Industry Overview
Brewing is the production of beer by steeping a starch source, commonly cereal grains such as barley, in water and fermenting the resulting sweet liquid with yeast. Brewing has been practiced since around the 6th millennium BC, with archaeological evidence indicating beer production in ancient Egypt and Mesopotamia. The basic ingredients of beer are water and a fermentable starch source, most commonly malted barley, while hops and brewer's yeast are widely used for flavouring and fermentation. Other starch sources and adjuncts may include millet, sorghum, cassava, maize, rice, sugar and wheat.
The principal stages of beer production include malting, milling, mashing, lautering, wort boiling, fermentation, conditioning, filtration and packaging. Different fermentation approaches include warm, cool and spontaneous fermentation, with additional techniques such as barrel aging and secondary fermentation also used for particular beer styles.
In India, the beer and alcoholic beverage industry has historically operated alongside social and policy challenges, despite continued market growth. The report notes an organized beer and liquor industry valued at Rs. 60.0 Billion and highlights changing consumer preferences, including the shift from lager beer toward strong beer. The Indian market has also faced increasing competition following the removal of quantitative restrictions on imported bottled alcoholic beverages. Beer remains a widely consumed alcoholic beverage globally, with variations in alcohol content, ingredients and brewing practices according to regional preferences.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 427333 Bottle/Day |
| Land & Building (80000 sq.mt) | Rs. 53.30 Cr |
| Plant & Machinery | Rs. 120 Cr |
| Working Capital for 1 Month | Rs. 45.37 Cr |
| Total Capital Investment | Rs. 224.77 Cr |
| Rate of Return | 40% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- DOMESTIC INDUSTRY
- FORMULA NO. 1
- PREPARATION PROCESS
- FORMULA NO. 2
- FORMULA NO. 3
- A) PALE BEER
- B) DARK BEER
- C) STRONG BEER
- MARKET SURVEY
- INDUSTRY TREND ANALYSIS - NASCENT INDIAN BEER MARKET PICKS UP STEAM
- INDIA'S BEER GROWTH WILL COME FROM LOW BASE
- ONWARDS AND UPWARDS FOR INDIA'S BEER MARKET
- THREE KEY FACTORS DRIVING GROWTH
- HUGE GROWTH IN BEER IMPORTS
- INDIA - TOTAL BEER IMPORTS BY VOLUME (TONS) AND VALUE (USD '000)
- TOP 12 MOST POPULAR BEERS BRANDS OF INDIA
- MANUFACTURERS OF BEER
- INGREDIENTS OF BEER
- MALTED BARLEY BEFORE KILNING OR ROASTING
- WATER
- STARCH SOURCE
- HOPS
- YEAST
- CLARIFYING AGENT
- DETAILS OF BREWING PROCESS
- MASHING
- LAUTERING
- BOILING
- BREW KETTLE OR COPPER
- WHIRLPOOL
- HOPBACK
- WORT COOLING
- FERMENTING
- FERMENTATION METHODS
- WARM FERMENTATION
- COOL FERMENTATION
- CONDITIONING
- KRÄUSENING
- LAGERING
- SECONDARY FERMENTATION
- BOTTLE FERMENTATION
- CASK CONDITIONING
- FILTERING
- SHEET (PAD) FILTERS
- KIESELGUHR FILTERS
- PACKAGING
- BY-PRODUCTS
- STEPS IN BEER MANUFACTURE
- 2. MILLING
- 3. MASHING
- 4. LAUTERING
- 5. WORT BOILING
- 6. WORT CLARIFICATION
- 7. FERMENTATION
- 8. STORAGE
- 9. FILTRATION
- 10. FILLING
- QUALITY IN FREE TRADE ZONES
- THE INCENTIVES AVAILABLE IN THESE FREE TRADE ZONES ARE ENUMERATED BELOW
- SEQUENCES IN BEER MANUFACTURE
- CLEANING AND MILLING
- MASHING
- LAUTERING /WORT EXTRACTION
- WORT BOILING
- WHIRLPOOL
- WORT COOLING
- FERMENTATION
- FILTRATION
- BOTTLING
- PASTEURIZATION
- BREWING PROCESS
- MANUFACTURING PROCESS IN DETAILS
- MALTING
- PREPARING THE MASH
- BREWING THE WORT
- FERMENTING
- PASTEURIZING
- PACKAGING
- A) MALT GRINDING
- B) ADJUNCTS' TREATMENTS
- C) MASHING
- TABLE 4. CARBOHYDRATE COMPOSITION OF A NORMAL WORT
- PHASES IN ENZYMATIC BREAKDOWN OF PROTEIN
- SEPARATION OF MASH
- WORT BOILING
- TABLE 5. ANALYSIS OF WORTS
- TREATMENT OF THE WORK
- FERMENTAION
- FERMENTATION PROCESS
- SEPARATION OF GREEN BEER
- LAGERING
- FILTERING
- PACKAGING
- PROCESS FLOW SHEET FOR BEER
- PLANT LAYOUT OF BEER
- PLANT LAYOUT BARLEY MILLING SECTION YEAST TANK, WASH TANK
- PLANT LAYOUT OF PROCESS SECTION FERMENTATION SECTION
- LIST OF PLANT AND MACHINERY
