Attachment Report Brewing

ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY
COLLEGE OF APPLIED SCIENCE

DEPARTMENT OF INDUSTRIAL CHEMISTRY
INTERNSHIP REPORT ON BEER PRODUCTION @ HBSC
Prepared by:-Demeke Yosef ID No:-ETS 1121/09
Company Advisor: Mr. Ephremrem Hailemaryam
December 23, 2019

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Final internship report @ 23, 2019
Contents
Acknowledgments ........................................................................................................................... iv
Executive summery .......................................................................................................................... v
CHAPTER ONE BACKGROUND OF THE COMPANY
1.1 HEINEKEN .............................................................................................................................. 1
1.2 HEINEKEN IN ETHIOPIA.......................................................................................................... 1
1.3 WORK FLOW .......................................................................................................................... 2
1.4 OBJECTIVE OF THE INTRNSHIP .............................................................................................. 5
CHAPTER TWO PROCESS DESCRIPTION
1.0 Introduction ........................................................................................................................... 6
2.1 Raw material.......................................................................................................................... 7
2.2 Brewery additives, cleaning chemicals and packaging material ...................................... 11
2.3 Brewing ................................................................................................................................ 12
2.3.1 Brew house ....................................................................................................................... 12
2.3.2 Fermentation ................................................................................................................ 17
2.3.3 Filtration ....................................................................................................................... 22
CHAPTER THREE DEPARTMENT OF PACKAGING
3.1 Bottling. .............................................................................................................................. 24
3.2 Kegging ................................................................................................................................ 28
3.3 Key packaged beer parameters ........................................................................................... 30
CHAPTER FOUR DEPARTMENT OF UTILITY
4.1 Waste water treatment plant.............................................................................................. 31
4.2 Water treatment plant (WTP) ............................................................................................. 33
CHAPTER FIVE QUALITY CONTROL DEPARTMENT ......................................................... 37
5.1 The physicochemical laboratory.......................................................................................... 37
5.2 Laboratory Equipment and material ................................................................................... 37
5.1 lines follow up or line control.............................................................................................. 39
5.2 FST follows up ...................................................................................................................... 41
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CHAPTER SIX THE OVERALL INTERNSHIP EXPERIENCE

6.1 Improving Practical Skills ..................................................................................................... 44
6.2 Upgrading of Theoretical Knowledge .................................................................................. 44
6.3 Improving Interpersonal Communication Skills .................................................................. 44
6.4 Improving Team Playing Skills ............................................................................................. 45
6.5 Improving leadership skills .................................................................................................. 45
6.6 Understanding about work ethics related issues ................................................................ 45
6.7 Entrepreneurship skills ........................................................................................................ 46
6.8conclusion and recommendation......................................................................................... 46
List of figures
Figure 1 organizational structure .................................................................................................... 2
Figure 2 hop plant............................................................................................................................ 9
Figure 3 isomerization of alpha acid at higher temperature ......................................................... 10
Figure 4 amylose ........................................................................................................................... 13
Figure 5 amylopectin ..................................................................................................................... 14
Figure 6 block diagram of brewing process .................................................................................. 17
Figure 7 Overview of Saccharomyces metabolic activities influencing beer quality...................... 2
Figure 8 the simplified overview of yeast fermentation ................................................................ 21
Figure 9; Beer Membrane Filtration ................................................................................................ 1
Figure 10 Block flow diagram for filtration .................................................................................... 1
Figure 11 Bottle washer................................................................................................................. 25
Figure 12; temperature vs. pasteurizing plot ................................................................................. 27
Figure 13 flash pasteurization……………………………………………………………………28
Figure 14 keg line ......................................................................................................................... 29
Figure 15 Block Flow diagram of packaging ................................................................................ 30
Figure 16 block flow diagram for WWTP..................................................................................... 31
Figure 17 course screening……………………………………………………………………….31
Figure 18 FINE screening ............................................................................................................. 32
Figure 19 pre-clarifier ................................................................................................................... 32
Figure 20 calamity tank…………………………………………………………………………..32
Figure 21 Equalization tank........................................................................................................... 33
Figure 22 UASB tank .................................................................................................................... 33
Figure 23 CASS tank ..................................................................................................................... 33
Figure 24 rotary skimming ............................................................................................................ 33
Figure 25 General block diagram of water treatment plant ........................................................... 36
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List of tables
Table 1 Comparison among ale and lager beer ............................................................................................................. 7
Table 2 average chemical composition of barley malt .................................................................................................. 8
Table 3 secondary metabolite and their aromatic effect .............................................................................................. 21
Abbreviation and acronyms

AASTU; ……………………….Addis Ababa Science and Technology University
HBSC: ………………………….Heineken Beer Share Company
TBF: ………………………….. Two Brew Fermenter
YST: ………………………….. Yeast Storage Tank
YPT: …………………………. Yeast Propagation Tank
BBT: ………………………. .Bright Beer Tank
BMF………………………….…Beer Membrane Filter
DAW: ………………………..De aerated water
VDK: …………………….......vicinal di ketone
WWT: ………………………..Waste Water Treatment
WWTP: ………………………Waste Water Treatment Plant
CASS: ………………………..Cyclic Activated Sludge
UASB: ………………………..Up flow Anaerobic Sludge blanket
TSS: ……………………………Total Suspended Solid
COD: …………………………..Chemical oxygen demand
o
EBC:………………….. ……….European brewery convention
EDTA……………………………ethylene di amine tetra acetic acid
BB………………………………bright beer
DPD………………………………diethyl-p-phenylenediamine
ECD……………………………..electron capture detector
FID……………………………… flame ionization detector
OPD…………………………….. o-Phenylenediamine
GC………………………………...gas chromatography
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Acknowledgments
First of all I would like to thank almighty God, who helped me in all these things through
my living. My next gratified thankful of gratitude is going to Mr Zewdineh shibeshi Mr
Rekik H. for their help, advice and sharing their knowledge. I would to thanks Mr Habtay
.G, and Ephrem hailemariam quality analysts and my supervisor. And all the quality
control team. I would like to thank Mr birhan Zewde (brewing manager) my supervisor
on the brewing department and Mr selamihun Girma (quality control manager). I would
like deeply thankful to all workers (team leaders and operators) of green field Heineken
brewery who assisted me by providing all the relevant information and reading material
during I stay in the company. Finally I would like to express my great thanks to all my
friends for what we were together during the internship period.
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Executive summery
Heineken Brewery Company is one of the most productive which can produce in high
quality and quantity beer. In this summer I was applying and training on Heineken
Brewery Company; 4 week in brewing department and 6 week in the quality department.
I did not have the chance to stay for several week in packaging and utility due to shortage
of time to do with all department. But I have visited just for one day to know the general
over view. Brewing has vast process. But to make simple the internship paper is divided
in to six chapters. The first chapter contains the general introduction of the paper which
includes background of the company and its production, vision and mission of the
company, objectives of the internship, significance of the paper (the internship), and
organization of the paper. The second chapter deals about raw material of beer and
general process description of the brewing which are brew house, fermentation, and
filtration as well as figures and block diagram of the brewing processes. The third chapter
deals with bottling and kegging or collectively packaging, chapter 4 describes about the
utility department. Chapter 5 deals with the quality control department. Finally the sixth
chapter deals about the overall benefits or experience gained from the internship period in
Heineken brewery Share Company.
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CHAPTER ONE
BACKGROUND OF THE COMPANY
1.1 HEINEKEN
Heineken is one of the world’s most recognized breweries. The Heineken family entered
the beer business in 1864, when Gerard Adrian Heineken acquired a small brewery in the
heart of Amsterdam. This company is one of the most outstanding; largest European
brewer and the world’s second largest brewer by its consolidated volume. In 1900,
Heineken imports its first beer into Africa. In 1946, it enters Nigeria. In 1988, first local
sourcing project in Nigeria. In 2007, South Africa Green field brewery was opened. In
2009, the Heineken Africa foundation, designed to support and enhance the improvement
of health for people in sub-Saharan Africa, is established. In 2015, Heineken brewery
Share Company opened in Ethiopia, at Kilinto area.
1.2 HEINEKEN IN ETHIOPIA

Heineken first entered the local beer market after acquiring Harar and Bedele breweries
in 2011, at a cost of 78.1 million dollars and 85.2 million dollars respectively. In 2014
Green Field HBSC was built at kilinto AkakiKality sub city woreda 9 at about 17 km
south of the capital city of Ethiopia (Addis Ababa). At a time it has the capacity to
produce up to 3 million hector-liter of beer per year.
OBJECTIVES OF HBSC
The main objective of this company is to support the socio-economic development of
Ethiopia in particular and the overall development and well-being of the country; In
addition to this, has aim to ensure product consistency at the required level and to
enhance the country’s food and beverage industry product VISION OF HBSC
Its vision is to be the first and benchmark brewery in Africa.
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MISSION OF HBSC
Its mission is to deliver consistent quality products, on time and in full while working
safely and developing the company, the people and the country.
1.3 WORK FLOW

Here is the way How the work of the company is look like. HBSC has different working
and managing department with safe and continual effective production of the company
under the operation of total productive management.
Figure 1 organizational structure

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Production Department
Function
 On the basis of the marketing strategy and sales plan prepare production plan and
manage the production process according to the plan.
 Controlling and monitoring the production processes.

