BREWING PROCESS and productions PPT.pptx

Education

1. BREWING PROCESS B y NIRAJ PRAJAPATI (2017FTPB53) COLLEGE OF FOOD TECHNOLOGY Under Vasantrao Naik Marathwada Krishi Vidyapeeth , Parbhani

2. About Bira91 A refreshingly modern beer brand, imagined in India, Bira 91 aspires to bring flavorful beers to the new world. As one of the fastest growing beers in the world, Bira 91 has built a strong portfolio of essential beers and aims to drive the global shift in beer towards more color and flavor. Established in the summer of 2015 by B9 Beverages and headquartered in New Delhi, Bira 91 has quickly become the rage amongst urban millennials owing to its delicious beers, bold identity and a strong draft network. Driven by a dynamic and energetic team of over 500 passionate beer lovers, the company now operates four breweries in India, and has presence across nine countries. Bira 91 is backed by Sequoia Capital India and Sofina of Belgium. Crafted with the creative urban drinker in mind — someone who likes to have fun and doesn’t take life (or beer) too seriously, the brand aims to disrupt the global beer world with 21st century technology and its playful monkey mascot.

3. Beer Production

4. BEER Beer is a fermented, carbonated, alcoholic drink prepared by fermenting the malted cereal grains, mainly malted barley. Process of beer manufacturing is called brewing process. On the basis of alcohol content beer can be: light, medium, strong. On the basis of fermentation type it can be: Lager or ale beer.

5. BREWING PROCESS Brewing is the production of  beer  by  steeping  a  starch  source (commonly  cereal  grains, the most popular of which is  barley ) in water and  fermenting  the resulting sweet liquid with  yeast . The basic ingredients of beer are water and a  fermentable  starch source such as  malted barley . Most beer is fermented with a  brewer's yeast  and flavoured with  hops . Steps in the brewing process include  malting ,  milling ,  mashing ,  lautering ,  boiling ,  fermenting ,  conditioning ,  filtering , and  packaging

6. Ingredients The basic ingredients of beer are water, a starch source, such as malted barley, able to be fermented (converted into alcohol); A brewer's yeast to produce the fermentation; and a flavoring, such as hops, to offset the sweetness of the malt.

7. CLEANING AND MILLING Raw material from the raw material pits are transferred into the silos, from there it was transferred to the cleaning section. Cleaning of raw material includes various steps: Aspiration and cyclone cleaning. Done for the removal of dust and lighter particles. S i evin g : use s i e v es t o r e m o v e p art i c l es s i z e s m a l l er a nd lager than malts. D e- ston e r and ma g nat e : I n t h e p roc e ss s ton e s and a n y metallic particle is removed. Milling: Milling is done to break the malted grains into two or three smaller particles. The main purpose of milling is to break the grain particles into 2 or 3 smaller particles, so that its surface area increases, and it becomes easy for enzymes to penetrate into the grains as the broken particles have open side ends with peptide layers. So, they can directly act on the starch present inside the grain.

8. STARCH SOURCE The starch source in a beer provides the fermentable material and is a key determinant of the strength and flavour 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 will allow conversion from starches in the grain into fermentable sugars during the mash process.

9. HOPS Hops are the female flower clusters or seed cones of the hop vine Humulus lupulus , which are used as a flavouring and preservative agent in nearly all beer made today. Hops contain several characteristics that brewers desire in beer: they contribute a bitterness that balances the sweetness of the malt; they provide floral, citrus, and herbal aromas and flavours ; they have an antibiotic effect that favours the activity of brewer's yeast over less desirable microorganisms.

10. YEAST Yeast is the microorganism that is responsible for fermentation in beer. Yeast metabolizes the sugars extracted from grains, which produces alcohol and carbon dioxide, and thereby turns wort into beer. Yeast Cytology Life Cycle Of Brewing Yeast

11. DIFFERENT MASHING METHODS Different mashing methods are used for different type of the beers. Like decoction, infusion, time-temperature mashing, etc. Type of beer produced depends upon the mashing schedule used. Like a mashing schedule with more rest at different temperatures will have more amount of fermentable sugar, and hence may have more alcohol content.

