DEBRE BERHAN UNIVERSITY

INSTITUTE OF TECHNOLOGY
SCHOOL OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
FINAL INTERNSHIP REPORT FROM DASHEN BREWERY S.C

NAME: Mitku Molla

ID NO.O694/10 Submitted to: Mr.Fekremariam
Submission date:17/9/2014E.C
Executive summary
During our internship we worked in dashen brewery s.c. The company has four main
departments that are brew house, filtration, filling & packaging and utility. The raw material
handling handles the malt from the intake hopper to mill star. In brew house, the malt enters to
the mill star and finishes the brew house section after the wort from the whirl pool cooled by
wort cooler before it transferred in to beer processing. The main processes in beer processing
are yeast propagation fermentation and filtration. In bottling, the empty bottle feed in to
depalitizer and finally the end product (bottled beer) is palitiser by the caser. In keeping plant,
there are eight station stop reduce draft and one of the basic differences between bottled beer
and draft is the pasteurization temperature filling stages and amount of carbon dioxide usage.
Utility is the back bone of the company. The raw water heated, in CO 2 recovery plant (CO2
purified), NH3 plant for cooling purpose and boiler for production of steam and there is waste
water treatment that makes the environment safe. One of the objectives of maintenance
management is minimizing the loss of productive time and cost because of malfunctioning of
equipment’s and poor maintenance effects .Supply chain management manages all activities
from supplier to customers and suppliers can be controlled on suppliers’ service, installation and
support capabilities .In dashen brewery quality is assure data stage of production .The presence
of sensor and PLC makes the company modernizes and technologically developed brewery. In
this internship report document we I try to describe the overall internship experience and over all
benefits we gained from the company of dashen brewery during our four month internship
program

I
Acknowledgment
I would like to acknowledge first of all debre berhan institute of technology to give this grate
look for my next to that i would to acknowledge Debre Berhan brewery share company and it
shall employees for its unexpected experience to give for my next we would say thank you for
my advisor Mr. Fekremariam and Mr.zekarias to give a hint and correction from the beginning of
the report up to the final time of the report. Finally, I would like to thanks my mother to give
support.

II
ACRONYMS
BMF- Beer Membrane Filtration
PVPP- Poly Vinyl Poly Peptide
CIP- Clean In Place
HE- Heat Exchanger
SC- Share Company
FBI- Full Bottle Inspection
EBI- Empty Bottle Inspection
UV- Ultra Violet
AD- An aerobic Digester
MS- Mass of Stem
TDS- Total Dissolved Solids
WHC- Water Holding Capacity

III
 Catalog
ACRONYMS.....................................................................................................................................................................................................III
CHAPTERONE..................................................................................................................................................................................................1
1.INTRODUCTION............................................................................................................................................................................................1
CHAPTERTWO.................................................................................................................................................................................................5
2. Beer manufacturing technology.................................................................................................................................................................5
CHAPTER THREE............................................................................................................................................................................................34
3. Packaging house........................................................................................................................................................................................34
1. Bottle filling...............................................................................................................................................................................................35
2. Keg filling...................................................................................................................................................................................................35
Bottle.............................................................................................................................................................................................................35
Crate..............................................................................................................................................................................................................35
1. Temperature.............................................................................................................................................................................................37
2. Mechanical effect......................................................................................................................................................................................37
3. Effective cleaning agent............................................................................................................................................................................37
4. Exposure time...........................................................................................................................................................................................37
5. Conductivity..............................................................................................................................................................................................37
1. Temperature.............................................................................................................................................................................................37
2. Conductivity..............................................................................................................................................................................................38
1. Infeed monitoring sensor.........................................................................................................................................................................38
2. Temperature sensor..................................................................................................................................................................................38
3. Discharge monitoring sensor Filler machine............................................................................................................................................38
1. Glue...........................................................................................................................................................................................................40
2. Labeler paper............................................................................................................................................................................................40
3. Packed bottle beer....................................................................................................................................................................................40
The main components of draft machine.......................................................................................................................................................41
2 Filling head.................................................................................................................................................................................................41
3 Cleaning heads...........................................................................................................................................................................................41
4 Valves.........................................................................................................................................................................................................41
5 Intake station.............................................................................................................................................................................................41
6 Walking beam............................................................................................................................................................................................41
7 Out let station............................................................................................................................................................................................41
3.1.Air compressor........................................................................................................................................................................................44
1. Electrical boiler..........................................................................................................................................................................................51
2. Fuel boiler.................................................................................................................................................................................................51
3. Biogas boiler Electrical boiler....................................................................................................................................................................51
CHAPTER THREE............................................................................................................................................................................................63
CHAPTER FOURE...........................................................................................................................................................................................64
CONCLUSION.................................................................................................................................................................................................67
Recommendation..........................................................................................................................................................................................67
ACRONYMS....................................................................................................................................................................................................69
REFERENCE....................................................................................................................................................................................................70

IV
Figure 1 mash filter...................................................................................................................................................................19
Figure 2 brew house flow diagram............................................................................................................................................23
Figure 3 yeast fermentation.......................................................................................................................................................27
Figure 4 Bright beer tank (BBT)..............................................................................................................................................33
Figure 5 packaging room..........................................................................................................................................................35
Figure 6 keg plant.....................................................................................................................................................................42
Figure 7 keg washer.................................................................................................................................................................. 43
Figure 8 Keg filler.....................................................................................................................................................................44
Figure 9 Processflow diagram of air filter.................................................................................................................................46
Figure 10 ballon........................................................................................................................................................................ 47
Figure 11 co2 recovery............................................................................................................................................................. 48
Figure 12 . Simple flow diagram of boiler.................................................................................................................................53
Figure 13 Filtered water............................................................................................................................................................55
Figure 14 water treatment.........................................................................................................................................................58
DischargetoenvironmentFig2.Figure 15 Processflowdiagramofwastewatertreatment..............................................................60

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VI
VII
CHAPTERONE
1.INTRODUCTION
Beer production is one of the industrial processes in my country among the different beer in
dustries found in Ethiopia. Dashen brewing factory is the most popular one and this beer factory
used sophisticated technologies for the production of Dashen beer, Dashen
drought ,balageru.Dashen brewery has four main sections these are brew house ,beer processing,
packaging and utility. Beer is an alcoholic beverage that produces from malted barley hops, water
and yeast are the main raw materials to produce hopped cold worth that is ready for fermentation.
The main purpose of brew house is worth production and fifty percent of the beer production
process is perform, the main activities done in brew house are malt cleaning ,milling, mashing,
mash filter, wort boiling ,trub separating and worth cooling.

1
1.1. Background of the company
Debre Berhan Dashen Brewery Share Company was established in November 2008 E.C. The name
Dashen is taken from the famous mountain of Ras Dashen Brewery Share Company is located at
the city of Debre birhan, which is130km far from our capital city Addis Ababa .It is owned by the
Amhara National Regional state Rehabilitation/Development organization .Dashen brewery S.C is
a modern plant which is a branch of Gondar Brewery Company. Debre berhan dashen brewery S.C
Company occupying 8.5 hectares with building area 1.2hectare., 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 fore front of the local market even at its infant stage .now the time
it have three lines that is line one ,line two and the newest line three work 24 hr per a day
effectively .

