Detailed Project Report on microbrewery & imfl distillation
Detailed Project Report on microbrewery & imfl distillation
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MICROBREWERY & IMFL DISTILLATION
[CODE NO.4068]
Alcohol has been widely consumed since prehistoric times by people around the world, as a component of the standard diet, for hygienic or medical reasons, for its relaxtant and euphoric effects, for recreational purposes, for artistic inspiration, as aphordisiacs, and for other reasons. Some drinks have been invested with symbolic or religious significance suggesting the mystic use of alcohol, e.g. by Greeo-Roman religion in the ecstatic rituals of dionysus (also called Bacchus), god of wine and revelry; in the christian eucharist, and on the Jewish Shabbat and Festivals.
Humans have been drinking alcohol for thousands of years. Alcohol is both a chemical and a psychoactive drug. In chemistry, an alcohol exists when a hydroxy group, a pair of oxygen and hydrogen atoms, replaces the hydrogen atom in a hydrocarbon. Alcohols bind with other atoms to create secondary alcohols. These secondary alcohols are the three types of alcohol that humans use every day: methanol, isopropanol, and ethanol.
In India, 'drinking' has remained a bad word, clubbed with the other vices. While the beer and liquor market continuous to grow at an impressive rate even against an impressive rate even against an economic reassion, the social stigma remains in place which manifests itself in anti-growth state policies. United Breweries (UB), shaw Wallacs and McDowell Cpart of UB group) presently dominate the liquor and beer market. The structure of the industry is clearly influenced by the regulatory environment and the consequent fragmentation of markets. The regulatory framework covers all these categories.
Besides these, there is a significant presence of illicitly brewed alcoholic beverages, which escapes the tax and regulatory net. We can have a look at an overview of Alcoholic beverage industry.
The Potable Sector Market
1. Indian Made Foreign Liquor (IMFL) –Whisky, Rum, Brandy, Gin & Vodka -180 million cases p.a.
2. Country Liquor –222 million cases p.a.
3. Beer (made from Barley and Malt)-170 million cases p.a.
4. Wine Domestic –1.5 million cases p.a.
IMFL and country liquor goes through the same manufacturing process and is distilled from the same agricultural source (molasses). The differences are in strength (the percentage of alcohol) and flavours. Add whisky or brandy flavours, for instance, and it becomes IMFL. Take the flavour to a tangier side, it’s desi daru.
“Both IMFL and country liquor use the same commercial reactive enzymes and multi-column distillation process. At a basic level, it’s the same. That’s the standard distillation equipment that gives rectified spirit.
Extra Neutral Alcohol (ENA) is the primary raw material for making alcoholic beverages. It is a colourless food-grade alcohol that does not have any impurities. It has a neutral smell and taste, and typically contains over 95 per cent alcohol by volume. It is derived from different sources — sugarcane molasses and grains — and is used in the production of alcoholic beverages such as whisky, vodka, gin, cane, liqueurs, and alcoholic fruit beverages.
Neutral spirits, also known as neutral alcohol, rectified spirits, rectified alcohol or ethyl alcohol is highly concentrated ethanol distilled until it reaches a min. ABV of 95% (190 proof). Neutral spirits can be made from grains, grapes, molasses, potatoes, and other agricultural origins. As the name suggests, neutral spirits are considered neutral in flavour, odour and are colourless. Having said that, there are some slight “flavour” variations among the neutral spirits, leading some to question if neutral spirits are truly flavourless.
Neutral spirits are widely used to make spirits such as vodka and gin, as well as to ‘cut’ liqueurs and make bitters, besides from its use in the spirits production the neutrality of rectified spirits also makes it useful in other industries such as the food, non-alcoholic beverage, pharmaceutical, perfumery, and cosmetics industry. It is common for neutral spirits intended for cosmetics and perfumes use to have denaturing agents added to it to reduce tax and to prevent human consumption.
Though consumption is still low, pattern of alcohol consumption vary widely through the country. Punjab, Andhra Pradesh, Goa and the north eastern states have a much higher proportion of male alcohol consumer than the rest of the country. Women tend to drink more in the state of Arunachal Pradesh. Assam and Sikkim in north-east; Madhya Pradesh, Chhattisgarh, Orissa and Andhra Pradesh in central and east India, and Goa in the west, compared to other states. Alcohol also provides and ‘excuse’ to behave in an uncontrolled manner, which make ‘controlled’ societies, like in many Asian countries, including India, even more at risk, where alcohol consumption tend to done without the knowledge of parents and family.
