BEER FACTORY PROJECT

Prepared By

Ram Kumar

Dept. Of Food

Technology

student of Government Polytechnic, Mandi

Adampur, Hisar, Haryana, India- 125052

Mobile No. 9034432892

Email Id r4ramtiwari007@gmail.com

Acknowledgements

Firstly, I would like to express my deep and sincere regards towards our food

tech department for giving me this great opportunity to widen my horizon of

knowledge.

I would like to thank the Mr. KULVEER AHLAWAT, (H.O.D.FOOD

TECHNOLOGY) for their immense support through the training.

It is not just acknowledgment rather it’s my deepest gratitude towards our

ATPO Mr. VEDPAL YADAV (Lecturer in Food Technology) who made my

training at MOHAN MEAKIN LIMITED, SOLAN BREWERY. DISTT.SOLAN {H.P},

INDIA, 17321

I would also extend my deep gratitude to Mr. BANSI LAL (Lecturer in Food

Technology) & entire food department staff for their constant support,

guidance and help.

The history of this company can be traced back to the establishment of a Brewery at Kasauli by Edward Dyer in 1855. It was the India’s brewing pioneer who brought to this sun-drenched land of ours the bliss of a real thirst quencher – the modern beer, to refresh and pep up a people hanging over in sweltering clime that is so peculiar to this part of the World. He realized for the first time that there were a few spots on earth where a really good drink was more welcome.

But, in his flush of enthusiasm he had set before himself such a big task of quenching the thirst of a nation as obviously could not be expected to reach fulfillment by his one, howsoever efficiently working brewery at Kasauli. Consequently, with ardourous zeal he scaled the whole width of this subcontinent and established breweries and distilleries at Simla, Solan, Lucknow and Mandalay (Burma).

During the same century, another enterprising man, named H.G. Meakin, coming from a well known brewing family of Burton-on-Trent where he was trained, came forward with enviable enthusiasm and founded Meakin & Co. Ltd. He bought the old Simla and Kasauli Breweries and built others at Dalhousie, Ranikhet, Chakrarta, Darjeeling and Kirkee.

HISTROY

Both these firms E. Dyer & Co., and Meakin & Co. Ltd., continued doing business separately up till after the second decade of the 20th century. During the first World War (1914-18), when it was a big job to import beer, the two firms quenched the hugely increased thirst of India with superb beer at a rock-bottom price. Vast quantities of Malted Barley were sent to Egypt, to help keep soldiers’ beer at a reasonable price.

Following these successes, the two firms joined hands and started a new joint stock venture under the style of Dyer Meakin & Co.Ltd. Brewing was suspended at the Kasauli Brewery and a latest brewing and bottling plant was installed at conveniently placed Solan. Extensive malting at Kasauli were, however, continued in operation. There are few places on earth where the water is ideally suited to brewing. Solan is one. Those who fancy the hill-climb would like to see our famous springs high up on Karol Mountain, far from everything, a lovely lookout, with the source of crystal clear spring water that drew our pioneer to Solan.

With the times, as modern scientific progress made it possible to augment production several times with the latest machinery, the unproductive centres were closed down one by one retaining distilleries at Kasauli and Lucknow and brewery at Solan (Simla Hills) ; all the three centres enormously expanded to meet any expected demand.

During the World War II, Solan Beer played its valuable part by keeping the soldiers of the allied nations in perfect pep and cheer. After the War, all manufacturing plants at Solan, Kasauli and Lucknow were replaced by the new latest automatic ones.

In 1935 when Burma was dismembered from India the name of the Company with Indian assets and liabilities was changed to Dyer Meakin Breweries Ltd., from Dyer Meakin & Co. Ltd., and the assets and liabilities of Burma Brewery in Burma were separated. Thereafter the Company’s name was changed from Dyer Meakin Breweries Ltd., to Mohan Meakin Breweries Ltd., w.e.f. 1.11.1966 and from 24.4.1980 the name was further changed to Mohan Meakin Ltd., and as such the Company is now known as Mohan Meakin Limited.

