PRODUCTION OF BEER BY THE PROCESS OF FERMENTATION IN BIOREACTOR

CONDUCTED ATMOHAN MEAKIN LIMITED, MOHAN NAGAR

GHAZIABAD (U.P.)

 

A MINOR PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY IN BIOTECHNOLOGY

PROJECT GUIDE:

Mr. Harish Datta

Production Manager / Coordinator

SUBMITTED BY:

ABHISHEK PATHAK

DEPARTMENT OF BIOTECHNOLOGYSIR CHHOTU RAM INSTITUTE OF ENGINEERING &

TECHNOLOGYC.C.S UNIVERSITY (CAMPUS) MEERUT.

2009

1

ACKNOWLEDGMENT

Though only my name appears on the cover of this dissertation, many people have contributed to its production. I owe my gratitude to all those people who have made this dissertation possible and because of whom my graduate experience has been one that I will cherish forever.

I would especially like to thank Mr. Harish Datta Production Manager/ Coordinator, for his generous time and commitment throughout my practical training.

I am extremely grateful for the assistance, generosity, and advice I received from Dr. H.S Singh Director S.C.R.I.E.T and Dr. Pratibha Malik, (Coordinator) Department of Bio Technology.

I extend many thanks to my colleagues and friends for being so organized and helpful. Finally, I'd like to thank my family a constant source of support, for their encouragement and enthusiasm.

At last I would like to thanks almighty who kept his blessing through out on me to finish this entire project.

Abhishek Pathak

2

CONTENTS

Introduction of Industry and Practical Training

Beer and its History

Beer Brewing Process

Principle

Sugar Catabolism In Yeast

Methodology

Step 1 Malting Barley

Step 2 Mashing

Step 3 Wort Separation

Step 4 Wort boiling

Step 5 Wort cooling and aeration

Step 6 Fermentation

Step 7 Filtration

Step 8 Beer carbonation

Step 9 Bottling

Result and Discussion

List of Figures

3

Bibliography

INTRODUCTION ABOUT THE INDUSTRY & PRACTICAL

TRAINING

A saga that began over a century and a half ago, continues on its path of service to the world with dedication, courage and an unflinching commitment to quality. Over the years the Company has embraced modernity and adapted to changing times. Yet, its basic values remain the same--Integrity, Craftsmanship, and Tradition. From old tradition sprang Mohan Meakin where the sanctity of ancient culture, technological development and craving for quality are artfully blended into the products.

The origin of Mohan Meakin traces back to Edward Dyer from United Kingdom who set up the first-ever brewery and made indigenous beer available to the Indians as well as Britons. He set up more Breweries at Solan, Simla, Murree, Rawalpindi and Mandalay. Another entrepreneur H G Meakin came to India from Britain and bought the old Simla and Solan Breweries from Edward Dyer and added more at Ranikhet, Dalhousie, Chakrata, Darjeeling and Kirkee. A distillery was then set up at Kasauli instead. Another distillery was set up in the historic city of Lucknow. In addition to meet the increased demand of Mohan Meakin Products an Industcrial Complex on 150 acres of land was set up in the year 1960 near Dehli in Ghaziabad Distt. of Uttar Paresh. Mohan Meakin have established fully equipped labratories at its various manufacturing centres manned by highly qualified and experienced technical persons to ensure the maintenance of high standard quality products.During the training period I gone through the various techniques & procedures which are being used in the production of Beer by fermentation process by using s. cerevisiae as the microorganism.The main emphasis is focused on the temperature control, pH maintenance and alcohol concentration (approx. 4.5% in 650ml of Beer). Which is necessary for maintaining the quality of Beer.  In 1949 Mr. N. N. Mohan took over the management of the Company. Under the dynamic stewardship of  Mr. N. N. Mohan the Company’s assets and profits registered a manifold increase. To mark the contribution of Mohans the Company’s name was changed from Dyer Meakin Breweries Limited to Mohan Meakin Breweries Limited in 1967.  On passing away of Mr. N. N. Mohan in 1969, his eldest son Col. V.R. Mohan took over as the Managing Director of the company. He introduced a number of new products that are brand leader even today.  In the Seventies the manufacturing activities of the company were diversified into other fields under the leadership of Brig. Kapil Mohan, VSM, who became the Managing Director of the company in 1973.

4

Subsequently the word Brewery was dropped in 1982 to remove the impression that the Company is engaged only in beer making.

PRODUCTS OF MOHAN MEAKIN LTD.

WHISKY PRODUCTS

SOLAN NO. 1 :Solan No.1 distilled out of Malt made at Kasauli, Simla Hills, matured in oakwood casks and diluted to desired strength with Himalayan Water has come to be known as Scotch of India. The Royal Institute of Public Health & Hygiene, London has certified it as a product of high quality conforming to international standards.

COLONEL’S SPECIAL :The heart of this blend is matured  in oakwood casks longer than any other Indian Whisky.

RUM PRODUCTS              OLD MONK RUM The Country’s most popular rum is Old Monk Rum. A superlative drink whose popularity has spread in other countries of the world. This legendary drink has been awarded gold medals at Monde World Selection since 1982 for its quality.

OLD MONK GOLD RESERVE RUMOld Monk Gold Reserve is an epitome of unflinching dedication to quality. Blended with highly matured spirits, most of them 12 years old, Old Monk Gold Reserve is becoming popular amongst younger generation.

BRANDY PRODUCTS The graceful way to round off a good meal. The ideal warm-up when chilly winds blow. Mohan Meakin’s brandies come brimful with delightful promise.

GOLDEN EAGLE DOCTOR’S BRANDYWonderfully warming for that  rosy glow of contentment.

DOCTOR RESERVE NO.1 BRANDY

5

It has carved a lace for itself  in bars across the country.

TRIPLE CROWNSmooth and subtle Gently poured when the perfect evening is drawing to a close.

GIN PRODUCTS Smooth and excellent by itself, superb in cocktails. As a long drink Mohan Meakin’s Gins are well known. Their popularity is every increasing.

BIG BEN DELUXE LONDON DRY GINBeautifully  dry, flavoured just right with juniper berries. Found frequently in tall frosted glasses.

VODKA PRODUCTS The epicurean’s delight.For the perfect Bloody Mary. A Vodka even Russians will welcome.

KAPALANSKYFor the pleasures of a superbly balanced drink.The connoisseur’s delight.

BEER PRODUCTS The rich amber liquid that is so indispensable in India’s long, hot, thirsty summer. Mohan Meakin has been quenching a nation’s thirst for over a century & quarter now.

