Summer Internship Report

On

MANAGEMENT OF PROCESS AND BOTTLING IN UNITED BREWERIES LIMITED, KALYANI (WEST BENGAL)

By

Vijay Kumar JaiswalA0101909012

MBA Class of 2011

Under the Supervision ofMs. Bhavna Ranjan

Department of Finance

In Partial Fulfillment of Award of Master of Business Administration

AMITY BUSINESS SCHOOLAMITY UNIVERSITY UTTAR PRADESH

SECTOR 125, NOIDA - 201303, UTTAR PRADESH, INDIA2010

1

AMITY UNIVERSITY UTTAR PRADESH

AMITY BUSINESS SCHOOL

DECLARATION

I, Vijay Kumar Jaiswal student of Masters of Business Administration from Amity Business

School, Amity University Uttar Pradesh hereby declare that I have completed Summer

Internship on “MANAGEMENT OF PROCESS AND BOTTLING IN UNITED BREWERIES

LIMITED, KALYANI (WEST BENGAL)” as part of the course requirement .

I further declare that the information presented in this project is true and original to the best of

my knowledge.

Date: 16/07/10 Vijay Kumar Jaiswal

Enroll. No: A0101909012

Place: Noida MBA Class of 2011

2

UNITED BREWERIES LIMITED KALYANI

CERTIFICATE

I, hereby certify that Vijay Kumar Jaiswal student of Masters of Business Administration at

Amity Business School, Amity University Uttar Pradesh has completed Summer Internship on

project “Management of Process and Bottling at United Breweries Limited Kalyani ”, under my

guidance.

Mr. G. S. Lodh

Head Brewer

United Breweries Limited

Kalyani, India

3

AMITY UNIVERSITY UTTAR PRADESH

AMITY BUSINESS SCHOOL

CERTIFICATE

I hereby certify that Vijay Kumar Jaiswal student of Masters of Business Administration at

Amity Business School, Amity University Uttar Pradesh has completed Summer Internship on

“MANAGEMENT OF PROCESS AND BOTTLING IN UNITED BREWERIES LIMITED,

KALYANI (WEST BENGAL)”, under my guidance.

Ms. Bhavna Ranjan

(Lecturer/Asst. Prof./Prof.)

Department Finance

4

Acknowledgement

Several people have been very helpful in making this project. At the very onset I would like to

acknowledge the assistance of Mr. G. S. Lodh, my Industry Mentor and the Head Brewer of

United Breweries Limited, Kalyani unit. Without his support and permission this project would

have been an impossible task.

I would like to deeply appreciate the contribution of Mr. Rakesh Bhattacharya, the General

Manager of the company for guiding me in this project with the required information about the

unit.

I am grateful to Mr. Bhaskar Sen, the HR Manager of the unit for helping me out in

understanding the company and its processes from the very first day in the plant till the

completion of the project.

I also thank Mr. Arpon Banerjee (Shift Brewer), Mr. Surajit Saha (Assistant Brewer) and

Mr. Acharjee (Shift Brewer) for their support in making in understand all the minute details of

the different processes employed in the manufacture of beer.

Further, I would like to convey my gratitude to all the workers of the plant of all the different

departments in helping me out in knowing the details of all the respective departments of the

plant and the processes involved in it.

I would like to thank Ms. Bhavna Ranjan my Faculty Guide for her guidance throughout the

project.

Last but not the least I would like to thank Amity Business School for providing me with an

opportunity of getting practical knowledge about the procedures and systems of an industry and

helping me in structuring my future domain.

Vijay Kumar Jaiswal

Enrollment No.-A0101909012

MBA Class of 2011

5

TABLE OF CONTENTS

Declaration

Certificate from Industry Guide

Certificate from Faculty guide

Acknowledgement

S. No. Chapter Name Page No.

1. Introduction 7-8

2. Executive Summary 9

3. Literature Review 10

4. Company Profile 11-28

5. Research Methodology 29-30

6. Process of Beer Manufacture 31-54

7. Key Discussion and Analysis 55-58

8. Recommendation 59-60

9. Conclusion 61-62

10. References 63

6

Introduction

United Breweries Limited (UBL) is the flagship company of the UB Group. Founded in 1915

from the merger of five breweries in India, the company is headquartered in Bangalore and

commands 40% of the domestic market with leading brands such as Kingfisher, UB Export,

London Pilsner, Premium Ice and Kalyani Black Label. The UB Group is 3rd largest spirits

marketer in the world, with overall sales reaching 60 million cases. Subsequent to the acquisition

of Shaw Wallace & Company Limited, The UB Group spirits division offers 140 brands at

varying price points, attracting consumers of every taste. Combined with its unparalleled reach it

has become an object of envy for the competition. Five of UB Group's brands, viz., Bagpiper

Whisky, McDowell’s No.1 Whisky, Director's Special Whisky, McDowell’s No.1 Brandy and

McDowell’s Celebration Rum have been included in Impact International's Top 100 Distilled

Spirits Brands Worldwide by Retail Value.

The Castle Brewery which dates back to 1857 (the year of the Indian mutiny) was set up for the

European planters scattered over the Nilgiris. So was the Nilgiris Brewery Company. The British

Brewing Corporation set up in Madras (1902) catered to the elite of the port town of Madras

while the Bangalore Brewery Company had been supplying beer for the troops stationed at Pune

and Bangalore since 1885.

United Breweries Limited (UBL) was founded on March 15, 1915, in Madras by Thomas

Leishman, a Scotsman, also its first Managing Director. UBL manufactured and sold only bulk

beer for troops of both the world wars. It was a classic case of role reversal – India being

introduced to this ‘exotic’ brew and in turn becoming its major exporter.

The Indian beer industry has witnessed a big change during the last five years. The industry was

previously dominated by competition between the Vijay Mallya controlled United Breweries

Group and the Manu Chabbria-controlled Shaw Wallace. The scenario changed, however, with

the entry of SABMiller in India. The international beer giant started by acquiring small breweries

in the south but then completely changed the landscape with the acquisition of Shaw Wallace’s

beer portfolio for a reported US$264m in 2003.

7

India is predominantly a hard spirits market and beer is a minority preference for those who

consume Beverage Alcohol. Beer makes only 4% by revenue of the total alcoholic market. It

would be pertinent to mention that while per capita consumption of spirits in India is 65% of

global average, in the case of beer it is a mere 3% of global average.

With the global market experiencing low/stagnating growth in recent years, the focus is now on

the Asia-Pacific region specially. For instance, the Chinese beer market has grown at an

astounding pace in recent years, spurred on by the massive levels of foreign investment in the

market, along with the rise in the average levels of consumer spending and thanks to the

economic reform policies of the government. Total consumption of beer in China grew by

33.56% between 2000 and 2006 to reach a total market volume of 30.47 billion litres. With the

per capital consumption of 22 litres, China has now overtaken the US to become the largest

national beer market in the world. The brewing industry in China has been one of those quickest

to modernize and Indian beer Industry should look to model themselves on their neighbors.

The United Breweries Limited, Kalyani is a manufacturing unit which is meant for producing

Kingfisher Lager Beer, Kingfisher Strong Beer, Kalyani Black Label Premium, Kalyani Black

Label Strong, Sandpiper, and Kingfisher Premium Pites. This unit of UB ltd at Kalyani is headed

by assistant vice president. Reporting to him are departments like process, engineering, quality

assurance, commercial, human resource (hr) and finance, each headed by one departmental head

to whom other officials are accountable, the total of this complement represent the

managerial/supervisory group numbering 32.

.

8

Executive Summary

Brewing is almost certainly the most ancient manufacturing art known to man, and is probably as

old as agriculture. Beer is regarded as the first alcoholic beverage ever produced, dating back to

as early as the sixth millennium B.C. The Chinese brewed beer called 'Kui' some 5,000 years

ago. In Mesopotamia, a 4,000 year-old clay tablet indicates that brewing was a highly respected

profession - and the master brewers were women. Today, the brewing industry is a global

business, consisting of several dominant multinational companies and many thousands of smaller

producers ranging from brewpubs to regional breweries. More than 133 billion liters (35 billion

gallons) are sold per year (the equivalent of a cube 510 meters on a side), producing total global

revenues of $294.5 billion (£147.7 billion) in 2006. 

The report covers the entire process of beer manufacturing starting from the scratch till the

bottling and dispatch of the final product at UBL Kalyani. Further beer is a product which comes

under the food and beverages sector and is consumed by human beings at a large scale. Thus

maintaining quality standards at every level of the process forms the very basic for the success of

the product as well as of the entire company. Beer is a fermentation product and is rich in alcohol

and glucose content and is very susceptible to contamination from microorganisms at each and

every step in the process of its making. Thus a strict control should exist at each and every step

in the process and every process should be carried out in a closed environment which is taken

care in the plant with full efficacy and efficiency. The higher the microbial compliance greater is

the life of the beer and better is the quality. In spite of various control measure taken by the plant

certain things are overlooked by the unskilled workers in the plant during handling of the

equipments and this brings contamination of the beer and hence increases the dissolved oxygen

level of the beer which is not desired. Thus this report surpasses through the various regions

which are overlooked by the workers of the beer plant in compliance with the contamination of

beer and further finds out method to overcome such trivial mistakes and increase the microbial

compliance and the life of the beer.

This report thus is a tool for learning the entire process of beer manufacture and enhancing the

quality of the beer by increasing the microbial compliance in different process of beer

manufacture and further increasing the life of the beer.

9

Literature Review

Beer is the world's most widely consumed and probably oldest alcoholic beverage, and the third

most popular drink overall after water and tea. It is produced by the brewing and fermentation of

starches, mainly derived from cereal grains—most commonly malted barley, although wheat,

maize (corn), and rice are widely used. Most beer is flavored with hops, which add bitterness and

act as a natural preservative, though other flavorings such as herbs or fruit may occasionally be

included.

The process of making beer is known as brewing. A dedicated building for the making of beer is

called a brewery, though beer can be made in the home and has been for much of its history. A

company that makes beer is called either a brewery or a brewing company. Beer made on a

domestic scale for non-commercial reasons is classified as homebrewing regardless of where it is

made, though most homebrewed beer is made in the home. Brewing beer is subject to legislation

and taxation in developed countries, which from the late 19th century largely restricted brewing

to a commercial operation only. However, the UK government relaxed legislation in 1963,

followed by Australia in 1972 and the USA in 1979, allowing homebrewing to become a popular

hobby. The purpose of brewing is to convert the starch source into a sugary liquid called wort

and to convert the wort into the alcoholic beverage known as beer in a fermentation process

affected by yeast.- Prescott and Harley( A text book of microbiology).

