MURREE BREWERY COMPANY LIMITED RAWALPINDI,

PAKISTAN

Report By:
Usman Sarfraz
BS Mechanical Engineering
Ghulam Ishaq Khan Institute of Engineering Sciences and Technology, Topi,
Swabi.

1
2
 ACKNOWLEDGEMENT

I am extremely grateful to Almighty ALLAH for providing me with the ability, understanding
and insight and blessed me whatever I have. All the praises for Holy Prophet Hazrat Muhammad
(PBUH) through which Allah, the Exalted bestowed upon us the blessings of Islam, Knowledge,
and awareness.

The internship opportunity I had with Murree Brewery Company was a great chance for
learning and professional development. Therefore, I consider myself a very lucky individual as
I was provided with an opportunity to be a part of it. I am also grateful for having a chance to
meet so many wonderful people and professionals who led me though this internship period. I
would like great gratitude to the General Manager and Murree Brewery Co. Ltd for their kind
permission to complete my internship under their supervision.

Also, I would like to express my gratitude to Mr. Khalid in Boiler and Pump section for
conveying their knowledge to me.

Special thanks to Mr. Imran (Assistant Manager HR), Mr. Qasim Ali (QC Manager) for
providing me with this great opportunity of learning. Also, special thanks to Murree Brewery
management and working staff for their sincere cooperation.
I perceive this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, to attain desired career objectives. Hope to continue cooperation with all of you
in the future.

USMAN SARFRAZ

3
 LIST OF FIGURES

Figure 1.1: Quality Council Management ................................................................ 1

Figure 2.2: Quality Vs Quantity ............................................................................... 1

Figure 3.3: Hierarchy of MBC ................................................................................. 1

Figure 5.5: Flow Diagram of Beer Bottling Hall 1 (BBH-1) ................................... 1

Figure 6.6: Flow Diagram of Beer Bottling Hall 2 (BBH-2) ................................... 1

Figure 7.7: Flow Diagram of Non-Alcoholic Bottling Hall (NABH) ...................... 1

Figure 10.1: Process Flow Diagram of Beer Production ......................................... 1

Figure 11.2: Process Flow Diagram of Brew House ................................................ 1

Figure 12.3: Process Flow Diagram of Still House .................................................. 1

LIST OF TABLES

Table 1.1: Products of Murree Brewery Company Ltd ............................................ 1

Table 29.28: Haze of samples (EBC) ....................................................................... 1

Table 30.29: Color of Samples (EBC) ..................................................................... 1

Table 31.30: Brix of Samples (o).............................................................................. 1

Table 32.31: Alcohol of Beer Samples (%) ............................................................. 1

Table 33.32: Bitterness of Samples (Bu) ................................................................. 1

Table 35.34: Standards of PET Plant ....................................................................... 1

Table 38.37: Standards of Non-alcoholic Beer Bottling Hall .................................. 1

4
 SYMBOLS AND DEFINITIONS

MBC: Murree Brewery Company

ISO 9001: Quality Management System
ISO 14001: Environmental Safety Standard
Halal: Food permitted by Allah in QURAN
HACCP: Hazard Analysis Critical Control Point
OHSAS 18001: Occupational Health and Safety Assessment Series
EMS: Environmental Management System
URS: United Registrar of Systems
HRM: Human Resource Management
CIP: Clean in place
QMS: Quality Management System
HSE: Health Safety Environment
CX: Chief Executive
GM: General Manager
TM: Technical Manager
QCM: Quality Control Manager
AC: Assistant Chemist
QCO: Quality Control Officer
AHS: Air in head space
R-OH: Alcohol Percentage
DO: Dissolved Oxygen
TDS: Total Dissolved Solids
TH: Total Hardness

5
 ABSTRACT
The Murree Brewery Company Limited was established in 1860. It is one of the most
important beverage industries of Pakistan which contributes to the GDP of the country. Murree
Brewery aims to have a good quality of products and it is providing different types of liquids as
alcoholic and non-alcoholic beverages. The internship was necessary for the completion of the
degree and for the professional skills improvement. The aim was the quality analysis of raw
material, and final products.

There are over 50 products of Murree Brewery Company and 5 production departments in
which the production and processing is done. Production departments include Brew House, Still
House, Whisky Plant, Spirit Storeroom and Maturation Cellar.

Production of malt (germinated grains of barley) is the most important economic factor in
the overall processing of malts and beer from the raw to the finished product. After kilning and
germination malt is converted into brew which is cooled and subjected towards fermentation to
produce alcohol and desired flavors for alcoholic beers production while for non-alcoholic malt
drinks are prepared by screening brew and addition of ingredients, carbonated non-alcoholic drinks
are prepared with the addition of flavours and colours. Aseptic sterilization takes place for the
complete removal of microorganism.

The drinks undergo testing and should possess appropriate characteristics for further
processing e.g., pH of Beer ranges from 4.2 to 4.5. Turbidity ranges from 0.01 to 0.9. Alcohol
percentage ranges from 3.5 to 7.5%. Dissolved Oxygen less than 0.3%. The color of the beer ranges
from 8.0 to 9.5 EBC. Brix of malt drinks is 10o. The pH ranges from 3.2 to 3.5. Turbidity ranges
from 0.01 to 0.9 EBC. Color ranges from 8.0 to 9.0 EBC.

This internship program helped me in polishing communication and professional skills, a

must-have to survive and make it big in the present world. It even gave a good understanding of
the behavior of workers when placed in different situations. It was a good opportunity to work on
the skill of patience. It helped in developing the kind of relations one needs to uphold in the
corporate world and it helped in building up the right attitude.

6
 INTRODUCTION

Company Profile
Murree brewery established in 1860, is the only industry in Pakistan which has the licence
of producing alcoholic products and alcoholic beers. Consequent to the British annexation of the
Punjab in 1849 from Sikh rule, and more so after 1857 when the British Crown formally extended
its sovereignty over India, a structured administration commenced in the Punjab. To meet the beer
requirements of British personnel (mainly army), the Murree Brewery was established in 1860 and
incorporated a year later at Ghora Galli, located in the Pir Punjal range of the Western Himalayas
at an elevation of 6000 ft. above sea level, near the resort town of Murree. MBC is engaged in the
production of alcoholic and non-alcoholic, carbonated, and non-carbonated beverage products.
Today, we are proud of holding ISO 9001:2008, ISO 14001:2004, Halal, HACCP & OHSAS
18001:2007 certifications.

The Murree Brewery Company has long stood commitment not only to customer
satisfaction but also to the fragile environment. Our Company is always motivated to invest in new
technologies to contribute and support the green economy.

Murree Brewery Company Ltd.

7
 History
• Consequent to the British annexation of the Punjab in 1849 from Sikh rule, and more so after
1857 when the British Crown formally extended its sovereignty over India, a structured
administration commenced in the Punjab. To meet the beer requirements of British personnel
(mainly army), the Murree Brewery was established in 1860 and incorporated a year later at
Ghora Galli, located in the Pir Punjal range of the Western Himalayas at an elevation of 6000'
above sea level, near the resort town of Murree.
• Between 1885 & 1890 the Company established Breweries in Rawalpindi & Quetta &
acquired an interest in the Oticum and (South India) & Norailiya (Ceylon) breweries. A
distillery was also established in the above period in Rawalpindi, next to the Brewery. The
Murree Brewery at Ghora Galli was therefore among the first modern beer breweries
established in Asia.
• Murree Beer proved to be very popular among the British troopers who were largely barracked
in the 'Galis' of these hills. The virtues of beer brewed from barley malt & hops as a light
alcoholic beverage were not lost on the local population who rapidly became avid consumers.
By the turn of the 20 centuries, the name "Murree" was famous for its beer in keg and bottle
in the bars, beer halls and army masses of British India. Murree Beer was first awarded a
medal for product excellence at the Philadelphia Exhibition in 1876, followed by numerous
awards over the past 140 years.
• In 1935, a massive earthquake demolished the Quetta brewery as well as substantial parts of
Quetta town, killing thousands of persons, including a number of our employees. At Ghora
Galli (Murree), the scarcity of water became an emerging problem. By the 1920s, brewing
was mostly transferred to the Rawalpindi brewery, but malting continued at Ghora Galli till
the 1940s, when this property was sold. This historic brewery built in Gothic style architecture
was burnt during the partition riots of 1947/48.
• Park Lodge, a handsome residential property was purchased by the company from Mrs.H.
Whymper in 1888. It was the principal residence and head office of the company till 1959,
when it was taken over by the Government of Pakistan to house the office of the President of
Pakistan. It remains an office of the Head of State of Pakistan from 1960 till the present day.
Two English families were closely connected with the founding of the original brewery.
Edward Dyer was the first General Manager of the company. He was also the founder of Dyer