 Ensures that the right quality and quantity of raw materials and manpower are
available for the production function.
Marketing Department
Function
 Strategic thinking, planning and implementing of the marketing function of
HBSC private leading company.
 Developing/Designing price policy, promotional strategy, distribution mechanism
and implementing after approval by the general managers
 Ensuring that effective customer service is produced at all levels
Human Resource
Function
 Design and develop human and marketing policies and procedure to ensure
performance standards, consistency and transparency in the course of human
resource management.
 Carry out proper manpower planning to ensure supply of man power in terms of
quality and quantity.
 Carry out induction and orientation program for newly recruited staff.
 Design and Developing trained and developed policies and procedure.
Finance Department
Function
 Develop financial strategies and policies that help the company competitively
and profitability.

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 Design financial procedure and guides with their objectives

 Maintain clear/clean recording standardized manner
 Established standardized reporting formats.
 Prepare and consolidate periodic, financial reports/statements as required by low
and to help management decision making.
 Prepare short term (annual budget and long term financial plan within the frame
work of the company’s strategic plan.
Purchasing department
Function
 Its main aim is to support and facilitate the company’s operations

with an uninterrupted flow by supplying the right materials and
services at the right time, the right price, the right place, from the
right source.
Maintenance Department
Function
 Plan preventive maintenance parts and major law.

 Carry out preventive maintenance based on preplanned
programmed.
 Central maintenance costs and maintains aim operating records to
help in budgeting and procurement policy formulation.
 Evaluate of machinery performance and suggest equipment that
need mass disposal.
 Prepare maintenance schedule tooth for machinery and vehicles.
 Advice and assist the deputy general manager technical on matters
related to maintenance.
Supply Department

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Function
 Manage the receipt and ware housing of raw and input materials and their
distribution to user department as they are required.
 Plan and control inventory of input materials using property inventory
management techniques. Manage ware housing and distribution of finished
products.
Quality Assurance Department

Function
 Monitor the performance of production machines, preservation and production

processes.
 Conducting incoming in processes and final inspection of final product.

 Ensures availability of safety precaution and procedure of the company.
 Initiate internal and external training regarding quality management system.
 Ensure the document control system is functioning well.
END USERS OR CUSTOMERS OF HBSC

The end users/customers are every person aged above 18 years old. There is no any limit
or boundary in order to be a customer for Heineken product.
MAIN PRODUCT OF HBSC

The main products of Heineken brewery are Heineken beer, Walia beer, Harar beer,
Bedele special and regular beer, sofi malt and Draught beer (locally called draft beer).
1.4 OBJECTIVE OF THE INTRNSHIP

General Objective
The general objective of the internship is to improve and integrate the theoretical concept
with practical applications and to know what look like the practical work and to find the
application of the knowledge acquired from the college of the university.

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We Students undergo an internship or apparent ship program to prepare ourselves for the
real world. We take advantage of internship to gain practical, professional experience
during the education and make us to contact outside of the university environment.
Specific Objectives
The specific objectives of the internship include
 To understand the fundamental processes involved in brewing

 To know the raw materials used and understand the reason why
 To develop basic analytical skill applicable in quality control
 To know the instrument used for analysis of the quality parameters for beer and
their working principle of those instrument
 To reflect the experience and knowledge gained during the internship program
 To know standard and quality of different types of beer product.
CHAPTER TWO
Process description
1.0 Introduction
What is Beer?
Beer is the oldest and the most widely consumed alcoholic drink in the world it is the
third most popular drink next water and tea. The process of producing beer is known as
brewing. A dedicated building for making of beer is called brewery. Beer is an alcoholic
beverage produced by the scarification of starch and fermentation of the resulting sugar.
It was the first alcoholic beverage known to civilization. The first to brew is still not clear
but it is believed to be 4000 years ago in Mesopotamia. And brewing beer categorized
into Two main types: - ales and lagers

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Types of beer Ale beer Lager beer
Types of fermentation Top Bottom
Color Highly colored Relatively low
Bitterness High Less
Temperature of fermenting Prefers warmer Prefers cooler temperature

temperature(20-250c)
Main area of production Mainly republic of Ireland Globally
and United kingdom
Table 1 Comparison among ale and lager beer
2.1 Raw material

Generally beer is made up of just four main ingredients.
1) Malt
2) Water
3) Hop
4) yeast
By varying those ingredients, brewers develop the uniqueness in their beer brands
(Heineken, harer, walya and sofi for HBS.C). When we come to Heineken brewery Sc
Company it has five departments; ware house, brewing house, utility, packaging and
guilty control house.
Those listed on the above raw materials are distributed as required to each department
and give to the final production of the beer.
 Water;
Water is the principal ingredient quantitatively approximately 96% of beer production.

The water used in beer production will have significant influence on the beer quality
character at several processing stages. The water supplied to the brewery is the treated
ground water at utility house. Heineken brewery Share Company has six wall water used
as source of raw water and used for brewing. Washing and rinsing.

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 Barley; Malt
Malt when raw barley gets appropriate moisture content and temperature it start to
germinate and after it drains it is called malt .there should no further germination. From
local the company obtains from Asela and Gonder; while the foreign malts are obtained
from different foreign company of malt.
The malts from the ware house includes foreign malt and local malt used as proportional
as required, for the production of different types of brands. As a brewing cereal, barley
has is ideally suited for brewing for the following reasons:
 It has high complement of enzyme for converting its starch supply into
simple sugar.
 The gelatinization temperature (i.e., the temperature at which the starch is
converted into a water soluble gel) is 52-59°C much lower than the
optimum temperature of alpha-amylase(70°C) as well as of beta-amylase
(65°C) of barley malt. The effect of this is to bring the starch into solution
and to hydrolyze it in one operation.
 Barley has a high starch and low protein content which needed for yeast
nutrition
Total carbohydrate 70-85% Other substance 1.0-2.0%
Fat 10.5-11.5% Protein 1.5-2.0%
Inorganic malt 2.0-4.0%
Table 2 average chemical composition of barley malt
This barley comes from Poland, Portugal, Egypt, France, Germany, Munich, and
Belgium from abroad. Before the malt processed, parameters such as starch content,
protein content, nitrogen level, moisture content of the malt measured and ascertained by
the quality assurance department.

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 Hop
Hop Hops are the green cone shaped flowers of the female hop plant,also known by its
scientific name (HumuluslupulusLinnaeus). It is a dioeciously, perennial plant
belonging to the Cannabaceae family of the Urticales order (Roberts and Wilson 2006).
Besides the common hop, the Humulus genus includes 2 other species,
HumulusjaponicusSiebold&Zucc and HumulusyunnanensisHu, but only
Humuluslupulusis of industrially used [1]. Those species of plant can secrete resin called
hop resin from their lupulin gland of hop cons in the form of yellow powder.
Figure 2 hop plant

The female cones of the hop plant (Humuluslupulus) are known primarily as raw material
supplying characteristic bitterness and aroma to beer. those green ,con shaped flowers
contains hop resin and alpha acid is important fraction of hop resin that occur almost
exclusively in hops which makes beer to have the desired flavor; bitterness as well as
aroma. They balance the sweetness of the malt with bitterness and variety of flavours and
aromas. Hops are also used in brewing as anti-bacterial effect over less desirable
microorganisms and when beer is made with hops it is noticed that to be less prone to
spoilage. The Heineken brewery Share Company uses tow forms of hop. The hop extract
or they called first hop since it is added during the starting of boiling in the wort copper
and hop pellet or second hop; since it is added during the post boiling.
Hop extract; is a form of hop which contains high concentration of alpha acid which is
the primary constituent of beer bitterness. This form of hop is added at the initial step of
boiling because the alpha acid is very resistive to heat but at higher temperature it
isomerized in to iso alpha acid and gives very bitter test.

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Figure 3 isomerization of alpha acid at higher temperature
Hop pellet; this form of hop which contains the aromatic and volatile component of the
hop for this reason it is added at the post boiling of wort copper in order to not escape
during boiling at high temperature. Hop pellet is very sensitive to heat it can escape or
evaporate during wort boiling. Nowadays hop extracts are becoming favored in place of
dried hops. The importance of hop is to provide bitterness and aroma .
 Brewer’s Yeasts
Yeast is a living organism and therefore it should not properly be considered as raw
material. Yeast is largely responsible for making beer.
The growth and multiplication of this living organism are inseparable from the metabolic
products which produce ethanol, carbon dioxide and the whole range of metabolic
products which contribute to the flavor of the finished product. Yeast magnificently
enhances and reveals the fundamental flavor of beer derived primarily from malt and
hops.
There are numerous types of brewing yeast. Some examples of yeast types are: ale yeast,
lager yeast (top yeast, bottom yeast) Saccharomyces cerevisiae (Ale yeast) or
S.carlsbergensis(Lager yeast)[3]. This means simply downstream and upper stream
fermentation remember in HBSC only lager yeast are used and lager beer production.
Yeast can grow aerobically or anaerobically. In the former case the cells are said to be
respiring; this step is called propagation just before pitching and in the latter fermenting.

