Beer Production

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1. DESCRIPTION OF BEER 1.1. Definition of Beer

Beer is made by transforming barley to malt and fermentation of malt in some conditions,

then this fermentated juice aramatized with hop and leaved for fermantation. It contains

carbondioxide in form of solution, has a smell and taste of own and it is a soft drink (3-5 % in

volume). Gas bubbles in it is the result of naturally occuring carbondioxide. Alcohol in beer,

is made on its own during fermentation, it is impossible to add alcohol in beer in production

process.

Alcohol degree of beer, decreases or increases according to malt quantity in beer juice. Beer

,its production is goes to B.C. 6000 years is stillone of the most consumed drinks in world.

Raw materials, used in beer production and required amount for 1 litre of beer are showned

on the chart below.

Raw materials

Unit Required amount for 1 kg

malt

Barley Kg. 1,3

Required amount for

production of 1 litre beer

Malt Gr. 175

Malt Additive

(Rice)*

Gr. 30

Hop Gr. 1,7

Beer Fermentation Gr. 5

• Malt additive and amount varies according to beer type and production methods. In

our country, usually rice is used as malt additive.

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Mainly known bottom fermentation beer types are; Pilsen, Münih, Dortmunt, top fermentation

beer types are; Ale, Stant and Porter. In Turkey, bottom fermantation beer types are being

produced.

1.2. Classification of Beer and Beer Types

Beers, generally, differentiates as bottom and top fermentation beers and these beers

differentiates according to their own known types. Beer is classified according to its

production , extract amount of juice, variety and type.

• Bottom and top fermentation beers according to production.

• It’s seperated and called as 2-5%,5,7-8%,11-14% and 16% according to it’s juice’s

extract amount. This classification is very important for tax in some countries.

• As to it’s variety, generally beers that are used in trade are understood. ( Special beer,

export beer, diet beer etc.)

It’s seperated as colour, bitterness of hop and malt taste. For instance; Pilsen beer, Dortmund

beer and Münih beer etc.

1.3. Beer Types According to Production

1.3.a Bottom Fermentaton Beer Types

Mainly known beer types, generally are taking the names of their production cities. It was

thought that these beers were only produced in those cities.

Mainly known bottom fermentation types are Pilsen, Münih and Dortmund.

Pilsen beer is light coloured (0,5 N/10 L) and hop amount is high (400gr/hl) and its foam

lasts for a long time. Its characteristic feature is its bitter taste.

Dortmunt beer is also light coloured but its taste is softer,stout and its alcohol is high.

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Münih beer is dark coloured, aromatic, stout and little bitter. Aromatic malt taste is its

characteristic feature.

Pilsen beer is made of 11-12 balling juice. Malt is well dried in the oven and leaved in 80°C

for 4-5 hours. Malt is kight coloured and in mashing very soft water is used. It’s boiled once

or twice ; fermentated in low tenperature and reposed for 3 months.

Dortmund beer barley’s sprout time is longer but parching-drying is same with pilsen. In

other words, totally melt and malt, that has dried like Pilsen, is used. Water, used in mashing,

contains carbonate, sulfate, CaCl2 . balling of juice is 13-14. double boiling is made. Amount

of hop is between Pilsen and Münih beers.

Münih beer is made of 11-14 boiling juice. Barleys, that is high in protein, are used. To make

sprout is contunued until complete melt. Amount of carbonate is high in water which was

used for mashing, but other kind of salts are not present. Tripartite method is applied. A little

hop is added. Fermentation is made in low temperature and reposed for 3 months.

1.3.b Top Fermentation Beer Types

Most known beer types are English Ale, Staut and Porter. Actually, when it’s spoken about

top fermentation beer, firstly English beers come to mind. Top fermantation beer are

produced in litte amounts in Europe, Germany and Belgium. Top fermantation beer produced

in Germany is 7% amount of total beer production. Main top fermentation German beers are

Berliner Weissbier, Bayerischen Weissbier, Bitterbier and Malzbier. Belgium’s Lambic beer

is in this group. Weissbier, is made by mixing wheat malt to barley malt.

• Ale : It’s light coloured and made of well melt malts.

• Hop amount is high.

Beer factories in England use six ordinals California winter barley.

Added water is rough and jips are added. “ Enfusion” method is used. Balling of juice is 11-

12. there are types as Pale – ale, Bitter – ale, Mild – ale, Scotch – ale. Generally hop amount

is high ( 350 – 900 gr / hl). Also, 100-120 gr hop is added to barrels

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• Staut : It’s dark coloured and contains hop. %10 black malt or parched barley and

sometimes caramel is added to well “melt” malt. Hop amount is high. (600-700gr/hl)

• Porter : Light Staut beers are called as Porter.

• Berliner Weissbier : It is made of 1/3 or ¼ barley wheat malt mix. Juice is not melt for

this type of beer. Balling of juice is 7-8. fermentation is made in 14-20°C. These beers

are sore because its leaved for fermentation by mixing lactic asid bacteria to top

fermantation leaven. To repose is done by leaving in bottle for 2-3 weeks in 12-16°C.

• Bayerischen Weissbier : Wheat malt is 60-70%. Mashing is same as in bottom

fermentation beers. Balling of juice is 11-13 and fermentation is done in 12-25 °C.

Lactic acid bacteria are not used. After fermentation beer is bottled and for 3-4 days in

10-12°C then 3-4 weeks in 4-5°C reposed.

• Bitterbier : It is produced with enfusion method and a lot of hop added. Fermentation

is made in 9-13°C, reposing is made in 5-7°C for 2-3 months. During reposing, again

30-50 gr hop is added for one hectolitre.

• Malzbier : It is dark coloured, contains little hop and it is sweet. After fermantation

sugar is added, reposing is made in bottle or thank. When enough amount of

carbondioxide is present it should be pastorized of filter immediately.

• Lambic : It is peculiar to Brussels. 60% malt and uncooked wheat are used. The most

important feature is not adding leaven and spontane fermentation. In spontane

fermentation, termobacteria, wild leavens, lactic acid bacteria and Brettanomyceses

are active.

1.4. Beer Types As to Varieties

They are produced in a different way and have some features. These are export, light and

alcohol – free beers.

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• Export Beers : Because these beers are sent to far and different clima countries,

their stability has to e very good, in other words they have to stay clear for a long

time without sedimentation for production of this beer, barleys, that gives high

enzimatic malt. So, proteins are shattering good while making malt. Malt shoul be

“completely melt”. Because there are melanoidins that plays as productive colloid,

it is colour is dark. At the end of mashing, PH should be 5,2-5,4 and for this reason

appropriate water mixture is used. In juice, dextrin amount should be high, so

mashing should not be in 62-63°C. Hop should be fresh and for good coagulation,

it should put to boiler when juice is just starting to bail. Juice should not e boiled

for a long time.

In export beer production, beer should be clear at the end of fermentation. It is

better not to make thrashing beers even malts, because it destroys colloidal

balance. For botting beer without contact with air and for keeping used capsule’s

cork for a long time, it should be covered with aluminium.