Year 1949 saw a dynamic transformation in the fortunes of the Company, with late Padamshree N.N. Mohan at the helm of affairs. With his far-sightedness he set up big industrial hub near Ghaziabad (U.P.) known as Mohan Nagar by establishing there various manufacturing Units namely Brewery, Distillery, Malt Houses, Glass, Ice, Break-fast Food, Fruit Products and Juices, Malt Extract factories, Cold Storage and Mohan Engineering Works etc. and there has been no looking back since then.

The Company’s remarkable performance is not limited to liquor, its business interests are manifold. Turning foresight into reality is the Fruit juices, Breakfast Foods, Mineral Water and Glass Factory – a strategic diversification to further re-inforce its business interests.

Mohan Meakin Limited also exports its beer, rum, whisky, brandy, and gin products to the United States, the United Arab Emirates, Singapore, Qatar, Germany, Australia, Estonia, Malaysia, China, Japan, Italy, the Netherlands, Canada, Hong Kong, and Korea.

What is Beer?

Beer is generally defined as an alcoholic beverage made by fermentation of farinaceous extract that is obtained from a starchy raw material that is barley in the form of malt. Although it is possible to replace some part of barley in the from of other starchy materials (eg.Corn, wheat, oak, potatoes) It is usually the main constituent of brewing materials.

Beer is the world's oldest, possibly dating back to 6000 BC, and most widely consumed alcoholic beverage and the third most popular drink after water and tea.

 Brewing was one of the earliest processes undertaken as commercial scale and became one of the first processes that developed from an art into a technology.

What’s in a Beer?

• BARLEY – the body & soul of beer

• YEAST – the life of beer

• HOPS – the spice of beer

• WATER – the integrity & purity of beer

• ADJUNCTS – Additive grains like rice or corn, fruit or spices

Barley – “Body & Soul”

Barley malt gives beer:

• NATURAL enzymes to covert starch to sugar needed for fermentation

• MALTY sweet flavor

• COLOR

• FOAMY head

Two row & six row barley malt are used in the brewing process.

Variety of barley malts helps determine the color, texture and flavor of beer.

Yeast is the catalyst of change:

• one cell micro-organism

• produces carbon dioxide and alcohol

Two types of yeast are used to produce beer:

• ALE – top fermenting

• LAGER – bottom fermenting

There are literally thousands of brewers yeast that create a variety beer styles.

Yeast – “Life of Beer”

Water – “Integrity & Purity”

Water’s role in beer:

• water makes up 92% of beer

• through filtration or boiling; impurities, aromas & flavor differences can be mitigated

Water styles can effect flavor:

• hard water – helps add crisp cleaness

• soft water – adds smoothness

Adjuncts – “The Wild Card”

Adjuncts add to beer:

• adjuncts are added to change the flavor, character or profile of beer.

• used to supplement main starch source to provide better foam retention, color or aroma

Adjuncts fall into two categories:

• Grains:

• corn, rice, wheat, oats or rye

• Specialty Ingredients:

• sweets – honey or maple

• fruits – raspberry, cherry or cranberry

• spices – cinnamon, coriander or clove

BEER

Ale( top-fermented) Lager(Bottom fermented)

Pale

Middle/Brown

Stout(Porter) Pale Dark

Pilsner

Dortmunder

Munchener

BockAle

PRODUCTION OF BEER

BrewingThe process of making beer is known as brewing. 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 effected by yeast.

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

Malting barley

The mature barley grain comprises the embryo and the endosperm, which provides a store of carbohydrates (mainly starch) and protein to support the initial growth of the germinating embryo. The endosperm comprises the starchy endosperm, which is a non-living storage tissue, surrounded by a living non-starch cell layer called aleurone. The grain is protected by an outer husk.

VitalityWhen stored at very low temperatures and low moisture content, barley may keep its vitality for centuriesshould be kept at a moisture content of below 12 % and at temperatures below 12 °C.

Fungal contamination during storageBarley with a moisture content of above 14 % may be attacked by fungi during storage especially by species Aspergillus , Fusarium, and Penicillium. Secondary metabolites of these fungi cause gushing.

1. rapid and uniform germination, 2. the synthesis of hydrolytic enzymes in the scutellum and aleurone

tissues surrounding the endosperm and 3. finally the degradation of endosperm cell walls, described as

modification. (Gibberellin, which regulates these physiological events, is a plant hormone produced by the germinating embryo.)

