTED MALT: MOSTLY 2 ROW THEY ARE GENERALLY AVAILABLE IN FOLLOWING CAPACITY(KG) 1. 50 KG BAGS (INDIAN) 2. 45 KG BAGS (INDIAN) 3. 25 KG BAGS (IMPORTED)
  • 4.
    Sl noMalt type Avgprice india(Rs/kg) Avg price imported (Rs/kg) 12 row 60-70 90-135 26 row 40-50 70-90 3wheat malt 50-70 115-145 4dark malt 110-120 115-190 6roasted malt 140-160 115-200 7speciality malt 110-130 170-195
  • 5.
     HOPS HOPS AREDERIVED FROM CONES OF CONIFEROUS TREES. THEY AREPREDOMINANTLY GROWN IN EUROPE.RESPONSIBLE FOR THE TYPICAL FLAVOUR OF BEER, OWING TO FOLLOWING TYPES OF HOPS 1. BITTERNESS HOP VARIETIES 2. AROMATIC HOP VARITEIS THEIR MORE THAN 300 TYPES OF HOPS AND MOSTLY THEY ARE AVAILALE IN FOLLOWING FORMS: 1. WHOLE HOP CONES 2. DRY PELLETS 3. HOP OILS 4. HOP EXTRACTS HOP CONES ARE THE NATURAL FORM HOWEVER THEY YEILD LOW AROMA AND BITTERNESS POTENTIAL AND ARE REQUIRED IN HUGE QUANTITIES, AT THE SAME TIME BEING IN VEGETATIVE FORM THEY ARE DIFFICULT TO MAINTAIN, HENCE ARE NOT SO COST EFFECTIVE FOR RECURRING BEER STYLES.
  • 6.
     HOP OILSAND EXTRACTS ARE PRE ISOMERIZED FORMS AAND REQUIRED IN MUCH LOWER QUANTITY, HOWEVER PROCUREMENT AND MAINTENANCE OF NECESSARY TYPES IS DIFFICULT APART FROM BEING EXPENSIVE. HOP PELLETS ARE THE MOST COST EFFECTIVE EASILY AVAILABLE HOP FORM THAT IS EASY TO STORE FOR LONGER DURATIONS, HENCE BEING USED MOST WIDELY BOTH IN COMMERCIAL AND MICROBREWERY.  HOPS ARE GENERALLY NOT GROWN IN INDIA AND MOSTLY IMPORTED THROUGH IMPORT AGENTS. THEY ARE GENERALLY AVAILABLE IN 5 KG BAGS.  HOPS ARE ADDED AT THE END OF BOILING. HOWEVER DRY HOPPING IS ALSO PRACTICED IN VARIOUS STYLES OF BEER AFTER MATURATION FOR DISTINCT AROMA AND BITTERNESS.
  • 7.
    Sl no Hopstype Avg price(Rs/kg) 1 bitter 1450-1800 2 aroma 2150-4500
  • 8.
     YEAST MICROORGANISMS, MODIFIEDOR TRUE FORM RESPONSIBLE FOR FERMENTATION PROFILES IN BEER. IT USES AVAILABLE FERMENTABLE SUGARS OBTAINED AFTER THE MASHING OF MALT IN PRESENCE OF INTRINSIC ENZYMES TO CONVERT THEM TO ALCOHOL AND CARBONDIOXIDE. EACH YEAST HAS ITS OWN CHARACTERESTIC FACTORS: 1. FLAVOUR IMPARTED TO BEER 2. TYPE OF RAW MATERIAL IT USES 3. VIABILITY 4. PITCHING TEMPERATURE 5. ACIDITY 6. CELL COUNT FOR ACTIVITY 7. PRECIPITATION COEFFICIENT 8. MODE OF ACTION YEASTS ARE MOSTLY IMPORTED FROM USA AND EUROPE BASED ON THE TYPICAL STYLE OF BEERTHEY ARE BEING USEDFOR. THERE ARE OVER 100 TYPICAL POPULAR STYLES OF YEAST AVAILABLE
  • 9.