• Light Beers : Light beers are high attennuationy and must not include

carbonhydrate that harmful for diabetics more than 0,75 gr/100 ml. The protein

amount is maximum 0,5gr/100ml and alcohol amount 4,3% and also these beers

calory amount is low. To create this, by the beer producing,it must be waited a

long time between 62-64°C that maltot oceurs mashing. Apart from that, in

fermantation drastase enzyme preparate or malt extraer or for one hectolitre 500-

800 gr malt flour is added. Than the remained dextrin shattered and it is prowded

to have fermentation by leavens for this reason, light beers, contains more alcohol

also amount of hop is high.

• Alcohol free beers : the beers that contains 0,5-1,5% alcohol are called as less

alcohol beer, the beer that has less alcohol than 0,5% are called as alcohol free

beer.

These beers are being produced in different ways for example. It is marketed by mixing beer

and juice or fermentation of juice is stopped by pastorization or filteration. Also, to have less

alcohol in beer, a mashing process may applied that has little fermentable sugars (malt)in

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juice. In some countries, alcohol free beer is being produced by taking alcohol in beer with

vacuum distillation. But the beers that has less alcohol than 1,5% are not prefered much.

1.5. The Materials Used In Beer Production

1 – BARLEY : It is a one of year plant of Mordeum gramine family.

In Turkey, two ordinals barleys are used (Mordeum disdichum). Although, in Europe, the two

ordinals barleys that harvested in summer are efficient, in Turkey, the barleys that harvested

in winter are efficient.

The chemical composition of ordinal barley which is an important factor in beer production

is;

Protein 11,1%

Starch 63,2%

Oil 2,94%

Cellulose 5,83%

Other materials with azote 14,0%

Ash 2,93%

The most important material of marley is starch. Because the alcohol in beer occurs by

shattering of starch. While the amount of protein in the barley increases, the sprout of barley

becomes forceful. So, it makes harder to control beer production. The amount of protein in the

particle, starch and extract are converse commensurate.

2 – HOP : Hop that being used in beer production is a more years plant from canabinaceae

family. Although, being more wild species of hop in Turkey, the culture races are more

efficient.

The main factors of hop that makes producing beer more valuable are alpha acid, essential oil

and wetness.

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The most important section of hop is yellow lupuline. This section includes preservative and

taste giving materials. The composition of yellow lupuline has two sections. These are

essential oils that give to the beer its flavoring and rosins that gives to the beer its bitterness

and preservative. Also, the reason of using hop in beer production is “lupuline dust”.

The chemical composition of hop is;

Water 12,5%

Ash 7,5 %

Cellulose 13,3%

Materials with azote 17,5%

Ether oils 0,4%

Ether extracts 18,3%

Tanine 3,0%

Azote free extract 27,5%

The most important materials in beer production between these are ether oils and rosins.

Especially lupuline dusts include ether oils and rosins.

3 – WATER : Water is important in beer production as much as barley and hop. Water is

being used for making barley sprout, preparing mash, feeding to vapor boiler and cleaning.

The water, being used in beer production, is much more than the beer producted. Due to the

fact that 80% percent of beer is water, it is important and it must be qualified as clear drinking

water.

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2. Beer Production in Turkey and In World

2.1. Beer Production In The World

Beer is a drink made from grains (especially from barley) and it gets its special smell and

taste from hop.

The history of beer is as old as beginning of grain farming. 8000 years earlier, the people who

has lived in Maditerranean producted beer first. Old Egyptians thought that Farming God

Ostristaught people to make beer. In addition to be understood from the written sources,

before making beer,viniculture and wine pressing in Babil, making beer is also known in

Mediterranean.

Today, thousands barrels of beer is being prıduced in beer companies. But modern production

techniques are not much different from the old Egyptian kitchens and the middle ages

monasteries. It is being supposed, the beer and bread founded with a coincidence. For both of

them leaven is needed and cause of these living beings are small that can not be seen with

necked eyes, nobody could know to make a frothy drink with adding leaven to grassy barley

and first made beers did not include hop. Since many centuries, people looked for different

tastes by adding to beer many different horbs. The beer with hop is needed first at 14. century.

Especially, beer that went into wine’s place at North countries where the climate was not

convenient to product beer, is the traditional drink of Germans’, Englishs’ and

Scandinavians’. Today, there are so many beer species being produced with special names in

Germany and England. German and English beers are seperated from each other with leaven

techniques and hop amount. English beers are being produced with top beer techniques and its

alcohol amount is 4% - 6,5%. The beers named “Lager”in german includes hop and its

alcohol amount is low. German beers that produced with bottom fermenting includes 3% - 5%

alcohol.

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World’s Biggest Beer Producers and Markets

According to 1998 (million hectoliters)

Beer Producers Production Amounts Beer Market Market Size

Anheuse-Busch 130 USA 226

Heineken NV 79 China 199

Miller Brewing Co. 56 Germany 105

Interbrew 48.3 Brasil 82

South African Breweries 47.7 Japan 72

Source: Impact Databank

2.2. Beer Production In Turkey

In Turkey, the first beer company was found by private sector in İstanbul in 19. century , but

before this, it was known in Turkey. For example, according to some formal documents dated

1842, the beer was being produced with a name “Barley Water”. After the first beer company

that was found by Swiss Bomonti brothers, an another company was found in 1909 in

İstanbul, called as Nektar. In 1912, these two company united with a name Bomonti Nektar

In İzmir. The company in İstanbul was producing beer and malt, the company in İzmir was

producing just beer with the malt produced in İstanbul.

In 1926, at the time of republic, the beer production entered to government monopoly. But a

special permission was given to Bomonti- Nektar company for producing beer by government

till 1938.

In 1934, the first beer company of government was found in Atatürk Orman Çiftliği in

Ankara. In 1955, the beer was started to produce by private sector with getting out the beer

from monopoly products. Today 85% of the total beer production of turkey is belong to

private sector.

Tables about beer and malt are in appendix.

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3. Description of Process

Beer is a beverage made of malt including alcohol and CO2. As another saying; germinated

grain aromatized with hopfen. This means “malt must” enters alcohol fermentation. There are

5 sections in beer production:

1. Grinding the malt

2. Mashing and Boiling

3. Fermentation and Maturing

4. Filtration

5. Bottling, barrelling and Pastorisation

3.1 Grinding The Malt

Malt is need to be grinded and mixed with water for mashing for beer production. After

grinding of malt, endosperms must be like flour. On the other hand the shells of malt must

remain in big particles. This can happens if the malt is easily melting and fully dry.

Uncracked shells prevents the materials causes unwanted smells and also they are required in

the straining of mash. In straining process, they are used as filters.

The mill used in grinding of malt is located above the mashing-boiling section. The malt

coming from the silos passes from magnets to be seperated from iron particles within. Then

grinded malt is weighted in automatic scales. Dusts in malt are absorbed while entering the

mill from malt silos.

