1.

DESCRIPTION OF BEER
1.1. Definition of Beer
Beer is made by transforming barley to malt and fermentation of malt in some conditions, then this fermentated juice aramatized with hop and leaved for fermantation. It contains carbondioxide in form of solution, has a smell and taste of own and it is a soft drink (3-5 % in volume). Gas bubbles in it is the result of naturally occuring carbondioxide. Alcohol in beer, is made on its own during fermentation, it is impossible to add alcohol in beer in production process. Alcohol degree of beer, decreases or increases according to malt quantity in beer juice. Beer ,its production is goes to B.C. 6000 years is stillone of the most consumed drinks in world. Raw materials, used in beer production and required amount for 1 litre of beer are showned on the chart below. Raw materials Barley Unit Kg. Required amount for 1 kg malt 1,3 Required amount for production of 1 litre beer Malt Malt Additive (Rice)* Hop Beer Fermentation Gr. Gr. 1,7 5 Gr. Gr. 175 30

Malt additive and amount varies according to beer type and production methods. In our country, usually rice is used as malt additive.

Mainly known bottom fermentation beer types are; Pilsen, Mnih, Dortmunt, top fermentation beer types are; Ale, Stant and Porter. In Turkey, bottom fermantation beer types are being produced.

1.2. Classification of Beer and Beer Types

Beers, generally, differentiates as bottom and top fermentation beers and these beers differentiates according to their own known types. Beer is classified according to its production , extract amount of juice, variety and type. Bottom and top fermentation beers according to production. Its seperated and called as 2-5%,5,7-8%,11-14% and 16% according to its juices extract amount. This classification is very important for tax in some countries. As to its variety, generally beers that are used in trade are understood. ( Special beer, export beer, diet beer etc.) Its seperated as colour, bitterness of hop and malt taste. For instance; Pilsen beer, Dortmund beer and Mnih beer etc.

1.3. Beer Types According to Production 1.3.a Bottom Fermentaton Beer Types
Mainly known beer types, generally are taking the names of their production cities. It was thought that these beers were only produced in those cities. Mainly known bottom fermentation types are Pilsen, Mnih and Dortmund. Pilsen beer is light coloured (0,5 N/10 L) and hop amount is high (400gr/hl) and its foam lasts for a long time. Its characteristic feature is its bitter taste. Dortmunt beer is also light coloured but its taste is softer,stout and its alcohol is high.

Mnih beer is dark coloured, aromatic, stout and little bitter. Aromatic malt taste is its characteristic feature. Pilsen beer is made of 11-12 balling juice. Malt is well dried in the oven and leaved in 80C for 4-5 hours. Malt is kight coloured and in mashing very soft water is used. Its boiled once or twice ; fermentated in low tenperature and reposed for 3 months. Dortmund beer barleys sprout time is longer but parching-drying is same with pilsen. In other words, totally melt and malt, that has dried like Pilsen, is used. Water, used in mashing, contains carbonate, sulfate, CaCl2 . balling of juice is 13-14. double boiling is made. Amount of hop is between Pilsen and Mnih beers. Mnih beer is made of 11-14 boiling juice. Barleys, that is high in protein, are used. To make sprout is contunued until complete melt. Amount of carbonate is high in water which was used for mashing, but other kind of salts are not present. Tripartite method is applied. A little hop is added. Fermentation is made in low temperature and reposed for 3 months.

1.3.b Top Fermentation Beer Types

Most known beer types are English Ale, Staut and Porter. Actually, when its spoken about top fermentation beer, firstly English beers come to mind. Top fermantation beer are produced in litte amounts in Europe, Germany and Belgium. Top fermantation beer produced in Germany is 7% amount of total beer production. Main top fermentation German beers are Berliner Weissbier, Bayerischen Weissbier, Bitterbier and Malzbier. Belgiums Lambic beer is in this group. Weissbier, is made by mixing wheat malt to barley malt. Ale : Its light coloured and made of well melt malts. Hop amount is high.

Beer factories in England use six ordinals California winter barley. Added water is rough and jips are added. Enfusion method is used. Balling of juice is 1112. there are types as Pale ale, Bitter ale, Mild ale, Scotch ale. Generally hop amount is high ( 350 900 gr / hl). Also, 100-120 gr hop is added to barrels

Staut : Its dark coloured and contains hop. %10 black malt or parched barley and sometimes caramel is added to well melt malt. Hop amount is high. (600-700gr/hl)

Porter : Light Staut beers are called as Porter. Berliner Weissbier : It is made of 1/3 or barley wheat malt mix. Juice is not melt for this type of beer. Balling of juice is 7-8. fermentation is made in 14-20C. These beers are sore because its leaved for fermentation by mixing lactic asid bacteria to top fermantation leaven. To repose is done by leaving in bottle for 2-3 weeks in 12-16C.

Bayerischen Weissbier : Wheat malt is 60-70%. Mashing is same as in bottom fermentation beers. Balling of juice is 11-13 and fermentation is done in 12-25 C. Lactic acid bacteria are not used. After fermentation beer is bottled and for 3-4 days in 10-12C then 3-4 weeks in 4-5C reposed.

Bitterbier : It is produced with enfusion method and a lot of hop added. Fermentation is made in 9-13C, reposing is made in 5-7C for 2-3 months. During reposing, again 30-50 gr hop is added for one hectolitre.

Malzbier : It is dark coloured, contains little hop and it is sweet. After fermantation sugar is added, reposing is made in bottle or thank. When enough amount of carbondioxide is present it should be pastorized of filter immediately.

Lambic : It is peculiar to Brussels. 60% malt and uncooked wheat are used. The most important feature is not adding leaven and spontane fermentation. In spontane fermentation, termobacteria, wild leavens, lactic acid bacteria and Brettanomyceses are active.

1.4. Beer Types As to Varieties

They are produced in a different way and have some features. These are export, light and alcohol free beers. 4

Export Beers : Because these beers are sent to far and different clima countries, their stability has to e very good, in other words they have to stay clear for a long time without sedimentation for production of this beer, barleys, that gives high enzimatic malt. So, proteins are shattering good while making malt. Malt shoul be completely melt. Because there are melanoidins that plays as productive colloid, it is colour is dark. At the end of mashing, PH should be 5,2-5,4 and for this reason appropriate water mixture is used. In juice, dextrin amount should be high, so mashing should not be in 62-63C. Hop should be fresh and for good coagulation, it should put to boiler when juice is just starting to bail. Juice should not e boiled for a long time. In export beer production, beer should be clear at the end of fermentation. It is better not to make thrashing beers even malts, because it destroys colloidal balance. For botting beer without contact with air and for keeping used capsules cork for a long time, it should be covered with aluminium.

