Includes the various steps involved in beer manufacturing. Gives a view about the various brewing processes.

1. BREWING PROCESS
B E E R M A N U F A C T U R I N G
P R O C E S S ( B R E W I N G )
B Y : T A R U N Y A D A V
B . T E C H , F O O D T E C H N O L O G Y A N D
M A N A G E M E N T , N I F T E M

2. BRANDS

3. BEER
• Beer is a fermented, carbonated, alcoholic drink prepared
by fermenting the malted cereal grains, mainly malted
barley.
• Process of beer manufacturing is called brewing process.
• On the basis of alcohol content beer can be: light, medium,
strong.
• On the basis of fermentation type it can be: Lager or ale
beer.

4. BREWING PROCESS
Cleaning and
Milling
Mashing
Lautering/wort
separation

5. Wort Boiling
Whirlpool
Wort Cooling

6. Fermentation
Maturation
Filteration

7. Bottling
Pasteurization
Labeling and
packging

8. CLEANING AND MILLING
• Raw material from the raw material pits are transferred into
the silos, from there it was transferred to the cleaning
section.
• Cleaning of raw material includes various steps:
1. Aspiration and cyclone cleaning. Done for the removal of
dust and lighter particles.
2. Sieving: use sieves to remove particles size smaller and
lager than malts.
3. De-stoner and magnate: In the process stones and any
metallic particle is removed.

9. • Milling: Milling is done to break the malted grains into two or
three smaller particles.
• The main purpose of milling is to break the grain particles
into 2 or 3 smaller particles, so that its surface area
increases and it becomes easy for enzymes to penetrate into
the grains as the broken particles have open side ends with
peptide layers. So they can directly act on the starch
present inside the grain.

10. DIFFERENT MASHING METHODS
• Different mashing methods are used for different type of
the beers. Like decoction, infusion, time-temperature
mashing, etc.
• Type of beer produced depends upon the mashing schedule
used. Like a mashing schedule with more rest at different
temperatures will have more amount of fermentable sugar,
and hence may have more alcohol content.

11. MASHING
• Mashing: Mashing is a process in which mash material(
malted barley grains and adjuncts) are subjected to
different time temperature conditions.
• The main purpose of mashing is to convert the starch
available in the grains into fermentable sugars.
• Therefore, mash mass is allowed to rest at different
temperature for different time periods.
• These rests provide the required temperature conditions at
which different enzymes gets activated and cause the
required change in the mash.

12. MASHING
• During mashing , water at 45˚C is pumped in the mash
tuns. Malted barley grains are hydrated and mixed with this
water by using hydrators.
• Then the mash mass is allowed to rest at 45˚C for nearly
10-15 minutes.
• Then the temperature is slowly increased to 55˚C and then
allowed to rest for 20-30 minutes.
• Then again temperature is raised to 62˚C and like this upto
73-75˚C with a rest of nearly 25-30 minutes at each
temperature.
• For increasing the temperature either the vessel is heated
using steam or hot water is added.

13. MASHING SCHEDULE
• Mashing schedule includes rest of mash material( mashing
liquor + malted barley) at different time-temperature
profiles.
•

14. LAUTERING/WORT EXTRACTION
• Wort: wort is a sugary liquid obtained from the mashing of
malted grains . Wort consist high amount of fermentable sugars
which are required by the yeast as a food during fermentation.
• Lautering is the process which is used for the extraction of wort
from the mash mass after mashing process.
• Lautering is done in lauter tuns.
• Mash mass after mashing is transferred in the lauter tun from
the mash tun. Then the mash is allowed to stand for nearly 10-
15 minutes and then wort is extracted.
• Generally wort is recirculated in the lauter tuns to obtain clear
wort. Settled grains at the bottom of the lauter tun acts as a
filter. Hot water at 72˚C is sprinkled on the grains to remove all
the sugar from the mashed grains.

15. WORT BOILING
• The next step includes boiling of the obtained wort.
• For this purpose wort boiling kettles are used. Wort is
generally boiled at high temperatures of nearly 110-140˚C
under pressure or without pressure.
• Wort boiling plays a number of roles, it kills all the microbes
and makes the wort sterile, it causes mallard's reaction and
therefore helps In the development of the color of the beer,
degrades the proteins which can be removed as hot turbs
therefore makes the wort clear, high temperature also
isomerize the alpha-acids of the hops which gives the
characteristic flavor of the beer. therefore hops addition is
done during this step.

