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S.D.M.V.M's COLLEGE OF FOOD TECHNOLOGY,
AURANGABAD.

(Affilated To Vasantrao Naik Marathwada Krishi Vidhyapeeth, Parbhani.)

INPLANT TRAINING REPORT

“UNITED BREWERIES LIMITED (UNIT ELLORA) ;,

AURANGABAD.

2017-2018
Submitted by

Dhirajsing Shivsing Gour

CFTGT 14/A/14

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 PROF. S.R.Patharkar

(In plant training in charge)

ACKNOWLEDGEMENT
Food technology is an integrated degree course which aims to provide a right platform in
food technology through theoretical, practical and industrial operations.

We have great pleasure to express our deep sense of gratitudeness and sincere sentiment of
thanks to Principle of our college, Prof. G.R Bhumre Sir , Gahervar S.A, Garude H.S,
Kamble S.B, Choudhary M.M, Ingole S.S, Waghmare U.D,College of food technology and
for this opportunity to undergo inplant training in “UNITED BREWERIES LIMITED
(ELLORA UNIT) , AURANGABAD” for this privilege we would like to thanks Mr. Ravindra
Chavan Sir(Chairman)

We would like to express our sincere gratitude and thanks to Mr.V Srinivas sir A
(Sr.Manager – quality Assurance, United Breweries, Ellora, Aurangabad) for granting us the
permission to undertake in-plant training in this esteemed organization. We also extend our
thanks to Mr. Ravi Chindhe sir (Head of Brewing Department), Mr. Swaroop Banergy sir
(Sr.HR Manager) without whose support, co-operation and guidance this training would not
have been a success. We would also like to give our heartiest thanks to Mr. M. H. Patil (Q. A.
Officer), Mr. Arun Patil (Microbiologist), Mr. Pravin Kathar (Senior Chemist), Mr. Pravin
Ingle (senior Chemist), Mr. Sujit Jadhav (Senior Chemist), for their helpful guide lines and
valuable assistance and top of all for sharing their rich experience with a fresher’s like us.

Last but not the least we would like to say a big thank to all employees & my best
friends Sneha Waghmode at United Breweries, Ltd. For their kind help and endless patience for
making us learn the minutes of brewery under their guidance.

We convey depth of our heartfelt thanks our family, friend who helps us directly or
indirectly and offered their excellent company and affection throughout my stay in this
University.

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 We also thanks of their co-operation which we forget to mention by mistake.

CANDIDATE’S DECLARATION

hereby declare that this report on “INPALNT TRAINING” is a consolidated

report of training undergone by me at “UNITED BREWERIES LIMITED
(ELLORA UNIT) , AURANGABAD “for a period of four month in 8th semester
of my B. Tech ( FOOD TECHNOLOGY) four year degree programme. I have
been well trained in Beer processing operations, Management, Processing,
Marketing, and Quality Control. Moreover, I declare that this report is neither
produced from any other document nor it is submitted to any other company and
universe.

Date: 15/04/2018

Submitted By

Dhirajsing Shivsing Gour

CFTGT 14/A/14
.

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 Affiliated to Vasantrao Naik Marathwada Krushi Vidhyapeeth, Parbhani

S.D.M.V.M.S College of Food Technology,

Aurangabad
Paithan Road Aurangabad
E-Mail; sdmvmfoodtech15@gmail.com

CERTIFICATE
This is to certify that, the In-Plant Training project in “United Breweries
Limited”(Ellora Unit) submitted by Mr. Dhirajsing Shivsing Gour CFTGT 14/A/14
student of B. Tech. (Food Technology) of this College of Food Technology, Aurangabad in
partial fulfillment of the requirement for the Degree of B. Tech. (Food Technology) under my
guidance and supervision is a result of original project work and is of sufficiently high standard
to warrant its presentation to the examination. I also certified that no part of this report has been
submitted by them for the award of Degree or Diploma of any University or Institution.

Prof.S.R.Patharkar prof.G.R Bhumre

In-plant training in charge principle

Dr.B.S.Agarkar

EXTERNAL EXAMINER

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 INDEX
SR.NO TITLE PAGE NO
1 Introduction

2 Brewery History & Profile

3
Raw Materials
4 Flow Chart of Beer Manufacturing

5 Process of Brew House

6 Fermentation

7 Filtration

8 Bottling

9 Quality Assurance Department

10 Water Treatment Plant

11 Effluent Treatment Plant

12 Refrigeration & Air Conditioning

13 Boiler

14 Conclusion

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 INTRODUCTION
What Is Beer?

The World BEER stems from the Latin word “Bibber’ means “to drink”

Beer is an uninstalled alcoholic drink.

Definition of Beer

 Beer is an alcoholic beverage produced by the fermentation of sugars derived

from malted barley & flavored with hops.
 Extracting malted barley with water, other carbohydrate rich material may also
be employed.
 Boiling this extract with hops and cooling the extract and fermenting using
yeast.

The fermenting beverage is than normally clarified and dispersed in an effervescent condition. UB group
started in 1935, with Thompsons Leishman, a Scotishman, who combined five small breweries
in South India ,the oldest being Castle Breweries, which was as old as 1857, two from United
breweries Ltd .This company was brought over by Late Vittal Mallya in 1947

United breweries group or UB group based in Bangalore, is a conglomerate of different

companies with a major focus on the brewery (beer) and alcoholic beverage industry. The
company market most of its beer under the Kingfisher brand and has also launched Kingfisher
airline a domestic airline service in India

This man machines and five raw materials combination along with location
advantage makes Kingfisher cost effectively and quantity supplier of Beer. Today each one of
the near about the more than 32000 beer outlets in India sells one brand or the other from United
Breweries.

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 BREWERY HISTORY & PROFILE

The group has a long history of more than 100 years of operations. The Group
was founded by a Scotsman, Thomas Leishman in 1857 as bulk producer of beer from South
Indian based British breweries. United Breweries Limited (UBL) was founded on March 15,
1915, in Madras by Thomas Leishman, a Scotsman, also its first Managing Director. UBL
manufactured and sold only bulk beer for troops of both the world wars. Vittal Mallya was
closely associated with the growth of the firm in early days and during 1940s it was he who
shaped Indian operations of the firm. Seeing his dynamic leadership and diligence, he was
elected to the Board of Directors of UBL in 1947 at the age of 22 and a year later became its
Chairman.

MISSION

We constitute a large global group in India. We associate with World leader in order to
adopt technologist and processes that will enable a leader in order to adopt technologist and
processes that will enable a leadership in a large spectrum of activities.

 Focus on assuming leadership in all our target markets.

 Seek to be the most preferred employer wherever it operates.
 The partner of choice for customer and other creator of innovative concepts.
 Continually increase the long term value our group for the benefits of our share holder
 Operator has a decentralized organization and allow each business to develop within its
stated value.
 Major contributor to our National Economy and take full advantage of its strong resource
base.
 Its commits its selves to the ongoing mission of achieving Scientific Excellence

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UB QUALITY OBJECTIVES

The breweries division quality objectives were based on the UB group quality, policy and are as
follows

 India’s foremost producer of quality beer.

 Satisfy and even exceed consumer satisfaction.
 Stay ahead in competition in term of product and packaging quality.
 Improve economics of production through reduction in process Non-conformities.
 Maintain highest housekeeping, healthy, safety and environmental standards.

ACHIVEMENTS

 The largest selling beer in India.

 Commands a 34% market share in country.
 Near about 7 bottle of Kingfisher are sold every second in India.
 Available in 52 countries across the globe.
 The first among Indian brand to launch its own range of designer wear.
 Won the World’s best lite Lager Award at the Stockholm Beer festival in 1994.
 Won the Gold Medal at the World Beer Championship held in Chicago in 1997.
 Won the first prize for the label work category at the Asian Grand Prix Cyrel 2000 label
award.
 Won the World’s Beer Award in 2013.

A summary of key Efficiencies of the unit:

KPI Summary (YTD 16-17)

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Sr number KPI Status
1 OPINONA 74.90%
2 Water (KL/KL) 3.01%
3 Power (KWH/KL) 85.3%
4 Fuel (MJ/HL) 121.33%
5 Bottle Breakage 0.71%
6 Extract Loss 3.72%
7 Carton Loss 1.60%
9 Beer Loss 4%

DIFFERENT PRODUCT OF COMPANY

1 Kingfisher Premium lager Beer

2 Kingfisher strong Premium Beer
3 Kingfisher strong Premier malt Beer
4 Kingfisher Special Strong
5 London Pilsner Premium Beer
6 London Pilsner Premium Strong Beer
7 Cannon 10000 Super strong beer
8 Zingaro(Super strong premium beer)
9 Kingfisher Mega Strong Premium Beer
10 Kingfisher Extra Strong
11 Kingfisher special strong beer

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The first and the foremost element that was introduced was Safety. To enter the Brewery,

Safety Shoes are mandatory. Safety briefing of basic Industrial Safety was given at the
entrance gate.

2.1. What is Safety?

Safety is a practice, which minimizes the possibility of danger and injury.

This is a safety pyramid, which instates all injury, results due to unsafe acts and unsafe
Conditions. About 10% of such instances will result in a near miss. About 10% of near
misses will result in minor injury and so on.
Thus, minimizing/getting rid of all unsafe acts and unsafe conditions is our goal.
Execution of Safety Practices:

A Safety Manager manages and monitors all the aspects pertaining to safety. He executes
all
his work through:

 Safety Cards: These cards/tags are used by everyone to report unsafe acts, unsafe
conditions and near misses.
 Work Permit: Any repair, maintenance, fabrication work done in the unit needs a work
permit issued by the Safety Manager. He must show all the PPEs and tools that will ensure
the work is done safely.

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 Statutory Requirements: The safety manager also takes care of compliance to pollution
control norms by the govt.
 PPE Audits.

RAW MATERIAL

Purchasing of raw materials

Malt – Punjab, Haryana, Rajasthan

UB groups have their own UB malt division which supplies malt to UB
units in India.
Maize flakes – Banglore, Karnataka
Sugar – Maharashtra, Karnataka, Goa.
Hops – Germany, England
Cartons – Maharashtra (local suppliers)
Bottles – New – Pondicherry and Nasik
Old - Margoa
Crowns – Bangalore
Labels – Bangalore
Foil – Bangalore

RAW MATERIALS FOR PRODUCTION OF BEER

Raw Materials:

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 Malt

 Hops

 Rice Flakes

 Broken Rice

 Sugar

 Water

Additives:

 Calcium Chloride

 Calcium Sulphate

 Lactic Acid

 Termamyl

 Ultraflow Max

 Ceremix

 Attenuezyme

 Aqungel

 Caramel

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 Handling of Raw Material:

There are designated unloading areas for Raw Materials. The

Raw Materials are brought in a truck and manually unloaded
in the specified area.

There is a dust aspirator in the unloading area which absorbs all

the fine particles of Malt and Rice.
From the Unloading Point, these material gets automatically
transferred to their rerespecti Silos by a Suction Pump and a
BlBlowe From the silos, these material are used as required.
Each beer has a different recipe.

Materials:

Malt

Malted barley is the main raw material used in the brewing of beer. Malt provides the sugar
that will be fermented into alcohol in the brewing process. Barley is a cereal traditionally grown
in mild maritime climates and for centuries it has been used in the production of beer.
Commonly two species of barley are used for Brewing:
Hordeum vulgare – 6 rowed barley
Hordeum distichon – 2 rowed barley

Six row Barley Malt

Six-row barley has higher enzyme content for converting starch into fermentable sugars, more
protein, less starch, and a thicker husk then two row barley. The higher level of diastase enzymes
makes six row barley desirable for conversion of adjunct starches (those that lack enzymes)
during mashing. On the down side, the higher protein content can result in greater amount of
break material (protein polyphenol complex) during wort boiling an cooling, as well as possibly
increased problems with haze in the finished beer. The husk of the malt is high in polyphenols
(tannins) that contribute not only to haze but also imparts an astringent taste.

Two row Barley Malt

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Two –row barely has lower enzyme content, less protein, more starch, and a thinner husk than
six row barley. The higher starch content of the two row barley is the principal contributor to
extract.

Two rowed barley varieties produce plumper more symmetrical grains than six rowed and as a
result, six rowed barleys incur greater losses when harvested as smaller grains are screened out.
Over the past thirty years there has been a global move towards growing and malting two rowed
barleys due to their greater yield per hectare.

Activate enzyme systems

– Preserve for brew house

In all the above steps it require complete control of Temperature, Humidity and Airflow.

Malting

Malt is germinated cereal grains which have been dried in a process known as
"malting". The grains are made to germinate by soaking in water, and are then halted from
germinating further by drying with hot air. Malting grains develops the enzymes required to
modify the grain's starches into sugars, including monosaccharaides such as glucose or
fructose, and disaccharides, such as sucrose or maltose. It also develops other enzymes, such
as proteases, which break down the proteins in the grain into forms which can be used by
yeast.

Malting is the process of converting barley into malt, for use in brewing or distilling,
and takes place in a maltings, sometimes called a malt house, or a malting floor. The sprouted
barley is kiln-dried by spreading it on a perforated wooden floor. Smoke, coming from
anroasting fireplace (via smoke channels) is then used to heat the wooden floor and the
sprouted grains. The temperature is usually around 55 °C (131 °F). A typical floor maltings is
a long, single-story building with a floor that slopes slightly from one end of the building to
the other. Floor maltings began to be phased out in the 1940s in favour of "pneumatic plants".
Here, large industrial fans are used to blow air through the germinating grain beds and to pass
hot air through the malt being kilned. Like floor maltings, these pneumatic plants are batch

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 processes, but of considerably greater size, typically 100 tons batches compared with 20 tons
batches for a floor malting’s.

The malting process starts with drying the grains to a moisture content below 14%, and
then storing for around six weeks to overcome seed dormancy. When ready, the grain in
immersed or "steeped" in water two or three times over two or three days to allow the grain to
absorb moisture and to start to sprout. When the grain has a moisture content of around 46%,
it is transferred to the malting or germination floor, where it is constantly turned over for
around five days while it is air dried. The grain at this point is called "green malt". The green
malt is then kiln dried to the desired colour and specification. Malts range in colour from very
pale through crystal and amber to chocolate or black malts.

