BEER INDUSTRY

CONTENTS:• INTRODUCTION• HISTORY OF BEER• GLOBAL BEER MARKET• INGREDIENTS OF BEER• BEER PRODUCTION PROCESS• PROCESS FLOWSHEET• PROCESS DESCRIPTION

ALL THE IMAGES AND DATA IS OBTAINED FROM: HTTP/HOMEBREW.COM(OFFICIAL SITE)HTTP/BREWSMITH.COM(OFFICIAL SITE)OPEN ACCESS IMAGES AND DATA

BEER IS NATURE’S GIFT

• BEER IS AN ALCOHOLIC DRINK BREWED MAINLY FROM MALTED BARLEY, HOPS, YEAST AND WATER ALTHOUGH OTHER SOURCES OF FERMENTABLE CARBOHYDRATE (EG. MAIZE, WHEAT, RICE) AND OTHER NATURAL INGREDIENTS MAY BE ADDED TO CREATE DIFFERENT STYLES AND FLAVOUR.

HISTORY OF BEER…• IN 4000 B.C SUMER PEOPLE FERMENTING A BREAD TO FORM FERMENTED PULP-INTOXICATING

EFFECT-”DIVINE DRINK”.• 3000 BC THE BABYLONIANS HAD UP TO 20 DIFFERENT TYPES OF BEER.• 1550 BC THE EGYPTIANS WERE ALSO KEEN BREWERS.• THE MIDDLE AGES IN THE MIDDLE AGES THE LARGEST BREWERS WERE THE MONASTERIES.• THE INTRODUCTION OF HOPS: HOPS ARE MENTIONED IN RECORDS IN GERMANY AS EARLY

AS 822 AD .• THE LAW OF 1516 THE WORLD'S FIRST FOOD INGREDIENT REGULATION IS THE GERMAN

PURITY LAW-THE LAW STATED THAT BEER COULD ONLY BE BREWED FROM WATER, HOPS AND MALT -- THE USE OF YEAST WOULD COME LATER, AFTER IT HAD BEEN IDENTIFIED AS THE ORGANISM RESPONSIBLE FOR FERMENTATION

GLOBAL BEER MARKET• WITH A PRODUCTION VOLUME OF 46.5438 MILLION

KILOLITRES.•  CHINA IS THE WORLD'S LARGEST PRODUCER OF BEER,

12 YEARS RUNNING. IT PRODUCES MORE THAN DOUBLE THAT OF THE US, AND HAS INCREASED PRODUCTION BY MORE THAN 4.9% SINCE JUST LAST YEAR.

• EUROPEAN COUNTRIES ON TOP AS DRINKING THE MOST BEER IN THE WORLD PER PERSON. 

• CZECH REPUBLIC CONSUMED THE HIGHEST AMOUNT OF BEER PER HEAD WITH 143 LITRES AND A NATIONAL TOTAL OF 1.5 BILLION LITRES FROM 2013 TO 2014, ACCORDING TO DATA RELEASED FROM EURO MONITOR INTERNATIONAL.

• HTTP/HOMEBREW.COM

WHY DRINK BEER?• BEER DRINKERS LIVE LONGER. BEER, IF DRANK WITH MODERATION, SOFTENS THE

TEMPER, CHEERS THE SPIRIT, AND PROMOTES HEALTH.• BEER IS ALL-NATURAL: THE TRUTH IS THAT BEER IS AS ALL-NATURAL AS ORANGE JUICE OR

MILK(NO ADDED PRESERVATIVES !)• BEER IS LOW IN CALORIES, LOW IN CARBOHYDRATES AND HAS NO FAT OR

CHOLESTEROL(0% FATS OR CHOLESTEROL , ONLY 43 CALORIES/100ML).• BEER HELPS YOU CHILL-  IN OTHER WORDS, TO GET OUT EVERY NOW AND THEN AND

RELAX WITH YOUR BUDDIES OVER A COUPLE OF BEERS.

CONTINUED…• BEER HAS PLENTY O' B VITAMINS.• BEER IS SAFER THAN WATER.• BEER PREVENTS HEART ATTACKS.(ANTIOXIDANTS).• BEER FIGHTS CANCER (XANTHOHUMOL, A FLAVONOID FOUND ONLY IN HOPS.