3.2 Mashing and Boiling

MASHING

The seperation of starch into yeastible sugar particles called as mashing. Grinded malt mixes

with water in mash boiling tank and warmed up to various temperatures.

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Purpose of Mashing

To make the enzymes influence the extract materials in malt and splitted them into low

molecules to pass into must, so that the best extract from malt can be gained.

Mashing Methods

The mixture formed of malt and water is called the mash. There are two types of mashing;

1. Decoction

2. Infusion

Infusion Method

The main principle of this method is rising the temperature of mash slowly to 75-78°C. No

boiling happens in this method. So the enzymes do not get damages. In brewering mashing is

made with good soluble malt. Besides this another method called “Double Mashing” can be

used. A lot of diastase is required to sugarize the additive starch. For this reason infusion

method is important.

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Infusion Diagram

Double Mashing Method

Malt starch is an expensive ingredient. To reduce the cost of beer, the starches of rice and

corn are used. But the starch must be pasted, else amilase can’t influence the starch. To

prevent this, the additives must be boiled before addition. During the boiling, both rice and

corn particles must be in small pieces. During this operation starch becomes sticky and then

can be added to grinded malt.

This method is prefered in bright colored beer production. In fact double mashing is a type of

infusion method.

Straining of the Mash

The seperation of extract gained in mashing and strainig of must have to be complete and

done in a short time. This operation is done in two stages;

1. First must is strained

100°C

90

80

70

60

50

40

30

1 2 3 4 5 (hour)

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2. Remaining crashed seeds are washed in hot water at 80°C, then sent to straining tank

to be strained.

3.3 Straining Tank

This tank is used for straining of mash. It looks like mashing tank. The shells in mash settle

on the perforated base and form a filtering layer. After the main must flows, the remained

extracts on the filter are gained with hot water. Straining tanks are cylindrical in shape and

have perforated bases. The holes are like long cracks. The equipment is made of stainless

steel. There is a plate layer 1 cm below the base. Strained must passes from the perforated

base and accumulate here. Then must is sent to boiling tank. To prevent themust to become

cooler straining tank is built double sided.

Crashed Seeds

After the straining lots of crashed seeds remain. 110 kg grained malt leaves 110-120 kg

crashed seeds including %80 water. Wet crashed seeds can be fermentated to sugar up to

%0.5. Crashed seeds are transfered to their tanks via air flow.

3.4 Boiling

The must gained from straining tank is sent to must boiling tank. The boiling of must is the

turning point in the production. Practically, all the malt must and hopfen are boiled 1-2hours

together. Nothing can be added meanwhile.

Some or all of the hopfen can be exchanged with hopfen extract. If the hopfen is seperated

from the extract and independently isomerizeda it can be more efficient. Previously

isomerized hopfen will be added to beer after fermentation.

Many complex reactions occurs during te boiling process. By the heating of the must all

enzymes like amilase, whick stabilized the carbohydrate composition, become ineffective. At

boiling temperature the must is purified from germs. During the boiling, proteins collapse and

some of them react each other with the help of some simple nitrogen mixtures and

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polyphenoles. Remaining unsoluble precipitate is called sediment. Some of the sediment is

seperated in the boiling of must and called hot sediment. But the remaining spare part collapse

during the cooling of must. This is called cold sediment. After 1 hour boiling %10 of volume

is vaporized. By the vaporizing volatile aromatic compounds are removed.

Purpose of Boiling

1. Evaporating the water to set the extract concentration in required levels.

2. Demolishing the ferments and sterilize the must.

3. Collapsing the proteins.

4. Transfering the characteristics of beer, the flavour materials in hopfen, into must.

Boiling of Hopfen

Hopfens can be added to the boiling tank after the hot sediment collapses. To prevent foaming

a little amount of hopfen(less tan %10 of whole hopfen) can be added in the beginning of

boiling.

Hopfens must be added in three stages;

First addition, %25 of whole hopfen, to help the sediment to collapse 15-25 minutes after the

most efficient part of boiling.

Second and major addition, %50 of whole hopfen, 30 minutes after the beer gets bitter.

Last addition, before discharging the boiling tank or 15 minutes before the boiling ends.

Cooling of Must

After boiling must is sent to cooler. There are two types of coolers;

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a) Open Coolers: In this type of coolers must is in contact with air

b) Close Coolers: During the cooling the contact with atmosphere is cut.

Well-known close coolers :

1) Double piped Coolers

2) Plate Coolers

3) Shell and Tube Coolers

4) Must Ventilating Coolers.

3.5 Fermentation and Maturing

Introduction to Fermentation

Fermentation is the cracking of big molecules of carbonhydrates by the help of

microorganisms. Fermentation can be divided into two parts, according to the existence of

oxygen in the cracking reaciton;

1. Oxidative Fermentation: Oxygen is used in oxidative fermentation. In formula;

C6H12O6 + 6O2 → 6CO2 + 6H2O + 72 cal.

Eg.: Acetic acid, citric acid, oxalic acid and formic acid fenmentation

2. Inoxidative Fermentation: Oxygen is not used. Examples of Inoxidative Fermentation

are, Ethyl alcohol(as in beer production), lactic acid, propionic acid and butic acid

fermentations.

C6H12O6 → 2C2H5OH + 2CO2 + 28 cal.

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When the must is cooled to required temperature, it is mixed with yeast and sent to floatation

pools. Thereare two types of fermentation;

1. Top Fermentation

2. Bottom Fermentation

Bottom Fermentation

There are three stages in this fermentation;

1. Floatation

2. Major Fermentation

3. Maturing of second Fermentation

3.6 Floatation

The must coming from cooling, is fermented before transfering to floatation pools. How must

is fermented is explained below;

Before dosing the yeast an air flow is given from the bottom to obtain homogenization. At the

moment of must entering the tank dosing starts and finishes just before the flowing stops.

Entering the floatation pool fermented, the must is matured there for 6 days. At this time

period must is warmed up to 8-9°C, so the yeasts increase. After the finish of floatation,

fermented must is pumped to fermentation tanks.

Purpose of Floatation

1. To sediment the dead yeasts

2. To float the unwanted materials gained from hopfens

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3. To sediment the cold sediments.

3.7 Beer Yeasts

Beer yeasts are members of the Saccharomyces genus and in bottom fermentation the name of

the culture yeasts used is Saccharomyces Carlsbergensis. There is an important role of the

yeasts in beer quality. The must does not include any microorganisms because of the mashing

and boiling processes. Fermentation is totally done by the beer yeasts. In brewery the pure

yeasts are called “culture yeast” and the rest is called untamed yeasts. The yeasts we are using

can not include dead ones over %5 also can’y include foreign microorganisms especially

bacteries.

In brewery bottom fermentation yeasts are divided into two groups; Lump

Yeasty(Bruchhefen) and Powder Yeast(Staubhefen). Lump yeasts sediments the bottom near

the end of fermentation but their fermentation degree(atteniation) is lower than Powder

Yeasts.

Floatation Pools

Floatation cellar is located below the must coolers. The cellar have to be easily cleaned, have

the required equipment to release the CO2, have adjustable temperature control and beer must

be in full control.