Lager is the English name for cool fermenting beers of Central European origin. Pale lagers are

the most commonly consumed beers in the world. The name lager comes from the German

lagern for "to store", as brewers around Bavaria stored beer in cool cellars and caves during the

warm summer months. These brewers noticed that the beers continued to ferment, and to also

clear of sediment, when stored in cool conditions.[74]

Lager yeast is a cool bottom-fermenting yeast (Saccharomyces pastorianus) and typically

undergoes primary fermentation at 7–12 °C (45–54 °F) (the fermentation phase), and then is

given a long secondary fermentation at 0–4 °C (32–39 °F) (the lagering phase). During the

secondary stage, the lager clears and mellows. The cooler conditions also inhibit the natural

production of esters and other byproducts, resulting in a "cleaner"-tasting beer- A. H. Patel( A

text book of industrial microbiology)

10

COMPANY PROFILE-THE UNITED BREWERIES

GROUP

Brewing is almost certainly the most ancient manufacturing art known to man, and is probably as

old as agriculture. Beer is regarded as the first alcoholic beverage ever produced, dating back to

as early as the sixth millennium B.C. The Chinese brewed beer called 'Kui' some 5,000 years

ago. In Mesopotamia, a 4,000 year-old clay tablet indicates that brewing was a highly respected

profession - and the master brewers were women.  During the Industrial Revolution, the

production of beer moved from artisanal manufacture to industrial manufacture, and domestic

manufacture ceased to be significant by the end of the 19th century. The development

of hydrometers and thermometers changed brewing by allowing the brewer more control of the

process and greater knowledge of the results. Today, the brewing industry is a global business,

consisting of several dominant multinational companies and many thousands of smaller

producers ranging from brewpubs to regional breweries. More than 133 billion liters (35 billion

gallons) are sold per year (the equivalent of a cube 510 meters on a side), producing total global

revenues of $294.5 billion (£147.7 billion) in 2006.

Global Brewing Scenario

The global beer industry is consolidating. Consolidation started 10 years ago and probably has

10 more to go before it winds down. China is the biggest market for beer followed by the US,

Germany, Brazil, Russia, Japan, UK, Mexico, South Africa and Spain. The paradox in China is

that although the retail price of beer is very low in terms of the market, it has very high profit

margins as far as international players are concerned.

With the global market experiencing low/stagnating growth in recent years, the focus is now on

the Asia-Pacific region specially. For instance, the Chinese beer market has grown at an

11

astounding pace in recent years, spurred on by the massive levels of foreign investment in the

market, along with the rise in the average levels of consumer spending and thanks to the

economic reform policies of the government. Total consumption of beer in China grew by

33.56% between 2000 and 2006 to reach a total market volume of 30.47 billion litres. With the

per capital consumption of 22 litres, China has now overtaken the US to become the largest

national beer market in the world. The brewing industry in China has been one of those quickest

to modernize and Indian beer Industry should look to model themselves on their neighbors.

Major Global Players

Anheuser-Busch Companies Inc,

Carlsberg Breweries As,

China Resources Enterprises,

Femsa Cerveza Sa De Cv,

Heineken Nv,

Inbev Sa,

Modelo Brewing Group,

Molson Coors Brewing Co,

Sabmiller Plc,

Tsingtao Brewery Company Ltd

Indian Beer Brewing Scenario

The first modern brewery in India was set up in Kasauli, in the Himalaya Mountains,

near Shimla in the late 1820s by the Englishman Edward Dyer. Dyer's brewery produced Asia's

first beer, called Lion. Today no brewer in India makes India Pale Ale. All Indian beers are either

lagers (5 % alcohol — such as Australian lager) or strong lagers (8 % alcohol - such as the

popular MAX super strong beer). International Breweries Pvt. Ltd. have recently announced an

intention to work with Mohan Meakin to produce and launch an India Pale Ale called Indian IPA

from India's first brewery at Solan. Kingfisher, Haywards, Kalyani Black Label, Golden Eagle,

Australian, Max, Royal Challenge, Kings and Belo are popular Indian beer brands. With the

average age of the population on the decrease and income levels on the increase, the popularity

12

of beer in the country continues to rise. Indian growth rates compare favorably with the global

beer industry, which grew by about 2.6 per cent in 2001-02 apart from providing strong growth;

India also provides attractive profit margins due to the consolidated nature of the industry. The

effect of this consolidation can be seen in the fact that beer prices in India rarely go down with

the competitive pressures of new product or brand launches. In the past, whenever beer prices

have gone down, it has been due to either the lowering of duties by the government or the

deregulation of distribution (leading to lower margins for the distribution channel partners). In

neither scenario have the margins or revenues of beer manufacturers been affected.

The brewing industry in India is characterized by a large number of small sized units. Over 57

breweries produce only 6 million hectoliters representing about 76 millions cases. By way of

comparison, SABMiller produces 31.7 million hectoliters in South Africa through just 7 plants.

The Indian beer market has been growing rapidly over the last 10 years, due to the positive

impact of demographic trends and expected changes, like:

Rising income levels

Changing age profile

Changing lifestyles

Reduction in beer prices

Source: Industry sources

13

In India the future of beer industry is very much optimistic because:

1. India has predominantly a warm/hot climate

2. The beer-drinkers in the country are much younger than the average beer-drinker

elsewhere in the world. This makes them more likely to carry the brand with them for a

lifetime.

3. Increasing exposure to beer and wine drinking, mainly due to media and consumer

mobility.

All these factors combined together make the scenario very promising for beer industry and are

'in sync' with their strategy for India.

The Indian beer industry has witnessed a big change during the last five years. The industry was

previously dominated by competition between the Vijay Mallya controlled United Breweries

Group and the Manu Chabbria-controlled Shaw Wallace. The scenario changed, however, with

the entry of SABMiller in India. The international beer giant started by acquiring small breweries

in the south but then completely changed the landscape with the acquisition of Shaw Wallace’s

beer portfolio for a reported US$264m in 2003.

India is predominantly a hard spirits market and beer is a minority preference for those who

consume Beverage Alcohol. Beer makes only 4% by revenue of the total alcoholic market. It

would be pertinent to mention that while per capita consumption of spirits in India is 65% of

global average, in the case of beer it is a mere 3% of global average.

Hence, despite the recent growth, there still exist numerous challenges for the beer industry.

Beer Highly Taxed

Most Regulated Industry

Price Restrictions

Inadequate Market Infrastructure

Restriction of Movement of Beer

14

The Indian beer brewing industry is experiencing a steady growth in middle of the negative and

the positive aspect of the Indian economy. This industry can manage better share in the market

provided the following measures are taken into consideration:

Uniform Policy and Taxation

Free Pricing

Preferential Treatment to beer

Lower Consumer Prices

Market driven Retail Sector

Better Beer selling practices

Formation of a Beer Board

Moreover, the Indian beer industry is plagued with myriad taxes & levies that vary from state to

state. In fact no two states or UTs have a same or even a similar policy.

The brewing industry is a very dynamic industry to work in. The Indian beer industry has been

witnessing steady growth of 10 - 17% per year over the last ten years. The rate of growth has

increased in recent years, with volumes passing 170 million cases during the 2008-2009 financial

year. With the average age of the population on the decrease and income levels on the increase,

the popularity of beer in the country continues to rise and is poised fir further growth.

United Breweries Limited (UBL) is the flagship company of the UB Group. Founded in 1915

from the merger of five breweries in India, the company is headquartered in Bangalore and

commands 40% of the domestic market with leading brands such as Kingfisher, UB Export,

London Pilsner, Premium Ice and Kalyani Black Label. The UB Group is 3rd largest spirits

marketer in the world, with overall sales reaching 60 million cases. Subsequent to the acquisition

of Shaw Wallace & Company Limited, The UB Group spirits division offers 140 brands at

varying price points, attracting consumers of every taste. Combined with its unparalleled reach it

has become an object of envy for the competition. Five of UB Group's brands, viz., Bagpiper

Whisky, McDowell’s No.1 Whisky, Director's Special Whisky, McDowell’s No.1 Brandy and

McDowell’s Celebration Rum have been included in Impact International's Top 100 Distilled

Spirits Brands Worldwide by Retail Value.

15

The Castle Brewery which dates back to 1857 (the year of the Indian mutiny) was set up for the

European planters scattered over the Nilgiris. So was the Nilgiris Brewery Company. The British

Brewing Corporation set up in Madras (1902) catered to the elite of the port town of Madras

while the Bangalore Brewery Company had been supplying beer for the troops stationed at Pune

and Bangalore since 1885.

United Breweries Limited (UBL) was founded on March 15, 1915, in Madras by Thomas

Leishman, a Scotsman, also its first Managing Director. UBL manufactured and sold only bulk

beer for troops of both the world wars. It was a classic case of role reversal – India being

introduced to this ‘exotic’ brew and in turn becoming its major exporter.

The Company’s brewing tradition has a legacy of nearly 130 eventful years. Along its journey

through the global Alcoholic Beverages landscape, UBL has consistently influenced business

paradigms, beer-drinking habits and conventional mindsets. One man played a pivotal role in the

Group’s growth – Vittal Mallya who was elected to the Board of Directors of UBL in 1947 at the

age of 22 and a year later became its Chairman. Bangalore has been at the core of UBL’s

existence. The Registered Office of UBL was shifted to Bangalore in June 1952, into the

spacious 22-acre factory of the Bangalore Brewery Company. The Bangalore Brewery buildings,

dating as far back as 1885, have since given way to newer construction. The only relic that still

stands is the present godown adjacent to the UB Towers building, which earlier housed the

bottling cellars, pasteurizing and packing departments. The five acres of land across the road

donated to the Jesuit Society now forms the campus of St Joseph’s Indian High School.

Exploring Opportunities

In 1951, United Breweries Limited added liquor to its product cabinet when McDowells became

its first subsidiary. Under the dynamic guidance of Vittal Mallya, the Company became the first

to manufacture Indian substitutes of foreign liquor. This gave rise to a new term – IMFL (Indian

Made Foreign Liquor). McDowell has since then been the undisputed market leader and one of

the largest and fastest moving consumer goods companies in the country. Vittal Mallya was not a

man to rest on his laurels. He continued to pursue opportunities in the Alcoholic Beverages

business and at the same time diversified into Polymers and Batteries in addition to

Pharmaceuticals and Foods that the Company had been making till then.

