Addis Ababa Science and Technology University

College of Biological and Chemical Engineering

Department of Chemical Engineering

Internship Hosting Company: BGI Ethiopia

Internship Report: 31 /09/2019 –31 /02/2020

Prepared by: Gebre Shumuye

ID No: ETS 0506/09

University Supervisor: -Mr. Demelash T.

Company Supervisor: -Mr. Andualem
BGI report 2012E.C

Submission date: 03/02/2020

Acknowledgment

Initially I would like to thank Addis Ababa Science and Technology University for providing me
with such an opportunity to develop my practical skill. Secondly, I would like to express my
sincere gratitude to BGI Ethiopia for letting to work in this brewery company for my internship
program that has lasted for 4 months. Special thanks go to my company advisor, Mr. Andualem,
and his co-workers for helping and supporting me in every aspect on my stay there. Here after, I
would be thanking our department advisor, Mr. Demelash Tilahun for guiding me on my
internship program including advices and corrections on my project and report.

Addis Ababa Science and Technology University II

BGI report 2012E.C

Abstract

This report contains historical background about B.G.I Ethiopia and also about the raw materials
used for beer production that is barley malt, hops, water and yeast and also the various unit
operations and their operating mechanisms used in this brewery. This report also contains the
challenges that I have faced and how I overcome them. And also what I have gained in terms of
improving my practical skills, what I have gained in terms of upgrading my theoretical
knowledge, what I have gained interims of improving my inter personal communication skills,
and also improving my leader ship skills and so on. And at last it contains my recommendation
to the company that I have seen some problems. On this paper I tried to do my project on how to
decrease the beer loss from the packaging section.

Addis Ababa Science and Technology University III

BGI report 2012E.C

Table of Contents

ACKNOWLEDGMENT...............................................................................................................................II
Abstract........................................................................................................................................................III
1.1. Objectives of the company............................................................................................................2
1.3 Main products and service of the company......................................................................................... 3
1.4 Overall organizational structure and work flow...........................Error! Bookmark not defined.
2. Introduction............................................................................................................................................... 3
2.1 Beer......................................................................................................................................................3
Bioglucanase: enzyme required in degradation of β – glucanase inside the malt..................................... 5
2.3. Types of Beer......................................................................................................................................5
3. Brewing Process Description.....................................................................................................................5
3.1 Malt Storage.........................................................................................................................................6
3.4 Filtration section................................................................................................................................ 12
3.5. Packaging.........................................................................................................................................15
3.5.1. Bottling...................................................................................................................................... 15
3.5.2 Kegging.......................................................................................................................................18
3.6 Utility.................................................................................................................................................19
3.7. BGI Ethiopia Quality Management Department.............................................................................. 24
4. Material and Energy Balance...................................................................................................................25
4.1 Material balance.................................................................................................................................25
4.2Energy Balance...................................................................................................................................28
6. Project………………………………………………………………………………………..33

7. Conclusion and Recommendation………………………………………………....................38

List of Figures

Addis Ababa Science and Technology University IV

BGI report 2012E.C

Figure 3.: Overall Process Flow Diagram.........................................................................6

Figure 3.1: Brew House Process Flow Diagram................................................................8

Figure 3.2: Fermentation process...................................................................................... 12

Figure 3.4: Filtration Process Flow Diagram....................................................................14

Figure 6.1: Laboratory result for beer contamination detection…………………………36

Figure 6.2: Flow diagram of beer recovery ………………………………………………38

Addis Ababa Science and Technology University V

BGI report 2012E.C

List of Acronym

1. TOD = Tank out door

2. BBT = Bright Beer Tank

3. CIP = cleaner in place

4. HGB = High gravity beer

5. LGB = Low gravity beer

6. VDK = Vicinal Dike tones

7. DMS = Dimethyl Sulphur

8. KMS = Potassium di methane sulphide

9. O
p =Degree Plato

Addis Ababa Science and Technology University 1

BGI report 2012E.C

1. Background of the Company

The St. George Brewery is the most popular company situated near the Mexico square, Addis
Ababa, and occupies an area of 20,000 sq. Meters of land. The founder of St. George Brewery,
according to some sources, is Mussie Dawit Hale who is a Belgian, other sources say that the
Brewery was owned and operated by a Germen company. In fact, the Brewery was set up by
Mussie Dawit Hale who lately sold it to a Germen company. The Brewery stands right on the
same site it was 80 years ago. During the time of last Emperor, it was known as marshal Smut
Street. It was a fine and a fairly big building and it started off as one of the pioneers in Ethiopia’s
industrial development.
The factory started with machineries that were operated by hand and foot and work was done by
direct human labor. Transporting of raw material to the silo, fermenting of the malt, boiling the
barely, filtering the beer, filling the bottle’s, etc. were all done manually. Basic raw materials like
barely and hops were imported from Europe. The management staff of the factory and the
leading technicians who controlled the brewery’s activities was all foreigners. During its first
years about 200 bottles (half litter size) were produced daily. Some sources say that the brewery
was closed during the five years of Italian occupation.
The company continues its work after the occupation, and according to some reports there arose
problems related to ownership. Eventually, however, an Ethiopian company takeover the
brewery in 1952/3. This Company was said to have been organized as a shareholding entity, the
larger share of which was owned by Emperor Haile Selassie.
Towards the end of the 1950s the annual production of the brewery had reached 50,000
hectoliters.

According to the review made on ‘The Ethiopian trade Journal’ the brewery had 53 silos, which
had the capacity of 100-hectoliters each. There were about 300 employees who worked in two
shifts for 24 hours. Trucks were also introduced that transported beer through the empire. Slowly,
but steadily, St. George Brewery continued to grow in the early years of the 1970’s the brewery
was in good shape in terms of its machineries, physical buildings, vehicles, marketing network,
etc.
On the other hand, the brewery was lacking the finance it needed to introduce new technologies
they come in the 1970s. The name of the brewery was also changed as ‘’Pilsner Brewery’’ and

Addis Ababa Science and Technology University 1

BGI report 2012E.C

later as ‘’Addis Ababa Brewery’’. Most of all, the workers showed a great commitment and
dedication to keep the brewery and its product popular. The role played by the brewery was
significant in supporting and promoting other social activities include St. George sport club. St.
George Breweries once again privatized. The factory is now owned by BGI, an internationally
acclaimed Brewing Company that operates in many countries. Nowadays St. George Brewery
has excellent reputation in producing quality beer and standardized beer over the other three
branches such as, Kombolcha, Hawassa and the one and the most famous within the country as
well as outside the country Bgi Ethiopia.

From store, the beer is sold to wholesalers and consumers. Trucks transport the distribution of
the product to different regions of the country. The distributions are managed and controlled by
the sales department of the company. Apart from local, the company is also exporting beers to
Djibouti and sometimes to USA and Europe. Different societies are its product user. The sales
representative of the company distributes the product fairly to satisfy its customer. Currently
BGI has so many costumers; its product is not kept in store since the produces are familiar.

Generally main consumer or end users are: wholesalers, consumers in over all the country and
foreign country such as Djibouti, USA and Europe.

1.1. Objectives of the company

Some of them are as follows:

• To improve the type, quality and quantity of product

• To advertise the product by erecting artistic notice boards in towns, at main public station,
using internet, and soon.
• To provide practical education for students, research institutes, technical personnel, etc.

• To allocates a large amount of budget every year for providing refrigerators, modern
washing machines, donating professional.
• To produce beer and draft with quality within country as well as export in Europe.

Addis Ababa Science and Technology University 2

BGI report 2012E.C

1.2 Mission and Vision of the company

• Mission: Providing efficient and standardized service towards the first choice of
customers, consumers as well as team members.
• Vision: To be the leading company in image, visibility, product mix and volume
and market share.
• Main Focus: increasing the sales volume of castle and lunching its draft as well
as increasing our visibility and help and high standard quality of service on draft.

