Executive Summary

The beer manufacturing unit of United Breweries is located in Maharashtra Industrial

Development Corporation (MIDC) at Taloja in Navi Mumbai. The UB group has a state-of-the-
art fully automated manufacturing unit at Taloja in Navi-Mumbai. This plant maintains a very
high standard of hygiene. The division has comprehensive quality assurance system which
ensures that products are backed by the best of quality processes and ingredients, and measure up
to world - class hygiene standards. The unit is spread over sprawling area of 22 acres and was the
first green field project of the UB group.
The report covers the process of beer manufacturing starting from the scratch till the bottling and
dispatch of the final product at UBL Navi Mumbai. Further beer is a product which comes under
the food and beverages sector and is consumed by human beings at a large scale. Thus
maintaining quality standards at every level of the process forms the very basic for the success of
the product as well as of the entire company. Beer is a fermentation product and is rich in alcohol
and glucose content and is very susceptible to contamination from microorganisms at each and
every step in the process of its making. Thus a strict control should exist at each and every step
in the process and every process should be carried out in a closed environment which is taken
care in the plant with full efficacy and efficiency. The higher the microbial compliance greater is
the life of the beer and better is the quality. In spite of various control measure taken by the plant
certain things are overlooked by the unskilled workers in the plant during handling of the
equipments and this brings contamination of the beer and hence increases the dissolved oxygen
level of the beer which is not desired. Thus this report surpasses through the various regions
which are overlooked by the workers of the beer plant in compliance with the contamination of
beer and further finds out method to overcome such trivial mistakes and increase the microbial
compliance and the life of the beer.

This project tries to find out most effective manufacturing process by decreasing the time and
wastage of raw materials and tries to ensure the smooth flow of men and material throughout the
organization.
 Chapter 1
INTRODUCTION
REASON FOR CHOOSING THIS INDUSTRY:

The brewery (beer) sector is very booming sector. There are lots of competitors in this
industry. There are always modifications and innovations used in brewery (beer) industry.

The reason behind choosing this company for doing summer project is that, I thought it
will be helpful for my career in brewery sector. I have chosen this company to get the full
knowledge about the demography, satisfaction and prospective customers.

With the help of this project, I will make it possible to expose myself to the corporate
world and learn the practical knowledge related to my topic.

THEROTICAL BACKGROUND:

Production:

Production or Operation can be defined as “the process of changing inputs into outputs
thereby adding value to some entity”. The value is added to the entity by one or more following
ways:

 Alteration: refers to the change in form or state of inputs. Such a change may be physical
as in machine shop/press shop/assembly shop operation, or psychological as the feeling
of comfort after getting cured from illness.

 Transportation: refers to the movement of the entity (i.e. entity may be people, goods or
garbage) from one place to another. The entity has more value if it is located at
somewhere other than where it currently is.

 Storage: refers to the process of keeping an entity in a protected environment (i.e. storing
food grains in warehouses) for some period of time.

 Inspection: refers to the process of verification of entity for its properties and thereby
taking more informed decisions concerning their purchase, use, repair, etc.
Production as the conversion process:

Since production is the process of changing inputs into output, every organization
therefore, can be considered as the conversion system.

The inputs to the production system are raw materials, parts, consumables, energy,
engineering details, production schedules, information technology, capital or management and
outputs are the produced goods, transported goods, delivered messages, cured patients, serviced
customers, etc.

Adjustments Monitor
needed Output

Inputs Outputs
Conversion
Labor Process Goods and Services
Material

Equipments

Capital

Management

Comparison:

Actual

V/S

Planned
For example,

 In manufacturing organization like steel plant, inputs are materials like iron ore, coke,
lime stone, dolomite, etc., labour, machines, capital and outputs are steel sections like
channels, rods, bars, sheets, etc.
 In a service organization like banks, inputs are customers and outputs are serviced
customductioners.
 In a hospital inputs are patients and outputs are cured patients.
 In a public transport, inputs are commuters and outputs are serviced (or transported)
commuters.
 In a post and telegraph office, inputs are letters or messages and outputs are delivered
letters or messages.

BATCH PRODUCTION:

Batch production is the method used to produce or process any product in groups or
batches where the products in the batch go through the whole production process together. Batch
production is used in many different ways and is most suited to when there is a need for a
quality/quantity balance. 