GOLDEN EAGLEThe discerning drinker’s  beer for millions. Sunday afternoons are incomplete without it. Golden Eagle, the drinker’s preference  has come to be known as the king of beers in India. South after in International Markets for its taste and quality this beer has won gold Medals at Monde World Section since 1982.

SOLAN Made with the clear spring water of the Solan Peaks. Bubbling freshness only this special water can bring.

GYMKHANAAn old favorites mentioned in the book, The World’s  Beers.

ASIA 72The people’s choice brewed to perfection.

LIONFor the lion-hearted also mentioned in the book, The World’s Beers.

OLD MONKIt can wash away the righours of the longest hottest summer with a distinctive taste.

BLACK KNIGHT SUPER STRONG

6

The thirst quencher that packs quite a punch. The regular drinker’s beer

HISTORY OF BEER

ANTIQUITY

Beer has been brewed since time immemorial. It is thought that it was first made in Palestine around ten thousand years ago, in 8000 BC, by macerating barley bread in water.

The Sumerians developed no fewer than ten varieties of beer, and the Babylonians added at least 34 more. Later on, the Egyptians developed what can be called government breweries, making brewing a state monopoly. These "barley wines" were used as offerings to the gods. Pharaoh Ramses II, who is referred to as the "brewing Pharaoh", imposed very strict rules on the making of beer.

Beer made its way to Europe around 5000 - 4800 BC along two routes: the Danubian route (Eastern Europe) and the Mediterranean route (south of France). Contrary to what is generally believed, beer was brewed and consumed very early in Greece and Rome until it was to some extent replaced by wine.

However , while the Romans were more fond of wine, this did not prevent them from appreciating beer, in particular in the northern regions, where conditions were better for barley fields than for vineyards. For example, the remains of a Gallo-Roman villa were found to contain a brewery dating from the 3rd or 4th century. Among Belgium's ancestors, the Gauls, the brewing of barley beer was a cottage industry; it was brewed within the family by the women. It were the Gauls who came up with the idea of replacing recipients made of pottery by wooden barrels, which, by the way, they invented. They called malt "brace", a word that has come down to us in the French terms brassin (beer mix), brasseur (brewer), etc.

After the fall of the Roman Empire, the church took control of the land. The monks took an interest in this beverage, and eventually it appears that there were breweries in every abbey in Christendom. And brewing also went on in inns, castles and homesteads.

7

THE MIDDLE AGES

In spite of barbaric invasions, brewing never quite disappeared from our regions. As early as the 7th and 8th centuries, the first monastic communities consumed beer, which had by then become a popular beverage. At that time, monks lived just like everyone else, but of course they were isolated from society. In the region of the Meuse, the oldest monastery appears to be the Grand-Axe, which is first mentioned in documents in the year 805.As we have just seen, the first Belgian abbeys already each had their own brewery. This was the case for Villers-la-Ville, which has had a community of monks since 1146. The immense abbey they built was inspired by the architecture of the Cîteaux (the order of the Cistercians). The brewery, in the Romanesque style, was built in the first half of the 13th century. However, the abbey destroyed waste in the religious wars of the 16th century and the French Revolution. Also around this time, the first guilds were set up. The purpose of guilds was to maintain the quality of products and to ensure respect for traditions.

Breweries then proliferated in the 14th and 15th centuries, as beer became a popular beverage. Around this time, it was commonly believed that it was better to drink beer than water, because epidemics like cholera and the plague could be transmitted by water, while the cause of these diseases was eliminated in the brewing process. The Renaissance (around the 16th century) was the golden age of brewing. Their corporations were very rich. In Brussels, brewers bought the "Arbre d'or", a fine building that is now the "Maison des Brasseurs" (House of Brewers) on the Grand'Place. They restored this dwelling and embellished it in the 17th century. Although it was completely destroyed in the bombarding of Brussels by the Marshal de Villeroy, it was quickly rebuilt, at great expense, in the 18th century, when it was adorned with the facade that is still admired to this day by countless tourists. It was sold off by the French revolutionaries in the 18th century, and then in 1954 after some radical conversion work it once again became the "Maison des Brasseurs".

From the 17th century until the Second World War

8

In the 17th century, many different types of beer began to appear up and down the country. Each variety was characterized by the specific ingredients used and the quality of the water. Small breweries flourished at this time, and as in those days there were no sophisticated means of preserving the product, each village had its own brewery.At the end of the 18th century, a historical event took place that was anything but beneficial to the tradition of brewing: the French Revolution. In addition to the fact that it put an end to brewers' guilds, the Revolution led to

the destruction of many monasteries and abbeys, effectively wiping out much of the brewing industry. However, with the arrival of Napoleon on the scene brewing took off again thanks to a general economic recovery, although from that time on brewing would no longer be reserved for monks. It became a fully-fledged industry in its own right.

At the end of the 19th century, the scientific progress achieved by Louis Pasteur (1822-1895) in the study of yeast and the preservation of food by "pasteurization" gave breweries new impetus for some time. And these discoveries not only made it possible to preserve beer more efficiently, but they also improved the quality of beer, as the various types of yeast produce different flavors.

By the year 1900, there were 3,223 registered breweries in Belgium, including Wielemans' Brewery in Forest (Brussels), which was considered to be the biggest and most modern in Europe. It was also in Brussels (in the brewery called the Grande Brasserie de Koekelberg, to be precise) that the first bottom-fermenting beer (Pills) was brewed in 1886.

After the First World War, there was a considerable drop in the number of breweries. In fact, by 1920 there were only 2,013. The reason was that there was a dearth of the raw materials and manpower needed for brewing, and the few breweries that resumed production had to be mechanized. In the 1930s, the economic crisis made the situation even worse, and the Second World War caused a further reduction in the number of breweries. As a result, in 1946 Belgium had only 755.

9

TYPES OF BEER

Beer can be divided into, depending on the fermentation method.

Bottom-fermenting beer is the most recent type. The process dates from 1840 and produces a specific type of beer, Pils or lager. This type accounts for 90% of worldwide beer production. Pils is a light, clear, golden beer. It has a fresh, bitter and refined hoppy flavour.

Top-fermenting beer is a much older and more traditional variety. This process is involved in the production of many different types of beer, in particular Amber or "Special Belgian" beer. Originally, this type of beer had the same density and alcohol content as Pils. The amber colour is obtained by using coloured or caramelised malt. The alcohol content is now slightly higher, and this beer is considered to be typical "sampling" beer.

White beer is non-filtered and cloudy in appearance. In addition to barley malt, the ingredients include unmalted wheat and sometimes oats. Also, during the heating process, coriander and orange peel are added to give it its characteristic refreshing taste.

