BREWINGOperations and Material Management

Presented by:Pradeep Chauhan(71)Prince Gahlot(76)Ritesh Bansal(88)Shagun Joshi(99)

BEERBeer has been used over the centuries to:

quench a thirst, add flavor to a barbecue, add shine when you wash your hair, and to forget about one's worries for awhile.

HISTORY Beer is older than recorded history

How and when it was discovered is unknownEvidence that barley was used for fermentation

prior to the baking of breadLikely accidental discovery:

Grain at some stage of germination immersed in water Wild airborne yeasts land in water Natural fermentation Some brave soul drinks this water Not only was it tasty, but it got him/her buzzed!!!!

DEFINITION AND COMPOSITION… Brewing is the production of beer through

steeping a starch source (commonly cereal grains) in water and then fermenting with yeast.

The basic ingredients of beer are: Water, A starch source, such as malted barley, which is

able to be fermented (converted into alcohol), A brewer's yeast to produce the fermentation, And a flavoring such as hops, A secondary starch source (an adjunct) may be

used, such as maize (corn), rice or sugar.

A SMALL BREWERY

STEPS IN BREWINGmalting

milling

lautering

boilingfermenti

ngconditioni

ngfilteringpackagin

g

mashing

MALTING It consists of three processes: Steeping- The grain is added to a vat with

water and allowed to soak for approximately 40 hours.

Germination- the grain is spread out on the floor of the germination room for around 5 days. This allows the starches in the barley grain to breakdown into shorter lengths. After this step, the grain is called green malt.

Kilning- the green malt goes through a very high temperature drying in a kiln. The temperature change is gradual so as not to disturb or damage the enzymes in the grain. The finished product is Malt.

MILLING Here, the grains that are going to be

used in a batch of beer are cracked. Milling the grains makes it easier for

them to absorb the water that they are mixed with and which extracts sugars from the malt.

MASHING Mashing is the process of combining a

mix of milled grain (typically malted barley with supplementary grains such as corn, sorghum, rye or wheat), known as the "grain bill", and water, known as "liquor", and heating this mixture in a vessel called a "mash tun".

Mashing allows the enzymes in the malt to break down the starch in the grain into sugars, typically maltose to create a malty liquid called wort.

MASH TUN

The mash tun is a vessel in which the milled malted barley is mixed with waterAnd the enzymes are allowed to degrade the starches and proteins intoSubstrates that the yeast can utilize during fermentation

MASH

These photos show the milledMalted barley being mixed withWarm water. The enzymes Convert the starch to maltose and The proteins to amino acids creatingWhat is known as sweet wort.

LAUTERING Lautering is the separation of the wort (the

liquid containing the sugar extracted during mashing) from the grains.

This is done either in a mash tun outfitted with a false bottom, a lauter tun, or a mash filter. Most separation processes have two stages: first wort run-off, during which the extract is

separated in an undiluted state from the spent grains,

and sparging, in which extract which remains with the grains is rinsed off with hot water.

LAUTERING

The sweet wortIs separted from The spent barleyBy a filtration stepKnown as Lautering. The Barley husks serveAs the primaryFiltering material.Here, the remainingSpent grains areBeing removed fromThe sweet wortWith this screen.

BOILING Boiling prevents a lot of infections. During the boil hops are added that

bring bitterness, flavor and aroma. The boil lasts between 50 and 120

minutes, depending on its intensity, the hop addition schedule, and volume of wort the brewer expects to evaporate.

Boiling is followed by whirlpooling, hopback and wort cooling.

FERMENTING After the wort is cooled, yeast is added

to it, and it begins to ferment. Fermentation tanks are typically made

of stainless steel. Fermentation can be done in following

ways: Warm fermenting Cool fermenting Spontaneous fermenting Secondary fermenting

FERMENTATION TANKS

After the yeast is added to the hopped wort, fermentation of the maltose toEthanol occurs in these tanks.

CONDITIONING At the end of fermentation, the yeast

starts to settle down to the tank’s bottom.

The beer is then cooled to freezing due to which proteins settle out with yeast and are separated.

Conditioning can take from 2 to 4 week, depending on the type of beer.

FILTERING Filtering the beer stabilizes the flavour,

and gives beer its polished shine and brilliance.

Filtering is of three types: Rough filtration Fine filtration Sterile filtration

PACKAGING Packaging is putting the beer into the

containers. Typically this means putting the beer

into bottles, aluminium cans and kegs. It may include putting the beer into bulk

tanks for high-volume customers.

STATE WISE BEER CONSUMPTION

India's beer consumption extended robust growth for the third year in a row with 14.5% volume jump in FY08.

State wise Consumption

Andhra Pradesh 15.4%

Tamil Nadu 11.6%

Karnataka 24%

Maharashtra 5 – 6%

Rajasthan 26%

Haryana 30%

Delhi 3%

Orissa, West Bengal and Jharkhand 20 – 25%

Uttar Pradesh (de-growth) 7%

THE INDIAN BEER INDUSTRY The beer market accounts for roughly 10% of all

alcohol sales in the country. The beer market in India is estimated to be over

Rupees 3000 corers. It is estimated at around 7 million hectoliters. Beer consumption has increased by 9% over the

last 5 years. In India, beer sales grew at nearly 90% compared

to, less than 60% growth for other alcoholic drinks. The top 2 beer players in India account for about

75% of the market. The spirit to beer consumption in India is 7:1.