A I T H

A REPORT OF

SUMMER TRAININGAT

MOHAN GOLDWATER BREWERIES LIMITED

DALIGANJ, LUCKNOW (U.P)DURATION

16/06/2010 TO 28/07/2010

For the Partial Fulfilment of B.Tech Programme in Chemical Engg. F Year

Submitted By : KRISHNA GOPAL SHANKWAR

B.Tech. (CH F Year) Roll.No- 0616651032

Department of Chemical EngineeringDr. Ambedkar Institute of Technology for Handicapped, U.P.

Awadhpuri, Kanpur-208024

A I T H

A REPORT OF

SUMMER TRAININGAT

MOHAN GOLDWATER BREWERIES LIMITED

DALIGANJ, LUCKNOW (U.P)DURATION

16/06/2010 TO 28/07/2010

For the Partial Fulfilment of B.Tech Programme in Chemical Engg. F Year

Submitted By : KRISHNA GOPAL SHANKWAR

B.Tech. (CH F Year) Roll.No- 0616651032

Department of Chemical EngineeringDr. Ambedkar Institute of Technology for Handicapped, U.P.

Awadhpuri, Kanpur-208024

CONTENTS

1. ACKNOWLEDGEMENT

2. CERTIFICATE

3. PREFACE

4. INTRODUCTION

5. HISTORY

6. ABOUT BEER

7. RAW MATERIALS FOR BEER

8. MANUFACTURING OF BEER

9. RESEARCH AND DEVELOPMENT

10. PLANT DESIGN AND CALCULATIONS

11. CONCLUSION

12. BIBLOGRAPHY

ACKNOWLEDGEMENT

The efforts of many people associated directly or indirectly with this training have lead to its successful completion. I would like to explore this opportunity by showing my gratitude to all of them who were a great source of help of me during the period of my training in this industry.

My training in, Mohan Gold Water Breweries Ltd, Daligang Lucknow was a fruitful and learning experience for me. It helped me to familiarize myself with all the conditions present in this industry.

I am thankful to MR.RAJESH JAIN (General Manager), A.K. SRIVASTAVA (Brewing chemist), MR. VIVEK SHARMA and MR. MANU DUBEY for giving me opportunity to carry out the above project in the factory premises.I would like to thank Er. Ashutosh Mishra, H.O.D. Chemical Engg, Er. S.C.Srivastava & Er. Rakesh Kumar and all the faculty members of the Deptt. Of Chemical Engg. A.I.T.H. Kanpur to give me such valuable guidance and support. I would also like to thank the operators and workers of decorative liquid section to create such healthy atmosphere of working and encouraging me to do my work more effectively.

At last, special thanks are extended to the staff and officers of the Daliganj, Lucknow unit without whose support and co-operation my training could not have been so successful.

KRISHNA GOPAL SHANKWAR

PREFACE

There are two aspects of knowledge – one is theoretical and other is practical. Theoretical knowledge is which we get during the span of our engineering life in colleges and institutes. The practical implementation of the theories and laws which we study is the main aim of an engineer.To be familiar with this industrial trainings are conducted. Keeping in view this fact, the reputed Engineering Colleges and Universities have given the importance to the practical knowledge in their syllabus. The basic reasons for which one takes training are –

To be familiar with the industrial environment. To be aware what is happening in the fast growing professional world. To acquire knowledge about every department, technical or non technical. To visualize the studied text through the practical happening. To keep knowledge of latest technologies trends. To find out one’s field of interest.

It is incumbent me to greet the Department of Chemical Engineering for successful arranging summer training opportunities for me in prominent plant industry- MGBL.

Last but not least I am deeply indebted to the employees of the company for their cooperation and advice in presenting this report at Mohan Goldwater Breweries Limited, Daliganj, Lucknow.

INTRODUCTION

The training deals with the brewing and fermentation process at Mohan Gold Water Ltd. For the production of ethyl alcohol from malt and other raw materials by means of yeast cells. The products of fermentation units are matured by cold storage and waste products are treated chemically and biologically for reducing the biochemical oxygen demand of the waste to be disposed off.

The filtered beer obtained after filtration is mixed with carbon dioxide by carbonation process as cut off oxygen in the beer which might lead to disturbance in turbidity, color, flavor, of the beer thereby decreasing the life of beer. The filtered beer is then bottled and then marketed.

The report is divided into several sections as those in the industry. Each section deals with the process and drawing of the major equipment, material of construction of each unit, an estimated cost of the plant. The assumptions made are suitably specified.

Hope that the readers will enjoy reading the report and would come to know something new.

HISTORY

M/S MOHAN GOLD WATER LIMITED is a leading autonomous beverage manufacturing industry in the field of fermentation products such as beer.

The company was established in the year 1968 and was licensed in the year 1969. It is suited in Daliganj, Sitapur road, Lucknow. It is situated near about 10 kilometers from the Charbagh railway station, Lucknow. Today, the industry has its production unit at Ghaziabad, Lucknow and Mumbai and various projects work are in progress in southern India. The production unit in Maharashtra is under the name of,” MOHAN ROCKY SPRINGWATER BREWERIES” in Khopoli Raigarh district with residential office at Mazagaon, Mumbai. Both Lucknow and Ghaziabad unit have their residential office at Solan breweries, Solan, Shimla, and Himachal Pradesh.

AIMS AND OBJECTIVES OF MOHAN GOLDWATER BREWERIES:

The key objectives of Mohan Goldwater Breweries are listed below: To promote the undertaken development and expansion of brewery

industry. Production, processing and marketing of liquor and mild beer. Render technology, finance administration and all necessary assistance to

member societies. Take up the survey of new areas. Assist member’s societies in the selection of sites for brewery building

centre. Advice guide and assist them in management and conduct of their

business. Provide essential training to staff and students. Provide welfare amenities to the workers of Mohan Goldwater Breweries. To provide an efficient consultative service which aim at creating mutual

faith among those who work in industry. Provide financial assistance to employees inside and outside the work

establishment.

