CONTENTS

 Introduction of Industry and Practical Training

 Beer and its History

 Beer Brewing Process

 Principle

 Sugar Catabolism In Yeast

 Methodology

 Step 1 Malting Barley

 Step 2 Mashing

 Step 3 Wort Separation

 Step 4 Wort boiling

 Step 5 Wort cooling and aeration

 Step 6 Fermentation

 Step 7 Filtration

 Step 8 Beer carbonation

 Step 9 Bottling

 Result and Discussion

 List of Figures

 Bibliography
 INTRODUCTION TO THE INDUSTRY

A saga that began over a century and a half ago, continues on its path of service to the world with
dedication, courage and an unflinching commitment to quality. Over the years the Company has
embraced modernity and adapted to changing times. Yet, its basic values remain the same--
Integrity, Craftsmanship, and Tradition. From old tradition sprang Lokranjan Breweries where
the sanctity of ancient culture, technological development and craving for quality are artfully
blended into the products.

The origin of Lokranjan Breweries traces back to Edward Dyer from United Kingdom who set
up the first-ever brewery and made indigenous beer available to the Indians as well as Britons.
He set up more Breweries at Solan, Simla, Murree, Rawalpindi and Mandalay. Another
entrepreneur H G Meakin came to India from Britain and bought the old Simla and Solan
Breweries from Edward Dyer and added more at Ranikhet, Dalhousie, Chakrata, Darjeeling and
Kirkee. A distillery was then set up at Kasauli instead. Another distillery was set up in the
historic city of Lucknow. In addition to meet the increased demand of Lokranjan Breweries
Products an Industrial Complex on 150 acres of land was set up in the year 1960 near Delhi in
Ghaziabad Dist. Of Uttar Pardesh. Lokranjan Breweries have established fully equipped
laboratories at its various manufacturing centre’s manned by highly qualified and experienced
technical persons to ensure the maintenance of high standard quality products. During the
training period I gone through the various techniques & procedures which are being used in the
production of Beer by fermentation process by using s. cerevisiae as the microorganism. The
main emphasis is focused on the temperature control, pH maintenance and alcohol concentration
(approx. 4.5% in 650ml of Beer). This is necessary for maintaining the quality of Beer.
In 1949 Mr. N. N. Lokranjan took over the management of the Company. Under the dynamic
stewardship of Mr. N. N. Lokranjan the Company’s assets and profits registered a manifold
increase. To mark the contribution of Lokranjan’s the Company’s name was changed from Dyer
Meakin Breweries Limited to Lokranjan Breweries Limited in 1967. On passing away of Mr. N.
N. Lokranjan in 1969, his eldest son Col. V.R. Lokranjan took over as the Managing Director of
the company. He introduced a number of new products that are brand leader even today. In the
Seventies the manufacturing activities of the company were diversified into other fields under
the leadership of Brig. Kapil Lokranjan, VSM, who became the Managing Director of the
company in 1973. Subsequently the word Brewery was dropped in 1982 to remove the
impression that the Company is engaged only in beer making.
 PRODUCTS OF LOKRANJAN BREWERIES PVT LTD.

 WHISKY PRODUCTS

SOLAN NO. 1 :

Solan No.1 distilled out of Malt made at Kasauli, Simla Hills, matured in Oakwood casks and
diluted to desired strength with Himalayan Water has come to be known as Scotch of India. The
Royal Institute of Public Health & Hygiene, London has certified it as a product of high quality
conforming to international standards.

COLONEL’S SPECIAL :
The heart of this blend is matured in Oakwood casks longer than any other Indian Whisky.

 RUM PRODUCTS

OLD MONK RUM

The Country’s most popular rum is Old Monk Rum. A superlative drink whose popularity has
spread in other countries of the world. This legendary drink has been awarded gold medals at
Monde World Selection since 1982 for its quality.

OLD MONK GOLD RESERVE RUM

Old Monk Gold Reserve is an epitome of unflinching dedication to quality. Blended with highly
matured spirits, most of them 12 years old, Old Monk Gold Reserve is becoming popular
amongst younger generation.

 BRANDY PRODUCTS

The graceful way to round off a good meal. The ideal warm-up when chilly winds blow.
Lokranjan Meakin’s brandies come brimful with delightful promise.

GOLDEN EAGLE DOCTOR’S BRANDY

Wonderfully warming for that rosy glow of contentment.

DOCTOR RESERVE NO.1 BRANDY

It has carved a lace for itself in bars across the country.

TRIPLE CROWN
Smooth and subtle gently poured when the perfect evening is drawing to a close.
  GIN PRODUCTS
Smooth and excellent by itself, superb in cocktails. As a long drink Lokranjan Meakin’s Gins are
well known. Their popularity is every increasing.

BIG BEN DELUXE LONDON DRY GIN

Beautifully dry, flavored just right with juniper berries. Found frequently in tall frosted glasses.

 VODKA PRODUCTS
The epicurean’s delight. For the perfect Bloody Mary. A Vodka even Russians will welcome.

KAPALANSKY
For the pleasures of a superbly balanced drink. The connoisseur’s delight.

 BEER PRODUCTS
The rich amber liquid that is so indispensable in India’s long, hot, thirsty summer. Lokranjan
Breweries has been quenching a nation’s thirst for over a century & quarter now.

GOLDEN EAGLE
The discerning drinker’s beer for millions. Sunday afternoons are incomplete without it. Golden
Eagle, the drinker’s preference has come to be known as the king of beers in India. South after in
International Markets for its taste and quality this beer has won gold Medals at Monde World
Section since 1982.

SOLAN
Made with the clear spring water of the Solan Peaks. Bubbling freshness only this special water
can bring.

GYMKHANA
An old favorites mentioned in the book, The World’s Beers.

ASIA 72
The people’s choice brewed to perfection.

LION
For the lion-hearted also mentioned in the book, The World’s Beers.

OLD MONK
It can wash away the rig hours of the longest hottest summer with a distinctive taste.

BLACK KNIGHT SUPER STRONG

The thirst quencher that packs quite a punch. The regular drinker’s beer
HISTORY OF BEER

ANTIQUITY

Beer has been brewed since time immemorial. It is thought that it was first made in Palestine
around ten thousand years ago, in 8000 BC, by macerating barley bread in water.

The Sumerians developed no fewer than ten varieties of beer, and the Babylonians added at least
34 more. Later on, the Egyptians developed what can be called government breweries, making
brewing a state monopoly. These "barley wines" were used as offerings to the gods. Pharaoh
Ramses II, who is referred to as the "brewing Pharaoh", imposed very strict rules on the making
of beer.

