BREWING PROCESSBEER MANUFACTURING PROCESS ( BREWING)

BY: TA R U N YA D AVB . T E C H , F O O D T E C H N O LO G Y A N D M A N A G E M E N T, N I F T E M

BRANDS

BEER• Beer is a fermented, carbonated, alcoholic drink prepared by

fermenting the malted cereal grains, mainly malted barley. • Process of beer manufacturing is called brewing process.• On the basis of alcohol content beer can be: light, medium,

strong.• On the basis of fermentation type it can be: Lager or ale

beer.

BREWING PROCESSCleaning and

Milling

Mashing

Lautering/wort separation

Wort Boiling

Whirlpool

Wort Cooling

Fermentation

Maturation

Filteration

Bottling

Pasteurization

Labeling and packging

CLEANING AND MILLING• Raw material from the raw material pits are transferred into

the silos, from there it was transferred to the cleaning section.

• Cleaning of raw material includes various steps:1. Aspiration and cyclone cleaning. Done for the removal of

dust and lighter particles.2. Sieving: use sieves to remove particles size smaller and

lager than malts.3. De-stoner and magnate: In the process stones and any

metallic particle is removed.

• Milling: Milling is done to break the malted grains into two or three smaller particles.

• The main purpose of milling is to break the grain particles into 2 or 3 smaller particles, so that its surface area increases and it becomes easy for enzymes to penetrate into the grains as the broken particles have open side ends with peptide layers. So they can directly act on the starch present inside the grain.

DIFFERENT MASHING METHODS• Different mashing methods are used for different type of the

beers. Like decoction, infusion, time-temperature mashing, etc.

• Type of beer produced depends upon the mashing schedule used. Like a mashing schedule with more rest at different temperatures will have more amount of fermentable sugar, and hence may have more alcohol content.

MASHING • Mashing: Mashing is a process in which mash

material( malted barley grains and adjuncts) are subjected to different time temperature conditions.

• The main purpose of mashing is to convert the starch available in the grains into fermentable sugars.

• Therefore, mash mass is allowed to rest at different temperature for different time periods.

• These rests provide the required temperature conditions at which different enzymes gets activated and cause the required change in the mash.

MASHING• During mashing , water at 45˚C is pumped in the mash tuns.

Malted barley grains are hydrated and mixed with this water by using hydrators.

• Then the mash mass is allowed to rest at 45˚C for nearly 10-15 minutes.

• Then the temperature is slowly increased to 55˚C and then allowed to rest for 20-30 minutes.

• Then again temperature is raised to 62˚C and like this upto 73-75˚C with a rest of nearly 25-30 minutes at each temperature.

• For increasing the temperature either the vessel is heated using steam or hot water is added.

MASHING SCHEDULE• Mashing schedule includes rest of mash material( mashing

liquor + malted barley) at different time-temperature profiles.

•

LAUTERING/WORT EXTRACTION• Wort: wort is a sugary liquid obtained from the mashing of malted

grains . Wort consist high amount of fermentable sugars which are required by the yeast as a food during fermentation.

• Lautering is the process which is used for the extraction of wort from the mash mass after mashing process.

• Lautering is done in lauter tuns.• Mash mass after mashing is transferred in the lauter tun from the

mash tun. Then the mash is allowed to stand for nearly 10-15 minutes and then wort is extracted.

• Generally wort is recirculated in the lauter tuns to obtain clear wort. Settled grains at the bottom of the lauter tun acts as a filter. Hot water at 72˚C is sprinkled on the grains to remove all the sugar from the mashed grains.

WORT BOILING• The next step includes boiling of the obtained wort.• For this purpose wort boiling kettles are used. Wort is

generally boiled at high temperatures of nearly 110-140˚C under pressure or without pressure.

• Wort boiling plays a number of roles, it kills all the microbes and makes the wort sterile, it causes mallard's reaction and therefore helps In the development of the color of the beer, degrades the proteins which can be removed as hot turbs therefore makes the wort clear, high temperature also isomerize the alpha-acids of the hops which gives the characteristic flavor of the beer. therefore hops addition is done during this step.

WORT BOILING• Hops in the form of hops extract and hops pellets are added

in the wort. Hops addition is done through the hops dosing tank which pumps and mixes the hops by circulating it through the whole tank at high pressure.

