BEER PLANT

[EIRI/EDPR/3877] J.C.: 1991

INTRODUCTION

The world of today is changing fast. India is no exception. Especially after the opening
up of the economy, the pace of change that India and its people are experiencing in their
socio-cultural milieu is mind-boggling. India, with its wide diversity, offers a fascinating
scope to study the host of changes which developmental activities have brought about in
its social and economic fabric1. While it is possible to get any accurate measure of the
subjective experiences that proceed, accompany or follow such changes. However, the
fact remains that the profile of the Indian market is vastly different from what it was five
years ago. Although these changes are difficult to measure at the micro level,
nevertheless, they have been of great significance to markets. Any market is keen to
closely monitor the changes in terms of numbers and specially to keep regular track of
the changing pattern of consumer’s aspirations and competitive actions.

Fast Moving Consumer Goods usually refer to non-durable products. Examples include
soft drinks, toiletries, grocery items, etc. A customer usually spends a minimum of effort
to procure them. However, much of astute marketing activities have evolved from this
class of products, where consumers show low involvement, put wider choice and allured
by a host of inducements.

Beer is an alcoholic beverage with low alcoholic content (2 to 7 % by volume) produced

by the saccharification of starch and fermentation of the resulting sugar. Starch and
enzymes used for saccharification are derived from cereal grains most commonly barley,
malted to develop essential enzymes and produce the desired flavor, and adjuncts such
as rice, sugar, cassava, and corn. Other basic raw materials include hops, which is used
mainly to impart a more or less bitter taste to the beer; water, which comprises 90-95%
of the product; and yeast, which is used in fermentation to produce ethanol and CO2.

All beers are brewed using a process based on a simple formula. Key to the beer making
process is malted grain, depending on the region traditionally barley, wheat or
sometimes rye. The beer productions consist of 9 steps: Grinding, Mashing, Lautering,
Wort boiling, Cooling, Fermentation, Storage, Filtration, Filling.

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The basic ingredients of beer are water; a starch source, such as malted barley, able to
be saccharified (converted to sugars) then fermented (converted into alcohol and carbon
dioxide); a brewer's yeast to produce the fermentation; and a flavouring such as hops.
Traditionally there are two styles of beer: ale and lager. Most types of beer will either fall
into one category or the other.

History of Beer

History of Beer - Beer has been brewed prior to written history. But ironically, the oldest
known recipe set down by man appears to be one for brewing beer, found on stone
tablets in Sumer, in southernMesopotamia, the “fertile crescent” or “cradle of
civilization” between the Tigris and Euphrates Rivers that includes modern Iraq,
northeastern Syria, southeastern Turkey, and southwestern Iran.

Beer is the most frequently-consumed beverage in the world, after water and tea! Some
scholars believe that it has been brewed since the sixth millennium B.C.E. By 4000
B.C.E., the Babylonians were brewing at least sixteen varieties of beer (when you see all
of the different styles in this glossary, you won’t be surprised at that number). The
Pharaohs of Egypt paid their workers with jugs of beer (later, the Romans would pay
their legions in salt, leaving us with the phrase, “worth his salt” rather than “worth his
beer”).

For those of you who have never been exactly clear on the difference between all the beer
types—ale, pale ale, bock, pilsner, and lager.

The histories of bread and ale are interlinked as they use much the same raw materials
and the English poet John Taylor called beer ' a loaf out of a brewer's basket.' And
although methods of brewing have changed over the years the essential process remains
the same even today.

In Europe, monks were the principal brewers of ale, then a sweet and glutinous drink.
Not only was ale food but because it was boiled it was considerably safer to drink than
water. Beer needed something extra and that was hops which not only added extra
flavor but also acted as a preservative.