The various famous brands that are manufactured and marketed at Mohan Goldwater Breweries Ltd. are:

1. Kingfisher premium (strong) 2. Black gold (super strong and mild)3. Sunbird (mild)4. Red feather (mild)5. Ego (super strong and mild)6. Panther (super strong)

ABOUT BEER

Beer is one of the world’s oldest beverages, possibly dating back to the 6th millennium BC, and is recorded in the written history of ancient Egypt and Mesopotamia. The earliest Sumerian writings contain references to beer. A prayer to the goddess ninkasi known as “the Hymn to Ninkasi” serves as both a prayer as well as a method of remembering the recipe for beer in a culture with few literate people.

The earliest known chemical evidence of beer dates to circa 3500-3100 BC from the sites of Godin Tepe in the Zagros Mountains of western Iran. As almost any substance contains Carbohydrates, namely sugar or starch, can naturally undergo Fermentation, it is likely that beer-like beverages were independently invented among various cultures throughout the world. The invention of bread and beer has been argued to be responsible for humanity ability to develop technology and built civilization.

In ancient china rice was used to make a rice beer and in pre Columbian civilization an the Americas used corn instead of barley and without knowing it added their own enzyme to breakdown the starch by chewing the corn before placing it in the fermentation tank. The saliva from the mouths served as enzymes in the of starch conversion to sugar and gave their beer its improved and distinct flavor. In rural bread to malt, flour sugar and allowing the mixture to ferment.

As for the close link between bread-and-making, women produced most beer prior to the introduction of hops in the thirteenth century, selling the beverage from their homes as a means of supplementing the family income. However, by the 7th century AD beer was also being produced and solid by European monasteries. During the industrial revolution, the production of beer moved from artisanal manufacture ceased to be significant by the end of the 19 th

century. The development of hydrometers and thermometers changed brewing by allowing the brewer more control of the process, and greater knowledge of the results.

Beer was also known by Slavic tribes in early 5 th century. The most common method of categorizing beer is by the behavior of the yeast used in the fermentation process. In this method of categorizing, those beers which use fast-acting yeast, which leaves behind residual sugars, are termed ales, while those beers which use slower and longer acting yeast, which removes most of the sugars, leaving a clean and dry beer, are termed lagers.

The following common types of beer are found:

1. LAGER (Bottom fermented beers): lager yeast is a bottom-fermenting yeast (e.g., saccharomyces pastorianus), and typically undergoes primary fermentation at 7-12 0c (the “fermentation phase”), and then is given a long secondary fermentation at 0-40c (the “laggering phase”). During the secondary stage, the lager clears and mellows. The cooler conditions also inhibit the natural production of esters and other by products, resulting in a “cleaner” tasting beer.

2. ALE (Top fermented beers): beer made with yeasts that floats on the top of the brewing vats resulting in a color beer which have higher alcohol content than lagers.

Ale is typically fermented at temperatures between 15 and 24 0c. At these temperatures, yeast produces significant amounts of esters and other secondary flavor and aroma products, and the result is often a beer with slightly “fruity” compounds resembling apple, pear, pineapple, banana, plum, or prune, among others. Typical ales have a sweeter fuller body than lagers.

A particularly well- known ale type is India pale ale (or “IPA”), developed by British brewers in the 19th century.

3. LAMBIC (Spontaneous fermentation): Limbic beer, an especially of Belgian beers, use wild yeast rather than cultivated ones. Many of these are not strains of brewer’s yeast (saccharomyces cerevisiae), and may have significant differences in aroma and sourness. Yeast varieties such as Brettanomyces bruxellensis and brettanomyces lambicus are quiet common in lambics. In addition , other organisms such as lactobacillus bacteria produce acids which contribute to the sourness.

4. Treated water used for this type of beer tends to be harder with a higher calcium and magnesium content than wort used for larger. The colour of the pilsner is also lighter than that of the lager beer.

5. PORTER (ale beer type): it is a very dark coloured ale beer. Its special flavor comes from toasting the malt before brewing. This usually results in stronger taste and higher alcohol content.

5. STOUT (ale beer type): it is a very dark, almost black coloured ale beer. The dark color and roasted flavor is derived from the barley and roasted malt.

DEFECTS OF BEER:

Beer deteriorates with age particularly as regards changes in flavor and appearance. This deterioration is caused by sunlight storage at worm temperature shaking or agitation of the containers and internal oxidation caused by residual oxygen. Turbidity is most apparent and quickly spotted from the deterioration and this is caused by unstable protein tannin complexes.

S.N. PARAMETERS UNITS LOWER LIMIT

TARGET UPPER LIMIT

REST VOLUME

Primary parameters

1. Original gravity

0P 15.50 15.70 15.90 15.68

2. Apparent extract

0P 1.80 2.00 2.20 2.10

3. Alcohol %V/V 7.00 7.10 7.20 7.144. Ph 4.00 4.20 4.40 4.225. Diacetyl PPM <0.07 0.0626. Colour EBC 9.00 10.00 11.00 9.857. CO2 g/lt 5.40 5.50 5.60 5.90/5.608. Head retention Sec >1409. Total haze EBC >0.710. SO2 PPM 9.00 10.00 12.00 10.0011. Iron PPM <0.1512. Calcium PPM 40.00 50.00 60.00 49.56

Secondary parameters

1. Real extract 0P 4.40 4.60 4.80 4.562. Apparent

degree fermentation

% 85.00 87.00 89.00 86.67

3. Real degree fermentation

% 70.00 71.00 72.00 70.90

4. Calorific value Cal/100 ml

55.00 57.00 59.00 57.00

"BEER" AN ALCOHOLIC BEVERAGE

Beer is an alcoholic beverages produced by the fermentation of sugar derived from starch material. It is the world’s oldest and most popular alcoholic beverage. Some of the earliest known writings refer to the production and distribution of beer.