8
 Meaken breweries, Si mLa hills. Edward Whymper, a member of this family was the first
person to climb the Matterhorn Mountain in 1865. The Rawalpindi brewery is blessed with
deep aquifers of good water. A railway siding was extended to the premises in the 19th
century, which is now derelict.
• Under the present prohibition law, only non-Muslims and foreigners are permitted to consume
alcohol. Notwithstanding the consequent reduction in demand, the Company decided as policy
to concentrate on product excellence. It was decided to modernize the plants. A Ziemann
(German) brew house was installed in 1967, 'Saladin' Box Malting in 1971. Also, in the late
sixties, it was decided to embark on an ambitious long-term program to mature Malt Whiskies.
• Over the past four decades white oak casks and vats have been procured from North America,
Australia, and Spain. Our two underground cellars now hold over half a million liters of Malt
Whisky for varying periods of maturation up to 12 years under controlled temperature
conditions.
• Another wave of modernization was undertaken in the 1990s. New beer canning and modern
bottle filling facility from Holstein and Kappert (Germany) was installed. Two units of alcohol
rectification columns for producing extra neutral grade of potable alcohol from Molasses were
procured from France and Italy, respectively, to give our Vodkas and Gins a qualitative edge.
Also in this period, the beer fermentation capacities were renewed.
• It is pertinent to point out that our basic beer fermentation system installed in the 1930s was
then at the cutting edge of this technology. Known at the time as the Nathan system, it
incorporates fermentation and the lagering of beer in a single double jacketed vessel. A
variation of this system is now in extensive use worldwide.
• Tops Food and Beverages a division of the Company was established in 1969. It processes
fruits and markets, fruit juices and allied food products. Two manufacturing units are in
Rawalpindi and Hattar (KPK) respectively. A Tetra Pak packaging facility was added in 2001.
The Hattar plant was installed in 1992.
• The plant is based on a Recuperative Melter and two Emhart I.S. container manufacturing
machines and has the latest quality control equipment for online inspection of containers. The
Murree Brewery is one of the oldest public companies of the sub-continent. Its shares were
traded on the Calcutta Stock Exchange as early as 1902 and is now the oldest continuing
industrial enterprise of Pakistan.

9
• In 1997-1998 and 1998-1999, we were judged among the top 25 performing public companies
by the Karachi Stock Exchange.

Vision
To fulfill customer requirements & expectations through Care.

Mission
We, the people of Murree Brewery Company Ltd, make personal commitment to first
understands our customers requirement then to meet and exceed their expectations, by performing
the correct tasks on time and every time through: Continuous improvement, Alignment of our
Mission & goals. Responsibility and respect of our jobs and each other, educating one another.

Certifications
The Murree Brewery Company Ltd has been certified from ISO 9001 (Quality
Management System), ISO 14001 (Environmental Management System), HACCP (Hazard
Analysis Critical Control Point), Halal (Food permitted by Allah in Quran on Muslims), OHSAS
18001 (Occupational Health and Safety Assessment Series).

Motto
“We respect our past. We are the industry leader in present and accepts the challenges of
the future.”

Quality Policy
• Updating of employee skills by training

• Acquisition of new technology

• Re-evaluation of its quality control and quality assurance system

• Prepare the best quality products, believing that quality is priority and will take all steps
to encourage quality consciousness.

• Meet all applicable regulatory requirements and system standards.

• To recognize that our workforce is our strength.

• To satisfy the customer.

10
 • Continuously improve the skills systems and business of the organization.

• They are committed to consistently meeting their customer’s needs and expectation on
product quality and performance of optimum cost through their competent human
resource and continual improvement of process and system.

Environmental Policy
Murree Brewery Company is committed to environmental leadership and providing quality
products in a manner that ensures a safe and healthy workplace for our employees. This requires
the commitment of everyone working in this institution to pursue our activities safely to minimize
our potential impact on the environment (Alloway B, Ayres DC. 1997). We will operate in
compliance with all relevant environmental legislation and will strive to use pollution prevention
and environmental best practices in all we do. We will:
• Integrate the consideration of environmental concerns and impacts into all our decision
making and activities.
• Promote environmental awareness among our employees and encourage them to work in
an environmentally responsible manner.
• Train, educate and inform our employees about environmental issues that may affect their
work. encourages efficient use of energy, utilities and
• Natural resources particularly those that are non-renewable,
• avoid unnecessary use of hazardous materials and products, seek substitutions when
feasible, and take all reasonable steps to protect human health and the environment when
such materials must be used, stored, and disposed off,
• Purchase products and services that do the least damage to the environment and encourage
others to do the same,
• Convey to our customers, industry associates, vendors, and public our strong
environmental safety and health commitment,
• Strive to continuously improve our commitment to the above stated principles through
exercise of our EMS, improved technology, production changes and due diligence.

11
 Environmental Management Certificate
Murree Brewery Company is EMS ISO 14001:2004 certified by United Registrar of
Systems (URS), an internationally recognized institution for ISO certifications. This
environmental standard ensures that we not only comply with the legislation, but also excel in this
area by achieving targets and objectives higher than those specified in the standard.
Murree Brewery Company has received the 9th Annual Environmental Excellence Award
2012 for its excellent track record, services, and performance on Green Economy.

QUALITY MANAGEMENT SYSTEM

Quality and food safety policy

We the people of Murree Brewery Company make the personal commitment to first
understand the customer requirements to provide safe, hazard free products through.
Quality purchases of raw materials and by processing under hygienic conditions in order
to meet and exceed customer satisfaction through the implementation of HACCP system by
fulfilling national and international legal requirements, by performing the correct tasks in time and
every time through.
• Continuous improvement
• Alignment of our missions and goals
• Responsibility and respect for our jobs and each other
• Educating one another

Quality management system certificate

Murree Brewery Company has received QMS ISO 9001:2008 certification by United
Registrar of Systems (URS) for our quality management system. This system focuses on continual
improvement and customer satisfaction by ensuring that our products, processes, and services meet
and exceed our customers' expectations. This is achieved through implementing a broad range of
quality management procedures and product quality is monitored by reviewing the past
performance of our key suppliers as well as our own performance.

Food Safety Management

Murree Brewery Company has implemented HACCP system to cover important elements
to ensure food safety, interactive communication, systems management, control of food safety

12
hazards through pre-requisite programs. This demonstrates our ability to control food safety risks
and ensures that our products are safe for our customers to enjoy.

Safety, Health, and environment

We are strongly committed to conducting our business in ways that provide all personnel
with a safe and healthy work environment. Our HSE management system ensures worker safety
and incidence of occupational injuries and illness. Our systematic approach to manage
Occupational Safety & Health under well-defined standards and requirements.
We have integrated safe working practices in all the corners of our organization by
developing a rigorous set of operational controls to manage the known aspects and risk of all
operations. Full implementation of these controls ensures that we are providing a safe workplace
for our employees.
This HSE management system also recognizes the risks and mitigation controls unique to
our operations. Our cross functional team is a part of integrated management system which
incorporates food safety, quality, environment & occupational safety, and health into a single
framework. Periodic internal audit process helps us to implement our operational controls and to
assess the compliance status of our manufacturing operations with applicable laws and regulations.
We often do safety meetings and toolbox talks with our workers and maintain best health and
safety culture in our organization.

Quality Council MBC

Figure 1.1: Quality Council Management

The council is referred to as the central laboratory in the organization. The central
laboratory is concerned with the Research and development division. The Primary of the central
laboratory is the assurance of the quality of the product and keep a constant watchful eye on the

13
production of the product. Quality and quantity are the two main factors of bottling. BS (bottling
superintendent) is responsible for the quantity of the filled bottles and QCM (quality control
manager) is responsible for the final quality of product.

Figure 2.2: Quality Vs Quantity

Figure 3.3: Hierarchy of MBC

14
 Products
The Murree Brewery produces a wide variety of Beer’s, Liquor’s, and non-Alcoholic
products. Premium Products include Murree Beer, Classic Beer, Millennium Beer, Wheat Beer,
Special Strong brew, Stout Beer, Lite Export Pils, Twelve & Eight years old single Malt Whiskies,
Vintage with a blend of a scotch Grain Whisky, Murree’s Vodka, Murree’s Green Apple Vodka,
Silver Top Gin, Bolskaya Vodka and Doctor’s Brandy etc.

Table 1.1: Products of Murree Brewery Company Ltd

Lemon Malt.
Apple Malt.
Peach Malt.
Non-Alcoholic: Strawberry Malt.
Cindy Malt.
1. Beer Malt - 79.

Strong Beer.
Alcoholic: Millennium Beer.
Classic Lager Beer.
Wheat Beer.
Murree Beer.
Stout Beer.
Light Beer.
VAT Whiskey.
Malt Whiskey.
1. Liqour Alcoholic Products: Vodkas.
Gin.
Bigg Apple.
Bigg Lychee.
1. CSD Carbonated Soft drinks: Bigg Anaar.
Bigg Ice.
Bigg Peach.