1.3 Main products and service of the company

BGI Addis Ababa brewery is huge company that produces both beer and draft. Now a day the
company produces St. George, Castel beer, and Panache. All are differing by their alcoholic
content, additive added into them and packaging system. Generally, the qualities of BGI Ethiopia
product have high quality than the other beer. Because of high degree Plato, good foam stability,
almost none turbidity, and have bright color. Additionally, the company gives aid for the society
in different social networks; youth involve themselves in the company.
Generally, the company plays an important role in: supporting and promoting social activities,
committing with socio-economic problems of the country, Training the workers to upgrade them
a high level of competence and all the workers show great commitment and devotion to keep the
brewery and its product popular

2. Introduction

2.1. Beer

Beer is one of the oldest and most widely consumed alcoholic drinks worldwide. Beer is brewed
from cereal grains: most commonly from malted barley although maize (corn), wheat and rice
can also be used. During brewing process, fermentation of starch extract, i.e., fermentable simple
sugar found in the wort produces ethanol and Carbon dioxide in the beer. Most modern beer use
hop, which add bitterness and other flavors. It also acts as a natural preservative and stabilizing
agent. Other flavoring agents such as herbs or fruits may be included or used instead of hops.
The strength of modern beer is usually around 4 to 6 % alcohol by volume. Beer is distributed in
bottles and cans.

2.2. Major Raw Materials

Addis Ababa Science and Technology University 3

BGI report 2012E.C

 Barley malt
 Water
 Yeast
 Hop

Barley Malt

Malt can be of any type of cereal grain. But barley malt is preferable due to:

Has enough enzyme, Has balanced and enough carbohydrate, Has Minimum amount of protein ,

Little amount of fats/oils which decreases foam formation, has husk which facilitates filtration by
trapping unwanted materials. Have its own preferable color, mouth feel and texture.

Water
Water is needed in every process of production of beer either as steam, boiling or cooling agent
and some portion of the water is used directly in the beer which contains about 95 % of water in
it and sometime for the condensers of cooling equipment.
Yeast
Different types of Beer yeast help to give Beer its various tastes. During beer production the
sugar in the wort is fermented by yeast to alcohol, for productions in BGI yeast fungi known as
lager yeast is used.

Hop

Hops are grown in special growing regions where the necessary growth conditions exist. After
the harvesting of the hops, they are dried and processed to avoid a reduction in their value. The
variety of hops used, will leave its own distinct flavor / aroma. Here there are 3 types of hops
used namely the CO2 Extract, IKE and tetra hops.

Other Raw Materials include:

Caramel: It is used for coloring the beer.

Addis Ababa Science and Technology University 4

BGI report 2012E.C

Calcium chloride: It can be used as a nutrient for yeasts and to enhance the texture of beer. It
also helps in separation of protein molecules by forming flocculants inside the wort kettle and
separation of yeasts by increasing their densities in fermentation tanks.
Hydrochloric acid: Is used to regulate PH and to provide favorable PH for enzymes to work in
the mash tun.
Zinc Sulfate: Provides nutrients for yeast growth.

Sugar: Is to increase fermentable sugar amount needed in fermentation and also to provide
sweeter test for the beer.
Bioglucanase: enzyme required in degradation of β – glucanase inside the malt.

2.3. Types of Beer

• Ale Beer: are top fermented beers that use yeast named Saccharomyces Cervisiae, and a
relatively higher fermentation temperature with respect to lager and a complex filtration
mechanism is required.
• Lager Beer: are bottom fermented beers that use yeast named Saccharomyces uvarum,
and a cooler fermentation temperature and easier filtration mechanism. They are stored
for some time after fermentation has ended.
• Wheat Beer: is produced from wheat malt by using top fermentation method but is not
advisable due to its high protein content and absence of husk.
 Stouts: are dark colored beer brewed from amber malts or over-kilned malts with either
top or bottom fermentation

3. Brewing Process Description

The overall flow diagram will be discussed in figure 3 below
Overall Process Flow Chart

Addis Ababa Science and Technology University 5

BGI report 2012E.C

Figure 3: Overall Process Flow Diagram

3.1. Malt Storage

Malt used in this factory is of two types. It is either imported or local. Imported malts come from
three European Countries namely France, Belgium and Netherlands. This imported malt come in
containers thus are immediately transported to silos.

On their way to the silos dusts and any metallic substances are removed by the help of dust
removers and magnets attached on their flow path. And, any foreign materials with larger size
are screened out from the malt. There are 4 silos found in BGI Company in Addis.

Addis Ababa Science and Technology University 6

BGI report 2012E.C

However, local Malts are delivered from Assela Malt factory and Gonder Malt factory in bags of
each 50 kilograms, so manual labor is used to transport malts to storage rooms.

When malt is needed in the milling section it is transported in pipes with the help of air pressure.

Local malt is screened, dust and metal removed before passing onto the pipes of malt intake.

3.2. Brew House Processes

The following figure 3.1 will shows the detail description of brew house process.

Process Flow Chart

Addis Ababa Science and Technology University 7

BGI report 2012E.C

Figure 3.1: Brew House Process Flow Diagram

A. Milling

It is process of size reduction for better extraction by increasing surface area of malt for
enzymatic actions. This factory uses hammer mill which the malts are milled to sizes of less than
2.75mm.

B. Premashing

Addis Ababa Science and Technology University 8

BGI report 2012E.C

Mechamasher is the place where grist, process water and steam are mixed in. The temperature of
this tank is set to be maintained at 62.4 0 C. this is done by varying and maintaining the steam
and process water inlet amounts. Carbon dioxide is used here to transfer mash to mash tune by
providing pressure.

c. Mashing

mash tun is the tank where mashing process occurs in. It’s the process of degradation of larger
molecules to smaller ones. It includes breaking of proteins to amino acids, polysaccharides
(starch) to fermentable and non- fermentable sugars, and also breaking of fats to fatty acids. This
all processes occur with the help of enzymes. Barley contains α and β amylases and proteases
which converts starches and proteins, respectively.

Mash tun uses agitator for uniform mixing and is heated to provide favorable temperature for the
0
enzymes. Proteases work well at 55 C, β amylases work well at 64 0 C, and α amylases work
well at 74 0 C. Additives in this stage are CaCl2, HCl, and Bioglucanase.

Enzymatic reactions in Mash Tun are the following

1. β - glucanase degradation:

The cell wall of barley endosperm consists of a fixed network of proteins, cellulose and
hemicelluloses which are linked together by β - glucanase. The starch reserve is in the
endosperm so the β - glucanase should be degraded first by endo β glucanase.

2. Starch degradation:

The most important component of beer is the alcohol formed during fermentation from sugars. It
is therefore important to degrade the starch to a large extent to fermentable sugar like maltose.
Starch degradation occurs in three stages namely gelatinization, liquefaction and saccharification.

Gelatinization: Each cereal has its own gelatinization temperature. Malt starch will gelatinize at
600 C in the presence of amylase. Simply gelatinization means swelling and bursting of starch
granules in hot aqueous solution. A viscous (sticky) solution is formed and the degree of
viscosity is dependent on the extent of water. At this stage there is no chemical degradation
happening.

Addis Ababa Science and Technology University 9

 BGI report 2012E.C

Liquefaction: It is the reduction in the viscosity of the long chain glucose in starch

(Amylase and amylo pectin) or gelatinized starch by α-amylase. The long chain glucose
in starch are very rapidly broken to form smaller chains by α-amylase. The α-amylase is
active at the temperature of 72 – 75 o C and the PH range is 5.6 – 5.8.

