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Summer Internship Report
On
MANAGEMENT OF PROCESS AND BOTTLING IN UNITED BREWERIES LIMITED, KALYANI (WEST BENGAL)
By
Vijay Kumar JaiswalA0101909012
MBA Class of 2011
Under the Supervision ofMs. Bhavna Ranjan
Department of Finance
In Partial Fulfillment of Award of Master of Business Administration
AMITY BUSINESS SCHOOLAMITY UNIVERSITY UTTAR PRADESH
SECTOR 125, NOIDA - 201303, UTTAR PRADESH, INDIA2010
1
AMITY UNIVERSITY UTTAR PRADESH
AMITY BUSINESS SCHOOL
DECLARATION
I, Vijay Kumar Jaiswal student of Masters of Business Administration from Amity Business
School, Amity University Uttar Pradesh hereby declare that I have completed Summer
Internship on “MANAGEMENT OF PROCESS AND BOTTLING IN UNITED BREWERIES
LIMITED, KALYANI (WEST BENGAL)” as part of the course requirement .
I further declare that the information presented in this project is true and original to the best of
my knowledge.
Date: 16/07/10 Vijay Kumar Jaiswal
Enroll. No: A0101909012
Place: Noida MBA Class of 2011
2
UNITED BREWERIES LIMITED KALYANI
CERTIFICATE
I, hereby certify that Vijay Kumar Jaiswal student of Masters of Business Administration at
Amity Business School, Amity University Uttar Pradesh has completed Summer Internship on
project “Management of Process and Bottling at United Breweries Limited Kalyani ”, under my
guidance.
Mr. G. S. Lodh
Head Brewer
United Breweries Limited
Kalyani, India
3
AMITY UNIVERSITY UTTAR PRADESH
AMITY BUSINESS SCHOOL
CERTIFICATE
I hereby certify that Vijay Kumar Jaiswal student of Masters of Business Administration at
Amity Business School, Amity University Uttar Pradesh has completed Summer Internship on
“MANAGEMENT OF PROCESS AND BOTTLING IN UNITED BREWERIES LIMITED,
KALYANI (WEST BENGAL)”, under my guidance.
Ms. Bhavna Ranjan
(Lecturer/Asst. Prof./Prof.)
Department Finance
4
Acknowledgement
Several people have been very helpful in making this project. At the very onset I would like to
acknowledge the assistance of Mr. G. S. Lodh, my Industry Mentor and the Head Brewer of
United Breweries Limited, Kalyani unit. Without his support and permission this project would
have been an impossible task.
I would like to deeply appreciate the contribution of Mr. Rakesh Bhattacharya, the General
Manager of the company for guiding me in this project with the required information about the
unit.
I am grateful to Mr. Bhaskar Sen, the HR Manager of the unit for helping me out in
understanding the company and its processes from the very first day in the plant till the
completion of the project.
I also thank Mr. Arpon Banerjee (Shift Brewer), Mr. Surajit Saha (Assistant Brewer) and
Mr. Acharjee (Shift Brewer) for their support in making in understand all the minute details of
the different processes employed in the manufacture of beer.
Further, I would like to convey my gratitude to all the workers of the plant of all the different
departments in helping me out in knowing the details of all the respective departments of the
plant and the processes involved in it.
I would like to thank Ms. Bhavna Ranjan my Faculty Guide for her guidance throughout the
project.
Last but not the least I would like to thank Amity Business School for providing me with an
opportunity of getting practical knowledge about the procedures and systems of an industry and
helping me in structuring my future domain.
Vijay Kumar Jaiswal
Enrollment No.-A0101909012
MBA Class of 2011
5
TABLE OF CONTENTS
Declaration
Certificate from Industry Guide
Certificate from Faculty guide
Acknowledgement
S. No. Chapter Name Page No.
1. Introduction 7-8
2. Executive Summary 9
3. Literature Review 10
4. Company Profile 11-28
5. Research Methodology 29-30
6. Process of Beer Manufacture 31-54
7. Key Discussion and Analysis 55-58
8. Recommendation 59-60
9. Conclusion 61-62
10. References 63
6
Introduction
United Breweries Limited (UBL) is the flagship company of the UB Group. Founded in 1915
from the merger of five breweries in India, the company is headquartered in Bangalore and
commands 40% of the domestic market with leading brands such as Kingfisher, UB Export,
London Pilsner, Premium Ice and Kalyani Black Label. The UB Group is 3rd largest spirits
marketer in the world, with overall sales reaching 60 million cases. Subsequent to the acquisition
of Shaw Wallace & Company Limited, The UB Group spirits division offers 140 brands at
varying price points, attracting consumers of every taste. Combined with its unparalleled reach it
has become an object of envy for the competition. Five of UB Group's brands, viz., Bagpiper
Whisky, McDowell’s No.1 Whisky, Director's Special Whisky, McDowell’s No.1 Brandy and
McDowell’s Celebration Rum have been included in Impact International's Top 100 Distilled
Spirits Brands Worldwide by Retail Value.
The Castle Brewery which dates back to 1857 (the year of the Indian mutiny) was set up for the
European planters scattered over the Nilgiris. So was the Nilgiris Brewery Company. The British
Brewing Corporation set up in Madras (1902) catered to the elite of the port town of Madras
while the Bangalore Brewery Company had been supplying beer for the troops stationed at Pune
and Bangalore since 1885.
United Breweries Limited (UBL) was founded on March 15, 1915, in Madras by Thomas
Leishman, a Scotsman, also its first Managing Director. UBL manufactured and sold only bulk
beer for troops of both the world wars. It was a classic case of role reversal – India being
introduced to this ‘exotic’ brew and in turn becoming its major exporter.
The Indian beer industry has witnessed a big change during the last five years. The industry was
previously dominated by competition between the Vijay Mallya controlled United Breweries
Group and the Manu Chabbria-controlled Shaw Wallace. The scenario changed, however, with
the entry of SABMiller in India. The international beer giant started by acquiring small breweries
in the south but then completely changed the landscape with the acquisition of Shaw Wallace’s
beer portfolio for a reported US$264m in 2003.
7
India is predominantly a hard spirits market and beer is a minority preference for those who
consume Beverage Alcohol. Beer makes only 4% by revenue of the total alcoholic market. It
would be pertinent to mention that while per capita consumption of spirits in India is 65% of
global average, in the case of beer it is a mere 3% of global average.
With the global market experiencing low/stagnating growth in recent years, the focus is now on
the Asia-Pacific region specially. For instance, the Chinese beer market has grown at an
astounding pace in recent years, spurred on by the massive levels of foreign investment in the
market, along with the rise in the average levels of consumer spending and thanks to the
economic reform policies of the government. Total consumption of beer in China grew by
33.56% between 2000 and 2006 to reach a total market volume of 30.47 billion litres. With the
per capital consumption of 22 litres, China has now overtaken the US to become the largest
national beer market in the world. The brewing industry in China has been one of those quickest
to modernize and Indian beer Industry should look to model themselves on their neighbors.
The United Breweries Limited, Kalyani is a manufacturing unit which is meant for producing
Kingfisher Lager Beer, Kingfisher Strong Beer, Kalyani Black Label Premium, Kalyani Black
Label Strong, Sandpiper, and Kingfisher Premium Pites. This unit of UB ltd at Kalyani is headed
by assistant vice president. Reporting to him are departments like process, engineering, quality
assurance, commercial, human resource (hr) and finance, each headed by one departmental head
to whom other officials are accountable, the total of this complement represent the
managerial/supervisory group numbering 32.
.
8
Executive Summary
Brewing is almost certainly the most ancient manufacturing art known to man, and is probably as
old as agriculture. Beer is regarded as the first alcoholic beverage ever produced, dating back to
as early as the sixth millennium B.C. The Chinese brewed beer called 'Kui' some 5,000 years
ago. In Mesopotamia, a 4,000 year-old clay tablet indicates that brewing was a highly respected
profession - and the master brewers were women. Today, the brewing industry is a global
business, consisting of several dominant multinational companies and many thousands of smaller
producers ranging from brewpubs to regional breweries. More than 133 billion liters (35 billion
gallons) are sold per year (the equivalent of a cube 510 meters on a side), producing total global
revenues of $294.5 billion (£147.7 billion) in 2006.
The report covers the entire process of beer manufacturing starting from the scratch till the
bottling and dispatch of the final product at UBL Kalyani. Further beer is a product which comes
under the food and beverages sector and is consumed by human beings at a large scale. Thus
maintaining quality standards at every level of the process forms the very basic for the success of
the product as well as of the entire company. Beer is a fermentation product and is rich in alcohol
and glucose content and is very susceptible to contamination from microorganisms at each and
every step in the process of its making. Thus a strict control should exist at each and every step
in the process and every process should be carried out in a closed environment which is taken
care in the plant with full efficacy and efficiency. The higher the microbial compliance greater is
the life of the beer and better is the quality. In spite of various control measure taken by the plant
certain things are overlooked by the unskilled workers in the plant during handling of the
equipments and this brings contamination of the beer and hence increases the dissolved oxygen
level of the beer which is not desired. Thus this report surpasses through the various regions
which are overlooked by the workers of the beer plant in compliance with the contamination of
beer and further finds out method to overcome such trivial mistakes and increase the microbial
compliance and the life of the beer.
This report thus is a tool for learning the entire process of beer manufacture and enhancing the
quality of the beer by increasing the microbial compliance in different process of beer
manufacture and further increasing the life of the beer.
9
Literature Review
Beer is the world's most widely consumed and probably oldest alcoholic beverage, and the third
most popular drink overall after water and tea. It is produced by the brewing and fermentation of
starches, mainly derived from cereal grains—most commonly malted barley, although wheat,
maize (corn), and rice are widely used. Most beer is flavored with hops, which add bitterness and
act as a natural preservative, though other flavorings such as herbs or fruit may occasionally be
included.
The process of making beer is known as brewing. A dedicated building for the making of beer is
called a brewery, though beer can be made in the home and has been for much of its history. A
company that makes beer is called either a brewery or a brewing company. Beer made on a
domestic scale for non-commercial reasons is classified as homebrewing regardless of where it is
made, though most homebrewed beer is made in the home. Brewing beer is subject to legislation
and taxation in developed countries, which from the late 19th century largely restricted brewing
to a commercial operation only. However, the UK government relaxed legislation in 1963,
followed by Australia in 1972 and the USA in 1979, allowing homebrewing to become a popular
hobby. The purpose of brewing is to convert the starch source into a sugary liquid called wort
and to convert the wort into the alcoholic beverage known as beer in a fermentation process
affected by yeast.- Prescott and Harley( A text book of microbiology).