The optimum capacity of floatation pools are arranged as the %25 volume of must gained

once from mashing. Because the foam needs %25 volume not be overflowed. The depth of

the pools are 1-2 m. They are made of stainless steel. There are cooling pipes located at the

basements.

Major Fermentation

The fermented must at 9°C is sent to fermentation tanks. In there it is warmed up to 12°C and

stays at 12°C for 6 days to be fermented. At the end of major fermentation the yeast collapses

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to base and the young beer gets brighter. The bitter and dark layer in the surface of the beer is

cleaned and then beer is pumped to maturing tanks. The main event in the major fermentation

is the ethyl alcohol fermentation.

3.8 Chemical Mechanism of Ethyl Alcohol Fermentation

Lavosier found that the products of fermentation are CO2 and alcohol in 1789. In 1815 Gay-

Lussac formulized this;

C6H12O6 → 2C2H5OH + 2CO2

Glucose Ethanol

2 mols of ethyl alcohol and 2 mols of CO2 are produced from 1 mol glucose. Also many by

products are produced too.

The enyzm, generating alcohol from sugar is zymase. It is a copmplex one originated from a

mixture of enzymes. They generate the alcohol in continious reacitons following each other.

According to the theory of Meyerhor et al., alcohol fermentation occurs in 12 stages; 6

carboned hexoz is divided into 3 carboned trioses, glycerin aldehyte and dioxiacheten. These

trioses tranformed into pyruvic acid. 2carboned acet aldehyte and 1 carbone CO2 is generated

from pyruvis acid. Acet aldehyte produce alcohol by gaining H.

Enzymes used in ethyl alcohol fermentation;

1. Hexocinase

2. Oxoisomerase

3. Phosphohexocinase

4. Aldolase

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5. Phosphotrioisomerase

6. Phosphatedehidrase

7. Phosphoglicerineacidcinase

8. Phosphogliceremutase

9. Enolase

10. Pyruvatecinase

11. Carboxilase

Maturing

After the major fermentation young beer still contains fermetable extracts. This is %1-2 in

volume. To ferment the remained sugar young beer is sent to maturing tanks. Bottom

fermentation beers stays in maturing 3 weeks at 0-2°C. this time can be changed according to

season and sales.

At the end maturing, tanks can be mixed with each other to obtain the wanted gas, color and

extract values, then sent to filtering. Before the filtering the beer cooled to -1°C with the

gluchol at -2°C.

Introduction to Filtration

To obtain the required brightness, beer must be filtered at least one time. Various types of

straining methods can be applicated. These are; Kieselguhr filters, Sheet filters and Pulp

filters.

Filtration Theory

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At the end of maturing some amount of sediment collapses to bottom. This causes turbidity in

beer. To prevent this event beer must be filtered. After the filtration;

1. Beer must be sterile and clean as availible.

2. Losses of CO2 must be prevented.

3. The contact of beer with air must be prevented.

4. No infections can be occured.

To get the best result from filtration beer must be cooled as much as possible. The more the

beer cold the more the cold sediment arise. Good filtration means, preventing the warming up

of beer itself and seperating the sediments.

3.9 Introduction to Bottling

The bottles come to Bottle Washing Machine by conveyors.

Washing

The bottles are located the hives in the machine. The washing operation takes 20-30 minutes.

In this operation bottles are washed internally and externally. The washing operation stages;

a) Upside and down the bottles to discharge the remainings

b) Approximately 20 minutes, washing with %1 caustic solution at 90°C.

c) Spraying caustic solution into bottles

d) Spraying hot water to external sides to remove the stickers

e) Spraying cold water to inside of bottles and then bottles leave the machine clean, dry

and empty.

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Washed bottles are controlled by “Empty Bottle Control” equipment. If the bottle is not clean

as wanted it is sent to washing again.

Filling

The bottles are filled with the ventilles of the filling machine. In this operation;

a) The air inside is sucked with vacuum

b) CO2 at 1.5 bar pressure is given to the bottle

c) While CO2 is releasing beer is filled to the bottles

d) A tiny layer of water is charged to the bottle to make the beer foamed.

e) Taps are pressed to bottles by capsulling pistons and bottles leave the bottle filling

machine

Pasteurising

After the filling the bottles are sent to tunnel pasteur. In here the temperature of beer is risen.

Holding the beer at this temeperature for while then temperature is decreased. This cycle sets

beer’s biological stability.

Passing of bottles from hot to cold areas is the principle of Pasteur. Water is sprayed to

passing bottles. The temperature of sprayed water can be adjusted to wanted beer temperature

in bottles. The wanted temperature is obtained at preheat andsuper heating areas.

Tunnel Pasteurising

After the bottles are filled and tapped, they enter the tunnel pasteur. The bottles are transfered

in conveyors during this operation. During the operation water is sprayed over the bottles. The

pasteur temperature of beer is gained by adjusting the tenperature of spraying water. The

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pasteur temperature is usually 63°C. Beer stays 20 minutes at this temperature. Then cold

water is sprayed over and leave the system.

The water used in pasteur is very important. It must be clean and have a pH degree of 8. Else

pasteur doesn’t works.

3.10 Introduction to Barreling

The main subject is to fill the pasteurised beer into barrels made of aliminium and stainless

steel. Aliminium barrels are preferred to be light and cheaper.

Preperation of Barrels for Filling

Empty barrels come to “barrel reverser”. Filling is done from bottom to barrels. So the tap of

barrel must be downwards. Then the barrels come to pressure kontrol section. Here the

pressure is controlled to be 1.5 atu. Passing the pressure control, the barrels come to external

washer. Here, the barrels are washed with hot water and brushes, then pass to intermal

washing.

Internal Washing

1st Head: Churn beer is discharged with air. Cold water is given and discharged with air

2nd Head: Hot water is given and discharged with air.

3th Head: Caustic is given and discharged with air

4th Head: Caustic is given. Some of it remains inside the barrels. Barrell with caustic comes

to filling machine.

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Pasteurising for Barreling

The beer coming from filtering at 2-3°C is pasteurised before filling. Dry-Pasteur is used in

barrelling. It has 4 stages;

1) Regeneration

2) Heating

3) Holder Tube

4) Cooling

Beer is pumped to first stage. There, it is heated by counter-flowing hot beer. It is warmed up

to Pasteur temperature. It done by counter-flowing by hot water. After than stays in tube for a

calculated time. This beer is then comes to first stage. When the filling starts, pasteurised beer

is pumped to buffer tank and then to filling machine.

Filling

1st Head: Caustic is discharged with air. Hot water is given and discharged with air.

2nd Head: Hot water is given and discharged wtih air. Acid is given and discharged with air.

3rd Head: Cold water is given and discharged with air. Saturated steam at 130°C is given.

4th Head: Steam is discharged by giving CO2

5th Head: CO2 is given. Filling starts slow and then speed up. While beer entering the barrell

CO2 is discharged.

After the filling, the barrells are again turned upwards.

