BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULITY OF CHEMICAL AND FOOD ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEEERING
INTERNSHIP REPORT BY:-
NAME ID No.

1) SEMON WORKU 0601458

2) LEMLEM MESFIN 0601059
3) WORKINEH ALEMU 0601762

HOSTING COMPANY: B.G.I ETHIOPIA A.A

DURATION OF INTERNSHIP: 4 MONTHS (Mar 1 – Jun 30, 2017 G.C)

Submission Date

21/10/2009 E.C

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 Declaration
We hereby declare that this report is based on our experience in B.G.I. Ethiopia from March 1,
2017 – June 30, 2017 G.C under our faculty mentor Ms. Mahider and Company Advisor Mr.
Wasihun. The report has been submitted to Bahirdar University in partial fulfillment of the
requirements of engineering internship program in Chemical engineering department.
Name of student Signature Date
1. Semon Worku _____________ ________________
2. Lemlem Mesfin _____________ ________________
3. Workineh Alemu _____________ ________________

Mentor approval
This is to certify that the above statement made by the candidates is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.
Name of mentor ______________________________ Signature ______________

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 Acknowledgment
First and for most we would like to give great praise to our Lord, Jesus Christ, for his kindness,
forgiveness and guidance in our life. Second we would like to give our gratitude to Bahir Dar
University for giving us this opportunity to develop practical skills. We also would like to thank
B.G.I. Ethiopia Brew Industry for letting us work and have fruitful experience of internship with
operators and workers in the company. Also we would like to thank all of the company technicians
especially our Company adviser Mr. Wasihun for his encouragement, advice and support. Lastly,
we would like to thank our Faculty advisor Ms. Mahider Who gave us different advises and
comments regarding to the internship & the project.

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 Executive Summary
This paper basically contains two parts; the company’s internship report and Project work. The
First chapter of the report contains history of beer and types of it produced all over the world, well
known beers in Ethiopia, Significance and Objective of the internship. The second chapter talks
about the company’s (B.G.I Ethiopia) profile including its vision, mission, Main products, Main
customers, objectives and management structure. The third one briefly describes the general beer
production process. Fourthly we tried to explain in depth the unit operations involved in beer
production process and raw materials used through the process and also we tried to see how quality
of beer is maintained in the lab of the company. CIP & utility sectors of the company are also
included in this portion of the report. In the fifth chapter, we tried to explain what we gained from
this internship experience such as improving practical skills, upgrading theoretical knowledge,
leadership skills and so on. In the sixth part we tried to do material and energy balance of selected
unit operations of the company. And lastly, we included our conclusion and recommendation on
some of the company’s unit operations. The project work was on local hop (Gesho) extraction
using liquid carbon dioxide as a solvent. In this project the main task was analysis of the extract
and determination of bittering effect. Lastly we included our conclusion and future work for the
project.

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List of Acronym
 L - liter
 Cl – Centiliter
 Hl – Hectoliter
 B.G.I – Brother Group International
 CIP – Clean in Place
 TOD – Tank out Door
 BBT – Bright Beer Tank
 CO2 – Carbon dioxide
 o
P – Degree of Plato
 KMS – Potassium dimethane sulphied
 VDK – Vicinal Diketones
 DMS – Dimethyl Sulphur
 ATR acid – Phosphoric acid solution
 Sept acid – Sulfuric acid solution
 HG – High gravity beer
 LCO2 – Liquid Carbon dioxide
 Kg – Kilogram
 mg – Milligram
 g - gram

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List of Figure – Part One
Figure 1 – Organization Chart ……………………………………….………..………………… 21
Figure 2 – Flow chart from Silo to Hammer mill ……………………………………………...... 22
Figure 3 – Flow chart from Mash tun to Whirlpool …………………………………………….. 24
Figure 4 – Flow char from BBT to bottling and kegging …..…………………………………… 26
Figure 5 – Over all work flow of the company ……………………………….……………….... 26
Figure 6 – Hop dosage tanks …………………………………………………………………..... 28
Figure 7 – Malt storages …………………………………………………...………………….… 31
Figure 8 – Hammer Mill …………………………………………………..…………………….. 32
Figure 9 – Meca Masher ……………………………………………….………..…………….… 33
Figure 10 – Mash Tun …………………………………………………..……………….……… 36
Figure 11 – Mash Filter ………………………………………………………………………..... 37
Figure 12 – Yeast Storage Tanks ………………………….……………………………..……… 42
Figure 13 – Fermentation Tanks …………………………………………….……………..…… 46
Figure 14 – Filtration Units …………………………………………………….…………..…… 47
Figure 15 – Process flow diagram of bottled beer packaging ………………………..……….… 52
Figure 16 – Process flow diagram of draught beer packaging ……………….………………..... 53
Figure 17 – water treatment plant ……………………………………………………………..… 58

List of Figure – Part Two

Figure 18 – Hop leaf ……………………………………………………………….…………..... 80
Figure 19 – Structure of Geshoidin (β-sorigenin-8-O-β-D-glucoside) ………….………….…… 82
Figure 20 – Chemical structure of α & β acids ……………………………..…………………… 84
Figure 21 – Flow diagram of the extraction process …………………………….……………… 94

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List of Table – Part One
Table 1 – Number of Employees in all branches …………………..…….……………………… 19
Table 2 – Components and Compositions of Hop ………………..…………..………………..... 28
Table 3 – Difference between Bottom fermenting and Top fermenting yeasts ………..…….….. 42
Table 4 – Difference between Bottled and Draught Beer ……………………………………..... 53

List of Table – Part Two

Table 5 – Components and Composition of Gesho Leaf ………………………………..………. 82
Table 6 – Extracting and Analyzing Equipments …………………...…………………………. 92

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 Table of Contents
Acknowledgment ......................................................................................................................................... iii
Executive Summary ..................................................................................................................................... iv
List of Acronym ............................................................................................................................................ v
List of Figure – Part One ............................................................................................................................. vi
List of Figure – Part Two ............................................................................................................................. vi
List of Table – Part One .............................................................................................................................. vii
List of Table – Part Two ............................................................................................................................. vii
Part One – Internship Report on B.G.I Ethiopia ......................................................................................... 12
1. Introduction ............................................................................................................................................. 12
1.1 History of Beer .................................................................................................................................. 12
1.2 Types of Beer .................................................................................................................................... 12
1.3 Well Know Beers in Ethiopia ............................................................................................................. 13
1.4 Significance of the Internship Program............................................................................................. 15
1.5 Objective ........................................................................................................................................... 15
1.5.1 General Objective .............................................................................................................................. 15
1.5.2 Specific Objective .............................................................................................................................. 15
1.6 Limitation and Challenges during Internship .................................................................................... 16
2. About the Company ................................................................................................................................ 16
2.1 Background of the company ............................................................................................................. 16
2.1.1 Vision ................................................................................................................................................. 18
2.1.2 Mission............................................................................................................................................... 18
2.2 The Main Products and Services ....................................................................................................... 19
2.3 The Main Customers or End Users.................................................................................................... 19
2.4 Branches and Number of Employees ................................................................................................ 19
2.5 Management Structure of the Company .......................................................................................... 20
3. General Beer Production Process Flow Description ............................................................................... 22
4. The Process of Beer Production .............................................................................................................. 27
4.1 Raw Materials of Beer Production .................................................................................................... 27
4.1.1 Malt .................................................................................................................................................... 27
4.1.2 Water .................................................................................................................................................. 27
4.1.3 Hop..................................................................................................................................................... 28

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4.1.4 Yeast .................................................................................................................................................. 28
4.2 Unit Operations of Beer Production ................................................................................................. 30
4.2.1 Malt Storage and Milling ................................................................................................................... 30
4.2.2 Mashing.............................................................................................................................................. 32
4.2.3 Mash Filter ......................................................................................................................................... 36
4.2.4 Wort Pre-run Tank ............................................................................................................................. 38
4.2.5 Wort Kettle......................................................................................................................................... 38
4.2.6 Wort Clarification (Whirlpool) .......................................................................................................... 40
4.2.7 Wort Cooling (Wort Chiller).............................................................................................................. 40
4.2.8 Wort Aeration .................................................................................................................................... 41
4.2.9 Addition of Yeast (Pitching) .............................................................................................................. 41
4.2.10 Fermentation .................................................................................................................................... 43
4.2.11 Beer Filtration .................................................................................................................................. 46
4.2.12 Beer Blending .................................................................................................................................. 48
4.2.13 Beer Carbonation ............................................................................................................................. 48
4.2.14 Bright Beer Storage (BBT) .............................................................................................................. 48
4.3 Beer Packaging .................................................................................................................................. 49
4.3.1 Bottling .............................................................................................................................................. 49
4.3.2 Kegging .............................................................................................................................................. 52
4.4 CIP (Cleaning in Place) ....................................................................................................................... 54
4.5 Utility ................................................................................................................................................. 55
4.5.1 Boiling Plant ...................................................................................................................................... 55
4.5.2 CO2 Recovery Plant ........................................................................................................................... 55
4.5.3 Air Compressor Plant ......................................................................................................................... 56
4.5.4 Cooling Plant ..................................................................................................................................... 56
4.5.5 Raw Water Treatment Plant ............................................................................................................... 56
4.5.6 Waste Water Treatment Plant ............................................................................................................ 57
4.6 Quality Control .................................................................................................................................. 58
4.6.1 Beer testing ........................................................................................................................................ 58
5. Overall Benefit That We Gained From the Internship ............................................................................ 65
5.1 In Terms of Improving Our Practical Skills ........................................................................................ 65
5.2 In Terms of Upgrading Our Theoretical Knowledge ......................................................................... 65

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 5.3 In Terms of Improving Interpersonal Communication Skills............................................................. 66
5.4 In Terms of Team Playing Skills ......................................................................................................... 66
5.5 In Terms of Leadership Skills ............................................................................................................. 66
5.6 Understanding of Work Ethics Related Issues .................................................................................. 66
5.7 In Terms of Entrepreneurship Skills .................................................................................................. 66
6. Material and Energy Balance on Selected Equipments .......................................................................... 67
6.1 Material Balance ............................................................................................................................... 67
6.2 Energy Balance .................................................................................................................................. 73
7. Conclusion and Recommendation .......................................................................................................... 77
7.1 Conclusion ......................................................................................................................................... 77
7.2 Recommendation.............................................................................................................................. 77
Part Two – Project ...................................................................................................................................... 79
Production of CO2 Hop Extract from Gesho............................................................................................... 79
Executive Summary .................................................................................................................................... 79
1. Introduction ............................................................................................................................................. 80
1.1 What are Hops? ................................................................................................................................ 80
1.1.1 Types of Kettle Hop ........................................................................................................................... 81
1.2 The Big Three .................................................................................................................................... 82
1.3 What is CO2 Hop Extract?.................................................................................................................. 84
1.3.1 Why CO2? .......................................................................................................................................... 85
1.4 Statement of the Problem ................................................................................................................ 86
1.5 Objective ........................................................................................................................................... 87
1.5.1 General Objective .......................................................................................................................... 87
1.5.2 Specific Objectives ......................................................................................................................... 87
1.6 Significance of the Project ................................................................................................................ 87
1.7 Scope of the Project .......................................................................................................................... 87
2. Literature Review.................................................................................................................................... 88
3. Material and Methods ............................................................................................................................. 92
3.1 Materials ........................................................................................................................................... 92
3.1.1 Equipments ........................................................................................................................................ 92
3.1.2 Chemicals........................................................................................................................................... 92
3.2 Method ............................................................................................................................................. 93

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3.2.1 Liquid carbon dioxide hop extraction process ................................................................................... 93
3.2.2. Extract Analysis ................................................................................................................................ 95
3.2.2.3 Yield of bitter substance ................................................................................................................. 95
3.3 Expected Extract Result ........................................................................................................................ 96
4. Future work & Conclusion...................................................................................................................... 96
4.1 Future Work ...................................................................................................................................... 96
4.2 Conclusion ......................................................................................................................................... 96
Reference .................................................................................................................................................... 97

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 Part One – Internship Report on B.G.I Ethiopia
1. Introduction
1.1 History of Beer
Beer is one of the oldest beverages humans have produced, dating back to at least the fifth
millennium BC and recorded in the written history of ancient Egypt and Mesopotamia and was
spread out to the world. No one is exactly sure how the process of beer making was discovered or
who first discovered it, but it is thought that some bread or grain got wet, fermenting into an
inebriating pile of mush thanks to yeast in the air.

Despite all the scientific developed in the last century, some brewing information remains
culturally derived. Some of the pioneers of beer production are the Sumerians of ancient
Babylonia, the Egyptians, the Jews, the Greeks and the Romans, the Indians in the Americas, Great
Britain and Germanic peoples.

Beer is an alcoholic drink made from the saccharification of starch in malt, flavored with hops,
and fermentation of the resulting sugar. Although it is possible to replace some part of the barley
with other starchy raw materials (e.g., corn, rice, wheat, oats or potatoes), it is usually the main
constituent. Other raw materials are water hops and yeast. The starch and saccharification enzymes
are often derived from malting cereal grains. The preparation of beer is called brewing and the
person in charge of it is called the brew master. The purpose of brewing is to convert the starch
source in the sugary liquid called the wort and to convert the wort in to the alcoholic beverage
known as beer in a fermentation process affected by yeast. Beer is the world most widely consumed
alcoholic beverage, and the third most popular drink overall, after water and tea. The strength of
beer is usually around 4% to 6% alcohol by volume.

1.2 Types of Beer

There are two main types of beer that we need to know: ales and lagers. All beer is made from four
basic ingredients: malted barley, hops, yeasts and water. The only difference between ales and
lagers is the type of yeast used.

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 A. Lagers
Lagers are relatively new types of beer, dating back to the mid-19th century. Lagers are made using
bottom-fermenting yeast and are fermented at cooler temperatures around 46-55oF. Pale lager is
one of the most popular type of lager, boasting a lighter color and body which is highly carbonated
and have a much lighter taste. Pilsner is another lager beer created in the 1840s in Pilzen,
Czechoslovakia. It’s similar to the pale lager in color, but is much bitterer. Light lager also falls
under lager category which contains less hops and barley in an attempt to make a low calorie beer.
Dark lager, not like their counter type light lagers, are much more full-bodied and flavorful. They
are typically very malty with a gentle hops flavor.

B. Ales
Ales are the oldest types of beer and have been around for thousands of years. Ales are made using
top-fermenting yeast and are fermented at warmer temperature around 65-76oF. Pale Ale is one
type ale of beer is made with gently roasted barley and pale malt. It is a bitter and spicy brew.
Another ale beer which falls to this category is Brown ale which ranges from dark amber to copper
in color and contains a higher level of malt. These beers are mild in flavor and tastes ranges from
sweet to hoppy to earth. Porter another ale type of beer that are very dark in color and nearly
opaque. These are made with roasted malt and barley and some even taste like chocolate. Stouts
are very known kind of ale beer that are the darkest and thickest type of beer and are typically
made with highly roasted malt or barley. These beers have a thick, creamy head and are very full-
bodied.

1.3 Well Know Beers in Ethiopia

Today, there are about many breweries including B.G.I. Ethiopia that commercially produce beer.
They are; Diageo Ethiopia (Meta Abo Brewery), Harrar Brewery, Bedele Brewery, and Dashen
Brewery. These breweries produce total of about 3,300,000 hectoliters of beer per annum. Just to
mention the breweries on Ethiopia;

A. St. George Beer: St. George beer the national beer of Ethiopia is the most popular and the
oldest beer. Brewed by BGI Ethiopia, St.George is named after the patron saint of Ethiopia.
It is light much similar to American beers. This golden-yellow colored beer with a mild
touch of amber taste malty sweet with only a hint of Dimethly Sulfide.

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B. Amber Beer is also a product of BGI Ethiopia. This is light copper colored dark beer’s
aroma and dry with a nutty caramel and light chocolate note. The taste is a medium sweet
and a light bitter. This Smell of sweet corn adjuncts with some light hops in the aroma
with no carbonation or head, something that would serve as a perfect accompaniment to
spicy and salty Ethiopian food. B.G.I produces St. George beer with alcoholic content of
4.5% and 5.5% for amber of both being bottled in 33cl.

