Technological part

Annotation

 

 

In given course work are described studies in the development of technology intensive of brewing syrup from different kinds of cereals raw material, modern technological scheme production of brewing syrup, selection and justification of the technological scheme, characteristics of raw materials, auxiliary materials, finished goods, the calculation of the annual fund of working time, calculation of performance, calculation of consumption of raw, the calculation of basic technological equipment.

This course work consists of five sections: an analytical review, including a patent search; selection and justification of the technological scheme; calculation of consumption of raw, the calculation of basic technological equipment and safety; out at 34 pages, 3 tables, 3 figures.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Contents

 

 

Normative references	5
Definition	6
Designations and reductions	7
Introduction	8
1 Analytical part	10
1 Analytical review. Modern technology production of brewing syrup	11
2 Technological part	16
2.1 Selection and justification of the technological scheme	16
2.2 Description of the technological lines	19
2.3 Characteristics of raw materials, auxiliary materials, finished goods	21
2.4 Technological conclusion	24
2.4.1Annual working time fund 2.4.2The calculation of the production of products	25
2.4.3 The calculation of basic technological equipment	27
3 Safety	32
Conclusion	39
List of used literature

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Normative references

 

 

In the present course work references to the following documents are used:

GOST 21947-76. Hops are pressed. Technical conditions.

GOST 12786-80. Beer. Acceptance rules and methods of sampling. 

GOST 12787-81. Beer.  Methods for determination of alcohol, real extract and calculation of solids.

GOST 27186 86 Beer. Terms and concepts in the field of brewing. 

GOST 5060-86. Malting barley. Technical conditions.

GOST 12788-87. Beer. Methods for determination of acidity.

GOST 12789-87. Beer. Methods for determination of color.

GOST 29294-92. Malt Brewing barley. Technical conditions.

GOST 30060-93. Beer. Methods for determination of the organoleptic indicators and volume production.

GOST 51174-98 (01.07.2008) Beer. General technical conditions.

GOST r 51154-98. Beer. Methods for determination of carbon dioxide and resistance. 

GOST r 53070-2008. Beer. Methods for determination of Ph. 

GOST r 53358-2009. Products of brewing. Terms and definitions.

GOST 53459-2009. Beer special. General technical conditions. 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Definition

 

 

Beer - is bubbly, refreshing, low-alcohol drink, carbonated, with a pleasant hop bitterness and flavor. Beer quenches thirst, increases overall body, contributes to proper metabolism, as it contains carbohydrates, proteins, vitamins and organic acids, the energy capacity of lager 1700-2200 kJ / kg, dark - 3400kDzh/kg

Beer - low-alcohol (1.5 to 6% by volume of alcohol) frothy drink. Manufactured alcoholic fermentation of malt with brewer's yeast. In most varieties of beer hops are added. Besides the traditional malt from barley, must be produced from other sugar-containing products (eg, rice, beer, fruit beer, honey beer, etc.).

Fermentation - the process of fermentation is the conversion of carbohydrates by culturing the yeast into ethanol (alcohol) and carbon dioxide (carbonic acid). There is the main fermentation and maturation. The main fermentation takes place in several stages, which are characterized by a change in temperature, decrease wort extract content and the degree of lightening. The duration of the main fermentation is between 7 to 10 days. At the end of the main surface of the fermenting young beer foam covered with a uniform layer thickness of 1 cm There are upstream and downstream, depending on the fermentation of yeast used.

Maturation - after main fermentation, young beer is not suitable for use, as it has a significant turbidity, distinctive taste and aroma. He was sent to closed apparatus for fermentation, where a small amount of slow fermented sugar, beer lightened and saturated with carbon dioxide, becomes clear and creamy. Different varieties of maturation takes a different time, for example, for Zhiguli beer - 21 days.

Spent grain beer - formed during the filtration of congestion as a precipitate after the separation of the liquid phase (wort). Fresh grains is a thick light brown color with a specific aroma and flavor. It contains covers of grain, neosaharenny starch, proteins, tannins.