15
BEERS:
Following are the types of beer:

1) Murree Beer

An all-time favorite since 1860. Alcohol contents 4.5% v/v.

Brewed from local six row barley, malts, and Bavarian hop products.

Has a distinctive taste and flavor.

2) Murree’s Classic Larger Beer

Premium beer, inputs identical to the millennium Beer.
Alcohol 5.5% v/v. A real classic.
Taste and flavor close to classic European lagers.

16
 3) Murree’s Millennium Beer
Our flagship beer 6.5% Alc. v/v. Brewed from highest grade Australian malt and Hallertau a
German Hops.
The millennium is celebration brew for special occasion.

4) Murree’s Light Beer

Murree’s Light beer is lowest in the alcohol percentage with 3.5% alcohol.

5) Murree’s Special Strong Beer

Special strong beer contains 7.5% alcohol. Product with highest alcohol percentage.

6) Murree’s Wheat Beer

Wheat beer is the only beer of Murree Brewery which is brewed by wheat. Wheat beer contains
5.5% alcohol content. It is cloudy and hazy therefore no turbidity test is done.

17
 7) Murree’s Stout Beer

Stout beer is the only beer with caramel color added in it.

The alcohol percentage in stout beer is 5.5%.

• VODKAS
All Vodkas of Murree brewery contain 43% alcohol v/v.

• Gins:
All Gins of Murree brewery contains 37% alcohol v/v.

18
• WHISKYS
All Whiskies of Murree brewery contain 43% alcohol v/v.

• CSD (Carbonated Soft drinks)

• MALT DRINKS

19
 • Murree’s Rum and Murree’s Doctor’s Brandy

• Lite Export Pils

Lite export pills are brewed from continental malts and hops. Correspond in flavor and
quality to the famous beer brewed in Pilsen, Czech Republic. It is an ideal summer drink.

QUALITY ASSURANCE DEPARTMENT:

Following points highlight yhe Quality Assurance Department:

a. Priorities of Quality Assurance Department

Q.A Department is the backbone of every food industry that ensures quality products. The
following are the main functions of the quality assurance.
• Inspection of the incoming raw material using physical, chemical, biological, and sensory
tests procedures.

20
 • Inspection of the production during manufacturing process.

• Research and Development.

• ISO, HACCP, GMP, GHP application.

• The sanitation department runs according to QA department. QA department also

inspects utensils cleaning, personal hygiene, and CIP.

b. Laboratories in Quality Assurance Department:

There are 5 labs which are as follows.
• Central laboratory.

• Line control laboratory.

• Microbiology laboratory.

c. Central Laboratory:
All the incoming raw materials are tested for their predefined Murree Brewery’s quality
standards. If the incoming raw material fulfills the quality requirements, then the product is passed
if not then the product is failed and returned to supplier as no compromise on quality inputs. pH,
TDS, Hardness, Chlorine of boiler water & Tap water are tested, and a daily report is sent to the
Boiler Engineer. pH, ROH, Color, Haze, CO2, Brix is also tested in the laboratory.

d. Line Control Laboratory:

This is a very critical lab for checking the online production in the NABH and BBH hall
for its best-defined quality. The instrument that is used in the lab is calibrated according to the ISO
standards. The titratable acidity, brix, CO2, Steam Pressure, pH and filling temperature of the
product is noted if it matches with the predefined standards then well and good if not then the
production supervisor is given the suitable suggestions to adjust these parameters.

e. Microbiology Laboratory:
Microorganisms play a very important role in beer production, not only deteriorates the
products but also create health hazardous. Microbial testing is carried out to determine the safety
of workers, products and process and working environment. Moreover, water and Air microbial

21
load is also checked on monthly basis. All microbiology tests are carried out in the micro
laboratory.
Yeast growing is done in this lab. The temperature and air and light is under control
conditions.

BOTTLING HALLS OF MURREE BREWERY

1. Beer Bottling Hall 1 (BBH-1)

2. Beer Bottling Hall 2 (BBH-2)

3. Non-Alcoholic Bottling Hall (NABH)

4. PET Plant.

• Beer Bottling Hall 1 (BBH-1)

In BBH-1 only can filling is done i.e., 330 mL, 500 mL.

• Non-Alcoholic Bottling Hall (NABH)

In the Non-alcoholic Bottling Hall only non-alcoholic beverage filling is done.

Figure 6.7: Flow Diagram of Non-Alcoholic Bottling Hall (NABH)

22
Rinser

Here empty bottles are washed.

Screening 1

Screening of empty bottles is done to check the impurities like dust particles.

Screening 2

Screening of filled bottle (check the particles).

23
Pasteurization
Pasteurization is a process of heating a beverage to a specific temperature for a definite length of
time, and then cooling it immediately. This process slows microbial growth in beer/malt drinks.
Pasteurization is not intended to destroy all pathogenic micro-organisms in the food or liquid. In
that unit, the temperature gradually increases and decreases from 25 to 60oC. Pasteurization is done
in 4 to 5 zones with ranging temperatures from 25 to 60oC.

Labelling

Labelling of glass bottles is done after pasteurization and drying. Labels are applied by the label
machine.

24
Screening 3

Screening of final product in bottle (again check the particles).

Packaging

Packaging is done automatically by the Samovi packing machine.

• PET Plant

The polymer used in the plastic bottle is actually pet abbreviated as Polyethylene teraphthalate
that’s why named as PET plant. There are four sizes of bottle used in the pet plant i.e. 300 mL,
500 mL, 1000 mL and 1.5 liter. Bigg apple and Bigg Lychee have all the four sizes. There are 5
flavors i.e Bigg Apple, Bigg Lychee, Bigg Anaar, Blitz, and Bigg peach. Bigg apple and Bigg
Lychee are the famous products and mostly used. The shelf life of all these products are 6 months.
Full efforts are employed to remove oxygen from the product. If oxygen is present in the product,
it will cause the growth of bacteria and fungi. The filling temperature is less than 10oC. Basically,
it is called carbonated soft drink (CSD) plant. If there is no CO2 in the drink, then there is no CSD
drink.

Rinsing

Empty bottles are passed to rinser through air conveyer and are washed.

25
Filling

Counter pressure filling of carbonated soft drinks is done on pet plant. Other types of filling are
vaccum and gravity filling.

Drying

Wet bottles are dried here.

Warmer
o
Warmer is used to increase the temperature of filled bottles to 27-28 C. Pasteurization is not
necessary here, because it’s synthetic products and there are no chances of microbial growth.
Screening

Screening of final product in bottle (check the particles).

Packing

Manual packing is done on pet plant.

a. Batch Room:
The water used in the batch room comes from a tube well treated with Reverse osmosis process
and all the impurities are removed from it. Syrup is prepared in the batch room. First of all, add
water in the syrup tank up to the specific level. The required amount of sugar is added in it. Sodium
Benzoate is added as a preservative and increases the shelf life of the product. Citric acid is also
used which increases the acidity in the drink. Color and flavor are also added. All these ingredients
are added as per recipe. Mix all the ingredients in the syrup tank. After this filter the syrup so there
should be no impurities in it. Transfer it to the syrup tank. Here steam is applied, and agitators are
used to mix all the ingredients. 1 hour mixing time is required for uniform mixing of all ingredients.

26
And then transfer it to the storage tank. From storage tank with the CO2 pressure the syrup is
transferred to carbocooler.

b. Carbo Cooler:
Carbo cooler is the very crucial machine used here. It is also called the heart of the process.
All the functions perform here like mixing syrup, punching of CO2, low temperature etc. syrup in
carbocooler have 50o brix. Water is mixed in the syrup to dilute it and maintain the brix required
for the specific drink. Water first goes to the aerator which reduces dissolve oxygen. Ammonia
coils are used as a cooling medium.

27
 REVERSE OSMOSIS PLANT

a. Reverse Osmosis:

Reverse Osmosis (RO) is a filtration method that removes many types of large molecules
and ions from solutions by applying pressure to the solution when it is on one side of a selective
membrane. The result is that the solute is retained on the pressurized side of the membrane and the
pure solvent is allowed to pass to the other side. To be "selective," this membrane should not allow
large molecules or ions through the pores (holes) but should allow smaller components of the
solution (such as the solvent) to pass freely.
Reverse osmosis is most commonly known for its use in drinking water purification from
seawater, removing salt and other substances from the water molecules.

The sources of water are tube wells. Through turbines water is pumped into the water tanks.
Raw water hardness is 400-450 ppm. Require beverage hardness for water is less than 30 ppm.
First of all in the RO treatment bag filters are present. When water passes from it all the mud
present in water remove from water and water passes through sand filter and course and nano
particles removed from water. Water is entering in sand filter from top and also removed from top.
After sand filter there is jumbo filter. Membranes are present in jumbo filter and water passes from
it. Than it passes through carbon and charcoal filter. Its design is same like carbon filter but it has
activated charcoal. It has black color so it absorbs smell color and shade present in water. After
passing through carbon filters the total hardness and chlorine in water is changed. After this water
passes from membranes. 16 membranes are present and each membrane is 3.5 feet. It is cylindrical
type. Main hole is in center and small holes are in side. Anti-scaling and disc scaling are used to

28
avoid scaling. After it passes from ultra violet lights. All the microorganisms are killed in it. Store
it and used as per required.

