Technological part

After completion of the fermentation, most beer is filtered through diatomaceous earth, which ensures the separation of yeast. Recently, however, is increasing worldwide popularity of unfiltered and unpasteurized beer. It is very useful, as it contains live yeast cells, which also give the beer more flavors.

Maturation (maturation) of beer. As a result of fermentation are immature, or so-called "green" beer, which has yet to mature, it takes a few weeks to four months. Fermentation (a secondary fermentation, quiet fermentation) and the maturation of beer is in large stainless steel tanks. Camp (aged) beer must be maintained at a temperature of 2,5-5oC in special tanks for 1-4 months without oxygen.

The exception is white wheat beer and some upland varieties, which at the end of the main fermentation once bottled, where they ripen. By exposing the bottom-fermented beer is very important to carefully follow the temperature and maintain a constant pressure in fermentation tanks. This is followed by automatic equipment, which does not allow these indicators deviate from the desired level. After maturing beer further purified and filtered, and then bottled in various product packages.

Bottling. Filling is carried out in metal drums, kegs, plastic bottles and aluminum cans, but the main cash container in beer production is still a glass bottle.

Glass bottles are carefully sorted, inspected and cleaned, and only then they poured beer and sealed under pressure to prevent foaming during filling beer. Filled with beer bottles pasteurized - heated slowly to about 65oC. Pasteurization stops fermentation and significantly increases the resistance of beer. After the bottles of beer cooled in the future, up to the implementation, stored and transported in the dark and cool.

Range of beers shared depending on the formulation and manufacturing of two types: light and dark. Blonde beers are amber and heady flavor, dark - brown color and malty flavor. Certain types of beer for different organoleptic characteristics, particle mass of solids in the wort and alcohol.

Certain kinds of different beers for flavor and aroma. So, for beer Donetsk characteristic soft, intoxicating taste, light for Kiev - pronounced hop flavor with slight aftertaste guilty to Ukrainian - slightly sweet taste and a malty flavor yasnovirazheny.

In recent years the range of light beer has expanded to almost every brewery develops his view, although the known and traditional: Obolon, Golden Spike, Slavic, Galich, Podolsk, Pereyaslavske, Amber and others have developed national mass beers, Ukrainian and Ukrainian special light instead zhigulevskogo special and high-quality types - Ukrainian and Ukrainian original golden color, which is manufactured by technology of beer from a persistent storage life of at least 3 months.

Beer by the method of processing is divided into filtered and unfiltered, filtered beer - pasteurized and unpasteurized, unfiltered - for clarification and unclarified.  
Russian beer market with an extensive product range, which is the main part of the five basic types: light, dark, red, white and strong. About 90% of the domestic beer market is occupied light varieties, which account for the bulk of sales, with the remaining 10% share the other varieties, mostly dark. Now "in fashion" unfiltered beers.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2 Technological part

 

2.1 Selection and justification of the technological scheme

 

Beer production is composed of the following stages: preparation of wort, fermentation, maturation, clarification, bottling, pasteurization, processing, bottles, storage of beer.

Preparation of wort produced in the cooking compartment. Pulping process used to complete extraction and dissolution of extractives dry malt, unmalted materials used and hops, creating favorable conditions for the enzymatic hydrolysis of starch, protein, fiber and other components of the raw material. requires a certain acidity (pH 5.2-5.6), and at its alkalization water use lactic acid, etc.

Preparation of wort is polishing and grinding of malt and unmalted materials (up to 40% instead of malt, most often corn or barley flour and semolina), cooking and saccharification of wort, wort filtration, boiling it with the hops, hop pellets department.

Polished malt on polishing machine SP-54, which made the selection of germs, dust and dirt, and then load the malt into the key device for up to 30% moisture, and then sent to four or six rolls crusher for crushing the shells with minimal disruption. Products are characterized by the following composition (%): 12-20 husks, large grit 20-35, 25-50 middlings, wheat 15-20.

Mashing grain products are mainly for decoction method, as now, along with the malt used unmalted materials that are best processed through it. Decoction way is that to increase the mash temperature part (otvarku) were taken to another machine to boil, then mixed with boiled otvarku part of the mash.