The Trappist Order is abbey beers. They are marketed under protected copyright names that belong to the Cistercian Order. This legal protection entails certain rules. This type of beer must be brewed in a Cistercian abbey under the supervision of monks belonging to the Trappist Order. There are various types: blonde, double, dark and triple. Each of the three abbeys has its own recipes.

The other abbey beers are marketed under licenses which are granted to lay brewers, whose trademark refers to an abbey that may exist or may have disappeared. There are various types of abbey beer: Lagers, which are characterized by a mild, slightly malty aroma, a neutral or slightly sweet taste and an often very bitter after-taste. The double or dark beers, so called because the brewer uses more malt. Nowadays this type of beer is darker and has a sweetish, sometimes sugary taste and a bitter after-taste). Finally, triple beers, in which the

10

brewer uses even more malt and which undergo triple fermentation, the final stage of fermentation being in the bottle.

Strong blonde beers are often clear. They are generally served with a large head. They undergo triple fermentation and contain aromatic malts.

Seasonal beers are typically brewed in Wallonia, especially in the districts of Hainaut and Walloon Brabant, and are sparkling and fruity summer beers. They involve the use of raw hopping and sometimes secondary fermentation in the bottle.

The regional and special beers are fine examples of the creativity and know-how of our local brewers. They are all very different. Each variety has its own characteristic manufacturing process and ingredients (spelt, honey, Liège syrup, mustard, etc.).

Scotch is a beer of Anglo-Saxon origin which, over the years, has become a specialty of the Walloon Brabant and Hainaut district. It is characterised by a very malty and slightly smoky taste. Its sugary taste is due to the addition of candy sugar.

Spontaneous fermentation, a process that is characteristic of the Brussels region, is used to produce Lambic. Lambic is a flat beer with no head. It is produced through spontaneous fermentation of the yeasts found specifically in the valley of the river Senne. It matures in barrels made of different types of wood and has a wide range of tastes.

Gueuze is obtained by the fermentation caused by mixing "old" Lambic (that has not completely fermented) and "young" Lambic. This new fermentation produces a sparkling, sharp beer, the "champagne of beers".

Fruity beers are basically made by mixing different fruits (cherries for Kriek) and Lambic. Traditional Kriek is a mixture of 50 kg of cherries and around 250 litres of Lambic. This mixture matures for 6 months in the barrel and produces a beer with a fruity but not sugary taste. The industrial process involves fruit juice and extract. he result is a sweet, fruity beer.

11

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

12

PRINCIPLE

YEAST METABOLISM

Metabolism refers to the biochemical assimilation (in anabolic pathways) and dissimilation (in catabolic pathways) of nutrient by a cell. Like in other organisms, in yeast these processes are mediated by enzymatic reactions and regulation of the underlying pathways have been studied in great detail in yeast. Anabolic pathways include reductive processes leading to the production of new cellular material, while catabolic pathways are oxidative processes, which remove electrons from substrate or intermediate that are used to generate energy. Preferably, these processes use NADP or NAD, respectively, as co-factors.

Although all yeast are microorganisms that drive their chemical energy in the form of ATP, from the breakdown of organic compounds, there is metallic in how these organism generate and consume from these substrates. Knowledge of the underlying regularity mechanism is not only valuable in the understanding of general principle of regulation but also of great importance in biotechnology, if new metabolic capabilities of particular yeast have to be exploited.

It is now well established that the most yeast employ sugars as their main carbon source, but there are particular yeast which can utilize non-conventional carbon sources. With regard to nitrogen metabolism, most yeast is capable of assimilating simple nitrogenous sources to biosynthesize amino acids and proteins. Aspects of phosphorus and sulphur metabolism as well as aspects of metabolism of other inorganic compounds have been studied in some detail, predominantly in the yeast, sacchromyces cerevisiae.

13

NUTRIENT FOR GROWTH OF YEAST CELLS ( S. CEREVISIAE )

Substrate for growth of s.cerevisiae

Saccharose (>Glucose + Fructose) Invertase

Maltose (> Glucose)

Mellblose (> Glucose + Galactose)

Glucose (>Glycol sis)

Ethanol (>Acetaldehyde > Acetyl- CoA > Oxaloacetate > Gluconeogenesis) ADH2

Lactate (> Pyruavte > Gluconeogenesis)

Glycerol (> Glycerol -3- phosphate > DAP > Gluconeogenesis)

Amino acids

Glutamine

14

SUGAR CATABOLISM IN YEAST

Principle pathways:

The major source for energy production in the yeast, saccharomyces cerevisiae, is glucose and glycol sis is the general pathway for conversion of glucose to pyruvate, whereby production of energy in the form of ATP is coupled to the generation of intermediate and reducing power in form of NADH for biosynthetic pathways.

Two major modes of the use of pyruvate in further energy production can be distinguished: respiration and fermentation. In the presence of oxygen and absence of respiration pyruvates enters the mitochondrial matrix where it is oxidative decarboxylated to Acetyl CoA by the pyruvate dehydrogenase multi enzyme complex. This reaction links gylcolysis to the citric acid cycle, in which the Acetyl CoA is completely oxidized to give two molecules of co2 and reductive equivalents in the form of NADH and FADH2, however, the citric acid cycle is an amphibolic pathway, since it combines both catabolic ad anabolic functions. The latter results, for example, from the production of intermediate for the synthesis of amino acids and nucleotides.

Replenishment of compound necessary to drive the citric acid cycle, such as oxaloacetate and α-ketoglutarate, are:

(1)The fixation of co2 to pyruvate by the action of the enzymes pyruvate carboxylase (ATP dependent) and phosphoenolpyruvate carboxykinase,

(2)The glyoxalate cycle (a shortcut across the citric acid cycle ), which is important when, yeast are grown on two – carbon sources, such as acetate or ethanol

Microorganisms

15

Brewing utilizes strains of saccahromyces carlsbergensis, bottom yeast, and saccharomyces cervisiae, both bottom and top yeast strains. Top yeast to the surface during the fermentation while bottom yeast settles to the bottom. Top yeast are used for the production of ale distillers. Bakers and wine yeast also are top yeast. However, beer fermentation employs bottom yeasts.

Yeast strains are specially selected for their fermenting ability to flocculate at the proper time near the end fermentation. Brewery itself can select and propagate these strains as well as produce the inoculums. Brewing is different from much other industrial fermentation, in that cell for pitching are often those recovered from a previous fermentation. Fresh inoculum is not necessarily prepared for each fermentation run and in fact, fresh yeast inoculum is required only when contamination presents a real problem or when the vigor, of the yeast has begun to decline. Before being employed as inoculums, the yeast cells from a previous fermentation are washed (with phosphoric acid, tartaric acid or ammonium per sulphate) by setting, process that reduces the pH value to about 2.5 and removes considerable bacterial contamination.