C. Meta Abo Beer: It is the only brewery which gets water from a big reserve of soft spring
water (locally known as holy water of St. Abo). The spring water meets the international
brew standard to be used without any treatment. The brewery produces bottled and draught
beer. The brewery has recently been taken over by the English company Diageo. This beer
is produced with alcoholic content of 5% and volume of 33cl bottle.

D. Dashen Beer: Brewed by Dashen Brewery, Dashen beer is pale yellow with foamy small
white head, yeast aroma slightly sour yeast taste with a metallic tang. Dashen beer is bottled
with 33cl bottle having alcoholic content of 4.5%.

E. Harer Beer: Harer Brewery’s Beer is among the most preferred ones, it’s pretty sold in
the Northern regions of the country. It has a perfect blend of hops and malt add an enticing
golden color with a small white head. This light bodied beer is bottled with a moderate
carbonation and alcoholic content of 5% bottled in 33cl bottle.

F. Bedele Beer: The brewery is well known for Bedele beer and more recently for its bottled
beers Bedele premium and Bedele special. More recently, it has started supplying draught
beers which is becoming well received by the customer base. Bedele beer has an alcoholic
Content of 4.5% for normal beer and 5.5% for bedele special of both being bottled in 33cl
bottle.

G. Walia Beer: Walia is the other well-known beer in the country. Walia is brewed in Ethiopia
by HBSC (Heineken Brewery Share Company). This is light gold colored, mildly bitter

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 beer carries the aroma of banana-pear soufflé and honeyed hominy flavors of pretzel bread
and sprouts. Walia has an alcoholic content of 5% and is being bottled in a 33cl bottle.

H. Habesha Beer: Habesha beer also known as “Cold Gold” is one of the beer types which is
produced in Ethiopia and took the market by surprise. This beer has an alcoholic content
of 5% with 33cl total bottle volume.

Therefore the potential for the industry to grow in Ethiopia has become unquestionable. The
challenge however is how the industry can reduce production cost by the use of cheaper sources
of raw materials or availability of raw materials from the country not abroad. In addition, the
breweries need to constantly look for ways to improve beer quality and reduce energy and
manufacturing costs.

1.4 Significance of the Internship Program

The significance of this internship includes studying the management structure of the company,
understanding the beer production processes and flow, analyzing the important quality control
parameters, problem identification, and overall factory performance analysis. Most importantly,
this internship included applying what we have learned in class in an actual industrial environment.

1.5 Objective
1.5.1 General Objective
The objective of this report is to put in writing our experiences and understanding of the beer
production process in the four months we have stayed at B.G.I. Ethiopia.

1.5.2 Specific Objective

1) Describing the overall organization and work flow of the company
2) Identifying every raw material and additive used in production
3) Studying the processes of beer production
4) Understanding process data and parameters and how to record them
5) Conducting material and energy balance and performance analysis on selected unit
operations
6) Identifying problems and offering recommendations

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1.6 Limitation and Challenges during Internship
i) Lack of chemical engineers in the company to give description from an engineering
point of view.

ii) Some technicians do not have full knowledge about the place they work so they cannot
give us full information about the work.

iii) Lack of opportunities to work or operate by ourselves on specified tasks due to the
automation of every single process.

2. About the Company

2.1 Background of the company

The year 1922 is way back in time to be referred to as the old days. The Ethiopia of those days
was under the rule of Empress Zewditu Menlik and Addis Ababa was not even 3 decades old. That
Addis Ababa was a scene of huge crowed of what the foreigners call tukuls (grass roofed cottages).
It was just beginning to get ready to host things like modernism, the light of civilization, new
development/progress, etc. Roads had been paved, cars were coming, construction of modern
houses began, newspapers appeared, schools opened, and the railway was streaming in. One of the
modern things that happened then was the opening of the brewery. Many got stunned at wonders
of modernity. True, people have heard about the wonderful things made in Europe and America.
But witnessing these things on one’s own land is something different.

The founder of St. George Brewery, according to some sources, is Mussie Dawit Hale who is
Belgian. Other sources say that the brewery was owned and operated by a German company. In
fact, the brewery was set up by Mussie Dawit Hale who lately sold it to a German company. Some
43 years ago, the Ethiopian Trade Journal, (Vol 1, No 1, August 1960) wrote: The St. George
Brewery is situated near the Mexico Square. Addis Ababa, and occupies an area of 20,000
Sq.Meters of land. The beer factory was started 36 years ago by a German Company and an
Ethiopian Company took it over six years ago. The brewery stands right on the same site it was 80
years ago. During the time of the last Emperor it was known as Marshal Smut Street. It was fairly
big building and it started off as one of the pioneers in Ethiopia's industrial development.

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The factory started with machineries that were operated by hand and foot and work was done by
direct human labor. Transporting of the raw material to the silo, fermenting of the malt, boiling
the barley, filtering the beer, filling the bottles, etc. were all done manually. Basic raw materials
like barley and hops were imported from Europe. The management staff of the factory and the
leading technicians who controlled the brewery's activities were all foreigners. During its first
years about 200 bottles (half liter size) were produced daily.

In those days, liquor houses were not many and the people had no choice apart from drinking the
traditional tella and tejj. Going to bars, in the manner that people are doing now, was not practiced
by most people. According to some senior people in the brewery who claim to have the first
customers were members of the royalty. Some unauthentic sources say that the brewery was closed
during the five years of Italian occupation. The factory resumed its work after the occupation and
according to some reports there arose problems related to ownership. The exact nature of the
argument stood unclear. Eventually, however, an Ethiopian company took over the brewery in
1952/3. This company was said to have been organized as a shareholding entity, the larger share
of which was owned by Emperor Haile Selassie.

Generally, St. George Brewery could be said as having scored good results in the 1940s and 1950s.
Towards the end of the 1950s the annual production of the brewery has reached 50,000 hectoliters.
According to the review made on The Ethiopian Trade Journal the brewery had 53 silos, which
had the capacity of 100 hectoliters each. There were about 300 employees who worked in shifts
for 24 hours. Trucks were also introduced that transported beer throughout the empire. The brew-
master and other technical staff were Ethiopians.

Some of the old machineries were changed and a few semi-automatic machines installed. Although
the brewery was modern for its time most of the work was still done manually. A testimony made
by a senior member, Ato Haddis Negash Tassew, who joined the Brewery in 1960 explains the
situation. .... There were no boilers that were heated by electrical or fuel energy. Timber wood was
used to make fire and the flame was too big to get near. In those days everything was done by
human labor, and it was tough and difficult. Workers were obliged to carry a sack full of barley up
the stairs. The filtered beer was filled by manual filter with five spouts. The bottles were also

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crowned with corks by machines operated manually. Slowly, but steadily, St. George Brewery
continued to grow. In the early years of the 1970's the brewery was in good shape in terms of its
machineries, physical buildings, vehicles, marketing network, etc. It even had planned to open a
new plant for the production of soft drinks. In 1974 the brewery as nationalized. Even though this
created some obstacles the Brewery pulled through with some improvements particularly with
regard to manpower development and betterment in workers engagement. It also started to produce
draught beer that enjoyed popularity and big sales. On the other hand the Brewery was lacking the
finance it needed to introduce new technologies that came in the 1970's. The name of the Brewery
was also changed as Pilsner Brewery and later as Addis Ababa Brewery. Most of all the workers
showed great commitment and dedication to keep the Brewery and its product popular. The role
played by the Brewery was significant in supporting and promoting other social activities including
St. George Sport Club. St. George Brewery is once again privatized. The factory is now owned by
BGI, an internationally acclaimed Brewing Company that operates in many countries. It has
excellent reputation in producing quality beer and brought St. George to the same standard. Today,
St. George is the oldest beer in Ethiopia and is certainly also the youngest with the fresh dynamism.

2.1.1 Vision
i) To be leader in countries beer industries with respect to quality, competitive price, using
high technology and international orients as well as sample for the overall industrial sector
in the country.
ii) To make B.G.I the central venue for quality beer celebrities.

2.1.2 Mission
i) It is an endowment form established to contribute for the development of a region
introducing and selling customer proffered quality beer at competition reasonable and
generate a reasonable price.
ii) To by generated profit to improve the socio-economic wellbeing of the whole region.
iii) To product and seek quality beer at reasonable profit.

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2.2 The Main Products and Services
The main products of the B.G.I St. George Brewery S.C are Normal Beer and Draught Beer
namely;

Normal Beer - St. George, Castle and Amber

Draught Beer – also called draft locally, St. George and Amber

2.3 The Main Customers or End Users

The products are distributed across the country in different cities including:- Ambo ,DebereMarkos
, Butajira , DebreBirhan, Dire Dewa, Gambella, Jimma, Minjar,Adama, Nekemt, WelisoSubeta,
Buraue etc.. And also exports their product to the following foreign countries:-U.S.A, Europe,
Australia, Djibouti, and South Sudan.

2.4 Branches and Number of Employees

B.G.I. Ethiopia has 3 branches around the country that it uses to process beer namely Addis Ababa,
Kombolcha, Hawassa and currently Catle wine factory is under construction in Ziway.

The Company has created a lot of job opportunities for the communities living nearby. It has about
2717 employee under it working in all of its braches around the country. Below is B.G.I’s
employees with their respective branches.

Table 1: Number of Employees in all branches

A.A Kombolcha Castle Winery Hawassa Total

Permanent 523 367 99 243 1232

Temporary 228 233 774 250 1485

Total 751 600 873 493 2717

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2.5 Management Structure of the Company
BGI Ethiopia is a For-Profit organization meaning it is formed to make money, or profits by
offering products or services. The management structure of BGI is a very common one and is
called the functional structure (grouping by similar work specialties). The management structure
of the brewery can be represented in an organization chart. This chart shows the formal lines of
authority and the organization’s official positions and work specializations.

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Figure1: Organization Chart

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3. General Beer Production Process Flow Description
First, imported malt from containers and local malt from sacks is separated from dust by a dust
separation machine. Then the malt is stored in a silo (four in numbers) each with a capacity of
holding 700 tons of malt. The malt enters the silo at 35 tons/hr with the help of a pneumatic
conveyor. Upon request, malt from the container is further transported to the milling machine
(hammer mill) by a pneumatic conveyor where its size is considerably reduced. The hammer mill
can handle up to 9tons/hr. of malt and the local and imported malt are milled in a 50%-50%
combination sequentially. The milled malt is called the grist and is then stored in the grist bin
which not only stores the grist but also measures its amount in kilogram.

Figure 2: Flow Chart from Silo to Hammer Mill

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Once the grist is in the grist bin in amounts predetermined, the meca masher is ready to start the
mashing-in process. Here the grist is continuously mixed with a blend of hot and cold water
thoroughly. The cold and hot water are taken from the hot and cold water tank respectively for
good enzyme activation. Mashing-in can basically be operated at any temperature but is influenced
by the optimum temperature of the enzyme which the brewer wants to act first. Mashing-in is very
essential because it makes pumping to mash tun easy and most importantly it activates malt
enzymes. The meca masher can mash up to 50tons of malt per hour.

The mash from the meca masher is then pumped to the mash tun which operates as a batch process.
The mash that enters the tun is subjected to heat from saturated steam in a jacket. The steam is
used for the enzymes to act at their own specific temperatures and perform the degradation process.
The temperature of the mash is increased gradually with rest times in between for best enzyme
activity. The temperature is kept uniform throughout the mash by means of a stirrer and the process
is halted once the starch and other malt components have been fully degraded.

The mash from the mash tun is then transported to the mash filter where it is separated in to wort
and spent grain. The first wort obtained is the clear wort or the first extract. However, the spent
grain may still have some extract left in it so it must be recovered. Hence sparging (washing out)
of the spent grain is carried out by sparging water and the extract retained by the spent grain is
washed out giving the second wort or the extract at the end of sparging. Finally the spent grain
remaining on the frame of the mash filter is compressed to obtain the final wort or last running
extract. The sweet wort from the mash filter is then pumped to and stored in a storage tank waiting
to be boiled in the wort kettle.

The wort from the mash filter is then heated in a preheater before entering the wort kettle in order
to decrease the residence time in the wort kettle for boiling to occur. The wort continuously enters
in and out of the plate type heat exchanger being heated by steam. The heated wort is then pumped
to the wort kettle to be boiled. Once the wort has entered the wort kettle, it is subjected to very
high temperature by steam in an internal boiler (tubular heat exchanger) with vertical bundles of
tubes through which the wort ascends while being heated by the steam which surrounds the tubes.

The boiled wort leaving the wort kettle enters the whirl pool tangentially by means of a pump and
the coarse trub in the wort settles at the bottom by centrifugal force action. The trub is then

23
collected at the bottom leaving the clear wort behind. Afterwards, the hoppy wort is transferred to
the wort chiller where it is cooled to an optimum working temperature of yeast cells for
fermentation. On the way to the fermentation cellar (TOD), the cooled hoppy wort is aerated and
the respective amount of yeast cells is pitched with the first brew (1 TOD can hold from 4 to 8
brews and 1 brew is approximately 280 hectoliters of hoppy wort).

Figure 3: Flow Chart from Mash tun to Whirlpool

Once the fermentation cellar is ready, the cooled wort is pumped to the cellar according to its
holding capacity. Since fermentation is an exothermic reaction and since yeasts operate actively
between 4 and 20 0c, the cellar is jacketed through which a cooling medium can flow. The Products
of fermentation are alcohol (ethanol) and carbon dioxide and the CO2 pressure build up is
monitored by a manometer and is adjusted by a balance which opens and closes CO 2 outlet pipe.
The fermentation process can take several days and each and every hour if every day should be
monitored for best conversion and quality of beer. When the fermentation process has ended, the

24
yeast cells that settled are either recollected to the yeaster tanks if they are going to be reused or
purged to the thermolizer if they are no longer needed.

After Fermentation, the high gravity beer enters mechanical separation equipment called the
centrifuge. It separates the yeasts from the beer by a high speed rotational movement which throws
the yeast cells outwards from the center and collects and ejects them at the bottom. Before
centrifuge is commenced silica gel and water are mixed and stored in tank then high gravity beer
is dosed with the silica gel solution and pumped to a chiller where it is cooled by a glycol stream.
Using silica gel improves agglomeration during the filtration process in the centrifuge system.
Using centrifuge system before filter bed eases the load of clarifying for the proceeding filtration
process.

After that, the beer is continuously fed to the horizontal filter which is a series of filter sheets
aligned on frames and coated with filter aids. The filter aids are prepared in a kieselguhr tank and
are passed through the filter before beer is passed. Once the aids are perfectly coated, the beer is
allowed to pass the filter first at constant rate and then at constant pressure. When the pressure
difference between the ingoing and outgoing beer exceeds 4 bars, the filter must be dissembled
and the filter cake removed and cleaned. After filtration, the high gravity beer is blended with
dearated water to lower the original gravity and alcoholic content of the beer. The dearated water
is obtained from the water dearator where dissolved oxygen is separated from the water in a series
of steps. Once the beer is blended and low gravity beer is obtained, the beer is dose with finishing
additives and carbon dioxide which differ in kind and amount for beer and draft. Finally, the low
gravity beer is stored in bright beer tanks (BBT). The bright beer can consequently go to packaging
(bottling for beer and kegging for draft).

25
Figure 4: Flow Chart from BBT to Bottling and Kegging

Figure 5: over all work flow of the company

26
4. The Process of Beer Production

4.1 Raw Materials of Beer Production

The main raw materials for beer production are:

1) Malted barley
2) Water
3) Hops and
4) Yeast

4.1.1 Malt
Malted barley is the main raw material used in the brewing of most beers. Malt provides the
necessary sugars that will be fermented into alcohol in the brewing process. Barley is the principal
grain used in brewing for a numbers of reasons which include; It’s uniform and convenient size
makes it easy to handle on an industrial scale, The plant can be grown in many parts of the world
ranging in latitude from near the polar circles to the equator, The husk is relatively tough, and can
form a filter bed in the brew house, The grain contains 60 – 65% by dry weight of starch. Together
with protein, enzymes, vitamins and minerals; the grain provides a complete package for yeast
nutrition.

