2. History abounds in colorful unity that led to the
formation of McDowell & company. In the late
nineteenth century, Angus McDowell set out from
the scenic northern land of Gaelic Britannica. The
purpose was to make available the product of the
industrial revolution of thousands of expatriate
Britons serving the empire in various parts of
globe. It was this sprit to adventure that launches
McDowell and Co. in India.
3. The genesis of UB takes back to 1857 wherein the
company made a modest beginning with five
breweries in south India. The oldest among them
was the castle brewery which started operation in
the year 1957.
In 1915 a Scotsman named Thomas Leishman
combined the five breweries to form the UB. He
was then selected as the first director of the
company since then it has come a long way with
the turnover of around 4600million
4. In the year if India’s independence 1947 the UB
was brought by late Mr. Vittal Mallaya who took
up the responsibilities of a director and then
becomes the company’s chairman in 1948.
Mr.Vittal Mallaya then acquired kissan products
and formed a long term relationship with Hoechst
AG Germany to promote what is now known as
Aventis pharma. In the field of sprits the UB was
also the first company to manufacture “Indian
made foreign liquor (IMFl)”.
5. Sales of UB sprit division exceeds 60 Million during the
fiscal year 2005-07 making the group the 3rd largest
manufacturer of sprits products in world in addition
this division is one of only three in the world to 7
milliner brands & at least 5 brands rated by Drinks
international UK to be amongst ten fastest growing
brands in the world in their respective categories.
The market share of spirit division in India is currently
60% & export to the Middle East Africa & Asian
countries The UB group today controls 60% of the total
manufacturing of capacity for Beer in India. The
flagship brand kingfisher is now sold over 50 countries
worldwide.
6. The word Beer comes from the Latin word “bibere” meaning “to
drink”. It is an undistilled alcoholic drink.
Beer is the world’s oldest and most popular alcoholic
beverage. It is produced by the fermentation of sugars derived
from starch based material-the most common being malted
barley ; however, wheat, corn and rice are also widely used,
usually in conjunction with barley.The starch source is
steeped in water. Enzyme in malt break down the starch
molecules, producing a sugary liquid known as wort, which is
then flavoured with hops, which acts as natural preservative.
Other ingredients such as herbs or fruit may be added. Yeast
is then used to cause fermentation, which produce an alcohol
and other by-products from anaerobic respiration of the yeast
as it consumes the sugars. The process of beer production is
called brewing.
8. Water is the predominant brewing raw material with
most beers composed of 90-95% water.
The importance of water used in the brewing industry is
traditionally so significant.
It is easy to ignore the fact that water has its own unique
taste.
Being a good solvent, water also provides the macro and
micro elements that favour fermentation activities
carried out by yeast to a significant extent.
9. Malted barley is the main raw material used in the brewing
of beer. Malt provides the sugar that will be fermented
into alcohol in the brewing process. Barley is a cereal
traditionally grown in mild maritime climates and for
centuries it has been used in the production of beer.
Commonly two species of barley are used for Brewing:
Hordeum vulgare – 6 rowed barley
Hordeum distichon -2 rowed barley
10. Six-row barley has higher enzyme content for converting
starch into fermentable sugars, more protein, less starch,
and a thicker husk then two row barley.
The higher level of enzymes makes six row barley
desirable for conversion of adjunct starches during
mashing.
The husk of the malt is high in polyphenols (tannins) that
contribute not only to haze but also imparts an astringent
taste.
11. Two –row barely has lower enzyme content, less protein,
more starch, and a thinner husk than six row barley.
The higher starch content of the two row barley is the
principal contributor to extract.
Over the past thirty years there has been a global move
towards growing and malting two rowed barleys due to
their greater yield per hectare.
12. Barely is the main cereal used for the production of
brewer’s malt. However, many unmalted cereals are used
as brewing adjuncts. Adjuncts are regarded, by the
uniformed, as a cheap substitute for malt. The brewing
adjuncts contribute mainly carbohydrates to the wort;
their value to the brewer is also related to the flavour and
other quality properties which they contribute to the
finished beer.
13. The benefits claimed for solid adjuncts usage are:
Reduced starch extracts cost.
Improved beer stability and shelf-life especially when
maize and rice adjuncts are used, improved retention
properties, especially when barleys or wheat adjuncts are
used.
To change the character of the beer by altering its colour
and flavour.
To improve the quality of the beer for example, its
fermentability or its haze potential.
To reduce production costs.
14. Sugar can be grown naturally as in the case of sugar cane or
beet.
Sugar is highly fermentable and is usually added to the
boiling vessel.
It supplies the necessary carbohydrate source that stimulates
fermentative pathways in yeast for production of alcohol.
Sucrose can also be added to the beer after fermentation as
‘primings’ to provide sugar to encourage conditioning or
increase sweetness.
It is used to supplement the malt where malt processing
plant (storage, mills, mash tuns etc.) is a limiting factor.
15. Yeast is the unicellular microorganism that is responsible
for fermentation and production of beer.
Yeast metabolises the sugars extracted from grains,
which produces alcohol and carbon dioxide, and thereby
converts wort into beer.
In addition to fermenting the beer, yeast influences the
character and flavour.
16. Hops are the female flowers of Humulus lupulus.
Hops, other herbs and spices were probably first added to
finished beer to produce special flavours and cover up “off-
flavours” imparted by microbial contaminants during the
earlier days of brewing.
Hops are still added to beer during production.
Hops are historically recognised to conform the bitterness and
flavour to the beer.
