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 A

REPORT ON

STUDENTS INDUSTRIAL WORK EXPERIENCE

SCHEME (SIWES)

BY

ANUMBA MICHAEL

CHE/13/422
 A TECHNICAL REPORT
ON
STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME
(SIWES)

UNDERTAKEN AT
NIGERIAN BREWERIES
NO. 1 MAKIRA ROAD INDUSTRIAL LAYOUT KAKURI KADUNA.

PERIOD OF ATTACHMENT
1ST MAY, 2017 TO 16TH OCTOBER, 2017

BY
ANUMBA MICHAEL
CHE/13/422

SUBMITTED TO THE DEPARMENT OF CHEMICAL ENGINEERING,

FACULTY OF ENGINEERING AND TECHNOLOGY, MADONNA
UNIVERSITY, AKPUGO CAMPUS, ENUGU STATE, NIGERIA.

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE

AWARD OF BACHELOR OF ENGINEERING (B.ENG) DEGREE IN
CHEMICAL ENGINEERING.

DECEMBER, 2017
 DEDICATION

I dedicate this report to God almighty whom has been the source of my strength
and health throughout my training programme and also my parents especially my
mother.

I
 ACKNOWLEDGEMENT
I want to thank God almighty in a special way for giving me life, strength of mind
and body to carry out the training scheme successfully. Not forgetting my loving
mum who has also been my source of inspiration and motivation not just during
the programme but in life generally.

I also appreciate the ITF body and those in-charge of this work experience scheme
for giving me the opportunity to learn outside the lecture hall and have an insight
on what working entails, coupled with acquisition of certain industrial skills.

I also want to use this medium to acknowledge the very hardworking and
wonderful Head of the Department of Chemical Engineering, Madonna University
Nigeria, Engr. .M. Omotioma for his invaluable and periodic advice, during the
training experience

II
 ABSTRACT

This report contains information pertaining to the Students Industrial Work

Experience Scheme (SIWES)/industrial training programme undertaken in a
brewing company (Nigerian breweries) that lasted for a duration of six (6) months.
The Students Industrial Work Experience Scheme (SIWES) is the accepted skill
training program which forms part of the approval of minimum academic standard
in the various degree programs for all Nigerian universities. The training was
centered on beer production processes for different brands, done majorly in the
brewing department of the company. Brewing is the production of beer by steeping
a starch source (commonly cereal grains, the most popular of which is barley) in
water and fermenting the resulting sweet liquid with yeast. For the Brewing of
Beer, four (4) essential raw materials are needed they are: Malt and Adjuncts, Hops
and Hop Products, Water and Yeast. Steeped grains such as malted barley are
milled to grist, then the grist is soaked with water and heated at a specific
temperature known as Mashing, the mash is then filtered to get spent grain and
wort, the wort is boiled furthermore and during this process, hops and adjuncts are
added to the wort. The wort is allowed to cool through the action of a plate heat
exchanger and then allowed to clarify. Yeast introduction known as yeast pitching
commences on the clarified wort and fermentation process begins. After
fermentation must have lasted for about 2-5 days the young beer is then filtered
with the aid of the Kiehsigur powder after which it is referred to as matured beer.
The matured beer is stored in a Bright beer tank (BBT) which is then sent to
bottling hall for packaging. The packaged beer is then sent to the logistics
department for sales and distribution to vendors.

III
 TABLE OF CONTENT
Cover Page

Title Page

Dedication.............. I

Acknowledgement...... II

Abstract... III

Table of Contents.... IV

List of Figures.. X I

CHAPTER ONE

INTRODUCTION

1:0 Background 1

1:1 Brief history of Nigerian breweries plc. . 2

1:2 Kakuri brewery products. 4

1:3 The mission of Nigerian brewery plc.. 4

1:4 The vision.... 4

1:5 The Kaduna brewery organogram... 5

CHAPTER TWO

2:1 Brief History of Beer.... 6

2:2 Raw Materials for Beer Production.. 6

2:3 Malt and Adjuncts..... 6

IV
2:3:1 Malting....... 7

2:3:2 Malting Process...... 8

3:3:3 Degree of modification.. 10

2:3:4 Adjuncts..... 11

2:3:4:1 Categories of Adjunct .....11

2:4 Hops...... 11

2:5 Water..... 12

2:6 Yeast...... 13

CHAPTER THREE

3:0 Beer Production Process... 14

3:1 Grains for Brewing.... 14

3:1:1 Silo Activities and Operations.... 16

3:1:2 Grains Intake .......... 17

3:1:2:1 Intake equipment...... 18

3:1:3 Milling..... 19

3:1:3:1 Milling Equipment.... 19

3:1:4 Description and Functions of Silo Equipment. 22

3:2 Brewing.... 29

3:2:1 Brewing: Mashing..... 29

3:2:2 Brewing: Mash Conversion.... 30

V
3:2:2:1 Biochemical Changes During Mashing... 32

3:2:2:2 Protein Rest.. 34

3:2:2:3 Gelatinization... 34

3:2:2:2 Protein Rest...... 35

3:2:2:3 Gelatinization... 35

3:2:2:4 Liquefaction..... 35

3:2:2:5 Saccharification... 35

3:2:3 Brewing: Mash Filtration... 35

3:2:4 Brewing: Wort Boiling... 36

3:2:4:1 Wort Concentration and Standardization. 37

3:2:4:2 Sterilization of Wort..... 37

3:2:4:3 Termination of Residual Enzyme Activities 37

3:2:4:1 Wort Concentration and Standardization. 38

3:2:4:2 Sterilization of Wort.... 38

3:2:4:3 Termination of Residual Enzyme Activities.... 38

3:2:4:4 Colour and Flavor Development.... 38

3:2:4:5 Eradication of Volatiles... 38

3:2:4:6 Formation and Precipitation of Hot Trubs... 38

3:2:4:7 Addition of Wort Copper Additives.... 38

3:2:5 Brewing: Wort Clarification... 39

VI
3:2:6 Brewing: Wort Cooling... 39

3:2:7 Brewing Wort Aeration... 40

3:2:7:1 Sterility of Air Used For Wort Aeration... 41

3:3 Fermentation.... 42

3:3:1 Fermentation Stages.. 43

3:3:3 CO2 Purity and CO2 to Engine room... 43

3:3:4 Dead Cell Purge.... 44

4:3:5 AE Weighing of the FV.... 44

3:3:6 Daily Temperature Check..... 45

3:3:7 Pressure Control.... 45

3:3:8 Duration of Primary Fermentation.... 45

3:3:6 Daily Temperature Check..46

3:3:7 Pressure Control.... 46

3:3:8 Duration of Primary Fermentation.... 46

3:3:9 RuH- Rest Under Heat (Warm Maturation) . 47

3:3:10 Yeast Harvest.. 47

3:3:11 Deep Cooling... 47

3:3:12 Cold Purging........ 47

3:3:13 Phases of Yeast growth during fermentation.. 47

3:3:9 RuH- Rest Under Heat (Warm Maturation) . 48

VII
3:3:10 Yeast Harvest.. 48

3:3:11 Deep Cooling.. 48

3:3:12 Cold Purging... 48

3:3:13 Phases of Yeast growth during fermentation.. 48

3:3:14 Fermentation Card... 48

3:4 Beer maturation/storage/lagering......... 48

3:5 Beer filtration... 48

3:9 Yeast and yeast management in Kaduna brewery 51

3:9:1 Yeast Rehydration and Propagation.. 51

3:9:1:1 Yeast Rehydration Tank. 51

3:9:1:2 Preparations for Rehydration. 51

3:9:1:3 Yeast Rehydration. 52

3:9:2 Primary Propagation. 53

3:9:3 Secondary Propagation. 53

3:9:4 Fermentation Stage...... 53

3:9:5 Yeast Generation and Nomenclature... 53

3:9:6 Yeast Pitching.. 54

3:9:7 Yeast Storage.... 54

3:9:6 Yeast Pitching... 55

3:9:7 Yeast Storage.... 55

VIII
3:10:1 Depalletiser. 56

3:10:2 Conveyor. 56

3:10:6 Empty Bottle Inspection (Ebi) .... 58

3:10:7 Filler/Crowner. 58

3:10:8 Full Bottle Inspector (F.B.I) .. 58

3:10:9 Pasteurizer... 59

3:10:9:1 Factors Affecting Pasteurization.. 59

3:10:10 Labeler... 60

3:10:11 Coding... 60

3:10:12 Packer 60

3:10:13 Full Crate Inspection (F.C.I) 60

3:10:14 Palletizer 61

3:11:0 Water Quality and Beer... 61

3:11:1 Water Treatment Plant.. 61

3:11:2 Raw Water Supply 63

3:11:3 Pre-Treatment 63

3:11:4 Lime and Alum Preparation and Dosing... 63

3:11:5 Sand Filters 63

3:11:6 Noritz Filter and Water Quality... 63

3:11:7 Softened (Service) Water 63

IX
3:11:8 Product Water.. 64

3:11:9 Ultra Violet Unit.. 64

CHAPTER FOUR
CONCLUSION AND RECOMMENDATION
4.1 Conclusion.... 65
4.2 Recommendations 65
Reference.... 67

X
 LIST OF FIGURES

FIG 1 The Kaduna brewery organogram... 5

FIG 2:1 Kilning.. 9

FIG 2:2 longitudinal section through a Barley grain.. 10

FIG 2:3 Structure Of Acids & Isomerization to Iso-- Acids... 12

FIG 3:0 Beer Production Process... 13

Fig 3:1 Brewing Operations Process Flow. 15

FIG 3:2 Typical Grain Intake Diagram.. 17

FIG 3:3 Typical Milling diagram... 20

FIG 3:4 Grain Milling Flow Chart. 21

FIG 3:5 Intake and milling diagrammatic representation... 21

FIG 3:5:1 Screw Conveyor. 22

FIG 3:5:2 Chain Conveyor. 23

FIG 3:5:3 Rotary Drum.. 23

FIG 3:5:4 Shaker Unit 24

FIG 3:5:5 Blower 24

FIG 3:3:7 Cyclone.. 25

FIG 3:5:8 Shaker Unit 26

FIG 3:5:9 De-Stoner... 27

FIG 3:5:10 Dust Aspirator.. 27

XI
FIG 3:5:11 Hammer Mill.. 28

FIG 3:6:0 catalytic cleavage action of -amylase 33

FIG 3:6 Mash filter.... 36

FIG 3:7 CO2 Purity Tester. 44

FIG 3:8 Brewing process flow... 50

FIG 3:8 Brewing process flow... 51

FIG 3:9 Depalletiser....... 56

FIG 3:10 conveyor.. 57

FIG 3:11 unpacker.. 57

FIG 3:12 Palletizer.. 61

FIG 3:13 Sand filter.... 64

FIG 3:14 UV unit.... 66

XII
 CHAPTER ONE
INTRODUCTION

1:0 Background

The Student Industrial Work Experience Scheme (SIWES) is a skill training

programme, which form part of the approved minimum academic standards in
various degree/diploma/NCE/B.ED programme for all tertiary institutions. It seeks
to bridge the gap existing between theory and practice of engineering, technology,
sciences and other professional educational programme in Nigeria tertiary
institution.

It is aimed at exposing students to machine and equipment, professional work

methods and way of safe guarding the work areas and workers in industries and other
organizations.

The scheme involves the tertiary institution, the industry (employers of the labour)
and the Industrial Training Fund (ITF). This was designed to improve technology on
how to meet with the condition of modern economic development. Again, there is
need for improving the efficiency of the countrys work force to keep developments
on the rise in the country. In order to achieve these developments in technology, the
scheme was introduced to supplement the theoretical aspect of learning for students
from the institutions with exposure to practical activities in various disciplines.

