Attachment Report Brewing
Attachment Report Brewing
Attachment Report Brewing
Contents
Acknowledgments ........................................................................................................................... iv
Executive summery .......................................................................................................................... v
CHAPTER ONE BACKGROUND OF THE COMPANY
1.1 HEINEKEN .............................................................................................................................. 1
1.2 HEINEKEN IN ETHIOPIA.......................................................................................................... 1
1.3 WORK FLOW .......................................................................................................................... 2
1.4 OBJECTIVE OF THE INTRNSHIP .............................................................................................. 5
CHAPTER TWO PROCESS DESCRIPTION
1.0 Introduction ........................................................................................................................... 6
2.1 Raw material.......................................................................................................................... 7
2.2 Brewery additives, cleaning chemicals and packaging material ...................................... 11
2.3 Brewing ................................................................................................................................ 12
2.3.1 Brew house ....................................................................................................................... 12
2.3.2 Fermentation ................................................................................................................ 17
2.3.3 Filtration ....................................................................................................................... 22
CHAPTER THREE DEPARTMENT OF PACKAGING
3.1 Bottling. .............................................................................................................................. 24
3.2 Kegging ................................................................................................................................ 28
3.3 Key packaged beer parameters ........................................................................................... 30
CHAPTER FOUR DEPARTMENT OF UTILITY
4.1 Waste water treatment plant.............................................................................................. 31
4.2 Water treatment plant (WTP) ............................................................................................. 33
CHAPTER FIVE QUALITY CONTROL DEPARTMENT ......................................................... 37
5.1 The physicochemical laboratory.......................................................................................... 37
5.2 Laboratory Equipment and material ................................................................................... 37
5.1 lines follow up or line control.............................................................................................. 39
5.2 FST follows up ...................................................................................................................... 41
List of figures
Figure 1 organizational structure .................................................................................................... 2
Figure 2 hop plant............................................................................................................................ 9
Figure 3 isomerization of alpha acid at higher temperature ......................................................... 10
Figure 4 amylose ........................................................................................................................... 13
Figure 5 amylopectin ..................................................................................................................... 14
Figure 6 block diagram of brewing process .................................................................................. 17
Figure 7 Overview of Saccharomyces metabolic activities influencing beer quality...................... 2
Figure 8 the simplified overview of yeast fermentation ................................................................ 21
Figure 9; Beer Membrane Filtration ................................................................................................ 1
Figure 10 Block flow diagram for filtration .................................................................................... 1
Figure 11 Bottle washer................................................................................................................. 25
Figure 12; temperature vs. pasteurizing plot ................................................................................. 27
Figure 13 flash pasteurization……………………………………………………………………28
Figure 14 keg line ......................................................................................................................... 29
Figure 15 Block Flow diagram of packaging ................................................................................ 30
Figure 16 block flow diagram for WWTP..................................................................................... 31
Figure 17 course screening……………………………………………………………………….31
Figure 18 FINE screening ............................................................................................................. 32
Figure 19 pre-clarifier ................................................................................................................... 32
Figure 20 calamity tank…………………………………………………………………………..32
Figure 21 Equalization tank........................................................................................................... 33
Figure 22 UASB tank .................................................................................................................... 33
Figure 23 CASS tank ..................................................................................................................... 33
Figure 24 rotary skimming ............................................................................................................ 33
Figure 25 General block diagram of water treatment plant ........................................................... 36
List of tables
Table 1 Comparison among ale and lager beer ............................................................................................................. 7
Table 2 average chemical composition of barley malt .................................................................................................. 8
Table 3 secondary metabolite and their aromatic effect .............................................................................................. 21
Acknowledgments
First of all I would like to thank almighty God, who helped me in all these things through
my living. My next gratified thankful of gratitude is going to Mr Zewdineh shibeshi Mr
Rekik H. for their help, advice and sharing their knowledge. I would to thanks Mr Habtay
.G, and Ephrem hailemariam quality analysts and my supervisor. And all the quality
control team. I would like to thank Mr birhan Zewde (brewing manager) my supervisor
on the brewing department and Mr selamihun Girma (quality control manager). I would
like deeply thankful to all workers (team leaders and operators) of green field Heineken
brewery who assisted me by providing all the relevant information and reading material
during I stay in the company. Finally I would like to express my great thanks to all my
friends for what we were together during the internship period.
Executive summery
Heineken Brewery Company is one of the most productive which can produce in high
quality and quantity beer. In this summer I was applying and training on Heineken
Brewery Company; 4 week in brewing department and 6 week in the quality department.
I did not have the chance to stay for several week in packaging and utility due to shortage
of time to do with all department. But I have visited just for one day to know the general
over view. Brewing has vast process. But to make simple the internship paper is divided
in to six chapters. The first chapter contains the general introduction of the paper which
includes background of the company and its production, vision and mission of the
company, objectives of the internship, significance of the paper (the internship), and
organization of the paper. The second chapter deals about raw material of beer and
general process description of the brewing which are brew house, fermentation, and
filtration as well as figures and block diagram of the brewing processes. The third chapter
deals with bottling and kegging or collectively packaging, chapter 4 describes about the
utility department. Chapter 5 deals with the quality control department. Finally the sixth
chapter deals about the overall benefits or experience gained from the internship period in
Heineken brewery Share Company.
