Dashen Brewery internship report on beer production process and quality control

DASHEN BREWERY S.
C FINAL INTERNSHIP REPORT
ETHIOPIAN INSTITUTE OF TECHNOLOGY-MEKELLE
Department of Chemical Engineering
My hosting company is Dashen Brewery
Final internship report on Dashen beer
BY: Asmare Tezera ID.№ 0827/03
Submitted date 24 |10

| 06
PREPARED BY ASMARE TEZERA 28/06/2014 Page 1

DASHEN BREWERY S.C FINAL INTERNSHIP REPORT
ACKNOWLEDGEMENT
I have taken efforts in this project; however, it would not have been possible without the find
Support and help of many individuals of the company civil service who invites the field.
I wish to express my special thanks & sincere gratitude to Mentors name Real chemists MR.Melkie
& Daniel
Real Chemical Engineers MR.Dilnesaw Lemma & Aschalew Fasil who of those people are
:Knowledgeable ,Experienced & Intellectual people. I take this opportunity to express my
profound gratitude and deep regards to for your exemplary: Guidance ,Monitoring &
Encouragement
Throughout the semester of this internship. Thanks once again for your endless support &
encouragement

EXECUTIVE SUMMERY
In Dashen Brewery S.C I have working in utility section for one month & beer processing section for
three months and in this time I have got practical skill more and I knew the aim of the internship.
Dashen brewery S.C produces different type of products like Dashen beer, cellar and draught. To
produce such things it needed to pass such like process, first of all to get pure malt, wort production,
fermentation takes place, flirtation occurs, and go to the filtration beer to different ways like cellar,
draught and bottle beer.
In Dashen brewery S.C there are many problems are occurred such as reprocessed beer w/c leads to
infection of beer,high fuel consumption & aerobic waste water treatment w/c causes env'tal
pollution. So that I am interested to do research on biogas production from BSG(brewer's spent
grain) w/c used to save money from expens. And also in this internship time I gained over all
benefits like improving practical skills, theoretical skills, interpersonal communication skills, team
playing skills, leadership skills, work ethics related issues, and entrepreneurship skill

Table of content Page
Acknowledgement…………………………………………………………..………………………2
Executive summery ............................................................................................................................3
Quality assurance……………………………………………….……………………………………3
Quality policy………………………………………………………….……………………………..7
Environmental mgt system…………………………………………….……………………………8
Abstract................................................................................................................................................9
Introduction……………………………………………………………………….…………………9
Chapter one ......................................................................................................................................10
1. Background of dashen ...............................................................................................................10
1.1. History of dashen......................................................................................................................10
1.2. Product and customer..............................................................................................................11
1.3 Organization Structure.............................................................................................................12
1.4 Work flow ..................................................................................................................................12
Problem statement...............................................................................................................................13
Problem justification........................................................................................................................14
General objective………………………………………………..………………………….......15
Specific objectie..........................................................................................................................15
Literature review..............................................................................................................................16
Raw materials....................................................................................................................................16
Water analysis & evaluation……………………………………………………………………….17
Malt,Hop.........................................................................................................................................18
Yeast, types of yeast .......................................................................................................................20
Beer production process.................................................................................................................22
Quality control ……………………………………………………………………….………….25
1. Sensory method…………………………………………………………….………………25
2. Instrumental analysis………………………………………………………….……………25
Whey adjuncts...............................................................................................................................26
Cleaning & grading the barley…………………………………………………………………..26
1.Brewhous section …………………………………………………………….………………….27
Steeping…………………………………………………………………………………………27
Germination………………………………………………………………...…………………..28
Kilning………………………………………………………………………………………………29
Malt milling………………………………………………………………………………..…….29
Mashing………………………………………………………………………………………….31
Lautering………………………………………………………………………………………..32
Boiling & hopping……………………………………………………….……………………..33
Whirlpooling……………………………………………………………………………………34
Wort cooling & aeration…………………………………………………….………………….36
2.Yeast propagation section……………………………………………………...………………..37
3. Fermentation section……………………………………………………………………………..37
Primary fermentation………………………………………………………………………….37
Maturation…………………………………………………………………………………….38
Lagering…………………………………………………………………………………….....39
4.Filtration section………………………………………………………………………………40
How to contol oxygen……………………………………………………………………………….41
Production & filling section………………………………………………….…………………….42
Crowner cork……………………………………………………………………………………….43
Pasteurization…………………………………………………………………………..…………..44
Labeler……………………………………………………………………………………………..45
Packaging………………………………………………………………………………………….47
Chapter two………………………………………………………………………………………..48
2. Over all internship experience………………………………………………………………..48
2.1 I have selected the company…………………………………………………………………49
2.2 Section of I have been working……………………………………………………………..50
2.3 Work flow of the section……………………………………………………………………..50
2.4 Challenges that face me………………………………………………………………………51
2.5 Measures to overcome these challenges…………………………………………….………..51
Chapter three………………………………………………………………………………….……51
3.Overall benefit I have gained from the internship interms of:
3.1 Practical skill……………………………………………………………….……………..52
3.2 Theoretical knowledge………………………………………………………..…………52
3.3 Problem solving capacity………………………………………………………………..52
3.4 Team playing skill………………………………………………………………………..53

3.5 Leadership skill………………………………………………………………………….53

3.6 Work ethics issue………………………………………………………………….…..…54
3.7 Entrepreneurship skill…………………………………………………………….…….54
3.8 interpersonal communication skill…………………………………………………..….55
CIP & COP………………………………………………………………………………………….56
Waste water treatment……………………………………………………………………….…….57
1.physical treatment…………………………………………………………………………58
2.Chemical treatmet……………………………………………………………….……….59
3. Biological treatment………………………………………………………….………..59
a. Aerobic treatment……………………………………………………….…….….60
b. Anaerobic '' ……………………………………………………….………..60
Chapter four………………………………………………………………………………………..61
4.Material balance…………………………………………………………………………………62
4.1 Mass balance…………………………………………………………………….…….63
4.2 Equipment sizing……………………………………………………………….……..67
4.3 Energy balance………………………………………………………………….……..67
Conclusion…………………………………………………………………………………………..68
Recommendation……………………………………………………………………………………69

Quality assurance in brewing

Prerequisites for breweries includes the ff aspects
 There should be a food safety policy outlining the brewery's commitment to Producing safe
products. This should be disseminated to all staff.
 Potential contamination from surrounding industries should be assessed and suitable
precautions taken.
 Site boundaries should be sufficiently protected to avoid accidental or malicious
contamination.
 High risk areas should be identified; this includes areas where there is open product, package,
process or raw material (e.g. open fermentations, bottling and canning areas). These areas
require more stringent controls and should be protected from the outside. Eating, drinking
and smoking is not permitted in these areas.
 Buildings used for storage or production should be fit for their purpose, adequately
maintained and cleaned.
 Equipment should be suitable for its intended purpose, easily cleaned and subject to a
planned maintenance programme.
 Suppliers of raw materials and packaging materials should be controlled.
 Goods should be checked on receipt to ensure that the correct grade has been delivered and
the packaging is intact.
 Housekeeping and hygiene should be maintained to a high standard to prevent contamination
from the surroundings.
 Suitable toilets and hand-washing facilities should be available; these must not open directly
into production areas.
 A pest control programme should be in place to minimise pests.
 Precautions should be taken to prevent the materials used from contaminating product.
 The use of glass in production areas should be minimised to prevent product contamination.
 There should be a glass policy which states the glass breakage procedure. A glass register
should also be available.
 Vehicles used for raw materials or products shall be suitable and should avoid deterioration
of loads carried. Vehicles should be loaded and unloaded so as to avoid contamination or
deterioration.
 All staff, including temporary staff, shall be adequately trained before carrying out a task.

 A Team Leader should be appointed to coordinate activities and ensure that a systematic
approach is followed.
Quality policy
 D.B.SC is established to produce & sell quality bottle & draught beer using state of
the art of technology & qualified experts. It is located generally in E/A particularly in
Amhara region. The vision of the company is to be best brewing company, winning
with quality branches in E/A. top mgt of D.B.SC is committed toimplement,maintain
& continuely improved the established quality mgt system based on ISO 9001:2008
standards.This enables the brewery to:
 produce & avail quality products preferred by customers with respect to price & on
time delivery at the right place.
 Meet regulatory & statutory requirements
 Implement techniques & tactics that can help to reduce cost of non conformity &
produce economically
The company insure customer satisfaction & continually through understanding & meeting
customers' requirements & expectation. The company develops employs competence, teamwork,
motivation & participation. It also creates conductive work environment.
Environmental management system (mgt)
D.b.sc confirm to the required standared of environmental mgt system based on ISO 14001:2004.The
mgt systems are as follows
 To use the resourse properly

 To prevent pollution
 Respect legal & legally principles
 To train & develop employees awareness concerning the environmental issue
 To work with interested party on environmental protection The company committed to
revealed through performing brewery expansion & new product development in a manner
consistent with environmental mgt system.
Abstract
We can produce beer by using these raw materials such as yeasts ,hops,water ,barley &
chemicals . the main production of beer processing sectionS are:
1.precleaner section :removal of dust particles takes place
2.brewhous section :conversion of starch to sugar takes place

(wort production)
3.fermentation section : conversion of sugar to ethanol takes

(flavour production)
4.filteration section : removal of yeast & hop resins take places
5. product filling & packaging s/n: filling, pasteurizing, labeling & packing takes place.
Introduction
Beer is an alcoholic beverage produced by the saccharification of starch and fermentation of the
resulting sugar. The starch and saccharification enzymes are often derived from malted cereal grains;
most commonly malted barley and malted wheat. Most beer is also flavored with hops, which add
bitterness and act as a natural preservative, though other flavorings such as herbs or fruit may
occasionally be included. The preparation of beer is called brewing.
The brewing process is energy intensive and uses large volumes of water. The production of beer
involves the blending of the extracts of malt, hop sand sugar with water, followed by its subsequent
fermentation with yeast. The brewing industry employs a number of batch-type operations in
processing raw materials to the final beer product.
In the process,large quantities of water are used for the production of beer itself, as well as for
washing, cleaning and sterilising of various units after each batch are completed. A large amount of
this water is discharged to the drains. The mainwater use areas of a typical brewery are brewhouse,
cellars, packaging and general water use.
CHAPTER ONE
1. BACKGROUND OF THE COMPANY