24

4. Capacity Choose

The annual beer production of Turkey is 8 millions hl. EFES PİLSEN provides the %75 or 6

millions of this production.

We are willing to establish a factory to be able to produce annually 1200000 hl of malt beer

according to the marketing location and natural underground waters capacity. According to

this quantity our montly production is 100000 hl.

However we have to rearrange our production according to some conditions. For example we

take a break to production in Ramazan Fests. In these times our factory stops for planned

yearly upkeeping. In statistics of beer sales it seems that the major proportion of the sales are

made in May-December 6 months period. This is approximately 800.000 hl of our production.

So we have to produce 800.000 hl of beer in 6 months in a year. The beer production

capacities during the most of the sales are made;

800.000 hl hl= 130.000 6 months month

130.000 hl hl= 5000 26 days day

According to these values we need 3 pieces of 1500hl and 1 piece of 500 hl capacity pulling

tanks for daily 5000 hl production.

Filters loose 8 hours of time during the fill-up and excretion, so they are working;

5000 hl hl= 350 16 hours h

flux.

The mass balance calculation is built up in the basis of boiling tank capacity. If we go rewind

the process from the end, the producti losses are; %0.2 in fermentation and %0.4 in filtration.

So for monthly 130.000 hl/month production;

25

hl 1 1 hl130.000 = 138.000 month 0.96 0.98 month

× ×

The fermentation tank is designed to be filled with %75 liquid and %25 foam. This process is

done twice in month so;

hl 30days 69.000hl138.000 = month 15days 15 days

×

For the 3000 hl liquid portion;

69.000 hl product = 233000 hl volume

pieces of tank.

The %25 of the tanks are departured for foam so:

3000 4000 hl0.75

= is the capacity, one of 23 tanks.

Amount of malt required monthly;

hl kg-malt tons138.000 15 = 2.070.000 kg-malt = 2.070month hl month

×

Amount of malt required daily;

tons month malt2070 1 = 80 tons month 26 days day

×

One month is taken as 26 days because of the weekends. So if we want to use 80 tons-

malt/day we need to choose the capacity of boling tank 10.000lt to make 8 times boiling a

day.

26

5. Flow Diagrams

5.1. Block Flow Diagram

5.2. Process Flow Diagram Process Flow Diagram is in appendix.

6. Mass and Energy Balances

6.1 Mass Balances

Basis: One Boiling Tank

System: Mill + Malt-10.000 kg + Malt Mashing Tank

Malt-10.000 kg → Mill → Grinded Malt → +380 hl water Malt Mashing Tank →Main Mash

In mashing tank 3.8 hl water is added per 100 kg malt. So;

Malt Mill Malt Boiler

Straining Tank

Boiling Tank

Plate Cooler

Fermentation Tank

Filtering Bottling

Malt

Water Water Water

Beer

27

3.8 hl10.000 kg malt = 380 hl 100 kg

× water.

Input :

Malt = 10.000 kg

Water = 380 hl = 38.000 hl = 38.000 kg

Input = Output → 10.000 + 38.000 = 48.000 kg = Main Mash

Basis: A Boiling Process

System: Straining Tank

Water used in straininng tank can be assumed to be 1/1 proportion to water used in mashing

tank. Mash required for one boiling can be strained in 3 hours.

Input:

Main Mash = 48.000 kg

Washing Water = 37.000 lt = 37.000 kg

Output:

Must = 750 hl = 75.000 lt = 75.000 kg

Input = Output → 48.000 + 37.000 = 75.000 + Crushed seeds.

Crushed Seeds = 10.000 kg.

Crushed seeds are %80 water and %20 dry portion.

28

Water in crushed seeds;

8010.000100

× = 8000 kg = 80 hl

Dry portion in crushed seeds = 10.000 – 8000 = 2000 kg.

Basis: A Boiling Process

System: Boiling Tank

Input:

Must = 750 hl =75.000 kg

Hopfen used in boiling = 100g750 hl1hl

× = 75000 g = 75 kg

Output:

Hot Must = 675 hl = 67500 kg

Input = Output → 75.000 + 75 = 67.500 + Steam Losses

Steam Losses = 7575 kg

This means, %10 of the Must is evaporated during the boiling process.

Basis : A Boiling Process

System : Cooling

Input:

29

Hot Must = 675 hl = 67500 lt = 67500 kg

Output :

Cold Must = 650 hl = 65000 lt = 65000 kg

Input = Output → 67500 = 65000 + Cooling Losses

Cooling Losses = 2500 kg.

This means, %4 of the Must is lost during the cooling process.

6.2 Energy Balances

1.Boiling:

1.1 Malt Mashing Boiler:

In this tank the mixture is warmed up to 80°C from 35°C. So the mashing occurs in 2 hours

50 minutes. The required heat and steam:

Q = m.c.∆T m = Total Mash

m = Malt + Water for Malt

m = 10.000 kg + 38.000 kg = 48.000kg

Basis : 1 hour of Mashing

Cp of Malt = 1 kcalkg.°C

Q = 48.000 1 (80-35)× × = 2.160.000 kcalh

30

Malt Mashing Process = 60 min(2 hours ) 1 hour

× + 50 min = 170 minutes.

Q = kcal 60 min 1 mashing kcal2.160.000 762.350 mashing 1 hour 170 min h

× × ≅ heat is required.

Looking up the saturated steam heat tables:

P = 3 Atü y = 1 → H = 2676.1 kJkg

x = 1 → h = 419.04 kJkg

∆H = H-h = 2676.1 – 419.04 = kJ 1 kcal2257.06 kg 4.18 kj

× ≅ 540 kcalkg

.

Basis : Amount of steam for 1 hour of mashing

m = amount of steam

Q = m.∆H m =

kcal(762.350 )h

kcal540kg

≅ 1411 kg-steamh

1.2 Boiling Tank

Must is boiled from 65°C to 100°C. This process occurs in 2.5 hours. Boiling occurs in two

parts:

a) Heating

b) Vaporizing

31

a)Heating:

Takes 1 hour to complete:

t2 = 100°C t1=65°C → ∆t = 35°C

Amount of Must from mass balance → m = 75.000 kg-must

QI = m.Cp.∆t kcal kcal= 75.000 1 35°C = 2.625.000 kg.°C h

× ×

Used Steam; mI =

kcal(2.625.000 )Q kg-steamh= 4860 kcalH h540 kg

≅∆

b)Vaporizing:

Takes 1.5 hours to complete. The amount of steam given to the system is equal to the amount

of steam lost in boiling of the must. Because the energy of steam given to system is equal to

the loss of vapor during the boiling. So steam loss calculated previous mass balance;

Basis : A Boiling Process

msteam = kg7575 vaporizing

QB = B B kcal kcalm H = 7575 kg 540 = 4.090.500 kg vaporizing

×∆ × .