16. WORT BOILING
• Hops in the form of hops extract and hops pellets are added
in the wort. Hops addition is done through the hops dosing
tank which pumps and mixes the hops by circulating it
through the whole tank at high pressure.
• Wort boiling is done till the wort’s specific gravity reached to
the required range specific gravity.
• Specific gravity of wort increases during wort boiling
because water is evaporated during this process.

17. WHIRLPOOL
• Whirlpool is a device which is used by all the major
breweries.
• Whirlpools are used for the clarification the boiled wort. It
also removes the suspended protein which gets denatured
due to high temperature of boiling.
• In whirlpool, hot wort is injected tangentially at 30˚to the
tangent to the vessel wall.
• The tangential injection causes the wort to rotate and the
centrifugal force due to rotation cause the big particles to
get accumulated on the top of the wort.

18. WORT COOLING
• Wort form the whirlpools are then either stored in wort
storing kettles and then transferred to the Plate heat
exchangers(PHE) or directly transferred to the PHE.
• In PHE, wort temperature is reduced to the temperature
which is required for the fermentation process, which is 10-
12˚C.
• Then this cooled wort is transferred to the conical
fermenters situated in the fermentation section.

19. FERMENTATION
• Fermentation of the beer is done for 7-8 days.
• For the first 3-4 days fermentation is done at
temperature between 10-12 ˚C.
• After 3-4 days of fermentation at 10-12˚C, yeast starts
producing di-acetyl, which gives undesirable taste to the
beer.
• At 15˚C, yeast doesn’t secret di-acetyl and consumes
the produced di-acetyl, therefore for next 3-4 days
fermentation is carried out at 15˚C.
• Then the temperature is reduced to 4˚C suddenly.
• Maturation is done at 0-(-1)˚C.

20. FILTRATION
• One of the major characteristic of beer is, its sparkling clear
appearance.
• Therefore beer after maturation is required to be cleared by
passing it through filters.
• Filtration is done to remove tanins, cold turbs( denatured
proteins), dead yeast cells and other products which formed
during the beer manufacturing and may cause problem in
the beer clearance.
• Filtration of beer is done at sub-zero or zero degree
temperature.

21. FILTRATION
• Beer at 0 or sub-zero ˚C is first filtered through kiseleghur
filters, in which filter aids like fine sand or high flow powder
are used for filtration.
• Then the beer is passed through the multi-bag filters, in
order to remove or filter out the remaining particles and if
any filter aid comes into the beer.
• After filtration bio-form and KMS are pumped through
chemical dosing tanks and then Carbonation of beer is
done.

22. BOTTLING
• After filtration, beer is stored in Bright Beer Tanks( BBT)
from where it is pumped into the bottling section.
• Bottles after washing from the washer are then filled with
beer at high carbon di-oxide pressure.
• Then the bottles are capped with crown caps and then
forwarded to the pasteurization section for the beer
pasteurization.

23. PASTEURIZATION
• Pasteurization of beer is generally carried out in a tunnel
pasteurizers.
• In tunnel pasteurization bottles or cans are filled and closed
in the normal way. The tunnel has a low ceiling with spray
heads at regular intervals.
• The tunnel is divided into many temperature zones to slowly
bring the product up to temperature, keep them at a
specified holding temperature and then bring them back
down to room temperature.
• As the beer moves through the tunnel it is gradually heated
to the pasteurization temperature of 60°C(140°F) and held
at that temperature for a defined period of time before
being cooled back down to 20°C (68°F).

24. WATER TREATMENT PLANT
Water
From Bore
well
MGF/Sa
nd filter
Softene
r
ACF
Disinfect
ant
MCF R.O
R.O
tank

25. CLEAN IN PLACE
In the company CIP is carried out in
following manners:
1. Three step CIP.
2. Five step CIP.
3. Seven Step CIP.

26. CIP
THREE STEPS CIP
Pre rinse with water
for 10 minutes
Rinse with hot water
for 20 minutes at 85⁰C
Final rinse with RO
water for 10 minutes

27. CIP
FIVE STEPS CIP
Pre rinse with water for 10 minutes
Rinse with hot water using caustic for 20
minutes at 65⁰C
Rinse with water for 10 minutes for complete
removal of caustic
Rinse with hot water for 20 minutes at 85⁰C
Final rinse with RO water for 10 minutes

28. CIP
SEVEN STEPS CIP
Final rinse with RO water for 10 minutes
Rinse with hot water for 20 minutes at 85⁰C
Rinse with water for complete removal of acid for 10 minutes
Acid circulation for 20 minutes at 65⁰C
Rinse with water for complete removal of caustic for 10 minutes
Rinse with caustic for 20 minutes at 65⁰C
Pre rinse with water for 10 minutes

29. Thank You !