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2.2 Brewery additives, cleaning chemicals and packaging material

I. Artificial enzyme; Term amyl and Ultra flow max, those enzymes are used for the
improvement of the extracting of fermentable sugared during the mash in.
II. Calcium chloride for mineral adjustment of the wort
III. Caramel for improvement of color
IV. Phosphoric acid is used for the maintenance of acidity for the mush in process
V. Antifoam this is chemical called ferm cup which is used for prevention of un
necessary foam formation
VI. Pvpp and silcagel fitration aids used for the size enlargement of very fine particles
by adsorbing them on their surface
VII. Zink sulphate is used as primary nutrient for yeast during propagation
Cleaning chemicals and disinfectant

A. WPS
B. Septic acid
C. Costic
D. Suporaoxide or real solution
Brewery packaging material

1. Crate
2. Bottles
3. Corke
4. Lebler

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2.3 Brewing
For the first four weeks of my internship period I was attending in the brewing
department where the bright beer is produced. The brewing department has three sub
sections those are;
brew house
fermentation
filtration
2.3.1 Brew house

The Brewing house is the place where malted cereals and adjuncts are changed in to
sugary liquid which can be fermented by the yeast to make a beer; this liquid is known as
sweet wort.
Milling
Malt contains everything for a successful manufactured beer except water and energy.
Milling or grinding is crushing malt keeping husk fairly intact. The main objective is to
leave the malt husk as intact as possible in order to prevent the undesirable tannins,
bitter compounds or coloring substance appearing in our final product. With milling the
husk exposes the enzymes and the food polymers. Another objective is to produce
crushed malt with the ideal spectrum of particles to extract production and recovery.
That leaves the husk as filtration aid. This takes 1 to 2 hours and it operates in ambient
temperature.
The milled malt is called grist. It is possible to add cereal adjuncts for minimizing the
cost during milling then they will go milled to gather.
Mashing (mash tun) and wort separation (mash filter)

The mashing is basically the process of involving activated enzymes in the malted
barley (and artificial enzymes when required) as improvement for the natural enzymes
to change starches in to sugar, ultimately providing the necessary food for the yeast.
During the mashing the grist beans are solubilized by the action of brewing water (hot
water) and the enzymes formed during the previous steps. The objectives of this step are
to promote the enzyme action and solubilize extract malt solids.
In side mash tun there are three basic steps;
1. Mash in (Liquefaction): Is the first phase refers to the grist mix with water and
unwanted fat is removed. Controlling the conversion temperature of the mash is critical,
because the process is extremely temperature sensitive.

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2. Protein rest: is the temperature zone in the range of 45°-55 0c to break down any
remaining large proteins into smaller proteins and amino acids. Here proteins are break
down in to amino acids by the help protease enzyme at 53oc.
The two main enzymes responsible for protein degradation are peptidase and protease.
 Peptidase provides the wort with the amino acid nutrients used by the yeast.
 Protease breaks down the larger proteins which help enhance head retention and
reduce haze.
3. Scarification rest: is the temperature zone in which starch is converting in to simpler

sugars by the help of alpha amylase and beta amylase at 65oc.
o Remember; it is important to understand that although mash enzymes have

an optimum temperature, they will work over a wide range, and most of
the time, the activity of enzymes overlap within that range. Both alpha-
amylase and beta-amylase will work well together within the range of 63°-
70°C.
 Alpha-amylase chops up starch molecules randomly into chunks that beta-
amylase can then work on by acting on the alpha glycosidic bond. Until these
molecules are chopped up, they are fermentable and called dextrins.
 Mash schedules that target the alpha-amylase enzymatic action (optimum
at 500c) yields a wort with a high percentage of fermentable sugars, or
dextrins. The beer produced is very rich, with a thicker body and mouth
feel.
Figure 4 amylose

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 Beta-amylase breaks down starch and dextrins into glucose (one molecule),
maltose (two molecules) and maltotriose (three molecules) by acting on the beta
glycosidic bond or glycosidic linkage. After beta-amylase is through working, the
starch has been broken down into fermentable sugar.
 Mash schedules that target the beta-amylase enzymatic action (optimum at
60°-650c) yield a wort that is highly fermentable. The beer produced will
be drier tasting and contain more alcohol.
Branched chaine
Figure 5 amylopectin
Next to the mash tun the given mash is transfer to mash filter where it is going to be
separated from the husk which is called brewery spent grain. There are two methods to
do wort separation: lautering and mash filters. The main objectives are filtering wort
and getting the maximum extract of desired ferment ability from this step sweet wort is
comes out. These two steps take to 1 or 2 hours [2]. I was involving in removing of the
spent grain from the filter membrane of mash filter at the end of filtration.
I was also involving in checking of the optimum desertification by iodine test after the
mash off.
Boiling in wort copper
In this point of brewing sweet wort which is obtained from the total process, with hops,
and process aids, like syrups or sugars are boiled in a tank called wort copper. Usually
syrups are derived from barley maize, or wheat. Sugars are usually sucrose. When it is
used in the kettle (copper), it is referred to as "copper sugar". The raw materials on the
previous steps are only malt, water and some cereal adjuncts. Just before boiling hops,
one of the four principal raw materials are added. In Heineken brewery share company
Hops are used with two forms like hops pallets or hop extract. Hops and hop-derived
products have very significant use mainly to impart flavour to beer. Bitterness is the
primary flavour impact of hops though under some processing conditions their aroma
character can survive into beer. This mix boils in a kettle at a temperature above 100 °C

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and at a time between 30 minutes and 1 hour and 30 minutes [1]. I have involved here
also in Hop dosing and other operation like controlling the system on the computer
software called brew max.
The objectives of wort boiling include the following:
sterilization of the wort

cessation of all enzyme activity
reduction of wort volume, which thus increases wort gravity
isomerization of alpha acids from the hops
coagulation and subsequent precipitation of proteinaceous matter (trub,
pronounced “troob” like “food”)
dissipation of volatile constituents of wort, primarily s-methyl methionine
(SMM), the precursor to dimethyl sulfide (DMS)
Reduction of kettle pH by 0.2–0.3.
Sterilization of the wort is obviously important; boiling would be required even if only
to ensure contaminant-free fermentable. Some bacterial and fungal enzymes that may be
present in the mash can actually survive up to temperatures as high as 93 °C. Certainly
these are exceptions, and not all enzymes can survive to those temperatures, but boiling
ensures that any remaining enzyme systems in the wort are deactivated. This effect is
especially important considering that amylase enzymes remain active in mashes that are
not heated to 76 °C before lautering.
Reduction of wort volume is an important factor in determining the actual original wort
gravity (OG) and final beer gravity. The length of the boil can be used to control these
numbers.
Hop utilization is another key aspect of wort boiling. Although much has been written on
this subject, the basics can be summarized as follows: The raw hop bittering compounds,
alpha acids, are isomerized through the boiling action into iso-alpha-acids (at high
temperature isomerization reaction is the basic property of alpha acid), which are much
more soluble in wort. The amount of hop bitterness realized in the kettle is based on the
utilization factor and the amount of raw alpha acids in the hops. Pellets used in a vigorous
boil for 45–60 min will result in 30–40% utilization factors, whereas with whole hops
utilization factors are closer to 20–25%.
The coagulation and precipitation of proteins is a key factor in producing clear, stable
beer. Boiling the wort drives off volatile wort compounds, one of the most important of
which is SMM, the precursor to DMS. DMS can impart cooked corn aromas and flavors

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to beer and is generally undesirable at high levels. Last, boiling the wort decreases its
pH by about 0.2 as a result of the action of calcium and magnesium ions, residual
alkalinity, and the formation of Maillard products and by the addition of bittering
substances.
Secondary effects: The secondary effects of wort boiling include the following:
 adjustment of the wort color as a result of melanoidin production
 dissolution of some hop flavor and aroma compounds (mostly a result of
essential oils in hops)
After boiling the wort is called hopped wort. At the post boiling of the wort copper the
hop pallet is added for the impartment of aromatic flavour.[3]
Wort clarification in whirlpool

Wort clarification consists in straining, settling or centrifugation the hopped wort in order
to remove the spent hops or hop debris and hot break (trub) to clarify wort. Wort
clarification is used for the separation of coagulated proteins and polyphenols collectively
known as trub or hot break and hop debris.
The temperature of the clarification process is between 100 – 80 ºC and it takes less than
one hour [2].
Wort Aeration
For initial respiration of yeasts air is required. The wort is aerated after cooling. Wort
aeration at high temperature results in extensive oxidation. As a result the wort becomes
darker and bitter. The presence of oxygen is however, absolutely essential for yeast
growth. Under anaerobic condition (absence of air) yeast growth is inhibited and
fermentation processed slowly or even stops. This defect can be prevented by optimal
aeration of the cold wort approximately (6 – 12 ppm oxygen). Yeast Pitching Yeast is
the main agents for the transformation of wort components to beer. Wort from each brew
pitched according to the amount needed and send to fermentation.