Saccharification: It is the complete degradation of starch to maltose and dextrin’s by β amylases.

β -amylase progressively breaks down chains of amylose and amylopectin to form dextrin’s
containing up to 12 glucose residuals. It is active at the temperature of 60 – 65 o C and the PH
range is 5.4 – 5.5.

3. Protein degradation:

The breakdown of proteins such as albumins, globulins and glutens start during malting and
continues during mashing by proteases which breakdown proteins to peptones to polypeptides
and poly peptidases which breakdown the polypeptides to amino acids. The enzymes proteases
and peptidase are two main enzymes of this group. Protease is responsible for degrading
albumins already dissolved in the wort, along with insoluble globulins, into simpler medium-
sized proteins (peptones and peptides).

Iodine test is done during mashing to identify if starch has degraded to fermentable sugar or not.
If sample from mash tun changes color to blue black, starch is still present so requires additional
time. But when sample changes color of iodine to yellow, it represents all starch has degraded to
simple sugar thus mashing ends here.

E. Mash Filtration

Mash filter is a plate and frame filter which uses membranes. There are 4 stages which are first
sparging, second sparging, third sparging and finally compression. The wort is transferred to
holding vessel and spent grain is discharged to hopper after compression. Then spent grain is
transported from hopper to trucks using screw conveyor.

Addis Ababa Science and Technology University 10

 BGI report 2012E.C

F. Wort boiling
0
Wort kettle is a cooking section rising the temperature to 99.9 C. It is a tank where wort is
heated for: Removal / Evaporation of extra water, fully denaturing enzymes Hop isomerization,
Killing micro- organisms Better coloring Additives in this step are hop of two types called IKE
and Extract, caramel, ZnSO4, Sugar, and CaCl2. Overall process takes 1 hour, hop and CaCl2 are
added at the start of the process, sugar in the form of syrup is added at 50 minute of process and
ZnSO4 is added a minute before sugar.

G.Claris aver

Claris saver is a tank with a conical shape at the bottom of it. It is where heavy materials settle
down by the principle of precipitate

3.3. Fermentation section

The brief description of fermentation section is explained in figure 3.2 below

Process flow diagram

Figure 3.2: Fermentation process

Addis Ababa Science and Technology University 11

 BGI report 2012E.C

A. Wort Cooling and Wort Aeration: Is decreasing temperature of clarified wort (98 0 C) to
0
10 C using plate heat exchanger and dosing of Oxygen to wort required for aerobic
respiration of yeasts in the fermentation process for yeast propagation.

B. Yeaster: Is a tank where yeast propagation and homogenization of powder yeast with wort
occurs in. There are two Yeaster tanks. Yeasts are dosed to the wort going to fermentation
tanks from these tanks on the pipes where aerated, cold wort is passes through.

C. c.Fermentation: Fermentation occurs in large TODs for about 12 – 15 days. Fermentation is

the process of converting/ decomposition of fermentable sugar to alcohol (ethanol), carbon
dioxide and energy (heat) with the help of yeasts. Yeasts used here are lager yeasts, which
apply bottom fermentation process.

A. Fermentation is initially maintained at 12.5 0 C. Yeasts work well at this temperature, and when
extract reaches.
0
Some specified amount, specifically for BGI 8, temperature is rose to 16 C. This is to reduce
the VDK amount produced by side reaction during fermentation. After this when VDK is below
0.15, temperature is decreased back to 4 0 C.

And again, at this time limit extract is approximately reached. Limit extract is the maximum
amount of production of ethanol from the extracted sugar using yeast.

E. Maturation: It is stage of taking extra time in fermentation tanks for better coloring of the
beer and removal of yeasts due to precipitation. When TOD tanks reach 4 0 C, yeasts are
removed by the help of conical shaped bottom of TODs. Then after removing yeasts, temperature
is decreased to – 2 0 C. Fermenters use glycol to decrease temperature.

3.4 Filtration section

The overall process of filtrations is explained in figure 3.3 below.

Process Flow Chart

Addis Ababa Science and Technology University 12

BGI report 2012E.C

Figure 3.3: Filtration Process Flow Diagram

A. High Gravity Beer (H.G. Beer)

H.G. beer is the beer transferred from the fermentation process to filtration section. It contains
15 % yeast, alcohol and Carbon dioxide. H.G. beer uses Lantern A and B are used as transferring

Addis Ababa Science and Technology University 13

BGI report 2012E.C

mechanisms to the filtration process to remove any gap that might be formed in the pipes which
would let air in pipes. Lantern B is used as a reservoir for continuity of fluid transportation.

B .H.G. Beer Cooling

Is cooling of H.G. Beer from about – 1.5 0 C to – 2 0 C using glycol with a plate heat exchanger.

C.Centrifuge

It is separation of yeasts (heavier substances) from the lighter liquid beer. Centrifuge is a
machine which rotates with a very high speed to separate materials. The centrifuge used here
0
rotates with 4840 rpm (revolutions per minute). It is re- cooled again to -2 C, because it will
gain some amount of heat due to collision between molecules during spinning.

D.Silica gel unit

It is the addition and homogenization of silica gel with the H.G. Beer to increase size of
impurities especially proteins found in the beer. This is done to increase shelf life of beer by
further purification.

E. Buffer Tank 1

Is tank used for settling of impurities and stabilization of the beer since it was in high speed
revolution in the centrifuge as well as in the silica gel unit agitation processes. Out flow from this
tank occurs when amount of beer in it has reached 80 % of the full capacity.

F.H.G. Beer Filtration

Filtration at this stage requires use of filter aid. The filter aid known as clarcel or kieselguhr has 3
types that are speed plus, speed flow and super aid. These are mixed in kieselguhr with the beer.
Then they are passed to plate type filter. Then it is passed into the filtered outlet beer tank or
buffer tank 2.

G. Blending

Based on the alcohol content, amount of water required to produce 4.7 % alcohol in final beer is
known, thus degassed water will be added and blended with the beer.

Addis Ababa Science and Technology University 14

BGI report 2012E.C

H. Additives

Filter outlet beer is stored in Buffer tank 2 for laboratory testing and stability. Sample is taken
from this tank and tests like bitterness, color, CO2, Dissolved O2, and alcohol are done. If
bitterness is not in the specified range, hop is added or dosed into it. If color is not in specified
range, caramel is added. In addition to this, KMS (Potassium Meta Bi-Sulfate) is added to beer
which increases the shelf life of the beer and Vitamin C (Ascorbic acid) is added to the Draft
which gives it flavor.

If the amount of the above tested parameters is above ranging, the filtered beer will be blended
with another filter outlet with lesser quantity of above parameters.

I. Carbonation

Carbon dioxide is finally dosed, 4.5 for beer and 2 for draft. It is then stored for a short while in
BBT (Bright Beer Tank). And lastly BBT is tested for surety, the tests include: Haziness,
Bitterness, PH, and Color.

3.5. Packaging

3.5.1. Bottling

It is final stage of producing beer to supply for customers. Bottles have a shelf life of 1 year.

A. De-palletizer

Forklifts move stored craters with empty bottles from warehouse to pallets. Then pallets are
transported on to de-palletizer machine. De-palletizer transfers crater from pallets to roller
conveyor by the help of photo electric sensors.

B. Lubricator

Before going to lubricator, it passes direction convertor which arranges the direction of crates.
Then lubricator sprays water onto the crates to moisturize crates and bottles for easier removal of
bottles from the crates.

Addis Ababa Science and Technology University 15

BGI report 2012E.C

C.Decamatic: It uses pneumatic system to pull out bottles from the crates to transfer crates to
crate conveyor and bottles to bottle conveyor. It consists of a crate stopper, crate centering and
crate sensor.

