Dashen Brewery Company Profile

BAHIR DAR UNIVERSITY INSTITUTE OF TECHNOLOGY 2005 EC
CHAPTER – ONE
BACKGROUND OF THE COMPANY
1.1 Brief history of the company
Dashen's modern plant, occupying an area of 8.5 hectors, was completed with an initial capital
investment of over 340 million Birr. The Brewery is located in the historical town Gondar which
is annually visited by more than 95,000 tourists. It's named after Mount Dashen, Ethiopia's
highest mountain elevation 4523 meters), and a home to rare endemic fauna and flora and
renewed for its breath taking scenery. The principal aim of Dashen Brewery is meeting the
customer requirements for quality beer and to offer customers more choice in the market without
affecting the environment .Thus, the brewery is highly committed to waste reduction, waste
management and satisfying customer need and expectations. Dashen brewery utilizes state of the
arts technology and has a highly qualified professional work force that will enable it to complete
on the export market with the leading international beer producing and marketing companies.
Dashen Brewery has an initial annual total capacity of 500,000 hectoliters (151 million bottles )
current production output stand at 300,000 hectoliters (91 million bottles ).Despite its young age,
Dashen brewery has already been a beer tycoon and a pioneer in customer satisfaction, which is
confirmed by being awarded two internationally, recognized certifications, ISO9001 and ISO
14001.
As a result of relentless effort of its professionals, its high-tech technology and appropriate
strategy designed to penetrate the seemingly congested local market, the brewery is now in a
position where its supply could not meet the demand created for its products .This has therefore
put the brewery in the forefront of the local market even at its infant stage. Hence, the work to
expand the Brewery to three fold of its actual current capacity has already begun. The new
capacity after expansion, assumed to be finalized in the coming August, will put the brewery at
number one position with respect to both quantity and quality. The brewery has above 600
employees; a figure anticipated to increase within the next 6 months as the company steadily
expands its market share and plant capacity to 750,000 hectoliters (or 225,225,225Bottles).In line
with this, modern technology diffusion and vigorous human resource capacity development work
DASHEN BREWERY SHARE COMPANY Page 1

is under taken at all levels. As to the raw materials the brewery uses the most suitable water; two
raw spring barley malt, carefully selected yeast and hops only. The Brewery is currently
undertaking projects of malt factory to supply the Brewery and other Brewery's with a
sustainable supply of quality malt produced in the unique two-raw barely grown in the high lands
of the region. The project aims to benefit the farmers of the area by integrating them as suppliers
of the Barely for the factory Dashen Brewery is taking in various activities as part of its social
responsibility to the society. The Brewery has been working with youth associations and clubs in
the fight against HIV/AIDS. Helping street children, creating self-help job opportunities etc.
Dashen brewery is the only and first ISO 9001 and ISO 14001 certified company in Ethiopia
which are passports for the global market. The Brewery's ISO 9001 Quality Management system
has won customer confidence that the brewery is supplying products of desired quality with its
internationally recognized system .Dashen's ISO 14001Environmental Management System will
enable the company to formulate a policy and objectives by taking in to account regulatory
requirements and information on activities with significant environmental impacts. Dashen
brewery utilizes state of the arts technology and highly qualified experts that will enable it into
compete on the export market with the leading international beer producing and marketing
companies. The brewer has modern technology diffusion vigorous human resource capacity
development work is under taken at all levels. The brewery uses the most suitable water for
brewing quality beer; two row springs, barley, malt, yeast and hops nothing else added.
1.2 The main products & service

The main products of Dashen brewery are Dashen beer, royal beer, draught beer (locally
called draft beer) and cellar. The end users/customers are every person aged above 18 years old.
There is no any limit or boundary in order to be a customer for Dashen beer.
The products are distributed across the country in four regions and three warehouses. The
regions are:
Region 1: covers Amhara, Benishangul and Afar region.
Region 2: this covers the whole Tigray region.
Region 3: covers central and western part of Ethiopia.
Region 4: east and south parts of Ethiopia. There are three warehouses: thus are Gondar, Woldia
and Addis Ababa.

Dashen brewery was export its products to the following foreign countries:
California, Chicago in America, Australia, Israel, and Southern Sudan. But nowadays due to the
rapid increment of local customers it cannot export to these countries.
Agents distribute 90% of the product and 10% distribution done by direct distribution to
retailers.
Vision
-To make Dashen the central venue for quality beer celebrities
-Building the brands that people love/prefer to drink
Mission
It is an endowment fund established to contribute for the development of Amhara region by
producing & selling customer proffered quality beer at competitive price & generate reasonable
price.
To be the best Ethiopia beer lead drinks company with sustained revenue growth and
consistently improving returns on invested capital.
Employees of the Brewery:
Employees of the Brewery has a fair commitment and owner ship feeling (specially the technical
team), their commitment is increasing. Generally employees in production, Quality, Production
and Maintenance departments are highly committed and energetic and with a fair composition.
Purpose
By generating profit it aims to improve the socio-economic well-being of the Amhara region
Commercial Rational
To produce & sell quality beer at reasonable profit
Value Rational
1. To support the socio-economical development of the Amhara region in particular & the
overall development well-being of the country in general.
2. Dashen brewery has customer focused orientation
3. Dashen brewery has prevalence of accountability
4. Dashen brewery has well trained & committed work force
5. It gives value for the eco-environment friendly manner.
6. Economic use of resources
7. To involve in export market.

8. To reduce productions loss.

9. To reduce breakage.
10. Determination of safety stock and recording level and implementation.
11. To reduce water consumption.
12. To reduce power consumption.
13. To ensure product consistency at the required level.
14. To train all employees of the brewery is to the end of the next
2. Marketing Department
Function
1. Strategic thinking, planning and implementing of the marketing function of Dashen
brewery private leading company.
2. Developing /Designing price policy, promotional strategy, distribution mechanism and
implementing after approval by the general managers and appropriate decision making
body as per company policy,
3. Ensuring that effective customer service is produced at all levels.
3. Human Resource
Function
1. Design and develop human and marketing policies and procedure to ensure performance
standards, consistency and transparency in the course of human resource management.
2. Carry out proper manpower planning to ensure supply of man power interms of quality
and quantity.
3. Carry out recruitment and selection of employers based on the man power plan.
4. Carry out induction and orientation program for newly recruited staff.
5. Design and Developing trained and developed policies and procedure.
4. Finance Department
Function
1. Ensure that the company has adequate financial policies and procedure with built in
internal control system.

2. Develop financial strategies and policies that help the company competitively and
profitability.
3. Design financial procedure and guides with the objectives of
4. Maintain clear/clean recording standardized manner
5. Established standardized reporting formats.
6. Prepare and consolidate periodic, financial reports/statements as required by low and to
help management decision making.
7. Prepare short term (annual budget and long term financial plan within the frame work of
the company’s strategic plan.
8. Manage working capital cash receivables internal payables etc.
5. Purchasing department
Function
1. Thus proper purchasing policy and procedure should be established for the well being of
the company’s operations.
2. Basically purchasing the acquisition of materials and services from suppliers.
3. Its main aim is to support and facilitate the company’s operations with an uninterrupted
flow by supplying the right materials and services at.
 the right time
 t he right price
 the right place
 From the right source.
6. Maintenance Department
Function
1. Plan preventive maintenance parts and major law
2. Carryout preventive maintenance and over based on preplanned programmed.
3. Central maintenance costs and maintains aim operating records to help in budgeting and
procurement policy formulation.
4. Evaluate of machinery performance and suggest equipment that need massed disposal
5. Prepare maintenance schedule tooth for machinery and vehicles.