Beer made its way to Europe around 5000 - 4800 BC along two routes: the Danubian route
(Eastern Europe) and the Mediterranean route (south of France). Contrary to what is generally
believed, beer was brewed and consumed very early in Greece and Rome until it was to some
extent replaced by wine.

However , while the Romans were more fond of wine, this did not prevent them from
appreciating beer, in particular in the northern regions, where conditions were better for barley
fields than for vineyards. For example, the remains of a Gallo-Roman villa were found to contain
a brewery dating from the 3rd or 4th century. Among Belgium's ancestors, the Gauls, the brewing
of barley beer was a cottage industry; it was brewed within the family by the women. It were the
Gauls who came up with the idea of replacing recipients made of pottery by wooden barrels,
which, by the way, they invented. They called malt "brace", a word that has come down to us in
the French terms brassin (beer mix), brasseur (brewer), etc.

After the fall of the Roman Empire, the church took control of the land. The monks took an
interest in this beverage, and eventually it appears that there were breweries in every abbey in
Christendom. And brewing also went on in inns, castles and homesteads.

THE MIDDLE AGES

In spite of barbaric invasions, brewing never quite disappeared from our regions. As early as the
7th and 8th centuries, the first monastic communities consumed beer, which had by then become
a popular beverage. At that time, monks lived just like everyone else, but of course they were
isolated from society. In the region of the Meuse, the oldest monastery appears to be the Grand-
Axe, which is first mentioned in documents in the year 805.
As we have just seen, the first Belgian abbeys already each had their own brewery. This was the
case for Villers-la-Ville, which has had a community of monks since 1146. The immense abbey
they built was inspired by the architecture of the Cîteaux (the order of the Cistercians). The
brewery, in the Romanesque style, was built in the first half of the 13th century. However, the
abbey destroyed waste in the religious wars of the 16th century and the French Revolution. Also
around this time, the first guilds were set up. The purpose of guilds was to maintain the quality of
products and to ensure respect for traditions.

Breweries then proliferated in the 14th and 15th centuries, as beer became a popular beverage.
Around this time, it was commonly believed that it was better to drink beer than water, because
epidemics like cholera and the plague could be transmitted by water, while the cause of these
diseases was eliminated in the brewing process.
The Renaissance (around the 16th century) was the golden age of brewing. Their corporations
were very rich. In Brussels, brewers bought the "Arbre d'or", a fine building that is now the
"Maison des Brasseurs" (House of Brewers) on the Grand'Place. They restored this dwelling and
embellished it in the 17th century. Although it was completely destroyed in the bombarding of
Brussels by the Marshal de Villeroy, it was quickly rebuilt, at great expense, in the 18th century,
when it was adorned with the facade that is still admired to this day by countless tourists. It was
sold off by the French revolutionaries in the 18th century, and then in 1954 after some radical
conversion work it once again became the "Maison des Brasseurs".

From the 17th century until the Second World War

In the 17th century, many different types of beer began to appear up and down the country. Each
variety was characterized by the specific ingredients used and the quality of the water. Small
breweries flourished at this time, and as in those days there were no sophisticated means of
preserving the product, each village had its own brewery.
At the end of the 18th century, a historical event took place that was anything but beneficial to
the tradition of brewing: the French Revolution. In addition to the fact that it put an end to
brewers' guilds, the Revolution led to

the destruction of many monasteries and abbeys, effectively wiping out much of the brewing
industry. However, with the arrival of Napoleon on the scene brewing took off again thanks to a
general economic recovery, although from that time on brewing would no longer be reserved for
monks. It became a fully-fledged industry in its own right.

At the end of the 19th century, the scientific progress achieved by Louis Pasteur (1822-1895) in
the study of yeast and the preservation of food by "pasteurization" gave breweries new impetus
for some time. And these discoveries not only made it possible to preserve beer more efficiently,
but they also improved the quality of beer, as the various types of yeast produce different flavors.

By the year 1900, there were 3,223 registered breweries in Belgium, including Wielemans'
Brewery in Forest (Brussels), which was considered to be the biggest and most modern in
Europe. It was also in Brussels (in the brewery called the Grande Brasserie de Koekelberg, to be
precise) that the first bottom-fermenting beer (Pills) was brewed in 1886.

After the First World War, there was a considerable drop in the number of breweries. In fact, by
1920 there were only 2,013. The reason was that there was a dearth of the raw materials and
manpower needed for brewing, and the few breweries that resumed production had to be
mechanized. In the 1930s, the economic crisis made the situation even worse, and the Second
World War caused a further reduction in the number of breweries. As a result, in 1946 Belgium
had only 755.

TYPES OF BEER

Beer can be divided into, depending on the fermentation method.

Bottom-fermenting beer is the most recent type. The process dates from 1840 and produces a
specific type of beer, Pils or lager. This type accounts for 90% of worldwide beer production.
Pils is a light, clear, golden beer. It has a fresh, bitter and refined hoppy flavor.

Top-fermenting beer is a much older and more traditional variety. This process is involved in
the production of many different types of beer, in particular Amber or "Special Belgian" beer.
Originally, this type of beer had the same density and alcohol content as Pils. The amber colour
is obtained by using colored or caramelized malt. The alcohol content is now slightly higher, and
this beer is considered to be typical "sampling" beer.

White beer is non-filtered and cloudy in appearance. In addition to barley malt, the ingredients
include unmalted wheat and sometimes oats. Also, during the heating process, coriander and
orange peel are added to give it its characteristic refreshing taste.

The Trappist Order is abbey beers. They are marketed under protected copyright names that
belong to the Cistercian Order. This legal protection entails certain rules. This type of beer must
be brewed in a Cistercian abbey under the supervision of monks belonging to the Trappist Order.
There are various types: blonde, double, dark and triple. Each of the three abbeys has its own
recipes.

The other abbey beers are marketed under licenses which are granted to lay brewers, whose
trademark refers to an abbey that may exist or may have disappeared. There are various types of
abbey beer: Lagers, which are characterized by a mild, slightly malty aroma, a neutral or slightly
sweet taste and an often very bitter after-taste. The double or dark beers, so called because the
brewer uses more malt. Nowadays this type of beer is darker and has a sweetish, sometimes
sugary taste and a bitter after-taste). Finally, triple beers, in which the brewer uses even more
malt and which undergo triple fermentation, the final stage of fermentation being in the bottle.

Strong blonde beers are often clear. They are generally served with a large head. They undergo
triple fermentation and contain aromatic malts.

Seasonal beers are typically brewed in Wallonia, especially in the districts of Hainaut and
Walloon Brabant, and are sparkling and fruity summer beers. They involve the use of raw
hopping and sometimes secondary fermentation in the bottle.