CHAPTER ONE
1.1 HEINEKEN
Heineken is one of the world’s most recognized breweries. The Heineken family entered
the beer business in 1864, when Gerard Adrian Heineken acquired a small brewery in the
heart of Amsterdam. This company is one of the most outstanding; largest European
brewer and the world’s second largest brewer by its consolidated volume. In 1900,
Heineken imports its first beer into Africa. In 1946, it enters Nigeria. In 1988, first local
sourcing project in Nigeria. In 2007, South Africa Green field brewery was opened. In
2009, the Heineken Africa foundation, designed to support and enhance the improvement
of health for people in sub-Saharan Africa, is established. In 2015, Heineken brewery
Share Company opened in Ethiopia, at Kilinto area.
OBJECTIVES OF HBSC
The main objective of this company is to support the socio-economic development of
Ethiopia in particular and the overall development and well-being of the country; In
addition to this, has aim to ensure product consistency at the required level and to
enhance the country’s food and beverage industry product VISION OF HBSC
MISSION OF HBSC
Its mission is to deliver consistent quality products, on time and in full while working
safely and developing the company, the people and the country.
Production Department
Function
On the basis of the marketing strategy and sales plan prepare production plan and
manage the production process according to the plan.
Marketing Department
Function
Strategic thinking, planning and implementing of the marketing function of
HBSC private leading company.
Developing/Designing price policy, promotional strategy, distribution mechanism
and implementing after approval by the general managers
Ensuring that effective customer service is produced at all levels
Human Resource
Function
Design and develop human and marketing policies and procedure to ensure
performance standards, consistency and transparency in the course of human
resource management.
Carry out proper manpower planning to ensure supply of man power in terms of
quality and quantity.
Carry out induction and orientation program for newly recruited staff.
Design and Developing trained and developed policies and procedure.
Finance Department
Function
Develop financial strategies and policies that help the company competitively
and profitability.
Maintenance Department
Function
Supply Department
Function
Manage the receipt and ware housing of raw and input materials and their
distribution to user department as they are required.
Plan and control inventory of input materials using property inventory
management techniques. Manage ware housing and distribution of finished
products.
We Students undergo an internship or apparent ship program to prepare ourselves for the
real world. We take advantage of internship to gain practical, professional experience
during the education and make us to contact outside of the university environment.
Specific Objectives
The specific objectives of the internship include
CHAPTER TWO
Process description
1.0 Introduction
What is Beer?
Beer is the oldest and the most widely consumed alcoholic drink in the world it is the
third most popular drink next water and tea. The process of producing beer is known as
brewing. A dedicated building for making of beer is called brewery. Beer is an alcoholic
beverage produced by the scarification of starch and fermentation of the resulting sugar.
It was the first alcoholic beverage known to civilization. The first to brew is still not clear
but it is believed to be 4000 years ago in Mesopotamia. And brewing beer categorized
into Two main types: - ales and lagers
Water;
Barley; Malt
Malt when raw barley gets appropriate moisture content and temperature it start to
germinate and after it drains it is called malt .there should no further germination. From
local the company obtains from Asela and Gonder; while the foreign malts are obtained
from different foreign company of malt.
The malts from the ware house includes foreign malt and local malt used as proportional
as required, for the production of different types of brands. As a brewing cereal, barley
has is ideally suited for brewing for the following reasons:
It has high complement of enzyme for converting its starch supply into
simple sugar.
The gelatinization temperature (i.e., the temperature at which the starch is
converted into a water soluble gel) is 52-59°C much lower than the
optimum temperature of alpha-amylase(70°C) as well as of beta-amylase
(65°C) of barley malt. The effect of this is to bring the starch into solution
and to hydrolyze it in one operation.
Barley has a high starch and low protein content which needed for yeast
nutrition
This barley comes from Poland, Portugal, Egypt, France, Germany, Munich, and
Belgium from abroad. Before the malt processed, parameters such as starch content,
protein content, nitrogen level, moisture content of the malt measured and ascertained by
the quality assurance department.
Hop
Hop Hops are the green cone shaped flowers of the female hop plant,also known by its
scientific name (HumuluslupulusLinnaeus). It is a dioeciously, perennial plant
belonging to the Cannabaceae family of the Urticales order (Roberts and Wilson 2006).
Besides the common hop, the Humulus genus includes 2 other species,
HumulusjaponicusSiebold&Zucc and HumulusyunnanensisHu, but only
Humuluslupulusis of industrially used [1]. Those species of plant can secrete resin called
hop resin from their lupulin gland of hop cons in the form of yellow powder.
Hop extract; is a form of hop which contains high concentration of alpha acid which is
the primary constituent of beer bitterness. This form of hop is added at the initial step of
boiling because the alpha acid is very resistive to heat but at higher temperature it
isomerized in to iso alpha acid and gives very bitter test.