Thus, each pound of yeast added to the fermentation at inoculation yields approximately 3 to 4 pounds liquid yeast at harvest, and the excess yeast, which is not required for further inoculums, becomes a b product of the fermentation.

16

METHODOLOGY

STEP – 1

MALTING BARLEY

Barley selected for use in the malting industry must meet special quality specification as mentioned below. Accepted malting barley varieties have to modify evenly and produce finished malt whose properties lie within the brewer’s specifications. The malt quality of given barley variety is determined by its genetic background and the physical conditions during the growth, harvest and storage.

Malting barley has to be tested in micro malting trials, pilot malting and industrial malting trials; and brewing trials also in pilot and production scale.

The physical conditions of the barley must meet specification concerning:

Factor RangeGermination % Minimum 97% after 3 daysGermination index Minimum 6, 0Water content 12, 0%; maximum 13, 0%Protein content > 9, 0% and <11, 5%Grading Minimum 90% > 2, 5mmβ- glucan content Maximum 4%Micro-organism Below a set levelPesticide residues According to national lawOchratoxin According to national lawAflatoxin According to national lawVariety purity Minimum 99%

17

STORAGE CONDITIONS

Vitality

During prolonged storage, barley grain will slowly loose its vitality, causing a slower germination and even grain death, and will therefore be of o less value for the maltster.

The rate at which barley loses its vitality is dependent on the storage conditions. When stored at very low temperatures and low moisture content, barley may keep its vitality for centuries, but with increasing temperature and moisture, the deterioration processes faster and barley can loose its germination ability in a very short time. Malting barley stored for1 to 1.5 years, should be kept at a moisture content of below 12% and at temperature below 120 C.

More information about the influence of temperature and moisture on vitality can be seen in the table below.

Fungal Contamination During storage Fungi may attack barley with moisture content of above 14% during storage especially by species aspergillus and penicillium. Most fungi produce secondary metabolites, some of which cause gushing in beer, where the beer spontaneously gushes from a bottle on opening. It is therefore, important that malting barley is stored under conditions, which prevent fungal growth.

Maximal length of storage for maintaining malting barley quality under different storage conditions

18

Temperature

Seed moisture content

10% 12% 14% 16% 18%0oC 16 years 6 years 2 years 1 years 190 days2 oC 14 years 5 years 1.8 years 315 days 160 days4 oC 11 years 4 years 1.5 years 260 days 130 days6 oC 9 years 3 years 1.3 years 210 days 105 days8 oC 7.5 years 2.5 years 1 years 170 days 89 days10 oC 6 years 2 years 300 days 140 days 70 days12oC 5 years 1.6 years 240 days 110 days 55 days14 oC 3.8 years 1.3 years 190 days 85 years 45 years16 oC 3 years 1 years 150 days 50 Days 25 Days18 oC 2.3Years 290 Days 115 Days 40 Days 25 Days20 oC 1.8Years 220 Days 90 Days 30 Days 20 Days22 oC 1.4Years 170 Days 70 Days 25 Days 15 Days24 oC 1Years 130 Days 55 Days 18 Days 12 Days26 oC 290

Days100 Days 40 Days 13 Days 9 Days

28 oC 210 Days

70 Days 30 Days 10 Days 7 Days

30 oC 160Days 55 Days 22 Days 10 Days 5 Days

At the Carlsberg research laboratory loss of seed vigour has been studied intensively ( EBC 1989 and 1991 .)Barely seeds lose both their ability to germinate fast as a consequently of storage. The rate at which seed vigour is lost is dependent on the storage condition . It is our experience that malting barley can be stored safely for the maximal lengths of time indicate in the table.

Malting

19

Barley , which is the fundamental raw material of beer , does not give , just as it , a fermentable extract by yeast.

By mashing it in hot water we could get a bad use of it. We have a let it go through a beginning of germination. Enzymes, which attack the grain and dissolved it in water, are produced during the mashing.

This beginning of germination is called malting. This preliminary step of the production of an constitutes an industries on its own: the malt house . The brewere” Grain d’orge ” buys directly the malt in a malt – house .

Malting consist first of a soaking in water during about three days. Then it is spread inlayer to let it germinate during eight days and finally we stop germination by the desiccation on a kiln or killing. After this operation, the color of the malt varies between yellow and brown going through every golden hue. According to his will of making of lager or brown beer, the brewer chooses one or the other malt.

Malting Process

In the malt house, barley grain germinate is initiated by the uptake of water in a steeping vessel (A). The grain imbibes water during controlled cycles of water spraying or water immersion followed by aeration, until the water content of he grain reaches 42 to 48 % .water enter enters the grain via the embryo and after approximatelyt24 hours, hours, the first visible sign of germination is the appearance of the root, as a white chit. The grain are then transferred to malting beds where germination is allowed to proceed over a period of around five days (b). The speed of germination is controlled by temperature and aeration of the malt bed, while moisture content is maintained by spraying. Further embryo growth, with the appearance of the root lets and acrospires, can lead to root entangling. The grain bed is regularly

turned with a rotating screw to prevent grain malting together. Green malt, produced after 5 days of germination, in kiln dried and partly cooked in a forced flow of hot air (C). Hydrolysis produced during malting are partly inactivated during this process. Malt color, enhanced by kilning at higher temperature, may be desirable for production of darker beer, but it leads to further heat inactivation of hydrolysis. The brittle malt rootlets are separated from the malt and utilized in animal feeds.

20

STEP – 2

MASHING

The goal of mashing is to obtain from the raw material (water, malt and hop) sweet and flavored wort, which will then go through alcohol fermentation.Mashing includes the three following operations:

Malt crushingMashingWort filtration

During the mashing, the malt that was crushed before is mixed with water. This mixture of water, crushed malt with other various ingredients is the mash.The mash is heated at accurate temperature during predetermined laps of time, in order to have a complete transformation of the starch from the malt and of the cereals used for sugar:That is the mashing.This transformation of starch into sugar by the enzyme was lightly initiated during malting. It is essential because yeast can not transform directly starch into alcohol. Starch has to be first transformed into sugar by the enzyme developed during malting.

Once these transformations into sugar finished, the liquid is filtered to eliminate the husk oh the malt grain. The product that is then obtained is the wort; it is a sweet liquid, which already has the colour of beer.