Vaporizing takes 1.5 hour;

QB kcal 1 vap 60min kcal= 4.090.500 = 2.727.000vap 90min 1hour h

× × (Energy in 1 hour)

Basis : Steam used in 1 hour vaporizing

32

mB

kcal(2.727.000 )Q kg-steamh= = = 5050 kcalH h540kg

∆

Amonunt of steam required for total Boiling;

mT = mB + mI = 5050 + 4860 = 9910 kg-steamh

.

Basis : 1 hour of boiling and mashing

Total heat for boiling; QT = QI + QB = 2.727.000 + 2.625.000 = 5.352.000 kcalh

Total heat for mashing and boiling; QT = QBoiling + QMashing

= 762.350 + 5.352.000 = 6.114.350 kcalh

Total steam for mashing and boiling; ST = SB + SMash

= 9910 + 1411 = 11.320 kg-steamh

Efficiency of the tanks assumed η = 0.90;

Total heat for the system; Maximum Heat = 1006.114.350 6.793.720 90

× ≅kcal

h

(mmax)steam = QmaxH ∆

= 6.793.720540

= 12.580 kg-steamh

PLATE COOLERS

Must enters the cooler at 100°C and leaves at 9°C. Cooling water enters at 2°C and leaves at

85°C. Basically cooling time is assumed to be 1 hour.

33

ρmust = 105 kglt

mmust = 675 hl × ρmust = 67500 lt × 1.05 = 70.875 kg-must

%88 of must is water and rest of it is extract.

Cpwater = 1 kcalkg.°K

Cpextract = 0.38 kcalkg.°K

Cpmixture = 0.88 × Cpwater + 0.12 × Cpextract = (0.88 × 1) + (0.38 × 0.12) = 0.925 kcalkg.°K

Qmust = mmust × Cpmust × ∆T = 70.875 × 0.925 × (100-9) = 5.965.903 kcalh

According to these data and %2 leakage in the system;

Heat gained = Heat given. From this we can calculate the amount of the cold water.

Qmust x 0.96 = mwater x Cpwater x ∆T

mwater = mustwater

0.96 0.96Q = 5.965.903 =Cp T 1 (85-2)

× ××∆ ×

69.000 kg water is required.

2. FERMENTATION

Two types of reaction occur in the fermentation tank.

a) Oxidative reaction : C6H12O6 + 6O2 → 6CO2 + 6H2O

b) Unoxidative reaction : C6H12O6 + O2 → 2C2H5OH + 2CO2

Every fermentation tank can cover the boiling capacity.

34

Fermentation process takes 6 days and 2 days for cooling also 7 days for maturing, totally

takes 15 days to complete.

Sugar percentages in the tank:

0th day → %12.5 4th day → %2.60

1st day → %10.90 5th day → %2.20

2nd day → %6.15 6th day → %2.10

3rd day → %3.70 Cooling starts

According to this heat transfer during the fermentation;

1st day: Neither fill-up nor pour-out happen. Temperature rises from 9°C to 12°C

2nd day : Sugar fermentation from %10.9 to %6.15 (12°C)

3th day : Sugar fermentation from %6.15 to %3.70 (12°C)




135 kcal heat is gained from 1 kg of sugar and %75 (3000hl) of a fermentation tank is liquid;

1st day : No cooling

2nd day : 1 tank × (3000 hl1tank

) × (10.9 - 6.15)100

× 135kcal/1kg-sugar = 1.923.750 kcalday

heat exit.

35

3th day : 1 tank × (3000 hl1tank

) × (6.15 - 3.70)100

× 135kcal/1kg-sugar = 992.250 kcalday

heat exit.


) × (3.70 - 2.60)100


heat

exit.


) × (2.60 - 2.20)100


heat

exit.


) × (2.20 - 2.10)100


heat exit.

QTotal = 3.564.000 kcalday

Energy Exchange during Maturing

Q = m.C.∆T → Q = 1 tank × 300 hl1tank

× 100 lt1hl

× 1 × (12-(-1)) = 3.900.000 kcalday

T1 = 12°C T2 = -1°C → In two days time

Cp = 1 kcalkg.°C

Q = 3.900.000 kcal2days

= 1.950.000 kcalday

36

3. BOTTLING AND BARRELING

According to our factory’s capacity our daily production is 5000 hlday

. %60 of this production

will be saled in bottles and te rest in barrels.

According to our standarts;

Bottle washing 9500 kcalhl

Barrel washing 5600 kcalhl

Bottle Pastorization 9000 kcalhl

a) Bottle Beer Production

5000 hlday

× 0.60 = 3000 hlday

For bottle washing;

Qw = 9500 kcalhl

× 3000 hlday

×1day

24 hours= 1.187.500 kcal

h

For bottle pastorization;

Qp = 9000 kcalhl

× 3000 hlday

× 1day24 hours

= 1.125.000 kcalh

For bottling;

QTotal = Qw + Qp = 2.312.000 kcalh

37

Amount of steam used for bottling;

m = TotalQH ∆

= 2.312.500540

= 4282 kg-steamh

b) Production rate for barrels;

5000 hlday

× 0.40 = 2000 hlday

Energy consumption for barreling; Q = 5600 kcalhl

For barrel washing;

Qw = 5600 kcalhl

× 2000 hlday

× 1day24 hours

= 466.600 kcalh

Amount of steam required;

m = wQ H∆

= 466.600/540 = 864 kg-steamh

7. Design of Process Units

Malt Boiler:

The boiler has two inlets. These are water and malt. Approximately every 100kg-malt

requires 3.8hl water add-on. Also 100kg malt has a 0.7hl volume. For these reasons we

assume the boiling process in a basis of 10.000kg malt;

0.7hl10.000 kg-malt 70 hl100 kg-malt

× = volume

38

3.8 hl-water10.000 kg-malt 380 hl100 kg-malt

× = water’s volume

According to this maximum volume of our boiler;

maxV (70 380) 1.6 720 hl= + × =

However we are designing 550hl “Mashing Boiler” via engineering approach.

These boiler are have to be made of stainless steel and in cylindrical shape. Mashing boiler is

designed to be 5m in diameter and 3m height. This boiler has heating sites both in bottom and

lateral surface. Our boiler has 100m2 heating area and a mixer to obtain homogeneous mixing.

For the calculation of heating area required for the mashing process, we need to look up for

the amount of heat given in 1 hour time:

QM = 762.350 kcalh

U = 1950 kJh.°C

Q = U.A.∆T (Process is thought like an evaporator)

kcal 4.18 kJ762.350 1950 A (80-35)h 1 kcal

× = × × →A=36 m2

Fermentation Tank:

Fermentation occurs in the boiler in a 15 days period. This means two fermentation can be

made in a month time. According to our monthly production capacity;

hl 30 days 69.000hl138.000 month 15 days 15 days

× = is the total capacity of a fermentation process. For the

3000hl liquid phase of the fermentation process;

39

69.000 233000

= tanks are required.

The %25 part of the tank is seperated for foams;

3000 4000 hl0.75

= one of 25 tanks.

4000hl volumed tank is made of stainless steel. We are designing a tank with a diameter of

6m and 18m height.