16

Dr. Vijay Mallya

Chairman

The UB Group is one of India’s largest conglomerates with annual sales of over US$ 4 billion

and a market capitalization of approximately US$ 12 billion. The Group has diverse interests in

brewing, distilling, real estate, engineering, fertilizers, biotechnology, information technology

and aviation. It is also the largest Indian manufacturer of beverage alcohol (beer and spirits). Dr.

Vijay Mallya is the Chairman of the Group. Dr. Mallya, was elected by shareholders as

Chairman of UB in 1983, at the age of 28. He previously assisted his father, the former

Chairman, who passed away in the same year. Prior to being entrusted with the responsibilities

of a classical Indian corporate conglomerate, Dr. Mallya worked for the American Hoechst

Corporation (now Sanofi-Aventis) in the USA and with Jenson & Nicholson in the U.K. Since

1980, he assisted his father, the then Chairman of The UB Group, in managing the important

Brewing and Spirits Divisions and in re-launching the Kingfisher Brand of Beer. In 1983, the

sales volume of the UB Spirits division was approximately 2.85 million cases and UB’s beer

business trailed behind that of Golden Eagle from Mohan Meakins.

Also included in the Group were activities such as pharmaceuticals, agrochemicals, paints,

petrochemicals and plastics, the manufacture of electro-mechanical batteries, the manufacture of

food products and carbonated beverages, a fast-food pizza chain and several medium and small

scale industries.

Upon assuming the position of Chairman in October 1983, Dr. Mallya initiated the process of

defining a corporate structure with performance accountability, inducting professional

17

management and consolidating the unwieldy empire into individual operating divisions.

In 1988, Dr. Mallya became a non-resident Indian to pursue global opportunities and to

transform the UB Group into India’s first multinational company. While, in the initial stages,

overseas representative offices had been commissioned, the real break came in 1988 when Dr.

Mallya, in a leveraged buyout, acquired the global Berger Paints Group with operating

companies across four continents. The exit strategy for this investment was profitably executed

when Dr. Mallya successfully directed five Initial Public Offerings on the London, Singapore

(Main Boards), Nairobi, Jamaica and Abidjan Stock Exchanges. The paints business was

divested for significant value in1996.

Dr. Mallya also founded a software company in the USA in 1993 which was subsequently listed

on the NASDAQ in 1996 and which provides a considerable window of opportunity to the vast

US market. He also initiated several ventures for the promotion and globalization of UB brands

and, in particular, Kingfisher and McDowell.

In 1990, following the Government of India’s liberalised economic policies, Dr. Mallya decided

that the UB Group would only retain interests in businesses that were globally competitive and

which did not depend upon fiscal tariff protection. He also decided to focus on areas of core

competence and transformed the vastly diversified UB conglomerate into a handful of key

operating businesses. On entering the new millennium, the UB Group is considerably more

focused and has dramatically increased value for its shareholders through its various operating

businesses. Sales of the UB Spirits Division have crossed 90 million cases (9 litres each) during

the fiscal year 2008-09. In addition, this Division is one of only three in the world to own

nineteen millionaire brands and at least five brands rated by Drinks International, UK to be

amongst the ten fastest growing brands in the world in their respective categories. The market

share of the Spirits Division in India is currently 60% and exports to the Middle East, Africa and

Asian countries are growing rapidly.

In 2007, United Spirits Limited, the flagship of The UB Group, acquired a hundred percent of

premium scotch distillers Whyte & Mackay and Liquidity Inc, a United States-based maker of

specialty vodkas. The Delaware-based Liquidity Inc produces speciality brands like Pinky Vodka

18

and Marakesh.

The UB Group’s Brewing Division has also assumed undisputed market leadership with a

national market share in excess of 48%. Through a process of aggressive acquisition and market

penetration, The UB Group today controls 60% of the total manufacturing capacity for beer in

India. The flagship brand, Kingfisher, is now sold in over 50 countries worldwide having

received many accolades for its quality.

Kingfisher, one of the flagship brands of The UB Group, has partnered with NDTV, India’s

leading broadcast group in a first-of-its-kind media alliance for the promotion of NDTV Good

Times.

The UB Group’s Kingfisher Airlines is today the undisputed market leader in India’s aviation

market. In the short span since it was launched, Kingfisher Airlines has redefined the whole

experience of flying and has raised the bar by unleashing a host of product and service

innovations. It has received numerous awards since its inception.

Kingfisher Airlines offers Full Service and an unparalleled experience to the Indian air traveller.

In-flight entertainment has been taken to a new level with the introduction of Live TV to

compliment the latest and finest Audio and Video on Demand system that is available. With the

merger of Air Deccan and Kingfisher Airlines, the airline covers all segments of air travel from

low fares to premium fares and offers the maximum number of flights offered by any single

airline network in India.

Dr. Mallya is the Chairman of public companies both in India as well as in the USA. He has been

the Chairman of Aventis Pharma India (previously Hoechst) as well as the Chairman of Bayer

Crop Science in India (previously Agrevo) for over 20 years, in addition to his Chairmanship of

several other corporations.

Dr. Mallya is the first Indian ever to become the owner of a Formula One Team. The

Netherlands-based Mol Family and Dr. Mallya have formed a consortium that is now the joint

owner of Force India Formula One, which is also India’s first-ever Formula One Team and

represents India’s first, truly global sports foray.

He is a keen sportsman and is an ardent aviator and yachtsman of distinction. He not only

participates in various sporting events but also supports various sporting activities worldwide,

particularly for the under privileged.

19

THE UB LOGO and its Evolution

The emblem of the UB Group- the winged horse of Greek mythology-has evolved as a very

strong brand identity and has become synonymous with United Breweries. The origin of the logo

is unknown but as far back as 1944, the flying horse with a cask of beer on its back and between

its wings became part of the UB lore with the UBL's diversification and changed image, the cask

is gone.

Then, the highflying Pegasus symbolizing the Group's forays into hitherto unexplored avenues,

its wings flapping tirelessly and assuredly, in its journey towards a beckoning future. The colors

of gold and the UB blue denoted exclusivity and dynamism.

Rationale behind the latest UB Group Logo

Reflecting the ever renewing force behind the UB Group, the new UB Group identity, the well

know UB Pegasus, has been redesigned to emphatically reflect the spirit of an organization

which is becoming younger, Global, Energetic and ever ready to take a leap forward.

The Pegasus has been completely redrawn and relationship with the letterform UB made more

unique and emphatic. The letterform UB itself has been redesigned so that the U and B are

interlinked making it more distinctive. The Pegasus leaps forward, ever in motion and the new

Blue will help it stand out in crowded visual spaces.

The new identity will go a long way to add value to each of the Group companies and the UB

Group as a whole.

20

Mission and Quality Statement:

Mission statement

We constitute a large, global group based in India. We associate with world leaders in order to

adopt technologies and processes that will enable a leadership position in a large spectrum of

activities.

We are focused on assuming leadership in all our target markets.

We seek to be the most preferred employer wherever we operate.

We recognize that our organization is built around people who are our most valuable asset.

We will always be the partner of choice for customers, suppliers and other creators of innovative

concepts.

We will continually increase the long-term value of our Group for the benefit of our

shareholders.

We will operate as a decentralized organization and allow each business to develop within our

stated values.

We will be a major contributor to our National Economy and take full advantage of our strong

resource base.

We commit ourselves to the ongoing mission of achieving Scientific Excellence.

Quality statement

Quality leadership is vital to the long-term success of the UB Group in an increasingly

competitive marketplace.

Building quality into our workplace, products and service is essential to a successful future for

our customers, employees, supplier’s communities and shareholders.

The UB Group will work to provide products and services that always meet or exceed

expectations

Management will commit resources and create an environment in which each employee can

contribute skills, talents and ideas to a never-ending process of improvement and innovation in

all aspects of our business.

 

 Dr.VijayMallya

Chairman

21

Business of UB Group

United Breweries Limited-

United Breweries Limited (UBL) is the flagship company of the UB Group. Founded in 1915

from the merger of five breweries in India, the company is headquartered in Bangalore and

commands 48% of the domestic market with leading brands such as Kingfisher, UB Export,

London Pilsner, Premium Ice and Kalyani Black Label. The beer manufacturing giant owns 11

factories and has five regional offices. The company was bought by late Mr. Vittal Mallya in

1947, and since then has never looked back. Today each one of the 32,000 Beer outlets in India

sells one brand or the other from United Breweries.

On March 15th Mr. Thomas Leishman purchased 5 breweries to form United Breweries Ltd.

which had its registered office at 17 Armenian Street, Chennai-1. In 1944 first bottled beer under

the label “export beer” was produced. In the year 1948 Mr. Vittal Mallya became the first

chairman of UB group. In 1950 registered office move to Bangalore. In the year 1960 the

Kalyani Breweries was set up. After 5 years Kesarwal beverage was set up in Goa. In 1972 high

range breweries was set up in Chertalla in Kerala. UB beer started to export in Aden ad Middle

22

East in the year 1947. Soon after, in 1978 the Punjab Breweries was formed. Canned beer was

introduced in 1981. In 1982 UB’s kingfisher lager hit parlous in England and USA. After one

year UB invested in Brewing business in USA by purchasing 6 Micro breweries. In the year

2001 MABL was formed.

Here, innovative, creative and aggressive marketing is complemented by a strong distribution

network. A management focused on building brand equity on one hand and exploiting it to the

hilt on the other. A concerted emphasis on quality is maintained here.

UBL today boasts an impressive spread of own and contract manufacturing facilities throughout

the Country.

Its flagship brand 'Kingfisher', has achieved international recognition consistently, and has won

many awards in International Beer Festivals. Kingfisher Premium Lager beer is currently

available in 52 countries outside India and leads the way amongst Indian beers in the

International market. It has been ranked amongst the top 10 fastest growing brands in the UK.

In addition, UBL has also entered into multi-faceted strategic alliance with Scottish & New

Castle Plc (S&N), an international brewery major, with $6 billion in revenue and a market

capitalization of $5.4 billion. This alliance, apart from having a joint venture in India, will allow

S&N to market it International brands like Kronenbourg in India, while UBL will utilize S&N's

global network to further globalize its Kingfisher.