The most common starch source for beer is malted barley; however, wheat, corn, and rice are also widely used, usually in conjunction with barley. The starch source is mashed, steeped in water while enzymes in the malt break down the starch molecules, producing a sugary liquid known as wort, which is then flavored with hops, which act as a natural preservative. Other ingredients such as herbs or fruit may be added. Yeast is then used to cause fermentation, which produces alcohol and other waste products from anaerobic respiration of the yeast as it consumes the sugars. The process of beer production is a branch of zymurgy called brewing.

Beer uses many varying ingredients, production method and traditions. Different types of yeast and production methods may be used to classify beer as ale, lager or spontaneously fermented beer. Some beer writers and organizations differentiate and categorize beers by various factors into beer. Alcoholic beverages fermented from non- starch sources such as grape juice (wine) or honey (mead) as well as distilled beverage, is not classified as beer.

RAW MATERIALS FOR BEER

RAW MATERIAL : The key ingredients of beer are :Demineralized water ( D M Water ),Malt , Rice Flakes , Yeast & Hops. Each of these ingredients of beer is described as follows.

1. DEMINERALIZED WATER (DM WATER): In the production of beer a large amount of water are required. In production of beer the following are required in water.

pH Value Alkalinity Hardness Sulfate Content Chloride Content

In DM Water hard chemicals are removed in DM water treatment plant. Some important physical constant which have be maintained in DM water before using it for various purpose in beer manufacture are,,

pH - 7.0 Hardness = 4-5 ppm Alkalinity = 6-7ppm Temperature = as instructed

by a brew master

2. MALT: Malt is prepared from carefully selected barley in a process called Malting. Malting is thus a combination of two major processes; notably the steeping process (A),germination process (B) ,and the kiln dry process (C) so as to create enzymes, notably ά-amylase and β-amylase, which is used to convert starch in the grain in to sugar.

(A): In the malt house , barley grain germination is initiated by the uptake of water in a steeping vessel (A) .The grain imbibes water during control cycle of water spraying or water immersion followed by aeration, until the water content of the grain reaches 42-48% . Water enters the grain via embryo, and after approximately 24 hrs. , the first visible sign of germination is the appearance of the root, as a white chit.

(B): The grains are then transferred to malting beds where germination is allowed to proceed over a period of around 5 days (B). The germination of is controlled by temperature and aeration of the malt bed, while moisture content is maintained by spraying. Further embryo growth, with the appearance of rootlets and acrospires, can lead to root entangling. The grain bed is regularly turned with a rotating screw to prevent grains matting together.

(C) Green malt produced after five days of germination, is kiln dried and partially cooked in a forced flow of hot air. ( C ). Hydrolyses produced during malting are partially 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 activation of hydrolyses .The brittle malt rootlets are separated from the malt and utilized in animal feed.

The kilned malt is stable for storage and has a friable texture suitable for milling process which proceeds brewing. Malting can thus be summarized as:

The composition of malt onDry basis is as follows:-Starch = 58%Insoluble Proteins = 3%Reducing Sugar = 4%Protein alcohol soluble = 4%Sucrose = 5%Protein salt – 5% Soluble pentose = 1%

Insoluble pento hexose = 9%Proformal nitrogen = 0.7 – 1.0%True cellulose = 6%Lipids =2.5%Proteins = 10%Minerals =2.5%

In addition to above constituents malt also contains small amount of coloring matter, tannin, bitter resins etc.

3. HOPS:- Hops are the female flower cone of the hop plant (Humulus lupulus) they are primarily as a flavoring and stability agent in beer, and also in other beverages and in herbal medicine. The first documented use in beer is from the eleventh country. Hops contain several characteristics favorable to beer, balancing the sweetness of the malt with bitterness , contributing flowery, citrus, fruity or herbal aromas and having an antibiotic effect that favors the vigorous climbing herbaceous perennial, usually grown up strings in a field called a hop field, hop garden or hop yard.

Hops have to be dried in an oats before they can be used in the brewing process. Hop resins are composed of two main acid; alpha and beta acid.

Alpha acid have a mild antibiotic/ bacteriostatic effect against Gram- positive bacteria, and favor the exclusive activity of brewing yeast in the formation of beer. These acids isomerize during boiling and impart bitterness to the wort.

Beta acid do not isomerizes during the boil of wort, and have a negligible effect on beer flavor. Instead they contribute to beer’s bitter aroma and high beta acid hop varieties are often added at the end of wort boil for aroma. Beta acid may oxidize in to compounds that can give beer off-flavors of rotten vegetables or cooked corn.

Hops contain several characteristics that brewers desire in beer.

Bitterness effect: - Hops contribute bitterness that balance the sweetness of malt; hops also contribute floral, citrus, and herbal aromas and flavors of beer.

Antibiotic effect:- Hops have an antibiotic effect that favors the activity of brewer’s yeast over less desirable microorganisms.

Head retention effect:- The use of hops acid in “head retention”, the length of time that a foamy head created by carbonation will last.

.Preservative Effect: - The acidity of hops acts as a preservative that, after its introduction, gave brewers the ability to transport their product over longer distances, thereby allowing for the rise to commercial breweries.

Metabolizes the sugar extracted from grain, which produces alcohol and carbon dioxide and thereby turns wort in to beer. In addition to fermenting the beer, yeast influences the character and flavor. The dominant types of yeast used to make beer are ale yeast (Saccharomyces uvarum); their use distinguishes ale and lager.

4. CEREAL ADJUNCTS: Rice flakes and other cereals are used in beer making to provide supplemental Carbohydrate. Without these adjunct cereals the limiting nutritional factor for yeast in fermentation would be protein. This means that carbohydrate would remain after fermentation and produce a heavier type beer.

MANUFACTURING OF BEER

Beer is made by brewing .brewing is a fundamental natural process. Its art and science of brewing lies in converting natural food material in to pure pleasuring beer. The essential stages of brewing are milling, mashing, sparging, boiling, fermentation, and packing.