B.G.I Ethiopia uses malt both from local and abroad. Local supplier are Assela & Gonder malt
Factory and the rest by importing from foreign countries. Currently out of the total malt amount
used for one brew of St. George beer which weighs about 7500 Kg, half is malt from Assela &
Gonder and the remaining is imported malt. For Amber beer, caramelized malt is imported.

4.1.2 Water
Breweries use large amount of water, quantitatively water is the major raw material used in the
beer production. Water makes up 95% of beer, apart from brewing, sparing and dilution water.
Water is used for a range of other purpose this includes cleaning in place (CIP), cooling, heating
and steam generation in boiler plant.

27
4.1.3 Hop
Hops (Humulus lupulus) are a perennial plant of the Cannabaceae family that also includes the
genus Cannabis. In beer hops provide bitterness to balance the sweetness of malt sugars, as well
as flavors, aromas, resins that increase head retention, and antiseptics to retard spoilage. B.G.I uses
imported hops from experienced beer Producers like Germany. At this time, B.G.I uses CO2 extract
at wort kettle and this hop will be added at the initial stages of the boiling process because it needs
time to isomerize and give beer its bitter taste.

Figure 6: Hop dosage tanks

Table 2: Components and Compositions of Hop

Component Percentage Uses

Proteins 20 Contribute to the yeast culture
expansion.
Hop resins 18.5 Contribute to the bitterness of the beer.
Minerals 8 Contribute to the yeast growth.
Polyphenols 3.5 Contribute to the astringent (mouth
puckering) taste of beer.
Hop oil 0.5 Contribute to the aroma of the beer.

4.1.4 Yeast
Yeast is the most important and mysterious ingredient which turns wort into beer and produces
more of itself. Through anaerobic respiration, it converts the malt sugar into alcohol, CO2, and
other by-products. In a brewery, the quantity of yeast required for fermentation is obtained by
propagation of a pure yeast culture. This consists of isolating suitable vigorous yeast cells and
multiplying their number until there is sufficient to pitch in to a fermenter. The yeasts are often
removed after fermentation and can be reused after being stored in a suitable environment.

28
Brewery yeast can be classed as top fermenting and bottom fermenting. Top fermenting yeasts are
called because they form a foam at the top of the wort during fermentation. Typical example could
be Saccharomyces cerevisiae, sometimes called an “ale yeast”. Bottom fermenting yeast are
typically used to produce lager-type beers, though they can also produce ale-type beers. Typical
example would be Saccharomyces uvarum. B.G.I uses the later one.

Yeasts has nutritional requirements other than just sugar including; Protein or nitrogenous
compounds in the form of amino acids. These are derived from the barley protein during malting
and mash conversion, Lipids or fatty material. This is also supplied by the malt, Vitamins from the
malt, Trace metals. Calcium is usually present in the brewing water, if not it must be added. Zinc
may be present in the hop products, if not it can be added to the wort. Copper may also be present
in the hop products, but if stainless brewing plant is used, may have to be added to the wort,
Oxygen is usually dosed into the wort. It is essential for the healthy yeast growth and a large yeast
population is required to ensure that the fermentation is healthy and fast.

Other than yeast, water, hops and malted barley, there are some other things added that affects the
quality and effectiveness of the processed beer. These include:-

a) H2SO4/HCl: for adjustment of pH since the malt enzymes are affected by pH.
b) CaCl2: for mineral source for yeast and protein precipitation purpose.
c) Hitampase 2xl: is a commercial enzyme used for aiding barley enzymes.
d) Biogulucanase HAB: is a commercial enzyme used for aiding degradation of beta-
glucan.
e) Caramel: for color adjustment/caramelization.
f) Sugar: for extra source of carbon for yeast to undergo fermentation and produce
high gravity beer.
g) H3PO4: for adjusting pH of hot water for mashing.
h) ZnSO4: yeasts need zinc for their growth. It is an important building component of
yeast’s nucleic activity.

i) Anti-foam: agent that can be used during fermentation to eliminate messy blow off. It
can also be added in during boiling to reduce the risk of blow over.

29
 j) Maturex: to reach targeted VDK concentration with time saving in TOD occupancy.
It lowers the time required for VDK reduction.

k) Ascorbic Acid (vitamin C): used because malt has a very low vitamin C content and
it is an oxygen scavenger so it is added to draught beer for a longer shelf life.

l) Tetra Hop: used when the filtered beer is not bitter enough due to bitterness loss in
fermentation and filtration.

m) KMS: is an oxygen scavenger added to bottle beer for longer shelf life.

n) CaSO4: For mineral source of yeast and yeast flocculation purpose.

4.2 Unit Operations of Beer Production

4.2.1 Malt Storage and Milling

4.2.1.1 Silo
Silos are vertically installed cylindrical containers used for malt storage purpose. In B.G.I. there
are 4 silos installed each having a 700 tons of capacity and are only used to store imported malt.
The imported malt enters the silo at the rate of 35tons/hr. It is brought in large containers and
putted on the sack unloading ramp which will be, mechanically, send to the intake transfer whereas
the local malt is manually fed from sacks to the intake transfer manually. Dust will be separated
using the dust separater using air, provided by the air compressor plant in utility section, from the
imported malt before entering to the silo. The amount of dust separated is considerable and is
about 0.2 to 0.3 Kg per 100 Kg of malt charge. Stones, metallic substances, heavy unwanted
materials will be removed using destoner and magnet from the imported malt and will be stored
using sacks.

Transport system for malt to be transferred to and from the silo to milling machine and also for
local malt to milling machine is by a pneumatic conveyor with a carrying capacity of 10 tons/hr. a
heavy-duty pump propels the malt u to the milling station. The outlet pipe mean while returns the
filtered air back to the nozzle filter. Along the way it sucks all the dusts out of the malts using the
air.

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 A) Local malt storage room B) Silo tank

Figure 7: Malt storages

4.2.1.2 Hammer Mill

The purpose of milling is to prepare the malt for mashing and starch conversion by making the
center of the malt corn accessible. Where a wort separation system like mash tun or lauter tun is
used, milling must crush the starch into fine particles while preserving the husk so that it can be
utilized as an effective filter during separation.

In B.G.I the hammer mill is employed. It is an impact mill employing a high speed rotating disc,
to which are fixed a number of hammer bars which are swung outwards by centrifugal force. The
local and imported malt are milled in 50%-50% combination sequentially and the mill has with a
capacity of milling 9 tons of malt per hour. In order to prevent the plant from the risk of explosion
the malt dusts are removed before it goes to milling and also pipes are used for releasing pressure
in to the atmosphere during milling. The mesh size at BGI is 2.75 mm. The powdered grist is
carried out of the mill in the airflow, which transports it to the grist bin.

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Figure 8: Hammer mill

4.2.1.3 Grist Bin

It is storage for milled malt (grist). Since it is equipped with a mass measurement system at its
bottom, it not only stores the grist but also measures its amount in mass (Kilograms). At BGI, the
grist bin has a storage capacity of 9 ton.

4.2.2 Mashing
4.2.2.1 Meca Masher
The grist from the grist bin will be transferred to this unit and mixed with both hot and cold
water, from raw water treatment plant, to attain the preferred temperature for enzyme activation.
Using automatic system, the water temperature will be set around 52oC.

Mixing of the process water and grist must be done in such a way as to minimize clumping and
oxygen uptake. Clumping reduces extract recovery, and no segregation of the grist components.
The meca masher in BGI has a capacity of mixing 50tons/hr. and it is basically a tube where the
entering grist is sprayed with water and the wetted grist is driven along the tube by a screw
conveyor and is then mixed by a series of short beater-rods mounted on the same shaft as the
conveyor screw. After this the mash will be transferred to the mash tun (Lauter tun).

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Figure 9: Meca Masher

4.2.2.2 Mash Tun

Mashing is the most important process in wort production. In this process starch is converted to
simple fermentable sugar called sweet wort by enzymes found in the malt namely α-amylase and
β- amylases.

During mashing:-

i) Cell wall components may be broken to release the starch.

ii) Proteins are broken down to amino acids.
iii) Starch is broken and converted to fermentable sugar.
iv) The PH drops.

There are two types of mashing methods. These are

a) Infusion mashing
b) Decoction mashing

A. Infusion mashing: - the entire mash is heated up (with appropriate rest times) to the final
mashing temperature. It works batch wise which means no mash will be transferred during
the mashing process.

B. Decoction mashing: - the temperature is increased by moving part of the mash from the
mash tun to the wort kettle where it is boiled (possibly also with carbohydrate rest periods
in the mash cooker) then pumping it back to the remainder of the mash the temperature of
the total mash is increased to the next higher temperature.

33
The advantages of the infusion method are that this process can be easily automated and controlled,
and energy consumption is 20–30% lower, less destruction of enzymes, high degree of
fermentation than the decoction method. Here in B.G.I infusion mashing method is used.

What happens during mashing Process?

A. Beta glucan degradation

Cell wall of barley is mainly composed of beta glucan and hemi-cellulose. If beta glucan is not
degraded sufficiently, filtration problems in mash & beer filter will occur and also haze problem
may occur.

B. Protein degradation

Protein degradation is one of the reactions that takes place during mashing. Degraded protein
products has an influence on beer flavor, beer foam, color, PH and stability of the beer.

C. Starch degradation

This degradation step is the most important of all. Starch will be degraded using the enzymes in
the malt called alpha and beta amylase. This process has 3 steps:-

1) Gelatinization - is the swelling and bursting of starch granules in hot aqueous solution. The
starch molecules set free in to this viscous solution are more easily attacked by amylases
than non-gelatinized starch.
2) Liquefaction - is meant the size reduction of long chained gelatinized starch by alpha
amylase.
3) Saccharification - is meant the complete degradation of starch to glucose, maltose,
maltotriose and dextrin's by alpha and beta amylases.

Additives used in mash tun

i) HCl (6Kg) – used for PH adjustment to create a suitable condition for the enzymes.
ii) Biogulucanase HAB (1.7Kg) – used to degrade bioglucane content in the wort.
iii) CaCl2 (7 Kg) – used as a source of Ca for the beer.
iv) Hitammpase (0.5 Kg) – is a commercial enzyme used for aiding barley enzymes.

34
The mash tun in B.G.I. is made of stainless steel and is jacketed by a coil of semicircular stainless
steel pipes welded on its body and bottom. The steam enters through these pipes and leaves them
as condensate. The jacket is insulated with fibers so that there is minimum loss of heat to the
surrounding. The mash tun is also equipped with a stirrer for maintaining uniform temperature of
the mash.

In the mash tun, tests will be taken to ensure quality of beer. These include:-

i) PH test - PH in mash tun will be in the range of 5.2- 5.56. if in any case the PH fluctuates,
H3PO4 will be used to adjust it
ii) Iodine Test - starch degradation is one of the changes which will occur in mashing process
and for the yeasts to convert the fermentable sugar to alcohol, starch must be fully-
degraded. This will be known though iodine test. A sample of the wort will be taken and a
drop of iodine will be added. If the wort color changes to blue-black, it means the starch
did not fully-degraded therefore the mash tun will continue its work till the iodine test
shows yellowish color which indicates full degradation.

Enzymatic Activity in Mash Tun

1) Alpha Amylase
i) Activation time: 72-75oC
ii) Deactivation time: 80oC
iii) It is a protein enzyme that hydrolyses alpha bonds of large, alpha-linked
polysaccharides, such as starch and glycogen, yielding glucose and maltose.

2) Beta Amylase

i) Activation time: 60-65oC

ii) Deactivation time: 70oC
iii) It hydrolysis of 1, 4-alpha-D-glucosidic linkages in polysaccharides so as to
remove successive maltose units from the non-reducing ends of the chains.

35
Figure 10: Mash Tun

4.2.3 Mash Filter

In this unit operation, liquid part of the mash called sweet wort is filtered from the solid part, the
spent grain. The mash filter is becoming more popular worldwide due to the rapid turnaround times
and high extract achievable. Its numerous plates and frames, which overall form a very large area
of very thin beds rather than a single smaller area of deep bed enable a very fast run-off of wort
and effective sparging.

In B.G.I, Meura 2001 is used as mash filter which is constructed of alternate frames to hold the
mash and plates to channel wort run-off and sparging, all separated by filter clothes which either
are hand from individual plates. The mash filter is fitted with fine polypropylene filter sheets which
last longer (five times or more) as compared to ordinary cotton cloth hence do not require frequent
cleaning and are easier to clean.

In this type of filter, filtration process is done by the help of compressed air running through
diaphragm in the frame were mash enters. When the compressed air enters the diaphragm, it will
expand thereby pushing the slurry beside it. At this point, the wort will be squeezed in to the
adjacent plates through the filter cloth whereas the spent grain stains mounted on the frame. At
this stage, the wort draining off from the spent grains is called the first wort.

B.G.I’s mash filter, each frame, has a capacity of receiving 525kg of mash and the duration for the
first wort collection is roughly 45 minutes theoretically. The volume of first wort recovered from
one brew (5938kg of grist and 130 hl of water) is 85 hl theoretically and the extract in degree Plato
is 27.04 0p. The Plato scale is a measurement of the density of liquid. The number tells brewers
how big or small a resulting beer will be – the larger the number, the bigger the beer. Subsequently,
sparging is carried out in order to get the remaining extract from spent grains by washing with hot

36
water. The amount of sparging water used depends on the amount and concentration of the first
wort and the concentration to be reached in the kettle. Sparging water of volume 145 hl at a
temperature of 78 0c and pH roughly about 3.28 is used.

The wort recovered is called the second wort, duration at this stage exceeds 85 minutes and the
extract of the second wort is 0.8 0p. During sparging, the pressure of in going stream is gradually
increased due to the deposition of the cake hence the resistance of the cake to flow. Finally the last
running of wort is recovered by compression of the plates and frames.

The general operating principles of a mash filter are explained below:-

I. The filter is first pre-heated and flushed with hot water before the converted mash from the
mash tun is transferred into the mash frames.
II. After cleaning, Mash from mash tun is pumped at lower pressure.
III. The solid part (spent grains) will form cake on the surface of the filter cloth as the filter
fills and the clear wort will be transferred to a storage tank.
IV. Once all the mash has been transferred, it is inflated with compressed air to squeeze the
grain bed, extracting much of the entered wort, so improving the extract yield.
V. When most of the strong wort has been squeezed from the grain, the membrane pressure is
slowly released and sparging water is pumped through the mash inlet.
VI. When sparging is complete, the expandable membranes are then inflated in order to extract
much of the remaining weak wort. This also gives a much drier spent grain cake with a
lower effluent loading.
VII. Finally the spent grain is dropped from the filter at the end of the cycle when the filter is
opened.

Figure 11: Mash Filter

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4.2.4 Wort Pre-run Tank
The wort that runs off from the mash filter is collected in wort pre-run tank which is used as a
reservoir of the wort. The wort, before entering into the wort kettle, is preheated using Preheater
which will be supplied of steam from wort kettle evaporating process. This genius energy recovery
process saves not only energy but also time used for boiling process in wort kettle unit.

4.2.5 Wort Kettle

The wort from wort pre-run tank will be transferred to wort kettle and boiled for 2 hours while hop
will be added to the hop dosage tanks which are installed beside the wort kettle.

There are several reasons for boiling of the wort. This include:

A. To sterilize the wort. Brewing raw materials such as malt, hops and occasionally brewing
water itself are infected by micro-organisms. Therefore have to be killed during the
brewing process to prevent wort and beer spoilage.

B. To stabilize the wort. Above 50 – 80oC, enzyme structure is broken down and the enzymes
lose their activity. It is important that all enzymes are destroyed by boiling, otherwise they
would continue working, which would change the profile of the beer.

C. To evaporate away unpleasant aromas associated with the wort. DMS, the sulphury
character found in lagers is generated on the malt kiln and during boiling. It is volatile and
is boiled of in the wort kettle.

D. To dissolve the bittering resins from the hops and to stabilize them. Hops or hop extracts
are added because the bitter resins (alpha acids) dissolve better in hot wort. These alpha
acids need to be modified by isomerization reactions which are heat induced to stabilize
the bitterness that is typical of beer flavor.

E. To dissolve oils that contribute to hop aroma in the final product, though these generally
only remain if the hops are added late, and oils are not given time to be off.