1.1 history of the company
The name dashen is taken from the famous mount Rasdashen, which is located 100km from the
brewery; Ethiopia’s highest mountain (Elevation 4523 meters) and a home for rare endemic found
and flora. Dashen brewery share company (DBS.C) is located in historical town of Gondar, which is

620km far from mekelle and annually visited by about 95,000 tourists. The brewery is situated on the
area of 85,000 square meters with building area of 12,000sqm DBS.C is established in September
1992 e.c, with an initial /WC capital of over 340 million birr. It is owned by Amhara regional state
rehabilitation development organization. Dashen brewery utilizes state of the art technology and
highly qualified exports that will enable it to compete on the exports market with the leading of the
international beer producing and marketing companies.
Dashen brewery S.C is the first brewery to be ISO 14001, 2004 EMS (Environmental management
system) and ISO 9001, 2008 QMS (Quality management system) certified which enables the
company to focus on customer satisfaction measurement, formulate policy and objective by taking in
to account regulatory requirement and information on activities with significant environmental
impact.
Before expansion dashen brewery had annual production capacity300.000 hectoliter by expanding its
capacity in to three fold the brewery has now annual production capacity 769000 hecto liter or 42000
bottle/hr.
The brewery is currently undertaking projects of malt factory to supply the brewery and other
breweries with a sustainable supply of quality malt produced in the unique two raw barley grown in
the high land of the region. The project aims to benefit the farmers of the area by integrating them as
suppliers barley for the factory. Currently, the total work force in the dashen brewery S.C 760
employees of which 666 permanent and 94 are contracts employees. Dashen brewery S.C
participates in different development activities such as education, health, sports art and
environmental conservation and job opportunities.
1.2. Products & customers

The main raw materials for beer production are malt, water, yeast, hop & adjuncts.
The main product of dashen brewery S.C:
 Dashen beer
 Dashen draught & royal draught
 Royal cellar & dashen cellars.
Dashen brewery has four customer region and three ware house throughout the country
i. Region 1 Amhara and afar

ii. Region 2 Tigray

iii. Region 3 Addis Ababa & South west Ethiopia

iv. Region 4 South Ethiopia
The three ware houses thus are, Gondar, Waldia and Addis Ababa
The main customer of dashen brewery is north part of Ethiopia especially.
Humera, Metema, Sherri & Woldia.
The end user/customer is every person. There is no any limit or boundary in order to be a customer
for Dashen beer.
1.3 organization stracture Board of director
General manager
Deputy General Manager
Executive secretay Audit service
Typist Legal service
Plan, programFLOW
1.4 WORK & R.dev.t
Quality Production Maintenan

procurement Finance dep't Admi/n
Dep't Dep't ce Dep't
service dep't
Quality Secretary
assurance sec/n General acount Market&sales Budget & cost
dep't
Garage &
work shop
Finance recored & control
Beer processing Bottle sec/n
Region 1 Region 2
Ele/ca l& Prod/n Utility sec/n sales sales
instru/n sec/n machinery
PREPARED BY ASMARE TEZERA AA coordination office 28/06/2014 Page 11

Region 3
sales
1.4 Work flow
1.4.1 Physical treatment of malt

The malt is imported from Belgium without purification. Like addition of metal, stone, other gain
straw and other objects, so to need purifications:
Intake Hooper -The purpose of this is to discharge the malt into pre cleaner by bucket conveyors
(elevators)
Pre cleaner -Pre cleaner is installed with inclination, because easily remove straw, sack binders,
piece of wood etc.
Dry destoner-The pre cleaned malt is intake to the destoner the main purpose of this they are used
to separate granular material according to specific weights,Less than malt size , Equal to malt size
and Greater than malt size like coffee and other grain
Pipe magnet -Magnet devices are built into operate near the start of processing, so that iron parts
flowing with the product can not cause any damage. Simply remove metal part from the malt.
Mechanical weigher-Pure malt is before it release into malt mill weigher records the weigher
release 50 kg in one time they it moves by chain convey to malt mill
Cyclones
A cyclone consists of a cylindrical upper part into which air is blow tangentially the cyclone tappers
conically down ward. The dust particle are forced outward by centrifugal force slide down ward and
are discharge through in out let hopper and packed in to sacks.
Problem statement1: regarding to reprocessed beer

As I have seen in practical there is a problem regarding to the reprocessed beer: the breweries
reprocessed the beer which are not matched the adjusting set/target point so that there are machines
(FBI & EBI ) which rejects the bottles those of are : over filled ,under filled , half filled & uncrown
from surplus yeast ,cold tank, bottom filter interface & packaging fob. Following various
clarification treatments the reprocessed beer is dosed back into main stearm beer at rates typically
5% by volume. The reprocessed beer is open to contaminated by microorganisms & it losts its
alcohol content besides that the reprocessed beer becomes a set of infection b/c :
 Microorganisms naturally accumulates in solids& foams

 Many d/t batches of beer are blended together
 Processing is slow due to the nature of solid needing removal
 Slow processing allows growth of any infection present
Problem justification
There for as far as I concerned the solution might be the operating point should be correctly matched
to the adjusting set point that prevents the bottles from under fill ,over fill & uncrown if this so ,
 There may not be a need of reprocessed beer

 There will not be a loss of energy ,time & money
 There will not be infection of beer at all
Problem statement 2: regarding to recycling of wastes & import of r.m

As I have obserbed in practical in Dashen brewery factory, it has the following problems:
 Dashen brewery factory waste water treatment is aerobic which produce high amount of
sludge that may cause environmental pollution.
 The factory do not change spent grain, spent malt and discharged yeast to usable products.
 Dashen brewery do not produce multi products from byproducts
 The factory do not use alternative malt substitution like wheat,maiz ,corn rice instead of
barley malt.
 Still The factory import glue, yeast ,hop , 80% foreign malt
 The factory expenses a lot of money for fuel

Problem justification
The breweries will be innovative to upgrade thire profitability it can treat the waste water
anaerobically w/c has no impact on the inviroment & it is the biological treatment of wastewater
without the use of air or elemental oxygen.
Anaerobic treatment is characterized by biological conversion of organic
compounds by anaerobic microorganisms into biogas which can be
used as a fuel-mainly methane and carbon dioxide.
In addition to that the company can also prepare glue from wheat & it will have planned to use 80%
of local malt.
From BSG we can produce fuel(biogas) specifically, my selected project title rewinds about this one.
Objective of the project
A .General objective
1. Developing theoretical knowledge through practical

2. Developing knowledge how to solve challenges that faces the company
3. Developing knowledge about ways of production of beer
B.Specific
objective
1. Developing each &every process of operation
2. Developing each operational procedures
3. Knowing what type of operation is applied weather batch or continuous
Literature review
Raw Materials for Beer Production
There are four main raw materials are required for beer production. These are: Barley , hops , H2O
& yeast.The quality of these raw materials has a decisive influence on the quality of the beer (the
final product). Knowledge of the properties of raw materials and their effects on the process and the

final product provides the basis for their handling on the process and the final product provides the
processing with such knowledge it is possible to control the technological process rationally.
Water: it must be pure, with no trace of bacteria. This is vital,because it allows the other
ingredients to release all their flavour.95% of breweries have their own spring or natural well.
Raw water sources:

One can distinguish between surface water, which is water derived from lakes, rivers, man-made
reservoirs or dams, and well water from underground.
Surface water is more susceptible to seasonal changes due to rainfall or drought periods. It usually
contains small quantities of minerals and high organic loads and is microbiologically contaminated.
Well water from a suitable depth is usually protected from the surface and therefore its supply
fluctuates far less.
Depending on the hydrogeological situation, though, it can contain a lot of minerals. Its
microbiological quality is usually good. Care has to be taken to use a well properly to prevent
overuse which eventually can cause it to dry up.
Water analysis and evaluation
Very often it is not acceptable to rely on a fluctuating water supply. Apart from obtaining
hydrogeological data to determine whether water is sufficiently available, analysis should ideally
also be carried out over at least a one-year period to determine seasonal fluctuations.
 But what should be analysed to evaluate the water composition?
Of course, the analysis is not confined to these parameters (such as color, , ,turbidity smell ,taste
,temperature ) and specific site-related
problems may require in-depth analysis. In most cases, though, analysing the above parameters
would be sufficient.
As an aside, total hardness of water is defined as the sum of all earth alkali
ions, in this context Ca2+ + Mg2+.
 Total hardness can be divided into carbonate and noncarbonated hardness, the former being
Ca(HCO3)2 and Mg(HCO3)2 and the latter CaCl2, CaSO4, Ca(NO3)2, MgCl2, MgSO4 and
Mg(NO3)2

