Beer Production

1 A Report By Animesh Ranjan 5101045 C-2 (biotechnology) Jaypee be of In sortation Technology For Mr. Chakresh Jain Course Coordinator (biotech plant site lay out(p)) surgical incision of Biotechnology Jaypee Institute of Information Technology Noida 2 CONTENTS Kool Breweries Ltd An Overview deluge Beverages get from bleak stuff How Beer is made Brewing Process Overview Beer mathematical product F pitiablech artwork Beer Production Ingredients Beer Production Process o o o o o o o Mashing Lautering Boiling and Hopping Hop Separation and Cooling tempestuousness Filtration Packaging 13 13 14 14 15 16 17 18 4 5 8 9 10 11Quality Control in Beer Production 3 Kool Breweries Ltd An Overview Kool Breweries Limited is a premium-branded drunkenness comp both dedicated to delivering forest products enjoyed by millions around the world each day. An academic visit to the Kool Brewery manufacturing plant in Haryana was organized as a part of the natur bothy Biotech Plant Site Layout on the 19th inch 2007. This visit resultd with the opportunity to observe the different processes involved in the beer manufacturing, i. e. suppressing, lautering, rumpus pooling, fermentation, filtration and packaging.Also the quality control measures being adopted to master(prenominal)tain the quality of the beer to planetary standards and the basic layout of the plant were also observed. The visit was a very profitable academic as well as practical exposure and we odour forward to more of such(prenominal) visits in future to enhance both our theoretical, technical and practical knowledge. 4 Alcoholic Beverages An intoxicantic crapulence containing ethanol. is a drink Ethanol is a psychoactive drug, a depressant, and numerous societies rate or restrict its sale and consumption.Countries place various legal restrictions on the sale of alcoholic drinks to young people. The manufacture and consumption of alcohol is notably found (to just about degree) in most cultures an d societies around the world, from hunter-gatherer tribes to organized nation-states. The consumption of alcohol is often important at social events in such societies and may be an important aspect of a communitys culture. The meanness of alcohol in a drink may be specified in percent alcohol by volume (ABV), in percentage by weight ( well-nigh whiles abbreviated w/w for weight for weight), or in proof.Most yeast cannot grow when the concentration of alcohol is higher than closely 18% by volume, so that is a practical limit for the strength of fermented beverages such as wine, beer, and sake. Strains of yeast consent been developed that can survive in solutions of up to 25% alcohol by volume, exclusively these were bred for ethanol go off issue, not beverage production. 5 Alcoholic Beverages Mead fermented honey and water, scratch in honey is too concentrated for yeasts to grow so it essential be diluted. Probably made by early humans by calamity initially.Mead is made no w by boiling diluted honey and adding nitrogencontaining compounds, so yeast culture. Fermentation process takes 6-8 weeks. Wine Yeasts be present on fruit skins so fermentation can occur naturally. Wine was plausibly produced accidentally as long as 10,000 ybp but that is tho a guess. Beers have been made for at least 6000 years. Brewing has been a scud and miss process until around 200 years ago, until then it was knotty to control quality. High quality beer has three basic ingredients barley malt, cuts, and water. Adjuncts ar put on extensively in cheap beers. 6 Sake strain wine Conversion of rice stiffen to prick is done by Aspergillus (bread mold). Yeast argon then added for fermentation, final alcohol concentration is 19% and is fortified to 20-22%. Chicha corn beer, Central and S. America, made from chewed corn. distillation o Whiskeys distilled from beers and aged Scotch, Bourbon, Rye. o Cognacs and brandies distilled from wines. o Grain alcohol is 95% = 190 proof o Gin and vodka ethanol + water, gin is qualityed. o Rum fermented molasses or sugarcane juice 7 Brewing How Beer is do Brewing is the production of alcoholic beverages and alcohol fuel by fermentation.This is the system utilize in beer production. Brewing is constitutionally a natural process. The art and science of create from raw material lies in converting natural food materials into a pure, harming beverage. Although great strides have been made with the techniques for achieving high-quality production, beer today is still a beverage brewed from natural products in a traditional way. Although the main ingredients of beer have remained everlasting (water, yeast, malt and hops), it is the precise recipe and timing of the brew that gives one a different hear from an another(prenominal).The production of beer is one of the most closely superintend and controlled manufacturing processes in our society. Apart from brew company expenditures on research and quality control intentional to achieve the highest standards of uniformity and purity in the product, the production of beer is also subject to regular inspection and review by federal official and provincial Health Departments. Substances used in the brewing process argon approved by Health Canada. On average, a batch of beer lead take about 30 days to produce.To be more specific, brewing takes nine and a half hours, while fermentation and aging have take between 21 and 35 days for ales and lagers respectively. 