Lager is the English name for cool fermenting beers of Central European origin. Pale lagers are
the most commonly consumed beers in the world. The name lager comes from the German
lagern for "to store", as brewers around Bavaria stored beer in cool cellars and caves during the
warm summer months. These brewers noticed that the beers continued to ferment, and to also
clear of sediment, when stored in cool conditions.[74]
Lager yeast is a cool bottom-fermenting yeast (Saccharomyces pastorianus) and typically
undergoes primary fermentation at 7–12 °C (45–54 °F) (the fermentation phase), and then is
given a long secondary fermentation at 0–4 °C (32–39 °F) (the lagering phase). During the
secondary stage, the lager clears and mellows. The cooler conditions also inhibit the natural
production of esters and other byproducts, resulting in a "cleaner"-tasting beer- A. H. Patel( A
text book of industrial microbiology)
10
COMPANY PROFILE-THE UNITED BREWERIES
GROUP
Brewing is almost certainly the most ancient manufacturing art known to man, and is probably as
old as agriculture. Beer is regarded as the first alcoholic beverage ever produced, dating back to
as early as the sixth millennium B.C. The Chinese brewed beer called 'Kui' some 5,000 years
ago. In Mesopotamia, a 4,000 year-old clay tablet indicates that brewing was a highly respected
profession - and the master brewers were women. During the Industrial Revolution, the
production of beer moved from artisanal manufacture to industrial manufacture, and domestic
manufacture ceased to be significant by the end of the 19th century. The development
of hydrometers and thermometers changed brewing by allowing the brewer more control of the
process and greater knowledge of the results. Today, the brewing industry is a global business,
consisting of several dominant multinational companies and many thousands of smaller
producers ranging from brewpubs to regional breweries. More than 133 billion liters (35 billion
gallons) are sold per year (the equivalent of a cube 510 meters on a side), producing total global
revenues of $294.5 billion (£147.7 billion) in 2006.
Global Brewing Scenario
The global beer industry is consolidating. Consolidation started 10 years ago and probably has
10 more to go before it winds down. China is the biggest market for beer followed by the US,
Germany, Brazil, Russia, Japan, UK, Mexico, South Africa and Spain. The paradox in China is
that although the retail price of beer is very low in terms of the market, it has very high profit
margins as far as international players are concerned.
With the global market experiencing low/stagnating growth in recent years, the focus is now on
the Asia-Pacific region specially. For instance, the Chinese beer market has grown at an
11
astounding pace in recent years, spurred on by the massive levels of foreign investment in the
market, along with the rise in the average levels of consumer spending and thanks to the
economic reform policies of the government. Total consumption of beer in China grew by
33.56% between 2000 and 2006 to reach a total market volume of 30.47 billion litres. With the
per capital consumption of 22 litres, China has now overtaken the US to become the largest
national beer market in the world. The brewing industry in China has been one of those quickest
to modernize and Indian beer Industry should look to model themselves on their neighbors.
Major Global Players
Anheuser-Busch Companies Inc,
Carlsberg Breweries As,
China Resources Enterprises,
Femsa Cerveza Sa De Cv,
Heineken Nv,
Inbev Sa,
Modelo Brewing Group,
Molson Coors Brewing Co,
Sabmiller Plc,
Tsingtao Brewery Company Ltd
Indian Beer Brewing Scenario
The first modern brewery in India was set up in Kasauli, in the Himalaya Mountains,
near Shimla in the late 1820s by the Englishman Edward Dyer. Dyer's brewery produced Asia's
first beer, called Lion. Today no brewer in India makes India Pale Ale. All Indian beers are either
lagers (5 % alcohol — such as Australian lager) or strong lagers (8 % alcohol - such as the
popular MAX super strong beer). International Breweries Pvt. Ltd. have recently announced an
intention to work with Mohan Meakin to produce and launch an India Pale Ale called Indian IPA
from India's first brewery at Solan. Kingfisher, Haywards, Kalyani Black Label, Golden Eagle,
Australian, Max, Royal Challenge, Kings and Belo are popular Indian beer brands. With the
average age of the population on the decrease and income levels on the increase, the popularity
12
of beer in the country continues to rise. Indian growth rates compare favorably with the global
beer industry, which grew by about 2.6 per cent in 2001-02 apart from providing strong growth;
India also provides attractive profit margins due to the consolidated nature of the industry. The
effect of this consolidation can be seen in the fact that beer prices in India rarely go down with
the competitive pressures of new product or brand launches. In the past, whenever beer prices
have gone down, it has been due to either the lowering of duties by the government or the
deregulation of distribution (leading to lower margins for the distribution channel partners). In
neither scenario have the margins or revenues of beer manufacturers been affected.
The brewing industry in India is characterized by a large number of small sized units. Over 57
breweries produce only 6 million hectoliters representing about 76 millions cases. By way of
comparison, SABMiller produces 31.7 million hectoliters in South Africa through just 7 plants.
The Indian beer market has been growing rapidly over the last 10 years, due to the positive
impact of demographic trends and expected changes, like:
Rising income levels
Changing age profile
Changing lifestyles
Reduction in beer prices
Source: Industry sources
13
In India the future of beer industry is very much optimistic because:
1. India has predominantly a warm/hot climate
2. The beer-drinkers in the country are much younger than the average beer-drinker
elsewhere in the world. This makes them more likely to carry the brand with them for a
lifetime.
3. Increasing exposure to beer and wine drinking, mainly due to media and consumer
mobility.
All these factors combined together make the scenario very promising for beer industry and are
'in sync' with their strategy for India.
The Indian beer industry has witnessed a big change during the last five years. The industry was
previously dominated by competition between the Vijay Mallya controlled United Breweries
Group and the Manu Chabbria-controlled Shaw Wallace. The scenario changed, however, with
the entry of SABMiller in India. The international beer giant started by acquiring small breweries
in the south but then completely changed the landscape with the acquisition of Shaw Wallace’s
beer portfolio for a reported US$264m in 2003.
India is predominantly a hard spirits market and beer is a minority preference for those who
consume Beverage Alcohol. Beer makes only 4% by revenue of the total alcoholic market. It
would be pertinent to mention that while per capita consumption of spirits in India is 65% of
global average, in the case of beer it is a mere 3% of global average.
Hence, despite the recent growth, there still exist numerous challenges for the beer industry.
Beer Highly Taxed
Most Regulated Industry
Price Restrictions
Inadequate Market Infrastructure
Restriction of Movement of Beer
14
The Indian beer brewing industry is experiencing a steady growth in middle of the negative and
the positive aspect of the Indian economy. This industry can manage better share in the market
provided the following measures are taken into consideration:
Uniform Policy and Taxation
Free Pricing
Preferential Treatment to beer
Lower Consumer Prices
Market driven Retail Sector
Better Beer selling practices
Formation of a Beer Board
Moreover, the Indian beer industry is plagued with myriad taxes & levies that vary from state to
state. In fact no two states or UTs have a same or even a similar policy.
The brewing industry is a very dynamic industry to work in. The Indian beer industry has been
witnessing steady growth of 10 - 17% per year over the last ten years. The rate of growth has
increased in recent years, with volumes passing 170 million cases during the 2008-2009 financial
year. With the average age of the population on the decrease and income levels on the increase,
the popularity of beer in the country continues to rise and is poised fir further growth.
United Breweries Limited (UBL) is the flagship company of the UB Group. Founded in 1915
from the merger of five breweries in India, the company is headquartered in Bangalore and
commands 40% of the domestic market with leading brands such as Kingfisher, UB Export,
London Pilsner, Premium Ice and Kalyani Black Label. The UB Group is 3rd largest spirits
marketer in the world, with overall sales reaching 60 million cases. Subsequent to the acquisition
of Shaw Wallace & Company Limited, The UB Group spirits division offers 140 brands at
varying price points, attracting consumers of every taste. Combined with its unparalleled reach it
has become an object of envy for the competition. Five of UB Group's brands, viz., Bagpiper
Whisky, McDowell’s No.1 Whisky, Director's Special Whisky, McDowell’s No.1 Brandy and
McDowell’s Celebration Rum have been included in Impact International's Top 100 Distilled
Spirits Brands Worldwide by Retail Value.
15
The Castle Brewery which dates back to 1857 (the year of the Indian mutiny) was set up for the
European planters scattered over the Nilgiris. So was the Nilgiris Brewery Company. The British
Brewing Corporation set up in Madras (1902) catered to the elite of the port town of Madras
while the Bangalore Brewery Company had been supplying beer for the troops stationed at Pune
and Bangalore since 1885.
United Breweries Limited (UBL) was founded on March 15, 1915, in Madras by Thomas
Leishman, a Scotsman, also its first Managing Director. UBL manufactured and sold only bulk
beer for troops of both the world wars. It was a classic case of role reversal – India being
introduced to this ‘exotic’ brew and in turn becoming its major exporter.
The Company’s brewing tradition has a legacy of nearly 130 eventful years. Along its journey
through the global Alcoholic Beverages landscape, UBL has consistently influenced business
paradigms, beer-drinking habits and conventional mindsets. One man played a pivotal role in the
Group’s growth – Vittal Mallya who was elected to the Board of Directors of UBL in 1947 at the
age of 22 and a year later became its Chairman. Bangalore has been at the core of UBL’s
existence. The Registered Office of UBL was shifted to Bangalore in June 1952, into the
spacious 22-acre factory of the Bangalore Brewery Company. The Bangalore Brewery buildings,
dating as far back as 1885, have since given way to newer construction. The only relic that still
stands is the present godown adjacent to the UB Towers building, which earlier housed the
bottling cellars, pasteurizing and packing departments. The five acres of land across the road
donated to the Jesuit Society now forms the campus of St Joseph’s Indian High School.
Exploring Opportunities
In 1951, United Breweries Limited added liquor to its product cabinet when McDowells became
its first subsidiary. Under the dynamic guidance of Vittal Mallya, the Company became the first
to manufacture Indian substitutes of foreign liquor. This gave rise to a new term – IMFL (Indian
Made Foreign Liquor). McDowell has since then been the undisputed market leader and one of
the largest and fastest moving consumer goods companies in the country. Vittal Mallya was not a
man to rest on his laurels. He continued to pursue opportunities in the Alcoholic Beverages
business and at the same time diversified into Polymers and Batteries in addition to
Pharmaceuticals and Foods that the Company had been making till then.