38
 F. To denature and coagulate some of the protein derived from the malt. Protein has the
potential to make packaged beer go cloudy as it ages. Its removal at this stage will help
protect the beer’s stability.

G. Wort PH continues to fall during wort boiling. The drop in PH is mainly due to the
reaction of Ca2+ compounds with phosphates and polypeptides. These form insoluble
compounds releasing H+ so reducing the PH.

PH reduction is an extremely important reaction as lowered PH:-

a) Improves protein coagulation
b) Encourages yeast growth
c) Results in less color formation
d) Improves beer flavor stability in particular VDK reduction

The principal factors which will affect the evaporation of volatiles include:

1) Duration of boil
2) The temperature of wort
3) The intensity of boil

Additives in wort kettle

i) CO2 Hop Extract (7Kg) – to give the beer its specific bitterness, flavor and aroma.
ii) Caramel (7.5Kg) - for color adjustment /caramalization.
iii) CaSO4 (7 Kg) - for mineral source of yeast and yeast flocculation purpose.
iv) ZnSO4 (20 Kg) - yeasts need zinc for their growth. It is an important building component
of yeast’s nucleic activities.
v) Sugar (900 Kg) – the fermentable sugar which is extracted from the malt might not be
enough to result in acquired amount of alcohol production therefore additional sugar will
be added to the boiling process.

39
In B.G.I., Steam from boiler plant will be supplied for boiling process in wort kettle unit and a
specific kind of hop namely CO2 hop extract is used. This specifically extracted hop is imported
from foreign countries which contains the necessary α-acids, β-acids and hop oils for the brewing
process and will be added in the starting of the boiling process because it needs time to isomerize.
The main resins (α-acids) is modified during the boiling process when it is changed to isomerized
α-acid, which is more bitter, more stable and more soluble than the original α-acid. The isomerized
form survives in the finished beer to give the beer its bitter flavor.

4.2.6 Wort Clarification (Whirlpool)

For this process an equipment (unit) called clarisaver will be used. It is an empty tank where a
physical separation occurs separating coarse trub from the clear wort. After boiling process is done,
the wort will be pumped to the clarisaver tangentially at 30o tangent to the vessel wall which causes
the hot wort to rotate and deposit the coarse trub at the center bottom of the clarisaver tank. The
vessel is usually filled in 10 - 15mins and after 15 - 20mins of resting time the clear wort will be
separated from the trub. The coarse trub is usually composed of coagulated proteins, Tannin
material from the malt husk and from hops, lipids or fatty acids (mainly from the malt), spent hops
or debris from hop addition.

4.2.7 Wort Cooling (Wort Chiller)

Yeast cells are mesophilic microorganisms. They only tolerate ambient temperature (4-200c).
However, the wort leaving the whirlpool is at very high temperature (80-900C) due to boiling in
the kettle. Hence the wort must be cooled so that the yeasts can undergo fermentation on the wort
with in the fermentation cellar at their optimum working temperature. After clarification, the hot
wort must be cooled to the temperature at which it is pitched (inoculated) with yeast. Traditionally
this is about 15-22oC for ales and 6-12oC for lagers, but other temperatures can also be used.

In B.G.I., this stage is achieved through a plate and frame heat exchanger. A plate heat exchanger
has many plates, which form two separate paths. The wort is pumped into the heat exchanger, and
goes through every other gap between the plates. The cooling medium, usually water, goes through
the other gaps. The ridges in the plates ensure turbulent flow. A good heat exchanger can drop

40
wort at 80oC to 8oC, while warming the cooling medium from about 5oC to 80oC. The last few
plates often use a cooling medium which can be cooled to below the freezing point, which allows
a finer control over the wort-outlet temperature, and also enables cooling to around 10oC. At

B.G.I., the casting temperature of wort is 8oC.

4.2.8 Wort Aeration

Yeasts has the ability to respire anaerobically during fermentation, releasing energy from sugars,
and subsequent growth of yeast without constant presence of oxygen. However, yeast needs fatty
acids and sterols for cell wall formation and successful replication. These are absent in wort, but
the yeast can synthesis these if there is sufficient oxygen dissolved in the wort.

The absence of sufficient oxygen in the wort for the yeast to make these sterols and fatty acids lead
to:-

a) Sluggish fermentation – high final PH and other flavor changes.

b) Early finish to fermentation resulting in high final gravities.
c) Poor yeast growth – insufficient for repitching.

Before the wort is send to the fermentation tanks, air oxygen is introduced to it. To dissolve the air
in cold wort the air must be injected by venture pipes as very small bubbles and turbulently mixed
with the cold wort but before all that we can’t be 100% sure the oxygen is pure so the air oxygen
will first pass through an air filter to achieve maximum purification of the air and avoid any
contaminations because the air is directly injected to the cold wort and we need to be sure it is
clean. Using air a wort oxygen of 8 – 9mg/l is achievable and this is adequate for much
fermentation.

4.2.9 Addition of Yeast (Pitching)

Addition of yeast plays a crucial role on fermentation process. At the starting days of fermentation,
rapid yeast growth is encouraged and can be achieved by introduction of oxygen and efficient
mixing of the added yeast with the wort. At B.G.I, yeast is dosed to the wort in a spiraling way as
it passes to the fermentation tank to cause turbulent mixing which is good for effective mixing.

41
At B.G.I yeast is pitched either by returning from previous fermentation tanks checking its viability
& consistency or as a fresh if the used yeast couldn’t produce adequate products maintained in
yeast storage tanks as a slurry at <5oC.

The aim of selecting the correct pitching yeast are to:-

i) Ferment the wort to the desired temperature and gravity profile

ii) Achieve the desired flavor profile in the final beer.
iii) To obtain sufficient healthy yeast for re-pitching typically
a) Lager 15 – 20 million cells/ml
b) Ale 5 – 15 million cells/ml

Figure 12: Yeast Storage Tanks

There are two kinds of yeasts brewers use for fermentation process, Top Fermenting Yeast (ale)
& Bottom Fermenting Yeast (lager). Here in B.G.I they use bottom fermenting yeast.

Table 3: Difference between Bottom fermenting and Top fermenting yeasts

Saccharomyces Cervisiae (Ale Yeast) Saccharomyces Pastorianus (Lager Yeast)

The ‘top’ yeast used for fermenting ales The ‘bottom’ yeast used for fermenting lagers.
It floats to the top of the vessel at the end of It sinks to the base of the vessel at the end of
fermentation because the CO2 bubbles stick to fermentation because it has a different kind of cell
the yeast’s cell walls. wall.

It thrives on relatively high fermentation It likes low fermentation temperatures, for

temperatures, for example 20oC and example 10oC and fermentation are slower, for
consequently fermentation are fast, for example 7 days.
example 3 days.

Ale strains can’t grow at 37oC. Lager strains can’t grow above 34oC.
The system used for cropping the yeast at the The system used for cropping the yeast at the end
end of fermentation that is skimming the yeast of fermentation, that is collecting from the base of
off the top of the beer, naturally selects the the vessel is not selective and usually a pure
best yeast for repitching. culturing system is use to maintain yeast purity.
Often needs high wort oxygen level

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4.2.10 Fermentation
This is where the action happens. The main objective of fermentation is accessing the yeast
capability to convert the fermentable sugar to Ethanol and CO2 (main products) and Esters, acids
& Higher alcohols which contribute to flavor.

C6H12O6 yeast 2C2H5OH + 2CO2 + Energy

The main purpose of the breakdown glucose to alcohol and CO2 is to generate energy necessary
for yeast cells to survive and grow. Fermentation is dependent on the following factors:

A. The pitching rate of yeast

B. The yeast strain – including flocculation characteristics
C. The age of the yeast – older yeasts tend to produce more sluggish / abnormal
fermentation.
D. The wort oxygenation level
E. The wort temperature – including the control of the temperature rise
F. The wort composition in terms of nutrients – minerals, vitamins, amino acids.
G. The sugar concentration
H. The amount of alcohol produces associated with the alcohol tolerance of the yeast strain
used

There are 3 stages to fermentation process. These are Primary fermentation, Secondary
fermentation and Conditioning (Laagering).

4.2.10.1 Primary Fermentation

The primary stage of fermentation process starts when yeast is pitched to the cooled and aerated
wort. The main objective here is to ferment wort to the desired gravity which is called required
degree of attenuation. The yeast quickly utilize the available oxygen to produce sterols, a vital
compound for culture expansion. When the oxygen is gone, the yeast switch to the anaerobic phase
where the majority of wort sugars are reduced to ethanol and CO2.

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Yeast growth occurs during primary fermentation. The extent of fermentation is measured by
Sacchrometer in the lab. The wort’s PH falls as ammonium ions and amino acids are taken from
the wort by the yeast and organic acids are secreted. The beer at the end of the primary fermentation
is called green beer.

During this yeast growth stage,

a) Flavoring compounds like VDK will be produced
b) Most of the sugar will be consumed
c) Ethanol and CO2 will be produced
d) PH will be decreased from 5.3 – 5.6 in pitching wort to 4.3 – 4.4 in the beer
The extent and rate of yeast growth is directly related to the amount of production of alcohol,
aroma and flavor compounds.

Here in B.G.I, The temperature of primary fermentation is about 12oC for 4 days. After primary
fermentation, the amount of VDK and temperature are checked at the laboratory. The pressure is
0 bar for free movement of yeasts.

Primary Fermentation Summary

i. Depletion of dissolved oxygen

ii. Acidification (reduction in PH)
iii. Yeast growth or culture expansion
iv. Ethanol and CO2 production
v. Production of flavor compounds like esters, diacetyl, sulfur containing compounds
collectively known as VDK
vi. Consumption of most of wort sugars

4.2.10.2 Secondary Fermentation

The secondary stage of fermentation refers to the stage of fermentation after the majority of the
wort sugar have been consumed and there is a sharp decrease in the rate of fermentation. During
this period, most of the final sugars are depleted and some secondary metabolites are converted by
the yeast. The temperature is raised to 15oC until VDK concentration is reduced. Once VDK

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concentration is reduced, the temperature is lowered to 9oC. At this time, the yeast starts to settle
at the bottom of the fermenter tank. Yeast flocculation and settling begins to occur due to the
increase in alcohol content and the depletion of sugar and nutrients. Yeasts are collected and sent
to either yeast storage tank for re-pitching recycled up to 10 generations by checking their
consistency, viability and thickness or to the thermolizer if no longer needed to be boiled and
discarded.

Secondary Fermentation Summary

i. Decreased rate of ethanol and CO2 production

ii. Diacetyl Conversion
iii. Reduction of some flavor compounds by yeast metabolism or CO2 scrubbing as a result
of PH reduction
iv. Terminal gravity is reached
v. Yeast flocculation (clumping together) and settling is reached

4.2.10.3 Conditioning (Laggering)

The conditioning stage takes place when the terminal gravity has been reached and the tank is
cooled to refrigeration temperature. The processed beer from secondary fermentation stage will
be cooled to 1.5oC and transferred to another TOD for further cooling. The beer in the new TOD
is laggered to 0.5oC for 1 – 2 days. The mature beer will have mature aroma substances. These
include higher alcohols and esters. These determine the aroma of the beer and their presence is
essential for high quality beer.

Conditioning (Laggering) Summary

i. Most of the yeast is removed from the beer

ii. Formation and Precipitation of haze forming proteins
iii. Reduction of harsh flavors and having a pleasing flavor through aging
iv. Reduction of sulfur compounds, diacetyl and acetaldehyde
v. Flavor stabilization

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Fermentation can take months but at B.G.I it takes from 10-15 days due to high customer demands.
Because fermentation process is batch wise, B.G.I uses 24 fermentation tanks with different
holding capacity ratio. 2 TODs capable of storing 2100 Hl, 10 TODs capable of storing 2000 Hl,
6 TODs capable of storing 1250 HL and 6 TODs capable of storing 1000 Hl.

These tanks are jacketed and cylindroconical shape which makes it easy for yeast removal because
B.G.I. uses bottom fermentation type of process. Since fermentation is an exothermic process and
releases heat, it is imperative to cool down the tank using a coolant for the yeasts to continue their
work. Yeasts can only work in range of 4 – 20oC. Here in B.G.I, glycol is used as a coolant flowing
through the jacketed fermentation tank and cooling the process. This cooling mechanism is
controlled by an automatic valve.

Figure 13: Fermentation Tanks

4.2.11 Beer Filtration

Filtration process stabilizes the flavor, gives beer its polished shine. In B.G.I, this is achieved by
Centrifuge and Plate and Frame Filter.

4.2.11.1 Centrifuge
Centrifuges are machines that separate suspended materials from the medium they are mixed with,
here in this case mainly yeasts. This is done by spinning closed containers of the mixture very
quickly around a fixed, central point. These devices are used to separate yeast from the high gravity
beer that’s coming from fermentation. Here at B.G.I, centrifuge is used to reduce the load on the
subsequent unit operation, the Plate and Frame filtration. The high gravity beer from fermentation
tanks will be passed through lanterns to control the operating pressure and reduce bubble formation
then send to the centrifuge. The fermented wort before entering to centrifuge will be dosed with

46
silica gel to promote yeast coagulation. Yeasts particles are pressed against the disk walls and slide
down the inner sides to the outer sides. The yeasts are collected at the periphery of the rotating
bowl and is removed by automatic opening gate and washed away by deaerated water.

4.2.11. 2 Buffer Tank 1

The beer from centrifuge machine will be sent to Buffer tank 1 (BT1) which is used as storage
only. Maybe there is unfinished filtration in plate and frame or the carbonater is still in use so until
then the beer will be stored here.

4.2.11.3 Plate and Frame Filter

Beer from Buffer Tank 1 will be transferred to the plate and frame filter for further and more
purified filtration. Plate and frame filter consists of a frame in which alternating square frames and
plates are suspended. Filter sheets are hung over the plates on both sides and form seal between
the frames and the plates. The filter sheets are used together with filter aids. After filtration, the
filter aids is sprayed off and the filter sheet can be used again. Filter aids are powdery substances
such as kieselguhr (KG), filter aid and super air which are deposited on the filter sheet and facilitate
the filtration process, as a result of their shape and arrangement make filtration possible and
efficient.

A) Centrifuge B) Plate and Frame Filter

Figure 14: Filtration Units

4.2.11.4 Buffer Tank 2

The filtered beer from the plate and frame filter will transferred to buffer tank 2 (BT2) as used
before, this one is also used as a storage.

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4.2.12 Beer Blending
Here in B.G.I, First high gravity beer is brewed which is an advantage to blend it with deaerated
water after in terms of capacity and supply of beer. The high gravity beer produced is 17 oP. The
high gravity beer is blended with deaerated water in order to prevent oxygen pickup which converts
the alcohol (Ethanol) to aldehydes due to oxidation and cause off flavor to the beer.

Additives used during blending

1. Tetra Hop - is an isomerized form of hop which is used adjust bitterness & aroma if the
filtered beer does not contain the required amount of bitterness & aroma compounds due
to loss of content in fermentation both for bottle and draught beer per as needed amount.
2. Caramel – is used adjust color change due to fermentation process for both bottle and
draught beer as per needed amount.
3. Vitamin C – is used to increase life time and only for draught beer.
4. KMS – is an oxygen scavenger used for longer shelf life bottle beer only as per needed
amount.

4.2.13 Beer Carbonation

The purpose of carbonation is to increase the level of CO2 dissolved in the beer to the required
level. CO2 is a very important consistent of beer. It imparts sparkle and ‘mouth feel’ and sharpness
associated with its properties as an acid gas. Beer that lacks CO2 are lifeless and dull. This gas is
another product of fermentation process which will be processed in utility section and dosed to the
beer by carbonation process. The blended beer must be dosed with CO2 before transferred to bright
beer tank with 6.2 g/l and 5.4 g/l for bottle and draught beer respectively.

4.2.14 Bright Beer Storage (BBT)

The Filtered & processed beer from filtration room is transferred using pumps to the bright beer
storages for 2 – 3 days. These tanks are jacketed buffer vessels which are installed between the
filter and the filler. Using glycol as a coolant, these tanks are cooled to 0 – 2oC.