The attachment was a unique one in the sense that I was attached to all the sections
in the Brewing department. I was also attached to all the Shift Brewing Managers.
Thus, my overall experience went beyond the theory behind the chemistry,
enzymology, Carbohydrate catabolism and brewing.

More so, this report also contains a brief overview of the Silo, Brew house
Operations, Packaging and Water Treatment Process. Fortunately, during the period
of attachment in Kaduna Breweries, I was opportune to identify some unsafe
conditions in the environment, near misses and other environmental and energy
conservation problems.

In all, the attachment experience was a great one. A better understanding of the
brewing process, effects of enzymes, fermentation, yeast management and

1
carbohydrate catabolism was achieved. I also was able to find out key areas where I
needed improvements.

As part of the programme drawn for the attachment, I took charge of some Quality
Management Systems (QMS), management of floor stock of brewing materials,
Cold room stock management, weighing of enzymes and additives and lots more.
This provided me with more confidence and experience on the job and my discipline-
Chemistry Education. Severally, each day I always had discussions with My
Company Supervisor, The Data Admin Manager and other Shift Managers where
we discussed issues I had learnt as well as evaluating my learning process and
outcome. This was indeed very helpful.

At the end of the training attachment, we had a meeting with the Head Brewer, where
he discussed his assessment and evaluation of our performance during the period of
attachment. Aside commending our performances, he also highlighted areas of
improvements. He advised us on areas surrounding people (operator / other staff)
management, relationship with bosses, as well as how to be a good and competent
student and brewer.

1:1 BRIEF HISTORY OF NIGERIAN BREWERIES PLC.

Nigeria Breweries is proudly Nigerias pioneer and largest Brewing firm. The
company was incorporated in 1946 and in June 1949, it recorded a landmark when
the first bottle of STAR lager beer rolled off the Lagos Brewery bottling lines. This
first brewery in Lagos has undergone several optimization processes and as at today
boasts of one of the most modern brew house in the country.

In 1957, Nigerian Breweries commissioned her second brewery in Aba. The Aba
Brewery has also recently undergone several optimization processes and has been
fitted with best in brewery technology. 1963 witnessed the commissioning of the
Kaduna Brewery while Ibadan Brewery came on stream in 1982. In 1993, the
company acquired her fifth brewery in Enugu. A sixth brewery, sited at Ama-eke in
9th Mile, Enugu was commissioned and christened Ama Brewery in October 2003.
Ama Brewery is today the biggest and most modern brewery in Nigeria.

Operations in the Old Enugu Brewery were however discontinued in 2004. The
company acquired a malting Plant in Aba in 2008.

2
In October 2011, Nigeria Breweries bought majority equity interests in Sona
Systems Associates Business Management Limited, (Sona Systems) and Life
Breweries company Limited from Heineken N.V. This followed Heinekens
acquisition of controlling interests in five breweries in Nigeria from Sona Group in
January 2011. Sona Systems two breweries in Ota and Kaduna, and Life Breweries
in Onitsha have now become part of Nigerian Breweries Plc, together with the three
brands: Goldberg lager, Malta Gold and Life Continental lager.

In 2014, the company got approval from the Securities and Exchange Commission
and the respective shareholders of both Nigerian Breweries Plc and Consolidated
Breweries Plc to merge the operations of both companies. The merger became final
on December 31, 2014

Following the successful merger, we now have three additional breweries in Ijebu-
Ode, Ogun State, Awo-Omamma in Imo State and Makurdi in Benue State. The
merger also brought an additional seven brands into the companys portfolio.

Thus, from that humble beginning in 1946, The Company has now grown into a
Brewing Company with 11 breweries, 2 malting plants and 26 Sales depots from
which our high quality products are distributed to all parts of Nigeria.

Nigerian Breweries Plc has a growing export business which covers global sales and
marketing of our brands and dates back to 1986. NB Plc offers sales, logistics and
marketing support to make her brands shelf-ready in international markets, including
world-class outlets such as TESCO and ASDA Stores in the United Kingdom. Our
brands are available in over thirteen countries, across the United Kingdom, South
Africa, Middle-East, West Africa and the United States of America.

Kaduna Brewery is located in Kakuri area of Kaduna South Local Government Area.
The Brewery was commissioned in 1963.

The company is made of different departments listed below;

Human Resources Department

Administrative Department
Accounting Department
Logistic Department
Engineering Department
3
 Packaging Department
Brewing Department
Technological Department
Safety Department
Finance Department
Quality Assurance department.

1:2 KAKURI BREWERY PRODUCTS

Below are the list of products currently being produced by Kakuri Brewery:

Star
Gulder
Starlite
Goldberg
Life
33 Export
Maltina
Fayrouz (Pear and Pineapple)
MORE

1:3 THE MISSION OF NIGERIAN BREWERY PLC

"To be the leading beverage company in Nigeria, marketing high quality brands to
deliver superior customer satisfaction in an environmentally friendly way

1:4 THE VISION

To be a world class Company

4
1:5 THE KADUNA BREWERY ORGANOGRAM

Brewery
Financial
Controller

Security
Manager

ICT Manager ICM Relief

Regional
Logistics Mgr. Preventive
Maintenance Engr.
Brewery Safety
Engr. I/C Planned
Mgr.
Engineering

Engineering Automation Engr.

Mgr.
Automation Engr.
Brewery Human Resource Utility/BH
Manager Mgr.

Planning Mgr. Preventive

Maintenance Engr.
Technological
Controller
Process Technologist
Packaging
Packaging Manager

Shift Manager
Brewery Medical Doctor Packaging

Shift Manager Brewing

TPM Coordinator
Process Technologist
Head Brewer Brewing

Shift Manager Brewing

Public Affairs Analyst
Data Admin Mgr.

FIG 1 THE KADUNA BREWERY ORGANOGRAM

5
 CHAPTER TWO

LITERATURE REVIEW

2:1 Brief History of Beer

Beer was first brewed about 6000 years ago by the Sumerians. At about 14 th-15th
century, 275 liters of Beer was drunk in a year (460 bottles) as time went on beer
consumption increased as people took more beer and less water .Why? People
believed beer protected them from typhoid and cholera. This is not true anyway. But
beer was safer than the water they were drinking. How? Over the years, scientists
played important role to improve the quality of beer. Louis Pasteur discovered that
yeast is the microorganism responsible for beer production in sugar-containing
liquids.

Dr. Elion (A student of Pasteur) isolated the famous Heineken A yeast for the
production of Heineken beer.

2:2 Raw Materials for Beer Production

For the Brewing of Beer, four (4) essential raw materials are needed

They are:

Malt and Adjuncts

Hops and Hop Products
Water
Yeast

2:3 Malt and Adjuncts:

Cereal grains serve as source of sugar for brewing.

Several cereal grains are usually malted before they are used for Brewing to produce
Malt. Barley is the first cereal grains that was malted. Barley grain, just like other
cereals, contain starch as granules which are embedded in a protein matrix. This
matrix is surrounded by cell walls containing a gum called beta glucan. The starch
granules are therefore inaccessible to enzymes for conversion to sugar during
brewing. During the malting process the cell walls and the protein will be dissolved
6
by other enzymes which are produced naturally as the seed grows. This exposes the
starch for enzymatic breakdown during brewing.

2:3:1 Malting

The purpose of Malting is to:

1. Make the starch readily available during the mashing process to be converted
to a range of fermentable and non-fermentable sugars.
2. Provide a source of amino acids and proteins for the yeast to be able to grow
healthily during fermentation.
3. Develop desirable colours and flavors which are not present in barley itself
4. Produce a final product which is stable, capable of storage and transport to the
brewery.
5. Produce a food product which is wholesome and meets food quality criteria.

Cereal grains selected for Malting must meet certain specific requirements

It must be capable of germination, with a minimum 95% of the barley corns

ready to grow. Dormant cereal seeds are not suitable for malting.
The grains should be of an even size so that they are more likely to grow
evenly.
The grains should be of consistent colour. This helps to indicate that there is
no damage due to moisture etc. and also that they are of same variety.
The grains should be large. Large corns are easier to process when the malt
gets to the Brewery.
The corns must be undamaged, free of split or pre-germinated grains or dust.
The corn must be free of disease or pests such as beetles or moths.
They must be free of other cereals
The grains should be of same variety

2:3:2 Malting Process

There are 3 stages involved in the process of converting cereals (Barley, sorghum)
into malt:

Steeping
Germination
Kilning
7
 (A) STEEPING:

The grain is soaked in water to stimulate the conditions that start germination or
growth. This is carried out in a steep tank. During steeping, the grain is aerated. (By
draining and drawing air through the wet grain bed before resoaking).

Why aeration?

To reduce the number of grains dying off due to drowning.

To increase the rate of water uptake.

The barley is usually steeped and aerated a number of times-at the end of steeping
the moisture content of the grains should be around 45% depending on the type of
malt being produced.

(B) GERMINATION:

At the end of steeping the cereal seed is allowed to grow. During germination, two
major changes occur:

Firstly, Hormones stimulate the production of enzymes in the aleurone layer

Secondly, these enzymes start to act. During malting they will break down the
gummy cell walls and break down the protein matrix inside the starch
containing cells. This breakdown releases the starch granules making them
accessible for conversion into sugar. The changes taking place during
germination are called modification. The maltster can influence the degree
of modification during malting by controlling the moisture

FIG 2:0

8
Turners are also present in the germination chamber to turn/mix the grains from time
to time to prevent the growing roots from matting together and creating masses of
grains impermeable to the air. The time required for germination is basically around
4 days. Germination usually takes place in a chamber or vessel.

Air is blown or drawn through the growing malt for the following reasons:

To prevent it from suffocating in the CO2 produced

To control its temperature and moisture content

(C) KILNING

During this stage of the malting process, water is removed from the green malt. The
malt then becomes stable and can be stored without deterioration. The malt may also
be slightly roasted to give it colour and flavor. Some of the enzymes, for example
those required later in the brewing process for starch and protein conversion must
be preserved. The combination of high grain moisture and high temperature would
normally destroy or denature the enzymes developed during germination.

FIG 2:1 KILNING

3:3:3 DEGREE OF MODIFICATION

This is the extent to which the grains endosperm cell wall, proteins and to a lesser
extent the starch granules are broken down during malting.

9
The Malting Process produces Malted cereals as explained above. Barley is the first
cereal to be malted. Other cereal grains such as Sorghum, Wheat can also be malted.
Malted Barley is the major raw material for making beer.

Longitudinal section through a Barley grain

FIG 2:2 Longitudinal section through a Barley grain

2:3:4 Adjuncts

Other sources of starch apart from barley malt are regarded as adjuncts. These
include:

o Malted sorghum
o Raw Sorghum
o Barley
o Rice
o Sucrose (Sugar)
o Wheat etc.

2:3:4:1 Categories of Adjunct

Malted Cereals: Coloured Malt-Crystal Malt, Carapils and Munich Malt,

Amber Malt, Brown Malt, Black Malt and Chocolate Malt, Malted wheat,
Malted Sorghum
Processed Cereals: Roasted Barley, Torrified wheat, Wheat flour, Maize grits,
Maize flakes
Unprocessed Cereals-Rice, oat, wheat, sorghum, Rye, barley
Sugars or Syrups-Sucrose, Glucose, HMS, Lactose, Caramel
10
 2:4 Hops

Hops contribute to the flavor and appearance of beer. They provide beer with its
characteristic bitterness and aroma. The alpha acids from hops improve foam
stability and provide beer with protection against some spoilage organisms. Hops
provide the bitter taste in beer (with alpha acid the principal precursor). The oils
provide aroma. Hops contribute to beer texture (mouthfeel). Hops have bacteriostatic
properties which protects beer against some biological spoilage organisms. Hops
reduce over foaming during wort boiling. Hops aid in protein coagulation during the
boil. Hops are a foam active agent in beer.