COST ESTIMATION
Plant Capacity 25500 Bottles/Day
Land & Building (14,000 sq.mt.) Rs. 9.63 Cr
Plant & Machinery Rs. 4.87 Cr
Working Capital for 1 Month Rs. 11.00 Cr
Total Capital Investment Rs. 26.64 Cr
Rate of Return 46%
Break Even Point 34%
INTRODUCTION
THE POTABLE SECTOR MARKET
BEER
HISTORY OF BEER
MICROBREWERY
PLANT LOCATION: CHENNAI
CLIMATE
TRANSPORTATION
BY FLIGHT
BY BUS
BY TRAIN
CLASSIFICATION OF BEER
ALES
LAGERS
EXAMPLES OF ALES:
ALCOHOL (% BY VOLUME): 6-12
ALCOHOL (% BY VOLUME): 4.2–4.8
ALCOHOL (% BY VOLUME): 5.0–7.6
ALCOHOL (% BY VOLUME): 5.0–7.6
ALCOHOL (% BY VOLUME): 7.0-11.0
ALCOHOL (% BY VOLUME): 4.5-6.0
ALCOHOL (% BY VOLUME): 7.0-9.0
EXAMPLES OF LAGERS:
ALCOHOL (% BY VOLUME): 3.5-4.5
ALCOHOL (% BY VOLUME): 4.0-5.0
ALCOHOL (% BY VOLUME): 4.0-5.0
ALCOHOL (% BY VOLUME): 5.0-6.0
ALCOHOL (% BY VOLUME): 3.8-5.0
ALCOHOL (% BY VOLUME): 4.5-5.4
ALCOHOL (% BY VOLUME): 5.0-5.6
ALCOHOL (% BY VOLUME): 4.3-4.8
BEER STRENGTH
BREWING-RAW MATERIALS
BREWING - THE RAW MATERIALS
MALT
GRAIN
BARLEY- PATIALA (OWN FIELDS)
MALT:
MALT BEFORE LOADING FOR MILL
HOPS
THERE ARE 3 FORMS OF HOPS
HOPES IN THE FORM OF FLAKES
YEAST
YEAST UNDER A MICROSCOPE.
WILD YEAST
ALE YEAST
LARGER YEAST
WATER
ADDITIVES & PROCESSING AIDS
ADDITIVES
ASCORBIC ACID (VITAMIN C)
SULPHUR DIOXIDE
CARAMEL
PROPYLENE GLYCOL ALGINATE
PROCESSING AIDS
LIST OF MACHINERY
MACHINERY TECHNICAL DETAILS
MILL SYSTEM
MASH TUN&LAUTER TANK
BREW KETTLE&WHIRLPOOL
HOT WATER TANK
REFRIGERATING SYSTEM - GLYCOL WATER TANK
BEER MANUFACTURE PROCESS
PROCESS OF BEER MANUFACTURING
MALT MILL
BREW HOUSE
MASH KETTLE
LAUTERTUN
WORT KETTLE
PLATE HEAT EXCHANGER
FERMENTATION
LAGGERING
PROCESS OF LIQUOR MANUFACTURING
THE MAKING OF MALT WHISKY
1. MALTING
2. MASHING
3. FERMENTATION
4. POT STILLS
5. DISTILLATION
6. SPIRIT SAFE
THE MAKING OF GRAIN WHISKY
THE MATURATION PROCESS
THE ART OF BLENDING
DIFFERENT TYPES ALCOHOL
THE THREE TYPES OF ALCOHOL
DISTILLED AND UN-DISTILLED ALCOHOL
UNDISTILLED DRINKS
BEER
WINE
HARD CIDER
MEAD
SAKÉ
DISTILLED DRINKS (LIQUORS AND SPIRITS)
GIN
BRANDY
WHISKEY
RUM
TEQUILA
VODKA
ABSINTHE
EVERCLEAR
ETHANOL FERMENTATION
MOLASSES
MOLASSES – FERMENTATION
THEORETICAL YIELD OF 37.5 GRAMS OF MOLASSES:
SUCROSE - FERMENTATION
THEORETICAL YIELD OF 37.5 GRAMS OF SUCROSE:
GLUCOSE – FERMENTATION
MATERIALS NEEDED
METHODOLOGY A. PREPARATION OF WORT
METHODOLOGY B. PREPARATION OF YEAST INOCULUM AND FERMENTATION
METHODOLOGY C. DISTILLATION OF ETHANOL
BEVERAGE ALCOHOL LABELING REQUIREMENTS
PACKAGING
: PACKAGING PLANT AT OF CANS AND BOTTLES
THERE ARE 3 TYPES OF PACKING MEDIA
CAN OF BEER OF 330 ML.