1. Milling: - The milling process is designed to reduced malt to a particular size suitable for rapid enzyme digestion and extraction with hot water during mashing. In a miller, malt is crushed either to rowed or six rowed. For this proposed plant six rowed malt crushing is done. The particle size must not be too small because wort off will be impaired not it must be too large so as to reduced the yield.

2. Mashing: - Mashing is done in a mash kettle or mash tank. The raw materials added to the mash tank are mash (a mixture of malt and rice flakes) and DM water. Rice flakes are added so as to maintain carbon-nitrogen ratio and to increase the sugar content of malt. During this process the temperature of water and mash is manipulated in order to convert starches to fermentable sugar. The mash goes through one or more stages of being raised to the desired temperature below the boiling point and left at that temperature for a period of time.

Increases in temp up to 52 0 C Increases in temp up to 63 0 C Increases in temp up to 63 0 C

Furthermore some chemicals are added Additionally in mash tank during the

process .These are Gypsum, Ultra flow, Formalin, Termamyle and ceramic. These chemicals are added to activate the starch completely. Two distinct stages can be distinguished in the enzyme breakdown of starch,

a. Gelatinization: At the optimum temperature of 45 0 C, the enzyme present in the starch such as Protease, alpha & beta amylase, cellulose, dextrinase etc. are activated. At 62 0 C, termamyle, gypsum, formalin, ceramix, and ultra flow are added to activate the starch completely. At higher temperature these enzymes breakdown the long chain present in the mash and starch (higher sugar) is converted lower sugar such as glucose, maltose, and dextrin. The PH of the medium is 6.5 and specific gravity b/w 16-17. Steam used to heat is at a pressure 6Kg/cm2.

b. Liquefaction: - Some ungelatinized granules which were still present during the above process are removed here. The amyl phosphate is considered to degrade phosphate, which are the major constituent of the ash, the phosphate free starch gives a limpid solution.

It now seems to clear that the liquefaction is due to the activity of alpha amylase. The optimum temperature of alpha amylase is and pH is equal to 5.8.

3. Lautering or Wort Separation:-

Lautering is done in a lauter tun. Mash tun is transferred to the lauter tun which contains 70 % fermentable sugar. The lauter tun has

horizontal agitators called rackers and sparging bulbs. These rackers rotate and Evenly distributed the husk and spent grains over the sieved plates. Thus the bed of husk, grains and the porous plates together act as sieve which separate wort from the mash. Thus the fermentable liquid, known as wort, is extracted from the malt mixture from the Mash Kettle.

In the wort becomes 14% v/v. Before the wort separation, mash is given rest so to complete its stabilization. The rest is for 30 min. The spent grains and insoluble proteins are utilized as cattle feed and wort obtain is transferred to copper boiling tun.

4. Copper boiling: - Sweet wort is brought to a rolling boil in large brew kettles, usually called coppers, which refers to the metal from which they have traditionally been made.

.

Boiling sterilizes the wort and increases the concentration of sugar in the wort. The wort is boiled for about one hour. During boiling, water in the wort evaporates, and a dark wort among flocculent precipitate comprised of protein, polyphenols (tannins) hop resins and metal ions is obtained, The destroyed proteins and polyphenols are removed or otherwise they may cause proteins hazes in the finish beer. Hops are added during boiling in order to extract bitterness, flavor and aroma from them. The color of the wort tends to become darker during kettle boil because a color enhancer called caramel is added to it.

5. Whirlpooling: - After boiling the wort is brought to the whirlpool tank. It contains a long stirrer. The stirrer rotates whenever power give. On circulation, the protein remains of the wort come to the center. At rest, the protein cells settle and are separated. Now this wort, free from any kind of impurities serves as a very good medium of the yeast growth.

6. Cooling: - From whirlpool tank the wort is passed through the heat exchanger where its temperature is reduced from the 90 0 C to nearly 14 0 C, which is the optimum temperature for fermentation, with the help of cool brine solution. The brine water is passed in the shell side at the same time.

So before inoculating yeast wort is cooled rapidly to 10 - 15 0 C to

7. Fermentation; - Fermentation can be defined as a process where a substrate is converted in to product by the means of microbes. Fermentation can be classified as according to:

a) Yeast Respiration : Here

fermentation can be of two types –

1) Aerobic 2) anaerobic

b)Yeast Settlement in the Fermentor

tank : Here fermentation is of two types ;

1) Top fermentation: Ale beers are fermented at relatively high temperature between 15-20 0 C with a different stage of yeast. The yeast rises to the surface of the fermenting wort and is skimmed off.

2) Bottom Fermentation: Lager beers are fermented at low temperature b/w 5-10 0 C with a special strain of yeast. The yeast falls to the bottom of the fermenting vessel.

A FERMENTATION FROFILE that is followed during fermentation process is given as:

Fermentation starts at the temp b/w 10-12 0 C when yeast is added to wort in the CCV/UT tank.

Yeast ferments the wort to form beer gradually along with the byproducts: Phenols, diacetyls &alpha acid. The specific gravity of wort is 5.8 nearly.

The temp of the medium is raised to b/w 15-16 0 C. At this temp yeast becomes volatile and reuses diacetyls formed earlier. Other byproducts are removed.

Now the temp of the medium is immediately dropped to 4 0 C. This stage is meant for Yeast Harvesting. At this temp yeast becomes dormant and begins to settle at the conical bottom of the CCV/UT tank. Chemical dosing with the chemicals known by their brand names KMS (Potassium meta sulphide), Profix and biofine, is done at this time. Chemical dosing helps faster settling of yeast cells as the + ve charge on the chemicals attract the – ve charged yeast cells. CO2 is added at this time.

Now the temperature is further dropped to 0 0C. This is the Laggering stage of beer. At this stage some yeast culture may be added to the beer. This result in secondary Fermentation leading to BEER MANUFACTURE.