Hop pellet; this form of hop which contains the aromatic and volatile component of the
hop for this reason it is added at the post boiling of wort copper in order to not escape
during boiling at high temperature. Hop pellet is very sensitive to heat it can escape or
evaporate during wort boiling. Nowadays hop extracts are becoming favored in place of
dried hops. The importance of hop is to provide bitterness and aroma .
Brewer’s Yeasts
Yeast is a living organism and therefore it should not properly be considered as raw
material. Yeast is largely responsible for making beer.
The growth and multiplication of this living organism are inseparable from the metabolic
products which produce ethanol, carbon dioxide and the whole range of metabolic
products which contribute to the flavor of the finished product. Yeast magnificently
enhances and reveals the fundamental flavor of beer derived primarily from malt and
hops.
There are numerous types of brewing yeast. Some examples of yeast types are: ale yeast,
lager yeast (top yeast, bottom yeast) Saccharomyces cerevisiae (Ale yeast) or
S.carlsbergensis(Lager yeast)[3]. This means simply downstream and upper stream
fermentation remember in HBSC only lager yeast are used and lager beer production.
Yeast can grow aerobically or anaerobically. In the former case the cells are said to be
respiring; this step is called propagation just before pitching and in the latter fermenting.
2.3 Brewing
For the first four weeks of my internship period I was attending in the brewing
department where the bright beer is produced. The brewing department has three sub
sections those are;
brew house
fermentation
filtration
2. Protein rest: is the temperature zone in the range of 45°-55 0c to break down any
remaining large proteins into smaller proteins and amino acids. Here proteins are break
down in to amino acids by the help protease enzyme at 53oc.
The two main enzymes responsible for protein degradation are peptidase and protease.
Peptidase provides the wort with the amino acid nutrients used by the yeast.
Protease breaks down the larger proteins which help enhance head retention and
reduce haze.
Figure 4 amylose
Beta-amylase breaks down starch and dextrins into glucose (one molecule),
maltose (two molecules) and maltotriose (three molecules) by acting on the beta
glycosidic bond or glycosidic linkage. After beta-amylase is through working, the
starch has been broken down into fermentable sugar.
Mash schedules that target the beta-amylase enzymatic action (optimum at
60°-650c) yield a wort that is highly fermentable. The beer produced will
be drier tasting and contain more alcohol.
Branched chaine
Figure 5 amylopectin
Next to the mash tun the given mash is transfer to mash filter where it is going to be
separated from the husk which is called brewery spent grain. There are two methods to
do wort separation: lautering and mash filters. The main objectives are filtering wort
and getting the maximum extract of desired ferment ability from this step sweet wort is
comes out. These two steps take to 1 or 2 hours [2]. I was involving in removing of the
spent grain from the filter membrane of mash filter at the end of filtration.
I was also involving in checking of the optimum desertification by iodine test after the
mash off.
Boiling in wort copper
In this point of brewing sweet wort which is obtained from the total process, with hops,
and process aids, like syrups or sugars are boiled in a tank called wort copper. Usually
syrups are derived from barley maize, or wheat. Sugars are usually sucrose. When it is
used in the kettle (copper), it is referred to as "copper sugar". The raw materials on the
previous steps are only malt, water and some cereal adjuncts. Just before boiling hops,
one of the four principal raw materials are added. In Heineken brewery share company
Hops are used with two forms like hops pallets or hop extract. Hops and hop-derived
products have very significant use mainly to impart flavour to beer. Bitterness is the
primary flavour impact of hops though under some processing conditions their aroma
character can survive into beer. This mix boils in a kettle at a temperature above 100 °C
and at a time between 30 minutes and 1 hour and 30 minutes [1]. I have involved here
also in Hop dosing and other operation like controlling the system on the computer
software called brew max.
The objectives of wort boiling include the following:
The coagulation and precipitation of proteins is a key factor in producing clear, stable
beer. Boiling the wort drives off volatile wort compounds, one of the most important of
which is SMM, the precursor to DMS. DMS can impart cooked corn aromas and flavors
to beer and is generally undesirable at high levels. Last, boiling the wort decreases its
pH by about 0.2 as a result of the action of calcium and magnesium ions, residual
alkalinity, and the formation of Maillard products and by the addition of bittering
substances.
Secondary effects: The secondary effects of wort boiling include the following:
adjustment of the wort color as a result of melanoidin production
dissolution of some hop flavor and aroma compounds (mostly a result of
essential oils in hops)
After boiling the wort is called hopped wort. At the post boiling of the wort copper the
hop pallet is added for the impartment of aromatic flavour.[3]
The temperature of the clarification process is between 100 – 80 ºC and it takes less than
one hour [2].
Wort Aeration
For initial respiration of yeasts air is required. The wort is aerated after cooling. Wort
aeration at high temperature results in extensive oxidation. As a result the wort becomes
darker and bitter. The presence of oxygen is however, absolutely essential for yeast
growth. Under anaerobic condition (absence of air) yeast growth is inhibited and
fermentation processed slowly or even stops. This defect can be prevented by optimal
aeration of the cold wort approximately (6 – 12 ppm oxygen). Yeast Pitching Yeast is
the main agents for the transformation of wort components to beer. Wort from each brew
pitched according to the amount needed and send to fermentation.