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4.3 Beer Packaging

It is the last section of beer production system where stored and cooled beer is packed and be ready
for customers to use. It constitutes a very modern and complex machines, mostly automatic, to
maintain high beer quality. In this section two types of beers are packed.

i. Bottled beer
ii. Kegged (Draught) beer

4.3.1 Bottling
In this section, beer from bright beer tanks (BBTs) is filled into the properly treated bottles, capped,
pasteurized and then labeled. To perform all this work, different machines are used and according
mentioned below.

1) De palletizer
Crates having empty bottles are manually putted to the roller conveyer using forklift from the
storage room. This roller conveyer has its own signal sensors which will send response if the
convey needs to roll or not which will depend on if next machine is available or not. The de
palletizer unit has the capacity to move 29crates per minute.

2) Decammatic
This machine is used to remove empty bottles from their crates. It works pneumatically (using air).
Here in B.G.I, this machine has 6 grippe head of each has a capability of removing 48,000
bottles/hr. This grippe heads are plastics and as they are lowered down and hold the bottles,
compressed air is supplied which will tighten up the heads and hold a good grip. After the bottles
are separated from their crates, they are transferred to the bottle washer for cleanup using belt and
roller conveyers for straight and curved paths respectively.

3) Bottle Washer
Here the empty bottles are washed thoroughly using water, steam and soda. This machine’s
objective is to remove dirt both from inside and outside of the bottle and sterilize it. It can wash
40,000 bottles/hr. In order to do this, it follows certain cleaning steps which are listed below.
i) Prewashing - water is sprayed to moisturize the bottles.

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 ii) Soaking - two step of soda washing is done here. First using 2.5M NaOH with hot water
at 75oC then secondly, 2.15M NaOH again with hot water at the same temperature.
After that, only using water the bottles will be rinsed.
iii) Drying - the rinsed bottles will be drier.

4) EBI (Empty Bottle Inspection)

Using hi-tech machine like this one, B.G.I inspects bottles with defects before filling such as:

 Bottles with cracks or notches

 Bottles with adhesive residues or contaminations
 Bottles with foreign bodies

5) Filler
The matured and cooled beer is pumped and transferred to filling machine from the BBTs. Filling
process has its own steps which are:

 First the bottles are vacuumed with air to remove any liquid or gas.
 Then bottles are vacuumed to purge CO2 in order to decrease the chance of oxidation due
to O2 contact with the beer.
 Using vent tube, CO2 will be removed and the bottles will be filled with the beer.
 After filling cork will be punched to each bottles as they go out through the system.

Filler, in B.G.I, can fill 35,000 bottles/hr and is washed with soda and steam once a month and
with steam once a day.

6) FBI (Full Bottle Inspection) 1

Due to the fast process of filling machine, there may be some problems. This machine therefore
separate or removes the defected bottles from the group. These include under fill, uncapped and
broken bottles.

7) Pasteurizer
Pasteurization is killing of micro-organisms in aqueous solution by means of heat for the beer to
have a long shelf life. Here in B.G.I, this is achieved by steaming the filled bottles to 30oC for

50
some time then increase the temperature to 65 –70oC then after that cooling down to the first 30oC.
The whole process takes about 30 – 45 minutes. The pasteurizer unit can sterilize 36,500 bottles/hr.

8) Labeler
The pasteurized bottles are send to the labeler through the belt conveyor. This machine stamps the
company’s label on the neck and body of the bottle using glue as a sticking material. It can label
40,000 bottles/hr.

9) Domino
It stamps the product and Expiration dates of the processed beer at the bottom of the bottle.

10) FBI (Full Bottle Inspection) 2

It inspects for unchecked bottles or due to high working speed of the process & unlabeled bottles
and removes them the group.

11) Incammatic
It operates pneumatically for the purpose of packaging the filled bottles into their crates. It can
operate on 48,000 bottles/hr.

12) Palletization
Again using forklifts, the crates are moved to the storage room manually waiting for customers.
The forklift in B.G.I, can move 50 crates at a time.

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 Depalletizer Decammatic Bottle EBI
Washer

Palletizer
Filler

Incammatic FBI 1

FBI 2 Domino Labeler Pasteurizer

Figure 15: Process flow diagram of bottled beer packaging

4.3.2 Kegging
A keg is a very largely standardized cylindrical metal barrel, made from chrome nickel steel which
possesses a special permanently installed fitting for filling, emptying, cleaning and sterilization.
These processes can be automated with kegs. The tare weight of chrome nickel steel kegs is 7.9 -
12.5 Kg/30l or 10 - 15Kg/50l with a wall thickness of 1 – 2mm.

Here in B.G.I, the draught beer from the bright beer tanks goes straight to a sterilization system
before getting packed. The sterilization system is a plate type heat exchanger which has a heating
and cooling section. The draught beer is heated to 720c by steam goes out of the heat exchanger in
a zigzag pipe to cool to ambient temperatures and goes back to the heat exchanger to be cooled to
0 to 10c by glycol. After getting sterilized, the draught beer is directed to a buffer tank. The buffer
tank is previously counter pressured with CO2 and then the beer is filled in it. Once the buffer tank
is filled, the beer can be filled in the kegs. The keg filler machine in BGI are ten in number each
having six heads having a capacity of filling 180Hl/hr. The heads are fitted on the machines and
the keg is fitted to the heads upside down.

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These heads have different purpose. Which are:-

i. First head-for rinsing the keg with hot water.

ii. Second head-for hot wash with ATR acid.
iii. Third head-for rinsing the keg with hot water.
iv. Fourth head-Resting, no cleanings.
v. Fifth head-for drying with steam and counter pressuring with CO2.
vi. Sixth head-for filling beer in to the keg from the buffer tank.

Bottled and draught beer have difference starting from sterilization system they use, CO2 content
and so on. Some of their differences is listed below.

Table 4: Difference between Bottled and Draught Beer

Bottled Beer Draught Beer

It is packed with bottle. It is packed with short cylindrical Kegs.
It can last about a year before expiration. It can last about a month before expiration.

It has 4.85 – 5.2% CO2 content in it. It has 5.86 – 6.00% CO2 content in it.
Pasteurization is done after filling at different Pasteurization is done before filling at 73oC for 30
temperatures for about 45 minutes. seconds.
It needs large packaging area. It needs small packaging area.

BBT Flash Pasteurizer Buffer Tank

Empty Kegs

Filler

Keg Washer Storage

Figure 16: Process flow diagram of draught beer packaging

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4.4 CIP (Cleaning in Place)

Cleaning in place of brewing has largely replaced traditional methods where plant was dismantled
for manual cleaning. It is the circulation of detergents, water rinses and sterilants through fixed
plant without dismantling. In order to achieve this, tanks have to be fitted with spray balls/heads
and pipework has to be linked into a ring main.

In B.G.I, chemicals that are used to disinfect (clean) equipments are listed below.

1) Caustic Soda (NaOH) - is a cleaning agent used to remove organic compounds and
disinfect from microorganisms. The Caustic Soda tank has the capability of holding 50Hl
with 1% concentration.

2) Sept Acid (desi) & ATR Acid - are used to remove inorganic matter and for the purpose of
neutralization. These acids are, mainly, used to clean dirty materials after Caustic Soda
cleaning. Each acid tanks have the capability of holding 50Hl and concentration of 0.5%
& 1.5% for Sept acid and ATR acid respectively.

3) Super Oxide - is a cleaning agent used to clean (disinfect) equipments soundly. Some of
this equipments include beer line and production section units.

Here in B.G.I, they use two kinds of CIP systems.

A. Cold CIP
B. Hot CIP

A. Cold CIP – in this case, cold water from cold water tank is mixed with caustic soda and
other chemicals before application. Fermentation tanks and Bright beer tanks are some of
the equipment which use Cold CIP.

B. Hot CIP – in this case, hot water from hot water tank is mixed with detergent chemicals
before application. Bottling line, Beer line, filling line, Yeast storage tanks, Filter, Yeast
line are some of the units which use Hot CIP.

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4.5 Utility

In B.G.I. , Utility is the power house of the brewery which supplies steam, Purified CO 2, Process
and service water, glycol and compressed air. Utility is composed of 6 plants. These are Boiling
plant, CO2 recovery plant, Air compressor plant, Cooling plant, Raw water treatment plant and
Waste water treatment plant.

4.5.1 Boiling Plant

Boilers are closed containers with arranged pipe which produce steam at higher than atmospheric
pressure and temperature. The main objective of this plant is steam generation. It uses softened
water for steam generation to prevent scale creation due to minerals deposition during boiling. So,
hard (service) water from raw water treatment plant is pumped to carbon filter vessels to remove
chlorine. Then to minimize hardness, the chlorine free water is send to the softener tank to remove
hardening minerals using caustic soda. Softened water before entering to the boiler, it is preheated
to 105oC with a preheater by steam supplied from the boiler evaporation outlet. Using this
preheater before the boiler reduced the time and energy cost and also remove 90% oxygen. After
the water is preheated, Amercite (NaSO4) is added to remove the remaining 10% oxygen from the
water to prevent corrosion. Here in B.G.I, the type of boiler they use to produce steam is called
fire tube boiler. It is double tube container with insulation coverage. In the inner tube, fossil fuel
with oxygen injection will be burned at 180oC where on the outer tube preheated softened water
will pass by picking the heat from the inner tube through conduction and converting to steam.
Controlling device called servo meter balances the fuel per oxygen level needed for the process.
B.G.I has 2 boiler units of which producing 10t/h and 12t/h steam. Some of units (Sections) which
need steam are Brew House, Bottling, CIP and Utilities.

4.5.2 CO2 Recovery Plant

Here CO2 is recovered and treated from the fermentation tanks. First the CO2 from the fermentation
tanks are pumped and send to the foam trapper. The foam trapper removes foam particles from the
gas while the gas is going to be collected in the CO2 gas container. Then using water scrubber,
water soluble impurities are removed and the gas is stored in a plastic balloon. Using compressors,
the CO2 gas is compressed to 2bars then 17bars then finally cooled. Cooled CO2 gas will pass
through activated carbon filters to remove odor forming substances. After that, the gas will be

55
dried by a drier to reduce moisture content of the gas. Using NH3, the gas will be condensed to
25oC and 15bars. For storage purpose, the CO2 will be cooled to 27oC in a solid form. Filtration
and Bottling are the major sections which use CO2.

4.5.3 Air Compressor Plant

Air is sucked from the atmosphere and passed through dust filter to remove unwanted particles.
The filtered gas is send to vacuum suction to form pressure difference to have the capability of
transferring the air to a desired location. Using compressor, the air is compressed to a desired
pressure with respect to temperature. The compressed air will be cooled and transferred to a storage
tank to be used for pneumatic systems to operate.

4.5.4 Cooling Plant

Glycol is used as a cooling agent, which itself is cooled by ammonia using heat exchanger, used
to chill beer to a desired temperature. First ammonia is cooled by water and air then ammonia is
used to cool glycol to a certain temperature. Because glycol has a low freezing point (can be in
liquid form) as low as -5oC, it’s the perfect cooling agent to be pumped through tubes to the needed
place such as fermentation tanks easily without ice formation. TODs, Ice water tanks and Beer
chillers are the major users of glycol.

4.5.5 Raw Water Treatment Plant

Water is the most important raw material for a plant, so before using the raw water for different
purpose it must be treated. The treatment is required because the raw water is not pure and might
contain microorganisms. These must be reduced before using the water, hence by using different
mechanism and disinfectant chemicals the water treatment plant reduce the impurity of water.

First water from underground is pumped to a storage tanks. Then water, from these storage tanks,
will be dosed with NaOCl (Sodium Hypo chloride) as it passes through a sand filter to remove
coarse impurities and will be stored in another storage tank. From the current storage tank, water
will be sent to pressure tank to be pressurized to acquire amount, using compressed air from air
compressor plant, to reach the desired place. In this plant, two types of waters are produced.
Process water also known as permeate water is used for beer processing and Service water also
called blend water is used for other cleaning purposes. Two water streams will be created after

56
pressurized tank. Service water will have no more treatment and directed to desired place in other
hand the process water will be sent to CO2 degasser for removal of CO2. Hydrex & Sodium
metabisulfite will be used to remove Cl2 before the process water enters to reverse osmosis system
for further treatment and ultra-separation because Cl2 damages the filter membranes. After
removal of Cl2, the Cl2 free water will be sent to activated carbon filter and then the treated process
water will be sent to storage tank until needed for usage.

4.5.6 Waste Water Treatment Plant

It is necessary to treat waste water before it is discharge to the environment. B.G.I uses anaerobical
system to treat water that after usage before release. Brew house and bottling are the major
contributors of waste water to this plant. So, water from brew house will be collected to brew
house pump pit and water from bottling house will be sent to filling line pump pit. These pits starts
to pump waste water to the next process as their sensor indicates 80% for brew house pump pit
and 60% for filling line pump pit. From these pits, water will be passed through primary screen
for removal of plastics. Then water will be transferred to influent pit which has deflator that
removes oil from water using density difference.

The oil free water will pass through static screen which traps materials that are larger than 0.5mm
in diameter. Then water will be pumped to equalization tank. In this tank, Sodium Hydroxide
(NaOH) and Carbon dioxide (CO2) will be used simultaneously to adjust the water’s PH. But if
this didn’t work, using PH correction tank it will be regulated. After that, the water will be sent to
anaerobic reactor which has an artificial bacteria at the bottom of the tank that will decompose the
sludge in the water. Here methane gas will be produced due to decomposition process but small
in amount. Methane gas can’t be used for bio-gas purpose due to small amount of production. So
it used to be separated and burnt using Bio-gas torch. But since last year the bio torch is out of
service so using bio filter methane is extracted and released to the atmosphere. And the water pass
through reparation tank for good mixing and air sacking before released to the nearby river.

57
Figure 17: Water treatment plant

4.6 Quality Control

4.6.1 Beer testing

Every brewer has the capability of monitoring the process and product to determine the level of
consistency and quality. In fact, basic record keeping is essential to establishing consistency and
developing a basic quality control program. Quality control programs should be run starting from
raw materials up to finished goods. One good definition for a quality beer is simply "a beer that
consistently meets specification." The idea of a specification immediately requires that someone,
at some time and someplace, has decided what the beer's defining character(s) should be and how
it should be measured. The idea of consistency immediately requires a system of people, plant,
and process who are able to repeat exactly what they do time by time. Therefore, these ideas about
quality are complicated and expensive but most useful.

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4.6.1.1 Quality control program
In general, for quality control of beer, the quantitative determination of these parameters below is
of high importance.

A. Wort Production: Process quality control parameters for wort production should be;
extract, color, bitterness (BU), PH and dissolved oxygen.

B. Pitching: Process quality control parameters for pitching yeast should be; cell count, dead
cell and yeast pitching rate. (Wort bacteria, wild yeast and lactic acid bacterial infection
may also be applied).

C. Fermentation: Process quality control parameters for beer fermentation should be;
Apparent extract (o Plato), temperature, pressure, cell count, dead cell, growth rate, pH,
VDK and Flavor control. (Wort bacteria, wild yeast and lactic acid bacterial infection may
also be applied).

D. Maturation: Process quality control parameters for beer maturation should be; temperature,
pressure, original extract (o Plato), alcohol, apparent extract, bitterness, pH, VDK, and
flavor control. (Wild yeast and lactic acid bacterial infection may also be applied).

E. Filtration: Process quality control parameters for filtration should be; turbidity (haze),
dissolved oxygen, CO2 content, original extract and alcohol. (Wild yeast and lactic acid
bacterial infection may also be applied).

F. Bright beer Handling: Process quality control parameters for bright beer handling should
be ; original extract, alcohol, real and apparent degree of fermentation(RDF and ADF) ,pH
,color, turbidity(Haze), CO2 content, dissolved oxygen, head retention(foam
stability),bitterness, VDK and flavor control. (Wild yeast and lactic acid bacterial infection
may also be applied).

G. Packaging: Process quality control parameters for packaging should be; CO2 content, total
oxygen content and air in head space.

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4.6.1.1.1 Quality control procedures done in the laboratory
There are two types laboratory procedures are employed here in B.G.I. These are;

 Physic-chemical laboratory procedures and

 Microbiological laboratory procedures.