A significant innovation in the launch of a pint pack of UB export lager in a several critical

market of the country has opened up a new segment, driving both volumes and market share.

This innovation which delivered superior price value equation to the consumer offers a value

330ml pack in key market, mainly UB export in Karnataka, Kingfisher premium lager in Goa

and Kalyani Black Label in Kolkata. This growth deliver not only increased the volumes but it

has also succeeded in expanding the market, of which the company has taken a significant share.

The company’s market share improved by 330 basis point to 40%, replicating a growth of 300

basis points in the previous year. Significantly, in a very short span of time, kingfisher strong has

established a sizeable 20% market share of the strong beer market, making it one of the most

successful brand launches in the industry in recent times.

The company continues to invest in its brands ensuring top of mind recall with customers. The

UBL has now stretched its business from its traditional sector of beverage alcohol to various

other sectors under the umbrella named UB group.

23

Aviation

Kingfisher Airlines is now one of the most famous airlines which has access to both domestic as

well as international arena. In the very beginning it took over Jet Sahara and gained the

international access. It claims to be the only 5 star airlines in India.

Fertilizers

Located in Karnataka, the only fertilizer company under UB's management has affected an

amazing turnaround to become one of the most efficient and profitable naphtha based urea

producers in the country. In 1990, the Government of Karnataka had selected the UB Group to

take over Mangalore Chemicals & Fertilizers (MCF) - a "potentially sick" unit with accumulated

losses in access of 600 million rupees. The careful nurturing and astute management under UB

ensured the remarkable turnaround. Since last six years, the company has recorded profits every

year and cash flows have sufficed for repayment of accumulated debts. With an investment of

over Rs.400 Crores, the Company is the only large scale fertilizer project in the State of

Karnataka. The Company achieved a turnover of Rs. 614 crores, up 9% over the previous year.

Engineering

The UB Group's Engineering Division - is one of the foremost Indian engineering companies in

the field of installation of industrial plants. UB Engineering's activities are strongly focused on

the Turnkey Division for projects in Power, Fertilizers, Oil & Gas, Fire Fighting, Effluent

Treatment, Agrotech and other sectors - concept to commissioning, on-site fabrication,

installation, overhauling and maintenance. The range of its operations and concept to

commissioning services combined with excellent track record in industrial construction

worldwide has allowed UB Engineering to cut across geographical and political boundaries.

International Trading

International Business Division of the UB Group, in exports of

Beverage Alcohol

Processed Foods

Leather Footwear

Apparel

24

Infrastructure

United Breweries (Holdings) Ltd. has also pioneered the development of prized real estate in the

heart of Bangalore. It is constructing one of the largest mixed-use developments - UB CITY, in

the heart of Bangalore. UB CITY will stand tall at the corner of Vittal Mallya Road and Kasturba

Road, just 600 metres away from Bangalore's commercial hub, M. G. Road. Its internet ready

intelligent buildings will demonstrate how chrome, glass and greenery can seamlessly blend

between modern edifices and serene flora.

It has also stretched its business to pharmaceuticals, media and world of glamour and

entertainment and s successfully managing to handle all the sectors efficiently.

25

The Alcoholic Beverage Business of the UB Group

The various alcoholic beverages the UB Group manufactures are spirits, wines and beer.

United Spirits Limited (USL) - the INR 5700 crore spirits arm of the UB Group – is India’s

largest and the world’s 2nd largest spirits company. USL was earlier McDowell and Company

Limited. USL has a portfolio of more than 140 brands, of which 19 are millionaire brands*

(selling more than a million cases a year) and enjoys a strong 59% market share for its first line

brands in India. United Spirits recorded global sales of 90 million cases for the fiscal year that

ended on March 31, 2009.

USL Millionaire Brands (Those that sell more than a million cases per annum)

Whisky Brandy Rum Vodka & Gin

• Bagpiper

• McDowell’s No.1

• Director’s Special

• Old Tavern

• Haywards

• McDowell’s Green Label

• Gold Riband

• Royal Challenge

• DSP Black

• Signature

• McDowell’s No.1

• Honey Bee

• John Ex-Shaw

• Celebration Rum

• Old Cask Rum

• Old Adventurer Rum

• White Mischief

• Romanov

• Blue Riband

Wines

The different varities of wines manufactured by UBL are Kingfisher Bohemia, Pinotage,

Chenin Blanc Chardonnay, Pinotage Rosé, Bouvet Ladubay.

26

Beer

United Breweries Limited

The beginning of what is today The UB Group is rooted in the flagship company, United

Breweries Limited, (UBL) also referred to as the Beer Division of the UB Group. Led by Mr.

Kalyan Ganguly, President & Managing Director, it has around 48% market share in the country.

United Breweries Limited has an association with brewing, dating back over five decades;

starting with 5 breweries in South India in 1915. From bullock cart-loaded barrels or 'hogsheads'

of frothing ale, the Beer business has gone on to become the undisputed 'king' in the Indian beer

market.

The company manufactures beer in 650 ml in bottles and 330 ml in cans and small bottles. The

different varities of beer manufactured by the UBL are:

Kingfisher Premium Kingfisher Strong Kingfisher Blue

Kingfisher Red Kingfisher Ultra Kingfisher Draught

27

Zingaro Sand Piper UB Premium Ice

Kalyani Black Label Premium

Profile of UBL Kalyani:

The United Breweries Limited, Kalyani is a manufacturing unit which is meant for producing

Kingfisher Lager Beer, Kingfisher Strong Beer, Kalyani Black Label Premium, Kalyani Black

Label Strong, Sandpiper, and Kingfisher Premium Pites. This unit of UB ltd at Kalyani is headed

by assistant vice president. Reporting to him are departments like process, engineering, quality

assurance, commercial, human resource (hr) and finance, each headed by one departmental head

to whom other officials are accountable, the total of this complement represent the

managerial/supervisory group numbering 32

28

RESEARCH METHODOLOGY

Research methodology is the arrangement of condition for collection and analysis of data in a

manner that aims to combine the relevance to the research purpose with economy in procedure.

Research is conceptual structure within which research is conducted. It is way to systematically

study and solve the research problems.

Primary Objective:

The basic objective of the research was to understand the entire process of beer making and

bottling and thereby identifying the status of microbial loading in different processes and

improving the microbial compliance in those processes. The plant was facing a problem of

contamination of the beer even though strict measures were taken to eradicate it. As because the

product comes under food and beverages and is consumed by people hence care is taken that the

quality of beer is not hampered due to contamination of the beer by other microorganisms and

further due to contamination the life of the beer also decreases.

Data Collection:

The various methods of data collection are as follows:

Primary Data Collection:

Personal Observation:

The method of data collection was through personal observation of each and every process used

in manufacture of beer and learning it thereby. The entire process of beer starting from the

milling to the bottling and starting was carefully observed and noted down to study the status of

microbial contamination.

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Personal Interview:

Personally asking the personnel involved in each process of each department about the process

and the various materials involved in it and thereby noting it down. Further personally asking the

engineers of different sections such as Brew House, Filtration, Fermentation and bottling about

the process gave me a clear picture about the entire process of beer making. This further helped

me in recognizing the status of microbial loading in different processes.

Secondary Data Collection:

The help of secondary data was also sought in learning the process of beer making. The help of

various books related to brewing was studied. Internet formed as a source of great help in

gaining secondary information and adding to whatever had missed during personal observation.

Scope of the Study:

The scope of the study is to have an in depth knowledge of the entire operational procedure of

beer manufacturing and the problems involved in such an industry. Further, the study also

involves in finding the remedies of certain problems faced during the process which is otherwise

overlooked by the workers due to various reasons. These things if properly handled can improve

the quality of beer and the life of it and thus increasing the brand image of the product and of the

company as a whole.

Limitations of the Study:

The authenticity of the suggestions and recommendations depend upon the rationality of

the data provided to me.

Have to rely upon the data supplied.

Executives are not ready to part with the information beyond a limit as the process is

trade secret and is not to be exposed.

30

The Process of Beer Manufacture In United Breweries

Limited Kalyani

In any beer industry there are basically 3-4 sections depending on the process. These are as

follows:

The Brew House.

The Fermentation section.

The Lagaring and Filtration section.

The Bottling section.

Each of these sections and the processes involved in each are discussed as follows:

The Brew House

The main raw material for making beer is malt which is processed from barley. Barley is

processed in mills into malt which contains the required enzymes to convert the insoluble starch

in the barley to soluble and simple sugar molecules. This process of converting barley into malt

is known as Malting. The process of malting is described as follows:

Malting

Malting serves the purpose of converting insoluble starch to soluble starch, reducing complex

proteins, generating nutrients for yeast development, and the development of enzymes. The three

main steps of the malting process are steeping, germination, and kilning.

a) Barley Steeping

The purpose of steeping is to evenly hydrate the endosperm mass and to allow uniform growth

during germination. Steeping begins by mixing the barley kernels with water to raise the

moisture level and activate the metabolic processes of the dormant kernel. The water is drained,

and the moist grains are turned several times during steeping to increase oxygen uptake by the

respiring barley. A wide variety of steeping regimes are used, depending on the steep vessel

configuration, barley variety, barley quality, kernel size, brewery specifications, and maltster

preferences (21).

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b) Barley Germination

In the next step, the wet barley is germinated by maintaining it at a suitable temperature and

humidity level until adequate modification has been achieved. The techniques most commonly

used for germinating barley are floor malting and pneumatic malting. Floor malting is an old

process in which the chitted malt is spread on the floor to a height of 10 to 20 cm. Pneumatic

malting uses forced air for the germination process. There are numerous mechanical designs for

pneumatic malting such as drum malting, compartment malting, continuous malting, and tower

and circular malting, and flexi malting.

c) Malt Kilning

The final step is to dry the green malt in the kiln, which is done at different temperatures. The

temperature regime in the kiln determines the color of the malt and the number of enzymes

which survive for use in the mashing process. For example, low temperature kilning is more

appropriate for malts when it is essential to preserve enzymatic (diastatic) power. These malts

are high in extract but low in coloring and flavoring compounds.