SWOT ANALYSIS

a. Strengths
• Company has a lot of products (Malt whisky, nonalcoholic and alcoholic beers and
juices).

• Company has set up a good monopoly in the market.

• Company has very large area for further development.

• Company have very good relationship with the government.

• Smooth relation with employee.

• Good working environment.

• Rich experience of the management.

• Good brand equity.

• Giving the very good return from inception Well combination of new energetic and
experienced employees.

• Have very large area for the production.

• Production capacity.

• Premium Quality Product.

b. Weakness
• Not all employees have his/her cabin.

• Not very popular in rural area.

• Low Advertising & Promotion Spends.

• Low Market Share.

• Inefficient Distributors.

29
 b. Opportunities

• Company exists in very financial products (liquor division, glass division) it provide a
better opportunity to the company.

• Company has power to lead their competitor.

• Stability through increased brand awareness, market penetration and Service offerings.

• Regional Expansions.

• Production Volumes.

• Higher Profits.

• Increased Market share.

c. Threats
• Competition from local and multinational players.

• A lot of company has enter in this field.

• Rising inflation could reduce savings and investments.

• Competitors High Spends.

• Government Laws.

PRODUCTION & PROCESSING

• BREW HOUSE

The main product in the brew house is barley which is exported from Australia or
Ukraine.

30
 a) Screening
First of all the screening of barley is done to remove the foreign matter.

b) Steeping
First of all feed the barley in the steep tank where barley is soaked in water for 24 hours.
The purpose of steeping is to hydrate the barley for the activation of enzymes and remove
impurities from barely. The moisture is obtained required for germination. Temperature of
steeping is 21-22oC. Air should also be provided from bottom of steep tank through the small
holes. Pure barley settles down and impurities float on surface. Make sure the moisture of barley
after steeping should be 42-43% which is called steep moisture of barley. Then transfer the barley
in the germination box for 4-5 days (Smith, Elliot Blair 2002).

c) Germination

Germination box which is named as Saladin malt box. Wet barley goes through pipes to
the germination box. The capacity of germination box is 22MMT. Barley spread in the box. The
temperature of box should be maintained 15-18oC. Temperature is maintained through chillers.

31
The process of germination is of 5 days (Hübner F et. al., 2010). Water sparging is done on the
2nd day to maintain the moisture. Only roots of barley should germinate, not shoots. The grain is
aerated and stirred, which causes it to germinate, releasing enzymes such as malt diastase. Malt
diastase converts the starches contained in the grain to sugar for fermentation. When 98%
germination is achieved transfer it to the kiln tank.

d) Kilning

After germination the barley is transferred to kilning box for the inactivation of the
enzymes which are produced during germination. The barley is roasted with the help of steamed
air with temperature 122oF (50oC) and the temperature is further increased up to 176oF (80oC). Hot
air is provided from bottom to roast the barley. Moisture content reduce to 5% and barley again
come to his hard form. The germ portion is removed in this process. When the upper and lower
temperature of the kiln is equals, it means the barley is fully roasted. The grains are roasted to stop
the germination process. The exact point at which the roasting starts and ends affects the flavor
and color of the beer. The product at this point is referred to as Malt.

e) Milling
After kilning the barley is stored in silos for future processing. From silo transfer the malt
in the malt screening machine for screening and then transfer into the malt grinding machine which
grind it and convert it into grist for proper mashing.

f) Mashing

The malt is crushed using iron rollers and transferred to the mash tank (or “mash tun”).
This tank is a large copper or stainless steel vessel that mixes the malt with warm water until it is

32
of porridge-like consistency. This mixture is called mash. Purpose of mashing is to activate the
enzymes which break the starch in the grain and convert it to simple sugars. At 52 oC Gluconase
and protease enzymes activates. At 62oC beta amylase activates and at 70oC alpha amylase
activates. And then at 78oC all enzymes become inactive. Than wort boiling and hops are added.
After this wort is chilled at 7-9oC through plate heat exchangers. Than transfer it to fermentation
vessels and yeast is added to start fermentation.

a. Extraction in Lauter Tun

The mash is transferred into another tank called a lauter tun. This is accomplished by
drawing the liquid out through the bottom layer of mash solids, which acts as a filter. Hot water is
added to the top of the mash tank to rinse the remaining liquid, now called wort, from the mash.
The solid remains of the grain are dried and sold by the brewery as animal feed.

b. Wort Boiling & Hops addition

The wort travels on to the brew kettles, where it is boiled and prepared hops are added
carefully. The addition of the hops is important because they contribute to the bitterness of the
beer. The brew kettles are the most impressive equipment in the process. Boiling take placed in 1
hour and temperature is maintained 100oC.

33
 c. Wort Chilling
The wort is chilled at 7-9oC through plate heat ex changers. Then transfer it to fermentation
vessels and yeast is added to start fermentation. Before fermentation, the CIP of the fermentation
tanks is done through hot water and caustic soda.

d. Fermentation
In the fermentation tanks, the atmosphere must be carefully controlled to prevent any
"rouge" bacteria from interfering with the yeast. Carefully maintained yeast (approximately one
pound per barrel of wort) is added in the wort. The specie used for beer fermentation is
Saccharomyces Uvarum and Saccharomyces cerevisiae (Obisanya M et. al., 1987). The
temperature of the mixture is slowly reduced between 50°F and 60°F (10-15°C). In this
temperature range, the yeast grows, consuming the sugar in the wort, and bubbles of carbon dioxide
form. Glucose (C6H12O6) is converted by the action of yeast in two ethanol molecules and two
carbon dioxide molecules under anaerobic conditions. The wort has now become beer.
There are two types of fermentation in beer production. One is Ale and second is Lager.
Ale is top fermentation using yeast Saccharomyces cerevisiae. Lager is bottom fermentation using
yeast Saccharomyces uvarum.

34
 e. Maturation

After fermentation the beer is stayed for 7-10 days in the fermentation vessel (FV) for the
maturation and production of specific alcohol percentage in the wort according to the product
requirement.

f. Filtration

After fermentation beer is filtered through a filter unit which has a series of 12 filtered sheets. The
haze of beer is controlled by the filtration.
• After fermentation, maturation and filtration the beer is transferred to the Beer Brine Tank
(BBT) room where conditioning is done by adding flavors, and batch is prepared according
to product requirement. The final beer is transferred to the BBH where filling,
pasteurization and packaging is done.

35
• Flow Diagram Of Beer Production

Figure 7.1: Process Flow Diagram of Beer Production

36
 Flow Diagram of Brew House

Figure 8.2: Process Flow Diagram of Brew House

Boiler Section:

Murree Brewery has three boilers:

1. DESCON Boiler
2. PAK Boiler
3. Wooden Boiler

A boiler is a closed vessel or container used to heat water or generate steam. It is commonly used
in residential, commercial, and industrial settings for various applications such as heating
buildings, providing hot water, and powering steam engines or turbines.

Boilers work by transferring heat to the water inside the vessel, raising its temperature and
converting it into steam. The heat is usually generated by burning fuels such as natural gas, oil,
coal, or biomass, or through electric resistance heating. The generated steam or hot water is then
circulated through pipes to the desired location for its intended use. Boilers are typically
comprised of several components, including a burner, combustion chamber, heat exchanger,

37
controls, and safety devices. The burner is responsible for igniting and combusting the fuel,
while the combustion chamber contains the flames and directs the hot gases toward the heat
exchanger. The heat exchanger transfers the heat from the combustion gases to the water, raising
its temperature.

There are different types of boilers available, including:

1. Fire-tube boilers: In these boilers, hot gases generated by the burner pass through tubes
surrounded by water. The heat is transferred through the walls of the tubes to the water.

2. Water-tube boilers: These boilers have water-filled tubes that are heated externally by hot
gases. The heat is transferred from the combustion gases to the water flowing through the tubes.

3. Electric boilers: These boilers use electric resistance heating elements to generate heat,
eliminating the need for burning fuels. They are often used in areas where other fuel sources are
not readily available.

Boilers are an important part of many heating systems, providing warmth and hot water for
residential and commercial buildings. They require regular maintenance to ensure efficient and
safe operation, including cleaning, inspection, and occasional repairs.

Scales:

"scales" refers to mineral deposits that can accumulate on the internal surfaces of the boiler and
its pipes. These deposits are primarily composed of minerals such as calcium, magnesium, and
iron, which are present in the water used in the boiler system.