6. Advice and assist the deputy general manager technical on matters related to
maintenance.
7. Supply Department
Function
1. Procure all materials needed for all running of the company
2. Prepare vender document invite bindles and evaluate after in line with company polices
and procedure.
3. Carry out economical buying from authentic supplies that fulfill iso goal; 2000
requirement.
4. Manage the receipt and ware housing of raw and input materials and their distribution to
user department as they are required.
5. Plan and control inventory of input materials using property inventory management
techniques.
6. Manage ware housing and distribution off finished products.
8. Quality assurance Department

Function
1. Ensure inspection and testing is carried out in accordance with plan documented
processes.
2. Ensure inspection records are maintained.
3. Monitor the performance of production machines, preservation and production processes.
4. Conducting incoming in processes and final inspection of final product
5. Ensures availability of safety precaution and procedure of the company.
6. Ensures non-conforming products are handled according to the procedure and criteria
document.
7. Ensure the process needed for the quality management system is established implemented
and maintained.
8. Coordinate quality management system audit to confirm compliance with the require

Organization structure
Board of director
General Manager
Planning and
information system Internal audit service
Legal service
Deputy General Manager Finance Supply Human resource

of marketing department department administration
Customer service Sales and distribution Deputy General

and promotion division Manager
division Market research and of Technical
development division
Production
department
Region Region Region Region
1 2 3 4 Maintenance
department
Quality assurance
department
Figure 1.1 flow chart of the organizational structure of the company

1.3 Process description of the company
Beer production
Introduction
The main raw materials for beer production in Dashen brewery are barely malt, water, hops and yeasts.
Water is the principal ingredient of beer production about greater than 90% of the beer. It is used for:
1. wort production
2. alcohol content standardizing
3. yeast line washing
4. washing and sterilizing of all beer process contact surfaces
Malt is a germinated barely which contains starch that is degraded in mashing in to a fermentable sugar. Barely
has low nitrogen content and it has also low protein content which makes the beer haze. Barley malt also contains
amylase and prolytic enzymes which are used in starch degradation.
Hopes are added as a source of tannins, resins and essential oils for the following purposes: - provide the beer with
bitter test, give the characteristics hop aroma to the beer, promote head formation and retention, promote shelf life,
aids protein precipitation during wort boiling, and acts as a filter medium in the hop back.
Yeasts are unicellular micro organisms which can obtain the energy they need. In the presence of oxygen (aerobic)
by respiration and in the absence of oxygen by fermentation. Yeast utilizes carbohydrates in the form of sugar.
1.3.1 Beer house operations
Beer house operations are pretreatment of malt, malt milling, mashing, lautering (wort separation), wort boiling,
wort clarification, wort cooling , wort aeration, and pitching.

1.3.1.1 Pretreatment of malt
Before malt milling the malt is free from impurities and the amount required for the brew is weighed out. The malt
is treated by the following equipments
Dust removal and collector used to remove the dust of the malt.
Distoner used to remove high density materials and stones.
Screen used to remove over sized malt.
Precleaner used to elevate the malt to segregate impurities.
1.3.1.2 Malt milling
Milling is a mechanical process and during it the husks must be treated carefully because they are used as a filter
material during lautering.
Objective of malt milling
1. To split the malt husks longitudinally to expose the starch endosperm maintaining the husk integrity to aid
wort separation.
2. To crush the endosperm, making its contents accessible to enzyme action.
3. To jeep the amount of fine particles to avoid clogging the bed during wort separation.
Malt milling is performed by mill star with malt hopper in dashen brewery. Mill star with malt hopper used to
steep and rough grinding of the malt. Steeping is performed by using 200 hl water at 62 oc.ype of milling is wet
milling by using two rollers. The most important part of wet milling is the pair of crushing rollers with a very
narrow roller gap. Parameters monitored and measured in mill star with malt hopper are degree of steep,
presteeping time, steep liquor temperature, mashing water flow rate, water pressure and total mash in water
volume.

Amount of malt milled in different brands for one brew
Brand Amount in kg
Dashen 4950
Royal 5300
High gravity 5700
Table 1.1
1.3.1.3 Mashing
It is a process in which malt grist and water are mixed at a suitable temperature. Mashing is performed by mash tun
kettle. The types of processes in mash tun kettle are
1. Heating of the mash

2. Rest for starch degradation
3. Receiving of part mash from the mill star
4. Saccharification test
5. Heating of combined mash
6. Transferring of the total mash to lauter tun.
Parameters monitored and measured in MTK are temperature, time and iodine test.
Starch degradation
Starch is degraded by alpha and beta amylase in to limit dixterins, maltase and saccharase. Beta amylase is present
during malting but is not active. It becomes active during mashing rest periods at 62 – 65 oc (maltose rest). It
produces maltose, beta dextrin glucose and maltotriose. Alpha amylase is active during mashing but it is much
more active in gelatinized starch. It produces dextrin during degradation. Steps of starch degradation are
gelatinization, liquefaction and Saccharification. Gelatinization is the swelling and bursting of starch granules in

hot aqueous solution. Liquefaction is the reduction of viscosity of gelatinized starch by amylase. Saccharification
is the complete degradation of starch to maltose, beta dextrin, glucose, and maltotriose.
Iodine test used to know the presence of starch in the mash. The test is performed by adding an iodine solution
from the mash. If the result is negative, starch is completely converted to simple sugars if not the mash is heated
until the result is obtained. Chemicals added in MTK during mashing are Cacl2, Caso4 and H3po4. Artificial
enzymes added during mashing are termamyl and ultraflomax.
Purpose of Cacl2
1. Used to increase the yeast density during fermentation

2. Used for beer full flavor
3. Used to flocculate the yeast and easily settle at the end of primary fermentation from the bottom of the
fermentor.
Purpose of Caso4
1. Used to form a buffer to prevent the varation of PH during the transfer of milling to mashing
2. Gives the beer for dry flavor
3. Increase plate and after palate
Purpose of H3po4
1. Used to adjust the color of the beer

2. Since it has a food content it used as food.
Amount of chemicals added in different brands for one brew
chemicals brand
dashen royal High gravity

Cacl2 13 kg 15 kg
Caso4 7 kg 7 kg
H3po4 As needed As needed
Table 1.2

Termamyl enzyme is used to liquefy starch and assist in reducing viscosity to improve Sparging. It contains heat
stable alpha amylase. The enzyme hydrolyses alpha glycoside linkages in amylase and amyo pectin the two
components of starch. The starch is therefore break down rapidly to soluble dextrines.
1.3.1.4 Wort separation
Wort separation or lautering is a filtration process where the undissolved substances are separated from the wort.
The insoluble part or spent grain consists of the husks, the settling and other insoluble materials. Wort separation is
achieved by a lauter tun. The types of processes which are performed in lauter tun;
1. Cloudy wort circulation

2. Running off of first wort
3. Sparging of hot water for further extraction
4. Last running
5. Spent grain removal
The husks used as a filter medium and the denser substances are settle together and removed at the bottom by
using pump. The temperature of the wort is increased to 86 oc. 145 hl first wort is sent to wort pre run tank
(WPRT) the rest is added by Sparging by using 160 hl warm water for 8 times. Types of processes performed in
WPRT
1. Heating and holding of lautred wort

2. Wort filling from WPRT to LPB wort kettle
Caramel is added in wort pre run tank when the first wort starts to enter. Amount of caramel added to WPRT for
dashen and royal brands; Dashen = 2.5 liter and Royal = 9 liter
Purpose of caramel is to give the color of beer to wort and to adjust the color. After the wort is heated up to 92.5
oc it goes to wort kettle.
1.3.1.5 Wort boiling
Objective of wort boiling is

1. extraction and isomerization of hop products ; sustaining a high temperature to obtain a high
isomerization yield of the alpha acids to impart bitterness
2. hot and cold break formation
3. wort sterilization and enzyme inactivation
4. formation of coloring substances
5. acidification of the wort
6. evaporation of water to concentrate the wort
Wort boiling is achieved by wort kettle (WK). The types of processes in the WK are;
1. heating up of the wort from 92.5 to 103 oc

2. pre boiling
3. pressure boiling
4. pressure decrease boiling
5. post boiling
6. transferring the wort whirl pool
The hop dosage and an external boiler are equipped outside the WK. hop dosage is used to add the hop products
during wort boiling. Boiler is used to evaporate much amount of water when it heats up by steam. Parameters
monitored and measured are extract, PH, and color. Hop products which are added during wort boiling are extract
hop and pellet hop.
Purpose of extract hop
1. give the beer a bitter taste

2. improve foam stability
3. acts as antiseptic towards microorganisms
Purpose of hop pellet
1. give the beer aroma of the quality of beer

2. promote head formation and retention
3. aids protein precipitation during wort boiling

Amount of hop products in different brands
Hop product brand

dashen royal
Extract hop 3 kg 2 kg
Hop pellet 10 kg 15 kg
Table 1.3
1.3.1.5 Wort clarification
After boiling the hot wort is transferring or is pumped through whirl pool. This device removes the plant residues
together with some of the hot break. Hop pellet and hop extract were added in the wort kettle, the hot trub is settle
in whirl pool. The hot trub is then goes to a hot trub tank and the hot trub is sent to weak wort tank during the 7th
Sparging. In whirl pool the excess protein or tannin compounds in the wort are precipitate and removed.
1.3.1.6 Wort cooling
The aim of wort cooling is to precipitate cold breaks during fermentation and to lower the temperature of the wort
because yeasts are used in the fermentation processes. If the wort do not cool the yeasts will be denatured before
used. The wort cooled rapidly from boiling point to the fermentation temperature (11 to 12.5 oc) to increase
dissolved oxygen level. The cooler is a counter current plate heat exchanger. The counter current heat exchanger
can drop the temperature within a short period of time. The wort is cooled by chilled water by cooling it by glycol.
1.3.1.7 Wort aeration
The wort is aerated before it goes to fermentation; to promote yeast growth. During wort aeration oxygen is added
to the wort for the activity of yeasts. The parameter to monitored and measured is the concentration oxygen. Wort
aeration is achieved by wort aerator.
1.3.1.8 Pitching
By pitching is meant the addition of yeast to the wort and thus the starting of primary fermentation. The wort that
is pitched at a temperature of 11oc and an extract of 11.5 to 12.5op.the concentration of the yeast goes to the
fermentor in Dashen brand is 8 – 10 mg/l and in royal brand is 7 – 10 mg/l.