Depending on the number otvarok distinguish DHTO, two - and how trehotvrochny mashing. Duration mashing increases with the number otvarok - 3.5 h, 4-5h, 6-6.5 h, similar increases and steam consumption. Zhigulevskoe, Moscow and Leningrad beer is ready for a more rational way dvuhotvarochnomu. 
When mashing the machine collect water: 3.0 - 4.0 liters per 1 kg of raw material temperatures up to 45 C, with the agitator making malt, barley and enzyme preparation after mixing determine the pH of mash and, if necessary, add lactic acid, about 0 , 09% by weight of the grist. At a temperature of 40 C content is kept for about 15 minutes, then heated to 52 C at 1 C for 1 minute and make a protein pause (at this temperature, hydrolyzed protein in 20 - 30 minutes. Again raise the temperature at the same speed of up to 72 C and maintained 40 minutes to complete saccharification. Having defended the liquid portion by clamping the pipe is lowered into the other machine, mixed with the previously rolled out the liquid portion and at 76 C for 15 - 20 minutes all saccharifying mash.

Saccharified mash is pumped to filter and filter through their same pellet at 76 - 78 C. The first wort is first separated and then washed with hot water from the spent grain left in her extract. Filtration through filter wort - press accelerates and improves the extract yield of 1%. Pellet was removed or steam ejector pump with water.

After filtration, the wort is boiled in the brew kettle, hops enter depending on the type of beer just before boiling or in 2-3 hours and in order to save his recently boiled wort pressure 0.02 - 0.03 MPa. The duration of boiling 1.5 - 2 hours. Then measures the volume of wort, and non passed hop peeling apparatus. 
The diagram shows four vessel apparatus.

Brewery. These units are designed for 3 tons of raw materials and provide 4 cooking daily. When replacing the filter - the filter unit - press the number of brews increases up to 5 times a day. In six vessel mash unit includes two boilers, two filters - the unit and two brewing apparatus. When you load 3 tons of raw materials, they allow you to do six brews a day, with a heavy load - 5 brews.

 

 

Figure 1. Flow sheet of production of beer.

From brew kettle hopped wort gravity to a hop peeling apparatus for separating sieve pellet hops, it is washed and the wash water with the filtered wort is pumped out to lighten the pump and cooling.

Wort clarification is achieved by boiling remove coiled proteins, giving a rough beer bitterness. Clarification process is carried out by settling or separation. After clarification of the wort is cooled in a heat exchanger type irrigation "Ruba in the pipe" and plate heat exchangers to a temperature of 5 - 6 C and produces seeds for sowing yeast.

The process of fermenting wort is carried out in two stages in two separate areas and under different conditions and modes. The first stage - the main fermentation (Figure) - is in the fermentation room and ends with the receipt of the wort and yeast, green beer. The second stage - maturation - is carried out in the basement of the camp, freed from the green beer yeast saturated CO2, matures and becomes ready to drink.

Clarified wort is fermented brewer's yeast bottom fermentation at 6 - 9 dobrazhivayut C and at 1 - 2 ° C. at the end of fermentation, the yeast settles to the bottom and lighten beer. Settling yeast reuse 10 - 15 times as seed.

There are different lines for beer. They may contain a cavity equipped with a line that is a bottling machine, washing machine. But there are lines that perform these operations in other shops. The different types of lines for the production of beer.

 

 

Figure 2. Hardware and technological scheme of beer

 

Below is a complicated scheme of beer production. The circuit consists of the following units: hopper, roller mill, automatic scales, conveyors, silos, malt, mash devices, filtration devices, brewing machine, hop separator, fermentation tanks, tanks for fermentation, apparatus for carbonization, sterilizer bottle machine filling

machine, labeling apparatus, trucks, tank trucks and measuring tanks.

 

 

Figure 3. Hardware and technological scheme of beer

 

Below is a schematic flow diagram of beer (expand), that is, with all the intermediates and outgoing products.

This circuit (shown below) corresponds to the scheme of the apparatus of beer and wheat is the main raw materials and operations and the main unit.

 

 

Figure 4. Hardware and technological scheme of beer

 

Figure 5.Scheme of beer on the mini-breweries

 

 

2.2 Description of the technological scheme

 

Mass production of beer is based on the technological schemes, and provides extensive use of mechanization and automation of certain processes.

Machine-circuit instrumental complex technological equipment for unfiltered beer is shown in Fig. 1. The system is designed for the production of unfiltered and unpasteurized beer with improved taste and high biological value, as well as other varieties of beer.