Yeast - single-celled organisms of plant origin, which are the causative agents of fermentation. In brewing used eukaryotic yeast fermentation Saccaromyces cerevisiae and bottom-fermenting Saccaromyces carlsbergensis. Fermenting yeast at the end of fermentation, rise to the surface and bottom - deposited a thick layer on the bottom of the tank.

Mashing -the process of mixing the crushed malt or a mixture of crushed malt and unmalted raw materials and water, with the addition of enzymes to bring in a dissolved state the maximum number of agents. There infusion and decoction mashing ways. The use of a particular method of mashing on the quality of malt and beer names. Mashing is a mash vehicles.

Malt - it is barley that has been soaked, proraschen, and then dried. Variety of barley germination and length of drying temperature affects the taste of malt beer. There are also wheat, rye and other malt.

Malt-house - this is a room intended for making malt. It is carried out soaking, germination and drying malt.

Malting - the purpose of malting is the synthesis and activation of inactive enzymes, which influenced the process of mashing achieved dissolution of reserve substances grain. This is the process by which soaked grains germinate within 7-9 days

Hop - this is a climbing perennial plant of the family Konoplev. Brewing hops grown relating to the form of an ordinary hop (Humulus lupulis L.), and uses only bumps.

Hops -  these include briquetted hop pellets, hop extracts, combined preparations of hops. The world market is supplied 30% of granulated hops, hop extract 30%, and 40% of natural Shishkov hops.

Six-row barley - barley, which develops from the seed of each flower. This spring and winter barley. Its grains are heterogeneous in size.

Extract of barley - it is the sum of all substances of barley, expressed in% by weight of dry matter, which go into solution.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Designations and reductions

 

 

Ton- tone

kg – kilogram

g - gram

m² - square meter

m³ - cubic meter

l – liter

Mm – millimeter  

h – hours

Min-minute

 l / h - liters per hour

%- humidity by percent

°С- temperature by degree Celsius

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Introduction

 
 
     Beer is a sparkling, refreshing drink with a distinctive hoppy aroma and a pleasant bitter taste, saturated with carbon dioxide (carbon dioxide) produced in the fermentation process. It not only quenches thirst, but also increases the overall tone of the human body, promotes better metabolism.

Brewing is one of the oldest industries. It is assumed that even a 7 th century BC Babylon beer brewed from malted barley and wheat. The method then brewing spread among the people living in the Caucasus and south of Europe, and later in Europe.

The most important starting point for the development of industrial brewing was the invention of the steam and chiller. By the late 19th century, about a third of the plants were equipped with steam engines, and then some of them began to use electricity.

Currently, many enterprises have up to date high-performance equipment. Special attention is given to improving clarification and bottling of beer. 
When brewing takes many physico-chemical, biochemical and other processes causing the quality and taste of the final product performance. Control of these processes and getting a drink of high quality requires working knowledge of the technology and equipment, advanced methods of work, high responsibility for their work. Volumes of production of amber drink in Russia has increased over the past five years, largely due to increased foreign investment, modernization of equipment, marketing policy.

In the modern, highly competitive ability of beer stored for a long time was a prerequisite for its successful implementation. This usually helps brewers quality filtration and as a complement to it, pasteurization. Unfortunately, both of these methods damage the original organoleptic beer, but a radical alternative to them has not. The necessary degree of transparency of beer traditionally achieved through the quality filtering. A filtration, in this case, refers to the separation from beer suspended particles, yeast cells and microorganisms.

The purpose of this course work is development of intensive technology of brewing syrup from different kinds cereals raw material

 

 

 

 

 

 

 

 

 

 

 

 

1 Analytical review. Modern technology production of brewing syrup

 

 

The modern process of beer consists of six main stages:

• Preparation of malt (malting);

• mashing;

• cooking the main (primary) must;

• fermentation;

• maturation (ripening);

• bottling.

Preparation of malt (malting). Malt - a specially worked grains, germinated and dried. Malting raw materials in beer production is mandatory operation, which causes further successful completion of the fermentation process.