CaSo4, Cacl2 and H3po4
Termamyl and ultraflomax
malt Treatment of malt Malt milling by mash Mashing

mill star by MTK
Sparging water caramel Hop extract and hop pellet
Wort separation by Wort Wort pre run tank Wort boiling

lauter tun by wort
kettle
Spent grain
Wort
clarification by Wort cooling Chilled water
whirl pool
Hot trub
Wort aeration
Oxygen
Fig 1.2 process flow diagram of beer house operation

1.3.2 Fermentation
Fermentation is the conversion of sugars to alcohol and carbon dioxide by using a live yeasts under an aerobic
condition.
C6H12O6 YEAST 2C2H5OH +2CO2 + ENERGY
Fermentation is an exothermic process in other wards a process in which, as a chemical energy can be obtained,
stored and used by yeasts. The speed of sugar conversion during fermentation is influenced by the following
factors. These are wort properties, temperature, and amount of yeast, movement, yeast strain and pressure.
Wort properties: - the fermentation rate is dependent on the extent to which hot and cold breaks are removed
from the wort, how intensively it is aerated and to what extent its composition corresponds to the requirement of
yeasts.
Fermentation temperature: - alcohol producing fermentation is accelerated with increasing temperature whilst it
proceeds only slowly at low temperature. But higher temperature causes the formation of higher alcohols so it
must be controlled.
Amount of yeast: - with an increasing yeast concentration the contact surface is increased. The amount of yeast is
reported in millions of cells per ml. in the most growth phase the cell concentration is 30 to 40 million cells per ml
and in many processes up to 100 million cells per ml. As a rule yeast is pitched into wort at a rate of 20 million cells
per ml.
Movement: - the contact between the cells and wort is improved by movement (pumping) and as a result, a more
vigorous fermentation can be obtained.
Yeast strain: - rate of fermentation is depends on the genetic characteristics of the yeast strain used and these
various from strain to strain of yeast.
Pressure: - increasing over pressure retards fermentation, yeast multiplication and the formation of fermentation
by products. This can be attributed to the increasing dissolved carbon dioxide concentration in the fermenting beer.

Stages of fermentation are Primary fermentation, Secondary fermentation, Maturation, and lagering.
1.3.2.1 Primary fermentation
The primary stage of fermentation begins when yeast is introduced into cooled and aerated wort. During this yeast
growth occurs, production of flavor compounds like VDK, consumption of most wort sugars, ethanol and CO2
production, and reduction in PH from 5.3 to 5.6 in the pitching wort to 4.3 to 4.4 in the beer.
During the reduction of PH organic acids are produced by damnation, up take of potassium ions by the yeast and
release of hydrogen and the primary use of phosphate ions by the yeast. The beer PH of between 4.2 and 4.4 is
recommended because it accelerates precipitation of colloidal unstable protein and polyphenol complexes; it is an
essential requirement for good biological stability of the beer. But lower PH values less than 4.1 causes acidic beer
taste and must be avoided.
The temperature of primary fermentation is from 12.5 oc to 14.5 oc for four days. After primary fermentation the
amount of VDK and the temperature are checked by laboratory. The pressure is 0 bar for the freely movement of
yeasts. At the end of primary the yeasts are harvested during these yeasts are transferred to yeast storage tank and
recycled up to nine generations by checking their consistency, viability and thickness.
1.3.2.2 Secondary fermentation
It refers to the stage of fermentation after the majority of the wort sugars have been consumed and there is a sharp
decrease in the rate of fermentation. Generally diacetyl is converted or consumed by yeasts, decrease the rate of
ethanol and CO2 production, Yeast flocculation and settling begins because yeasts feed on calcium ion they
become massive and they flocculate easily. Reduction of some flavor compounds by yeast metabolism or CO2
scrubbing as the result of decrease in PH during fermentation a number of colloid dissolved substances and
polyphenol are precipitated as surface active compounds on CO2 bubbles and carried up wards with them as a
result of the adsorption on yeast cells. Part of isohumulene also precipitates on the top covering surface of scrubber
because isohumulene are very surface active and they are captured by the CO2 bubbles and carried upward.
The foam trap is separated from CO2 by absorption with water in the CO2 foam trap tank counter currently. The
CO2 is transferred to the utility. The temperature for secondary fermentation is 14.5 and the pressure is 0.5 for three
days.

1.3.2.3 Maturation
The maturation takes place with thermal gravity has been reached and the tank is cooled to 5 oc within two days.
During maturation; Yeasts continue to flocculate and settle, Most of yeasts removed from cellar, Formation and
precipitation of haze forming proteins, Stabilization of flavor, Reduction of harsh flavors (SO42-).
1.3.2.4 Lagering
Lagering is a method of storing a fermented beer at low temperature for extended periods. During this method the
temperature is lowered from 5 oc to -1 oc and the pressure is 0.8 bars. After 17 days the fermented cellar is
transferred in to the cooler and cooled by glycol (-4 oc) to -1.5 oc. Some of the cooled beer is transferred to
unfiltered beer tank (UBT) and some yeasts and suspensions are settled. If the amount of yeasts are very much the
cellar is stored in pre and after run tank for the settlement of yeast to avoid the filtration problem. Dashen brewery
follows short fermentation and long lagering time.
Formations of fermentation by products affect the beer taste, aroma, foam and flavor. But in Dashen brewery sc
these by products are controlled. Parameters which can be monitored and measured in fermentation process are
temperature, pressure, extract and amount of VDK.
At the end of fermentation the apparent extract is 2.2 to 2.5op and the VDK must be less than 0.015op. Dashen
Brewery has 20 fermentation tanks because fermentation is a batch process. The amount that can they hold and
their code number is as follows: -
1. From 201 to 203 tanks can hold 900 hl wort and 950 kg yeast.
These tanks are jacketed and conical type tanks. The type of fermentation is bottom fermentation and the yeast
type used to this fermentation is saccharomysis servsciae. These yeasts have the ability to settle at the bottom of the
fermentor so it is easy to harvest them at the end of primary fermentation. To lower the temperature during
fermentation glycol is used as a coolant. When the ammonia cools the glycol it can cool the beer. The temperature
and pressure during fermentation are controlled by automatic valve.

On the other hand there may be fouls during the process then it is corrected the necessary chemicals for example
caramel in reserved tank and the cellar is cooled by plate heat exchanger and then mixing with chemicals this
process is called beer treatment. After that the beer is filtered by KG filter which is a bed type filter.
1.3.2.5 Yeast propagation
Yeast propagation is a process in which buying small amount of yeast and multiplies them to a
large amount in a long period of application. Dashen brewery buys a small amount of yeast and
use by multiply them for ten generations. Yeast propagation and storage plant consists of closed
vessels of different sizes, made of chrome nickel steel in which the yeast is multiplied until there
is sufficient to pitch the vessel or tank. Multiplication of yeasts occurs in multiplying tanks
(propagator) of increasing sizes up to the size which makes it possible to pitch a cylindro conical
fermentor. Yeast storage tanks are used to store yeasts when they are harvested from the
fermentor. They stored by considering their viability, consistency and thickness. Yeasts are
stored at a pressure of 0.5 bars to avoid the eating of them because at this pressure they cannot
move freely. The yeasts taken in the logarithmic phase offers many advantages for fermentation.
These advantages are rapid initial fermentation, shorter fermentation time, rapid drop in PH,
more rapid and more extensive diacetyl removal and a clear and more rounded beer.
1.3.3 Filtration
It is a process of separation of solid with the liquid on the filter medium. The unfiltered cellar
from UBT is transferred to the KG filter which has around 34 sieves with 3 mm in diameter.
1.3.3.1 KG filter
In KG filter turbing causing materials like protein and polyphenol complexes and some yeasts
are separated. For filtration the process on sieves are made and body feed is added continuously
to compete yeasts. The pre coat and body feed are made from diatomaceous earth or kieselguhr
which has a food grade (sio2 and al2o3).
Raw materials for pre coat preparation
1 FW14 (fine white) F60 coarse
2. FP3 (fine pink) F15 medium
3. FP2 (fine yellow) F10 fine.
1.3.3.2 Dosing tank: - 600 liter process water and FW14 22.7 kg and FP3 22.7 kg are mixed within the dosing
tank by agitator. KG filter is filled by process water which has 3.5 and 3 bars inlet and outlet pressure to pressurize
the filter aid during pre coat making. The filter aid saluting is dosed to the KG filter to build pre coat on the sieves.
The filter aid solution is circulated for 30 minutes and the pre coat formation is growth. Finally pure water
circulated and the pre coat making is completed next to this the cellar is also allowed to circulate through the KG
filter for 30 minutes and the clarity, haziness, extract, color, taste and foam stability are checked by laboratory. This
helps to correct fouling parameters by additive tank.
1.3.3.3 Continuous dosing (body feed): - during beer filtration the filter aid continuously dosed (FW14 =22.7
KG, FP3 =25 KG, FP2 = 25 KG and stabilizer = 10 kg for first body feed). Additives like becosorve is added and
solutions are mixed with the beer to facilitate the filtration by competing with the yeast to increase the shelf life of
the pre coat.
The filtration process depends on: -
 Change in pressure (pressure drop)