Hops are also recognised to improve beer stability (in terms of
clarity), head stability, anti-microbial activity and light
stability.
17. Enzymes are usually added for following reasons:
For better conversion of complex carbohydrate to simpler
once to avail ready source of reducible sugars for
assimilation by yeast.
Also some enzymes facilitates breakdown of complex
proteo glycol to simpler amino acids and sugars which
can be easily assimilated by yeast.
Some enzymes help in better protein coagulation
facilitating haze reduction in beer.
20. Barley is spread out on the floor of a malthouse during a traditional
malting process.
The malting process starts with drying the grains to a moisture
content below 14%, and then storing for around six weeks to
overcome seed dormancy.
When ready, the grain is immersed or steeped in water two or three
times over two or three days to allow the grain to absorb moisture and
to start to sprout.
When the grain has a moisture content of around 46%, it is transferred
to the malting or germination floor, where it is constantly turned over
for around five days while it is air-dried.
21. The grain at this point is called "green malt".
The green malt is then kiln-dried to the desired colour and
specification.
Malts range in colour from very pale through crystal and
amber to chocolate or black malts.
22. STEEPING
STEEPING
GERMINATION
KILNING
(The seed is soaked in
water start it growing)
(The barley grows under
controlled conditions and the
“changes” occur inside the
seed)
(The malt is dried out and
colour and flavor are
developed.)
23. Processing of milling:
ASPERATOR(dust particles)
CLASSIFIER (foreign materials)
MAGNETIC SEPERATOR(metals)
BUCKET ELEVATORS
DESTONER(stone particles)
24. The objective of milling is to break up malt to such an
extent that the greatest yield of extract is produced in
the shortest time in the mash filter.
Separation systems it is desirable to keep malt husk as
intact as possible, to help for maintain an open filter
bed that favours wort separation.
Milling systems may use roller milling, impact milling
with disc- or hammer-mills, and wet milling.
25. A hammer mill may be used if the mash is to be separated
in a mash filter.
A hammer mill produces a very fine grind.
Hammer mills differ in detail, but the principles of
operation are the same.
The malt must be scrupulously cleaned to remove stones,
pieces of metal and `heavy objects'.
The chamber may be mounted vertically or horizontally
and strongly ventilated.
The milling chamber contains a spinning rotor on which
are mounted freely swinging pieces of metal, the beaters or
`hammers', which travel at about 100 m/s.
The rotor spins at 1500rpm.
26. Mashing is the process where the crushed malt or grist
is mixed with water under specified conditions so that
enzymatic action can take place to convert the starch
into fermentable sugars and in certain cases break
down of proteins into more soluble forms also occur.
The temperature of water used for mashing initially
should be at 45oc.
The process of degradation of starch into sugars is
called Saccharification. To know the degree of
Saccharification IODIEN TEST is done.
27. When the mash temp reaches 70 ± 2°C collect the
sample from the mash tun to find whether
Saccharification is completed or not.
The temperature maintenance was crucial as it
activates the starch degrading enzymes in the malt.
To the sample add iodine solution.
If the colour of the solution changes to blue, it
indicates incomplete Saccharification.
On the other hand, if the colour of that iodine solution
is not changed, it indicates starch degradation is
complete.
28. CONDITION LOW OPTIMUM HIGH
TEMPERATURE Low temperatures donot
effect the enzymes
much,but starch must be
gelatinised
first.Gelatinisation temp
for malt starch is 65°C.
65°C. High temperatures
inactivate enzymes
including amylases.The
action of amylases is
stopped at over
temperatures 70°C.
PH Acidic conditions kill the
enzymes.Enzyme action
is stopped at PHs 5.0
5.4 High PHs slow enzyme
action,but it does
continues at PHs of7.0
and above.
WATER Enzymes are more
sensitive to heat in a thin
mash.There is a lower
concentration of enzyme
and starch in a thin
mash.
Between 2.5and3.5 liters
of water/kilogram of dry
grist.
Enzymes are less
sensitive to heat in a
thick mash.There is a
higher concentration of
enzyme starch in thick
mash.
TIME Enzymes take time to
attack the
starch.Conversion will
be incomplete in
30 minutes. Conversion will be
virtually complete after
30 minutes.A longer
time will not increase the
29. Ceramix To deactivate the enzyme
activity.
Ultra flow To smoothen the movement of
produce.
Thermamyl For gleatinizationtion.
Gypsum to maintain the PH.
Calcium chloride To maintain the calcium level.
Lactic acid To maintain the PH.
30. When conversion is complete, the mash will consist of
a sugar solution called wort and the husks of the
malted barley.
The purpose of wort separation is to remove these
husks and any other particles which are not wanted in
the wort.
The husks and other particles contain tannin which is
bitter and will make the beer unstable after packaging.
They also contain fatty substances like lipids which
will reduce head stability and will also make the beer
go stale.
31. The objectives of effective wort separation are the
removal of unwanted material while at the same time
extracting all the available wort.
There are many systems to separate the wort from the
mash, the most common being:-
The mash tun.
The lauter tun.
The mash filter.
32. When the wort has been separated from the malt husk, it is
boiled. There are several important reasons for doing this:-
To sterilise the wort. Malted barley is contaminated with
moulds, and bacteria mainly on its surface. These
contaminants are extracted into the wort and need to be
destroyed.
To stabilise the wort. The enzymes that converted the
starch into sugar and the protein into amino acid will
continue to work.