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FIG 2:3 STRUCTURE OF ACIDS & ISOMERISATION TO ISO-- ACIDS

Although alpha acids are the source of bitterness in beer, they are largely insoluble
in cold water. During wort boiling the alpha acids are isomerized into iso-alpha acids
which are much more soluble.

The hops being used in Nigeria Breweries are hop extracts containing isomerized
alpha acid and we use it in the Wort Copper. Isomerized alpha acid can also be added
after fermentation.

11
Processed hop products like pre isomerized hops (pre isomerized alpha acid) are a
convenient and controlled system for adding bitterness and aroma to the beer.

Hop extracts are produced by extracting the bittering compounds from the
hops using solvents such as ethanol and CO2 (Liquid CO2)

2:5 Water

Beer contains almost 95% water. Water could be from any source i.e. borehole,
surface water (river), Public water supply. Water must be of the highest quality
(Water used in NB Plc for brewing meets world class standards.)

2:6 Yeast

A living micro-organism that converts malt sugars through cell division

into alcohol during fermentation. There are two types of yeast:
bottom and top yeast. Beers fermented with bottom yeast are called lager and those
fermented with top yeast ales.

12
 CHAPTER THREE

3:0 BEER PRODUCTION PROCESS

Six major steps are involved in Beer Production Process

FIG 3:0 Beer Production Process

For the Brewing department, its own leg of Beer Production starts at milling and
stops at Filtration. Milling is, however preceded by grains receipt and storage

13
 WEAK SUGAR/HOPS
HOT WATER 850C WORT
TANK
YSV
PITCHED
WORT
MC MT ALCOHOL
WATER IN
GRITS GRITS WATER

BIN
WATER WC
Ma
MIXER sh W
FERMENT
Filt
P P
ING
er O H
MAS MAS VESSELS
OL
H H
E
COP TUN

MASH
COOLE TRUB OUT
R HOLD REMOV OUT
SPENT ING.V AL
GRAIN ESSEL
STEAM SILO .
AMBIENT
WATER
STEAM

RECYCLED

WORT

Fig 3:1 BREWING OPERATIONS PROCESS FLOW

3:1 GRAINS FOR BREWING

Grains are primary material/substance required for brewing of beer the

administration and processing of the grains are been carried out in the SILO
department. Below are the activities and operations carried out in the department

3:1:1 SILO ACTIVITIES AND OPERATIONS

There are Ten Silos in all. Eight (Silo 1-Silo 8) of which has a capacity of 250
tons, while the remaining two Silos (Silo 9 and Silo 10) are of 150 tons
14
capacity. Silo 9 is currently not in use due to damages, although its been
programmed for Repair. Operations around the Silo is currently monitored by
the Brew House operators, in conjunction with a third party Contractor. They
report directly to the Shift Brewer on duty. More so, third party cleaning
contractors are responsible for cleaning the silos, the immediate environment
and changing of dust bags in the silo.

The duty of the silo operator are:

Receipt of grains and grits into the designated silos.

Milling of grains / transfer of grits to brew house.
Autonomous Maintenance
Call technicians (mechanical/automation) during breakdowns.
Documentation of the quantity of grains / grits received.
Silo reconciliation when empty.
Notification of fitter for mechanical and fitting jobs.
Weekly cleaning of dust lines and dust chambers.
Notification of lab analyst to check the moisture and fats content of
grains / grits before intake.
Notification of senior lab analyst to take samples during milling for sieve
analysis.
Inter silo transfer of grains.
Daily stock taking.
Documentation of all process carried out.
Operation of panels in the silo.

3:1:2 GRAINS INTAKE

The vehicle for grains discharge is weighed into the premises by the weigh
bridge clerk and also confirmed by the shift brewer. The truck is driven to the
silo and positions itself on the grains intake pit. The truck position itself in
such a way that there can be no fuel or oil ingress into the intake pit. Silo
operator confirms the type of grains in the lorry and on the waybill and also
confirms from the shift brewer which silo the grains will go to.
15
Silo Operator calls lab analyst (Entrance control) to take samples for analysis
(grains like malted sorghum and malted barley come with certificate of
analysis, but raw/ white sorghum dont). He confirms the silo to receive the
grains has been cleaned, fumigated and fumigant removed. After, the silo
operator confirms the silo to receive grains has the same grains and that the
lines to receive the grains has previously been cleared; the conveyors the
rotating screen; the shaker, scale and cyclone has been cleared of dust, chaffs,
stones, iron particles and other foreign grains. If not, the silo operator does the
cleaning.

As soon as all the necessary due process are confirmed and the grains are
confirmed to be received, the operator opens the grains from the lorry
positioned on top of the grains intake pit and regulate flow of the grain into the
intake pit. Hence, grain receipt commences and are stored in the silo.

16
FIG 3:2 Typical Grain Intake Diagram

3:1:2:1 Intake equipment

Troughed chain conveyor

Screw conveyor
Bucket elevator
Weighing scale
Rotary drum
Cyclone
Dust blower
Dust chamber
Classifier ( Shaker)
Bar magnet
De-stoner
Storage Silo

17
3:1:3 MILLING

This is the process of size reduction of grains, so as to release trapped extracts in the
grain and to increase the surface area of contact of the grains for mashing. Milling
is also necessary so that enzyme can easily reach and transform the endospermic
materials in grains like starch, protein, -glucan etc. into soluble constituents.

To begin the brewing process, malted barley is run through the mill to crush the husk
of the barley this in turn exposes the fermentable starches within. After being milled
the grain is referred to as grist. The grist is then fed into the Mash Tun kettle (Tank).
Other adjuncts like malted sorghum, raw sorghum, maize are fed into the Mash
Copper.

3:1:3:1 Milling Equipment

Storage Silo
Discharge conveyor
Screw conveyor
Bucket elevator
Classifier ( Shaker)
Bar magnet
De- stoner
Weighing scale
Hammer mill
Dust blower
Dust chamber

18
FIG 3:3 Typical Milling diagram.

19
FIG 3:4 Grain Milling Flow Chart.

In general, the intake and milling diagrammatic representation is as follow:

FIG 3:5 Intake and milling diagrammatic representation

20
3:1:4 DESCRIPTION AND FUNCTIONS OF SILO EQUIPMENT

(a) Intake-Pit

The standard method of unloading malt from bulk road transport is by tipping the
malt into a reception pit (intake-pit). Bulk malt intake rates vary. It is essential that
the malt offloading pit be protected from the weather both during and between uses.

(b) The Screw Conveyor

This is used to transport the bulk of the grain in horizontal direction only. It consists
of a screw in a horizontal or slightly inclined tube. They are gentle in action. It is
usually used for moving grains and grist to the designated grain or grist case.

FIG 3:5:1 Screw Conveyor

(c) Bucket Elevator

This is used for vertical transportation of the grains .The bucket elevator is made of
continuous synthetic fabric, rubber coated belt. This is housed in a metal trucking
that runs vertically over a top pulley and under a boot pulley.This is achieved by
means of the cups which are secured onto the endless canvas belt at an interval of 5
cups per meter length of the belt.The elevator casing is fitted with explosion relief
flaps for over load.

21
 (d) Chain Conveyor

This is responsible for the horizontal transportation of the grains. This is achieved
by means of screwed on scrappers who run through the trough. The scrappers are
fixed on the single bush roller chain. The chain and flight conveyor is enclosed. It
consists of a continuous chain. This bears transverse flights that run over drive and
guide sprockets at each end of the run. The upper part of the chain is supported on
guides. The lower part slides along the base of the case. Malt is fed into the top of
the casing through the chain links at one end and discharged from the bottom at the
other end.

FIG 3:5:2 Chain Conveyor

(e) Rotary Drum

This is used to separate chaff, straw, leaves and other coarse impurities from the
grains. The grains pass through the holes on the rotating drum sieve while the other
impurities are separated and discharged at the inclined end of the reel. A hood
mounted on the unit is connected to the dust aspiration unit for dust extraction. The
screens are circular. They rotate and the grain moves along.

FIG 3:5:3 Rotary Drum

(f) Classifier(Shaker)

This is the unit where heavy dirty particles are removed by the action of a vibrating
screen. It has dual screens. The grains fall through the first screen which entraps
coarse materials. On the second screen, sand and other fine impurities are separated

22
and they are discharged through the chute which leads into a hopper at the bottom
of the screen. The grain is further passed into a sifter by means of a regulating flap
where the content is subjected to high aspiration. This fluidises the grains and any
leftover impurities are finally separated. The sifted grains then falls through a
chamber that has a bar magnet, this will attract any iron particle carried over in the
grains to safeguard the mill from wear.

FIG 3:5:4 Shaker Unit.

(g) Dust Extraction (Blower)

The process for malt intake, storage and treatment is described in the process
description Raw Materials Intake, Storage and Treatment The silo equipment are
equipped with dust aspiration units. This sucks the dust resulting from the grains and
prevents emission of the dust into the surroundings. Blowers serve same purpose
during intake and milling of grains.

FIG 3:5:5 Blower

23
 (h) Weighing Machine

This is an automatic mechanical weighing machine. It works on the principle of

moments and lever. A predetermined quantity of grain will cause the hopper to tip
over and dump the content into elevator bucket to the storage silo. The unit has an
automatic closing flap to prevent grains entering during discharge.

FIG 3:5:6 Weighing Machine

(i) Storage Silo

The silo is where grains used for the brewing process are cleaned, preserved and
stored separately until required for processing.The gross capacity of silos for the
storage of raw materials will be determined with the net Consumption of raw
materials in tons per week. The valley angle should be at least 35 degree from the
horizontal to ensure clean emptying.

(j) Cyclone The dust cyclone is use to exhaust effluent air full of dust during
grain intake. The receiver and dust cyclone are often combined into a single
vessel.

FIG 3:3:7 Cyclone

24
 (k) Classifier (Shaker)

These are sieves with vibrator motors to separate grains from husks and light
particles by air stream from the aspiration box sifter unit. There are some small
rubber balls that tossed by the vibration against the sieves to ensure that no grain or
particles are trapped in the sieve holes in order to keep the screen clean.

It is essential that pieces of metal that may be in the malt should be removed before
they reach the mill, because such metal can cause a spark and start a fire or explosion.
Separation is effected by placing permanent magnets either in the malt chute to the
dressing machine or across the feed to the mill. Malt should flow over the magnet in
a thin layer and at the same rate as it is being ground, thus allowing the magnet to
extract any metal that may be in the malt.

FIG 3:5:8 Shaker Unit.

(l) De-Stoner This is the machine where any leftover stones in the grain are
removed. The machine comprises a special wire mesh mounted in a sieve box
mounted on springs with vibrators and air aspirator unit. The entire assembly
is inclined by means of an adjuster to keep it at the required angle to effect de-
stoning operation. Due to the vibration and cushion of air, the grains are
fluidised (lifted) and suspended by the air. The grains will migrate towards
the upper part of the screen while the stones because of weight are not affected
by the air cushion will travel to the lower side of the screen from where they
are discharged into a container for disposal. The angle of tilt and air flow must
adjusted to suit the type and condition of grain being handled.

25
 FIG 3:5:9 De-Stoner

(M) Dust Aspirator (Blower)

Dust is a dangerous substance because of the risk of explosion and also Irritation to
the lungs. It is now covered by COSHH (Control of Substances Hazardous to Health
Act) regulations and it is extremely important that dust is not allowed to accumulate.
If a film of dust appears, measures must be taken to eliminate the source of dust and
vacuum any deposits the presence of dust would indicate a failure in the dust
extraction system or leak in the plant.

An electrically driven fan sucks the dust through metal ducts or pipes from various
points such as the elevator, dresser and weighing machine. There are several ways
of dealing with the dust collected; it may be blown into a cyclone from which it
drops down into a bagging point.