Calculation of the heat transfer area for fermentation process in the fermentation tank:

The energy exchange in the fermentation process is:

QTotal = 3.564.000 kcal/day

In fermentation process, in the cooling we are always using the same heating pocket so we are

taking the daily maximum heat transfer value. This amount of heat is for 2 days time:

2 days kcal 4.18 kJ 1 day kJQ = 1.923.750 335.053 day 1 kcal 1 kcal h

× × ≅

Q = U.A.∆Tlog → U = 460 kJh

T1 = T2 = 12°C t1 = -4°C t2 = 0°C

1 2log

1

2

T T (12 0) (12 ( 4))T 14T 12lnln( )16T

∆ −∆ − − − −∆ = = ≅

∆∆

kJ kg335.053 460 A 14h h= × × → A=50 m2

40

Calculation of the heat transfer area in the fermentation tank for the maturing process:

Before we calculated the amount of energy exchange in maturing process;

kcal kcal kj 1dayQ = 1950000 = 1950000 4.18 = 339625day day 1 kcal 24 hours

× × kJh

U = 460 kj/h T1 = 12°C T2 = -1°C t1 = -4°C t2 = 0°C

1 2log

1

2

T T (12 ( 3))T 6.5T 12lnln( )4T

∆ −∆ − +∆ = = ≅

∆∆

Q = U.A.∆Tlog → 339625 = 460 A 6.50 × × → A = 114 m2

In conclusion the heat transfer areas for fermentation and maturing processes happening in

different times in the fermentation tank are different either. And the area for maturing is

bigger.

Boiling Tank:

As told above we are designing a set of tanks willing to make 8 times boiling a day in which

each of them has the capacity of 10.000hl and the total for 80tons of malt. These tanksa are

again made of stainless steel. Our tanksa are 6m in diameter and 3.6 m in height. Boiling

process happens in outer boilers so we are using pipe type heat exchangers.

We took the basis 1 hout for boiling;

Looking to the amount of the energy in the heating section of the boiling process:

QI = 2625000 kcalh

41

Q = U.A.∆T →2625000 4.18 = 1950 A (100-65)× × × → A=160 m2

Straining Tank:

In this tank water is sprayed from perforated trays. To obtain this 200kg-malt is strained in a

standart 1m2 staining area. For our capacity of 10.000kg-malt;

2

21m10.000kg-malt = 50m 200kg-malt

× area is needed.

This 50m2 area is designed to be 8m in diameter and 25m in circumference. Again this tank is

made of stainless steel.

According to literature for the straining flippers, 6 armed 8.1 rpm system is enough for our

process. Straining tank is shaped cyclindrical like mashing tank is. This tank is 8m in

diameter, 1.8 m in height and has a capacity of 900hl. Orifices in the tank are thin and

splitted.

These straining tanks must have the capacity to strain the required malt in 3 hours period.

Plate Cooler:

We are planning to cool the must in 100°C to 2°C in plate coolers. The heat transfer area of

our cooler according to previous mass and energy balances is calculated as;

log(100 85) (9 2)T 10.5015ln

7

− − −∆ = ≅

Qgained = Qgiven = U.A.∆T→U = 1972 2

kcalm .h°C

Q = mwater x Cpwater x ∆T = U.A.∆Tlog

69.000 1 (85 2) 1972 A 10.50× × − = × × →A = 276m2.

42

We assumed the cooling liquid is cold water in 2°C.

Filters:

Beer is being filtered to obtain the required clearness. There are many types of filtering;

Kieselguhr Filter, Horizontal Filter, Vertical Fitler and Plate Surrounding Filter. We prefer to

use Kieselguhr Filter and PVPP(PoliVinilPoliPolidan). PVPP is made of plastic and polimer

inert material.

Pumps:

We are using 4 HP powered 4 pumps to meet the water need in our plant. These pumps have

total 40 tons water/h pumping capacity. Our plant needs 350 hl water/ hour.

Bottling Machine:

Our beer production capacity is 5000 hl/day. %60 of this amount is for bottling and the rest is

for barreling.

8. Location and Layout

The most important raw material of beer is water. Approximately %90-92 of beer consists of

water. For this reason the land of the factory must be rich in ground water.

Also product wastes need to be removed by the water arcs from the factory.

The other important ingredient of beer is malt. So it must be easy to supply the required malt

for production. The factory can be nearby the malt factories. We also need hopfen for

production. This ingredient can be imported.

Another important factor in the choice of the location is marketing strategies. For example

factories can be established in cities , in which the beer consumption is too much. If we want

43

to export our production our factory must be nearby the export centers such as airports and

seaports. By the way we must pay attention to the land prices, construction expenses.

In conclusion we decided to establish our factory in Lüleburgaz according to all factors told

above.

Another factor is the structure of the soil in factory land. The land structure have to be enable

to allow locating pipes underground to pump the products to the tanks.

The lay out of the plant can be arranged according to process flow. We are establishing the

equipments according to their location in the process. So we don’t have to pay extra money

for pumping anf piping.

The main production plan of beer;

Malt → Boiling → Fermentation → Maturing → Filtration → Bottling.

Our plant lay-out is in appendix.

9. Economical Analysis

Total Instrument Costs

Instruments Quantity Price Total

Mashing Tank 1 120.000$ 120.000$

Straining Tank 1 30.650$ 30.650$

Boiling Tank 2 147.750$ 295.500$

Plate Cooler 1 150.110$ 150.110$

Fermentation Tank 23 192.690$ 4.431.870$

Filter 1 304.000$ 304.000$

Pumps 4 350$ 1400$

44

Bottling Machine 1 900.000$ 900.000$

TOTAL 6.233.530$

Capital Estimation Based on Instrument Price

Proportion of

Instrument Cost

Cost

Instruments 100 6.233.530$

Building Instruments 47 2.929.759$

Instruments and

Control

18 1.122.035$

Piping 66 4.114.129$

Electric System 11 685.688$

Buildings 18 1.122.035$

Enlarging 10 623.353$

Service Processes 70 4.363.471$

Land 6 374.011$

Direct Expenses 346 21.568.013$

Engineering and

Control

33 2.057.064$

Construction Expenses 41 2.555.747$

Indirect Expenses 74 4.612.812$

Total Expenses 420 26.180.826$

Contractor Expenses 21 1.309.041$

Unexpected 42 2.618.082$

Fixed Capital 483 30.107.949$

Managing Capital 86 5.360.835$

45

TOTAL CAPITAL 569 35.468.735$

Total Product Cost Estimation

As the capacity is assumed 1.200.000 hl/year

Unit Cost(kg/$) Proportion of

mass(%)

Net Mass(kg) Cost($)

Malt 0.25 20,5 24.600.000 6.150.000

Hopfen 1.5 0,17 204.000 204.000

So 1 lt of beer costs 6.354.000 $ / 120.000.000 lt = 0,053 $ as raw material.