I) Physic-chemical laboratory procedures

Producing beer with consistent high quality requires continual moniteration of certain
parameters. These include:-

a. Analysis of beer to determine extract and alcohol content, the final attenuation, PH….
b. Determination of diacetyl content.
c. Measurement of bitterness.
d. Measurements of dissolved oxygen content in the beer.
e. Determination of the colloidal stability of beer by a forcing test.

Now let’s see some of the procedures done on mash, wort and finished beer.

A. Iodine reaction of mash:

i) Objective - the quantitative determination of starch in mash/wort using iodine solution.
ii) Field of application - The method can be applied to all pale worts.
iii) Principle - To all products to be examined, a dilute iodine solution is added. A blue-
black color developed at the interface of iodine solution and wort indicates the
presence of starch. No color change, i.e. when the wort keeps its yellow color, it
indicates the complete degradation of starch.

B. pH measurement:
i) Objective - pH determination.
ii) Field of application - the method is applicable for wort and beer.
iii) Principle - getting the pH from a working pH meter. Uniformity of sample can be
attained by using a magnetic stirrer or pH meter with combined glass electrode.

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C. Vicinal Diketones, VDK:
i) Objective - determination of vicinal diketone content in beer.
ii) Field of application - The method can be applied to all filtered beers. In unmatured
beers, the precursors (indicators) of vicicinal diketones are also measured.
iii) Principle - The vicinal diketones, diacetyl and pentanedione are distilled from beer and
then combined with α-phenylene diamine to form derivatives of quinoxaline. The
amount of these compounds is measured by the absorbance at 335nm by a
spectrophotometer against a blank of distilled water.

D. Color:
i) Objective - Determination of the color of wort and beers using spectrophotometers.
ii) Field of application - The method can be applied to all types of wort and beers.
iii) Principle - by a spectrophotometer, the absorbance of the sample against distilled
water is measured at 430nm then multiplied by an appropriate factor. Turbid samples
are first clarified by a centrifuge. The unit of measurement for color is EBC.

E. Bitterness:
i) Objective - Determination of bitterness.
ii) Field of application - wort and beer with bitterness content up to 70BU (bitterness
unit). The method shows a blank value of 8 BU for wort and 2-3 BU for beer.
iii) Principle - The results are only valid if the beer doesn’t contain the following
compounds; n-heptyl-4-hydroxybenzoate, saccharin, salicylic acid, sorbic acid. These
compounds are extracted by isooctane and absorb at 275nm but their presence can be
detected because they change the shape of the absorption curve.

F. Dissolved Oxygen:
i) Objective - Determination of oxygen content.
ii) Field of application - Applied to all filtered beers, bright beers and beer in packaging.
iii) Principle - getting the oxygen content from a properly working oxymeter.

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G. CO2:
i) Objective - Determination of CO2 content.
ii) Field of application - Applied to all fermented beers, filtered beers, bright beers and
beer in packaging.
iii) Principle - getting the CO2 content from a properly working galtmeter.

H. Haze(Turbidity):
i) Objective - Determination of haze stability of beer.
ii) Field of application - Applied to all filtered beers, bright beers and beer in
packaging.
iii) Principle - sample of degassed beer is inserted in turbidity meter equipment and the
corresponding value is read from it at two different angles namely; 90o & 25o.

I. Foam Stability:
i) Objective - Determination of the foam stability of beer.
ii) Field of application - Applied to bright beers and beer in packaging.
iii) Principle - sample of the beer in a glass cup where the entire beer is first change to foam
is inserted in a foam stability tester and the amount of seconds the foam keeps its height
is recorded.

J. Polyphenol Content:
i) Objective - The determination of total polyphenols in beer by spectrophotometer.
ii) Field of application - The method can be applied to all beers.
iii) Principle-
a. Treatment of the sample with a solution of carboxymethyl cellulose and EDTA.
b. Reaction of polyphenols with ferric ions in alkaline solution. Then, measurement
of the absorbance of the red colored solution at 600nm against a blank solution is
recorded from the spectrophotometer.

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K. Foreign gases:

i) Objective - the determination of foreign gases in bottled beer.

ii) Field of application - The method can be applied to all beers.
iii) Principle - Transferring all the dissolved gas in beer into the Zham absorption
burette and reading the volume of the gas.

L. Total Hardness of water:

i) Objective - determination of total hardness.
ii) Field of application - treated and untreated water.
iii) Principle - Taking a sample of water and adding a pinch of EBT which will give the
water a violet color. Then titrate the sample with an EDTA solution at pH 9.5-10 until
end point is reached. We will know end point is reached when the violet color changes
to blue black.

Other very important parameters in wort and beer quality such as;

a. Original Gravity – is a measure of the initial specific gravity of wort.

b. Apparent Gravity – is the false measurement of density due to light-weight
property of alcohol within the wort.
c. Real Gravity – is the corrected specific gravity amount measurement of wort.
d. Real Extract – is the actual amount of total solids in a wort corrected for the actual
amount of alcohol in the wort.
e. Apparent Extract – is the false reading of specific gravity by the hydrometer due
to alcohol production since alcohol has lighter density.
f. Apparent degree of fermentation – the observed reduction in wort concentration
resulting from fermentation (as measured by SG) and not the actual or real values
(due to the imperfect nature of a hydrometer's readings in a solute containing
alcohol).
g. Real degree of fermentation – the corrected amount of SG of reduced wort from
fermentation
h. Alcoholic Content – is a measure of the amount of alcohol in beer typically refers
to amount of ethyl alcohol.

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 i. Specific Gravity – is the ratio of the density of a substance at the temperature
under consideration to the density of water at the temperature of its maximum
density (4oC).
j. CO2 content – is mount of CO2 dosed in a beer.

All the above done by an equipment called Alcolyzer plus. This high-tech equipment first takes a
sample of distilled water and then takes the sample of beer and wort and measures the parameters
above using water as a referring value. This is because all the above parameters have a value of
zero for distilled water.

II) Microbiological laboratory procedures

Microbiological laboratory procedures are done on yeast, wort and beer. It is possible for micro-
organisms to pass from wort or beer production route to finished beer. If these micro-organisms
multiply they at first form a slight deposit in the beer which make the beer turbid and through the
formation of various metabolic products spoil its taste and even make it undrinkable. Basically
three groups are categorized with respect to spoilage micro-organisms.

Harmless accompanying micro-organisms, potentially damaging micro-organisms and Obligatory

spoilage micro-organisms.

1. HARMLESS ACCOMPANYING MICRO-ORGANISMS: - consists of mold spores and

many species of bacteria and yeasts. They cannot grow and eventually die but their presence often
indicates the presence of more micro-organisms.

2. POTENTIALLY DAMAGING MICRO-ORGANISMS: - this type of micro-organisms can

only multiply in finished beer and conditions must be set like oxygen content of beer must be high,
beer PH is relatively high and hop bitterness is very low.

3. OBLIGATORY SPOILAGE MICRO-ORGANISMS: - the obligatory beer spoilage

organisms also develop in a beer containing no oxygen and with low PH value. They are immune
to such influencing factors. When they have sufficient time they multiply, even in the filled bottle,
and first of all form a deposit and then make the entire content turbid.

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Yeast can also spoil beer by disturbing fermentation or performing secondary fermentation. Beer
spoilage yeasts are yeast cells that are still present in beer after filtration and foreign yeast which
are that are not wanted and cause deposit turbidities and flavor defects if they multiply.

The task of micro-biological control department is to make checks at many locations as possible
and as frequently as possible in order to determine where and how the micro-organisms enter the
wort or the beer. The foreign micro-organisms are called contaminating organisms. Harvested and
pitching yeast, water, air…etc. are all possible sources of contamination must be monitored
because the more thorough the monitoring, the greater the chance of finding the source of
contamination in the bud.

Micro-biological monitoring is a very important control measure in the brewery. By this method
contamination sources can be detected in good time and this contributes decisively to the biological
stability of the beer.

5. Overall Benefit That We Gained From the Internship

5.1 In Terms of Improving Our Practical Skills

In process control operations we could get skills about the following issues:

i. Demonstration of the control of the quality of each raw material

ii. Flow rate of each raw material
iii. Process parameters used at each unit operation
iv. The operating principle of each machine
v. Stages where inspection or testing is done
vi. Effective material handling at all parts of the production line

5.2 In Terms of Upgrading Our Theoretical Knowledge

We could improve our theoretical knowledge by relating the knowledge that we have to the
production processes and by further reading the operation manual of the processes as well as from
different books internet websites.

65
5.3 In Terms of Improving Interpersonal Communication Skills
By identifying problems and trying to find out the solution by discussing with the workers and our
friends we could improve our interpersonal communication skills.

5.4 In Terms of Team Playing Skills

Being with different students with different ideas and knowledge has given us an opportunity to
discuss different issues and to come to a conclusion by sharing different ideas.

5.5 In Terms of Leadership Skills

The supervision of different activities in the production line needs knowledge of the processes,
parameters of process control, etc. and this could give us an idea of company process leadership
skills.

5.6 Understanding of Work Ethics Related Issues

We could understand the importance of work ethics related issues such as punctuality, reliability,
honesty, cooperation with others, etc. while we were practicing in the factory.

5.7 In Terms of Entrepreneurship Skills

The internship program has given us a chance to know about entire premiership, i.e. the creation
of different work and job opportunities for different people by observing problems and setting
solutions.

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 6. Material and Energy Balance on Selected Equipments

6.1 Material Balance

1. Meca Masher
Inputs
Inputs
Grist = 7,500Kg
Water = 152Hl

Meca Masher
Required
Mash in Kg?

Overall material balance

Mash
Grist + water = Mash

Input water = 152Hl = 15,200l (Since 1Hl= 100l)

Density of Water = Mass of water/Volume of water

Mass of Water = Density of Water * Volume of Water

= 1 Kg/l * 15200l
= 15,200 Kg.
Therefore,
Mash = Grist + mass of water = 7500Kg + 15200Kg = 22,700 Kg

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 Inputs

2. Mash Tun
Mash Tun
Inputs
Mash in = 22,700Kg
HCl = 6Kg
Mash Out
Hitammpase = 0.5Kg
Bioglucanase = 1.7Kg
CaCl2 = 7Kg

Required
Mash out in Kg?

Overall mass balance

Mash Out = Mash in + HCl + Hitammpase + Bioglucanase + CaCl2

Mash out = 22,700Kg + 6Kg + 0.5Kg + 1.7Kg + 7Kg
Mash out = 22,715.2 Kg

3. Mash Filter

Inputs
Wort in = 22,715.2Kg
Sparging Water = 152Hl

Output
Wort out = 345 Hl

Required
Spent Grain in Kg?

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Volume of wort = 345Hl = 34,500l
Volume of Sparging water = 152Hl = 15,200l
Density of Sparging water = Mass of Sparging water/Volume of Sparging water
Mass of Sparging water = Density of Sparging water * Volume of Sparging water
= 1Kg/l * 15,200l
= 15,200 Kg

Wort extract content is 18.02oP (from laboratory mass percent of the wort)
Specific gravity = (extract content of wort * 0.004) + 1 = 1.07208.
Density of final wort = specific gravity * density of the water
=1.07208 * 1Kg/l
= 1.07208Kg/l.

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Now finding for sweet wort,
Mass of sweet wort = volume of wort * density of final wort
= 34,500l * 1.07208Kg/l
= 36,986.76Kg.

Sweet wort = volume of 1st wort + volume of Sparging wort

But volume of Sparging wort = volume of Sparging water + volume of 2nd wort
So, Sweet wort = volume of 1st wort + volume of Sparging water + volume of 2nd wort

Extracted pure wort (without water) = extracted wort – volume of Sparging water
= 36,986.76Kg – 15,200Kg
= 21,786.76Kg.

Now, finding for spent grain

Input = Output
Mash in + Sparging water = extracted wort + spent grain
Spent grain = (Mash in + Sparging water) –extracted wort
= 22,715.2 + 15,200 – 36,986.76
= 928.44 Kg.

So, the mash filter from one brew of 21,786.76Kg wort filters 928.44Kg of spent grains.

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 4. Wort Kettle
Evaporated Water
Inputs
Extracted wort = 36,986.76Kg
CO2 Hop Extract = 7Kg Inputs Cast Wort

Caramel = 7.5Kg
CaSO4 = 7Kg
ZnSO4 = 20Kg
Sugar = 900Kg

Outputs
Cast wort = 336Hl

Required
Evaporated water in Kg? Wort Kettle

Extracted wort = 36,986.76Kg

Volume of cast wort = 336Hl = 33,600l
Mass of cast wort = volume of cast wort * density of cast wort

Finding for density of cast wort,

Density of cast wort = specific gravity of cast wort * density of water

Finding for specific gravity of cast wort (just like we did before),
S.G of cast wort = (19.14 * 0.004) +1
= 1.07656.

Density of the cast wort = specific gravity of cast wort * density of water
= 1.07656 * 1Kg/l
= 1.07656Kg/l.

Now for mass of the cast,

Mass of cast wort = volume of cast wort * density of cast wort
= 33,600l * 1.07656Kg/l
= 36,172.416Kg.

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Finding for Evaporated water,
Overall material balance
Inputs = mass of evaporated water + output (cast wort)
Mass of evaporated water = (36,986.76 +7 + 7.5 + 7 + 20 + 900) Kg – 36,172.416Kg
= 1755.844Kg

5. Whirlpool Cast Wort Clear Wort

Inputs
Cast wort = 336Hl
Clear wort = 320Hl

Whirlpool
Required
Mass of trub in Kg?

Mass of Trub
Cast wort = 336Hl = 33,600l
Clear wort = 320Hl = 32,000l
Mass clear wort = Density of clear wort * Volume of clear wort
= 1.07656Kg/l * 32,000l
= 34,449.92Kg.

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Overall material balance
Input = output
Volume of trub = Cast wort – Clear wort
= 336Hl – 320Hl
= 16Hl

Or in terms of Kilograms,
Mass of trub = mass of cast wort- mass of clear wort
= 36,172.41Kg – 34,449.92Kg
= 1722.496Kg

6.2 Energy Balance

1. Hammer Mill

Energy consumption of Hammer Mill

E/M = 0.136 Wi [(1/Dpb 0.5) – (1/Dpa0.5)]
Where
Wi – working index
Dpa – Size of malt before milling
Dpb – Size of malt after milling
M – Mass of malt

Data
Wi = 12.74
Dpa = 3mm
Dpb = 2.75mm
M = 7,500Kg
Required
Energy, E in KJ?

Therefore,

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E = 0.136 Wi M [(1/Dpb 0.5) – (1/Dpa0.5)]
= 0.136 * 12.74 * 7500 [(1/2.750.5) - (1/30.5)]
= 750KW (i.e. for 7,500Kg of malt, the hammer mill uses 750KW)

2. Mash Tun

Q = Ms * Hfg@T=420
Where
Ms – Mass flow rate of steam
Hfg – Vaporization enthalpy of steam

Data
Ms = 2,700Kg/hr.
Hfg@T=420k = 2,123KJ/Kg

Required
Qsupplied by the steam
Therefore,
Qsupplied by the steam = Ms * Hfg@420k
= 2,700 Kg/hr. * 2,123KJ/Kg
= 5.7 KJ/hr. (i.e. the mash tun needs 5.7KJ of heat hourly)

3. Wort Kettle
Mv = 1,755.844Kg
Hfg@T=566.4K = 1429KJ/Kg & Hfg@T=420K = 2123KJ/Kg

Required
Qsupplied by the steam

Mv – Mass of evaporated water

Hfg – Vaporization enthalpy of steam

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Ms – Mass of steam
Qsupplied by the steam = Qgained by the wort 0
Qsupplied by the steam = Qlatent heat of the wort +Qsensible heat of the wort

Qsupplied by the steam = Qlatent heat of the wort

Ms = (Mv Hfg@T=566.4k)/ (Hfg@T=420k)

Ms = (1,755.844 * 1,429KJ/Kg) / (2,123KJ/Kg)
Ms = 1,181.865Kg

Qsupplied by the steam = 1,181.865Kg * 2,123KJ/Kg = 2.509 GJ is supplied by the steam.