H3po4,
Hot
Water AMG, water
Malts: foreign CaCl2
2.3.2 Fermentation
In general terms, fermentation is the metabolic process of converting sugar to alcohol,
acids or/and gases by yeast or bacteria. In addition it is the key step for the releasing of
the aromatic compounds which are responsible for the flavor and smell of the final
product beer. The main products of fermentation are ethanol and carbon dioxide. Other
reaction products include: higher alcohols, aromatic alcohols, esters, organic acids,
carbonyl compounds, sulphur-containing compounds and polyhydric alcohols; all of
which are important for the properties and the quality of the resulting finished product
beer. All the compounds formed have a different taste. Their combined contribution
makes up or off-flavor beer. During fermentation period there are fermentation control
parameters. These are:-
temperature
pressure and
yeast count
The cooled aerated wort made in the brew house is fermented by yeast to make an
immature beer. The most commons fermentable sugars present in the wort are; maltose,
maltotriose and lesser amounts of sucrose, glucose and fructose. Before fermentation
there is aerobic respiration of yeast in the yeast propagation tank contains one brew
wort and yeast. During this process, yeast reproduces. After the all sugar extract are
consumed the wort is transferred in to two fermenter tank then add about one brew
batch to that tank from brew house for further reproduction. Then ready for pitching for
every FST.
For yeast to live and grow, wort must contain a sufficient supply of nutrients.
Nutritional deprivation leads to incomplete and inadequate fermentation. Yeast needs
fermentable carbohydrate, assimilable nitrogen, molecular oxygen, the vitamin biotin,
sources of phosphorus and sulphur, calcium and magnesium ions and trace elements
such as copper and zinc ions [5].
Pitching
The first step of fermentation is pitching. Pitching is simply a brewer’s term meaning
adding yeast to the wort and fill into fermenter. But, before the pitching we have to
consider many things. Next, there is a short list of the most important issues to take into
consideration:[4]
The pitching rates should be adjusted to account for the number of viable cells rather
than the total number of cells. That concept is called viability. Dead cells can be
determined by staining with methylene blue and counting with a hemacytometer, the
most common method to determinate the viability [6].
Fermentation phase
Lag phase: take 3-15hrs after pitching yeast. When yeast is pitched in to the Wort, they
began process to adapt the Wort environment condition known as the log phase.
Expositional growth phase: 1- 4 days after pitching yeast. As the yeast comes out of the
log phase, it starts to consume the sugars in the Wort. Aerobic respiration occurs during
this phase so the cell counts increases rapidly.
Stationary Phase: 4-10 days after pitching yeast. This phase is when the yeast stops
replicating because of anaerobic condition. It involves the reduction of unwanted flavors
produced during the growth phase such as acetaldehyde and diacetyl or VDK.
Sedimentary/death phase: When nutrients are exhausted the yeast cells clump together.
They flocculate. This is harvested and used again. Some of the yeast will die and settle to
the bottom. These yeasts are purged. The inputs of fermentation are cold Wort, air and
yeast. The Ruh Period (Lasts for about 2 days) is very necessary for the quality of beer
because during fermentation substances other than alcohol are produced by the yeast such
as Diacetyle (VDK). This has a buttery taste. The yeast itself breaks down the VDK
during this period. Then the yeast will be harvested and sent to Yeast storage tank. These
yeasts can be used again up to seventh generation.[4]
2.3.2.2 Maturation
Maturation starts at the end of primary fermentation, when the green beer transfer in to
maturation cellar it pass through heat exchanger and cooled between 10c to -
10c.Sediments and yeast purged every 72 hrs after maturation started. The reason for
maturing beer is:-
2.3.3 Filtration
It is Saied that “people drinks beer with their eye”. The important index of beer
stability is the visual appearance of the product. So for this reason it is needed to
filter the mature beer to remove or reduce the concentration of so many biological
and non-biological hazes, other colloidal and suspended particles like yeast.
Key; turbidity which is the result of complex of proteins and polyphenols refers to
haze.
Filtration is the process by which mature beer which comes from fermentation
room is filtered.
Mature beer from the fermentation tank still contains some yeast and haze
particles. The mature beer from MBT is passing through BMF in order to remove
Yeasts, Proteins, Poly phenols, Suspended particles and others. Here before
interring to BMF silcajel is dosed to unfiltered beer thank as coagulant for yeast
i.e yeasts are adsorbed to the surface of the silcajel and they will become large in
size so that they will not pass through the membrane of the filtration membrane.
Other surface active substance such as excess proteins may also adsorb on it.
PVPP is also used to complex poly phenols and precipitate and then they will be
ready to remove easily by membrane filtration. Oxalic acid which is toxic
compound for human diet is also chelating with calcium and ready to remove
during filtration. Generally filtration uses so many adsorbent substances in order
to adsorb the surface active substances (adsorbate) like yeast, proteins, poly
phenols and other unwanted substance like oxalic acid.