To dissolve the Bittering resins from the hops and to
stabilise them.
33. To denature and coagulate some of the protein derived
from the malt.
To develop wort colour and flavour through the action of
heat on sugars and amino acids.
The chemical reaction between sugars and amino acids is
known as the Maillard Reaction.
Finally, and most importantly, to increase the strength or
concentration of the wort. Wort concentration is a
factor in ensuring that the chemical changes described
above actually occur.
It is also important in the production of strong beers
whose original gravity is higher than that of the wort
coming from the wort separation system.
34. At the end of the boil, the wort will be bright but there
will be large particles floating in it. These particles
contain:-
Coagulated protein or ‘break’, which if allowed to
remain, would cause haze problems in the finished
beer.
Tannin is very astringent and would pass this
character on to the beer.
It will also combine with protein to cause haze
problems.
35. Tannin material from the malt husk and from the
hops.
Lipids or fatty material that will destroy the beer’s
head stability and will also make the beer taste stale as
it gets older.
Spent hops or debris from hop pellets.
36. It is necessary to remove this ‘trub’ to protect the beer’s
quality. There are four main ways of doing this
depending on the type of hops used and the
requirement for absolute wort clarity:-
Filtration through the spent hops (Hop Back)
Use of a Hop Separator
Sedimentation in a Whirlpool.
37. The wort coming from the kettle will be at 100°C, after
clarification.Wort is cooled to 12oC before yeast pitching
is done.
Originally wort was cooled in shallow open vessels or vertical open
coolers, but now the plate heat exchanger is used exclusively for
wort cooling. This is because:-
Plate heat exchangers are very efficient and can cool the
wort down in a short time.
Nearly all the heat from the wort can be recovered to
generate a hot water supply for brewing and other
production uses.
They are enclosed and are easy to clean in line. Therefore
they keep the wort sterile.
38. The yeast is pitched in the wort during transfer of wort
from plate heat exchanger to fermenter, which is
carried out in pitching room.
Pitching yeast must have the following characteristics:-
The right strain for the beer to be fermented.
Free from contamination by bacteria and other yeasts.
Healthy and viable.
Cropped from a healthy and consistent fermentation
itself. Yeasts selected from a slow or sticking
fermentation are likely to repeat the problem.
39. Selection will be based on laboratory analysis like Solids,
Viability and Microbiological status (free of infection) and
fermentation records like Gravity drop, Storage
temperature and duration of Yeast.
CHEMICAL USED IN PITCHING:
Orthophosphoric acid- for acid wash of yeast at a pH
between 2.1 to 2.3. This will inhibit bacterial
contamination during fermentation.
Zinc Sulphate- For supply of micro element Zinc for yeast
enzymatic activities.
Biofoam- To generate foam and increase the surface area
for better fermentation.
40. Brew length in HL X 0.0259 X Required pitching cell count in millions X 104
YeastSolids%XViability%
= HL of Yeast for pitching
For eg: For pitching yeast which has 95% viability and
60% Solids into a 400 HL fermentor, the above
formula can be applied as follows:
400 X 0.0259 X 18 X 104 = 3.27 HL of Yeast
60x95
41. The aerated wort is cooled to approximately 10 to
110c and then placed in a pre sanitised closed
fermentation tank containing cooling coils.
The cold sterile wort is collected through PHE at 10-
120 C, during which aeration is done for 30-40min.
Although an open tank can be used, the closed tank is
preferred to prevent contamination as well the
evolved carbon dioxide can be collected for later
carbonation of the product.
42. Approximately three quarters to one pound of yeast
are added for each barrel of wort.
Within 24 hrs after pitching, foam begins to appear
on the surface of the medium, first along the wall of
the tank and then gradually across the surface.
The carbon dioxide evolution then increases so that
the yeast cells become suspended in the medium.
Initially the temperature of the fermentor post
pitching is maintained at 12oC to facilitate yeast
growth.
43. By approximately 40-60 hours after pitching, the
surface foam layer becomes very thick and can
measure up to almost 12 inches in depth.
During this time that the most rapid yeast – cell
multiplications occur, and considerable heat, which is
associated with this high metabolic activity, is evolved.
This heat evolution causes a temperature rise to
approximately 12-15 oc, the peak temperature for this
fermentation.
44. This will enhance the activity of enzymes involved in
fermentation that convert all the reducible sugars to
alcohol and Co2.
By approximately the fifth day of fermentation, there
is no longer enough carbon dioxide evolution to
support the heavy foam and, therefore, the foam
begins to collapse.
The yeast settle to the bottom, and the medium is
further cooled to below 5oC to fasten settling.
45. Yeast is collected in storage tanks maintained at
temperature 4.5oC, which can further be used for next
batch of fermentation.
Post separation of yeast from fermentor the
temperature of the medium is further cooled to
around -1oC.
This facilitates the precipitation of suspended solids,
there by clarification of the beer to promote
clarification lager chemicals like Shine aid, KMS,
Flocaid are added and beer is left for 5-7days.
This process is called Maturation/Aging.
46. From Fermentor beer is sent to Pre Buffer Tank. In Pre
buffer tank the beer is stored in order to reduce the
flow pressure.
From this the beer is send to FILTROX1 it is composed
of steel candles. These candles are deposited with
Hyflo Food Grade Powder (Diatomite). This powder
will help in removal of yeast, other suspended
particles and dust in the beer.
Now the beer is send to FILTROX2. It is composed of
several candles they will remove the dust and
suspended particles.