The cost of beer is %20 of Total Production Expenses

So total production cost is 31.770.000 $

Total cost of 1 lt beer is 31.770.000 $ / 120.000.000 lt = 0,265 $ /lt

Marketing Price will be 0.413$ / lt

TOTAL COST PRODUCT = PRODUCTION COSTS + GENERAL EXPENSES

PRODUCTION EXPENSES = DIRECT PRODUCTION EXPENSES + FIXED

EXPENSES + COMPANY EXPENSES

GENERAL EXPENSES = MANAGEMENT EXPENSES + TRANSPORTATION +

R&D

46

Production Costs

Proportion of Total

Cost(%)

Cost ($)

Raw Materials 20 6.354.000$

Labor 20 6.354.000$

Control Labor 5 1.588.500$

Maintenance and Repair 5 1.588.500$

Laboratory 10 3.177.000$

TOTAL 60 19.062.000$

Fixed Expenses

Proportion of Total

Cost(%)

Cost ($)

Corrosion 3 953.100$

Tax 3 953.100$

Insurance 4 1.270.800$

TOTAL 10 3.177.000$

Company Expenses

Proportion of Total

Cost(%)

Cost ($)

Company Expenses 5 1.588.500$

47

General Expenses

Proportion of Total

Cost(%)

Cost ($)

Management Expenses 5 1.588.500$

Transportation 15 4.765.500$

R&D 5 1.588.500$

TOTAL 25 7.942.500$

GENERAL TOTAL 100 31.770.000$

Salary Distrubition

Total Labor Cost is 6.354.000 $

Position Person Salary ($/month) Cost ($/month)

General Director 1 7000 7000 $

Chemical

Engineering

9 4200 37800 $

Mechanical

Engineering

5 4900 24500 $

Electrical

Engineering

5 4200 21000 $

Chemist 8 2100 16800 $

Workers 200 1400 280.000 $

Security 20 1400 28.000 $

Drivers 20 1400 28.000 $

Managing Officials 30 2800 84.000 $

TOTAL(Monthly) 527.100 $/month

TOTAL(Annual) 6.354.000 $/year

48

Recovery

In one year period company will gain 120.000.000 x 0.413 = 49.560.000 $

Net Profit = 49.560.000 – (120.000.000 x 0.265) = 17.760.000 $

As the capital estimation is calculated = 35.468.735 / 17.760.000 ≈ 2 years

Cash Flow Diagram

Total Investment = 35.468.735 $

Fixed Capital Investment = 30.107.949 $

Working Capital = 5.360.835 $

Working life = 10 years

Cost of Land = 374.011 $

Money Invested at the end of first year = 14.866.969 $

Money Invested at the end of second year = 14.866.969 $

Depreciation = Double Declining Balance Depreciation Method

dk = 2/n(FCI - ∑dk)

dk3 = 2/10 x (30.107.949 – 0) = 6.021.589,8 $

dk4 = 2/10 x (30.107.949 – 6.021.589,8) = 4.817.271,85 $

dk5 = 2/10 x (30.107.949 – (dk3 + dk4) = 3.853.817,5 $

dk6 = 3.083.054 $

dk7 = 2.466.443 $

dk8 = 1.973.154,5 $

dk9 = 1.578.523,7 $

dk10 = 1.262.819 $

dk11 = 1.010.255,1 $

dk12 = 808.204,1 $

R – COMd = 49.560.000 – 31.770.000 = 17.790.000 $

From the equation; (R - COMd – dk) x (1-t) + dk

3rd year = 14.847.897,5 $

4rd year = 14.546.818 $

49

5th year = 14.305.954 $

6th year = 14.113.263 $

7th year = 13.959.110 $

8th year = 13.835.788 $

9th year = 13.737.131 $

10th year = 13.658.205 $

11th year = 13.595.064 $

12th year = 13.544.551 $

The sum of these values = 140.143.781,5 $

Profit = 140.143.781,5 – 35.468.735 = 104.675.046,5 $

Annual Profit = 104.675.046,5/12 = 8722920,5 $

Cash Flow Diagram

-40.000.000

-20.000.000

0

20.000.000

40.000.000

60.000.000

80.000.000

0 5 10 15

Year

Mon

ey

50

10. Conclusion Beer production of Turkey is sufficient for its own needs. %75 of beer sales are made by

EFES PİLSEN. Our project is planned to produce %15 need of country’s beer poverty. In

consideration with the potential working power and qualified persons, there will be any

problems on operating this plant. However, most of the equipments, have to be used in beer

production, must be imported from foreign countries, especially from Germany. This causes

the establishing expenses to be increased. With hardworking and enough R&D studies on this

subject can solve the expensive imported instruments costs problem. Beside this the whole

raw materials used in beer production can be gained from our country’s own agriculturel

production. So there is no shortage of raw materials indeed. According to economical

analyses, our factory’s payback time is approximately 2 years. This result is satisfactory and

the investment seems feasible.

51

11.Appendix • Tables of Beer Productions and Consumptions

• Tables of Malt Production

• Factory Lay-out Plan

• Fermentation of Etyhl Alcohol

• Process Flow Diagram

• Change of Parameters During Fermentation

• Pictures of Equipments

52

Security

Firehouse

Mashing +

Malt Boilers

FermentationTanks

Maturing Tanks

Filtering

Bottling +

Bottle Washibg

Warehouse

Waste Water Treatment +

Steam Production

LabDining Hall

+ Lockers

Management Building

Workshop

53

Change of Parameters During Fermentation

Day P(BAR)

1 0,4

2 0,4

3 0,4

4 0,4

5 0,4

6 0,4

7 0,4

8 0,4

9 0,4

10 0,4

11 0,4

12 0,4

13 0,4

14 0,4

15 0,4

Day Ph

0 5

1 4,58

2 4,33

3 4,23

4 4,19

5 4,22

6 4,22

7 4,22

8 4,22

9 4,22

10 4,22

11 4,22

12 4,22

13 4,22

14 4,22

15 4,22

54

Day T(°C) 0 9

1 12

2 12

3 12

4 12

5 12

6 0

7 -1

8 -1

9 -1

10 -1

11 -1

12 -1

13 -1

14 -1

15 -1

Day Extract(%)

0 12,5

1 10,9

2 6,15

3 3,7

4 2,6

5 2,2

6 2,1

7 2,1

8 2,1

9 2,1

10 2,1

11 2,1

12 2,1

13 2,1

14 2,1

15 2,1

55

Some Pictures of Equipments Used in Breweries

Fermentation Tanks

56

57

12. Preferences

• ÖZEN, Işıl, (1988), ODTÜ Intership Report

• PALACIOĞLU, Sibel, (1999) Gazi Üniversitesi Project

• KUNZE, International Edition, (1995) Technology Brewing

and Malting

• BİNGÜLLÜ, Feyza, (1999), Bira Üretim Teknolojisi

• YAVUZLUHANOĞLU, Burç, Private Meeting, İstanbul

Internet Resources

• www.efespilsen.com.tr

• www.steinecker.com

• www.tuborg.com.tr

• www.kimyamuhendisi.com

• www.odevsitesi.com

• www.kimyaevi.org

Documents

Beer Production