• Wort boiling is done till the wort’s specific gravity reached to the required range specific gravity.

• Specific gravity of wort increases during wort boiling because water is evaporated during this process.

WHIRLPOOL• Whirlpool is a device which is used by all the major

breweries.• Whirlpools are used for the clarification the boiled wort. It

also removes the suspended protein which gets denatured due to high temperature of boiling.

• In whirlpool, hot wort is injected tangentially at 30˚to the tangent to the vessel wall.

• The tangential injection causes the wort to rotate and the centrifugal force due to rotation cause the big particles to get accumulated on the top of the wort.

WORT COOLING• Wort form the whirlpools are then either stored in wort

storing kettles and then transferred to the Plate heat exchangers(PHE) or directly transferred to the PHE.

• In PHE, wort temperature is reduced to the temperature which is required for the fermentation process, which is 10-12˚C.

• Then this cooled wort is transferred to the conical fermenters situated in the fermentation section.

FERMENTATION

• Fermentation of the beer is done for 7-8 days.• For the first 3-4 days fermentation is done at temperature

between 10-12 ˚C. • After 3-4 days of fermentation at 10-12˚C, yeast starts

producing di-acetyl, which gives undesirable taste to the beer.• At 15˚C, yeast doesn’t secret di-acetyl and consumes the

produced di-acetyl, therefore for next 3-4 days fermentation is carried out at 15˚C.

• Then the temperature is reduced to 4˚C suddenly. • Maturation is done at 0-(-1)˚C.

FILTRATION• One of the major characteristic of beer is, its sparkling clear

appearance.• Therefore beer after maturation is required to be cleared by

passing it through filters.• Filtration is done to remove tanins, cold turbs( denatured

proteins), dead yeast cells and other products which formed during the beer manufacturing and may cause problem in the beer clearance.

• Filtration of beer is done at sub-zero or zero degree temperature.

FILTRATION• Beer at 0 or sub-zero ˚C is first filtered through kiseleghur

filters, in which filter aids like fine sand or high flow powder are used for filtration.

• Then the beer is passed through the multi-bag filters, in order to remove or filter out the remaining particles and if any filter aid comes into the beer.

• After filtration bio-form and KMS are pumped through chemical dosing tanks and then Carbonation of beer is done.

BOTTLING• After filtration, beer is stored in Bright Beer Tanks( BBT) from

where it is pumped into the bottling section.• Bottles after washing from the washer are then filled with

beer at high carbon di-oxide pressure. • Then the bottles are capped with crown caps and then

forwarded to the pasteurization section for the beer pasteurization.

PASTEURIZATION • Pasteurization of beer is generally carried out in a tunnel

pasteurizers. • In tunnel pasteurization bottles or cans are filled and closed

in the normal way.  The tunnel has a low ceiling with spray heads at regular intervals.

• The tunnel is divided into many temperature zones to slowly bring the product up to temperature, keep them at a specified holding temperature and then bring them back down to room temperature.

• As the beer moves through the tunnel it is gradually heated to the pasteurization temperature of 60°C(140°F) and held at that temperature for a defined period of time before being cooled back down to 20°C (68°F).

WATER TREATMENT PLANTWater

From Bore well

MGF/Sand filter

Softener ACF

Disinfectant

MCF R.O

R.O tank

CLEAN IN PLACEIn the company CIP is carried out in following manners:1. Three step CIP.2. Five step CIP.3. Seven Step CIP.

CIP

THREE STEPS CIP

Pre rinse with water for 10 minutes

Rinse with hot water for 20 minutes at 85 C⁰

Final rinse with RO water for 10 minutes

CIP

FIVE STEPS CIP

Pre rinse with water for 10 minutes

Rinse with hot water using caustic for 20 minutes at 65 C ⁰

Rinse with water for 10 minutes for complete removal of caustic

Rinse with hot water for 20 minutes at 85 C ⁰

Final rinse with RO water for 10 minutes

CIP

SEVEN STEPS CIP

Final rinse with RO water for 10 minutes

Rinse with hot water for 20 minutes at 85 C ⁰

Rinse with water for complete removal of acid for 10 minutes

Acid circulation for 20 minutes at 65 C ⁰

Rinse with water for complete removal of caustic for 10 minutes

Rinse with caustic for 20 minutes at 65 C ⁰

Pre rinse with water for 10 minutes

Thank You !