Adjuncts

Barely is the main cereal used for the production of brewer’s malt. However, many unmalted
cereals are used as brewing adjuncts. Adjuncts are regarded, by the uniformed, as a cheap
substitute for malt. The brewing adjuncts contribute mainly carbohydrates to the wort; their
value to the brewer is also related to the flavour and other quality properties which they
contribute to the finished beer. The benefits claimed for solid adjuncts usage are:
1. Reduced starch extracts cost.
2. Improved beer stability and shelf-life especially when maize and rice adjuncts are
used, improved retention properties, especially when barleys or wheat adjuncts are used.
3. To change the character of the beer by altering its colour and flavour.
4. To improve the quality of the beer for example, its fermentability or its haze
potential.
5. To reduce production costs.

Water

Quantitatively water is the predominant brewing raw material with most beers composed of 90-
95% water. Therefore, the condition of this water is of paramount importance to the brewer, as
this will have consequences for the quality of the beer. The importance of water used in the
brewing industry is traditionally so significant (in terms of availability and suitability) that the
location and survival of a brewery has been determined by its water supply. It is easy to ignore
the fact that water has its own unique taste and that this taste differs from geographical area

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where it is present. Let us consider the production of the same beer in different worldwide
locations. If the production conditions are the same, in each brewery, then any differences in
taste may be attributed to the different water source – even if the beers are intended to be the
same. In addition of being a good solvent, water also provides the macro and micro elements that
favour fermentation activities carried out by yeast to a significant extent.

Hops

Hops are the female flowers of Humulus lupulus. Hops, other herbs and spices were probably
first added to finished beer to produce special flavours and cover up “off-flavours” imparted by
microbial contaminants during the earlier days of brewing. Hops are still added to beer during
production. Hop addition is historically recognised to confer bitterness and distinctive aroma or
flavour to the beer, but today hops are recognised as also being able to improve beer stability (in
terms of clarity), head stability, anti-microbial activity and light stability.

Hop varieties are divided into 2 distinct categories:

Bittering hops
Aroma hops

In terms of the bitterness of the beer, the hops that are added are key, as its compounds
originating from them that account for the bitter flavour. Hops contain organic compounds called
alpha and beta acids. Most of the bitterness comes from alpha acids, of which there are many,
but five main compounds: humulone, cohumulone, adhumulone, posthumulone and
prehumulone. During the brewing process, they are degraded to form iso-alpha acids; these
compounds are more soluble, and contribute much of the bitterness associated with beer.

Alpha and beta acids have a number of other properties that can be both beneficial and
detrimental to beer brewers. Firstly, both classes of compound have antiseptic properties,
preventing unwanted growth of bacteria and prolonging shelf life, and also enhancing the ability
of the yeast to grow during the fermentation stage. Alpha acids, however, have an unwanted
effect; the iso-alpha acids produced by their degradation can react with light and riboflavin from
the malt to produce unpleasant tasting compounds. Beer in which this occurs is known as
‘lightstruck’, and in order to prevent this from occurring, beer is always stored in opaque
containers or vessels made of dark glass.

Whilst alpha and beta acids provide the bitterness of the beer, essential oils from the hops are
responsible for the bulk of the aroma and flavour. Some of these oils are very volatile,
evaporating easily; for this reason, they are usually obtained by adding hops later in the brewing
stage, or by utilising ‘dry hopping’, a technique which involves soaking hops in the finished beer
for several days or weeks. Some hops are actually specifically grown as ‘finishing hops’ for the
purpose of adding later in the brewing process to produce these essential oils.

Bittering hops (high in Alfa-acids) predominantly provide bitterness although they do confer
aroma. Aroma hops (containing high proportions of essential oils) provide the hoppy aroma, and

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to varying extents bitterness. However, each will impart varying degrees of both bitterness and
aroma.

YEAST:

Yeast is the microorganism that is responsible for fermentation in beer. Yeast metabolizes
the sugars extracted from grains, which produces alcohol and carbon dioxide, and thereby
turns wort into 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
cerevisiae) and lager yeast (Saccharomyces carlsbergenesis); their use distinguishes ale and
lager. Before the role of yeast in fermentation was understood, fermentation involved wild or
airborne yeasts.

 Yeast is unicellular fungi

 Yeast used in brewing have basic similarities in their properties and therefore can be
classified as one or other of the species of genus Saccharomyces.
 Most top fermentation yeast belong to Saccharomyces cerevisiae and strain R131 is used.
 Most bottom fermentation yeast belongs to Saccharomyces carlsbergenesis.
 Presence of wild Yeast or other non-culture yeast causes haze and off flavor, therefore
every measure available must be taken to eliminate such contamination.

Types of Brewing Yeast

• Two types of brewing yeasts, originally classified on flocculation behavior…

• Top-fermenting
– Ale yeast
• Bottom-fermenting
– Lager yeast

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Enzymes:

Enzymes are usually added for following reasons

 For better conversion of complex carbohydrate to simpler once to avail ready source of
reducible sugars for assimilation by yeast.
 Also some enzymes facilitates breakdown of complex proteo glycol to simpler amino
acids and sugars which can be easily assimilated by yeast.
 Some enzymes help in better protein coagulation facilitating haze reduction in beer.

Additives:

Caramel: Imparts colour to the beer and it is usually added during wort boiling.
Firm aid: Enhances fermentation rate of yeast
Gypsum & Calcium Chloride: It provides macro elements for nutrition of yeast.

Lactic acid & Ortho phosphoric acid: For pH adjustment of wort

Potassium Meta bi sulphate: Used as Anti Oxidant for reduction of D.O.
Shine aid, Icing Clair & Flock aid: Facilitates the suspended particles of beer and promote
filtration.
Zinc Sulphate: Provide Zinc cofactor for metalo enzymes like Zymase and Invertase.
Usually ZnSo4 is added to achieve 0.3 ppm of Zinc in cooler wort.

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 FLOW CHART FOR BEER MANUFACTURING

Malt storage in silos

Cleaning

Magnetic separator, Screener & De-stoner

Milling of malt @6 roller milling or hammer mill

Sieving
Ambient temp
Conveying & storage of milled malt in grist case

Broken rice cooking & cooked rice transfer to mash kettle

Adding exogenous enzyme
Mashing- mixing of grist water in mash kettle

Lauter tun/mash filter- separation of extract from mash Spent grain

Sugar & Hops addition. Wort kettle

Whirlpool-transfer and rest

Aerations & yeast pitching Wort cooler-wort cooling

Co2 recovery
Unitank-fermentation maturation and storage
Yeast harvest - yeast
Filtration of beer storage vessel/ spent
yeast
Beer bright beer tank- filtered beer storage

Bottling

Pasteurization

Dispatching

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 PROCESS OF BREW HOUSE

Actual Processing at Brew House

MALTING:
There are three stages in the process of converting barley into malt:-

Steeping: Barley is soaked in water to simulate the conditions that start germination or growth.
This is done in a steep tank and usually the tank is aerated to encourage fast moisture uptake by
the barley.

Germination: On completion of steeping, the barley seed is allowed to grow at 16-22oC.

During germination there will break down break down the protein matrix releases the starch
granules making them accessible for conversion into sugar.
The changes taking place during germination are called ‘modification’. During germination the
seed grows rootlets and a shoot.

Kilning: During this stage of the malting process, water is removed from the green malt. The
malt then becomes stable and can be stored without deterioration. The malt is also slightly
roasted to give it colour and flavour. The combination of high grain moisture and high
temperature would normally destroy the enzymes developed during germination. Some of the
enzymes, The malt kilning process is manipulated so that the malt is dried at a relatively low
temperature using high flows of air. Then when the malt is dry with a moisture content of around
10%, the kilning temperature is increased so that the malt develops colour and flavour. At the
completion of kilning, the malt’s moisture content will be 4-5%.

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 MILLING:
Preparation for milling:

From the silos’ the malt is sent to ASPERATOR, here all the dust particles present in
malt is removed. Then the malt is sent to CLASSIFIER its function is to remove the foreign
materials like threads and plastic pieces. Then the malt passes through the MAGNETIC
SEPERATOR, to remove metals if any. From there with the help BUCKET ELEVATORS
the malt is sent to DESTONER to remove stone particles.

Principles of Milling:
The objective of milling is to break up malt to such an extent that the greatest yield of
extract is produced in the shortest time in the mash filter. With most wort separation systems
it is desirable to keep malt husk as intact as possible, to help for maintain an open filter bed
that favours wort separation. Only comparatively coarse grist’s can be used in mash tuns. If
the grist is too fine (has too high a proportion of small particles) the wort will not separate
from the spent grains. The grist should be uniform in appearance, be free from taints and
insects or other contaminants and should not contain any whole grains or large grain pieces
that indicate that part of the grist has not been effectively milled.
Milling systems may use roller milling, impact milling with disc- or hammer-mills,
and wet milling.

Hammer Mill
A hammer mill may be used if the mash is to be separated in a mash filter.
Here the filter bed is very thin and husk protection is not necessary. A hammer mill
produces a very fine grind.
Hammer mills differ in detail, but the principles of operation are the same. Malt,
sometimes mixed with adjuncts, is fed at a pre-determined rate through a rotary valve or a feed
roll, into the milling chamber, which is strongly ventilated.

The chamber may be mounted vertically or horizontall. The milling chamber contains a
spinning rotor (e.g. turning at 1500rpm) on which are mounted freely swinging pieces of metal,
the beaters or `hammers', which travel at about 100 m/s. The inertia of the rotors is such that
they may take 20±30min.

23
 Fig: Hammer Mill
The impacts of the hammers on the malt smash it up and this process continues until the
fragments escape through the semicircular screen that makes up part of the wall of the chamber.
Sometimes the inner wall of the chamber also carries short projections against which the moving
malt can impact. The screens may have mesh widths of 0.5, 1.0mm or even 2±4mm. The
powdered grist is carried out of the mill in the airflow, which transports it to the grist case, which
is equipped with explosion vents.

MASHING:
From the grist case the required quantity is sent to the MASH KETTLE for mashing. The
purpose of the mashing was to make the unfermentable sugars to fermentable ones. There is an
agitator inside the mash kettle. It is designed such a way that minimum disruption of the husk will
occur.

Mashing is the process where the crushed malt or grist is mixed with water under specified
conditions so that enzymatic action can take place to convert the starch into fermentable sugars
and in certain cases break down of proteins into more soluble forms also occur.

Beer production starts in the brew house where the malt is processed to release fermentable
sugars.

The production of fermentable sugars from starch is a complex biochemical reaction starting
with ‘gelatinisation’ of the starch by heat. This is where the spiral configuration of the starch
molecule is unwound so the enzymes can attack.
The range of sugars produced during conversion determines the fermentability of the
wort. If the enzyme attack is complete, the wort will be very fermentable. If the enzyme attack is
incomplete, the wort will be only partially fermentable.

24
 Enzymes are sensitive to the conditions that they work in, they are affected by how much
water is present, temperature and pH or mash acidity. They take time to work, so the length of
time that is allowed for mash conversion will affect the degree of conversion.
There are optimum conditions for mashing and these are illustrated in the table below:-

The process of degradation of starch into sugars is called Saccharification. To know the
degree of Saccharification IODIEN TEST is done.

Iodine Test:

When the mash temp reaches 70 ± 2°C collect the sample from the mash tun to find
whether Saccharification is completed or not. The temperature maintenance was crucial as it
activates the starch degrading enzymes in the malt.

To the sample add iodine solution. If the colour of the solution changes to blue, it
indicates incomplete Saccharification. On the other hand, if the colour of that iodine solution is
not changed, it indicates starch degradation is complete.

Careful control of pH during mashing is essential. Thus, peak enzymatic activity occurs
at the optimum pH for individual enzymes, and the optimum pH is often different for different

enzymes. Thus the mashing pH can affect the relative activities of the various enzymes. There pH
also controls, in part, the amount s of extractives obtained from the malt adjuncts, as well as the
extraction of tannins and bitter resins from the barely husks.

During mashing the liquor to grist ratio should be 2.7-3.3 : 1.

A temperature controlled infusion mash or single decoction mash with an adjunct, should be followed as
specified below.

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      The temperature profile to be followed in adjunct kettle:

 Filling of adjunct kettle: 550 C

 Rest at: 550 C for 5 mints
 Raise from 550 C-85 in 20mins
 Rest for 30mins.
 Raise to:98 0 C in 7 mints
 Rest for 20min Transfer to MASH KETTLE

The temperature profile to be followed for malt is as given below:

 Filling of mash kettle: 450 C

 Rest at: 450 C for 10 mints
 Raise to: 510 C in 6-7 mints
 Rest at: 51 0 C for 25 mints 
 Now the content from ADJCENT KETTLE is mixed with mash kettle content time
taken for this mixing is 7mins.
 Rest for 30mins.
 Rise to: 640C.
 Rest for 30mins
 Rise from 64-720C.
 Rest for 30mins.
 Raise from72-760C in 5-6mins
 Iodine test: +VE
 Transfer to MASH FILTER.

CHEMICALS USED IN MASH KETTLE:

 Ceramix : To deactivate the enzyme activity.

 Ultra flow : To smoothen the movement of produce.

 Thermamyl : For gleatinizationtion.

 Gypsum : To maintain the PH.

 Calcium chloride : To maintain the calcium level.

 Lactic acid : To maintain the PH.

Adjunct Cooking:

26
 The adjunct i.e. broken rice is cooked in adjunct kettle.

CHEMICALS USED IN ADJUNCT KETTLE:

 Thermamyl : For gleatination.

 Gypsum : To maintain the PH.

 Calcium chloride : To maintain the calcium level.