When water is heated in a boiler, especially in areas with hard water (high mineral content), the
minerals can precipitate and form scales. Over time, these scales can build up and cause various
issues, including reduced heat transfer efficiency, increased energy consumption, and potential
damage to the boiler.

The formation of scales is undesirable because it insulates the heat transfer surfaces, reducing the
efficiency of the boiler. The insulating effect of scales requires the boiler to consume more
energy to heat the water or generate steam, resulting in higher operating costs. Additionally, the
accumulation of scales can lead to overheating, localized hotspots, and potential damage to the
boiler's components.

38
To prevent or mitigate scale formation, water treatment methods are employed. These methods
include:

1. Water softening: Water softeners remove or reduce the concentration of calcium and
magnesium ions through ion exchange processes, thereby reducing the likelihood of scale
formation.
2. Chemical treatment: Chemical additives, such as scale inhibitors or dispersants, can be
used to control or minimize scale formation. These additives work by either inhibiting
scale formation or dispersing the formed scales, preventing them from adhering to
surfaces.
3. Blowdown: Regular blowdown of the boiler involves draining a portion of the water to
remove accumulated impurities, including dissolved minerals. This helps to reduce the
concentration of minerals and minimize scale formation.

39
Pumps:

Pumps are mechanical devices used to move fluids (liquids or gases) from one place to another.
They are commonly used in various industries, residential and commercial applications, and even
in everyday household items. Pumps work by imparting energy to the fluid, increasing its
pressure and facilitating its flow.

There are many different types of pumps, each designed for specific applications and operating
conditions. Some common types of pumps include:

1. Centrifugal Pumps: These pumps use centrifugal force to increase the fluid's velocity and
convert it into pressure energy. They are widely used in industries and are efficient for
pumping water and thin fluids.
2. Positive Displacement Pumps: Unlike centrifugal pumps, positive displacement pumps
move fluid by trapping a fixed volume and then forcing it out. They are effective for
pumping thick, viscous fluids and can generate high pressure.
3. Reciprocating Pumps: Reciprocating pumps use a piston or plunger to create a
reciprocating motion, drawing in and expelling the fluid. They are often used for high-
pressure applications and in hydraulic systems.
4. Diaphragm Pumps: Diaphragm pumps use a flexible diaphragm to push and pull the
fluid, creating suction and discharge. They are commonly used for metering and dosing
applications, as well as in the medical field.
5. Submersible Pumps: These pumps are designed to be submerged in the fluid they are
pumping. They are commonly used in wells, sump pits, and sewage systems.
6. Vacuum Pumps: Vacuum pumps are used to create and maintain a vacuum by removing
air or other gases from a system. They find applications in industries such as
manufacturing, chemical processing, and scientific research.

40
Pumps can be powered by various energy sources, including electricity, engines, or even manual
operation. They are used in a wide range of applications, including water supply and distribution,
wastewater treatment, oil and gas extraction, heating and cooling systems, and many others.

Cooling Towers:

Cooling towers are specialized heat rejection devices used in industrial and commercial
applications to remove excess heat from processes or equipment. They are large structures that
facilitate the cooling of water or other fluids by allowing heat to dissipate into the surrounding
air through evaporation and convection.

The primary purpose of a cooling tower is to transfer the heat generated by industrial processes
or equipment to the atmosphere, thereby maintaining the desired temperature and preventing
overheating. They are commonly used in power plants, manufacturing facilities, refineries,
HVAC systems, and other applications where significant heat removal is required.

41
Forced-draft and Induced draft:

Forced-draft fans focus the pressure and volume at the outlet of the fan to push air through a
system, creating positive air pressure. Industrial induced draft fans operate by focusing the
pressure and volume at the inlet of the fan to pull air through a system.

Condenser:

A condenser is a device used to condense a substance from its gaseous state to its liquid state by
removing heat. It is commonly used in various industrial processes, refrigeration systems, air
conditioning systems, and power plants. The primary function of a condenser is to transfer heat
from the substance being condensed to a cooling medium, typically air or water.

In refrigeration and air conditioning systems, a condenser plays a crucial role in removing heat
from the refrigerant gas, converting it back into a liquid state. The process begins with the high-
pressure, high-temperature refrigerant gas entering the condenser. As the gas flows through the
condenser, it releases heat to the surrounding environment or a cooling medium, which causes
the refrigerant to condense into a liquid.

42
 Still House:

Still house is very important part of Murree Brewery in which the production of alcohol is
done by the fermentation of molasses. It is also called Firilli Ethanol Distillation Plant. In still
house distillation of alcohol is done to obtain maximum percentage of alcohol (Buncombe,
Andrew 2009). The raw material for the production of alcohol is molasses. You can produce
alcohol with other sources but molasses is the cheapest source of alcohol. Molasses is the
byproduct of sugar industry.

Alcohol Production

• For distillation first of all, all the raw molasses is stored in the storage tank. From storage
tank with the help of pumps transfer the molasses in to dilution tanks.

• In dilution tanks dilution of molasses is done. The purpose of dilution is to decrease the
brix of molasses. Brix of raw molasses is 90o. Water is added in raw molasses for dilution
purpose and maintains the brix 17o. Transfer it to the bub vat and add yeast in bub vat for
the fermentation. The yeast specie used for this purpose is Saccharomyces Cerevisae.
Allowed to grow the yeast specie in the bub vat. Half of the tank is transferred in the next
tank. Remaining DT has much numbers of yeasts cells. From but vat transfer it to the
fermenter tank.

• Now prepare another DT of brix 26o and transfer it to the fermenter. Now after transferring
brix reached up to 18o. After 2 to 3 hours its brix reaches 15o. Now again prepare DT of
26o brix and add in the fermenter. Repeat this process until 9300 bulk gallons of the
fermenter is filled.

• Sodium Fluoride is added in dilution tank to avoid contamination. Sulfuric Acid is added
to maintain pH. Optimum pH required for yeast to grow is 4.5.

43
• Air is used for two purposes. First purpose is to use air in DT for mixing. And second is
used for aerobic fermentation. Its temperature is 26o C.

• Two types of fermentation is done i.e. Aerobic and Anaerobic fermentation.

• When 9300 BG is fully filled the process of fermentation starts. And obtained alcohol is
8% by volume.

• Now distillation process starts to obtain 96.5% alcohol. Fermented wash is transferred in
the wash tank. The impurities settle down and transfer wash in the other tank. From this
tank fermented wash is transfer to the pre heaters. These pre heaters provide heat to the
wash and transfer it to the C10 column.

• Indirect heat is provided in C10 column and distillation starts. 8% alcohol by volume is
obtained in the form of vapors. The stillage remains in the bottom which is the waste
product and transfer to the biogas plant to make it environment friendly and drained in Nala
Lai.

• The alcohol vapors are transfer to the condenser and convert them into liquid form. From
condenser P50 pump sucks it and transfer it to the C50 column.

• Live/direct heat is provided in C50 column. When alcohol is transferred from C10 column
to C50 column its percentage reaches up to 70-75%. The wash is again diluted with water
in C50 column and lower its percentage and reaches to 25-30%. Boils it and at alcohol
boiling point alcohol starts vaporizing and transfer in to the condenser. The lutter water
remain in the bottom which can be filter again and feed in the C50 column. After
condensation alcohol vapors converted into liquid form.

• Now transfer the alcohol vapors into C40 column provided by live steam. Distillation starts
again. Final alcohol with 96.5% strength is obtained in this column. Fusel oil remain as the
waste product.

• The alcohol is transferred in alcohol collecting tanks.

• The final alcohol is sent to the SSR for the production and processing in the alcoholic
products. In Distillation Unit Alcohol is produced through fermentation of Molasses.

44
Distillation

Distillation is a method of separating mixtures based on differences in their volatilities in

a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not
a chemical reaction. Distillation of fermented solutions has been used since ancient times to
produce distilled beverages with higher alcohol content. The premises where distillation is carried
out, especially distillation of alcohol are known as a distillery.
Fractional Distillation
Fractional distillation is the separation of a mixture into its component parts, or fractions,
such as in separating chemical compounds by their boiling point by heating them to a temperature
at which several fractions of the compound will evaporate. It is a special type of distillation.
Generally the component parts boil at less than 25 °C from each other under a pressure of one
atmosphere (1 bar). If the difference in boiling points is greater than 25 °C, a simple distillation is
used.

Fermentation

Fermentation is a metabolic process whereby electrons released from nutrients are

ultimately transferred to molecules obtained from the breakdown of those same nutrients. Yeast
carries out fermentation in the production of ethanol in beers, wines and other alcoholic drinks,
along with the production of large quantities of carbon dioxide.
Molasses

Molasses is a viscous byproduct of the processing of sugar cane or sugar beets into sugar.
The quality of molasses depends on the maturity of the sugar cane or sugar beet, the amount of
sugar extracted, and the method of extraction.
Fermenter

Yeast is added in the fermenter for fermentation and 8% alcohol is obtained by volume.
Condenser

A device or unit used to condense vapor into liquid. E10, E11, E50, E51, E43 are
condensers.