D. Crate Conveyor: It transports empty crates to crate washer, which only uses water for
cleaning the crate.

E. Bottle Conveyor

This transfers bottles to in-fit conveyor, which passes bottles into introducer for washing. Here
after, introducer transfers to pusher that pushes bottles to fit into the pocket. Bottles in pocket
have inclined sitting to easily remove wastes by gravitational force. In addition to this
pressurized water is also used.

F. Bottle Washer

Washing has 4 soaking stages that are:

i. First and second soaking: This two are together, but initially a chemical named PT
100 is added to easily remove labels strongly attached to the bottles. Labels are
moved out of the washing process using conveyors and a brush removes labels from
conveyor to the garbage. Then soaking of bottles uses caustic soda and steam to wash
bottles.
ii. Third soaking: is washing bottles using lesser amount of caustic soda to remove
leftover dirty or wastes which haven’t been removed in earlier washing stages.
Iii.Fourth soaking: it uses small amount of acid to neutralize soda left in the bottles
and is then finally drained and washed with pure water to finish washing.
G. Bottle size Inspector

It has photoelectric sensor to test if bottle is of right size. Foreign bottles either longer or shorter
are removed with the help of mono-rejecter.

G. Empty Bottle Inspector

Addis Ababa Science and Technology University 16

 BGI report 2012E.C

It checks overall cleanliness of the bottle. It has testers for the mouth, bottom, base, and internal
parts to check if any broken area is present and not purely cleaned. It also takes a picture of each
bottle and writes, saves information about the clean and rejected bottles.

I. Filling

Bottle presence sensor initially gives information to the filler. If bottles are present vacuum
pumper starts up. It removes any materials that might have entered bottle from the air when
being transferred from washer to this region. Then passes to Carbon dioxide pumper where CO2
is filled onto the bottle to remove any moisture or air that can spoil the beer within short period
of time. If pressure in bottles is high during CO2 addition, bottles will explode. Then filler fills
bottles with beer with the help of Umbrella and corks are immediately closed. There are 72
valves for filling process. Then chrome has hot water and air which is used to take CO2 to the top
of the bottle to maintain amount of CO2 needed, if greater than needed it will be removed.

J. Full Bottle Inspector 1: Full bottle inspector is a sensor to test and rejects with mono-
rejecter.

K. Pasteurizing Section: This is heating of beer to increase the shelf life. It uses hot water and
overall process of pasteurization takes about 40 minutes. If not pasteurized, beer will be
spoiled within 12 hours. Pasteurization has 3 zones; these are:

i. Heating zone: it has internally again 3 zones. The first zone is heating to a
temperature of 38 0 C, then second zone is heating to a temperature of 44 0 C and third
zone is heating to a temperature of 58 0 C.
0
ii. Pasteurizing zone: It has again 3 zones. First zone heats to a temperature of 63 C,
0
then second zone heats to a temperature of 56 C and third zone heats to a
temperature of 63 0 C.
iii. Cooling zone: It has also 3 zones. First zone cools to 58 0 C, then second zone cools
0 0
to 44 C and third zone cools to 38 C. Cooling is done to decrease expansion of
molecules caused due to heating of molecules. If not cooled down bottles will
explode.
L. Labeling: Its body and neck labels are done here using glue to attach labels to the bottle.

Addis Ababa Science and Technology University 17

 BGI report 2012E.C

M. Domino: Is attaching expiry date to the bottle using inks sprayed onto the bottles.

N. Full Bottle Inspector 2: It tests proper attachment of labels on the body and neck and if
improper, improper label rejecter rejects bottles. In addition to the above, there is an ultrasonic
cork sensor to test presence of corks. After this, Optical chemical is sprayed on bottles to
brighten up the bottles or to give a shining glow to the bottles.

O. O.Incamatic: It fills crater with full bottles using pneumatic system to pick and put bottles. Bottles are
transferred from full bottle conveyors to craters.

P. Full Crater inspector: It checks presence of 24 bottles in each crate.

Q. Palletizer: Transports crates from full crate conveyor to pallets to be stored in stocks.

3.5.2 Kegging
It is other form of supplying beer to customers. Draft has a shelf life of 30 days or 1 month.
Saint George draft is pasteurized draft, where pasteurization occurs before packaging. There are
two buffer tanks (BT) used as a storage tank each with capacity of 80 hl. One buffer tank stores
beer sent from BBT and the other stores pasteurized draft ready for filling. The draft or low
gravity Beer (L.G. Beer) stored in BT 1 is passed to and initially heated used a plate heat
0
exchanger with water of temperature 80 C. Then after heating, it is cooled back using cold
water with a temperature of 4 0 C and is stored in BT 2. BT starts process when reaching above
66 hl.

3.5.2.1 The Keg Line System

a. De-palletizer: Is transferring Keg from pallets to roller conveyor that transports keg.

b. Turner: It turns keg mouth from top to bottom.

c. Inspector: It checks if cap is present or not, if present it rejects.

d. Washer: Is external washing of the body of the keg using caustic and hot water.

e. Piston: It divides keg onto channels. There are 11 channels divided into 2 paths. The first path
contains channels 1 to 6 and second path contains channels 7 to 11.

Addis Ababa Science and Technology University 18

 BGI report 2012E.C

f. Filler: It has 6 stages on each channel:

g. First Stage (head 1): is internal washing by initially draining any leftover draft in the keg and
sterilizing check is done in here. Then it is washed with mixed water, i.e., acid and water, and
caustic soda and is drained. It is then finally soaked with caustic soda.

i. Second Stage (head 2): washes with caustic A, i.e., mixed caustic and water. Then it
is washed with caustic B, i.e., pure caustic.
ii. Third Stage (head 3): is washing with acid and mixed water.

iii. Fourth Stage (head 4): washing with low flow and mixed water. Then it is drained
and finally steam is filled into it, this is done to kill micro-organisms.
iv. Fifth Stage (head 5): it is stage of cooling down the keg and injecting CO2 into it. And
the mouth is washed with hot water.
v. Sixth Stage (head 6): Filling keg with draft

g.Turner: It turns direction of the mouth of the keg from bottom to top.
Spray alcohol (medical) on the moth and Close mouth with cap.

H. Domino and Label: It’s attaching expiry date to keg And attaching
label to keg.

Q. Palletizer: Transfers keg from conveyor to pallet.

3.6. Utility
Utilities are not main processes but are supporting units for the process.

A. Ground Water Process

Initially, ground water is pumped out from 250 m deep bore hole below the ground. Ground
water might contain ions, minerals, micro-organisms and suspended solid particles which require
further treatment to be used.

Two chemicals NaClO3 and HCl are reacted in a tank to produce ClO2. This ClO2 is used to kill
micro- organisms which are present in the original water. The ground water is mixed with ClO2 in
3 tanks where water is initially stored in and passed to sand filter. The sand filter has 3 layers

Addis Ababa Science and Technology University 19

BGI report 2012E.C

namely coarse, medium and fine. These layers are used to filter out suspended solids of different
sizes and also dead micro- organisms.

After passing this step of filtration, the chlorinated (mixed with ClO2) and filtered (sand filtered)
water is passed to and stored in the chlorinated and filtered water tank. Here after, the water is
passed through a 20 µ filter. This is done to trap particles with larger sizes greater than 20 µm
particle diameter. Then the water that has passed through is either transferred to 5 µ filter or
softener.

When passed to softener, Resins are used to remove ions of Calcium (Ca) and Magnesium (Mg)
present in the water. These resins contain Na+ (Sodium ions), but when removing Ca2+ and Mg2+
ions, Na+ ions are lost thus needs to be recovered. Recovery of resins is done by washing
softener with NaCl. Soft water is then directed to blending tank to be mixed with permeate water.