The regional and special beers are fine examples of the creativity and know-how of our local
brewers. They are all very different. Each variety has its own characteristic manufacturing
process and ingredients (spelt, honey, Liège syrup, mustard, etc.).
Scotch is a beer of Anglo-Saxon origin which, over the years, has become a specialty of the
Walloon Brabant and Hainaut district. It is characterized by a very malty and slightly smoky
taste. Its sugary taste is due to the addition of candy sugar.

Spontaneous fermentation, a process that is characteristic of the Brussels region, is used to

produce Lambic. Lambic is a flat beer with no head. It is produced through spontaneous
fermentation of the yeasts found specifically in the valley of the river Senne. It matures in barrels
made of different types of wood and has a wide range of tastes.

Gueuze is obtained by the fermentation caused by mixing "old" Lambic (that has not completely
fermented) and "young" Lambic. This new fermentation produces a sparkling, sharp beer, the
"champagne of beers".

Fruity beers are basically made by mixing different fruits (cherries for Kriek) and Lambic.
Traditional Kriek is a mixture of 50 kg of cherries and around 250 litres of Lambic. This mixture

matures for 6 months in the barrel and produces a beer with a fruity but not sugary taste. The
industrial process involves fruit juice and extract. he result is a sweet, fruity beer.
 Fig (1):- Out line diagram for production of beer
PRINCIPLE

YEAST METABOLISM

Metabolism refers to the biochemical assimilation (in anabolic pathways) and dissimilation (in
catabolic pathways) of nutrient by a cell. Like in other organisms, in yeast these processes are
mediated by enzymatic reactions and regulation of the underlying pathways have been studied in
great detail in yeast. Anabolic pathways include reductive processes leading to the production of
new cellular material, while catabolic pathways are oxidative processes, which remove electrons
from substrate or intermediate that are used to generate energy. Preferably, these processes use
NADP or NAD, respectively, as co-factors.

Although all yeast are microorganisms that drive their chemical energy in the form of ATP, from
the breakdown of organic compounds, there is metallic in how these organism generate and
consume from these substrates. Knowledge of the underlying regularity mechanism is not only
valuable in the understanding of general principle of regulation but also of great importance in
biotechnology, if new metabolic capabilities of particular yeast have to be exploited.

It is now well established that the most yeast employ sugars as their main carbon source, but
there are particular yeast which can utilize non-conventional carbon sources. With regard to
nitrogen metabolism, most yeast is capable of assimilating simple nitrogenous sources to
biosynthesize amino acids and proteins. Aspects of phosphorus and sulphur metabolism as well
as aspects of metabolism of other inorganic compounds have been studied in some detail,
predominantly in the yeast, sacchromyces cerevisiae.
 NUTRIENT FOR GROWTH OF YEAST CELLS (S. CEREVISIAE)

 Substrate for growth of s.cerevisiae

 Saccharose (>Glucose + Fructose) Invertase

 Maltose (> Glucose)

 Mellblose (> Glucose + Galactose)

 Glucose (>Glycol sis)

 Ethanol (>Acetaldehyde > Acetyl- CoA > Oxaloacetate > Gluconeogenesis) ADH2

 Lactate (> Pyruavte > Gluconeogenesis)

 Glycerol (> Glycerol -3- phosphate > DAP > Gluconeogenesis)

 Amino acids

 Glutamine
 SUGAR CATABOLISM IN YEAST

Principle pathways:

The major source for energy production in the yeast, saccharomyces cerevisiae, is glucose and
glycol sis is the general pathway for conversion of glucose to pyruvate, whereby production of
energy in the form of ATP is coupled to the generation of intermediate and reducing power in
form of NADH for biosynthetic pathways.

Two major modes of the use of pyruvate in further energy production can be distinguished:
respiration and fermentation. In the presence of oxygen and absence of respiration pyruvates
enters the mitochondrial matrix where it is oxidative decarboxylated to Acetyl CoA by the
pyruvate dehydrogenase multi enzyme complex. This reaction links gylcolysis to the citric acid
cycle, in which the Acetyl CoA is completely oxidized to give two molecules of co 2 and
reductive equivalents in the form of NADH and FADH 2, however, the citric acid cycle is an
amphibolic pathway, since it combines both catabolic ad anabolic functions. The latter results,
for example, from the production of intermediate for the synthesis of amino acids and
nucleotides.

Replenishment of compound necessary to drive the citric acid cycle, such as oxaloacetate and α-
ketoglutarate, are:

(1) The fixation of co2 to pyruvate by the action of the enzymes pyruvate carboxylase (ATP
dependent) and phosphoenolpyruvate carboxykinase,
(2) The glyoxalate cycle (a shortcut across the citric acid cycle ), which is important when,
yeast are grown on two – carbon sources, such as acetate or ethanol
 Microorganisms

Brewing utilizes strains of saccahromyces carlsbergensis, bottom yeast, and saccharomyces

cervisiae, both bottom and top yeast strains. Top yeast to the surface during the fermentation
while bottom yeast settles to the bottom. Top yeast are used for the production of ale distillers.
Bakers and wine yeast also are top yeast. However, beer fermentation employs bottom yeasts.

Yeast strains are specially selected for their fermenting ability to flocculate at the proper time
near the end fermentation. Brewery itself can select and propagate these strains as well as
produce the inoculums. Brewing is different from much other industrial fermentation, in that cell
for pitching are often those recovered from a previous fermentation. Fresh inoculum is not
necessarily prepared for each fermentation run and in fact, fresh yeast inoculum is required only
when contamination presents a real problem or when the vigor, of the yeast has begun to decline.
Before being employed as inoculums, the yeast cells from a previous fermentation are washed
(with phosphoric acid, tartaric acid or ammonium per sulphate) by setting, process that reduces
the pH value to about 2.5 and removes considerable bacterial contamination.

Thus, each pound of yeast added to the fermentation at inoculation yields approximately 3 to 4
pounds liquid yeast at harvest, and the excess yeast, which is not required for further inoculums,
becomes a b product of the fermentation.
 METHODOLOGY

STEP – 1

MALTING BARLEY

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

Malting barley has to be tested in micro malting trials, pilot malting and industrial malting trials;
and brewing trials also in pilot and production scale.

The physical conditions of the barley must meet specification concerning:

Factor Range
Germination % Minimum 97% after 3 days
Germination index Minimum 6, 0
Water content 12, 0%; maximum 13, 0%
Protein content > 9, 0% and <11, 5%
Grading Minimum 90% > 2, 5mm
β- glucan content Maximum 4%
Micro-organism Below a set level
Pesticide residues According to national law
Ochratoxin According to national law
Aflatoxin According to national law
Variety purity Minimum 99%
 STORAGE CONDITIONS

Vitality

During prolonged storage, barley grain will slowly loose its vitality, causing a slower
germination and even grain death, and will therefore be of o less value for the maltster.