47. Now the beer is send to Post Buffer Tank. From there it
is send to Corboblender.
The function of Corboblender is that is addition of
carbon dioxide and also to control the foam in the
beer.
The Corboblender is attached with an equipment
called ANTENPAAR helps in on line monitoring of
critical parameters like Co2, Gravity, Alcohol content,
which work with the principal of Henry’s law.
48. Then the beer is passed CONTROLLING VALVE to
reduce pressure.
Now it is send to BIGHT BEER TANK (BBT). For the
storage, through PLATE HEAT EXCHANGER to
maintain the temp at -1 0 C. from BBT the beer passed
through TRAP FILTER.
During filtration the chemical added to beer are:
Shine aid: to remove chill haze from the beer
KMS: antioxidant agent to reduce D.O.
Biform P: for the easy separation of particle from beer.
50. WATER ANALYSIS:
CHLORIDE IN WATER.
HARDNESS OF WATER.
ALKALINITY.
TOTAL DISSOLVED SOLIDS.
FREE CHLORINE.
PH.
APPEARANCE.
ODOUR.
TASTE.
51. CHLORINE IN WATER:
Procedure:
Take 100 ml. water sample in 250 ml. capacity
conical flask then add 1 ml. of potassium chromate
(5% solution).
Then full the burette with 0.1 AgNO3 solution and
titrate, the end point is yellow to brick red.
Calculation:
Burette reading X35.45XN1000 =ppm
100
52. HARDNESS OF WATER:
Reagents: NH4OH, NH4Cl, Buffer, 16.85 grams of NH4Cl,
142.5 ml. of NH4OH make the total volume to 250 ml. in
volumetric flask using distilled water.0.02N EDTA.
Procedure:
Take 50 ml. of water sample in 250 ml. capacity flask.
Add 1 ml of ammonia buffer and 10 drops E.B.T indicator.
Then titrate it against 0.02N EDTA, then the end point is
pink to blue.
Calculation:
Burette reading X 20 = Hardness of water in ppm.
53. ALKALINITY:
It is caused by calcium carbonate (caco3). More
alkalinity will lead to formation scales in the
boilers.
Take 100ml sample.
Add 3 to 4 drops of methyl orange.
Titrate against 0.1N HCL.
Calculation:
Titer value X 50.
54. TOTAL DISSOLVED SOLIDS:
It gives the amount of dissolved and suspended material
present in the water sample.
Take 100ml of water sample
Filter through wattman filter paper No-542
Keep it for drying in an oven. Initially 98 c for evaporation
to prevent boiling and splattering
Dry at 103-105c for 1-2 hour
Cool in desiccators.
Note the final weight.
Calculation:
Tds (mg/l) = (b-a) X1000/ volume of sample.
55. FREE CHLORINE:
This gives that are free to react with other
component.
Take 50ml water.
Add 5ml of chloride reagent.
Observe the colour the specification.
56. PH:
The ph is determining using ph meter.
Take some sample of water in the beaker and
record ph using ph meter.
Specifications:
lower limit 6.0
Upper limit 8.0
Target 7.0
57. Appearance: the appearance water should be clear,
colour less, sparking and free from any
suspended solid.
Odour: the odour should be reported as colour less
and abnormal or anything abnormal
Taste: taste of water should be normal it should
not give any unnecessary taste that might have
been incorporated into it.
59. SPECIFIC GRAVITY:
Procedure:
The sample was collected and cooled to around 150C so that
the temperature of sample does not go beyond 200C at the
time of weighing
The pycnometer was filled with sample, and its outside was
dried by rubbing with a clean cloth
As the temperature of the sample reached 200C weight of the
pycnometer with sample was noted.
Calculation:
Specific gravity (g/cc)= (Weight of pycnometer with extract –
Weight of empty pycnometer)
(Weight of pycnometer with water – Weight of empty
pycnometer)
60. COLOUR:
Procedure:
The sample was degassed and filtered, and the
filtrate was taken.
Absorbance of filtrate was noted at 430 nm in
spectrophotometer, using water as blank.
Calculation:
Colour in EBC units = Absorbance at 430 nm x 25.
62. APPERANCE:
Sugar is observed against white back ground. Any colour
matter present will indicate that sugar is not clear.
MOISTER CONTENT:
High moister will lead to the formation of lumps and also
increase its weight.
Take 5grams of sample in moister estimation. Allow it to
stand for a while until the moister content is displayed on
the screen.
Moister should not exceed 1%.
63. COLOUR OF 10% SOLUTION:
Weigh 50g of sample and mix it will with warm
water then make it to 500ml at 20c.
Filter it to make it free from turbidity.
Centrifuge the extract at 5000rpm for 5mins.
Take the reading at 430nanometer.
PH OF 10% SOLUTION:
Take 10% solution in a beaker. Note the ph using ph
meter.
65. APPERANCE:
The rice used should of whitish yellow in colour and
free from dust, sand particles.
MOISTER CONTENT:
High moister will lead to bacterial growth. And also
increase its weight.
Take 5grams of sample in moister estimatator.
Allow it to stand for a while until the moister
content is displayed on the screen.
SPECIFICATION: should be less than 15%.
66. KETTLE TEST:
This test is performed to determine the odour.
Take a clean conical flask.
Fill its half volume with water and allow it to
boil on heater.
Add little quantity of broken rice to it. Cover the
mouth of flask with foil.
Now slowly note the odour by smelling it.
68. APPERANCE:
Malt should be of golden brown colour without any
black spots.