 Load of mass on each sieve (amount of filter aid)
 Flow rate of cellar and filter aid mixture
 Water circulation flow rate which is 600 liter per hour
 Cellar filling flow rate which is 150 – 180 hl/hr to prevent abrupt pressure and pre coat
damage
 Cellar circulation flow rate (beer filtration) is 200to 210 hl/hr
The quality of filter aid to be dosed in and composition depends very much on the filterability
the beer. The maximum total quantity of filter material that can be used in this filter is not
exceeding 10 kg/ m2 of filtration area (i.e. 336 kg). Since the filter aid is adsorbent surface the
yeast cells and turbid causing materials are adsorbed on the surface of the pre coat. The
unwanted materials are sent to the sludge tank and the beer is pumped to the filter bag for further
filtration by pressurizing with CO2. Then the beer is stored in BBTs at lower temperatures.
1.3.3.4 Bright beer tanks (BBT)
BBTs are used to store the filtered beer until it is bottled. In Dashen brewery sc there are 6 BBTs
which have different volumes.
1. Tank number from 901 to 904 can hold 900 hl filtered beer.
2. From tank number 905 to 906 can hold 1200 hl filtered beer.
1.3.3.5 CO2 content of the beer
Lively beers with a good amount of foam have a CO2 content of 47 to 53 mg/l and a pressure of
0.5 bars. The amount and temperature of CO2 in BBTs is measured by jalto meter. This CO2 is
dissolved within the beer at high pressure and low temperature. It is used as a preservative to
displace oxygen to the preventation of further fermentation by the remaining yeast cells.
Parameters which are monitored and measured in filtration plant are flow rate of the filtered beer,
inlet and outlet pressure of the KG filter, inlet and out let pressure of the filter bag and the
temperature. As the change in pressure is increased the flow rate is decreased and it indicates that
the filter area available is small therefore the precoat efficiency becomes lower and haziness of
the beer may exceed more than one.
Fermentation by 20 Cooling Storing the beer

Wort and yeast fermentors the beer by UBT
Filter aid
Filtration by Filtration by Storing the
Fermented beer KG filter filter bag filtered beer

by 6 BBTs
Sludge tank bottle filling
Fig 1.3 process flow diagram of filtration and fermentation of the beer.

1.3.4 Bottle washing
The bottles are transported in rows through the bottle washer during passage through the
machine the bottles are presoaked in one or more bathes at increasing temperature, passed
through several hot, rinsed with hot caustic, rinsed with hot water, rinsed with cold water, and
finally rinsed with fresh water.
The entire process takes place 10 to 15 minutes. The bottle to cleaned are delivered to the bottle
washer by a slat conveyor chains 40*542 = 21680 bottles by ones time.
The bottle washer contains the following certain components
1. The bottle loading and discharging unit
2. The bottle conveyor compressing bottle cell components
3. The presoak station
4. The immersion steep
5. The rinsing station
6. The label remover
7. The caustic and water bathes
1.3.4.1 Bottle loading and discharging unit
In bottle loading and discharging unit it is important that
1. Loading and discharge are performed gently and without much noise
2. Bottle cannot fall over
3. Any bottles which are broken do not interfere
1.3.4.2 Pre soaking
The purpose of pre soaking is to remove residues of drink from the interior bottle to there by pre
cleaning the bottle, to remove easily soluble external dirt, to pre warm the bottles especially in
the winter, and o start the cleaning process. It is performed by service water.
1.3.4.3 Immersion soak
The emptied bottles are now immersed in a bath of caustic and are conveyed in one or more
loops through this bath in order to prolong the residence time and to increase the cleaning effect.

Then the same caustic solution is jetted again over the bottles in order to remove remaining part
of labels which have been soaked off but still remain in the bottle cells.
Requirements of caustic is the ability to remove dirty, an inhibiting or lethal effect on bacteria,
good wetting ability, rapid generation of the label paper and great ability to dissolve glue, it must
not form scare deposits, it should not create foam, it should easy to dose in, and it must not
expensive as possible.
1.3.4.3 Rinsing station
The bottles which are now in the upper part of washer with the bottle mouth facing down wards
are jet rinsed several times inside and outside of the bottle part with hot caustic 1 and 2 at 80 oc ,
hot water for intermediate rinsing which is used again for a pre soak , warm water at lower
temperature to obtain a step wise cooling, cold water for complete cooling and removal of all
residues, and fresh water which ensures that the bottle is cooled and sterilized.
1.3.4.5 Removal and compression of labels
The cleaning caustic is pumped round inside the bottle washing machine and is maintained at a
predetermined temperature by additional heating. During this circulation the soaked off labels in
the caustic stream are conveyed to the suction region of the circulation pump and retained there
by sieving device from which they are removed. This removal must be performed immediately
after release of the labels from the bottles in order to avoid disintegrating the labels and forming
a terrible soggy mass in the washer.
1. The labels are still soaked with caustic and cannot be deposited of in this condition. There is therefore a
label press attached to the bottle washer which is located beneath the label remover.
2. In the label press the labels are about 80% dewatered by a hydraulic cylinder with a pressure of 12.5 t and
there by reduced to 50 to 75% of their soaked volume.
3. The caustic pressed out is collected in a collection through and added back to the washer.
4. The pressed labels dry further whilst ascending the wide pipe and are emptied drained in to a waiting
wagon.
Caustic and water containers
The water or caustic passes over a sieving devices to a pump which recalculates the caustic used water is led back
to the pre soaking section.

Temperatures during bottle washing
1. Pre warming presoak 35 to 40oc

2. Second soak 55 to 60oc
3. Caustic bath 1st and 2nd 80oc
4. Intermediate rinsing 45 to 50oc
5. Warm water 35 to 40oc
6. Cold water 20 to 25oc
7. Fresh water 10 to 15oc
Factors influencing the washing machine
Effect of soaking: - removal of dirt requires a dissolving and soaking time which is affected by
various factors; this also applies to the removal of labels. The soaking time is
Mechanical effect of jetting: - cleaning is reinforced by the mechanical effect of rinsing the
flasks in the upper part of the bottle washer.
Washing temperature: - higher temperatures always speed up the removal of dirt. Temperatures
of 60 to 80oc are used to obtain good biological cleaning.
Cleaning effects: - cleaning agents are alkaline and therefore also kill microorganisms
particularly at high temperature.
1. They release and dissolve dirt; dirt removal depends on this.
2. The effectiveness of cleaning agent depends on the temperature.
3. The higher the temperature the lower the concentration of the cleaning agent.
The following rule of thumb applied.
1 An increase in concentration by 50% of the cleaning agent or

2 An increase of temperature of 5.5oc has the same cleaning effect.
Visual inspection by using light

In this process persons who sit on the chair and they look the bottles when they pass through the
lighted passage and these persons detect the bottles which have a soil and a foam and also the
cracked bottles by using light. If the bottles are cracked or contains a soil they picked up by these
persons. This method aids the EBI. Before this inspection method or after washing of the bottles,

the bottles are checked by laboratory which contains caustic and microorganisms. The caustic is
tested by phenophitaline.
Empty bottle inspection (EBI)
It is used to remove cracked bottles and bottle which contain microorganisms and other residual
materials.
1.3.5 Bottle filling
Filling the cleaned bottles is now the most important task. During this
 Loss of beer must avoided

 The nominal of every bottle must be ensured and
 The quality of the beer must be maintained
For this the following are important
1. The avoidance of contamination

2. The preventation of air entry and consequent oxidation
3. The avoidance of CO2 loss from the beer.
Types of bottle filling are vacuum filling; high vacuum filling, normal pressure filling and high pressure filling
(counter pressure filling).
Counter pressure or high pressure filling
These are used for filling CO2 containing drinks. Beer fillers are always counter pressure fillers.
Dashen brewery follows this type of filling. Beer fillers are height or level fillers. In them every
bottle is filled to a preset height or a sensor. This is possible because all bottles are within the
tolerance limits and consequently a desired volume is filled.
Types of filling according to temperature are
1. Cold filling up to about 8oc. Beer filling is cold filling.