Batch production is used when a demand for a product is more regular than one off; it is
divided into a number of different parts or operations.

Typical examples of batch production are:

 Medium and heavy engineering industry engaged in the manufacture of electric motors,
switch gears, heavy motor vehicles, internal combustion machines
 Process industries such as pharmaceuticals, paints, chemicals
 Manufacturers of readymade garments
 Manufacturing and assembly shops such as machine tools
 Sub-contractors which take on machining of batches of components to the drawings of a
large manufacturer

Advantages of batch production:

 Less boredom for employees because they are working on more than one product

 Business can make and offer a variety of products

Disadvantages of batch production:

 It needs High storage costs

 Time is wasted

 The equipment needed for the production must be stopped, re-configured, and its output
tested before the next batch can be produced.

NEED OF THE STUDY:

 Materials control and tools control functions are important. Some kind of replenishment
system needs to be used to ensure routine replenishment.

 Detailed operational layout and route sheets are prepared for each part of the product.

 Loading and scheduling needs to be more detailed and more sophisticated since every
machine requires to be individually scheduled.

 Progressing function is very important to collect information on progress of work. A

separate progress card needs to be maintained to record progress of each component.

 Expediting is generally necessary since quite often jobs, due to imbalance in work
content, tend to lag behind.

PLANT LAYOUT:

Definition:

Plant layout is the disposition of the various facilities and services of the plant within the
area of the site selected previously. The work of the plant layout begins with the location of
the work centers. According to Riggs, “the overall objective of plant layout is to design a
physical arrangement that most economically meets the required output-quantity and
quality.”

Essentials:

An efficient plant layout is one that can be instrumental in achieving the following
objectives:

 Proper and efficient utilization of available floor space

 To ensure that work proceeds from one point to another point without any delay
  Provide enough production capacity

 Reduce material handling costs

 Reduce hazards to personnel

 Utilize labor efficiently

 Increase employee morale

 Reduce accidents

 Provide ease of supervision and control

 Provide for employee safety and health

 Allow ease of maintenance

 Allow high machine or equipment utilization

 Improve productivity

Plant layout of united breweries limited:

Plant layout at mfg unit is well designed and very systematic, it is continuous flow starting from
the introduction of Raw Materials to final product which is Beer.
GENERAL PROCESS OF MANUFACTURING OF BEER:

Manufacturing process of beer starts with procurement of the raw material and ends with the
dispatching of packed beer.

A general manufacturing process of beer can be displayed as follows:

 RAW MATERIAL PROCUREMENT

BREW HOUSE

FERMENTATION SECTION

LAGARING AND FILTERATION SECTION

BOTTELING SECTION

PACKAGING

DISPATCHING

Raw material procurement:

Marketing Department gives production schedule of approximately 3 months to the

production department along with the priorities depending on market demand and demand of the
client.

Three month schedule is then divided in to the monthly schedule, considering the factors
like capacity of the plant, time required to complete each batch and availability of the manpower,
etc.
 A requisition of raw material is then sent to stores department. Stores department checks
the availability of raw material and informs the production department with which batch they can
start and calculate the deficit based on production schedule and sends it to purchase department.
Purchase department then places the order for deficit considering the priorities.

New raw material has to go through a series of checks before entering the company. First
of all, all the documents are checked properly. Documents are checked for

 Whether the material belongs to company

 Delivery challan
 Octroi receipt
 Whether the material is received as per order
 Whether the material is received from approved supplier.

Then the vehicle is checked for cleanliness. After thorough inspection, material is
unloaded .while unloading, labelling and sealing of each container is checked. Also each
container is checked for damage, breakage or leakage. Containers are then cleaned for
dust. Before transferring the material into store room, it should be checked for

 Name of the material

 Quantity per container or packet
 Manufacturing date
 Expiry date
 Manufacturing license number
 Batch number
 Net weight, gross weight, tare weight
 Storage condition on pack

The material is transferred to temporary store room or quarantine room, where all the
material is labelled as quarantine and sampling is done by the Q.C Department for the
analysis.