The rate at which barley loses its vitality is dependent on the storage conditions. When stored at
very low temperatures and low moisture content, barley may keep its vitality for centuries, but
with increasing temperature and moisture, the deterioration processes faster and barley can loose
its germination ability in a very short time. Malting barley stored for1 to 1.5 years, should be
kept at a moisture content of below 12% and at temperature below 120 C.

Fungal Contamination During storage

Fungi may attack barley with moisture content of above 14% during storage especially by
species aspergillus and penicillium. It is therefore, important that malting barley is stored under
conditions, which prevent fungal growth.

Maximal length of storage for maintaining malting barley quality under different storage
conditions
Temperature Seed moisture content
10% 12% 14% 16% 18%
o
0C 16 years 6 years 2 years 1 years 190 days
o
2 C 14 years 5 years 1.8 years 315 days 160 days
4 oC 11 years 4 years 1.5 years 260 days 130 days
o
6 C 9 years 3 years 1.3 years 210 days 105 days
8 oC 7.5 years 2.5 years 1 years 170 days 89 days
o
10 C 6 years 2 years 300 days 140 days 70 days
12oC 5 years 1.6 years 240 days 110 days 55 days
o
14 C 3.8 years 1.3 years 190 days 85 years 45 years
o
16 C 3 years 1 years 150 days 50 Days 25 Days
18 oC 2.3Years 290 Days 115 Days 40 Days 25 Days
o
20 C 1.8Years 220 Days 90 Days 30 Days 20 Days
22 oC 1.4Years 170 Days 70 Days 25 Days 15 Days
o
24 C 1Years 130 Days 55 Days 18 Days 12 Days
26 oC 290 Days 100 Days 40 Days 13 Days 9 Days
o
28 C 210 Days 70 Days 30 Days 10 Days 7 Days
o
30 C 160Days 55 Days 22 Days 10 Days 5 Days
At the Carlsberg research laboratory loss of seed vigour has been studied intensively ( EBC 1989
and 1991 .)Barely seeds lose both their ability to germinate fast as a consequently of storage. The
rate at which seed vigour is lost is dependent on the storage condition . It is our experience that
malting barley can be stored safely for the maximal lengths of time indicate in the table.

Malting
Barley , which is the fundamental raw material of beer , does not give , just as it , a fermentable
extract by yeast.

By mashing it in hot water we could get a bad use of it. We have a let it go through a beginning
of germination. Enzymes, which attack the grain and dissolved it in water, are produced during
the mashing.

This beginning of germination is called malting. This preliminary step of the production of an
constitutes an industries on its own: the malt house . The brewere” Grain d’orge ” buys directly
the malt in a malt – house .

Malting consist first of a soaking in water during about three days. Then it is spread inlayer to let
it germinate during eight days and finally we stop germination by the desiccation on a kiln or
killing. After this operation, the color of the malt varies between yellow and brown going
through every golden hue. According to his will of making of lager or brown beer, the brewer
chooses one or the other malt.

Malting Process

In the malt house, barley grain germinate is initiated by the uptake of water in a steeping vessel
(A). The grain imbibes water during controlled cycles of water spraying or water
immersion followed by aeration, until the water content of he grain reaches 42 to 48 %
.water enter enters the grain via the embryo and after approximatelyt24 hours, hours, the
first visible sign of germination is the appearance of the root, as a white chit. The grain are
then transferred to malting beds where germination is allowed to proceed over a period of
around five days (b). The speed of germination is controlled by temperature and aeration of
the malt bed, while moisture content is maintained by spraying. Further embryo growth,
with the appearance of the root lets and acrospires, can lead to root entangling. The grain
bed is regularly

turned with a rotating screw to prevent grain malting together. Green malt, produced after 5 days
of germination, in kiln dried and partly cooked in a forced flow of hot air (C). Hydrolysis
produced during malting are partly inactivated during this process. Malt color, enhanced by
kilning at higher temperature, may be desirable for production of darker beer, but it leads to
further heat inactivation of hydrolysis. The brittle malt rootlets are separated from the malt and
utilized in animal feeds.

STEP – 2
 MASHING

The goal of mashing is to obtain from the raw material (water, malt and hop) sweet and flavored
wort, which will then go through alcohol fermentation.
Mashing includes the three following operations:

Malt crushing
Mashing
Wort filtration

During the mashing, the malt that was crushed before is mixed with water. This mixture of water,
crushed malt with other various ingredients is the mash.
The mash is heated at accurate temperature during predetermined laps of time, in order to have a
complete transformation of the starch from the malt and of the cereals used for sugar:
That is the mashing.
This transformation of starch into sugar by the enzyme was lightly initiated during malting. It is
essential because yeast can not transform directly starch into alcohol. Starch has to be first
transformed into sugar by the enzyme developed during malting.

Once these transformations into sugar finished, the liquid is filtered to eliminate the husk oh the
malt grain. The product that is then obtained is the wort; it is a sweet liquid, which already has
the colour of beer.

The brewer can, by choosing the temperature level, act on the composition of the wort. For
maltose is fermentescible and for starch gums aren’t he can obtain beer that is more or less rich
in alcohol. The duration of mashing is more or less two ours. Then the mash is filtered in a filter
press. The insoluble materials are the spent grains (25% of the weight of the malt). The wort is
pumped into a brew kettle heated by vapor coils.

Mashing involves heating the crushed malt and rice flakes mixture in the mash kettle in order to
convert the starches in the malt, and adjuncts if added, into fermentable and unfermentable
sugars.

Mash kettle: 150 HL

Mashing 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
favors one enzyme, which degrade cell walls and protein are rather heat labile, it is important for
their function that mashing begins at a low temperature. Subsequent mashing at 65 oC, 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)- β-glucanase and xylanase for cell wall
degradation, endo-peptidase and carboxypeptidase’s for protein degradation; and amylase, limit
dextrinase and α- glucosidase for starch degradation.
Temperature controlled mashing
Mashing extracts those materials from the malt and malt adjuncts, which can be solublized under
the particular mashing conditions being employed, also allows the malt amylases and proteases
to degrade starch and protein, respectively. A portion of the starch must be partially degraded to
dextrins and the rest totally degraded to maltose and glucose. In the same manner, the proteins
must be partially degraded to peptones and peptides as well as totally degraded to amino acids.
The degree of enzymatic hydrolysis of these compounds is influenced strongly by temperature
and to some extent, by pH. The temperature program is yield defined mixtures of particularly and
totally degraded enzymatic products.