2. Warm filling up to about 20oc
3. Hot filling above 60oc with simultaneous pasteurization of beverage.
Principles of bottle filling machine

Bottle filling machines are always built as rotating machines with up to 200 filling valves. The
bottles are delivered on a conveyor belt separated to a predetermined spacing by a separating
device and position plate form under the filling elements by a star while loading device.

1.3.6 Pasteurization
By pasteurization is meant the killing of microorganisms in aqueous solution by heat. There are
two types of pasteurization these are flash and tunnel pasteurization. In flash pasteurization the
beer is heated by a plate heat exchanger to at least 68 to 72oc and held at this temperature for
about 42 seconds in Dashen brewery. Then it is cooled down again. In the case of tunnel
pasteurization the bottled beer is heated by steam and water at different temperatures by using
shell and tube heat exchanger for one hour in Dashen brewery. In pasteurization the bottled beer
passes through the following sections.
1. Pre warming section
2. Super heating section
3. Pasteurized section
4. Cooling section
The conveyor speed must be adjusted according to the operating condition. For water
circulation a pump is provided in each super caustic surge section. The containers are conveyed
in to the pasteurizer by in feed conveyor salt chain. The feed conveyor in driven by adjustable
gear motor which is mounted on the machine side of the conveyor end. To prevent damage to the
containers lateral plastic guide is provided. In the case of an under temperature in the cooling
zone (at the start of production) the water is pre heated via a counter current heat exchanger. The
pre warming water is feed by the pumps of the cooling section to the pre warming section where
it is shed over the cold containers entering the machine. The pumping of super heating section
feed the water via heat exchanger to the supper caustic surge units of the supper heating and
pasteurization section. The water is heated by the pasteurized containers in the cooling section, it
is then pumped in to the pre warming sections they by completing the heat recovery cycle.
1.3.7 Labeling
The essential components of labeling machine are the label holder and the label transferring
device. The label holder receives the labels and ensures a continuous feeding of the labels.
Adjustable fingers at the front end of the label holder prevent labels falling out. On the other
hand the labels are continuously pushed forward by a strong pressure. This is provided by a

spring or a pulling cable operated by gravity. In the case of labelers with a high throughout put
often a very heavy glass ball is used to produce the necessary pressure. The label transfer device
removes the glued label and transfer it to the bottle with glued side against the bottle. This device
operates either a vacuum or a gripper cylinder. Label transfer by a griper cylinder has the
following components. These are glue pallet, label, gripper cylinder, gripper finger, trip cam and
bar shaped stop. In dashen brewery the label paper contains volume of the beer, food grade of the
beer, name of factory but it is not include expiration and production date.
Full bottle inspector (FBI)
Used to identify under and over filled bottles
Used to identify cracked and uncracked bottles
Used to identify labeled and unlabeled bottles
1.4 Utility
Steam Boiler Plant
Steam boiler or simply a boiler is basically a closed vessel into which water is heated until the
water is converted into steam at required pressure. Working principle of boiler: The basic
working principle of boiler is very very simple and easy to understand. The boiler is essentially a
closed vessel inside which water is stored. Fuel (generally coal) is bunt in a furnace and hot
gasses are produced. These hot gasses come in contact with water vessel where the heat of these
hot gases transfer to the water and consequently steam is produced in the boiler. Then this steam
is piped to the turbine of thermal power plant. There are many different types of boiler utilized
for different purposes like running a production unit, sanitizing some area, sterilizing equipment,
to warm up the surroundings etc.
Types of boiler: There are mainly two types of boiler – water tube boiler and fire tube boiler. In
fire tube boiler, there are numbers of tubes through which hot gases are passed and water
surrounds these tubes. Water tube boiler is reverse of the fire tube boiler. In water tube boiler the
water is heated inside tubes and hot gasses surround these tubes. These are the main two types of
boiler but each of the types can be sub divided into many which we will discuss late.

O2
NaOH (advantage)
Activated Softener Feed tank Boiler

Furnace oil
carbon filter
Service
water
Na2SO4
Table Salt
Steam
(regeneration
distributor
softener)
Fig 1.4. Flow sheet of steam boiler plant

Cooling Plant
A refrigerating system, such as Glycol, is used in cooling the hot wort, and/or the young beer,
during fermentation and maturation. Glycol freezes at a very low temperature. As a result, it’s
convenient to use it when cooling media below 0 0C is required. Used Glycol is returned to the
utilities room and refurbished for another use. Steam, hot water, cold water and chilled water are
utilities used to adjust the wort, fermenting beer or bright beer to a desired temperature using a
heat exchanger. It is one of the cooling elements because its boiling point is-37oC. Ammonia cools glycol
which is used to chill the beer at the fermenter so the hot glycol is piped to cooling plant and heat exchanged
with ammonia. The ammonia compressor is screw type. Ammonia is condensed from outside
and condensed by water.

Glycol cold Heat

exchanger
tank glycol
Expansion
valve
NH3
evaporator
NH3 receiver
NH3
condenser
Non-condensableNH3 recycles
NH3
Compressor
Fig1.5. Cooling Plant flow sheet
CO2 recovery plant

A CO2 recovery plant consist of first of foam separator (scrubber) in which the foam particles
carried over are removed whilst the gas collects in a large CO2 gas container. Then after feed
into scrubber, CO2 is freed from water soluble impurities. Then the gas stored in the ballroom.
From this balloon the gas is transferred to a compressor and compresses it into two stages. In the
first compression CO2 from the atmosphere temperature raised in to 1200c and cools to 350c.
but the temperature in the second compressor reaches to1400c and cools down into 220c in the
second cooler during this the pressure is increased to 15 bar. The job of compressor is to suck
vapour from the gas and force it in to the activated carbon filter. Because the gas becomes very
hot as a result of this, it must be cooled again in a cooler coupled to a compressor. In the
following carbon filters undesirable aroma compounds still present are adsorbed in dehydrator
which contain silica gel in it then transferred to reboiler. in the reboiler, where the cold CO2 at
the low temperature and the CO2 from dehydrator exchange heat and transferred to condenser.
The main purpose of condenser is to remove the amount of heat that is equal to the sum of the
heat absorbed in the evaporator and the heat produced by compression.
CO2 foam Scrubber

Balloon
trap
Impure CO2
98.6%
Activated carbon CO2 compressor (1st
Reboiler Dehydrator (Dryer) filter & 2nd stage)
CO2 condens or CO2 storage CO2

(NHs evaporator) evaporator 99.98%. CO2
Fig 1.5 flow diagram of CO2 recovery plant

Compressed air
Air from the atmosphere is sucked and filtered by dust filter in order to remove undesired
particles. the filtered gas is then transferred to vacuum suction to form pressure difference which
enables to transfer the sucked air to the desired location .this air is transferred to the compressor
in order to be compressed to develop pressure in parallel with temperature and then cooled in
two stages in both cases. after this air is stored storage tank and used for pneumatic valves,
sieves in malt pretreatment etc.
Atmospheric Suction Dust filter Vacuum Compressor
air suction
unit
storage Cooler
Air to Use
tank
Fig 1.6 flow diagram of compressed air
Raw Water treatment plant

The principal aim of this plant is to produce the required amount of water for beer processing
and other related uses to there guired degree of treatment through a modified and scientific
treatment plant. Here is the way how raw water will be treated into service and process water.
In this plant raw H2O is firstly filtered by sand filter tank to remove some of the impurities from
the water by the help of raw water pumps. And some amount of water will be stored in back
wash blower outside the plant by dosing NaOCl (sodium hypochlorite) before storage i.e. on
lined addition. The storage tank used as a reservoir. From the storage tank service water will be
pressurized tank to reach the water to the required place at a pressure from compressed air room.
The outlet H2O from the pressurized tank will separately flow into two conduits; one into service
water line, the other into carbon dioxide degasser by adjusting the PH of the water (adding rock
salt on the water.)

