BEER PRODUCTION
Prepared By:
Disha
Reg.no: 11008017
And
Fouzia Ashraf
Reg.no: 11008018
Of Food Process Engg. (Final Year)
Sub-Food Plant Layout and Design
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Contents
1.
2.
3.
4.
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6.
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9.
Introduction
Materials
Nutritive Value
Plant Layout
Production
Flow-chart
Machineries
Conclusion
References
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Introduction:
Beer is the world's most widely consumed and probably oldest alcoholic beverage; it is the third
most popular drink overall, after water and tea. It is produced by the brewing and fermentation of
sugar, mainly derived from malted cereal grain most commonly malted barley and malted wheat.
Sugars derived from maize (corn) and rice is widely used adjuncts because of their lower cost.
Most beer is flavored with hops, which add bitterness and act as a natural preservative, though
other flavorings such as herbs or fruit may occasionally be included.
Today, the brewing industry is a global business, consisting of several dominant
multinational companies’ and many thousands of smaller producers ranging from brewpubs to
regional breweries.
The strength of beer is usually around 4% to 6% alcohol by volume though may range from less
than 1% abv, to over 20% abv in rare cases.
Brewing:
The process of making beer is known as brewing. A dedicated building for the making of beer is
called a brewery though beer can be made in the home and has been for much of its history. A
company that makes beer is called either a brewery or a brewing company. Beer made on a
domestic scale for non-commercial reasons is classified as home brewing regardless of where it
is made, though most homebrewed beer is made in the home. Brewing beer is subject to
legislation and taxation in developed countries, which from the late 19th century largely
restricted brewing to a commercial operation only. The purpose of brewing is to convert the
starch source into sugary liquid called wort and to convert the wort into the alcoholic beverage
known as beer in a fermentation process affected by yeast.
Ingredients:
The basic ingredients of beer are as follows Water
 a starch source, such as malted barley, able to be fermented (converted into alcohol);
 a brewer’s yeast to produce the fermentation flavorings such as hops.
Water:
Beer is composed mostly of water. Regions have water with different mineral components; as a
result, different regions were originally better suited to making certain types of beer, thus giving
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them a regional character. For example, Dublin has hard water well suited to making stout, such
as Guiness; while Plzen has soft water well suited to making pale lager, such asPlisner Urquell
The waters of Burton in England contain gypsum which benefits making pale ale to such a
degree that brewers of pale ales will add gypsum to the local water in a process known as
Burtonisation.
Starch source:
The starch source in a beer provides the fermentable material and is a key determinant of the
strength and flavor of the beer. The most common starch source used in beer is malted grain.
Grain is malted by soaking it in water, allowing it to begin germination and then drying the
partially germinated grain in a kiln. Malting grain produces enzymes that convert starches in the
grain into fermentable sugars. Different roasting times and temperatures are used to produce
different colors of malt from the same grain. Darker malts will produce darker beers.
Nearly all beer includes barley malt as the majority of the starch. This is because of
its fibrous husk, which is not only important in the sparging stage of brewing (in which water is
washed over the mashed barley grains to form the wort, but also as a rich source of amylase a
digestive enzyme which facilitates conversion of starch into sugars. Other malted and unmalted
grains (including wheat, rice, oats, and rye, and less frequently, corn and sorghum) may be used.
In recent years, a few brewers have produced gluten free beer made with sorghum with no barley
malt for those who cannot consume gluten containing grains like wheat, barley, and rye.
Hops:
Flavouring beer is the sole major commercial use of hops. The flower of the hop vine is used as a
flavouring and preservative agent in nearly all beer made today. The flowers themselves are
often called "hops". Hops contain several characteristics that brewers desire in beer. Hops
contribute a bitterness that balances the sweetness of the malt; the bitterness of beers is measured
on the International Bitterness Unit scale. Hops contribute floral, citrus, and herbal aromas and
flavors to beer. Hops have an antibiotic effect that favors the activity of brewer’s yeast over less
desirable microorganisms, and hops aids in "head retention”. The length of time that a foamy
head created by carbonation will last. The acidity of hops is a preservative.