The main purpose of filtration is to remove or reduce the concentration of large and small
undesirable molecules which are found in beer make a beer turbid or unclear. Once the
beer is filtered again it passes through security filter for further filtration then it is
transferred to the BBT, which serves as a storage tank till the beer is needed for
packaging. But before entering the BBT it is diluted with DAW for OG adjustment. It is
also blended with carbon dioxide to give the beer its characteristics.
The filtrate are stay attached on the filtration membrane and the BMF is washed by
caustic soda and hot water in order to remove the attached filtrate.
Silica gel
Filtered beer
Carbonation
Daw blending Bright beer tank
CHAPTER THREE
DEPARTMENT OF PACKAGING
I have seen the general over view of the packaging plant at the end of my internship
period. Due to the shortage of time I have not got time to see all the manufacturing
process.
Once the beer has been produced and stored in the bright beer tank, it is then ready for
packaging. The main requirement of packaging is to protect the product from
deterioration, to present an attractive consumer product, to meet local government
regulation in terms of consumer information and to meet any consumer safety
requirements. In Heineken brewery beer packed in bottles, and draft beer in kegs.
3.1 Bottling this step is dealing about filling of the filtered beer in to glass bottle.
Collection of empty bottles
Empty bottles in crates collected from customers, and stored until use. When packaging
starts these bottles conveyed to De-pelletizer machine on roller conveyer.
De-palletizer- the de-palletizer is used to remove the new bottles from their pallets
and assemble them on a conveyor ready to move through to the rinse.
Bottle washer
Bottle Washing Bottles contain unfinished beer, fur, dirty labels and foreign matters in
and on their body. Thus it is essential to clean them and make nice for containing the
finished product beer. Bottle washing has the following Purposes:
Method of operation:
Bottle In feed and discharge takes place at different locations and thus assures the best
possible hygienic conditions. The pre-cleaning system heats the bottles and removes glass
fragments and coarse contamination. Subsequently the bottles run through various caustic
baths in vertical loops, in order to completely wash away dirt or labels. Before the bottles
leave the machine, they are cooled in the post treatment zones with a small quantity of
fresh water and freed of any remaining dirt or caustic residues. Check: washing is
completed the presence of caustic is detected as: add distilled water to the bottles and
shake, then add few droplets of phenolphthalein indicator. If there is no color change, the
bottles are clean and sent to the next step. If not, they are again washed.
Crate washer
The Un-caser (un-packer) machine left the crate empty and conveyed to crate washer.
Here pre-caustic solution/low concentrated caustic/ is sprayed on the crates, and rinse by
hot water to remove dirt.
Empty bottle inspection (EBI): the bottles are checked and either passed or rejected.
There are two types of rejection soft rejection and hard rejection.
Foreign bottle rejection: In this inspection there are set parameters (like height, color,
etc.) and if the parameters are not met they will be rejected; this is called hard rejection.
On the other hand soft rejections are: neck inspection, side one inspection, Side two
inspection (180o each), caustic inspection, bottom inspection. If the bottles pass all five of
the inspection it will go to the filler or else it will be rejected.
integrating a vacuum feature providing an option for double pre-evacuation of the bottles
– thus assuring low oxygen pick-up during the beer bottling operation. This equipment
has a maximum filling capacity of 42,000 bottles per hour. During filling: loss of beer
must be avoided, avoidance of contamination and quality of beer must be maintained,
Avoidance of CO2 loss from if not quality and shelf life is lowered.
During filling the air inside bottle is sucked through vacuum chamber and the bottle
pressurized with CO2 and filled with beer here since CO2 is denser then O2 oxygen will
not get in to the bottle during filling. Finally the bottle reaches the required level it stops
filling and discharge out for crowing.
Crowning: immediately after filling the bottles are crowned using corks to prevent loss
of beer component.
Pasteurization
Beer in bottles pasteurized in order:
Bottle Labeling
The appearance of the bottles is important for competitive market. Walia brewery has
neck and body labels. Company name with its trade mark, alcohol content (v/v %),
amount of extract (in ° P), volume per bottle, and customer information line are
information found on the labels. Pentair made labeling machine called Solomatic,
performs a precise label application. Low glue consumption and a high hygiene standard
are some of the features that make this cold glue labeling system stand out. Depending on
the labeling concept involved, body or neck, tamper-evident labels can be applied. It
labels a maximum of 55,000 bottles per hour.
It is a machine which contains a sensors that is activate by the presence of light. These
sensors used to select:
Casing (packer)
Now the bottle beer finished all the process and proceeds to casing. Casing machine puts
bottled beer into crates. It can fill six crates at a time with a capacity of casing 2,400
𝑏𝑜𝑡𝑡𝑙𝑒𝑠 per hour. Bottled beer now piled on metal supports and transport to pelletizer.
Palletizer: the crate will now assembled on to the bottle, transferred to storage using
fork lift so it’s easy to transportation.
3.2 Kegging
Beer is also packaged in keg with the name draft beer. Cellar, unfiltered beer, is packed
in keg. Bright beer from BBT filled in kegs. Prior to filling the beer is pasteurized at 74℃
for 30 seconds using flash pasteurizer.
Collection of empty kegs: similar to bottles empty kegs collect from customers.