1. Co2 degasser: - is used to vent some of the impurities to the atmosphere like Co2
2. Carbon filter tank: is used to remove all types of minerals like Mg, Cl2 and Ca ions in the
water. The principle of filtration is the substance to be absorbed towards carbon is active in nature.
The substance to be absorbed is known as absobate.
The substance to be causing absorbed is known as absorbent
The water at this stage is almost expected to be free from any type of minerals and is ready for beer fermentation.
Materials and chemicals used in water treatment plant

- NaOCl - sand filter tank
- Rock salt - pressurized tank
- HCl - Carbon filter tank
- NaOH - Co2 degasser
Service water
HCl
Raw water Sand filter Softener

Service water Pressure tank CO2-
tank degasser for
Cl2 process water
NaOCl
Carbon filter
Process water
Fig.1.7 Flow sheet of raw water treatment.
Process Waste Management
In most food and chemical plants in Ethiopia, brewery Wastewater is discharged into a water body such as
drainage systems, lakes or rivers. Some plants also may send their waste product to municipal sewer line. In both
cases, the waste is sent either after treating or without treating. Dashen, one of the popular breweries in Ethiopia,
treats its waste product before releasing to the environment. Treatments may include but not limited to:

Ø Physical Treatment: - Removing any solids in the treatment pond, making the pond free of bottle fragments,
bottle cups and labeling stickers, malt grist; and also use of sedimentation methods in order to remove organic and
inorganic matters that are suspended on solids in the treatment pond.
Ø Chemical Treatment:- Unlike physical treatment, this is treating the waste water chemically in order to remove
toxicants and impurities by fixing proper pond pH and agitating the pond in order to enforce coagulation.
Coagulation in turn encourages sedimentation.
Ø Biological Treatment: - This treatment deals with activities such as deactivating or removing yeasts in the pond
and treatment of other living organisms that are bad for water bodies and land.
Waste Water treatment

H2S04 O2
Influent In let pumping station Screen and Grit Selector Aeration tank
chamber tank
Returned sludge (80%)
Clarified water
From settling tank Clarified
air water
20% Settling
Sludge dewatering Sludge pumping
Dewatering Sludge
tank
sludge System Station
Polymer effluent
to sewer + service water
Fig. Wastewater treatment plant.

Chapter two
Project work on preparation of brick from spent diatomaceous earth
(kieselguhr sludge)
2. Introduction
2.1 Background
Brick making is an important industry in many parts of the world. It is an activity that can take
place in many forms, in large modern factories to small rural businesses. Although the process is
simple, many techniques involved in the brick making process are subject to error, possibly
reducing the quality of bricks. This project will present a background of minimum conditions
needed to begin brick making production, as well as an overview of the process of brick making
from spent diatomaceous earth. This project will also consider possible problems that occur in
the brick making process that reduce the quality of the finished product. There are many ways to
increase the efficiency of energy use in the firing process of brick making, and the final section
of this project will show some techniques that can be employed to save energy and fuel during
firing.
Diatomite rock is a loose, earthy or loosely cemented porous and lightweight rock of
sedimentary origin, mainly formed by fragments of armor (skeletons) of diatom algae. Diatomite
is a microscopic diatom alga whose size ranges from 0.75 to 1500 m; sometimes this rock is
called infusorial earth, kieselguhr, or mountain meal. The main components of the siliceous
armor are silica hydrates of a different degree of water content (opals) SiO2 _nH2O. Diatomite
rock belongs to the group of silica-bearing materials. Diatomite has its origin from a siliceous,
sedimentary rock consisting principally of the fossilized skeletal remains of diatom, a unicellular
aquatic plant related to the algae, during the tertiary and quaternary period.

2.2 Statement of the problem

The breweries spent diatomaceous earth or Kieselguhr sludge is important due to their cheap and
easily availability in the brewery. In many breweries in Ethiopia the spent diatomaceous earth
has not gained consideration for further production rather than lands filling until know. Spent
diatomaceous earth of breweries mainly consist the silicon dioxide of the raw material of the
filter aid which is able to produce the simplest unit of bricks under successful technological
process. So as the spent diatomaceous earth becomes beneficial for the process economy of the
factories. Considering the importance of these materials in the context of environmental
pollution this project provides the preparation of bricks from those spent diatomaceous earth
2.3. Objectives
2.3.1 General objective
 To produce brick from spent diatomaceous earth for construction of house.
2.3.2 Specific objective
 To learn the characteristics of each component of spent diatomaceous earth or kieselguhr
sludge.
 To produce the qualified bricks.
 To know the composition of other materials needed for brick production.
 To know the procedure and needed materials of the bricks from spent diatomaceous earth
of breweries.
2.4 Literature review
In brick-making terms, clay covers a range of naturally occurring raw materials which are used
to make a product. The clays vary considerably in physical properties, colour, hardness etc, and
mineralogical content. They do, however, have certain properties in common. They have the
ability to be crushed and mixed with water to form a plastic material which can be molded into
various shapes. This can then be fired to a high temperature during which process it attains a
hard, weather resistant characteristic. The key, in geological terms, is the mineral content of the
raw material. This is common to all clay types. Pure clay mineral is formed from the erosion and

weathering of primary igneous rocks. The clay mineral is transported away by the action of
water, wind, ice etc., and re-deposited elsewhere. In the process it picks up a number of
impurities, Quartz, mica, Calcium Carbonate (lime), Iron Oxide etc. The subsequent deposit
becomes a sedimentary rock. Due to variances in the age of the deposit, the conditions of its
deposition and the impurities involved there will be variations between different clay types and
even on occasions within the same deposit. These variations may affect the brick making process
and the properties of the finished product. Clay preparation methods may have to accommodate
the physical characteristics of the raw material and special provision may have to be made to
deal with certain impurities. Preparation consists of transforming the clay rock into plastic
moldable material by a process of grinding and mixing with water. A typical factory might have
a Primary crusher, these are used to break down large lumps of rock to manageable size, which
can then be fed to a Secondary crusher, for example Pan mill, where the clay is reduced in size
further. Water can be added here or if it is a dry pan the clay is reduced to dust and water added
later. Further crushing takes place through conveyor rollers reducing the clay particles to about
1-2mm. Tempering is adding water to the clay soil in order to make it more workable. Too much
water added to the clay mix will decrease quality, though.
2.4.1 Properties of bricks
A brick is a block or a single unit of a ceramic material used in masonry construction. Typically
bricks are stacked together or laid as brickwork using various kinds of mortar to hold the bricks
together and make a permanent structure. Bricks are typically produced in common or standard
sizes in bulk quantities. They have been regarded as one of the longest lasting and strongest
building materials used throughout history.
In the general sense, a "brick" is a standard-sized weight-bearing building unit. Bricks are laid in
horizontal courses, sometimes dry and sometimes with mortar. When the term is used in this
sense, the brick might be made from clay, lime-and-sand, concrete, or shaped stone. In a less
clinical and more colloquial sense, bricks are made from dried earth, usually from clay-bearing
subsoil. In some cases, such as adobe, the brick is merely dried. More commonly it is fired in a
kiln of some sort to form a true ceramic. Modern clay bricks are formed in one of three processes
– soft mud, dry press, or extruded. Normally, brick contains the following ingredients:

Silica (sand) – 50% to 60% by weight

Alumina (clay) – 20% to 30% by weight
Lime – 2 to 5% by weight
Iron oxide – ≤ 7% by weight
Magnesia – less than 1% by weight
2.4.2 Characterization of bricks
A bigger brick makes for a thicker (and thus more insulating) wall. Historically, this meant that
bigger bricks were necessary in colder climates (see for instance the slightly larger size of the
Russian brick in table below), while a smaller brick was adequate, and more economical, in
warmer regions.
The correct brick for a job can be selected from a choice of color, surface texture, density,
weight, absorption and pore structure, thermal characteristics, thermal and moisture movement,
and fire resistance.
Some brick makers create innovative sizes and shapes for bricks used for plastering (and
therefore not visible) where their inherent mechanical properties are more important than their
visual ones. These bricks are usually slightly larger, but not as large as blocks and offer the
following advantages:
a slightly larger brick requires less mortar and handling (fewer bricks), which reduces cost
their ribbed exterior aids plastering
More complex interior cavities allow improved insulation, while maintaining strength.
2.4.3 Application of bricks

Bricks are used for building, block paving and pavement. In the USA, brick pavement was found
incapable of withstanding heavy traffic, but it is coming back into use as a method of traffic
calming or as a decorative surface in pedestrian precincts. For example, in the early 1900s, most
of the streets in the city of Grand Rapids, Michigan were paved with brick. Today, there are only
about 20 blocks of brick paved streets remaining (totaling less than 0.5 percent of all the streets
in the city limits).

