“Brewing Beverages” (Marks – 20)

Content

4.1 Vinegar Process: Introduction - Types of vinegar

4.2 Mechanism of acetic acid fermentation process - slow and quick process. Brewing raw
materials and its role.
4.3 Process of wine: Process technology of white wine-grape preprocessing, grape juice
treatment, fermentation, clarification and aging.
4.4 Process technology of Red, Rose, fortified and sparkling wine.

Unit Outcomes (UOs)

4a.Describe the given terms related to brewing.

4b.Describe with sketches any one given process (malting, mashing or fermentation).
4c.Describe the properties of the given type of wine.
4d. Explain the hygienic and safe practices to be followed for the specified beverages
manufacturing process technology.
4e. Describe the process technology of the given type of wine.

Introduction

• The beverage industry (also known as the drink industry) manufactures drinks and ready
to drink products.
• Examples are bottled water, soft drinks, energy drinks, milk products, coffee and tea-
based products, nutritional drinks, and alcohol products.
• The beverage industry is traditionally a market with specific high demands with regards
to hygiene and its related technologies.
• Exquisite hygiene is needed to maintain the high-quality standards and shelf life of the
end product, whether it is mineral/drinking water, lemonade, fruit juice, beer, wine, or
(sparkling) wine.
• Beverage production varies largely depending on the product being made.
• The beverage industry consists of two major categories:

Alcoholic beverage industry:

• The alcoholic beverage industry includes distilled spirits, (sparkling) wine, cider, and
brewing.
• Non-alcoholic beverage industry:
• The non-alcoholic beverage industry is comprised of soft drink (or soft beverage
industry) or syrup manufacture; soft drink and water bottling and canning), fruit juices
bottling, canning, and boxing, the coffee industry, and the tea industry.
• Brewing :
To make (beer, ale etc.) by steeping, boiling and fermenting malt and hops.
To make or prepare beverages by mixing, steeping, soaking or boiling solid ingredients in
water.
• Steeping :
Steeping is the soaking in liquid (Usually water) of a solid, so as to extract flavours.
• Malt :
Malt is a substance made from grain (barley or other grain ) that has been soaked in water
and then dried in a hot oven.
Malt is used in the production of alcoholic beverages like Whisky, Beer and other
alcoholic drinks.
• Hops :
Hops are the flowers of the hop plant. They are used as a flavouring agent in beer and
other alcoholic beverages.
• Beverages :
Beverages are drink other than water.
A liquid to consume, usually excluding water.
It includes tea, coffee, liquor, beer, milk, juice or soft drink.

Alcoholic beverages:
Alcoholic beverages is simply any drink contains ethanol, ethyl alcohol etc.
Beer, wine and sprits drinks are alcoholic beverages.
Other examples – Vodka, gin, rum, whisky, brandy are example of distilled drinks.
Beer, wine are example of fermented drinks.

Vinegar Process

• Vinegar:
The word vinegar is derived from the French word “Venaigre” meaning “Sour wine”.
Vinegar is an aqueous solution of acetic acid and trace chemicals.
Vinegar typically contains 5-20 % acetic acid by volume.
Usually acetic acid is produced by the fermentation of ethanol or sugars by acetic acid
bacteria.
Generally 6-10 % solution of acetic acid has been known as vinegar.

• Vinegar Process:
Vinegar process is the two- steps process of fermentation from a carbohydrate to an
alcohol to an acetic acid, which is then fermented in to vinegar.
Carbohydrate + Alcohol ----Fermentation---------------- Acetic acid
Acetic acid -------------Fermentation------------ Venegar
 Types of vinegar

• There are many types of vinegar, depending upon the source of materials are –
1. White Vinegar
2. Apple cider vinegar
3. Wine vinegar
4. Rice vinegar
5. Malt vinegar
6. Cane sugar vinegar etc.

Mechanism of acetic acid fermentation

• Production of Vinegar –
• Wine or apple juice is the best raw material for manufacture of vinegar.
• The fruit juice or other sugar containing material is converted to alcohol by yeast
fermentation.
Invertase
C12H22O11 ------------------------------- C6H12O6 + C6H12O6
Maltose Glucose Fructose
Zymase
C6H12O6 ------------------------------- 2C2H5OH + 2CO2
Fructose Yeast Ethyl alcohol

Diastase
Starch ------------------------- Maltose
 Invertase
Maltose ------------------------ Fructose
Zymase
Fructose --------------------------- Ethyl Alcohol

• Diastase – Diastase in the human body, convert the carbohydrates in to sugar.

