BEER PROCESSING FLOW DIAGRAM

Operations and processes for beer:

Beer production in this flowchart involved processes such as malting, milling,
mashing, lautering, boiling, fermenting, conditioning, filtering, and packaging. The
objective of the process is to convert grain starches to sugar, extract the sugar with
water, and then ferment it with yeast to produce the alcoholic, lightly carbonated
beverage.
Steps involved in beer production are:
1. Malting:
 Beer is produced from barley grains.
 Barley grains are first cleaned and then soaked in water for about 2 days.
Then excess water is drained away and the barley are incubated for 4-5 days
to allow germination
 The germination steps allow the formation of highly active α-amylase, β-
amylase and proteases enzymes as well as various flavor and color
components
2. Kilning:
 The germinated seed are then killed by slow heating at 80° This process is
called kilning.
 The kilning temperature must not harm amylase enzyme. Furthermore, if
kilning temperature is higher, darker will be the beer produced.
3. Mailing:
 The dried barley grains are then crushed between rollers to produced coarse
powder called grist
4. Mashing:
 Grist is mixed with warm water and the resulting materials is maintained at
65°C for about 1 hour.
 In doing so, starch is hydrolyzed by amylase enzyme to produce single sugar,
maltose, dextrose etc. similarly, protein is hydrolyzed by proteolytic enzymes
into small fragments and amino acids.
 The liquid obtained by mashing is called wort. The husks and other grains
residue as well as precipitated proteins are removed filtration.
5. Boiling of wort:
 The filtrate is then bolied with stirring for 2-3 hours and hop flowers are added
at various interval during boiling.
 Reasons for boiling of wort:
o For extraction of hop flavor from hop flower
o Boiling coagulate remaining protein and partially hydrolyze protein and
help in removal of protein
o Boiling inactivates enzymes that were active during mashing,
otherwise causes caramelization of sugar
o Boiling also sterilize and concentrate the wort

6. Hops:
 Hops are dried female flower of hop plant Humulus lupulus. Approximately
one quarter pound of hop flower is added per barrel of beer and up to 2
pound per barrel of ale.
 Advantages of hop addition in beer are;
o Provide beer with its pungent and aromatic character
o Provide tannin which helps in coagulation of remaining protein
o Contains α-resin and β-resin which gives bitter flavor as well as
preservative action against gram Positive bacteria
o Contains pectin which is responsible for foam characteristic of beer
 JUICE PROCESSING FLOW DIAGRAM

Operations and processes for juice:

Drinks made from natural fruit juice, also known as "original juice," "fruit juice," or
"fruit juice with pulp," all follow roughly the same basic principles and manufacturing
procedures. Fruit juice production process mainly includes fruit raw material
pretreatment, juice extraction, clarification and filtration, homogenization, deoxidization,
concentration, ingredient adjustment, packaging and sterilization.
Steps involved in juice production are:
 Selection of fruit raw materials

o Fruit raw materials should have good flavor and aroma, stable color and
moderate acidity. In the process of processing and storage, they still maintain
these excellent qualities and have no obvious adverse changes.
o The fruit juice is rich and easy to take, and the extraction rate of juice is high.
 o The fruit is fresh and not rotten.

 Fruit juice extraction

o The purpose of crushing is to increase the yield of the juice.
o Pretreatment before squeezing: Heating or adding pectinase.
o The method of juice extraction varies according to the structure of the fruit,
the existence part of the fruit juice, the nature of the tissue and the quality
requirement of the finished product.

 Homogenization and degassing of fruit juice

o Determination and adjustment of sugar degree.
o Determination and adjustment of acid content.

 Concentration of fruit juice

o Vacuum concentration method.
o Freeze concentration method.
o Reverse osmosis concentration method.
o Aromatics recovery.