The brewer can, by choosing the temperature level, act on the composition of the wort. For maltose is fermentescible and for starch gums aren’t he can obtain beer that is more or less rich in alcohol. The duration of mashing is more or less two ours. Then the mash is filtered in a filter press. The insoluble materials are the spent grains (25% of the weight of the malt). The wort is pumped into a brew kettle heated by vapor coils.

Mashing involves heating the crushed malt and rice flakes mixture in the mash kettle in order to convert the starches in the malt, and adjuncts if added, into fermentable and unfermentable sugars.

21

Mash kettle: 150 HL

Mashing are normally performed at pH 5.5 at which most malt-derived enzymes exhibit high activity. Conditions include a controlled stepwise increase in temperature that preferentially favors one enzyme, which degrade cell walls and protein are rather heat labile, it is important for their function that mashing begins at a low temperature. Subsequent mashing at 65oC, or higher, is particularly geared to control conversion of gelatinized starch into fermentable sugars using malt derived starch degrading enzymes.

Principal mashing enzymes include (1-3, 1-4)- β-glucanase and xylanase for cell wall degradation, endo-peptidase and carboxypeptidase’s for protein degradation; and amylase, limit dextrinase and α- glucosidase for starch degradation.

Temperature controlled mashing

Mashing extracts those materials from the malt and malt adjuncts, which can be solublized under the particular mashing conditions being employed, also allows the malt amylases and proteases to degrade starch and protein, respectively. A portion of the starch must be partially degraded to dextrins and the rest totally degraded to maltose and glucose. In the same manner, the proteins must be partially degraded to peptones and peptides as well as totally degraded to amino acids. The degree of enzymatic hydrolysis of these compounds is influenced strongly by temperature and to some extent, by pH. The temperature program is yield defined mixtures of particularly and totally degraded enzymatic products.

The temperature optima for the alpha amylase and beta amylases of malt occur within the range of approximately 55 to 77oC. The beta amylase with a temperature optimum at 57 to 65oC, cleaves maltose units from the ends of linear glucose polymers but can degrade only the short side chains not including the branches. Alpha amylase with a temperature optimum in the range of 70 to 75oC, cleaves starch at random yielding large fragment dexrtins with or without branching units so as to make straight chains available for beta amylase activity. Proteolytic activity of the malt at temperature of approximately 60oC allows the formation of the higher molecular weight peptones and peptides but at about 50oC the enzymatic activity yields a higher proportion of amino acids and low molecular weight peptides.

22

The peptones and peptides resulting from the Proteolytic activity of the malt provider flavour, foam, and foam stabilization. The dextrins being non-fermentable, provider low alcohol beer and certain flavor characterstics. Chemical changes at mashing

The mashing process is conducted over a period of time at various temperature in order to activate the enzymes responsible for the acidulation of the mash (traditionally for lagers) and the reduction in proteins and carbohydrates. Enzymes are biological catalyst responsible for initiating specific chemical reactions. Although there are numerous enzyme present in the mash, each with a specific role to play, this discussion is limited to the three principal groups and their respective processes. These enzymes are:

Phytases (acidifying),

Proteolytic enzymes (protein-degrading ) and

Carbohydrase enzymes (starch-degrading).

Starch conversion

By far the most important change brought about in mashing is the conversion of starch molecules into fermentable sugars and unfermentable dextrins. The principal enzymes responsible for starch conversion are alpha and beta amylase. Alpha and beta amylase very rapidly reduces insoluble and soluble starch by splitting starch molecules into many shorter chins (i.e., partially- fermentable polysaccharide fractions – dextrins and maltotiose) that can be attacked by beta amylase. Given a long enough “rest”, the alpha – amylase can dismantle all the dextrins to maltose, glucose, and small, branched “limit dextrins”. However, starch conversion is more effective by the faster acting beta amylase. Beta amylase is more selective than alpha amylase since it breaks off two sugar at a time from the starch chain. The disaccharide it produces is maltose, the most common sugar in malt. Together, alpha and beta amylase are capable of converting only 60 to 80 % of the available starch to fermentable sugars.

Factor affecting mashing conditions

23

Temperature

Temperature influences the amount of extract produced (yield) and the fermentability of the wort during mashing. In general, the higher the temperature, the greater the yield but the lower the fermentability of the wort. At lower temperature less extract is produced, but fermentability is higher. Only at very high temperature will extract begin to drop off.

Mash times

Mash times another factor influencing yield and the fermentability of the wort.In general, longer mash times increases the concentration of the extract, but the rate of increase becomes slower and slower. In general, short mash times at high mash temperature will produce more dextrinous worts, while longer mash times at high temperature will produce more dextinous worts, while longer mash times at higher temperature produce more fermentable worts.

Mash pH

The optimum pH range for mashing is generally at 5.5 to 5.6 for both amylases. The “normal” mash pH, however, depends on the type of malts employed, the pH of the water, the method of mashing. The mash cycle should not be started until the proper initial mash is approximated (within pH 0.2).

Water ions

The nature of the mashing water has an important influence on mash reactions. The ions of major importance at mashing are those of calcium and carbonate, with magnesium and sodium ions playing lesser roles. Calcium lowers the pH of the mash mainly by its interaction with phosphates and to a lesser degree with protein from the malt. Carbonate ions operate in the reverse direction.

STEP - 3

24

WORT SEPERATION

After mashing, when the starch is broken down, it is necessary to separate the liquid extract (the wort) from the solids (spent grain particles and adjuncts). Wort separation is important because the solids contain large amount of protein, poorly modified starch, fatty material, silicates, and polyphenols (tannins).

Lauter tun

Figure:2

The lauter tun is equipped with a sparing system to wash the extract from the mash. The top of the tun is usually spherical or conical and fitted with a vent for relieving the vapor of the hot mash to the atmosphere. The bottom of the tun may be flat or sloped, or it may be constructed with several concentric valleys with intervening ridges. Suspended above the true bottom of the tun is a false bottom of milled, slotted, or welded wedge wire steel plates that act as the filtering system. Free surface area ( the area through which the wort can flow) varies 8 to 15% foe milled bottoms and up

25

to 25% on welded screen bottoms. The false bottom is not a filter plate but acts as a support for the grain bed.

Typically, false bottoms in craft brewery lauter tuns do not consist of the pie- shapedSections of the machined plate, but rather of the rectangular wedge sections of “wedge” – or “v”- wire screen. Their cost is considerable cheaper than machined bottoms, and the screens perform reasonably well. The lauter tun, is equipped with rakes to assist mash transfer and for leveling the bed and facilitating filtration of the, liquid from the mash. Rakes are more important when the mash is stirred and mixed, such as with temperature controlled infusion or decoction mashing. Unlike single temperature infusion mashing, the mash loses its entrained air and sinks onto the false bottom in a dense bed.