MOISTER CONTENT:
High moister will lead to bacterial growth. And also
increase its weight.
Take 5grams of sample in moister estimatator.
Allow it to stand for a while until the moister
content is displayed on the screen.
SPECIFICATION: should be less than 5%.
69. KETTLE TEST:
This test is performed to determine the odour.
Take a clean conical flask.
Fill its half volume with water and allow it to
boil on heater.
Add little quantity of broken rice to it. Cover the
mouth of flask with foil.
Now slowly note the odour by smelling it.
70. TOTAL CORN WEIGHT:
The test is performed to find out the amount of waste and
foreign matter present in malt sample.
Take 40g of sample.
Remove all the half corns and foreign matters then subtract
the removed weight from initial weight. Count the number of
corns in each lot.
Total corn weight = W*1000(100-M)/N*100.
Where, W=weight of malt taken (40)
N= number of corns.
M= moister of malt.
SPECIFICATION: Total corn weight should be 38-40 grams.
71. SIEVE ANALYSIS:
Procedure:
This test is performed to know whether all the grains are of
similar size.
Take 100g of sample and put it in sieve top then set the
apparatus on motion. For 5 mints.
Open the apparatus and collect the grains at different sieves,
note their weights.
%of malt in each fraction = weight of malt*100/weight of
sample.
SPECIFICATION: 2.8and2.5mm sieve – 90-95%.
2.2mm sieve - 0-4%.
Less than 2.2mm - 0-1%.
73. Cartons:
The qualities of cartons are important in the store age and
transport of beer. The bottom end of the croton especially
should be of good quality. Cartons can fit for 12 bottles.
Weight of cartons:
The weight of the cartons is recorded by the weighing machine
and express in grams. The weight should not go beyond 250
grams.
Bursting strength:
It can be defined as the amount of stress the carton is able to
with stand. It is an important parameter of cartons analysis. It
is recorded by use sing pisto meter. The bursting strength
should not be less than 6.
74. Length, width, height:
This is recorded by using the measuring scale. 300,
230, 296cm are specification respectively
Flutes:
Good number of flutes will provide better coshing
effect to the bottle around 54 flutes should be
present for 300cm of cartons.
Pins:
The cartons should be provided with 9 pins.
75. Cobb value:
Cut the piece of carton sufficed enough to fit in
equipment and take its weight.
Fill the equipment with water and leave it with carton for
30 mints.
Then removed the cartons and dry it and take weight.
Cobb value = initial weight – final weight*100.
This test perform to find out to which extended the carton
can observe external moister
Specification: 96.91.
76. GSM:
Take 10*10 cut area of craft and soak in water for 10-
15mins. Then individual layers are serrated and
dried in oven then its weight is taken (g/m2).
Specification: outer layer-4.3
Corrugated layer-1.966
Inner layer-2.
77. MOISTER:
It is recorded by using of HYDROMETER.
Increase in moister will lead to the soften of
cartons.
The moister should not exceed 8%.
79. WEIGHT:
Weight is determined by weighing machine.
SPECIFICATION: front-0.5305
Back-0.3499
Neck-0.1492
GSM:
It is similar to carton but we should take 5*5 cut.
SPECIFICATION: front-76.8
Back-79.16
Neck-81.25
80. COBB VALVE:
Take initial weight; dip the label in water facing up
said for 45sec. Then place it on filter paper to
remove excess water then take weight.
To get cob valve multiply difference of average
weight of three by 100.
SPECIFICATION: front-12.63
Back-16.21
Neck-3.77.
81. GRAIN DIRECTION:
Labels are dipped in water facing upside down for
few seconds and folding patens are absovered
along the vertical axis.
SPECIFICATION: front- horizontal direction
Back label-horizontal direction.
82. CROWNS ANALYSIS:
SKIRT DIAMETER.
INTERNAL DIAMETER.
WEIGHT OF CROWN.
WEIGHT OF LINER.
LAQUER TEST.
83. SKIRT DIAMETER: its recorded using vernier scale.
SPECIFICATION: 31.58MM.
INTERNAL DIAMETER: it’s recorded using vernier
scale.
SPECIFICATION: 26.48MM.
WEIGHT OF CROWN: it’s recorded using weighing
equipment.
SPECIFICATION: WEIGHT OF 2.23184grams.
84. WEIGHT OF LINER:
The liner is removed and its weight is noted.
SPECIFICATION: 0.232 grams.
LAQUER TEST:
It is done to check improper lacquering which may cause
rusting of crown.
The crown is kept for 10mins in acidified cuso4.5h2o
solution.
Place the crown on white paper and observe for presence
of any black or brown spots.
85. BEER ANALYSIS:
IRON-TESTING.
CALCIUM TESTING.
DISSOLVED O2 IN BEER BOTTLE / CAN.
DIACETYLE IN BEER.
ALCHOL IN BEER.
SO2 IN BEER.
FOAM STABILITY IN BEER.
86. IRON TESTING:
Reagents:
2.5% Ascorbic acid (fresh), 0.3% Orthophenanthralone (colour
reagent).
Procedure:
25 ml. of sample in (degasses in 3 separate test tubes)
Shake well
Add 2 ml, Orthophenanthrolene to samples and 2 ml
D.W. in blank solution.
Mix well and keep it for ½ hour.
Take absorbance at 505 nm and read iron from standard
graph.