FIG 3:5:10 Dust Aspirator

26
(n) Hammer Mill

The machine consists of a cylindrical chamber onto which shafts are mounted. Each
shaft has plates [beaters] fitted onto it. The cylinder is fitted onto a shaft driven by
an electric motor. The motor has dual rotation capability. This is used intermittently
during operation to use either sides of the beaters and ensure uniform wear. The end
of the beaters can be interchanged when one is worn out so that the other end can be
used. The feed box to the mill has a flap that direct the grains to the milling chamber
depending on the direction of rotation of the machine. This is achieved by means of
a pneumatic cylinder. The direction changeover can only be done when the machine
is not running. When the selector switch is changed, the flap actuating cylinder will
activate a micro switch which changes the pole of the motor connection. A magnetic
separator mounted in the feed box removes ferrous material to prevent damage to
the machine.

In a hammer mill all raw material can be milled: malted barley/malted sorghum,
barley, rice, sorghum. Note that the husks are milled as well. By means of

Mechanical transport (e.g. chain or screw conveyor) the grist are transfer to the brew
house and stored in the grist-bin until required for processing.

FIG 3:5:11 Hammer Mill

27
3:2 BREWING

Brewing itself involves the following processes:

Mashing
Mash conversion
Mash Filtration
Wort boiling
Wort Casting
Wort Clarification
Wort Cooling
Wort Aeration
Wort Pitching

3:2:1 Brewing: Mashing

Mashing a brewing term used to describe when ground malt and solid adjuncts (grist)
are mixed with a set volume of water. A specific temperature is used. The
temperature is set to get the best action from the enzymes in the malt.

The mash can be slightly thicker or thinner depending on the recipe.

The malt enzymes convert the starch to sugars. This makes wort.

During Mashing,

Starch is converted to sugar.

Proteins are broken down to Amino Acids.
PH drops. This is due to Calcium reacting with malt compounds.
And at the end of mashing:
Most enzymes become inactivated during the mashing process

3:2:2 Brewing: Mash Conversion

The rate and nature of extraction of the soluble materials during mash conversion
depends on:

Temperature
pH
concentration(Mash thickness)
28
 time
a. Temperature:

Temperature is one of the most important factors in controlling enzyme reactions.

The initial mashing temperature is set by a combination of the mashing water

temperature (the strike heat) and the temperature of the ground grist. It is important
to take account of the malt temperature. The heat it contains affects the final mash
temperature and is subject to seasonal variations.

Before mashing it is usual to preheat the mash vessel. This prevents a reduction in
mash temperature. All connecting pipework should be similarly heated to prevent
heat loss.

b. Mash pH

The correct mashing pH is essential for correct enzyme action and extraction. The
following table shows some mashing pH required to optimize the saccharification
process.

Character pH Value
Shortest saccharification 5.3 to 5.6

Greatest extraction-infusion 5.2 to 5.4

Greatest extraction-decoction 5.3 to 5.9
Highest fermentability 5.3 to 5.4
Mash will not filter < 4.7

Favorable adjustment of mashing pH ensures:

Improvement in extract and TSN (Total Soluble Nitrogen)

Reduction in wort color
Improved wort filtration performance
Improved break formation in the kettle
Improved break gives improved beer clarity
Lower pH results in more protein breakdown and less polyphenol
extraction. This gives better shelf life.

29
pH has a major effect on enzyme activity.

pH is controlled mainly through the composition of the brewing water. The

additions of calcium and magnesium ions lower the mash pH. They react with
proteins and phosphates from the malt. Bicarbonate salts from the liquor raise the
mash pH by reacting with hydrogen (H+) ions.

It is therefore necessary to reduce the bicarbonate (temporary hardness of the

brewing water) and to add mineral salts to regulate the pH for brewing.

The final pH of the mash is a compromise between the best pH for the different
enzymes present.

Mashing event Best pH

alpha-amylase activity 5.3
beta-amylase activity 5.7
Protease activity 4.6 - 5.0

c. Mash Thickness (Concentration):

Mash thickness affects wort composition. Thinner mashes encourage greater heat
inactivation of beta-amylase enzymes. This leads to a beer with a reduced extract of
fermentable sugars.

Typical mash thickness is 2.5 litres of liquor to 1 kilo of grist for infusion systems.
It is up to 5 litres (usually around 3.5 litres) of liquor to 1 kilo of grist for decoction
and temperature-programmed mashes.

In addition to an increase in beta-amylase activity, thicker mashes will protect the

more heat sensitive proteolytic enzymes.

3:2:2:1 Biochemical Changes During Mashing

In this section we will identify the biochemical changes during mashing, name
FOUR important enzymes in malt and identify the optimum temperatures and pH
for enzymes to work.

These Enzymes can break down starch to sugar. The two important ones are:

30
 Alpha Amylase
Beta Amylase:

There are two other important enzymes in malt.

Protease
Beta Glucanase.
a. - and Amylases:

In barley, -amylase occurs naturally in the barleys endosperm, while -amylases

are developed during malting in the aleurone layer. Only little -amylases are
developed compared to the level of -amylases present. Both attack the -1, 4-
glycosidic bonds of amylose and amylopectin molecules. In the case of -amylase,
it is an endothermic enzyme, leaving the -1, 4-glycosidic bonds at random giving
basically glucose and limit dextrin. While the -amylase also attacks -1, 4-
glycosidic bonds, giving pairs of glucose units (maltose) and in some few cases
maltotriose, living limit dextrines.

Both - and - amylases do not attack branched chains, i.e. at the -1, 6-glycosidic
bond.

Diagram to show the catalytic cleavage action of -amylase

Glucose
unit

Diagram to show the catalytic cleavage action of -amylase

FIG 3:6:0 catalytic cleavage action of -amylase

31
 b. Limit Dextrinases:

These are endo-enzymes that cleave both -1, 4- and -1,6- glycosidic linkages to
convert the limit dextrins to fermentable sugars. They are mostly added as
exogenous enzymes, but when added in large amount,

Will greatly increase the attenuation limit of the beer by giving more of
fermentable sugars.
They will lead to the production of less palate full beer.
c. -Glucanases:

These enzymes are produced in limited quantity during malting of barley. They are
small in quantity in poorly modified malt; so exogenous -glucanases are used
during mashing, when brewing with these types of grains. They cleave the -1, 3-
and -1,4-glycosidic bonds. In well-modified malt, these enzymes should degrade
about 70% of the -glucans present in the endosperm. Beta Glucanase breaks down
beta glucan. If Beta Glucan is not broken down it can cause filtration difficulties and
extract loss.

d. Proteolysis Enzymes:

These are responsible for the breakdown of proteins into amino acids and peptides.
They cleave proteins at their amino-carboxyl bonds (peptide bonds). They include,
exo-carboxy/amino peptidases, endo proteases etc. Carboxyl peptidases occur
naturally in barleys endosperm. They are responsible for degrading about 40% of
barleys protein during malting for good malt and degrade substantial amount of the
remainder proteins during protein rest in mashing.

Protease breaks down protein to give Amino Acids. These are essential for yeast
growth.

3:2:2:2 PROTEIN REST

Proteolysis is a term used to describe enzyme action that breaks down proteins into
simpler soluble forms. The action of proteolytic enzymes is very similar to that of
starch breakdown enzymes, except that their optimum temperature is slightly lower
at 50-54oC and pH 5.5. It becomes necessary for proteolysis to take place during
mashing in when the malt is under modified and the protein surrounding the starch
granules have not been completely broken down.

32
Mashes with under modified malt, for example, Lager (Beer) malt, will allow this
by having a low temperature stand for proteolytic enzymes to work (Protein rest),
followed by a saccharification stand for the starch enzymes to work. Mashes with
well modified malt only need a saccarification stand. At the end of Protein rest, about
35-40% of the mash protein are dissolved .This is known as Total Soluble Nitrogen.
Amino acids are formed. Much of the surplus protein is left behind in the spent grains

Amino acids make up 10-15% of the TSN and are an essential source of nutrient for
yeast growth. The usual concentration of soluble (free) amino nitrogen (FAN) in
wort is required to be above 160 mg/l. lower levels can lead to a bad fermentation.
Amino acids are also involved in a number of other growth mechanisms. They
produce flavor active compounds. These contribute to the final flavor of beer.

3:2:2:3 GELATINIZATION

In hot aqueous solution a large amount of water is absorbed by the starch granules
to swell and finally burst to release a viscous solution. The degree of viscousity
depends on the extent of water uptake and varies from one grain type to another.
This physical process of swelling and rupturing (bursting) is called gelatinization,
and occurs at different temperature for different grains.

3:2:2:4 LIQUEFACTION:

This is the enzymic reduction in the viscosity of the starch solution by essentially -
amylases activities. This action prevents the formation of set mash. This process, is
a very critical process in brewing.

3:2:2:5 SACCHARIFICATION

This is the complete breakdown of starch and complex sugars to produce simple
sugars and few dextrins by amylases (mostly -amylase). Starch degradation is
monitored using iodine test which gives blue black colouration when added to starch.
Undegraded starch and larger dextrins cause starch haze in beer.

Saccharification at temperatures below 68oC favours formation of more simple

sugars than dextrins (because of optimum temperature of -amylase being 66oC),
while temperatures above 68oC up to 72oC favour formation of more dextrins.

33
3:2:3 Brewing: Mash Filtration

During Mash Conversion, several products are extracted into the mashing water.
Mash Filtration process separates this liquid, called wort from the Separate grains.
Mash Filtration is achieved in either a lauter tun, a wide vessel with a false bottom,
or a mash filter, a plate-and-frame filter designed for this kind of separation. Mash
filter is the separation equipment in use in Nigeria Breweries. A mash filter is a plate-
and-frame filter. The empty frames contain the mash, including the spent grains. The
plates contain a support structure for the filter cloth. The Mash is pumped against
the Filter cloth and clear liquid (wort) is produced.

FIG 3:6 Mash filter

During this step, the filtration cake is going to be formed progressively on the filter
cloths. The mash flow into the Filter from the mash tun, controlled by the set point
of the wort flow and is limited by a maximum pressure at the mash inlet. The clothes
filter the mash to produce clear worts which is collected in the Holding Vessel or in
the Wort Copper. When the minimum level in the mash tun is reached the mash tun
is rinsed with hot brew water.

The main wort filtration stops when the mashtun is empty.

3:2:4 Brewing: Wort Boiling

After mash filtration/wort separation the wort is boiled. Hops and sugar/liquid
adjunct (if required) are added at this stage.

34
Wort boiling is the most energy intensive stage of the brewing process. Not only
does the wort have to reach boiling point, but it is usual to evaporate between 2%
and 10% of the kettle contents. A successful boil must be vigorous.

The wort is boiled for about an hour in a kettle or copper. Hops are added during
the boil to provide bitterness and aroma. Boiling also improves the physical (haze)
stability of the beer and kills any micro-organisms which could infect the beer and
cause flavor problems

Benefits of Wort Boiling

Inactivation of enzymes
Sterilisation of the wort
Coagulation of proteinaceous material out of the wort
Formation of proteinaceous/polyphenol complexes
Formation of flavour and colour complexes.
Fall in wort pH
Concentration of the wort gravity through evaporation of water.
Removal of volatile compounds from the wort.

3:2:4:1 Wort Concentration and Standardization

This involves the evaporation of excess sparge water used during sparging, or
concentration of the wort via evaporation. Since boiling involves a lot of energy
consumption, it is necessary not to over boil more than requirements, so that energy
can be conserved. The norm for evaporation rate is (5-8%.)

According to Heineken standard,

Eqtn.

Evaporation rate = (A-B) x 100%

Where, A= initial volume of wort after filtration and before boiling.