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H3po4,
Hot
Water AMG, water
Malts: foreign CaCl2
Cara malt grist wort Holding

Milling Mash Mash filter
vessel
tun
Spent grain Pre heater

Tru
b
Cold wort
Wort copper
Wort cooling Whirlpool
Figure 6 block diagram of brewing process

Znso4
Hop
2.3.2 Fermentation
In general terms, fermentation is the metabolic process of converting sugar to alcohol,
acids or/and gases by yeast or bacteria. In addition it is the key step for the releasing of
the aromatic compounds which are responsible for the flavor and smell of the final
product beer. The main products of fermentation are ethanol and carbon dioxide. Other
reaction products include: higher alcohols, aromatic alcohols, esters, organic acids,
carbonyl compounds, sulphur-containing compounds and polyhydric alcohols; all of
which are important for the properties and the quality of the resulting finished product
beer. All the compounds formed have a different taste. Their combined contribution
makes up or off-flavor beer. During fermentation period there are fermentation control
parameters. These are:-
 temperature
 pressure and
 yeast count

December
Figure 7 Overview of Saccharomyces metabolic activities influencing beer quality
The cooled aerated wort made in the brew house is fermented by yeast to make an
immature beer. The most commons fermentable sugars present in the wort are; maltose,
maltotriose and lesser amounts of sucrose, glucose and fructose. Before fermentation
there is aerobic respiration of yeast in the yeast propagation tank contains one brew
wort and yeast. During this process, yeast reproduces. After the all sugar extract are
consumed the wort is transferred in to two fermenter tank then add about one brew
batch to that tank from brew house for further reproduction. Then ready for pitching for
every FST.
For yeast to live and grow, wort must contain a sufficient supply of nutrients.
Nutritional deprivation leads to incomplete and inadequate fermentation. Yeast needs
fermentable carbohydrate, assimilable nitrogen, molecular oxygen, the vitamin biotin,
sources of phosphorus and sulphur, calcium and magnesium ions and trace elements
such as copper and zinc ions [5].
Pitching
The first step of fermentation is pitching. Pitching is simply a brewer’s term meaning
adding yeast to the wort and fill into fermenter. But, before the pitching we have to
consider many things. Next, there is a short list of the most important issues to take into
consideration:[4]
- the temperature of the wort: The metabolism of yeast changes as the

temperature changes;
- the concentration of the oxygen in the wort;
- the amount of nutrients in wort;
- the amount of yeast that will be pitched;

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The pitching rates should be adjusted to account for the number of viable cells rather
than the total number of cells. That concept is called viability. Dead cells can be
determined by staining with methylene blue and counting with a hemacytometer, the
most common method to determinate the viability [6].
Fermentation phase
Lag phase: take 3-15hrs after pitching yeast. When yeast is pitched in to the Wort, they
began process to adapt the Wort environment condition known as the log phase.
Expositional growth phase: 1- 4 days after pitching yeast. As the yeast comes out of the
log phase, it starts to consume the sugars in the Wort. Aerobic respiration occurs during
this phase so the cell counts increases rapidly.
Stationary Phase: 4-10 days after pitching yeast. This phase is when the yeast stops
replicating because of anaerobic condition. It involves the reduction of unwanted flavors
produced during the growth phase such as acetaldehyde and diacetyl or VDK.
Sedimentary/death phase: When nutrients are exhausted the yeast cells clump together.
They flocculate. This is harvested and used again. Some of the yeast will die and settle to
the bottom. These yeasts are purged. The inputs of fermentation are cold Wort, air and
yeast. The Ruh Period (Lasts for about 2 days) is very necessary for the quality of beer
because during fermentation substances other than alcohol are produced by the yeast such
as Diacetyle (VDK). This has a buttery taste. The yeast itself breaks down the VDK
during this period. Then the yeast will be harvested and sent to Yeast storage tank. These
yeasts can be used again up to seventh generation.[4]
2.3.2.1 Fermentation secondary metabolite

Once pitched into wort, yeast cells use the nutrients from the wort to provide energy
The yeast consumes and metabolizes sugars present in the wort. .Acetaldehyde, ethyl
acetate, isoamyl acetate, ethylhexanonate, ethyloctanoate, ethylbutyrat, n-Propanol,
isobutanol, N-amyalcohol and dimethyl sulphur. These ten compounds could be
classified in four categories: aldehydes, esters, higher alcohols and sulphur compounds,
but there is certainly an excess of 700 of such constituents in a beer. [7]

December
Name of the nature Name of the nature

aromatic compound aromatic compound
Acetaldehyde Green apple Estery Fruits & roses
Diacetyl Butter, butterscotch isoamyl acetate pleasant

fruity smell
DMS (dimethyl Sweet cooked higher alcohols solvent
sulfide) canned corn
Table 3 secondary metabolite and their aromatic effect
Figure 8 the simplified overview of yeast fermentation
2.3.2.2 Maturation
Maturation starts at the end of primary fermentation, when the green beer transfer in to
maturation cellar it pass through heat exchanger and cooled between 10c to -
10c.Sediments and yeast purged every 72 hrs after maturation started. The reason for
maturing beer is:-
 To continue fermentation to remove undesirable flavoring substance.

 Clarify the beer through the settlement of yeast and suspended solids
 Improve flavor of beer through slow secondary fermentation.
Finally the matured beer after fulfilling the required quality parameter transfer to
filtration section.

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2.3.3 Filtration
It is Saied that “people drinks beer with their eye”. The important index of beer
stability is the visual appearance of the product. So for this reason it is needed to
filter the mature beer to remove or reduce the concentration of so many biological
and non-biological hazes, other colloidal and suspended particles like yeast.
Key; turbidity which is the result of complex of proteins and polyphenols refers to
haze.
Filtration is the process by which mature beer which comes from fermentation
room is filtered.
Mature beer from the fermentation tank still contains some yeast and haze
particles. The mature beer from MBT is passing through BMF in order to remove
Yeasts, Proteins, Poly phenols, Suspended particles and others. Here before
interring to BMF silcajel is dosed to unfiltered beer thank as coagulant for yeast
i.e yeasts are adsorbed to the surface of the silcajel and they will become large in
size so that they will not pass through the membrane of the filtration membrane.
Other surface active substance such as excess proteins may also adsorb on it.
PVPP is also used to complex poly phenols and precipitate and then they will be
ready to remove easily by membrane filtration. Oxalic acid which is toxic
compound for human diet is also chelating with calcium and ready to remove
during filtration. Generally filtration uses so many adsorbent substances in order
to adsorb the surface active substances (adsorbate) like yeast, proteins, poly
phenols and other unwanted substance like oxalic acid.
The main purpose of filtration is to remove or reduce the concentration of large and small
undesirable molecules which are found in beer make a beer turbid or unclear. Once the
beer is filtered again it passes through security filter for further filtration then it is
transferred to the BBT, which serves as a storage tank till the beer is needed for
packaging. But before entering the BBT it is diluted with DAW for OG adjustment. It is
also blended with carbon dioxide to give the beer its characteristics.
The filtrate are stay attached on the filtration membrane and the BMF is washed by
caustic soda and hot water in order to remove the attached filtrate.