- PLANT LAYOUT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT AND MACHINERY
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
The main raw materials used in beer production are water, malted barley, hops and brewer's yeast. Malted barley provides fermentable sugars and contributes to the body and flavour of the beer. Hops provide bitterness, aroma and flavour, while yeast converts fermentable sugars into alcohol and carbon dioxide. Depending on the formulation, adjunct materials such as maize, rice, sugar, wheat, millet, sorghum or cassava may also be incorporated to achieve particular characteristics or production objectives.
The major stages in beer manufacturing include malting, milling, mashing, lautering, wort boiling, wort clarification, cooling, fermentation, conditioning, filtration and packaging. During mashing, enzymes convert starches into fermentable sugars. Lautering separates the liquid wort from spent grains, while boiling develops the desired wort characteristics and incorporates hops. After cooling, yeast is added for fermentation. The finished beer may then undergo conditioning, filtration, pasteurization and filling before distribution.
Warm and cool fermentation use different temperature conditions and yeast behaviour to produce distinct beer characteristics. Warm fermentation is commonly associated with ale-style brewing and generally uses yeast strains that perform actively at relatively higher temperatures. Cool fermentation is traditionally associated with lager-style brewing and uses yeast that works at lower temperatures. Fermentation temperature influences yeast activity, flavour development, attenuation and maturation requirements, making temperature control an important part of consistent beer production.
Mashing converts the starch present in milled malt and other suitable materials into fermentable sugars. The milled grain is mixed with water under controlled conditions so that naturally occurring enzymes can break down starches and proteins. The resulting liquid, known as wort, contains sugars and soluble compounds required for fermentation. Mash temperature, time, water quality and the composition of the grain bill influence the characteristics of the wort and ultimately affect the body, alcohol level and flavour profile of the finished beer.
Lautering is important because it separates the liquid wort from the solid grain material after mashing. The process typically involves allowing the wort to pass through a grain bed while retaining the spent grain. Proper lautering supports efficient recovery of soluble extract while limiting unwanted solids and excessive extraction of undesirable compounds. The clarified wort is subsequently transferred for boiling and further processing. Lautering performance depends on factors such as milling, mash composition, grain-bed permeability and process control.
The project report specifically identifies pale beer, dark beer and strong beer as beer categories. These styles can differ in colour, flavour, body, bitterness and alcohol characteristics because of differences in malt selection, formulation, brewing conditions and fermentation. Pale beers generally have lighter colour characteristics, while dark beers typically obtain deeper colour and flavour from darker or roasted malts. Strong beer is formulated to have a higher alcohol strength than standard beer, with the final characteristics depending on the recipe and production process.
A commercial beer manufacturing plant generally requires equipment for grain handling and milling, mashing, lautering, wort boiling, whirlpool separation, wort cooling, fermentation, conditioning, filtration and packaging. Depending on the process configuration, additional equipment can include yeast-handling systems, storage tanks, filling and bottling equipment, pasteurization systems and cleaning facilities. Plant design also needs appropriate utilities, process piping, quality-control facilities and material-handling arrangements. Equipment selection depends on the product range, process technology, production capacity and desired level of automation.
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