16
Dr. Vijay Mallya
Chairman
The UB Group is one of India’s largest conglomerates with annual sales of over US$ 4 billion
and a market capitalization of approximately US$ 12 billion. The Group has diverse interests in
brewing, distilling, real estate, engineering, fertilizers, biotechnology, information technology
and aviation. It is also the largest Indian manufacturer of beverage alcohol (beer and spirits). Dr.
Vijay Mallya is the Chairman of the Group. Dr. Mallya, was elected by shareholders as
Chairman of UB in 1983, at the age of 28. He previously assisted his father, the former
Chairman, who passed away in the same year. Prior to being entrusted with the responsibilities
of a classical Indian corporate conglomerate, Dr. Mallya worked for the American Hoechst
Corporation (now Sanofi-Aventis) in the USA and with Jenson & Nicholson in the U.K. Since
1980, he assisted his father, the then Chairman of The UB Group, in managing the important
Brewing and Spirits Divisions and in re-launching the Kingfisher Brand of Beer. In 1983, the
sales volume of the UB Spirits division was approximately 2.85 million cases and UB’s beer
business trailed behind that of Golden Eagle from Mohan Meakins.
Also included in the Group were activities such as pharmaceuticals, agrochemicals, paints,
petrochemicals and plastics, the manufacture of electro-mechanical batteries, the manufacture of
food products and carbonated beverages, a fast-food pizza chain and several medium and small
scale industries.
Upon assuming the position of Chairman in October 1983, Dr. Mallya initiated the process of
defining a corporate structure with performance accountability, inducting professional
17
management and consolidating the unwieldy empire into individual operating divisions.
In 1988, Dr. Mallya became a non-resident Indian to pursue global opportunities and to
transform the UB Group into India’s first multinational company. While, in the initial stages,
overseas representative offices had been commissioned, the real break came in 1988 when Dr.
Mallya, in a leveraged buyout, acquired the global Berger Paints Group with operating
companies across four continents. The exit strategy for this investment was profitably executed
when Dr. Mallya successfully directed five Initial Public Offerings on the London, Singapore
(Main Boards), Nairobi, Jamaica and Abidjan Stock Exchanges. The paints business was
divested for significant value in1996.
Dr. Mallya also founded a software company in the USA in 1993 which was subsequently listed
on the NASDAQ in 1996 and which provides a considerable window of opportunity to the vast
US market. He also initiated several ventures for the promotion and globalization of UB brands
and, in particular, Kingfisher and McDowell.
In 1990, following the Government of India’s liberalised economic policies, Dr. Mallya decided
that the UB Group would only retain interests in businesses that were globally competitive and
which did not depend upon fiscal tariff protection. He also decided to focus on areas of core
competence and transformed the vastly diversified UB conglomerate into a handful of key
operating businesses. On entering the new millennium, the UB Group is considerably more
focused and has dramatically increased value for its shareholders through its various operating
businesses. Sales of the UB Spirits Division have crossed 90 million cases (9 litres each) during
the fiscal year 2008-09. In addition, this Division is one of only three in the world to own
nineteen millionaire brands and at least five brands rated by Drinks International, UK to be
amongst the ten fastest growing brands in the world in their respective categories. The market
share of the Spirits Division in India is currently 60% and exports to the Middle East, Africa and
Asian countries are growing rapidly.
In 2007, United Spirits Limited, the flagship of The UB Group, acquired a hundred percent of
premium scotch distillers Whyte & Mackay and Liquidity Inc, a United States-based maker of
specialty vodkas. The Delaware-based Liquidity Inc produces speciality brands like Pinky Vodka
18
and Marakesh.
The UB Group’s Brewing Division has also assumed undisputed market leadership with a
national market share in excess of 48%. Through a process of aggressive acquisition and market
penetration, The UB Group today controls 60% of the total manufacturing capacity for beer in
India. The flagship brand, Kingfisher, is now sold in over 50 countries worldwide having
received many accolades for its quality.
Kingfisher, one of the flagship brands of The UB Group, has partnered with NDTV, India’s
leading broadcast group in a first-of-its-kind media alliance for the promotion of NDTV Good
Times.
The UB Group’s Kingfisher Airlines is today the undisputed market leader in India’s aviation
market. In the short span since it was launched, Kingfisher Airlines has redefined the whole
experience of flying and has raised the bar by unleashing a host of product and service
innovations. It has received numerous awards since its inception.
Kingfisher Airlines offers Full Service and an unparalleled experience to the Indian air traveller.
In-flight entertainment has been taken to a new level with the introduction of Live TV to
compliment the latest and finest Audio and Video on Demand system that is available. With the
merger of Air Deccan and Kingfisher Airlines, the airline covers all segments of air travel from
low fares to premium fares and offers the maximum number of flights offered by any single
airline network in India.
Dr. Mallya is the Chairman of public companies both in India as well as in the USA. He has been
the Chairman of Aventis Pharma India (previously Hoechst) as well as the Chairman of Bayer
Crop Science in India (previously Agrevo) for over 20 years, in addition to his Chairmanship of
several other corporations.
Dr. Mallya is the first Indian ever to become the owner of a Formula One Team. The
Netherlands-based Mol Family and Dr. Mallya have formed a consortium that is now the joint
owner of Force India Formula One, which is also India’s first-ever Formula One Team and
represents India’s first, truly global sports foray.
He is a keen sportsman and is an ardent aviator and yachtsman of distinction. He not only
participates in various sporting events but also supports various sporting activities worldwide,
particularly for the under privileged.
19
THE UB LOGO and its Evolution
The emblem of the UB Group- the winged horse of Greek mythology-has evolved as a very
strong brand identity and has become synonymous with United Breweries. The origin of the logo
is unknown but as far back as 1944, the flying horse with a cask of beer on its back and between
its wings became part of the UB lore with the UBL's diversification and changed image, the cask
is gone.
Then, the highflying Pegasus symbolizing the Group's forays into hitherto unexplored avenues,
its wings flapping tirelessly and assuredly, in its journey towards a beckoning future. The colors
of gold and the UB blue denoted exclusivity and dynamism.
Rationale behind the latest UB Group Logo
Reflecting the ever renewing force behind the UB Group, the new UB Group identity, the well
know UB Pegasus, has been redesigned to emphatically reflect the spirit of an organization
which is becoming younger, Global, Energetic and ever ready to take a leap forward.
The Pegasus has been completely redrawn and relationship with the letterform UB made more
unique and emphatic. The letterform UB itself has been redesigned so that the U and B are
interlinked making it more distinctive. The Pegasus leaps forward, ever in motion and the new
Blue will help it stand out in crowded visual spaces.
The new identity will go a long way to add value to each of the Group companies and the UB
Group as a whole.
20
Mission and Quality Statement:
Mission statement
We constitute a large, global group based in India. We associate with world leaders in order to
adopt technologies and processes that will enable a leadership position in a large spectrum of
activities.
We are focused on assuming leadership in all our target markets.
We seek to be the most preferred employer wherever we operate.
We recognize that our organization is built around people who are our most valuable asset.
We will always be the partner of choice for customers, suppliers and other creators of innovative
concepts.
We will continually increase the long-term value of our Group for the benefit of our
shareholders.
We will operate as a decentralized organization and allow each business to develop within our
stated values.
We will be a major contributor to our National Economy and take full advantage of our strong
resource base.
We commit ourselves to the ongoing mission of achieving Scientific Excellence.
Quality statement
Quality leadership is vital to the long-term success of the UB Group in an increasingly
competitive marketplace.
Building quality into our workplace, products and service is essential to a successful future for
our customers, employees, supplier’s communities and shareholders.
The UB Group will work to provide products and services that always meet or exceed
expectations
Management will commit resources and create an environment in which each employee can
contribute skills, talents and ideas to a never-ending process of improvement and innovation in
all aspects of our business.
Dr.VijayMallya
Chairman
21
Business of UB Group
United Breweries Limited-
United Breweries Limited (UBL) is the flagship company of the UB Group. Founded in 1915
from the merger of five breweries in India, the company is headquartered in Bangalore and
commands 48% of the domestic market with leading brands such as Kingfisher, UB Export,
London Pilsner, Premium Ice and Kalyani Black Label. The beer manufacturing giant owns 11
factories and has five regional offices. The company was bought by late Mr. Vittal Mallya in
1947, and since then has never looked back. Today each one of the 32,000 Beer outlets in India
sells one brand or the other from United Breweries.
On March 15th Mr. Thomas Leishman purchased 5 breweries to form United Breweries Ltd.
which had its registered office at 17 Armenian Street, Chennai-1. In 1944 first bottled beer under
the label “export beer” was produced. In the year 1948 Mr. Vittal Mallya became the first
chairman of UB group. In 1950 registered office move to Bangalore. In the year 1960 the
Kalyani Breweries was set up. After 5 years Kesarwal beverage was set up in Goa. In 1972 high
range breweries was set up in Chertalla in Kerala. UB beer started to export in Aden ad Middle
22
East in the year 1947. Soon after, in 1978 the Punjab Breweries was formed. Canned beer was
introduced in 1981. In 1982 UB’s kingfisher lager hit parlous in England and USA. After one
year UB invested in Brewing business in USA by purchasing 6 Micro breweries. In the year
2001 MABL was formed.
Here, innovative, creative and aggressive marketing is complemented by a strong distribution
network. A management focused on building brand equity on one hand and exploiting it to the
hilt on the other. A concerted emphasis on quality is maintained here.
UBL today boasts an impressive spread of own and contract manufacturing facilities throughout
the Country.
Its flagship brand 'Kingfisher', has achieved international recognition consistently, and has won
many awards in International Beer Festivals. Kingfisher Premium Lager beer is currently
available in 52 countries outside India and leads the way amongst Indian beers in the
International market. It has been ranked amongst the top 10 fastest growing brands in the UK.
In addition, UBL has also entered into multi-faceted strategic alliance with Scottish & New
Castle Plc (S&N), an international brewery major, with $6 billion in revenue and a market
capitalization of $5.4 billion. This alliance, apart from having a joint venture in India, will allow
S&N to market it International brands like Kronenbourg in India, while UBL will utilize S&N's
global network to further globalize its Kingfisher.