XANTHOHUMOL IS A POTENT ANTIOXIDANT THAT INHIBITS CANCER-CAUSING ENZYMES)

INGREDIENTS OF BEER…• BARLEY: CEREAL GRAIN TO THANK FOR THAT LOOPY FEELING YOU GET AFTER DRINKING A

FEW BOTTLES.• HOPS: “HUMULUS LUPULUS!”-NO IT’S NOT A HARRY POTTER SPELL, IT’S THE SCIENTIFIC

NAME FOR THE “SPICE” OF BEER.• YEAST: OH THE ENVIABLE LIFE OF A YEAST CELL !!!• ADJUNCTS: ADD SOME TOPPINGS • WATER : OVER 90% OF WHAT IS IN YOUR PINT GLASS.• SUGAR: AAAH ! SWEET MYSTERY OF LIFE !!

WHY BARLEY FOR BEER PRODUCTION?

• BARLEY IS THE MOST COMMONLY USED GRAIN IN BEER MAKING. • OTHER GRAINS ARE ALSO USED BUT ONLY TO PROVIDE THEIR CHARACTERISTIC FLAVOUR

AND DIFFERENT LEVEL OF COMPLEXITY.• SPECIALTY GRAINS(ADJUNCTS) ARE USED TO ENHANCE THE BARLEY, NOT REPLACE IT• BARLEY’S ROLE IN BEER MAKING IS EQUIVALENT TO GRAPES’ ROLE IN WINEMAKING.

WHAT ARE HOPS?

• THE HOPS WE USE IN OUR BEER ARE ACTUALLY FLOWERS, FROM THE PLANT HUMULUS LUPULUS.

• HOP VARIETIES ARE DESCRIBED AS BITTERING, AROMA, OR DUAL PURPOSE.

WHY EXACTLY DO WE USE HOPS IN BEER THEN?

•  THE MOST IMPORTANT REASON TO USE HOPS IS TO BALANCE THE SWEETNESS FROM MALT AGAINST THE BITTERNESS FROM THE ALPHA-ACIDS.

• AROMA• FLAVOUR• NATURAL PRESERVATIVE

YEAST?

• CONVERSION OF SUGARS TO ALCOHOL AND CO2 .• THOUSANDS STRAINS OF YEAST BUT ONLY CULTIVATED ONE MUST BE USED FOR BREWING.

(NO WILD STRAIN ALLOWED)• REASON: IF OTHER YEAST CONTAMINATE THE BEER, THE RESULTS CAN BE OVER

CARBONATION, STRANGE FLAVOURS, AND ALL KINDS OF FERMENTATION PECULIARITIES.

YEAST TO BE USED?

Yeast

Ale-Top Fermenting

Yeast

Lager-Bottom Fermenting

Yeast

TYPES OF YEASTWeiss Ale

Lager Lab

ALE-TOP FERMENTING YEAST• THE "TOP-FERMENTING" TYPE, SACCHAROMYCES CEREVISIAE.• SUITABLE TEMPERATURE RANGE:10OC-25OC.• THEY RISE THE SURFACE DURING FERMENTATION AND FORMS A THICK AND RICH YEAST

HEAD.• FERMENTATION BY ALE YEASTS AT THESE RELATIVELY WARMER TEMPERATURES PRODUCES

A BEER HIGH IN ESTERS, WHICH MANY REGARD AS A DISTINCTIVE CHARACTER OF ALE BEERS. 

• TOP-FERMENTING YEASTS ARE USED FOR BREWING ALES, PORTERS, STOUTS, ALTBIER, KÖLSCH, AND WHEAT BEERS. 

LAGER-BOTTOM FERMENTING YEAST

•  LAGER YEAST -THE "BOTTOM-FERMENTING" TYPE, SACCHAROMYCES UVARUM, FORMERLY KNOWN AS SACCHAROMYCES CARLSBERGENSIS.

• SUITABLE TEMPERATURE-7OC-15OC•  THEY TEND TO SETTLE OUT TO THE BOTTOM

OF THE FERMENTER AS FERMENTATION NEARS COMPLETION.

• SOME OF THE LAGER STYLES MADE FROM BOTTOM-FERMENTING YEASTS ARE PILSNERS, DORTMUNDERS, MÄRZEN, BOCKS, AND AMERICAN MALT LIQUORS.

THE TASTE OF WATER• BEER IS MOSTLY WATER ~90%• WATER CONTRIBUTES TO THE UNIQUE TASTING OF BEER.• THE REASON IS-MINERALS PRESENT IN THE WATER AFFECTS THE STARCH

CONVERSION(IN MASHING PROCESS).• WATER AFFECTS THE PERCEIVED BITTERNESS AND HOP UTILIZATION.• WATER ADDS DIRECTLY TO FLAVOUR.• WATER IS USED BASED ON THEIR PROFILES(IONS CONC.)