Alternative terms used are temporary and permanent hardness, because a strong acid like HCl can
make the Ca(HCO3)2 disappear and form CO2, whereas the HCl has no effect on the non-carbonate
hardness and is thus permanent.
Depending on the system used, hardness and alkalinity can be defined as

ppm CaCO3, ëF (degree French hardness), ëG (degree German hardness)
Beer, depending on the type, contains approximately 90–95% water. Since water is the largest single
component of beer it is predictable that its composition has a dramatic impact both on the finished
product and on the brewing process.
In a broader sense, aside from its use as an ingredient of beer, water is used as a process aid for
duties such as:
As a Generation of steam,
 as a Coolant,
 as a method of de-aerating pipe work and plant,
 as a suspending agent or solvent for the preparation of various slurries and
solutions and
 as in CIP system various instruments .
Water usage by individual Breweries is highly variable and in terms of the ratio of volumes of water
used to produced beer.
Finished beer contains more than 90% water. The quality and characteristics of the water used for
brewing greatly affects the taste of the finished beer.
The amount and composition of dissolved minerals, such as calcium and magnesium, play a large
part the taste of the beer. Brewing water must, therefore, be clean, healthy, and of the right
composition
Malt: it is a germinated barley/c is cereal that offers a key advantage: it can be preserved for a long
time after harvesting. In order for barley to be used in the making of beer, it must first be malted. It is
malted barley that gives beer its characteristic color and taste

Malt is a grain product that contributes flavor and color to the beer. Barley is the most commonly
used grain for malting and beer making, but some malt is also made from wheat, rye, and dinked
(spelt wheat).
Grain is "malted" by first allowing it to germinate. This germination converts the grain's starch into
sugar. This sugar (called "maltose") that is needed by the fermentation process (the yeast converts
the sugars into carbon dioxide and alcohol).
Once the grain germinates, it is dried by exposing it to hot temperatures. This kills the grain but
maintains the natural sugar found within the grain. The temperature of the grain is exposed to
determines the color and flavor of the sugar, or finished malt. A low temperature results in pale
Most commonly we choose malt for brewery the reason behind is that Malt have :
 high starch content

 Golden color than other cereals
 Enzymes such as ᵃ & ᵝ amylase
 Relatively low nitrogen content
 It retains its husk on threshing
 It obeys GPL(Germany purity law)
Hops or “green gold” come from a climbing plant with male and female flowers; only the female
flowers are used. There are various varieties, ranging from very bitter to aromatic.
In antiquity, it could be replaced by mixtures of aromatic herbs, in particular rosemary and thyme,
which had the same preserving effect as hops but of course gave the resulting beverage a quite
different flavour. Yes, it is hops that give beer its characteristic bitterness
Advantage of hops in brewing:
 To import bitterness & mouth fill

 To import other flavour & aroma
 To reduce acid surface tension & prevent over boiling
 Acid in protein coagulation
 Modify yeast performance
 Produce beer foam property
 Protect the beer against deterioration

Hop products are two types:
A .Hop extract : are supplied in the form of liquid & that poured to get the bitterness taste
B.HOP PELLETS: are volatile matters which are added in a powdered moisture form after boiling.
They contribute for the sake of beer aroma taste.
Fig 2.1 hops
Objective of hops
(1) To remove excess proteins in the unfermented beer,
(2) They are a natural preservative (against decay)
(3) They enhance the creaminess of the beer's head foam
(4) To prevent kettle over boiling
(5) To clarify hop back & to enhance beer stability
Yeasts : it is a unicellular microorganism w/c can obtain the energy it needs.In the absence of
oxygen(anaerobic) by fermentation. In the presence of oxygen (aerobic)by respiration. During beer
production the wort is fermented by yeast to alcohol & co2 .

During respiration: C6H12O6 +6O2 yeast 6H2O+6CO2+ATP+ADP
During fermentation: C6H12O6 yeast 2C2H5OH+CO2+(-274kj)
The yeast cell has complicated:
 Carbohydrate metabolism
 Nitrogen metabolism
 Fat metabolism
 Inorganic substance metabolism
Yeasts transform the sugars in the must into alcohol and carbon dioxide. The type of yeast used
varies according to the type of beer. There was a time when man had no control over yeasts in beer.
Nowadays there are two main varieties of yeasts that are used in brewing.
Yeasts are selected with reference to:
 Their rate & extent of growth .

 The rate & extent of fermentation
 The flavour & aroma of the beer
 Are a good foam of head & seddment clearness
1.Top fermented yeast :
 It produces much aroma & flavour

 It is lighter & more digestable
 Relatively it ferments at high temp
 It forms multi budded cells
 Mother & daughter cell attaches one another
 It is not used by Dashen brewery
2.Bottom fermented yeast :
 It has little flavour & a fairly natural taste

 It deposed during fermentation hence name
 Relatively ferment at low temp
 Occur almost exclusively as single cell or pairs of cell
 Mother& daughter cell separate one another
 Dashen brewery uses lager type beer

 Also known as". Bottom-cropping yeasts w/c are typically used to produce lager-
type beers, though they can also produce ale-type beers.
Fig 1.0 yeast propagator device
Laboratory yeast propagation

Whether pure yeast strains on slope or liquid culture are sourced internally or externally, the
objective of the laboratory phase of propagation is to grow sufficient biomass to enter the brewery
propagation phase without issue. This is achieved by serial transfers of increasing culture volume
that meet the twin needs of scale-up and hygiene.
Although the timeline of these steps is clearly important, the potential threat to hygiene overrides all
considerations and, accordingly, this determines a `safety-first' mix of culture volume, yeast
concentration and incubation time.

BEER PRODUCTION PROCESS
H20
malt STEPPING milling
Griest
hop caramel spent grain H3PO4(aq)
Wort kettle Wort prerun tank Lautering M.T.K(m.mixer)
trub caso4 cacl2
Cooling&
Whirl pool Fermentation lagering
aeration
plate HX
yeast
Filtration filling Pasteurization Packaging

beer
Silica gel fig 1.1 Beer production flow diagram
Physical & chemical property of beer
Beer constituents can be divided into volatile & non volatile components
Volatile components:
 Have greater vapour pressure

 Resposible for aroma of beer
 Are concentrated on the head space above the liquid
 Resolved by gas-liquid chromatography
Nonvolatile compts

 It includes inorganic salt, sugar, aminoacid ,polypheno, hop resins,
nucleotide together with polysaccharide, protein & nucleic acid
 Are resolved by high precision liquid chromatography(HPLC)
Brewing is the production of alcoholic beverages and alcohol fuel through fermentation. This is the
method used in beer production
The production process involves, steeping, germinating,kilning, milling, mashing,lautering ,wort

boiling, whirl pooling, wortcooling & aeration, fermentation, maturation, filtration, pasteurization &
packaging.
The object of the entire process is to convert grain starches to sugar, extract the sugcer with water,
and then ferment it with yeast to produce the alcoholic, lightly carbonated beverage.
Brewing is fundamentally a natural process. The art and science ofbrewing lies in converting natural
food materials into a pure, pleasing beverage.Although great strides have been made with the
techniques for achieving high-quality production, beer today is still a beverage brewed from natural
products in a traditional way. Although the main ingredients of beer have remained constant (water,
yeast, malt and hops), it is the precise recipe and timing of the brew that gives one a different taste
from another. The production of beer is one of the most closely supervised and controlled
manufacturing processes in our society.
Apart from brewing company expenditures' on research and quality control designed to achieve the
highest standards of uniformity and purity in the product, the production of beer is also subject to
regular inspection and review by federal and provincial health departments. On average, a batch of
beer will take about 30 days to produce. To be more specific, brewing takes nine and a half hours,
while fermentation and aging combined take 35 days for lagers.
QUALITY CONTROL IN BEER PRODUTION
Setting up specifications is done all the time. Brewers decide on the basic properties of original
gravity, color, and flavor and from this develop a formulation of raw materials and a process to
extract what is wanted from them.

1. Sensory methods: Sensory methods are not necessarily easy to apply (and often ill used) but are
useful and quit cheap to do. They include an analysis of beer flavor (undoubtedly beer's most
important attribute), beer clarity, color, and foam. Brewers who do not regularly and critically taste
and visually examine their beers in a formal setting deny themselves much critical information. Beer
color, on the other hand, can be measured in a comparator better at this than most instruments) or by
quite cheap instruments, such as a tintometer. A standard beer set aside for color matching remains
stable for quite a long time if kept cold & in the dark. Observers can rate the beers on some sensory
scale. Putting numerical values from instruments on flavor, haze, foam, color, and so forth is where
the trouble starts, but that isn't really necessary for a simple quality-control program
2. Instrumental Analysis: The second kind of specification and analysis is not amenable to sensory
testing. high on this list of "invisible" specifications has to be the original gravity (OG) and the
degree of fermentability (hence alcohol content) of beers.These are most easily determined on wort
but require an investment in some simple apparatus - a hydrometer and measuring cylinder. The wort
OG and fermentability are fundamental specifications for a beer, because beer is made from the
fermentable portion of the wort. These values also allow a brewer to calculate extract yield from raw
materials (brewhouse yield) and predict beer yield.
The degree of fermentability can be determined by a rapid fermentation test in which a high
population of yeast cells, with frequent agitation, rapidly ferments out the wort. At the same time,
wort flavor and clarity can be noted. A sample of wort, taken under aseptic conditions and set aside
in the archive, will reveal its microbiological status in a few days and tell a good deal about the
sanitary status of the brew house. Package beer, on the other hand, must be analyzed for CO2content
(carbonation) and bottle "air" for flavor stability.
Why use adjuncts?
It has been reported that when the total cost of beer production is taken into consideration (from raw
material purchase and processing through to packaging, sales and taxation), then malt costs in
general have been estimated to represent just ~3.5% of the total cost. Therefore, it becomes apparent
that grain costs represent only a relatively minor contribution to the total cost of beer production.
Then, why replace malted barley with an unmodified substrate `adjunct'? In less developed
countries, malting facilities and malting conditions are quite often less than optimal. Therefore,

because of its lower price, locally produced adjunct material can be used to supplement malted
barley grain.
Apart from the direct cost benefits of using cheaper raw materials, indirect costs (much greater than
the direct costs) can also influence raw material selection
Cleaning & grading the barleyCleaning is the application energy to remove soil & product residue
from the surface of the plant & equipment. Barley cleaning consists of removing everything w/c is
not barley. This includes the ff:eg fragment of straw, sack binders, piece of food, nails screw wire
etc.The preparation of barley cleaning consists of the ff process stages:Removal of:
 Coarse impurities
 foreign seeds
 sand, stones, dust
 foreign & broken kernel iron objects
The purpose of the brew house: is to receive the main ingredients of beer, being malted barley,
cereal, hops, and water, and to process these materials to produce a hopped cold wort ready for
fermenting. There have been various attempts to design a continuous process, none of which have
found acceptance, so the current and foreseeable technologies are a batch process.
The performance of the brewhouse is normally measured by the quantity of cold wort per brew and
the number of brews per week including downtime for cleaning and maintenance. In addition the
overall extract from the raw materials is measured as a percentage of the extract which results from a
standard laboratory procedure such as the European Brewery Convention (EBC) method. Lastly
some measure of quality of cold wort is usually specified in terms of suspended solids and/or
turbidity.
All of these measures are affected by the type and quality of the malted
barley and cereal adjuncts, and as a consequence engineers have sought to
design equipment which can accommodate the natural variation in incoming
1.Steeping

malting begins by immersing barley into water to. During this steeping period, the barley may be
drained and given air rests, or the steep may be forcibly aerated.
fig 2.3 steep vessel
During steeping :
 water is supplied to the interior of the kernel