The other path where water from 20 µ filter passes to is 5 µ filter where pretreatment occurs in.
Then after passing through the filter Sodium Meta bi sulfate is added to the water to remove
ClO2 by forming NaCl salt. Then Hydrex Is added to the water. Hydrex is used as an anti-
scaling, i.e., to prevent scale formation. If scale is formed in Reverse Osmosis, membrane will be
damaged. And the membrane is very expensive thus pretreatment mechanisms are required to
prevent damaging of membranes.

From Hydrex water is transferred to reverse osmosis section. Water leaving Hydrex contains
high amount of salt content which is removed in reverse osmosis by process of moving ions from
high to low concentration and moving water from low to high concentration.

Water leaving reverse osmosis section is known as permeate water which has a hardness of about
0.25%. This water is used in brewing process as process water either as steam, hot water or cold
water. And blended water contains this permeate water. Blended water is used in utility system
as a heat exchanger for heating or cooling systems and in washing purpose.

After this Carbon filter is used for further purification. It has 4 filters. Permeate water is
transferred to 1 and 2 Carbon filters, which is used to remove any odor causing ions and minerals
like chlorine (Cl). Blended water is transferred to 3 and 4 Carbon filters, which are used to
remove ions.

Addis Ababa Science and Technology University 20

BGI report 2012E.C

Gas filter is the last filtration stage where de- chlorination process takes place in. This is done if
incase there is passing of molecules of chlorine in the above stage of carbon filtration. Finally,
water is treated and prepared to be used in the factory for the above different processes.

B. Boiler House

It is where permeated and blended water are boiled in, to produce steam and hot water. Boiling
0 0
for steams is at 300 C and for hot water is at 120 – 130 C. It uses diesel oil for boiling the
water.

C. Carbon Dioxide

Carbon dioxide (CO2) is a byproduct produced in the fermentation process of converting sugar
into alcohol. Though it is a byproduct it is used in the production process and can be sold out
thus carbon dioxide needs to be recovered.

The first step is transferring Carbon dioxide (CO2) from the Fermenters to Foam Separator. In the
separator foam is separated from the carbon dioxide gas. After this, purified Carbon dioxide is
transferred to collector. The collector is also known as a balloon. It is the area where the Carbon
dioxide is collected in.

Then Gas Washer is the place where other gases are separated and removed from Carbon dioxide
by showering the collected Carbon dioxide with water. After this Pure Carbon dioxide is
compressed using the compressor with about 17 bar pressure for further treatment.

It is then passed to Activated Carbon filter/ Drier, where activated carbon filter is used for odor
maintenance and removal and drier is used to remove any moisture and dusts will settle after
burning. After this it is passed to Carbon dioxide Condenser/ Re- boiler. Here Carbon dioxide
(CO2) is changed from its gaseous form into liquid state and CO2 gas will be free. Here NH3 is
used to decrease the temperature or as a cooling agent for Carbon dioxide (CO2). There are two
condensers available in the plant.

Then after this it is passed to Caron dioxide buffer tank as a stabilizing or cooling area. Then it is
passed to evaporator to prepare it in gaseous form to be used in filter blending with beer or
Carbon dioxide storage tanks (cylinders).

D. Glycol Cooling System

Addis Ababa Science and Technology University 21

BGI report 2012E.C

Glycol is initially imported at room temperature in tanks. It is a colorless chemical with high
viscosity thus is mixed with water to make it less viscous for easier circulation in pipes. Then
density is tested and when it reaches 1.025 g/ cm 3, it is introduced to Buffer Tank 1 and is
cooled to – 1 0 C using Ammonia. After this once glycol is stored in Buffer Tank 1 it can be re-
used for many times, as a cooling agent.

0
i. Buffer Tank 1: stores glycol at – 1 C and is re-cooled for usage in the production
process.

ii. Cooling plants: there are 4 cooling heat exchangers used to decrease temperature of
glycol to – 5 0 C using Ammonia.
0
iii. Buffer Tank 2: stores re-cooled glycol with temperature of – 5 C. It is then
transported to different places from this tank with a pressure of 7 bar.

0
Glycol is used in different areas at a temperature of – 5 C. Some are: BBT, TODs, Ice water
Cooling, Beer transfer lines, Flash Pasteurizer, etc.

E. Air System

Air is needed in pneumatic systems but cannot be directly used from the surrounding thus needs
to be processed.

Air is initially sucked from the surrounding using two sucking units. Then air is compressed
using 7.1 bar pressure to fit in storage tanks. It is then stored in tanks for a short time. It is next
transferred to dryer recovery vessels. Here it is burned to remove dusts and moisture. Then it is
finally transferred to air networking tank. It is stored in here until it is needed in the process. It is
then pumped to all pneumatic systems of the factory from this storage area.

F. Ammonia (NH3) recycling

Ammonia (NH3) is the best cooling agent from all forms of chemicals with very low freezing
point. But it is poisonous chemical if in case it meets beverages, so cannot be directly used for
cooling areas in the production. Ammonia is used for cooling glycol and CO2.

Ammonia is initially evaporated when cooling glycol since it receives heat from glycol. Thus, as
soon as it evaporates it goes onto compressor. Here it is compressed to have a high pressure in a
vapor form. Then it is sent onto a condenser to be changed into liquid state. Condenser uses air,

Addis Ababa Science and Technology University 22

BGI report 2012E.C

fan and water. Air spins the fan and cools the water then sprays it on the condenser. And
internally in the condenser moisture and droplets of compressed NH3 would form liquid, high
pressure NH3. Then it is transferred to expansion valves which would lower the pressure and
give off liquid, low pressure NH3. Finally, this ammonia is re-used for cooling plants.

G. Waste water Treatment

Waste water collected in the factory is mainly from Brew house wastes and bottling wastes.
Brew house wastes include all waste waters from brew house, fermentation, filtration, boiler
house and some utilities. They are initially stored in septic tanks. And when volume of waste
water in septic tank reaches 60 – 80 % of its total holding capacity, it is transferred to treatment
plant.

When being transferred to the process it is initially screened for removing larger materials which
might block flow of materials. Then it passes through a de-fatter section for removal of oils
which might be present due to leakage from motors. Then it goes into influent pit for checking
the temperature and PH using sensors. After this it passes through a static screen of 1mm by
1mm size.

Then it goes to Equalization Tank or Buffer Tank. It stays here for 6 hours and based on its PH
additives might be added to neutralize the waste water. If PH is > 7.5, CO2 and sometimes HCl is
injected into it and if PH < 6, NaOH is injected into it.

Then it is passed to PH correction tank for further correction and evaluation of its PH. PH has a
very high effect on bacteria’s to be used in the next stage. These bacteria’s must be kept under
optimum PH and temperature for longer use in anaerobic reactors. If affected by any means
including fuels from furnace or any other toxic substances, bacteria will be damaged and dead.
Then if PH is between 6 and 7.5, it is passed to UASB (Upper Anaerobic Sludge Broke). Here it
stays for 6 to 8 hours and bacteria produce Biogas named methane gas from byproducts.

After this, treated water is passed to re-aeration section/tank to oxygenate water to be released to
river and also to make it odorless by ventilation. And bio-filter is then used to separate biogas
from water. It gives off 78% biogas at this stage. Then finally biogas is passed to biogas torch to
be burnt into water vapor and carbon dioxide which can be easily released to the atmosphere.

Addis Ababa Science and Technology University 23

BGI report 2012E.C

H. CIP

There are two types of CIP: namely cold and hot.