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1.2 Objective
1.2.1 General objective

 Toimproveandbuiltupourunderstandingonthepracticalindustrialpracticeandrelatesourtheor
etical knowledge with the practical world.
1.2.2 Specific objective

 To detail know what position were engaged after graduation as a profession.

 To know about raw material ,unit operations, equipment’ sand utilities in detail.
 Also it informs us detail data about the process flow.
 To estimate and understand basic environmental issues regarding with the industry.
 To develop professional skill.
 To solve the factories problem as much as possible.
 To know working ethics briefly.

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1.3 Literature review
Beer is a beverage obtained from cereal malt (mainly barley) and other raw materials to which
process water and hop flowers were added. This mixture is called mash and is goes through a
process of alcoholic Fermentation by the action of yeasts. Yeasts are a single-cell fungus from
the Saccharomyces strain ,is added to the hopped mash after it has been cooled.This
transformation also helps to form the products which provide beer with its
characteristics(aromatic alcohols, esters, etc.). The used yeast plays a fundamental role in the
final definition of beer. In short, beer is an alcoholic drink made from the scarification of starch
by the help of scarification enzymes as a substrate in malt, flavored with hops, and fermentation
of the resultingsugar.Thestarchandscarificationenzymesareoftenderivedfrommalting cereal
grains. The preparation of beer is called brewing and the person in charge of it is called the brew
master where us a dedicated factory for making beer is called a brewery. Beer is the world most
widely consumed alcoholic beverage, and the third most popular drink overall, after water and
tea. The strength of beer is usually around 4.8% to 5.4% alcohol by volume (above) although it
may varybetween0.5%.
Vision
To be leader in countries beer industries with respect to quality, competitive price, prospect to
high technology and international orients as well as sample for the overall industrial sector in the
country. To make dashen beer is the central venue for quality beer celebrities.

Mission
It is an endowment form established to contribute for the development of a region by producing
and selling customer proffered quality beer at competition reasonable price and generate a
reasonable price.

To by generated profit to improve the socio-economic well being of the Amhara region.
To product and seek quality beer at reasonable profit.

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 CHAPTERTWO

2. Beer manufacturing technology

Beer production is one of the industrial processes in our country among the different beer
industry found in Ethiopia. Dashen beer factory is the most popular one and this beer factory
used sophisticated technology for the production Dashen beer and Dashen draft. Dashen brewery
has four main sections these are brew house, packaging (production), utility and boiler room.

5
 Beer is alcoholic beverage that produces from malt; hop, yeast an water are main raw material to
produce cold worth that is ready for fermentation. The main purpose of brew house is to sweet
wort production and fifty percent of the beer production process is perform the main activate
done in brew house are malt cleaning, milling, trub separator, worth cooling, fermentation and
filtration.

2.1. Basic raw material

1. Malted barley

2. water

3. hop

4. yeast

i. Malted barley

The oldest where the most predominant malt ingredient in brewing is barley that has higher
extract and fewer husk preferable for both at home and industrial. it is important to emphasize
then malted grains are the dormant seed of grass plant but in the malting process the grains are
germinated controllable to produce the cross pending grains malt however the correct extent of
germination is the key for producing good malt during germination the embryo grow at the
expense or reverse material stored in the kernel. As well as the grain makes contact with suitable
condition during steeping (moisture)and adequate temperature .all enzymatic apparatus is
gradually activated to brake the starch and protein to form new plant. Malt is cereal grain that
have been germinated and dried in a process called malting .the starch source in a beer provide
the fermentable material and a key determinate of strength and flavor of beer .the most common
primary starch source used in beer is malted barley.

Malting is the process to produce yeast nutrient such as fermentable sugar and free amino acid by
active of enzyme synthesized during seed germination.

Steps of malting

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Drying

 Steeping

 Germination

 Killing

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Killing

A. Drying

The grains are dried to moisture content below 14 percent and then stored for six weeks to over
come seed dormancy (tendency of seed to remain inactive) or notable to grow.

B. Steeping

The barely is sprayed with water and soaked for about 3 day to activate enzyme system preserve
of brew house.

C. Germination

The socked barely grow acrospires in the germination room large number of enzyme such as
alpha and beta amylase are used to convert grains in to sugar enzyme are released that break
down the protein and starch in to simple sugar mean to nourish the baby plant.

D. Killing

After germination the barley is dried up in kill to preserve the enzyme in the grain. it is important
note that the flavor of beer is related to the temperature at which it is killed higher temperature
result in heavier flavor the killing (drying) process is performed by spreading the germinated
barley on wooden floor with tiny hole that smoke at 55oc

Acrospires eat endosperm as they grow during malting endosperm is food source of acrospires
because it is full of starch. Acrospires will continue to eat endosperm until they are stopped by
heating and drying

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Longer acrospires growth leads to

 More endosperm consumed

 Less fermentable sugar present

 More yeast nutrient are released

 More amylase are activated

 Clear beer and more complete fermentation

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In dashen malted barley is the main raw material because it has higher extract and fewer husk
which preferable for beer production.

Due to the following reason malted barley more preferable than other grains

 High water absorption and low water sensitivity

 High sprouting by time of malting

 High yield extract during malt

 It has high starch and protein content which need for nutrition

 It contain small amount of oil(fat) which cause foam damage the husks of barley malt

 Malted barley has high complement of enzyme for convert starch to sugar

 Malted barley gelatiniz at low temperature.

ii. HOP

Hops are the small green cone like fruit of vine plant. They provide bitterness to balance out all
the sugar in the wort and provide flavor. Hop is one of the most important and expansive raw
material in brew factory its scientific name is humulu siupulus .Although hop is
dioeciously(they are separate male and female plant) \b+
ut only the female plant are cultivated by hop growers because the part important to beer making
is its female flower. Flower is a plum sized cone that looks similar to miniature artichokes. On
the inside of flower is cluster of tiny sticky yellow goblets called lupines. Lupines store acid and
oil that give bitterness and aroma for beer.

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Additionally hops flower serve the following purpose in beer production

1. They aid in the removal of excess protein in the unfermented beer

2. They are natural preservative

3. They are used to improve foam and stability of beer

4. They contain acid provide bitter taste and flavor

5. It contain oil from the plant add flavor aroma

Dashen import hop from foreign country which has largest growing region that is from Germany.
The composition of hop is extremely important for quality of beer production.

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1. Bettering varieties

They are characterized by higher acid content above10%

2 .Aroma varieties

They are characterized more intense and pleasant aroma resulting from higher content of certain
hop oils but amount of  acid content is low. According to studies the average composition of
dry hop weight is approximately.