December
Figure 9; Beer Membrane Filtration
Silica gel
Mature beer transfer Coolant UN filter beer tank
Security filter Membrane filter

Filtered beer tank
Filtered beer
Carbonation
Daw blending Bright beer tank
Figure 10 Block flow diagram for filtratio

December
CHAPTER THREE
DEPARTMENT OF PACKAGING
I have seen the general over view of the packaging plant at the end of my internship
period. Due to the shortage of time I have not got time to see all the manufacturing
process.
Once the beer has been produced and stored in the bright beer tank, it is then ready for
packaging. The main requirement of packaging is to protect the product from
deterioration, to present an attractive consumer product, to meet local government
regulation in terms of consumer information and to meet any consumer safety
requirements. In Heineken brewery beer packed in bottles, and draft beer in kegs.
3.1 Bottling this step is dealing about filling of the filtered beer in to glass bottle.
Collection of empty bottles
Empty bottles in crates collected from customers, and stored until use. When packaging
starts these bottles conveyed to De-pelletizer machine on roller conveyer.
De-palletizer- the de-palletizer is used to remove the new bottles from their pallets
and assemble them on a conveyor ready to move through to the rinse.
Uncasing (UN packer)

It is a machine that Uncases 6 crates (6× 24 = 144 bottles) of empty bottle at a time and
puts the bottles on a conveyer that takes them to a washer, and the crates to crate washer.
It can Uncases a maximum of 2,400 crates (i.e. 2,400 × 24 = 57,400 𝑏𝑜𝑡𝑡𝑙𝑒𝑠) per hour.
Bottle washer
Bottle Washing Bottles contain unfinished beer, fur, dirty labels and foreign matters in
and on their body. Thus it is essential to clean them and make nice for containing the
finished product beer. Bottle washing has the following Purposes:

December
 To remove dirt from the inside and outside of the bottles;

 To ensure the bottles are sterilized- removing pathogenic organism.
Bottle washer: a machine with continuous belt holding about 33 bottles in separate holes
and it contains three baths for soak cleaning. It has an integrated glass fragment removal
unit and coarse bottle cleaning before use of soak cleaning (water- caustic soda mixture).
This machine represents a highly efficient cleaning technology. The bottle washer is
equipped for removing pressure-sensitive labels.
WASHING TEMPERATURE high temperature favors the removal of waste matters. A

temperature of 80° C employed. In addition to water three agents are used: Caustic,
disinfectant for prevention
Method of operation:
Bottle In feed and discharge takes place at different locations and thus assures the best
possible hygienic conditions. The pre-cleaning system heats the bottles and removes glass
fragments and coarse contamination. Subsequently the bottles run through various caustic
baths in vertical loops, in order to completely wash away dirt or labels. Before the bottles
leave the machine, they are cooled in the post treatment zones with a small quantity of
fresh water and freed of any remaining dirt or caustic residues. Check: washing is
completed the presence of caustic is detected as: add distilled water to the bottles and
shake, then add few droplets of phenolphthalein indicator. If there is no color change, the
bottles are clean and sent to the next step. If not, they are again washed.
Figure 11 Bottle washer

December
Crate washer
The Un-caser (un-packer) machine left the crate empty and conveyed to crate washer.
Here pre-caustic solution/low concentrated caustic/ is sprayed on the crates, and rinse by
hot water to remove dirt.
Empty bottle inspector (EBI)
Empty bottle inspection (EBI): the bottles are checked and either passed or rejected.
There are two types of rejection soft rejection and hard rejection.
Foreign bottle rejection: In this inspection there are set parameters (like height, color,
etc.) and if the parameters are not met they will be rejected; this is called hard rejection.
On the other hand soft rejections are: neck inspection, side one inspection, Side two
inspection (180o each), caustic inspection, bottom inspection. If the bottles pass all five of
the inspection it will go to the filler or else it will be rejected.
Filling & Crowning

BOTTLE FILLER The Mechanical fill is an electro-pneumatic filling system. It works by
integrating a vacuum feature providing an option for double pre-evacuation of the bottles
– thus assuring low oxygen pick-up during the beer bottling operation. This equipment
has a maximum filling capacity of 42,000 bottles per hour. During filling: loss of beer
must be avoided, avoidance of contamination and quality of beer must be maintained,
Avoidance of CO2 loss from if not quality and shelf life is lowered.
During filling the air inside bottle is sucked through vacuum chamber and the bottle
pressurized with CO2 and filled with beer here since CO2 is denser then O2 oxygen will
not get in to the bottle during filling. Finally the bottle reaches the required level it stops
filling and discharge out for crowing.
Crowning: immediately after filling the bottles are crowned using corks to prevent loss
of beer component.
Pasteurization
Beer in bottles pasteurized in order:

December
 to stabilized the beer micro biologically,

 to destroy pathogenic microorganism,
 To insure long storage life.
Heineken brewery employs Pentair made pasteurizing technology which features a
unique channel concept, low water consumption in each treatment zones, fine-tuned
control, and the resource-saving central heating exchange system supply (CHESS). The
temperature is gradually rise from room temperature to 66° C, and returns back to room
temperature. The pasteurization used for bottle is tunnel pasteurization.
Figure 12; temperature vs. pasteurizing plot

It can pasteurize up to 42,000 bottles in per hour duration.
Bottle Labeling
The appearance of the bottles is important for competitive market. Walia brewery has
neck and body labels. Company name with its trade mark, alcohol content (v/v %),
amount of extract (in ° P), volume per bottle, and customer information line are
information found on the labels. Pentair made labeling machine called Solomatic,
performs a precise label application. Low glue consumption and a high hygiene standard
are some of the features that make this cold glue labeling system stand out. Depending on
the labeling concept involved, body or neck, tamper-evident labels can be applied. It
labels a maximum of 55,000 bottles per hour.

December
Full bottle inspection/FBI/
It is a machine which contains a sensors that is activate by the presence of light. These
sensors used to select:
 uncrown (unsealed) bottle;

 under fill and over fill bottles;
 Miss labeled bottles.
The machine can inspect 55,000 𝑏𝑜𝑡𝑙𝑙𝑒𝑠𝑝𝑒𝑟 ℎ𝑜𝑢𝑟.
Date decoder/DD/ or video jet printer

A machine used to decode production and expiry dates on bottles. It uses black color.
Casing (packer)
Now the bottle beer finished all the process and proceeds to casing. Casing machine puts
bottled beer into crates. It can fill six crates at a time with a capacity of casing 2,400
𝑏𝑜𝑡𝑡𝑙𝑒𝑠 per hour. Bottled beer now piled on metal supports and transport to pelletizer.
Palletizer: the crate will now assembled on to the bottle, transferred to storage using
fork lift so it’s easy to transportation.
3.2 Kegging
Beer is also packaged in keg with the name draft beer. Cellar, unfiltered beer, is packed
in keg. Bright beer from BBT filled in kegs. Prior to filling the beer is pasteurized at 74℃
for 30 seconds using flash pasteurizer.

December
Figure 13 flash pasteurization Figure 14 keg line

Filling proceeds as follows:
 Collection of empty kegs: similar to bottles empty kegs collect from customers.
 Washing: removing dirt and residual beer. The procedure is
 Washing the external part by blowing hot water while they are conveyed.
 Applying caustic solution to the inside part and rinse by hot water.
 Blowing out the hot water by steam.
Before filling the steam is removed to avoid condensation problems in the keg. If
condensation or water droplets are formed, it favors the growth of microorganisms and
this lower the quality and shelf life. Then the keg pressurized using CO2 and filled by
beer. The keg should contain 30 𝑙𝑖𝑡𝑟𝑒𝑠 of beer. This is checked by weighing filled keg. It
should weigh between 39 and 41 kg. If it lowers the sensor push out & filled again. Kegs
piled in metal supports and transported by forklifts and stored until sale.
Due to their pasteurization time bottled beer and Draft beer differ in preservation times or
shelf life. Draft beer has short storage life (maximum of two months) but Walia beer can
be stored for maximum of one year.[9]

December
3.3 Key packaged beer parameters

Those key parameter are cheeked or measured on the quality control the main lab before
sending to the customer (market)
Alcohol content (ABV): Reflects strength of beer and value as such to consumer
Present gravity: Indicates degree of fermentation
Original gravity: Reflects strength of beer and value as such to consumer
Color: immediately perceived by consumer, sometimes as indicator of strength
CO2: Dissolved CO2 creates a fizzy character and ‘bubble rise’ in glass
Figure 15 Block Flow diagram of packaging

December
CHAPTER FOUR
DEPARTMENT OF UTILITY
In this department there are seven plants. These are: waste water treatment plant
(WWTP), Water treatment, steam boiler plant, CO2 recovery plant, Cooling plant,
Compressed air plant, generator (power supply) plant and waste water treatment.
4.1 Waste water treatment plant

Waste water treatment is removing the harmful chemical from the waste water of the
bearing as well as the whole plants of the factory. This harmful chemical is pollutant of
the atmosphere as well as the community. To remove this harmful chemical uses different
chemical in different process in order to purify the waste water. The overall process is
shown as below.
Figure 16 block flow diagram for WWTP

December
Influent pump pit

The wastewater from the brewery will be collected in influent pump pit, and will be
pumped to pre-treatment system by influent pumps .A coarse screen is installed in the
influent channel, it is used to remove big particles, make sure influent pumps running
normally. The residual trapped by coarse screen will fall into the container, which should
be cleaned in time. Also a fine screen is installed for removing fine materials to prevent
solids accumulated in tanks
Figure 17 course screening Figure 18 FINE screening
Pre-clarifier is the removal of suspended solids in wastewater; to prevent inorganic

matters like sand, coal ash, diatomite etc. accumulation in UASB reactor. Pre-clarifier is
vertical flow type and two parallel pre-clarifiers are designed.
Figure 19 pre-clarifier

December
Calamity tank
It is a holding tank for temporarily storing high organic concentration wastewater or
severely high pH or severely low pH wastewater, also can be used as a holding tank for
temporarily storing normal wastewater being out of specification. As calamity tank is a
buffering tank, normally calamity tank should be controlled at low level.
Figure 20 calamity tank Figure 21 Equalization tank
Equalization tank
It is a wastewater holding tank to make sure equalization of flow, also acidification
reaction will happens in equalization tank, which is much helpful for anaerobic process
unit. As equalization tank is also a pre-acidification tank, normally hydraulic retention
time (6 - 10 hours) needs to be ensured for the pre-acidification degree.
UASB
UASB (Up-flow anaerobic sludge
blanket) uses an anaerobic process
whilst forming a blanket of granular
sludges which suspends in the tank.
Wastewater flows upwards through the
blanket and is processed (degraded) by Figure 22 UASB tank
the anaerobic microorganisms.