Broken rice and water are measured and mixed in the adjunct kettle at 650 C. followed by
premashing of hot water and grist or rice. Addition of Termamyl is done. Lactic acid is added to
maintain pH. The temperature profile to be followed is given below:

Process Temperature (0 C) Time

Premashing 65 10
Reset at 65 10
Raise to 85 20
Reset at 85 25
Raise to 98 10
Reset at 98 20
Transfer to Mash kettle 10

Wort Separation:

When conversion is complete, the mash will consist of a sugar solution called wort and
the husks of the malted barley. The purpose of wort separation is to remove these husks and
any other particles which are not wanted in the wort. The husks and other particles contain
tannin which is bitter and will make the beer unstable after packaging. They also contain
fatty substances like lipids which will reduce head stability and will also make the beer go
stale.

The objectives of effective wort separation are the removal of unwanted material
while at the same time extracting all the available wort.

There are many systems to separate the wort from the mash, the most common
being:-
• The mash tun.
• The lauter tun.
• The mash filter.

Modern Thin-Bed Mash filter

The filter is constructed of alternate frames to hold the mash and plates to
channel wort run-off and sparging, all separated by filter cloths which hang over the
plates.

27
 The modern thin-bed mash filter (e.g. Meura 2001) has several important
refinements as can be seen in the diagram below:-

Plate

Filter cloth

Membrane

Frame

The Mash frames are fitted with an expandable membrane which is inflated in order to
squeeze the mash beds gently and improve yield (extract). This also gives a much drier

spent grain cake with a lower effluent loading.

• The filter is filled from the bottom channel which reduces mash aeration and fills
the chambers evenly.
• The modern filters have polypropylene plates as opposed to the cast iron or stainless
steel of the classical filter making them lighter and easier to handle.

The operating principles of the modern mash filter are explained below:-

1. The filter is filled from the underside:-

2. Wort is filtered through the grain bed supported by the cloths:-
3. The grain bed is compressed to extract the maximum amount of strong wort
(wort is still being filtered at this stage):-
4. Sparge is run in through the mash infilling system (wort is still being filtered at this
stage):-
5. The grain bed is compressed again to extract all the weak wort.
6. The spent grain is dropped from the filter at the end of the cycle when the filter is
opened.

The mash filter is gives good quality wort, excellent extract recovery and a fast turn
round time.

Mash filter (total time 10 minutes) (comparison between batches)

Std time Actual Temperat Pressure Volume Gravity Haze
time ure
Filling 6 6 6 76.6
Filtration 28 20 29 76.6 122 138 152 152 26 26. 7

28
 3
Pre 7 8 7 73 16 14 23 20 5
compressi
on
First 16 15 18 76 443 590 87 82 20 12. 4.9
spargung 7

WORT BOILING:
When the wort has been separated from the malt husk, it is boiled. There are
several important reasons for doing this:-

• To sterilise the wort. Malted barley is contaminated with moulds, and bacteria mainly
on its surface. These contaminants are extracted into the wort and need to be destroyed.

• To stabilise the wort. The enzymes that converted the starch into sugar and the protein
into amino acid will continue to work. Boiling stops any enzymic action and fixes the
mixture of sugars that has been created.

• To evaporate away the unpleasant aromas that are associated with the wort. DMS,
the sulphury character found in lagers is generated on the malt kiln and during boiling,
it is also evaporated off in the kettle. Aldehydes, the substances t hat give beer an

29
 unpleasant straw/grassy aroma are evaporated off.

• To dissolve the Bittering resins from the hops and to stabilise them..

• To denature and coagulate some of the protein derived from the malt.
Protein has the potential to make packaged beer go cloudy as it ages. Its removal it at
this stage will protect the beer’s stability.

• To develop wort colour and flavour through the action of heat on sugars and amino
acids (the chemical reaction between sugars and amino acids is known as the Maillard
Reaction).

• Finally, and most importantly, to increase the strength or concentration of the wort.
Wort concentration is a factor in ensuring that the chemical changes described
above actually occur. It is a l s o i m p o r t a n t i n t h e production of strong beers whose
original gravity is higher than that of the wort coming from the wort separation system.

Kettle additions:
The boiling stage is the correct time to add certain other raw materials and process
aids to the brew:-

• Hops or hop extracts are added because the bitter resins (alpha acids) dissolve better in hot
wort. These alpha acids need to be modified by ‘isomerisation’ reactions which are heat
induced to stabilise the bitterness that is typical of beer flavour.

• Adjuncts like sugar are added here because they need to be dissolved and well
mixed. They also need to be sterilised by the boiling wort.

Wort Clarification:

At the end of the boil, the wort will be bright but there will be large
particles floating in it. These particles or flocs contain:-

• Coagulated protein or ‘break’, which if allowed to remain, would cause haze

problems in the finished beer.

• Tannin material from the malt husk and from the hops. Tannin is very
astringent

and would pass this character on to the beer. It will also combine with protein to
cause haze problems.

30
 • Lipids or fatty material that will destroy the beer’s head stability and will also
make the beer taste stale as it gets older.

• Spent hops or debris from hop pellets.

It is necessary to remove this ‘trub’ to protect the beer’s quality. There are four main
ways of doing this depending on the type of hops used and the requirement
for absolute wort clarity:-

• Filtration through the spent hops (Hop Back)

• Use of a Hop Separator
• Sedimentation in a Whirlpool.
• Centrifugation where the removal of any particles is essential.

WHIRLPOOLING:

The wort from the kettle is transferred to the whirlpool at a tangent, and
the whole contents of the tank spin. The solids (proteins and hop debris)
aggregate in the centre and continue to settle down. This increases their mass as
they reach to the bottom of the tank.

The solids are spun to the centre and settle into a “trub cone” whilst the
clarified wort can be drawn off from a number of wort outlets for cooling

Wort Cooling:
The wort coming from the kettle will be at 100°C. After clarification and cooling
of the wort yeast i s a dded. The optimum temperature for the start of fermentation,
depending on the yeast strain, will be between 6°C and 20°C. This is why the wort has to
be cooled down before yeast is pitched in. In the present study wort is cooled to 10 0C before
yeast pitching is done.

Originally wort was cooled in shallow open vessels or vertical open coolers, but
now the plate heat exchanger is used exclusively for wort cooling. This is because:-
• Plate heat exchangers are very efficient and can cool the wort down in a short time.
There is a large plate surface area for wort/coolant and the liquids’ flow across the
surface is very fast.
• Nearly all the heat from the wort can be recovered to generate a hot water
supply for brewing and other production uses.
• They are enclosed and are easy to clean in line. Therefore they keep the wort

31
 sterile.

The hot wort is cooled in a counter current direction against the brewing liquor.
• In general 400 hl of hot wort at around 98 C will be cooled to say 12 C by
around 410 hl of incoming brewing water at 10 C which in turn will be heated to
around 85 C.
• This makes wort cooling a very efficient process recovering most of the sensible
heat from wort boiling which can be used for brewing. The hot water generated
being used for brewing purposes.

100C

The wort that leaves the cooling system is now ready for the next stage of the brewing
process, that is, fermentation.

32
Wort Oxygenation / Aeration:

Yeast needs oxygen to encourage growth and the wort cooling stage is the
ideal time for aeration.
It is usual to inject air or sometimes oxygen into the wort stream and as the
amount of dissolved oxygen in the wort affects yeast growth so much, some form of
control is required to guarantee consistency. The control may be by an air flow meter
backed up by dissolved oxygen (DO) measurement.

Aeration can take place before or after cooling. The advantages and disadvantages
of either choice are listed in the table below:-

System Advantages Disadvantages

Hot wort aeration Air is sterilised by the hot Wort colour increase.
Wort. Flavour change.
Air is dissolved effectively as
Cold wort aeration it
Nopasses
effectthrough
on wortthe cooler.
quality. Need to provide sterile air.
Need to assist air solubility by
injecting small bubbles or
ensuring vigorous mixing.

In present case air is infused in to cold wort during collection in to Fermentor.

It should be noted that different yeasts need different levels of oxygen for
adequate yeast growth. Since yeast growth has a direct effect on the level of higher
alcohols and esters produced during fermentation, then it follows that different beers
will need different levels of dissolved oxygen to provide the correct amount of esters
and alcohols.

In practice, levels of dissolved oxygen are finely tuned by each brewery for each
quality to give fermentations that ferment on profile, give an acceptable flavour
match and minimise excessive yeast growth and losses.
In mash filter, filtration is done by using filter plates which have membrane at one side and cloth
at other side. There are 80 plates for filtration and which hydraulic unit is having pressure 80
bars. Sweet wort is added having gravity 25-26. Water sparging is done three times.

33
Compression is done to remove extract. Spent grains are removed and this waste of industry is
used for cattle feed.

Yeast Pitching:

Pitching is the term used for adding yeast to the wort to start the fermentation. The choice
of pitching yeast has a major influence on the performance of the fermentation and its
outcome.
Brewing utilizes strains of Saccharomyces carlsbergensis bottom yeast, and
Saccharomyces cereviceae Top yeast. Yeast strains are specially selected for their fermentation
ability to flocculate at the proper time beat the end of the fermentation. As a result, a separate
industry may select and propagate these strains as well as production of inoculums, although
these functions also can be carried out by the brewery itself.

Pitching yeast must have the following characteristics:-

• The right strain for the beer to be fermented.

• Free from contamination by bacteria and other yeasts.
• Healthy and viable.
• Cropped from a healthy and consistent fermentation itself. Yeasts selected from a
slow or sticking fermentation are likely to repeat the problem.

Selection will be based on laboratory analysis like Solids, Viability and

Microbiological status (free of infection) and fermentation records like
Gravity drop, Storage temperature and duration of Yeast.

The yeast is pitched in the wort during transfer of wort from plate heat exchanger to fermentor,
which is carried out in pitching room.

Chemical used in pitching:

1. Orthophosphoric acid- for acid wash of yeast at a pH between 2.1 to 2.3. This
will inhibit bacterial contamination during fermentation.
2. Zinc Sulphate- For supply of micro element Zinc for yeast enzymatic activities.
3. Biofoam- To generate foam and increase the surface area for better fermentation.

Yeast Pitching Rate is calculated by the following formulae:

34
Brew length in HL X 0.0259 X Required pitching cell count in millions X 104 = HL yeast of
Yeast Solids % X Viability % for pitching

For eg: For pitching yeast which has 95% viability and 60% Solids into a 400 HL fermentor, the
above formula can be applied as follows:
400 X 0.0259 X 18 X 104 = 3.27 HL of Yeast
60 X 95

Brewing is different from much other industrial fermentation in that the cell for pitching are
often those recovered from a previous fermentation. In other words, fresh inoculums is not
necessarily prepared for each fermentation run and, in fact, fresh-yeast inoculums usually is
required only when contamination present a real problem or when the viability of the yeast has
began to decline. Before being employed as inoculums, the yeast cells from a previous
fermentation are washed (with phosphoric acid, tartaric acid, or ammonium per sulphate) by
settling, as procedure that reduces the pH value from 2.1 to 2.3 and removes considerable
bacterial contamination, if present. Thus each pound of yeast added to the fermentation at
inoculation yields approximately 3-4 pounds liquid yeast at harvest, and the excess yeast not
required for further use as inoculums becomes a by – product of the fermentation.

FERMENTATION AND LAGERING:

The aerated wort is cooled to approximately 10 to 110c and then placed in a pre sanitised
closed fermentation tank containing cooling coils. The cold sterile wort is collected through PHE
at 10-120 C, during which aeration is done for 30-40min. Then yeast is pitched via
pipelines.Although an open tank can be used, the closed tank is preferred to prevent
contamination; as well the evolved carbon dioxide can be collected for later carbonation of the
product.

Approximately three – quarters to one pound of yeast are added for each barrel of wort, and
within 24 hrs after pitching, foam begins to appear on the surface of the medium, first along the
wall of the tank and then gradually across the surface. The carbon dioxide evolution then
increases so that the yeast cells become suspended in the medium. Initially the temperature of
the fermentor post pitching is maintained at 12oC to facilitate yeast growth. Thus it should be
noted that the

brewing fermentation is again unusual as regards the of these very low incubation temperature.
By approximately 40-60 hours after pitching, the surface foam layer becomes very thick and can
measure up to almost 12 inches in depth. It is during this time that the most rapid yeast – cell
multiplications occur, and considerable heat, which is associated with this high metabolic
activity, is evolved. This heat evolution causes a temperature rise to approximately 12-15 oc, the

35
peak temperature for this fermentation. This will enhance the activity of enzymes involved in
fermentation that convert all the reducible sugars to alcohol and Co2.The Original gravity of the
wort gradually drops from 15.5 to 2.2 due to conversion to sugars to alcohol by yeast. Diacetyl is
a significant intermediate produced by yeast during fermentation, which is further metabolised to
aldehydes and Co2 at temperature about 15oC.

By approximately the fifth day of fermentation, there is no longer enough carbon dioxide
evolution to support the heavy foam and, therefore, the foam begins to collapse. Also, the
decreased evolution of heat by the cells allows the medium to be cooled by the cooling coils.
From seven to nine days, the last phase of the fermentation, the yeast become starved and
flocculate, the “yeast break”. The yeast settle to the bottom, and the medium is further cooled to
below 5oC to fasten settling. At this time, the Diacetyl of the fermentor checked to confirm its
consumption by yeast. Or, Diacetyl left in significant levels in fermentor (>0.07ppm) would
often contribute Buttery flavour which is undesirable in finished beer. Some of the surface scum
may be removed to help improve flavour.

Yeast is collected in storage tanks maintained at temperature 4.5 oC, which can further be used
for next batch of fermentation.

Post separation of yeast from fermenter the temperature of the medium is further cooled to
around -1oC, This facilitates the precipitation of suspended solids, there by clarification of the
beer to promote clarification lager chemicals like Shine aid, KMS, Flocaid are added and beer is
left for 5-7days.This process is called Maturation/Aging.

FILTRATION:

From Fermenter beer is sent to Pre Buffer Tank. In Pre buffer tank the beer is stored in
order to reduce the flow pressure. From this the beer is send to FILTROX1 it is composed of
steel candles. The se candles are deposited with Hyflo Food Grade Powder (Diatomite). This
powder will help in removal of yeast, other suspended particles and dust in the beer. Now the
beer is send to FILTROX2. It is composed of several candles; they will remove the dust and
suspended particles, if any. Now the beer is send to Post Buffer Tank. From there it is send to
Corboblender. The function of Corboblender is that is addition of carbon dioxide and also to
control the foam in the beer. The Corboblender is attached with an equipment called
ANTONPAAR helps in on line monitoring of critical parameters like Co2, Gravity, Alcohol
content, which work with the principal of Henry’s law (with the help of temp and pressure
carbon dioxide can be calculated).