Washing: removing dirt and residual beer. The procedure is
Washing the external part by blowing hot water while they are conveyed.
Applying caustic solution to the inside part and rinse by hot water.
Blowing out the hot water by steam.
Before filling the steam is removed to avoid condensation problems in the keg. If
condensation or water droplets are formed, it favors the growth of microorganisms and
this lower the quality and shelf life. Then the keg pressurized using CO2 and filled by
beer. The keg should contain 30 𝑙𝑖𝑡𝑟𝑒𝑠 of beer. This is checked by weighing filled keg. It
should weigh between 39 and 41 kg. If it lowers the sensor push out & filled again. Kegs
piled in metal supports and transported by forklifts and stored until sale.
Due to their pasteurization time bottled beer and Draft beer differ in preservation times or
shelf life. Draft beer has short storage life (maximum of two months) but Walia beer can
be stored for maximum of one year.[9]
Alcohol content (ABV): Reflects strength of beer and value as such to consumer
CO2: Dissolved CO2 creates a fizzy character and ‘bubble rise’ in glass
CHAPTER FOUR
DEPARTMENT OF UTILITY
In this department there are seven plants. These are: waste water treatment plant
(WWTP), Water treatment, steam boiler plant, CO2 recovery plant, Cooling plant,
Compressed air plant, generator (power supply) plant and waste water treatment.
Figure 19 pre-clarifier
Calamity tank
It is a holding tank for temporarily storing high organic concentration wastewater or
severely high pH or severely low pH wastewater, also can be used as a holding tank for
temporarily storing normal wastewater being out of specification. As calamity tank is a
buffering tank, normally calamity tank should be controlled at low level.
Equalization tank
It is a wastewater holding tank to make sure equalization of flow, also acidification
reaction will happens in equalization tank, which is much helpful for anaerobic process
unit. As equalization tank is also a pre-acidification tank, normally hydraulic retention
time (6 - 10 hours) needs to be ensured for the pre-acidification degree.
UASB
UASB (Up-flow anaerobic sludge
blanket) uses an anaerobic process
whilst forming a blanket of granular
sludges which suspends in the tank.
Wastewater flows upwards through the
blanket and is processed (degraded) by Figure 22 UASB tank
the anaerobic microorganisms.
Rotary skimmer
Rotary skimmers are installed for clean water drainage, 2 sludge recycle pump are
installed for sludge recycling and discharging, 2 DO meters are installed for monitoring
DO when in aeration phase and control blowers running frequency.
to the desired quality. The main aim of WTP is to treat untreated water to get clear water.
In order to be suitable for use in brewing, water must be: Microbiologically pure, Clear
and colorless (turbidity and color can be caused by suspended solids), Tasteless and
odorless (chlorinated water can affect beer flavor), pH neutral (pH 7 or slightly acidic),
Free from heavy metal ions. The water treatment plant at Heineken brewery is designed
for treatment of well (underground) water. The main substances or chemicals that used
for WTP are: Ferric chloride, Anti scale, Sodium hydro oxide, Sand, Chlorine and Active
carbon filter.
In Heineken brewery water comes from underground by the help of centrifugal pumps in
to water treatment plant using six walls (now wall three not functioned). Then its
turbidity is checked online by amplifier, and if turbidity less than 3 NTU it enters in to
well water tank otherwise drain.
Steps of water treatment plant in Green Field Heineken brewery are: Storage (well water
tank), Mechanical Treatment, Membrane Filtration (reverse osmosis) Cooling System
and Advanced Treatment Storage (active carbon filter).
1 Well water tank: -The well storage tank has the following functions: Serves as
temporarily storage to maintain a continuous operation mode, Supplies water for the
media filtration backwash wet, Control station for the turbidity of the well water
2. Mechanical Treatment: in this steep flocculation, aeration and multimedia filter are
involved. liquid minerals like Aluminum and Manganese are Eliminated by dosing
flocculants (ferric chloride, FeCl3); for the elimination of colloids and unwanted species
like aluminum and Aerate to facilitate the reaction.
Multimedia Filter: It used as a filter media, it has different size of sand that is fine,
medium and course all are used to Retention of un dissolved suspended, turbid and dirt
particles.
Osmosis is the passage of water through a semi permeable membrane from a lower
concentration to a higher concentration due to osmotic pressure. So reverse osmosis is the
passage of water through a semi permeable membrane from a higher concentration to a
lower concentration by applying pressure, which is higher than the osmotic pressure.
Green field Heineken brewery has two reverse osmosis equipment which are work
alternately.
The water from the media first enters the security filter then enters the reverse osmosis. In
the RO, the applied pressure overcomes the osmotic pressure to remove the salt ions and
many types of molecules from the water. Anti-scale is added to prevent scaling, which
would block the membranes. Once the water is treated with in the RO it will be blended
with some amount of water from the media filter. This is done to adjust the water quality
according to Heineken standard. But before the blending process water for boiler is taken
and stored in the boiler feed tank.
4. Cooling Systems: -The well water with an inflow temperature up to 38°C is cooled
down by cooled water in plate type heat exchanger and cooling down to 27°C. Then the
cooled water enters in to soft water tank.