Brewhouse equipped crusher 1 for malt and unmalted materials, filtration 3, Mash Tun 4, 6 hydrocyclone apparatus, plate heat exchanger 8, trolley pellet 2, hot water tank 9, remote management and control of electrical power panel. Mash Tun device comes with an integrated steam generator.

Branch fermentation and maturation are equipped with three vertical fermenter 10, nine vertical beer fermentation apparatus 11, with a capacity for storage and bottling of the finished beer 15.

The feedstock enters the Mash Tun device 4 for mashing crushed malt with water and further processing of the mixture: saccharification, mash and wort boiling with hops. The unit is equipped with a propeller stirrer driven gearbox and motor to heat the mash and wort boiling equipped steam jacket. Cooking process, in some cases, completely automated.

3 filter apparatus for separating the wort from the spent grain and subsequent leaching of spent grains with hot water, is a cylinder with a flat bottom, upon which collapsible filtration sieve with slotted and ribbed mechanism with a drive. 
After filtration, the spent grains in the remaining 30% must, for its extraction pellet was washed with hot water, using irrigation and baking powder filtration apparatus. Water for washing is heated in the cylinder with a pumping station. Filtered wort is pumped back into the touch-brewing machine 4 for boiling and hopping. Next wort enters the hydrocyclone unit 6, which advocated. The device is equipped with two valves - one for the descent must on a plate heat exchanger, the second - sludge and wash water.

After completion of settling wort is pumped to the final cooling to 12-18o C through the plate cooler 8. Cooling sections dividing plates produced brine.

The cooled wort goes into a fermentation tank 10 to the main fermentation. The process is accompanied by the release of heat, which is drained by means of external cooling jackets.

Figure 6.  Hardware and technological scheme of beer from wheat

 

2.3 Characteristics of raw materials, auxiliary materials, finished goods

 

The main raw material for the production of beer is barley.

Characteristics of  barley. The main raw material for beer is barley malt (sprouted barley), derived from the brewing barley. Barley belongs to the family Gramineae, family Gordeum. Two-row and six-row happens. In Figure 7 Showing ears and double-row and six-row barley used and the shape and location of the grain on the rods. Two-row barley, mostly spring and six-row - spring and winter. Used for beer-row barley, six-row is used for animal feed (fodder).

In brewing barley thinner shell grain, high starch content and protein content, is lowered. The structure of the barley grain. Barley grain (Fig. 2.) Consists of two germ, endosperm (mealy body) 6 and membranes 8.9. The embryo is at the lower end of the grain. Consists of embryonic leaf-plumule 3 and embryonic root 1. embryo is the main part of the grain which is responsible for its germination. The germ is separated from the endosperm flap 5, through which the cells during germination are fed nutrients. Endosperm of the grain-powdery. Composed of large cells filled with starch and protein. Thin cell walls are composed of hemicellulose. The outer part of the endosperm is the aleurone layer 7, which consists of three layers of thick-walled cells containing the protein and fat. As we approach the embryo thickness decreases, and near the aleurone layer of the embryo disappears. 4 near the endosperm cell embryo does not contain starch, unnecessarily it was spent during ripening and storage of grain. In this layer, during germination, it's a big part of the enzyme. Shell. Grains surrounded by a shell, which are located in the following order: external - Floral film 9, beneath the fruit, then the seed of the film 8. If floral film fused with endosperm, a barley called filmy, if not healed, the hull-less. In hull-less barley film, threshing, separate. In brewing barley use filmy.

Membrane protects the grain from damage, passed into the water, but retain salt. In a lot of them are in the pulp, which has no value in brewing. Some substances membranes (polyphenol, nitrogen, lipids, silicic acid, bitter substances) affect the quality of the beer.

The chemical composition of the grain. The chemical composition of the grain complex. Dry matter is the amount of organic and inorganic substances. Organic is mostly protein and carbohydrates, and fats, polyphenols, organic acids, vitamins, etc. is Inorganic phosphorus, sulfur, silicon, potassium, sodium, magnesium, calcium, iron and chlorine. Some of them are associated with organic compounds.

 

Figure 7. Ears two-row (a) and six-row (b) barley

 

Brewer's yeast.

Races of brewer's yeast. In breweries use only cultural yeast, which belong to the family saharometsetatsea (Saccharomycetaceae) and the genus saharomitses (Saccharomyces). Bottom-fermenting yeast distinguish saharomitses karlsbergensis (Saccharomyces carlsbergensis) and fermenting yeast - saharomitses tserevizie (Saccharomyces cerevisiae).