Then the beer is passed CONTROLLING VALVE to reduce pressure. Now it is send to BIGHT
BEER TANK (BBT). For the storage, through PLATE HEAT EXCHANGER to maintain the
temp

36
at -1 0 C. from BBT the beer passed through TRAP FILTER. Where the haze presents in the beer
is removed than the beer is send to BOTTLING and KEG FILLING.

Beer packaged in barrels or kegs is not pasteurized and, hence, has a relatively
short storage life. Beer for bottles and cans, however, often is pasteurized after capping
of the bottles or closing of the cans, although bulk pasteurizes are now employed by
many breweries. The pasteurization of beer, however, affects its flavour and, to correct
this situation, recent innovations now allow the sterilization of beer without the use of
pasteurization so that the keg flavorful is maintained along with good keeping quality.

During filtration the chemical added to beer are:

Shine aid: to remove chill haze from the beer

KMS: antioxidant agent to reduce D.O.

Biform P: for the easy separation of particle from beer.

Carbonation
Carbonation of the beer is accomplished either by injecting of cleaned carbon
dioxide recovered from the evolved fermentation gas, or by the “Krause’ process in which
actively fermenting yeast is added to provide the so-called “natural carbonation”. Addition
of carbon dioxide which is the most common practice, provides a final dissolved carbon
dioxide dissolved oxygen, which is detrimental to the stability of the beer, and helps in
the production and retention of foam and in the preservation of the beer.

Bright Beer Tank (BBT)

            Beer from the B.B.T is issued to bottling by maintaining a counter   pressure of 3.5 to 4.2
kg/cm2. The CO2 of beer issued to bottling / kegs   should be maintained between 2.8 to 3.2%
v/v.

            The parameter such as D.O, Color, Alcohol content, CO 2, Haze Bitterness, O.G, A.E,
Diacetyl & pH are analyzed from the B.B.T, Beer.

Bottling of Beer:

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

The bottling of beer follows these steps:

37
 1. Bottle washing

2. Slighter Station 1

3. EBI

4. Bottle filling

5. Bottle crowning

6. Tunnel pasteurization

7. Bottle labelling

8. Case packing

1. Bottle washer: - Empty bottles are unloaded from trucks and the bottles having perfect shape
without any crakes or damage are only used. The bottles are separated manually according to the
brand they belong to. These bottles are then pre-rinsed with normal water to remove any dust or
mud particles from bottles for prolong life of caustic. Now the bottles are sent to washer where
they are washed with hot water of 80oC and caustic. The washer is provided with jetters that
flush the bottles from inside as well as from outside. There are 3 caustic zone in washer.
a) 1st zone- in this zone the caustic level is maintained at min 2.5%.
b) 2nd zone- in this zone the caustic level is maintained at min 2.5%.
c) 3rd zone- in this zone the caustic level is maintained at min 2.0%.
The bottles washed with caustic are germ free and all kind of dirt is removed along with labels
and foils. After treating with caustic, bottles are subjected to wash with soft water to remove
caustic traces. The capacity of washer is 36000bottles/hr and 47 bottles/line can be washed in it.

2. Sighter Station 1:- Sighters are the people who ensure the proper washing of bottles. There are
4 sighter stations after washer. The sighters observe the bottle coming out of the washing and
remove the bottle having:
a. Any damage or crack.
b. Any foreign matter.

38
 c. Any dirt.
d. Presence of caustic.
The observation is done with back ground as white screen for better vision of bottle.

3. E.B.I.:- Empty Bottle Inspector

E.B.I. is an electronic device created for detection bottles left from observation of sighters. It
detects only empty bottles and removes the bottles having any dirt, caustic or foreign material
remaining in it from line an sends them back to the washer. E.B.I. is provided with a camera at
bottom which takes the photograph of each bottle and gives the number of bottles passed through
it. Defective bottles observed in camera are isolated from line and sent to bottle washer or scrap
based on the type of defect in them. The functional sensitivity of EBI determines the degree of
defective bottles rejection.

4. Filler and Crowner: - Filler is the important part of packaging. The bottles must be filled with
accurate amount and pressure of beer and carbon-di-oxide. Carbon-di-oxide is the best
preservative for beverages. The filler has double evacuation system. Jetter implies the pressure of
0.85bar on bottles to suck out all air from bottle. It this process some bottles may burst because of
being old or losing their strength. The bottles are filled with carbon-di-oxide and sucked out twice.
Now the bottle is filled with beer at the temperature of 0 0C. Again carbon-di-oxide is passed in
bottle at high pressure that helps to throw out other unwanted gases from beer filled bottle. 104
bottles are filled in each single rotation of filler. A fobbing Jetter passes a rapid vapour of hot
water and removes surface oxygen over beer in the bottle, before crowning. The bottles are now
crowned in crowner which can crown 13 bottles per rotation. Thus, it runs 8 times faster than
filler.
1) Pre-evascuation - 400ms
2) Rinsing- 300ms
3) Pre-evascuation- 800ms
4) Blowing out- 70ms

4. Sighter Station 2:- At this sighter station sighters check bottles of following types and
remove them from line. a) Empty bottle b) Low fill c) High fill d) Chipped bottle e) bottle
with dirt e) Bottle with suspended particles in beer f) Other brand embossed bottles g)
Bottles with plastic sachet or any foreign matter in beer h) uncrowned bottles i) Bottles with
label carry over j) bottles with external damage at shoulder or base k) Bottles with defective
crowns (leakage). l) Bottles filled with water or any chemical liquids

5. Pasteurizer:- Pasteurization is the process of removing microbial contamination from the

food product by giving a short span of treatment of rising temperature of the product up to
certain level at which its taste or flavour are not altered. The high temperature minimizes the
possibility of survival of any kind of microbial contaminants in it. Tunnel pasteurizer is used
for pasteurization of beer. In this, temperature of 620C is maintained by passing steam in

39
 controlled manner. A typical tunnel pasteurizer has different zones in it as shown below.
Beer bottles are passed through different zones of pasteurizer in the sequential manner. The
temperature starts from 250C in R1H, increases to 350C in R2H followed by 450C in R3H
then to Pasteurization at 620C in P1, P2, P3, and P4. Now it again decreased in R3C to 45 0C,
to 350C in R2C and to 250C in R1C. This whole process takes place in 56.9 minutes.

Table2:- Showing the sequential rise and fall in temperature in Pasteurizer

R1H R2H R3H P1 P2 P3 P4 R3C R2C R1C

25.0 35.0 45.0 62.0 62.0 61.9 61.8 45.0 35.0 25.0

BOTTLE BOTTLES
S IN OUT

6. Sighter Station 3:- Sighters perform the same work as they do in sighter station -2 to ensure
quality of the product bottles.

7. Case Packer and Palletizer: case packing is done with the help of packing machineries
which take the bottles from line by creating vacuum between bottle and holder and put into
case. The case is packed with 12 bottles in it.
Wooden or plastic pallets are arranged by palletizer such that each pallet takes up
68 cases. The pallets are then shifted to warehouse by fork lift machine for dispatch after
quality approval.

Caustic analysis
Total Caustic strength:

 Take 10 ml of sample in a 250 ml conical flask.

 Add 2-3 drops of phenolphthalein indicator. After adding pink color appears.
 Titrate against 1N HCL until it becomes colorless.
 Mark this titer value as “P1”.

40
ALUMINATES:

 To the same colorless solution.

 Add one full spoon of sodium fluoride.
 Titrate against 1N HCL till pink color disappears.
 Note this titer value “P2”.

Carbonates

 Take 10 ml of sample.
 Add one full spoon of barium chloride.
 Add 2-3 drops of phenolphthalein indicator. After adding pink color appears.
 Titrate against 1N HCL until it becomes milky white.
 Mark this titer value as “P3”.

%Caustic strength= (P1-P2/3)×0.04

% Aluminate = P2×0.01

% Carbonates = (P3-P1)×0.053

Surface Tension = 2304/No of Drops

Yeast Propagation
The development of pure yeast strains and their importance in the brewing process has been
going on for over a century and is still an active area of research.  In 1883, Emil Christian
Hansen described the first techniques for successfully isolating single yeast cells and
propagating them to a larger scale.  This was a landmark finding since up until then all yeasts
were a mixture containing various forms of brewing yeast, wild yeast, bacteria, and
molds.  Brewing with these mixtures of micro-organisms was difficult.  Beer spoiling was
common and there was wide variability in beer quality.  Hansen's techniques changed all that
and were quickly applied to improving large scale beer production; first in the Carlsberg brewery
and a few years later in American breweries.  Current propagation techniques remain similar to
those first described by Hansen. Further characterizations of yeast physiology and fermentation
technology, however, have also influenced the current methods used to propagate and maintain
yeast.  

Principles of Yeast Growth and Fermentation

Yeast is a facultative anaerobe which is just a fancy way of saying that it can survive and grow
in the presence (aerobic) or absence (anaerobic) of oxygen.   The presence of oxygen determines
the metabolic fate of the cell.  In terms of the yeast cell, its survival, growth and metabolism is

41
optimal in the presence of oxygen.  In this case, yeast will rapidly grow to high densities and will
convert sugar (glucose) to carbon dioxide and water.  Under anaerobic conditions, yeast grows
much more slowly and to lower densities and glucose is incompletely metabolized to ethanol and
carbon dioxide.  It is important to realize that optimal yeast growth is distinct from
fermentation.  Therefore, the conditions and methodologies used for propagating and
maintaining yeast need not be identical to those used for fermenting wort.  The purpose of a
yeast starter is not to produce an enjoyable fermented beverage but rather to produce a sufficient
quantity of yeast for subsequent fermentation.  Propagation conditions should be such that a
maximal amount of yeast is produced which provides optimal fermentation performance once
pitched.  What do we mean by fermentation performance?  The main criteria for fermentation
performance is based on the rate and extent of fermentation as well as the production of a beer
with a balanced sensory profile with no off-flavors/aromas or inappropriate esters.  The former
refers primarily to attenuation (technically referred to as the apparent attenuation) and is usually
indicated by the percent reduction in gravity or:
                        Apparent Attenuation =         (O.G. - F.G)
                                                                              (O.G)
  Apparent attenuation between 70-85% is normal for most yeast.  Also fermentation should
occur rapidly and be completed within 3-5 days. 
 
Factors influencing yeast growth

Several factors influence both yeast growth (and fermentation) and therefore should be
considered when propagating and maintaining, and yeast.  The most important are oxygen, pH,
temperature, and wort composition. 

Oxygen.  As mentioned above oxygen or aeration is essential for good yeast growth and is the
driving force behind many aspects of yeast metabolism including fermentation.  Oxygen is
quickly absorbed by yeast and is used to synthesize unsaturated fatty acids and sterols which
form the cell membrane.  These molecules are important for both growth and fermentation and
serve as a means of storing oxygen within the cell.  They are also necessary for increasing cell
mass (growth), improving the overall uptake of nutrients, and determining alcohol
tolerance.  Oxygen also stimulates synthesis of molecules necessary for yeast to metabolize and
take up maltose, the primary sugar in wort. 
Well since oxygen directly correlates with rapid growth and increase in yeast mass (cell
number), aeration during yeast propagation should increase the overall number of yeast cells.  In
other words, your starters need to be well-aerated.

In terms of fermentation, aeration is also important but only in the early stages (first 6-24
hours).  Aeration in later stages can oxidize beer constituents and lead to the development of off-
flavors.  Since aeration sets the stage for maltose fermentation and alcohol tolerance.
  The levels of oxygen necessary for optimal fermentation vary depending on the yeast
strain.  Ale strains usually need between 8-12 part per million (ppm) while lager strains
require slightly higher amounts (10-15 ppm).

Temperature.  Another important factor which influences yeast growth and metabolism is

temperature. Most brewing yeasts will actually grow and ferment at temperatures up to 98 °F (37
°C).  These high temperatures are not optimal for yeast propagation or fermentation, since they
produce numerous esters and affect the overall viability and stability of the yeast. 86 °F (30 °C)
is the usual temperature for the growth and propagation of laboratory yeast but this is still too
high for brewing yeast.  Room temperature or 77°F (25 °C) is the recommended

42
 temperature for propagating brewing yeasts.  At this temperature rapid growth and
fermentation occurs without any adverse affects on subsequent fermentation performance.
 Lagers, however, should be pitched at lower temperatures (60 °F or lower).  In this case it

may be necessary to acclimate the starters to a lower temperature to prevent cold shocking
them.  This can be done by slowly lowering the temperature of the starter the day before.  Yeast
growth and fermentations are energy generating processes and therefore generate heat.  The
temperature within the fermenter can be as much as 8 °F higher than outside of the fermenter
during the first few days of fermentation. So beers that are fermenting in refrigerators set at 65
°F are most likely fermenting at about 72 °F.

Wort or media composition.  Wort (or media) composition also determines yeast growth and
fermentation performance and is important in maintaining and storing viable, stable yeast.  In
terms of fermentation, standard brewing wort contains most of the ingredients necessary for
fermentation.  Problems arise only if the nitrogen composition is low.  This occurs only if a
cheap or poor quality malt extract is used or if there are a large amount of adjuncts added.  
Some experiments indicate that the addition of certain yeast nutrients can increase the rate of
yeast growth but not the overall concentration or yield of yeast.  Thus the addition of yeast
nutrient to starters can help accelerate their growth. 
Zinc also supposedly improves yeast growth and fermentation and is added to the propagation
tanks in some British breweries.  0.5 ppm zinc is optimal.  

pH.  The last factor to affect yeast growth is pH (a measure of acidity).  Yeast grow well at
acidic pH.  They grow best between pH 4 to pH 6.  Normal wort is acidic with a pH near
5.2.  During growth and fermentation the pH drops to about 4.1-4.2 and in some cases even
lower.  The further acidification of the wort helps to prevent bacterial infection.  (Most bacteria
cannot tolerate acid pH). Yeast can survive at very low pH, as low as 2.0.  This is the basis of
acid washing where the bacterial load of a yeast slurry is reduced prior to repitching by lowering
the pH to 2.2.  Most bacteria will be destroyed at this pH while a good percentage of the yeast
will survive.  