Yeast:
Yeast is the microorganism that is responsible for fermentation in beer. Yeast metabolizes the
sugars extracted from grains, which produces alcohol and CO2, and thereby turns wort into beer.
In addition to fermenting the beer, yeast influences the character and flavour. The dominant
types of yeast used to make beer are the top-fermenting Scccharomyces cerevisiae and bottomfermenting Saccharomyces uvarum.
Clarifying agent:
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Some brewers add one or more clarifying agents to beer, which typically precipitates (collect as a
solid) out of the beer along with protein solids and are found only in trace amounts in the
finished product. This process makes the beer appear bright and clean, rather than the cloudy
appearance of ethnic and older styles of beer such as wheat beers. Examples of clarifying agents
include isinglass, obtained from swim bladders of fish; Irish moss, seaweed; kappa carrageenan
from the seaweed Kappaphycus cottonii; Polycar (artificial); and gelatin.
Health Effects and Nutritive Value:
The main active ingredient of beer is alcohol, and therefore, the health effects of alcohol apply to
beer. The moderate consumption of alcohol, including beer, is associated with a decreased risk of
cardiac disease, stroke and cognitive decline. The long term health effects of continuous, heavy
alcohol consumption can, however, include the risk of developing alcoholism and alcoholic liver
disease. Brewer’s yeast is known to be a rich source of nutrients; therefore, as expected, beer can
contain significant amounts of nutrients, including magnesium, selenium, potassium,
phosphorus, biotin, and B vitamins. In fact, beer is sometimes referred to as "liquid bread". Some
sources maintain that filtered beer loses much of its nutrition.
A 2005 Japanese study found that low alcohol beer may possess strong anti-cancer properties.
Another study found nonalcoholic beer to mirror the cardiovascular benefits associated with
moderate consumption of alcoholic beverages. However, much research suggests that the
primary health benefit from alcoholic beverages comes from the alcohol they contain.
Related Beverages:
Around the world, there are a number of traditional and ancient starch-based beverages classed
as beer. In Africa, there are various ethnic beers made from sorghum or millet such as Oshikundu
in Namibia and Tell has a beer made from millet; it is a low alcohol, somewhat porridge-like
drink called "Bozo”. Bhutan, Nepal, Tibet , and Sikkim also use millet in Chhaang, a popular
semi-fermented rice/millet drink in the eastern Himalayas. Further east in China are found
Huangjiu and Choujiu—traditional rice-based beverages related to beer.
The Andes in South America has Chicha, made from germinated maize (corn); while the
indigenous peoples in Brazil have Cauim, a traditional beverage made since pre-Columbian
times by chewing manioc so that enzymes present in human saliva can break down the starch
into fermentable sugars; this is similar to Masato in Peru.
Some beers which are made from bread, which is linked to the earliest forms of beer, are Sahti in
Finland, Kvass in Russia and the Ukraine, and Bouza in Sudan.
Plant Layout:
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Production:
The brewing industry is a global business, consisting of several dominant multinational
companies and many thousands of smaller producers ranging from brewpubs to breweries. More
than 133 billion liters (35 billion gallons) are sold per year—producing total global revenues of
$294.5 billion (£147.7 billion) in 2006.
A microbrewery, or craft brewery, is a modern brewery which produces a limited amount of
beer. The maximum amount of beer a brewery can produce and still be classed as a
microbrewery varies by region and by authority, though is usually around 15,000 barrels (18,000
hectoliters/ 475,000 US gallons) a year.
Flow-Chart:
Malting
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Milling
Mashing
Lautering
Boiling
Fermentation
Conditioning
Filtering
Packaging
Explanation of flow-chart:
1. Malting: Malting is the process where the barley grain is made ready for brewing. Malting
is broken down into three steps, which help to release the starches in the barley. First, during
steeping, the grain is added to a vat with water and allowed to soak for approximately 40
hours. During germination, the grain is spread out on the floor of the germination room for
around 5 days. The goal of germination is to allow the starches in the barley grain to
breakdown into shorter lengths. When this step is complete, the grain is referred to as green
malt. The final part of malting is kilning. Here, the green malt goes through a very high
temperature drying in a kiln. The temperature change is gradual so as not to disturb or
damage the enzymes in the grain. When kilning is complete, there is a finished malt as a
product.
