SUMMER TRAINING

AT UNITED BREWERIES LTD. LUDHIANA

ABHISHEK GARG 100901001

Company Profile
UB Group was founded by a Scottish gentleman Thomas Leishman in 1915. In August 1947, Vittal Mallya became the company's first Indian director. Vijay Mallya assumed the mantle of the group in 1983. UBL, Ludhiana is a kingfisher beer manufacturing plant.

Brands
Kingfisher Strong Kingfisher Light Kingfisher Black Label Kingfisher Red

Whats in a Beer?
BARLEY the body & soul of beer

YEAST the life of beer

HOPS the spice of beer WATER the integrity & purity of beer

ADJUNCTS Additive grains like rice

or corn, fruit or spices

Brewery process

Malting
Malting is a process applied to cereal grains converting their insoluble starch to soluble starch, reducing complex proteins, generating nutrients for yeast development, and the development of enzymes.

Handling of raw material:

Screw conveyors: one of the oldest, versatile conveyor consists of helicoids flight, mounted on a shaft and turning in a trough. Bucket elevators: simplest for vertical lifts, equipped with buckets and mounted on a belt or a chain, handle any free flowing or small- lump material.

 Steeping:
To hydrate the endosperm mass and to allow uniform growth during germination, begins by mixing with barley kernels with water to raise moisture level and activate metabolic processes. Major functions: i. Raise the moisture content from 12% to 40%. ii. Wash the grain and remove floating material.

 Germination:
Barley is germinated by maintaining at a suitable temperature, creates a number of enzymes, notably -amylase and -amylase to convert grain starch into sugar. Objectives: i. control breakdown of cell wall ii. produce optimal level of enzymes

 Kilning:
When hot air dries and kills green malt which is then heated at temperatures beginning at about 50C and reaching a final temperature between 80C and 100C, releases a wide variety of flavors and colors by a series browning reactions between sugars and amino acids called Maillard Reactions. Objectives: i. Terminate the modification process and the growth of the plant. ii. Reduce moisture to levels suitable for grain storage. iii. Conserve enzyme complexes developed during malting.

 Drying:
The process can be managed by the temperature of fresh air and performance of the fan.
The drying process starts at the lower layer and constantly develops through the bed. After 10 12 hrs, the temperature above the bed is rising and relative humidity of the exhaust air is decreasing.

Screening
Foreign objects, such as stones or stray metal parts, can ruin a mill. Therefore they must be removed from the malt before milling. In a dry mill, such objects can also generate sparks, which pose an explosion danger. So before milling, we screen the grains two times through shaking or vibration screens, to remove dust particles, small stones, stray metal parts and other rags. After screening, malt is sent to roller mill through bucket elevator.

Milling
Objectives:
Split the husk longitudinally, exposing and separating the endosperm, without tearing the hulls Crush the endosperm allowing complete wetting and therefore rapid extraction and enzymic digestion. Minimize the quantity of fine flour produced.

Six-roller mill

Rice cooker
Two types of rice are used: Rice flakes Broken rice

Ingredients we put in rice cooker:

Broken rice Water Gypsum Termamyl

Mashing
Pre mashing is done Add adjuncts Malt is delivered to mash tun Heat is applied Ingredients to add Gypsum Calcium chloride Lactic acid Promalt Iodine test

Lautering
Lautering is the separation of the extracts during mashing from the spent grain. The filtration can be carried out with lauter tun . Two stages: First wort run-off: During which the extract is separated in an undiluted state from the spent grains Sparging: In which extract which remains with the grains is rinsed off with hot water.

Wort Boiling
Wort: filtrated fluid obtained from the mashing and lautering process. aqueous liquid that contains mainly fermentable sugars. Wort boiling is a complex process during which a wide range of chemical, physico-chemical, physical and biochemical reactions take place. It is the most energy intensive stage in the brewing process. Process operation through external heating system (vertical calandria)

Hops Spice of Beer

Hop flowers are used for:
Microbial stabilization Hop aroma Bitterness Foam stabilization

Whirlpooling
The whirlpool kettle is used to separate undesirable substances from the hot wort. The particle size of these substances is only 30-80 m. A whirlpool is a hydrodynamic trub separator using centrifugal forces to sediment insoluble substances from the wort after boiling. Further, wort must be cooled i.e., carried out in a close system, mainly plate heat exchangers and after that sent to another sections viz. fermentation section, etc. for further processes to make a beer.

Conclusion

This six week training led me to conclude and analyze the importance of our chemical branch knowledge in various aspects of society and our life.

How about a beer?

Thank you.