YEAST PROPAGATION PROCEDURE:

Yeast is the unicellular fungi which give the best conversion rate of sugars to alcohol. Yeast has
the special character that it is facultative and can live as haploid when starved, as well as diploid
when there is a plenty of nutrition. Thus, it divides rapidly and delivers the sufficient quantity of
invertase and zymase that convert sugars into alcohol and carbon dioxide in anaerobic
conditions. Thus, even at low concentrations the yeast is efficient in carrying out fermentation.
Yeast Propagation refers to culture the yeast in wort itself from small quantity to Hectoliters to
maintain the viability of Yeast and Yeast solids in UniTanks. Culturing of yeast in wort make
yeast’s progeny to become habitual of the conditions of wort

STAGE 1 -- 500ml medium inoculation

1. Wort collection (500ml) from whirlpool into 1 lit round bottom flask.
2. Addition of 1ppm Zn to the collected wort (add 2.2mg of Zinc Sulphate to 500 ml of wort) in
flask.
3. Cotton plugging of flask and double sterilization of wort at 121°c temp, 15 lb pressure for 20
min each.
4. Transfer of yeast from slant to 500ml of wort.
5. Viability, cell count of inoculum from slant.

43
6. Culture purity testing by inoculation of sample from slant, on WLD,YMCA, MRS and Lysine
media.
7. Incubation of inoculated flask at 20-25°c for two days.

STAGE 2 -- 3 liter medium inoculation

1. Wort collection (3 lit.) from whirlpool into 5 lit round bottom flask.
2. Addition of 1ppm of Zn to the collected wort (Add 13.23 mg of zinc sulphate to 3 lit of wort).
3. Cotton plugging of flask and double sterilization of wort at 121°c temp, 15 lb pressure for 20
min each.
4. Transfer of yeast from 500ml to 3 lit wort in flask.
5. Viability, cell count of inoculum from 500ml flask.
6. Culture purity testing by inoculation of sample from 500 ml flask, on WLD,YMCA, MRS and
Lysine media.
7. Incubation of inoculated flask at 20-25°c for two days.

STAGE 3 – Carlsberg flask inoculation

1. Wort collection (18 lit) from whirlpool into 20 lit Carlsberg flask.
2. Addition of 1ppm Zn to the collected wort (Add 80.2 mg of zinc sulphate to 18 lit of wort).
3. Cotton plugging of air vents and sample cock of Carlsberg flask.
4. Double sterilization of wort at 121°c temp, 15 lb pressure for 20 min each.
5. Transfer of yeast from 3 lit to 18 lit of wort in flask.
6. Viability, cell count of inoculum from 3 lit flask.
7. Culture purity testing by inoculation of sample from 3 lit flask, on WLD,YMCA, MRS and
Lysine media.
8. Oxygen supply to the Carlsberg flask through 0.2 µ sterile air filters.
9. Incubation of Carlsberg flask at 20-25°c for two days.

STAGE 4 -- YPV II (4 HL) inoculation

1. CIP of YPV II (4 HL) and sterilization air line filter cartridges in yeast room.
2. Wort collection in YPV II (3HL) from whirlpool and steam sterilization for 15 min.
3. Cooling of wort in YPV II (3 HL) at 18°c and addition of 1. 32 gm of Zinc sulphate.
4. Transfer of yeast from Carlsberg flask to YPV II (3 HL).
5. Aeration of culture at YPV II (3 HL) at interval of every 4hrs, for 5 min each time.
6. Viability, cell count of inoculum and gravity monitoring after every 12hrs to ensure active
growth of yeast.
7. Incubation of yeast culture in YPV II till cell count reaches above 80 millions.
8. Culture purity testing by inoculation of sample from YPV II, on WLD, YMCA, MRS and
Lysine media.

STAGE 5 – YPV III (40 HL) inoculation

1. CIP of YPV II (40 HL) and sterilization air line filter cartridges in yeast room.
2. Wort collection in YPV II (30 HL) from whirlpool and steam sterilization at 100°c for 15 min.
3. Cooling of wort in YPV II (30 HL) at 15°c and addition of 13.23 gm of Zinc sulphate.
4. Transfer of yeast from YPV II (30 HL) to YPV III(30 HL).
5. Aeration of culture at YPV II (30 HL) at interval of every 4hrs, for 5 min each time.
6. Viability, cell count of inoculum and gravity monitoring after every 12hrs to ensure active
growth of yeast.
7. Incubation of yeast culture in YPV III till cell count reaches above 80 millions.
8. Culture purity testing by inoculation of sample from YPV II, on WLD,YMCA, MRS and Lysine
media.

44
 SATGE 6 – Unitank inoculation
1. CIP of 311 and ensuring micro clearance of CIP sample.
2. 100 HL Wort collection into 311 and addition of 44.1 gm of Zinc sulphate.
3. Transfer of yeast from YPV III (30 HL) to 311.
4. Aeration of culture at 311 by passing oxygen through pre-sterilized 0.2 µ filters.
5. Viability, cell count of inoculum and gravity monitoring after every 12hrs to ensure active
growth of yeast.
6. Culture purity testing by inoculation of sample from YPV II, on WLD, YMCA, MRS and
Lysine media.
7. After cell count in UT 311 reaches 60 millions/ml, Top up the UT 311 with 260 HL of wort
(with 114.4 gm of Zinc sulphate in it) to get final volume of 400 HL.

Aseptic transfer of yeast inoculum was done for scale up of culture up to fermentor stage. For
every stage of yeast propagation Cell count, Viability and Gravity were monitored.

Materials and Methods of Cell Count, Viability and Yeast Solids:

1. Cell Count:-
Cell count was done on Heamocytometer for estimation of approximate no. of cells in tank.
Procedure:
 Sample was collected in a screw-cap tube and mixed well on vortex.
 9 ml of saline solution was taken in a test tube and 1ml of sample was added in it.
 The diluted sample was mixed well for 10 to 15 sec on vortex.
 A cover slip was put on Haemocytometer and carefully the diluted sample was applied between
the cover slip and Haemocytometer through the Grove.
 The preparation was observed under microscope using 40X lens.
 Cells visible in four corner squares and one centre square (out of 25 squares) were counted
 In each square, cells present on left and bottom lines were only counted. Each budding cells with
daughter cell with at least of half of the mother cell size were counted as two.

Calculations-
 Total cell count = Total no of cells in 5 squares X 5 X dilution factor X 104.

2. Viability:-

Viability of Cells was measure to know the active stage of yeast growth in propagation stages.
Procedure-
 1 ml of the sample diluted in saline solution was taken in micro pipette and added to 1 ml of 0.01
% Methylene Blue solution and mixed well on vortex.
 Dead cells uptake the Methylene Blue and get stained with blue colour.
 Cells were observed under microscope with 40X lens.
 Observation of at least 200 or more total cells was done for accurate study of viability.
Calculations-
Viability = No. of viable cells X100
No. of Viable cells + No. of Dead cells.

45
3. Gravity Measurement: After yeast culture was transferred to Yeast propagation vessels, gravity
was monitored at interval of every 12 hours to ensure proper growth rate.
Procedure:
 Sample from propagator was collected and thoroughly agitated for mixing and degassing.
 Pycnometer was filled with sample and thermometer was inserted without any air bubbles.
 Sample weight at 200C was taken and compared with reference table for specific gravity.
Calculation:
Specific gravity (g/cc) = (Weight of pycnometer with extract – Weight of empty pycnometer)
(Weight of pycnometer with water – Weight of empty pycnometer)

QUALITY ASSURANCE DEPARTMENT

INWARD INSPECTION

Once the raw materials are produced they are sent in the quality control department for
assessment. The quality chemist will check whether the raw material is up to specification and if
there any rejection notes are sent to supplier along with defect details. After the inspection the
raw materials are sending to production.

BARLEY

Appearance:

Malt Should be golden brown in colour without any spot and free from foreign matter like straw,
stones and broken grains.

Adjuncts like broken rice /rice flakes should be clear from dust and whitish in colour.

Kettle test

 Place about 1 inch of malt in a 250 ml steel beaker or glass beaker.

 Half fill the beaker with boiling water, stir and allow standing for 30 seconds and covering the
beaker or glass with a plate.
 Smell the vapor for any tarry, medicinal (phenolic) aromas, chemical contaminants or any other
obvious taints.
 Malt should have the normal malty aroma. Reject any supplies that show obvious taints.

46
Moisture content

Apparatus:

1. Buhler universal laboratory disc mill set to a gap of 0.2 mm to give fine grind/ grinder.

2. Moisture Analyzer

High moisture will lead to microbial growth and also increases its weight in spite of less content of
original material.

Procedure:
 5grams of grinded malt or broken rice sample was taken in moisture analyzer
 Temperature of moisture analyzer was set at 105 oC
 The instrument was left undisturbed, until the moisture content was displayed on the screen.

Specification: 3.5-5.0% for malt

and for rice and rice flakes it should be < 15%

1000 corn weight

Apparatus:

Analytical balance

Procedure:

 Weigh 40 g of sample in duplicates

 Remove half corns and foreign matters and subtract the weight
 Count the corns in each lot

Calculation:

47
1000 corn weight on dry weight basis = W x 1000(100-M)

N x 100

Where,

W = Weight of lot of malt taken in gram.

M = Moisture percentage (w/w basis).

N = Number of corns in lot taken.

Specification: Minimum 38gMaximum 40g

Sieve analysis:

Apparatus:

1. Magnetic sieve Shaking machine (300-320 rpm),

2. Three sieves, width of the slots should be 2.8, 2.5 and 2.2 mm
3. Analytical balance
Procedure:

 Take 100 g of malt

 Put it on the top sieve and set the apparatus in motion
 Continue sieving for 5 minutes
 Open the machine, collect and inspect the four fractions for foreign matter and broken grains and
weigh separately
Calculation:

% of malt in each fraction = Weight of malt in the fraction x 100

Weight of sample taken

Specification:

2.8 and 2.5mm sieve – Minimum is 88%

2.2mm sieve - Maximum is 10%

Less than 2.2 - Maximum is 12%.

48
Broken Rice

Principle

A test portion of the broken rice is added to a solution containing two pH specific indicators. The colour
change of the solution is a measure of the formation of fatty acids by oxidation during storage, and is
therefore a measure of the freshness of the rice.

Reagents

1. Methyl Red (4.2 – 6.2 Red – Orange – Yellow)

2. Bromothymol Blue (6.0 – 7.6 Yellow – Green – Blue)

3. Mixture of (1) and (2) 4.2 – 6.0 Orange – Yellow - Green

Preparation of the indicators:

1. Solution A: Dissolve 0.1 g (± 0.005 g) Methyl Red and 0.3 g (± 0.005 g) Bromothymol Blue in about
150 ml of analytical pure ethanol in a 200 ml glass-stoppered volumetric flask, and make up to the mark
with distilled water.

2. Solution B: Dilute 1.0 ml of solution A to 50 ml of distilled water.

Apparatus & requirements:

i. Analytical balance, accuracy ± 0.001 g

ii. Volumetric flask, with a ground glass stopper, 200 ml

iii. Glass beakers, 100 ml tall form

iv. Pipettes, 1ml and 10 ml

Preparation of the samples

Ensure that the test samples are fully representative of the lots from which they are drawn. Therefore, mix
carefully before sampling.

Procedure

1. The analysis must be done right after sampling from container.

2. Put 5 g (± 0.01 g) of rice in a 100 ml beaker, and add 10 ml of solution B (4.4).
3. Shake for a while and observe the colour change of solution after 10 minutes.
4. If the rice is fresh , the colour of the solution is green.
5. If the rice is old and oxidized, the colour of the solution is turning from yellow to orange.

49
Stage of oxidation:

Green → → Yellow →→ Orange

Fresh → → Old→ → → Very old

Expression of results

Note the colour of the solution and report the freshness (i.e. fresh, old or very old).

Notes

Unbroken rice samples may also be tested by this method. However, in the experience the colour change
(from green to yellow) is not observed within the first year. In view of the long storage period required,
this test is not normally recommended for unbroken rice.

ANALYSIS FOR SUGAR

Appearance:

Observe against white background and report as white, cream, amber, brown, buff, gray etc. Observe for
intensity and uniformity.

Specification:

Colorless to white crystalline powder

Color of 10% sugar solution

Procedure:

 50 gm representative sample of Sugar was mixed well.

 The sample was dissolved in warm water and quantity was made to 500ml in volumetric flask.
 The solution was filtered until it was free from turbidity.
 The solution was then centrifuged at 5000 rpm for 5 minutes
 Optical density of the prepared sample was recorded at 430 nm using distilled water as a blank

Calculation:

Colour = absorbance X 25 (EBC)

50
PH of 10 % Sugar solution

Procedure:

Sufficient volume of 10% sugar solution was taken in a glass beaker which is enough to dip the
tip of electrode. PH reading was noted when it attained constant value.

Extract of 10% Sugar Solution:

Procedure:

 50 gm representative sample of Sugar was mixed well.

 The sample was dissolved in warm water and quantity was made to 500ml in volumetric flask and
filtered.
 Specific gravity of filtrate was measured at 20 ºC.
 Using the reference table º Plato value was determined.