• Invertase – It is an enzyme produced by yeast.

• Zymase – It is a mixture of enzymes obtained from yeast which convert sugar in to

alcohol.

Process - Slow and Quick Process

Vinegar is produced from ethyl alcohol by the quick vinegar process.

• Quick Vinegar Process –

In this process, 10-13 % alcohol is used to bacterial oxidation (acetobacter aceti) to form
acetic acid.

Quick Vinegar Process

In the process beech wood shavings are inoculated with a species of the genus
acetobacter. Acetobactor – Bacteria that oxidise organic compounds to acetic acid, as in
vinegar formation.
• The solution of alcohol mixed with nutrients for the growth of acetobacter is applied in a
trough at the top of the chamber and allowed to trickle down over the shavings.
• As the mixture passes through the saving the acetobactor oxidises some of the alcohol to
acetic acid.
• The mixture is collected at the bottom.
• The mixture may be recirculated in to the shavings for further oxidation of alcohol until
vinegar of the desired strength is obtained.
• Large quantities supply of air is essential as this is an aerobic process. The temperature
maintained between 150 C to 340 C.
• Acetobacter
• C2H5OH + O2 ------------------------------- CH3COOH + H2O
• Ethyl alcohol Acetic acid
• (Vinegar)
• There are several kinds of vinegar.
• Distilled vinegar is produced from distilled alcohol.
• Cider vinegar is produced from alcoholic apple juice.
• Corn sugar vinegar is made by the fermentation of corn sugar and then oxidation.

• Uses of Vinegar –
1. Vinegar is an ingredient used in cooking as well as baking.
2. Vinegar is an essential part of making salad dressing and can transform milk in to a
butter milk substitute.
Slow Method
• It is the oldest method of vinegar production otherwise known as ‘let alone’ method in
which wine left in open vats became converted to vinegar by acetic acid bacteria entering
it from the atmosphere.
• Later the wine was put in casks and left in the open field in the ‘fielding processes’.
• A small amount of vinegar was introduced into a cask of wine to help initiate
fermentation.
• The introduced vinegar lowered the pH and inhibiting other bacteria and promotes the
growth of acetic acid bacteria.
• The casks are made up of wood and should not fill beyond about two-thirds of its
capacity, so that there was always a large amount of air available above the wine.
• A thick film of acetic acid bacteria formed on the wine and converted it in to vinegar in
about five weeks.
• About 10-20% of the vinegar was drawn off at weekly intervals and replaced with new
wine.
• The main advantage of this method was it produces good quality vinegar.

• The method has many disadvantages:

• (a) It was slow method taking up to five weeks, hence; it is also known as the slow
method,
• (b) The yield is very less, and
• (c) The ‘mother of vinegar’ filled the cask and effectively killed the process.
 Brewing Raw Materials and its Role

• Brewing is a traditional process with a long history that focuses on major raw
materials are :
• 1. Barley grain
• 2. Barley malt
• 3. Hops
• 4. Water
• 5. Yeast
• 6. Carbon dioxide etc.

• Role of raw materials in brewing :

• 1.Malted Barley :
• Malted barley is the source of the sugars (Maltose) which are fermented in to beer.
• 2.Hops :
• The plant part used in brewing beer is the hop flower. It give a beer bitterness when used
early in the brewing process and aroma when added at the end. Hops are a preventive and
extend the life of beer.
• 3.Water :
• Water is essential in brewing as an ingredient and as a process facilitator.
• 4.Yeast :
• Yeast is a little, single cell organism one of the simplest forms of plant life, which is
responsible for the fermentation process in brewing.
• Yeast convert sugar (Glucose, Maltose) in to carbon dioxide and alcohol.
• 5.Carbon dioxide :
• Carbon dioxide is a gas produced by yeast during fermentation and creates ‘Fizz’
chacteristics of beverages.