Hydrolase Action and Modification

Malting In the malt house, barley grain germination is initiated by 1. the uptake of water in a steeping vessel

(A). The grain imbibes water during controlled cycles of water spraying or water immersion

2. followed by aeration, until the water content of the grain reaches 42 to 48%.

3. The grains are then transferred to malting beds where germination is allowed to proceed over a period of around 5 days (B).

4. Green malt, produced after five days of germination, is kiln dried and partly cooked in a forced flow of hot air (C). Hydrolases produced during malting are partially inactivated during this process.

Mashings are normally performed at pH 5.5 at which most malt-derived enzymes exhibit high activity.Conditions include a controlled stepwise increase in temperature that preferentially favours one enzyme over the other, eventually degrading cells walls, proteins and starch. Since the enzymes which degrade cell walls and proteins are rather heat labile, it is important for their function that mashing begins at a low temperature. Subsequent mashing at 65°C, or higher, is particularly geared to control conversion of gelatinized starch into fermentable sugars using malt-derived starch degrading enzymes.Principal mashing enzymes include (1-3,1-4)-ß-glucanase and xylanase for cell wall degradation, endo-peptidase and carboxypeptidase for protein degradation; and amylases, limit dextrinase and a-glucosidase for starch degradation.

Mashing Mashings

The brew kettle, a huge cauldron holding from 70 to 1,000 hectoliters and made of shiny copper or stainless steel, is probably the most striking sight in a brewery. It is fitted with coils or a jacketed bottom for steam heating and is designed to boil the wort under carefully-controlled conditions. Boiling, which usually lasts about two hours, serves to concentrate the wort to a desired specific gravity, to sterilize it and to obtain the desired extract from the hops. The hop resins contribute flavor, aroma and bitterness to the brew. Once the hops have flavored the brew, they are removed. When applicable, highly-fermentable syrup may be added to the kettle. Undesirable protein substances that have survived the journey from the mash mixer are coagulated, leaving the wort clear.

Boiling and Hopping

At the end of the boil, the wort is sent into a whirlpool. The so-called teacup effect forces the more dense solids (coagulated proteins, vegetable matter from hops) into a cone in the centre of the whirlpool tank.In most large breweries, these is a separate tank for whirlpooling. These tanks have a large diameter to encourage settling, a flat bottom, a tangential inlet near the bottom of the whirlpool, and an outlet on the bottom near the outer edge of the whirlpool.

Whirlpool

After the whirlpool, the wort must be brought down to fermentation temperatures before yeast is added. In modern breweries this is achieved through a plate heat exchanger. A plate heat exchanger has many ridged plates, which form two separate paths. The wort is pumped into the heat exchanger, and goes through every other gap between the plates. The cooling medium, usually water goes through the other gaps. The ridges in the plates ensure turbulent flow. A good heat exchanger can drop 950C. The last few plates often use a cooling medium which can be cooled to below the freezing point, which allows a finer control over the wort-out temperature, and also enables cooling to around 11 0C. After cooling, oxygen is often dissolved into the wort to revitalize the yeast and aid its reproduction

Wort cooling

The traditional quantitative description of the brewery fermentation has been the anaerobic process of yeast converting glucose to ethanol and carbon dioxide. Despite its complexity fermentation is largely dependent upon three basic parameters, namely the wort composition (nutrient for the yeast), the yeast, and the processing conditions

Fermentation:

Quality Control during fermentationDuring fermentation strict quality control should be enforced to assure that the progress of fermentation proceeds normally; that the yeast is healthy and free from contamination; and that it behaves as expected both in suspension and flocculation.Physical and chemical method may include checking parameters such as time, temperature, ph, extract and alcohol contents, flavor analysis, and yeast cell concentrations.

Basic functions of fermenter or Bioreactor:The main function of a fermenter is to provide a controlled environment for the growth of a microorganism or a defined mixture of microorganism to obtain a desired product.The vessel should be capable of being operated aseptically for a number of days and should be reliable for long term operation. The inadequate aeration and agitation should be provided to meet the metabolic requirements of the microorganism.Criteria used for the selection of microorganism for fermentation:The strain should be genetically stable.The strain should readily produce many vegetative cells, spores or other structure.The strain should grow vigorously and rapidly after inoculation in the vessel.The strain should be pure culture and free from other microorganism including bacteriophage.Fermentation consists of four phases:Lag phase: Fermentation remains in this phase for the initial 10-12 hours. During this period yeast gets acclimatized to its new environment. Log phase: This phase starts after 12 hours of fermentation. In this phase vigorous fermentation starts.Peak fermentation: This phase comes around 45-48 hours after pitching of yeast. Fermentation is at its peak during this phase.End fermentation: This phase comes after 120 hours of fermentation.