 As a result enzymes active & life process k/n as germination begins
 It performed in a steeping vessel . Barley must be take up water, supplied with oxygen,
clean.
 The warmer the steep water the faster the water it taken up.
2. Germination
It activated by water and oxygen, the root embryo of the barleycorn secretes a plant hormone
called gibberellic acid, which initiates the synthesis of α-amylase.

During germination process there is
 Growth process
 Enzyme formation
 Metabolic change
 Aeration system
 Proteins break down into amino acids
The α- and β-amylases then convert the starch molecules of the corn into sugars that the embryo can
use as food. Other enzymes, such as the proteases and β-glucanases, attack the cell walls around the
starch grains, converting insoluble proteins and complex sugars (called glucans) into soluble amino
acids and glucose. These enzymatic reactions are called modification.
The more germination proceeds, the greater the modification. Over modification leads to malting
loss, in which rootlet growth and plant respiration reduce the weight of the grain. Because
respiration of the grain causes oxygen to be taken up and carbon dioxide and heat to be produced,
control of aeration, ventilation, and temperature was achieved by manually turning the grain. .
In some malting operations, gibberellic acid is sprayed onto the barley to speed germination, and
bromates are used to suppress rootlet growth and malting loss. Although less-modified malts are
traditionally used in lagers and well-modified malts in ales, it is now usual to produce well-modified
malts regardless of whether lager or ale is to be made.
3.Kilning :It is dried malted barley in w/c malt is dried to remove most of the moisture, leaving 7%
percent in lager. This process arrests enzyme activity but leaves 40 to 60 percent in an active state.
Curing at higher temperatures promotes a reaction between amino acids and sugars to form
melanoidins, which give both colour and flavour to malt.
During killing:
 Water content is lowered

 Germination & modification are stopped
 Colour & flavour CPDs are formed
 DMS(CH4-S-CH4) is produced
 The heat splits SMM librating DMS

The temperature & period of time have a decisive factor on the quality of malt & beer. The two
aspects are initial drying & kilning
Objective of kilning:
 To stop germination
 To stabilize malted barley
Malting :
Malting is the process of converting barley into malt w/c modifies barley to green malt, which can
then be preserved by drying. The process involves steeping and aerating the barley, allowing it to
germinate, and drying and curing the malt takes place in malt houses Occasionally in a brewery It
includes steeping, germinating & kilning. Controlled germination of barley are moisture, temperature
& carbon dioxide
Purpose
 Produce enzymes useful for brewing Amylases & protease.

 Allow for controlled germination: Maximum enzyme production , minimum enzymatic
activity and plant growth
In order to be fermented by yeast, the food reserve of barley, starch, must be converted by enzymes
into simple sugars. Two enzymes, α- and β-amylases, carry out the conversion. The latter is present
in barley, but the former is made only during germination of the grain. Specially bred strains of
barley (generally low in nitrogen content) are used for malting. Other important characteristics are
yield, even germination, ability to produce enzymes, and highly extractable malt
4.Malt Milling :The purpose of milling is to reduce the size of the malt particles and to expose the
endosperm to attack by enzymes during the mashing process, so that the greatest conversion of starch
to fermentable sugar is achieved in the shortest possible time.
The principal objectives of malt milling are:
• To split the malt husks longitudinally to expose the starch endosperm
• To crush the endosperm for accessible enzyme action
• To keep the fine particles from clogging the bed during wort sepa/n

• to retain the husk relatively intact while breaking up brittle,
• starch into particles
Malt milling is used to give malt enzymes, the opportunity during mashing to act on the malt
contents and break down them. During milling the husk must be treated carefully because they are
used as filter material during lautering. Design of the mill and the gap between the rolls are important
in obtaining the correct reduction in size of the malt. Particle size is important for the performance of
the mash separation system, and for lauter tun performance it is considered beneficial to preserve the
husk portion of the malt grain. For mash filters, this is not critical as the filter bed is comparatively
thin and the pressure differential across the filter back is comparatively high.
For a lauter tun, poorly modified malt should be milled more finely to give
enzymes access to the starch which can be shrouded behind cell wall material which has not been
broken down adequately in the malting process. However, the smaller particle size impacts
negatively on the rate of run-off of wort. Conversely a well-modified malt can be milled more
coarsely to permit faster separation without sacrificing extract performance.
Steep conditioned milling :In steep conditioned milling the malt is fed into a conditioning chamber
prior to milling where it is sprayed with warm mashing liquor for a Brewing.
9
10

Fig1.1 mill star mashin

5.Mashing
Mashing is the process of combining a mix of milled grain and water and heating this mixture in
vessel called a mash tank kettle.
Malt is added to heated, purified water and, through a carefully controlled time and temperature
process, the malt enzymes break down the starch to sugar and the complex proteins of the malt
tosimpler nitrogen compounds. Mashing takes place in a large, round tank called a "mash mixer" or
"mash tun" and requires careful temperature control. At this point, depending on the type of beer
desired, the malt is supplemented by starch from other cereals such as corn, wheat or rice.
Objective of mashing.
 To dissolve immediately soluble substance.
 To convert substances that is initially insoluble substance.
 To convert the extracted substances into fermentable extract, through enzymatic action.
 The maximum enzyme activity is reached after 10-20minutes and the maximum enzyme
activity is higher at a temperature of 62-680
Fig 2 mash mixer

6.Lautering
The mash is transferred to a straining (or lautering) vessel which is usually cylindrical with a slotted
false bottom two to five centimetres above the true bottom. The liquid extract drains through the
false bottom and is run off to the brew kettle. This extract, a sugar solution, is called "wort" but it is
not yet beer.
Water is "sparged" (or sprayed) though the grains to wash out as
much of the extract as possible. The "spent grains" are removed
and sold as cattle feed.
Fig1.3 lauter tun mashin
At the end of mashing process the mash consist of a water mixture of dissolved and un dissolved
substances The temperature of the transferring mash to the lauter tank should be at 860C. The
aqueous solution of the extract is called wort, & the insoluble part is spent grain.
The spent grains consist essentially of the husk, the seedling & other materials which do not go into
solution on mashing The spent grains serve as the filter media.

7.Wort boiling & hopping
Wort boiling requires a lot of energy (24-54 MJ/hl ) with a temp of 118-122 C0 & it is fitted with
coils or a jacketed bottom for steam heating and is designed to boil the wort under carefully-
controlled conditions
Hop is added to wort kettle during wort boiling so as to contribute:
 Bitterness & aroma

 Prevent kettle over boiling
 Enhance beer foam
 Adds to microbial stability of beer
 Helps clarification hop back
Boiling, which usually lasts about two hours, serves to concentrate the wort to a desired specific
gravity, to sterilize it and to obtain the desired extract from the hops.
The hop resins contribute flavour, aroma and bitterness to the brew. Once the hops have flavoured
the brew, they are removed. When applicable, highly-fermentable syrup may be added to the kettle.
Undesirable protein substances that have survived the journey from the mash mixer are coagulated,
leaving the wort clear.
The wort obtained is boiled for one to two hours, during this time hops are added in the dosing tank.
In this process it has four stages;
 Pre-boiling – In this stage the temperature raised to for 10min, and hop is added for
bitterness.
 Pressure boiling – In this stage the temperature is raised and the aim is to inactivation of
enzymes action.
_
 Pressure decrease the temperature at which pressure decrease and the duration for the
decrease is 15 minutes
Post (end) boiling – To this stage hop pellet is added to give aroma on beer. Finishing (ending) time
of this wort color is 30-40 minutes
Objective of wort boiling
 To stop enzyme rxn

 Falling of wort PH
 To sterilize wort
 To remove un wanted volatile
 Concentrate wort to specified protein
 To coagulate & precipitate protein
After the beer has taken on the flavour of the hops, the wort then proceeds to the "hot wort tank" is
k/n as whirl pool. It is then cooled, usualy in a simple-looking apparatus called a "plate cooler" or
plate heat exchanger.
Fig 1.4 wort kettle mashin
8.Whirl pool (wort clarification)
As the wort and a coolant flow past each other on opposite sides of stainless steel plates, the
temperature of the wort drops from boiling to about 10 to 15.5 °C, a drop of more than 65.6 °C, in a
few seconds.
After boiling, the hot wort is pumped through a hop back (whirlpool) . This device removes the hop
plant residues together with some of the “hot break. .After about one hour the wort leaves this vessel
through pipes at the base of the vessel ,so that collected trub will not be mixed with the collected trub
is sent to trub tank.