USE OF SUGARS

• TO SPEED UP FERMENTATION• TO REDUCE BITTERNESS• TO GIVE COLOUR IN THE FORM OF CARAMEL.• TO CAUSE SECONDARY FERMENTATION.

BEER PRODUCTION PROCESSES• STEEPING• MALTING• GERMINATION• KILNING• SIEVING• GRINDING• EXTRACTION OF

SUGARS-1.INFUSION; 2.DECOCTION

• BREW KETTLE- 1.HOP BACK; 2. HOP

EXTRACTION• FERMENTATION PARA

FLOW• LAGERING • FINING• CARBONATION• BOTTLING• PASTEURIZATION

FLOWSHEET FOR BEER PRODUCTION

Barley

Malting

Milling

Mashing

Lautering

Boiling

CoolingFermenti

ngCondition

ingFilteringPackagin

g

water

Flavours, SpicesYeast

Bottles Cans

Kilning

Germination

Steeping

BARLEY: PREPARATIONFeeding barley in separator.

MALTING• MALT IS OFTEN CALLED THE "HEART OF BEER" .• IT’S A 3 STEP PROCESS:1. STEEPING2. GERMINATION3. KILNING• FERMENTABLE SUGARS AND ENZYMES(AMYLASES) ARE

EXTRACTED IN THIS PROCESS.

MALTING PROCESS

Types of malt:1.Pale Malt :65oc2.Crystal Malt: 85oc3.Chocolate malt: 225oc

STEEPING• STEEPING, IS A METHOD USED TO EXTRACT COLOURS AND FLAVOURS FROM BARLEY.• ONLY <10% FERMENTABLE SUGARS ARE EXTRACTED.• WATER IS HEATED BETWEEN 150 AND 170 F.• THEN THE GRAINS ARE ADDED TO WATER.• WATER IS ABSORBED BY THE GRAINS AND GERMINATION BEGINS.• ITS IS KEPT IN WATER FOR 24-48 HOURS UNTIL THE MOISTURE CONTENT REACHES FROM

12% TO 44%.• ENZYMES GET ACTIVATED.• RAW BARLEY THAT HAS BEEN PROPERLY STEEPED IS REFERRED TO AS "CHITTED" BARLEY"

STEEPING CONTD..

GERMINATION• PROCESS CALLED "STEEP OUT," THE CHITTED BARLEY IS TRANSFERRED FROM THE

STEEP TANK TO THE GERMINATION COMPARTMENT.• STAYS THERE IN THE COMPARTMENT FOR 2-4 DAYS.• GERMINATION BEGINS IN STEEPING STAGE BUT THE COMPLETED IN THE

COMPARTMENT.• IN THIS STEP BARLEY KERNEL GOES UNDER MODIFICATION(BREAKING DOWN ON

PROTEINS AND CARBOHYDRATE RESERVES OF THE GRAIN).• GERMINATION IS TEMPERATURE CONTROLLED.

GERMINATION CONT.…

KILNING(HEAT DRYING)

• GERMINATION IS HALTED BY KILNING(HEAT DRYING).• BECAUSE IF THE GERMINATION IS ALLOWED FURTHER ALL THE STARCH

RESERVES REQUIRES BY THE BREWER WILL BE UTILISED BY GROWING PLANT.•  TYPICALLY DONE WITH A FINISH HEAT OF 180-190° F FOR 2-4 HOURS. • IT VARIES IN ACCORDANCE WITH FLAVOUR AND COLOUR REQUIRED.• IT MAY BE ROASTED OR HEATED (VARYING TIME RANGE).

KILNING CONT.…

MILLING• AFTER THE KILNING PROCESS THE MALT IS

FED IN THE MILL IN ORDER TO MASH THE MALT.

• MASHING THE MALT INCREASES THE SURFACE AREA OF THE GRAINS.

• LARGER THE SURFACE AREA GREATER IS THE FERMENTABLE SUGAR EXTRACTION.

MASHING• AFTER MILLING CRUSHED MALT IS HEATED

WITH WATER IN A VAT CALLED ‘MASH TUN’ FOR PROCESS CALLED MASHING.

• NATURAL ENZYMES BREAKS THE STARCH INTO FERMENTABLE SUGARS.

• STARCH> DEXTRINS >FERMENTABLE SUGARS

MASHING TUN

MASHING

TEMPERATURE RANGES FOR MASHING

 1. 104 °F or 40 °F Activates beta - glucanase, which breaks down gummy beta- glucans in the mash

2. 120 °F to 130 °F (49 °C to 55 °C)

Activates various proteinases, which break down proteins that might otherwise cause the beer to be hazy.