After analysis Q.C Department gives approval for the material. The approved is then
shifted to primary store room with properly labelled as ‘Approved’.
If the material does not comply with company standards then it is stored in ‘Rejected
material storage room’ with proper labels.

The Brew House

The main raw material for making beer is malt which is processed from barley. Barley is
processed in mills into malt which contains the required enzymes to convert the insoluble starch
in the barley to soluble and simple sugar molecules. This process of converting barley into malt
is known as Malting.

The Fermentation section

Fermentation is the process by which fermentable carbohydrates are converted by yeast into
alcohol, carbon dioxide, and numerous other byproducts. It is these byproducts that have a
considerable effect on the taste, aroma, and other properties that characterize the style of beer.

The most important thing in beer production is the microorganism which ferments the malt to
desirable level of alcohol. The microorganism which is used for the purpose is Yeast
(Saccharomyces sp.). The yeast strain itself is a major contributor to the flavor and character of
the beer. The company imports its characteristic yeast slant from abroad and grows it in the
plant. There is a separate room for the production of yeast to be used in the fermentation process.
The particular yeast strain is a company secret and is kept in strict supervision so that it is not
stolen or leaked.

Lagaring:

After the yeast taken out of the fermentors and left for maturation in either the lagar tank or the
unitank the process of lagaring starts. The process of maturation of beer is known as lagaring.
This is also known as secondary fermentation. In this process the beer is kept very low
temperature of nearly -1°C. At this temperature the beer matures and the characteristic flavor of
the beer comes in. This process goes on for 5 days and then the yeast is decanted of from the
vessel. This beer is known as green beer. This beer is sent for filtration.

Filtration:

After the fermentation is over the beer has to be filtered so that there is no haze in the beer and it
is free of any foreign particles and is crystal clear. This process is done in the filtration unit.
Although conditioning-maturation, clarification, and stabilization-plays an important role in
reducing yeast and haze loading materials, a final beer filtration is needed in order to achieve
colloidal and microbiological stability. The beer must be rendered stable so that visible changes
do not occur during its shelf life.

The Bottling Process in UBL Navi Mumbai:

The bottling usually deals with the cleaning of the used bottles, filling it with beer, pasteurizing it
and then labeling and packing it. The entire process could be described as follows:

 Dirty bottles are collected from the vendors who supply it to the company. These bottles
are processed and these are only filled. The entire system of bottling is automatic and
computerized. Volunteers only check the process if it’s going correct or not. The bottles
are placed on the conveyer which conveys the bottle to the KHS Washing Machine. This
machine has a capacity of washing 21000 bottles per hour if everything goes well. The
bottles enter the machine and are washed inside automatically by 2.5% caustic solution
and with 80°C hot water. At this acidic concentration and at this hot temperature the
microbes in the bottles are destroyed and become more or less sterile and free of any
foreign bodies. Further the labels and other things attached on the body of the bottle is
removed in the KHS machine in the washing process.
 The conveyer then arranges the bottles in a queue and is conveyed to a check point/EBI
where a volunteer checks whether the bottle is free of any foreign body against a bright
board which is illuminated for the purpose. If the bottle is not free of foreign bodies, it is
either destroyed or sent to the washing machine again depending upon the condition of
the bottle.

 The conveyer then conveys the bottles to another checkpoint/EBI. At this point the
volunteer checks the surface of the mouth of the bottle. If the surface of the mouth is
broken the bottle is destroyed then and there. Only bottles free of any cracks on the
surface of mouth are used for bottling.
 This bottle is then conveyed to the filling machine. This machine is also a KHS machine
and is fully automatic. The filling machine fills the bottle first with CO2 and then in
small quantities beer is filled in each bottle one by one such that the final quantity of beer
in the bottle is nearly 650ml. and no filler remains idle. The filling machine consists of
discs on which the bottles rest and are filled with small pipe like fillers. These discs are
63 in number and can fill 63 bottles in one round. The speed of the filling machine is
nearly18000 bottles/hour but usually due to certain halts in other process the speed limits
to 16000 bottles/ hour. After filling the capping is also done in the same machine.
 After the bottles are filled and capped properly it is conveyed to another check point
where a volunteer checks the capping, quantity of beer and entry of foreign particles in
the beer which might have occurred during the filling and capping of the same. If there is
any fault the beer is discarded.

