BOTSWANA COLLEGE OF AGRICULTURE

DEPARTMENT OF FOOD SCIENCE AND

TECHNOLOGY
NAME: MODIRI

SURNAME: SETLHOKA

STUDENT ID NUMBER: 201200117

PROGRAMME: BSC FST
COURSE: (FSB 412) BEVERAGE SCIENCE AND
TECHNOLOGY
A VISIT TO KGALAGADI BREWERIES LIMITED

INTRODUCTION
Kgalagadi Breweries Limited is a private business company in Botswana producing different
types of beer to supply the country and also for export. Kgalagadi brewery produce several beers
which include castle lite, black label, castle lager, St Louis expo, St Louis lager and Hansa. Beer
is the most popular and is the most widely consumed alcoholic beverage. At KBL beers are
processed from malted barley, water, hops, yeast and maize. The company uses the black, pale
and crystal malt. In most cases the malt is imported from Namibia or Europe (Germany and
France). The difference in these malts is due to the temperature at which they were made. It also
determines the beer colour. However, in other countries were barley malt is limited like in the
Southern and West Africa, beer is also produced from sorghum malt.
Objectives
To learn the brewing steps in beer production.
To have a visual observation of the brewing raw materials and equipment used.

MALTING STEPS
Malting
The kgalagadi breweries utilizes malted barley which come already malted from Namibia and
other suppliers, this malt has desired moisture content, desirable flavor and color. The malt is
stored before milling to mash. This malt is well dried malt and very stable and can be stored for
long periods under proper relative humidity of the storage environment.
Malt Intake
At first the adjunct (maize) is loaded into maize pit as well the malt. This is to say both maize
and barley malt has a loading pit where now the ingredients will be taken to the mash tank using
elevated bucket tank.
MILLING IN THE MILSTER
The malt is milled first to produce a range of smaller particles called grist. This makes the malt
easier to wet at the mashing stage and aids faster extraction of the soluble components from the
malt during the enzymic conversion. Roll mills are used to produce coarse grist for use with
lauter tuns. The fineness of grind is checked by analysis through a series of sieves. In this
company they also mill adjuncts inside the processing facility.

MASHING
Mashing is the process of mixing the crushed malt, and cereal adjuncts if used, with hot water
and letting the mixture stand while the enzymes degrade the proteins and starch to yield the
soluble malt extract, wort. The condition here favours beta amylase and alpha amylase in order to
give simple sugar. Mash separation is then carried out using equipment called a lauter tun.
During mashing, temperature, pH and mashing time are controlled because they determine the
quality of the beer produced and it depends on the type off yeast that is used either upper yeast or
bottom yeast. It is done at 70 C.
Wort Separation
For this company, the mash is then transferred to the lauter tun for extraction of the wort.
The principal objectives are to produce bright wort and to collect the maximum amount of sugars
(extract) from the residual solid materials. These solids are sold as animal feed.
Under Bag: temporary storage where the wort is kept awaiting to go to the wort kettle

Wort Boiling in the Wort Kettle.

Wort boiling is the process unique to beer production, as it is not required in the distilling or
wine production processes. The wort is boiled to concentrate and sterilize it. Boiling also
precipitates protein and induce colour development through Millard reaction. Addition of hops
also takes place here, together with adjunct and monosaccharide dextrose is added. This reduce
the chance of ending with many unwanted by products.
Whirlpool to remove the trub
The coagulated material formed during the boil is removed, after boiling the liquid containing
wort and hops for about 2.5 h, it is filtered through the hop residues. In this way the hop solids
and precipitated proteins are removed. In a whirlpool use high pressure (wheeling motion) for
sedimentation of the solids.
Wort Cooling/Aeration
The wort is cooled from almost boiling point to fermentation temperature through a heat
exchanger using water as the main cooling medium. The temperature for fermentation is
typically 8 to 13C for lager and 14 to 17C for ale. The resulting mash or wort is made ready for
fermentation. There is also oxygenation of the wort.

Yeast Pitching at Yeast Room

Yeast is pitched into the wort, directly into the cooled wort in the fermentation vessel. Typically,
5 to 20 million yeast cells are pitched per milliliter of wort. Air or oxygen is also added to the
wort as an essential factor for the production of yeast membranes and, hence, new cells.
Fermentation At the fermenting Vessel
Fermentation in brewing is the conversion of carbohydrates to alcohols and carbon dioxide or
organic acids using yeasts, bacteria, or a combination thereof, under anaerobic conditions. A
more restricted definition of fermentation is the chemical conversion of sugars into ethanol. After
the wort is cooled and aerated usually with sterile air yeast is added to it, and it begins to
ferment. It is during this stage that sugars won from the malt are metabolized into alcohol and
carbon dioxide, and the product can be called beer for the first time. Fermentation happens in
fermentation tanks. Fermentation stage starts at 18 C, 14C and then 0 and the beer stay for 18
days to complete the fermentation process

Yeast Removal
It is important to remove the bulk of the excess yeast before maturation, generally by removing
the beer from the sedimented yeast.
Aging
The maturation of the green beer to produce a stable, quality product suitable for filtration and
packaging is called aging or, alternatively, cold conditioning or cold storage.
In order to produce a beer of good colloidal stability in the final package, it is vital to promote,
by storage at low temperature, the formation of chill haze comprising flocs of polypeptides and
polyphenols. These can be removed by sedimentation (slow) or by filtration to give a bright,
stable product.
At KBL there is a trained personnel who is responsible for testing the maturity of the beer from
time and again.
Clarification

Some clarification is required for most beers. Filtration will produce a bright, sparkling
beer that will remain clear throughout its shelf life. A coarse depth filtration using
diatomaceous earth or perlite can remove most particles, but it can be followed by
filtration through a cellulose filter sheet to give a polished, almost sterile, product.

Packaging
At KBL the beer is packed in small pack that covers cans and bottles using the automatic filling
and sealing system that in installed in the processing facility.
Warehousing and Distribution
Finally, the beer is stored and distributed to the consumer in a good condition.
Conclusions
Kgalagadi breweries limited company is utilizing the most standardized system and procedures
of producing beer (brewing) which makes them to produce high quality beer which sells and
with acceptance to the consumers hence making profit.