B = final volume of wort after boiling.

3:2:4:2 Sterilization of Wort

Many destructive microbes, which pass from the malt into wort, are destroyed during
wort boiling. Many of the thermophilic (heat resistant) bacteria, which survived the
35
relatively lower temperatures of other processes before wort boiling, cannot survive
wort-boiling temperatures (which at or a little above 100oC). Heating up to 100oC
normally starts at a time, that boiling will corresponds with end of filtration, this is
to prevent rapid bacteria growth and adaptation (like the lacto bacteria growth.).

3:2:4:3 Termination of Residual Enzyme Activities

Any residual enzyme activity carried over from the mashing activity is stopped
during wort boiling. Especially those of thermos-stable enzymes like -amylase and
carboxyl peptidase.

3:2:4:4 Colour and Flavour Development

Wort boiling, results to the formation of Melanoidines from the reaction of amino
acids with simple sugars in the wort, which impact characteristics colour and flavour.
Also, during boiling there is caramelization of sugar extracts, to enhance colour.
Hops added during wort boiling, also impacts its own colour and flavour.

3:2:4:5 Eradication of Volatiles

Undesirable gases that are formed during mashing activities and boiling are
eliminated in the wort copper. Example, dimethyl sulphide (DMS), which is a very
volatile Sulphur compound, can be detected in beer at low flavour threshold by its
unpleasant smell and test.

3:2:4:6 Formation and Precipitation of Hot Trubs

The polyphenols of hops and cereals dissolve completely in wort and form complex
compounds with proteins. Such complexes are insoluble in hot wort and precipitate
during wort boiling as hot trubs (hot break). It is highly desirable to precipitate these
breaks as completely as possible during wort boiling, so that,

They do not precipitate much later downstream of product.

To reduce the level of trubs in the fermenting medium which will greatly blind
the yeast.
To reduce load during beer filtration.

Vigorous boiling, boiling at a reasonable time of roughly 1hour and boiling at an

optimum pH for breaks, which is at 5.2, enhances hot break formation.

36
3:2:4:7 Addition of Wort Copper Additives

These are added to enhance the quality of the wort in the following ways,

To concentrate the wort in terms of extracts yield. This is added as wort copper
adjuncts. These can be granulated sucrose sugars and caramelized dextrose
malt.
To improve wort inorganic nutrient for yeast. Example, Zn +2 (ZnCl2), this
assist protein synthesis in yeast cells and control their nucleic acid (DNA) and
carbohydrate metabolism. Ca+2 (CaCl2 or CaSO4) this is added to aid
flocculation of yeast after fermentation and assist in some important yeast
metabolism.

3:2:5 Brewing: Wort Clarification

When wort boiling is finished we must separate:

The hop debris (spent hops)

The coagulated protein (hot break or trub) before cooling

The break consists of Polyphenol-protein materials, Insoluble salts, and some hop
resin materials, Heavy metals such as copper or iron, and Trapped sweet wort.

Trub is being removed because if not, it can cause:

Poor yeast performance & poor attenuation

Poor fermentation : leading to infection
Difficulties at the filter
Hazes and flavour problems

The process of wort clarification is carried out by Sedimentation or filtration. In

Sedimentation solids are removed by:

Natural gravity: Settling Tank

Induced gravity, e.g. whirlpool.

The whirlpool is the common wort clarification system being used in Nigeria
Breweries. It is a circular vessel. The wort is introduced tangentially. A tangential
inlet of around 200 with an inlet velocity of 3.5 m/s generally performs satisfactorily.
The circulation makes a force. This accelerates the trub particles towards the centre.
37
They form large flocs which then settle down the centre line of the vessel to form a
trub cone. The trub is removed by spray jets in the base of the vessel.

3:2:6 Brewing: Wort Cooling

After boiling and clarification, the hot wort in the whirlpool, must be cooled to about
(8-9) oC before the introduction of yeast, else the yeast cells are killed. Rapid cooling
is usually done with the use of the Plate Heat Exchanger (PHE). It is important
that cooling is rapid, so as to prevent microbial activities, which is possible if the
wort is allowed to stand for too long at the intermediate temperature. Also, it is
necessary to cool rapidly in order to avoid the adaptation of the microbes to the high
temperature differential.

The temperature of fermentation is also important. Too high can produce undesirable
esters/higher alcohols. Too low and fermentation will slow and may not complete.
Wort cooling describes the process between the end of clarification and the actual
collection of wort in the fermentation vessel. If this process is not correctly managed,
it can have serious consequences for the subsequent beer quality.

Addition of yeast is done to the cold aerated wort during wort cooling. The process
of adding yeast to the cold aerated wort is known as Yeast Pitching. Cold wort
temperature is usually 7-9 deg.C for lager beer. During yeast pitching, the following
is taken into consideration:

Yeast Consistency: Expected consistency for good quality yeast slurry is

pegged at 60%
Yeast Viability-This measures no of live cells(norm:95% viability);and dead
cells(norm:5%dead-cells)
Yeast Vitality-The healthiness of Yeast Cells
The yeast slurry must also be free from microbiological contamination

During cooling of the wort, the reduced wort temperature results to an increase
in wort turbidity. This turbidity arises from the formation of protein/polyphenol
complexes, which are about 0.5m in diameter. These complexes are known as
cold breaks or fine breaks or cold trubs. Because of the small sizes of these
cold breaks, they settle with much more difficulties than hot breaks, as such, can
easily adhere to the yeast cells, thereby blinding or coating them. This prevents
any nutrient uptake, leading to prolonged fermentation.
38
3:2:7 BREWING WORT AERATION

As soon as the wort leaves the PHE it is aerated. There is a wort aeration panel beside
the PHE that guarantees a sterile aeration with the aid of pall air filters. Wort is
aerated because oxygen is needed for cell wall formation via synthesis of unsaturated
fatty acids and sterols by yeast cells, prior to fermentation. Wort is never aerated at
high temperature because, this might result in the formation of irreversible oxidation
coloured complexes that are detrimental to beer flavor and quality in general.

Over aeration of cold wort can result in over multiplication of yeast cells, which in
turn translates to high extract losses. Under aeration on the other hand, will result to
sluggish cell wall formation and ultimately a prolonged fermentation.

The norm for oxygen content in cold wort is (7-9) mg of O2/litre of cold wort at
15oC. The aeration of cold wort for yeast nourishment is the only time during the
entire beer production process that oxygen is deliberately added. The oxygen is taken
up within few hours and as such does virtually no damage to the wort quality.

The wort for malt drinks (unfermented products) are not aerated, but carbonated. In
this case the wort aeration line is changed with the CO2 line for carbonation. Apart
from carbonating the wort for malt drinks, the carbonation also prevents aerobic
microbes from thriving in the wort.

A rich wort will provide

All the nutrient energy (Carbohydrate in form of sugar)

Growth materials such as amino acids, vitamins and minerals to support yeast
growth.

3:2:7:1 STERILITY OF AIR USED FOR WORT AERATION

This is very necessary in brewing, so that wild yeasts, bacteria, other air microbes,
oil and other impurities are not introduced into the wort. The process of aerating
with sterile air starts from the engine room (utilities) to the aeration point in the
brew house.

The air is taken from suction points in the engine room, which are equipped with
air filters. From these suction points, the air is admitted into the compressors,
which compresses the air to high pressure of 6.0bar and resultant high temperature.
The high pressure and temperature ensures that all living microbes are destroyed,
39
since no living organism can survive at the pressure of 6.0bar.The air is passed
through the dryer for de-moistening and temporary storage at the dry air storage
tank. From this dry air storage tank, the air is taken to the brew house for aeration.

At the brew house, the air is passed through a micro-filter known as PALL filter
(after the designers of the filter) and the pressure reduced to 4.0bar from
6.0bar.The micro-filter (PALL filter) is made up of membrane materials with pore
size of less than 0.1m which prevents the passage of bacterial (which has size of >
0.4 m) and other microbes from passing. Giving relatively clean air.

From time to time, (about one day frequency check), the laboratory checks the
purity of the air, using deferential algae culture.

3:3 FERMENTATION (5 10 DAYS)

Fermentation involves simply the utilization of wort sugars. The yeast also
nourishes itself with other nutrients in the wort. It utilizes the oxygen in the wort to
make cell wall materials. As soon as yeast is added into the wort, it begins to
breakdown the sugar during respiration in the presence of the added oxygen to yield
CO2 and water. (Aerobic respiration)

During the aerobic respiration, the yeast cells undergoes multiplication (by budding)
so that we have large amount of yeast cells in the wort.

After sometime (<2 days), the yeast exhausts all the oxygen in the system. Further
breakdown of sugar continues in the absence of oxygen to yield alcohol and
CO2.This process is known as fermentation.

Yeasts find it more and more difficult to ferment the larger saccharides. Hence,
Sugars are taken up in a specific order,

Firstly the mono-saccharides, glucose and fructose

Then the Di-saccharides, maltose
Then the tri-saccharides 3 molecules, maltotriose

40
Yeast is the only living organism which can change from respiration to fermentation.
During fermentation, the concentration of sugar (original gravity) reduces, alcohol
production increases, CO2 and heat is also produced. About 80% of the sugar in the
wort is broken down by the yeast in 6-8 days. The heat produced increases the
temperature of the Fermenting wort. Because of the heat generated, the fermenting
vessels is equipped with cooling systems.

The temperature of the fermenting wort is maintained at 15-16C during

fermentation.

3:3:1 Fermentation Stages

Cleaning and Disinfection

The FV for wort receipt should have been cleaned and disinfected before wort
cooling. In Kaduna a combination of Soda, ATR B and Septacid are used for
cleaning and disinfection. The Date/hour of cleaning and type of disinfectant used
(septacid) are documented in the fermentation card

3:3:2 Filling of the FV

FVs in cellars 2, 3 and 4 are filled with 2, 5 and 5 brews respectively

Usually the first brews are pitched, while all the brews are aerated (Lagers
only)
It takes about 4hrs to fill a cellar 2 tank and about 12 hours to fill the FVs in
cellars 3 and 4. This also depends on the location of the FVs
The time it takes to fill the tanks are also documented in the fermentation card

3:3:3 CO2 Purity and CO2 to Engine room

At (Twenty-Four) 24 hours after the end filling, the purity of the CO2 emitted from
the FV is measured with the CO2 purity tester and if found to be at least 99.7% pure,
it is the diverted to the engine room. Prior to this desired purity, the CO2 is assumed
to be impure is vented to the atmosphere. In some cases, some vessels do not emit a
reasonable amount of CO2 and even when they do, the purity could still be below
the norm. There could be various reasons for this ranging from under-pitching, over-
aeration/under-aeration, the temperature of the FV being lower than normal due to
cooling not closed to the tank, the yeast used to pitch the wort could be infected, of

41
low consistency, vitality and viability. The sent time, hour and day and purity value
of CO2 sent is also documented on the fermentation card

Each of the FVs has a foam catcher to help trap foam to avoid foam and liquid carry
over to the CO2 compressor. In Kaduna, there is a central foam catcher where all the
CO2 lines from the FVs in the cellar are connected to. This helps to trap any foam
that could have been trapped on the CO2 lines. The water level in this central foam
catcher should always be monitored to ensure it does not dry up or fall below the
level mark

The CO2 Purity Tester

KOH Funnel
CO2 inlet valve
KOH inlet valve
CO2 Bulb
Calibrated column
Hose to connect burette
to AP sampling point

Flask containing 33% KOH

solution

FIG 3:7 CO2 Purity Tester

3:3:4 Dead Cell Purge

Dead Cell Purge is done 24 hours into filling, to purge off the yeast dead cells from
the cone of the FV. The dead cells are the highly flocculent yeasts of low viability
and vitality, most of which would have been dead. These dead cells could impart off
flavours and reduce the microbial stability of the young fermenting beer, hence the
need to purge them out. Dead cell purge is done by flash purging the FV. Swiftly
opening and closing the outlet valve of the FV

4:3:5 AE Weighing of the FV

The tanks are weighed for AE at mid-night every 48 hours, and results
documented on the Fermentation Cards
42
 The AE drop will give an indication on when to declare RuH.
This weighing is done by the SMB with the aid of the Saccharometer. AE is
expected to drop within the range of the V5 (usually between 2.3 to 2.7 oP)

3:3:6 Daily Temperature Check

The fermentation temperature of 15.5 oC is maintained with the aid of the FGH
temperature controller
The fermentation card has provision for 8 hours temperature markings done
every 1200hrs, 0800hrs, and 1600hrs.
During the primary fermentation stage, the temperature of the tank is expected
to rise steadily (but not sharply) to about 15-15.5oC. Then fermentation
cooling is closed to the tank at least 24 hours prior to RuH. From experience,
when the AE drops to about 4-50P is when we close fermenting cooling.
The temperature then rises and maintained at 16 oC until the end of RuH and
deep cooling is opened to the tank and the temperature is expected to drop to
between 0 to -1oC.
Though the temperature of the tanks are controlled with the aid of the FGH
temperature controller on the control panel, still the manual cooling valves are
operated (closed or opened) to ensure adequate temperature control.

