Republic of the Philippines

Tarlac State University

College of Engineering and Technology
Department of Industrial Engineering
Tarlac City

BEER INDUSTRY

Submitted by:

Nicolas, Christian Rafael DC

BSIE 3A

Submitted to:

Ma’am Joycelyn Cabuang

2023
1. Milling the Grain - malt are crushed together to break up the grain kernels in order
to extract fermentable sugars to produce a milled product called grist.

2. Mashing Conversion - the grist is then transferred into a mash tun, where it is
mixed with heated water in a process called mash conversion.

3. Lautering - the mash is then pumped into the lauter tun, where a sweet liquid
(known as wort) is separated from the grain husks.

4. Brewing - the wort is then collected in a vessel called a kettle, where it is brought
to a controlled boil before the hops are added.

5. Cooling - after boiling, the wort is transferred into a whirlpool for the wort
separation stage. During this stage, any malt or hop particles are removed to leave a
liquid that is ready to be cooled and fermented.

6. Fermentation - to start the fermentation, yeast is added during the filling of the
vessel. Yeast converts the sugary wort into beer by producing alcohol, a wide range of
flavors, and carbon dioxide (used later in the process to give the beer its sparkle).

7. Conditioning/Maturation - after fermentation, the young “green” beer needs to be

matured in order to allow both a full development of flavours and smooth finish.
8. Filtration, Carbonation, and Cellaring - the beer is filtered, carbonated, and
transferred to the bright beer tank, where it goes through a cellaring process that takes
3-4 weeks to complete. Once completed, the beer is ready to be packaged.

9. Packaging - cans are first washed with pure water and then carbon dioxide is
injected into empty cans. Then they are filled with beer. After filling, lids are placed
on the top and it moved to seamer. After seaming, cans are moved to exterior rinsing
and packed in the pack of six for sale.

POLLUTANTS PRODUCED

The main sources of air pollution from the manufacture of alcoholic beverages are the
evaporation of ethanol, and the pollutants emitted from the combustion of fuel to
produce heat energy for building heat, process heat, etc.  While ethanol is the desired
attribute of an alcoholic beverage, when released to the atmosphere it leads to air
pollution.  Ethanol is considered a volatile organic compound that contributes to the
formation of ozone pollution, one of the main components of “smog”.
Ethanol is released to the atmosphere during fermentation, transferring between
process steps, cleaning, canning or bottling, and storage (especially if the storage
vessel is a wooden barrel). If the AQ&CD estimates that 5 tons/year or more of
ethanol are released to the atmosphere, then an air permit will be needed.  The permit
will require you to track and report your air emissions each year.
If the boiler(s) at the facility are large enough, then they might trigger the need for an
air permit.

Suspended solids, such as yeast and hop wastes, can also end up as sludge in the
wastewater treatment plan and result in additional disposal fees. During the
fermentation process, each barrel of wort produced emits nearly 10 pounds of carbon
dioxide. Breweries' water and energy consumption can also add up.

TREATMENT SCHEME

Pollution prevention strategies at breweries not only benefit the environment but can
also lead to greater efficiency and lower production costs. Increased brewing
efficiency reduces water usage, energy usage, air pollution emissions and generated
waste while simultaneously providing a return on the investment.

Reduction Opportunities

Energy – Refrigeration creates the largest electrical load, while brewing consumes the
largest amount of natural gas. Energy reduction efforts include:

 Install new seals, curtains, insulation & minimize the time the door is open to
coolers.
 Install insulated heat and condensate recovery systems to recycle heat.
 Switch to efficient lighting and controls.
 Repair air and steam leaks.
 Maintain operational equipment regularly.
 Install variable speed motors in bottling operations.
 Reduce compressed air usage, use lowest possible pressure.
 Switch to on-demand/tankless hot water heater.

Air – Volatile organic compounds (VOCs) from fermentation and filling processes,
and particulate matter (PM) from grain handling are the primary emissions from
breweries. In addition, carbon dioxide (CO2) is used and generated in the brewing
process. Boilers burn natural gas and emit nitrogen oxide (NOx). Examples of air
pollution reduction efforts include:

 Install low NOx burners on boilers.

 Install fabric filters to control PM emission from grain handling and drying.
 Reduce VOC emissions with carbon adsorption, incineration and wet scrubbing.
 Recapture CO2 generated during the fermentation process and reuse in brewing.

Water – Brewing beer consumes 3 to 7 times the amount of water contained in beer,
and approximately 70% of the water is discharged as wastewater. Wastewater pre-
treatment may be required by the local municipality to remove organics/solids and
adjust pH. Examples of water conservation efforts include:

 Install closed loop cooling systems for fermenters.

 Install a clean-in-place system (uses 60% less water).
 Reuse water where possible. Not all processes need clean water (irrigation, use
final rinse water as prerinse water).
 Check for water leaks and have a maintenance plan.
 Install high efficiency spray nozzles for cleaning.  Use dry cleaning methods
(broom, wipe, rake, etc.).
 Install xeriscape landscaping and rain water catchment system.

Waste – Spent grains are byproducts of the malting and lautering processes and are
the largest source of waste for most brewery operations. Packaging is the second
largest waste stream for breweries. Examples of waste reduction efforts include:

 Conduct a waste audit to identify reduction opportunities and increase your

landfill diversion rate. The goal is to reduce, reuse and recycle.
 Reuse spent grains and yeast as animal feed supplement.
 Compost spent grains.
 Save and reuse yeast to reduce the amount of new yeast that must be purchased.
 Seek light-weight, environmentally-friendly packaging made from recycled
materials.
 Train personnel to better sort, stage and store materials; and greater recycling
awareness.
 Consider onsite management strategies such as purchasing a cardboard baler,
establishing a compost bin, or reusing wood pallets.