A significant innovation in the launch of a pint pack of UB export lager in a several critical
market of the country has opened up a new segment, driving both volumes and market share.
This innovation which delivered superior price value equation to the consumer offers a value
330ml pack in key market, mainly UB export in Karnataka, Kingfisher premium lager in Goa
and Kalyani Black Label in Kolkata. This growth deliver not only increased the volumes but it
has also succeeded in expanding the market, of which the company has taken a significant share.
The company’s market share improved by 330 basis point to 40%, replicating a growth of 300
basis points in the previous year. Significantly, in a very short span of time, kingfisher strong has
established a sizeable 20% market share of the strong beer market, making it one of the most
successful brand launches in the industry in recent times.
The company continues to invest in its brands ensuring top of mind recall with customers. The
UBL has now stretched its business from its traditional sector of beverage alcohol to various
other sectors under the umbrella named UB group.
23
Aviation
Kingfisher Airlines is now one of the most famous airlines which has access to both domestic as
well as international arena. In the very beginning it took over Jet Sahara and gained the
international access. It claims to be the only 5 star airlines in India.
Fertilizers
Located in Karnataka, the only fertilizer company under UB's management has affected an
amazing turnaround to become one of the most efficient and profitable naphtha based urea
producers in the country. In 1990, the Government of Karnataka had selected the UB Group to
take over Mangalore Chemicals & Fertilizers (MCF) - a "potentially sick" unit with accumulated
losses in access of 600 million rupees. The careful nurturing and astute management under UB
ensured the remarkable turnaround. Since last six years, the company has recorded profits every
year and cash flows have sufficed for repayment of accumulated debts. With an investment of
over Rs.400 Crores, the Company is the only large scale fertilizer project in the State of
Karnataka. The Company achieved a turnover of Rs. 614 crores, up 9% over the previous year.
Engineering
The UB Group's Engineering Division - is one of the foremost Indian engineering companies in
the field of installation of industrial plants. UB Engineering's activities are strongly focused on
the Turnkey Division for projects in Power, Fertilizers, Oil & Gas, Fire Fighting, Effluent
Treatment, Agrotech and other sectors - concept to commissioning, on-site fabrication,
installation, overhauling and maintenance. The range of its operations and concept to
commissioning services combined with excellent track record in industrial construction
worldwide has allowed UB Engineering to cut across geographical and political boundaries.
International Trading
International Business Division of the UB Group, in exports of
Beverage Alcohol
Processed Foods
Leather Footwear
Apparel
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Infrastructure
United Breweries (Holdings) Ltd. has also pioneered the development of prized real estate in the
heart of Bangalore. It is constructing one of the largest mixed-use developments - UB CITY, in
the heart of Bangalore. UB CITY will stand tall at the corner of Vittal Mallya Road and Kasturba
Road, just 600 metres away from Bangalore's commercial hub, M. G. Road. Its internet ready
intelligent buildings will demonstrate how chrome, glass and greenery can seamlessly blend
between modern edifices and serene flora.
It has also stretched its business to pharmaceuticals, media and world of glamour and
entertainment and s successfully managing to handle all the sectors efficiently.
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The Alcoholic Beverage Business of the UB Group
The various alcoholic beverages the UB Group manufactures are spirits, wines and beer.
United Spirits Limited (USL) - the INR 5700 crore spirits arm of the UB Group – is India’s
largest and the world’s 2nd largest spirits company. USL was earlier McDowell and Company
Limited. USL has a portfolio of more than 140 brands, of which 19 are millionaire brands*
(selling more than a million cases a year) and enjoys a strong 59% market share for its first line
brands in India. United Spirits recorded global sales of 90 million cases for the fiscal year that
ended on March 31, 2009.
USL Millionaire Brands (Those that sell more than a million cases per annum)
Whisky Brandy Rum Vodka & Gin
• Bagpiper
• McDowell’s No.1
• Director’s Special
• Old Tavern
• Haywards
• McDowell’s Green Label
• Gold Riband
• Royal Challenge
• DSP Black
• Signature
• McDowell’s No.1
• Honey Bee
• John Ex-Shaw
• Celebration Rum
• Old Cask Rum
• Old Adventurer Rum
• White Mischief
• Romanov
• Blue Riband
Wines
The different varities of wines manufactured by UBL are Kingfisher Bohemia, Pinotage,
Chenin Blanc Chardonnay, Pinotage Rosé, Bouvet Ladubay.
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Beer
United Breweries Limited
The beginning of what is today The UB Group is rooted in the flagship company, United
Breweries Limited, (UBL) also referred to as the Beer Division of the UB Group. Led by Mr.
Kalyan Ganguly, President & Managing Director, it has around 48% market share in the country.
United Breweries Limited has an association with brewing, dating back over five decades;
starting with 5 breweries in South India in 1915. From bullock cart-loaded barrels or 'hogsheads'
of frothing ale, the Beer business has gone on to become the undisputed 'king' in the Indian beer
market.
The company manufactures beer in 650 ml in bottles and 330 ml in cans and small bottles. The
different varities of beer manufactured by the UBL are:
Kingfisher Premium Kingfisher Strong Kingfisher Blue
Kingfisher Red Kingfisher Ultra Kingfisher Draught
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Zingaro Sand Piper UB Premium Ice
Kalyani Black Label Premium
Profile of UBL Kalyani:
The United Breweries Limited, Kalyani is a manufacturing unit which is meant for producing
Kingfisher Lager Beer, Kingfisher Strong Beer, Kalyani Black Label Premium, Kalyani Black
Label Strong, Sandpiper, and Kingfisher Premium Pites. This unit of UB ltd at Kalyani is headed
by assistant vice president. Reporting to him are departments like process, engineering, quality
assurance, commercial, human resource (hr) and finance, each headed by one departmental head
to whom other officials are accountable, the total of this complement represent the
managerial/supervisory group numbering 32
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RESEARCH METHODOLOGY
Research methodology is the arrangement of condition for collection and analysis of data in a
manner that aims to combine the relevance to the research purpose with economy in procedure.
Research is conceptual structure within which research is conducted. It is way to systematically
study and solve the research problems.
Primary Objective:
The basic objective of the research was to understand the entire process of beer making and
bottling and thereby identifying the status of microbial loading in different processes and
improving the microbial compliance in those processes. The plant was facing a problem of
contamination of the beer even though strict measures were taken to eradicate it. As because the
product comes under food and beverages and is consumed by people hence care is taken that the
quality of beer is not hampered due to contamination of the beer by other microorganisms and
further due to contamination the life of the beer also decreases.
Data Collection:
The various methods of data collection are as follows:
Primary Data Collection:
Personal Observation:
The method of data collection was through personal observation of each and every process used
in manufacture of beer and learning it thereby. The entire process of beer starting from the
milling to the bottling and starting was carefully observed and noted down to study the status of
microbial contamination.
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Personal Interview:
Personally asking the personnel involved in each process of each department about the process
and the various materials involved in it and thereby noting it down. Further personally asking the
engineers of different sections such as Brew House, Filtration, Fermentation and bottling about
the process gave me a clear picture about the entire process of beer making. This further helped
me in recognizing the status of microbial loading in different processes.
Secondary Data Collection:
The help of secondary data was also sought in learning the process of beer making. The help of
various books related to brewing was studied. Internet formed as a source of great help in
gaining secondary information and adding to whatever had missed during personal observation.
Scope of the Study:
The scope of the study is to have an in depth knowledge of the entire operational procedure of
beer manufacturing and the problems involved in such an industry. Further, the study also
involves in finding the remedies of certain problems faced during the process which is otherwise
overlooked by the workers due to various reasons. These things if properly handled can improve
the quality of beer and the life of it and thus increasing the brand image of the product and of the
company as a whole.
Limitations of the Study:
The authenticity of the suggestions and recommendations depend upon the rationality of
the data provided to me.
Have to rely upon the data supplied.
Executives are not ready to part with the information beyond a limit as the process is
trade secret and is not to be exposed.
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The Process of Beer Manufacture In United Breweries
Limited Kalyani
In any beer industry there are basically 3-4 sections depending on the process. These are as
follows:
The Brew House.
The Fermentation section.
The Lagaring and Filtration section.
The Bottling section.
Each of these sections and the processes involved in each are discussed as follows:
The Brew House
The main raw material for making beer is malt which is processed from barley. Barley is
processed in mills into malt which contains the required enzymes to convert the insoluble starch
in the barley to soluble and simple sugar molecules. This process of converting barley into malt
is known as Malting. The process of malting is described as follows:
Malting
Malting serves the purpose of converting insoluble starch to soluble starch, reducing complex
proteins, generating nutrients for yeast development, and the development of enzymes. The three
main steps of the malting process are steeping, germination, and kilning.
a) Barley Steeping
The purpose of steeping is to evenly hydrate the endosperm mass and to allow uniform growth
during germination. Steeping begins by mixing the barley kernels with water to raise the
moisture level and activate the metabolic processes of the dormant kernel. The water is drained,
and the moist grains are turned several times during steeping to increase oxygen uptake by the
respiring barley. A wide variety of steeping regimes are used, depending on the steep vessel
configuration, barley variety, barley quality, kernel size, brewery specifications, and maltster
preferences (21).
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b) Barley Germination
In the next step, the wet barley is germinated by maintaining it at a suitable temperature and
humidity level until adequate modification has been achieved. The techniques most commonly
used for germinating barley are floor malting and pneumatic malting. Floor malting is an old
process in which the chitted malt is spread on the floor to a height of 10 to 20 cm. Pneumatic
malting uses forced air for the germination process. There are numerous mechanical designs for
pneumatic malting such as drum malting, compartment malting, continuous malting, and tower
and circular malting, and flexi malting.
c) Malt Kilning
The final step is to dry the green malt in the kiln, which is done at different temperatures. The
temperature regime in the kiln determines the color of the malt and the number of enzymes
which survive for use in the mashing process. For example, low temperature kilning is more
appropriate for malts when it is essential to preserve enzymatic (diastatic) power. These malts
are high in extract but low in coloring and flavoring compounds.