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2.
Milling: The next step in the brewing process is milling. This is when the grains that are
going to be used in a batch of beer are cracked. Milling the grains makes it easier for them to
absorb the water that they are mixed with and which extracts sugars from the malt. Milling
can also influence the general characteristics of a beer.
3. Mashing: Mashing is the next step in the process. This process converts the starches
released during the malting stage, into sugars that can be fermented. The milled grain is
dropped into hot water in a large vessel known as a mash tun. In this vessel, the grain and
water are mixed together to create a cereal mash. The leftover sugar rich water is then
strained through the bottom of the mash in a process known as lautering. Prior to lautering,
the mash temperature may be raised to about 75 °C (165-170 °F) (known as a mash out) to
deactivate enzymes. Additional water may be sprinkled on the grains to extract additional
sugars (a process known as sparging).
At this point the liquid is known as wort. The wort is moved into a large tank
known as a "copper" or kettle where it is boiled with hops and sometimes other
ingredients such as herbs or sugars. This stage is where many chemical and technical
reactions take place, and where important decisions about the flavor, color, and aroma of
the beer are made. The boiling processes serves to terminate enzymatic processes,
precipitate proteins, isomerizes hop resins, and concentrates and sterilize the wort. Hops
add flavour ,aroma and bitterness to the beer. At the end of the boil, the hopped wort
settles to clarify in a vessel called a "whirlpool", where the more solid particles in the
wort are separated out.
After the whirlpool, the wort then begins the process of cooling. This is when the wort is
transferred rapidly from the whirlpool or brew kettle to a heat exchanger to be cooled.
The heat exchanger consists of tubing inside a tub of cold water. It is very important to
quickly cool the wort to a level where yeast can be added safely. Yeast is unable to grow
in high temperatures.
After the wort goes through the heat exchanger, the cooled wort goes into a fermentation tank. A
type of yeast is selected and added, or "pitched", to the fermentation tank. When the yeast is
added to the wort, the fermenting process begins, where the sugars turn into alcohol, carbon
dioxide and other components.
The second to last stage in the brewing process is called racking. This is when the brewer racks
the beer into a new tank, called a conditioning tank. Conditioning of the beer is the process in
which the beer ages, the flavour becomes smoother, and flavors that are unwanted dissipate.
After one to three weeks, the fresh (or "green") beer is run off into conditioning tank . After
conditioning for a week to several months, the beer enters the finishing stage. Here, beers that
require filtration are filtered, and given their natural polish and colour. Filtration also helps to
stabilize the flavour of the beer. After the beer is filtered, it undergoes carbonation, and is then
moved to a holding tank until bottling.
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Mashing is the process of combining a mix of milled grain (typically malted barley with
supplementary grains such as corn, sorghum, rye or wheat), known as the “grain bill", and water,
known as "liquor", and heating this mixture in a vessel called a "mash tun". Mashing allows the
enzymes in the malt to break down the starch in the grain into sugars, typically maltose to create
malty liquid called wort. There are two main methods – infusion mashing, in which the grains
are heated in one vessel; and decoction mashing, in which a proportion of the grains are boiled
and then returned to the mash, raising the temperature. Mashing involves pauses at certain
temperatures (notably 45°C, 62°C and 73°C), and takes place in a "mash tun" – an insulated
brewing vessel with a bottom. The end product of mashing is called a "mash".
Mashing usually takes 1 to 2 hours, and during this time the various temperature rests activate
different enzymes depending upon the type of malt being used, its modification level, and the
intention of the brewer.