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 CONTENTS

INTRODUCTION
PLANT LOCATION: KOLHAPUR CITY
KOLHAPUR AS THE MODERN CONFLUENCE
TRANSPORT
RAILWAY
KOLHAPUR RAILWAY STATION
ROAD
NATIONAL HIGHWAY 48 NEAR THE CITY
AIRPORT
CLASSIFICATION OF BEER
ALES
LAGERS
EXAMPLES OF ALES:
EXAMPLES OF LAGERS:
BEER STRENGTH
BREWING-RAW MATERIALS
BREWING - THE RAW MATERIALS
MALT
GRAIN
BARLEY- PATIALA (OWN FIELDS)
MALT:
HOPS
HOPES IN THE FORM OF FLAKES
YEAST
YEAST UNDER A MICROSCOPE.
WILD YEAST
ALE YEAST
LARGER YEAST
WATER
ADDITIVES & PROCESSING AIDS
ADDITIVES
ASCORBIC ACID (VITAMIN C)
SULPHUR DIOXIDE
CARAMEL
PROPYLENE GLYCOL ALGINATE
PROCESSING AIDS
LIST OF MACHINERY
MACHINERY TECHNICAL DETAILS
MILL SYSTEM

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MASH TUN & LAUTER TANK
BREW KETTLE & WHIRLPOOL
HOT WATER TANK
REFRIGERATING SYSTEM - GLYCOL WATER TANK
BEER MANUFACTURE PROCESS
PROCESS OF BEER MANUFACTURING
MALT MILL
MASH KETTLE
LAUTER TUN
WHIRLPOOL
FERMENTATION
LAGGERING
PACKAGING
THERE ARE 3 TYPES OF PACKING MEDIA
CAN OF BEER OF 330 ML.
BOTTLE OF BEER 650 ML.
PROCESS FLOW DIAGRAM
LICENSES REQUIRED
EXCISE, LICENSE, TAX, DUTY & OTHER LEGAL REQUIREMENTS:
OTHER LICENSES REQUIRED FOR THE SETUP:
MAHARASHTRA
PERMISSION TO USE OF SPIRIT UNDER MAHARASHTRA STATE EXCISE
DEPARTMENT
ANNEXURES:
HOW TO STORE BEER
SOME TIPS TO STORE BEER ARE:
TOP INTERNATIONAL BRANDS LIST
SOME INDIAN BRANDS ARE :-
MARKET POSITION
MARKET SEGMENTATION
COMPETITIVE LANDSCAPE IN INDIA BEER MARKET
BEER MEASURES
SERVICE OF BEER
FAULTS IN BEER
BOTTLED/CANNED BEER STORAGE
GLOSSARY OF TERMS
PRINCIPLES OF PLANT LAYOUT
SOME OF THE FACTORS IN RAIL-TRACK PLANNING ARE:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
RAW MATERIAL SUPPLIERS
MALTS
HOPS
YEAST

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MACHINERY SUPPLIERS
COMPLETE MACHINERY
DESTONER
MALT MILL
BEER FILTER
FERMENTER
PASTEURIZER
FILLED BOTTLE INSPECTOR
PRODUCT PHOTOGRAPHS
MACHINERY PHOTOGRTAPHS
MILL SYSTEM
MASH SYSTEM (MASH TUN&LAUTER TANK)
HOT WATER TANK
MASH PUMP
PLATE HEAT EXCHANGER
HOPS FILTER
WORKING PLATFORM
WORT INSPECTION PLATFORM
WORT BALANCE TANK
COMBINATION OF MASH PIPELINE
VENTURIFOUR-WAY（THERMOMETRIC
OXYGENATION COMBINATION）
MEASURING TUBE
BRIX MEASURING UNIT
SPENT GRAINS DISCHARGE RAKE
ELECTRIC STEAM HEATER
FERMENTATION TANK
REFRIGERATING SYSTEM - GLYCOL WATER TANK
STERILIZATION TANK
CONTROL CABINET
RAW MATERIAL PHOTOGRAPHS
MALTS
HOPS
YEAST

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APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

COST ESTIMATION

Plant Capacity 1500 Bottles/Day

Land & Building (3000 sq.mt.) Rs. 2.04 Cr
Plant & Machinery Rs. 67 Lac
Working Capital for 1 Month Rs. 25 Lac
Total Capital Investment Rs. 3.12 Cr
Rate of Return 18%
Break Even Point 67%

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