Malt Constituents
Malt is largely made up of carbohydrates, which are composed of starch, sugars, insoluble
cellulose, and soluble hemicellulose. Starch, the most important constituent, accounts for about
60 to 65% of the malt's weight, is composed of amylose, which is reduced to maltose and
maltotriose and amylopectins that decompose into glucose. Glucose, a monosaccharide, accounts
for about 1 to 2% of the total starch found in a barley kernel. Cellulose constituents do not
contribute to fermentable extract or desirable flavors in the malt. Hemicellulose is a constituent
of the endosperm cell walls, which consist largely of beta-glucan.
The company buys the malt from suppliers and does not do the processing part of barley to
malt.The process of beer making in the plant starts from milling of the malt. This is known as
malt grinding. The company has its own grinding mill in the plant itself
1. Malt Grinding
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The objective of milling is to reduce the malt to particles sizes, which will yield the most
economic extract (wort) and will operate satisfactorily under brew house conditions and
throughout the brewing process. The more extensive the malt is milled, the greater the extract
production. However, the fine grind can lead to subsequent wort separation problems and a loss
of extract in the spent grains during wort separation. As a result, the brewer needs to consider the
equipment used in the brew house when determining the particle size when milling the malt. For
example, mash tuns require comparatively coarse grists while lauter tuns can use finer grists and
mash filters still finer grists.
Weighing and Cleaning
For larger breweries, a typical flow of malt upon arrival at the brewery begins by weighing the
vehicle on the weigh-bridge and unloading the malt via a hopper. After unloading, the vehicle is
tare-weighted, with the difference in weights being the weight of the malt.
Silos
Once weighed and cleaned, the malt is conveyed to silos for storage. Silos are constructed of
either corrugated galvanized steel, which is considerably cheaper or welded steel, which
reportedly offers a higher level of protection from moisture. The minimum size for silos is
usually 800 cubic feet, large enough to accommodate one truckload of malt.
Hopper
Before milling, malt is removed from the silo and transferred to the feed hopper supported on a
mechanical platform located at the grist case-a buffer containing the milled malt before the mash
vessel.
Grist Case
After milling, the milled malt is transferred to a temporary storage hopper, commonly called the
grist case, that feeds the mash tun.
Dry Milling
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Usually mills are of two types roller and hammer mills. In UBL brewery, dry milling is
commonly performed by roller mills. Since the wort separation involves using a lauter tun, roller
mills are employed. Hammer mills are largely used for the later generation of mash filters and
continuous brewing systems.
Sieve Analysis of Crushed Malt
Not only is the grist profile critical to achieving maximum conversion of available extract during
mashing but it is also important for efficient wort filtration and sparging. Consequently, a
complete screen analysis of the crushed malt when milling should be made on a regular schedule,
with any adverse change in the mill's performance warranting an immediate correction.
Screen analysis consists in placing a sample of grist in the top set of horizontal sieves, which is
shaken manually or mechanically for a set period of time.
After the malt is grinded according to the predefined texture and the sieve analysis is being done
the grinded malt is ready for Mashing.
Beer Adjuncts
Adjuncts are nothing more than unmalted grains such as corn, rice, rye, oats, barley, and wheat.
Adjuncts are used mainly because they provide extract at a lower cost (a cheaper form of
carbohydrate) than is available from malted barley or to modify the flavor of the beer. Adjuncts
are used to produce light-tasting, light-colored beers that have the alcoholic strength of most
beers. Adjunct use results in beers with enhanced physical stability, superior chill-proof qualities,
and greater brilliancy. The greater physical stability has to do with the fact that adjuncts
contribute very little proteinaceous material to wort and beer, which is advantageous in terms of
colloidal stability. Rice and corn adjuncts contribute little or no soluble protein to the wort, while
other adjunct materials, such as wheat and barley, have higher levels of soluble protein. Except
for barley, adjuncts also contribute little or no polyphenolic substances.
Adjuncts can be used to adjust fermentability of wort. Many brewers add sugar and/or syrup
directly to the kettle as an effective way of adjusting fermentability, rather than trying to alter
mash rest times and temperatures.
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Adjuncts are often used for their flavor contribution. For example, rice has a very neutral aroma
and taste, while corn tends to impart a fuller flavor to beer. Wheat tends to impart a dryness to
beer. Semi-refined sugars add flavor to ales that has been described as imparting a luscious
character. Adjuncts will also alter the carbohydrate and nitrogen ratio of the wort, thereby
affecting for formation of byproducts, such as esters and higher alcohols.
The adjuncts commonly used in UBL Kalyani are either broken rice or maize grits or sometimes
rice flakes. Broken rice and or maize grits are processed before mixing it with the grounded malt
in the mash kettle. So the usual process of Beer making starts with the processing of the adjuncts.
Rice or maize grits are usually processed in the same way both being the source of sugar. These
adjuncts are made ready by boiling them in specialized cooker and in the mean time the
processing of the grounded malt goes simultaneously in the mashtun. The process of rice
cooking is described below:
2. Processin g of broken rice/ maize grits in the Rice Cooker
Rice is boiled in a rice cooker which is a massive container designed specially for boiling
rice which is finally mixed with the mash. The gross capacity of the rice cooker is 120
HL and the working volume of the rice cooker is 80 HL. For preparing a wort of 220 HL,
41HL of sterile water is added in the cooker together with it 640 kg of rice is added.
Temperature of the cooker is maintained at 45°C . This activates beta-glucanase, which
breaks down gummy beta-glucans in the mash, making the sugars flow out more freely
later in the process. To this 6kg of gypsum and 1.5 lts of biotempase is added and lid of
the cooker is closed.
The temperature is then allowed to rise to 55°C and together with it continuous stirring is
don inside the container (the cooker is specially designed and has a stirrer in it which stirs
the entire contain of the rice cooker at a constant speed). Then a rest of 10 mins is given
to the entire thing, temperature being constant. This activates various proteinases, which
break down proteins that might otherwise cause the beer to be hazy.
Then the temperature is allowed to rise to 85°C. This takes a lot of time. When the
temperature in the computer shows 85°C the stirring operation is stopped and a rest of 20
min is given to the entire system.
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After this the temperature is raised to 95°C and a final rest of 20 min is given to the entire
system. This rice is now ready to be added to the mash tun. It is to be remembered that
the gradual rise in temperatute with intermittent break in between has is because for some
biochemical reactions occurring inside the rice cooker which is favourable for the process
of beer making.
3. Mashing in the Mash Tun
By the time the rice is getting boiled in the rice cooker simultaneously the malt is also getting
boiled im the mashtun . The resulting grist which is formed after the malt is crushed in the malt
mill to break apart the grain kernels, increase their surface area, and separate the smaller pieces
from the husks is mixed with heated water in a vat called a "mash tun" for a process known as
"mashing". During this process, natural enzymes within the malt break down much of the starch
into sugars which play a vital part in the fermentation process. Mashing usually takes 1 to 2
hours, and during this time various temperature rests (waiting periods) activate different enzymes
depending upon the type of malt being used, its modification level, and the desires of the brew
master. The activity of these enzymes converts the starches of the grains to dextrines and to
fermentable sugars like maltose. In UBL Kalyani the following procedure is adopted in mashing:
For preparing 220 HL of wort grounded mash of near about 2750 kg is added in the mash
tun which takes 20 minutes to fall in the mashtun from the mill. To this 195 HL of water
is added which is at 45 °C. This activates beta-glucanase, which breaks down gummy
beta-glucans in the mash, making the sugars flow out more freely later in the process.
To this 1.5 kg calcium chloride, 6kg gypsum,1.5 kg beta glucanase, 0.8 kg of promalt,
termamoil and 5 lts of lactic acid id added and the lid of the mash tun is closed for the
heating of the mixture. The temperature of the whole content is allowed to rise to 52°C
together with continuous stirring of the whole mixture.
As soon as the temperature rises to 52°C the whole content of the mashtun is allowed to
rest for 20 minutes. This is known as protein rest. This activates various proteinases,
which break down proteins that might otherwise cause the beer to be hazy. But care is of
the essence since the head on beer is also composed primarily of proteins, so too
aggressive a protein rest can result in a beer that cannot hold a head.
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After this the rice from the rice cooker which is at 95°C is allowed to pass into the
mashtun through which connects the two. When the whole rice of the rice cooker is
passed into the mashtun the temp of the mashtun automatically rises to 64°C and if not
the temperature of the whole system is raised to 64°C and a rest of 50 minutes is given to
the system. This is used to convert the starches in the malt to sugar, which is then usable
by the yeast later in the industrial brewing process\.
After this the temperature of the entire content is raised to 71°C. As soon as the
temperature rises to 71°C the whole wort is given a rest of near about 30- 40 minutes.
This is known as saccharification rest. At this temperature the beta amylase of the malt
gets activated and cleaves all the starch molecules of the malt to simple molecules of
glucose and maltose on which the yeast feeds and ferments it to alcohol. As soon as the
saccharifiaction is confirmed the temperature of the entire content is again raised to 76°C
and then the mash is sent to the lautert tun for wort clarification. At this temperature all
other enzymes in the malt gets deactivated.
4. Wort clarification in the Lauter Tun
After the mash is ready it is transferred to the lauter tun which is the traditional vessel used for
separation of the extracted wort. A Lauter tun has two bottoms, one the false bottom for filtration
and the other the collecting bottom which collects the filtered wort. The false bottom in a lauter
tun has thin slits or perforations to hold back the solids and allow liquids to pass through. Before
the wort enters the Lauter tun 5HL of water is collected on the false bottom of the LT. This is
done because when the mash enters the LT it is very hot and thick in consistency and this may
choke the perforations of the LT which may hamper the entire process of wort clarification.
The solids, not the false bottom, form a filtration medium and hold back small solids,
allowing the otherwise cloudy mash to run out of the lauter tun as a clear liquid. The false
bottom of a lauter tun is today made of wedge wire, which can provide a free-flow
surface in the bottom of the tun
The lauter tun has rotating rake arms with a central drive unit. Cutting blades hang from
these arms. The blade is usually wavy and has a plough-like foot. Each blade has its own
path around the tun and often the whole rake assembly can be raised and lowered.
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Attached to each of these arms is a flap which can be raised and lowered for pushing the
spend grains out of the tun.