December
CASS CASS (cyclic activated sludge

system) is mainly uses aerobic and
facultative bacteria to degrade organic
matters in wastewater. CASS is an
aerobic process unit, both aeration and
settling will be finished in the tank.
Figure 23 CASS tank
Rotary skimmer
Rotary skimmers are installed for clean water drainage, 2 sludge recycle pump are
installed for sludge recycling and discharging, 2 DO meters are installed for monitoring
DO when in aeration phase and control blowers running frequency.
Figure 24 rotary skimming
Chemicals used in WWTP

HCL (Hydro chloric acid) it dosed in the Equalization tank is used to adjust the PH of
waste water by lowering when it is high; NaOH (Sodium hydro oxide) it dosed in
Equalization tank also used as PH adjustment when the PH of waste water getting low.
FeCl 3 (ferric chloride) it is added at UASB and CASS which used coagulate the sludge
and settled down by the force of gravity.
4.2 Water treatment plant (WTP)

Water is the major raw material for beer processing. It must be free from impurities and
microorganisms. Water in Green Field Heineken is taken from underground and treated

December
to the desired quality. The main aim of WTP is to treat untreated water to get clear water.
In order to be suitable for use in brewing, water must be: Microbiologically pure, Clear
and colorless (turbidity and color can be caused by suspended solids), Tasteless and
odorless (chlorinated water can affect beer flavor), pH neutral (pH 7 or slightly acidic),
Free from heavy metal ions. The water treatment plant at Heineken brewery is designed
for treatment of well (underground) water. The main substances or chemicals that used
for WTP are: Ferric chloride, Anti scale, Sodium hydro oxide, Sand, Chlorine and Active
carbon filter.
In Heineken brewery water comes from underground by the help of centrifugal pumps in
to water treatment plant using six walls (now wall three not functioned). Then its
turbidity is checked online by amplifier, and if turbidity less than 3 NTU it enters in to
well water tank otherwise drain.
Steps of water treatment plant in Green Field Heineken brewery are: Storage (well water
tank), Mechanical Treatment, Membrane Filtration (reverse osmosis) Cooling System
and Advanced Treatment Storage (active carbon filter).
1 Well water tank: -The well storage tank has the following functions: Serves as
temporarily storage to maintain a continuous operation mode, Supplies water for the
media filtration backwash wet, Control station for the turbidity of the well water
2. Mechanical Treatment: in this steep flocculation, aeration and multimedia filter are
involved. liquid minerals like Aluminum and Manganese are Eliminated by dosing
flocculants (ferric chloride, FeCl3); for the elimination of colloids and unwanted species
like aluminum and Aerate to facilitate the reaction.
Multimedia Filter: It used as a filter media, it has different size of sand that is fine,
medium and course all are used to Retention of un dissolved suspended, turbid and dirt
particles.

December
3. Membrane Filtration (Reverse Osmosis, RO)
Osmosis is the passage of water through a semi permeable membrane from a lower
concentration to a higher concentration due to osmotic pressure. So reverse osmosis is the
passage of water through a semi permeable membrane from a higher concentration to a
lower concentration by applying pressure, which is higher than the osmotic pressure.
Green field Heineken brewery has two reverse osmosis equipment which are work
alternately.
The water from the media first enters the security filter then enters the reverse osmosis. In
the RO, the applied pressure overcomes the osmotic pressure to remove the salt ions and
many types of molecules from the water. Anti-scale is added to prevent scaling, which
would block the membranes. Once the water is treated with in the RO it will be blended
with some amount of water from the media filter. This is done to adjust the water quality
according to Heineken standard. But before the blending process water for boiler is taken
and stored in the boiler feed tank.
4. Cooling Systems: -The well water with an inflow temperature up to 38°C is cooled
down by cooled water in plate type heat exchanger and cooling down to 27°C. Then the
cooled water enters in to soft water tank.
5. Advanced Treatment: The advanced treatment step maintains the required water
quality for brewing water by disinfection with chlorine followed activated carbon
filtration (ACF) for de chlorination and polishing. The main purpose of chlorine is used
as disinfectant by killing the microorganisms like bacteria and algae. Then soft water
enters in to ACF by the help of centrifugal pump. The function of ACF is to absorb
chlorine and odor of other substance.

December
Finally water qualities will be produced:
 Chlorinated :Soft water,

 De-chlorinated: Product water. Standardization water is to be made from Product
Water.
 Treated brewing water used for cleaning (CIP) and totally for brewing
process.
 Softened water used for bottle and crate washing and for pasteurization.[8]
Well Water Multimedia Reverse Osmosis

Well water Tank Filter
Product Cl2
ACF Soft water
Water Tank Cooling
Tank
Figure 25 General block diagram of water treatment plant

December
CHAPTER FIVE
Quality control department
5.1 The physicochemical laboratory

After the first month I have taken about six weeks to seen quality department. Heineken
brewery Share Company has its own recipe of production in order to produce each types
of brand.
In the company quality control room all the input, process (semi-finished product) and
output (finished product) are followed and checked if they are on the specification of
standard quality measure of Heineken brewery. And other new material or any inputs are
also checked here for their validity.
In the quality control the (Main) lab the quality analyst divide their work as follow
Line control; follow up of packing beer
1. Complete for BBT to release in to line of packaging and keg
2. Filer check up
3. Pu checkup or follow up if completely pass
4. Water analysis
FST follow up; fermentation follow up during fermentation period
 Ea- Apparent Extract during all the day of fermentation
 Alcohol during all the day of fermentation
 Bitterness after 9th day of fermentation
 VDK and Color after 8th day of fermentation
 AL – attenuation limit1st day of fermentation
 T0- temperature
 PH during all the day of fermentation
 OG Original gravity during all the day of fermentation
 Er –real extract during all the day of fermentation
Heineken breweries share company uses instrumental analysis for most analysis doing.
5.2 Laboratory Equipment and material

December
 Haze meter:-is a device which used to measure the haze.

 Foam stability:-is a device which used to measure the foam
 Mechanical shaker:-used to shake the attenuation.
 Centrifuge:-used to settle down the yeast and used in micro lab for
consistency.
 Magnetic stirrer:-used mix or stir.
 Conductivity meter:-a device used to measure conductivity and TDS
 PH meter:-a material used measure the PH.
 Hatch photometer:-used to measure amount of chlorine.
 Helmanex soaking container:-It used to soak the cuvet, pipet, and the like.
 Vortex:-a machine used to mix well.
 Shelf:-a material used to store chemicals, flask…..soon.
 Foreign gas taster:-used to taste foreign gas for instant oxygen, nitrogen
 Bottle turner:-which used turn the bottle.
 Falling device:-used to measure CO2 there is also Huffman CO2 meter
 Auto clave:-a device which is used to sterilize.
 Oven:- equipment used to avoid moisture content from the material (dry).
 Refrigerator:-a material used to maintain with its quality of property for a long
time and also used to cold down.
 Water bath 570c:- a material used to maintain a beer and other to stay at 570c.
 Water bath 0 0c:- a material used to maintain a beer and other to stay at 0 0c.
 Alcoholizer:-a device used to measure alcohol content, apparent extract,
original gravity degree of fermentation ,real extract and density
 Analytical balance:-which used to weigh the weight.
 UV visible spectroscopy:-a device used measure color, FAN, VDK and
bitterness.