4. Lautering: Lautering is the separation of the wort (the liquid containing the sugar extracted
during mashing) from the grains. This is done either in a mash tun outfitted with a false
bottom, a lauter tun, or a mash filter. Most separation processes have two stages: first wort
run-off, during which the extract is separated in an undiluted state from the spent grains, and
sparging, in which extract which remains with the grains is rinsed off with hot water. The
lauter tun is a tank with holes in the bottom small enough to hold back the large bits of grist
and hulls. The bed of grist that settles on it is the actual filter. Some lauter tuns have
provision for rotating rakes or knives to cut into the bed of grist to maintain good flow. The
knives can be turned so they push the grain, a feature used to drive the spent grain out of the
vessel. The mash filter is a plate-and-frame filter. The empty frames contain the mash,
including the spent grains, and have a capacity of around one hectoliter. The plates contain a
support structure for the filter cloth. The plates, frames, and filter cloths are arranged in a
carrier frame like so: frame, cloth, plate, cloth, with plates at each end of the structure. Newer
mash filters have bladders that can press the liquid out of the grains between spargings. The
grain does not act like a filtration medium in a mash filter.
5. Boiling: Boiling the malt extracts, called wort, ensures its sterility, and thus prevents a lot
of infections. During the boil hops are added, which contribute bitterness, flavor, and aroma
compounds to the beer, and, along with the heat of the boil, causes proteins in the wort to
coagulate and the pH of the wort to fall. Finally, the vapors produced during the boil
volatilize off flavors, including dimethyl sulphide precursors. The boil must be conducted so
that it is even and intense. The boil lasts between 50 and 120 minutes, depending on its
intensity, the hop addition schedule, and volume of water the brewer expects to evaporate.
6. Fermentation: Fermentation in brewing is the conversion of carbohydrates to alcohols and
carbon dioxide or organic acids using yeasts, bacteria, or a combination thereof, under
anaerobic conditions. A more restricted definition of fermentation is the chemical conversion
of sugars into ethanol. The science of fermentation is known as zymurgy.
After the wort is cooled and aerated – usually with sterile air – yeast is added to it, and it begins
to ferment. It is during this stage that sugars won from the malt are metabolized into alcohol land
carbon dioxide, and the product can be called beer for the first time. Fermentation happens in
tanks which come in all sorts of forms, from enormous cylindro-conical vessels, through open
stone vessels, to wooden vats.
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Most breweries today use cylindro-conical vessels, or CCVs, which have a conical bottom and a
cylindrical top. The cone's aperture is typically around 60°, an angle that will allow the yeast to
flow towards the cone's apex, but is not so steep as to take up too much vertical space. CCVs can
handle both fermenting and conditioning in the same tank. At the end of fermentation, the yeast
and other solids which have fallen to the cone's apex can be simply flushed out of a port at the
apex.
Open fermentation vessels are also used, often for show in brewpubs, and in Europe in wheat
beer fermentation. These vessels have no tops, which makes harvesting top fermenting yeasts
very easy. The open tops of the vessels make the risk of infection greater, but with proper
cleaning procedures and careful protocol about who enters fermentation chambers, the risk can
be well controlled.
Fermentation tanks are typically made of stainless steel. If they are simple cylindrical tanks with
beveled ends, they are arranged vertically, as opposed to conditioning tanks which are usually
laid out horizontally. Only a very few breweries still use wooden vats for fermentation as wood
is difficult to keep clean and infection-free and must be repitched more or less yearly.
After high krausen occurs, a bung device (German: Spundapparat) is often put on the tanks to
allow the CO2 produced by the yeast to naturally carbonate the beer. This bung device can be set
to a given pressure to match the type of beer being produced. The more pressure the bung holds
back, the more carbonated the beer becomes.
7. Conditioning: When the sugars in the fermenting beer have been almost completely
digested, the fermentation slows down and the yeast starts to settle to the bottom of the tank.