Light Beers : Light beers are high attennuationy and must not include carbonhydrate that harmful for diabetics more than 0,75 gr/100 ml. The protein amount is maximum 0,5gr/100ml and alcohol amount 4,3% and also these beers calory amount is low. To create this, by the beer producing,it must be waited a long time between 62-64C that maltot oceurs mashing. Apart from that, in fermantation drastase enzyme preparate or malt extraer or for one hectolitre 500800 gr malt flour is added. Than the remained dextrin shattered and it is prowded to have fermentation by leavens for this reason, light beers, contains more alcohol also amount of hop is high.

Alcohol free beers : the beers that contains 0,5-1,5% alcohol are called as less alcohol beer, the beer that has less alcohol than 0,5% are called as alcohol free beer.

These beers are being produced in different ways for example. It is marketed by mixing beer and juice or fermentation of juice is stopped by pastorization or filteration. Also, to have less alcohol in beer, a mashing process may applied that has little fermentable sugars (malt)in

juice. In some countries, alcohol free beer is being produced by taking alcohol in beer with vacuum distillation. But the beers that has less alcohol than 1,5% are not prefered much.

1.5. The Materials Used In Beer Production

1 BARLEY : It is a one of year plant of Mordeum gramine family. In Turkey, two ordinals barleys are used (Mordeum disdichum). Although, in Europe, the two ordinals barleys that harvested in summer are efficient, in Turkey, the barleys that harvested in winter are efficient. The chemical composition of ordinal barley which is an important factor in beer production is; Protein Starch Oil Cellulose Ash 11,1% 63,2% 2,94% 5,83% 2,93%

Other materials with azote 14,0%

The most important material of marley is starch. Because the alcohol in beer occurs by shattering of starch. While the amount of protein in the barley increases, the sprout of barley becomes forceful. So, it makes harder to control beer production. The amount of protein in the particle, starch and extract are converse commensurate. 2 HOP : Hop that being used in beer production is a more years plant from canabinaceae family. Although, being more wild species of hop in Turkey, the culture races are more efficient. The main factors of hop that makes producing beer more valuable are alpha acid, essential oil and wetness.

The most important section of hop is yellow lupuline. This section includes preservative and taste giving materials. The composition of yellow lupuline has two sections. These are essential oils that give to the beer its flavoring and rosins that gives to the beer its bitterness and preservative. Also, the reason of using hop in beer production is lupuline dust. The chemical composition of hop is; Water Ash Cellulose 12,5% 7,5 % 13,3%

Materials with azote 17,5% Ether oils Ether extracts Tanine Azote free extract 0,4% 18,3% 3,0% 27,5%

The most important materials in beer production between these are ether oils and rosins. Especially lupuline dusts include ether oils and rosins. 3 WATER : Water is important in beer production as much as barley and hop. Water is being used for making barley sprout, preparing mash, feeding to vapor boiler and cleaning. The water, being used in beer production, is much more than the beer producted. Due to the fact that 80% percent of beer is water, it is important and it must be qualified as clear drinking water.

2. Beer Production in Turkey and In World

2.1. Beer Production In The World
Beer is a drink made from grains (especially from barley) and it gets its special smell and taste from hop. The history of beer is as old as beginning of grain farming. 8000 years earlier, the people who has lived in Maditerranean producted beer first. Old Egyptians thought that Farming God Ostristaught people to make beer. In addition to be understood from the written sources, before making beer,viniculture and wine pressing in Babil, making beer is also known in Mediterranean. Today, thousands barrels of beer is being prduced in beer companies. But modern production techniques are not much different from the old Egyptian kitchens and the middle ages monasteries. It is being supposed, the beer and bread founded with a coincidence. For both of them leaven is needed and cause of these living beings are small that can not be seen with necked eyes, nobody could know to make a frothy drink with adding leaven to grassy barley and first made beers did not include hop. Since many centuries, people looked for different tastes by adding to beer many different horbs. The beer with hop is needed first at 14. century. Especially, beer that went into wines place at North countries where the climate was not convenient to product beer, is the traditional drink of Germans, Englishs and Scandinavians. Today, there are so many beer species being produced with special names in Germany and England. German and English beers are seperated from each other with leaven techniques and hop amount. English beers are being produced with top beer techniques and its alcohol amount is 4% - 6,5%. The beers named Lagerin german includes hop and its alcohol amount is low. German beers that produced with bottom fermenting includes 3% - 5% alcohol.

Worlds Biggest Beer Producers and Markets According to 1998 (million hectoliters) Beer Producers Anheuse-Busch Heineken NV Miller Brewing Co. Interbrew South African Breweries Production Amounts 130 79 56 48.3 47.7 Beer Market USA China Germany Brasil Japan Market Size 226 199 105 82 72

Source: Impact Databank

2.2. Beer Production In Turkey

In Turkey, the first beer company was found by private sector in stanbul in 19. century , but before this, it was known in Turkey. For example, according to some formal documents dated 1842, the beer was being produced with a name Barley Water. After the first beer company that was found by Swiss Bomonti brothers, an another company was found in 1909 in stanbul, called as Nektar. In 1912, these two company united with a name Bomonti Nektar In zmir. The company in stanbul was producing beer and malt, the company in zmir was producing just beer with the malt produced in stanbul. In 1926, at the time of republic, the beer production entered to government monopoly. But a special permission was given to Bomonti- Nektar company for producing beer by government till 1938. In 1934, the first beer company of government was found in Atatrk Orman iftlii in Ankara. In 1955, the beer was started to produce by private sector with getting out the beer from monopoly products. Today 85% of the total beer production of turkey is belong to private sector. Tables about beer and malt are in appendix.

3. Description of Process
Beer is a beverage made of malt including alcohol and CO2. As another saying; germinated grain aromatized with hopfen. This means malt must enters alcohol fermentation. There are 5 sections in beer production: 1. Grinding the malt 2. Mashing and Boiling 3. Fermentation and Maturing 4. Filtration 5. Bottling, barrelling and Pastorisation 3.1 Grinding The Malt Malt is need to be grinded and mixed with water for mashing for beer production. After grinding of malt, endosperms must be like flour. On the other hand the shells of malt must remain in big particles. This can happens if the malt is easily melting and fully dry. Uncracked shells prevents the materials causes unwanted smells and also they are required in the straining of mash. In straining process, they are used as filters. The mill used in grinding of malt is located above the mashing-boiling section. The malt coming from the silos passes from magnets to be seperated from iron particles within. Then grinded malt is weighted in automatic scales. Dusts in malt are absorbed while entering the mill from malt silos. 3.2 Mashing and Boiling MASHING The seperation of starch into yeastible sugar particles called as mashing. Grinded malt mixes with water in mash boiling tank and warmed up to various temperatures.