 The bottles from this check point are conveyed for pasteurization. Pasteurization is the
process of heating liquids at high temperature for killing microbes and making the liquid
sterile. The pasteurizer used here is known as Tunnel Pasteur. This machine consists of
6 chambers in which water flows at 6 different temperatures. In the first three chambers
the temperature of water used for pasteurization is 45°C, 50°C and 60°C respectively and
then next three chambers have water falling at 50°C, 45°C and 35°C the beer which is
filled in the bottles may contain microbes from various processes of fermentation and
filtration. This machine ensures the sterility of the beer as because if there is any microbe
 in the beer it may spoil the beer and hence reduce the shelf life of the beer. The gradation
in temperature is because as the bottle is filled with chilled beer if it suddenly comes in
contact with 60°C hot water the bottle might burst thus loss of beer. Hence if temperature
is slowly raised the chances of bursting of bottles is nullified.

 After the pasteurization is over the bottles are conveyed to a check point where the final
checking of dirt, foreign bodies and quantity of the beer is done.

 After this the bottles are conveyed to the labeling unit where labeling is done together
with the printing of MRP, batch no. and date of manufacture.
 After this the bottles are conveyed to a check point where MRP, batch no. and date of
manufacture is checked.
 After this the bottles are conveyed to the packaging unit where the bottles are packed in
cartons. 12 bottles of beer are packed in 1 carton. These are then conveyed for storage in
the warehouse for dispatch.

This completes the process of beer manufacture in the UBL Navi Mumbai beer factory.
Dispatching:

Releasing of finishing product is the last activity in the manufacturing and packaging
operations at the factory this is extremely imperative activity and should be passed out with
extra care.

All the documentation is completed before the batch is sent for dispatching. Bottles are
stored properly with ‘under test’ labels unless and until approval from Q.C Department is
obtained.
 CHAPTER: 2

COMPANY PROFILE
HISTORY OF COMPANY:

United Breweries Limited (UBL) is the flagship company of the UB Group. Founded in
1915 from the merger of five breweries in India, the company is headquartered in Bangalore and
commands 40% of the domestic market with leading brands such as Kingfisher, UB Export,
London Pilsner, Premium Ice and Kalyani Black Label. The UB Group is 3rd largest spirits
marketer in the world, with overall sales reaching 60 million cases. Subsequent to the acquisition
of Shaw Wallace & Company Limited, The UB Group spirits division offers 140 brands at
varying price points, attracting consumers of every taste. Combined with its unparalleled reach it
has become an object of envy for the competition. Five of UB Group's brands, viz., Bagpiper
Whisky, McDowell’s No.1 Whisky, Director's Special Whisky, McDowell’s No.1 Brandy and
McDowell’s Celebration Rum have been included in Impact International's Top 100 Distilled
Spirits Brands Worldwide by Retail Value.

The Castle Brewery which dates back to 1857 (the year of the Indian mutiny) was set up
for the European planters scattered over the Nilgiris. So was the Nilgiris Brewery Company. The
British Brewing Corporation set up in Madras (1902) catered to the elite of the port town of
Madras while the Bangalore Brewery Company had been supplying beer for the troops stationed
at Pune and Bangalore since 1885.

United Breweries Limited (UBL) was founded on March 15, 1915, in Madras by Thomas
Leishman, a Scotsman, also its first Managing Director. UBL manufactured and sold only bulk
beer for troops of both the world wars. It was a classic case of role reversal – India being
introduced to this ‘exotic’ brew and in turn becoming its major exporter.

The Indian beer industry has witnessed a big change during the last five years. The
industry was previously dominated by competition between the Vijay Mallya controlled United
Breweries Group and the Manu Chabbria-controlled Shaw Wallace. The scenario changed,
however, with the entry of SABMiller in India. The international beer giant started by acquiring
small breweries in the south but then completely changed the landscape with the acquisition of
Shaw Wallace’s beer portfolio for a reported US$264m in 2003.
 India is predominantly a hard spirits market and beer is a minority preference for those
who consume Beverage Alcohol. Beer makes only 4% by revenue of the total alcoholic market.
It would be pertinent to mention that while per capita consumption of spirits in India is 65% of
global average, in the case of beer it is a mere 3% of global average.
With the global market experiencing low/stagnating growth in recent years, the focus is
now on the Asia-Pacific region specially. For instance, the Chinese beer market has grown at an
astounding pace in recent years, spurred on by the massive levels of foreign investment in the
market, along with the rise in the average levels of consumer spending and thanks to the
economic reform policies of the government. Total consumption of beer in China grew by
33.56% between 2000 and 2006 to reach a total market volume of 30.47 billion liters. With the
per capital consumption of 22 liters, China has now overtaken the US to become the largest
national beer market in the world. The brewing industry in China has been one of those quickest
to modernize and Indian beer Industry should look to model themselves on their neighbors.