To carry out the fermentation is necessary that the fermented wort contain a certain percentage of sugar, which is the main substrate for the yeast, during the life of which sugars are converted into alcohol and carbon dioxide.

When germinated grain in it starts to flow a set of complex biochemical processes, the main of which is the enzymatic decomposition of starch polysaccharides and plant proteins of grain to simple sugars.

In brewing malt is used in various types of grain, mainly wheat and barley. However, in various regions of the world other than barley and wheat used rice, corn, oats, millet, sorghum, cassava, rye, soybeans and other crops that contain starch. Naturally, this is not the barley beer flavor, and this lack of manufacturers often try to eliminate by artificial flavors.

Barley malt of high quality can be easily processed, gives the wort a lot of extractives, beer out of the malt is suitable for long term storage.

Wheat should meet as rigorous requirements, and barley. Wheat, in contrast to barley, have spines - long sharp processes required to perform filtering mash mass grains do not stick together and freely passes through a must. However, wheat malt is prepared in much the same way as barley. But mealy barley grow better and produce more quality malt.

Preparation consists of soaking the malt grain germination, drying, separation and purification of germs finished malt. Barley is soaked (with simultaneous washing) for a few days, changing the water twice a day. In this case, the moisture content in the grain increases to 50%. The old brewery grain germinated malt houses - in basements and currents, which maintains a constant temperature and high humidity, provides fresh air and clean carefully observed. Soaked barley is spread in a thin layer on a clean concrete floor and stir every few hours.

After 36 hours the grain begins to germinate, and therefore it is noticeably warm. Germination to remain normal, grain temperature should be 17-18oC, and in any case not exceed 22,5 oC, otherwise germs will die. Germination usually done within 4-10 days, depending on the initial condition and quality of incoming grain for malting. During this time, the roots grow from the seeds of a length of about 1-1.5 length of grain.

At this stage in the grain produced the greatest number of substances needed for the fermentation process. Further growth leads to the fact that the embryo begins to absorb monosaccharides formed, so at this stage malting stopped.

To stop further germination finished malt, it is dried in a well ventilated area or in elevators. Sprouted grains purged air temperature is gradually increased. During the drying of the grain moisture is almost completely removed (residual content of 2-4%), in addition, the grain is destroyed at the cellular level, resulting in an additional enzymes are released.

For dark beers used the so-called color (caramelized) malt, which is made from malt, prozharivaya it at 170-200oC in rotary drum furnaces, such as those which are used for roasting coffee. Strongly roasted malt can be chocolate, dark brown or almost black. Adding only 1-2% colored malt, which turned into starch caramelized sugar gives the beer a dark rich color.

The dried and roasted malt is treated in special machines to remove germs that contain a set of substances with a bitter taste, which can affect the taste of beer. At this malting ends. Before the next stage, when the grain is crushed, ready to stand up for a while malt, usually at least 4-6 weeks. However, the malt should not be stored for too long or in the wrong circumstances. After 3 months of storage malt, especially dark, loses its characteristic flavor.

Barley even one species can produce uneven quality malt. It depends on the area of its cultivation, just as in the wine extremely important is the location of the vineyard. Variations in climatic conditions during the year also affect the important qualities of barley - the water content and grain protein and its germination. Why not buy some brewers barley on the market and deal directly with the farmers who grow the raw materials for their orders.

Mashing. Mashing for each beer is held with its technological nuances, but the overall situation remains unchanged. First malt is ground in the mill. Ground malt should not be uniform, but consist of both shallow and of coarse grains, as well as the fine flour, and corn spine should remain almost intact. Different beers require different ratios of small and large particles in the crushed malt.

Crushed malt and water are mixed in a vat smoothers (a mixture of crushed malt and water is called wort), and the renewed activity of enzymes, stalled since the drying malt. Reactivated enzymes begin to convert the starch, which contains 70% of grain, malt sugar. To speed up the fermentation process, congestion is gradually heated to a temperature of saccharification - 76oC. As a result, almost all of the remainder is split starch into sugars and dextrins which are in the process of mashing water soluble.