12. MASHING Mashing: Mashing is a process in which mash material( malted barley grains and adjuncts) are subjected to different time temperature conditions. The main purpose of mashing is to convert the starch available in the grains into fermentable sugars. Therefore, mash mass is allowed to rest at different temperature for different time periods. These rests provide the required temperature conditions at which different enzymes gets activated and cause the required change in the mash. During mashing , water at 45˚C is pumped in the mash tuns . Malted barley grains are hydrated and mixed with this water by using hydrators. Then the mash mass is allowed to rest at 45˚C for nearly 10-15 minutes. Then the temperature is slowly increased to 55˚C and then allowed to rest for 20-30 minutes. Then again temperature is raised to 62˚C and like this upto 73-75˚C with a rest of nearly 25-30 minutes at each temperature. For increasing the temperature either the vessel is heated using steam or hot water is added.

13. MASHING SCHEDULE Mashing schedule includes rest of mash material( mashing liquor + malted barley) at different time-temperature profiles.

14. These principles are illustrated in the examples below: Ale mash with final temperature rise(White) Rising temperature infusion mash – lager(BSL)

15. Adjunct mash / double mash Adjuncts with higher gelatinisation temperatures than barley must be pre-cooked before addition to the main mash, and hence the double mash system. The maize or rice grits are boiled up in the cereal cooker to gelatinise the starch. Once gelatinised, the adjunct is added to the main malt mash. The two mashes are carried out concurrently in separate vessels and combined to give a single temperature rise. Generally, other temperature rises if required are made by heating the mash vessel, rather than transferring a portion back to the cooker. The following diagram shows an example of an adjunct mash requiring gelatinisation of maize grits.

16. LAUTERING/WORT EXTRACTION Wort : wort is a sugary liquid obtained from the mashing of malted grains . Wort consist high amount of fermentable sugars which are required by the yeast as a food during fermentation. Lautering is the process which is used for the extraction of wort from the mash mass after mashing process. Lautering is done in lauter tuns .

17. Mash mass after mashing is transferred in the lauter tun from the mash tun . Then the mash is allowed to stand for nearly 10- 15 minutes and then wort is extracted. Generally wort is recirculated in the lauter tuns to obtain clear wort . Settled grains at the bottom of the lauter tun acts as a filter. Hot water at 72˚C is sprinkled on the grains to remove all the sugar from the mashed grains. Spent grain consists of the residue of malt and grain which remains in the mash-kettle after the mashing and lautering process. SPENT GRAIN

18. Wort Separation With Respect To Specific Gravity

19. WORT BOILING The next step includes boiling of the obtained wort. For this purpose wort boiling kettles are used. Wort is generally boiled at high temperatures of nearly 110-140˚C under pressure or without pressure. Wort boiling plays a number of roles, it kills all the microbes and makes the wort sterile, it causes mallard's reaction and therefore helps In the development of the color of the beer, degrades the proteins which can be removed as hot turbs therefore makes the wort clear, high temperature also isomerize the alpha-acids of the hops which gives the characteristic flavor of the beer. therefore hops addition is done during this step.

20. WORT BOILING Hops in the form of hops extract and hops pellets are added in the wort. Hops addition is done through the hops dosing tank which pumps and mixes the hops by circulating it through the whole tank at high pressure. Wort boiling is done till the wort’s specific gravity reached to the required range specific gravity. Specific gravity of wort increases during wort boiling because water is evaporated during this process.

21. WHIRLPOOL Whirlpool is a device which is used by all the major breweries. Whirlpools are used for the clarification the boiled wort. It also removes the suspended protein which gets denatured due to high temperature of boiling. In whirlpool, hot wort is injected tangentially at 30˚to the tangent to the vessel wall. The tangential injection causes the wort to rotate and the centrifugal force due to rotation cause the big particles to get accumulated on the top of the wort.

22. WORT COOLING Wort form the whirlpools are then either stored in wort storing kettles and then transferred to the Plate heat exchangers(PHE) or directly transferred to the PHE. In PHE, wort temperature is reduced to the temperature which is required for the fermentation process, which is 10- 12˚C. Then this cooled wort is transferred to the conical fermenters situated in the fermentation section.