The temperature optima for the alpha amylase and beta amylases of malt occur within the range
of approximately 55 to 77oC. The beta amylase with a temperature optimum at 57 to 65 oC,
cleaves maltose units from the ends of linear glucose polymers but can degrade only the short
side chains not including the branches. Alpha amylase with a temperature optimum in the range
of 70 to 75oC, cleaves starch at random yielding large fragment dexrtins with or without
branching units so as to make straight chains available for beta amylase activity. Proteolytic
activity of the malt at temperature of approximately 60oC allows the formation of the higher
molecular weight peptones and peptides but at about 50oC the enzymatic activity yields a higher
proportion of amino acids and low molecular weight peptides.

The peptones and peptides resulting from the Proteolytic activity of the malt provider flavor,
foam, and foam stabilization. The dextrin’s being non-fermentable, provider low alcohol beer
and certain flavor characteristics.

Chemical changes at mashing

The mashing process is conducted over a period of time at various temperature in order to
activate the enzymes responsible for the acidulation of the mash (traditionally for lagers) and the
reduction in proteins and carbohydrates. Enzymes are biological catalyst responsible for
initiating specific chemical reactions. Although there are numerous enzyme present in the mash,
each with a specific role to play, this discussion is limited to the three principal groups and their
respective processes. These enzymes are:

 Phytases (acidifying),

 Proteolytic enzymes (protein-degrading ) and

 Carbohydrate enzymes (starch-degrading).

Starch conversion
By far the most important change brought about in mashing is the conversion of starch
molecules into fermentable sugars and unfermentable dextrins. The principal enzymes
responsible for starch conversion are alpha and beta amylase. Alpha and beta amylase very
rapidly reduces insoluble and soluble starch by splitting starch molecules into many shorter
chins (i.e., partially- fermentable polysaccharide fractions – dextrins and maltotiose) that can
be attacked by beta amylase. Given a long enough “rest”, the alpha – amylase can dismantle
all the dextrins to maltose, glucose, and small, branched “limit dextrins”. However, starch
conversion is more effective by the faster acting beta amylase. Beta amylase is more selective
than alpha amylase since it breaks off two sugar at a time from the starch chain. The
disaccharide it produces is maltose, the most common sugar in malt. Together, alpha and beta
amylase are capable of converting only 60 to 80 % of the available starch to fermentable
sugars.

Factor affecting mashing conditions

Temperature

Temperature influences the amount of extract produced (yield) and the fermentability of the
wort during mashing. In general, the higher the temperature, the greater the yield but the
lower the fermentability of the wort. At lower temperature less extract is produced, but
fermentability is higher. Only at very high temperature will extract begin to drop off.

Mash times

Mash times another factor influencing yield and the fermentability of the wort.In general,
longer mash times increases the concentration of the extract, but the rate of increase becomes
slower and slower. In general, short mash times at high mash temperature will produce more
dextrinous worts, while longer mash times at high temperature will produce more dextinous
worts, while longer mash times at higher temperature produce more fermentable worts.

Mash pH

The optimum pH range for mashing is generally at 5.5 to 5.6 for both amylases. The
“normal” mash pH, however, depends on the type of malts employed, the pH of the water,
the method of mashing. The mash cycle should not be started until the proper initial mash is
approximated (within pH 0.2).

Water ions

The nature of the mashing water has an important influence on mash reactions. The ions of
major importance at mashing are those of calcium and carbonate, with magnesium and
sodium ions playing lesser roles. Calcium lowers the pH of the mash mainly by its interaction
with phosphates and to a lesser degree with protein from the malt. Carbonate ions operate in
the reverse direction.
STEP - 3
 WORT SEPERATION

After mashing, when the starch is broken down, it is necessary to separate the liquid extract
(the wort) from the solids (spent grain particles and adjuncts). Wort separation is important
because the solids contain large amount of protein, poorly modified starch, fatty material,
silicates, and polyphenols (tannins).

Lauter tun

Figure: 2

The lauter tun is equipped with a sparing system to wash the extract from the mash. The top
of the tun is usually spherical or conical and fitted with a vent for relieving the vapor of the
hot mash to the atmosphere. The bottom of the tun may be flat or sloped, or it may be
constructed with several concentric valleys with intervening ridges. Suspended above the true
bottom of the tun is a false bottom of milled, slotted, or welded wedge wire steel plates that
act as the filtering system. Free surface area ( the area through which the wort can flow)
varies 8 to 15% foe milled bottoms and up

to 25% on welded screen bottoms. The false bottom is not a filter plate but acts as a support
for the grain bed.
Typically, false bottoms in craft brewery lauter tuns do not consist of the pie- shaped
Sections of the machined plate, but rather of the rectangular wedge sections of “wedge” – or
“v”- wire screen. Their cost is considerable cheaper than machined bottoms, and the screens
perform reasonably well. The lauter tun, is equipped with rakes to assist mash transfer and
for leveling the bed and facilitating filtration of the, liquid from the mash. Rakes are more
important when the mash is stirred and mixed, such as with temperature controlled infusion
or decoction mashing. Unlike single temperature infusion mashing, the mash loses its
entrained air and sinks onto the false bottom in a dense bed.

Procedure

Lauter tun with a perforated base is used to separate wort from the husk & other matter. Once
the wort stops passing out through the base & a bed of huskies formed, water is sprayed from
the top by a shower at a pressure of 2Kgcm -2 and water bed is formed which keeps seeping
through the husk bed and dissolving the remaining glucose & maltose with it, if present.

(Total time required: 3.5 hr)

STEP – 4
 WORT BOILING

Following extraction of carbohydrates, proteins, and yeast nutrients in the mash, the clear wort
must be conditioned by boiling the wort in the kettle. The purpose of wort boiling is to stabilize
the wort and extract desirable components from the hops. The principle biochemical changes that
occur during wort boiling are as follows:

Sterilization
Destruction enzyme
Protein ppt.
Color development
Isomerization
Dissipation of volatile constituents
Concentration
Oxidation

Figure: 3
KETLE

Operating the kettle

Traditionally , the kettle times lasted between 90 and 120 min., wit a minimum of 10 %
evaporation per hour. However, today kettle times for an all – grain beer last from 60 to 90 min
with 8 to 10 % evaporation ate. In order save time, most brewers begin applying heat as soon as
the wort covers the kettle to minimize charring (or scoring), and to prevent damage to the kettle.
Some systems may be require that the kettle be more than halfway full before applying heat.
Care must be taken when using direct gas fire since the first running are easily caramelized. if
system jackes are used, heating may be started as soon as several inches of wort are in the kettle
by shutting off the side jacket.