C12H22O11 + H2O Maltase 2C6H12O6

Maltose Glucose

2C6H12O6 Zymase 4C 2H5OH + CO2

Ethyl Alcohol

The yeast given initially is of concentration about 10 cells per ml. Before Yeast involution, the fermentor vessels are cleaned with the help of water, acid, alkali and disinfectant in order to remove any microbial contamination from the vessels. The yeast undergoes aerobic as well as anaerobic fermentation to

convert wort to beer. During fermentation, foaming starts to appear in the form of a ring. After 4-5 days of involution foaming starts to reduce and by 6 to 7 day it totally disappears. The temperature maintained is b/w 13-15ºC by cooling coils and at initial pH( of wort ) 4.5 -5.5. The carbon dioxide evolved during fermentation is recovered, purified and stored as a liquid. This carbon dioxide is utilized for carbonation during finishing. At the end of primary fermentation, chemical dosing is done which helps in settling most of yeast in suspension. The temperature of the fermentator is reduced to 0ºC or -1ºC.

8. Cold Storage Maturation/Beer Conditioning: Most breweries today use cylindroconical vessels or CCV’s, have a conical bottom and a cylindrical top. CCV’s can handle both fermenting and conditioning in same tank. Therefore in the same CCV tank where fermentation took place, maturation procedure is employed. At OºC/-1ºC some active yeast (not always) culture is added to the beer during ageing. This results in to a secondary fermentation of remaining sugar. This prevents the formation of unwanted flavors and harmful components such as acetaldehydes, which are commonly blamed for hangovers.

During this maturation process chill proofing is commonly practiced to help maintain turbidity level of the beer. However, chill proofing is done by proteolysis enzyme to reduce the molecular size of the residual proteins and protein hydrolysis product.

Antioxidants are usually added. It prevents the later oxidative changes in the beer which affects flavor. Sulfur dioxide (sulfites) and ascorbic acid are commonly used to accomplish this end.

9. Filtration: Filtering the beer stabilizes the flavor, and gives beer its polished shine and brilliance. Filtration removes the yeast and any solids (e.g. hops, grain particles) left over. It almost removes all microbes in the beer.

Sheet Filter. The beer first passes through Kiselghur filter and then from sheet filter.

Kieselguhr filters (Continuous Pressure filter)Common media include diatomaceous earth or kieselguhr and perlite. Here, the

chemicals used are an-oxidant KMS(Potassium Meta Sulphate) and a power called as hi-flow super sol. These chemicals are mixed in kieselguhr tank to form a cake. The cake is pumped into the yeast absorber tank along with the beer periodically. The vertical plates in the tank separates yeast from the beer and a clear solution beer is achieved.

Sheet (Pad) Filters: These filters use pre made media and are relatively straightforward. The sheets are manufactured to allow only particles smaller size. The sheets are placed in to the filtering frame, sterilized (with hot water, for example) and then used to filter the beer. The sheets can be flushed if the filter becomes blocked, and usually the sheets are disposable and are replaced between filtration sessions. Often the sheets contain powered filtration media to aid in filtration.

The filter sheets have two sides. One with loose holes, and the other with tight holes. Flow goes from the side with loose holes to the with the tight holes, with the intent that large particles get stuck in the large holes while leaving enough room around the particles and filter medium for smaller particles to go through and get stuck in tighter holes.

Sheets are sold in nominal ratings, and typically 90% of particles larger than the nominal rating are caught by the sheet.

10. Carbonation: After filtration carbonation of beer is performed in the BBT (Bright Beer Tanks) tanks by injection of cleaned carbon dioxide recovered from the evolved fermentation gas, final dissolved carbon dioxide content of approximately 2.8% v/v in beer. This CO2 displaces dissolved O2, which is detrimental to the stability of the beer and help in the production and retention of foam and in the preservation of beer.

Bottles are purchased from the market. These are kept over the moving conveyer belt. The ‘hard ped’ bottles i.e. bottles having impurities stuck to the base and ‘chipped neck’ bottles are sorted out. The bottles are washed by an automatic washing machine, using water and some chemicals like polytex, caustic soda (2.5-3.0%) and excon (bottle shiner). The temperature of washing is around 70-80ºC.

Then the bottles are filled by a filter machine where beer is filled under

pressure. The filler machine has 36 valves. Here the temp is 0ºC and pressure of about 50lb/inch2 . After beer is filled, CO2 is filled by counter pressure and the bottles are immediately crowned. The rate of filling is 7000 bottles per hr. The bottles are now sent to the pasteurization unit.

11. Pasteurization: Beer is slowly heated and cooled to kill off any existing microorganism in order to maintain longer self life. It removes the oxygen fraction from the beer, if present. The temperature is maintained by condensing steam. It consists of the following seven temperature zone.

Pasteurizer consists of the above temp. zones. Packed bottles enter continuously in this zone 1 to 7 and leave the pasteurizer. Total residence time of bottle is in the pasteurizer is 90 min.

Pasteurization unit (PU):

PasteurizationZone

Temperature(ºC)

I 35II 45III 55IV 65V 55VI 45

VII 35

Pasteurization is measured in PU. 1 PU is the LETHEL EFFECT which the beer achieves at 60ºC in 1 min.

12. Labeling : After pasteurization these are transported to labeling machine. Each bottle is labeled with brand and company’s name. The brand name is either strong or weak according to percentage of alcohol and state concerned.

13. Packaging: Beer bottles are put into cartoons. Each cartoons has got 12 beer bottles. Thus packing prepares the beer for distribution and consumption.

RESEARCH AND DEVELOPMENT

Throughout the past 100 years there has been reduction in the number of companies till today. It is due to the merger campaign that resulted in the formation of a handful of dominant brewers.In order to increase the output the brewers have devised methods. This had been accomplished by the use of larger batch sizes. Vessel productivity has been further improved by the practice of high quality brewing, in which concentrated wort is fermented and the resultant beer diluted to the desired strength.