    BASED ON ITSMODE OF ACTION,YEAST CAN BE USED TO MAKE 2 KINDS OF BEER: 1. LAGER STYLES USED BOTTOM FERMENTING YEAST 2. ALE STYLES USE TOP FERMENTING YEAST ALSO FOR CIDER, A SPECIALIZED YEAST WHICH RESEMBLES CHAMPAGNE/WINE YEAST IS USED. YEAST CAN BE OBTAINED IN 2 FORMS: 1. POWDERED DRY YEAST: AVAILABLE IN 500 GM PACKS 2. LIQUID YEAST: AVAILABLE IN 100 ML VIALS A YEAST CAN BE REUTLIZED BASED ON ITS QUALITY/VIABILITY AND CELL COUNT, THIS IS CALLED HARVESTING OF YEAST AND REPITCHING. IT CAN BE CARREID OUT AS LONG THE ABOVE FACTORS ARE VERIFIED IN LABORATORY. GENERALLY A YEAST TYPE CAN BE USED FOR MINIMUM 8 GERNATIONS IF HANDLED PROPERLY. YEAST STORAGE AND PROPAGATION IS ALSO CARREID TO INCREASE THE SUBSEQUENT GENERATIONS OF A BACTH OF YEAST MULTIPLE TIMES AND REQUIRES A SPECIALIZED LABORATORY AND EQUIPMENT. LIQUID YEAST IS MOSTLY USED IN THIS PROCESS, DRY POWDERED YEAST CAN ALSO BE FOR DIRECT PITHING.
  • 10.
    Sl no Yeasttype Avg price(Rs/kg) 1 ale yeast 11000-15000 2 wheat yeast 14000-18000 3 lager yeast 17500-21500 4 cider yeast 8000-10000
  • 11.
     ADJUNCTS (IFREQUIRED) ACCORDING GERMAN BEER PURITY LAW OF REINHEITSGEBOT, BEER PRODUCTION SHOULD NOT USE ANY OTHER RAW MATERIAL OTHER THAN MALT, YEAST, HOPS AND WATER. HOWEVER SOME BREWERS USE VARIED SUGAR SOURCES FOR FOLLOWING REASONS: 1. INCREASED SUGAR POTENTIAL OF MASH, THUS YIELDING HIGHER ALCOHOL 2. CHEAPER SOURCE OF SUGAR AS COMPARED TO MALT 3. MAY BE EASY TO USE AND STORE 4. PROVIDE DIFFERENT TEXTURE AND FLAVOUR PROFILE TO BEER THEY ARE GENERALLY LOCALLY AVAILABLE (MOSTLY IN 50 KG BAGS) AND CAN BE PROCURED EASILY. USE OF ADJUNCTS IS POPULAR IN COMMERCIAL BREWERIES. GENERALLY THEY ARE EITHER ADDED DURING MASHING OR DURING BOILING, DEPENDING ON THE NATURE OF ADJUNCTS.
  • 12.
     SOME EXAMPLESFOR THEM ARE AS FOLLOWS: 1. PRE GELATINIZED RICE FLAKES 2. PRE GELATINIZED OAT FLAKES 3. PRE GELATINIZED CORN FLAKES 4. PRE GELATINIZED RYE FLAKES 5. NON GELATINIZED WHEAT/OATS 6. SUGAR 7. MAPLE OR OTHER SUGARY SYRUPS 8. MOLASSES  GENERALLY THEIR PRICE RANGE VARIES FROM RS 55-90 PER KG.  THEIR USE SHOULD ALWAYS BE BELOW 50% OF THE TOTAL MALT QUANTITY.  SOME EXAMPLES OF STYLES THAT USE TYPICAL ADJUNCTS: 1. STOUT 2. BLONDE ALES 3. LAGERS
  • 13.
     FLAVOURANTS SOME OTHERMATERIALS MAY BE ADDED TO A BEER FOR TYPICAL FLAVOUR AND MOUTH FEEL CHARACTERESTICS.  CLARIFIERS NATURAL AND ARTIFICIAL CLARIFIERS MAY BE USED IN PROCESSING TO GET A CLEARER BEER. HOWEVER MOST CRAFT BEERS AVOID USING THEM EXCEPT FOR A FEW NATURAL ONES ADDED AT THE TIME OF BREWING.  ANTIOXDANTS OXYGEN SCAVENGING AGENTS ARE OFTEN USED IN COMMERCIAL BEERS TO REDUCE CHANCES OF OFF FLAVOURS DUE TO HIGH DISSOLVED OXYGEN IN BEER. HOWEVER CRAFT BEERS TRY TO AVOID THEM BY KEEPING A CLOSE VIGIL ON THE PROCESS, THUS AVOID ADDING CHEMICAL FLAVOURS COMING FROM THE ANTIOXIDANTS.
  • 14.