45
C10

It is a Feed Column and boiling is done here.

C50

It is Impurity Column. Alcohol is passed to C40 and Vapours are condensed in E50 & E51.
C40

It is Rectifying Column. 96% alcohol is obtained here and remaining fusel oil (have 30 –
40 % alcohols) is passed to C10 with wash.

Frilli Distillation Unit Flow Diagram

Figure 9.3: Process Flow Diagram of Still House

QUALITY CONTROL ANALYSIS

Central Laboratory
Laboratory is the main hub of Murree Brewery. All the raw materials coming in Murree
Brewery are tested in laboratory according to Murree Brewery quality standards. If the incoming
raw material fulfill the quality requirements then the product is passed if not then the product is
failed and returned to supplier as no compromise on quality inputs. The raw material include Sugar,
Barley, Citric acid, Sodium Benzoate, Colors, Flavors, Molasses, Hops, Glass bottles, Pet bottles,

46
Crowns, Plastic caps. There are so many tests performed on daily basis in laboratory to check the
quality of raw and finish goods of Murree Brewery. pH, TDS, Hardness, Chlorine of boiler water
& Tap water are tested and a daily report is sent to the Boiler Engineer. pH, ROH, Color, Haze,
CO2, Brix of final product are also tested in the laboratory. Hardness of water, Barley Germination,
Moisture determination of barley, Sieve test, Steep moisture of barley, Sugar analysis is also done.
For all these experiments different equipment’s are used.

RAW MATERIAL ANALYSIS

The raw material include Sugar, Barley, Citric acid, Sodium Benzoate, Colors, Flavors,
Molasses, Hops, Alcohol, Glass bottles, Pet bottles, Crowns, Plastic caps, Yeast etc.

a.Analysis of Sugar

b. Solubility
• Take 50 g sugar in a beaker.

• Add 50 g water.

• Mix on a magnetic stirrer.

• Observe the solubility.

c. Colour

• Colour is tested by Spectrophotometer.

• Sugar syrup is placed in spectrophotometer at 420 nm wavelength and check the absorption.

• The value of absorption is then multiplied with 162.66 and the colour is calculated.

47
 d. Turbidity
Turbidity is measure by subtracting the absorption of filtered sugar solution by the
absorbance of unfiltered sugar solution. Then the value is multiplied by 162.66 and the turbidity
is calculated.

Calculation

Turbidity: Before filtration – after filtration x 162.66

Color: After filtration x 162.66

BARLEY
Germination test of Barley

Procedure

• Take 100 grains of barley in beaker.

• Add 200 mL water.

• Add 5 mL hydrogen peroxide (35%)

• Stay for 2-3 hours.

48
• Place the grains on jute.

• Stay for 2-3 days in germination box (Hübner F et. al., 2010).

• Note that how many grains germinate and that will be the germination percentage.

• The test was performed and the germination was 76%.

Sieve Test
Procedure

• Sieve test is done by the sieve tester equipment (Wainwright T, Buckee G. 1977).

• 100 g grains are weighted in the weighing balance and are placed in the sieve tester.

The sieve tester is shaken well so the grains are sorted according to their size. (I.e. 2.8mm,
2.5mm, 2.2mm, <2.2mm)

49
• The grains are weighted separately according to their size.

• Petri dish is weighted and subtracted from total weight.

• The foreign matter is separated and weighted.

Moisture Content of Barley

Procedure

• The most accurate method of determining grains moisture content is the standard oven-
based test, which uses an ISO-specified protocol to dry a prepared sample of ground grain in
a special laboratory oven (ISO712) (Ananthaswamy H et. al., 1971).

• Take 5g sample in reweighed oven dry china dish.

• The dish is placed in the oven for 3 hours at 105oC – 110oC.

• After 3 hours the sample is weighted again and the weight of the sample is subtracted by the
total weight and divided by the weight of the sample and then multiplied by 100.

• Repeat the process until constant weight is obtained.

50
• The moisture percentage is determined.

Steep moisture of Barley

Procedure

• Take 50 g barley and steep it in water for 24 hours.

• After 24 hours take the sample and weight it and calculate the moisture percentage by
following this formula:

• Total weight (After steeping) + 5 - 50 / Total weight x 100

Friability Test of Barley

Procedure

• To check the friability of the barley, 50 gram sample of barley is taken.

• Put the sample in the friabilimeter for 8 minutes for grinding.

• After 8 minutes take the grind sample and weight it.

• Calculate the percentage of the sample from total weight of the sample.

• Friability percentage is determined.

a.1000 Grains Test

• Count and take 1000 grains of barley.

• Weight it on weighing balance.

51
• Standard weight should be in between 40 - 45 grams. It indicates good quality of barley.

Sample (1) Sample (2)

1000 grains weight = 45.3 g 1000 grains weight = 43.8 g

Calculations

Both samples indicates good quality of barley.

Specific gravity of Barley

Procedure

• Take two samples of 55 gram of barley. One is finely ground and the other is coarse ground
in the mashing machine.

• Add 200 mL water in each sample.

• Mix the samples at 40oC for 30 minutes.

• Then again add 100 mL water in each sample.

• Mix at 70oC for 1 hour.

• After 1 hour, stay the sample for 10 minutes so that it will cool down.

• Mashed samples are filtered by the filter paper in the cylinder.

• Take 50 mL filtered sample.

• Weight the gravity flask.

• Put the sample in the gravity flask and weight the flask with the sample.

• Subtract the weight of the gravity flask from the total weight and then divide it with the
weight of the water.

• Specific gravity will be calculated.

52
 Protein Test of Barley
Procedure
• Take 1 g sample of barley.

• Add 10 g reagent selenium.

• Add 10 mL sulphuric acid (H2SO4).

• Heat it until green colour is obtained, barley will dissolve in it.

• Take 200 mL distilled water in distillation flask.

• Add 100 mL 45% NaOH solution.

• Add selenium solution in it.

• Starts distillation and take 200 mL distillate.

• Add 3-4 drops of bromocresol green indicator.

• Pink colour will be obtained.

• Titrate it with 0.1 N NaOH.

Formula

W x 0.14 x 100
g of sample (100 - percentage of moisture) = Nitrogen
Nitrogen x 6.25 = Protein %

Acid (W)

To calculate acid, volume used of 0.1 N NaOH in tiration is divided by 2 and then that reading in
subtracted by the original volume of acid. Acid is denoted by W.

53
1. WATER

• Raw Water Analysis

a. Total hardness of water

Procedure

• Take 100 mL water in conical flask.

• Add 2-3 drops of E-Black Tea.

• Add 2-3 mL Ammonia buffer.

• Titrate against EDTA(ethylene diamine tetra acetic acid) (0.2N)

• End point will give blue colour.

• Note the reading of EDTA used and multiply with 10.

• Hardness of water is determined in ppm.

A = Phenolphthalein

B = EBT + Ammonium buffer

C = EBT + Ammonium buffer + EDTA

54
b. Permanent hardness of water
Procedure

• Take 100 mL sample in titration flask covered with a watch glass.

• Boil it on a slow flame for 15-20 minutes.

• Cool down under tap water.

• Titrate against EDTA (ethylene diamine tetra acetic acid) (0.02N)

• End point will be of blue colour.

c. Temporary hardness of water

Procedure

• Total hardness - permanent hardness = Temporary hardness.

Hardness as CaCO3 test

Procedure

• Take 50 mL sample.

• Add 2 mL 1N NaOH in it.

• Add 0.2 mg murexide indicator.

• Titrate with 0.02N EDTA solution.

• End point from pink to purple.

• Calculate as above.

Hardness as MgCO3 test

Procedure

• Temporary hardness - Hardness as CaCO3 = Hardness as MgCO3

55
 Hardness as Ca test
Procedure

• Take 100 mL sample.

• Add 2 mL 1N NaOH in it.

• Add 0.1 mg calcone.

• Titrate with 0.02N EDTA solution.

• End point from purple to blue.

• Calculate as above.

Hardness as Mg test
Procedure
• Total hardness - Hardness as Ca = Hardness as Mg

Chlorides test
Procedure

• Take 100 mL sample.

• Add 2 mL 10% potassium chromate in it.

• Titrate with 0.1N Silver Nitrate (AgNO3) solution.

• End point will be of reddish color when well shaken.

• mL of 0.1N AgNO3 used x 35.5 = mgcl/1000 mL.

Chlorine test
Procedure

• Take 100 mL sample of water.

• Add few drops of 0.1% orthotoulodiene.

• Match the color in chlorine tintometer.

56
• If the color of sample become yellow, the test is positive, if the sample is colorless, the test
is negative.

Chlorine Tintometer

Tube well water samples testing

Three tubewell samples are tested in the laboratory.
1. Soft water.