STRAIN IMPROVEMENT:

Brewing yeast strain has been subjected to various taxonomic revisions over the years. In the older system. Ale strain was classified as saccharomces crevisiae and lagger strain as either s carlsbergenis or s uvarum . subsequently, all lagger strains were placed within the species s uvarum. The current situation, based on DNA homology studies, is that all strains used for brewing may be assigned to the species S cerevisiae.

FERMENTATION CONTROL:

There is a recent development which allows the automatic control of pitching rate. It automatically doses yeast into wort using infra-red turbidometry. A dual beam arrangement corrects for non –yeast suspended solids in the unhitched wort. This method affords considerable improvements compared to traditional system of pitching rate control, although it still requires a separate viability collection and does not account for non-yeast material prese nt within the yeast slurry.

For maximizing the efficiency, efforts have been directed towards reducing costs of producing fermentabic carbohydrates. This may be accomplished by using sources of sugar less costly than malted barley , the wort may be treated with dextrinase to increase ferment ability , or yeast strain may be employed which have been selected for their ability to utilize an increased spectrum of carbohydrates.

Since other changes include the production of low carbohydrates product and low and zero alcohol beers. These latter products have arisen within the past 10 years and have necessitated the introduction of technology entirely novel to the brewing industry.

Water in its natural form contains various minerals or salts dissolved in it, which render certain undesired properties to the water (hardness), making it useless for the most industrial purposes. For demineralization, water is required to be treated by deionising process which is carried out in a TWO BED DEIONISING SYSTEM, and the resultant product is called DM water.

The ‘TWO – BED deionising plant ‘ consist of two ion exchangers, the strong acid cation (SAC) and strong base anion (SBA), made up of either FRP or MSRL, designed fabricated and tested in accordance with the national and international standards . Arranged and operated in a series pattern, these units are charged with high capacity resins.

The regeneration frequencies being low, the time –loss are a bare minimum. The internal distribution and collecting systems are meticulously designed, extremely simple to assemble and trouble –free in operation. For water with high carbonate or bicarbonate content, a degasser tower is provided between the two exchangers. For higher purity of water, a third unit – a mixed – bed deionizer can be added.

A brief description for each component is given as:-

STRONG ACID CATION RESIN/ STRONG BASE ANION RESIN:

The cation exchanger converts alkalinity present in raw water to its equivalent acid, i.e. carbonic acid. When filtered water is passed through cation resin, ions like Ca++, Mg++ etc.

The anion exchanger absorbs the carbonic acid with other acids in cation exchanger treated water. Where water has a high alkalinity the ionic load on the anion can be brought down by using another method to remove carbonic acid. The carbon dioxide can be removed mechanically by means of degasser.

APPLICATIONS:

-boiler feed-cooling systems-foundries-distilleries-pharmaceutical companies

DEGASSER:

A degasser consists essentially of a degasser tower with integral tank, a degasser air blower and a degassed water pump with necessary piping and valves to connect this system to the ca unit. The tower portion is packed with pvc pall rings. The air blower is connected by air ducting to the tower just above the tank portion.

MIXED BED DEMINERALIZER:

When water with high purity is required a mixed bed demineralizer is used. The mixed bed demineralizer unit consists of strongly acidic cation resin

and strongly basic anion exchanger resin in a mixed form. The water passing through the mixed bed exchanger comes successfully in contact with cation and resin. This corresponds to an infinite stage demineralizing process and ensures high purity treated water.

The resin is separated prior to regeneration. The cation resin is regenerated with acid while anion resin is regenerated with alkali. After rinsing the resins are again – mixed with air.

When the raw water has very low IDS (less than 50 ppm) the mixed bed is sometimes used directly for demineralization of water.

- High pressure boiler feed - Distilleries- Pharmaceuticals- Laboratories

SOFTENER: sometimes a softener is also used to demineralise water. This type of demineralization system is used for reduction in alkalinity when the raw water contains permanent hardness.

The softeners contain strong acidic cation exchange resin in sodium form (tulsion T- 40). When hard water passes through the resin the calcium and magnesium ions are removed by the resin and equal number of sodium ions imparted to the water. The resin has finite capacity for removal of calcium for removal of calcium and magnesium ions and after this capacity is exhausted, the resin will have to be regenerated to bring in sodium form.

The resin is regenerated by passing 10 to 15% of NaCl solution through the resin. After the brine has been injected , the excess salt and regeneration products are washed out of the resin bed by first giving a slow rinse at he flow rate equal to the brine injection flow rate and then by giving first rinse at the flow rate equal to the service flow rate.

Softeners are basically of two types:

1. Down flow softeners 2. Up flow softeners

The vapor- compression cycle is used in most household refrigerators as well as in many large commercial and industrial refrigeration systems. Figure 1 provides a schematic diagram of the components of a typical vapor – compression refrigeration system.

The thermodynamics of the cycle can be analyzed on a diagram as shown in figure 2 . in this cycle , a circulating refrigerant such as Freon enters the compressor as a vapor. From point 1 to point 2, the vapor is compressed at constant entropy and exits the compressor superheated. From point 2 to point 3 and on to point 4, the superheated vapor travels through the condenser which first cools and removes the superheat and then condenses the vapor into a liquid by removing additional heat at constant pressure and temperature. Between point 4 and 5, the liquid refrigerant goes through the expansion valve (also called a throttle valve) where its pressure abruptly decreases , causing flash evaporation and auto- refrigerant of , typically , less than half of the liquid.

PLANT DESIGN AND CALCULATION

INTRODUCTION: The proposed plant consists of different units and subunits. The

coordinated activity of these units and subunits results into beer production. The description of these units and subunits are as follows:

BREW HOUSE:The brew house plays a key role in beer production. The finished

products of brew house are the WORT and the SPENT GRAINS. Following equipments become part of brew house.