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Purpose of Mashing To make the enzymes influence the extract materials in malt and splitted them into low molecules to pass into must, so that the best extract from malt can be gained. Mashing Methods The mixture formed of malt and water is called the mash. There are two types of mashing; 1. Decoction 2. Infusion Infusion Method The main principle of this method is rising the temperature of mash slowly to 75-78C. No boiling happens in this method. So the enzymes do not get damages. In brewering mashing is made with good soluble malt. Besides this another method called Double Mashing can be used. A lot of diastase is required to sugarize the additive starch. For this reason infusion method is important.

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100C 90 80 70 60 50 40 30 1 2 3 4 5 (hour)

Infusion Diagram Double Mashing Method Malt starch is an expensive ingredient. To reduce the cost of beer, the starches of rice and corn are used. But the starch must be pasted, else amilase cant influence the starch. To prevent this, the additives must be boiled before addition. During the boiling, both rice and corn particles must be in small pieces. During this operation starch becomes sticky and then can be added to grinded malt. This method is prefered in bright colored beer production. In fact double mashing is a type of infusion method. Straining of the Mash The seperation of extract gained in mashing and strainig of must have to be complete and done in a short time. This operation is done in two stages; 1. First must is strained 12

2. Remaining crashed seeds are washed in hot water at 80C, then sent to straining tank to be strained. 3.3 Straining Tank This tank is used for straining of mash. It looks like mashing tank. The shells in mash settle on the perforated base and form a filtering layer. After the main must flows, the remained extracts on the filter are gained with hot water. Straining tanks are cylindrical in shape and have perforated bases. The holes are like long cracks. The equipment is made of stainless steel. There is a plate layer 1 cm below the base. Strained must passes from the perforated base and accumulate here. Then must is sent to boiling tank. To prevent themust to become cooler straining tank is built double sided. Crashed Seeds After the straining lots of crashed seeds remain. 110 kg grained malt leaves 110-120 kg crashed seeds including %80 water. Wet crashed seeds can be fermentated to sugar up to %0.5. Crashed seeds are transfered to their tanks via air flow. 3.4 Boiling The must gained from straining tank is sent to must boiling tank. The boiling of must is the turning point in the production. Practically, all the malt must and hopfen are boiled 1-2hours together. Nothing can be added meanwhile. Some or all of the hopfen can be exchanged with hopfen extract. If the hopfen is seperated from the extract and independently isomerizeda it can be more efficient. Previously isomerized hopfen will be added to beer after fermentation. Many complex reactions occurs during te boiling process. By the heating of the must all enzymes like amilase, whick stabilized the carbohydrate composition, become ineffective. At boiling temperature the must is purified from germs. During the boiling, proteins collapse and some of them react each other with the help of some simple nitrogen mixtures and 13

polyphenoles. Remaining unsoluble precipitate is called sediment. Some of the sediment is seperated in the boiling of must and called hot sediment. But the remaining spare part collapse during the cooling of must. This is called cold sediment. After 1 hour boiling %10 of volume is vaporized. By the vaporizing volatile aromatic compounds are removed. Purpose of Boiling 1. Evaporating the water to set the extract concentration in required levels. 2. Demolishing the ferments and sterilize the must. 3. Collapsing the proteins. 4. Transfering the characteristics of beer, the flavour materials in hopfen, into must. Boiling of Hopfen Hopfens can be added to the boiling tank after the hot sediment collapses. To prevent foaming a little amount of hopfen(less tan %10 of whole hopfen) can be added in the beginning of boiling. Hopfens must be added in three stages; First addition, %25 of whole hopfen, to help the sediment to collapse 15-25 minutes after the most efficient part of boiling. Second and major addition, %50 of whole hopfen, 30 minutes after the beer gets bitter. Last addition, before discharging the boiling tank or 15 minutes before the boiling ends. Cooling of Must After boiling must is sent to cooler. There are two types of coolers;

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a) Open Coolers: In this type of coolers must is in contact with air b) Close Coolers: During the cooling the contact with atmosphere is cut. Well-known close coolers : 1) Double piped Coolers 2) Plate Coolers 3) Shell and Tube Coolers 4) Must Ventilating Coolers. 3.5 Fermentation and Maturing Introduction to Fermentation Fermentation is the cracking of big molecules of carbonhydrates by the help of microorganisms. Fermentation can be divided into two parts, according to the existence of oxygen in the cracking reaciton; 1. Oxidative Fermentation: Oxygen is used in oxidative fermentation. In formula; C6H12O6 + 6O2 6CO2 + 6H2O + 72 cal. Eg.: Acetic acid, citric acid, oxalic acid and formic acid fenmentation 2. Inoxidative Fermentation: Oxygen is not used. Examples of Inoxidative Fermentation are, Ethyl alcohol(as in beer production), lactic acid, propionic acid and butic acid fermentations. C6H12O6 2C2H5OH + 2CO2 + 28 cal.

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When the must is cooled to required temperature, it is mixed with yeast and sent to floatation pools. Thereare two types of fermentation; 1. Top Fermentation 2. Bottom Fermentation

Bottom Fermentation There are three stages in this fermentation; 1. Floatation 2. Major Fermentation 3. Maturing of second Fermentation 3.6 Floatation The must coming from cooling, is fermented before transfering to floatation pools. How must is fermented is explained below; Before dosing the yeast an air flow is given from the bottom to obtain homogenization. At the moment of must entering the tank dosing starts and finishes just before the flowing stops. Entering the floatation pool fermented, the must is matured there for 6 days. At this time period must is warmed up to 8-9C, so the yeasts increase. After the finish of floatation, fermented must is pumped to fermentation tanks. Purpose of Floatation 1. To sediment the dead yeasts 2. To float the unwanted materials gained from hopfens 16

3. To sediment the cold sediments.

3.7 Beer Yeasts Beer yeasts are members of the Saccharomyces genus and in bottom fermentation the name of the culture yeasts used is Saccharomyces Carlsbergensis. There is an important role of the yeasts in beer quality. The must does not include any microorganisms because of the mashing and boiling processes. Fermentation is totally done by the beer yeasts. In brewery the pure yeasts are called culture yeast and the rest is called untamed yeasts. The yeasts we are using can not include dead ones over %5 also cany include foreign microorganisms especially bacteries. In brewery bottom fermentation yeasts are divided into two groups; Lump Yeasty(Bruchhefen) and Powder Yeast(Staubhefen). Lump yeasts sediments the bottom near the end of fermentation but their fermentation degree(atteniation) is lower than Powder Yeasts. Floatation Pools Floatation cellar is located below the must coolers. The cellar have to be easily cleaned, have the required equipment to release the CO2, have adjustable temperature control and beer must be in full control. The optimum capacity of floatation pools are arranged as the %25 volume of must gained once from mashing. Because the foam needs %25 volume not be overflowed. The depth of the pools are 1-2 m. They are made of stainless steel. There are cooling pipes located at the basements. Major Fermentation The fermented must at 9C is sent to fermentation tanks. In there it is warmed up to 12C and stays at 12C for 6 days to be fermented. At the end of major fermentation the yeast collapses 17

to base and the young beer gets brighter. The bitter and dark layer in the surface of the beer is cleaned and then beer is pumped to maturing tanks. The main event in the major fermentation is the ethyl alcohol fermentation. 3.8 Chemical Mechanism of Ethyl Alcohol Fermentation Lavosier found that the products of fermentation are CO2 and alcohol in 1789. In 1815 GayLussac formulized this; C6H12O6 2C2H5OH + 2CO2 Glucose Ethanol