Were originally known fermenting yeast as fermentation took place only under normal temperature (as in wine making, bread making). wanting to get drinks, carbonated, began to carry out the fermentation at low temperatures. Under the influence of the changing external environment, and obtained top-fermenting yeast with certain properties.

brewing yeast species used, differing from each other by one or more features. They are produced from a single cell. such cultures are called races (strains). 
Fermenting yeast in intensive broeniya resurfacing fermented fluid to accumulate in the form of a layer of foam, and remain in that form until the end of fermentation. Then they settle, forming a very loose layer on the bottom of the fermentation unit. Structure of these yeasts are pulverized yeast, not stuck together as opposed to a bottom-flake yeast hulls sticky, which leads to adhesion (agglutination) and rapid sedimentation of cells.

Bottom-fermenting yeast does not go into the surface layer of beer foam, and quickly settle to the bottom of the fermenter.

The ability of yeast to flocculation is important for digestion technology wort as lightening speeds up and facilitates the removal of beer yeast from the fermenter after fermentation and then use them as a seed yeast. Low temperature during fermentation contributes flocculation.

The reaction medium strongly influences the properties of yeast. For example, in an acid medium at pH less than 3 and in the alkaline pH of more than 8 flocculating yeast are dust-like. Flocculating yeast compared with dust-like cells have larger, less prone to autolysis, give a large increase in biomass are less fermentative activity, produce less diacetyl and higher alcohols in beer, which is good for its quality.

Bottom-fermenting yeast different from yeast fermentation so that they are fully fermented raffinose. Bottom-fermenting yeasts have an optimum temperature for growth of 25 - 27C, minimum 2-3C, and at 60-65c, they die. Maximum development of grassroots yeast occurs rN4,8-5, 3. Oxygen dissolved in the wort, promotes proliferation of yeast, while the fermentation products (ethanol, carbon dioxide, higher alcohols, acetaldehyde, acids), as well as an increased concentration of glucose inhibits the development of yeast.

Brewer's yeast should meet the following requirements: Fast fermenting wort well to form flakes and clarify the beer during fermentation, give the beer a clean taste and pleasant aroma.

Malt. Getting freshly sprouting malt. Schematic diagram of the malt.

 

grain

 

Storage of grain

 

Secondary treatment of grain

 

Sort of grain

 

Cleaning and disinfection of grain

 

Soaking of grains

 

Sprouting of grains

 

Drying of freshly germinated malt

 

Separation of malt sprouts

 

Curing dry malt

 

on production

 

1 Sort

 

2 Sort

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 8.  The scheme of the barley malt

The main raw material for production of beer is malt, barley germination obtained at a certain temperature and humidity. This process is called malting, and the product was fresh sprouted malt. The main purpose of malting - accumulation in the grain maximum number of enzymes.

Freshly sprouting malt is dried at an elevated temperature. In this case, it accumulates aromatic and coloring agents. As a result of drying malt freshly sprouting increases it further storage. Separated from the dried malt (kicking) germs.The figure 8 above shows the scheme of the barley malt.

 

2.4 Technological conclusion

 

2.4.1Annual working time fund

 

Annual fund-time 365-109 = 256 working days, which is composed of the following deduction stops factory in days:

Holiday………………………………………………………………………….8

Day off .………………………………………………………………………..75

For major repairs............................................... ............................................... 17

Retiring at the expense of pre-holiday

and day off………………............................................... ................................... 9

Total…………………..………………………………………………………109

 

2.4.2The calculation of the production of products

 

Background: 
Annual capacity for the production of beer М _ац = 2,2 million dal / year

Annual capacity for the production of bottled beer V = 0,5 L

М_бут = 1,1 million dal / year

Annual capacity for production of vatted beer V = 50 L

М _боч = 0,55 million dal / year

Annual capacity on shipping in tank-car М _ац = 0,55 million dal / year

consumption malt mashing g _с = 85/100 kg of grain products

Consumption of barley flour for mashing g _я = 15/100 kg of grain products

Light malt moisture W _с = 5.6%

moisture barley flour W _я = 15%

Light malt extract content Э _с = 76%

extract content of barley flour Э _я = 72%

normal spoilage hop g _нх =22 g/dal

the initial concentration of the wort С = 11%

the relative density of the wort d=1,0442

 

1. Consumption of commercial malt light gts, kg/100 kg of grain products,