Hop trub particles results reduced fermentation degree, beer with a darker color, rough taste and poor
stability.
Thus hop trub and spent hops should be removed to achieve the following objective.
 To ensure flavor and colloidal stability
 To avoid blocking of heat exchanger during wort cool
 To avoid fouling of yeast cell wall and yeast sedimentation during fermentation.
During whirl pool wort stripping has the following advantage
 Removing volatiles formed during whirl pool stand

 Reducing overall evaporation rate
 Producing beers with fuller mouth feel
9.WORT COOLING & AERATION
In Dashen brewery wort cooling is achieved through plate heat exchanger. A plate heat exchanger
has many ridged plate which form two Separate path .the wort has been pumped into the heat
exchanger.
• During wort cooling cold trub has been formed. Afte rwort chilled the cooling medium
(warm water) has been returned to hot water storage.
The main functions of wort boiling together with the parameters which are
believed to affect them are as follows:
 Volatile removal: evaporation ,two-phase flow
 Isomerisation :temperature, time
 Flocculation :two-phase flow, low shear
 Sterilization: temperature, time
 Enzyme inactivation: temperature, time
 Concentration : evaporation
Advantage of wort cooling:
 Low pressure drop

 good heat exchanger

 Flow direction can be easy

 Low space requirement
 Low residence time
 Easy cleaned by CIPs/m
The evaporation of water is not often a substantial issue in many breweries and not of primary
interest, and the only other function requiring evaporation is the removal of unwanted volatiles.
There is no good reason to assume that the evaporation of water in itself correlates to effective
evaporation of volatiles. It is clear that vigorous mixing is essential to cause coagulation of proteins
and form flocks, but shear forces must be minimised to prevent disruption of flocks.
Over heating should be avoided as it will adversely affect foam retention, will `burn-on' and
caramelise sugars, and will lead to the formation of usually undesirable flavours
Wort aeration : Cold wort ready for yeast pitching must be saturated with dissolved oxygen inorder
for the yeast to perform in the first stage of fermentation. The injection of sterile filtered air is still
widely used
The advantage of plate heat exchanger is:
 It is easy to clean and connect to clean in space(CIP)
 It requires very little floor space
 Wort remains short time in the cooler
10.Fermentation
There are four aspects to fermentation management, excluding cleaning:
1. Establishment of desired conditions at the completion of fermenter fill
2. Monitoring and control of the progress of fermentation
3. Identification of the endpoint
4. Removal of the yeast crop and emptying the fermenter.

Secondary fermentation/maturation
Beer at the completion of primery fermentation is called green beer/young beer.It contains little
entrained CO2, it is hazy & having un acceptable flavour, & its taste & aroma are inferior to beer. In
order to refine green beer it must be matured/conditioned
In maturation or conditioning phase there are two additional process
 Saturation of the beer under exess pressure

 Removal of all haze forming CPDs from beer
Fermenter fill
At the beginning of fermentation it is necessary to fill the vessel with a measured volume of wort of
a chosen concentration and temperature, containing dissolved oxygen at a desired concentration and
an evenly distributed suspension of yeast cells at a desired viable concentration.
Clearly the control of total extract delivered to the fermenter cannot be better than the accuracy of
all the controlling and monitoring component parts of the process.
The main objective of beer fermentation is to utilize the ability of the yeast cells to convert sugars
into ethanol and carbon dioxide.
Fermentation rxn: C6H12O6 yeast 2C2H5OH+CO2+heat
function of fermentation:
Starch/po ᵝ-amylase maltose/di
Enzymatic conversion of maltose ᵃ-amylase sugar/mo
• Extraction of hop flavours & aroma CPDs

• sterilize maltose & hop flavour
Classes of carbohydrate
 Monosaccharide’s-simple sugars- fructose, glucose , galactose

 Disaccharides-maltose, lactose , sucrose
 Polysaccharides- starch, cellulose, glycogen

In Dashen brewery fermentation is performed in 20 fermentation tank each of fermenter tanks can
contain from 2500-3000hl of pitched wort. Fermenters are cylindrical conical vessels which
have a conical bottom and cylindrical top part. Fermentation is energy yielding process in which
organic compounds are metabolized under anaerobic or micro aerobic conditions. Two types of
fermentation under which Dashen Brewery would be applied.Primary fermentation & Secondary
fermentation(maturation)
Yeast, which is a living, single-cell fungi, that breaks down the sugar in the wort to carbon dioxide
and alcohol. After the yeast is added to the hopped wort, fermentation of the maltose to Ethanol
occurs in the fermentation tanks. Fermentation produces both ethanol and carbon dioxide. The
carbon dioxide is allowed to vent out through these blow-off hoses whose ends are immersed in a
tank of water, producing an air-lock apreventing oxygen from entering the fermentation taks 1.5
Fig 1.2 fermenter & BBT tanks

11.Lagering
Fig 1.5 lagering
In laggering the ff conditions are takes place
 Carbonation
 Flavour maturation
 young beer maturation
12.filteration
It is a separation process in w/c the yeast cells & other turbidity causing materials still present
in the beer are removed.The purpose of filteration is to make beer so stable thatno visible changes
occur for a long time and so the beer looks the same as when it was made.
Filtering the beer stabilizes the flavour, and gives beer its polished shine and brilliance. Not all beer
is filtered. When tax determination is required by local laws, it is typically done at this stage in a
calibrated tank.Filters come in many types.
Many use pre-made filtration media such as sheets or candles, while others use a fine powder made
of, for example, diatomaceous earth, also called kieselguhr, which is introduced into the beer and
recirculated past screens to form a filtration bed.Filters range from rough filters that remove much of
the yeast

and any solids (e.g. hops, grain particles) left in the beer, to filters tight enough to strain color and
body from the beer. Normally used filtration ratings are divided into rough, fine and sterile. Rough
filtration leaves some cloudiness in the beer,but it is noticeably clearer than unfiltered beer. Fine
filtration gives a glass of beer that you could read a newspaper through, with no noticeable
cloudiness. Finally, as its name
implies, sterile filtration is fine enough that almost all microorganisms in the beer are removed
during the filtration process.
The driving force during filtration is the pressure difference between the filter inlet and the filter out
let. The pressure at the inlet side is always greater than the pressure at the outlet side. The greater the
pressure difference the filter opposes filtration.
How to control oxygen?
Role of oxygen
 it allows yeast to take in the fermenter
 It causes spoilage of beer
 It cuts the shelf life of beer
 it needs for compressed air added to the cooled wort
The uptake of oxygen into beer is primarily a fu/n of the d/nce in partial pressure b/n the beer & the
gas in contact with it . Minimizing this is the basic of successful oxygen control.Turbulence during
movement must be avoided. Turbulence causes the loss of CO2 & uptake of oxygen. Beer must there
be moved gently through the correctly sized pipes
Fig1.6 filter mashine

13. Filler machine

Bottle filling machines are always built as rotating machines with up to 120 filling values
During rotation of the filler the bottle are:
1. Pressed against the filling element
2. Evacuated and counter pressurized once or twice Filled
3. The filling height in them is corrected
4. The pressure is released and
5. The bottle are lowered again and mixed away
Fig1.8a filler mashine outer view
14.Crowner cork
The crown cork pass and magnetic conveyor band a slide or other conveying device into the storage
hopper of the bottle closer and there is brought in to the correct orientation by a sorting devices. The
crown cork which may be turned 1800 from the correct positioned can thereby is brought in to the
correct position by a simple guide device. The closing element it is lowered by the curved track on to
the bottle until the crowner corks rests on the bottle mouth then the springs forces the closure on to
the bottle and the closing comes forces it down.

fig1.8b inner view of filler mashine
15.Pasteurization
It is the total destruction of all micro/ms by supplying heat at a temperature of 66 degree

celcious/hr.Microbiological stabilization of beer by thermal treatment is still the most common
method.
Alternatives are sterile filtration as described above and inclusion of a culture of brewing yeast in the
pack (e.g. cask-conditioned or bottle-conditioned beers).
The issue with pasteurization is that oxidative damage occurs. Staling and ageing occur very rapidly
in the short pasteurization time.
Advantage of pasteurization:
 Excellent of quality of beer

 Homogeneous heating
 Mimum loss of heat

 Reliability
 future up grading
 Easy maintenance
 Small space requirement
There are incentives for brewers to reduce the number of `Pasteurisation Units' employed, otherwise
the microbiological stabilisation is at the expense of colloidal and flavour stability. This reduction is
achieved through lower pasteurisation temperature and/or time. Thus there is an incentive to develop
a new technology that employs another mechanism, which supplements the effect.fig 1.5pasteurizer
16. Labeler
The main function of labeler is labeling on neck and body of the beer bottle. The appearance of the
bottle is extremely depending on the quality of the labeling to be able to do this label paper must
have the following propeties are contained.
1) Amount (volume)
2) Expired date
3) Production date
4) In gradiate(food grades)

Generally for labeling process glue and air are the two important materials coating of the label.
Fig 1.8 labeler mashin
17.Full bottle inspection (FBI)

The full bottle inspector defects
Neck label , Body label , Missed label , Proper closing of crown cork and Under fill and overfill
The presence and arrangement of the labels are checked by using photo electric sensor if there is a
problem or error it sends a signal to a rejection.
18.Caser (loading)
Its pneumatic operated machine which can put down the bottle with in the crate. Note: caser and UN
caser machine.
The bottle in a crate are fitted from the create by a gripper head and set down at a predetermined
position. The sequences of operation are performed continuousl.

