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.

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,