     COLORS ADDING ARTIFICIALAND VEGETATIVE COLORS ARE ALSO AT USED IN COMMERCIAL BREWING. HOWEVER MOST CRAFT BREWERS DO NOT ADVICE IT.  ENZYMES TO INCREASE SUGAR EXTRACT WHICH FURTHER FERMENTS TO PRODUCE HIGHER ALCOHOL IN BEER, COMMERCIAL LAGERS OWING TO HIGH PRODUCTION VOLUME UTILIZE ARTIFICAL ENZYME MIXTURES. BUT IN MICROBREWERIES, ALCOHOL CONTENT OF THE BEER IS MOSTLY BELOW 5% ABV, AND INCREASED ALCOHOL LEADS TO ADDITIONAL EXCISE DUTY. THUS MOSTLY ARE NOT USED. ALSO SINCE MOST OF THIS ARTIFICAL ADDITIVES WHICH ARE OF ORGANIC NATURE MAY USE GLYCEROL AS A PRESERVATIVE MAY IMPART A TYPICAL OFF FLAVOUR IN COMMERCIAL LAGERS, WHICH IS WHY THEY ARE PREDOMINANTLY AVOIDED BY CRAFT BREWERS
  • 15.
     FINING AGENTS SEAWEEDBASED AND OTHER NATURAL FINING AGENTS ARE COMMONLY USED DURING BOILING PROCESS OR AFTERWARDS TO OBTAIN CLEARER WORT AND FINAL PRODUCT.  YEAST PRECURSORS ORGANIC AND CHEMICAL YEAST PRECURSORS ARE AT TIMES ADDED DURING PITCHING FOR SWIFT TRANSITION OF YEAST FROM CULTURE TO WORT SUGAR CLIMATE AND ACLAMATIZE FOR LOWER LAG PHASE DURATION.  DRY HOPPING A COMMON PRACTICE OF ADDING HOPS AFTER OR DURING MATURATION OF BEER FOR ADDITIONAL AROMA OR BITTERNESS. MOSTLY PRACTICED IN DOUBLE AND TRIPLE IPA.
  • 16.
     SALTS VARIOUS SALTSMAY BE ADDED TO MODIFY THE CHEMICAL STRUCTURE OF THE WATER FOR PREPARATION OF SPECIFIC BEER STYLES.  SPICES SOME SPECIFIC BEER STYLES REQUIRE SPICE ADDITIONS IN ADDITION TO AROMATIC SPICE NOTES AQUIRED FROM HOPS.  ORGANIC FLAVOURANTS FRUITS AND OTHER ADDTIVES TO ENHANCE SUGAR AS WELL ADDING CHARATERSTIC FLAVOUR TO THE BEER MAY BE ADDED DURING PROCESS OR AFTER MATURATION FOR SPECIFIC BEER STYLES. HONEY,ORGANIC SYRUPS AND LACTOSE POWDER MAY ALSO BE USED FOR SPECIFIC STYLES OF BEER.
  • 17.
     INVERT SUGAR SOMEHOME BREWERS WHO BOTTLE THEIR CRAFT BEER ADD INVERT SUGAR/CORN SUGAR TO BEER BEFORE CAPING IT. THIS LEADS TO SECONDARY FERMENTATION AND PRODUCES EXCESS CARBONATION IN BEER.  GASES CARBON DI OXIDE IS A BY PRODUCT OF FERMENTATION AND RESPONSIBLE FOR THE HEAD/FROTH IN BEER. IT IS ADDED TO BEER EXTRINSICALLY FRO VARIOUS REASONS: 1. MAINTAIN BODY OF BEER OVER A PERIOD OF TIME 2. USED AS COUNTER PRESURE FOR DISPENSING BEER OXYGEN IS INTIALLY REQUIRED BY YEAST IN GROWTH AND INCREASE ITS POPULATION TO CATER THE AVAILABLE SUGAR IN THE WORT PRESENT. DURING PITCHING AND TRANSFER OF WORT TO FERMENTERS, OXYGEN IS MIXED ALONG WITH THEM TO FACILITATE THE MENTIONED IN APPROPRIATE QUANTITY. HOWEVER APART FROM THIS PROCESS, USE OF OXYGEN IS TOXIC TO BEER QUALITY.
  • 18.
     GLYCOL USED TOLOWER THE FREEZING POINT OF WATER. IT USED AS A CHILLING MEDIUM, MIXED IN APPROPRIATE QUANTITIES WITH WATER AND CIRCULATED THROUGH CHILLING LINES FOR REGULATING TEMPERATURE IN TANKS (FERMENTERS, BBT’S AND PHE). CHILLING IS FACILITATED BY VARIOUS GRADES OF REFRIGERANT GASES ACROSS RUN BY A COMPRESSOR OF APPROPRIATE TR.  EQUIPMENT MAINTENANCE 1. SOLUTIONS TO CLEAN SS/COPPER TANK BODY 2. GREASE AND OIL FOR MOVING PARTS IN MOTORS, VALVES ETC FOR ROUTINE MAINTENANCE ACTIVITIES.