Bricks in the metallurgy and glass industries are often used for lining furnaces, in particular
refractory bricks such as silica, magnesia, chamotte and neutral. This type of brick must have
good thermal shock resistance, refractoriness under load, high melting point, and satisfactory
porosity. In Northwest Europe, bricks have been used in construction for centuries. Until
recently, almost all houses were built almost entirely from bricks. Although many houses are
now built using a mixture of concrete blocks and other materials, many houses are skinned with
a layer of bricks on the outside for aesthetic appeal. Engineering bricks are used where strength,
low water porosity or acid (flue gas) resistance are needed.
2.5 Methodology
Materials
The materials that I use to do my project are: -

 Kieselguhr sludge
 Small vessel
 Water
 Molding box
 Balance
 Sand
 Lime stone
2.5.1 Pretreatment of kieselguhr sludge or spent diatomaceous earth
The DE and its waste (i.e., SDE) were obtained from Dashen Brewery Factory. The chemical
compositions from the manufacturer mainly consist of 91.5% SiO2, 4.0% Al2O3, and 1.1%
Fe2O3. Diatomaceous sludge is pumped into a heated vessel and caustic solution is added, up to
5% concentration of the total volume. The mixture is then washed and neutralized, then kept
moist to prevent structural changes from occurring. Each time it is washed not all of the organics
are removed and these build up with subsequent filtration. On the basis of the etching reaction
between silica (i.e., SiO2) and a strong base (i.e., NaOH), 5-25 g of the dried SDE was mixed

with 100 mL of the NaOH solutions with various concentrations. Under holding times of 0.5-
24.0 h and temperatures of 25-100 °C (boiling condition), the alkaline activation was carried out
on a stirrer/hot plate with a boiler/reflux condenser. Afterward, the sample solution was filtered
in a vacuum filter flask and washed sequentially with deionized water five times to remove the
salt ions and other residues. The resulting solid was finally dried at 105 °C for 24 h and stored in
a desiccator after drying.
2.5.2 Clay Preparation

In brick-making terms, clay covers a range of naturally occurring raw materials which are used
to make a product. The clays vary considerably in physical properties, colour, hardness etc, and
mineralogical content. They do, however, have certain properties in common. They have the
ability to be crushed and mixed with water to form a plastic material which can be molded into
various shapes. This can then be fired to a high temperature during which process it attains a
hard, weather resistant characteristic. The key, in geological terms, is the mineral content of the
raw material. This is common to all clay types. Pure clay mineral is formed from the erosion and
weathering of primary igneous rocks. The clay mineral is transported away by the action of
water, wind, ice etc., and re-deposited elsewhere. In the process it picks up a number of
impurities, Quartz, mica, Calcium Carbonate (lime), Iron Oxide etc. The subsequent deposit
becomes a sedimentary rock. Due to variances in the age of the deposit, the conditions of its
deposition and the impurities involved there will be variations between different clay types and
even on occasions within the same deposit. These variations may affect the brick making process
and the properties of the finished product. Clay preparation methods may have to accommodate
the physical characteristics of the raw material and special provision may have to be made to
deal with certain impurities. Preparation consists of transforming the clay rock into plastic
moldable material by a process of grinding and mixing with water. A typical factory might have
a Primary crusher, these are used to break down large lumps of rock to manageable size, which
can then be fed to a Secondary crusher, for example Pan mill, where the clay is reduced in size
further. Water can be added here or if it is a dry pan the clay is reduced to dust and water added
later. Further crushing takes place through conveyor rollers reducing the clay particles to about

1-2mm. Tempering is adding water to the clay soil in order to make it more workable. Too much
water added to the clay mix will decrease quality, though.
2.5.3 Disintegration and Crushing
An alternative to tempering is disintegration or weathering, which involves allowing clay to dry

in the sun and accept moisture from rain and dew. The repeated drying and moistening of clay
will bring clay to a plasticity and workability appropriate for brick making. Crushing will make
the mixture more homogeneous.
2.5.4 Mixing
Mixing is done to make the clay soil homogeneous and smooth. There are different techniques
that can be used to do this, including using animal power or letting humans mix the clay with
their feet. Different admixtures such as coal or sawdust can be added to the clay for two
beneficial reasons: 1) reduce cracking during drying and 2) reduce fuel usage during firing.
2.5.5 Molding
Importance of Standardizing the Brick making Process
Bricks should have standard characteristics if they are to be used in construction. For example,
contractors may buy bricks from several different sources for one project: the bricks must be the
same size or there will be problems matching the construction of different sections of the
building. Moreover, a standard brick size will allow a contractor to more accurately determine
how many bricks will be needed for a project. A new brick maker, therefore, should follow local
standards, checking with other brick makers in the area or with local authorities or construction
contractors
Shrinkage
When determining the size of a mold for brick making, a necessary consideration must be
shrinkage. Bricks will shrink when drying, so the mold size must be larger than the intended
finished brick.
Slop Molding

In slop molding, a wet clay mixture is used- the mix is put into a rectangular form without a top
or bottom. A problem with this technique is that because the mix is so wet, the brick may deform
under its own weight and the surface can be marked easily.
Sand Molding
Sand molding utilizes a drier clay mix, formed into a wedge and thrown into a mold. A bow
cutter will be used to smooth the top of the brick, and the form will can be released because of a
hinged bottom. Since the clay is drier, the brick can be moved with wooden pallets which can
reduce the amount of surface marks. There are multiple benefits to using sand molding instead of
slop molding, such as:
Less water is used, so there is less cracking and the bricks are stronger.
Fewer molds are needed because they can be removed from the brick right away.
The work space is cleaner because of less splashing of the drier mix.
The worker is standing up instead of squatting down, so they are more comfortable.
The bricks are more regular because they don't deform like slop molded bricks, so a better
product is produced. Therefore, better construction and better looking buildings will be possible.
Slop molded bricks can be imprinted with the brick maker's name, called a "frog," on the flat
side of the brick. This helps the brick dry and fire better, and is a good form of advertising.
2.5.6 Drying
Water was added during clay preparation to increase workability of the mixture, but in drying it
is removed for several reasons. First, there will be less cracking in fired bricks with less water
content. Second, additional fuel is needed, beyond what is used for firing, to dry the bricks in the
kiln. Proper drying of bricks will involved rotating the bricks for different exposures to ensure
even drying rates.
For best results, drying should be done slowly. This will help with more even drying. Also, the
best drying technique may change from location to location, so the brick makers must gain
experience to determine the best way to dry bricks for each production process.
2.5.7 Firing
Laying out and constructing a clamp

A clamp is a field kiln built from the green bricks that will be fired. Clamps vary with size and
shape and must be oriented with respect to wind direction. Once a clamp is laid out and
constructed, it must be insulated.
Finally, the process of firing the clamp will take place in several steps. First, pre-heating, or
water-smoking, will remove the water leftover from the drying process. This process is still
physical. The second stage is firing, where the clay bricks will vitrify through a chemical
process. The temperature must remain constant at this stage for complete verifications. Finally,
for the cooling stage, the temperature must be slow and steady. A clamp may take two weeks to
cool.
Treatment Drying the Crushing

of treated the sludge
kieselguhr sludge
sludge
Mixing Drying
Molding
Firing
Fig 2.1 process flow diagram for brick production

2.8 Results and discussion

When I use the following materials the molded sample is broken.
1. Crushed sludge 60 % by weight

2. Sand 25% by weight
3. Crushed stone 15% by weight
When I use
1. 50% crushed sludge

2. 40% crushed lime stone
3. 10% sand by weight
From the second result I get the expected result until drying but due to lack of clamp burner I
cannot see the fired brick.
2.9 Challenges I Have Been Facing During My Project Work:

During my project work there was different challenges exist to decline my readiness & moral to
minimum point, some of these are;
 the company government system,
 Less willingness of worker to show something what I want to ask,
 Over work of the manager in each department,
 guards who those keep the inside & outside entrance gate of the company,
 Non voluntary body (department managers)to give data & make an interview,
 Lack of library access to read manuals & some reference about the operation machines.
2.10 Measures I have taken to overcome these Challenges:
To make my project successful or to lead it to the completion, I tried my best as much as

possible. Some measures that I have taken are:
 Make close relationship with each of worker & operator of the company,
 Being patient to get something what I want