87. CALCIUM TESTING:
Reagents:
NaOH solution 5N, Calcien solution flurometric (Reagent
grade), dissolve 1 gr. In 50 ml distill water to which 0.56 ml
of sodium hydroxide (5N) has been added.
EDTA solution – 1.8612, EDTA dissolve in 500 ml distill water
0.01 M. Take 50 ml of 0.01M and dilute to 100 ml with
distill water – 0.005M.
Procedure:
20 ml beer + 10 ml distil water + 3 ml 5N NaOH + 0.5 ml
Calcien indicator.
Titrate against 0.005M EDTA solution till green
fluorescence fades.
88. Use a blank background for titration.
At the end of the yellow green fluorescence is
replaced by an orange brown colour.
Calculation:
T.R X 0.2004 X 1000 = ppm.
20
89. DISSOLVED O2 IN BEER BOTTLE / CAN:
Principle:
To decrease or increase shelf life of beer bottle O2 plays a
key role. Higher D.O. level in beer less is the shelf life of
beer. Hence it is necessary to keep an eye on D.O. level in
bottle.
Procedure:
Take pasteurized or UN pasteurized beer bottle (Freshly
filled).
Cool it to 15-200 C .
Shake for few seconds.
See the D.O. with the help of D.O. meter.
90. Air Content:
Till the Hoffman instrument with 40-50 ml caustic.
Place the chilled bottle under the piercing needle
and pierce it.
Release the pressure developed shake the bottle
with the instrument note the head space in ml.
Release the pressure and note down the total in ml.
Calculation:
TA in ml X 100 = TA % v/v
650
91. DIACETYLE IN BEER:
Reagents:
8.5 % dehydrogenate PO4
8 % hydroxyl ammonium hydrochloride
Apparatus:
• Distillation unit marked test tube.
• Pipette.
• Oil bath.
92. Procedure:
Take 3.5 ml 8.5 % disodium hydrogen PO4 in 100 ml round flask.
Add 1000 ml. under gassed beer sample in 1000 ml round
bottom flask .
Start distillation with tip of delivery tube dipping into 2 ml of
distilled water.
Collect 18-19 ml. adjust the volume to 20 ml with distilled water
Distribute 20 ml. in tow test tube 10 ml. each marked as blank
and sample .
Add 1 ml of 8 % hydroxyl ammonium HCl in test tubes marked
as sample.
Keep both t.t in oil bath at 800 c for 15 min.
93. Raise temp after 15 mm up to 1100 c (temp. should
not be exceed over 1100 c) and allow to evaporate
contents up to 4-5 ml.
Cool test tubes.
Add 1 ml. of 8 % hydroxyl amm. HCl in test tubes
marked as blank.
Adjust volume up to 10 ml. by distilled water.
Observe the absorbance at 230mm by using blank
on spectrophotometer.
Calculate on standard graph.
94. ALCHOL IN BEER:
Apparatus:
Distilled unit volumetric flask 100 ml.
Procedure:
Take 100 ml decarbonised beer at 200 c.
Using a 100 ml, volumetric flask pur the beer into
1000 ml. distilled flask
Rinse the volumetric flask 2-3 times with distilled
water not more than 50 ml.
Add the rinse water to distilled flask.
95. Use 100 ml. volumetric to receive distillate .
Surrounded the receive with ice or ice water.
Distilled about 96-97 ml. at a uniform rate i.e.
30-60 minutes.
Adjust the distillate up to 100 ml mark with
distilled water and mix well.
Determine the Sp. Gravity at 200 c.
96. Calculation:
Specific gravity = weight of Sp. Gravity bottle with
alcohol – weight of empty specific gravity
bottle/weight of water.
98. Procedure:
Take 10 ml. of conc. HCl in round bottom flask add 250 ml.of
un – gassed beer in round bottom flask
Arrange distillation apparatus
Dip at receiver in beaker contains 15 ml. of distilled water
Start distillation, add few drops of starch in beaker
Take 0.025 N iodine in bottle and iodine in beaker as blue
colour disappears.
Add iodine till colour persists for 1 min.
Calculation:
SO2 in beer = Burette X 12.8ppm
4
99. FOAM STABILITY IN BEER:
Procedure:
The beer bottle temperature should be 5-70 c pour the beer in
a clean dry glass from a height so that it generates a foam of
about 1½ to 2 inch.
Place the glass with beer on the travelling microscopic
platform.
Adjust the eye piece of tm. so that the foam is in view and at
the same again in view.
Immediately stop the stop – watch.
Note down the time in seconds i.e. foam stability.
Calculations:
CO2 % w/v/ X 0.197/s g X 1010 = CO2 gm/litre.
100. APPARENT EXTRACT:
Apparatus:
• Analytical balance.
• Thermometer
• Pycnometer
• Water bath
Procedure:
Determine the specific gravity of decarbonated beer at
20°C/20°C and read g of extract per 100g of
solution from the standard table.
101. Calculation:
Specific gravity of decarbonated beer = W1-W2
W3-W2
Where,
W1 = Weight of pycnometer with dealcoholized
beer.
W2 = Weight of empty pycnometer.
W3 = Weight of pycnometer with water.
102. REAL EXTRACT:
Apparatus:
• Volumetric flask 100 ml
• Analytical balance
• Thermometer
• Pycnometer
Procedure:
Transfer the residue from the distillation flask
quantitatively after the alcohol distillation to a 100ml
volumetric flask with the aid of hot water, cool and make
up the volume at 20°C.