  • 19.
     CAUSTIC SODA USEDIN SPECIFIC QUANTITIES FOR HOT AND COLD CIP OF SPECIFIC CIP PROCEDURES FOR SPECIFIC DURATION. CAUTION HAS TO BE MAINTAINED.  ACID ALSO USED AFTER CASUTIC CIP TO NEUTRALIZE ITS EFFECTS AND FACILITATE MORE EFFECTIVE CIP PROCESS. WEAKER ACIDS ARE RECOMMENDED TO BE USED IN SPECIFIC QUANTITIES FOR SPCIFIC DURATION. ONLY COLD ACID CLEANING IS RECOMMENDED, CAUTION HAS TO BE MAINTAINED.  COMMERCIAL CLEANING AGENTS COMMERCIAL ALKALINE OR ACIDIC CONCOCTIONS ARE USED AS A FINAL STEP OF CLEANING AND DEODORIZATION. HOT AND COLD WATER FLUSHING IS A PRIMARY STEP FOR ALL CIP PROCESS BEFORE AND AFTER EVERY CIP PROCESS
  • 20.
    SL NO BEER TYPE COSTPER LTR 1 STANDARD BEER 98 2 PREMIUM BEERS 113 3 SEASONAL/EXOTIC BEERS 150 4 CIDERS 135
  • 21.
    SALIENT FEATURES  PRICESSTATED BELOW ARE CLACULATED FOR 1 LTR PILOT PLANT SIZES.  15%-20% REDUCTION IN PRICE IS CUSTOMARY FOR LARGER BATCHES.  YEAST HARVESTING AND REUSE REDUCES MAY REDUCE COST BY ADDITIONAL 30% BASED ON QUALITY OF ACTIVE GENERATIONS.  OTHER COST EFFECTIVE METHODS USED IN PROCESS ARE ALSO COMMON.  PRICES INCLUDE ONLY RAW MATERIAL COST.  WITH INCREASE IN GRADE MORE SPECIALIZED RAW MATERIALS IMPORTED/INDIAN WILL BE UTILIZED.  NO SUBSTANDARD RAW MATERAILS ARE TAKEN INTO CONTEXT, MUST BE VERIFIED BY HEAD BREWER/CONSULTANT
  • 22.
     UTILITY COST THISADDS 10%-15% OF EXSITING PRODUCTION COST. EXPENSES ARE RELATED TO FOLLOWING FACTORS: 1. ELETRICITY: CHARGED ON UNITS (KWH). COMMERCIAL LINE 2. FUEL FOR BOILER: IF APPLICABLE 3. ANNUAL MAINTENANCE CONTRACT: MECHANICAL/ELECTRICAL/PLUMBING/CIVIL (MINUS SPARES) 4. REFRIGERANT: TOPUP IF AND WHEN REQUIRED 5. WATER TREATMENT PLANT (WTP): RO/CANDLE FILTER COMMISSIOING DEPENDING ON QUALITY OF SOURCE WATER. REGULAR MAINTENANCE AND CLEANING CHEMICALS INCLUDED 6. EFFLUENT TREATMENT PLANT (ETP/STP): DEPENDING ON SCALE OF OPERATIONS. MAINTENANCE, REGULAR MONITORING AND CLEANING COSTS INCLUDED
  • 23.
     INVENTORY MANAGEMENT PROPERVENTILLATION AND AIR CONDITIOING FOR STORING RAW MATERAILS. PALLETS AND WEIGHING BALANCE ETC ARE ALSO INCLUDED.  LABORATORY BASIC LABORATORY APPARATUS, REAGENTS, CHEMICALS ETC. SEPARATE ROOM AND WITH AIR CONDITIOING AND ADEQUATE PLUMBING.  STATIONARY & MISCLENIOUS COMPUTER & BASIC STATIONARY AS PER REQUIREMENT  EXCISE, LICENSES, DUTIES AND LEGAL CAN BE ANNUAL AS WELL AS DUTY PAID PER MONTH OR AS AND WHEN REQUIRED. TO BE CONFIRMED BY LOCAL EXCISE AND LEGAL AUTHORITIES.
  • 24.