Calculation:

Extract%= P X BX 500

Where,

P= º Plato of 10% solution

B= Specific gravity of 10% solution

W= wt of the sample used

CARTON

51
  Length
 Width
 Height
 Number of flutes
 Outer (VK)
 Corrugated (ARK)
 Inner (SVK)
 GSM,
 Bursting Factor
 Moisture

BRAND KFS, KFL,KFB KFS,KFL,KFB

PACKAG
24 X 330 ml 12 X 650 ml
E (ml)

CARTON BROWN
DUPLEX
TYPE KRAFT
BOARD 3 ply 3PLY
NO. OF
50-56/30cm 50-56/30cm
FLUTES

DIMENSI 380x250x230(± 300x225x286(±

ONS 3mm) 3mm)
BURSTIN
G Min 5.2 Min 6.2
STRENG kg/Sq.cm kg/Sq.cm
HT

BOARD
Min 380 GSM Min 435 GSM
SUBSTAN
(+ 5%) (±5%)
CE

COBB
NMT 155g/smm NMT 155g/smm
VALUE

CUTTING
& SATISFACTOR SATISFACTOR
CREASIN Y Y
G

VISUAL SATISFACTOR SATISFACTOR

DEFECTS

52
 Y Y

PRINTED RED/BLACK/B MULTICOLOU

MATTER LUE R

NEW GLASS BOTTLES

 Bottle height
 Bottle weight
 Bottle Diameter (Shoulder)
 Bottle diameter (Label space)
 Bottle diameter (Bottom)
 Brimful capacity
 Fill point
 Volume at fill point
 Neck diameter
 Internal neck diameter
 Body label panel height
 Height of embossing

CROWN

 Internal defect
 Shade variation
 Change in text
 Peeing of lacquer

53
 Spot and smudges
 Without liner
 Other Brand
 CuSO4 test
 Dimension analysis
1. Skirt diameter
2. Internal diameter
3. Weight of liner
4. Height
5. Weight of Crown
6. Liner adhesion test

Sl.  Specification
No. Description  s

1 Dimensions  

Skirt Diameter 31.9-32.3 mm

Internal Diameter 26.7-26.8 mm

Height 5.78-6.18 mm

2 Weight Of The Liner 190-260 mgs

Weight Of The
3 Crown 2.25-2.40 g

Shall Pass
4 Liner Adhesion Test Test

Shall Pass
5 Lacquer Quality Test

Shall Pass
6 Taste Testing Test

Shall Pass
7 Pressure Retention Test

8 Pasteurization Test Shall Pass

54
 Test

Shall Pass
9 Visual Defects Test

LABELS

 Wrong labels
 Torn labels
 Legal declaration
 Defect in paper
 Color missing
 Incorrect or wrong color
 Labels sticking together
 Mutually displaced color
 Colors Partially missing
 Color coming off

Description Specification

Dimensions  

 Front Label Die Cut (86 x 83 x 70) /

Back Label 50 x 65 mm

Paper Wet Strength

Grammage 75 ± 3 g / Sq m

Grammage (After printing) 75 ± 3 g / Sq m

Varnish Scuff Proof Varnish( Coats of India )

Grain Direction Horizontal

Cobb Value Max. 15 g / Sq m

Border
Front label : A uniform border of 2.0mm± 0.25 mm &
Neck label : A uniform border of 2.0 mm ±0.25 mm

55
IN PROCESS INSPECTION

The store department passes these raw materials to the production department as per the
necessity. Here again the raw materials are inspected while they are in the process, these reduce
wastage and ensure optimum usage of resources. During their routine round they also check
whether the batch no is printed properly or not.

 Mashing of malt.
 Gravity (Mild – Low and Strong – High)
 Lautering. (Initial gravity or Final gravity)
 Wort kettle. (Bitterness according to European Brewing Convection ), Color
 Cold storage tank
 Della Tofolla Filtration. (Dissolve oxygen if DO is more than beer will be spoiled fast) ,
Haze
 Bottling hall
For washing the bottles the concentration of caustic is checked.
 Line inspection
Checking the bottles after bottling
 Shelf life of beer
Beer is placed in water at a temperature of 600C if turbidity occurs within one week than
the beer will remains only for two month
 Microbiological Analysis
Test to check whether the beer is not affected by micro-organism.
 Carbon dioxide test
To check the amount or concentration of CO2 present in beer.
 Sensory Analysis – Beer of every batch is tested by the chemist and head brewer
 Alcohol content and Effluent treatment plant.

56
 CHEMICAL ANALYSIS

Water analysis

1 Appearance:

The appearance of the water should be clear, colourless, sparkling and free from any suspended solids. Any
abnormality observed should be mentioned properly.

2. Odour:
The odour should be reported as odourless, abnormal or nothing abnormal.

3. Taste:
Taste of water should be normal. It should not give any unnecessary taste that might have been incorporated into it
from other sources. Any such abnormality should be reported.

57
CHEMICAL TESTS

1. pH

Apparatus:

 pH meter
 Thermometer
 Magnetic stirrer

Reagents:

Buffer solution (pH - 7, 4 & 9) which are used for calibration of the pH meter.

Procedure:

Take sufficient volume (50 ml) of water sample in a glass beaker which is enough to dip the tip of
electrode. Note the pH reading when it has attained constant value at 25°C

2. Chlorides

Principle:

Argent metric titration: The sample is titrated against standard silver nitrate solution (AgNO 3) using
potassium chromate as indicator. Silver chloride is precipitated before red silver chromate is formed.

Apparatus:

 Erlenmeyer flask 250ml

 Burette 50ml

Procedure:

58
  Take 100 ml of water in conical flask (Adjust the pH between 7-10 with sulphuric acid or sodium
hydroxide)
 Add 1 ml of 5% potassium chromate
 Titrate with 0.0141 N silver nitrate (Va)
 End point is appearance of pinkish yellow colour
 Establish reagent blank value by titration (Vb)

Calculation:

Chlorides (as Cl) in ppm = (Va – Vb) x N x 35,450

Vol. of sample

3. Total Hardness

Hardness in water is defined as presence of multivalent cation like carbonates and bicarbonates

Apparatus:

 Flasks
 Pipettes
 Burette 50ml

Principle:

This is complex metric titration of Ca2+ and Mg2+ using eriochrome black T (EBT) indicator. When EBT
is added to a solution containing Ca2+ and Mg2+ ions at pH 10 a wine red complex is formed. This solution
is titrated with standard solution of disodium salt of EDTA, which extracts Ca 2+ and Mg2+ ions from the
dye complex and the dye is changed to its original blue colour.

Reagents:

 Standard pH 10 Ammonium buffer solution

 Eriochrome Black T indicator
 Standard EDTA solution

59
Procedure:

 Pipette 50ml of sample into a 250ml conical flask

 Add 1 ml of hydroxylamine hydrochloride
 Add 1-2 ml of buffer and 2ml of EBT indicator
 Titrate with standard EDTA solution till the colour changes from wine red to blue
 Note the volume of EDTA consumed (A)
 Blank titration is carried out in similar way as sample and used for comparison (B)

Calculation:

Total hardness as CaCO3 in ppm = VOLUME OF EDTA TAKEN x 2

4. Total dissolved solids

Apparatus:

 Evaporating dish: 90mm diameter, 100ml capacity

 (Platinum/nickel/porcelain/silica/glass)
 Steam bath
 Analytical balance
 Drying oven
 Desiccators
 Whatman filter paper no. 542 (2-2.5µ)

Procedure:

 Take 100 ml of water sample (preferably a sample volume which will give 100-200mg of residue)
in a dried, pre- weighed evaporating dish
 Filter through Whatman filter paper No. 542
 Keep it for drying in a oven initially 98°C for evaporation to prevent boiling and splattering
 Dry at 103°C-105°C for 1-2 hours; dry to a constant mass.
 Cool in desiccator
 Note the final weight

Calculation:

60
 TDS (mg/L) = (B-A) X1000

Volume of sample in ml

Where,

A= Weight of empty dish

B= weight of dish after drying

5. Total acidity

Apparatus:

 pH meter
 Burette 50ml
 Magnetic stirrer

Principle: Acid based titration.

Reagents:

 0.02 N NaOH
 0.02 N potassium hydrogen phthalate
 Phenolphthalein indicator

Procedure:

 Take 20 ml or suitable aliquot of water free from turbidity in a conical flask

 Add 2-3 drops of phenolphthalein indicator
 Titrate against 0.02 N NaOH to permanent pale pink colour (Characteristic of pH 8.3)
 Note the ml of alkali consumed (BR)

Calculation:

Acidity at pH 8.3 as CaCO3 in ppm = BR x N x 50x 1000

61
 Volume of sample in ml

6. Total alkalinity

Apparatus:

 pH meter
 Burette 50ml
 Magnetic stirrer

Principle: Acid based titration

Reagents:

 0.02 N H2SO4
 Methyl orange indicator
 Phenolphthalein indicator

Procedure:

 Take 20 ml or suitable aliquot of water in a conical flask

 If pH of the sample is more than 8.3, add 2-3 drops of phenolphthalein indicator
 Titrate against 0.02 N sulphuric acid (color changes from colourless to light pink)
 Note the volume in ml of sulphuric acid required (A)
 Add 2-3 drops of mixed indicator to the solution in which phenolphthalein alkalinity has been determined
 Titrate against 0.02 N sulphuric acid to light pink colour
 Note the volume in ml of sulphuric acid required after the initial titration(B)

Calculation:

Total alkalinity ppm = vol of sulphuric acid x 61

WORT ANALYSIS

Specific Gravity

62
 Procedure:
 The sample was collected and cooled to around 150C so that the temperature of sample does
not go beyond 200C at the time of weighing
 The pycnometer was filled with sample, and its outside was dried by rubbing with a clean
cloth
 As the temperature of the sample reached 20 0C weight of the pycnometer with sample was
noted.
Calculation:
Specific gravity (g/cc) = (Weight of pycnometer with extract – Weight of empty pycnometer)
(Weight of pycnometer with water – Weight of empty pycnometer)
The obtained value was compared with reference table and specific gravity was determined.

Colour
Procedure:
 The sample was degassed and filtered, and the filtrate was taken.
 Absorbance of filtrate was noted at 430 nm in spectrophotometer, using water as blank.
Calculation:

Colour in EBC units = Absorbance at 430 nm x 25

Total polyphones:

Reagents Preparation:
 CMC-EDTA: Slowly add 10 g of sodium carboxymethyl cellulose and 2 g of disodium
EDTA to 500 ml water with continuous stirring. Dissolve the solid material by
homogenization and make the volume up to 1 liter. If required centrifuge the solution.
 Ferric reagent: Dissolve 3.5 g green ammonium iron citrate in 100 ml water. The
solution must be completely clear. Prepare freshly each week and store in the dark.
 Ammonium reagent: Dilute 100 ml of concentrated Ammonia to 300 ml with water.

Procedure:
 10 ml of malt extract was taken in 25 ml of volumetric flask
 8 ml of CMC-EDTA solution was added.
 Volumetric flask was stoppered and mixed thoroughly
 0.5 ml of green ferric ammonium citrate solution was added.
 0.5 ml of ammonia water was added.
 The final volume was made up to 25 ml
 In case of blank green ferric ammonium citrate was not added
 The preparation was mixed and kept for 10 minutes at room temperature
 The absorbance was recorded at 600 nm.

63
 Calculations:
Total polyphenols in ppm = Absorbance at 600nm x 820 x Dilution factor (if required)

Free amino nitrogen

Apparatus:
Reagents Preparation.
 Glycine: Dissolve 0.1072 gm of glycine in water and make up the volume upto100 ml.
Store the solution at 0 - 40C. For use dilute 1 ml to 100 ml so that the diluted solution
contains 2 mg amino nitrogen per litre.
 Potassium iodate (Diluting solution): Dissolve 2 g of potassium iodate (KIO3) in 600
ml water then adds 400 ml of 96% ethanol.
 Ninhydrin (Colouring reagent): Dissolve 10 g of disodium hydrogen phosphate
(Na2HPO4.12H20), 6 g of potassium hydrogen phosphate (KH2PO4), 0.3 g of fructose and
0.5 g of ninhydrin in water and make up the volume to 100 ml. The pH must be between
6.6-6.8.

Procedure:
 1 ml of wort sample was diluted to 100 ml with distilled water in a volumetric flask
 2 ml of wort ( sample) was taken in 2test tubes (For duplicates)
 1 ml of ninhydrin was added to each test tube
 The test tubes were Stoppard and placed in boiling water bath for 16 minutes
 The test tubes were cooled to room temperature by placing in ice bath for 20 minutes
 5 ml of KIO3 solution was added to each test tube and mixed thoroughly
 Reagents are added to 2 ml of water instead of wort and used as blank
 Reagents are added to 2 ml of glycine instead of wort and use as standard
 The absorbance was recorded at 570 nm.

Calculations:
FAN (ppm) = A1 x 2 x d
A2
Where,
A1 = Absorbance of test solution at 570 nm.
A2 = Mean absorbance of standard solution at 570 nm.
d = Dilution factor

WORT - RESIDUE: GRAVIMETRIC METHOD

64
Scope
The determination of the residue in wort using a gravimetric method.

FIELD OF APPLICATION
 The method can be applied to all worts.
 The gravimetric method is the reference method and the centrifugal method is given as
an alternative.

PRINCIPLE
A known quantity of wort, which should be representative for the entire brew, is filtered through
2
Previously weighed filters. The filters with the residue is rinsed, dried and weighed. The residue
content of the sample is calculated from the weight increased after drying.

REAGENTS
Desiccant of self-indicating silica gel or other effective drying substance.

APPARATUS
 Desiccator, containing a thick, perforated plate of metal or porcelain.
 Oven, set at 105.0 °C ± 0.5 °C.
 Analytical balance, accurate to 0.001 g.
 Measuring cylinders, 500 ml.
 Suction Erlenmeyer flasks, 1 litre, fitted with a set of conical rubber rings.
 Vacuum aspirator, water jet suction pump to give less than 20 mbar vacuum or vacuum
pump.
 Büchner funnels, porcelain type, 125 mm filter diameter.
 Filter paper circles, Schleicher & Schuell No 5891 (black ribbon), 125 mm diameter.
 Water bath, set at 20 °C ± 1.0 °C.

Preparation of samples:
 Samples should be shaken just before pouring the sampling onto the filter because solids
can sediment in the sample container.
 Samples have to be brought to room temperature by immersion the sample container into
a 20 °C water bath for 30 minutes.

Procedure:

 Dry the required number of filter paper circles (2 for each determination) at 105 °C for 6
hours. Allow to cool in a desiccator to room temperature (generally between 30 and 45
minutes), and determine the dry weight of each filter to the nearest 0.001 g; state this
figure on the filter.