 Asking them repeatedly without saying it is boring,

 By telling the problem to my advisor & to the general manager of maintenance
department,
 By following the company’s official rule to ask something.
CHAPTER- THREE
THE OVERALL BENEFITS I GAINED FROM THE Internship
3.1 Goals /Objectives:
1. To identify the major benefit that can be gained from an internship program,
2. To relate theoretical knowledge with the practical one,
3. To show to the interns what interface is there when they conduct in such area after graduation,
4. To relate the interns with the common obstacles who those must straggle
3.2 In terms of improving practical skills:

From this internship program, I have got a good chance to improve my practical skill highly. I
can develop my skill by participating myself into different part as I had learned theoretically in
my department course.
3.3 In terms of upgrading theoretical knowledge:

In terms of upgrading my theoretical knowledge I gained detail & clear way of the application of
equipments, machines, chemicals and instruments for the production of beer. I can also identify
the type of processes they used and the type of chemicals added in each type of processes. I have
gained also a permanent knowledge for the next courses to apply the application of the previous
courses to do projects and other needed works. And also how can order spare part list using their
item code by referring manual & using inventory list on the computer for each part according to
maintenance plan.
3.4 In terms of improving interpersonal communication skills:
1. Problem solving
2. Motivation
3. Negotiation & conflict control-to reach an agreement
4. Politeness

5. Being openness
6. Self – confidence
7. Honesty
8. Personal right & obligation
3.5 In terms of improving team playing skills:

I can develop very interesting behavior that is never happened before. I can improve
1. How can be patient
2. Giving respect for others
3. How can make Close relation with the community of my environment
4. Develop listening skill
5. Problem solving
3.6 In terms of improving leadership skills:

 How can establishing direction as a leader of a team
 Aligning people
 Motivating & inspiring
 Focus on team & overall goals
 Communication with each people under my control
3.7 In terms of understanding about work ethic related issues:
Work ethics is a set of values based on hard work and diligence. It is also a belief in the moral
benefit of work and its ability to enhance character. From this program I can develop how to
improve work related issues before I meet such an organization or when I contact myself in such
social network environment ,some of them includes punctuality, attendance, conducting quality
work, respect for fellow workers, honesty, and showing initiative. A work ethic includes being
reliable, having initiative, or pursuing new skills. And also I gained a good work ethics for better
positions, more responsibility & ultimately promotion(placed in positions of a greater
responsibility).These all are teaches me a lot for the future work life of myself. Characteristics
that I gained generally includes being:
1. Strong work ethics-learning the most efficient way to complete tasks &finding ways to
save time while completing daily assignments.

2. Dependable & responsible-come on time, responsible for the actions.

3. Adaptability-adapting to the personality & work habits of co- workers & supervisors
.Being open to change & improvements to complete work in more efficient
4. Possessing a positive attitude- to get the job done in a reasonable period of time
motivates others to do the same within challenges.
5. Honesty & Integrity- is the responsibility of each person to use their own individual
sense of moral & ethical behavior when working within the scope of their job
3.8 In terms of entrepreneurship skills:
As Entrepreneurship is the process of creating something new with value by devoting the
necessary time & effort, assuming the necessary risks, & expecting rewards for undertaking,
from this internship program I gained different ideas to:
Make myself free from the limit of standardized pay for standardized work (profit)
Freedom from supervision & rules of bureaucratic organizations (independence)
Freedom from routine, boring & unchallenging jobs (satisfying way ) And it makes me interested
in:
1. High need for achievement
2. Willingness to take risks
3. A need to exercise leadership
4. Self-confidence
5. Creativity

Chapter four
Conclusion
The operations which are performed in beer house, fermentation and filtration are controlled by
plc. When the problem is faced there is an alarm to tell the problem to the operators. This is the
main strength of the company. The pressure, temperature, PH, and extract are the main
parameters which are monitored and measured. Dashen Brewery follows a short fermentation
and long lagering time. The type of fermentation is a bottom fermentation that takes from 17 to
21 days. This is easy to harvest yeasts. The parameters in each operation are controlled and
measured at the exact time. This makes the beer to be qualified. At the end of fermentation
carbon dioxide is recovered because it uses for filling and filtration. Utility is the back bone of
the company because in this section the steam is produced, C02 is recovered, cooling of glycol,
waste water is treated, and treatment of raw water. Dashen brewery was export the beer but
nowadays it cannot export because the rapid increment of the costumer.

Recommendation
The carbon dioxide content, the temperature and pressure are measured by jalto meter but this
instrument cannot read the pressure so it must be installed to keep the quality of the beer. During
wort boiling much amount of water is evaporated to avoid this loss of water a condenser must be
equipped at the top of the wort kettle. After the bottle is washed it is tested by laboratory but the
result is known after three days. But in one hour 48,000 bottles are going to filling machine if
these bottles are detected by bacteria much amount of beer is spoiled. During bottle washing
labels are removed and these labels are burned. During the burning of these labels they affect the
environment to avoid this problem make an activated carbon from these label papers. During
filtration of the beer the company uses diatomaceous earth to filter the beer and they remove this
filter aid sludge but this sludge uses for the production of brick, fertilizer, asphalt and concrete.
So the company must use this sludge rather than disposing it.

References
 Aragus, Philippe (2003) (in French), Brique et architecture dans l'Espagne médiévale, Bibliothèque de la
Casa de Velazquez, 2, Madrid
 Badstübner, E; Schumann, D, eds. (since 1997) (in German), Studien zur Backsteinarchitektur, 7, Berlin
 Campbell, James W.; Pryce, Will, photographer (2003), Brick: a World History,, London & New York
 Coomands, Thomas; VanRoyen, Harry, eds. (2008), "Novii Monasterii, 7", Medieval Brick Architecture
in Flanders and Northern Europe, Koksijde: Ten Duinen
 Cramer, J.; Sack, D., eds. (since 2004) (in German), Berliner Beiträge zur Bauforschung und
Denkmalpflege, 5, Petersberg

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BAHIR DAR UNIVERSITY INSTITUTE OF TECHNOLOGY 2005 EC

DASHEN BREWERY SHARE COMPANY Page 1

1.2 The main products & service

DASHEN BREWERY SHARE COMPANY Page 2

DASHEN BREWERY SHARE COMPANY Page 3

8. To reduce productions loss.

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8. Quality assurance Department

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Deputy General Manager Finance Supply Human resource

Customer service Sales and distribution Deputy General

Figure 1.1 flow chart of the organizational structure of the company

DASHEN BREWERY SHARE COMPANY Page 7

1.3 Process description of the company

1.3.1 Beer house operations

DASHEN BREWERY SHARE COMPANY Page 8

1.3.1.1 Pretreatment of malt

Distoner used to remove high density materials and stones.

Screen used to remove over sized malt.

Precleaner used to elevate the malt to segregate impurities.

1.3.1.2 Malt milling

Objective of malt milling

DASHEN BREWERY SHARE COMPANY Page 9

Amount of malt milled in different brands for one brew

1. Heating of the mash

DASHEN BREWERY SHARE COMPANY Page 10

1. Used to increase the yeast density during fermentation

1. Used to adjust the color of the beer

Amount of chemicals added in different brands for one brew

dashen royal High gravity

DASHEN BREWERY SHARE COMPANY Page 11

1.3.1.4 Wort separation

1. Cloudy wort circulation

1. Heating and holding of lautred wort

1.3.1.5 Wort boiling

Objective of wort boiling is

DASHEN BREWERY SHARE COMPANY Page 12

1. heating up of the wort from 92.5 to 103 oc

Purpose of extract hop

1. give the beer a bitter taste

Purpose of hop pellet

1. give the beer aroma of the quality of beer

DASHEN BREWERY SHARE COMPANY Page 13

Amount of hop products in different brands

Hop product brand

1.3.1.5 Wort clarification

1.3.1.6 Wort cooling

1.3.1.7 Wort aeration

DASHEN BREWERY SHARE COMPANY Page 14

CaSo4, Cacl2 and H3po4

Termamyl and ultraflomax

malt Treatment of malt Malt milling by mash Mashing

Sparging water caramel Hop extract and hop pellet

Wort separation by Wort Wort pre run tank Wort boiling

Fig 1.2 process flow diagram of beer house operation

DASHEN BREWERY SHARE COMPANY Page 15

C6H12O6 YEAST 2C2H5OH +2CO2 + ENERGY

DASHEN BREWERY SHARE COMPANY Page 16

1.3.2.1 Primary fermentation

1.3.2.2 Secondary fermentation

DASHEN BREWERY SHARE COMPANY Page 17