Malt Constituents

Malt is largely made up of carbohydrates, which are composed of starch, sugars, insoluble

cellulose, and soluble hemicellulose. Starch, the most important constituent, accounts for about

60 to 65% of the malt's weight, is composed of amylose, which is reduced to maltose and

maltotriose and amylopectins that decompose into glucose. Glucose, a monosaccharide, accounts

for about 1 to 2% of the total starch found in a barley kernel. Cellulose constituents do not

contribute to fermentable extract or desirable flavors in the malt. Hemicellulose is a constituent

of the endosperm cell walls, which consist largely of beta-glucan.

The company buys the malt from suppliers and does not do the processing part of barley to

malt.The process of beer making in the plant starts from milling of the malt. This is known as

malt grinding. The company has its own grinding mill in the plant itself

1. Malt Grinding

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The objective of milling is to reduce the malt to particles sizes, which will yield the most

economic extract (wort) and will operate satisfactorily under brew house conditions and

throughout the brewing process. The more extensive the malt is milled, the greater the extract

production. However, the fine grind can lead to subsequent wort separation problems and a loss

of extract in the spent grains during wort separation. As a result, the brewer needs to consider the

equipment used in the brew house when determining the particle size when milling the malt. For

example, mash tuns require comparatively coarse grists while lauter tuns can use finer grists and

mash filters still finer grists.

Weighing and Cleaning

For larger breweries, a typical flow of malt upon arrival at the brewery begins by weighing the

vehicle on the weigh-bridge and unloading the malt via a hopper. After unloading, the vehicle is

tare-weighted, with the difference in weights being the weight of the malt.

Silos

Once weighed and cleaned, the malt is conveyed to silos for storage. Silos are constructed of

either corrugated galvanized steel, which is considerably cheaper or welded steel, which

reportedly offers a higher level of protection from moisture. The minimum size for silos is

usually 800 cubic feet, large enough to accommodate one truckload of malt.

Hopper

Before milling, malt is removed from the silo and transferred to the feed hopper supported on a

mechanical platform located at the grist case-a buffer containing the milled malt before the mash

vessel.

Grist Case

After milling, the milled malt is transferred to a temporary storage hopper, commonly called the

grist case, that feeds the mash tun.

Dry Milling

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Usually mills are of two types roller and hammer mills. In UBL brewery, dry milling is

commonly performed by roller mills. Since the wort separation involves using a lauter tun, roller

mills are employed. Hammer mills are largely used for the later generation of mash filters and

continuous brewing systems.

Sieve Analysis of Crushed Malt

Not only is the grist profile critical to achieving maximum conversion of available extract during

mashing but it is also important for efficient wort filtration and sparging. Consequently, a

complete screen analysis of the crushed malt when milling should be made on a regular schedule,

with any adverse change in the mill's performance warranting an immediate correction.

Screen analysis consists in placing a sample of grist in the top set of horizontal sieves, which is

shaken manually or mechanically for a set period of time.

After the malt is grinded according to the predefined texture and the sieve analysis is being done

the grinded malt is ready for Mashing.

Beer Adjuncts

Adjuncts are nothing more than unmalted grains such as corn, rice, rye, oats, barley, and wheat.

Adjuncts are used mainly because they provide extract at a lower cost (a cheaper form of

carbohydrate) than is available from malted barley or to modify the flavor of the beer. Adjuncts

are used to produce light-tasting, light-colored beers that have the alcoholic strength of most

beers. Adjunct use results in beers with enhanced physical stability, superior chill-proof qualities,

and greater brilliancy. The greater physical stability has to do with the fact that adjuncts

contribute very little proteinaceous material to wort and beer, which is advantageous in terms of

colloidal stability. Rice and corn adjuncts contribute little or no soluble protein to the wort, while

other adjunct materials, such as wheat and barley, have higher levels of soluble protein. Except

for barley, adjuncts also contribute little or no polyphenolic substances.

Adjuncts can be used to adjust fermentability of wort. Many brewers add sugar and/or syrup

directly to the kettle as an effective way of adjusting fermentability, rather than trying to alter

mash rest times and temperatures.

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Adjuncts are often used for their flavor contribution. For example, rice has a very neutral aroma

and taste, while corn tends to impart a fuller flavor to beer. Wheat tends to impart a dryness to

beer. Semi-refined sugars add flavor to ales that has been described as imparting a luscious

character. Adjuncts will also alter the carbohydrate and nitrogen ratio of the wort, thereby

affecting for formation of byproducts, such as esters and higher alcohols.

The adjuncts commonly used in UBL Kalyani are either broken rice or maize grits or sometimes

rice flakes. Broken rice and or maize grits are processed before mixing it with the grounded malt

in the mash kettle. So the usual process of Beer making starts with the processing of the adjuncts.

Rice or maize grits are usually processed in the same way both being the source of sugar. These

adjuncts are made ready by boiling them in specialized cooker and in the mean time the

processing of the grounded malt goes simultaneously in the mashtun. The process of rice

cooking is described below:

2. Processin g of broken rice/ maize grits in the Rice Cooker

Rice is boiled in a rice cooker which is a massive container designed specially for boiling

rice which is finally mixed with the mash. The gross capacity of the rice cooker is 120

HL and the working volume of the rice cooker is 80 HL. For preparing a wort of 220 HL,

41HL of sterile water is added in the cooker together with it 640 kg of rice is added.

Temperature of the cooker is maintained at 45°C . This activates beta-glucanase, which

breaks down gummy beta-glucans in the mash, making the sugars flow out more freely

later in the process. To this 6kg of gypsum and 1.5 lts of biotempase is added and lid of

the cooker is closed.

The temperature is then allowed to rise to 55°C and together with it continuous stirring is

don inside the container (the cooker is specially designed and has a stirrer in it which stirs

the entire contain of the rice cooker at a constant speed). Then a rest of 10 mins is given

to the entire thing, temperature being constant. This activates various proteinases, which

break down proteins that might otherwise cause the beer to be hazy.

Then the temperature is allowed to rise to 85°C. This takes a lot of time. When the

temperature in the computer shows 85°C the stirring operation is stopped and a rest of 20

min is given to the entire system.

35

After this the temperature is raised to 95°C and a final rest of 20 min is given to the entire

system. This rice is now ready to be added to the mash tun. It is to be remembered that

the gradual rise in temperatute with intermittent break in between has is because for some

biochemical reactions occurring inside the rice cooker which is favourable for the process

of beer making.

3. Mashing in the Mash Tun

By the time the rice is getting boiled in the rice cooker simultaneously the malt is also getting

boiled im the mashtun . The resulting grist which is formed after the malt is crushed in the malt

mill to break apart the grain kernels, increase their surface area, and separate the smaller pieces

from the husks is mixed with heated water in a vat called a "mash tun" for a process known as

"mashing". During this process, natural enzymes within the malt break down much of the starch

into sugars which play a vital part in the fermentation process. Mashing usually takes 1 to 2

hours, and during this time various temperature rests (waiting periods) activate different enzymes

depending upon the type of malt being used, its modification level, and the desires of the brew

master. The activity of these enzymes converts the starches of the grains to dextrines and to

fermentable sugars like maltose. In UBL Kalyani the following procedure is adopted in mashing:

For preparing 220 HL of wort grounded mash of near about 2750 kg is added in the mash

tun which takes 20 minutes to fall in the mashtun from the mill. To this 195 HL of water

is added which is at 45 °C. This activates beta-glucanase, which breaks down gummy

beta-glucans in the mash, making the sugars flow out more freely later in the process.

To this 1.5 kg calcium chloride, 6kg gypsum,1.5 kg beta glucanase, 0.8 kg of promalt,

termamoil and 5 lts of lactic acid id added and the lid of the mash tun is closed for the

heating of the mixture. The temperature of the whole content is allowed to rise to 52°C

together with continuous stirring of the whole mixture.

As soon as the temperature rises to 52°C the whole content of the mashtun is allowed to

rest for 20 minutes. This is known as protein rest. This activates various proteinases,

which break down proteins that might otherwise cause the beer to be hazy. But care is of

the essence since the head on beer is also composed primarily of proteins, so too

aggressive a protein rest can result in a beer that cannot hold a head.

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After this the rice from the rice cooker which is at 95°C is allowed to pass into the

mashtun through which connects the two. When the whole rice of the rice cooker is

passed into the mashtun the temp of the mashtun automatically rises to 64°C and if not

the temperature of the whole system is raised to 64°C and a rest of 50 minutes is given to

the system. This is used to convert the starches in the malt to sugar, which is then usable

by the yeast later in the industrial brewing process\.

After this the temperature of the entire content is raised to 71°C. As soon as the

temperature rises to 71°C the whole wort is given a rest of near about 30- 40 minutes.

This is known as saccharification rest. At this temperature the beta amylase of the malt

gets activated and cleaves all the starch molecules of the malt to simple molecules of

glucose and maltose on which the yeast feeds and ferments it to alcohol. As soon as the

saccharifiaction is confirmed the temperature of the entire content is again raised to 76°C

and then the mash is sent to the lautert tun for wort clarification. At this temperature all

other enzymes in the malt gets deactivated.

4. Wort clarification in the Lauter Tun

After the mash is ready it is transferred to the lauter tun which is the traditional vessel used for

separation of the extracted wort. A Lauter tun has two bottoms, one the false bottom for filtration

and the other the collecting bottom which collects the filtered wort. The false bottom in a lauter

tun has thin slits or perforations to hold back the solids and allow liquids to pass through. Before

the wort enters the Lauter tun 5HL of water is collected on the false bottom of the LT. This is

done because when the mash enters the LT it is very hot and thick in consistency and this may

choke the perforations of the LT which may hamper the entire process of wort clarification.

The solids, not the false bottom, form a filtration medium and hold back small solids,

allowing the otherwise cloudy mash to run out of the lauter tun as a clear liquid. The false

bottom of a lauter tun is today made of wedge wire, which can provide a free-flow

surface in the bottom of the tun

The lauter tun has rotating rake arms with a central drive unit. Cutting blades hang from

these arms. The blade is usually wavy and has a plough-like foot. Each blade has its own

path around the tun and often the whole rake assembly can be raised and lowered.

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Attached to each of these arms is a flap which can be raised and lowered for pushing the

spend grains out of the tun.