3. 149 to 160 °F (65 to 71 °C)

Convert the starches in the malt to sugar.

MASHING CONT.

• TYPES OF MASHES1. SINGLE INFUSION MASH2. TEMPERATURE MASH3. DECOCTION MASH4. MULTI-STEP MASHING

LAUTERING/SPARGING• END OF THE MASHING PROCESS WHERE HOT

WATER IS RUN THROUGH THE GRAIN BED TO EXTRACT A SWEET LIQUID CALLED WORT.

• GRAINS, SUGAR AND WATER AND OTHER PARTICLES ARE ALSO IN THE MASH CONTAINER.

• WORT COLLECTION IS DONE.• THERE IS FALSE SCREEN AT THE BOTTOM OF

THE MASH TUN.

SPARGING/LAUTERING

SPARGING

BOILING

• SWEET WORT IS TAKEN FROM MASHING AND ADDED TO BOILING UNIT.

Hops are added to create hopped

wort.

Brew kettle

BOILING CONT.• BOILING STERILIZES THE WORT, KILLING OFF ANY BACTERIA AND PREVENTING INFECTIONS.• BOILING HOPS RELEASES CRITICAL ALPHA ACIDS THAT BITTER THE BEER TO OFFSET THE

SWEETNESS OF THE MALT. THE LONGER HOPS ARE BOILED, THE MORE BITTERNESS THEY WILL RELEASE.

• BOILING VAPORIZES MANY UNDESIRABLE COMPOUNDS THAT CAN CAUSE OFF FLAVORS AND AROMAS.

• BOILING CAUSES COAGULATION OF UNDESIRABLE PROTEINS IN THE WORT, ALLOWING THEM TO FALL OUT DURING COOLING.

BOILING CONT.• BOILING IS GENERALLY DONE IN OPEN POT.• 10-20% HEAD SPACE FOR FOAMING TO PREVENT OVERFLOW IN COMMERCIAL BREWERS.• EXCESS BOILING HAS TO BE AVOIDED AS IT MAY CAUSE THE FLAVOURS TO GO OFF AND

ALSO AFFECT THE AROMA AND QUALITY OF THE BEER.• TEMPERATURE CONTROL IS MOST IMPORTANT FACTOR IN THE PRODUCTION OF QUALITY

BEER.

COOLING • COOLING IS A CRITICAL STEP IN BREWING PROCESS.• BEST TO COOL THE WART QUICKLY AS IT PREVENTS BACTERIAL INFECTION –GIVING A

HEAT SHOCKS.• IT ALSO PRECIPITATE OUT COAGULATED PROTEINS, HOPS AND OTHER DEBRIS LEFT

OUT OF BOILING.

COOLING

FERMENTATION• FERMENTATION IS A NATURAL PROCESS WHERE YEAST CONVERTS SUGAR INTO ALCOHOL

AND CARBON DIOXIDE (CO2).• SUGAR PRODUCED IN MASHING STAGE IS CONVERTED INTO ALCOHOL.• CO2 IS THE BY PRODUCT OF FERMENTATION WHICH IS UTILISED IN NATURAL CARBONATION

FOR BREWING.

FERMENTATION PATHWAY

FERMENTATION

TYPES OF FERMENTATION

• PRIMARY FERMENTATION • SECONDARY FERMENTATION• CONDITIONING AND FILTERING.

PRIMARY FERMENTATION

• IT IS FIRST STEP IN FERMENTATION AFTER THE WORT IS PRODUCED.

• PRIMARY FERMENTATION STARTS WHEN YEAST IS ADDED TO THE WORT RIGHT AFTER THE BOILING AND COOLING STEPS. ONCE THE YEAST IS ADDED, WE CALL THE MIXTURE BEER AS OPPOSED TO WORT. THE PRIMARY, OR ACTIVE FERMENTATION.

• TAKES 3-5 DAYS.• CO2 PRODUCED IS STRONG IN THIS PHASE

PRODUCING A FOAMY HEAD ON THE TOP THE BEER.

SECONDARY FERMENTATION• SEPARATES BEER FROM THE TRUB.• TRUB INCLUDES : YEAST CAKE , SEDIMENTS AS HOPS SEDIMENTS ,

GRAIN AND TANNIN PIECES.• SECONDARY FERMENTATION IS NOT USUALLY A FERMENTING

STAGE.• SLOW REDUCTION OF REMAINING FERMENTABLES.• ITS GENERALLY A SEPARATION STAGE.• EXCESS FORMATION OF YEAST COLLEGE CAUSES OFF

FLAVOURING • PRODUCES AMINO ACIDS IF ALLOWED TO FOR LONGER TIME.