2 mols of ethyl alcohol and 2 mols of CO2 are produced from 1 mol glucose. Also many by products are produced too. The enyzm, generating alcohol from sugar is zymase. It is a copmplex one originated from a mixture of enzymes. They generate the alcohol in continious reacitons following each other. According to the theory of Meyerhor et al., alcohol fermentation occurs in 12 stages; 6 carboned hexoz is divided into 3 carboned trioses, glycerin aldehyte and dioxiacheten. These trioses tranformed into pyruvic acid. 2carboned acet aldehyte and 1 carbone CO2 is generated from pyruvis acid. Acet aldehyte produce alcohol by gaining H. Enzymes used in ethyl alcohol fermentation; 1. Hexocinase 2. Oxoisomerase 3. Phosphohexocinase 4. Aldolase

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5. Phosphotrioisomerase 6. Phosphatedehidrase 7. Phosphoglicerineacidcinase 8. Phosphogliceremutase 9. Enolase 10. Pyruvatecinase 11. Carboxilase Maturing After the major fermentation young beer still contains fermetable extracts. This is %1-2 in volume. To ferment the remained sugar young beer is sent to maturing tanks. Bottom fermentation beers stays in maturing 3 weeks at 0-2C. this time can be changed according to season and sales. At the end maturing, tanks can be mixed with each other to obtain the wanted gas, color and extract values, then sent to filtering. Before the filtering the beer cooled to -1C with the gluchol at -2C. Introduction to Filtration To obtain the required brightness, beer must be filtered at least one time. Various types of straining methods can be applicated. These are; Kieselguhr filters, Sheet filters and Pulp filters. Filtration Theory

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At the end of maturing some amount of sediment collapses to bottom. This causes turbidity in beer. To prevent this event beer must be filtered. After the filtration; 1. Beer must be sterile and clean as availible. 2. Losses of CO2 must be prevented. 3. The contact of beer with air must be prevented. 4. No infections can be occured. To get the best result from filtration beer must be cooled as much as possible. The more the beer cold the more the cold sediment arise. Good filtration means, preventing the warming up of beer itself and seperating the sediments. 3.9 Introduction to Bottling The bottles come to Bottle Washing Machine by conveyors. Washing The bottles are located the hives in the machine. The washing operation takes 20-30 minutes. In this operation bottles are washed internally and externally. The washing operation stages; a) Upside and down the bottles to discharge the remainings b) Approximately 20 minutes, washing with %1 caustic solution at 90C. c) Spraying caustic solution into bottles d) Spraying hot water to external sides to remove the stickers e) Spraying cold water to inside of bottles and then bottles leave the machine clean, dry and empty.

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Washed bottles are controlled by Empty Bottle Control equipment. If the bottle is not clean as wanted it is sent to washing again. Filling The bottles are filled with the ventilles of the filling machine. In this operation; a) The air inside is sucked with vacuum b) CO2 at 1.5 bar pressure is given to the bottle c) While CO2 is releasing beer is filled to the bottles d) A tiny layer of water is charged to the bottle to make the beer foamed. e) Taps are pressed to bottles by capsulling pistons and bottles leave the bottle filling machine Pasteurising After the filling the bottles are sent to tunnel pasteur. In here the temperature of beer is risen. Holding the beer at this temeperature for while then temperature is decreased. This cycle sets beers biological stability. Passing of bottles from hot to cold areas is the principle of Pasteur. Water is sprayed to passing bottles. The temperature of sprayed water can be adjusted to wanted beer temperature in bottles. The wanted temperature is obtained at preheat andsuper heating areas. Tunnel Pasteurising After the bottles are filled and tapped, they enter the tunnel pasteur. The bottles are transfered in conveyors during this operation. During the operation water is sprayed over the bottles. The pasteur temperature of beer is gained by adjusting the tenperature of spraying water. The

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pasteur temperature is usually 63C. Beer stays 20 minutes at this temperature. Then cold water is sprayed over and leave the system. The water used in pasteur is very important. It must be clean and have a pH degree of 8. Else pasteur doesnt works.

3.10 Introduction to Barreling The main subject is to fill the pasteurised beer into barrels made of aliminium and stainless steel. Aliminium barrels are preferred to be light and cheaper. Preperation of Barrels for Filling Empty barrels come to barrel reverser. Filling is done from bottom to barrels. So the tap of barrel must be downwards. Then the barrels come to pressure kontrol section. Here the pressure is controlled to be 1.5 atu. Passing the pressure control, the barrels come to external washer. Here, the barrels are washed with hot water and brushes, then pass to intermal washing. Internal Washing 1st Head: Churn beer is discharged with air. Cold water is given and discharged with air 2nd Head: Hot water is given and discharged with air. 3th Head: Caustic is given and discharged with air 4th Head: Caustic is given. Some of it remains inside the barrels. Barrell with caustic comes to filling machine.

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Pasteurising for Barreling The beer coming from filtering at 2-3C is pasteurised before filling. Dry-Pasteur is used in barrelling. It has 4 stages; 1) Regeneration 2) Heating 3) Holder Tube 4) Cooling Beer is pumped to first stage. There, it is heated by counter-flowing hot beer. It is warmed up to Pasteur temperature. It done by counter-flowing by hot water. After than stays in tube for a calculated time. This beer is then comes to first stage. When the filling starts, pasteurised beer is pumped to buffer tank and then to filling machine. Filling 1st Head: Caustic is discharged with air. Hot water is given and discharged with air. 2nd Head: Hot water is given and discharged wtih air. Acid is given and discharged with air. 3rd Head: Cold water is given and discharged with air. Saturated steam at 130C is given. 4th Head: Steam is discharged by giving CO2 5th Head: CO2 is given. Filling starts slow and then speed up. While beer entering the barrell CO2 is discharged. After the filling, the barrells are again turned upwards.