After the mash is filtered the liquid free of the spent grains is collected on the main

bottom of the Lauter tun. This is known as First Wort. This wort is again recirculated

from the spent grain and within 5 minutes a clear wort enters the Lauter tun. After this

water is sparged on the spent grains so that the sugar left in the spent grains could be

extracted and collected with the Firlearst Wort. This is done once again to accomplish the

same purpose. After the wort is collected in the lauter tun the purpose of the lauter tun is

served. This clear wort is then collected in a Wort Collecting Vessel. This vessel just

collects the clear wort from the lauter tun and has no other function. This vessel comes

into action only when the wort kettle is in work or else the wort from the lauter tun is

directly collected in the Wort Kettle for boiling.

After the last wort has left the lauter tun, spent grains are removed from the lauter tun and

discarded. The grain-out doors are opened, the rakes are raised out of the grain bed, and

the knife angles are changed to the grains-out position. The spent grains thus collected is

discarded out of the lauter tun with steam pressure which forces the spent grains to pass

out of the lauter tun. This spent grain is sold as cattle feed in the market.

5. Boiling of the wort in the Wort Kettle

After the entire wort is collected in the wort kettle the next step of wort boiling is carried on.

The entire process of wort boiling is completed in 70 mins. As soon as the wort enters the

wort kettle all the ingredients required in the process of boiling and imparts taste to the beer

is added in the wort kettle. Hops, a vital ingredient is added to the wort. This imparts the

characteristic bitter taste to the beer. This hops is in pellet form and is nearly 2.4 kg in

weight. Together with 5 cans of hops extract is also added to the wort. This is company

specific and is calculated according to the quantity of the wort prepared. The hops pellet and

the wort extract imparts the bitterness to the beer. The major flavor contribution of hops in

beer is bitterness from iso-alpha acids. During the boil, the insoluble alpha acid extracted

from hops is converted to a more soluble iso-alpha acid.

The major reasons for wort boiling are as follow:

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Sterilization

Although the wort separation and sparging processes are normally conducted at

elevated temperatures (76-80°C), wort entering the kettle contains numerous

microorganisms-yeast, molds, and bacteria-which can result in off-flavors and

numerous other problems.

Enzyme Inactivation

Boiling fixes the carbohydrate composition of the wort by inactivating residual

enzymes that are responsible for carbohydrate and protein degradation and that may

have survived mash-off or sparging.

Protein Precipitation

During the boiling process, it is necessary to decrease the level of high molecular

weight nitrogen found in the malt. Protein precipitation occurs as the wort loses its

turbidity during boiling, and material breaks out of suspension and precipitates as

proteins coagulate.

Color Development

During boiling, the color of the wort becomes darker. This is brought about by the

formation of pigments (melanoidins), the oxidation of polyphenols, and the

caramelization of sugars.

Production of Melanoidins

The production of melanoidins-the Maillard reaction-occurs when reducing sugars

from carbohydrates react with amino acids that are derived from the proteins during

mashing.

Oxidation of Polyphenols

The oxidation of polyphenols is another source of color formation. Polyphenols are

sometimes referred to as "tannins" and may be derived from malt husks and hops.

39

Carmelization of Sugars

Caramelization is a chemical process that affects sugars subjected to temperatures of

200°C or greater.

Isomerization

The major flavor contribution of hops in beer is bitterness from iso-alpha acids.

During the boil, the insoluble alpha acid extracted from hops is converted to a more

soluble iso-alpha acid.

Dissipation of Volatile Constituents

Boiling of wort drives off volatile wort compounds, including dimethyl sulfide,

aldehydes, and hydrocarbon components of the hop oils. The principal malt derived

volatile lost during boiling is dimethyl sulfide or DMS which is rapidly lost through

evaporation.

Concentration of Wort

The wort must be concentrated by evaporation since the water used in mashing and

sparging has produced wort lower in specific gravity than the target gravity.

Reduction in Wort pH

As previously mentioned, the pH of the wort starts to decrease during mashing and

continues to fall during wort boiling to reach a final pH of between 5.2 and 5.3.

After the addition of hops and hops extract 1.2 kg of caramel is also added to the wort and the

whole thing is allowed to boil. Just before 15 mins. of completion of boiling nearly 600kgs of

sugar is added to the boiling wort . this imparts the taste and colour to the wort together with

fermentation medium for the yeast.

Further prior to 5 mins of completion of the boiling sazz is added to the boiling wort to add taste

to the beer.

After this the specific gravity of the boiled wort is noted which is nearly 15.8. This completes the

wort boiling. The boiled wort is then carried to the Whirlpool in which the wort clarification

takes place.

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6. Wort Clarification in Whirlpool

Usually there are various method cleaning the wort of its debris, like hop strainers,

hop back, etc. but the equipment used in the plant is known as the Whirlpool. It is a

circular vessel into which wort is introduced tangentially. The tangential inlet is

responsible for the centrifugal force that accelerates the trub outside of the wall and

downwards. The transfer rate from wort kettle to whirlpool is 4000 HL/ hr but care is

taken to avoid shear forces.

The trub initially forms a cone and then settles down with clear wort taken off from

various outlets at different levels.

The objectives of wort clarification are as follows:

Removal of coagulated protein- polyphenol flocs called hot break.

Removal of hop debris and other solids.

Maintaining sterility.

7. Wort Cooling

Wort needs to be cooled to 12°-16°C for fermentation as this is the optimum temperature for

yeast to function and the required flavor development. The process of cooling is carried out

in plate heat exchangers. The plate heat exchangers operate in counter flow for optimum heat

transfer with principal cooling agent being chilled brewing water. The wort after clarification

is being passed through the PEC. On one side of the plate cold water flows and on the either

side of it the hot wort. as son as the wort comes in contact with the plate due to counter flow

action of the PEC and due to the effect of the cool water the wort temperature falls down to

12°C which is the fermenting temperature.

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8. Wort Aeration

During wort cooling one more important aspect is wort aeration. The microorganism yeast is

a facultative anaerobe and the fermentation process is anaerobic i.e. without oxygen, but for

the yeast to replicate and live it needs dissolved oxygen which is not present in the wort.

Aeration is done in the cold wort as oxygen absorption is more at low temperature.

This is the final wort which is ready for fermentation by the microorganism yeast. After

aeration the wort is collected in large fermentors in which fermentation of the wort takes

place.

The Fermentation section

Fermentation is the process by which fermentable carbohydrates are converted by yeast into

alcohol, carbon dioxide, and numerous other byproducts. It is these byproducts that have a

considerable effect on the taste, aroma, and other properties that characterize the style of beer.

The most important thing in beer production is the microorganism which ferments the malt to

desirable level of alcohol. The microorganism which is used for the purpose is Yeast

(Saccharomyces sp.). The yeast strain itself is a major contributor to the flavor and character of

the beer. The company imports its characteristic yeast slant from abroad and grows it in the

plant. There is a separate room for the production of yeast to be used in the fermentation process.

The particular yeast strain is a company secret and is kept in strict supervision so that it is not

stolen or leaked.

The preparation of yeast in the yeast room takes place in the following manner:

At first the slant culture of yeast in grown in 250 ml of nutrient medium and after 1 day of

incubation it is transferred to 1 litre of medium and allowed to grow. This thing goes on in the

laboratory and after this the yeast is grown in the yeast room. The yeast is transferred to 5 litres

of wort and after full growth the yeast is transferred to a a large vessel which contains 5 HL of

wort and after this it is stored in YSV 1 and YSV 2. Temperature , pH and pressure is taken care

of for the optimal growth of the yeast.

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Yeast pitching:

The brewer's ability to pitch the correct number of yeast cells to initiate fermentation is crucial to

consistently producing a product of superior and constant quality. Pitching rates are governed by

a number of factors, including yeast strain, fermentation capacity of the yeast, yeast viability,

flocculation characteristics, previous history of the yeast, and desired beer flavor characteristics.

Other considerations when choosing pitching rates include wort gravity, wort constituents,

fermentation temperature, and the degree of wort aeration. For example, highly flocculent yeast

strains may settle prematurely, requiring the brewer to either over-pitch or to mix and aerate the

yeast by "rousing."

The generation of the yeast is of utmost important and before pitching it with wort the cell count

of the yeast stored in yeast vessel and the viability and the generation of the yeast is ckecked. If

the yeast is newly grown then it is directly pitched with the wort. If the yeast has already

undergone 1 cycle of fermentation and then stored for the next fermentation then it has to

undergo acid wash treatment.

Before pitching yeast the yeast is washed with ortho phosphoric acid. Usually 180 kg of yeast is

pitched for 1 single fermentation of 1100 HL of wort. This amount of yeast is collected in the

yeast collecting vessel.

In an acid addition vessel nearly 370 ml of said acid is poured with some water . Yeast from the

yeast collecting vessel is allowed to collect in another vessel known as acid- yeast mixing vessel

and then acid is passed into this is vessel and is mixed for half an hour.and then is stored for

further fermentation.

Reasons for acid wash of yeast which is already used for fermentation:

a) Before addition of yeast the pH of yeast is near about 4-5 whereas after addition of acid the pH of

yeast falls to 2-3 and this enables the yeast to synchronise with the pH of the wort.

b) Acid wash enables the old yeast to rejuvenate as well as the dead yeast to purify from that of the

living yeast.

c) Further at this low pH the chances of contamination of the yeast culture and that of the whole

wort is very low and hence this maintains the sterility of the entire culture.

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After the yeast is ready for fermentation it is pitched into the unitanks or the fermentors in which the

fermentation of the wort is going to take place. The yeast pipeline is joined with that of the wort pipeline

and they together enter into the fermentor in a mixed state and hence this solves the problem of mixing of

the yeast culture in the wort.

Fermentation vessel used in the process:

Unitanks: There are altogether 11 unitanks in the plant. Of these 8 unitanks are of 1120

HL and 2 are of 1080 Hl capacity and 1 is of 1600HL capacity. The unitanks are denoted

as UT 1-11. Unitanks are cylindroconical tanks and are also called CCTs. They have a

conical bottom and a cylindrical top. The cone's aperture is typically 60°, an angle that

will allow the yeast to flow toward the cones apex, but is not so steep as to take up too

much vertical space. CCTs can handle both fermenting and conditioning in the same

tank. At the end of fermentation, the yeast and other solids which have fallen to the cones

apex can be simply flushed out a port at the apex

Lagar Tank: these tanks are cylindrical in shape and is used only for maturation of beer

that is lagaring of beer. There are 8 small capacity lagar tank in the plant of 120 HL each

and 5 lagar tanks of larger capacity. The lagar tanks are denoted as LT with the tank

number.