3:3:7 Pressure Control

The pressure safety valves (over pressure and under pressure valve) must be
in good working conditions
During Filtration, a pressure of about 1 bar is applied on the FV to suppress
foam and guard against over foaming
During the CIP, the tanks are depressurized

3:3:8 Duration of Primary Fermentation

The primary fermentation usually lasts 5 to 7.5 days During this stage the
temperature is maintained at 15 15.5 oC and only allowed to rise to 16 oC at least
24 hours to the end of this stage (i.e. 24 hours to the declaration of RuH.

3:3:8 AEFA (Apparent Extract Final Attenuation)

Theoretically this means the final attenuation AE of the young beer. It is the stage at
which further fermentation cannot lead to a fall in the extract content of the beer.
43
This is analyzed in the lab by subjecting the wort/beer into a sequence of forceful
fermentation until no subsequent drop in the AE is noticed. The AEFA value usually
in the range of 1.4 to 1.8 oP gives us an idea of the AE at start of RuH. Usually RuH
is declared at a range of AE close to the value of (AEFA + 0.5)

3:3:9 RuH- Rest Under Heat (Warm Maturation)

This is a period of warm maturation during which the temperature of the young beer
is allowed to rise to about 16oC. This is to guarantee vigorous yeast activity to mop
up some flavor compounds like VDK (diacetyl inclusive), esters, fusel alcohols,
aldehydes, etc.The yeast mop up these flavor compounds to bring them within norm
characteristic of the ideal flavor profile of the beer. In Kaduna, cooling is closed to
the tank at least 24 hours to the commencement of RuH. This is to ensure a quick
kick off of this warm maturation phase. RuH is usually done for 2 -3days depending
on the duration of the primary fermentation stage. Normally, RuH is declared when
the AE reaches a value equal to (AEFA + 0.5). The RuH is expected to bring down
the diacetyl norm to about <1.0 mg/l before cooling can be opened to the FV

3:3:10 Yeast Harvest

The yeast is harvested 28 4 hours into RuH. The tank if flash purged, about 10 hl
harvested to the Spent Yeast Tank (SYT) and about 2000 liters harvested into the
Yeast Cropping Vessel (YCV). All harvest must be captured and measured using the
harvest flow meter. There is a main yeast harvest pump and a second pump to boost
the pumping efficiency of the main pump. This is owing to the fact that the harvested
yeast had to travel a long distance to the only flow metre used for yeast harvest.

3:3:11 Deep Cooling

At the end of the RuH period, deep cooling is opened to the tank to enable the
temperature of the beer drop to as low as 0 to -1oC. At this temperature the remaining
yeast cells flocculate and sediments to the cone of the CCV. It takes about 2 3 days
to achieve this fall in temperature. It is not always unusual to have the beer remain
in storage at this low temperature for an extended number of days. There is no harm
in this as long as the FV is constantly flash purged to remove flocculated yeast cells.

44
3:3:12 Cold Purging

Prior to filtration, the FV is cold purged into one of the storage lines to the centrifuge.
The centrifuge recovers more beer from the yeast bottom/cold purge. Before the
yeasty bottom enters the centrifuge, there is a mixer (new construction) to reduce the
yeast load by introducing DAW to mix with the yeasty bottom before entering into
the centrifuge

The use of the Centrifuge helps to combat extract loss at the cellars

3:3:13 Phases of Yeast growth during fermentation

The initial phase of fermentation reveals a "lag phase" in yeast growth. This is caused
by the yeast re-adjusting to its environment and beginning to absorb the nutrients
ready for growth. This is followed by a rapid growth phase, starting between 6 and
12 hours after pitching. By 24 hours the growth phase is well under way with a
logarithmic growth pattern. Growth is only limited by physical parameters such as
temperature and the availability of nutrients such as amino acids (F.A.N.) and by the
presence of oxygen. The growth phase is followed by a fermentation phase which is
limited by available sugars, free nitrogen, and the increase in alcohol level and to a
degree by temperature. The final stages of fermentation are slow and it is where the
yeast tends to "mop up" available nutrients that are available.

Most of the yeast flocculates and settles to the bottom after the sugar in the wort is
exhausted/after the fermentation is completed. Flocculated yeast is removed from
the fermenting vessels (Yeast harvesting/cropping) and stored for reuse/re-pitching
or drained if it will not be needed for repitching.

After fermentation is completed, most of the yeast settles but some yeast remains in
suspension in the green beer. Still at temperature of 15-16 C, Some intermediate
fermentation products still present in the green beer is broken down further or
reduced by the yeast in suspension .This takes about 2-3 days and the period is
known as ruh. This helps to remove some undesirable flavor in the green beer.
(Warm Maturation). After 2-3 days ruh (Rest under Heat) period, the green beer is
cooled from 15-16C to Zero.

While the beer is being chilled to zero and at zero degrees, some other suspended
materials in the beer settle to the bottom and can be removed.

45
The beer can be kept /stored for 1 or more days at zero degrees. (Cold
maturation/Cold Storage)

3:3:14 Fermentation Card

The fermenting card is a card that shows details of fermentation within a particular
storage vessel. Each fermentation vessel has its own card that would give a quick
summary of the fermentation stage of that particular vessel. By looking at an updated
fermentation Card, one can predict any activity or information about the content of
the vessel and the vessel itself.

In Kaduna brewery, the fermenting card is opened by the brew house operator. The
left figures on the fermenting card represent 0P (for AE). While the right represents
temperature measured in 0C.

3:4 BEER MATURATION/STORAGE/LAGERING

Reasons for storage (lagering) are to:

Continue fermentation to scavenge air.

Continue fermentation to remove undesirable flavor substances.
Increase the CO2 Saturation of the beer (Conditioning)
Aggregate and precipitate the haze forming compounds of protein and
polyphenols
Clarify the beer through the settlement of yeast and suspended solids
Improve flavor through slow secondary fermentation.

3:5 BEER FILTRATION

Beer has to be clear when packaged to:

Prevent further biological changes taking place during or after packaging due
to yeast or haze particles

Beer Filtration is the operation that gives the beer its clear quality, eliminating the
last remaining traces of clouding still in suspension. It consists of pumping the liquid
through a suitable filter. The filtered bright beer is then stored in tanks, now ready
to be bottled.

46
Filtration is passing un-clarified beer through a porous medium, the solids are
retained in or on the medium. The clarified product stream passes through the size
of the pores and the depth of the filter path determines the size and number of the
particles which are retained.

47
Summarily, we have the Brewing process flow thus:

B K
r .
e B
.
w F
2
i 1 Grist Bin
Grist Bin 2 0
n (Malted 1 sorghum &
(Malted
5
Maize)
g barley)
:
Steam Steam
B Process Water - 3
* Mash Tun *4Mash Copper Process Water -
03
rBrewing Additives - 03
Brewing Additives -
02 02
e *5Mash
w Cold Water Cooler Hot Water
h
o *6Mash Filter 7 Distribution e.g.
u Spent Grain to farmers
s 8 Silo
Weak Wort
e*
Vessel
Water *9HoldingVesse
l
Steam
Process Water -
03 & Sugar -
Hops *10Wort Copper Evaporated
01 Water
Brewing Additives -
02

Process Water -
03 *11Whirlpool Trub
Trub collection
Alcohol tank
Water Tank
Hot Water
Cold Water *12PHE - 02 SMT - 02

Aeration - 04 Carbonation - 04

13
YSV - Yeast FV - 02
02 Pitching
FIG 3:8 Brewing process flow

48
3:9 YEAST AND YEAST MANAGEMENT IN KADUNA BREWERY

It has been an age long axiom that the greatest friend of a brewer is the yeast. This
has placed yeast management at the centre stage in beer production. In Kaduna
brewery, yeast management encompasses the following
1. Yeast Rehydration and Propagation
2. Yeast Pitching
3. Yeast Harvesting
4. Yeast Storage
5. Yeast Disposal

3:9:1 Yeast Rehydration and Propagation

Yeast is rehydrated to bring it back to life, since the yeast is supplied in dried forms.
Propagation is aimed at producing a large proportion of yeast in the most stable
condition to ferment wort and be subsequently cropped, stored and re-pitched into
subsequent brews.

3:9:1:1 Yeast Rehydration Tank

The rehydration of yeast is done in the yeast rehydration tank (which is in an

enclosed, sterile room often referred to as the yeast rehydration room. The YRT is a
cylindrical vessel with capacity of 165 litres. It has the wort, hot water and DAW
supply lines. It has a stirrer, driven by a motor of frequency 50 hertz, for
homogeneous mixture of the wort and yeast during propagation. There is also a
pump that serves both for CIP circulation within the YRT and the adjoining hose
connections up to the inlet of the yeast propagation vessel (YPV) and also for
pumping the rehydrated yeast from the YRT into the YPV at the end of rehydration

3:9:1:2 Preparations for Rehydration

Prior to the main rehydration stage, the sterilization of the YRT and the lines up to
the YPV is carried out. Hot water (80 85 oC) is used for the proper sterilization
which also involves circulating the hot water within the YRT for about 30 minutes.
Then the lines are chilled down with DAW admitted into the vessel from the DAW
line that leads into it. About 40 litres of Star wort cooled to the rehydration
temperature of about 11oC is admitted into the YRT form the YPV. The wort must

49
have received a double dose of ZnCl2 and should have been adequately hopped
during the boil in the wort boiler.

Achieving a Sterile/Aseptic Condition during Rehydration

The rehydration room must be germ free to guarantee a microbiological stable

rehydration cum propagation.
The floor and walls of the room should be confirmed neat
The air conditioning system should be up and running effectively
The yeast pack, scissors used for cutting the pack, the lid of the YRT and the
walls and floors of the room should be disinfected with the aid of alcohol
(80% vol)
All human contact with the yeast pack, the rehydration room and tank must
be done aseptically.
There should be no more than one person in the room.
The door must always be shut and properly too.
There should be no chewing, coughing, spitting, laughing or talking while in
the Rehydration room

3:9:1:3 Yeast Rehydration

Three packs (i.e. 3 kg) of the LM 07 yeast is rehydrated

40 liters of star wort is used (since this is the minimum for an effective
rehydration).
The camping gas (burner) is lit and place on the top of the tank, very close to
the lid.
The scissors and the yeast pack are sterilized. The scissors is sterilized by
dipping in alcohol for about 5 minutes. It is removed, the alcohol allowed to
dry up for a while and completely dried up by gently moving it over the flame.
Care must be taken as alcohol is highly inflammable. The yeast pack is
sterilized by using cotton wool soaked in alcohol to clean/wipe the pack.
The inlet of the tank should have also been sterilized with the alcohol.
The scissors is then used to cut open the vacuum pack to let off the vacuum.
Gentle pressing of the yeast pack is done to remove the clogs.
The powdery yeast is then emptied into the tank, the stirrer put on to prevent
clogging.