1. Cold CIP

It is used to clean TODs, Bright Beer Tanks, Buffer Tanks, and all other tanks. All chemicals
used here are at room temperature. It uses 4 types of chemicals called caustic soda, ATR acid,
Sept acid and cold water. And cleaning has 3 stages, this are:

i. 1st Cleaning: Wash with caustic soda then rinse with cold water.

ii. 2nd Cleaning: Circulating the tank with ATR acid, to neutralize the tank.

iii. 3rd Cleaning: Circulating tank with septic acid for disinfection / sterilizing tank. And
finally drain.

2. Hot CIP
It is used for cleaning pipes/ tubes. All chemicals used here are at 80 0 C. It uses 3 types
of chemicals named as caustic soda, ATR acid and hot water. And it has 3 cleaning stages,
this are:
i. 1st Cleaning: Wash with caustic soda then drain.

ii. 2nd Cleaning: Circulating the tank with ATR acid, to neutralize the tank. iii.
3rd Cleaning: wash and rise with hot water for cleaning and sterilizing the tank.

Tanks use cold CIP not to heat up tanks and if there is presence of caustic in tanks and hot water
is added to it, it would form a vacuum which might cause tanks to collapse.

3.7. BGI Ethiopia Quality Management Department

BGI had two laboratories which were working under the Quality Management Department of the
company. These two laboratories were the Raw Material Laboratory and Physio-chemical
Laboratory.

Addis Ababa Science and Technology University 24

BGI report 2012E.C

The Raw Material Laboratory, as the name implies, is a laboratory where almost all main raw
materials are tested in to check the quality of input materials. These raw materials to be tested are
malt, bottle, and cork.

The Physic- Chemical Laboratory is the other laboratory where all in process tests are done in.

The tests include:

• Brew house tests like extract, PH and color in every stage,

• Fermentation tests such as apparent extract, yeast population, and VDK (VicynlDiketone)

• Filter outlet tests like bitterness, haziness, color, dissolved oxygen, Carbon Dioxide,
alcohol content, PH, and extract.
• Bright beer tank tests include haziness, bitterness, PH, and Color.

• Water treatment tests like total hardness, phosphate content, sulfite content, alkalinity,
and conductivity.
• Waste water treatment tests like BOD, COD, PH, fat content, etc.

4. Material and Energy Balance

4.1 Material balance

Objective: Is to calculate amount of spent grain released per one brew.

1. Hammer Mill

A single brew takes an average of 7200 Kg malt where about 2700 Kg is of imported malt and
4500 Kg is of local malts. Here losses are very small thus are negligible.

7200kg 7200kg
HAMMER MILL

2.mecha-masher

Solution

Mass is conserved thus

Addis Ababa Science and Technology University 25

BGI report 2012E.C

ᵄᵄᵆᵆ ᵅᵅᵅᵆᵆ = ᵅᵄᵆᵆ ᵅᵆᵆᵅᵆᵆ

Water (m1) + Grist (m2) = Mash (m3)

V1 = 155 hl

V1 = 155 hl * 100 l/hl * 10-3 m3/l = 15.5 m3 m1 =

1000 Kg/m3 *15.5m3
CaCl2
m1 = 15,500 Kg m2 =
7200 Kgm3 = m1 +
MASH TUN
m2 = 15,500 Kg + HCl
7,200 Kg m3 =
22,700 Kg

Mash to Mash filter

3. Mash Tun
Mash

Solution

Mass is conserved thus

ᵄᵄᵆᵆ ᵅᵅᵅᵆᵆ = ᵅᵄᵆᵆ ᵅᵆᵆᵅᵆᵆ

Addis Ababa Science and Technology University 26

BGI report 2012E.C

Mash from pre-masher (m3) + CaCl2 (m4) + HCl (m5) + Bioglucanase (m6) = mash to mash filter
(m7)

m3 = 22,700 Kg m4 = 7 Kg m5 = 3 Kg m6 = 2 Kg m7 = m3 + m4 + m5 + m6 = 22,700 Kg + 7 Kg +
3 Kg + 2 Kg
m7= 22,712 Kg

4. Mash Filter

Wort from mash tun. Filtered Wort

MASH FILTER
Sparging Water

Spent grain

Solution

Mass is conserved thus

ᵄᵄᵆᵆ ᵅᵅᵅᵆᵆ = ᵅᵄᵆᵆ ᵅᵆᵆᵅᵆᵆ

Wort from mash tun. (m7) + Sparging water (m8) = Filtered wort (m9) + Spent Grain

(m10)

m7 = 22,712 Kg

V8 = 152 hl

Addis Ababa Science and Technology University 27

BGI report 2012E.C

V8 = 152 hl *100 l /hl * 10-3 m3 /l = 15.2 m3 m8 =

15.2 m3 * 1000 kg / m3
m8 = 15,200 Kg
V9 = 346hl

V9 = 346 hl * 100 l /hl * 10-3 m3 = 34.6 m3

m9 = V wort * ₰ wort
₰. Wort = S.G c.wort * ₰water

S.Gc. wort= (mass percent*0.004) + 1

Laboratory measured extract content of cast wort is 18.1 0 P (degree Plato)

S.Gc. wort= (18.1 * 0.004) + 1

S.G wort = 1.0724

₰c.wort=1.0724 * 1000 kg/m3= 1.0724* 1000 kg/m3 = 1072.4 kg/ m3

Mwort = Vwort * ρc.wort m9 = 34.6 m3 *

1072.4 Kg /m3 m9 = 37,105.04 Kg m10 =
15,200 + 22,712 – 37,105.04
m10 = 806.96 Kg
Analysis: 806.96 Kg of spent grain is released per brew of mashing 7200 kg of malt.

4.2.Energy Balance

1. Hammer Mill

Objective: Energy Consumption of Hammer Mill per Brew

Analysis

From Bond’s Law: E/m = 0.3162 Wi [(1/√Dp) – (1/√Df)]

Wi = 12.74

Addis Ababa Science and Technology University 28

BGI report 2012E.C

m = 7200 Kg
DP = 2.75mm, since >80 % of product passes through this sieve DF = 3mm, since
>80 % of feed passes through this sieve size.
E = 0.3162 * 12.74 * 7200 [(1/√2.75) – (1/√3)]

E = 742.5 KW

Thus 742.5 KW of energy is consumed in crushing malt needed for a single brew.

5. CONCLUSION AND RE COMMENDATION

5.1. CONCLUSION
Generally, beer is an alcohol beverage made by fermentation of farinaceous extract that is obtain
from starchy raw material which is barley in the form of malt. The aim of malting is to bring
forth enzyme that will hydrolyze the starch and protein to less complex water-soluble
compounds, Amino acids, fermentable sugars and small peptides. These compounds are
dissolved in water resulting in a liquid known as wort. In B.G.I the yeast is originally propagated
from a single cells structure and recovered after fermentation. Generally, there are also two types
of yeast in brewing that is top and bottom type but in B.G.I Company it used the bottom type one
due to which does not usually for spore. This is well adapted slow fermentation at low
temperature and settles to the bottom of the tank at the end of fermentation. Finally, filtration
commenced, this process is a separation process in which the yeast cells and other turbidity
causing still presents in the beer are removed from the beer. At the same time substance is which
would, during the next weeks or months; they precipitate and make the beer turbid. Once the
desired quality of the beer is attained in the bright beer tank, the beer will finally ready to be
filled in the bottle or keg.
5.2. RECOMMENDATION
Malt storage
In B.G.I, the silo is made from stainless steel container and they are planted out in the open field
and there is no mechanism of controlling parameters such as temperature and humidity. If these
parameters increase in the storage it will cause physical and chemical changes in the endosperm
of the malt and this make it difficult for fermentation and other process. In order to fix this
problem, the malt must be stored in dry and cold environment. I want to recommend that some
controlling device fitted in the silo to monitor and stated parameters and there by adjusting the

Addis Ababa Science and Technology University 29

BGI report 2012E.C

environment of the malt storage for getting a massive amount of yield.