Hops and Hop Products

Substances that are important in beer

Bitter substance 19.0 %

Oils 0.5 %
Polyphcnols 4.0 %
Protein 20.0 %
Minerals 8.0 %

A good beer need a good aroma acceptable plate and a deal of that in beer is provide by hops . It
has been said: “ Malt is the soul of beer and yeast gives it life but the kiss of the hop is the
consummation of that life .” the lupulin glands of the female flower cones f the hop plant provide
the different biter substances, which are the basis for beer bettering . Hop cones or hop extract
are added during the wort boiling where the largely insoluble
α -acids (humulones) from the hops are isomerized to the more soluble Iso - α –acids, the main
bettering substances found in the beer. Hopes also contain  –acids (Iupulones), which are
claimed to add bitterness to bee, especially after oxidation. Analysis of the hop acids in hop
products is important for quality control. The analysis is performed by HPLC ( high pressure
liquid chromatography ) using a reverse phase C18 column especially developed for this
purpose, and elution with acidic , aqueous methanol.

Hoes are added to he boiler tank as the boiling is started. Hopes are the agent , which impart
flavor ( bitterness ) to the beer.

Two types of Hopes are used:

 Pellets
 Slimy extract

Sugar is added at the start of the boiling to have the require amount of the fermentable sugar in
the wort to obtain a desired concentration of alcohol in the bee finally obtain.
After boiling the wort in transferred to the whirlpool for the susended hops particles, sugar
impurities etc. to settle down.
Wort boiling system
Traditionally , wort was boiled in direct – fired kettles, often made of copper. Since the heat ,
source is localized at the bottom of the kettle, these vessels are not efficient in transferring heat
into the wort , can scorch the wort, and are restrict by the volume of wort, that can be boiled at
anyone time.

“ The advent of steam coils and internal heating system allowed for more efficient heat transfer
and larger kettle for boiling larger volume of wort . the disadvantage with steam coils are that
they are difficult to clean , prone to corrosion , and limited the circulation of wort. ”

However , internal cookers offers several advantages , A circulation pump ( and its additional
energy consumption) is not necessary since natural convection of the wort takes place in the
kettle. The degree of efficiency of an internal cooker is significantly higher than that of an
external cooker even without considering the forced circulation of the latter. This is because of
the internal cooker is always completely surrounded by the wort. Wort is subject to less thermal
stress . the boiling temp. of the wort using an internal boiler is approximately 101 0C. using an
external boiler; outlet temp. of the wort is approximately 106 to 107 0 C, such high wort temp. in
external boiler are to a pseudo pressure cooking effect, which man brew masters is
approximately four times the no. of forced circulation of wort in an external boiler.

STEP – 5
 WORT COOLING AND AERATION

After boiling and clarification , the wort is cooled in preparation for the addition of yeast and
subsequent fermentation. Te principle changes that occur during wort cooling are follows:

Cooling the wort to yeast pitching temp.

The formation and separation of break and
Oxygenation of the wort to support yeast growth.

Wort cooling systems

After boiling and clarification , the wort leaving the whirlpool has to be cooled in preparation
for the addition of yeast and subsequent fermentation. Wort is usually cooled though plate
heat exchanges.

Heat exchangers are of two types:

1. Single – stage ( Chilled water only ) or
2. Multi - stages ( amient water , glycol).
Wort enters the heat exchanger at approximately 96 to 990 C and exists one – stage cooling .
The first stage utilizes water to remove the bulk of the heat, cooling the incoming water to
within 30 C of fermentation temp.

In the second stage , the wort is cooled to the fermentation temp. by a secondary refrigerant ,
e.g.; glycol. Some craft brewers , in an attempt to reduce capital expenditure, ill use the same
glycol system that provides the cooling for the fermentation. Most small brewers would
prefer two – stages cooling but use one – stages cooling to save money .Alternatively ,the
cooling operation can be achieved in a single stages using a glycol – jacked cold water to
approximately 30 C below that of the required wort temp. In both systems, the heat from the
wort is transferred to the water. That water cant hen be used other purposes , but mainly as a
source of warm brewing water.

Aeration and chilled water

Aeration of the chilled wort is needed in order to provide the yeast with sufficient oxygen for
growth during fermentation . The amount of oxygen required depends on yeast strain, wort
temp. wort gravity, amount of tub in the wort, and a no. of other factors. Foe e.g.; wort at
high temp. and high specific specific gravity has greater oxygen require than wort at lower
temp. and specific gravities. Wort low in trub generally has high oxygen requirement ,while
wort with high trub levels have lower oxygen requirements.

The oxygen requirements for individuals for brewing strains can range from 3 to 30 mg,O 2 / l
but usually it I in the range of 7 to 18 mg O 2 / l . Yeast strains with low O2 requirements can
be aerated using sterile air since it contains approximately 8 mg O 2/l, while strains with high
O2 requirements must be aerated with pure gaseous O2.
STEP – 6
 FERMENTATION

figure: 4

Wort is cooled and added with yeast, which transforms the fermentation sugar dissolved in water
into alcohol and carbon dioxide. After about eight days, this fermentation is finished.

We distinguish two main types: the bottom fermenting beers, fermented at a law temp. (12 to 150
C) with yeast that settle at the bottom of the ale and the top – fermenting beers, fermented at 20 –
250 C with yeast that rise to the top of the beer after the fermentation.

Bottom yeast gives a smother, less flavoured and almost neutral taste that makes the taste of the
flavour and of the hop stronger. It is the yeast used foe classical beers.

Top yeast is energetic yeast that reproduce a lot and that only works well with a temp. higher
than 200 C. It produce more ethereal and flavoured beers that seem to be light and easily
digestible , even when their density . It is the ideal yeast for specially for specialty beers.

After fermentation is complete, the beer is set in the fermenter for several weeks at 00 C. The
goal of this is to refine the taste, clarify partly the beer and o saturate it with CO2 . Top beers only
undergo a shot cooling.

During the primary fermentation (H), the fermentable sugars, mainly maltose and glucose are
converted to ethanol and CO2 . This action is performed by the brewing yeast , which during the
brewing process also procedure many of the characteristic aroma compound found in beer. At the
end of the primary fermentation , the yeast cells flocculate and sediment at the bottomof the
fermentor and can be cropped and used for a new fermentation. Not all yeast cells sediment,
some will remain sin suspension , and these cells are responsible for maturation of the beer .
During this process the off – flavor , diacetyl is degraded to below the taste threshold. The
fermentation characteristics of brewer’s yeast are strain – dependent , and are genetically
inheritated. Much of the genetics of sacchromycse yeast has been elucidated , and the knowledge
gained , forms the basis for breeding of brewing yeast. Thus , new t5ypes of beer with altered
aromas can be produced with yeast strains selected through breeding.

COLD STORAGE
The completed fermentation medium is transfer to storage tanks and held at approximately 0 –
30 C for a period of time. During this “cold storage maturation ” coagulated nitrogenous
substances, resins, insoluble phosphates , and yeast cells sediments from the beer. In addition,
esters are formed, and the beer matures so that it looses its harshness .