After the mash is filtered the liquid free of the spent grains is collected on the main
bottom of the Lauter tun. This is known as First Wort. This wort is again recirculated
from the spent grain and within 5 minutes a clear wort enters the Lauter tun. After this
water is sparged on the spent grains so that the sugar left in the spent grains could be
extracted and collected with the Firlearst Wort. This is done once again to accomplish the
same purpose. After the wort is collected in the lauter tun the purpose of the lauter tun is
served. This clear wort is then collected in a Wort Collecting Vessel. This vessel just
collects the clear wort from the lauter tun and has no other function. This vessel comes
into action only when the wort kettle is in work or else the wort from the lauter tun is
directly collected in the Wort Kettle for boiling.
After the last wort has left the lauter tun, spent grains are removed from the lauter tun and
discarded. The grain-out doors are opened, the rakes are raised out of the grain bed, and
the knife angles are changed to the grains-out position. The spent grains thus collected is
discarded out of the lauter tun with steam pressure which forces the spent grains to pass
out of the lauter tun. This spent grain is sold as cattle feed in the market.
5. Boiling of the wort in the Wort Kettle
After the entire wort is collected in the wort kettle the next step of wort boiling is carried on.
The entire process of wort boiling is completed in 70 mins. As soon as the wort enters the
wort kettle all the ingredients required in the process of boiling and imparts taste to the beer
is added in the wort kettle. Hops, a vital ingredient is added to the wort. This imparts the
characteristic bitter taste to the beer. This hops is in pellet form and is nearly 2.4 kg in
weight. Together with 5 cans of hops extract is also added to the wort. This is company
specific and is calculated according to the quantity of the wort prepared. The hops pellet and
the wort extract imparts the bitterness to the beer. The major flavor contribution of hops in
beer is bitterness from iso-alpha acids. During the boil, the insoluble alpha acid extracted
from hops is converted to a more soluble iso-alpha acid.
The major reasons for wort boiling are as follow:
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Sterilization
Although the wort separation and sparging processes are normally conducted at
elevated temperatures (76-80°C), wort entering the kettle contains numerous
microorganisms-yeast, molds, and bacteria-which can result in off-flavors and
numerous other problems.
Enzyme Inactivation
Boiling fixes the carbohydrate composition of the wort by inactivating residual
enzymes that are responsible for carbohydrate and protein degradation and that may
have survived mash-off or sparging.
Protein Precipitation
During the boiling process, it is necessary to decrease the level of high molecular
weight nitrogen found in the malt. Protein precipitation occurs as the wort loses its
turbidity during boiling, and material breaks out of suspension and precipitates as
proteins coagulate.
Color Development
During boiling, the color of the wort becomes darker. This is brought about by the
formation of pigments (melanoidins), the oxidation of polyphenols, and the
caramelization of sugars.
Production of Melanoidins
The production of melanoidins-the Maillard reaction-occurs when reducing sugars
from carbohydrates react with amino acids that are derived from the proteins during
mashing.
Oxidation of Polyphenols
The oxidation of polyphenols is another source of color formation. Polyphenols are
sometimes referred to as "tannins" and may be derived from malt husks and hops.
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Carmelization of Sugars
Caramelization is a chemical process that affects sugars subjected to temperatures of
200°C or greater.
Isomerization
The major flavor contribution of hops in beer is bitterness from iso-alpha acids.
During the boil, the insoluble alpha acid extracted from hops is converted to a more
soluble iso-alpha acid.
Dissipation of Volatile Constituents
Boiling of wort drives off volatile wort compounds, including dimethyl sulfide,
aldehydes, and hydrocarbon components of the hop oils. The principal malt derived
volatile lost during boiling is dimethyl sulfide or DMS which is rapidly lost through
evaporation.
Concentration of Wort
The wort must be concentrated by evaporation since the water used in mashing and
sparging has produced wort lower in specific gravity than the target gravity.
Reduction in Wort pH
As previously mentioned, the pH of the wort starts to decrease during mashing and
continues to fall during wort boiling to reach a final pH of between 5.2 and 5.3.
After the addition of hops and hops extract 1.2 kg of caramel is also added to the wort and the
whole thing is allowed to boil. Just before 15 mins. of completion of boiling nearly 600kgs of
sugar is added to the boiling wort . this imparts the taste and colour to the wort together with
fermentation medium for the yeast.
Further prior to 5 mins of completion of the boiling sazz is added to the boiling wort to add taste
to the beer.
After this the specific gravity of the boiled wort is noted which is nearly 15.8. This completes the
wort boiling. The boiled wort is then carried to the Whirlpool in which the wort clarification
takes place.
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6. Wort Clarification in Whirlpool
Usually there are various method cleaning the wort of its debris, like hop strainers,
hop back, etc. but the equipment used in the plant is known as the Whirlpool. It is a
circular vessel into which wort is introduced tangentially. The tangential inlet is
responsible for the centrifugal force that accelerates the trub outside of the wall and
downwards. The transfer rate from wort kettle to whirlpool is 4000 HL/ hr but care is
taken to avoid shear forces.
The trub initially forms a cone and then settles down with clear wort taken off from
various outlets at different levels.
The objectives of wort clarification are as follows:
Removal of coagulated protein- polyphenol flocs called hot break.
Removal of hop debris and other solids.
Maintaining sterility.
7. Wort Cooling
Wort needs to be cooled to 12°-16°C for fermentation as this is the optimum temperature for
yeast to function and the required flavor development. The process of cooling is carried out
in plate heat exchangers. The plate heat exchangers operate in counter flow for optimum heat
transfer with principal cooling agent being chilled brewing water. The wort after clarification
is being passed through the PEC. On one side of the plate cold water flows and on the either
side of it the hot wort. as son as the wort comes in contact with the plate due to counter flow
action of the PEC and due to the effect of the cool water the wort temperature falls down to
12°C which is the fermenting temperature.
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8. Wort Aeration
During wort cooling one more important aspect is wort aeration. The microorganism yeast is
a facultative anaerobe and the fermentation process is anaerobic i.e. without oxygen, but for
the yeast to replicate and live it needs dissolved oxygen which is not present in the wort.
Aeration is done in the cold wort as oxygen absorption is more at low temperature.
This is the final wort which is ready for fermentation by the microorganism yeast. After
aeration the wort is collected in large fermentors in which fermentation of the wort takes
place.
The Fermentation section
Fermentation is the process by which fermentable carbohydrates are converted by yeast into
alcohol, carbon dioxide, and numerous other byproducts. It is these byproducts that have a
considerable effect on the taste, aroma, and other properties that characterize the style of beer.
The most important thing in beer production is the microorganism which ferments the malt to
desirable level of alcohol. The microorganism which is used for the purpose is Yeast
(Saccharomyces sp.). The yeast strain itself is a major contributor to the flavor and character of
the beer. The company imports its characteristic yeast slant from abroad and grows it in the
plant. There is a separate room for the production of yeast to be used in the fermentation process.
The particular yeast strain is a company secret and is kept in strict supervision so that it is not
stolen or leaked.
The preparation of yeast in the yeast room takes place in the following manner:
At first the slant culture of yeast in grown in 250 ml of nutrient medium and after 1 day of
incubation it is transferred to 1 litre of medium and allowed to grow. This thing goes on in the
laboratory and after this the yeast is grown in the yeast room. The yeast is transferred to 5 litres
of wort and after full growth the yeast is transferred to a a large vessel which contains 5 HL of
wort and after this it is stored in YSV 1 and YSV 2. Temperature , pH and pressure is taken care
of for the optimal growth of the yeast.
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Yeast pitching:
The brewer's ability to pitch the correct number of yeast cells to initiate fermentation is crucial to
consistently producing a product of superior and constant quality. Pitching rates are governed by
a number of factors, including yeast strain, fermentation capacity of the yeast, yeast viability,
flocculation characteristics, previous history of the yeast, and desired beer flavor characteristics.
Other considerations when choosing pitching rates include wort gravity, wort constituents,
fermentation temperature, and the degree of wort aeration. For example, highly flocculent yeast
strains may settle prematurely, requiring the brewer to either over-pitch or to mix and aerate the
yeast by "rousing."
The generation of the yeast is of utmost important and before pitching it with wort the cell count
of the yeast stored in yeast vessel and the viability and the generation of the yeast is ckecked. If
the yeast is newly grown then it is directly pitched with the wort. If the yeast has already
undergone 1 cycle of fermentation and then stored for the next fermentation then it has to
undergo acid wash treatment.
Before pitching yeast the yeast is washed with ortho phosphoric acid. Usually 180 kg of yeast is
pitched for 1 single fermentation of 1100 HL of wort. This amount of yeast is collected in the
yeast collecting vessel.
In an acid addition vessel nearly 370 ml of said acid is poured with some water . Yeast from the
yeast collecting vessel is allowed to collect in another vessel known as acid- yeast mixing vessel
and then acid is passed into this is vessel and is mixed for half an hour.and then is stored for
further fermentation.
Reasons for acid wash of yeast which is already used for fermentation:
a) Before addition of yeast the pH of yeast is near about 4-5 whereas after addition of acid the pH of
yeast falls to 2-3 and this enables the yeast to synchronise with the pH of the wort.
b) Acid wash enables the old yeast to rejuvenate as well as the dead yeast to purify from that of the
living yeast.
c) Further at this low pH the chances of contamination of the yeast culture and that of the whole
wort is very low and hence this maintains the sterility of the entire culture.
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After the yeast is ready for fermentation it is pitched into the unitanks or the fermentors in which the
fermentation of the wort is going to take place. The yeast pipeline is joined with that of the wort pipeline
and they together enter into the fermentor in a mixed state and hence this solves the problem of mixing of
the yeast culture in the wort.
Fermentation vessel used in the process:
Unitanks: There are altogether 11 unitanks in the plant. Of these 8 unitanks are of 1120
HL and 2 are of 1080 Hl capacity and 1 is of 1600HL capacity. The unitanks are denoted
as UT 1-11. Unitanks are cylindroconical tanks and are also called CCTs. They have a
conical bottom and a cylindrical top. The cone's aperture is typically 60°, an angle that
will allow the yeast to flow toward the cones apex, but is not so steep as to take up too
much vertical space. CCTs can handle both fermenting and conditioning in the same
tank. At the end of fermentation, the yeast and other solids which have fallen to the cones
apex can be simply flushed out a port at the apex
Lagar Tank: these tanks are cylindrical in shape and is used only for maturation of beer
that is lagaring of beer. There are 8 small capacity lagar tank in the plant of 120 HL each
and 5 lagar tanks of larger capacity. The lagar tanks are denoted as LT with the tank
number.
