1.

PURPOSE
1.1. This work instruction describes the flow of final molasses to fermented beer.
1.2. The purpose of this procedure is to make the beer ready for distillation. This
procedure provides for the communication between the operators of the
equipment in this section.

2. SCOPE
2.1. Includes molasses transfer and weighing, wort preparation, yeast cultivation
and final fermentation.

3. RECORDS
3.1. Record tonnage of molasses and nutrients used in wort preparation.
3.2. Record brix and pH of prepared wort.
3.3. Record attenuation of yeast before transferring in the cultivators.
3.4. Record attenuation of yeast from the final fermenters prior to distillation.

4. ASSOCIATED DOCUMENTS
4.1.
5. DEFINITIONS
5.1. Attenuation - the rate of lowering of brix in an alcoholic fermentation.
5.2. Beer – the feremented alcoholic liquid.
5.3. Brix – the percent by weight of soluble solids in solution as indicated by a brix
hydrometer.
5.4. Fermentation – the biochemical process of converting sugar into alcohol.
5.5. Fermentation time – time required for fermentation of wort before it is ready
for distillation.
5.6. Nutrients – the chemical substances added to the wort to enhance the growth
of yeast.
5.7. pH – refers to the acidity of fermented liquor.
5.8. Wort – the diluted molasses solution for fermentation wherein the nutrients
have been added, except the addition of yeast.
5.9. Yeast – single-celled micorganism that converts sugar into alcohol and carbon
dioxide.
6. RESPONSIBILITY
6.1. The department supervisor shall maintain this instruction.
6.2. The Wort Mixer shall maintain the availability of prepared wort,with specific pH
and brix based on the wort formula, and communicate the fermentation man
regarding the transfer of wort to different cultivators and fermenters and to
follow this procedure.
6.3. The Fermentation Aide shall ensure accurate amount of wort, yeast, time and
brix prior to transferring to pre-fermenters, follow this procedure and not move
on to another section without inspection.
6.4. The Fermenter Tender shall ensure accurate amount of wort, yeast, time and
brix prior to transferring to main fermenters (vats), follow this procedure and
not move on to another section without inspection.
6.5. The Fermentation man shall ensure accurate amount of wort, yeast and
attenuation prior to transferring to beer supply tanks, follow this procedure and
not move on to another section without inspection. He shall ensure continuity
and regularity of the operation.

7. TOOLS, GAUGES, FIXTURES

8. SAFETY REQUIREMENTS

9. INSTRUCTIONS
9.1. Molasses Transfer and Weighing
9.1.1. The Wort Mixer (WM) opens the discharge valve of the molasses storage
tank.
9.1.2. The WM then starts the molasses pump and fills to capacity the molasses
supply tank. Discharge valve of molasses supply tank must be closed.
This tank must be normally full at all times.
9.1.3. The WM opens the discharge valve of molasses supply tank and loads the
molasses weighing tank to the desired weight using the Servo Balans.
Discharge valve of molasses weighing tank must be closed at this stage.
Manual weighing scale is used only when the Servo Balans is off line.
 9.1.4. Once gross weight of molasses is recorded, he opens the discharge valve
of the molasses weighing tank to the molasses mixer and starts the
electric motors of the mixer and dilution water pump.
9.1.5. The WM closes the discharge valve of the molasses weighing tank when
the desired weight of molasses had been discharged to the mixing tank
through the molasses mixer.
9.1.6. Wort mixer stops the electric motors of the mixer and dilution water pump
when he has ascertained that the liquid left in the mixer is almost free of
molasses.