During this maturation process, “chill proofing ” is commonly practiced to help prevent turbidity
development on letter exposure of finished beer to cold . much of turbidity can be attributed to
unstable protein in the beer, and chill proofing can mean merely the removal by ppt. or
adsorption of these unstable residual proteins or partial protein hydrolysate products.

Chill proffering ,is practiced by employing proteolysis enzymes to reduce the mol. Size of the
residual protein and protein hydrolyses produce, so as to insure their solubility even at cold temp.

Antioxidants are also added during cold storage during maturation to prevent later oxidative
changes in the beer, which affects flavor . Sulfur dioxide ( sulfites ) and ascorbic acid are
commonly used to accomplish this end.

STEP-7
 FILTRATION

Extended laagering periods and the addition of flocculation adds both greatly reduce yeast and
haze loadings. Centrifuges are mainly used in the preliminary reduction of suspended particles ,
primarily in yeast before sending to the conditioning tanks. Although these method are very
effective in prefiltering the beer, a final filtration is needed to removed residual yeast , other
turbidity – causing materials, and micro-organisms in order to achieve colloidal and
microbiological stability.

If there is a significant quantity of suspended material to be removed , powder filters using

diatomacesous earth or perlite must be employed. Although powder filter can produced beer of
acceptable brilliance after a single filtration, a to stage filtration process is need to a final polish.
Polish filtration may employ a sheet filter, used as an intermediate step in handling heavier
loads , followed by a cartridge filter.

TYPES OF FILTERS USED FOR FILTRATIONS OF BEER

SCHENK FILTER

Yeast, protein and carbohydrates particles must be removed from the beer to achieve the
necessary clarity. As the first step in filtration, powder filters are used for removing these
suspended particles, the help of high flow super cell powder makes the powder filter . The
powder is injected at the point where the beer stream, together with yeast and other suspended
solids, forms and incompressible mass referred to as the “filter – cake”. The porous bed creates a
surface that traps suspended solids, removing them from beer . Not all of the particles will be
trapped at the surface, some especially the finer material, will pass into the filter cake and be
trapped – a process referred to as “depth filtration”. These beds retain up to 99% of the culture
and suspended particles. Depth filtration is not as effective as surface filtration, but is still a
significant mechanism of filtration by filter aids. Powder filtration is generally regarded s
providing the most economical forms of filtration. The cost of filter aids is quite low , and long
filtration cycles at high flow rates are possible.

The haziness of the beer is seen under a yellow lamp , and until the haziness disappears, the beer
is continuously recycled and refiltered through these powder beds in the schenk filter.

For 110 HL of beer , approximately 13 KG of powder is used .

Types ( qualities ) of powder is used

 White powder
 Yellow powder

Yellow powder is of higher quality and higher efficiency than the white powder but is costlier
and has a short self life compared to the white powder.

To counter the deficiencies of yellow powder and to be cost effective , a combination of both
powders is used to make filter beds .

PATE AND FRAME FILTER

The plate and frame filter has been the work house in breweries around the world for many
decades for filtering beer. It is robust and reliable, consistently filtering beer to the specified .
Standards plate and frame filter consists of a series of chamber enclosed within a metal frame
. Between adjacent frames is a double sided porous filter plate covered by either a fine mesh
or a sheet. The filter sheet acts as a trap for the filter aid, which other wise might bleed
through , their by assuring excellent a clarity . Filter sheet are generally made with cellulose
fiber, diatomaceous earth , perlite, and a resin for bonding to give dry and wet strength .
Some are available only with filtration fiber. The average pour size of filter sheet is between
4 – 20 microns , therefore plate and frame filter are readily precoated and less susceptible to
malfunction . each plate alternates with a frame with the entire system held together by a
screw or hydraulic clamp mechanism. This type of filter is very similar in appearance to the
sheet filter, except it has sludge frames. The inlet pressure of the beer into these type of filter
is approximately 0.7 – 0.8 bar .

This step is good enough to retain the remaining 1% of the culture / suspended particles so
that the beer is completely free of any particles.

STEP - 8
 BEER CARBONATION

Secondary fermentation in carbonating Beer

The traditional method involves carbonating the beer during secondary fermentation at low temp.
and under counter pressure. The beer transferred to the conditions tank should have at least 0.5 to
1.00 C of fermentable extract and be placed under pressure from 12 to 15 PSI in conditioning
tanks. Munroe reports that if the pressure is to high during sec. fermentation yeast growth may be
affected and change the flavor characteristics of the beer. While in the tank , the remaining
extract ferments and creates sufficient carbon dioxide to saturated the beer to equilibrium.

Mechanical Beer Carbonation

Mechanical carbonation is accomplished either by in line or in tank techniques. Carbon dioxide
may be purchased from supplies of industrial gases. Alternatively , CO 2 may be recovered from
fermentation vessels and then purified, liquefied ,and stored until needed for carbonation .
However, this collection system can be too expensive for most craft brewers. In general, the
viability of collection CO2 depends on an alternatively cost of purched CO 2, is availability, and
the quantity used in the brewery. Some brewers report that use of mechanical carbonation
actually has a greater influence on reducing acetaldehyde levels than does kraeusening the beer.

PRINCIPLES OF BEER CARBONATION

The time required to reach a desired CO 2 concentration depends on a no. of physical factor.
Temp. and pressure play an imp. Role in determining the equilibrium concentration of CO 2 in
solution. At equilibrium the same amount of CO 2 is diffusing out of the beer as is being
dissolved back into solution . Increasing the pressure leads to a linear increase in the weight of
CO2 dissolving in the beer of water. Decreasing the temp. gives a non- linear increasing CO 2
solubility in beer. Consequently, the equilibrium concentration can not be attended without either
increasing the pressure or decreasing the temp. Thus , the closer the carbonating temp. is to 00C ,
and the higher the pressure , the greater the CO2 absorption .
Approximately two cylinder of CO2 gas are added to every storage tank of beer of approximately
vol. of 120 HL.

STEP – 9
 BOTTLING

Figure: 5

Before the bottling or the kegging, the beer is filtered to eliminate yeast and the suspension
materials. There after, it is pasteurized (flash pasteurization or tunnel pasteurization for the
bottles and flash pasteurization for the kegs).

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

The bottling of beer can be divided into the following steps:

 Bottle – feeding,
 Bottle rinsing,
 Bottle filling,
 Tunnel pasteurization,
 Bottle labeling and ,
 Case packing

Beer Bottle Feeding

The first in bottling beings with loading the empty bottles on the unscrambling table. In craft
breweries, loading with prepacked bottles is usually done manually at a rate of 80 100
bottles per minute ( bpm). The table funnels the wide mass of bottles into a single stream.
 Several types of mechanism prevent the bottles from bridging as they are funneled to a single
line. These include mechanical joggers, reverting chains, and good inheriting design.