2. Brine water.

3. Khokha Tank water.

• The hardness and pH of the soft water and khokha tank water is measured and the strength
of the brine water is measured (Dickson AG. 1993).

• The hardness of soft water should be less than 10 and the pH in range of 7-7.5

• The hardness of khokha tank water should be less than 500 and pH in range of 7-7.6

• Strength of brine water is measured by taking the water sample in 250 mL cylinder and
dipping the salt meter in it. It will show the strength percentage.

• The strength of brine water should be in between 23-25%.

Descon boiler water samples testing

Three samples of descon boiler water is tested in laboratory.

1. Soft water.

57
2. Brine water.

3. Blow down water.

• The hardness and pH of the soft water is measured, and the strength of the brine water is
measured.

• The pH and TDS of the blow down water is measured.

The hardness of soft water should be less than 10 and the pH in range of 6-7

• Strength of brine water is measured by taking the water sample in 250 mL cylinder and
dipping the salt meter in it. It will show the strength percentage.

• The strength of brine water should be in between 23-25%.

• The pH of blow down water should be in range of 11-12.

• TDS is measured by TDS meter. The electrode of TDS meter is dipped in the sample and
temperature of the sample is set on TDS meter, it will show the TDS which is in ppm.

Brewing Liquor
Brewing liquor is the water which is used for the mashing of barley in the brew house. The
hardness of brewing liquor should be 180 - 200 ppm.

Iron test of Blow down water

Iron can exist as ferrous (Fe2+) or ferric (Fe3+) ions. Determine total iron levels in water via a
colorimetric method. First all feric ions are reduced by sodium sulfite to ferrous ions.

58
Phenanthroline complexes with ferrous ion to form an orange colored solution. The color
intensity of the solution determines the iron concentration.

Procedure

• Remove the cap from the plastic vessels.

• Rinse the plastic vessel with water sample.

• Fill the vessel to 10 mL mark.

• Add 1 packet of reagent HI 3834-0.

• Replace the cap and mix the solution until solids dissolves.

• Remove the cap and transfer the solution into the color comparator cube. Let set for 4
minutes.

• Determine which color matches the solution in the cube and record the result as mg/L (ppm)
iron.

1. YEAST
Yeast is propagated in yeast propagation room. Yeast used for beer fermentation are

• Saccharomyces uvarum

• Saccharomyces cerevisiae

2. CITRIC ACID
The moisture content of citric acid was determined by hot air oven method.
Moisture content was 0.17 %.

59
 3. HOPS ANALYSIS
Hops are added in beer and malt drinks for bitterness. Hops are imported from Germany by
MBC.

Procedure

• Check absorbance at wavelength 325, 355, 275 by spectrophotometer with reference to

ASBC (American Society of Brewing Chemists) method.

• Alpha beta acids test are done.

• Alpha acids are humulones.

• Beta acids are lupolones.

• Both are bitter taste chemical compounds.

• Bitterness of these concerned with their content.

• Test was not performed.

pH Determination

Procedure

• pH is determined by using pH meter.

• Sample is taken in the beaker and electrodes of pH meter is dipped in the sample.

• It shows the pH and temperature on the screen of the pH meter (Pagenkopf GK. 1983).

60
 Sample 07-Jul 09-Jul 12-Jul 14-Jul

Bigg Apple 2.92 ± 0.01 c 2.88 ± 0.01 c 2.91 ± 0.01 b 2.89 ± 0.01 a

Bigg Lychee 2.85 ± 0.01 d 2.85 ± 0.01 c 2.86 ± 0.01 b 2.87 ± 0.01 a

Murree Beer 4.47 ± 0.04 c 4.48 ± 0.02 c 4.51 ± 0.01 b 4.51 ± 0.07 a

Classic beer 4.44 ± 0.01 c 4.43 ± 0.01 c 4.48 ± 0.04 b 4.45 ± 0.01 a

Haze Determination
Procedure

• Turbidity is the cloudiness or haziness of a liquid caused by large numbers of individual

particles that are generally invisible to the naked eye. The measurement of turbidity is a key
test of malt drink HYPERLINK "https://en.wikipedia.org/wiki/Water_quality" quality.

• Haze is determined by the turbidity meter (Lin EY, Teng J. 1990).

• The liquid sample is poured in the glass container of turbidity meter. Make sure the bubbling
will not formed in the glass otherwise it will give wrong reading.

• Place the glass container in the turbidity meter.

• Starts the turbidity meter and it will show the reading.

• Haze should be less than 1 according to the standards.

61
 Table 2.28: Haze of samples (EBC)

Sample 14-Jul 16-Jul 17-Jul 19-Jul

Lemon Malt 0.27 ± 0.04 c 0.36 ± 0.06 c 0.29 ± 0.07 b 0.37 ± 0.16 a

Apple Malt 0.33 ± 0.09 d 0.34 ± 0.11 c 0.44 ± 0.1 b 0.36 ± 0.05 a

Millennium Beer 0.57 ± 0.07 c 0.55 ± 0.01 c 0.52 ± 0.18 b 0.52 ± 0.14 a

Strong Beer 0.54 ± 0.17 c 0.43 ± 0.11 c 0.49 ± 0.08 b 0.65 ± 0.2 a

Colour Determination

Procedure

• Colour is tested by the Lovibond EBC Color pod.

• The Lovibond EBC Color pod is based on the photometric evaluation of EBC colour that
uses a wavelength of 430nm and a cell path length of 10 mm as per Method 3.4A of
Analytical EBC.

• The sample is poured in the cuvette and the cuvette is placed in the colour pod.

• Colour is compared using colour discs (Callemien D, Collin S. 2007).

• Light of colour pod is switched on and colour of sample is compared with that of colour
discs (Brenner M, Khan A. 1975).

• Point where the colour matches is noted in EBC.

62
 Table 3.29: Color of Samples (EBC)

Sample 02-Aug 04-Aug 07-Aug 08-Aug

Classic Beer 9.5 ± 0 c 9.4 ± 0.1 c 9.47 ± 0.15 b 9.47 ± 0.06 a

Murree Beer 9.2 ± 0.2 d 9.27 ± 0.06 c 9.43 ± 0.12 b 9.4 ± 0.1 a

Lemon Malt 8.03 ± 0.06 c 8.07 ± 0.06 c 8.1 ± 0.1 b 8.1 ± 0.1 a

Peach Malt 8.03 ± 0.06 c 8.1 ± 0.1 c 8.23 ± 0.23 b 8.23 ± 0.21 a

Brix Determination

Procedure

• Brix is the total dissolved sugar and salts in the solution.

• Brix is determined by the hand Refractometer or digital refractometer.

• First degas the sample and then put 2-3 drops of sample on the refractometer.

• Cover it with the glass and observed the reading in light by lens.

• It will show the brix.

63
 Table 4.30: Brix of Samples (o)

Sample 10-Jul 12-Jul 13-Jul 17-Jul

Bigg Apple 10.13 ± 0.06 c 10.07 ± 0.06 c 10.13 ± 0.06 b 10.1 ± 0 a

Bigg Lychee 12.87 ± 0.06 d 13.03 ± 0.06 c 13 ± 0.2 b 12.9 ± 0.1 a

Peach Malt 10.2 ± 0.1 c 10.13 ± 0.06 c 10.17 ± 0.06 b 10.1 ± 0.1 a

Big Anaar 13.03 ± 0.06 c 13.03 ± 0.06 c 13.13 ± 0.06 b 13.03 ± 0.06 a

BEER ANALYSIS

a.R-OH Test
Procedure

• R-OH test is done to check the percentage of the alcohol in the sample.

• The Ebullio meter is used to measure the alcohol percentage.

• 50 mL sample is taken.

• Add 1-2 drops of Octanol in the sample for degassing and to avoid foaming in the sample
(Rudin A. 1957).

• Put the sample in the Ebullio meter.

• The water is added in the upper cylinder of the ebullio meter.

• Thermometer is placed and the flame is turned on from bottom.

• After 10 to 12 minutes the thermometer shows the maximum temperature of the sample.

• The temperature is then noted and is compared with the Veritable Ebulliometre chart.

64
• Reference temperature is set on the chart and the temperature of the sample is observed
according to the temperature of the sample. It shows the percentage of the alcohol in the
drink.

Ebullio Metre & Veritable Ebulliometer chart

Table 5.31: Alcohol of Beer Samples (%)

Sample 16-Aug 18-Aug 21-Aug 24-Aug

Millennium Beer 6.23 ± 0.06 c 6.47 ± 0.06 c 6.33 ± 0.06 b 6.3 ± 0.1 a

Classic Beer 5.37 ± 0.06 d 5.5 ± 0.1 c 5.33 ± 0.06 b 5.33 ± 0.12 a

Wheat Beer 5.17 ± 0.06 c 5.3 ± 0 c 5.23 ± 0.06 b 5.27 ± 0.06 a

Light Beer 3.17 ± 0.12 c 3.27 ± 0.06 c 3.37 ± 0.06 b • 0.06 a

65
 Bitterness test

Procedure

• Take 10 mL sample of beer in falcon tube.