Vision:

 To be the recognized leader in our

target markets.
 To be the preferred employer
wherever we operate.
 To recognize the value of our human
assets.
 To be the partner of choice for
customers, suppliers, and other
creators of innovative concepts.
UBL is committed to,
 Manufacture and market world-class beer.
 Innovate and continually improve the quality management system to confirm the current
regulations and expectations of the customers.

UBL focuses on:

 Participation of all employees in achieving objectives of Q.C.
 Enhancing capabilities of employees to pace up with changing environment and
technology through continuous process of training.
 Improving process and performance to attain world-class norms of quality in
manufacturing and safety.

ABOUT UBL:

UBL has an association with brewing dating back over nine decades, starting with 5
breweries in South India in 1915. From bullock cart-loaded barrels or 'hogheads' of frothing ale,
the beer business has gone on to become the undisputed 'king' in the Indian beer market. UBL
today boasts an impressive spread of own and contract manufacturing facilities throughout the
country. Here, innovative, creative and aggressive marketing is complemented by a strong
distribution network. A management focused on building brand equity on one hand and
exploiting it to the hilt on the other.

Quality and hygiene are the key elements of the United Breweries' manufacturing
philosophy. To this end, the Central Scientific Laboratory (CSL), headquartered at Bangalore
sets standards for all its breweries. Quality Management Systems laid out along the lines of ISO
9000 are strictly adhered to, controlling quality at every stage of production, from raw materials
to the end product. Also, besides controlling the production process, the CSL analyses the
Company's beer taken off market shelves all over the country, the competition's beers and beers
from across the world. These beers are tested as per the standards laid down by the European
Brewery Convention on 40 different parameters. By these standards, United Breweries' beers
don't just equal, but even surpass, several Dutch and American beers.

Its flagship brand 'Kingfisher', has achieved international recognition consistently, and
has won many awards in International Beer Festivals. Kingfisher Premium Lager beer is
currently available in 52 countries and leads the way amongst Indian beers in the International
market. It has been ranked amongst the top 10 fastest growing brands in the UK.

ALLIANCE WITH HEINEKEN:

Heineken Group (Heineken) holds 37.5% equity shares in United Breweries Ltd. The
alliance will offer consumers the best portfolio of national and international brands in India,
including Kingfisher, the number one Indian brand, and Heineken, the largest global beer brand.

UBL's outstanding skills as India's leading brewer and Heineken's global best practices
will provide further strength to the business. 
Different locations of UBL:

UBL MILESTONES:
 "The retail value of beer that UBL has sold in 2009-10 is approximately Rs.8200 cr.
 UBL contributes around Rs 3200 cr. to the revenue of the government, in various forms
of taxes and government income
 UBL’s volumes have doubled in the last 4 years
 UBL has the number one brand in the mild & strong beer segments – Kingfisher
Premium & Kingfisher Strong, respectively
 Kingfisher Strong is the single largest beer brand in India and has grown almost 3 times
in the last 4 years
 UBL has been the Pioneer in Product Innovation by being the first to launch draught beer,
cans and 5 liter kegs
 UBL has also been the first in the alco – beverage category to bring exciting,
differentiated consumer experiences
 India has changed and UBL and its portfolio reflect the new UBL and India. Kingfisher
has moved from being a brand to an icon of an emerging lifestyle."