8 Brewing Process Overview The grain used as the raw material is usually barley, but rye, maize, rice and oatmeal are also employed. In the frontmost stage the grain is malt, either by causing it to germinate or by artificial means. This converts the carbohydrates to dextrin and maltose, and these sugars are then extracted from the grain by boozer in a romance tun (vat or cask) and then agitating in a lauter tun.The resulting liquor, known as sweet wort, is then boi led in a bull vessel with hops, which give a bitter savour and helps to preserve the beer. The hops are then separated from the wort and it is passed through chillers into fermentation vessels where the yeast is added-a process known as pitching-and the main process of converting sugar into alcohol is carried out. (For discussion of fermentation see the chapter Pharmaceutical industry. ) The beer is then chilled to , centrifuged and filtered to enlighten it it is then ready for dispatch by keg, bottle, aluminium can or bulk transport. Figure 65. 8 is a flow chart of the brewing process. Beer Production Flowchart 10 Beer Production Ingredients The water must be pure, with no trace of bacteria. This is vital, because it bequeaths the other ingredients to release all their flavour. 95% of breweries have their own spring or natural well. Barley is a food grain that offers a key advantage it can be preserved for a long time after harvesting. In order for barley to be used in the making of beer, it must first be malted. It is malted barley that gives beer its mark wile and taste. hops or green aureate come from a climbing plant with male and female flowers only the female flowers are used.There are various varieties, ranging from very bitter to aromatic. Hops grew naturally in our regions in ancient times, and this plant has been used by brewers since time immemorial. In antiquity, it could be re displace by mixtures of aromatic herbs, in cross rosemary and thyme, which had the same preserving effect as hops but of course gave the resulting beverage a quite different flavour. Yes, it is hops that give beer its characteristic bitterness, and this plant became so successful that in the 18th century all varieties of beer contained hops. 11 Yeasts transform the sugars in the must into alcohol and carbon dioxide.The character reference of yeast used varies according to the type of beer. There was a time when man had no control over yeasts in beer. Louis Pas teur was able to exempt their role in the brewing process, and yeast culture was developed thank to the work of the Danish scientist Hansen. Nowadays there are two main varieties of yeasts that are used in brewing saccharomyces cerevisiae and saccharomyces carlsbergensis ( permeatefermenting). genuine other products are used in the making of beer, in ill-tempered spices coriander, ginger, cloves, sage, fennel, mustard seeds, aniseed, cinnamon, etc. 12 Beer Production Process MashingMalt is added to heated, purified water and, through a carefully controlled time and temperature process, the malt enzymes break down the amylum to sugar and the complex proteins of the malt to simpler nitrogen compounds. Mashing takes place in a large, round tank car called a mash mixer or mash tun and requires careful temperature control. At this point, depending on the type of beer desired, the malt is supplemented by starch from other cereals such as corn, wheat or rice. Lautering The mash is tra nsferred to a straining (or lautering) vessel which is usually cylindrical with a slotted false bottom two to five centimetres above the rue bottom. The liquid extract drains through the false bottom and is run off to the brew kettle. This extract, a sugar solution, is called wort but it is not yet beer. Water is sparged (or sprayed) though the grains to wash out as much of the extract as possible. The spent grains are remote and sold as cattle feed. 13 Boiling and Hopping The brew kettle, a huge cauldron holding from 70 to 1,000 hectolitres and made of shiny copper or stainless steel, is probably the most striking sight in a brewery. It is fitted with coils or a jacketed bottom for steam heating and is designed to boil the wort nether carefully-controlled conditions.Boiling, which usually lasts about two hours, serves to concentrate the wort to a desired specific gravity, to sterilize it and to obtain the desired extract from the hops. The hop resins contribute flavour, aroma and bitterness to the brew. Once the hops have flavoured the brew, they are removed. When applicable, highly-fermentable syrup may be added to the kettle. Undesirable protein substances that have survived the journey from the mash mixer are coagulated, leaving the wort clear. Hop Separation and Cooling by and by the beer has taken on the flavour of the hops, the wort then proceeds to the hot wort tank.It is then cooled, usually in a simple-looking apparatus called a abode cooler. As the wort and a coolant flow past each other on opposite sides of stainless steel scales, the temperature of the wort drops from boiling to about 10 to 15. 5 C, a drop of more than 65. 6 C, in a few seconds. 14 Fermentation The wort is then moved to the fermenting vessels and yeast, the follow central mystery of ancient brewers art, is added. It is the yeast, which is a living, single-cell fungi, that breaks down the sugar in the wort to carbon dioxide and alcohol. It also adds many beer-flavouring compon ents.There are many kinds of yeasts, but those used in making beer belong to the genus saccharomyces. The brewer uses two species of this genus. One yeast type, which rises to the top of the liquid at the completion of the fermentation process, is used in brewing ale and stout. The other, which drops to the bottom of the brewing vessel, is used in brewing lager. During fermentation, which lasts about seven to 10 days, the yeast may multiply six-fold and in the open-tank fermenters used for brewing ale, a creamy, frothy head may be seen on top of the brew. 15 