Fermentors: These tanks are only made for fermentation and after its purpose is being
solved the content of these vessels are piped to lagar tanks where lagaring is done. There
are in totality 12 fermetors in the plant for only the purpose of fermentation.
Fermentation :
After the wort is cooled in the PHE after wort clarification in the whirlpool the wort is pipes
through motor in the fermentors either in FV or the UT for fermentation. The yeast is pitched
together with it and they enter into the fermenting vessel ina mixed state. The capacity of UT is
1120 HL and hence near about 5 worts are allowed to collect in each vessel and after each wort
collection of 220 HL from the brew house east is pitched alternatively. The entire fermenting
vessel is airtight and the entire fermentation carries on in an anaerobic state.
Everyday the gravity of the wort is checked and after the gravity of the wort falls to a
desired level of 2.2 due to fermentation of the wort and alcohol formation the
fermentation of the wort is stopped. The yeast is the organism which converts the sugar
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of the wort into alcohol and as soon as the alcohol level in the wort reaches 7% the
fermentation is stopped.
Diacetyl Rest
Employing high temperatures at the end of primary fermentation are for reducing diacetyl and
2,3-pentanedione (collectively referred to as vicinal diketones or VDKs). This procedure is
known as a diacetyl rest. VDKs, which are assimilated by yeast toward the end of fermentation,
are responsible for off-flavors in beer. The diacetyl rest reinvigorates the yeast culture so that it
metabolizes those byproducts-such as diacetyl and 2,3-pentanedione-that are excreted early in the
fermentation, thereby removing them from solution. Depending upon the yeast type, the medium,
and the physical environment, this process is variable in time and temperature.
Employing a diacetyl rest is particularly important when producing beers with high adjunct
fraction due to the high levels of diacetyl produced.
This is done by fullcooling the vessel to 4°C. at this temperature the activity of the yeast
seizes and they start to percolate at the bottom of the tank.
It usually takes 10 days for the entire process of fermentation.
The chemicals used in the fermentors are fermaid and or finizyme for some biochemical
procedure of the fermentation process.
Racking:
After the process of fermentation is stopped by fullcooilng the tank the yeast present in the tank
is piped out of the tank and stored in the yeast storing vessel for the next batch of fermentation
after acid treatment f the yeast. This process of taking out the yeast from the fermentation
vessel.is known as Racking.
As the yeast collects at the bottom it could be easily piped out by simply putting on the motor
and sucking out the yeast from the vessel. From unitanks it is easily piped out as the yeast
percolates at bottom of the cone. It is rather difficult to suck out the yeast from the fermentors
denoted as FV which are round bottomed. In these fermentors the wort is decanted from the top
and the fermented wort is passed into lagaring tank for maturation. The leftover yeast is then
stored in yeast storage vessel.
After racking is done some chemicals known as racking chemicals are added in the lagar tank ao
the unitanks. These chemicals help out in the percolation of the leftover yeast which might be
45
left over after fullcooling of the yeast. Further these chemicals also impart some effect in the
maturation of the beer in the lagaring stage. These chemicals are biofine, kms, profix, lucilite and
CO2.
Lagaring:
After the yeast taken out of the fermentors and left for matauration in either the lagar tank or the
unitank the process of lagaring starts. The process of maturation of beer is known as lagaring.
This is also known as secondary fermentation. In this process the beer is kept very low
temperature of nearly -1°C. At this temperature the beer matures and the characteristic flavor of
the beer comes in. This process goes on for 5 days and then the yeast is decanted of from the
vessel. This beer is known as green beer. This beer is sent for filtration.
Filtration:
After the fermentation is over the beer has to be filtered so that there is no haze in the beer and it
is free of any foreign particles and is crystal clear. This process is done in the filtration unit.
Although conditioning-maturation, clarification, and stabilization-plays an important role in
reducing yeast and haze loading materials, a final beer filtration is needed in order to achieve
colloidal and microbiological stability. The beer must be rendered stable so that visible changes
do not occur during its shelf life.
The filtration unit is known Della Toffola. This is a filtration equipment which works on the
mechanism of powder filter. The company employs powder filter for single pass filtration and is
able to produce beer that are suitable for packaging. In a powder filter, filtration is achieved with
the use of filter aids that form a filter bed on stainless wire mesh inside a pressurized vessel; or,
on cellulose sheets in a plate and frame filter; or, in the form of small holes in a candle filter.
While the screens and/or cellulose do not filter at all, but act as septum for the filter aids, it is the
applied "cake" of filter aid which does the filtration. The mechanics are very similar to those of
sheet filters. The chemicals which forms the bed for filtration are profix and KMS. These
chemicals are added in the chemical dozer. The beer pipeline is connected with the chemical
dozer and to the filtration pipe.
The beer together with chemicals falls into the filtration vessel and forms a bed on circular discs
which are inside the filtration vessel. At first the whole content is recirculized in the vessel and
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after the bed is properly formed the beer is filtered which is free of any free bodies. After the
filtration is over the haze of the beer is calculated and this beer is stored in tanks known as Bright
Beer Tank or simply BBT. There are altogether 9 BBTs in the plant for storing the filtered beer
for bottling and corbonation of the beer. The sediments from the beer are then discharged from
the filtration unit which is known as cake discharge which is collected and used in land filling.
The filtered beer passes through PHE which brings the temperature of the beer to 1°C. Biofoam
is then puched into this beer which is then stored in BBT.
BBT: In BBT the beer is properly carbonated. This is done by passing carbon dioxide into the
BBT. This is done to bring the tingy taste of the beer. Further carbonation brings the dissolved
oxygen of the beer to near to zero. The DO in any beer should be zero or nearer to it as this
increases the shelf life of the beer.
After the beer is properly carbonated the beer is ready for bottling and hence is sent for bottling.
The Bottling Process in UBL Kalyani:
The bottling usually deals with the cleaning of the used bottles, filling it with beer, pasteurizing it
and then labeling and packing it. The entire process could be described as follows:
Dirty bottles are collected from the vendors who supply it to the company. These bottles
are processed and these are only filled. The entire system of bottling is automatic and
computerized. Volunteers only check the process if its going correct or not. The bottles
are placed on the conveyer which conveys the bottle to the KHS Washing Machine. This
machine has a capacity of washing 21000 bottles per hour if everything goes well. The
bottles enter the machine and are washed inside automatically by 2.5% caustic solution
and with 80°C hot water. At this acidic concentration and at this hot temperature the
microbes in the bottles are destroyed and becomes more or less sterile and free of any
foreign bodies. Further the labels and other things attached on the body of the bottle is
removed in the KHS machine in the washing process.
The conveyer then arranges the bottles in a que and is conveyed to a check point where a
volunteer checks whether the bottle is free of any foreign body against a bright board
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which is illuminated for the purpose. If the bottle is not free of foreign bodies, it is either
destroyed or sent to the washing machine again depending upon the condition of the
bottle.
The conveyer then conveys the bottles to another checkpoint. At this point the volunteer
checks the surface of the mouth of the bottle. If the surface of the mouth is broken the
bottle is destroyed then and there. Only bottles free of any cracks on the surface of mouth
is used for bottling.
This bottle is then conveyed to the filling machine. This machine is also a KHS machine
and is fully automatic. The filling machine fills the bottle first with CO2 and then in
small quantities beer is filled in each bottle one by one such that the final quantity of beer
in thr bottle is nearly 650ml. and no filler remains idle. The filling machine consists of
discs on which the bottles rest and are filled with small pipe like fillers. These discs are
63 in number and can fill 63 bottles in one round. The speed of the filling machine is
nearly 18000 bottles/hour but usually due to certain halts in other process the speed limits
to 16000 bottles/ hour. After filling the capping is also done in the same machine.
After the bottles are filled and capped properly it is conveyed to another check point
where a volunteer checks the capping, quantity of beer and entry of foreign particles in
the beer which might have occurred during the filling and capping of the same. If there is
any fault the beer is discarded.
The bottles fro this check point is conveyed for pasteurization. Pasteurization is the
process of heating liquids at high temperature for killing microbes and making the liquid
sterile. The pasteurizer used here is known as Tunnel Pasteur. This machine consists of
6 chambers in which water flows at 6 different temperatures. In the first three chambers
the temperature of water used for pasteurization is 45°C, 50°C and 60°C respectively and
then next three chambers have water falling at 50°C, 45°C and 35°C the beer which is
filled in the bottles may contain microbes from various processes of fermentation and
filtration. This machine ensures the sterility of the beer as because if there is any microbe
in the beer it may spoil the beer and hence reduce the shelf life of the beer. The gradation
in temperature is because as the bottle is filled with chilled beer if it suddenly comes in
contact with 60°C hot water the bottle might burst thus loss of beer. Hence if temperature
is slowly raised the chances of bursting of bottles is nullified.
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After the pasteurization is over the bottles are conveyed to a check point where the final
checking of dirt, foreign bodies and quantity of the beer is done.
After this the bottles are conveyed to the labeling unit where labeling is done together
with the printing of MRP, batch no. and date of manufacture.
After this the bottles are conveyed to a check point where MRP, batch no. and date of
manufacture is checked.
After this the bottles are conveyed to the packaging unit where the bottles are packed in
cartons. 12 bottles of beer are packed in 1 carton. These are then conveyed for storage in
the warehouse for dispatch.
This completes the process of beer manufacture in the UBL Kalyani beer
factory.
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OVERALL PROCESSING
Raw Materials(Grinded)
Brew Water
Brew House
Whirl Pool
CO2
OUTLINE OF THE BREWING PROCESS
50
Spent gram
Boiled Wort
Yeast Storage tank Cold Wort
Yeast Pitching Fermenter CO2 Plant
Largaer Cellcarbonation
KMS, Profix & biofine
Plate & Frame Filter Press
Polisher Bright Beer tank
Biofarm
Packaged Beer
Production Line
Malt & adjuncts
FERMENTATION
OUTLINE OF THE PROCESS
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Water Treatment
Milling
Whirl Pool
Mash Tun
Lauter Tun
Wort Kettle
Hot Wort
Cold Wort To Fermenter
Spent Gram
Brew water
Air Sparging PHE
LAGERING AND FILTRATION
OUTLINE OF PROCESS
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Cold Wort
Yeast Pitching Fermenter CO2
Yeast Storage Vessel
CO2 Plant
Beer
Settled Yeast
Carbonation p=3kg/cm2
Beer Without Lagering &
PasteurizationLarger Cells(4/5 Days)
Plate & Frame Filter PressDiatomaceous Earth
Fermenter
Polisher
Can Beer (Without Lagering &
Pasteurization)Bright Beer TankProduction Line
Biofoam
BOTTLING OF BEER
OUTLINE OF THE PROCESS
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Empty Recyclable Bootles
Bottle Washer
FilterCrownerTunnel PasteuriserBottle Labeling CodingPackaging & StorageDispatch InspectionBBT Tank InspectionBottle Counter Inspection
KEY DISCUSSION AND ANALYSIS
Status of microbial loading in different processes and methods to improve the
microbial compliance.