Table2.1 composition of dray hop

Bitter substance of hop resin 18.5%

Hop oil 1%
Poly phenol 3.5%
Protein 20%
Inorganic compound 8%
Cellulose and other material 49%

iii. Yeast

Yeast is single called unicellular microorganism that has ability to ferment carbohydrate in
various substances which turn sweet wort in to ethanol, carbon dioxide, Ester, ketone, aldehyde
and energy that is carbon dioxide and Ester is good flavor, but ketone and aldehyde off
flavor.Fermentationisexothermicreactionitreleaseheatintheprocessthrough anaerobic respiration.

C6H12O6Yeast 2C2H5OH+2CO2+ENERGY

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 iv. Water

Is the most useful and highly consumed substance it is not only used for brewing also used for
different purposes about 3 to 5 times greater water used than the volumes of beer produced apart
from brewing sparing and dilution liquors. water is used for cleaning in place (CIP) system,
coolant, heater (either as hot water or after conversion into steam in a boiler).water to occupy the
lines before and after running beer through them, for loading filter aids such as for washing the
waste slurry also to conveying away wastes as well as for washing beer container and treatment
of liquor and the disposal of the brewery effluents are expensive processes.

There are 3 main concerns when choosing brewing water. These are:-

a. Flavor of water:- Finished beer consist water more than 90% so The quality and characteristics
of the water used for brewing is greatly affects the taste of the finished beer, The amount and
composition of dissolved minerals, such as calcium and magnesium, play a great role on the taste
of beer.

b. Nutrients for yeast:-distilled water cannot be used because it is not enough of minerals which
are necessary nutrients for yeast growth. Ion concentration of minerals is very important for the
propagation of yeast. E.g.:-Ca2+, Mg2+.

c. Ph:-it affects how enzymes make maltose. Usually, mashing water PH is kept between 5-
5.5.Darker malts have lower PH than lighter malts. For the beer production cleaning and
removing impurities from brewing water is very necessary the produced beer is also being
attuned to the brewing water

Additives

Additives are any substances added to impart desirable characteristics to the product such as:-

1. CaCl2:it used for mineralsourceforyeast,proteinprecipitationandTopreventspoilage

2. Caramel :used for color adjustment/ caramelization

3. H3PO4:used for adjusting PH of hot water for mashing

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 2.2 Preparation of malt for milling
Malt is already prepared in beljegem country. Then the main raw martial imported to our country
special in debre berhan dashen brew Share Company. Malt transferred from one silo in to other
by mechanical conveyer.

1. Chain conveyer

2. Screw conveyer

3. Bucket conveyer

4. Motor

Chain conveyer

It is transport device for horizontal and inclined. The troughed chain conveyer is transporting
device for horizontally and also inclined transport. When the chain moves it carries the malt with
it. Chain conveyer has advantages and disadvantage.

Advantage it's power consumption is equal or better than other conveyer

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Disadvantage

The trough is not completely empty.

Screw conveyer
It used for horizontal transport of malt. When rotating the screw push the barely or malt gently
forward to the discharge position provided in the form of discharge slide.

Advantage of screw conveyer

Even if It use high energy usage it used to transfer short distance in

malting It's an inexpensive conveying device for horizontal transport.
Disadvantage there must be 3 to 5mm clearance between the trough and path of the screw
otherwise the screw scraps against the trough.

Consequently it is impossible to empty the trough completely

Bucket conveyer
It is transporting device used for vertical transportation of malt. Advantage of bucket conveyer
(bucket elevator)

 It is low energy usage

 It is the cheapest conveyer for vertical

transport disadvantages of bucket conveyer
 The bottom trough is never completely empty

 The trough must be cleaned after each usage

2.2.1 Malt milling

In order to give the malt enzyme the opportunity, during mashing, to act on the malt contents and
break down them, the malt must be broken in to smaller fragments, this process is called Milling.
The objectives of milling are to break up malt and adjuncts to such an extent that the greatest
yield of extract is produced in the shortest time in the mashing equipment in use. The milled malt
is called the grist and the amount used in brewing is called grist charge .Before malt enters the

15
 Milling chamber, once again all iron and other unwanted bodies must be removed so that the mill
sieve is not damage.

2.2.2.Mash tune
During mashing the grist and water are mixed together (mashed) and the contents of the malt are
there by brought in to solution and the extract obtained. The process of mashing refers to the
conversion of brewing materials in the presence of enzymes, in to a fermentable extract suitable
for yeast growth and beer production. The aim of mashing is to form an extract with a desired
profile of sugars and a desired level of proteins and other minor chemical constituents.

The mash temperature is raised to the ideal temperature for natural enzymes to act on the
starch from malt and other grains, and converts it into fermentable sugar. Controlling the
conversion temperature of the mash is critical, because the process is extremely temperature
sensitive. Small temperature variations can result in significant changes in wort composition and
ultimately the flavor of the beer. More conversion means higher levels of fermentable sugar and
lower levels of un fermentable“ dextrin’s”(short sugars chain that are tool arger for yeast to be
metabolize),

16
Which remain be body of the beer. This process takes places at64-650c.Agreater degree of
conversion means:
1. Higher potential alcohol in the wort

2. Lower calories and carbohydrates for a given alcohol

level Starch

Degradation
The most important component of beer is the alcohol formed during fermentation from sugars.
Therefore the starch is degraded from large extent to fermentable sugar like maltose. Starch
degradation occurs in three stages namely gelatinization, liquefaction and scarification
1. Gelatinization: Each cereal has its own gelatinization temperature.

Malt starch will gelatinize at 60c in the presence of amylase. Gelatinized starch is attacked more
easily by amylase than UN gelatinized starch. To form gelatinization process breaks down of
intermolecular bond of starch molecule into simple sugar by the process of water and heat.
2. Liquefaction: It is the reduction in the viscosity of the long chain glucose in starch (amylase
and amylopectin) by α-amylase. In this device there is agitator or mixer which used to
uniform mixing with at temperature of 71dueto the supply of steam.
3. Scarification: It is complete breakdown of starch in to simple sugars.

There is agitator used tomixingandthereishightemperaturearound78.Inthissectionsacharifcation

process performed (occur) due to high temperature enzyme and protein start to denature.
Scarification process means completely the breakdown of starch in to simple sugar.
Iodine Test

During mashing starch must be completely degraded. to know whether it is completely degraded
or not use the test called iodine test( i.e. drop a solution of iodine on the part
mash).Positiveiodinetestgivesblueblackcolorwhichindicatesthepresenceofstarch(notcompletelyde
graded)otherwisecolorlesswhichindicatesthecompletedegradationofstarchintofermentable sugars.
If a negative result for iodine test occurs on a sample of mash then the temperature adjusted to
780c and the degradation process has ended so it will be ready to move
inmashfilter.Foodgradeadditiveslikesulfuricacidandcalciumchlorideandcommercialenzymes such
as hitampase and biogulucanase also added to the mash with their own specific purpose
17
PHTest