December
5.1 lines follow up or line control

In the line control there are so many tasks to do like the analysis of packaging beer from
the packaging line, water from the utility department, BBT from the brewing department
and other non-routine sample analysis comes from the different sites of its department or
production plant.
Water analysis
As it discussed above; green field Heineken brewery has six wall water for different
purpose during brewing packaging and other. So it needs keep the quality of the water
safe for drinking as beer is over 90% water.
The water samples was collected from different port of sampling point of the water
treatment plant
▪ Raw water tank
▪ MMF (1,2,3,4&5)
▪ RO water(1&2)
▪ ACF feed
▪ ACF out let(1,2,3&4)
First of all each of the collected samples should be conditioned to their room temperature
because the analysis should be done at normal temperature unless it will give missed
measurement.
Next the following measurement are taken
TDS and conductivity are measured by using the instrument called conducto
meter
 the electrode of the conductometer is immersed in to the sample the read the
conductivity and TDS
PH is measured by using the PH meter, just immersing the electrode of the
conduct meter in to the sample. Water should optimally be slightlyacidic or close
to neutral pH (7.0).
Here the PH of water should be on the spec. of the drinkable water

Total chlorine content is measured by Hatch photometer. In case here the
sample uses chlorine tabulate called DPD. fill the cuvette up to the leveling then
put on the Hatch photometer by selecting free chlorine measurement click
zero then on the second round add the DPD reagent and then by closing the lead
click read. The reagent DPD is called di phenyl di methyl amine. This reagent
react with the free chlorine and forms pinkish colored solution due to the

December
formation of the wurstr daye. This reagent is detected and indirectly the amount of
free reactive chlorine is measured.
Alkalinity is also measured by the method of titration with hydro chloric acid as
titrant using phenolphthalein indicator.
Total hardness is measured by titration at the basic media by using Erichrom
black T indicator with EDTA as titrant since EDTA has high coordination number
it binds many metal at the end point and gives blue color that’s indicate for the
end point. By recording the amount of EDTA solution consumes we can find the
concentrations of the total hardness (Mg2+&Ca2+)
BBT complete or BBT release Analysis

The brewing team asks confirmation to the quality in order to release the beer in to the
packaging line after they filter and blend it with de aerated water and CO2.
Before the BB is sent to the packaging line the following parameter should measured
Dissolved oxygen and CO2 are measured during the sample taking from the BBT
tank which is going to be analyzed this instrument used to measure the DO and
CO2 is called Huffman CO2 meter
Alcohol content, EA, Er, OG are measured by alcoholizer by loading the degased
and conditioned beer sample in to alcoholizer after it cleaned and adjusted to zero
by distilled water. Not degased beer and non-conditioned beer will give missed
result.
Haze consists of small particles suspended in the beer. Hazes develop after packaging.
This result the interaction b/n polyphenol and proteins this increase by high temperature
in the presence of oxygen.
 Haze potential is important measure of shelf life

 We need to test the beer and predict the formation of haze by a device
called haze meter.
Steps of measuring haze
- Beer is poured into a cuvette then the cuvette is placed in haze meter.
- A light beam shone in at an angle. The haze breaks up the light
- The dispersed light is converted to a digital read out of haze. And the haze
is displayed in EBC unit.

December
Bitterness to measure the bitterness means just measuring the amount of phenol
lipids and iso alpha acid concentration. The procedure is the same as described on
the FST analysis below.
Color the degased, filtered and conditioned beer was filled to the optical glass
cuvette then read the absorbance at 430 nm wavelength just by loading in the uv
visible spectro meter. by multiplying the value of the absorbance by 25 gives the
color in EBC.
PH the filtered and degased beer is measured by PH meter just by immersing the
electrode on the sample.
Packing and packed beer analysis; after the beer gets confirmation by the quality
analyst the filtered beer from the BBT tank pass to the packaging line. From each phase
of packaging line three bottles of beer are taken just as the BB arrived and starts bottling
then check all the parameter for BB to see if there is or there is not contamination on the
line during coming in to the bottles or the filler. In here the dissolved oxygen and CO2
critically checked before the line is proceeding.
For packed beer or final product six bottled beer two bottles labeled and four un labeled
are taken in to the main lab then one for shelf life, one for seven day stability, one for
three hour stability, one for foam stability, one for foreign gas and the left one is for
dissolved oxygen and CO2 testing.
 The three hour stability is for haze of covalent protein polyphenol complex; its
haze is measured after it stays for three hours inside the zero degree water bath.
This is why because the turbidity is visualized as the temperature is decreased
more.
 The seven day stability is for haze of ionic polyphenol protein complex this bottle
stay in 57 degree water bath in order to brake the ionic complex of proteins and
polyphenol and then put it in the zero degree water bath after the seven day in the
57 degree after it is freezes its haze is measured this method is used to see what
about if the beer gets out of the fridge; if its haze increase more so our beer is not
filtered much.
5.2 FST follows up

By taking sample from the fermentation vessel or fermentation tank the degree of
fermentation is measured every day until the fermentation is reached its final attenuation
limit that is pre seated just on first day after filling. During the sampling; alcohol should
be sprayed after the sample taken for prevent growth microorganism in the sampling
point.

December
The samples from each requested FST thank ware taken by plastic bottle in to laboratory.
See all the parameters listed above. The sample taken was filtered by filter aid known as
kieselgur.
1. Alcohol content EA, Er, OG and degree of fermentation are measured by instrument
called alcoholizer. The samples was filtered by the help of filter paper & filter aid
powder and filled to vial. It loaded in to the sample injection point of the alcoholizer.
Finally press start then read the Alcohol content EA, Er, OG and degree of
fermentation at the same time from the alcoholizer. At the first day just during filling
time the OG and EA are the same and the alcohol content is zero. Through time the
fermentable sugar is degraded by yeast and the OG will gradually decrease –the
alcoholic content is becoming increase during repeatable analysis of each day until it
reachs its final attenuation limit.
2. Color color of beer is derived from the caramelaization of sugar or glucose obtained
from malt in different stages of brewing. Color is measured by the instrument called
UV visible spectroscope; by measuring the absorbance of the filtered and conditioned
(20oc) sample of FST. The result is reported in EBC.
3. PH; it is known that PH is the measurement of acidity and basicity of solution. PH is
measured by PH meter. This value should be on the range of living condition of yeast.
For repeated analysis of each day of fermentation PH value is decrease gradually
through time. This is due to yeast cell consumes the ammonium ion for its nutrient
and release Varity of organic acids.
4. Vicinal di ketones (VDK) are all di ketones like pentadione and hexadione which are
formed during fermentation the step of synthesizing some amino acid required by the
yeast cell. VDK is measured by two method GC and Colourimetric (steam
distillation)
 For gas chromatography the sample is prepared by adding detective aid reagents
like ECD and FID which helps to amplify the detection. The prepared sample is
loaded on the sample injection point by GC vial the instrument takes sample by
itself the then read the value on the screen of the detector or computer. This
method is more accurate and provides more information.
 For steam distillation OPD solution was added into our sample in order to extract
the VDKs. First OPD (O-Phenyldiamine) is prepared using 10 ml 4N HCl with
0.1 gm of OPD. Then 100ml of beer FST with 2 drop of silca gel (antifoam) at
distillation flask and heated. The vapor passes over to the cooling column then it
condenses here. The condensate is known as the distillate and part of distillate is
treated. The treated distillate is total VDK because this ketone group has low
boiling point than water so it collected easily by distillation then prepared two 10
ml of alcohol and 10 ml of distilled water (blank). Shake using vortex. It placed

December
about 25 minute in dark place and after placed in a spectrophotometer. The fixed
diacetyle absorbs radiation at 530 nm range the result is displayed on the
computer this is also in EBC unit.
Higher value than the threshold concentration of VDK leads to very bad smell like
spoiled butter.
5. Bitterness; Bitterness is a taste that is detected mostly by the back part of the tongue.
It is a sensation that grows more pleasurable with age. The bitterness sensation
appears to be initiated by phenol lipids and iso-alpha acids. The most important
compound in beer bitterness is iso-alpha acid, which is derived from hops. Bitterness
is an essential flavor characteristic of beer. Taste testing gives indication of the
bitterness of a finished beer. Iso alpha acids are more soluble in organic solvents than
in water. (Beer is 95% water).This property is used to measure the bitter substance
from beer. Adds 1ml HCl with 20 ml iso-octane then, shake up to 5 minute by
mechanical shaker this is used for removing of the CO2 gas and wait for 30 minute.
A spectrophotometer is used to measure the absorbance of the Iso octane extract at
275nm and the result is expressed in bitterness units.
6. Attenuation limit is the minimum degree of fermentation which is measured by
alcoholizer.
First 3-4 gram of yeast was added to 250 ml of beer sample (FST) the shake on the
mechanical shaker for 24 hours at 150rpm at the end of 24±1 hours the sample was
filtered by the help of filter aid powder, and then measures its AL that is its EA result. So
this EA result is called final attenuation limit after reach this valve EA the FST goes to
the end of fermentation.
NB It is important to de-gas samples for the most instrumental analysis test as bubbles of
gas released in the optical cell may interfere with the assessment of brightness.[7] in here
I was involving in measuring a lot of parameter almost all listed above parameters I have
done myself with them.
They have shewart sample which is controlled sample. They use as reference or standard
I was trying to calibrate and standardize the instruments by using the controlled sample.