Procedure

Lauter tun with a perforated base is used to separate wort from the husk & other matter. Once the wort stops passing out through the base & a bed of huskis formed, water is sprayed from the top by a shower at a pressure of 2Kgcm-2 and water bed is formed which keeps seeping through the husk bed and dissolving the remaining glucose & maltose with it, if present.

(Total time required: 3.5 hr)

STEP – 4

26

WORT BOILING

Following extraction of carbohydrates, proteins, and yeast nutrients in the mash, the clear wort must be conditioned by boiling the wort in the kettle. The purpose of wort boiling is to stabilize the wort and extract desirable components from the hops. The principle biochemical changes that occur during wort boiling are as follows:

SterilizationDestruction enzyme Protein ppt.Color developmentIsomerization Dissipation of volatile constituentsConcentration Oxidation

Figure: 3KETLE

27

Operating the kettle

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

Hops and Hop Products

Substances that are important in beer

Bitter substance 19.0 %Oils 0.5 %Polyphcnols 4.0 %Protein 20.0 %Minerals 8.0 %

A good beer need a good aroma acceptable plate and a deal of that in beer is provide by hops . It has been said: “ Malt is the soul of beer and yeast gives it life but the kiss of the hop is the consummation of that life .” the lupulin glands of the female flower cones f the hop plant provide the different biter substances, which are the basis for beer bettering . Hop cones or hop extract are added during the wort boiling where the largely insoluble α -acids (humulones) from the hops are isomerized to the more soluble Iso - α –acids, the main bettering substances found in the beer. Hopes also contain –acids (Iupulones), which are claimed to add bitterness to bee, especially after oxidation. Analysis of the hop acids in hop products is important for quality control. The analysis is performed by HPLC ( high pressure liquid chromatography ) using a reverse phase C18 column especially developed for this purpose, and elution with acidic , aqueous methanol.

Hoes are added to he boiler tank as the boiling is started. Hopes are the agent , which impart flavour ( bitterness ) to the beer.

28

Two types of Hopes are used:

Pellets Slimy extract

Sugar is added at the start of the boiling to have the require amount of the fermentable sugar in the wort to obtain a desired concentration of alcohol in the bee finally obtain.After boiling the wort in transferred to the whirlpool for the susended hops particles, sugar impurities etc. to settle down.

Wort boiling system

Traditionally , wort was boiled in direct – fired kettles, often made of copper. Since the heat , source is localized at the bottom of the kettle, these vessels are not efficient in transferring heat into the wort , can scorch the wort, and are restrict by the volume of wort, that can be boiled at anyone time.

“ The advent of steam coils and internal heating system allowed for more efficient heat transfer and larger kettle for boiling larger volume of wort . the disadvantage with steam coils are that they are difficult to clean , prone to corrosion , and limited the circulation of wort. ”

However , internal cookers offers several advantages , A circulation pump ( and its additional energy consumption) is not necessary since natural convection of the wort takes place in the kettle. The degree of efficiency of an internal cooker is significantly higher than that of an external cooker even without considering the forced circulation of the latter. This is because of the internal cooker is always completely surrounded by the wort. Wort is subject to less thermal stress . the boiling temp. of the wort using an internal boiler is approximately 1010C. using an external boiler; outlet temp. of the wort is approximately 106 to 107 0 C, such high wort temp. in external boiler are to a pseudopressure cooking effect, which man brewmasters is approximately four times the no. of forced circulation of wort in an external boiler.

STEP – 5

29

WORT COOLING AND AERATION

After boiling and clarification , the wort is cooled in preparation for the addition of yeast and subsequent fermentation. Te principle changes that occur during wort cooling are follows:

Cooling the wort to yeast pitching temp.The formation and separation of break and Oxygenation of the wort to support yeast growth.

Wort cooling systems

After boiling and clarification , the wort leaving the whirlpool has to be cooled in preparation for the addition of yeast and subsequent fermentation. Wort is usually cooled though plate heat exchanges.

Heat exchangers are of two types:

1. Single – stage ( Chilled water only ) or 2. Multi - stages ( amient water , glycol).

Wort enters the heat exchanger at approximately 96 to 990 C and exists one – stage cooling .

The firs stage utilizes water to remove the bulk of the heat, cooling the incoming water to within 30 C of fermentation temp.

In the second stage , the wort is cooled to the fermentation temp. by a secondary refrigerant , e.g.; glycol. Some craft brewers , in an attempt to reduce capital expenditure, ill use the same glycol system that provides the cooling for the fermentation. Most small brewers would prefer two – stages cooling but use one – stages cooling to save money .Alternatively ,the cooling operation can be achieved in a single stages using a glycol – jacked cold water to approximately 30 C below that of the required wort temp. In both systems, the heat from the wort is transferred to the water. That water cant hen be used other purposes , but mainly as a source of warm brewing water.

Aeration and chilled water

30

Aeration of the chilled wort is needed in order to provide the yeast with sufficient oxygen for growth during fermentation . The amount of oxygen required depends on yeast strain, wort temp. wort gravity, amount of tub in the wort, and a no. of other factors. Foe e.g.; wort at high temp. and high specific specific gravity has greater oxygen require than wort at lower temp. and specific gravities. Wort low in trub generally has high oxygen requirement ,while wort with high trub levels have lower oxygen requirements.

The oxygen requirements for individuals for brewing strains can range from 3 to 30 mg,O2 / l but usually it I in the range of 7 to 18 mg O2 / l . Yeast strains with low O2 requirements can be aerated using sterile air since it contains approximately 8 mg O2/l, while strains with high O2 requirements must be aerated with pure gaseous O2.

STEP – 6

FERMENTATION

figure: 4

Wort is cooled and added with yeast, which transforms the fermentation sugar dissolved in water into alcohol and carbon dioxide. After about eight days, this fermentation is finished.

We distinguish two main types: the bottom fermenting beers, fermented at a law temp. (12 to 150 C) with yeast that settle at the bottom of the ale and the top – fermenting beers, fermented at 20 – 250 C with yeast that rise to the top of the beer after the fermentation.

31

Bottom yeast gives a smother, less flavoured and almost neutral taste that makes the taste of the flavour and of the hop stronger. It is the yeast used foe classical beers.

Top yeast is energetic yeast that reproduce a lot and that only works well with a temp. higher than 200 C. It produce more ethereal and flavoured beers that seem to be light and easily digestible , even when their density . It is the ideal yeast for specially for specialty beers.

