Detailed Project Report on beer plant (brewery)

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The beer plant assists in the brewing process to manufacture beer by steeping a starch source in water and fermenting the liquid with yeast. Various traditional methods are otherwise used to produce beer. It needs to be noted well that the brewing industry is developed since the 19th century and has been active in most western economies.

The modern beer plant used in the brewing industry uses the basic ingredients of beer – which are water and fermentable starch source (such as barley). The beer plant us used to ferment the beer with brewer’s yeast. The starch sources that are typically used for the brewing process in the beer plant include sorghum, cassava and millet. The secondary sources include rice, maize (corn) or sugar.

The typical steps that are involved in the brewing process of the beer plant include malting, milling, mashing, lautering, boiling, fermenting, conditioning, filtering and then packaging. The three main fermentation methods used in the beer plant include warm, cool and spontaneous. The beer plant equipments have become more sophisticated with time and cover most aspects related to the brewing process.

The beer plant is installed by many dominant multinational players in the brewing industry. The 10 steps involved for manufacturing beer in the beer plant are mentioned in detail below:

1. MALTING

This is the first step in the production of beer. The fresh barley needs to be soaked well in water and put for germination. The enzyme – amylase is formed for the separation of starch. The germination stage is interrupted by drying. The green malt is carefully dried at 80 degree celsius. The malt sugar is then served well to feed the cultures of yeast.

2. MILLING

This is the second step in the process of brewing. The malt is then milled well in the making of the flour for better dissolution in water. Different grades of croshed malt are produced in malt mills such as semolina, meal, husks, groats, and so on.

3. MASHING

The third step in brewing in the beer plant is mashing. During this process, the starch in grist dissolves and tannin, sugar and protein are released. The malt extract is produced via this process of mashing.

4. LAUTERING

The brewing process in the beer plant involves this fourth step wherein the mash is filtered in the lauter tun as the worts separate and the husks sink from the solid substances. The spent grains are used as cattle fodder and the wort is used in process of brewing.

5. WORT BOILING

In this fifth step of brewing in the beer plant, the wort is boiled and the hops are added. The taste of beer depends on the amount of hops used. The tannin and protein elements are separated out to form the so-called ‘trub’ and the enzymes are deactivated during this process.

6. WORT CLARIFICATION

During this step, the wort is fed into the whirlpool and starts to rotate. The clear wort is cooled to a temperature between 10 degrees to 20 degrees celsius in the wort cooler.

7. FERMENTATION

This step takes place in the fermentation tank wherein special brewing yeast is added. The yeat is known to turn the malt sugar into carbon dioxide and alcohol.

8. STORAGE

The young beer is stored anywhere from between three months in a storage tank between 1 degree-2 degree celsius. The beer becomes clear and acquires the best of color.

9. FILTRATION

At this step, the substances still remaining after fermentation, such as – protein, hop resin and yeast particles are extracted and beer gets the final color.

10. FILLING

During this stage, the bottled beer and cans are filled in from the filling station. The beer is filled well using counter pressure to prevent any escaping or carbon dioxide. Barrels are filled in directly in the brewery.

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