65
  After the sample has been well mixed by manually shaking, 500 ml of it are measured
into a measuring cylinder.

 Connect a suction Erlenmeyer flask with the vacuum aspirator and place a Büchner
funnel into the suction Erlenmeyer flask (use the conical rubber rings).

 Place 2 dried and pre-weighed filter paper circles into the Büchner funnel and fix the
filters (by suction) with a little bit of distilled water at 20 °C.

 Filter 500 ml of wort through the Büchner funnel. Stop suction when the residue appears
dry. Rinse the residue on the filters three times with approximately 20 ml of distilled
water at 20 °C. Finally, take the filters from the funnel and fold together.

 Dry the filters at 105 °C for 24 hours, allow to cool in a desiccator to room temperature
(generally between 30 and 45 minutes), and weigh to the nearest 0.001 g.

 Execute the determination in duplicate.

Expression of results
Calculation:
Calculate the residue per litre of wort by adding up of the results of two 500 ml
determinations.
Express the residue in mg/litre to the nearest 10 mg.

THIOBARBITURIC ACID INDEX (TBI) :

Principle:
The TBI provides an indication of the quantities of substances present in 100 ml of wort or malt
extract which give rise to a yellow coloration using acetic acid thiobarbituric acid. The
thiobarbituric acid number is obtained by multiplying the adjusted absorption value with a factor
10 and a dilution factor, and, if necessary, standardizing the result to a 12 % m/m (= 12 °Plato)
product.

Reagents:
1. Acetic acid 90 % solution
Dilute 225 g 100 % Acetic acid with distilled water to 250 g.

2 .Thiobarbituric acid 0.02 molar solution of thiobarbituric acid in 90 % acetic acid

66
Dissolve 0.288 g thiobarbituric acid (M = 144.15 g/mol) in a 100 ml volumetric flask with 90 %
acetic acid solution by warming in the water bath at 70 °C. After cooling down to 20 °C, make
up to the mark with 90 % acetic acid solution .The solution should be made fresh every day.

3. Kieselguhr, if necessary

Apparatus:
1 Spectrophotometer, to determine absorbance at 448 nm (accuracy at least ± 0.5 nm; this can
be checked using a holmium oxide filter)
2. Cuvettes, glass or polystyrene, optical path length 10 mm3. Water bath, set at 70 °C (± 1 °C)
4. Brown reagent bottles: 20 or 25 ml
5. Orbital shaker, the same shaking device as described in the determination of the apparent
attenuation limit
Preparation of samples:
Samples must be bright. If a sample is not bright it must be clarified with kieselguhr.
The dilution needs to be chosen as such that the final absorbance after reaction with
thiobarbituric acid is
in the range of 0.1 to 0.5.
Under normal circumstances the following dilutions are applicable:
- Congress wort (from pale and dark malt): 5-fold dilution with distilled water
- Production wort: 20-fold dilution with distilled water.

Expression of results
Calculation
Thiobarbituric acid Index (TBI) in the test sample by using the following formula:
TBI = 10 · F · (ER – Ew)
Where:
TBI = Thiobarbituric Acid Index (dimensionless)
F = dilution factor
ER = absorbance at 448 nm of the test sample
EW = absorbance at 448 nm of the blank sample.
10 = conversion factor
Standardize, if necessary, to 12 % m/m (= 12 °Plato) wort by multiplying the TBI value found
with the ratio
of [12 %m/m] / [extract value of the initial wort in %m/m].
8.1.2 Express and report the TBI value rounded off to the nearest whole number.
8.2 Precision
This has not yet been established.

CAUSTIC ANALYSIS

67
Caustic test

 Take 10ml sample in conical flask.

 Add Phenolphthalein indicator 2-3 drops.
 Titrate against 1N HCL
 End point – Color change from pink to colorless.

Caustic test:-

Take 10 ml (zone 1) Caustic solution

Add a spoon barium chloride dehydrate

Add phenophthein indicator

Titration by 3N HCL

1st Reading- (end point- white precipitation)

Add spoon of sodium floride

Titration

2nd Reading- (end point-white precipitation)

Add Tashiro’s indicator in 2nd conical flask

Titration

3rd Reading –( end point-pink precipitation)

68
QUALITY CONTROL

- It is the most important section as the quality of the final product that is ready for sale
needs to be checked very keenly

- The QC laboratory of UBL is highly equipped with sophisticated & computerized

instruments for checking the quality of product.

- Some of this instruments with their use are as follows:

The different physico-chemical analyses carried out in Q. A. are as follows

1. Air test
2. Alcohol test, Original gravity, Present Gravity and Haze
3. Bitterness test
4. Calcium test
5. Color test
6. CO2 purity test
7. DO test
8. Diacetyl test
9. Iron test
10. Invertase test
11. Polyphenol test
12. SO2 test
13. Yeast Analysis

BEER ANALYSIS

Alcohol in Beer:
Procedure:
 100 ml of decarbonized beer at 20o C was taken in 500ml round bottom flask.
 The volumetric flask was rinsed with distilled water not more than 50 ml &added this
rinsed water to distillation flask.
 The distillation apparatus was assembled and 100 ml volumetric flask was used to
receive the distillate.
 The distillate was collected about 96-97 ml and made up to 100ml with distilled water,
mixed thoroughly & the Specific Gravity was measured at 200 c.

69
 Calculations:
Specific gravity (g/cc) = (Weight of Pycnometer with extract – Weight of empty Pycnometer)
(Weight of Pycnometer with water – Weight of empty Pycnometer)

Reference table was used to note down the alcohol content as w/v and v/v.

Apparent extract:

Procedure:
The specific gravity of de-carbonated beer was measured at 20°C.
Calculation: Specific gravity of de-carbonated beer = W 1-W2 / W3-W2 Where, W1 = Weight
of Pycnometer with de-alcoholised beer.
W2 = Weight of empty Pycnometer.
W3 = Weight of Pycnometer with water.

The value of apparent extract in °P, i.e. grams of extract in 100 grams of de-carbonated beer was
recorded by using standard table.

Real extract:

Procedure:
 The residue from the distillation flask after alcohol distillation was transferred
quantitatively to 100ml volumetric flask with the aid of hot water, cooled and made the
volume up to 100ml with distilled water at 20°C.
 Specific gravity of the solution is measured at 20°C and by using Pycnometer.

Calculation:
Sp.gr. of de-alcoholised beer = W1-W2
W3-W2
Where,
W1 = Weight of Pycnometer with de-alcoholised beer.
W2 = Weight of empty Pycnometer
W3 = Weight of Pycnometer with water.
The value of real extract in grams of extract in 100 grams of de-alcoholised beer ( oP) was
recorded by using the standard table.

70
Beer bitterness:

Principle:
The bitter substances are extracted from acidified Beer with iso-octane. After Shaking the
absorbance of the iso octane layer is measure at 275 nm against a reference of pure iso-octane.
Reagents:
 Iso-octane(2,2,4 trimethyl pentane): the absorbance of this solution must be 0.01 when
measured at 275nm in a 1cm cuvette against a reference of distilled water
 Hydrochloric Acid (HCl): 6M

Procedure:
 10ml of de-carbonated beer was taken in a 50ml conical flask
 .1ml of
 3N hydrochloric acid (HCl) and 20ml iso-octane were added
 The conical flask was closed tightly with stopper.
 The flask was shaken for 20minute at 20°C at 300rpm, on a wrist action shaker.
 The absorbance of iso-octane layer was measured at 275 nm using pure iso-octane as
blank

Calculation:

Bitterness units (BU) = A275 x 60 (iso hops)

Where,
A275 = Absorbance at 275 nm measured against a reference of pure iso-octane.

Foam Stability:

Apparatus:
 Travelling microscope
 Stop watch

Procedure
 The beer at 5-7oC was poured in a clean dry glass from a height so that it generates a
foam of about 1½ to 2 inch
 The glass with beer was placed on travelling microscopic platform

71
  The eye piece was adjusted so that the foam is in view and started the stop watch.
 Stopped stop watch after foam settle down.
 The time was recorded in seconds i.e. foam stability

Haze in Beer:

Apparatus:
 Haffmans Laboratory Haze meter-VOS Rota 90

Procedure:
 Fresh beer sample was poured in haze cuvette and it was cooled to 0°C (for 0°C
Haze)
 The cooled beer cuvette was kept in haze meter and the reading was recorded which
appears on display of Haze meter

Dissolved O2 in Bottled Beer:

Principle:
To decrease or increase shelf life of beer bottle, O 2 plays a key role. Higher D.O. level in
beer less is the shelf life of beer. Hence it is necessary to keep an eye on D.O. level in bottle.
Apparatus: D.O. Meter
Procedure:
 Pasteurized or unpasteurized beer bottle (Freshly filled) was taken.
 It is Cooled to 15-200 C and shaken for few seconds
 The D.O. was measured with the help of D.O. meter
.

Carbon dioxide (CO2) content:

Apparatus:
 Haffmans In pack CO2 & Air Meter
Procedure:
 The instrument was adjusted at right height of the bottle or can
 The bottle was Pierced, While piercing the needle valve should be closed
 The value was recorded which appear on the gauge.
 The instrument was shaked for awhile with pierced bottle or can till the gauge value does
not increase any more.
 Slowly the needle valve was opened, the bottle was removed and the sample temperature
is recorded.

72
  By using this temperature and pressure values the CO2 content was noted by means of
standard table.

Total air content:

Apparatus:
 Haffmans In pack CO2 & Air Meter
Reagents:
 30% KOH or NaOH solution (Caustic Lye)

Procedure:
 30% caustic lye was taken in measuring burette (with the help of levelling vessel in case
of Haffmans in pack Air meter. This vessel should be at higher position, about 8cm than
measuring burette. There should not be any air in between the stopper of Haffmans In
pack Air Meter
 The instrument was adjusted at right height of the bottle or can
 Pierced the bottle. While piercing the needle valve should be closed
 After piercing, the needle valve was opened slowly a bit and let the head space gas
bubble through the caustic lye in the measuring burette.
 Then the needle valve was closed immediately when no more gas escapes from the bottle
or can
 The instrument was shaked along with the pierced bottle or can again and opened the
needle valve slowly. Repeated this till no gas escapes from the bottle or can.
 The levelling vessel was moved so that the liquid levels from the levelling vessel and the
measuring burette are on the same height.
 Recorded the level of lower meniscus.
Precautions:
 The sample should be shaken before handling.
 If a bottle has a neck foil, it has to be removed.

Calcium:
Reagents:
 5N NaOH solution.
 Calcein Indicator OR P&R reagent

 EDTA solution: 1.8612 EDTA dissolve in 500 ml distilled water for 0.01 M. Take 50 ml
of 0.01M solution and dilute to 100 ml with distil water i.e. 0.005M.

73
Procedure:
 20ml of degassed sample was taken in a 250ml conical flask and 100ml of distilled water
was added.
 3ml of 5N NaOH, 0.5ml Calcein indicator were added and mixed thoroughly
 The sample is titrated with EDTA solution till colour changes from yellow green to
orange brown under black back ground.
Calculation:
Ca (in ppm) = ml EDTA used X 20

Iron

Reagents:
 2.5% Ascorbic acid (fresh)
 0.3% Orthophenanthralone (colour reagent)
Procedure:
 25 ml of sample (degassed) was taken in duplicates, and marked as sample and blank.
 2 ml of Orthophenanthralone was added to the sample and 2 ml distilled water to the
blank.
 1ml of 2.5% Ascorbic acid was added to the tubes

 The tubes are heated at 60oC for 15min and then cooled to room temperature
 The absorbance was recorded at 505nm.
Calculation:
Iron = F (As – Ab)
Where
F = 7.12
As = Absorbance of Sample

Ab = Absorbance of Blank

Diacetyl in Beer:

Reagents:
 8.5% dehydrogenate PO4
 8 % hydroxyl ammonium hydrochloride

Procedure:
 100ml of un degassed beer sample was taken in 500ml round bottom flask.
 3.5 ml 8.5 % disodium hydrogen PO4 was added.

74
  Distillation was started and tip of the delivery tube was kept in 2ml distilled water.
 Distillate was collected up to 18-19 ml and made up to 20 ml with distilled water.
 This 20 ml of distillate was distributed to two test tubes as 10 ml and labelled as blank
and sample.
 1 ml of 8 % hydroxyl ammonium hydrochloride was added to the test tube marked as
sample.

 The test tubes were heated to 80◦C for 15min and the solution is concentrated to 4-5ml.
 Test tubes were cooled and 1 ml of 8 % hydroxyl ammonium hydrochloride was added to
the test tubes marked as blank.
 1ml of 8.5%Na2HPO4was added to both tubes.
 Made up the volume to 10 ml by distilled water.
 The absorbance was recorded at 230mm on spectrophotometer

Calculation:
Diacetyl = Absorbance X Regression factor
Regression factor = 0.3

Precautions:
 The sample should be shaken before handling.
 If a bottle has a neck foil, it has to be removed.
SO2 In Beer:

Reagents:
 0.025 N iodine
 starch indicator
 Conc. HCl
Procedure:
 250 ml of undegassed beer was taken in 500ml round bottom flask, 10 ml. of conc. HCl
was added to it.
 Distillation apparatus was arranged and the tip of the receiver was dipped in beaker
contains 15 ml. of distilled water
 Few drops of starch was added in beaker as indicator and few drops of 0.025 N iodine
solution was also added
 The sample was allowed to rapid boil
 As distillation proceeds keep adding 0.002N Iodine solution to sample till colour persists
for 1 min.

Calculations:

75
 SO2 in beer = Burette Reading X 2.56
content as w/v and v/v.

1.CO2 purity Test

This test gives the purity of CO2.