Process of Wine
• Wine is an alcoholic drink made from fermented grape juice.
• Yeast consumes the sugar in the grapes and converts it to ethanol, carbon dioxide and
heat.
• In general, there are five basic components of the wine making process –
1. Harvesting
2. Crushing and Pressing
3. Fermentation
4. Clarification and Aging
5. Bottling.
 Flow sheet for manufacturing process of Wine
Grape

Harvesting

Crushing

Pressing

Fermentation

Clarification and aging

Bottling

Process Technology of…

• Wines are prepared by the fermentation of fruit juices.

• The most important and widely used is grape juice.
• Which contains glucose, fructose and various acid like tartaric acid.
• Following are the various process technology of white wine –
• 1. White wine-grape preprocessing
• 2. Grape juice treatment
• 3. Fermentation
• 4. Clarification and aging.

Grape Preprocessing

• Preprocessing means preliminary processing of grape.

• It includes several steps like – Harvesting of grape, cleaning of grape, Size reduction of
grape etc.
• The quality of grapes determines the quality of the wine, so selection of proper grape for
wine production.
• Select fully riped, firm, fresh and wholesome grape having good colour, aroma and
lustre.
• Wash the grape thoroughly with water to remove the dirt and dust present on the surface
of grapes.
• White wine is made by fermenting juice which is made by pressing crushed grapes to
extract a juice, the skins are removed.
• Generally white wine is made from red grapes.
• The alcohol content in white wine varies from 5% to 14% but comes in at an average of
10% ABV.

Grape Juice Treatment

• Clean grape juice without skin and seeds is used to make white wine.
• Grape juice is then allowed to settle for some period to settling down of any solids.
• The clear juice on the top is then taken in another tank for fermentation. Fresh grape juice
which is the outcome of the crushing process and contains seeds, solids and skins of the
grapes.
• If white whine is being made then the seeds, solids and skins are quickly separated from
the grape juice to prevent the tannins and colour of the wine.
• On the other hand, if red wine is being made, the seeds, solids and skins are allowed to
stay in contact with the juice to allow the juice to get additional tannins, flavor and
colour.
Fermentation
• Fermentation process turns grape juice into wine.
• The metabolism of yeast converts sugar to alcohol and carbon dioxide.
• Typically, red wines are fermented for 1-2 weeks at 50–86°F.
• White and rosé wines are fermented for 2-4 weeks at 50–68°F.
• Fermentation occurs in vats of stainless steel, lined concrete or wood.
• Fermenting at too low a temperature inhibits extracting the best material from the grapes;
too high and aromatic and flavor complexity are lost.
• After the destemmer the wine is pumped into tanks to begin fermentation.
• The process of fermentation in winemaking turns grape juice into an alcoholic beverage.
• White wines are typically fermented without their skins and other solids, while red wines
are fermented in contact with skins and other solids.
• By putting grape juice into a container at the right temperature, adding yeast which turns
the sugar in the juice into alcohol and carbon dioxide the grape juice will ferment.
• During fermentation, yeasts transform sugars present in the juice into ethanol and carbon
dioxide (as a by-product).
• The temperature and speed of fermentation are important considerations as well as the
levels of oxygen present in the must at the start of the fermentation.
• The more sugars in the grapes the higher the potential alcohol level of the wine if the
yeast is allowed to carry out fermentation to dryness.
• We will stop fermentation in some cases early in order to leave some residual sugars and
sweetness in the wine for example our Riesling.
• This can be achieved by dropping fermentation temperatures to the point where the yeast
are inactive and then sterile filtering the wine to remove the yeast.
• Fermentation may be done in stainless steel tanks, in an open plastic vat or inside a wine
barrel.
• All of our fermentation tanks are heated or cooled by a controlled glycol system that runs
through jacketed tanks.
• Red wine fermentation requires temperatures to reach 78.8 - 86°F for the pigments to be
extracted from the grape skins.
• It is common to warm the fermenting juice artificially to help this happen. This has to be
done carefully, as yeast die quickly in the heat.
• White wine fermentation may require the fermenting juice to be cooled to 53.6 - 59°F to
help preserve the delicate varietal characteristics.
• These flavor and aromatic compounds are destroyed in high temperatures.