Fig 1.7 uncaser mashin fig 1.8 caser mashin
19.Packging:
Even after filtration, however, some yeast may remain in the beer. To kill the remaining yeast, the
beer is pasteurized, or heated to 82° C (180° F) after it has been sealed in cans or bottles. Draught
beer, which is stored in metal kegs, usually is not pasteurized and must be kept refrigerated to
prevent it from spoiling.
Packaging is one of the important part of in the entire beer production process which use complex
machine and plant to maintain high quality of beer and to increase the demands of customer for a
particular beer by excellent of presentation of product.
The main activities of this section are:
Depalletiser Uncaser washer visual EBI filler pasteurizer

labeler FBI caser palletiser fork lift
In this department there are two products packed though bottle and keg this are:
i. Dashen beer packed by bottle
ii. Royal drought packed by keg
iii. Cellar drought un filtered beer packed by keg

Generally as I have seen In practical the bottle shop of a brewery, returned empty bottles go through
washers in which they receive a thorough cleaning. After washing, the bottles are inspected
electronically and visually and pass on to the rotary filler. Some of these machines can fill up to
1,200 bottles per minute. A "crowning" machine, integrated with the filler, places caps on the bottles.
The filled bottles may then pass through a "tunnel pasteurizer" (often 23 metres from end to end and
able to hold 15,000 bottles) where the temperature of the beer is raised about 66 °C. for a sufficient
length of time to provide biological stability, then cooled to room temperature. Emerging from the
pasteurizer, the bottles are inspected, labeled, placed in boxes, stacked on pallets and carried by lift
truck to the warehousing areas to await shipment. Also in the bottle shop may be the canning lines,
where beer is packaged in cans for shipment. Packaged beer may be heat-pasteurized or micro-
filtered, providing a shelf-life of up to six months when properly stored. Draught beer, since it is
normally sold and consumed within a few weeks, may not go through this process. The draught beer
is placed in sterilized kegs ready for shipment.
Fig1.9 crate washer

The crate can become dirty during transportation and in store after emptying they pass through a
create washer and turner are stacked in crate store until used after a filler.
CHAPTER TWO
2. OVER ALL INTERNSHIP EXPERIENCE

2.1 The reason why I have Selected the company

Firstly, I select this company, because Dashen Brewery is a big factory. So I think as I can get full
knowledge which is related to my course that I take when I was in campus. In D.B.S there are
different departments based up on this there are a very big and heavy machines in each department.
Then I get knowledge from the different departments like, how machines operate, its work and
function, its organizational and management structure, its work flow and work ethics. Secondly, I
select this factory because of shortage of finance. Mean the money which is given us from the
campus is not enough Because there is an expense of rent house, food and additional materials. Then
to solve this in some case I select this company in order to get a help from my family. Because the
company is near to the place which my family lives.
2.2.Section of I have been working
I have been working in beer production production department.
The organization stracture is look like the ff form.
Beer production house
Precleaning section
Brehouse section
milling mashing lautering Wort boiling whirlpooling
Fermentation section
1st storage tank carbonation 2nd storage tank

fermenter
Beer Processing
Beer filt/n Bottle washing filling Labeling & packaing

2.3The work flow in the section look like the ff form.
General Manager
Operator
Division Mnager
Forman Forman
order distributer
worker Forman & worker
2.4 Challenges that facing me during the intership
The planned schedule of mekelle university for registration was very late & there is also a down
payment of cost sharing .This is the university's problem having on this I have lost the first week of
a month. W/n I came to the second week this time was very bad for me, the companies said ''safety
first'' I'm stranger for the company even I didn't know what safety materials are full filled. W/n I
asked the company civil services who regards to them how could I found the safety materials,They
gave responces you haven't easily got it around here rather than Adis.Till the time is run, after 3days
I contact with one gay who is a driver to brought the safety from Adis. Due to this obstacles I lost
the second week. I have already been started on the 3rd week of the 1st mont.
Also there was aproblem regarding to assigning /grouping the internship student.Mr Asfaw was an
assigner of every student.Even he doesn't know w/c section of the company belongs to the student
related to their field.Eg he assigned me, to work on maintenance section but, maintenance but,
maintenance doesn't invite me b/c I am chemical student, I am not the only but, there are so many
students wrongly assigned without regarding their fields/Dep't.

2.5. Measures in order to overcome these challenges

The assigner should have ''a knowhow'' about each & every dep't of the internship student.In addition
1) In working area, I will give accuracy, punctuality and self confidence
2) The staff members should be oriented about the advantage of internship program to the
students.
3) Make close relationship with each workers and operator of the company.
4) Being patient to get something what I want.
5) By following the company’s official rule to ask something
CHAPTER THREE
3. Over all benefit I gained from the internship:

 This visit provided us with the opportunity to observe the different processes involved in the
beer manufacturing, i.e. Steeping, germinating, kilning, milling, mashing, lautering, wort
boiling, whirl pooling, wort cooling & aeration,fermentation,lagering, filtration,filling,
pasteurization and packaging.
 The quality control measures being adopted to maintain the quality of the beer to
international standards and the basic layout of the plant were also observed.
 The visit was a very useful academic as well as practical exposure and we look forward to
more future to enhance both our theoretical, technical and practical knowledge
3.1 In terms of improving practical skills
In Dashen brewery S.C. this internship program I will get much more experiences from
maintenance staffs. So I will improve practical skills like:
 Highly developed disassemble and assemble of the machine.
 Effective assessment and management risk, resource and time.
 Creativity and innovative approach to solving problems.
 The ability to analyze and interpret diverse, complexes data.
 Critical thinking and the ability to evaluate designs, plans and projects.

And also I could develop my skill by participating myself into different parts.As I have seen
in practical specially production house mainly & highly invite the fields such as chemical &
chemistry.As I have learnt in theoretical almost more than half courses relates the beer processing
operation.
3.2 In terms of improving theoretical knowledge

For working practically it also improve the theoretical skills by any means like, when working time
to asks the production staff, to read the manuals, also read reference books when working projects
and I could improve my theoretical skills.
3.3 In terms of improving industrial problem solving capacity
This was our main aim & is part of our project. Having a problem is very important because it leads
to try and read more.
I improved my industrial problem solving capability through observing when problems are present
by looking and asking where the problem and what procedure they consider, to identify the problem
and how they solve. In addition to this I develop my reading and understanding of manuals of d/t
chemicals & unit operations etc.
3.4 In terms of improving team playing skills
Team playing skills are one of the basic requirements for the proper working of a good company
regardless of its size and service and to improve like:
 To increase self confidence
 Easily control the environment
 Easily solve problems
 To sheared knowledge’s
 To give fast decision making
 To interpret the problems and solve the problems
 Giving respect for other
3.5 In terms of improving leadership skills
A leader is a person who has strong principles, courage and dedication of a clear vision, and
improving: Creating and managing the vision
1. Making good decision
2. Communicating effective
3. Using appropriate style and power

4. Leading change
5. Motivating and developing others
6. Resolving conflicts and issues
7. Creating positive culture and climate
8. Conducting meaningful evaluation
3.6 In terms of understanding about work ethics issue

If you have a strong work ethics ,you will be a productive. So that in working area you must should
have:
 Respect the rules and regulation of the company
 Accountability and responsibility

 Be punctual, motivated, confidant
 Give smooth relation to the partners
 Respect for all workers
 Focus on working area
3.7 In terms of improving entrepreneurship skills

Participating in the internship allows to me gain a better perspective of post graduations employee by
applying the principle and theories I have developed in the class room. This practical application
creates an easier transition for me from the class room to the working parts.
While participating in this internship I realize that creativity and problem solving is one if the
starting points of internship of entrepreneurs. This internship motivates me not to be employee
because it enables me to know more about my career, the real challenges and ways of business
establishment in this profession.
3.8 In terms of improving interpersonal communications

Developing interpersonal communication skill is vitally important in today’s work place. In the
company of Dashen brewery there are quite a few professional engineers so that to share the
knowledge from those people I have made good interpersonal communication skills as a result I have
improved my good playing skills to internship friends and I have got from mentors about everything
what I have needed.

Generally, I have got it by the help of good communication skills w/c leads me:
 To increase my practical skills & theoretical knowledge of each unit operations & chemicals
 To make good & smooth relation to other staff members
 For working my projects it was compulsory to communicate with my mentor's

1. CIP cleaning in place
Cleaning in place shall be defined as
 It is a method of cleaning equipment without the need to disassemble the equipment prior to
cleaning.
 It is commonly used for the interior cleaning of brewing equipment such as tanks, brewhouse
vessels, heat-exchangers, pipe-systems and hoses, and other production equipment such as
fillers, etc.
 The equipment is cleaned without any major modifications to the equipment itself
Cleaning solutions are generally transported via pumps or applied via special spraying devices.
Automated cleaning via CIP systems has the following benefits:
 Consistent and repeatable cleaning results

 Safe operation without much exposure to employees
 Very economical operation.
2. COP ( Cleaning out of place) : Cleaning out of place is essentially the opposite of CIP, and refers
to most manual cleaning applications.
 Either the equipment must be broken down into pieces or major modifications must be
performed before the cleaning can take place.
 Some equipment that is normally cleaned via CIP should be cleaned periodically in a COP
mode, such as heat-exchangers.
Therefore, COP cannot and should not be completely avoided. Some of the drawbacks and
benefits of COP are:
 Cleaning results may vary with operator/employee

 Exposure of employee to cleaning solutions
 Time-consuming process

 Easily verifiable through visual inspection

 May expose residuals left by CIP cleaning.
3. Foam cleaning
Foam cleaning is a method for cleaning large, exterior surfaces. Special with foaming agents or gels
are applied via low pressure foam units. Foaming is a very economical method for cleaning large
exterior surfaces that cannot be cleaned via CIP. Here is an example. One liter of chemical and 49
liters of water combined with 450 liters of air produces 500 liters of foam, which is enough foam to
cover an area of approximately 200m2.
Before applying foam, each surface should first be rinsed with ambient water. Pressure up to 30 bars
may be used for the rinse. The foam itself can be applied with either low or high pressure foamers.
However, low pressure foam cleaning has clear advantages over high pressure foam cleaning and is
today the preferred method of use.
Foam application with low pressure units has displaced high pressure for the following reasons:
 No physical/mechanical impact or damage on equipment