The resulting mass is transferred for treatment in a special container that resembles a large screen, which is still closed at the bottom. Nipped malt leave here for a while, to have settled to the bottom of insoluble particles, which are called 'grains. Thanks ostyam intact grains does not stick together, acting as an additional filter layer. When the screen is opened, through and spent grain mash leaks clear light, which is a solution of sugars that have fallen into it from the malt.

When mashing the special role played by the quality of water used to produce a mash. Ordinary water is not suitable for beer, as in excess contains lime salts - carbonates. Not suitable for the production of beer and drinking water, as some minerals, useful and desirable in drinking water, making it unsuitable for brewing. So the water for beer artificially soften. Summarizing, we can say that the water for the beer should not be too hard and alkaline

Cooking the main (primary) must. In the digester is heated and wort boiling. At this point in the future beer hops are added. The dose depends on many factors - the variety and quality of the hops, and the properties of water and beer, which are going to cook. This is a crucial decision brewer takes on the basis of their experience and intuition.

Hops (Homulus lupulus) - an annual climbing plant, belongs to the family Konoplev shoots which can climb to a height of 6-8 meters. Hops - bisexual (dioecious) plant. In brewing used only unpollinated female flowers - soft fluffy bumps. In them the necessary materials beer concentrated the most.

Hop cones secrete a bitter resinous substance - lupulin containing a large amount of aromatic resins and essential oils, in particular the alpha acids (humulone) and beta-acids (lupulony) and tannins, alkaloids, etc.

The most important for brewing are alpha acids. Hops gives the beer a pleasant bitterness and characteristic aroma, increases transparency, improves foam. In addition, hops - a natural antiseptic and preservative, it inhibits the activity of bacteria and prevents souring wort and finished beer. To cook one hectoliters (100 liters) of beer goes from 200-700 grams of hops.

Cooking main wort goes 1.5-3 hours. Under the influence of prolonged heating in the must kill all microorganisms and natural enzymes are destroyed, so the composition of the wort is not happening any biochemical changes. Contained in hop lupulin partially dissolved in the wort, reacting with components, and giving the beer a characteristic bitterness. While cooking, measure the level of extractive, or density, the main (primary) must. Wort density, measured as a percentage, is a very important indicator, the higher the density of the wort, the more strong beer is available during the subsequent fermentation process.

Boiled wort is filtered from the remnants of hops and let it settle. In this case, the bottom ends up even the smallest particles that were not removed by filtering. By accelerated technology precipitate is in the centrifuge.

Fermentation. Boiled wort passed through pipes to the fermentation vat. Before proceeding to the stage of fermentation, the wort is cooled. For mounted beer wort requires a temperature of 18 to 25oC, bottom-fermented beer - from 5 to 10oC. There is, however, a new technology accelerated bottom-fermenting beer, which allowed the wort temperature around 18-20oC, which reduces the duration of fermentation by about half.

Yeast used in beer production can be divided into three main categories - fermented, bottom fermented and "wild." In the process of fermentation mash fermenting yeast (S. cerevisiae) pop up. Bottom-fermenting yeast (S. uvarum) at the end of fermentation, fall to the bottom fermentation tank and prefer to grow at a much lower temperature than the horse's yeast (hence the separation of beer on upstream and downstream.) To "wild" yeast are S. candida and others (by spontaneous fermentation today prepare only some types of beer in Belgium). All know of at least 500 types of yeast, not counting the huge number of wild strains. 
100 liters of beer wort on average consumes 0.5 liters of bottom-fermenting yeast wiring or half the amount of wiring yeast fermentation. Of finished beer yeast is extracted four times more than had been made in the wort at the beginning of the fermentation process. Usually after ten cycles of fermentation yeast replaced with a fresh culture.

About a day after the laying of the yeast on the surface of wort thick yellowish-white foam. This shows that the yeast have already begun their livelihoods, in which malt sugar is converted into alcohol and carbon dioxide. The degree of attenuation is determined saccharometer beer.