PRODUCTS:

 Kingfisher Premium

 Kingfisher Strong

 Kingfisher Strong Fresh

 Kingfisher Draught
  Kingfisher Ultra

 Kingfisher Blue

 Kingfisher Red

 Kingfisher Bohemia

 Zingaro
  UB Export

 UB Export Strong

 London Pilsner Premium Strong

 Kalyani Black Label Strong

 Bullet
SOCIAL RESPONSIBILITY:

CSR Initiative
A business does not exist in isolation. It impacts and is impacted by
the environment it operates in. We, at United Breweries Limited
recognize this fact and thus feel as responsible for contributing
towards the creation of social capital as towards maximizing returns
for its stake holders. Over the past few years UB has undertaken
social programmes with a vision to bring about sustainable social
development.
CSR programmes at United Breweries Limited are not conducted as
an impromptu humanitarian activity but as a sustainable effort to improve the quality of life of
the employees and their families as well as of the local community and society at large. The
concept of CSR is deeply ingrained in UB's culture.
Mission:
To contribute positively to the community well being. 
Objective:
Undertake a comprehensive social development program in the identified areas to promote.
1. Primary Education:

Provide children with quality education and nutrition which will kindle their interest to study as
well as encourage families to support their education.

It includes:

 Awareness programmes
 Infrastructure for existing schools
 Financing payroll of teachers or support staff
appointed
 Providing meals
2. Primary Health Care:

To make primary health care more accessible and affordable.

It includes:
 Awareness programmes
 Health Camps
 Providing infrastructure to existing dispensaries,
clinic

3. Water Availability

Promote conservation of water resources and facilitate access to clean and portable drinking
water.

It includes:
 Rain water harvesting
 De-silting of tanks/ponds or other water bodies
 Providing portable drinking water to communities
 CHAPTER: 3

SCOPE OF THE WORK

SCOPE OF THE WORK:

1. The study will help company about process requirements for beer manufacturing.

2. Company knows that which area they have to improve so production get maximized.

3. To study quality management in beverage (beer) formulation manufacturing.

 CHAPTER: 4

OBJECTIVES OF THE PROJECT WORK

OBJECTIVES OF THE PROJECT WORK:

1. To study the manufacturing process for beer.

2. To study process requirements for beer manufacturing

3. To ensure control over production process by Q.C. Department, so as to produce high

quality of product.

4. To suggest areas of improvements to increase the organizational effectiveness and

efficiency.
 CHAPTER: 5

RESEARCH METHODOLOGY
RESEARCH DESIGN:

Sample of certain size (say, 4 or 5 observations) are selected, and the quality
characteristics (say, length, height, viscosity) is calculated based on the number of observations
in sample.

DATA COLLECTION FOR PROJECT:

Data constitutes the subject matter of analysis. The relevance, adequacy and reliability of
data determine the quality of the study. Information from the sources was analyzed and noted.

Sources of data collection:

Primary sources:

It is the first hand information collected directly from the sources required for the project
report. Data required for the project was directly collected from following sources:

For this project the primary sources of data collection were

 Observation of manufacturing process

 Observations of various Departments in Organization
 Discussions with managers and staff

Secondary sources:

Secondary data may be defined as data that has been collected earlier for some purpose
other than the purpose of present study. It acts as a reference for the present study. It includes:
Reference Books, Websites, Organizations report, other important documents and data provided
by the organization.

Secondary sources used in this project are:

 Reference Books
 Websites
 Batch Manufacturing Records
 Standard Operating Procedures(SOP’s) of the company
 CHAPTER: 6

DATA ANALYSIS
For better understanding of manufacturing process of beer (bottling) a case study is analyzed in
this project.

CASE STUDY:

Kingfisher Strong 650ml:

Let us consider the process of manufacturing of Kingfisher strong 650ml after completing of
brewing process, as procedure till this step is similar for all the products of kingfisher beer.