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4. Capacity Choose
The annual beer production of Turkey is 8 millions hl. EFES PLSEN provides the %75 or 6 millions of this production. We are willing to establish a factory to be able to produce annually 1200000 hl of malt beer according to the marketing location and natural underground waters capacity. According to this quantity our montly production is 100000 hl. However we have to rearrange our production according to some conditions. For example we take a break to production in Ramazan Fests. In these times our factory stops for planned yearly upkeeping. In statistics of beer sales it seems that the major proportion of the sales are made in May-December 6 months period. This is approximately 800.000 hl of our production. So we have to produce 800.000 hl of beer in 6 months in a year. The beer production capacities during the most of the sales are made;

800.000 hl hl = 130.000 6 months month 130.000 hl hl = 5000 26 days day

According to these values we need 3 pieces of 1500hl and 1 piece of 500 hl capacity pulling tanks for daily 5000 hl production. Filters loose 8 hours of time during the fill-up and excretion, so they are working; 5000 hl hl = 350 flux. 16 hours h The mass balance calculation is built up in the basis of boiling tank capacity. If we go rewind the process from the end, the producti losses are; %0.2 in fermentation and %0.4 in filtration. So for monthly 130.000 hl/month production;

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130.000

hl 1 1 hl = 138.000 month 0.96 0.98 month

The fermentation tank is designed to be filled with %75 liquid and %25 foam. This process is done twice in month so; hl 30days 69.000hl = month 15days 15 days

138.000

For the 3000 hl liquid portion; 69.000 hl product = 23 pieces of tank. 3000 hl volume The %25 of the tanks are departured for foam so: 3000 = 4000 hl is the capacity, one of 23 tanks. 0.75 Amount of malt required monthly; hl kg-malt tons 15 = 2.070.000 kg-malt = 2.070 month hl month

138.000

Amount of malt required daily; tons month malt 1 = 80 tons month 26 days day

2070

One month is taken as 26 days because of the weekends. So if we want to use 80 tonsmalt/day we need to choose the capacity of boling tank 10.000lt to make 8 times boiling a day.

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5. Flow Diagrams
5.1. Block Flow Diagram
Malt Mill Malt Boiler Straining Tank Boiling Tank

Malt

Water

Water

Water

Bottling

Filtering

Fermentati on Tank

Plate Cooler

Beer

5.2. Process Flow Diagram

Process Flow Diagram is in appendix.

6. Mass and Energy Balances

6.1 Mass Balances
Basis: One Boiling Tank System: Mill + Malt-10.000 kg + Malt Mashing Tank

Malt-10.000 kg Mill Grinded Malt +380 hl water Malt Mashing Tank Main Mash In mashing tank 3.8 hl water is added per 100 kg malt. So;

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10.000 kg malt

3.8 hl = 380 hl water. 100 kg

Input :

Malt = 10.000 kg Water = 380 hl = 38.000 hl = 38.000 kg Input = Output 10.000 + 38.000 = 48.000 kg = Main Mash
Basis: A Boiling Process System: Straining Tank

Water used in straininng tank can be assumed to be 1/1 proportion to water used in mashing tank. Mash required for one boiling can be strained in 3 hours.
Input:

Main Mash = 48.000 kg Washing Water = 37.000 lt = 37.000 kg

Output:

Must = 750 hl = 75.000 lt = 75.000 kg Input = Output 48.000 + 37.000 = 75.000 + Crushed seeds. Crushed Seeds = 10.000 kg. Crushed seeds are %80 water and %20 dry portion.

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Water in crushed seeds; 80 = 8000 kg = 80 hl 100

10.000

Dry portion in crushed seeds = 10.000 8000 = 2000 kg.

Basis: A Boiling Process System: Boiling Tank Input:

Must = 750 hl =75.000 kg 100g = 75000 g = 75 kg 1hl

Hopfen used in boiling = 750 hl

Output:

Hot Must = 675 hl = 67500 kg Input = Output 75.000 + 75 = 67.500 + Steam Losses Steam Losses = 7575 kg This means, %10 of the Must is evaporated during the boiling process.
Basis : A Boiling Process System : Cooling Input:

28

Hot Must = 675 hl = 67500 lt = 67500 kg

Output :

Cold Must = 650 hl = 65000 lt = 65000 kg Input = Output 67500 = 65000 + Cooling Losses Cooling Losses = 2500 kg. This means, %4 of the Must is lost during the cooling process.

6.2 Energy Balances

1.Boiling: 1.1 Malt Mashing Boiler:

In this tank the mixture is warmed up to 80C from 35C. So the mashing occurs in 2 hours 50 minutes. The required heat and steam: Q = m.c.T m = Total Mash

m = Malt + Water for Malt m = 10.000 kg + 38.000 kg = 48.000kg Basis : 1 hour of Mashing kcal kg.C

Cp of Malt = 1

Q = 48.000 1 (80-35) = 2.160.000

kcal h

29

Malt Mashing Process = (2 hours

60 min ) + 50 min = 170 minutes. 1 hour

Q = 2.160.000

kcal 60 min 1 mashing kcal 762.350 heat is required. mashing 1 hour 170 min h

Looking up the saturated steam heat tables: kJ kg kJ kg

P = 3 At

y = 1 H = 2676.1 x = 1 h = 419.04

H = H-h = 2676.1 419.04 = 2257.06

kJ 1 kcal kcal . 540 kg kg 4.18 kj

Basis : Amount of steam for 1 hour of mashing m = amount of steam

kcal ) kg-steam h 1411 kcal h 540 kg

(762.350

Q = m.H

m=

1.2 Boiling Tank

Must is boiled from 65C to 100C. This process occurs in 2.5 hours. Boiling occurs in two parts: a) Heating b) Vaporizing

30

a)Heating: Takes 1 hour to complete: t2 = 100C t1=65C t = 35C

Amount of Must from mass balance m = 75.000 kg-must kcal kcal 35C = 2.625.000 kg.C h

QI = m.Cp.t = 75.000 1

Q = Used Steam; mI = H

(2.625.000

kcal ) h 4860 kg-steam kcal h 540 kg

b)Vaporizing: Takes 1.5 hours to complete. The amount of steam given to the system is equal to the amount of steam lost in boiling of the must. Because the energy of steam given to system is equal to the loss of vapor during the boiling. So steam loss calculated previous mass balance; Basis : A Boiling Process kg vaporizing

msteam = 7575

QB = m B H B = 7575 kg 540

kcal kcal = 4.090.500 . kg vaporizing

Vaporizing takes 1.5 hour; kcal 1 vap 60min kcal = 2.727.000 (Energy in 1 hour) vap 90min 1hour h