 No aerosol formation
 No cross-contamination from deflected cleaning solutions into already cleaned areas
 Foam is visible during application and rinsing, making it easier to cover all areas.
The importance of a well-balanced mixture of air, water and chemical must be stressed. The most
desirable foam is wet foam; however, if the foam is too wet, sufficient contact times cannot be
achieved.
A perfect blend of water, air and chemical can yield very effective and highly cost-efficient cleaning
results. So- called hose-end foamers do a mediocre job at best, and usually do not allow for
adjustments of air. Commercial-grade foam units yield the best results and their slightly higher cost
will pay off quickly due to their ability to perfectly blend water, chemical and air.
Dry foam clings well to the equipment, but does not clean very well. Very wet foam cleans well, but
typically lacks the required contact times since it quickly runs off the equipment.
Brewery wastewater treatment
Wastewater treatment is an end-of-pipe means of controlling water pollution. The beer brewing
process often generates large amounts of wastewater effluent and solid wastes that must be disposed

off or treated in the least costly and safest way so as to meet the strict discharge regulations that are
set by government entities to protect life (both human and animal) and the environment.
It is widely estimated that for every one liter of beer that is brewed, close to ten liters of water is
used; mostly for the brewing, rinsing, and cooling processes. Thereafter, this water must be disposed
off or safely treated for reuse, which is often costly and problematic for most breweries. As a result,
many brewers are today searching for ways to cut down on this water usage during the beer brewing
process, and/or means to cost effectively and safely treat the brewery wastewater for reuse
1. Physical treatment
Physical treatment is for removing coarse solids and other large materials, rather than dissolved
pollutants. It may be a passive process, such as sedimentation to allow suspended pollutants to settle
out or float to the top naturally.
2. Chemical treatment
Among the chemical treatment methods, pH adjustment and flocculation are some of the most
commonly used at breweries in removing toxic materials and colloidal impurities.
3. Biological treatment
After the brewery wastewater has undergone physical and chemical treatments, the wastewater can
then undergo an additional biological treatment. Biological treatment of wastewater can be either
aerobic (with air/oxygen supply) or anaerobic (without oxygen).
3.1. Aerobic wastewater treatment
Aerobic biological treatment is performed in the presence of oxygen by aerobic microorganisms

(principally bacteria) that metabolize the organic matter in the wastewater, thereby producing more
microorganisms and inorganic end-products (principally CO2, NH3, and H2O).
Aerobic treatment utilizes biological treatment processes, in which microorganisms convert non
settleable solids to settleable solids. Sedimentation typically follows, allowing the settleable solids to
settle out. Common types of aerobic wastewater treatment plant (WWTP) systems for the treatment
of PWW are discussed below.
3.2. Anaerobic wastewater treatment

Anaerobic wastewater treatment is the biological treatment of wastewater without the use of air or
elemental oxygen. Anaerobic treatment is characterized by biological conversion of organic
compounds by anaerobic microorganisms into biogas which can be used as a fuel-mainly methane
and carbon dioxide.
CHAPTER FOUR
MATERIAL BALANCE
4.Mass balance, equipment sizing & Energy balance
The ff available tables are given for the calculation
Table 1.1
substance Density(kg/m3) Density(kg/lit) Cp (kj/kg.k)
ethanol 789 0.789 2.3

trub 150 0.15 1.7
hop 128 0.128 1.6
yeast 105 0.105 4.1
Cacl2(s) 2150 2.15 3.06
Caso4(s) 2320 2.32 1.01
caramel 1138 1.138 0.76
Malted barley 498 0.498 0.21
Spent grain 669 0.669 0.21
Water(l) 1000 1 4.2
Silicagel(s) 6000 6 1.13
H3PO4(aq) 1880 1.88 4.15
Unit Operations & their operating temperature with time

Table 1.2
Unit operations Temperature range/℃ ∇T(k°) Time taken

Steep vessel 50 673 20:16-20:18
Mill star 50 673 20:14-20:43
M.T.K 50-57 673 20:14-20:43
Lautertun 77-83 321 22:38-1:26
Wort prerun tank 83-89 321 22:48-1:19
Wort kettle 89-94 313 0:55-7:02
Whirl pool 94-85 228 6:44-8:40
Heat exchanger 85-12 -321
Primary fermentation 12-14.5 293 7-14 days
Maturation 14.5-5 197 14-21 days
Laagering 5-(-1) 225
Filtration -1-(-1.5) 269
Professionals as told me & as I have seen in practical there are 8 brewhouse.Therefore the amount of
each of the feed stream in each unit operation in the brewhouse should be multiplied by 8 per a day.
My calculation based on per a day
 Amount of malt added = 5900kg*8/day = 47,200kg/day added to steep vessel

 Amount of water = 204hl*8/day = 1712hl =171,200lit/day
 Amount of caso4 =7kg*8/day =56kg/day
 Amount of cacl2 =13kg*8/day=104kg/day added to m.t.k
 Amount of H3PO4(aq)= 3.2lit*8=25.6lit/day
 Amount of caramel=3.25lit*8=26liy/day (wort pre run tank)
 Amount of hop 15kg*8/day=120kg/day(wort kettle)
 Amount of wort transfer to the fermenter=309.0096hl*8/day=247,200lit
 Amount of yeast=2200-2500kg for 2400hl wort i.e 2300kg yeast(fermenter)
 Amount of silicagel for 1hl wort=180g,since z total amount of silicagel for 247,200lit wort
will be 247,200*180g=44,496000g=44,496kg silicagel(filtration unit)
 The operating temperature in each unit operation also should be multiply by 8.
 Working hour of the company 24hrs except for maintenance & cleaning purpose i.e it works
317 days out of a year(365 days)
 production capacity of the company 42000bottle/hr = 302,400lit/day

Before I am going to the calculation part it is important to remember the ff essential terms
according to my Dep't.
4.1a MASS BALANCES ON EACH UNIT OPERATION
Based on the above beer production flow diagram i.e fig1.1 Chemical processes may be
classified as batch, continuous or semi-batch and as either steady-state or transient. Although the
procedure required for performing mass, or material, balances depends on the type of process,
most of the concepts translate directly to all types.The general rule for mass balance in a system
box (a box drawn around the complete process or the part of the process of interest) is:
input+ generation - output - consumption = accumulation

where,
(i) input is the material entering through the system box. This will
include feed and makeup streams;
(ii) generation is the material produced within the system, such as thereaction products in a reactor;
(iii) output is the material that leaves through the system boundaries.
These will typically be the product streams of the process;
(iv) consumption is the material consumed within the system, such as the reactants in a reactor;
(v) accumulation is the amount of material that builds up within the
system.
The type of operation that usd by the company is '' Bath type operation''
What does mean Batch operation?

 it is a process that leads to the production of finite quantities a material
 It is easier to scale up
 it is un steady state operation
 It is performed in a sequential way.
So what are the batch plant advantages?
1) Multiple mixes can be produced in small quantities. However, the continuous plant can also
produce multiple mixes with multiple long term storage silos.
2) To meet specifications that require a batch plant.
3) A marketing advantage when properly applied in selling a multitude of different mix designs
to many different market segments

Assumptions for batch operation:

 No generation
 No accumulation
 No consumption
Key words: M=mass , V= volume , ρ=density
4.1 mass balance on steep vesel
141,200lit(water)
47,200kg(malt) Steep vessel out put
Input=output output=Mmalt+Mwater ,but mass of water
Mwater =Vwater*ρwater=1kg/lit*171,200lit =171,200kg

Out=171,200kg+47,200kg =218,200kg
4.2Mass balance on mill star
Mill star
218,200kg out
In =out out =218,200kg
4.3 Mass balance on m.t.k 104kg(cacl2) 58kg(caso4)
M.T.K
218,200kg out
27lit(H3PO4)

input = output
out =218,200kg+104kg+58k+MH3PO4 ,but MH3PO4=V*ρ =27lit*1.88kg/lit =51.76kg
so , output = 218200+104+58+51.76 = 218,414kg
4.4 Mass balance on lautertun 9440kg (spent grain 20% of mass of malt)
lautertun
218,414kg out
In = out out = 218,414kg-9440kg = 208,974kg
4.5 Mass balance on wortprerun tank(w.p.t) 26lit(caramel)
208974kg W.P.T out
208974kg+Mcaramel=out , but , Mcaramel= (V*ρ)caramel = 26lit*1.138kg/lit = 30kg
So, out = 208,974kg+3okg =209,004kg
4.6 Mass balance on whirl pool 12kg(trub 10% of hop resins)
209004kg Whirl pool out
In = out , out = 209004kg-12kg =208,992kg
4.7 Mass balance on fermenter 2300kg(yeast)
Fermenter
208,992kg out
In = out , out = 208,992kg+2300kg =211,292kg

4.8 Mass balance on filteratin unit 44496kg(sio2)
211,292kg Filtration unit out
In = out, out = 211,292kg+44,496kg = 255,788kg
4.9 Mass balance on the filler unit operation
Filler
255788kg out
In = out , out = 255,788kg
4.10 Mass balance on pasteurizer & labeler(P.A.L.E)

P.A.L.E
255,788kg out
In = out , ∴ out = 255,788kg
4.1b EQUIPMENT SIZING OF EACH UNIT

OPERATION
4.1 sizing /volume of steep vessel(S.V) 171,200LIT(H2O)
47,200kg(malt) Steep V(s.v)

vessel(S.V)
V(H2O)+V(malt) = V(S.V) , but ,V(malt) = M(malt)/ρmalt =47200kg/0.497kg/lit=94,970lit
, ∴ V(S.V) =171,200lit+94,970lit= 266,170lit
N.B Volume is not additive but , this summation indicates that the total volume occupied by a single
unit operation w/c is a step vessel.