18
The PH of produced wort is between the ranges of 5.2 -5.56.The influence of PH on the
composition of the wort is that it gives alkalinity(less acidity).If P H of the wort rises it is adjusted
by adding phosphoric acid (H3PO4). It has been shown that the p H value of the mash is an
essential parameter for the enzymes reactions. Thus a lowering of the pH results in;
 Reduction of the viscosity

 More rapid mash filter

2.2.3, Mash filter

Mash filter is a device which used to separate the wort and spent grain. The wort can
beseparatedintothreegroupsbasedonconcentrationofwort(gravityofwort).Thehighconcentration
goes in to wort holding vessel, the midum concept traction goes in g GIS tank and the low
concentration goes in to week wort tank, but GIS return to mash filter where as weak wort
directly goes in to mash in device or mega machine

Figure 1 mash filter

Then after that the wort transfer in to temporary buffer tank which can store clear wort (high
concentration wort)for a short period of time. After that the wort transfer in to holding vessel,but
spent grain transferred in to spent grain storage by screw conveyer and sold to customers for
animal feed.
Parameters of mash filter
.temperature
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.viscosity
.contact time
.Grist concentration

Wort holding vessel

Is a vessel used as storage of wort in this tank (vessel) we added caramels for color to make the
beer color are green? Before the wort transferred in to formation vessels isomer hop added in the
line automatically. Then after hat the wort transferred into formation vessels(boiling).

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2.2.4. Formation vessels(boiling vessel)
Wort is pure liquid brought to boil and bitter resins and aromatic hop oil are released the variety
of hop. The amount added and the point or points in the vessel at which they are added the all
contribute to the flavor of beer. They add bitterness which added early to the boil, flavor if added
in the middle and aroma when added at the end. The temperature is around 91due to high
temperature the concentration of wort increase and high volatile compound removed.

The Principal change that occur during wort boiling

 In activation of malt enzyme

 Sterilization of the wort

 Extraction and isomerization of compound derived from hop

 Coagulation of protein material in the wort

 Formation of poly phenol complex’s

 Formation of flavor and color complexes

 Fall in wort pH

 Concentration of wort gravity through evaporation of water

 Evaporation of volatile compound in the wort derived from mashing.

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2.2.5. Clarisever
It is conical shape vessel or tank which facilities process means separation of solid from liquid through gravity separation
of coagulation protein, separation hop trub.

2.2.6. Ecostripper
Is a device which used to separate clear wort? The wort contains malt, water, hop but
maltcontains the element like sulphr, phosphorus and like which is removed in this device to the
atmosphere, because the element is high volatile. And this device removed poly phenol that
causes turbidity of beer.

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2.2.7. Wort cooler(plate heat exchanger)
Is a device which used to exchange heat between hot wort and glycol in this cooling process
dashen brew factory used plate heat exchanger the working principal of plate heat exchanger is
hot wort pass through one side but glycol pass through the opposite side the hot wort. Hot wort
loses heat energy and glycol to gain heat energy. Therefore the wort become cold its
temperature must be 10 this cold wort (Sweet wort) transferred in to fermentation tank with a
catalyst of yeasts.

Hot water or weak wort CaCl2andH3PO4 SaintGrin Caramel

Mash in Mash Mash Holding

Milling Mashing
device vessel
in vessel Tune filter wor
t
device
Weakwort hop

Wot cooler(PHE) High volatile compound

Eco stripper Formationvessel
Clarisver

Coldwort
trub T
Fermentation

Figure 2 brew house flow diagram

2.2.8. Fermentation
Fermentation: The wort is then cooled and moved into a fermentation vessel. Yeast is added and
allowed to consume most or all of the sugars in the wort. This is the fermentation process during
which alcohol is produced. The process takes about ten days. Each brewery has its own strains of
yeast, and it is the yeast that determines the character of the beer. Yeast absorbs oxygen and
sugar, and reproduces asexually. When oxygen is used up, reproduction stops and fermentation
(anaerobic respiration) begins glucose produces molecules of ethyl alcohol andCO2.

C6H12O6 2CH3CH2OH + 2CO2+118kJ (2ATP)

Large amounts of CO2 are produced and must be recovered without letting oxygen in airlock
or water bubbler. When all fermentable sugars have been consumed, fermentation stops and

23
yeast

24
Begins to go dormant Yeast settle out and the beer clarifies this yields a “young beer” or
cellar .Once the yeast is removed the beer is passed from fermentation to storage vessels. During
transfer the beer is cooled to minus one degree centigrade. The beer stays in storage at this
temperature, and any material which might Yeast is essentially a fermentation catalyst it is also
known as biological catalyst. Yeast often removed after fermentation and can be reused after
being store in yeast tank. In Dashen brew factory we can recycle yeast 8 times by multiplying the
old yeast by new yeast.

There are two major types of yeast to make beer

5. Saccharomyces cerevisiae (ale yeast)

6. Saccharomyces uvarum(lageryeast)

7. Saccharomyces cerevisiae
Saccharomyce scerevisiae yeastpreferswarmertemperature20-250candwillflocculantsonthetopof
beer after fermentation stop.

Saccharomyces uvarum (lager yeast)

This yeast preferatcoolertemperatureandwillflocculentatthebottomofbeerafterfermentationis

finished it can work around5 temperatures

25
2.2.9. Yeast propagation
The quantity of yeast required for fermentation is obtained by propagation of a pure yeast
culturethisconsistofisolatingsuitablevigorousyeastcellsandmultiplyingtheirnumber.Thepropagatio
n of yeast is applied by wort and it takes 20-26 day to propagate sufficiently. The length of the
day to perform fermentation depends on the age of the culture and amount of yeast added to the
fermenter in which it also determines the length of time in each phase of yeast metabolism.
Yeasts can be propagate by themselves wit in up taking nutrients like amino acids(from
fermentation substrate or synthesize by itself), lipids (from wort in few amount, acetyl coenzyme
A), molecular oxygen & they also need minerals for stabilizing of their enzyme system. Yeast
normally reproduces by budding. When budding occurs a small bubble like protuberance from
the mother cell is formed into which part of the cytoplasm as well as a daughter nucleus, formed
by division, passes. In some yeast strains the mother and daughter cells separate from one
another completely, in other strains the cells remain connected to one another and form chains.
When the yeast is pitched into fresh wort in the brewery they begin to grow.

26
Figure 3 yeast fermentation

This growth does not occur at a constant rate but is divided into six phase.
Yeast Growth Phases
1. Lag Phase - The yeast cells metabolism becomes active, the length of this phase depends on
the type of yeast, its age and the conditions within the wort. The lag phase ends with the first cell
division.

2. Acceleration Phase- The rate of cell division continuously increases.

3. Exponential Phase - The growth rate is constant and at a maximum. The cell number
doublesevery90 to 120 minutes.

4. Deceleration Phase - Because of various factors such as the reduction in the amount of

27
Nutrient and increase in the amount of growth in hibiting products, the lag Phase occurs for
only a limited time. Then the growth rate gradually decreases.

28
5. Stationary Phase-There is a balance between the number of newly formed cells and the cells
which die.