4. Fermentation

Assumptions
 TOD’s capacity is 8 brew
 Using last generation of yeast
 Eliminating purge yeast

Required
- Pitching Quality
- Amount of CO2 produced and sent to the CO2 recovery plant

Quality of yeast pitching (PQ) can be calculated as

PQ = [(VTOD * 100)/ (V * C)] * DR

Where
VTOD – Volume of TOD = 2,560 Hl
V – Viability = 92.1%
C – Consistency = 51%
DR – Dosing rate = 60Kg/Hl

PQ = [(2,560 * 100)/ (92.1 * 51)] * DR

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PQ = 3270.103 Kg
General material balance
Cold wort + yeast = HG beer + CO2
Cold wort = 2,560Hl (from the 8 brews) = 256,000l * 1.072Kg/l = 274,432Kg
HG beer = 2328.4Hl = 232,840l * 1.072Kg/l = 249,604.48Kg
Yeast = 3,270.103Kg

CO2 = Cold wort + yeast - HG beer

= (274,432 + 3270.103 – 249,604.48) Kg
= 28,097.623 Kg

5. Centrifuge Efficiency

Counting by electro-microscope

 Before centrifuge = 30 million cells as measured by a hymocytometer slide.

 After centrifuge = 8 million cells as measured by a hymocytometer slide.

Therefore,

η = in – out * 100%

in

= 30*106 – 8*106 *100%

30*106

= 73.33% (i.e. Our centrifuge is efficient)

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7. Conclusion and Recommendation

7.1 Conclusion
Internships are arrangements in which university students lend their talents to companies in return
for an opportunity to develop business skills and gain exposure to the work environment. With this
regard, we found the internship program to be such an interesting phenomenon. From the
experience we had, we concluded that internship provides benefits not only for the intern, but also
for the hosting company. The benefits that the company gains could be increasing productivity,
finding future employees, advertising and so on. Beside this, the organization has the opportunity
to observe a student at work and review work habits, technical abilities, interpersonal skills and
adaptability before making a full time commitment.

Generally, beer is an alcohol beverage made by fermentation from fermentable sugar obtained
from starchy material which is barley in form of malt. The aim of malting to bring forth enzyme
that will hydrolyze the starch and protein to less complex water soluble compounds, i.e. amino
acids, fermentable sugars and small peptides. These compounds are dissolved in water resulting in
a liquid known as wort. Generally, there are also two types of yeast in brewing that is top and
bottom type but in B.G.I Company it used the bottom type one due to which does not usually for
spore. This is well adapted slow fermentation at low temperature and settles to the bottom of the
tank at the end of fermentation. Last but not least, filtration commenced, this process is a separation
process in which the yeast cells and other turbidity causing still presents in the beer are removed
from the beer. At the same time substance is which would, in the course of the next weeks or
months, they precipitate and make the beer turbid. Once the desired quality of the beer is attained
in the bright beer tank, the beer will finally ready to be filled in the bottle or keg.

7.2 Recommendation
B.G.I uses silos made from stainless steel to store the imported malt. The problem is there is no
system (mechanism) installed in the silos to control the internal environment like humidity and
temperature. If the malt is not handled adequately, we won’t get the needed yield later in the
production process. So we recommend that B.G.I should install temperature and humidity sensors
inside the silos and apply systems such as ventilations to control these parameters. After bottles
are filled, they need to be capped (sealed) in order not to have contamination. Here in B.G.I, the

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FBI machines remove under fill, overfill and uncapped bottles by inspection. This problem occurs
due to many reasons such as if the beer is hot and formed more foam, if the deflector valve changed
its shape due to misalignment with the bottle, if the snifit valve is filled by dust, if CO2 content is
increased above average son on. Due to this problem, B.G.I losses about 18 million birr annually.
So we recommend that B.G.I tackles the problem from the causes it is making it. Waste water
treatment plant in B.G.I uses anaerobical system for its process before water is discharged to the
environment. But integrating the anaerobical system with aerobical system could give us a higher
efficiency in treating the waste water. So we recommend for B.G.I to apply this principle.

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 Part Two – Project

Production of CO2 Hop Extract from Gesho

Executive Summary
Production of hop extract using liquid carbon dioxide provides a convenient method of obtaining
a high-quality product which usually contains over 90% of the available α-acids in the original
hops. Under suitably controlled conditions, this solvent does not extract significant amounts of
hard resins, fats, waxes, or pigmented materials which have negative impact on brewing process.
The extraction method consisted of hop drying, milling, injection of hop with liquid carbon
dioxide, spent hop removal and CO2 gas recovery for reuse. The extract then will be characterized
using appropriate methods and materials. The influence of different parameters on the extraction
process such as operating temperature and pressure of carbon dioxide were explored and optimum
conditions were recommended.

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1. Introduction

1.1 What are Hops?

Hops (Humulus lupulus) are a perennial (self-renewal) plant of the Cannabaceae family that also
includes the genus Cannabis. In the production of beer, hop is an essential component. Hops
provide bitterness to balance the sweetness of malt sugars, as well as flavors, aromas, resins that
increase head retention, and antiseptics to retard spoilage. Raw hop contains alpha acids, beta
acids, Hard resins (up to 25% in total), hop oils (up to 3%), hop polyphenols (up to 14%), cellulose
(up to 50%), water (up to 12%), protein (up to 22%), minerals (up to 10%) and lipids, waxes,
pectin and carbohydrates (each 2-3%). The composition of hops varies depending on the variety,
crop year and location. The lupulin glands of hop provide the essential components that brewers
need. These are the bittering compounds (α & ß acids) and hop oils.

Figure 18: Hop Leaf

Brewery industries use different types of hops as their interest, capacity to produce beer and kind
of process they use. Hops can be added at several points in the brewing process to enhance
bitterness, flavor and aroma. While most hops are added in the boil kettle, they can be added at
various stages prior to and after the boil as well. Kettle hops is the name given to those hops added
to the kettle during boiling process. These include early addition for bitterness and late addition
for flavor and aroma.

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1.1.1 Types of Kettle Hop
1. Bittering Hops – Bitterness from hops comes from alpha acids found in the lupulin glands
of the hop flowers. The main alpha acids are humulone, cohumulone and adhumulone. In
order to become bitter these acids must be chemically altered, isomerized, by boiling.
Isomerization is a chemical process in which a compound is changed into another form
with the same chemical composition but a different structure. The percentage of the
potential alpha acid that is isomerized is referred to as utilization. Because the length of the
boil determines degree of utilization, bittering hops are usually added at the beginning of
the boil or with at least 60minutes of boiling time remaining.

2. Flavor Hops – Hop flavor and aroma are derived from essential oils found in the lupulin
glands. These oils include humulene, myrcene, geraniol, and limonene, among others. The
flavors are released as these oils become dissolved into the wort during the boil. However,
these oils are highly volatile and are to a large degree lost to evaporation. For this reason
flavor hops are added with twenty to forty minutes remaining in the boil. This provides a
compromise between isomerization of the alpha acids and loss of essential oils.

3. Aroma Hops – Because the aromatic essential oils are highly volatile, aroma hops are added
in the last minutes of the boil to minimize their loss to evaporation.

In Ethiopia, Domestic beverages such as tella and tej are produced using the leaves and stems of
Rhamnus prinoides (Amharic name, Gesho). It is used to provide a special aroma and flavor.
Different chemical substances are found in Rhamnus prinoides such as chrysophanol, physcion,
emodin, prinoidin, musizin, β-sorigenin, rhamnocitrin, rhamnazin, quercetin and 3-O-
methylquercetin but from all these naphthalenic glucoside (Geshoidin) is the basic bittering agent
for beverages. Geshoidin is a non-toxic substance found in abundance amount in the stem and
leaves of Rhamnus Prinoides. Although Gesho may have antibacterial effect against some groups
of bacteria during fermentation process, its main purpose in the process is believed to impart the
typical bitter taste to local beer (tella or tej).

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From all the components gesho has, its leaf contain 1.13% w/w essential oil and 18.46% w/w total
resin & its stem contain 0.6% w/w essential oil and 17.16% w/w total resin.

Table 5 – Component and Composition of Gesho Leaf

Components Wt./100 gm
Moisture 8.9 – 10.6 gm
Nitrogen 1.1 – 2.1 gm
Protein 7.1 – 9.2 gm
Fat 2.0 – 4.0 gm
Carbohydrate 6.19 – 76.3 gm
Fiber 11.7 – 28.7 gm
Ash 5.8 – 11.5 gm
Calcium 1012 – 2392 mg
Phosphorus 100 – 190 mg
Iron 15.9 – 118 mg
Β-carotene equivalent 4.82 – 11.40 mg
Thiamine 0.04 – 0.08 mg
Riboflavin (Vitamin B2) 0.59 – 0.67 mg
Niacin 1.8 – 2.9 mg
Ascorbic acid 4 – 18 mg

Figure 19: Structure of Geshoidin (β-sorigenin-8-O-β-D-glucoside)

1.2 The Big Three

There are three main chemicals that hop contributes to the brewery process:

A. Alpha acids (α - acids) - are a class of chemical compounds primarily of importance to the
production of beer. They are found in the resin glands of the flowers of the hop plant. They
have two main purposes in beer. First, they give beer that unique bitter taste. Alpha acids
may be isomerized to form iso-alpha acids by application of heat in solution. Iso-alpha

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 acids (Iso -α - acids) are typically produced in beer from the addition of hops to the boiling
wort. The degree of isomerization and amount of bitter flavor produced by the addition of
hops is highly dependent on the length of time hops are boiled. Longer boiling times will
result in isomerization of more alpha acids and thus increased bitterness. Another very
important aspect of alpha acids are there antiseptic nature. Before the usage of hops, high
alcohol content was the only way to make beer last a long time. The addition of hops
(especially the alpha acids) to beer helped prevent unwanted growth of bacteria, and on the
other hand enhanced the ability of yeasts to grow and ferment the wort to beer.
Special care has to be taken with alpha acids though. If Iso-alpha acids are allowed to react
with light, and riboflavin (vitamin B2 coming from the malt), the beer will produce
unpleasant smell. This is why beers are bottled in brown glass, to prevent certain
wavelengths of light from starting this process.

Primary alpha acids include:

a) Humulone
b) Cohumulone
c) Adhumulone

B. Beta acids (β - acids) - do not contribute much to the beer as a whole, but help in two areas.
First, beta acids contribute some to the bitter flavor of the beer. Although the bitterness
from the beta acids are harsher than the alpha acids, due to their insolubility, not much
comes off in the beer. The beta acids do not isomerize like there alpha counterpart, but
rather oxide in the beer to produce bitter flavor.

Beta acids have also been shown to have great antiseptic qualities for the beer, aiding in
shelf life and yeast’s ability to grow. Some research has been done using from H. lupulus
to aid in the preservation of foods.

Primary beta acids include:

a) Lupulone
b) Colupulone
c) Adlupulone

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 C. Essential oils - are another key component of hop cones, adding aroma and flavor.
Extracting the oils takes very little time when brewing beer. Due to their volatile nature,
most of the initial oils from the starting hops (bittering hops) are evaporated off during the
boil. The strength of the oils is seen in the last minutes of boiling (around 5 minutes). These
oils produce most of the hop flavor and aroma smelled in beer. “Grassy” , “piney”, “earthy”
,”citrus”, or “spicy” are all the terms and fragrances that essential oils give to the beer.

Figure 20: Chemical Structure of α & β acids

1.3 What is CO2 Hop Extract?

CO2 Hop Extract (CO2 Extract) is a hop product developed from the extraction of the components
of hops that are important to brewers in the production of beer namely the alpha-acids and essential
oils that contribute to beer’s bitterness, aroma, foam, and microbiological stability. These are the
compounds of the most benefit to brewers that are utilized from whole hops and hop pellets in the
brew kettle during the brewing process that follow through into the final beer.

CO2 Extract eliminates a great deal of the inert materials that come with the vegetative portion of
hops and hop pellets, and thereby reduces weight, handling, and residual hop material that needs
to be removed from the wort during brewing.

CO2 Extract is designed for use in the brew kettle or whirlpool on the “hot side” of brewing.
Because the extract provides hop alpha acids – the same as those found in whole hops and hop
pellets – the isomerization of these alpha acids into iso-alpha acids is still necessary by means of

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the boiling process in the brew kettle (and to a lesser extent in the whirlpool). Also, as with whole
hops and hop pellets, the timing of the addition of CO2 Extract in the process will influence the
utilization of the various hop essential oils important in the flavor development in beer. Hop
utilization refers to how well the hops have imparted their taste and aroma into the beer.

CO2 Extracts have many advantages over other hop kettle products:

i. They are the most stable form of hop product. Pure resin extracts can be stored for several
years at ambient temperature with negligible loss of brewing value.
ii. Hop extract provides better utilization of alpha acids compared to other traditional non-
isomerized kettle products.
iii. Hop extracts are extremely uniform. The alpha acids content in the container can be
adjusted to customer specifications for optimum consistency.
iv. Shipping, storage weight, and volume are substantially reduced, as only the extract material
is retained and packaged (typically 20 to 25% of the original hop material for high-alpha
hops).

There are two types of CO2 hop extract productions; using subcritical or supercritical system.
Using subcritical system tends to pull out mostly light oils (Essential oils) and soft resins (mostly
the beer bittering acids) and leaves behind waxes, paraffin and hard resins. Extraction time can be
longer and yields can be lower due to its high selectivity. While supercritical system extracts the
higher molecular weight materials (like waxes, paraffin, lipids and hard resins) and chlorophyll
which give beer off-flavors and interfere with the solubility of iso-α-acids also its higher
temperature and pressure (120oF and 5000psi) can cause thermal degradation of the essential oils.

1.3.1 Why CO2?

There are a lot of reasons for the preference of CO2 as a solvent for hop extraction. These
include:

1) It is a harmless by-product of fermentation.

2) It is an effective solvent for soft resin and essential oils.
3) It is an effective solvent at sub-ambient temperatures.
4) It is a solvent that was chemically inert with respect to the compounds being extracted.

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 5) It is a solvent that provided its own inert atmosphere and hence prevented the access of
oxygen to the extracted material.
6) It is a solvent that exhibited unparalleled selectivity for the hop components of interest.
7) Using other solvents such as Methanol, Ethanol and Hexane might give us a good yield
but these solvents extract not only the bittering acids and essential oils but also all the
heavy weight materials such as hard resins, waxes and chlorophyll which are not needed
during the brewery process. But the bittering acids and essential oils dissolve to the liquid
CO2 at sub-critical condition due to its high selectivity to only extract the hop component
of desire.
8) Using other solvents such as ethanol and methanol, might change the extract flavor but
not CO2.
9) If an extracting plant is installed in a brewery factory, it’ll have abundant CO2 feed for
the extraction process from fermentation and since the extraction system uses cyclic
process using CO2 again and again, this will reduce the production cost further.

1.4 Statement of the Problem

The brewing industry is becoming more competitive and constantly looking for ways to improve
beer quality and reduce manufacturing costs in the worldwide. In tropical countries like Ethiopia,
Hops has been imported from other temperate countries and this involves the expenditure of scarce
foreign exchange. Rhamnus prinoides (Amharic, name: Gesho) is a cultivated indigenous shrub
which is also known to occur far west as Cameroon and as far south as South Africa, and Ethiopia.
It has a potential use as a commercial hopping agent in the beer industry. Gesho is a new potential
substitute for imported hops which can be used as an alternative substrate and also raise economic
benefits through import substitution.

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1.5 Objective

1.5.1 General Objective

Production of CO2 hop extract from Rhamnus prinoides (Gesho)

1.5.2 Specific Objectives

i) To extract CO2 hop extract.
ii) To analyze the extract.
iii) To give guidance on how to find the bittering yield of the extract on beer production.
iv) To identify the proper processing parameters such as temperature and pressure for
maximum and efficient hop extraction.

1.6 Significance of the Project

The reason behind doing this project is because:-

i) It provide an economically feasible option to produce hops locally, which will play a
major role to substitute the imported hops which saves foreign currency and create job
opportunity for people.
ii) It introduces the Gesho as a local raw material for use in the beer production process.
iii) It helps to encourage import substitution to meet growth and transformation plan.
iv) It helps to satisfy the brewery industry ensuring stability and sustainability of input raw
material.
v) It creates opportunity to increase domestic agricultural products as a raw material in the
industrialization effort.