Energy recovery
In the wort kettle, there is a large amount of water vapor evaporated and it enters the surrounding.
However, this water vapor is steam which is produced on boiling. Now a day, the wort produces
0.8 hl of hot water at 80oC. More over the evaporated water mass contains a great deal of energy.
In my recommendation the company has two options, and this helps saving a high amount of
heat energy from the vapor. These are, - I. Vapor compression II. Vapor condensation
Filtration house
The beers that passes through the filter sheet, the sheet should be clean frequently if not there
might pass unclear beer so that it wills decrease the beer quality.

6. PROJECT ON RECOVERY OF BEER FROM PACAGING SECTION

6.1. Introduction
Main sections BGI brewery has for the production of beer are brew house, fermentation,
filtration, bottling or packaging and utility sections. During the internship period wastage of beer
from bottle packaging was seen. This project will try to fix and recover the beer which is wasted
from FBI1 and FBI2. As the wasted beer is the end product and full fills all quality parameter
needed for beer, it can be injected by treating it with the necessary processes to protect microbe
contamination, oxygen dissolution and another exposure of physically hazardous substances
which will affect its quality and will make it dangerous for health.
However, there is huge loss in commercial grade beer from filling machine due to specific
program setting for FBI1 and FBI2.Due to the filler machine and bottle break the company loses
greater than 49 million birr per year out of it around 26 million is due to over and under beer
filled bottles rejection [reference]. Disposition of the rejected bottled beer directly to waste
treatment plant also increased the cost of treatment. The under and over filled bottles will be
opened by man power and drained directly on channel to wastewater treatment plant which
results in need of additional man power and loss of caps. Developing a system which minimizes
and recover the loss is a burning issue. In this project we prepared proposal which focuses on
recovery of rejected bottled beer.
6.2. Statement of the problem

Addis Ababa Science and Technology University 30

BGI report 2012E.C

In order to recover the rejected beer first we have to open and drain it on an equipment for
further processing. Opening of the bottle will expose the beer to atmospheric condition which
increases the dissolved oxygen (DO) amount above the standard. In addition to, opening makes
the beer contaminate with microorganisms. Under the presence of dissolved oxygen metabolism
of microorganisms will be favored and decrees the shelf life of the beer. Therefore, decreasing
DO amount and complete deactivation of microorganisms (sterilization) are critical issues in
beer recovery.
6.3. Significance of the project
The main target to do this project is concerned with:
 The recovered beer is already finished product so no need of extensive work as to
produce as the commencement one.
 To minimize wastage of resource.
 To make the company more profitable than it is now.
 to save the environment from contamination

6.4. Objective
6.4.1. General objective
The general objective of this project is to develop the system which can be used to recover the
rejected beer at FBI1 and FBI2 from bottle packaging.

6.4.2. Specific objective

 To Kill the microorganism or sterilize the beer which is exposed to atmospheric during
opening of the bottle
 To manipulate the standard amount of dissolved oxygen for recovered beer
 To choose the appropriate type of line and tank CIP
 To check and compare the standard quality of recovered beer with the unrejected bottled
beer
 To calculate the injecting recovery beer flow ratio to high gravity beer at filtration
section
 Sizing of equipment’s for recovery beer process
 To evaluate the effect of process variables

Addis Ababa Science and Technology University 31

BGI report 2012E.C

6.5. Scope and limitation of the project

6.5.1. Scope
Microorganisms will be completely killed by ultraviolet ray sterilizer. Removal of dissolved
oxygen to the standard amount increases the cost of beer recovery, therefore, the recovered beer
will be injected to the line of bright beer (with low DO amount) in proper proportion to adjust
the DO amount of the final beer.
6.5.2. Limitation
As the project needs modern and sophisticated equipment’s to be done it was not possible to
conduct practically with prototype and the general problem will be solved if the inadequate
accuracy of the rotary filler is corrected.
6.6 .Literature review
6.6.1. Wasted beer at FBI1 and FBI2
The amount of wastage of beer due to filler machine inefficiency will be different from company
to company. This beer is processed and end product but, it is rejected due to over fill and under
fill as well as uncorked bottle. 9-11 palates bear is wasted daily in BGI St. George. So, what
mechanism to minimize this lose? Maintenance and make update program for filler machine can
eliminate and minimize lose but, this mechanism is difficult since secured and complexity of the
program. Establish temporary bar house and sell this wasted beer by discount price but, the bottle
rejected at FBI1 is not pasteurized, some of the bottle are uncorked as well as it is not
engineering and scientific method. The other method is recovering and reprocessing this beer and,
selecting the appropriate injection point.

6.6.2. Injection point selection

Since the beer has no sugar content the injection point is selected based on its characteristics.
There are options like brew house but the beer is processed one, fermentation section but same
reason and favorable condition problem for fermentation, filtration section suitable one, and at
packaging itself but the beer should be blended.
So, the favorable injection point is at filtration room. This beer is end product and full fills all
quality parameter of beer except amount of dissolved oxygen and microorganism contamination.
therefore, if the risk can be controlled, the appropriate injection point is at filtration section with
high gravity beer.

Addis Ababa Science and Technology University 32

BGI report 2012E.C

6.6.3. Sterilization methods

Sterilization can be defined as a process by which all available forms of microorganisms are
destroyed or removed. There are three main methods of sterilization; these are physical method,
chemical method and mechanical method.

Physical method of sterilization-it includes the following methods of sterilization

a) dry heat sterilization - Dry heat sterilization (killing or removal of all microorganisms,
including bacterial spores) technique requires longer exposure time (1.5 to 3 hours)
and higher temperatures
b) Moist heat sterilization- Moist heat sterilization describes sterilization techniques that
use hot air that is heavily laden with water vapor and where this moisture plays the
most important role in the sterilization. Heating an article is one of the earliest forms
of sterilization practiced. The various procedures used to perform moist heat
sterilization
c) Sterilization by radiation- In physics, radiation is the emission or transmission of
energy in the form of waves or particles through space or through a material medium.
This includes: electromagnetic radiation, such as radio waves, microwaves, infrared,
visible light, ultraviolet, x-rays, and gamma radiation (γ) particle radiation, such as
alpha radiation.

Chemical sterilization- The active agent of the gas sterilization process can be ethylene oxide or
another highly volatile substance. The highly flammable and potentially explosive nature of such
agents is a disadvantage unless they are mixed with suitable inert gases to reduce their highly
toxic properties and the possibility of toxic residues remaining in treated materials. The whole
process is difficult to control and should only be considered if no other sterilization procedure
can be used. It must only be carried out under the supervision of highly skilled staff.
Advantage: dry heat sterilization has the following advantages:

Addis Ababa Science and Technology University 33

BGI report 2012E.C

 It is relatively inexpensive
 It does not release any harmful or hazardous fumes or pollutants
 It does not lead metals to corrode or rust
Disadvantages: for dry heat sterilization include:
• It is relatively slow (can take a couple hours)
• Many objects cannot withstand the very high temperatures required for dry heat
sterilization (ex: some plastics would melt)
 Not all objects can withstand the temperatures of dry heat sterilization

Advantages: sterilization by radiation

• No degradation of media during sterilization, thus it can be used for
thermally labile media
• Leaves no chemical residue
• Administration of precise dosage and uniform dosage distribution
• Immediate availability of the media after sterilization
Disadvantages: sterilization by radiation
• This method is a more costly alternative to heat sterilization
• Requires highly specialized equipment
6.7. Methodology
6.7.1. Data collection
The necessary data have been collected by interviewing skilled employer, by making laboratory
analysis at the factory and using different websites. Microbiologists provided laboratorial
analysis for the determination of microbial contamination. The result obtained showed that the
beer contain microorganism of mold and bacteria and it contains some oxygen more than the
standard value. Therefore, highly sensitive risk is due to microorganism but not oxygen and it is
recommended to focus on the sterilization of microorganism.