BIGGEST RISK IN SECONDARY FERMENTATION

•OXIDATION • DURING THE TRANSFER OF BEER FROM PRIMARY TO SECONDARY FERMENTING VESSEL

THE RISK IS THE EXPOSURE OF OXYGEN TO THE BEER.• DURING SIPHONING THERE ARE SPLASHES AND ONCE A BEER GETS EXPOSED TO OXYGEN

ITS GETS OXIDISED TO ACID.• ACID FORMATION TAKES PLACE• EVEN IF YOU USE GOOD SANITATION PRACTICES YOU ALWAYS RUN THE RISK OF POSSIBLE

CONTAMINATION.• SO ! PERFORM SECONDARY FERMENTATION ONLY IF YOU ARE A PRO!!

NEED A SOLUTION?• USE CONICAL FERMENTERS.• USE MODERN BREWING INGREDIENTS• USE ROBUST YEAST(GENETICALLY MODIFIED)• A PROPER MASH PH AND LONG BOIL WILL

REDUCE THE CHANCE OF EXCESSIVE TANNINS OR SEDIMENT PROBLEMS.

CONDITIONING: FERMENTATION’S GRAND FINALE!!

• THE REACTIONS THAT TAKE PLACE DURING CONDITIONING ARE PRIMARILY A FUNCTION OF THE YEAST.

• CONDITIONING PHASE INCLUDES- ENHANCING FLAVOUR, REMOVAL OF DORMANT YEAST IN ORDER PREVENT FROM PRODUCTION OF ACID.

• REMOVAL OF YEAST FLOCCULATES BY CHILLING THE BEER IS CALLED COLD CONDITIONING.• COLD CONDITIONING FOR A WEEK CLEARS THE BEER WITH OR WITHOUT THE USE FININGS.• THIS PHASE PROVIDES THE STABILITY TO THE BEER.

CONDITIONING CONT.

• AT THIS STAGE, BEER IS COOLED TO AROUND FREEZING.• ENCOURAGES THE SETTLING OF YEAST, AND CAUSES THE PROTEINS TO COAGULATE AND

SETTLE OUT WITH THE YEAST.• UNPLEASANT FLAVOUR SUCH AS PHENOLIC COMPOUNDS BECOMES INSOLUBLE IN THE

COLD BEER, AND BEER FLAVOURS BECOMES SMOOTHER.• CONDITIONING CAN TAKE PLACE IN THE SAME TANK AS FERMENTATION, OTHERWISE

SEPARATE TANKS MUST BE EMPLOYED.

FILTERING • ITS STABILIZES THE BEER FLAVOUR• GIVES THE BEER ITS POLISHED SHINE AND BRILLIANCE.• TYPES OF FILTRATION:1. ROUGH: FILTRATION LEAVES CLOUDINESS IN THE BEER, BUT ITS IS NOTICEABLY CLEARER

THAN UNFILTERED BEER.2. FINE: FINE BEER GIVES YOU A GLASS OF BEER THAT YOU COULD READ A NEWSPAPER

THROUGH, WITH NO NOTICEABLE CLOUDINESS.3. STERILE: IT REMOVES ALMOST ALL MICROORGANISMS FROM THE BEER .

PASTEURIZATION• IN THIS PROCESS BEER IS HEATED UP TO 60-66OC.• TIMING : LESS THAN 20 MINUTES.• KILLS BACTERIA AND REMAINING YEAST WHICH MAY CAUSE OFF FLAVOURING AND

FURTHER FERMENTATION.• IT MAY BE DONE BEFORE BOTTLING OR AFTER BOILING • ITS BETTER TO DO PASTEURIZATION AFTER BOTTLING SO THAT NO OTHER

CONTAMINATION IS FURTHER INTRODUCED INTO THE BOTTLE/PACKAGING.

PACKING AND BOTTLING• PUTTING THE BEER INTO THE CONTAINERS IN

WHICH IT WILL LEAVE THE BREWERY.• TYPICALLY MEANS BOTTLE AND KEGS, MIGHT

INCLUDE CANS OR BULK TANKS FOR HIGH VOLUME CUSTOMERS.

• LIFE SPAN:BOTTLED BEER : 6 MONTHSCANNED BEER : 1 YEARDRAUGHT BEER : 48 HRS AFTER TAPING

FINAL STAGE Without this stage all the stages are Worthless….

GETTING ME???

THANK YOU