When the sugar in the fermenting beer has been almost completely digested, the fermentation slows down and the yeast starts to the bottom of the tank. At this stage, the beer is cooled to around freezing, which encourages settling of the yeast, and causes proteins to coagulate become insoluble in the cold beer, and the beer’s flavor becomes smoother. During this time pressure is maintained on the tanks to prevent the beer from going flat.If the fermentation tanks have cooling jackets on them,as opposed to the whole fermentation cellar being cooled, conditioning can take place in the same tank as fermentation.Otherwise separate thank (in a separate cellar ) must be emploed

Conditioning

A centrifuge is basically a rotating container which separates the solid from the liquid using centrifugal force 5000 to 8000 times greater than the acceleration due to gravity. The magnitude of the centrifugal force is proportional to the square of the number of revolutions per minute multiplied by the effective radius.Centrifuges used for beer clarification are normally the disk self-opening type. Disk separation is about 0.5 mm, which means that the settling distance is less than 1.0 mm compared to the setting distance of several meter in a tank. Beer enters the top of the centrifuge and is distributed between each disk. Clarified beer work towards the center and is discharge by means of centripetal pump.

Centrifugation

Gravity sedimentation, fining and centrifugation clarify beer to a certain degree but do not give the brilliance required in the market place. It is normal to filter beer at least one time at the end of storage process prior to packaging to obtain brilliant clarity. Filtration is needed for various reason, they are:(1)To remove residual yeast and other turbidity causing material and microorganism in order to achieve colloidal and microbiological stability.(2)Lager period and addition of flocculation aids both greatly reduced yeast and haze loadingsFiltering the beer stabilizes the flavor, and gives beer its polished shine and brilliance.

Filtration

The next process which takes place after filtration is carbonation. CO2 not only contributes to perceived fullness or body and enhances foaming potentials, it also acts as a flavor enhances and plays an important role in extending the self life of product. The level of carbon dioxide in beer after normal, non-pressurised fermentation is 1.2 to 1.7 volumes of CO2 volume of beer. Common practice is to raise this to 2.5 to 2.8 v/v prior to packaging. The final level is lower than in soft drinks, which are about 3.5 v/v, but sufficient to properly enhance the flavor and drink ability of beer.

Beer Carbonation

In the BBT the beer is than stored thus beer is called draught because this is unpasteurized beer. The temp profile is 0 to 2 C.In the BBT CO2 is applied here for the following importance:To prevent contaminationTo protect from oxidationIncrease the shelf life of beerCO2 enhances its taste and refreshment value

Beer bottling tanks:

Health Benefits of Beer:-

•Up to two beers a day for men (women should only have one), will help to reduce your risk of having strokes, and heart disease. Light drinking appears to reduce the risk by as much as 20% according to research in United States.•Beer can help to increase the level of HDL (beneficial cholesterol) in the body and decrease the likelihood of blood clots.•A couple of beers can raise the level of anti-oxidants in the blood stream. This enables the cells to carry more oxygen around the body. More oxygen helps better muscle activity among other things.•Beer contains vitamin B6 which is needed to make hemoglobin,the red coloring in blood. This carries oxygen around the body. It also helps maintain correct blood sugar levels.•It is fat free, aids restful sleep and promotes relaxation.

•Beer contain vitamins B and B2 (as well as B6) and essential minerals like calcium, potassium, and phosphorus.•Dark beer is better for you than light.It contains more flavanoids which are natural oxidants that help to protect the body from disease.•For post menopausal women, beer may be a beneficial addition to the diet. Some hop flavanoids have properties like estrogen and research suggests that this property may make it possible to produce a natural form of HRT to replace the current one.•Beer can help to reduce blood pressure and levels of insulin in the blood.•Beer drinking can also reduce the incidence of kidney stones. This may be due to the water, the hops, or the alcohol, but, whatever the reason, it seems to help.

Thank You