Equipment Name Number CapacityMill Machine 1 3000 kg/hrs

D.M. Water Tank 2 200 hlMash Kettle 1 150 hlLauter Tun 1 150 hl

Boiling Kettle 1 300 hlHeat Exchanger 1 30 hl/hr

Whirlpool 1 300 hl

FERMENTATION SECTION:The finished product of this section is green beer by using wort as a

substrate. It consists of following equipments.Equipment Name Number Capacity

Fermentor 9 525 hlBrine Water Tank 2 200 hl

Ammonia Compressor 2 60 kV

FILTRATION SECTION:

Green beer is filtered and stored in this section for required storage time of nearly 7 days. Following equipment is present in this section.

Equipment Name Number CapacityKieselghur Filter 1 100 hl/hrs

Sheet Filter 1 100 hl/hrsFiltered beer is transferred from filtration section to the BBT or BRIGHT BEER TANKS. It is then carbonated and bottled, pasteurized, labeled and finally sealed in cartons. It consists of the following equipments.

Equipment Name Number CapacityBright Beer Tanks 2 300 hl

Auto washer 1 7000 bottles/hrBoiling Machine 1 7000 bottles/hr

Pasteurizer 1 8000 bottles/hrLabeling Machine 1 7000 bottles/hr

Carton Sealer 1 8400 bottles/hr

EFFLUENT TREATMENT PLANT:

The waste water from brewery is anaerobically treated in this plant. It consists of the following equipments.

Equipment Name Number CapacitySettling Time 1 100000 liters

Filter 1 1000 liters/dayUASB Reactor 1 100000 litersAerobic Ponds 2 20000 liters

BOILER HOUSE:It is used for steam generation of capacity between 2-3 tones/day. It

consists of capacity 37-47 HP approximately.

MASH KETTLE:Mash kettle is a vessel in which malt, rice flakes are boiled in D.M. water

upto 80°C temperature from a temperature of 45°C. In this process the starch of the malt is degraded into maltose, sugar, dextrin and other compounds.

Data: The specific heats of the following components are:

Component Specific Heat (Cp), cal/g°CDextrin 0.291Lactose 0.287Maltose 0.32

Sugar 0.291Sucrose 0.299

Cellulose 0.32Water 1.1

Rice flakes 0.2908Ash 0.25

Starch 0.25Steam at 150°C 4.233Steam at 100°C 4.218Water at 90°C 4.205

The densities of following components are:

Component Density (ρ), kg/m3

Ash 544.6Water 988

Starch/Rice 1537Sugar 688

The mash composition (w/w) is as follows:

Component % composition X (w/w)Malt 35

Rice Flakes 15Water 50

The malt composition (w/w) is as follows:

Component % composition X (w/w)Starch 57Sugar 3

Maltose 15Dextrin 10

Ash 10

BREW HOUSE MASHING OBSERVATIONS:

Date: 20/07/10 Mash No: 55 Brand: KPS Water in hl: 100

Mashing at 45°C 11:30 – 11:55 AMRise in temp to 52°C 11:55 – 12:05 PM

Rest 12:05 – 12:35 PMRise in temp to 67°C 12:35 – 12:50 PM

Rest 12:50 – 01:20 PMRise in temp to 71°C 01:20 – 01:25 PM

Rest 01:25 – 02:10 PMRise in temp to 76°C 02:10 – 02:20 PM

Transfer to Lauter Tun 02:20 – 02:35 PMRest 02:35 – 02:55 PM

Set Taps/ Transfer to Boiling Kettle 02:55 – 03:10 PM

CALCULATIONS:

Specific Heat of Malt = Cpstarch.Xstarch + Cpsugar.Xsugar + Cpsucrose.Xsucrose + Cpmaltose.Xmaltose + Cpdextrin.Xdextrin + Cpash.Xash

= 0.26*0.57 + 0.301*0.03 + 0.299*0.05 + 0.32*0.15 + 0.29*0.1

= 0.356 cal/g°C

Specific Heat of Mash = Cpmalt.Xmalt + Cprice.Xrice + Cpwater.Xwater

= 0.356*0.48 + 0.29*0.04 + 1.1*0.48= 0.71 cal/g°C

Density of Malt = ρstarch.Xstarch + ρsuagr.Xsugar + ρsucrose.Xsucrose + ρash.Xash

= 1537*0.57 + 688*0.15 + 1000*0.23 + 544*0.05 = 1236.49 kg/m3

Density of Mash = ρmalt.Xmalt + ρstarch.Xstarch + ρwater.Xwater

= 1236.49*0.35 + 988*0.50 + 1537*0.15= 1158.55 kg/m3

Mass of Mash in Mash Kettle = 3500 kg (water) + 2450 kg (malt) +1050 kg (rice flakes) = 7000 kg

Heat supplied tor raise temp form 45°C to 76°C: Heat load Q = m.Cpmash.∆T = 7000*0.71*(76-45)*1000 = 173.95 M cal

= 727 MJ

Since, the heating period is nearly an hour,Therefore, Q = 727000/3600 KJ/sec

= 202 KJ/sec

STEAM REQUIRED FOR HEATING:

Let ms = mass flow rate of steam, l = latent heat of condensationSteam is supplied at 150°C and it is cooled up to 76°C. Here three types of heat will be transferred into the process:

1. Sensible Heat2. Latent Heat of Condensation3. Heat of Condensation

The sum of all the heats mentioned above will give the net heat load:ms*Cpsteam*(T1-T2) + ms*1 + ms*Cpwater*(T1-T2) = Qms*(4.233*50 + 2257 + 4.206*20) = 202 KJ/secms = 0.07912 kg/sec or 284.86 kg/h

HEAT EXCHANGER

Heat exchanger as started earlier is used to cool the hot wort(80 ˚C) to 10 ˚C by using brine water as coolant. Sudden cooling of wort is required so that contamination of wort can be avoided and desired temperature for fermentation would be attained.

Shell Slide Construction Data:

Material of shell- Carbon SteelCorrosion allowance- 3mmNumber of shell- 1Number of passes- 1Fluid used for cooling- brine waterWorking pressure- 1.5 kg/cm2Design pressure- 2 kg/cm2Inlet temperature- 8 ˚COutlet temperature- 10 ˚CSegmental baffles (25% cut) with tie rods and spacers.