Fermentors: These tanks are only made for fermentation and after its purpose is being

solved the content of these vessels are piped to lagar tanks where lagaring is done. There

are in totality 12 fermetors in the plant for only the purpose of fermentation.

Fermentation :

After the wort is cooled in the PHE after wort clarification in the whirlpool the wort is pipes

through motor in the fermentors either in FV or the UT for fermentation. The yeast is pitched

together with it and they enter into the fermenting vessel ina mixed state. The capacity of UT is

1120 HL and hence near about 5 worts are allowed to collect in each vessel and after each wort

collection of 220 HL from the brew house east is pitched alternatively. The entire fermenting

vessel is airtight and the entire fermentation carries on in an anaerobic state.

Everyday the gravity of the wort is checked and after the gravity of the wort falls to a

desired level of 2.2 due to fermentation of the wort and alcohol formation the

fermentation of the wort is stopped. The yeast is the organism which converts the sugar

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of the wort into alcohol and as soon as the alcohol level in the wort reaches 7% the

fermentation is stopped.

Diacetyl Rest

Employing high temperatures at the end of primary fermentation are for reducing diacetyl and

2,3-pentanedione (collectively referred to as vicinal diketones or VDKs). This procedure is

known as a diacetyl rest. VDKs, which are assimilated by yeast toward the end of fermentation,

are responsible for off-flavors in beer. The diacetyl rest reinvigorates the yeast culture so that it

metabolizes those byproducts-such as diacetyl and 2,3-pentanedione-that are excreted early in the

fermentation, thereby removing them from solution. Depending upon the yeast type, the medium,

and the physical environment, this process is variable in time and temperature.

Employing a diacetyl rest is particularly important when producing beers with high adjunct

fraction due to the high levels of diacetyl produced.

This is done by fullcooling the vessel to 4°C. at this temperature the activity of the yeast

seizes and they start to percolate at the bottom of the tank.

It usually takes 10 days for the entire process of fermentation.

The chemicals used in the fermentors are fermaid and or finizyme for some biochemical

procedure of the fermentation process.

Racking:

After the process of fermentation is stopped by fullcooilng the tank the yeast present in the tank

is piped out of the tank and stored in the yeast storing vessel for the next batch of fermentation

after acid treatment f the yeast. This process of taking out the yeast from the fermentation

vessel.is known as Racking.

As the yeast collects at the bottom it could be easily piped out by simply putting on the motor

and sucking out the yeast from the vessel. From unitanks it is easily piped out as the yeast

percolates at bottom of the cone. It is rather difficult to suck out the yeast from the fermentors

denoted as FV which are round bottomed. In these fermentors the wort is decanted from the top

and the fermented wort is passed into lagaring tank for maturation. The leftover yeast is then

stored in yeast storage vessel.

After racking is done some chemicals known as racking chemicals are added in the lagar tank ao

the unitanks. These chemicals help out in the percolation of the leftover yeast which might be

45

left over after fullcooling of the yeast. Further these chemicals also impart some effect in the

maturation of the beer in the lagaring stage. These chemicals are biofine, kms, profix, lucilite and

CO2.

Lagaring:

After the yeast taken out of the fermentors and left for matauration in either the lagar tank or the

unitank the process of lagaring starts. The process of maturation of beer is known as lagaring.

This is also known as secondary fermentation. In this process the beer is kept very low

temperature of nearly -1°C. At this temperature the beer matures and the characteristic flavor of

the beer comes in. This process goes on for 5 days and then the yeast is decanted of from the

vessel. This beer is known as green beer. This beer is sent for filtration.

Filtration:

After the fermentation is over the beer has to be filtered so that there is no haze in the beer and it

is free of any foreign particles and is crystal clear. This process is done in the filtration unit.

Although conditioning-maturation, clarification, and stabilization-plays an important role in

reducing yeast and haze loading materials, a final beer filtration is needed in order to achieve

colloidal and microbiological stability. The beer must be rendered stable so that visible changes

do not occur during its shelf life.

The filtration unit is known Della Toffola. This is a filtration equipment which works on the

mechanism of powder filter. The company employs powder filter for single pass filtration and is

able to produce beer that are suitable for packaging. In a powder filter, filtration is achieved with

the use of filter aids that form a filter bed on stainless wire mesh inside a pressurized vessel; or,

on cellulose sheets in a plate and frame filter; or, in the form of small holes in a candle filter.

While the screens and/or cellulose do not filter at all, but act as septum for the filter aids, it is the

applied "cake" of filter aid which does the filtration. The mechanics are very similar to those of

sheet filters. The chemicals which forms the bed for filtration are profix and KMS. These

chemicals are added in the chemical dozer. The beer pipeline is connected with the chemical

dozer and to the filtration pipe.

The beer together with chemicals falls into the filtration vessel and forms a bed on circular discs

which are inside the filtration vessel. At first the whole content is recirculized in the vessel and

46

after the bed is properly formed the beer is filtered which is free of any free bodies. After the

filtration is over the haze of the beer is calculated and this beer is stored in tanks known as Bright

Beer Tank or simply BBT. There are altogether 9 BBTs in the plant for storing the filtered beer

for bottling and corbonation of the beer. The sediments from the beer are then discharged from

the filtration unit which is known as cake discharge which is collected and used in land filling.

The filtered beer passes through PHE which brings the temperature of the beer to 1°C. Biofoam

is then puched into this beer which is then stored in BBT.

BBT: In BBT the beer is properly carbonated. This is done by passing carbon dioxide into the

BBT. This is done to bring the tingy taste of the beer. Further carbonation brings the dissolved

oxygen of the beer to near to zero. The DO in any beer should be zero or nearer to it as this

increases the shelf life of the beer.

After the beer is properly carbonated the beer is ready for bottling and hence is sent for bottling.

The Bottling Process in UBL Kalyani:

The bottling usually deals with the cleaning of the used bottles, filling it with beer, pasteurizing it

and then labeling and packing it. The entire process could be described as follows:

Dirty bottles are collected from the vendors who supply it to the company. These bottles

are processed and these are only filled. The entire system of bottling is automatic and

computerized. Volunteers only check the process if its going correct or not. The bottles

are placed on the conveyer which conveys the bottle to the KHS Washing Machine. This

machine has a capacity of washing 21000 bottles per hour if everything goes well. The

bottles enter the machine and are washed inside automatically by 2.5% caustic solution

and with 80°C hot water. At this acidic concentration and at this hot temperature the

microbes in the bottles are destroyed and becomes more or less sterile and free of any

foreign bodies. Further the labels and other things attached on the body of the bottle is

removed in the KHS machine in the washing process.

The conveyer then arranges the bottles in a que and is conveyed to a check point where a

volunteer checks whether the bottle is free of any foreign body against a bright board

47

which is illuminated for the purpose. If the bottle is not free of foreign bodies, it is either

destroyed or sent to the washing machine again depending upon the condition of the

bottle.

The conveyer then conveys the bottles to another checkpoint. At this point the volunteer

checks the surface of the mouth of the bottle. If the surface of the mouth is broken the

bottle is destroyed then and there. Only bottles free of any cracks on the surface of mouth

is used for bottling.

This bottle is then conveyed to the filling machine. This machine is also a KHS machine

and is fully automatic. The filling machine fills the bottle first with CO2 and then in

small quantities beer is filled in each bottle one by one such that the final quantity of beer

in thr bottle is nearly 650ml. and no filler remains idle. The filling machine consists of

discs on which the bottles rest and are filled with small pipe like fillers. These discs are

63 in number and can fill 63 bottles in one round. The speed of the filling machine is

nearly 18000 bottles/hour but usually due to certain halts in other process the speed limits

to 16000 bottles/ hour. After filling the capping is also done in the same machine.

After the bottles are filled and capped properly it is conveyed to another check point

where a volunteer checks the capping, quantity of beer and entry of foreign particles in

the beer which might have occurred during the filling and capping of the same. If there is

any fault the beer is discarded.

The bottles fro this check point is conveyed for pasteurization. Pasteurization is the

process of heating liquids at high temperature for killing microbes and making the liquid

sterile. The pasteurizer used here is known as Tunnel Pasteur. This machine consists of

6 chambers in which water flows at 6 different temperatures. In the first three chambers

the temperature of water used for pasteurization is 45°C, 50°C and 60°C respectively and

then next three chambers have water falling at 50°C, 45°C and 35°C the beer which is

filled in the bottles may contain microbes from various processes of fermentation and

filtration. This machine ensures the sterility of the beer as because if there is any microbe

in the beer it may spoil the beer and hence reduce the shelf life of the beer. The gradation

in temperature is because as the bottle is filled with chilled beer if it suddenly comes in

contact with 60°C hot water the bottle might burst thus loss of beer. Hence if temperature

is slowly raised the chances of bursting of bottles is nullified.

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After the pasteurization is over the bottles are conveyed to a check point where the final

checking of dirt, foreign bodies and quantity of the beer is done.

After this the bottles are conveyed to the labeling unit where labeling is done together

with the printing of MRP, batch no. and date of manufacture.

After this the bottles are conveyed to a check point where MRP, batch no. and date of

manufacture is checked.

After this the bottles are conveyed to the packaging unit where the bottles are packed in

cartons. 12 bottles of beer are packed in 1 carton. These are then conveyed for storage in

the warehouse for dispatch.

This completes the process of beer manufacture in the UBL Kalyani beer

factory.

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OVERALL PROCESSING

Raw Materials(Grinded)

Brew Water

Brew House

Whirl Pool

CO2

OUTLINE OF THE BREWING PROCESS

50

Spent gram

Boiled Wort

Yeast Storage tank Cold Wort

Yeast Pitching Fermenter CO2 Plant

Largaer Cellcarbonation

KMS, Profix & biofine

Plate & Frame Filter Press

Polisher Bright Beer tank

Biofarm

Packaged Beer

Production Line

Malt & adjuncts

FERMENTATION

OUTLINE OF THE PROCESS

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Water Treatment

Milling

Whirl Pool

Mash Tun

Lauter Tun

Wort Kettle

Hot Wort

Cold Wort To Fermenter

Spent Gram

Brew water

Air Sparging PHE

LAGERING AND FILTRATION

OUTLINE OF PROCESS

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Cold Wort

Yeast Pitching Fermenter CO2

Yeast Storage Vessel

CO2 Plant

Beer

Settled Yeast

Carbonation p=3kg/cm2

Beer Without Lagering &

PasteurizationLarger Cells(4/5 Days)

Plate & Frame Filter PressDiatomaceous Earth

Fermenter

Polisher

Can Beer (Without Lagering &

Pasteurization)Bright Beer TankProduction Line

Biofoam

BOTTLING OF BEER

OUTLINE OF THE PROCESS

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Empty Recyclable Bootles

Bottle Washer

FilterCrownerTunnel PasteuriserBottle Labeling CodingPackaging & StorageDispatch InspectionBBT Tank InspectionBottle Counter Inspection

KEY DISCUSSION AND ANALYSIS

Status of microbial loading in different processes and methods to improve the

microbial compliance.