1.7 Scope of the Project

Since we did not do any experimental work, we can only show this project as a future work, that
can be commenced later, which ranges from extracting hop using CO2 as a solvent at sub-critical
temperature and pressure, analyzing and determination of the extract content and recommending
proper parameters for efficient extraction.

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2. Literature Review
I. S. Daoudand and S. Kusinski investigated both Liquid CO2 and Ethanol Hop extraction with
optimal parameters. For ethanol extraction first, Hop cones and pellets were milled through a 1
mm screen using a Wiley Knife mill then 1.5 kg of the milled hops was placed in a 10 liter glass
jar and 5 liters of AR quality ethanol was added. The jar was fitted with a lid and the contents
stirred vigorously for 5 hours at 30oC. The mixture was filtered through a Buchner Funnel and the
residual hops were washed with 500 ml of ethanol. The filtrate was sorted for 24 in a refrigerator.
The hop residue was returned to the glass jar, covered with 3 liters ethanol and mixed thoroughly
before being left unstirred at 30°C. After a further 24 hours the contents of the glass jar were
filtered through a Buchner Funnel and the residue washed with 1 liter ethanol. The two filtrates
were combined and the resulting solution evaporated slowly under reduced pressure to remove the
ethanol and for Liquid CO2 extraction, they used a twin column pilot scale extractor to extract hops
for 7-8 hours at a temperature of 7oC and at a pressure of 700-800 psig, using LCO2 flow rates
between 20 and 35 kg/hr. A description of the plant is given elsewhere for Commercial hop pellets
were milled through a 1 mm sieve using a Wiley Knife mill. Up to 4.3 kg of the powered hops
were then packed into each extraction column, which could be used separately or in series. The
liquid leaving the columns was passed into an evaporator at 40°C where the CO2 was boiled off.
The extract was collected periodically by opening the tap at the bottom of the evaporator. The
gaseous CO2 was passed through a column packed with activated charcoal before being discharged
to atmosphere. Finally they concluded that, the maximum achievable extraction efficiency of alpha
acids depends on the alpha acids content of the hops at the time of extraction [1].

Fekadu Ashine studied ethanol hop extract using local hop (Gesho) in well manner. First,
extraction of well vented and dried samples of Gesho was performed by socking in 97% ethanol
as an extracting agent. A weight of 750g of the dried and powdered Rhamnus prinoides leaves
with stem put in 2000 ml Erlenmeyer flask was soaked in 1500ml of 97% ethanol for a period of
about 72 hours with by shaking on a shaker Hy-5A Manoeuvre. Fresh solvent was used in every
12hr socking extract was filtered through a medium density filter paper fitted in Buchner funnel.
And the extract of Rhamnus prinoides i.e. ethanol extracted concentrated using rotary evaporator.
After ethanol extraction, using the extract he brewed a beer and found out that Rhamnus Priniodes

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(Gesho) could give comparable bitterness and aroma and finally recommended that partial
replacement of imported hop would give a better result out of the two[2].

On another study in Germany, Whole hops were mixed with a 90% ethanol and water solution in
a wt grinding mill. The slurry of hop powder and ethanol is the pumped into the continuous
counter-current extractor. Countercurrent to the flow of hops, ethanol is constantly percolated
though the hop bed and in this way it is enriched with hop components. After the hops have passed
through the extractor, they leave the extraction as spent material...The solution of ethanol and polar
hop material - referred to as “miscella” - is pumped to the evaporation stage. The ethanol is
removed by evaporation in a multistage vacuum evaporator. The resulting raw extract contains
hop acids as well as water soluble components such as polyphenols. After further reduction of the
ethanol content, the raw extract is separated into resin and hot water extract by means of separators.
The polyphenols polymerize due to thermal treatment. After the study, 25 – 55% w/w of α- acids,
15 – 35% of β-acids, up to 10ml/100gm of essential oils with viscous kind liquid of obtained [3].

F. R. Sharpe and D. Crabb milled the hop in a Wiley mill previously cooled with solid carbon
dioxide and containing a screen of 1 mm nominal mesh. The Milled hops (1 kg) were packed into
one of two stainless steel columns (internal diameter 2 in, length 8ft). The columns were connected
to a stainless steel tube evaporator (internal diameter 1 in, length 5 ft.). The empty column was
isolated and the column in use was filled with liquid CO2 previously sub-cooled to 6°C in a cooling
bath. The pressure of the system was then between 625 and 900 psig. Then the solution was heated
to 40°C by circulating water through a jacket via a thermostatically controlled water bath. The
evaporator was then connected in series with a carbon filter, a heater and a differential pressure
cell. The outlet from the differential pressure cell was led to waste. The filter removed particulate
matter and highly volatile hop components. The heater ensured that the CO2 was above its critical
temperature and the differential pressure cell controlled the rate of bleed of gaseous CO2 from the
system. The differential pressure cell adjusted the gaseous carbon dioxide flow rate to be 200 liters
per minute. The result shown that the extract performs as well as, and in some cases better than,
hops or conventional hop extracts, giving high utilizations and beers with longer shelf lives [4].

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C.L. Bodkin et al. Hop pellets were milled in a hammer mill, and the milled hops (normally 900
g) were packed by gravity into a single extraction column. Liquid CO2 was then passed upwards
through the hops at a flow rate of 20 kg/hr. for 4 hr. with an inlet temperature of +7°C and an
operating pressure of 5,500kPa (800 psi). At the end of the extraction period, during which the
liquid CO2 was vented to atmosphere as described above, the extract was recovered by being
drained from the bottom of the evaporator. The bittering acids content and Essential oil content
was determined using HPLC & vacuum steam distillation method respectively. Then concluded
that liquid CO2 may give a lower yield but have a good selectivity over supercritical CO2 [5].

Derek R. J. et al Powdered hops (200 g) were placed in the column of the extractor and carbon
dioxide gas was pumped from a storage tank to the condenser. At the condenser, the gas was
condensed by using cold water since it is jacketed followed by compression to extraction
condition. The liquid carbon dioxide then was injected to the column vessel containing the
powdered hops. The solution was then transferred to the evaporator to separate the extract and
the carbon dioxide in form of gas. At the bottom of the evaporator, using manual opening the
extract was removed and carbon dioxide was discharged into the atmosphere. Lead conductance
values were used as a guide to levels of α-acids in the extract. Β-acids and iso-α-acids were
estimated by column chromatography. They found that the liquid carbon dioxide extracted 81-
100% of the available α-acids, 56-91% of the β-acids, and 66—88% of the available oils and
recommended that using longer extraction times could increase degree of extraction [6].

Zoran Z.et al (2006) have done investigation on the extraction of five cultivars of hop by the
method of supercritical fluid extraction using carbon dioxide (SFE-CO2) as extracting agent. The
cultivars used are Magnum, Hallertau Tradition, Spalt select, Aroma and K-62. The extraction
(50g of hop sample using a CO2 flow rate of 97.725L/h) was done in the two steps: 1.extraction at
150 bar and 40°C for 2.5h (sample of series A was obtained) and, after that, the same sample of
hop was extracted in the second step: 2.extraction at 300 bar and 40°C for 2.5h (sample of series
B was obtained).The Magnum cultivar was chosen for the investigation of the extraction kinetics.
Two of four the most common compounds of hop aroma (alpha-humulene and beta-caryophyllene)
were detected in samples of series A. In addition, alpha-acids and a high content of beta-acids were
detected. The alpha-acids content in the samples of series B was the highest in the extract of the

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Magnum cultivar (It is a bitter variety of hop).The low contents of alpha-acids in all the other hop
samples resulted in extracts with low alpha-acids content, i.e. that contents were under the
prescribed alpha-acids content. In order to prevent the thermal decomposition of hop compounds,
the temperature of 40°C was selected for the SFE CO2.Two steps were used for the SFE–CO2 to
obtain extracts containing aroma and bitterness hop compounds: SFE–CO2 extraction of hop at
150bar, i.e., a solvent density of 0.790g/cm3, for 2.5h (Samples of series A) and, subsequently,
same sample of hop was extracted at 300bar, i.e., a solvent density of 0.915g/cm3,for2.5h(Samples
of series B). These samples showed, of course, a higher content of alpha-acids than the native hop
sample sand, again, the highest alpha-acids content in CO2-exract were obtained for Magnum hop
cultivar(41.0%).Finally from the investigation it was concluded that the extracts of the investigated
hop varieties are different in terms of their qualitative and quantitative composition [7].

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3. Material and Methods

3.1 Materials

3.1.1 Equipments

Table 6 – Extracting and Analyzing Equipments

Equipments
For Extraction Purpose
Miller to make the hop easy to handle and increase surface area
CO2 Storage to store liquid CO2 before further usage
Condenser to liquefy CO2 from gas state
CO2 Pump to compress CO2 to the desired pressure
Column Vessel to store hops and being a vessel for mixing with liquid
CO2
Filter To separate the extract containing solution from the Spent
hops
Carbon Filter to filter the CO2 gas efficiently for reuse
Sub cooler to cool CO2 to a separation temperature
Extract Storage to store extract that comes out of Evaporator
Pressure control valve (PCV) to adjust separation pressure for CO2
Heat Exchanger to adjust separation condition for CO2
Evaporator to separate CO2 from desired extract

For Analysis Purpose

Round bottom flask used in hop oil determination for distillation process
Distillation Column used in essential oil content determination to separate
water and oil content

High performance liquid used to determine α & β acids concentration

chromatography

3.1.2 Chemicals
CO2 – used as a solvent in the extraction process.
Methanol – used in HPLC method of determining α&β acids concentration.
Distilled Water – used in essential oil concentration determination.

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3.2 Method
3.2.1 Liquid carbon dioxide hop extraction process
Gesho leaves & stems will be collected from the local market with a sum amount of 1Kg in total.
To reduce the water content, the sample will be dried in an open air for about 5 days protected
from direct exposure to sunlight. After that, to obtain maximum surface area and efficient amount
of extracted hop, the dried hop (Gesho) will be powdered using hammer mill till 1mm nominal
mesh is gained. This dried and powdered gesho will be putted into the column vessel. At
atmospheric temperature and pressure, CO2 is gaseous so the CO2 pump will compress CO2 to the
desired pressure ~ 63 bars and the heat exchanger will temper CO2 to about 7oC to liquefying CO2.
The liquid CO2 will flow into the column vessel at about 4ml/min mixing and extracting the
essential components from the milled hop by the use of internally fitted stirrer for about 4hrs. Then
using filter, the hop component containing solution will be filtrated and spent hops will be removed
at the bottom of the filter. The PCV (pressure control valve) will depressurize reducing the
operating pressure to atmospheric pressure (1 atm) for purpose of separation. Then the solution
will be sent to the evaporator to separate liquid CO2 from the extract at 40oC. The extract will be
collected at the bottom of the evaporator and CO2 gas will be sent to the carbon filter to insure its
quality since it has been mixed with the extract. After that, using a condenser CO2 gas will be
cooled to storage condition before sent into the CO2 storage tank. Using a sub cooler, the gaseous
CO2 will be liquefied to 7oC followed by compression ~63 bars by CO2 pump for further usage
(cyclic process).

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Dried Hops
SC CST

CP
M

HE
CF
C

CV E

ES
PCV
F V

Spent Hops

Figure 21: Flow diagram of the extraction process

Where

M – Miller E – Evaporator HE – Heat Exchanger

CV – Column Vessel C – Condenser CF – Carbon Filter

F – Filter SC – Sub cooler

CST – CO2 Storage Tank PCV – Pressure Control Valve

ES – Extract Storage CP – CO2 Pump

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3.2.2. Extract Analysis
3.2.2.1 Determination of α-acids and β-acids by High Performance Liquid
Chromatography
High performance liquid chromatography is a technique in analytical chemistry used to separate,
identify, and quantify each component in a mixture. It relies on pumps to pass a pressurized liquid
solvent containing the sample mixture through a column filed with a solid adsorbent material. Each
component in the sample interacts slightly differently with the adsorbent material, causing
different flow rates for the different components and leading to the separation of the components
as they flow out of the column.
A sample of hop extract (~ 2 gm) will be accurately weighed and dissolved (dispersed) in 100 ml
with methanol. A Sample of the solution 5 ml to be exact will be diluted to volume (50 ml) with
methanol. The diluted methanolic sample will be mixed with an internal standard solution and the
resultant solution will be analyzed by high performance liquid chromatography (HPLC).

3.2.2.2 Determination of Total Essential Oil Content

A sample (10 g) of powdered hops will be placed in a round-bottomed flask (3-L) with distilled
water (1,500 ml). The mixture will be distilled with cohobation (repeatedly distilled by subjecting
the distillate to a new act of distillation) for about 2 hrs and the essential oil layer being collected
in an oil trap. At the end of the distillation period the volume of oil will be measured.

3.2.2.3 Yield of bitter substance

Bitterness yield of the CO2 hop extract from Gesho can be obtained by taking the ratio between
the remaining bitter substances after beer from gesho has been produced and amount of the
bittering substances which are mainly the alpha acids, in this case Geshoidin, dosed in the wort
kettle measured in AAU (alpha acid unit). So according to the following rule:

Yield = bitter compounds in the finished beer * 100%

Bitter hops dosed in wort kettle

And is calculated as the isomerization rate as follows:

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Rate of isomerization = iso-alpha-acids in the final beer * 100%
Alpha-acids dosed
Utilization of alpha acids is normally 25 – 45 %, typically 35%

3.2.2.4 Determination of proper parameters for maximum hop extraction

The maximum achievable extraction efficiency of alpha-acids depends upon the alpha-acids
contents of the hops at the time of extraction. Specifically, maximum extraction efficiency
increases with alpha-acid content. Improper storage of hops before extraction leads to hop
deterioration (loss of alpha acid) which has a great effect on quantity and quality of extraction.
Also the conditions (Temperature & Pressure) of the extracting solvent, in this case CO 2, during
extraction has a huge outcome of the final extract. A lot of studied have been done to know the
optimum extracting condition for CO2 and using food grade CO2 at extraction temperature of 5 -
15oC (41 -59oF) and Extraction Pressure 55 -70bar has shown to give a good of yield of extract.

3.3 Expected Extract Result

Since there was no experimental work, we can only predict the outcome based on previous studies.
After the extraction process, we should be able to find golden yellow colored solvent largely
consisting of α-acids, β-acids, essential oils and moisture.

4. Future work & Conclusion

4.1 Future Work

In the future, we should be able to do the project including raw material analysis such as moisture
content, ash content and comparison of the locally extracted and imported hop in terms of cost.

4.2 Conclusion
From different literatures we have found that, the maximum achievable extraction efficiency of
hop depends upon the desired components of hop contents at the time of extraction, the extraction
solvent characteristics and extracting conditions, amount of time taken for the extraction.

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Reference
1. I.S. Daoud and S. Kusinki, Liquid and Ethanol Extraction of Hops, Brewing Research
Foundation, Nutfield, Redhill, January-February, 1992,
2. Fekadu Ashine, Production of barley malt beer using Gesho (Rhamnus priniodes) in
Ethiopia Addis Ababa University, Addis Ababa, 2015
3. HHV Hallertauer Hopfenveredlungs GmbH, Germany
4. F.R. Sharpe and D. Crabb, Pilot plant extraction of hops with liquid carbon dioxide,
Brewing research foundation, Nutfilled, March – April 1980, Vol 86, pp. 60 – 64.
5. C.L. Bodkin et al, Preparation and Analysis of Liquid CO2 Hop Extracts, Carlton and
Breweries Limited, Melbourne, Autralia, May 14,1980
6. Derek R.J et al, Production of Solvent – free Isomerized Extract, Brewery Research
Foundation, Nutfield, Surry, Britain
7. Zoran Z.et al, Super Critical Fluid Extraction of Hops,Serbia,2006
8. The General Certificate in Brewing (GCB), Institute of Brewing and Distilling, 2014
9. The operational Manuals of different departments of B.G.I factory
10. Wolfgang Kunz, Technology of Brewing and Malting, 2nd Revised Edition, 1999
11. www.bgi.com

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