QB = 4.090.500

Basis : Steam used in 1 hour vaporizing 31

mB =

Q = H

(2.727.000

kcal ) h = 5050 kg-steam kcal h 540 kg

Amonunt of steam required for total Boiling; kg-steam . h

mT = mB + mI = 5050 + 4860 = 9910

Basis : 1 hour of boiling and mashing kcal h

Total heat for boiling; QT = QI + QB = 2.727.000 + 2.625.000 = 5.352.000 Total heat for mashing and boiling; QT = QBoiling + QMashing kcal h

= 762.350 + 5.352.000 = 6.114.350

Total steam for mashing and boiling; ST = SB + SMash kg-steam h

= 9910 + 1411 = 11.320

Efficiency of the tanks assumed = 0.90; 100 kcal 6.793.720 90 h

Total heat for the system; Maximum Heat = 6.114.350

(mmax)steam =

Qmax 6.793.720 kg-steam = 12.580 = 540 h H

PLATE COOLERS

Must enters the cooler at 100C and leaves at 9C. Cooling water enters at 2C and leaves at 85C. Basically cooling time is assumed to be 1 hour.

32

must = 105

kg lt

mmust = 675 hl must = 67500 lt 1.05 = 70.875 kg-must %88 of must is water and rest of it is extract. kcal kg.K kcal kg.K kcal kg.K

Cpwater = 1

Cpextract = 0.38

Cpmixture = 0.88 Cpwater + 0.12 Cpextract = (0.88 1) + (0.38 0.12) = 0.925

Qmust = mmust Cpmust T = 70.875 0.925 (100-9) = 5.965.903

kcal h

According to these data and %2 leakage in the system; Heat gained = Heat given. From this we can calculate the amount of the cold water. Qmust x 0.96 = mwater x Cpwater x T
0.96 0.96 = 5.965.903 = 69.000 kg water is required. Cp water T 1 (85-2)

mwater = Q must

2. FERMENTATION

Two types of reaction occur in the fermentation tank. a) Oxidative reaction : C6H12O6 + 6O2 6CO2 + 6H2O b) Unoxidative reaction : C6H12O6 + O2 2C2H5OH + 2CO2 Every fermentation tank can cover the boiling capacity.

33

Fermentation process takes 6 days and 2 days for cooling also 7 days for maturing, totally takes 15 days to complete. Sugar percentages in the tank: 0th day %12.5 1st day %10.90 2nd day %6.15 3rd day %3.70 4th day %2.60 5th day %2.20 6th day %2.10 Cooling starts

According to this heat transfer during the fermentation; 1st day: Neither fill-up nor pour-out happen. Temperature rises from 9C to 12C 2nd day : Sugar fermentation from %10.9 to %6.15 (12C) 3th day : Sugar fermentation from %6.15 to %3.70 (12C) 4th day : Sugar fermentation from %3.70 to %2.60 (12C) 5th day : Sugar fermentation from %2.60 to %2.20 (12C) 6th day : Sugar fermentation from %2.20 to %2.10 (12C) 135 kcal heat is gained from 1 kg of sugar and %75 (3000hl) of a fermentation tank is liquid; 1st day : No cooling hl (10.9 - 6.15) kcal 135kcal/1kg-sugar = 1.923.750 ) 1tank 100 day

2nd day : 1 tank (3000 heat exit.

34

3th day : 1 tank (3000 heat exit.

hl (6.15 - 3.70) kcal 135kcal/1kg-sugar = 992.250 ) day 1tank 100

4th day : 1 tank (3000 exit.

hl (3.70 - 2.60) kcal 135kcal/1kg-sugar = 445.500 ) heat day 1tank 100

5th day : 1 tank (3000 exit.

hl (2.60 - 2.20) kcal 135kcal/1kg-sugar = 162.000 ) heat day 1tank 100

6th day : 1 tank (3000 heat exit. kcal day

hl (2.20 - 2.10) kcal 135kcal/1kg-sugar = 40.500 ) 1tank 100 day

QTotal = 3.564.000

Energy Exchange during Maturing

Q = m.C.T Q = 1 tank 300

hl lt kcal 100 1 (12-(-1)) = 3.900.000 1tank 1hl day

T1 = 12C kcal kg.C

T2 = -1C In two days time

Cp = 1

Q = 3.900.000

kcal kcal = 1.950.000 2days day

35

3. BOTTLING AND BARRELING

According to our factorys capacity our daily production is 5000 will be saled in bottles and te rest in barrels. According to our standarts; kcal hl kcal hl kcal hl

hl . %60 of this production day

Bottle washing 9500

Barrel washing 5600

Bottle Pastorization 9000

a) Bottle Beer Production hl hl 0.60 = 3000 day day

5000

For bottle washing; kcal hl 1day kcal 3000 = 1.187.500 hl day 24 hours h

Qw = 9500

For bottle pastorization; kcal hl 1day kcal 3000 = 1.125.000 hl day 24 hours h

Qp = 9000

For bottling; kcal h 36

QTotal = Qw + Qp = 2.312.000

Amount of steam used for bottling; QTotal 2.312.500 kg-steam = 4282 = 540 h H

m=

b) Production rate for barrels; hl hl 0.40 = 2000 day day kcal hl

5000

Energy consumption for barreling; Q = 5600

For barrel washing; kcal hl 1day kcal 2000 = 466.600 hl day 24 hours h

Qw = 5600

Amount of steam required; Qw kg-steam = 466.600/540 = 864 H h

m=

7. Design of Process Units

Malt Boiler:

The boiler has two inlets. These are water and malt. Approximately every 100kg-malt requires 3.8hl water add-on. Also 100kg malt has a 0.7hl volume. For these reasons we assume the boiling process in a basis of 10.000kg malt; 0.7hl = 70 hl volume 100 kg-malt

10.000 kg-malt

37

10.000 kg-malt

3.8 hl-water = 380 hl waters volume 100 kg-malt

According to this maximum volume of our boiler; Vmax = (70 + 380) 1.6 = 720 hl However we are designing 550hl Mashing Boiler via engineering approach. These boiler are have to be made of stainless steel and in cylindrical shape. Mashing boiler is designed to be 5m in diameter and 3m height. This boiler has heating sites both in bottom and lateral surface. Our boiler has 100m2 heating area and a mixer to obtain homogeneous mixing. For the calculation of heating area required for the mashing process, we need to look up for the amount of heat given in 1 hour time: kcal h kJ h.C

QM = 762.350

U = 1950

Q = U.A.T (Process is thought like an evaporator) kcal 4.18 kJ = 1950 A (80-35) A=36 m2 h 1 kcal

762.350

Fermentation Tank:

Fermentation occurs in the boiler in a 15 days period. This means two fermentation can be made in a month time. According to our monthly production capacity; hl 30 days 69.000hl = is the total capacity of a fermentation process. For the month 15 days 15 days