 Sterilazation and packaging

o The selection principle of sterilization process is to kill the microorganism
and reduce the effect on the quality of the product as much as possible.
o The most commonly used method is high temperature and short time.
o High temperature filling (hot filling) and low temperature filling (cold filling).
Carbonated beverages generally use low temperature filling. The fruit
drinks, except for the paper containers, are almost filled with hot filling.]
 ASPHALT PRODUCTION FLOW DIAGRAM

Operations and processes for asphalt production:

o The starting point of the asphalt drum mix plant process is the continuous
feeding of cold aggregates into the feeder bins. Aggregates have to be fed
as per the size into different feeder bins. The number of bins are three,
four or even more. The flow of aggregates from individual bins are
controlled as required by the mix material design. This flow is also
controlled and regulated from the control panel.
o Primary vibrating screen will screen the over sized material and
aggregates will enter the drum for heating and then mixing. The drum
mixer will evenly apply heat to the aggregates and then coat it uniformly
with bitumen as aggregates pass from one end of the drum. The drum unit
is inclined and rotating that facilitates easy flow of aggregates from one
 end to the other. Fuel for bitumen tank drum burner is stored in a separate
tank.
o Bitumen and filler material are the ones that are added into the drum for
mixing with aggregates. Bitumen is stored in separate tanks and then
added into the drum by a pipe line by a bitumen pump controlled by a
variable speed drive motor. Filler material is stored in separate filler
hopper and transferred by means of a compressor
o Pollution control is taken care by dry and wet type pollution control
devices. After proper mixing, the hot mix is discharged to the other end of
the drum and onto a conveyor. This conveyor takes the HMA into the
waiting trucks or storage silos.
o All these processes are controlled by a computerized control panel that
comes with the asphalt mix plant.
 LIME PRODUCTION FLOW DIAGRAM

Operations and processes for lime production:

Countries that are subtropical or tropical often grow a lot of lime. Due to the
market's glut caused by their seasonal availability, growers do not receive the full
benefit of their labor. Lime juice is a perishable item. In a state where they still fetch a
good price, it is frequently challenging to transport them to the fruit market. These
issues may be alleviated by making lime juice from the limes. Lime juice is extremely
acidic (pH 2.0), so there are few issues with food spoilage or hygiene. The technology
required is simple. Lime juice is a common ingredient in many dishes and drinks due to
its importance. To reduce waste, the skin can be added to lime pickle.
Steps involved in lime production are:
o The production of lime cordial requires the juice to be clarified in order to
produce a crystal clear final product. Crude juice contains fruit debris and
a cloud caused by fruit pectins. The raw juice squeezed from the limes
needs to be 'racked' - or allowed to clear thus allowing the crude solid pulp
to settle. Calcium carbonate is added at this stage. This reacts with the
fruit pectins and produces calcium pectate which settles with fruit solids.
o In order to preserve the juice during this settling time, sodium
metabisulphite must be added at the rate of 3g/litre to provide a sulphur
dioxide level of 1000ppm (parts per million). After dilution with sugar
syrup, described below, this level will drop to meet legal limits.
o Racking can be carried out in a large wood or food grade plastic tank with
a lid and a drain-valve above the level of the solids that have settled.
Racking time will vary, but three to five weeks is normal. It should be
noted that provided SO2 levels are maintained, the juice can be stored in
racking tanks for some considerable time, thus allowing a production unit
to concentrate on juice extraction during the height of the lime season.
o Next the racked juice is clarified by the addition of a small quantity;
2.5g/litres of calcium carbonate (chalk powder) which precipitates the
pectin cloud. After the addition of calcium carbonate, the juice should be
allowed to stand for 48 hours, to settle. The main problem at this point is
to judge the boundary between the clear juice and the sediment. Inclining
the tank as shown in Figure 2 will make separation of the clear juice more
efficient.
o Batch preparation and pasteurisation The batch is prepared by mixing
together clarified lime juice and a previously prepared sugar syrup, the
whole being pasteurised by heating to 80ºC for 5 minutes. At the end of
this stage it will be found that the original sulphur dioxide level will be
reduced so as to conform with the generally acceptable legal maximum of
350ppm. The subtle flavour of lime is sensitive to heat and it has been
found that the following system, which minimises the heating time, gives a
very acceptable product.
o The hot lime cordial should be filled into clean steam sterilised screw cap
bottles. The use of good quality lacquered or plastic caps is essential due
to the high acidity of the product, cheap caps will be found to corrode
within a relatively short time. A small capping machine can be
manufactured locally. The hot, capped bottles should be allowed to cool.
Forced cooling, with cold water, is preferable to simple air cooling as it
reduces flavour changes. The final product may now be labelled.
 DEMINERALIZED WATER PROCESS FLOW DIAGRAM