Beer Bottle Rinsing

These are three types of bottles rinsers – twist, gripper, and rotary. Most craft breweries use
twist rinsers, which are design to invert the bottles before spraying. After being rinsed , the
bottles are allowed to drain before swung back up into the upright position and delivered to
the bottle filler. Each bottle size and shape requires a different “twister”, but the cost of twist
rinse is quit low. Gripper style rinser are a more compact alternative to twist rinser and can
handle various bottle size and shape without parts having to be changed. Rotary rinser, are
compact as well, and are known for their smooth bottle handling. However, rotary rinser, are
the most expensive option for rinsing. A rotary rinser can also be incorporated into a filler as
part of a “monobloc” arrangement. Monobloc machine also combine a crowner are better
than separate units, since the bottle must be capped as soon as possible after filling to exclude
air.

Before rising the bottles are washed with caustic soda, thus removing dust, labers etc. at 60 0
C for 30 min.

Beer Bottle Filling

Filling Process

The bottle goes into the machine, the gas is filled into the bottle s& a vacuum is created, the
bottle is lifted a bit ,the beer is filled into the bottle & the pressure is released. The filled
bottle is then passed on for the crowning of the filled bottles.

Crowning

After filling, the bottles are capped as soon as possible y the crowner. The caps have a
sprayed on, hot – passed PVC based sealing insert or a cold pressed sealing insert not
containing PVC. The caps are conveyed to the crown hopper means of a magnetic belt or a
pneumatic crown feed, or they can be dumped manually directly into the crown hopper.
Whatever method is used, the crown hopper should be kept only half full of caps. This is to
lessen the possibility of crowns becoming packed and not feeding into the chute fast enough.
In addition , then the caps become packed , the possibility of scratching the cap finish
increases.

After crowning the bottles are screened for the presence for the presence of any sort of
suspended articles or the haze in the beer in front of a a white lamp. If any such suspended
particles are detected , the bottles are returned and not sent for labeling.
 TUNNEL PASTEURIZAION USED IN THE BOTTING BEER

An alternative to flash pasteurization &sterile filtration is tunnel pasteurization. Tunnel

pasteurization is employed after bottles have been filled & sealed. The bottles are loaded at
one end of the pasteurizer &passed under sprays of the water as they move along the
conveyor. The sprays are so arranged that the bottles be subjected to increasingly hot water,
until the pasteurization temperature (usually 60oC) is reached by beer in the bottles. The
bottles are then gradually cooled with water until they are discharged from the end of the
pasteurizer. Temperature changes have to be made in the prevent he bottles from breaking.
Heating and cooling of the bottles is preformed using various water circulations, paths in
order to utilize recovered heat. In this way, heat usage by the tunnel pasteurizer can be
reduced t a minimum, Passage through the tunnel pasteurizer takes about an hour. Bottle
breakage is usually no more than 0.1 to 0.2 percent in the tunnel pasteurizer. If greater, it is
usually due either to poorly made bottles or he lack of head space.

Bottle Labeling

An in line labeler is a type of machine for which the bottle travels in a straight forward motion ,
and the label or labels are applied while the bottle is moving along the bottle conveyor. One such
type of in line labeler is the tandem labeler that is typically used in multiple or “ in tandem ”,
with each machine typically capable of running 60 to 80 bpm. Maintenance of the labelers is
fairly demanding; and even though parts are fairly inexpensive, they may be difficult to obtain.
tandem labels cannot do front and back labels at the same time, and does not bound labels with a
full width of glue, but rather with only two vertical strips one at each side of the label. The labels
may ape puckered due to moisture condensation or may be crooked or have corner flagged (edge
lifted). These limitations have increasingly contributed to the obsolescence of tandem labelers;
nonetheless, their low cost and simplicity assure their continued use, particular by craft brewers.

Case packing Beer Bottles

Case packing is done manually or br case packers. Two people standing at a discharge table can
pack up to 100 bpm. For rates above 10 bpm , an automatic case packers is required has a linea
collection table on which the bottles are automatically placed in ranks that mach the packing
pattern in the case. A conveyer supplies the packer with the shipping cases, and from the packer
the conveyor caries the filled cases to the palletizing.
 RESULT AND DISCUSSION

Beer ranges from less than 3% alcohol by volume (above) to almost 30% above. The alcohol
content of beer varies by local practice or beer style. The pale lagers that most consumers are
familiar with fall in the range of 4–6%, with a typical above of 5%. The customary strength of
British ales is quite low, with many session beers being around 4% above. Some beers, such as
tafelbier (table beer) are of such low alcohol content (1%~4%) that they are served instead of
soft drinks in some schools. In the United States beer with an alcohol content over a certain level
(? 5%) can not be called beer for marketing purposes. The term 'malt liquor' is often used instead.
Many imported 'beers', such as Singa Beer from Thailand, can not be labeled as beer in America
due to its high percentage of alcohol by volume.
The alcohol in beer comes primarily from the metabolism of sugars that are produced during
fermentation. The quantity of fermentable sugars in the wort and the variety of yeast used to
ferment the wort are the primary factors that determine the amount of alcohol in the final beer.
Additional fermentable sugars are sometimes added to increase alcohol content, and enzymes are
often added to the wort for certain styles of beer (primarily "light" beers) to convert more
complex carbohydrates (starches) to fermentable sugars. Alcohol is a waste product of yeast
metabolism and is toxic to the yeast; typical brewing yeast cannot survive at alcohol
concentrations above 12% by volume. Low temperatures and too little fermentation time
decreases the effectiveness of yeasts, and consequently decreases the alcohol content
 LIST OF FIGURE

1. FIGURE-1: OUTLINE DIAGRAM FOR PRODUCTION OF BEER

2. FIGURE-2: LAUTER TUN

3. FIGURE-3: BOILING TANK

4. FIGURE-4: FERMENTER IN BREWERY

5. FIGURE-5: BOTTLING SECTION

BIBLIOGRAPHY

1. http://en.wikipedia.org/wiki/History_of_beer

2. http://www.opt.be/contenus/history_of_beer/en/2100.html

3. http://www.brasserie-graindorge.com/history-beer.php

4. http://www.opt.be/contenus/beer_types/en/2180.html

5. http://www.opt.be/contenus/how_beer_is_made/en/2140.html

6. http://www.brasserie-graindorge.com/mashing.php

7. http://running_on_alcohol.tripod.com/id20.html

BOOKS

 How to Drink Beer and Save the World,

Christopher Mark O’Brien

 Beer, Its History and Its Economic Value as a National Beverage

By Frederick William Salem