After fermentation is complete, the beer is set in the fermenter for several weeks at 00 C. The goal of this is to refine the taste, clarify partly the beer and o saturate it with CO2 . Top beers only undergo a shot cooling.

During the primary fermentation (H), the fermentable sugars, mainly maltose and glucose are converted to ethanol and CO2 . This action is performed by the brewing yeast , which during the brewing process also procedure many of the characteristic aroma compound found in beer. At the end of the primary fermentation , the yeast cells flocculate and sediment at the bottomof the fermentor and can be cropped and used for a new fermentation. Not all yeast cells sediment, some will remain sin suspension , and these cells are responsible for maturation of the beer . During this process the off – flavour , diacetyl is degraded to below the taste tharshould. The fermentation characteristics of brewer’s yeast are strain – dependent , and are genetically inheritated. Much of the genetics of sacchromycse yeast has been elucidated , and the knowledge gained , forms the basis for breeding of brewing yeast. Thus , new t5ypes of beer with altered aromas can be produced with yeast strains selected through breeding.

COLD STORAGE

The completed fermentation medium is transfer to storage tanks and held at approximately 0 – 30 C for a peroid of time. During this “cold storage maturation ” coagulated nitrogenous substances, resins, insoluble phosphates , and yeast cells sediments from the beer. In addition, esters are formed, and the beer matures so that it looses its harshness .

During this maturation process , “ chill proofing ” is commonly practiced to help prevent turbidity development on letter exposure of finished beer to cold . much of turbidity can be attributed to unstable protein in the beer, and chill proofing can

32

mean merely the removal by ppt. or adsorption of these unstable residual proteins or partial protein hydrolysate products.

Chill proffering ,is practicd by emplying proteolytic enzymes to reduce the mol. Size of the residual protein and protein hydrolysate produc, so as to insure their solubility even at cold temp.

Antioxidants are also added during cold storage during maturation to prevent later oxidative changes in the beer, which affects flavor . Sulfur dioxide ( sulfites ) and ascorbic acid are commonly used to accomplish this end.

STEP-7

FILTRATION

Extended lagering periods and the addition of flocculation adds both greatly reduce yeast and haze loadings. Centrifuges are mainly used in the preliminary reduction of suspended particles , primarily in yeast before sending to the conditioning tanks. Although these method are very effective in prefiltering the beer, a final filtration is needed to removed residual yeast , other turbidity – causing materials, and micro-organisms in order to achieve colloidal and microbiological stability.

If there is a significant quantity of suspended material to be removed , powder filters using diatomacesous earth or perlite must be emploed. Although powder filter can produced beer of acceptable brilliance after a single filtration, a to stage filtation process is needd to a final polish. Polish filtration may employ a sheet filter , used as an intermediate step in handling heavier loads , followed by acartridge filter.

TYPES OF FILTERS USED FOR FILTRATIONS OF BEER

SCHENK FILTER

33

Yeast , protein and carbohydrates particles must be removed from the beer to achieve the necessary clarity . As the first step in filtration , powder filters are used for removing these suspended particles , the help of high flow super cell powder makes the powder filter . The powder is injected at the point where the beer stream , together with yeast and other suspended solids, forms and incompressible mass referred to as the “ filter – cake”. The porous bed creats a surface that traps suspended solids , removing them from beer . Not all of the particles will be trapped at the surface, some especially the finer material, will pass into the filter cake and be trapped – a process referred to as “ depth filtration ”. These beds retain up to 99% of the culture and suspended particles . Depth filtration is not as effective as surface filtration, but is still a significant mechanism of filtration by filtar aids. Powder filtration is generally regarded s providing the most economical forms of filtration. The cost of filter aids is quite low , and long filtration cycles at high flow rates are possible.

The haziness of the beer is seen under a yellow lamp , and until the haziness disappears, the beer is continuously recycled and refiltered through these powder beds in the schenk filter.

For 110 HL of beer , approximately 13 KG of powder is used .

Types ( qualities ) of powder is used

White powder Yellow powder

Yellow powder is of higher quality and higher efficiency than the white powder but is costlier and has a short self life compared to the white powder.

To counter the deficiencies of yellow powder and to be cost effective , a combination of both powders is used to make filter beds .

PATE AND FRAME FILTER

The plate and frame filter has been the work house in breweries around the world for many decades for filtering beer. It is robust and reliable , consistently

34

filtering beer to the specified . Standards plate and frame filter consists of a series of chamber enclosed within a metal frame . Between adjacent frames is a double sided porous filter plate covered by either a fine mesh or a sheet. The filter sheet acts as a trap for the filter aid, which other wise might bleed through , their by assuring excellent a clarity . Filter sheet are generally made with cellulose fiber, diatomaceous earth , perlite, and a resin for bonding to give dry and wet strength . Some are available only with filtration fiber. The average pour size of filter sheet is between 4 – 20 microns , therefore plate and frame filter are readily precoated and less susceptible to malfunction . each plate alternates with a frame with the entire system held together by a screw or hydraulic clamp mechanism. This type of filter is very similar in appearance to the sheet filter, except it has sludge frames. The inlet pressure of the beer into these type of filter is approximately 0.7 – 0.8 bar .

This step is good enough to retain the remaining 1% of the culture / suspended particles so that the beer is completely free of any particles.

STEP - 8

BEER CARBONATION

Secondary fermentation in carbonating BeerThe traditional method involves carbonating the beer during secondary fermentation at low temp. and under counter pressure. The beer transferred to the conditions tank should have at least 0.5 to 1.00 C of fermentable extract and be placed under pressure from 12 to 15 PSI in conditioning tanks. Munroe reports that if the pressure is to high during sec. fermentation yeast growth may be affected and change the flavor characteristics of the beer. While in the tank , the remaining extract ferments and creates sufficient carbon dioxide to saturated the beer to equilibrium.

Mechanical Beer CarbonationMechanical carbonation is accomplished either by in line or in tank techniques. Carbon dioxide may be purchased from supplies of industrial gases. Alternatively , CO2 may be recovered from fermentation vessels and then purified, liquefied ,and stored until needed for carbonation . However, this collection system can be too expensive for most craft brewers. In general, the viability of collection CO2

depends on an alternatively cost of purched CO2, is availability, and the quantity used in the brewery. Some brewers report that use of mechanical carbonation

35

actually has a greater influence on reducing acetaldehyde levels than does kraeusening the beer.