Operations and processes for water demineralization production:

Ion exchange is used to get rid of almost all inorganic salts in water during
demineralization. Strong base anion resin in its hydroxide form removes these acids
after strong acid cation resin in its hydrogen form transforms dissolved salts into their
corresponding acids. For most freshwaters, demineralization yields water of comparable
quality to distillation at a lower cost.
Steps involved in water demineralization are:
o In the presence of water, minerals and salts dissociate into their
constituent ions. These dissolved solids consist of negatively-charged ions
known as anions, and positively-charged ions known as cations, each of
which are attracted to counterions (or ions of an opposing charge).
Present within an IX column is a resin which consists of plastic beads to
which an ionic functional group has been bound. These functional groups
loosely hold ions of an opposing charge through mutual electrostatic
attraction. During an active IX cycle, a water with dissolved ions is
introduced to the resin. The ions in solution will exchange places with the 
ions on the resin beads, clinging to the resin’s functional groups even as
the resulting solution is drained away. IX happens when one ion has
greater affinity for the functional group than the ion that is already present.
The specific ionic contaminants present will dictate whether anionic and/or
cationic resin types are needed.
o In a typical IX reaction, the exchange of ions simply results in the
replacement of contaminant ions with other, less objectionable, ions. In an
IX sodium softening system, for example, the objective is to remove
hardness ions (e.g. Ca2+ or Mg2+) from solution by replacing them with
sodium ions (Na+). As a result, the treated solution will have little to no
hardness, but it will contain a greater concentration of sodium ions.
o While this is acceptable for many applications, some processes demand
near total removal of dissolved solids. That’s where demineralization
comes in. In demineralization, cations in the feed water are exchanged for
hydrogen (H+) ions and cations are exchanged for hydroxyl (OH –) ions. 
The result is water:  H+ + OH-OH → H2O. In general, demineralization IX
systems are available in either two-bed or mixed-bed configurations.
REFERENCE:

Beer processing PFD template. edraw. (n.d.). Retrieved February 27, 2023, from
https://www.edrawsoft.com/template-beer-processing-pfd.html

Fruit juice production process, Fruit Juice Processing Line for Sale. Avada Construction.
(2018, February 8). Retrieved February 27, 2023, from
http://www.fruitprocessingline.com/fruit-juice-production-process/

Home: Climate technology centre & network. Home | Climate Technology Centre &
Network. (n.d.). Retrieved February 27, 2023, from https://www.ctc-n.org/

How beer is processed. IFT.org. (n.d.). Retrieved February 27, 2023, from
https://www.ift.org/news-and-publications/food-technology-magazine/issues/2017/
november/columns/processing-beer

Juice and nectar - edrawsoft. (n.d.). Retrieved February 27, 2023, from
https://www.edrawsoft.com/templates/pdf/juice-and-nectar-pid.pdf

Karki, G. (2018, October 24). Brewing; beer production process. Online Biology Notes.
Retrieved February 27, 2023, from https://www.onlinebiologynotes.com/brewing-
beer-production-process/

Marshall, K. (2022, September 8). What is water demineralization and how does it work?
Samco Tech. Retrieved February 27, 2023, from https://samcotech.com/what-is-
demineralization-and-how-does-it-work/
 SAINT LOUIS UNIVERSITY
SCHOOL OF ENGINEERING AND ARCHITECTURE
DEPARTMENT OF MECHANICAL AND MECHATRONICS ENGINEERING

FLOW CHARTS OF OPERATIONS IN MANUFACTURING PLANTS

By:
SALINAS, MILTON D.
BS ME IV

Submitted To:
ENGR. BEA_ANN ANDDAYA
Instructor

In Partial Fulfillment
Of the Requirements for the Course
ME 4241: MANUFACTURING AND INDUSTRIAL PROCESSES
3294 (1:30-2:30 Pm MW)