• Add 0.5 mL 6.0N HCL solution (Weiner J. 1978).

• Add 20 mL isooctane solution.

• Centrifuge the solution at 3000 rpm for 15 minutes.

• Check the absorption at 275 nm wavelength in the spectrophotometer.

• Multiply the absorption with 50 and the value is bitterness of beer.

Table 6.32: Bitterness of Samples (Bu)

Sample 30-Jul 02-Aug 16-Aug 21-Aug

Millennium Beer 22.53 ± 0.32 c 22.13 ± 0.32 c 21.7 ± 0.2 b 22.53 ± 0.23 a

Murree Beer 18.7 ± 0.1 d 18.53 ± 0.25 c 18.37 ± 0.06 b 18.57 ± 0.21 a

Cindy Malt 12.23 ± 0.21 c 12.6 ± 0.1 c 12.6 ± 0.2 b 12.57 ± 0.06 a

Malt-79 11.93 ± 0.15 c 12.1 ± 0.2 c 12 ± 0.27 b 12.1 ± 0.2 a

66
 Density of Beer
Procedure
• Weight the gravity flask.

• Take sample in gravity flask.

• Weight the flask with the sample.

• Subtract the weight of the gravity flask from the total weight and then divide it with the total
volume of flask.

• Density will be calculated.

Calculations

Gravity flask weight = 24.49g

Total weight = 73.88g

Sample weight = 49.39 g

Density = 49.39/50 = 0.987

Strength of alcoholic products

67
Hydrometer Method

• Check the temperature of the sample.

• Take the alcohol meter of 15oC and check the dip of the sample.

• Note the dip.

• Take temperature difference of alcohol meter and temperature of the sample (Bjorndal M.
1937).

• Divide the temperature difference by 4.

• Subtract the temperature difference by the dip.

• Strength of alcohol is determined.

Whiskey Analysis

TDS Test
Procedure
• Weight the small beaker.

• Take 100 mL sample of whiskey.

• Heat the sample until it evaporates and dried.

• Place it in the oven for 1 hour at 110oC.

• After 1 hour take it out from the oven.

• Again weight the beaker accurately. Weight will be in grams.

68
• Take the weight difference and multiply it with 1000 to convert it into ppm.

• TDS will be determined.

• TDS of whisky should be less than 10 ppm before filling in the casks.

• After few years TDS of whisky increases which is again tested and is it is more than
standard than prior to filling again distillation is done to reduce the TDS (Delvaux F et. al.,
2004).

SOFT Drinks Analysis

a. PET PLANT Standards

Table 7.34: Standards of PET Plant

Parameters Parameters
Organoleptic OK Rinsing H2O after Negative/Positive
soda/Phenolphthalein Test
pH BA, BL, BP 3.0±0.2 Syrup Brix mixing 45°-50°C
BIce 4.0±0.2 Washing Machine/Dye OK
Test
Color 12 ± 1 EBC Rinser water Clean, Particle
Free
Haze <1 EBC Rinser Jet Pressure touch the roof of
rinser
Brix BA, BO 8.0 ±0.2 Foreign Matters Nil
BL 10±0.2 Cap sealing OK
BIce 11.3±0.2 Leakage nil
Soda Caustic 2% Actual Content 1500 mL ± 20
Strength mL, 500 mL ±10
mL, 300±5 mL

69
CIP temp 80-85% Carbo Cooler/Filling 0-5 °C / <10 °C
Temp
Water Hardness <10ppm Hot Water Injection crown of Foam
Water pH 6.5-7.5 CO2 v/v 3.9±0.1%
Production Date Correct, Easily CIP water Temp 80-85%
Readable
Labeling Printing Straight Warmer Water Temp/PH 45-50 °C, 6.5-7.5
Proper Pasting
Cartons packing OK, strong D.O <0.3ppm
Worker safety Shoes tidy/Uniform Plant House Keeping Clean
and Hygiene
Expiry Date Correct, Easily Stamping Correct
Readable
Bottle Temp After Ambient ± 3 °C
Warmer

NABH (NON-ALCOHOLIC BEER HALL)

a. Standards
Table 8.37: Standards of Non-alcoholic Beer Bottling Hall
Parameters Parameters
Worker safety and
Organoleptic OK shoes tidy/Uniform
Hygiene
Rinsing H2O after
pH NAB 3.3±0.2 soda/Phenolphthalein Negative/Positive
Test
M79, Cindy Washing Machine/Dye
Ok
4.2±0.2 Test
NAP 3.0±0.2 Rinser water Clean, Particle Free
touch the roof of
Haze <1 EBC Rinser Jet Pressure
rinser

70
Brix NAB 8.0 ±0.2 Foreign Matters Nil
Cap sealing OK
Color 7.5±0.5 EBC Leakage nil
Soda Caustic 500 mL ±5 mL,
2% Actual Content
Strength 245±5 mL
Carbo Cooler/Filling
CIP temp 80-85% 0-5 °C / 10 C max
Temp
Pasteurization
61±1 °C Hot Water Injection crown of Foam
temp
Pasteurization Unit 50-60PU CO2 v/v 3.0±0.2%
Correct, Easily
Production Date Air in Head Space <0.5 mL/500 mL
Readable
Printing Straight
Labeling <0.25 mL/250 mL
Proper Pasting
Pasteurization
25-30 °C D.O <0.3ppm
Outlet temp
Correct, Easily
Expiry Date Plant House Keeping Clean
Readable
Stamping Correct

BEER BOTTLING HALL

a. Standards
Table 9.42: Standards of Beer Bottling Hall

Parameters Parameters
Organoleptic OK Foreign Matters Nill
pH 4.2±0.2 Cap sealing OK
Brix 4.5±0.2 Leakage Nill

71
 500 mL ±5 mL, 245±5
Haze <1 EBC Actual Content
mL
BBT Temp/Filling
Color 7-12 EBC 0-5 °C / 10 oC max
Temp
Hot Water
ALC% LB =3.3-3.7% crown of Foam
Injection
MB = 4.3 -4.7% CO2 v/v 3.3±0.2%
CB = 5.3 -5.7% <0.5 mL/500 mL
Air in Head Space
MLB = 6.3 -6.7% <0.25 mL/250 mL
SSB = 7.6-8.0% D.O <0.3ppm
Plant House
Pasteurization temp 61±1 °C Clean
Keeping
Pasteurization Unit 30-40PU Stamping Correct
Correct, Easily Correct, Easily
Production Date Expiry Date
Readable Readable
Printing Straight
Labeling Rinser Jet Pressure touch the roof of rinser
Proper Pasting
Pasteurization Outlet
25-30 °C Rinser water Clean, Particle Free
temp
Washing Machine/Dye
Ok
Test

72
SUGGESTIONS

• There should be proper monitoring of personal hygiene of workers that can cause
contamination in product and can compromise the quality.

• Safety and training workshops should be held every month for employs.

• Arrange a workshop on safety of workers.

• Focus on regular cleaning of production area to reduce risk of physical hazards.

• There should be a proper implementation of integrated pest management. In this regard

use glue traps to control biological hazard.

• There is a need of proper HACCP implementation.

• Mention CCPs in production and processing area.

• Conduct workshops and training sessions of HACCP.

• Mention CCPs of production and processing area with labels at their point.

• Keep rotation of workers that are working on CCP points.

• There should be access of workers to head cover, gloves, face mask shoe cover and hand
sanitizer at daily bases.

• By using filter of 100 mesh the risk of physical hazard can be reduced at maximum level.

• Callibrate equipments timely.

73
CONCLUSION

I worked as an internee in the Murree brewery company. It was a great experience and I
am very glad that they believed and trusted in me and allowed me to work openly with all the
instruments and equipment.
The internship was necessary for the completion of the degree and also for the professional
skills improvement. The aim was the quality analysis of raw material, and final products.

This internship program helped me in the polishing of communication and professional

skills, a must-have to survive and make it big in the present world. It even gave a good
understanding of behavior of workers when placed in different situations. It was a good
opportunity to work on the skill of patience. It helped in developing the kind of relations one needs
to uphold in the corporate world and it helped in building up the right attitude.

There are over 50 products of Murree Brewery Company and 5 production departments in
which the production and processing is done. Production departments include Brew House, Still
House, Whisky Plant, Spirit Store Room and Maturation Cellar. The secondary processing is done
here and the final product is prepared which is the sent to the production halls for filling.

There is no company in this country that can match Murree brewery in history and keeping
it energetic progressing in the market with its methods and techniques. All of the employees are
proud of their organization, although the factory looks outdated, but the employees want to keep
it intact because in their mind they are safeguarding heritage which is spread over an era longer
than a millennium.

____________________________

74
75