Microbial contamination can originate from a variety of sources in the brewing process. Raw
materials, air, brewing water, additives, and even pitching yeast can act as a constant supply of
contaminants. Residues remaining in brewhouse tanks, pipelines, valves, heat exchangers, and
packaging equipment harbor microorganisms too that represent a potential source of
contamination. Some of the effects of contamination range from comparatively minor changes in
beer flavor and fermentation performance to gross flavor and aroma defects, turbidity problems,
abnormal attenuation rates, and reduced yeast crops.
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Microbial contamination is a huge loss in those food and beverage industry. Food items should
be always free from microbes as they prove hazardous both to the consumer as well as the
product itself.
A number of microorganisms have been reported to be beer spoilage microorganisms, among
which bacteria, as well as so-called wild yeast and molds. These may be summed as follows:
Bacteria
Gram-Positive Bacteria
Lactobacillus spp.
Pediococcus spp.
Gram-Negative Bacteria
Acetic Acid Bacteria
Zymomonas spp.
Pectinatus spp.
Enterobacteriaceae spp.
Wild Yeasts
Saccharomyces spp.
Non-Saccharomyces spp.
Brettanomyces spp.
Torulopsis, Pichia, and Candida spp.
According to the stages of production the species contaminating the beer changes from one
process to another.
Microbial loading in different processes and places in the plant:
In the brew house chances of microbial contamination is very liitle as because everything
in the brew house is processed at temperatures near to boiling point.
There is a chance of contamination when the wort comes in direct contact with the
PHE. If the PHE is not sterile it may contaminate the entire wort which in result may
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spoil the entire brew as its is the best medium for the growth of various types of
microorganisms.
There is also a chance of contamination when the wort is aerated. The air if by any
chance is not free of microbes it may contaminate the entire wort.
The racking pipe used for racking the chemicals in the tanks. These pipes are left open
in the air and hence there is a great chance for the pipe to harbor microbes in it. Further
the chemical dozer used for racking is also in free air and may contain microbes which
may infect the whole wort .
The box which contains the bend pipes used for various purposes in the flow plate is
kept in the yeast room. This trunk if not washed properly and daily may contain microbes
which may infect the pipe and thereby the wort.
The biofoam dozer which is used for dozing be biofoam to the filtered beer before it
enters the BBT also takes place in the free air. Hence there are chances that microbes
may infect the beer in the BBT and spoil it.
The chemical dozer used in the filtration for the filtration bed formation may also
harbor microbes as the whole operation is taking place in free air.
The various pipelines used in the transfer of wort and various other things should be
also sterile as this may infect the beer easily
Measures taken in the process for increasing microbial compliance:
The water used in the entire process is sterile and is checked routinely.
CIP (cleaning in place) insures the disinfection of all the equipments. This is done
routinely after any tank is emptied or before any tank is to be filled. Each and every
equipment and the pipeline used in the pipeline is properly washed with caustic acid and
divosan and with hot water. This reduces the chances of contamination by equipments
used in the process.
The air used in the process is sterile as it is properly filtered.
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The box which contains all the bend pipes in the yeast room is kept in divosan solution
which is a powerful disinfectant. Thus the chances of contamination from the bend pipes
which is attached with the flow plate is also low.
Observations in the bottling unit:
The major issue in the bottling section was bursting of bottles while filling it in the KHS filler. It
was seen that while filling the bottles in the filler near about 40 bottles burst on an average per
hour. The plant runs 24 hours a day and 7 days a week. Thus this is a loss for the company. This
means that everyday 960 bottles burst. The cost of each bottle is Rs.3. Thus every day the
company loses Rs. 28800/ day, i.e.
It was observed that the bottles burst in the filling when carbon-dioxide was pumped in the
bottles. Carbon-dioxide is pumped with pressure in the bottles and hence the bottles which are
weak burst out.
The following observation was made
CO2 pressure in
kg/m2
Bottles burst in hour 1 Bottles burst in hour 2 Mean bottles burst
2.4 39 41 40
2.1 23 25 24
1.8 15 17 16
Thus from the following observation it can be concluded that rise in CO2 pressure causes more
bottles to burst. The more the pressure of CO2 rises the more number of bottles burst.
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RECOMMENDATIONS
The present microbial compliance of the company is good and all the processes are sterile but
there are certain small things which if taken care would increase the microbial compliance.
These may be summed up as follows:
Proper documentation of all the processes which are overlooked by the workers. These
are small but may prove hazardous in the long run. These small things are like:
Proper documentation of the sanitization of the pipeline and the signature of the person
involved in it.
Proper documentation of the sanitization of the racking pipe used in racking/hosing. The
pipe after used should not be left in open and/or on the floor after its use but should be
kept in a sterile room.
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The chemical dozer used for the racking purpose should be sterilized properly and should
be documented.
The box in which the bend pipes and the connector pipes used for connecting with the
flow plate should be sterilized properly and the divosan used for sterilization should be
changed periodically. Documentation for this should also be done.
The biofoam dozer and the chemical dozer for filtration purpose is always in action as the
filtration goes on throughout the day. These should be sterilized together with the
sterilization of the filtration unit as all of the three are linked in function and work
together.
The dead ends of the pipeline should be sterilized and should be documented.
The company is undoubtedly having a very good microbial compliance but if these small things
are also kept in mind and not overlooked by the workers the microbial compliance would
increase and thus the quality of the product further decreasing the chances of contamination by
microbes caused due to these small things.
Proper documentation of these small things would not allow the worker to overlook these small
things and hence the process of beer making would be more sterile.
Recommendations’ for the bottling unit:
The solution to the problem of bursting of bottles during filling could be standardization of CO2
pressure of the inlet. When CO2 is released from its source it comes in tremendous pressure but
normally in its path it lowers down to 2.4. Thus if the pressure at the source is controlled the
pressure in the KHS filler would be automatically controlled.
Thus through various observations we may find that the optimal CO2 pressure required is 1.8-1.7
kg/m2. If pressure is controlled in this range while filling the number of bottles burst would be
reduced to 16 from 40 without a change in the quality of the beer.
Calculations:
When pressure is 2.4 kg/m2 the no. of bottles burst is 40.
When pressure is lowered to 1.8 kg/m2 the no. bottles burst is16.
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Thus number of bottles saved per hour =24.
Price of each bottle is Rs.3
Thus amount of money saved per day = 24*16*3
= Rs.1152.
Thus amount of money saved per month = Rs.34560
Thus we may conclude that standardization of CO2 pressure from 2.4 kg/m2 to 1.8 kg/m2 saves
cost and loss of resources. Further the less the number of bottles burst the less are the chances of
accidents occurring to the workers.
CONCLUSION
Today, the brewing industry is a global business, consisting of several dominant multinational
companies and many thousands of smaller producers ranging from brewpubs to regional
breweries. More than 133 billion liters (35 billion gallons) are sold per year (the equivalent of a
cube 510 meters on a side), producing total global revenues of $294.5 billion (£147.7 billion) in
2006. The global beer industry is consolidating. Consolidation started 10 years ago and probably
has 10 more to go before it winds down. China is the biggest market for beer followed by the
US, Germany, Brazil, Russia, Japan, UK, Mexico, South Africa and Spain. The paradox in China
is that although the retail price of beer is very low in terms of the market, it has very high profit
margins as far as international players are concerned.
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With the global market experiencing low/stagnating growth in recent years, the focus is now on
the Asia-Pacific region specially. For instance, the Chinese beer market has grown at an
astounding pace in recent years, spurred on by the massive levels of foreign investment in the
market, along with the rise in the average levels of consumer spending and thanks to the
economic reform policies of the government. Total consumption of beer in China grew by
33.56% between 2000 and 2006 to reach a total market volume of 30.47 billion litres. With the
per capital consumption of 22 litres, China has now overtaken the US to become the largest
national beer market in the world. The brewing industry in China has been one of those quickest
to modernize and Indian beer Industry should look to model themselves on their neighbors.
United Breweries Limited is the largest producer of beer and other spirits in India. The reason for
its predominant increase in market share is the control over its quality. It is an ISO.9001...2008
certified company and hence maintains the best quality.
Beer is a product which comes under the food and beverages sector and is consumed by human
beings at a large scale. Thus maintaining quality standards at every level of the process forms the
very basic for the success of the product as well as of the entire company. Beer is a fermentation
product and is rich in alcohol and glucose content and is very susceptible to contamination from
microorganisms at each and every step in the process of its making. Thus a strict control should
exist at each and every step in the process and every process should be carried out in a closed
environment which is taken care in the plant with full efficacy and efficiency. The higher the
microbial compliance greater is the life of the beer and better is the quality. In spite of various
control measure taken by the plant certain things are overlooked by the unskilled workers in the
plant during handling of the equipments and this brings contamination of the beer and hence
increases the dissolved oxygen level of the beer which is not desired. Thus this report surpasses
through the various regions which are overlooked by the workers of the beer plant in compliance
with the contamination of beer and further finds out method to overcome such trivial mistakes
and increase the microbial compliance and the life of the beer.
Thus it can be finally conclude that if proper care is taken of small things which are otherwise
overlooked in the plant due to the ignorance of the workers about the hazards it could create a far
more better and good quality of beer could be manufactured with a larger life and lesser risks.
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REFERENCES
Books
Prescott and Harley “Text book of Microbiology” , Prentice Hall of India, 2002
A.H.Patel “ A handbook of Industrial Microbiology”, Prentice Hall of India, 2002.
Articles from the Internet
http://www.studentsguide.in/microbiology/industrial-microbiology/steps-in-commercial-
production-of-beer.html
http://en.wikipedia.org/wiki/Beer
http://www.britannica.com/EBchecked/topic-art/58378/70929/The-process-of-beer-
production
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