50
 The yeast is rehydrated for about 4 hours before it is pumped into the yeast
propagation vessel for the primary propagation stage

3:9:2 Primary Propagation

At the expiration of the 4 hours of propagation, the yeast is pumped into the
YPV that already has about 40 hl of wort and a new fermenting card is opened
for the propagation tank
There is continuous aeration with sterile air, and the temperature is maintained
at 11oC
The AE is constantly monitored until it falls to between 6 8 oP
This then marks the end of the primary propagation

3:9:3 Secondary Propagation

One brew (270 Hl) (wort cooled to 11oC) is used to top up the yeast in the
YPV
Another fermenting card is opened to monitor the progress of AE drop
The temperature is also maintained at 11oC
There is 20 minutes aeration every 2 hours until the AE drops to between 6
8 0P
This marks the end of this stage of propagation.

3:9:4 Fermentation Stage

The fermenting wort is now transferred to the fermenting vessels and topped
up with either 3 brews (for the FVs in cellar 3) or 4 brews (for the FVs in
cellar 4)
The fermentation process progresses according to the basic recipe

3:9:5 Yeast Generation and Nomenclature

The same basic principles apply to yeast generation and nomenclature in Kaduna.
The only slight and negligible difference is with the yeast nomenclature. Freshly
propagated yeast is Generation 0 yeast. After its first harvest, it will become
Generation 1 yeast and subsequently Generations 2, 3, 4 and 5 after the 2nd, 3rd,
4th and 5th harvests respectively. Previously, the yeast nomenclature takes the form
S-A(X) B

51
Where

S stands for the brew used for propagation (usually Star brew)
A stands for the month of propagation (usually represented numerically from
1 12)
X (which could either be 1 or 2) stands for the number of propagation for
a particular month; and
B stands for the generation of the yeast

*Recently, due to the birth of SAP Heicore, the nomenclature now takes the form S-
A-B

Where
S and B still stand for the same as previously stated
A now stands for the number of propagation in a given year.

3:9:6 Yeast Pitching

Yeast pitching in Kaduna brewery has been simplified with the provision of a yeast
pitching table. In order to aid accurate pitching, there is a yeast pitching table that
shows the kilogram (kg) equivalent of the yeast pitching flow meter reading (in
liters). This table gives at a glance the amount of yeast to be pitched against a
corresponding yeast consistency (in %), number of brews, which depends on the
cellar in which the wort is cooled to (4 brews for the FVs in cellar 3 and 5 brews for
the FVs in cellar 4). It is always ideal to pitch the first brew going into a FV. If for
whatever reason the first brew is not pitched, with the knowledge of the Head
Brewer, the second brew to the same FV must be pitched.

3:9:7 Yeast Storage

Yeast cells harvested/cropped from the FVs are stored in the Yeast Cropping Vessels
(YVC). There are 3 YCVs. One of 30 hl capacity and the other two of 20 hl capacity.

The yeast is stored for a period not more than 72 hours. Ideally any storage lasting
more than 72 hours should be drained. The yeast cells are expected to be stored at
temperatures not more than 2 oC. The YCVs have cooling jackets to achieve this
storage temperature. A pressure of not more than 1 bar is expected to be put on the
vessels.

52
3:9:8 Yeast Harvest or Cropping

Yeast harvest is done from the FV 24 hours into RuH. Prior to harvest into the YCV,
about 10 hl is drained into the Spent Yeast Tank. Care is taken while doing this in
order not to drain more than necessary. Then about 2000 liters are harvested into the
YCV for storage. All harvest from the FV are captured and measured using the yeast
harvest flow metre.

3:9:9 Yeast Disposal

The brewery practically has nothing to do with the yeast drained into the Spent Yeast
Tank. Third party contractors come regularly to empty the tank.

3:10:0 PRODUCT PACKAGING

The bottling hall popularly called packaging department, performs the operation of
reducing large volume of the product to a smaller volumes (bottle). The department
also provides some useful information such as, the best before date, the ingredients
used, the brand name etc, to the consumer, by labeling the bottles.

The reduction of large volume into smaller volume is achieved by the use of
machines. The machines are listed below:

De-palletizer
Unpacker
Bottle Washer
Crate Washer
Empty Bottle Inspector (E.B.I.)

Filler/Crowner
Pasteurizer
Labeller
Full Bottle Inspector (F.B.I.)
Packer
Palletizer

53
3:10:1 DEPALLETISER

Depalletising is the removal of crates from the pallets and putting the crates on the
crate conveyors. The crates are stacked in five layers and two patterns. Using the
breadth of the crate, the pattern for a layer is four vertical crates, then three horizontal
crates, and a repetition in that order. For the next layer, the pattern will be reversed
starting with three horizontal crates.

The first step in depalletising is using forklift to put the pallet in the pallet
conveyor, which transports the pallet to the depalletiser. The bottling hall has four
independently operating depalletisers. The depalletiser removes (picks) the crates
layer by layer and puts the crates on the crate conveyor. The empty pallets will be
transported on a carriage (pallet conveyor) on rails to a pallet-checking zone. The
pallet inspection is performed by a group of rollers that exerts pressure on the pallet.
Depending on the response gotten, the bad ones will be rejected and stacked by the
pallet turner to be evacuated by forklift. Meanwhile, the empty good pallets will be
stacked by the pallet turner and transported on a pallet conveyor to the palletizing
group of four palletisers.

FIG 3:9 depalletiser

3:10:2 CONVEYOR

The conveyor conveys bottles or crates as the case might be from one machine to
another. The conveyors are chains that links up to all machines for without them,
there shall be no transfer of bottle or crate.

54
 FIG 3:10 conveyor

3:10:3 UNPACKER

The crates are transported to the unpacker on a crate conveyor. The function of the
unpacker is to remove used empty bottles from the crate.

FIG 3:11 unpacker

3:10:4 CRATE WASHER

The empty crates will be transported on a crate conveyor to the crate washer. The
crate washer washes the crates. It has two regions; the soda bath unit, and the risen
unit. For the crates to be washed, the crates first enter the soda bath unit, then into
the risen unit and come out cleaned. The crate washer has a crate turner that turns
the crate for proper washing.

3:10:5 BOTTLE WASHER

The used empty bottles will be transported on a bottle conveyor to the bottle
washer. The bottle washer washes the bottles. It has three regions; caustic soda unit
(which is at a temperature range of 70 80o C), the scraper unit (where the already
soaked labels will be scraped off the bottle and then be removed by the label press),

55
and the risen unit (where the bottles will be risen first with warm water and then with
cold water).

3:10:6 EMPTY BOTTLE INSPECTION (EBI)

The washed bottles will be transported on a bottle conveyor to the empty bottle
inspection unit en route to the EBI unit, the glide- liner makes the bottles to be in a
straight line. The unit has four cameras and a reject system. The first inspection is
the side- wall 1 inspection, in which 270o side wall of the bottle will be inspected.
The second inspection is the neck finish inspection, in which the unit checks for
cracked mouth (neck) and rusted mouth. The next inspection is the base inspection,
in which the base of the bottle is checked to see if it contains some dirt. Then comes
the residual liquid inspection, through which to check for any liquid soda residual
inside the bottle. The last inspection is the side-wall 2 inspection in which the
remaining 90 o side wall of the bottle will be inspected. To enable the unit do that,
the bottle will be turned by the help of a belt for the unit to inspect the remaining 90
o
side wall of the bottle. At the in feed of the EBI unit there is a foreign bottle
detection/rejection system, which checks the colour and height of the bottles.

3:10:7 FILLER/CROWNER

The inspected bottles will be transported on a bottle conveyor to the filler/crowner

to be filled with the product (beer), and corked. The filler/crowner is a single
machine that has 96 filling valves and 18 crowning heads. The filler/crowner has
three facilities for its smooth operation. These are the in-feed worm-like wheel
which spaces the bottles in the appropriate proportions, the in- feed star wheel, which
is at the center, and then the discharge star wheel. Next to the filler is a hopper for
the crown corks, and an automatic crown cork system/conveyor (magnetic type).

3:10:8 FULL BOTTLE INSPECTOR (F.B.I)

After filling and crowning, the crowned product will be transported on bottle
conveyor to the checkmate unit for inspection. This unit performs the following
inspections; filling height (level), crown cork, leakage inspections. Any product that
does not meet the requirements of the unit will be rejected by separating it from the
rest. This is done by the reject system of the unit. A proximity switch monitors the
speed of the product during these inspections.

56
3:10:9 PASTEURISER

Consequent to the inspections, the product will be transported on a bottle conveyor

to the tunnel pasteurizer. Pasteurization is processes that improves shelf life of the
treated products by kilning or inactivating the micro-organism that could develop
subsequently. The basic principle of the process is to preserve the products for a
period of time. The function of the pasteurizer are:

To inactivate the residual yeast that is present in the products.

To destroy the microbial life that picked up during processes.
To increase the shelf life of the products.
To impact pasteurization taste on the products.

The pasteurizer removes any remaining microbe that could not be removed during
brewing. The pasteurizer has a continuous running wire mesh conveyor belt made
of stainless steel. It also has an automatic dosing device for additives, and caustic
dosing unit for cleaning purposes. The pasteurizer has a cooling system. The system
works in a way that the incoming products will first meet a cold region, and as these
products move through the pasteurizer a steady increasing temperature will meet
them until the highest set temperature of the pasteurizer is reached. At this point, the
products are at the middle of the pasteurizer. Then as the products leave from the
middle to the outside of the pasteurizer, the temperature decreases until at the
discharge end of the pasteurizer, which is cold region. So the product (beer) comes
out of the pasteurizer been chilled.

3:10:9:1 FACTORS AFFECTING PASTEURIZATION

1. TEMPERATURE: - This refers to actual pasteurization temperature attained by

the product itself within the bottle. The lower the temperature, the lower the
effectiveness of the pasteurization and vice versa. The optimum temperature for
lager and Maltina are 620C and 650C respectively.

2. TIME: - This refers to the time for which the product is held at the pasteurization
temperature to attain complete pasteurization. If the time is too short, it will result to
under pasteurization and if the time is too long, over pasteurization will be the result.
Therefore, the optimum time is eight (8) minutes.

57
3. MIROBIAL LOAD/RESISTANCE: - It is expected that the higher the micro-
organism, the less the effectiveness of the pasteurization. For the pasteurization to
be effective on the product, the pasteurizer machine is divided into 8 zones:

Zone 1 heating, spraying with water of zone 8

Zone 2 - heating, spraying with water of zone 7
Zone 3 - heating, spraying with water of zone 6
Zone 4 super heating zone 5
Zone 5 pasteurizing zone 4
Zone 6 cooling, spraying with water of zone 3
Zone 7 cooling, spraying with water of zone 2
Zone 8 cooling, spraying with water of zone 1

3:10:10 LABELER

The already pasteurized product will be transported on bottle conveyor to the

labeler. The labeler beautifies the bottled product by putting on it body label and
neck label. The labeler has automatic magazine in-feed devices for the labels, a glue
pump, a steel glue roll and a sectionalized glue scraper.

3:10:11 CODING

After beautification, the decorated bottled product will be transported on bottle

conveyor to the laser jet unit for coding. The coding is done on the body label by the
use of laser beam which heats up part of the label that it touches. The coding
includes; the date of production, the expiration date, and the brewery location.