Clarification and Aging

• Clarification:
• Clarification is the process to remove suspended material in wines that are created via
chemical reactions during the winemaking process.
• They are insoluble and float around in the wine, creating a cloudy, dull appearance.
• Also these materials can change the flavor and aroma of the wine.
• When this occurs, the winemaker uses a clarification process to remove these particles
and ensure that the wine is clear and crisp.
• Only once the wine is clear does the winemaker then bottle it.
• Most of the wines that you see on the shelf of the liquor store have been clarified, or
have undergone some process by which these particles are removed.
• The process of clarification can be done naturally by aging the wine and racking it so that
the particles are easily removed, or clarification can be induced.
•
• There are several ways for clarification of wine are -
• 1.Fining:
• Using the chemicals to create bonds with the floating particles and make larger clumps
that are easy to remove.
• 2.Filtering:
• Using a filter – traditionally rough cloth-covered screens – to catch the larger particles.
• 3.Centrifugation:
• High-speed spinning to force the particles out of the wine.
• 4.Refrigeration:
• Using temperature reduction to prevent the growth of yeast and evolution of carbon
dioxide.

Aging
• Wine aging refers to a group of reactions that tend to improve the taste and flavor of a
wine over time.
• The term wine 'maturation' refers to changes in wine after fermentation and before
bottling.
• Some wines require only a short period to develop and generally do not benefit from
prolonged maturation and aging.
• The term wine aging should be reserved to describe changes in wine composition after
bottling.

• Changes in wine due to maturation and aging

• Many reactions occur during the maturing and aging phase which leads to significant
changes in the composition of the wine.
• Many of these changes are subtle and, in some cases, so small that their impact on the
sensory properties of wine is not noticeable.
• On the other hand, certain reactions have a noticeable effect on the various sensory
attributes of wine, and they play a significant role in wine maturation and aging.
• Generally, during the process of maturation and aging, the most obvious change occurs in
the wine are –
• 1. Colour
• 2. Taste and mouth feel
• 3. Aroma
• 4.Other changes and factors affecting wine aging are –
• a) Oxidation
• b) Temperature
• c) Light.

Process technology of…

• Red
• Rose
• Fortified and
• Sparkling Wine
• Wine can have anywhere between 5% and 23% ABV.
• The average alcohol content of wine is about 12%.

Red Wine
• Red wine is a type of wine made from dark coloured grape varieties.
• The actual colour of the wine can range from violet for young wine, brick red for mature
wine and brown for older red wine.
• The grape juice is greenish-white in colour, the red colour coming from anthocyan
pigments (also called anthocyanins) present in the skin of the grape.
• Red wine is made like white wine, but with one major difference.
• Generally, it ferments with the grape skins and juice combined in a tank or vat.
• White wines are pressed before fermentation, separating the juice from the skins.
• The skin contact in red wine production allows color, flavor and textural compounds to
be integrated into the juice, while the yeast converts sugar to alcohol.
• The skins contain most of the good stuff that gives red wine its color, while the pulp
mostly provides the juice.
• The alcohol content of red wine usually falls between 12% and 15%, with an average of
13.5% ABV.
• Red wine is very beneficial to human health. It prevents heart disease and cancer.
Steps for Manufacturing of
Red Wine
Grape

Harvesting

Pretreatment

Crushing

Fermentation

Clarification

Aging and Bottling

Steps for Manufacturing of Red Wine

• Harvesting –
The first step in making wine is harvesting. Harvesting can be done by hand or by
machines. Once the grapes are picked they are taken to winery and then sorted in
bunches. Separate the ripe and unripe grapes. Then grapes are send to the pretreatment.
• Pretreatment –
Wash the grapes thoroughly with water to remove the dirt and dust present on the
surface. For making of wine select fully riped, firm, fresh and wholesome grape having
good colour, aroma and luster.
• Crushing -
After pretreatment, grapes are then crushed. Crushing process used to be done by feet in
the past. Crushing is done by mechanically by using the crusher. After crushing remove
the grape juice and separate the skin of the grape. Crushing process remove the seeds,
solids and skins of the grapes.
• Fermentation -
Crushing and pressing is followed by the fermentation process. Fermentation is starts
with in 6 to 12 hours when yeast is added to it. Fermentation process transforms sugar in
 to alcohol. The total fermentation process can take about a week, month and even more
time.
During fermentation, yeast transforms sugar present in the juice in to ethanol and carbon
dioxide.
• Clarification –
Clarification is the process by which insoluble matter suspended in the wine is removed
before bottling. This matter may include dead yeast cells, bacteria, proteins and other
compounds. Also pieces of grape skin, pulp, stems and gums.
• Clarification involve –
1. Filtration, 2. Centrifugation. 3. Flotation etc.
• Aging –
The aging of wine is potentially able to improve the quality of wine. Wine aging refer to
a group of reaction that tend to improve the taste and flavor of a wine over time. The term
wine maturation refers to changes in wine after fermentation and before bottling.
During the aging process, the perception of wines acidity may change even through the
total measurable constant throughout a wines life. This is due to the esterification of the
acids, combining with alcohols in complex array to form esters.
 Rose Wine