5. Advanced Treatment: The advanced treatment step maintains the required water
quality for brewing water by disinfection with chlorine followed activated carbon
filtration (ACF) for de chlorination and polishing. The main purpose of chlorine is used
as disinfectant by killing the microorganisms like bacteria and algae. Then soft water
enters in to ACF by the help of centrifugal pump. The function of ACF is to absorb
chlorine and odor of other substance.
Product Cl2
ACF Soft water
Water Tank Cooling
Tank
CHAPTER FIVE
Heineken breweries share company uses instrumental analysis for most analysis doing.
First of all each of the collected samples should be conditioned to their room temperature
because the analysis should be done at normal temperature unless it will give missed
measurement.
Next the following measurement are taken
TDS and conductivity are measured by using the instrument called conducto
meter
the electrode of the conductometer is immersed in to the sample the read the
conductivity and TDS
PH is measured by using the PH meter, just immersing the electrode of the
conduct meter in to the sample. Water should optimally be slightlyacidic or close
to neutral pH (7.0).
formation of the wurstr daye. This reagent is detected and indirectly the amount of
free reactive chlorine is measured.
Alkalinity is also measured by the method of titration with hydro chloric acid as
titrant using phenolphthalein indicator.
Total hardness is measured by titration at the basic media by using Erichrom
black T indicator with EDTA as titrant since EDTA has high coordination number
it binds many metal at the end point and gives blue color that’s indicate for the
end point. By recording the amount of EDTA solution consumes we can find the
concentrations of the total hardness (Mg2+&Ca2+)
Haze consists of small particles suspended in the beer. Hazes develop after packaging.
This result the interaction b/n polyphenol and proteins this increase by high temperature
in the presence of oxygen.
Bitterness to measure the bitterness means just measuring the amount of phenol
lipids and iso alpha acid concentration. The procedure is the same as described on
the FST analysis below.
Color the degased, filtered and conditioned beer was filled to the optical glass
cuvette then read the absorbance at 430 nm wavelength just by loading in the uv
visible spectro meter. by multiplying the value of the absorbance by 25 gives the
color in EBC.
PH the filtered and degased beer is measured by PH meter just by immersing the
electrode on the sample.
Packing and packed beer analysis; after the beer gets confirmation by the quality
analyst the filtered beer from the BBT tank pass to the packaging line. From each phase
of packaging line three bottles of beer are taken just as the BB arrived and starts bottling
then check all the parameter for BB to see if there is or there is not contamination on the
line during coming in to the bottles or the filler. In here the dissolved oxygen and CO2
critically checked before the line is proceeding.
For packed beer or final product six bottled beer two bottles labeled and four un labeled
are taken in to the main lab then one for shelf life, one for seven day stability, one for
three hour stability, one for foam stability, one for foreign gas and the left one is for
dissolved oxygen and CO2 testing.
The three hour stability is for haze of covalent protein polyphenol complex; its
haze is measured after it stays for three hours inside the zero degree water bath.
This is why because the turbidity is visualized as the temperature is decreased
more.
The seven day stability is for haze of ionic polyphenol protein complex this bottle
stay in 57 degree water bath in order to brake the ionic complex of proteins and
polyphenol and then put it in the zero degree water bath after the seven day in the
57 degree after it is freezes its haze is measured this method is used to see what
about if the beer gets out of the fridge; if its haze increase more so our beer is not
filtered much.
The samples from each requested FST thank ware taken by plastic bottle in to laboratory.
See all the parameters listed above. The sample taken was filtered by filter aid known as
kieselgur.
1. Alcohol content EA, Er, OG and degree of fermentation are measured by instrument
called alcoholizer. The samples was filtered by the help of filter paper & filter aid
powder and filled to vial. It loaded in to the sample injection point of the alcoholizer.
Finally press start then read the Alcohol content EA, Er, OG and degree of
fermentation at the same time from the alcoholizer. At the first day just during filling
time the OG and EA are the same and the alcohol content is zero. Through time the
fermentable sugar is degraded by yeast and the OG will gradually decrease –the
alcoholic content is becoming increase during repeatable analysis of each day until it
reachs its final attenuation limit.
2. Color color of beer is derived from the caramelaization of sugar or glucose obtained
from malt in different stages of brewing. Color is measured by the instrument called
UV visible spectroscope; by measuring the absorbance of the filtered and conditioned
(20oc) sample of FST. The result is reported in EBC.
3. PH; it is known that PH is the measurement of acidity and basicity of solution. PH is
measured by PH meter. This value should be on the range of living condition of yeast.
For repeated analysis of each day of fermentation PH value is decrease gradually
through time. This is due to yeast cell consumes the ammonium ion for its nutrient
and release Varity of organic acids.
4. Vicinal di ketones (VDK) are all di ketones like pentadione and hexadione which are
formed during fermentation the step of synthesizing some amino acid required by the
yeast cell. VDK is measured by two method GC and Colourimetric (steam
distillation)
For gas chromatography the sample is prepared by adding detective aid reagents
like ECD and FID which helps to amplify the detection. The prepared sample is
loaded on the sample injection point by GC vial the instrument takes sample by
itself the then read the value on the screen of the detector or computer. This
method is more accurate and provides more information.