PRINCIPLES OF BEER CARBONATION The time required to reach a desired CO2 concentration depends on a no. of physical factor. Temp. and pressure play an imp. Role in determining the equilibrium concentration of CO2 in solution . At equilibrium the same amount of CO2 is diffusing out of the beer as is being dissolved back into solution . increasing the pressure leads to a linear increase in the weight of CO2 dissolving in the beer of water. Decreasing the temp. gives a non- linear increasing CO 2

solubility in beer. Consequently, the equilibrium concentration can not be attended without either increasing the pressure or decreasing the temp. Thus , the closer the carbonating temp. is to 00C , and the higher the pressure , the greater the CO2

absorption .

Approximately two cylinder of CO2 gas are added to every storage tank of beer of approximately vol. of 120 HL .

STEP – 9

BOTTLING

36

Figure: 5

Before the bottling or the kegging, the beer is filtered to eliminate yeast and the suspension materials. There after, it is pasteurized (flash pasteurization or tunnel pasteurization for the bottles and flash pasteurization for the kegs).

Once the final quality of the beer has been achievd , it is ready for bottling. The bottling of beer is one of the most complex aspects of brewery operations and the most labor intensive of the entire production process.

The bottling of beer can be divided into the following steps:

Bottle – feeding,

Bottle rinsing,

Bottle filling,

Tunnel pasteurization,

Bottle labeling and ,

Case packing

Beer Bottle Feeding

The first in bottling beings with loading the empty bottles on the unscrambling table. In craft breweries, loading with prepacked bottles is usually done manually at a rate of 80 100 bottles per minute ( bpm). The table funnels the wide mass of bottles into a single stream. Several types of mechanism prevent

37

the bottles from bridging as they are funneled to a single line. These include mechanical joggers, reverting chains, and good inherting design.

Beer Bottle Rinsing

These are three types of bottles rinsers – twist, gripper, and rotary. Most craft breweries use twist rinsers, which are design to invert the bottles before spraying. After being rinsed , the bottles are allowed to drain before swung back up into the upright position and delivered to the bottle filler. Each bottle size and shape requires a different “twister”, but the cost of twist rinse is quit low. Gripper style rinser are a more compact alternative to twist rinser and can handle various bottle size and shape without parts having to be changed. Rotary rinser, are compact as well, and are known for their smooth bottle handling. However, rotary rinser, are the most expensive option for rinsing. A rotary rinser can also be incorporated into a filler as part of a “monobloc” arrangement. Monobloc machine also combine a crowner are better than separate units, since the bottle must be capped as soon as possible after filling to exclude air.

Before rising the bottles are washed with caustic soda, thus removing dust , labers etc. at 600 C for 30 min.

Beer Bottle Filling

Filling Process

The bottle goes into the machine, the gas is filled into the bottle s& a vacuum is created, the bottle is lifted a bit ,the beer is filled into the bottle & the pressure is released. The filled bottle is then passed on for the crowning of the filled bottles.

Crowning

After filling, the bottles are capped as soon as possible y the crowner. The caps have a sprayed on, hot – passed PVC based sealing insert or a cold pressed sealing insert not containing PVC. The caps are conveyed to the crown hopper means of a magnetic belt or a pneumatic crown feed, or they can be dumped

38

manually directly into the crown hopper. Whatever method is used, the crown hopper should be kept only half full of caps. This is to lessen the possibility of crowns becoming packed and not feeding into the chute fast enough. In addition , then the caps become packed , the possibility of scratching the cap finish increases.

After crowning the bottles are screened for the presence for the presence of any sort of suspended articles or the haze in the beer in front of a a white lamp. If any such suspended particles are detected , the bottles are returned and not sent for labeling.

TUNNEL PASTEURIZAION USED IN THE BOTTING BEER

An alternative to flash pasteurization &sterile filtration is tunnel pasteurization. Tunnel pasteurization is employed after bottles have been filled & sealed. The bottles are loaded at one end of the pasteurizer &passed under sprays of the water as they move along the conveyor. The sprays are so arranged that the bottles be subjected to increasingly hot water, until the pasteurization temperature (usually 60oC) is reached by beer in the bottles. The bottles are then gradually cooled with water until they are discharged from the end of the pasteurizer. Temperature changes have to be made in the prevent he bottles from breaking. Heating and cooling of the bottles is preformed using various water circulation, paths in order to utilize recovered heat. In this way, heat usage by the tunnel pasteurizer can be reduced t a minimum, Passage through the tunnel pasteurizer takes about an hour. Bottle breakage is usually no more than 0.1 to 0.2 percent in the tunnel pasteurizer. If greater, it is usually due either to poorly made bottles or he lack of head space.

Bottle Labeling

An in line labeler is a type of machine for which the bottle travels in a straight forward motion , and the label or labels are applied while the bottle is moving along the bottle conveyor. One such type of in line labeler is the tandem labeler that is typically used in multiple or “ in tandem ”, with each machine typically

39

capable of running 60 to 80 bpm. Maintenance of the labelers is fairly demanding; and even though parts are fairly inexpensive , they may be difficult to obtain. tandem labels cannot do front and back labels at the same time, and does not bound labels with a full width of glue, but rather with only two vertical strips one at each side of the label. The label. The labels may ape puckered due to moisture condensation or may be crooked or have corner flagged (edge lifted). These limitations have increasingly contributed to the obsolescence of tandem labelers; nonetheless, their low cost and simplicity assure their continued use, particular by craft brewers.

Case packing Beer Bottles

Case packing is done manually or br case packers. Two people standing at a discharge table can pack up to 100 bpm. For rates above 10 bpm , an automatic case packers is requied has a linea collection table on which the bottles are automatically placed inranks that mach the packing pattern in the case. A conveyer supplies the the packer with the shiping cases, and from the packer the conveyor caries the filled cases to the palletizing.

40

RESULT AND DISCUSSION

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

41

LIST OF FIGURE

1. FIGURE-1: OUTLINE DIAGRAM FOR PRODUCTION OF BEER 2. FIGURE-2: LAUTER TUN

3. FIGURE-3: BOILING TANK

4. FIGURE-4: FERMENTER IN BREWERY

5. FIGURE-5: BOTTLING SECTION

42

BIBLIOGRAPHY

1. http://en.wikipedia.org/wiki/History_of_beer

2. http://www.opt.be/contenus/history_of_beer/en/2100.html

3. http://www.brasserie-graindorge.com/history-beer.php

4. http://www.opt.be/contenus/beer_types/en/2180.html

5. http://www.opt.be/contenus/how_beer_is_made/en/2140.html

6. http://www.brasserie-graindorge.com/mashing.php

7. http://running_on_alcohol.tripod.com/id20.html

BOOKS

How to Drink Beer and Save the World, Christopher Mark O’Brien

Beer, Its History and Its Economic Value as a National Beverage

By Frederick William Salem

43

44