FiltrationFiltering the beer stabilizes the flavour, and gives beer its polished shine and brilliance. Not all beer is filtered. When assess determination is required by local laws, it is typically done at this stage in a calibrated tank. Filters come in many types. Many use pre-made filtration media such as sheets or candles, while others use a fine powder made of, for example, diatomaceous earth, also called kieselguhr, which is introduced into the beer and recirculated past screens to form a filtration bed. Filters range from rough filters that remove much of the yeast and any solids (e. . hops, grain particles) left in the beer, to filters tight enough to strain comment and body from the beer. Normally used filtration ratings are divided into rough, fine and sterile. bowelless filtration leaves some cloudiness in the beer, but it is noticeably clearer than unfiltered beer. Fine filtration gives a glass of beer that you could read a newspaper through, with no noticeable cloudiness. Finally, as its name implies, sterile filtration is fine enough that almost all microorganisms in the beer are removed during the filtration process. 16 PackagingIn the bottle shop of a brewery, returned revoke bottles go through washers in which they receive a thorough cleaning. after washing, the bottles are inspected electronically and visually and pass on to the rotary filler. some(prenominal) of these machines can f ill up to 1,200 bottles per minute. A crowning machine, integrated with the filler, places caps on the bottles. The filled bottles may then pass through a burrow pasteurizer (often 23 metres from end to end and able to hold 15,000 bottles) where the temperature of the beer is raised about 60 C. or a sufficient length of time to provide biological stability, then cooled to room temperature. Emerging from the pasteurizer, the bottles are inspected, labelled, placed in boxes, stacked on pallets and carried by lift truck to the warehousing areas to ask shipment. Also in the bottle shop may be the canning lines, where beer is encase in cans for shipment. Packaged beer may be heat-pasteurized or micro-filtered, providing a shelf-life of up to six months when properly stored. Draught beer, since it is normally sold and consumed within a few weeks, may not go through this process.The draught beer is placed in sterilized kegs ready for shipment. 17 Quality Control in Beer Production Settin g up specifications is done all the time. Brewers decide on the basic properties of original gravity, color, and olfactory sensation and from this develop a formulation of raw materials and a process to extract what is wanted from them. Sensory methods Sensory methods are not necessarily easy to apply (and often ill used) but are useful and quite cheap to do. They include an compend of beer flavor (undoubtedly beers most important attribute), beer limpidity, color, and foam.Brewers who do not regularly and critically taste and visually examine their beers in a formal setting deny themselves much critical information. Beer color, on the other hand, can be mensurable in a comparator (just a light box set up for visually matching color the human eye is much break away at this than most instruments) or by quite cheap instruments, such as a tintometer. A standard beer set aside for color matching remains stable for quite a long time if kept cold and in the dark. Observers can rate the beers on some sensory scale.Putting numerical values from instruments on flavor, haze, foam, color, and so forth is where the put out starts, but that isnt really necessary for a simple quality-control program. 18 pass a beer on some regular schedule (e. g. daily) between a warm place (60 C) and a cold one (40 C) will create haze more stable beers withstand more cycles than less stable ones. Similarly, storing a beer at 25 C in an archive (a externalize name for a warm cupboard) will encourage microbial evolution and other sorts of beer breakdown. Instrumental Analysis The second kind of specification and analysis is not amenable to sensory testing. gh on this list of invisible specifications has to be the original gravity (OG) and the degree of fermentability (hence alcohol content) of beers. These are most soft determined on wort but require an investment in some simple apparatus a hydrometer and measuring cylinder. The wort OG and fermentability are fundamental specifica tions for a beer, because beer is made from the fermentable portion of the wort. These values also allow a brewer to calculate extract yield from raw materials (brewhouse yield) and telephone beer yield.The degree of fermentability can be determined by a speedy fermentation test in which a high population of yeast cells, with frequent agitation, rapidly ferments out the wort. At the same time, wort flavor and clarity can be noted. A sample of wort, taken under antiseptic conditions and set aside in the archive, will reveal its microbiological status in a few days and tell a good cut about the sanitary status of the brewhouse. Package beer, on the other hand, must be analyzed for CO2 content (carbonation) and bottle air for flavor stability. 19The microbiological status of a packaged beer, especially one destined for a distant market, is of prime concern for beer flavor and for the safety of the consuming creation (potential for exploding bottles). The only satisfactory microbiol ogical test is to pass at least speed of light ml of beer through a 0. 45 micrometer membrane, then plate the membrane on media (such as MRS) under conditions (for instance anaerobic at about 25 C) capable of detecting the target organisms in low numbers. A quick squint at a beer sample under a microscope doesnt cut it. 20