9.2. Wort Preparation

9.2.1. Upon instruction from the Fermentation Man (FM) and based on the issued
wort formulation, the Wort Mixer chlorinates the water in the mixing tank.
The mixing tank wort discharge valve, dilution water valve, steam valve
must be closed and the diluted molasses discharge valve from the mixer
must be opened to the mixing tank involved before actual mixing.
9.2.2. The WM then weighs and discharges the required amount of molasses to
the mixing tank involved, either mixing tank no. 1 or 2.
9.2.3. After the WM has weighed and discharged the molasses to the mixing
tank, the WM will prepare the desired weight of urea to be added and
measures the needed volume of sulfuric acid called for.
9.2.4. After all the required molasses had been transferred to the mixing tank,
the WM closes the diluted molasses valve, opens the dilution water valve
from the process water tank to complete the volume.
9.2.5. While the mixture is being diluted, the WM then adds the previously
measured chlorine, acid, urea, to the mixture in that order. Di-
ammonium phosphate is directly added to the vats/PFs and BCs.
9.2.6. When the desired volume for the mixture is attained, the dilution water
valve is close.
9.2.7. The electric motor drive of the mixing tanks stirrer is then started to
thoroughly mix the solution.
9.2.8. When the solution has been thoroughly mixed 15-20 minutes of stirring,
the WM presses the buzzer for the laboratory analyst to take the brix and
 pH of the mixture. The laboratory analyst will advise the WM if the Brix
and pH are within standard or may need further addition of acid.
9.2.9. If the mixture meets the standards the WM informs the FM/FA that the
wort is ready for transfer.
9.2.10. At a signal from the FM/FA, the WM opens the discharge valve of the
mixing tank and starts the electric motor of the wort transfer pump.
9.2.11. When the mixing tank is almost empty, the WM then rinses the inside part
of the mixing tank with water to recover most of the wort.
9.2.12. The WM then closes the discharge valve of the mixing tank when empty,
stops the wort transfer pump and informs the FM/FA that the mixing tank
is already empty.
9.2.13. The WM waits for the signal from the FM/FA to start preparation of the
next mixture.

9.3. Yeast Cultivation

9.3.1. Small Cultivator (1 unit)
9.3.1.1. The Fermentation Aide (FA) opens the top handholes and
washing discharge valves of the small yeast cultivator and
washes this vessel with high pressure water jet.
9.3.1.2. After washing, sterilization of the vessel for ten (10) minutes
follows by gradually opening the steam valves.
9.3.1.3. While sterilizing the vessel, the FA prepares a 46-liter wort of
10-12o Brix. Sufficient amount of sulfuric acid is added to
attain a pH of 3.8 – 4.2.
9.3.1.4. After ten (10) minutes sterilization of the vessels, the steam
valves and washing discharge valves of the small yeast
cultivator are closed and the prepared wort is poured into the
tank. Steam the wort to near boiling (for approximately 10
to 15 minutes).
9.3.1.5. Close the steam valves after sterilization and open cooling
water valve to allow water through the cooling coils.
9.3.1.6. At 8:00 AM daily, the day shift Fermentation Aide obtains
from the laboratory two 4-liter yeast cultures with the
 corresponding amount of acid, urea and diammonium
phosphate and introduces them into the small yeast
cultivator.
9.3.1.7. The top manholes are tightly closed and fermentation starts.
9.3.1.8. After then to twelve hours of fermentation, the brixes of the
yeast cultures are taken. They should be between 8 o – 10o
Brix. Open the yeast discharge valves and transfer the yeast
to the previously prepared and cleaned intermediate yeast
cultivator.

9.3.2. Intermediate Cultivator

9.3.2.1. Same procedure as Small Cultivator like cleaning, sterilizing
the vessel, filling of wort, boiling and cooling.
9.3.2.2. After 10-12 hours fermentation in the Small Cultivator (SC),
the 50 liters yeast transferred to seed 150 liters of wort at
10o-12o Brix with corresponding amount of acid, urea and
diammonium phosphate. Precede to steps 7 and 8.

9.3.3. Medium Yeast Cultivator (1 unit)

9.3.3.1. The Fermentation Aide (FA) opens the top handholes and
washing discharge valves of the two medium yeast
cultivators and washes these vessels with high pressure
water jet.
9.3.3.2. After washing, sterilization of the vessels for ten (10)
minutes follows by gradually opening the steam valves.
9.3.3.3. The steam valves are then closed after sterilization and the
washing discharge valves and top handholes are also closed.
CO2 gas vent must be open.
9.3.3.4. When the vessels had cooled doen to 30 o-32oC, the yeast
culture from the Intermediate cultivator is then charged
equally into the 2 medium yeast cultivators and at the same
tome the cooling water valves are opened to allow water
through the cooling coils.
 9.3.3.5. A 800-liter wort of 10o-12o Brix from mixing tank number 2 is
then pumped to these two vessels to complete the volume of
1000 liters. Fermentation then proceeds.
9.3.3.6. After 10-12 hours of fermentation, the yeast cultures are
then ready for seeding. The yeast discharge valves are
opened and the contents of both vessels are transferred into
one clean and empty big yeast cultivator.
9.3.3.7. Close the cooling water valves and repeat steps 1 to 6.