23. Observation Brand Date Process Time (Hours) BSL 09/03/21 Milling 1 Mashing 3 Lautering 3 Wort Boiling 2 Whirlpool 1:40 White 08/03/21 Milling 1 Mashing 2:20 Lautering 2:45 Wort Boiling 2:20 Whirlpool 1:40

24. FERMENTATION Fermentation of the beer is done for 7-8 days. For the first 3-4 days fermentatio n is done at temperature between 10-12 ˚ C. After 3-4 days of fermentation at 10-12˚C, yeast starts producing di-acetyl, which gives undesirable taste to the beer. At 15˚C, yeast doesn’t secret di-acetyl and consumes the produced di-acetyl, therefore for next 3-4 days fermentation is carried out at 15˚C. Then the temperature is reduced to 4˚C suddenly. Maturation is done at 0-(-1)˚C.

25. CONDITIONING (BEER AGING/MATURATION) When the fermentation is complete the brewer may rack the beer into a new tank, called a conditioning tank. Conditioning of the beer is the process in which the beer ages, the flavor becomes smoother, and flavors that are unwanted dissipate. After conditioning for a week to several months, the beer may be filtered and force carbonated for bottling, or fined in the cask

26. FILTRATION One of the major characteristic of beer is, its sparkling clear appearance. Therefore beer after maturation is required to be cleared by passing it through filters. Filtration is done to remove tanins, cold turbs( denatured proteins), dead yeast cells and other products which formed during the beer manufacturing and may cause problem in the beer clearance. Filtration of beer is done at sub-zero or zero degree temperature.

27. FILTRATION Beer at or sub-zero ˚C is first filtered through kiseleghur filters, in which filter aids like fine sand or high flow powder are used for filtration. Then the beer is passed through the multi-bag filters, in order to remove or filter out the remaining particles and if any filter aid comes into the beer. After filtration bio-form and KMS are pumped through chemical dosing tanks and then Carbonation of beer is done. SPADONI FILTER

28. BOTTLING After filtration, beer is stored in Bright Beer Tanks( BBT) from where it is pumped into the bottling section. Bottles after washing from the washer are then filled with beer at high carbon di-oxide pressure. Then the bottles are capped with crown caps and then forwarded to the pasteurization section for the beer pasteurization.

29. PASTEURIZATION Pasteurization of beer is generally carried out in a tunnel pasteurizers. In tunnel pasteurization bottles or cans are filled and closed in the normal way. The tunnel has a low ceiling with spray heads at regular intervals. The tunnel is divided into many temperature zones to slowly bring the product up to temperature, keep them at a specified holding temperature and then bring them back down to room temperature. As the beer moves through the tunnel it is gradually heated to the pasteurization temperature of 60- 6 5 °C(140°F ) and held at that temperature for a defined period of time before being cooled back down to 20°C (68°F).

30. WATER TREATMENT PLANT WATER FROM MIDC MGF SOFTENER ACF DISINFECTANT R.O R.O TANK SOFTENER STORAGE

31. CLEAN IN PLACE In the company CIP is carried out in following manners: Three step CIP. Five step CIP. Seven Step CIP.

32. CIP THREE STEPS CIP Pre rinse with water for 10 minutes Rinse with hot water for 20 minutes at 85 ⁰ C Final rinse with RO water for 10 minutes

33. CIP FIVE STEPS CIP Pre rinse with water for 10 minutes Rinse with hot water using caustic for 20 minutes at 65⁰C Rinse with water for 10 minutes for complete removal o f caustic Rinse with hot water for 20 minutes at 85⁰C Final rinse with RO water for 10 minutes

34. CIP SEVEN STEPS CIP Pre rinse with water for 10 minutes Rinse with caustic for 20 minutes at 65⁰C Rinse with water for complete removal of caustic for 10 minutes Acid circulation for 20 minutes at 65 ⁰C Rinse with water for complete removal of acid for 10 minutes Rinse with hot water for 20 minutes at 85 ⁰C Final rinse with RO water for 10 minutes

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