138.000

3000hl liquid phase of the fermentation process;

38

69.000 = 23 tanks are required. 3000 The %25 part of the tank is seperated for foams; 3000 = 4000 hl one of 25 tanks. 0.75 4000hl volumed tank is made of stainless steel. We are designing a tank with a diameter of 6m and 18m height. Calculation of the heat transfer area for fermentation process in the fermentation tank: The energy exchange in the fermentation process is: QTotal = 3.564.000 kcal/day In fermentation process, in the cooling we are always using the same heating pocket so we are taking the daily maximum heat transfer value. This amount of heat is for 2 days time: kcal 4.18 kJ 1 day kJ 335.053 day 1 kcal 1 kcal h

2 days Q = 1.923.750

Q = U.A.Tlog U = 460

kJ h t2 = 0C

T1 = T2 = 12C

t1 = -4C

Tlog =

T1 T2 (12 0) (12 (4)) = 14 12 T1 ln( ) ln 16 T2 kJ kg = 460 A 14 A=50 m2 h h

335.053

39

Calculation of the heat transfer area in the fermentation tank for the maturing process: Before we calculated the amount of energy exchange in maturing process; kcal kcal kj 1day kJ = 1950000 4.18 = 339625 day day 1 kcal 24 hours h T2 = -1C t1 = -4C t2 = 0C

Q = 1950000

U = 460 kj/h T1 = 12C

Tlog =

T1 T2 (12 (+3)) = 6.5 T1 12 ln( ) ln 4 T2

Q = U.A.Tlog 339625 = 460 A 6.50 A = 114 m2 In conclusion the heat transfer areas for fermentation and maturing processes happening in different times in the fermentation tank are different either. And the area for maturing is bigger.
Boiling Tank:

As told above we are designing a set of tanks willing to make 8 times boiling a day in which each of them has the capacity of 10.000hl and the total for 80tons of malt. These tanksa are again made of stainless steel. Our tanksa are 6m in diameter and 3.6 m in height. Boiling process happens in outer boilers so we are using pipe type heat exchangers. We took the basis 1 hout for boiling; Looking to the amount of the energy in the heating section of the boiling process: kcal h

QI = 2625000

40

Q = U.A.T 2625000 4.18 = 1950 A (100-65) A=160 m2

Straining Tank:

In this tank water is sprayed from perforated trays. To obtain this 200kg-malt is strained in a standart 1m2 staining area. For our capacity of 10.000kg-malt;
1m 2 = 50m 2 area is needed. 200kg-malt

10.000kg-malt

This 50m2 area is designed to be 8m in diameter and 25m in circumference. Again this tank is made of stainless steel. According to literature for the straining flippers, 6 armed 8.1 rpm system is enough for our process. Straining tank is shaped cyclindrical like mashing tank is. This tank is 8m in diameter, 1.8 m in height and has a capacity of 900hl. Orifices in the tank are thin and splitted. These straining tanks must have the capacity to strain the required malt in 3 hours period.
Plate Cooler:

We are planning to cool the must in 100C to 2C in plate coolers. The heat transfer area of our cooler according to previous mass and energy balances is calculated as;

Tlog =

(100 85) (9 2) 10.50 15 ln 7 kcal m 2 .hC

Qgained = Qgiven = U.A.TU = 1972

Q = mwater x Cpwater x T = U.A.Tlog

69.000 1 (85 2) = 1972 A 10.50 A = 276m2.

41

We assumed the cooling liquid is cold water in 2C.

Filters:

Beer is being filtered to obtain the required clearness. There are many types of filtering; Kieselguhr Filter, Horizontal Filter, Vertical Fitler and Plate Surrounding Filter. We prefer to use Kieselguhr Filter and PVPP(PoliVinilPoliPolidan). PVPP is made of plastic and polimer inert material.
Pumps:

We are using 4 HP powered 4 pumps to meet the water need in our plant. These pumps have total 40 tons water/h pumping capacity. Our plant needs 350 hl water/ hour.
Bottling Machine:

Our beer production capacity is 5000 hl/day. %60 of this amount is for bottling and the rest is for barreling.

8. Location and Layout

The most important raw material of beer is water. Approximately %90-92 of beer consists of water. For this reason the land of the factory must be rich in ground water. Also product wastes need to be removed by the water arcs from the factory. The other important ingredient of beer is malt. So it must be easy to supply the required malt for production. The factory can be nearby the malt factories. We also need hopfen for production. This ingredient can be imported. Another important factor in the choice of the location is marketing strategies. For example factories can be established in cities , in which the beer consumption is too much. If we want

42

to export our production our factory must be nearby the export centers such as airports and seaports. By the way we must pay attention to the land prices, construction expenses. In conclusion we decided to establish our factory in Lleburgaz according to all factors told above. Another factor is the structure of the soil in factory land. The land structure have to be enable to allow locating pipes underground to pump the products to the tanks. The lay out of the plant can be arranged according to process flow. We are establishing the equipments according to their location in the process. So we dont have to pay extra money for pumping anf piping. The main production plan of beer; Malt Boiling Fermentation Maturing Filtration Bottling. Our plant lay-out is in appendix.

9. Economical Analysis
Total Instrument Costs Instruments Mashing Tank Straining Tank Boiling Tank Plate Cooler Fermentation Tank Filter Pumps Quantity 1 1 2 1 23 1 4 Price 120.000$ 30.650$ 147.750$ 150.110$ 192.690$ 304.000$ 350$ Total 120.000$ 30.650$ 295.500$ 150.110$ 4.431.870$ 304.000$ 1400$

43

Bottling Machine TOTAL

900.000$

900.000$ 6.233.530$

Capital Estimation Based on Instrument Price Proportion of Instrument Cost Instruments Building Instruments Instruments and Control Piping Electric System Buildings Enlarging Service Processes Land Direct Expenses Engineering and Control Construction Expenses Indirect Expenses Total Expenses Contractor Expenses Unexpected Fixed Capital Managing Capital 41 74 420 21 42 483 86 2.555.747$ 4.612.812$ 26.180.826$ 1.309.041$ 2.618.082$ 30.107.949$ 5.360.835$ 66 11 18 10 70 6 346 33 4.114.129$ 685.688$ 1.122.035$ 623.353$ 4.363.471$ 374.011$ 21.568.013$ 2.057.064$ 100 47 18 6.233.530$ 2.929.759$ 1.122.035$ Cost

44

TOTAL CAPITAL

569

35.468.735$

Total Product Cost Estimation

As the capacity is assumed 1.200.000 hl/year
Unit Malt Hopfen Cost(kg/$) 0.25 1.5 Proportion of mass(%) 20,5 0,17 24.600.000 204.000 6.150.000 204.000 Net Mass(kg) Cost($)