Steps involved in the manufacturing of Kingfisher strong 650ml are:

 Washer
 EBI
 Filler
 Checkpoint
 Pasteurizer
 Checkpoint
 Labeler
 Checkpoint
 Packaging

Washer:

This step consists of several sub steps:

 Dirty bottles are collected from the vendors who supply it to the company.
 The bottles are placed on the conveyer which conveys the bottle to the KHS Washing
Machine. This machine has a capacity of washing 21000 bottles per hour if everything
goes well.
 The bottles enter the machine and are washed inside automatically by 2.5% caustic
solution and with 80°C hot water. At this acidic concentration and at this hot temperature
the microbes in the bottles are destroyed and become more or less sterile and free of any
foreign bodies.
 Further the labels and other things attached on the body of the bottle are removed in the
KHS machine in the washing process.
EBI:

 Here EBI checks whether the bottle is free of any foreign body against a bright board
which is illuminated for the purpose.
 If the bottle is not free of foreign bodies, it is either destroyed or sent to the washing
machine again depending upon the condition of the bottle.
 If the surface of the mouth is broken the bottle is destroyed then and there only bottles
free of any cracks on the surface of mouth are used for bottling.
 It also checks for other bottles which are not used for Kingfisher strong 650ml.

Filler:

 The filling machine fills the bottle first with CO2 and then in small quantities beer is
filled in each bottle one by one such that the final quantity of beer in the bottle is nearly
650ml.
 The filling machine consists of discs on which the bottles rest and are filled with small
pipe like fillers. These discs are 63 in number and can fill 63 bottles in one round.
 The speed of the filling machine is nearly18000 bottles/hour but usually due to certain
halts in other process the speed limits to 16000 bottles/ hour. After filling the capping is
also done in the same machine.

Checkpoint:

 Here a volunteer checks the capping, quantity of beer and entry of foreign particles in the
beer which might have occurred during the filling and capping of the same.
 If there is any fault in the bottle/beer then the bottle is discarded.

Pasteurizer:

 In this process liquid is heated at high temperature for killing microbes and making the
liquid sterile.
 This machine consists of 6 chambers from these chambers Kingfisher strong bottles flows
in which water flows at 6 different temperatures.
 In the first three chambers the temperature of water used for pasteurization is 45°C, 50°C
and 60°C respectively and then next three chambers have water falling at 50°C, 45°C and
 35°C the beer which is filled in the bottles may contain microbes from various processes
of fermentation and filtration.

Checkpoint:

 Here the final checking of dirt, foreign bodies and quantity of the beer is checked.

Labeler:

 Here labeling is done together with the printing of MRP, batch no. and date of
manufacture.
 On the bottle three labels are glued on top side, front side & back side.

Checkpoint:

 Here a volunteer checks all the labels of bottles glued.

 They also check the labels are properly placed or not.

Packaging:

 After this the bottles are conveyed to the packaging unit where the bottles are packed
in cartons.
 12 bottles of Kingfisher strong beer are packed in 1 carton.
 On the carton packing date and serial number is printed.
 After packaging cartons are checked for printing, leakage.
To brewing area

Brewing

To bottle washer area

Washer

To EBI area

EBI (overall bottle inspection)

To filler area

Filler

To check point area

Check for crown and half fill bottles

To pasteurizer area
Pasteurizer to increase the health of beer

To checkpoint area

Final check for dirt, foreign bodies and quantity of

beer

To labeler area

Labels are glued on bottle also MRP, date of

manufacturing and batch number is printed

To check point area

Check all labels of bottle glued and placed properly

or not

To packaging area

Bottles are packed in carton

Storage till dispatched

Control Charts:

Control chart is a graphical tool for monitoring the activity of an ongoing process.
Control charts are sometime referred to as Shewhart control charts, because Walter A. Shewhart
first proposed their general theory. The values of the quality characteristics are plotted along the
vertical axis, and the horizontal axis represents the samples, or subgroup (in order of time), from
which the quality characteristics is found. Sample of a certain size (say, 4 or 5 observations) are
selected, and the quality characteristics (say, length, height, viscosity) is calculated based on the
number of observations in sample. These characteristics are then plotted in the order in which
they samples were taken.

Statistical Process Control:

Statistical Process Control (SPC) is an effective method of monitoring a process through

the use of control charts. By collecting data from samples at various points within the process,
variations in the process that may affect the quality of the end product or service can be detected
and corrected.

Control charts as tool for process control:

 To show evidence off control.

 Various processes are observed during the production process.

 Data collected by taking samples at specific intervals.

 Then control charts are drawn. Control charts drawn for various processes showing that
the process used for production is suitable for producing the product with maximum
quality and safety.