At this stage, the beer is cooled to around freezing, which encourages settling of the yeast,
and causes proteins to coagulate and settle out with the yeast. If a separate conditioning tank
is to be used, it is at this stage that the beer will be transferred into one. Unpleasant flavors
such as phenolic compounds become insoluble in the cold beer, and the beer's flavour
becomes smoother. During this time pressure is maintained on the tanks to prevent the beer
from going flat. It can take from 2 to 4 weeks, sometimes longer, depending on the type of
beer. Additionally lagers, at this point, are aged at near freezing temperatures for 1–6 months
depending on style. This cold aging serves to reduce sulphur compounds produced by the
bottom-fermenting yeast and to produce a cleaner tasting final product with fewer esters.
If the fermentation tanks have cooling jackets on them, as opposed to the whole fermentation
cellar being cooled, conditioning can take place in the same tank as fermentation. Otherwise
separate tanks (in a separate cellar) must be employed. This is where aging occurs.
8. Filling: Filtering the beer stabilizes the flavour, and gives beer its polished shine and
brilliance. Not all beer is filtered. When tax 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.
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Filters range from rough filters that remove much of the yeast and any solids (e.g. hops, grain
particles) left in the beer, to filters tight enough to strain color and body from the beer. Normally
used filtration ratings are divided into rough, fine and sterile. Rough 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.
9. Packaging: Packaging is putting the beer into the containers in which it will leave the
brewery. Typically this means putting the beer into bottles, aluminum cans and kegs, but it
may include putting the beer into bulk tanks for high-volume customers.
Machineries:
1.
Fermenter: Fermentation tanks are typically made of stainless steel. If they are simple
cylindrical tanks with beveled ends, they are arranged vertically, as opposed to
conditioning tanks which are usually laid out horizontally. Only a very few breweries still
use wooden vats for fermentation as wood is difficult to keep clean and infection-free and
must be repitched more or less yearly.
2.
Mash tun: The mash tun, traditionally used in Britain, is a vessel that serves the dual
role of being used both for mashing and wort separation. They are the cheapest in terms
of capital expenditures and the simplest to operate, with little or no automation. The
combination of these factors makes the mash tun particularly attractive to craft brewers.
The disadvantages of mash tuns are their requirement for coarsely ground malt, the need
for well-modified malts, their limitations in working with adjuncts, and their inflexibility
in regard to maintaining mash temperature (
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3.
Lauter tun: The lauter tun is the most widely employed wort separation vessel system in
North America and Europe. Lauter tuns are, in general, designed much like infusion mash
tuns, but they are wider and shallower, as shown in Figure 10.1. Like the mash tun,
filtering is through slots in a false bottom that supports the grain bed. However, there are
some big difference between mash tuns and lauter tuns. Lauter tuns are suited for use of
under-modified malts and high adjunct rates. However, if the recipe has less than 50%
malt, there will be insufficient husk material to form an adequate filter bed (15). The
grists used in a lauter tun are finer, the mashes are more dilute, and the bed depth
shallower all of which helps in extract performance.
4.
Mash filter: Although lauter tuns are widely employed for wort separation, some largevolume brewers prefer mash filters. Mash filters are very much like plate and frame
filters consisting of a series of grid-type plates alternating with hollow frame plates that
are suspended on side rails. Each grid plate of the filter is covered on both sides with a
monofilament polypropylene cloth. Accordingly, the grist serves no purpose as a filter
medium and their particle sizes are of no consequence. Mash filters are more likely to be
used in larger breweries where throughput and floor space are priorities. To initiate the
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wort separation cycle, the mash filter is flushed, then preheated with hot water. The mash
is then pumped from the mash mixer into the filter through the top channel, completely
filling the filter frames. The entire transfer to the mash filter is completed in 20 to 30
.minutes (33).
Conclusion:
Beer is the world's most widely consumed and probably oldest alcoholic beverage; it is the third
most popular drink overall, after water. So we can say that brewery is a dedicated building for
the making of beer, though beer can be made at home, and has been for much of beer's history. It
has got some nutritive values along with some positive and negative health benefits.
Fermentation plays a major role in its distinct flavor and content of alcohol .Actually alcohol is
produced during fermentation only .Hops adds bitter distinct taste in beer.
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