For steam distillation OPD solution was added into our sample in order to extract
the VDKs. First OPD (O-Phenyldiamine) is prepared using 10 ml 4N HCl with
0.1 gm of OPD. Then 100ml of beer FST with 2 drop of silca gel (antifoam) at
distillation flask and heated. The vapor passes over to the cooling column then it
condenses here. The condensate is known as the distillate and part of distillate is
treated. The treated distillate is total VDK because this ketone group has low
boiling point than water so it collected easily by distillation then prepared two 10
ml of alcohol and 10 ml of distilled water (blank). Shake using vortex. It placed
about 25 minute in dark place and after placed in a spectrophotometer. The fixed
diacetyle absorbs radiation at 530 nm range the result is displayed on the
computer this is also in EBC unit.
Higher value than the threshold concentration of VDK leads to very bad smell like
spoiled butter.
5. Bitterness; Bitterness is a taste that is detected mostly by the back part of the tongue.
It is a sensation that grows more pleasurable with age. The bitterness sensation
appears to be initiated by phenol lipids and iso-alpha acids. The most important
compound in beer bitterness is iso-alpha acid, which is derived from hops. Bitterness
is an essential flavor characteristic of beer. Taste testing gives indication of the
bitterness of a finished beer. Iso alpha acids are more soluble in organic solvents than
in water. (Beer is 95% water).This property is used to measure the bitter substance
from beer. Adds 1ml HCl with 20 ml iso-octane then, shake up to 5 minute by
mechanical shaker this is used for removing of the CO2 gas and wait for 30 minute.
A spectrophotometer is used to measure the absorbance of the Iso octane extract at
275nm and the result is expressed in bitterness units.
6. Attenuation limit is the minimum degree of fermentation which is measured by
alcoholizer.
First 3-4 gram of yeast was added to 250 ml of beer sample (FST) the shake on the
mechanical shaker for 24 hours at 150rpm at the end of 24±1 hours the sample was
filtered by the help of filter aid powder, and then measures its AL that is its EA result. So
this EA result is called final attenuation limit after reach this valve EA the FST goes to
the end of fermentation.
NB It is important to de-gas samples for the most instrumental analysis test as bubbles of
gas released in the optical cell may interfere with the assessment of brightness.[7] in here
I was involving in measuring a lot of parameter almost all listed above parameters I have
done myself with them.
They have shewart sample which is controlled sample. They use as reference or standard
I was trying to calibrate and standardize the instruments by using the controlled sample.
CHAPTER SIX
How to take sample from mashing vessels, BBT and FST to lab. How to dose
hop
How to measure PH and original gravity of wort and overall control of quality
which described in detail in chapter five.
In general I was applying in to the three chemical process step in brewing
(mentioned in the chapter 2 above) to analysis process parameter.
use to communicate with the person who is the member of the company. In general, I
have observed that it is must to create smooth relationship among different workers in
order to get social life in addition to improving practical and theoretical knowledge.
factory to be productive; all of the employees have to be disciplined and ethical in their
working environment. Generally, work ethics have broad definition.
Including:-Punctuality, not absent without reason (except during special cases, dead of
family members, sickness etc.), respecting other workers, finding the development of
company, commitment in work place.
Conclusion
Generally the production of beer in general has three sections. The first is producing
brown sugary syrup called wort. Then the wort will be fermented with the help of
yeast. The alcohol produced is then filtered. But as easy as it may sound the actual
production is much more time consuming and need to be done with care. This is
because there are many ways it can be contaminated. Basically this production
involves three basic chemical reaction monomerisation reactions in the mash tun,
chemical reactions during boiling in the wort copper and during the fermentation
process.
Recommendation
Reference
[1] Marcel Karab´ın, Tereza Hudcova, Luk´ a´ˇs Jel´ınek, and Pavel Dostalek
ComprehensiveReviewsinFoodScienceandFoodSafety Vol.15,2016
[2] M. J. Lewis and T. W. Young, Brewing, 2nd ed., New York: Springer. Kluwer.
Academic/Plenum Publisher, 2002.
[3] H. M. Esslinger y L. Narziss, «Beer,» de ULLMANN’S Encyclopedia of
Industrial Chemistry,
vol. 4, Wiley-VCH Verlag GmbH & Co. KGaA, 2003, pp. 657-700.
[4] Dukes of Ale BJCP Study Course March 8, 2009Todd Coffey
[5] M. J. Lewis y C. W. Bamforth, «Yeast,» de Essays in Brewing Science, vol. 2,
Springer,2 007, pp. 114-130.
[6] T. Goldammer, «Pitching Beer Yeast,» de The Brewer's Handbook, 2nd ed., Apex
Pub,
2000.
[7]Formation and determination of aromatic compounds during beer fermentation
Student: Clara Bosch Codern Mentor: Annick Boeykens Dates: February 2013 – June
2013
[8] Water treatment operation manual
[9] Heineken laboratory manuals and operational manual