Reagent: NaoH

Procedure:

Trap CO2 gas in CO2 tester

Fill tester with 40% NaOH solution

Allow to pass the CO2 through caustic solution

Observe NaOH level on the scale of CO2 tester i.e. purity of CO2.
Note:
CO2 purity should be 99.99%

1. Invertase Test
Reagent:
20% sucrose solution
Fehling’s solutionA&B
Procedure:
Test Blank

20ml beer sample 20ml beer sample

20ml 20% sucrose solution

Heating at 55oC in Heating at 55oC in

Water bath for 1hr Water bath for 1hr

76
 Cool Cool

Test sample Add 20ml 20% sucrose solution

Take 1ml test sample Take 1ml blank sample

Add 5ml Fehling’s solutionA&B(1:1) Add 5ml Fehling’s solution(1:1)

Note:

Put these two samples undisturbed for 2hrs at R.T. If blur color turns to red then the
pasteurization is not effective and requires further pasteurization. If color color is not changed
then pasteurization iseffective.

2. Polyphenol test
Reagent:
i. CMC-EDTA 1%
ii. Ferric reagent (3.2gm 16%)
iii. Ammonia (1:3)
I. CMC / EDTA – 10gms of sodium CMC + 1000ml distilled water

+ 2grms of EDTA

Slowly add 500ml distilled water (Continuously Stirring )

Keep Still (3hrs)

Final volume 1000ml with distilled water

II. Ferric reagent- Dissolve 3.5 gms Ammonium iron citrate in 100ml distilled water.

-Store in dark

77
 Required concentration-5.6gm/I Fe 3+

III. Ammonia reagent- 100ml of concentration ammonia + 300ml distilled water

 Flow Chart =

Test Sample Blank Sample

Pipette 10ml wart sample

Add 8ml CMC

Add 0.5 ml ferric reagent only in test sample

Add 0.5 ml ammonia reagent in both the samples (Test & Blank Sample).

Mix well

Make volume upto 25ml with distilled water

Keep at room temperature for 10 mins

Run blank sample without addition of Ferric reagent

Blank make upto 25ml with distilled water used for adjusting zero on spectrophotometer

Measure the absorbance at 600nm ppm in gm/lit.

Polyphenol (mg/ lit) = Abs. 600nm × 820 ppm (mg/lit).

 Vicinal diketones analysis by Spectrophotometer:-

 diacetyl and 2-3 pentanedione filtered diketones.

Principle- The vicinal diketones are distilled from the beer. The distillate is mixed with
solution of o-phenylene diamine to form derivatives of quinoxaline.
After acidification, the amount of reaction products is measured spectrophotometrically.
The concentration of vicinal diketones is calculated with the help of fixed factor.

78
Reagents:-
 HCL:-395 grams conc. HCL IN 400ml distilled water. Cool and shake.
 O phenylenediamine solution :-250mg in 25ml 4ml/lit HCL keep solution in dark
place.
 -Silicon antifoam.

Apparatus:-
Distillation Unit.
Measuring Cylinder -25, 25<100ml.
Volumetric Flasks- 100 < 1000ml.
Spectrophotometer, Cuvette, Centrifuge.
Pipette-0.5, 2 < 10ml.
Test tubes.

Process Flow Chart-

Take 100ml sample in conical flask and add 1-2 drops of silicon antifoam reagent.

Distillation

15-20ml distillate collected. measuring cylinder with 2ml distilled water in about 10min.

Pipette 10ml distillate in dry test tube.

Pipette 0.5ml o-phenylenediamine solution in it.

Mix carefully swirling.

Allow it in dark place for 25 min.

Pipette 2ml HCL Solution and mix.

Measure at 335 nm within 30min after adding

Formula: - VDK (mg/lit) =2.5 (A 335 – A blank).

Results:
Absorbance Blank: 0.003
Sample Absorbance average: 0.236
VDK : 0.58 ppm

79
CIP Regime:

The below given points are common for all the CIP regimes:-

 CIP regime to be prominently displayed at relevant sections

 Sterilant solution to be held in the tank till 30 minutes before tank is ready to be filled. It can then
be recovered to reclaim water tank or drained if this facility is unavailable at some breweries.
 Sterilant should not be reused. If not drained can be reclaimed and used for pre-rinse.
 No water should be flushed after the sanitation cycle
 Spray ball / Fury to be checked for proper working each time CIP is conducted and recorded.
 Sample port to be kept open during CIP & closed after completion of the CIP cycle.
 SU 560 additive supplied by M/s Diversey Lever can be used by Units at a concentration of
0.5%, depending on the tank cleanliness. Unit to decide on the frequency of use along with
caustic solution.
 Last rinse water plating results to be mandatorily filled in the respective tank CIP format after
obtaining results from Lab
 CIP regime to be prominently displayed at relevant sections

UNITANKS, FERMENTATION & LAGER TANK SECTIONS:

Frequency : Before each fill

Cycle : 3 cycles Acid CIP followed by 1 cycle of Cold

Caustic CIP
1. ACID CIP (THREE CYCLES)

80
Sl. CIP Step Concentration Temperature( Minimum Time Remarks
No. (%) °C) (min)

1 Pre Rinse Reclaim Water Ambient 5 Drain water after

or fresh rinsing
Brewing water

2 Acidbrite Circulation 2.0 – 2.2 % Ambient 20 Dedicated tank for

Acid Brite.

3 Final Rinse Brewing Water Ambient 5 Recover water to

reclaim water tank

4 Divosan Active 0.3-0.5 % Ambient 15 Circulation through

Circulation disinfectant tank in CIP
system. Recover
solution to reclaim water
tank

Followed by Sanitation: Divosan Active solution as sanitizer

2.COLD CAUSIC CIP (ONE CYCLE)

Sl. CIP Step Concentration Temperature(°C) Minimum Time Remarks

No. (%) (min)

81
 1 Pre Rinse Reclaim Water Ambient 5 Drain water after
or fresh rinsing
Brewing water

2 Caustic 2.0 to 2.5 % Ambient 25 Recover or drain

circulation option depending
on strength, soil &
carbonates level

3 Intermediate Brewing Water Ambient 5 Recover water to

Rinse reclaim water tank

4 Acidbrite 2.0 – 2.2 % Ambient 15 or till caustic Recover to acid

Circulation free tank

5 Final Rinse Fresh water Ambient 5 Recover water to

reclaim water tank

Followed by sanitation

6 Divosan 0.3 - 0.5 % Ambient 15 Circulation through

Active disinfectant
Circulation collection tank in
system. Recover to
reclaim water tank

Divosan Active

Determination of user concentration of diluted solution

Reagents:
 8% H2SO4
 1 N Potassium Permanganate
 KI solution
 0.1 N Sodium Thiosulphate solution

Method of Analysis:
 Take 50 ml. of the user solution of Divosan Active in a 250 ml conical flask.
 Add 10 ml of 8% H2SO4 into flask.
 Add 1N Potassium Permanganate till colour turns pink.
 Add 10 ml KI solution, colour will turn yellow.

82
  Titrate above with 0.1 N Sodium Thiosulphate solution till colour changes from yellow to
colorless.

burette reading∗38
% User Concentration of Divosan Active=
500

= Burette reading (ml) * 0.076

PAA ppm in solution = % Divosan Active * 50

WATER TREATMENT PLANT

Plant Standards:

83
  Capacity of RO: 50 KL/Hr

 Conductivity = 500 uS/cm

 pH = 9

Equipment Details: -

Machine OEM Capacity

Softner Doshin 50 KL/Hr
Activated Carbon Filter 1 Doshin 50 KL/Hr
Activated Carbon Filter 2 Doshin 75 KL/Hr
Multigrade Filter 1 Doshin 50 KL/Hr
Multigrade Filter 2 Doshin 75 KL/Hr
Ultrafiltration DOW Water Soln 63 KL/Hr
Ultrafiltration Storage Tank 15 KL/Hr
CSRO Vessel Maxima 50 KL/Hr
Underground Storage 400 KL
Chemical Cleaning Tank 2 KL

Water Source:-

 MIDC Water.
 Tanker Water ( High TDS)
 ETP RO Water.
The Key increasing water Efficiency is high output and judicial used of ETP RO Water.
Treatment Process:
MGF: It is a filter that separates undissolved particles from the Water
ACF: It is a Filter made of Activated Carbon that separates Organic Matter and Chlorine from
the Water.
UF: It is a Filter with a very fine filter capacity. It separates micro sized particles from the
Water.
RO: It is a filter that works with the Principle of Reverse Osmosis. 6 Bar of pressure is applied.
Permeate Pressure 1.5 Bar.
Softener: Softener is used to prepare Soft Water. Soft Water does not go through UF and RO.
MIDC water supply

Storage tank = 400 KL

84
 MGF = 50 KL / Hr

ACF = 50 KL /Hr

UF = 50 KL/Hr

RO = 50 Kl/Hr

RO tank = 400 KL

EFFLUENT TREATMENT PLANT

Plant Standards :

Design Capacity = 1300 KL

ETP RO Capacity = 600 KL
ETP RO TDS = 150 ppm
United Breweries Ltd. Aurangabad have 7000 m 3/day capacity effluent treatment
plant. As it is basically Brewery industry consumption of water is very high. In United Brewery
continuous production of various alcoholic beverages like beer for all these production water
consumption rate is high.

85
 Effluent shows typical agro based effluent characteristics such as high biological
oxygen demand load, high chemical oxygen demand load, total dissolved solids , low pH
effluent , dark black or brown color and strong odor.

Brew House sump, Caustic sump and Non caustic sump

Raw Equalization Tank – 1

(pH neutralizotion and TDS moderation)

Buffer Tank
(Buffer maintained)

Tube settler
(Settled sludge is removed)

Anaerobic Hybrid Reaction

(Anaerobic digestion)

Clarifier 1

(To remove total soluble solids and to separate suspend solids)

Clarifier 2

Aeration 1

(Aerobic reaction through blowing the air)

Aeration 2

Flash Mixer

86
 (Dosing of Alum and Poly to separate suspended particles)

MGF

(Multigrade Fiter: Multiple layers of solid particles to remove suspended materials)

ACF(Activated carbon Filtre)

(To remove excess Chlo**rine)

MGF

UF Tank

(TDS and suspended particles are removed)

UF

RO

(Total Dissolved Solids are removed)

RO Reject RO Permeate

(High TDS) (Low TDS)

CETP RO Permeate Tank

Sludge Bed 10 nos.

(Settles sludge of tube settler, AHR, Buffer tank and clarifier are collected)

Sludge Dewatering

(Extract water from sludge drying bed)

87
 Water equalization Dried sludge

REFIGERATION & AIR CONDITIONING

Plant Standards:

 Maximum Load = 600 TR

 Glycol Discharge = 450 m³/hr
 VAM Chilled Water Capacity = 200 HL/hr
 Electricity Consumption = 8500 Units/day

Operation and Safety:

 Compressors are equipped with Soft Starters or VFD and are controlled through SCABA
and automation
 VFD on all daily operated Pumps and compressors to save Power.
 Multiple fans in Evaporative Condenser to facilitate multiple load operations.
 Safety valves compressors, steam line to save machines from high pressure.
 Pump, Condenser and Ammonia are interlocked. If one stops, all stop.
 Vapour Absorption Cycle used to prepare chilled Water.
 Provision for chilled water preparation through PHE against Ammonia is provided.
 Ammonia Detectors on locations to detect ammonia leakage.
 Insulation has been given in all chilled pipes.

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  Cooling Tower is fed with ETP RO Water.
 Float Sensors at all Surge Drums
 Compressor Load can be controlled though VFD and number of cylinders operating in the
condenser
 A PHE in Ammonia discharge line heats boiler feed water.
 Steam and Water Control in VAM
 Self-cooled KCX series of Ammonia Compressor, which uses suction Ammonia to cool
itself.

BOILER

Plant Standards:
 12 Tonnes/Hr Steam Production
 Steam Pressure = 16.5 Bar
 Steam Temperature = 210 C

Operations:
1. Maintaining feed water quality and temperature (above 95 C) is very critical
2. Using the drum level control effectively
3. Ensure all the air dampers are fully open( closed only during maintenance)
4. Monitor the stack temp
5. Maintaining fuel property is important.( GCV, Moisture, fuel size)
6. Cleaning the fuel path often, will ensures smooth running of fuel flow.
7. Use alarm system to check normal operation of grate system.
8. FD air dampers, ID fan speed and stack O2 readings are very good indicators of smooth
operation.
9. Ensure all ZSS are in use, all the time for Ash and fuel conveying equipments( Belt,
RALV)
10. Ensure cooling water availability all the time.

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 11. Avoid sudden dumping of ash.
12. Use the alarm facility.(Level-1,2,3,4,5,6,7)

Safety:
 Drum level- boiler low level and extra low level through mobery. Boiler extra extra low
level though PLC. Alarm level L2

 High steam pressure though steam Pr switch.

 Furnace high though furnace pr, Switch.

 Flue gas temp high through after ECO temp transmitter.

 Furnace temp high though furnace TC

 Feed water tank level goes low

 The boiler will stop instantly for all these . These safety interlocks are hardwired, I,e will
operate independent of PLC.
 The temp sensor on SSK hopper will indicate in case of back fire. If temp crosses set point
95deg., sprinkle valve will operate. In case temp does not come down below set point in 15
minutes, then boiler will stop.

 If O2 level goes below 5%, then fuel feed will stop. Will start again at 6,5%. This is to avoid
CO build up in furnace

BY PRODUCTS

 CO2
 Spent malt
 Yeast

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 CONCLUSION

It was a wonderful & memorable experience for me undergoing industrial

training in United Beverages Ltd ELLORA, Aurangabad in last four month. I
gained a valuable practical experience and it has made me aware that safety,
production, quality and time management is very important for all industries.

In last occasion I learned how to work in welfare established industry. It

was also taught me the difference between theory and actual experience
knowledge that I have gained in this industry. The helping and cooperative nature
of all workers and staff members to clear all the fundamental concepts cannot be
overlooked. They all are extremely Welcoming & Helpful and offered me
invaluable career advice. They had specified me deep knowledge of each and
every product, which will definitely help in future life.

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 I am very lucky to have In-plant Training in such established plant. This
training has definitely increased my interest in pursuing career in Beverage
industry. Once again Thank you for an excellent Four months.

UBL ELLORA has bright future. My best wishes are with UBL ELLORA
Quality Control Team.

May the,

Sweet success of UBL ELLORA

Will continue forever and ever…..........

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