Head Design:

Crown radius-400mmKnuckle-40mmPermissible stress-950 kg/cm2

Tube Side Construction Data:

Tube Sheet material-Stainless steel (IS, grade 10) Outside Diameter-18mmLength-12mmPitch (square)-25mmFluid-Worth (14% sugar solution)

Outlet temperature-10 ˚C

Permissible Stress-1060 kg/cm2

MECHANICAL DESIGNING

It is assumed that the 5500 liter wort is to be cooled, within two hours.

m=fv/t=1060/1000*5500/6400=0.81 kg/second

Heat loaded in the heat exchanger due to wort. Since wort has to be cooled so heat is transferred from wort to brine water.

HEAT TRANSFERRED FROM WORT TO BRINE WATER:

Q = mCpT

=0.81*0.988*1000*4.18*(90-10)

Let us assumed that overall heat is transferred coefficient for the system is 284 J/m2.sec.˚K

LOG MEAN TEMPERATURE DIFFERENCE:

T1=82 ˚C T2=16 ˚C

LMTD= (T1-T2)/ ln (T1/T2)

=40.38 ˚CCorrection Factor of MTD=0.85

Mean temperature Difference=0.85*LMTD=35 ˚C

Heat transferred from the hot wort to cold brine water will be equal.

Therefore, q=UAT

Area of heat transfer A=q/UT =267777 / (284*35) = 26.94 m2

Area of heat transfer of one tube =3.14 * DI.

Number of tubes employed in heat exchanger=26.94/DI =26.94/ (0.018)*12 =40.

Nominal diameter of tube, D0 = 80 mmLength of tube = 3.14 D0

Assuming the Heat Transfer Coefficient = 570 J/ m2 sec K

L.M.T.D. = Log Mean Temperature Difference

T1 = 85°C, T2 = 4°CL.M.T.D. = (T1 – T2) / [ln(T1/T2)] = 81/ ln(81/4) = 27°CArea of one tube = π2*D*D0 = 0.63 m2

Area of Heat Transfer, A = Q / (UT) =- 438000 /

(570*27) = 2.469 m2

Number of tubes = 2.469/0.63 = 4For proper heat transfer, mild agitation is done. Therefore, agitator is required for this purpose.Number of Agitators = Maximum liquid height * Average specific gravity / Tank Diameter = 1.5*1.2/0.8 = 1.8 = 2

Power required for agitation:

Da = Diameter of Agitator = 24 cm, N = 300 rev / min, µ = viscosity of fluidNRe = ρNDa

2 / µ = 1240*(300/600)*242/0.004 = 8925Np = Power Number = 6Np = Pgc / ρN3D0

5, where P = power requiredP = 0.039 HP, for two agitators power required = 0.079 HP

An extractor is used to separate the wort form the mash which contains 70% sugar. After wort separation, spent grain is obtained which is supplied as cattle feed.Working capacity of extractor is 1000 liters.Diameter of shell = 1.5 m

Height of tank = 0.9 mWorking capacity of agitator = 1000 litersDiameter of agitator = 500 mmSpeed of agitator = 100 rpmSpecific gravity of liquid = 1.2Viscosity = 400 centipose

AGITATOR:

Agitator is the main component of lauter tun. The agitator selected here is a pitched blade turbine type which gives both radial and axial flow. The axial flow in this type of agitator is the lesser of the two flows and varies with the number of blades, the pitch angle and the blade height. This can be constructed either with blade directly attached to a hub or blades attached to a centre disc. Generally diameter of agitator is kept between a third and sixth of the tank diameter.

TUBE SIDE DESIGN:

Number of Agitators = 0.9*1.2/1.5 = 0.72 ≈ 1Reynolds Number NRe = ρNDa

2/µ = 1248(100/60)(1000/1000)*2/0.004 = 2600Power Number Np = 5.8Power Required = NpρN3Da

5/gc*75On putting the values, we get, Power = 2.84 HPLosses incurred = 10%Input Power = 2.84 + 0.284 = 3.124 HPTotal Power for agitation = 3.124 + 0.625 = 3.7488 HP

SHELL SIDE DESIGN:

Material = Carbon SteelCorrosion Allowance = 3mmDiameter of Shell = 1.5mWorking Pressure = 1.0 kg/cm2

Permissible Stress = 950 kg/mm2

Shell Thickness, ts = PD / (2Jf + P) = 1.27 * 1500/(2 * 950 * 0.85 + 1.2) = 1.2 mm

Including corrosion allowance shell thickness will be 4.2mm but as per its standard table, shell thickness will be 6mm

CONCLUSION

In the end, I would say that Summer Training at MOHAN GOLD WATER BREWERIES was a wonderful task. The training gave me a lot of practical exposure in the field that was entirely new to us.

The concept of beer manufacturing could be successfully learnt and applied in the plight of the efforts and guidance of the experienced trainers at the industry.

From the training I learnt how a product can be manufactured by giving low capital input, less labor and effort, by employing skillful people and above all using better manufacturing techniques. so, the beer produced will meet the degree of excellence value demanded by our customers.

Thus to conclude, I would say that the training was very fascinating and enjoyable. It gave the apt knowledge in a new field and I felt that the six weeks time was a lot short.

BIBLIOGRAPHY

1. sources from internet: important websites visited are: www.google.com www.Wikipedia.org www.enefluidtek.com www.brewmashingteck.com www.brewfermentationtek.com www.yeastferment.org www.britannica.com

2. Perry J.H., green don W: “Perry chemical engineers handbook”; McGraw – Hill, New York (1995).

3. J.P. Holmann: “Heat Transfer”; McGraw- hill publications.

4. McCabe and smith: “Unit Operations In Chemical engineering”; Volume V; Tata McGraw- Hill Publications.

5. Information based on personnel discussion at “Mohan Goldwater Breweries Ltd.”