Mapúa University

Muralla St., Intramuros, Manila

GROUP 4 WRITTEN REPORT

ME148/E02

BEER MANUFACTURING
Group Members:

Medina, Jeremy D.

Ramos, Chester Jericho O.

Lizardo, Mark Jayson D.

Elizarde, John Lorenzo M.

Submitted on:

November 29, 2018

1
 Prof. Jaime Blanco

Instructor

TABLE OF CONTENTS

Page no.

I. BACKGROUND ................................................................................................................ 3

II. PROCESS ........................................................................................................................... 3

III. MAJOR EQUIPMENTS ..................................................................................................... 6

IV. BY PRODUCTS / WASTE ................................................................................................ 7

V. SAFETY ............................................................................Error! Bookmark not defined.

REFERENCES ............................................................................................................................... 9

2
 I. BACKGROUND
Beer - An alcoholic drink made from yeast-fermented malt flavored with hops. Beer

forms part of the culture of many nations and is associated with social traditions such as;

 Beer festivals, as well as a rich

 pub culture (pub crawling and pub games such as bar billiards).

The strength of modern beer is usually around 4% to 6% (ABV).

Four Main Ingredients of Beer:

1. Yeast – Creates 2 varieties ( Ale Yeast and Lager Yeast)

2. Water – Impacts quality

3. Grains – Provides color, flavour, maltose, proteins, and dextrins.

4. Hops – Provides bitterness, flavour, aroma, and stability.

II. PROCESS

Process Description

Brewing - is the production of beer by steeping a starch source in water and fermenting the

resulting sweet liquid with yeast.

It may be done in a;

 brewery by a commercial brewer,

 at home by a homebrewer,

 or by a variety of traditional methods such as communally by the indigenous peoples

in Brazil when making cauim

3
Brewing has taken place around 6th millennium BC. Where archeological evidence suggests

Ancient Egypt and Mesopotamia brewed beer.

Process Diagram

The following are the Brewery Process:

1. Milling

- Beginning In the brew house, different types of malt are crushed together to break up

the grain kernels in order to extract fermentable sugars to produce a milled product

called grist.

2. Mashing

- The grist is then transferred into a mash tun, where it is mixed with heated water in a

process called mash conversion. The conversion process uses natural enzymes in the

malt to break the malt’s starch down into sugars.

3. Lautering

- The mash is then pumped into the lauter tun, where a sweet liquid (known as wort) is

separated from the grain husks.

4. Boiling

- The wort is then collected in a vessel called a kettle, where it is brought to a controlled

boil before the hops are added.

5. Whirlpooling and Cooling

- After boiling, the wort is transferred into a whirlpool for the wort separation stage.

During this stage, any malt or hop particles are removed to leave a liquid that is ready

to be cooled and fermented.

4
6. Fermenting

- To start the fermentation, yeast is added during the filling of the vessel. Yeast converts

the sugary wort into beer by producing alcohol, a wide range of flavors, and carbon

dioxide (used later in the process to give the beer its sparkle).

7. Maturing

- After fermentation, the young “green” beer needs to be matured in order to allow both

a full development of flavors and a smooth finish.

8. Filtering

- After reaching its full potential, the beer is filtered, carbonated, and transferred to the

bright beer tank, where it goes through a cellaring process that takes 3-4 weeks to

complete. Once completed, the beer is ready to be packaged.

9. Packaging

Depalletising – In this, empty bottles are removed from pallets.

Bottle washing – Bottles are rinsed with filtered water to remove impurities and cleared of

labels. Sometimes carbon dioxide injected into bottles to reduce oxygen level.

Filling & capping – washed bottles are then sent to filling machine which fills the bottles

with beer. A few inert gases can be injected on the top to disperse the oxygen. Capper

applies bottle caps and sealed the bottles.

Pasteurization – Filled bottles are then pasteurized at 1400F for 2-3 minutes. This helps to

stops the growth of yeast that remains in the beer after packaging.

Labeling – After pasteurization labels are applied.

Box packing – Bottles are then packed into boxes and sent to the warehouse.
5
III. Major Equipments

1. Silo - Storage of malt. After soaking the wheat grains to water and roasted, it turns

into malt and stored in the silo.

2. Malt Mill - Malt grains are grinded into smaller pieces using malt mill. Milling allows

the mashing liquor to access the center of the barley. Milled malt causes inherent

substances to dissolve more effectively

3. Mash Tun - Malt and warm water are mixed together and constantly stirred. Mashing

converts the starches in crushed grains into sugar. It is maintain in a constant

temperature between 45°C to 78°C

4. Lauter Tun - The mash is purified in the Lauter Tun. Lautering separates the mash

into the clear liquid wort and the solid residues.