 By identifying the variations in the quality of product with the help of control charts the
necessary corrective actions has to be taken.
Process control record for finding bottle bursts:

Data Collected:

Sample No. CO2 pressure in kg/m2 Bottle Bursts (in an

hour)

1 2.7 72

2 2.6 60

3 2.5 49

4 2.4 39

5 2.3 30

6 2.2 23

7 2.1 20

8 2.0 19

9 1.9 17

10 1.8 15

UCL=40.20

CL=23.28

LCL=22.08
Control chart for defectives:

80

70

60

50

Bottle bursts
40 CL
UCL
LCL
30

20

10

0
1 2 3 4 5 6 7 8 9 10

Conclusion:

After filling of bottles from 10 different samples, and observed for defective bottles, and
then p charts are drawn from the same. From the above chart we can say that sample 1, 2, and 3
contains more defective bottles i.e. more bottle bursts as compare to other samples and remaining
samples are within acceptable control limit. Corrective action taken for the defective bottles and
reason for defects has to be found out.
 CHAPTER: 7

OBSERVATIONS AND FINDINGS

OBSERVATIOS AND FINDINGS:

Following are the observations and findings obtained after observing the entire manufacturing
process:

1. Materials handling was very poor .simple techniques of material handling which can be
installed at very low cost were not being used.

2. Scheduled for the preventive maintenance was not followed. Machines were used until
they are broken down.

3. Certain materials were stored for prolonged time and in improper way which resulted in
rejection of material by production department.

4. Atomization of certain processes can reduce the time requirement and wastage of
materials to great extent.
CHAPTER: 8

LIMITATIONS
Every project has its own limitations. But we have to work irrespective of these limitations and
find our way, so that we can achieve the required aim.

Some of the limitations of this project are:

1. Facts and figures cannot be represented in the project for the sake of confidential
information of the company, which makes the explanation of process difficult.

2. Entry to all departments was restricted in the company. So all the processes were not
observed properly.

3. Due to limited time some intricacies of manufacturing processes could not be studied.

4. Some important processes could not be observed because of company policies.

CHAPTER: 9

SUGGESTIONS
SUGGESTIONS:

1. Combination of processes

2. Materials Handling

3. Loading of material directly to the equipments

4. Proper maintenance of machines

5. Proper storage

6. Atomization of processes
CHAPTER: 10

CONCLUSION
CONCLUSION:

This project was a complete understanding experience of the batch manufacturing

process for beer (bottling) manufacturing. Manufacturing process is the most important process
among all processes as it is responsible for the quality products. Quality products result in
increased sales and ultimately increased profitability without any significant efforts. So by
legally focusing on the manufacturing process we can increase the profitability to great extent.

The project explains the manufacturing process of beer in details. This process consists of
many steps viz. raw material procurement, brew house, fermentation, lagaring and filtration,
bottling section, packaging and dispatching. Brew house and bottling are the key areas in beer
manufacturing. At UBL Navi Mumbai there is some scope for improvement like carton handling
and conveyor belt maintenance. This can reduce the manufacturing cycle time and hence
increase the organizational efficiency.

Areas like materials handling, storage and maintenance can also be improved. If these
areas are controlled properly, it may reduce the manufacturing cycle time to great extent. Also it
may help in reducing labor and material requirements which ultimately will result in increased
productivity and organizational efficiency and effectiveness.
 CHAPTER: 11

BIBLIOGRAPHY
BOOKS:

1. Prof. Jhamb L. C (2003); Manufacturing and Operations Management; Everest

Publishing House, Pune; Pg No. 1-50.

2. Patel, Chunawala SA (1997); Production and Operations Management; Himalaya

Publishing House, Mumbai; Pg No. 65-66

3. Kamal Kant Joshi, Fermentation Microbiology and Biotechnology; Manglam Publishers.

WEBSITES:

1. http://unitedbreweries.com/

2. http://en.wikipedia.org/wiki/United_Breweries_Group

3. http://www.kingfisherworld.com/

4. http://theubgroup.com/ubprofile_ubhl.aspx

5. http://www.ub-global.com/KF_Premium_Lager.html
CHAPTER: 12

ANNEXURE
LIST OF ABBREVIATIONS:

1. UBL: United Breweries Limited

2. Q.C: Quality Control

3. U.S: United State

4. ISO: International Standard Organization