Rose wines are made from a wide variety of grapes and can be found all around the
world.
Rose wine is the primary product, it is produced with the skin contact method.
Black-skinned grapes are crushed and the skins are allowed to remain in contact with the
juice for a short period, typically 2 to 20 hours.
Then the fermentation process done the dark colour of the final wine.
Rose wine (or rosé) falls on the color spectrum in between a red and white and has an
average alcohol content of 12% ABV.

Fortified Wine
• Fortified means strengthened, it makes sense that fortified wines are essentially those
which are stronger in alcohol.
• A fortified wine is a delicious, viscous wine based sipping treat that is often enjoyed as a
drink before or after dinner.
• Fortified wine is made by adding a sprit to a base wine to create a wine with a higher
alcohol content.
• Fortified wine has a higher content of alcohol or alcohol by volume content achived
through the addition of a distilled spirit at some point during the vinification process.
• Fortification is the process of adding a distilled spirit to fortify or increase the alcohol
content of a wine.
• Fortifying of the wine brings the average alcohol content up to around 17 to 20 percent
alcohol by volume.
• For all the major fortified styles of wine, law dictates that the alcohol used in fortification
must be a distilled grape spirit.
• This spirit can be something very simple like a brandy depending on the desired style of
fortified wine.
• Example of fortified wine are Sherry wine, port wine, madeira wine, marsala wine etc.

Sparkling wine
• Sparkling wine is a wine with significant level of carbon dioxide in it, making it Fizzy.
• Sparkling wine might just be the most technical of all wines in the world–even if it is so
easy to drink.
• The reason most sparkling wine is so complex is because of the need for two
fermentations; one to make wine and the other to make bubbles.
• Since sparkling wines were first introduced (starting in the mid 1500’s), several
processes have been developed and each result in a unique sub-style of sparkling wine.
• Take a look at the major sparkling wine production methods and which wines are made
with each technique.
 • There are 6 major methods by which sparkling wines are produced, each resulting in a
different carbonation level and, ultimately, a different style of bubbly.
• We’ll discuss all the styles, but the two worth paying attention to the most are Traditional
Method (used for Champagne, etc) and Tank Method (used for Prosecco, etc).
• Traditional Method, • Tank Method, • Transfer Method, • Ancestral Method
• Continuous Method, • Carbonation, Sparkling wine contains up to 12% of alcoholic
content.

Flow sheet diagram for Manufacturing

Assignment No. 4

Q.N Name of Question

1 Define Brewing.
2 Give the various types of beverages.
3 How do you make vinegar?
4 Give the uses of vinegar.
5 Give the types of vinegar.
6 List any four types of wine.
7 Name the various brewing raw materials and describe its role.
8 Define the process of Carbonation. Also give any four examples of carbonated
drinks.
9 Describe the manufacturing of vinegar.
(Mechanism of Acetic acid fermentation process.)
10 Describe the following-
a) Malting of Barley
b) Mashing
c) Brew kettle boiling
d) Carbonation
e) Packing
f) Pasteurization
11 Describe the process technology of white wine-
a) Grape pre processing
b) Grape juice treatment
c) Fermentation
d) Clarification and aging.
12 Describe with flow sheet diagram the process technology of-
a) Red wine
b) Rose wine
c) Fortified wine
d) Sparkling wine.
a) Give the classification of Wine. Describe the Fortified wine and
Sparkling wine.
13 Describe the process of manufacturing of Fruit Beverages.
14 Write the health benefits of Wine.