Detailed Project Report on Manufacture of Distilled Spirits & Alcoholic Beverages

MANUFACTURE OF DISTILLED SPIRITS & ALCOHOLIC BEVERAGES

[EIRI/EDPR/1440] J.C. 222

INTRODUCTION

Whisky:-

Gin, vodka and related spirits like aquarit are distinguishable from whisky, rum and brandy which themselves have a number of common characteristics. The most evident difference is in colour with gin an vodka normally being colourless white whisky, rum and brandy vary in shade from straw-coloured to the deepest brown. This immediate difference is linked with distinguishing features of composition and flavour which are reflected in the methods of production of the two troup of sprits. The aurd whisky comes from the Gaelic word wisge-beatha, as the Irish called it, incoming the water of life.

The colour in whisky, rum and brandy oves it origin to the practice of ageing or maturing these spirits in wooden casks, which as containers have previously used for transporting some compatible liquid such as slerry, wine or molasses. Residues of previous contents, together with substance extracted from the wood itself, serve to give the maturing spirit a brown colour which in interest of standardization, is supplmented by the addition of caremel. The requirement for maturation in wood is now codified in lay standing whisky is the potable spirit obtained by distillation of an aquons extract of an infusion of matted barly and after cereals that has been ferriented with strains of sacctromyus ceramisial. Various types of whisky are produced in a number of different countries in the world. They differ principally in the nature and proportion of the cerels used as a raw materials along with matted barly and also in the type of still used for distillation. The principal types of whisky are also characterized of particular geographical regions of the world.

In Scotland, the characteristics product is manufactured using only matted barlay as the raw material and the fermented malt wort is distilled in batches in relatively small pot stills. The product, known as scotch melt whisky, is manufactured in relatively small distillations of which there are over hundred in Scotland. Scotch melt whisky is marketed both as a straight malt whisky. Rum, the alcoholic beverage made from sugar cane has been known for centuries.

The origin of the name "rum" is obscure. It may have been derived from the latin for sugar, saocharum. Another and according to some sources more prpbable, origin of the word rum is the Devonshire diaret word run (=run), which British colonists took with them to the west Indies. Equally prpbables is a derivation from the spanish 'ran' (=run), for the spaniards may will have had distilleries in the west before the arrival of the British.

Rum production is centured on the west Indies. The best known distilleries are situated in Jameica, Martinigue, Puerto Rico and Cuba, but Barbados, Trinidad, Haiti,  Guadetoupe, the hirgin islands, the Dominican Republic and Guyana (known as Domeraca in the rum trade). All have told traditions of making rum. Rum is also produced in the U.S.A.; Brazil Peru, Mexico and parts of Asia and Africa. In general, rum is produced wherever the climate is suitable for the cultivation of sugarcane. man brands of which have recently become extremly popular throughout the world and also as a blend with another type of whisky produced in Scotland, namely scotch grain whisky, or because it is distilled continuously in coffey type patent stills, as patent-still whisky. Most scotch whiskies available on the international market consist of blends with 30-40% malt whisky. Within the blend, there may be as many as 20-30 individual malt whiskies and grain whiskies. These blends are, by law, matured for atleast three years and, in practice, this period is normally much layer. Unblended scotch malt whisky are usually matured for a minimum of 8 years.

Throughout the world since at least the middle ages wine has been distilled to concentrate the alcohol to a higher percentage than occured in the original wine. These wines distillates have ben called aquavini, eaux-vie, weinbrand, cognac, branntwein, aguardienrite, aquarit and in English-speaking countries.

Brandy is produced from wine in many parts of the world mainly in France. Some of it is for industrial use. A small amount is used for fortifying dessert wines. That produced for beverage purposes may be divided into the following classes-cognac, Armagnac, eaw-de-via and eaux-de-vie demarc. Brandy is also produced in most of the wine producing countries.

The term whisky without further qualification is universally understood to mean the product of alcoholic fermentation of the juice of the grape and other fruits. This not only excludes the fermented product of other fruit juices but when the definition is made more ridid, as in a legal standard it is usually specified that the whisky shall be made by the usual cellar treatment. The purpose of this is not only to restrict the original crude material to the grape juice also to limit all additions to those substances that occur naturally in sound grapes or which experience has shown to be of distinct benefit to the flavour or keeping qualities of the whisky.

Although brandy, rum, & gin are substantially items in world markets, whiskies are by far the leading distilled alcoholic beverages; with those from Canada, Scotland & the U.S. accounting for most of the sales.

There are 3 types of whisky manufactured from ripe grapes and to the fruits i.e. dry wine, Sweet wine and sparkling wine.

A dry wine is one in which practically all the sugar certainly all that can be perceived by the taste has been by fermentation. Dry wine is wine in which the fermentation of the sugars is practically complete.

A term 'proof' will always come in this report with which we must be familiar:-

Proof: This term is connected with alcoholic liquor, which contains one-half its volume of alcohol of a Sp.gravity of 0.7939 at 15.6oC. i.e. the figure for proof is always twice the alcoholic content by volume. For ex: 100o proof means 50% alcohol by volume.

COST ESTIMATION

Plant Capacity            60,000 Ltr./Day

Land & Building (10 Acres)    Rs. 6.21 Cr

Plant & Machinery                    Rs. 18.65 Cr

Working Capital for 3 Months    Rs. 16.05 Cr

Total Capital Investment          Rs. 49.57 Cr

Rate of Return                          23%

Break Even Point                      65%

CONTENTS

INTRODUCTION

USES AND APPLICATIONS

MARKET SURVEY

FERMENTATION ALCOHOL WITH A RAW MATERIAL WITH REFERENCE TO INDIAN CONDITIONS

B.I.S. SPECIFICATIONS

PRODUCTION OF BRANDY

PRODUCTION OF SPIRIT FOR GIN

MANUFACTURING PROCESS OF WHISKY

MANUFACTURERS OF ALCOHOLIC BEVERAGES

COUNTRY LIQUOR FROM MOLASSES

USES AND SCOPE OF COUNTRY LIQUOR

PROPERTIES OF ETHYL ALCOHOL IN COUNTRY LIQUOR

MANUFACTURE OF COUNTRY LIQUOR

ALCOHOL BY FERMENTATION AND DISTILLATION

PROCESS FLOW SHEET OF COUNTRY LIQUOR

POLLUTION CONTROL IN ETHYL ALCOHOL INDUSTRY

B.I.S. SPECIFICATION

VARIOUS TYPES OF INDUSTRIAL ALCOHOL

PROCUREMENT OF PLANT & MACHINERY

PROCUREMENT OF RAW MATERIAL

BOTTLING SECTION

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)