3:10:12 PACKER

From the coding unit, the product moves on bottle conveyor to the packer. The
packer then puts the bottled product into already washed crates that had been
transported to the packer on crate conveyor

3:10:13 FULL CRATE INSPECTION (F.C.I)

The full crate inspection unit follows the packer. This inspects the already loaded
crates in order to verify if the crate is actually having the required number of bottles
and with the required conditions. The unit makes use of photocells to perform this

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function. The unit has reject system that removes the crates that did not meet the
required conditions from the rest.

3:10:14 PALLETISER

After inspection, the crates move on crate conveyor to the palletizer. Before each
crate gets to the palletizer, there is a crate turner which arranges the crates into the
aforementioned pattern for putting onto the pallet. When the palletizer has put on 5
layers of crates on the pallet, the loaded pallet will automatically move out for the
next empty pallet to come in. The loaded pallet moves on a carriage on rails to the
pallet turner, which keeps the pallet in position for it to be evacuated by the forklift
into the full (drinks) store.

FIG 3:12 Palletizer

3:11:0 WATER QUALITY AND BEER.

Water is an important raw material for brewing and accounts for more than 90% of
the weight of the brewing products (lagers, ale and malt drinks). Though water
economy is highly encouraged.

There are different sources where the brewery can get its water, from surface water
source as obtained in Kaduna brewery.

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3:11:1 Water Treatment Plant

Introduction

The Water Treatment Plant for Kaduna Brewery is designed for the production of
softened (service) water and product water. The softened water is used as rinse water
for tanks and beer lines, internal and external rinsing of bottles, internal rinsing of
kegs and pasteurization of packaged product. Product water is used for all other
brewery activities.

A natural ground or surface water always contains ions from dissolved salts. Such is
the case with Kaduna brewerys water. Some of these ions are not desirable for use
in brewing. For an instance, iron has a negative influence on the flavour and the
colour of a beer. It inhibits saccharification and gives a hard bitterness. It supports
the oxidation of beer ingredients, which leads to a hazy beer that tends to gushing.
Manganese at higher levels has the same effect as the iron in beer. Magnesium has
a negative influence on foam stability and flavour.

On the other hand, ammonium in raw water is an indicator for organic contamination
and bears the risk of forming nitrate through a partial oxidation reaction. Nitrate is
toxic for yeast as it inhibits its growth and fermentation. Bicarbonates at higher
quantities is not fit for boiler usage as it leads to scaling of the walls of the boiler
during heating up of water inside the boiler. This can cause corrosion and subsequent
explosion of the boiler. Also some ions in the raw water cause hardness. As such,
these ions/impurities that have adverse effects on beer production need to be
removed. This is basically what is being done in the water treatment plant.

The basic units of the plant are as follows;

Raw water supply

Pre- treatment
Main treatment
Storage
Distribution

3:11:2 Raw Water Supply

The raw water is supplied from the Kaduna River to a mini well in the water
treatment plant area. The well-heads are connected with an individual supply line to
60
the plant. A control valve in each supply line opens slowly when a well pump comes
into operation. A sample point, a pressure gauge with over-pressure valve, and a
manual butterfly valve are installed near the well-head. A flow meter is connected
in each well supply line for flow measurement. The boreholes operate in alternating
modes.

3:11:3 Pre-Treatment

From the Kaduna River, the raw well water is being pre-treated before sending it to
the Kaduna Brewery Water Treatment Plant for further purification and treatment.
Water from the river has a very high turbidity, and from analysis, it was detected
that iron concentration exceeds that recommended by the EU-directives for drinking
water. Furthermore, the water is aggressive due to lack of calcium compared to the
carbonate content. Therefore first of all, calcium hydroxide, Ca(OH)2 (Lime) needs
to be added to meet the calcium specifications of softened water. Afterwards, comes
the aeration of the water before being filtered.

3:11:4 Lime and Alum Preparation and Dosing

Lime milk preparation is carried out manually in the lime preparation tank from
white Hydrated Lime and raw water. As the lime milk is being prepared, the mixture
is stirred by a stirrer (agitator). After thorough mixing, the lime milk will be
delivered into the lime saturator by the help of a pump. As the raw water enters the
Lamella Clarifier, there is dosing pipe for Ca(OH)2 (Lime)and AL2(SO4)3 (Alum)
respectively. The Alum and Lime mixes thoroughly with the raw water in the first
compartment of the Lamella and then the dirt flocculates and sediments leaving a
clearer water with less turbidity to enter into the second compartment. The third
narrow compartment at the centre of the Lamella contains a clean water that is
awaiting filtration.

After the whole process of clarifying the raw water to clean water, the water is sent
to the Sand Filter for filtration prior the disinfection using sodium hypochlorite.

3:11:5 Sand Filters

The sand filters are four in number. These are enclosed tanks that contain different
aggregates of gravel arranged in two different layers. The water flow rate through
each filter is 150 m3/hr. The filters are used to remove turbidity and the iron and the
manganese compounds made insoluble by oxidation.
61
During filtration, water flows from the top through the filter medium (gravel) to the
bottom of the filter. On the process, the layers of the gravel will trap the turbid
particles, both the iron and the manganese compound. The sand filter has two layers
with Coarse and Fine sand respectively.

On a normal, after every filtration of about 500m3 volume of water through the sand
filter, there is an automatic Regeneration. During regeneration, the air blower which
is connected to the bottom of the sand filter blows air at about 2-3bar automatically
to agitate the stratified aggregates of the sand filter. This is to enable the clogged
turbid particles and the insoluble iron and the manganese compounds to be easily
removed

Then already treated water will come in into the filter from the bottom and flows up
the filter. The water carrying the turbid particles, the iron and the manganese
compounds will leave the filter from the top back to the clarifier for fresh treatment.
The filter will be rinsed first with air, which enters the filter from the bottom and
leaves through the air outlet at the top. Then the filter will be rinsed the second time
with a mixture of air and water.

The sand filters are connected to one manifold and enters the Treated water tank. As
the clean filtered water is passing to the treated water tank, there is a pipe at right
angle to the sand filter, dosing in Sodium Hypochlorite (NaCLO). The chlorine
dioxide dosing is controlled by the flow rate of water.

The Treated Clean water is now sent to the Buffer tank (Concrete). From the buffer
tanks water is been transported as Service water or product water.

The picture below shows the sand filters.

FIG 3:13 Sand filter

62
s
3:11:6 Noritz Filter and Water Quality.

The treated water from the treatment plants is taken to the clear water pit where a
submersible pump, to the treated water tank, pumps it. From the treated water tank,
the water distribution pump pumps the water to the sand filter tank. This is for last
sand filtration. Part of the water from this sand filter tank is sent directly to different
points for general use as portable water, while the remaining part is sent to the Noritz
Filter, for brew technical water production. The Noritz filter is made up of Activated
Carbon Filters for basically,

De-chlorination of the water. This is necessary since the hypochloric acid is

harmful to the yeast and will also have corrosive effect on the boilers. Also
presence of free chlorine can lead to the formation of organo-halides during
mashing process.
Removal of nitrates to acceptable level. High nitrates can be converted to
nitrites (reduction) by bacteria, which is harmful to yeast and consumer.

3:11:7 Softened (Service) Water

To produce softened water, 50% of the pre-treated water is stored in a storage tank,
which has a total volume of 1,000 m3. From the storage tank, the softened water will
be supplied to the brewery at a constant pressure within the range of 3.5-4.5 bars by
means of three (3) frequency controlled distribution pumps.

On the on-line to the softened water storage tank, chlorine dioxide is dosed as
disinfections additive in the return linking line of the soft water distribution pumps
to obtain a free chlorine level of < or = 0.5 mg/l at the point of use. Service water is
only used in the bottling hall.

3:11:8 Product Water

For the production of product water, the treated water will flow through two
activated carbon filters. The flow rate of the water through each carbon filter is
controlled. The function of the carbon filter is for de-chlorination and removal of
colour, odour and turbidity from the treated water. These activated carbon filters are
backwashed and sterilized frequently. The purpose of the backwash is to get rid of
the fine carbon particles and filtered substances. The sterilization of activated carbon
filters is done with hot water circulation at a minimum temperature of 95 o C for a

63
period of 2 hours at least. When one activated carbon is in sterilization mode, the
other filter remains in operation.

3:11:9 Ultra Violet Unit

Before entering the distribution system from the product water storage tank, the
product water will pass an ultra violet (UV) unit for disinfection purpose by
minimizing the microbiology pollution of the treated water effluents.

The ultra violet (UV) destroys microorganisms by changing their genetic

information (UV), but does not produce residual or hazardous by-products, nor does
it affect the taste, odour or colour characteristics of the treated water. The UV is a
light with very high energy level and wavelength of 200-400 nanometer (nm).

The UV unit is installed after the distribution pumps that distribute the product water
to the brewery at a pressure of about 3.5-4.5 bars by means of frequency control.
This arrangement is so because the product water needed not to stay long after
passing through UV unit as if it does, microorganisms will start to grow in it prior
to its usage.

The product water is used for brewing and other general purpose usages such as
drinking.

The picture below shows the UV unit.

FIG 3:14 UV unit

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 CHAPTER FOUR

CONCLUSION AND RECOMMENDATION

4.1 CONCLUSION

The Six Months attachment with Kakuri brewery was indeed a thrilling experience
for me as a Chemical Engineering Student. This is because it has helped me
appreciate the level of responsibility of my discipline and boosted my level of the
knowledge of the science of brewing. A lot of planning and co-ordination is put in
place by the Engineering and brew-house management to achieve set objectives.

From the training, it can be appropriately established that the Students Industrial
Work Experience Scheme (SIWES) has achieved the objective for which it was
established. The work experience not only exposed me to the practical applications
of the knowledge obtained in the classroom but also conditions facing real working
environment, work ethics as well as how to adjust, cooperate with colleagues and
team members as regards real life experiences, and also to appreciate the field of
Engineering better.

4.2 RECOMMENDATIONS

Having undergone the Students Industrial Work Experience Scheme (SIWES), I

strongly recommend the following

1. A comprehensive and detailed directory of employers who accept students for

SIWES is urgently required to facilitate placement of students in industry
2. In order to guarantee quality assurance of the scheme, there is a need for
thorough supervision of SIWES participants by institutions and the ITF
3. Due to the scarcity of places of industrial attachment, students should be
encouraged to undergo SIWES in small- and medium-scale industries where
they can contribute to improving the production processes and also gain an
insight into entrepreneurship
65
4. The ITF should revisit, redesign and fine-tune the website (SIWES data.org)
created to facilitate online payment of student allowances in order to remove
the bottlenecks associated with its usage
5. The stipulation that employers should accept students for SIWES should be
strengthened with stiffer penalties put in place for defaulters

66
 REFERENCES

Brewing Department, Nigeria Breweries Plc, Kakuri, Kaduna

Brewing Department Presentation, pptx
Beer Filtration Learning Manual.doc
Nigerian Breweries Plc LM Water Plant Structure. doc
Packaging department, Nigerian Breweries Plc, Kakuri, Kaduna
Maintenance workshop, Nigerian breweries plc, Kakuri, Kaduna
Water Treatment Plant and Waste Water Treatment Plant, Kakuri, Kaduna
Https://en.wikipedia.org/wiki/Nigerian_Breweries
Uvah, I. I. (2004). The Place and Relevance of SIWES in the Curricula of
Science, Engineering and Technology (SET) Programmes. Workshop on the
Students Industrial Work-Experience Scheme, University of Lagos, Akoka,
Lagos
Federal Military Government (1990). Industrial Training Fund (Amendment)
Decree, 1990. Ministry of Information, Abuja
ITF (1973). Policy Document No 1. Industrial Training Fund, Jos, Nigeria

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