5. Brew Kettle - In brew kettle, the liquid wort is boiled up to more than 80°C for two

hours. Hops are added to the liquid wort. The beer’s taste and shelf life are determined

by the amount of hops used. Hops added ranges from 18- 40 mg/L

6. Whirlpool Tank - The boiling wort is pumped to the whirlpool to remove the residue

of hops and protein. Due to the rotation, the solid particles are separated from the

wort.

7. Plate Heat Exchanger - The hot wort is cooled using the plate heat exchanger. The

hot wort enters the cooler from the side and flows through profiled plates which is

cooled by iced water entering from the other side.

6
 8. Fermentation Tank - The cooled wort is placed in the fermentation tanks where the

yeast is added. Depending on the yeast used, the required temperature ranges from

5°C to 20°C

9. Storage Tank - The secondary fermentation continues in the storage tanks. The

remaining sugar is converted into alcohol. The taste is refined. The remaining yeast

and protein settles at the bottom. Depending on the type of beer, it stays on the storage

tanks up to 3 months.

10. Keiselguhr Filter - Yeast and other undesirable sediments are removed using filter.

Other Terms:

Raw Preparation and Hot Brewing Process – The beer wort Production

BBH - Brewhouses - the beer wort machines

MCS- Brewery measuring and control system

MMG- Malt mills - grinders

WCA - wort cooling and aeration

Cold brewing process - beer fermentation and maturation

BPS - Beer production tanks

CFS- Complete fermentation sets

MAT- Maturation lagering tanks

IV. BY PRODUCTS / WASTE

Beer brewing produces several by products that can be used by other industries.

7
 Grain - During the malting of the barley, rootlets form on the grain and drip off. These

can be collected and used for animal feed.

 Spent Hops - The Spent Hops that is filtered out from the finished wort can also be

collected and used again as fertilizer.

 Yeast - The residual yeast from the brewing process is a rich source of B vitamins. It

can be put to use by pharmaceutical companies to make vitamins or drugs, or used as a

food additive.

 Fibrous Materials

o Filter sheets – difficult to dispose because of asbestos (50%)

o Old ropes – taken by rag dealers

o Label pulp- disposed to paper manufacturers

o Hop pockets – should be used again or go to hessian dealers

 Crown Corks - There is some difficulty in disposing of these since manufacturers will

not take them back for re-making . In absence of any other outlet they should go as

scrap iron to the local Authority.

 Glass - Used beer bottles are routinely recycled.

 Saudust and Wood - Surplus Sawdust and small wood cuttings, used shives, and etc.,

should be burnt and the ash conserved are use for fertilizer.

8
  Detergent - Detergent from bottle washing machine. It is unlikely that any profitable

outlet could be found, but is possible that it could be economically regenerated by

treatment with lime followed by filtration.

V. SAFETY

The top hazards in breweries are similar to those in the general manufacturing industry.

Below are some of the top risks, as well as how you can control their impact on your

business;

 Ergonomics – repetitive motion, lifting, awkward postures

How to manage – automate processes (hoists, conveyors, keg robots), two-person

lifts, lift training for employees

 Walking and Working Surfaces – wet floors, trip hazards, improperly stacked items

How to manage – clean up spills immediately, monthly walk-throughs looking for

hazards, keep aisles, stairs, and platforms clear from clutter

 Fall Protection – elevated work platforms, stairways

How to manage – Handrails, 4” toeboard, slip resistant reads on stairs

 Powered Industrial Trucks – forklifts, pallet trucks, etc

9
 How to manage – written and documented training, daily inspections, never load

outside rated capacity

 Keg Safety

How to Manage – never alter or tamper with safety devices, systems connected to

kegs should have pressure regulator, only use kegs from your own brewery, inspect kegs

(Sankey valve, steel ball, and o-ring)

 Thermal hazards

How to manage – steam and hot water pipe insulation, label hot surfaces, written

procedures for employees, long sleeves and pants, safety goggles and gloves

 Personal Protective Equipment (PPE) - last line of defense

Safety glasses Resistant Boots

Goggles Hearing Protection

Gloves Respiratory Protection

Waterproof/Chemical

REFERENCES

• https://firstwefeast.com/drink/learn-how-to-brew-beer-with-these-fun-animated-gifs

• https://en.wikibooks.org/wiki/Brewing/Equipment

• http://www.czechminibreweries.com/production/brewery-components/
10
• https://en.wikipedia.org/wiki/Brewery

• http://www.brewforce.co.in/brewery.html