     FOLLOWING ARETHE TECHNICAL STAFF REQUIREMENTS FOR MAINTAINING A BREWERY: 1. HEAD BREWER/BREWMASTER-1 2. ASSISTANT BREWER-1 3. TRAINEE BREWER-1 4. HOUSEKEEPING-2  COST INCURRED FOR HIRING AND MAINTAINING STAFF WILL BE IN RANGE OF RS 1.7 LAC- 4 LACS PER MONTH.  FOR HEAD BREWER/ BREWMASTER, BREWERS WITH MORE THAN 3 YEARS EXPEREINCE IN CRAFT BREWING AND COMMERCIAL BREWING KNOWLEDGE ARE RECOMMENDED.
  • 25.
     ADDITONAL CERTIFICATEFROM INSTITUTE OF BREWING AND DISTILLING, LONDON (IBD) WHICH IS THE ONLY GLOBALLY ACEPTED COUNCIL WITH VALID ACCREDITION TO CERTIFY BREWERS SHOULD BE GIVEN MORE PREFERENCE.  REMUNERATION ARE NOT SPECIFIC TO PLANT CAPACITY OR BATCH SIZE, WILL REMAIN SAME FOR BATCHES RANGING FROM 2.5 HL SYSTEM TO 10 HL SYSTEMS.  ADDITIONAL PERKS MAY BE APPLICABLE  FOREIGN BREWERS FOR SHORT PERIODS AVAILABLE FOR PACKAGE OF ABOVE RS 3 LACS PER MONTH.  COST INCURRED TO PRODUCTION WILL BE INCREASED BY 25%-30% BASED ON BATCH SIZE AND NUMBER OF BREWS PER MONTH.
  • 26.
     FINAL COSTOF PRODUCTION OF BREWS ARE RANGE FROM: 1. STANDARD BEERS: RS 110/LTR 2. PREMIUM BEERS: RS 130 /LTR 3. SEASONAL/EXOTIC BEER: RS 160 /LTR 4. CIDERS: RS 155 /LTR  PRICES STATED INCLUDE MAXIMUM PRICES USING BEST GRADE OF RAW MATERIALS, HOWEVER NONE OF THEM INCLUDE 100% IMPORTED RAW MATERIALS.  PRICES ARE STATED CONSIDERING SMALLER BATCH SYSTEMS (3 HL). PRODUCTION COST WILL DECREASE ONCE THE BATCH SIZES AND STORAGE CAPACITY OF PLANT IS INCREASED.
  • 27.
     PRICES NONEXCLUSIVE OF LEGAL AND EXCISE CHARGES/DUTIES (LEVIED BY STATE).  PRICES DO NOT INCLUDE PLANT DEPRECIATION COST, RENT/LOCATION CHARGES AND ANY OTHER VERTICAL THAT HAS NOT BEEN DISCUSSED PREVIOUSLY IN THIS REPORT.  YEAST HARVESTING AND REUSE NOT INCLUDED IN THE PRICING. THUS PRICES ARE SUBJECT TO GET LOWER BY 20% MINIMUM. • THE 3 FACTORS THAT PLAY VITAL ROLE IN EVERY PERSPECTIVE OF YOUR CRAFT BREWERY: • 1. EQUIPMENT • 2. RAW MATERIALS • 3. BREWER WE WILL BE DISCUSSING THE 3 RD FACTOR VERY SOON.
  • 28.
     THE AUTHORHAS EXTENSIVE EXPEREINCE CLOSE TO 8 YEARS IN VARIOUS COMMERCIAL AND MICROBREWERIES ACROSS INDIA. AN AVID CONTRIBUTOR TO THE MICROBREWERY SCENE IN INDIA SINCE ITS INCEPTION IN 2007. HE HAS HNADLED DIFFERENT TECHNICAL ROLES WITH REGARD TO BREWING, EQUIPMENT DESIGN, MODIFICATION, CEHMICAL/BIOCHEMICAL/BIOCHEMICAL/SENSORY ANALYSIS OF BEER AND RAW MATERIALS, MANUFACTURING AND BOTTLING, RECIPE DEVELOPMENT, R&D, PRODUCT EXCELLANCE SERVICES, COST SHEET ESTIMATIONS, PROJECT SETUP, FINANCIAL AND MARKETING FORECASTING, INVENTORY MANAGEMENT, VENDOR DEVELOPMENT, ETP, WTP ETC  FOR FURTHER QUERIES, CONSULTATION OR QUOTES FEEL FREE TO SEND US AN ENQUIRY TO : brewindo@gmail.com ALSO CHECK OUT FACEBOOK PAGE(LIKE AND SHARE, FOR MORE INFOS) https://www.facebook.com/microbreweryindia?ref=bookmarks