So 1 lt of beer costs 6.354.000 $ / 120.000.000 lt = 0,053 $ as raw material. The cost of beer is %20 of Total Production Expenses So total production cost is 31.770.000 $ Total cost of 1 lt beer is 31.770.000 $ / 120.000.000 lt = 0,265 $ /lt Marketing Price will be 0.413$ / lt
TOTAL COST PRODUCT = PRODUCTION COSTS + GENERAL EXPENSES PRODUCTION EXPENSES = DIRECT PRODUCTION EXPENSES + FIXED EXPENSES + COMPANY EXPENSES GENERAL EXPENSES = MANAGEMENT EXPENSES + TRANSPORTATION + R&D

45

Production Costs
Proportion of Total Cost(%) Raw Materials Labor Control Labor Maintenance and Repair Laboratory TOTAL 20 20 5 5 10 60 6.354.000$ 6.354.000$ 1.588.500$ 1.588.500$ 3.177.000$ 19.062.000$ Cost ($)

Fixed Expenses
Proportion of Total Cost(%) Corrosion Tax Insurance TOTAL 3 3 4 10 953.100$ 953.100$ 1.270.800$ 3.177.000$ Cost ($)

Company Expenses
Proportion of Total Cost(%) Company Expenses 5 1.588.500$ Cost ($)

46

General Expenses
Proportion of Total Cost(%) Management Expenses Transportation R&D TOTAL GENERAL TOTAL 5 15 5 25 100 1.588.500$ 4.765.500$ 1.588.500$ 7.942.500$ 31.770.000$ Cost ($)

Salary Distrubition
Total Labor Cost is 6.354.000 $
Position General Director Chemical Engineering Mechanical Engineering Electrical Engineering Chemist Workers Security Drivers Managing Officials TOTAL(Monthly) TOTAL(Annual) 8 200 20 20 30 2100 1400 1400 1400 2800 16800 $ 280.000 $ 28.000 $ 28.000 $ 84.000 $ 527.100 $/month 6.354.000 $/year 5 4200 21000 $ 5 4900 24500 $ Person 1 9 Salary ($/month) 7000 4200 Cost ($/month) 7000 $ 37800 $

47

Recovery
In one year period company will gain 120.000.000 x 0.413 = 49.560.000 $ Net Profit = 49.560.000 (120.000.000 x 0.265) = 17.760.000 $ As the capital estimation is calculated = 35.468.735 / 17.760.000 2 years

Cash Flow Diagram

Total Investment = 35.468.735 $ Fixed Capital Investment = 30.107.949 $ Working Capital = 5.360.835 $ Working life = 10 years Cost of Land = 374.011 $ Money Invested at the end of first year = 14.866.969 $ Money Invested at the end of second year = 14.866.969 $ Depreciation = Double Declining Balance Depreciation Method dk = 2/n(FCI - dk) dk3 = 2/10 x (30.107.949 0) = 6.021.589,8 $ dk4 = 2/10 x (30.107.949 6.021.589,8) = 4.817.271,85 $ dk5 = 2/10 x (30.107.949 (dk3 + dk4) = 3.853.817,5 $ dk6 = 3.083.054 $ dk7 = 2.466.443 $ dk8 = 1.973.154,5 $ dk9 = 1.578.523,7 $ dk10 = 1.262.819 $ dk11 = 1.010.255,1 $ dk12 = 808.204,1 $ R COMd = 49.560.000 31.770.000 = 17.790.000 $ From the equation; (R - COMd dk) x (1-t) + dk 3rd year = 14.847.897,5 $ 4rd year = 14.546.818 $

48

5th year = 14.305.954 $ 6th year = 14.113.263 $ 7th year = 13.959.110 $ 8th year = 13.835.788 $ 9th year = 13.737.131 $ 10th year = 13.658.205 $ 11th year = 13.595.064 $ 12th year = 13.544.551 $ The sum of these values = 140.143.781,5 $ Profit = 140.143.781,5 35.468.735 = 104.675.046,5 $ Annual Profit = 104.675.046,5/12 = 8722920,5 $
Cash Flow Diagram
80.000.000 60.000.000 40.000.000 Money 20.000.000 0 -20.000.000 -40.000.000 Year 0 5 10 15

49

10. Conclusion
Beer production of Turkey is sufficient for its own needs. %75 of beer sales are made by EFES PLSEN. Our project is planned to produce %15 need of countrys beer poverty. In consideration with the potential working power and qualified persons, there will be any problems on operating this plant. However, most of the equipments, have to be used in beer production, must be imported from foreign countries, especially from Germany. This causes the establishing expenses to be increased. With hardworking and enough R&D studies on this subject can solve the expensive imported instruments costs problem. Beside this the whole raw materials used in beer production can be gained from our countrys own agriculturel production. So there is no shortage of raw materials indeed. According to economical analyses, our factorys payback time is approximately 2 years. This result is satisfactory and the investment seems feasible.

50

11.Appendix
Tables of Beer Productions and Consumptions Tables of Malt Production Factory Lay-out Plan Fermentation of Etyhl Alcohol Process Flow Diagram Change of Parameters During Fermentation Pictures of Equipments

51

Mashing + Malt Boilers

Fermentation Tanks

Maturing Tanks

Bottling + Bottle Washibg

Filtering

Security
Firehouse
Manageme nt Building

Warehouse

Work shop

Dining Hall + Lockers

Lab

Waste Water Treatment + Steam Production

52

Change of Parameters During Fermentation

Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Day 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

P(BAR) 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 Ph 5 4,58 4,33 4,23 4,19 4,22 4,22 4,22 4,22 4,22 4,22 4,22 4,22 4,22 4,22 4,22

53

Day 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

T(C)
9 12 12 12 12 12 0 -1 -1 -1 -1 -1 -1 -1 -1 -1

Day 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Extract(%) 12,5 10,9 6,15 3,7 2,6 2,2 2,1 2,1 2,1 2,1 2,1 2,1 2,1 2,1 2,1 2,1

54

Some Pictures of Equipments Used in Breweries

Fermentation Tanks

55

56

12. Preferences
ZEN, Il, (1988), ODT Intership Report PALACIOLU, Sibel, (1999) Gazi niversitesi Project and Malting BNGLL, Feyza, (1999), Bira retim Teknolojisi YAVUZLUHANOLU, Bur, Private Meeting, stanbul Internet Resources www.efespilsen.com.tr www.steinecker.com www.tuborg.com.tr www.kimyamuhendisi.com www.odevsitesi.com www.kimyaevi.org KUNZE, International Edition, (1995) Technology Brewing

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