BOTTLES –
BOTTLE OF BEER 650 ML.
PROCESS FLOW DIAGRAM
FLOWCHART
FLOW CHART SHOWING PRODUCTION OF IMFL FROM ENA
BUSINESS COMPLIANCE FOR MICROBREWERIES IN INDIA
HOW TO STORE BEER
SOME TIPS TO STORE BEER ARE:
TOP INTERNATIONAL BRANDS LIST
SOME INDIAN BRANDS ARE:-
MARKET SURVEY
EXTRA NEUTRAL ALCOHOL MARKET: KEY SEGMENTS
EXTRA NEUTRAL ALCOHOL MARKET: REGIONAL OUTLOOK
EXTRA NEUTRAL ALCOHOL MARKET: KEY PLAYERS
CHOICE OF THE MASSES
1/3RD BY VOLUMES OF INDIAN ALCOBEV INDUSTRY
EXPANDING CONSUMER BASE: ~40% OF POPULATION
INDIAN SPIRITS INDUSTRY
INDIAN MADE INDIAN LIQUOR (IMIL) INDUSTRY
INDIAN MADE FOREIGN LIQUOR (IMFL) INDUSTRY
BUSINESS OVERVIEW
MANUFACTURING BUSINESS
CONSUMER BUSINESS
RATIONALE FOR INVESTMENT
OLD IS ALWAYS GOLD, BUT WHAT ABOUT PRESENT INDIA?
A VIEW INTO THE PRESENT MARKET
BEER MEASURES
SERVICE OF BEER
GLASSWARE
FAULTS IN BEER
BOTTLED/CANNED BEER STORAGE
GLOSSARY OF TERMS
PRINCIPLES OF PLANT LAYOUT
SOME OF THE FACTORS IN RAIL-TRACK PLANNING ARE:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW - MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME TTACK:
14. FLOOD AND FIRE CONTROL:
PROCEDURE AND INSTRUCTIONS FOR PROCUREMENT
E N A APPROVAL
ENA STORAGE
ENA ISSUE
QUALITY CONTROL TEST:
LIQUOR LICENSE: PROCEDURE FOR OBTAINING IT IN INDIA
TYPES OF LIQUOR LICENSE
DOCUMENTS REQUIRED FOR OBTAINING LIQUOR LICENSE
PROCEDURE FOR APPLYING FOR A LIQUOR LICENSE
VALIDITY OF THE LIQUOR LICENSE
GUIDELINES ISSUED BY THE EXCISE DEPARTMENT
RAW MATERIAL SUPPLIERS
MALTS
HOPS
YEAST
RAW MATERIAL SUPPLIERS
RECTIFIED SPIRIT/ ENA FROM DISTILLERY
MAIIL
INS 150 A NATURAL COLOURS
MACHINERY SUPPLIERS
COMPLETE MACHINERY
DESTONER
MALT MILL
BEER FILTER
FERMENTER
PASTEURIZER
ALCOHOL BOTTLING
PRODUCT PHOTOGRAPHS
BEER
IMFL
MACHINERY PHOTOGRTAPHS
MILL SYSTEM
MASH SYSTEM (MASH TUN&LAUTER TANK)
HOT WATER TANK
MASH PUMP
PLATE HEAT EXCHANGER HOPS FILTER
WORKING PLATFORM
WORT INSPECTION PLATFORM WORT BALANCE TANK
COMBINATION OF MASH PIPELINE
VENTURIFOUR-WAY (THERMOMETRIC
OXYGENATION COMBINATION）
MEASURING TUBE
BRIX MEASURING UNIT
SPENT GRAINS DISCHARGE RAKE
ELECTRIC STEAM HEATER
FERMENTATION TANK
REFRIGERATING SYSTEM - GLYCOL WATER TANK
STERILIZATION TANK
CONTROL CABINET
ALCOHOL DISTILLATION & BOTTLING
ALCOHOL TANK
ALCOHOL BOTTLING PLANT
INDUCTION BOTTLE SEALING MACHINE
LIQUOR BOTTLING LINE MACHINE
RAW MATERIAL PHOTOGRAPHS
BEER
MALTS
HOPS
YEAST
ALCOHOL
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)
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