6. Declining Phase-In this last Phase the rate of cell death exceeds the rate of new cell
formation.

Condition ing maturation)

Small amounts of remain yeast continue to consume by products of initial fermentation

Conditioning or aging, development of flavor. When the sugars in the fermenting have been
almost completely digested, the fermentation slows down and the yeast starts to settle to the
bottom of tank. At this stage, the beer is cooled to around freezing, which encourages settling of
the yeast, and causes proteins to coagulate and settle out with the yeast. Un pleasant flavors such
as phenolic compounds become in soluble in the cold beer ,and the beer’s flavor becomes
smoother.

2.2.10. Filtration
The beer is then passed through a filtration system to remove surplus yeast and protein. Filtration
is a separation process in which the yeast cells and other turbidity causing materials still present
in the beer are removed from the beer. At the same time substances are removed which would, in
the course of the next few weeks or months, themselves precipitate and make the beer turbid.
Filtration stabilizes flavor and gives the beer its polished shine look. When tax determination is
required by local laws, it is typically done at this stage in a calibrated tank. Filtered beer is
qualified to be stable. That means there is no active process going on since all conditioning has
stopped when the yeast and other enzymes are removed in the process. Filtration can also remove
poly phenol and haze material at the same time substance are removed which would them selves
precipitate that makes beer turbid.

Reason for filter beer

 For test stability

 For foam stability

 For uniformity of product

29
 For long shelf life

30
  For polished shine look

 To get qualified stable beer

Dashen brew share company use four types of filtration

8. Beer membrane filtration (BMF)

9. Security filtration

10. Poly vinyl polypeptide(pvpp)

11. Bag filtration

a. Beer membrane filtration

Recent machine used to filter yeast protein without heal influence that trap protein and yeast
that is greater than 5ppmin size this filtration can filter 400hl/hr in dashen.

Advantage of beer membrane filtration

 The quality unchanged by filtration

 For natural fresh test

 To ensure complete confidence in beer stability

 For its marketable

 It is recently become very economical

b. Security filtration

Used to remove yeast, protein and haze particle that is less than 5ppm to ensure complete
confidence in beer stability and marketing. BMF filtration and security filtration also known as
primary filtration.

31
 c. Poly vinyl poly peptide filtration(PVPP)

It is also known as secondary filtration to ensure satisfactory clean and bright beer without any
visible particle or haze. PVPP is water insoluble powder used to remove poly phenol responsible
for turbidity to preserving high quality of beer.

32
 d. Bag filtration

Used to filter the precipitated hop and caramel when it added in to dosing tank in order to adjust
color and bitterness of beer to get acceptable and high quality of beer.

UN
Filteredbeer tank Securityfilte
Filterbeert BMF PVPP
r
ank

Dosingtank

Pasteuriz Carob Bagfilter

ation BBT lindi
ng

Figure 4 Bright beer tank (BBT)

The filtered beer is pumped to the pressure storage tank (bright beer tank) and stored for two or
three days in it. Bright beer tanks are buffer vessels between the filter and filler. They are
constructed as vertical chrome nickel steel tanks without internal fittings and the entire cellar is
cooled to 0 to 200c in a jacketed system. The bright beer tanks are the last stations before
filling .There are no safety devices after them. All safety measures must therefore be built in to
them. These include

 The tanks must be thoroughly cleaned by a CIP system

 The cleaning must be carefully controlled

 The tanks must have a smooth internal surface(little surface roughness)

 The tanks must be previously counter pressured with CO2 there must not be the oxygen

33
 In this brewery the brightening tank is identical to the fermentation tanks in structure but the
fermentation tank is not continued in the brightening tanks. There are five new BBT (bright beer
tank) with capacity of 2400hl. There would be cooling jackets on the sidewall of each tank which
would be hooked up to the chiller. The brightening tank’s main use is to take the filtered beer
produced from the fermentation tanks and store it for carbonation. CO2 would be drawn from an
outdoor holding tank and injected into the brightening tank in order to further carbonate the
fermented beer.

2.2.11. PASTEURISATION:

This is a process of heating and rapid cooling which prolongs shelf-life and destroys any bacteria
or other organisms in the beer. Draught and bottle beer is pasteurized by means of a special heat
exchanger called a flash pasteurization.

Beer can be pasteurized in two ways:

1. Flash pasteurization

2. Tunnel pasteurization

CHAPTER THREE

3. Packaging house

Bottle beer are filled in bottle where as drought beer are filled in kegs if the quality of beer is
achieve d in the bright beer tank is to be maintained in the filled bottle cane or keg.

The following rule must be observed during filling

1. During filling everything must be still be done to keep air away from the beer even small
amount seriously affect the beer.
2. During filling the room must be clean and free from oxygen if we can
34
 3. Every one must wear the safety like hair neat, eye glass and other

There are two types of filling and packaging process in dashen brew Share Company

1. Bottle filling

2. Keg filling

3.1 BOTTLEFILLING

Bottle and create from the customer Depalitizer unpaker create Crate washer

Bottle

Lable paper &glue Bottle washer water,NaOH

Paratisizer packer labeler Filler Beer,CO2
Crate
Figure 5 packaging room
Packaging proc eparatiser
It works by pneumatic system by comprised air at pressure of 5.5-6 bar. It is small machine also
known as raw separator when the foric lift transfer the crate that contain empty bottle in the roller
conveyer transfer the crate in to the grad place that is also known as safety center. the gripper
transfer crate from the roller conveyer in to plate conveyer at once the griper can hold 10 crate its
load is easy to transfer because crate contain empty bottle .to hold the crate that contain empty
bottle the griper need two piston.

UN packer

UN packer machine is one types of machine used to separate bottle from crate by griper. After
griper separate bottle from the crate bottle transfer to bottle washer and crate transfer in to crate
washer. UN packer machine work by pneumatic system by comprised air.

35
Crate washer

Empty crate transferred from UN packer machine in to crate washer by conveyer. Empty crate
from UN packer are washed with hot water at 50 and caustic soda acid inside the crate washer to
remove broken glass and any other microorganism.

Bottle washer

36
 It is the biggest machine in Debre berhan brew Share Company used to clean the bottle to get
germ free ,clean bottle, residue free bottle by different step. Bottle washer machine used
chemical in order to clean bottle like NaOH, deformer antirust.
. In dashen brewery company we used KRONS LAVATIC KD5model and KHS recent bottle
washer machine it can wash 49,500 bottle per hour.

Factor affecting bottle washer machine

There are so many factors that affect bottle washer machine

1. Temperature

2. Mechanical effect

3. Effective cleaning agent

4. Exposure time

5. Conductivity

1. Temperature
Caustic temperature is between 80-85 in order to remove the liable and dirt particle from the bottle.
If the temperature is not between them the machine will be damaged

37
 2. Conductivity

When we increase conductivity it can cause foam, but when we decrease conductivity cleaning is
less than it needs medium conductivity.