Microbial contamination can originate from a variety of sources in the brewing process. Raw

materials, air, brewing water, additives, and even pitching yeast can act as a constant supply of

contaminants. Residues remaining in brewhouse tanks, pipelines, valves, heat exchangers, and

packaging equipment harbor microorganisms too that represent a potential source of

contamination. Some of the effects of contamination range from comparatively minor changes in

beer flavor and fermentation performance to gross flavor and aroma defects, turbidity problems,

abnormal attenuation rates, and reduced yeast crops.

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Microbial contamination is a huge loss in those food and beverage industry. Food items should

be always free from microbes as they prove hazardous both to the consumer as well as the

product itself.

A number of microorganisms have been reported to be beer spoilage microorganisms, among

which bacteria, as well as so-called wild yeast and molds. These may be summed as follows:

Bacteria

Gram-Positive Bacteria

Lactobacillus spp.

Pediococcus spp.

Gram-Negative Bacteria

Acetic Acid Bacteria

Zymomonas spp.

Pectinatus spp.

Enterobacteriaceae spp.

Wild Yeasts

Saccharomyces spp.

Non-Saccharomyces spp.

Brettanomyces spp.

Torulopsis, Pichia, and Candida spp.

According to the stages of production the species contaminating the beer changes from one

process to another.

Microbial loading in different processes and places in the plant:

In the brew house chances of microbial contamination is very liitle as because everything

in the brew house is processed at temperatures near to boiling point.

There is a chance of contamination when the wort comes in direct contact with the

PHE. If the PHE is not sterile it may contaminate the entire wort which in result may

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spoil the entire brew as its is the best medium for the growth of various types of

microorganisms.

There is also a chance of contamination when the wort is aerated. The air if by any

chance is not free of microbes it may contaminate the entire wort.

The racking pipe used for racking the chemicals in the tanks. These pipes are left open

in the air and hence there is a great chance for the pipe to harbor microbes in it. Further

the chemical dozer used for racking is also in free air and may contain microbes which

may infect the whole wort .

The box which contains the bend pipes used for various purposes in the flow plate is

kept in the yeast room. This trunk if not washed properly and daily may contain microbes

which may infect the pipe and thereby the wort.

The biofoam dozer which is used for dozing be biofoam to the filtered beer before it

enters the BBT also takes place in the free air. Hence there are chances that microbes

may infect the beer in the BBT and spoil it.

The chemical dozer used in the filtration for the filtration bed formation may also

harbor microbes as the whole operation is taking place in free air.

The various pipelines used in the transfer of wort and various other things should be

also sterile as this may infect the beer easily

Measures taken in the process for increasing microbial compliance:

The water used in the entire process is sterile and is checked routinely.

CIP (cleaning in place) insures the disinfection of all the equipments. This is done

routinely after any tank is emptied or before any tank is to be filled. Each and every

equipment and the pipeline used in the pipeline is properly washed with caustic acid and

divosan and with hot water. This reduces the chances of contamination by equipments

used in the process.

The air used in the process is sterile as it is properly filtered.

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The box which contains all the bend pipes in the yeast room is kept in divosan solution

which is a powerful disinfectant. Thus the chances of contamination from the bend pipes

which is attached with the flow plate is also low.

Observations in the bottling unit:

The major issue in the bottling section was bursting of bottles while filling it in the KHS filler. It

was seen that while filling the bottles in the filler near about 40 bottles burst on an average per

hour. The plant runs 24 hours a day and 7 days a week. Thus this is a loss for the company. This

means that everyday 960 bottles burst. The cost of each bottle is Rs.3. Thus every day the

company loses Rs. 28800/ day, i.e.

It was observed that the bottles burst in the filling when carbon-dioxide was pumped in the

bottles. Carbon-dioxide is pumped with pressure in the bottles and hence the bottles which are

weak burst out.

The following observation was made

CO2 pressure in

kg/m2

Bottles burst in hour 1 Bottles burst in hour 2 Mean bottles burst

2.4 39 41 40

2.1 23 25 24

1.8 15 17 16

Thus from the following observation it can be concluded that rise in CO2 pressure causes more

bottles to burst. The more the pressure of CO2 rises the more number of bottles burst.

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RECOMMENDATIONS

The present microbial compliance of the company is good and all the processes are sterile but

there are certain small things which if taken care would increase the microbial compliance.

These may be summed up as follows:

Proper documentation of all the processes which are overlooked by the workers. These

are small but may prove hazardous in the long run. These small things are like:

Proper documentation of the sanitization of the pipeline and the signature of the person

involved in it.

Proper documentation of the sanitization of the racking pipe used in racking/hosing. The

pipe after used should not be left in open and/or on the floor after its use but should be

kept in a sterile room.

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The chemical dozer used for the racking purpose should be sterilized properly and should

be documented.

The box in which the bend pipes and the connector pipes used for connecting with the

flow plate should be sterilized properly and the divosan used for sterilization should be

changed periodically. Documentation for this should also be done.

The biofoam dozer and the chemical dozer for filtration purpose is always in action as the

filtration goes on throughout the day. These should be sterilized together with the

sterilization of the filtration unit as all of the three are linked in function and work

together.

The dead ends of the pipeline should be sterilized and should be documented.

The company is undoubtedly having a very good microbial compliance but if these small things

are also kept in mind and not overlooked by the workers the microbial compliance would

increase and thus the quality of the product further decreasing the chances of contamination by

microbes caused due to these small things.

Proper documentation of these small things would not allow the worker to overlook these small

things and hence the process of beer making would be more sterile.

Recommendations’ for the bottling unit:

The solution to the problem of bursting of bottles during filling could be standardization of CO2

pressure of the inlet. When CO2 is released from its source it comes in tremendous pressure but

normally in its path it lowers down to 2.4. Thus if the pressure at the source is controlled the

pressure in the KHS filler would be automatically controlled.

Thus through various observations we may find that the optimal CO2 pressure required is 1.8-1.7

kg/m2. If pressure is controlled in this range while filling the number of bottles burst would be

reduced to 16 from 40 without a change in the quality of the beer.

Calculations:

When pressure is 2.4 kg/m2 the no. of bottles burst is 40.

When pressure is lowered to 1.8 kg/m2 the no. bottles burst is16.

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Thus number of bottles saved per hour =24.

Price of each bottle is Rs.3

Thus amount of money saved per day = 24*16*3

= Rs.1152.

Thus amount of money saved per month = Rs.34560

Thus we may conclude that standardization of CO2 pressure from 2.4 kg/m2 to 1.8 kg/m2 saves

cost and loss of resources. Further the less the number of bottles burst the less are the chances of

accidents occurring to the workers.

CONCLUSION

Today, the brewing industry is a global business, consisting of several dominant multinational

companies and many thousands of smaller producers ranging from brewpubs to regional

breweries. More than 133 billion liters (35 billion gallons) are sold per year (the equivalent of a

cube 510 meters on a side), producing total global revenues of $294.5 billion (£147.7 billion) in

2006.  The global beer industry is consolidating. Consolidation started 10 years ago and probably

has 10 more to go before it winds down. China is the biggest market for beer followed by the

US, Germany, Brazil, Russia, Japan, UK, Mexico, South Africa and Spain. The paradox in China

is that although the retail price of beer is very low in terms of the market, it has very high profit

margins as far as international players are concerned.

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With the global market experiencing low/stagnating growth in recent years, the focus is now on

the Asia-Pacific region specially. For instance, the Chinese beer market has grown at an

astounding pace in recent years, spurred on by the massive levels of foreign investment in the

market, along with the rise in the average levels of consumer spending and thanks to the

economic reform policies of the government. Total consumption of beer in China grew by

33.56% between 2000 and 2006 to reach a total market volume of 30.47 billion litres. With the

per capital consumption of 22 litres, China has now overtaken the US to become the largest

national beer market in the world. The brewing industry in China has been one of those quickest

to modernize and Indian beer Industry should look to model themselves on their neighbors.

United Breweries Limited is the largest producer of beer and other spirits in India. The reason for

its predominant increase in market share is the control over its quality. It is an ISO.9001...2008

certified company and hence maintains the best quality.

Beer is a product which comes under the food and beverages sector and is consumed by human

beings at a large scale. Thus maintaining quality standards at every level of the process forms the

very basic for the success of the product as well as of the entire company. Beer is a fermentation

product and is rich in alcohol and glucose content and is very susceptible to contamination from

microorganisms at each and every step in the process of its making. Thus a strict control should

exist at each and every step in the process and every process should be carried out in a closed

environment which is taken care in the plant with full efficacy and efficiency. The higher the

microbial compliance greater is the life of the beer and better is the quality. In spite of various

control measure taken by the plant certain things are overlooked by the unskilled workers in the

plant during handling of the equipments and this brings contamination of the beer and hence

increases the dissolved oxygen level of the beer which is not desired. Thus this report surpasses

through the various regions which are overlooked by the workers of the beer plant in compliance

with the contamination of beer and further finds out method to overcome such trivial mistakes

and increase the microbial compliance and the life of the beer.

Thus it can be finally conclude that if proper care is taken of small things which are otherwise

overlooked in the plant due to the ignorance of the workers about the hazards it could create a far

more better and good quality of beer could be manufactured with a larger life and lesser risks.

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REFERENCES

Books

Prescott and Harley “Text book of Microbiology” , Prentice Hall of India, 2002

A.H.Patel “ A handbook of Industrial Microbiology”, Prentice Hall of India, 2002.

Articles from the Internet

http://www.studentsguide.in/microbiology/industrial-microbiology/steps-in-commercial-

production-of-beer.html

http://en.wikipedia.org/wiki/Beer

http://www.britannica.com/EBchecked/topic-art/58378/70929/The-process-of-beer-

production

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