103. Determine the specific gravity at 20°C/20°C and read gram of
extract per 100g of solution, corresponding to the specific
gravity of dealcoholized beer extract solution.
Calculation:
Sp.gr. of dealcoholized beer = W1-W2
W3-W2
Where,
W1 = Weight of pycnometer with dealcoholized beer.
W2 = Weight of empty pycnometer
W3 = Weight of pycnometer with water.
104. Now, determine the value of real extract in grams of extract
in 100 grams of dealcoholized beer (oP), from this
specific gravity value at corresponding temperature by
using the standard table.
Real extract, % by wt. in the beer (E) = G x specific gravity
of dealcoholized beer
Specific gravity of beer
Where,
G = g extract in 100g solution for dealcoholized beer.
105. COLOUR:
Apparatus:
• Spectrophotometer
• Membrane filter holder
• Membrane filters of pore size 0.45 microns
Procedure:
Take about 35 ml of degassed beer into centrifuge
tube.
Centrifuge for 5 minutes at 5000 rpm or filter the
sample through a membrane filter.
106. Measure the absorbance at 430nm, against
distilled water as blank.
Calculation:
Colour = A430 x 25
Where,
A430 = Absorbance at 430 nm in 1
cm cell.
107. BEER BITTERNESS:
Apparatus:.
• UV Spectrophotometer
• Centrifuge
• Rotary shaker, amplitude 2-3 cm
• Glass beads
• Pipettes 0.5 ml, 10 ml, and 20 ml
• Centrifuge tubes with screw thread necks and
plastic caps
108. Reagents:
Iso-octane(2,2,4 trimethyl pentane): the absorbance of
this solution must be 0.01 when measured at 275nm in a
1cm cuvette against a reference of distilled water
Hydrochloric Acid (HCl): 6M
Procedure:
Pipette exactly 10ml of decarbonated beer in a 35 ml
centrifuge tube. Add 0.5ml of hydrochloric acid (HCl)
followed by 20ml of iso-octane. Place 2 or 3 glass beads
(to prevent spattering) in the tube and close it tightly with
a cap
109. Shake the tube for 15 minute at 20°C at 130rpm, on a
rotary shaker and then centrifuge at 3000rpm for 3 min.
Measure the absorbance of iso-octane layer in 10 mm
cuvette at 275 nm using pure iso-octane as blank
Calculation:
Bitterness units (BU) = A275 x 50
Where,
A275 = Absorbance at 275 nm measured against a
reference of pure iso-octane.
110. HAZE IN BEER:
Apparatus:
Haffmans Laboratory Haze meter-VOS Rota 90
Volumetric flasks-100ml, 200ml
250ml dark bottle for storage of the formazinstock
suspension of 1000EBC
Procedure:
Dissolve 1g of hydrazine sulphate in distilled water and
dilute up to 100ml in a 100ml volumetric flask
Dissolve 10g of Hexamethylenetetramine in distilled
water and dilute up to 100ml in a 100ml volumetric flask
111. Mix the hydrazine sulphate solution and
hexamethylene solution in a 250ml dark bottle
and let the mixer stand for 48 hours at 25ºC, a
white polymer suspension will develop in the
solution during this period.
Keep prepared formazin stock suspension in
dark bottle at room temperature (eventually at
lower temperatures but not below 0°C .
112. HEAD-SPACE AIR CONTENT:
Apparatus:
Haffmans Inpack CO2 & Air Meter/Zahm & Nagel Air Meter
Procedure:
Take 30% caustic lye in the measuring burette (with the help
of leveling vessel in case of Haffmans inpack Air meter. This
vessel should be at higher position, about 8cm than measuring
burette. There should not be any air in between the stopper of
Haffmans Inpack Air Meter/Zahm & Nagel Air Meter.
Adjust the instrument at right height of the bottle or can.
Pierce the bottle. While piercing see to it that the needle valve
is closed.
113. After piercing, open the needle valve slowly a bit
and let the head space gas bubble through the
caustic lye in the measuring burette.
Bottle or can when liquid out of bottle or can enters
the hose of the IAM.
In case of Haffmans inpack Air meter, move the
leveling vessel so that the liquid levels from the
leveling vessel and the measuring burette are on the
same height.
Read the level of lower meniscus.
114. TOTAL AIR CONTENT:
Apparatus:
Haffmans Inpack CO2 & Air Meter/Zahm & Nagel Air Meter.
Procedure:
Take 30% caustic lye in the measuring burette (with the help
of leveling vessel in case of Haffmans inpack Air meter. This
vessel should be at higher position, about 8cm than measuring
burette. There should not be any air in between the stopper of
Haffmans Inpack Air Meter/Zahm & Nagel Air Meter
Adjust the instrument at right height of the bottle or can
Pierce the bottle. While piercing see to it that the needle valve
is closed
115. After piercing, open the needle valve slowly a bit and let the
head space gas bubble through the caustic lye in the
measuring burette.
Close the needle valve immediately when no more gas escapes
from the bottle or can when liquid out of bottle or can enters
the hose of the Inpack Air Meter.
Shake the instrument along with the pierced bottle or can
again and open the needle valve slowly. Repeat this until no
gas escapes from the bottle or can...
In case of Haffmans inpack Air meter, move the leveling
vessel so that the liquid levels from the leveling vessel and the
measuring burette are on the same height.
Read the level of lower meniscus.
116. CARBON DIOXIDE (CO2) CONTENT:
Apparatus:
Haffmans Inpack CO2 & Air Meter/Zahm & Nagel CO2 Meter
Procedure:
Adjust the instrument at right height of the bottle or can
Pierce the bottle. While piercing see to it that the needle valve
is closed
Read the value on the gauge.