In general Bottle washer machine has3sensors

1. Infeed monitoring sensor

2. Temperature sensor

3. Discharge monitoring sensor

Filler machine
Filler machine a machine used to fill beer and carbon dioxide to empty bottle those beer and
carbon dioxide coming from brew house but bottle coming from bottle washer machine. Be fore
bottle coming in to filler machine we used phinophtalen indictor in order to cheek presence of
base in the bottle if there is base the color changes to pink if not the color is color less.

Empty Bottle Inspection (EBI)

It is small, very complex and expansive machine used to separate unclean bottle, foreign
bottle ,broken bottle and liquid contain bottle by capturing the bottle in camera.

Thereare7 processes in filler machine that is

1. First evacuation it remove90%of oxygen by punching pump from empty bottle

2. Purge with co2the bottle cleaned byco2toremoveo2from the bottle

3. Second evacuationremove9%of o2

4. Pressurization close the bottle to protect the inlet ofo2into the bottle

5. Filling tube and centering bill used to fill beer and carbon dioxide

38
 6. End of filling beer and carbon dioxide

7. Shafting remove the bottle from pressure

value Cork machine
It is used to close full bottle. It has 18 cork head to cork the bottle its speed is very fast relatively
filler machine, because filler machine can fill 120 bottle per cycle but cork machine can cork 18
bottle per one cycle.

Full Bottle inspection(FBI)

It has sensor this sensor send message for cheek mate, this cheek mate used to cheek under
fill,over fill of bottle and also cheek uncork bottle if it present. Next to that cheek mate
sendmessageto pusher sensor then pusher separate under fill, overfill and uncork bottle.

Material used CIP

 Caustic soda

 Warm water

 Col d water

 Co2 to remove o2after cleaning

39
Labeling machine

Labeling is the display of information about the producton its container, packaging or the
product on itself on the bottle. It is also the process of putting the label on the bottle name of the
company which company produces the product .The input material of labeler machine

1. Glue

2. Labeler paper

3. Packed bottle beer

Glue

Glue comes from foreign from Germen country. Glue is adhesive agent used to attach the label
paper in the bottle. The temperature is 26-300c

Labeler paper

Display name of the company in which company it is made and also display alcoholic
concentration per volume. Packed Bottle transferred from filler machine is labeled in to labeler
machine. There are 3 aggregates station in dashen brew share company that is neck station (neck
lable) body station(body label)back station(back label

Video Jet

It is small machine used to print them manufacturing date and expired date of the beer.Generally
shelf life of the beer like that is best before.

40
 Packer machine
Packer machine is a machine it can work by pneumatic system by compressed air at the pressure of
5.5-5.6 bar. It received a labeled bottle from bottle table in to the insertion frame by gripper
system. The gripper holds the packed Bottle in to the crate once a time it insert five crate.

Palletizer machine
Palletizer is one component to machine in Debre berhan Brew Company it can work by compressed air
that is pneumatically by compressed and expand of the diaphragm. It is also known as grouping section
meaning that it collects the crate up to the crate number is ten. Once the griper can hold 10 crates in to the
pallet next to that fork left take 0tft machine is a machine stored a beer in kegs. Believe it or not
draft beer is made the same way as bottled beer. Draft beer just means that the beer is stored in a keg and
served via the sprout of beer faucent. A beer that served straight from a keg is often considered better
quality than most other beer because very secured packing, where either son light or oxygen cannot
penetrate the keg. This machine able to produce 400keg/hr. has 2 month validity.

The main components of draft machine

2 Filling head
3 Cleaning heads
4 Valves
5 Intake station
6 Walking beam
7 Out let station
Stapes of keg filler lines

41
 Ware house Keg turner Keg decapper Keg washer
Residual
pressure
Checker
j

Keg filler Keg weigher Exit turner Co2 leakage detector

Keg capper
Ware house INKJET

Figure 6 keg plant

Ware house- a place where many empty kegs stored coming from customer or any keg
production. Empty kegs on depalitizer machine, in one pallet put 15kegs at a time

Keg turner ( infeed turner )- turner enables empty kegs to be put on to keg line in an
ergonomically efficient way.

Keg de capper- after the keg is turn down then there is a cap comes from customer de capper
removes that cap in order to save the next step (remove any possible caps).

Keg washer- clean external keg parts by water caustic (NaoH and KOH). An important machine
to guaranty the best parameter of hygiene and safety to the beverage we are storing in to kegs.
Check caustic conductivity and spry jet and bush.

42
Figure 7 keg washer

Residual pressure check- the pressure remaining in a pipe during flow condition. Used to hold
pressure against spring in the drum (unwanted components) will sack.

Keg filler- keg is below the pressure in the supply keg the filler stop assembly a small hole that
meter the gas from receiving keg slowly in order to minimize foam.

43
Figure 8 Keg filler

CHAPTER THREE

3.Utility

3.1.Air compressor
Air from the atmosphere is sucked by micro tower and filtered by dust filter in order to remove
undesired particle. The filtered gas is transferred to vacuum suction by pressure difference which
enables to transfer the sucked air to desired location. The air is transferred to compressor in order
to be comprised. The comprised air transferred to reservoir tank in this tank water is removed by
manually opening the valve. After water is separated from air, air transferred to first air filter this
filter remove water and dust particle. After separate water, air is transferred to dryer. Drier is
used to dray air by heat energy in order to avoid moisture content. Then the dry air transferred
into 2nd and 3rd air filter in order to remove moisture content completely. Finally the comprised
air stored in to vertical air receiver tank. Generally compression takes place in compressor
44
actuallythecompressionofgasfromlowconcentrationtohighconcentrationorfromlowpressuretohig
Pressure at thes time temperature of air rise from low to high.

45
Air from the Air compresser
enviroment
prersor Receiver tank First air filer

Vertical air 2ndairfilter Dryer

3rdairfilter
receiver

Figure 9 Processflow diagram of air filter

After air is compressed it stored in vertical receiver tank and used for pneumatically valve, sieves
in malt pretreatment and packaging like pal and de pal.