December
CHAPTER SIX
THE OVERALL INTERNSHIP EXPERIENCE
6.1 Improving Practical Skills

During this internship program I have tried to grasp practical skills relating to the
theoretical knowledge gained in SIX semesters from AASTU industrial chemistry
department. This program is a great opportunity for developing practical skills and it is a
new world transferring from theory to practical. During the time of this internship
program, I have developed the following practical skill.
 How to take sample from mashing vessels, BBT and FST to lab. How to dose
hop
 How to measure PH and original gravity of wort and overall control of quality
which described in detail in chapter five.
 In general I was applying in to the three chemical process step in brewing
(mentioned in the chapter 2 above) to analysis process parameter.
6.2 Upgrading of Theoretical Knowledge

As we know coming before in the previous theoretical awareness or familiarity and actual
place could be distinguishable, so the objective reality and theoretical knowledge may be
slightly different. The above theoretical learning is upgrading during my internship
program by seeing and doing some work. So the internship program is essential for
students to upgrade theoretical knowledge’s.
6.3 Improving Interpersonal Communication Skills

Developing interpersonal communication skill and almost all kind of work requires
communicating with other persons who shares ideas. But peoples have different
behavioral characteristics, some are emotional and others are rational and so on. In this
company also have the above situation. So we readily know the behavior of those people
.In my day to day activities I contact with different person and I have developed the idea
of communication with each person in the company and also I know what type of word to

December
use to communicate with the person who is the member of the company. In general, I
have observed that it is must to create smooth relationship among different workers in
order to get social life in addition to improving practical and theoretical knowledge.
6.4 Improving Team Playing Skills

Team playing skills are one of the basic requirements for the proper working of a good
company, regardless of its size and service. A company with suitably functioning devote
to a special task will always have a graph going up words, with different workers
working in different sections such as, brew house, filtration, Packaging, and utility
section. Team playing is a basic requirement for getting solution for a specific problem
and to share experience. During internship I have developed a team playing skills with
operator to get experience, with engineers to grasp knowledge, and so on.
6.5 Improving leadership skills

Although leadership has many definitions, I want to talk any contextual meaning related
to this project, it is defined as the process of influencing an organized group towards
achieving its goal and a leader is a person who has strong principles, courage’s and
dedication to a clear vision, developing a powerful vision, building a strong team and
bringing out the best, in those our institution leader are key facts to experience success as
a leader. This indicates that the leader should accountable and transparent to their
follower’s. Generally, leader and followers should have integrated relations during
working time. In my internship program, I get leadership skills in terms of: How to
communicate with workers on working issue. How to give service for a person? Even
how to share knowledge? How to share experience?
6.6 Understanding about work ethics related issues

Actually any people should have ethics not only in the work place but also in the social
life. In my understanding work ethics is a set of values on hard work and diligence, it also
believes in normal benefit of work and its ability to enhance. However, in this company
some people loss their ethics. It may be due to personal case or the company leadership
system. Generally, work ethical employee is a key to productivity. This is to near for a

December
factory to be productive; all of the employees have to be disciplined and ethical in their
working environment. Generally, work ethics have broad definition.
Including:-Punctuality, not absent without reason (except during special cases, dead of
family members, sickness etc.), respecting other workers, finding the development of
company, commitment in work place.
6.7 Entrepreneurship skills

In this internship program I learned small business startup skills where we should be
empowered with knowledge and skills to become effective entrepreneur. The state of
being an entrepreneurship can be realized when one engages in profitable risks and
creates something of value. It is defined by their habit of innovating and redefines market
trends and limits. Generally, entrepreneurs who are able to create worthwhile good and
services give a greater impact to society; have faithful and often tested with good results.
Generally, entrepreneurship can be realized when we engage in profitable system and
create something value from theoretical to practical learning. This means a person who is
able to develop a new business area and affect the global economic condition
6.8conclusion and recommendation
Conclusion
Generally the production of beer in general has three sections. The first is producing
brown sugary syrup called wort. Then the wort will be fermented with the help of
yeast. The alcohol produced is then filtered. But as easy as it may sound the actual
production is much more time consuming and need to be done with care. This is
because there are many ways it can be contaminated. Basically this production
involves three basic chemical reaction monomerisation reactions in the mash tun,
chemical reactions during boiling in the wort copper and during the fermentation
process.

December
Recommendation
For the company

 Surplus yeast that is found after the fermentation has high content of organic
matter which could contribute to biogas production. And I recommend that they
should use for the biogas production and reduce energy consuming.
 Spent grain could be used as a source of energy by using a biomass steam boiler
which is fueled entirely by the spent grain. Spent grain is rich in nitrates and
sulfates that allow fungi to flourish. So by composting the spent grain it can be
used as a fertilizer.
 In the waste water treatment during the anaerobic treatment the CO2 emitted
should be reused for PH adjustment rather using HCl for PH adjustment of basic
effluent.
For the college

 The college does not give direction how can we going through the attachment
and Gide lines. So the department should give clear guide line and evaluation
paper with well-organized orientation.
 The internship program is very compulsory to grasp as much as you see new
thing and practical work in the hosting company. So I recommend that the
budget and the time for the internship program should ectended.

December
Reference
[1] Marcel Karab´ın, Tereza Hudcova, Luk´ a´ˇs Jel´ınek, and Pavel Dostalek
ComprehensiveReviewsinFoodScienceandFoodSafety Vol.15,2016
[2] M. J. Lewis and T. W. Young, Brewing, 2nd ed., New York: Springer. Kluwer.
Academic/Plenum Publisher, 2002.
[3] H. M. Esslinger y L. Narziss, «Beer,» de ULLMANN’S Encyclopedia of
Industrial Chemistry,
vol. 4, Wiley-VCH Verlag GmbH & Co. KGaA, 2003, pp. 657-700.
[4] Dukes of Ale BJCP Study Course March 8, 2009Todd Coffey
[5] M. J. Lewis y C. W. Bamforth, «Yeast,» de Essays in Brewing Science, vol. 2,
Springer,2 007, pp. 114-130.
[6] T. Goldammer, «Pitching Beer Yeast,» de The Brewer's Handbook, 2nd ed., Apex
Pub,
2000.
[7]Formation and determination of aromatic compounds during beer fermentation
Student: Clara Bosch Codern Mentor: Annick Boeykens Dates: February 2013 – June
2013
[8] Water treatment operation manual
[9] Heineken laboratory manuals and operational manual

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ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY

COLLEGE OF APPLIED SCIENCE

Prepared by:-Demeke Yosef ID No:-ETS 1121/09

Company Advisor: Mr. Ephremrem Hailemaryam

December 23, 2019

By Demeke Yosef AASTU Page i

CHAPTER SIX THE OVERALL INTERNSHIP EXPERIENCE

By Demeke Yosef AASTU Page ii

Abbreviation and acronyms

By Demeke Yosef AASTU Page iii

By Demeke Yosef AASTU Page iv

By Demeke Yosef AASTU Page v

BACKGROUND OF THE COMPANY

1.2 HEINEKEN IN ETHIOPIA

Its vision is to be the first and benchmark brewery in Africa.

By Demeke Yosef AASTU Page 1

1.3 WORK FLOW

Figure 1 organizational structure

By Demeke Yosef AASTU Page 2

 Controlling and monitoring the production processes.

By Demeke Yosef AASTU Page 3

 Design financial procedure and guides with their objectives

 Its main aim is to support and facilitate the company’s operations

 Plan preventive maintenance parts and major law.

By Demeke Yosef AASTU Page 4

Quality Assurance Department

 Monitor the performance of production machines, preservation and production

 Conducting incoming in processes and final inspection of final product.

END USERS OR CUSTOMERS OF HBSC

MAIN PRODUCT OF HBSC

1.4 OBJECTIVE OF THE INTRNSHIP

By Demeke Yosef AASTU Page 5

 To understand the fundamental processes involved in brewing

By Demeke Yosef AASTU Page 6

Types of beer Ale beer Lager beer

Types of fermentation Top Bottom

Color Highly colored Relatively low

Bitterness High Less

Temperature of fermenting Prefers warmer Prefers cooler temperature

2.1 Raw material

Water is the principal ingredient quantitatively approximately 96% of beer production.

By Demeke Yosef AASTU Page 7

Total carbohydrate 70-85% Other substance 1.0-2.0%

Fat 10.5-11.5% Protein 1.5-2.0%

Inorganic malt 2.0-4.0%

Table 2 average chemical composition of barley malt

By Demeke Yosef AASTU Page 8

Figure 2 hop plant

By Demeke Yosef AASTU Page 9

Figure 3 isomerization of alpha acid at higher temperature

By Demeke Yosef AASTU Page 10

2.2 Brewery additives, cleaning chemicals and packaging material

Cleaning chemicals and disinfectant

Brewery packaging material

By Demeke Yosef AASTU Page 11

2.3.1 Brew house

Mashing (mash tun) and wort separation (mash filter)

By Demeke Yosef AASTU Page 12

3. Scarification rest: is the temperature zone in which starch is converting in to simpler

o Remember; it is important to understand that although mash enzymes have

By Demeke Yosef AASTU Page 13

By Demeke Yosef AASTU Page 14

sterilization of the wort