4.2 Volume of mill star
266,170lit Mill star v
V(miller)= 266,170lit
104kg(cacl2),v2 58kg(caso4),v3
4.3 Volume of mash mixer

Mash mixer
266,170lit,v1 V
27lit(H3PO4),v4
V(mash mixer)= v1+v2+v3+ v4 , but
v2=m2/ρ2=104kg÷2.15kg/lit=48lit
V3=m3÷ρ3=58kg÷2.32kg/lit=25lit
∴ V =266,170lit+48lit+25lit+27lit=266,270lit
4.4 Volume of lautertun 9440gk(BSG),v1
lautertun
266,270lit V
V = 266,270lit-V1 ; V1=M1/ρ1 = 9440kg÷0.669kg/lit=14,111lit
∴ V =266,270lit-14,111lit=252,159lit

4.5 Volume of wort prerun tank (W.P.T)
26lit(caramel)
255,159lit W.P.T V
V = 255,159+26 = 255,185lit
4.6 Volume of wort kettle (W.T)
120kg(hop) ,V1
255,185lit W.T V
V = 255,185lit+V1 ;
but, V1=M1/ρ1=120kg÷0.128kg/lit=938lit
∴ V= 255,185lit+938lit=256,123lit
4.7 Volume of whirl pool (W.P)
12kg(trub) ,V1
256,123lit W.P V
V = 256,123lit-V1 ; but, V1 =M1/ρ1=12kg÷0.15kg/lit=80lit
∴ V =256,123lit-80lit=256,043lit
4.8 Volume of fermenter or fermentation vessel
2300kg(yeast),V1
fermenter
256,043lit V
V = 256,043lit+V1 ; but, V1=M1/ρ1=2300kg÷0.105kg/lit=21,905lit

∴ V = 256,043lit+21,905lit=277,948lit
4.9 Volume of filtration unit
44,496kg(sio2),V1
277,948lit Filtration unit V
V = 277,948lit+V1 ; but, V1=M1/ρ1=44,496kg÷6kg/lit=7416lit
∴ V = 277,948lit+7416lit=285,364lit
4.1C ENERGY BALANCE ON EACH UNIT OPERATION
4.1 Energy balance on steep vessel
171,200kg, Cp1
Steep vessel
47,200kg,Cp2 Q
Q=M1Cp1∇T +M2Cp2∆T=(47200kg*0.21kj/kg.k+171200kg*4.2kj/kg.k)*673k
Q = 491MJ
Where, Q = amount of heat in KJ
4.2 Energy balance on mill star
Mill star
491000000j Q
Q = 491000000j
Q = amount of heat
4.3 Energy balance on M.T.K 104kg,cp1 30kg,cp2

M.T.K
491000000j

52kg,cp3
Q = 491000000j+M1cp1∇T+M2cp2∇T+M3cp3∇T
Q = 491000000j+(104kg*3.06kj/kg.k+30kg*1.01kj/kg.k+52kg*4.1kj/kg.k)673k
Q = 869MJ
4.4 Energy balance on lautertun 9440kg,cp

Lautertun
869MJ
Q = 869MJ-Mcp∇T = 869MJ-9440kg*0.21kj/kg.k*321k=868MJ+63436.8KJ =
Q = 868MJ-63.4MJ =804.6MJ
4.5Energy balance on wort prerun tank
30kg,cp1,M1
Wort prerun tank
804.6MJ
Q = 868MJ+M1Cp1∇T= 868MJ+30kg*0.76kj/kg.k*321k
=804.6MJ+61632KJ , the dimension should be the same
∴ Q =804.6MJ+33.6MJ = 838.2MJ
4.6 Energy balance on wort kettle 120kg , cp1,M1
Wort kettle
838MJ
Q = 838MJ+M1Cp1∇T=838MJ+120kg*1.6kj/kg.k*312k=838MJ+59904LJ=838MJ+60MJ

Q = 838MJ+60MJ = 898MJ
4.6 Energy balance on whirl pool 12kg ,Cp1,M1
Whirl pool
898MJ
Q = 866.6MJ+M1Cp1∇T= 898MJ+12kg*1.7kj/kg.k *228k =898MJ+4.65MJ
Q = 903MJ
4.7 Energy balance on fermenter 2300kg ,Cp1,M1
Fermenter
903MJ
Q = 903MJ+M1Cp1∇T= 903MJ+2300kg*4.1kj/kg.k*217k = 903MJ+2046MJ
Q = 2949MJ
4.8 Energy balance on filtration 44,496kg ,M1,Cp1
2949MJ filtration
Q = 2949MJ+M1Cp1∇T= 2949MJ+44,496kg*1.13kj/kg.k*269k=2949MJ+13525MJ
Q = 16474MJ
 The malted barley supplier be replaced by one closer to the brewery factory
 An economical and technical analysis of malt factory will be organized around the company
for transportation facility, it is good the malt factory have already been organized around z
company.

 The return of glass bottles and plastic boxes as a reward for distribution centres and
consumers should be supported
 The substitution of the glass bottle supplier by one that is 99% recycled glass bottles will be
proposed.
“To meet the needs of the present without compromising the ability of future generations to meet
their own needs.”
REFERENCE
1. Technology of brew and Malt Production, Kunze, 1999GC in England.
2. Reid and Sanders, operation management, C. Wile Y. 2003 (my handout of PPC.I)
3. Manuals
4. Websites
http://www.investopedia.com/terms/c/capacity-management.asp#axzz2JvOo2hTF
http://www.tutor2u.net/business/production/capacity_introduction.htm
APPENDIX
HL= Hecto Liter
BSG=Brewery spaint grain
EBI= Empty Bottle Inspection
BBT =Bright beer Tank
MTK=mush tun kettle
WPT=wort prerun tank
CIP= Cleaning in Place
COP=Cleaning out of place
FBI= Full Bottle Inspection
℃= Degree Centigrade
K°= Degree Kelvin
Cp=specific heat capacity
DMS =Dimethyl Sulphide








The wort obtained is boiled for one to two hours, during this time hops are added in the dosing tank.
In this process it has four stages;

 Pre-boiling – In this stage the temperature raised to for 10min, and hop is added for
bitterness.
 Pressure boiling – In this stage the temperature is raised and the aim is to inactivation of
enzymes action.
_
 Pressure decrease the temperature at which pressure decrease and the duration for the
decrease is 15 minutes
 Post (end) boiling – To this stage hop pellet is added to give aroma on beer. Finishing
(ending) time of this wort color is 30-40 minutes.




















Dashen Brewery internship report on beer production process and quality control

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Dashen Brewery internship report on beer production process and quality control

Uploaded by

Copyright:

Available Formats

DASHEN BREWERY S.

C FINAL INTERNSHIP REPORT

ETHIOPIAN INSTITUTE OF TECHNOLOGY-MEKELLE

Department of Chemical Engineering

My hosting company is Dashen Brewery

Final internship report on Dashen beer

BY: Asmare Tezera ID.№ 0827/03

Submitted date 24 |10

PREPARED BY ASMARE TEZERA 28/06/2014 Page 1

PREPARED BY ASMARE TEZERA 28/06/2014 Page 2

PREPARED BY ASMARE TEZERA 28/06/2014 Page 3

Table of content Page

PREPARED BY ASMARE TEZERA 28/06/2014 Page 5

3.5 Leadership skill………………………………………………………………………….53

PREPARED BY ASMARE TEZERA 28/06/2014 Page 6

Quality assurance in brewing

PREPARED BY ASMARE TEZERA 28/06/2014 Page 7

 To use the resourse properly

1.precleaner section :removal of dust particles takes place

2.brewhous section :conversion of starch to sugar takes place

3.fermentation section : conversion of sugar to ethanol takes

4.filteration section : removal of yeast & hop resins take places

1. BACKGROUND OF THE COMPANY

PREPARED BY ASMARE TEZERA 28/06/2014 Page 9

1.2. Products & customers

i. Region 1 Amhara and afar

PREPARED BY ASMARE TEZERA 28/06/2014 Page 10

iii. Region 3 Addis Ababa & South west Ethiopia

The main customer of dashen brewery is north part of Ethiopia especially.

Humera, Metema, Sherri & Woldia.

1.3 organization stracture Board of director

Deputy General Manager

Executive secretay Audit service

Typist Legal service

Quality Production Maintenan

Beer processing Bottle sec/n

PREPARED BY ASMARE TEZERA AA coordination office 28/06/2014 Page 11

1.4 Work flow

1.4.1 Physical treatment of malt

Problem statement1: regarding to reprocessed beer

PREPARED BY ASMARE TEZERA 28/06/2014 Page 12

 Microorganisms naturally accumulates in solids& foams

 There may not be a need of reprocessed beer

Problem statement 2: regarding to recycling of wastes & import of r.m

PREPARED BY ASMARE TEZERA 28/06/2014 Page 13

Objective of the project

1. Developing theoretical knowledge through practical

1. Developing each &every process of operation

2. Developing each operational procedures

3. Knowing what type of operation is applied weather batch or continuous

Raw Materials for Beer Production

PREPARED BY ASMARE TEZERA 28/06/2014 Page 14

Raw water sources:

PREPARED BY ASMARE TEZERA 28/06/2014 Page 15

Depending on the system used, hardness and alkalinity can be defined as

PREPARED BY ASMARE TEZERA 28/06/2014 Page 16

 high starch content

Advantage of hops in brewing:

 To import bitterness & mouth fill

PREPARED BY ASMARE TEZERA 28/06/2014 Page 17

Hop products are two types:

They contribute for the sake of beer aroma taste.

Fig 2.1 hops