Carbon dioxide recovery

In this plant carbon dioxide produced in fermentation is recovered (treated). Carbon dioxide
recovery plant consist of foam it must be separated by foam separate in which the foam particle
carried over are removed while the gas collect in a large carbon dioxide container. Then the
trapped carbon dioxide inters in to balloon (storage). Balloon has liable sensor to adjust the start
point. When amount of carbon dioxide in the balloon is 15% the transfer of carbon dioxide from
balloon to boost compressor is stop and also the amount of carbon dioxide is between 16-64%the
compressor automatically start up, but the amount carbon dioxide in the balloon is greater than
91% the third compressor startup due to over load of gas. Boost compressor used to transfer
carbon dioxide from storage in to gas washer. In gas washer carbon dioxide washed (showered)
by process water to remove odor, color and other impurities aroma of the gas. In gas washer tank
water and gas separated with gravity difference, meaning the density of gas lower than density of
water then water removed at the bottom by pneumatic valve. Then after separation of gas and
water, gas transferred in to carbon dioxide compressor, but water transferred in to waste water
treatment. In carbon dioxide compressor the temperature of carbon dioxide rapidly increase
itreaches1400candalsopressureincreasemeaningthattemperatureandpressuredirectlyrelationship.D
uetohightemperaturecarbondioxideneedcondenserthiscarbondioxidecondenser condense by

46
Figure 10 ballon

ammonia by shall and tube heat exchanger in which carbon dioxide in ontube side and ammonia
on the shall side. In this heat exchanger pressure approximately 18
barsandtemperaturereaches240thiscondensedcarbondioxideisfollowingbygravityintostorage

47
tank. This condensed carbon dioxide also needs extra cooling by glycol. The cold carbon
dioxideneed dryer in order to remove moisture content of carbon dioxide. After that the
condensedcarbon dioxide need re boiler in order to remove amount of oxygen mix with carbon
dioxide nextto this carbon dioxide need cooling in order to change the gas in to liquid the liquid
carbondioxide store in carbon dioxide storage. This storage can hold 60hl liquid ammonia, but
thegaseous carbon dioxide need condenser to change the hot gas in to cold gas by
evaporativecondenserthis coldgas usedforbrew housefor carbonblinding, packaging in filler.

Carbondioxide CO2
Foamseparator Boostcompressor
fromfermintation balloon

Carbon dioxide
gaswasher

Carbondioxideco
mpressor

Shall and
tubeheatexchanger

Figure 11 co2 recovery

cooling Carbondioxide
reboiler Dryer Pre
coolerwithglycol

Evapo
HotGas condenser Used for
brewhouseandpackaging

Liquidstorage 48
Fig2.8.Carbondioxide recoveryflow diagram

49
 3.2.1 Refrigeration(cooling)
Refrigeration is the process of removal heat energy refrigerant is a closed circuit. During its flow
through the circuit refrigerant t change state twice. When the refrigerant is liquid it evaporate to
gas after that gas condense again to liquid up on the computation two cycle starts over again. Itis
a continuous process.

Compressor

Compression takes place in the compressor and actually the compression of gas from low
pressure to high pressure at the same time temperature of gas rise from low to high.

Condenser

In condenser the refrigerant gas condense to liquid at high pressure and temperature to liquid
condensation takes place from saturated gas to saturated liquid. The condensed heat is transferred
to the atmosphere.
.
Pleat heat exchanger

In this unit ammonia and glycol exchange heat. Glycol gain heat from hot ammonia than glycol
transferred to yeast propagation tank, wort cooler, flash pasteurization, but ammonia transfer
into low pressure separator. High pressure ammonia receiver liquefied in to evaporative
condenser will collect in to vessel cold high liquid receiver.

50
Boiler

Boiler is an apparatus that generate heat usually by burning fuel or by electric and use it to heat
circulating water. Boiler used to produce steam for space heating produce steam for heating
produce power generation in industrial process. There are two types of boiler that is fire tube
boiler and water tube boiler. In fire tube boiler fire inside the tube water is outside the tube
thereverseinwatertubeboilermeaningthatwaterinsidethetubeandfireoutsidethetube.Indashen Brew
Company we used water tube boiler. Boiler feed water treatment has two main function the first
being prevention of scale on the inside of the boiler. The second being the prevention of
corrosion on the heat exchanger and other part. Many types of scale can be removed by acid
washing. Corrosion also known as silent killer corrosion cell can be present with no external
evidence until actual failure occurs. Prevention of scale formation being with the selection of
proper method for removing the scale forming ingredient of raw water. Sodium zeolite softener
has better methods removing Ca2+,Mg2+hardness the two scale formation. Water hardness
indicates the amount of calcium and magnesium scale former. Dissolve doxygen is a corrosion
accelerate that must be completely removed the solubility of oxygen with water decrease with
temperature. Therefore the de arated or feed water tank must heat the boiler feed water and
vented so that gases driven off can easily escape to the atmosphere. The reaming oxygen must
be removed by using oxygen scavenger. In dashen Brew Company there are three types of boiler

1. Electrical boiler

2. Fuel boiler

3. Biogas boiler
Electrical boiler
Thenamesayitiselectricalboileroperatingwithouttheneedoftheuseoffuelcombinationsuch as oil or
gas, but it use electric to generate heat in the boiler. Only electrical boiler use water and current
to generate steam it can use11kv of current to generate steam.

51
Working principal of electrical boiler

First the electric runs through a heating device that has a resistance property there for allowing
heat to be created by resistance. When heat is crated the water comes through a pipe from the de
arated water tank to the heating device or close to it to get heated up. After that water is hot
enough and starts to produce steam once. Several reason make electrical boiler good device in
order to produce steam with the following advantage .None dcombustion fuel the use of electric
city makes absolute the use of combustion fuel such as gas or fuel. It save space because this
types of boiler does not use combustion fuel it do not need to added fuel storage close to the
boiler.

Fuel boiler

The name says it fuel boiler operate with fuel combustion such as oil or gas rather than electric
current to generate steam. Fuel boiler need air, high voltage transformer, water. Water passed
through a coiled wire like tube next to this fuel and air passes in to the boiler by pressure after
that high voltage transformer or burner start to burn fuel and heated watered coil with heat
energy .There are three fuel boiler it can produce 4 tone/hr of steam of capacity each of
them .Biogas boiler not functional but an assumption to produce1.2 tone/hr capacity.

52
 Water ROW
treatment Water
softener

Process

Fuelboiler Condensate
tank

Bio gas boiler

Electric
boiler De
aerated
tank
SteamstorageKegline
tank
Coldline,Brewhouse

Packagingline

Figure 12. Simple flow diagram of boiler

Water treatment and waste water treatment

A. Water treatment

Water treatment is mainly the individual process that makes water more acceptable for an end
use which may be drinking industrial or used in industrial. Water treatment is used to remove or
reduce water contaminate and impurity found in the raw water, may be the raw is ground water.
In dashen Brew Company the main source of water is from borehole water( ground
water).This ground water transported from borehole to the company by using pump.Then the
53
water stored in resoriver tank. This tank can hold 1300m amount water, but groundwater
contains UN dissolved soil plant material which has passed in to the water. The
suspendedsolidcanberemovedbyclarificationinresiorvertank,asaresultthereductionflowvelocity6

54
the water suspended water carried slowly settle down large settling tank the more effective the
clarification with the same through put because the flow velocity decrease to zero. All suspended
particle cannot be removed in settling tank therefore it is necessary to filter the water after this
process.

Raw water tank

In this tank ClO2 was added to remove pathogen, microorganism in each tank .Meaning remove
micro organisms in which cause disease like protozoa bacteria and other microorganisms.

Multimedia filter

It is used to filter suspended solid from water that is transferred from raw water tank in this
filtration method the filter mediais sand.
Rawater

Sand in
d/tsize

Figure 13 Filtered water

 This filtered water used for back wash SBR tank

 Fire water tank

Treated water tank
It used a store the treated water from multimedia filter.Itcan use store water before transferred
into activated carbon filter. Treated water used for many purpose like

 Filtration backwash

 Service water

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  Wash water

 Reverse osmosis
Activated carbon filter

56
The tank is packed with activated carbon. It can remove odor, color, and test and also it can
remove chlorine from the water, because chlorine is not necessary in brewing industries.