Shake the instrument with pierced bottle or can until the
gauge does not increase any more.
Open the needle valve slowly. Wait till the pressure reduces.
Remove the bottle and measure the liquid temperature.
117. BOTTLE WASHING.
SIGHTER STATION 1.
EBI.
BOTTLE FILLING.
BOTTLE CROWNING.
SIGHTER STATION 2.
TUNNEL PASTEURIZATION.
SIGHTER STATION 3.
BOTTLE LABELLING.
CASE PACKING.
118. BOTLLE WASHER:
Empty bottles are unloaded from trucks and the bottles
having perfect shape without any crakes or damage are
only used.
The bottles are separated manually according to the
brand they belong to.
These bottles are then pre-rinsed with normal water to
remove any dust or mud particles from bottles for
prolong life of caustic.
119. Now the bottles are sent to washer where they are washed
with hot water of 80oC and caustic.
The washer is provided with jetters that flush the bottles from
inside as well as from outside.
There are 3 caustic zones in washer:
1st zone- in this zone the caustic level is maintained at 2.5%.
2nd zone- in this zone the caustic level is maintained at 2.1%.
3rd zone- in this zone the caustic level is maintained at 1.8%.
120.
121. The bottles washed with caustic are germ free and all
kind of dirt is removed along with labels and foils.
After treating with caustic, bottles are subjected to wash
with soft water to remove caustic traces.
The capacity of washer is 36000bottles/hr and 47
bottles/line can be washed in it.
122. SIGHTER STATION 1:
Sighters are the people who ensure the proper washing of
bottles.
There are 4 sighter stations after washer.
The sighters observe the bottle coming out of the washing and
remove the bottle having:
Any damage or crack.
Any foreign matter.
Any dirt.
Presence of caustic.
The observation is done with back ground as white screen for
better vision of bottle.
123. E.B.I :
E.B.I. is an electronic device created for detection bottles
left from observation of sighters.
It detects only empty bottles and removes the bottles
having any dirt, caustic or foreign material remaining in
it from line an sends them back to the washer.
E.B.I. is provided with a camera at bottom which takes
the photograph of each bottle and gives the number of
bottles passed through it.
Defective bottles observed in camera are isolated from
line and sent to bottle washer or scrap based on the type
of defect in them.
124.
125. FILLER AND CROWNER:
Filler is the important part of packaging.
The bottles must be filled with accurate amount and
pressure of beer and carbon-di-oxide.
Carbon-di-oxide is the best preservative for beverages.
The filler has double evacuation system.
Jetter implies the pressure of -800bar on bottles to suck
out all air from bottle.
It this process some bottles may burst because of being
old or losing their strength.
126.
127. The bottles are filled with carbon-di-oxide and sucked
out twice.
Now the bottle is filled with beer at the temperature of
00C.
Again carbon-di-oxide is passed in bottle at high
pressure that helps to throw out other unwanted gases
from beer filled bottle.
108 bottles are filled in each single rotation of filler.
128. A fobbing Jetter passes a rapid vapour of hot water and
removes surface oxygen over beer in the bottle, before
crowning.
The bottles are now crowned in crowner which can
crown 18 bottles per rotation.
Thus, it runs 6 times faster than filler.
129. SIGHTER STATION 2:
At this sighter station sighters check bottles of following
types and remove them from line:
Empty bottle .
Low fill.
High fill .
Chipped bottle.
Bottle with dirt.
Bottle with suspended particles in beer.
130. Other brand embossed bottles.
Bottles with plastic sachet or any foreign matter in beer.
Uncrowned bottles .
Bottles with label carry over.
Bottles with external damage at shoulder or base.
Bottles with defective crowns (leakage).
Bottles filled with water or any chemical liquids.
131. PASTEURIZER:
R1H R2H R3H P1 P2 P3 P4 R3C R2C R1C
30.1 36.0 48.3 62.0 62.0 61.9 61.8 45.8 33.4 24.3
BOTT
LES
IN
BOTT
LES
OUT
Pasteurization is the process of removing microbial
contamination from the food product by giving a short
span of treatment of rising temperature of the product
up to certain level at which its taste or flavour are not
altered.
132. The high temperature minimizes the possibility of
survival of any kind of microbial contaminants in it.
Tunnel pasteurizer is used for pasteurization of beer.
In this, temperature of 620C is maintained by passing
steam in controlled manner.
A typical tunnel pasteurizer has different zones in it as
shown below.
133.
134. Beer bottles are passed through different zones of
pasteurizer in the sequential manner.
The temperature starts from 320C in R1H, increases to
360C in R2H followed by 480C in R3H then to
Pasteurization at 620C in P1, P2, P3, and P4. Now it again
decreased in R3C to 460C, to 330C in R2C and to 240C in
R1C.
This whole process takes place in 56 minutes.
135. SIGHTER STATION 3:
Sighters perform the same work as they do in sighter
station -2 to ensure quality of the product bottles.
CASE PACKER AND PALLETIZER:
Case packing is done with the help of packing
machineries which take the bottles from line by creating
vacuum between bottle and holder and put into case.
136.
137. The case is packed with 12 bottles in it.
Wooden or plastic pallets are arranged by palletizer such
that each pallet takes up 75 cases.
The pallets are then shifted to warehouse by fork lift
machine for dispatch after quality approval.