Addis Ababa Science and Technology University 34

BGI report 2012E.C

6.7.2 Microorganism killing

Microorganism can be killed by the method known as sterilization. Cold sterilization has been
chosen for this work which means radiation and filtration are selected. Uv-ray or x-ray machine
will be installed at the line of beer recycle. These rays can kill the microorganism by breaking
down their DNA. bacterial filter at the end of radiation is also situated to complete cleaning of
this contamination.
6.7.3. Laboratory analysis
A sample is always taken at the injection point before injection to ensure that the beer is free
from any contamination and to know the amount of oxygen dissolved in it. After the oxygen
content is determined, proportionality with high gravity beer is made to achieve the standard (the
oxygen content which should be present in beer i.e. ≤ 0.15ppb).
Experiment was conducted on the beer to be recovered to analyze the contamination amount
during opening and pouring of it to the sieve. Microbiologists in the laboratory identified that the
contaminant found in the beer is mostly yeast growth due to the dissolution of oxygen and other
contaminants are more or less noneffective. So, as the dissolution time increases the higher will
be yeast growth.

Figure 6.1: laboratory result for beer contaminant detection

6.7.4. Blending flow ratio

The wasted beer is 3456L daily. So, the blending ratio of recovered beer to the main stream can
be calculated. The smallest fermentation tanks, (TOD) have a capacity to hold 3 brews, (means
900hl) but, the recovered beer has a volume of 34.56hl. Therefore, the blending flow ration
should be 34.56hl/900hl=0.0384, this is the maximum blending ratio. Therefore, the amount of
dissolved oxygen is almost normal. Even if the wasted beer contains high level, the blending

Addis Ababa Science and Technology University 35

BGI report 2012E.C

makes it to be in the interval due to small ratio.

6.8. Process description of beer recovery and Flow sheet for beer recovery
system
a. Flow sheet for beer recovery system
The design is made as shown in the figure 6.2 below. It is extended from packaging section to
filtration section. First, there should be two sieves for screening solid material if the beer
contains and number of pumps are installed along the line where necessary to pump the beer and
other utilities. Two tanks (tank1 and tank2) which are holding vessels are installed, one next to
the sieves and the other near to micro filter and they should contain their own CIP line, CO2 line
and glycol line like BBT. Then text to tank1, uv-light, plate and frame heat exchanger and micro
filter are designed to sterilize, to cool and to filter respectively. Manual valves, at the bottom of
tank1 and tank2, are fitted to manipulate the flow and blending valve at the end is installed to
inject the beer properly into the main stream at filtration section. An actuator, before the
blending valve, is situated to regulate the flow. Small sized pipes are also connected from line to
line to transfer the beer and other utilities as needed.
The beer which is removed from FBI1 and FBI2 by the sensor due to under fill and overfill is
received by the receiver and then unpacked (when packed) and poured to recovery tank manually.
Here the beer is kept for some time until the required amount for pumping is reached. Then it is
pumped in the line which is extended from this tank to filtration room. On the way of
transferring it, sterilizer and micro filter (membrane filter) are installed. So, the beer is sterilized
using uv-light sterilizer which is a strong sterilizer of microbes. Then it is cooled to a required
temperature as it was heated during pasteurization and filtered using membrane filter to remove
microbes like bacteria and yeast which will be developed during contamination and killed during
sterilization. After this process, the beer is stored in tank2 and sample is taken to check for its
oxygen content to make it proportional for blending with high gravity beer. Then it is properly
injected using the actuator and blending valve.

Addis Ababa Science and Technology University 36

BGI report 2012E.C

Figure 6.2: Flow sheet for beer recovery system

6.9 Discussion
In the introduction the background is discussed regarding to the project mainly to ensure its
applicability as preliminary. Other contemporary works as supportive are tried to be included.
Figures and flow sheet are used as illustrative. Generally this project can be profitable if it is
subdued in the way it is designed to be done and actuated in plantation. Designing layout,
method of the project proposal, and som laboratory aspects have been incorporated to complete
the general aspects of the project. Moreover literature review, statements and scopes of the
project, to help it induced, have been explained. So, as it is a profitable one.

Addis Ababa Science and Technology University 37

BGI report 2012E.C

7.Concclusion and recommendation

7.1. concclusion
Beer production process is wide area of industrial process which includes raw material
preparation such as malt handling and purifications, brewing water treatment, choosing hops and
specific yeast that match the process and product specification. During the time of attending at
B.G.I, St. George beer company, a brief process operation is done in practical and the following
conclusion is drawn from observations. Generally, beer is an alcoholic beverage made by
fermentation of extract wort that is obtained from starchy raw materials which is barley in the
form of malt by passing through the main processes of beer production such as milling, mashing,
mash separation, heating and boiling of the wort, wort clarification, fermentation, filtration,
dilution and packaging. The aim of malting is to bring forth enzyme that with hydrolyze the
starch and protein to less complexes water soluble compound, i.e. amino acids, fermentable
sugar and small peptides. These compounds are dissolved in water resulting in liquid known as
wort.

In brew house the raw materal (malt) is weighted, crushed, mashed with hot water, boiled, mixed
with other additives, filtered or separated from spents, chilled with ice or cold water to (9-10)0C
and then becomes wort which is ready to be fermented. In fermentation, first it is pitched with
yeast, and then is transferred to fermentation tanks where the simple sugar is converted or
fermented to alcohol, CO2 and energy with the help of yeasts. After the stayment of the day to
(14-15)days, it is sent to filtartion room being separated from yeasts as much as possible. Here in
the room it is filtered from different micro-organisms, dead yeasts, other suspesions etc. this is
done by using differenr flocculants, palte and frame filter and centrifuge. Another thing which is
performed in the room is also the dilution or blending of high gravity beer with deaerated water,
colorization of beer and CO2 blending. Then it is pumped to packaging from its storage. Here in
the packaging bottle and keg are unpacke, washed, inspected, filled with beer, inspected again,
packed again and then be ready for sale to customers.

Addis Ababa Science and Technology University 38

BGI report 2012E.C

7.2. Recommendation
In the internship stayment at BGI, St. George beer company, a list of problem was observed
which are needed to be solved for the reduction of expenditure in terms of material and
resource of the plant and to maximize the profitability of the company.

 It is well known that the company imports malt from western countries and it costs a lot
for the long journey transportation. It is recommended that the company have to make
integration with ministry of agriculture to cultivate the known species of barely that uses
for brewing.

 The wort kettle high amount of energy is needed to attain the temperature 90 0C. In
order to minimize the energy consumption at this unit there should be pre heat
exchanger which will increase the temperature of the wort. So that the hot wort from
heat exchanger will attain the maximum temperature.

 Energy consumption in St. George brewery is equal to 3 – 8% of the production costs of

beer, making energy efficiency improvement is an important way to reduce and control
production costs.

Addis Ababa Science and Technology University 39

BGI report 2012E.C

REFERENCE
1. Wolfgang Kunze, Technology of brewing and malting fifth Edition.(the report written from)
2. Brewing Science and practice Dennis E. Briggs Edited Chris A. Bolton, Peter A. Brookes and
Roger Stevens.
3. Fermentation and Biochemical Engineering Handbook Principles, Process Design
4. The Operation Manuals of the different Departments of the Factory Web sites.
5. Brewing Science and practice Edited by Dennis E. Briggs, Chris A. Boulton, Peter A. Brookes
and Roger Stevens.
6. Technology Brewing and Malting International Edition by KUNZE, W. (1996).

Addis Ababa Science and Technology University 40