Treated water tank

Activated
carbon

Pure water

It is the application of pressure to concentrate solution which causes the passage of liquid from
concentrated solution across a membrane. The membrane allows the passage of water, but not
the dissolved solid and also not contains Mg+2, Ca+2.The liquid produced is de mineralized water
which used for clean steam generator in brew house and boiler house.

57
 Groundwater

Resoriver tank

Raw water tank CLO2

Multimida filter

Treated water tank

Activated carbon filter

Ultra violet light

Process water

Figure 14 water treatment

Fig2.11.Process flow diagramforwatertreatment

58
B. Waste water treatment
Storage
Brew waste water contain many substance and dissolve many
substance .Brew waste water contain
 Brew and waste water residue

 Waste water contain trube

 Contain yeast and waste water from CIP plant

 Waste NaOH and acid from CIP

 Waste water and waste caustic from bottle cleaning

 Insolublesubstancelikepaperfromlabelercorkfromfillerandsolublesubstance adhesive like

glue, trace of oil.

This substance increase concentration of impurities in waste water. This waste water load require
large capacity treatment plant and regular cleaning cost in the form of increasing waste water
charge. This entire waste store in storage tank underground, in this tank there is screen channel
to separate solid part like paper, crock ,and broken glass.

Equalization tank

PH the reactor feed measured by ph sensor. If the feed(wastewater)p H is high acid is added in the
store before the waste transferred to equalization tank ,but the fee dph is low caustic soda is
added to adjust the ph of waste. After that the stored water transferred to equalization tank by
centrifugal pump. In this tank there is mixing of waste and acid or waste and base. After that the
adjusted waste transferred in to rapid mixing tank that is underground tank. In this tank there is
agitator to rapid mixing of solid and liquid. In this tank there is height sensor to detect the hegh
to waste water in the tank.

An anaerobic digester

It is also know ns anaerobic treatment .Without the presence of oxygen waste water is
decomposed by petrifying Bactria. This result the production of organic acid by hydrolysis

59
because of of it methane produced, but Methane is transferred to methane boiler .From this
sludge is transferred to sludge tank, but water transferred to SBR tank.

SBR tank

It is also known as aerobic treatment of water which can decompose by microorganism. After
that the water transferred to supernatant tank. In this tank solid completely separated from
liquid.

Storag etank

Equalization tank

More rapid mixing

Anaerobic digester Methane Methane boiler

Sludge tank
SBRTANK

Super natant
ttttank tank

DischargetoenvironmentFig2.Fi
gure 15 Processflowdiagramofwastewatertreatment

60
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CHAPTER THREE

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CHAPTER FOURE

4.1 The overall benefits gained from the internship

I got benefit from internship the primary significance of this internship program is to
hold ,improve and opens opportunity to apply the theoretical knowledge in to practical
knowledge .Since our hosting company is Beer factory we saw many things particularly which
we know theoretically about it. The factory has many sections which have their own specific
tasks but each section is highly entered connected to each other. During our internship we were
a member of each section worker turn by turn. Therefore we able to know the process and
working principle of the machines in the company. Generally the overall benefits we have
gained from the internship experience include the following related skills and thanks to
technology.

4.1.1 Improving practical skills:-

Within an internship period different activities are taking place in the company and I practice
those activities and act to improve their problems through finding solutions. improve my
practical skills in many aspects. That is the best layout of malt storage, raw material handling,
brew house, beer processing, bottling, keg plant, utility and final product storage room which
enables the best process flow, integrity among different sections

 We developed the habit of being safe at work.

 Acton solving problems and work flow practically

 Principles of quality control and the major parameters to taste finished products

4.1.2 Upgrading theoretical

This internship program provided us with the opportunity to expand our intellectual knowledge
and practical skills. The work we did was related to production of brewery the lecture mainly
discussed about two concepts analysis and design. There are different courses we learn before
internship these courses are improved practically acting up on them. It helped us to have deep
knowledge about production process starting from beginning to finishing. So, in this internship,
we had improved a lot of theoretical knowledge. Among these

 We had known the effect of maintenance on product quality, service life of the

64
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machine ,operator safety and productivity.

 Know practical the cause of loss of production due to problem of material handling.

65
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 Observe how they handle material in each production steps.

 The process of beer production

 Understanding the obligation and responsibilities of all section to

the company. . the way the organizational goal is achieved.
 Understandmotivationmethodologytobeusedforthecompanyworkerstoincreasetheproductivityl
ike
 Scaling up workers position based on their performance.

 Giving learning opportunity and other responsibilities

4.1.3 Entrepreneurship skills:-

Emphasizing the growth of entrepreneurship would not only lead to a new robust industry of its
own but also is a basis for improving the social and economic capability of the country. We had
a wide range of entrepreneur skills from above skills including personal traits and management
skills.

 The ability to manage time and people(both our self and others)successfully.

 The ability to work both as part of a team and independently.

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CONCLUSION
The overall internship program is very interesting. We have got so many things including this
program including practical and theoretical knowledge. Generally we staying in dashen
brewery during internship program have helped to improve all our personalities just like
interpersonal communication skills and team playing skills. We can generally conclude that
this internship program helps our to improve and develop

 Practical and theoretical knowledge

 Interpersonal communication skills

 Team playing ability skills

 Leadership ability skills and

 Work ethics related issues and time management

Recommendation

o I would like to recommende this company is that the company may primerly give a chance to the student that
practice the internship in debre berhan dahen breweries company because those students know all about the
company even some students have done up to the operation stage in order to minimaize the training time .
o And when yeast specialist dosing yeast in yeast propagation tank a movable dosing tank has not agitator and
shack with human labor so, to reduce energy make it an agitator and well shack gently.
o In flash pasteurization when the beer pasteurize in order to free from any microbes and keep beer shelf life, high
steam is vaporized so the company save this steam since it is very pure steam recycle into boiler room
o In brewing house the brew use raw material mainly hop import from foreign country germany but the company
have to use local gesho relative to hop by character and optimize hop by alternative sourse of changing Ethiopian
gesho

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CEC- ACRONYMS
BMF- Beer membraneFiltration
PVPP- PolyVinylPolyPeptide
CIP- Clean In Place
HE- HeatExchanger
SC- ShareCompany
FBI- FullBottleInspection
EBI- EmptyBottleInspection
UV- UltraViolet
AD- AnaerobicDigester
MS- MassofStem
TDS- TotalDissolved Solids
WHC- WaterHoldingCapacity

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REFERENCE
1. Wolfgang kunz-technology of brewery.

2. DennisE. ,ChrisA., Brewing science and practice.

3. Organic fertilizer textbook.

4. The operator of the brew departments of the factory.

5. www.mura technology.com.

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