9.3.4. Big Yeast Cultivator (5units)

9.3.4.1. The cleaning procedure is the same as that of the medium
yeast cultivators except that these vessels are steam
sterilized only once a day, usually in the day shifts, not every
time they are emptied. Follow steps 1-3 above.
9.3.4.2. The yeast cultures from the medium yeast cultivators or an
equivalent volume of seed yeast from any of the other big
yeast cultivators are then charged into the empty big yeast
cultivator. The optimum brix of the seed yeast should be 3 o-
4o Brix.
9.3.4.3. Wort of 10o-12o Brix from the mixing tank number 2 in the
amount of 3,000 liters is then pumped to this vessel to
complete its volume to 4,000 liters. Fermentation then
proceeds. The attenuation or brix of the culture is taken
every two hours and recorded on logsheets.
9.3.4.4. After 8-10 hours of fermentation, the brix of the yeast
culture in the big yeast cultivator should be between 3 o-4o
brix. At this brix, the yeast is ready for transfer.
9.3.4.5. Open the yeast culture valve at the bottom of the big yeast
cultivator and discharge the 4,000 liters yeast culture to a
clean and empty pre-fermenter as seed yeast. Close the
cooling water valve.
9.3.4.6. After transfer of yeast, close the yeast transfer valve and
repeat steps 1-5.
9.3.5. Pre-Fermenters (4 units)
9.3.5.1. The Fermentation Aide of PFs (FAPF) opens the front-end
manhole and sludge discharge valve of an empty Pre-
Fermenter. He also closes the CO2 gas vent valve and
aeration line.
9.3.5.2. The pre-fermenter is washed using high pressure
water jet until fully cleaned. If the pre-fermenter has
stubborn slime which the water jet could not remove, the
inside part of the vessel is scrubbed by the FA PF using
continuous high pressure water jet. It should be noted
further that if the pre-fermenter will be scrubbed, the top
manhole should be opened and the vessel should be free of
any trace of carbon dioxide gas before the FA PF enters the
vessel.
9.3.5.3. After cleaning, the sludge discharge valve and the front-end
manhole are closed. The CO2 gas vent valve is opened to
low quality CO2 gas vent valve is opened to low quality CO2
gas foam trap which is vented to the atmosphere. The pre-
fermenter is then ready for loading.
9.3.5.4. Open the yeast transfer valve to load yeast from the big
yeast cultivator.
9.3.5.5. The FA opens the cooling water valves to allow the flow of
water on the external surface of the pre-fermenter through
the cooling water spargers.
9.3.5.6. After the yeast culture had been transferred from the big
yeast cultivator to the pre-fermenter, the yeast transfer
valve is closed and the wort transfer valve is opened.
9.3.5.7. The FA signals the WM to start the electric motor of the wort
transfer pump to transfer wort from the mixing tank number
2 to the pre-fermenter. The loading of the pre-fermenter is
done at the same time that the big yeast cultivator is being
loaded.
 9.3.5.8. After the pre-fermenter is filled up to a volume of 22,000
liters, the wort transfer pump is stopped and the wort
transfer valve is closed. Fermentation then proceeds. The
brix of culture is taken every even hour.
9.3.5.9. After the pre-fermenter had been fully loaded, the valve for
aeration vent is opened for 8 hours.
9.3.5.10. After 8-10 hours fermentation, the yeast culture should be
ready for transfer to the final fermenter at a brix of 3.0o-4.0o
brix and minimum of 100 x 106 cells/ml yeast population.
9.3.5.11. Upon the signal from the Fermentation Man (FM), the
Fermentation Aide, PFs (FAPF) opens the yeast discharge
valve at the front end of the pre-fermenter and starts the
yeast transfer pump. The cooling water valve is also closed.
Important: The 2-way CO2 gas foam trap and the aeration
line is closed for the whole duration of yeast transfer from
the pre-fermenter to the final fermenter.
9.3.5.12. The yeast transfer usually last from 20 to 30 minutes. Near
the end of this period, the FAPF opens slowly and slightly the
front and manhole to check on the level of the yeast in the
pre-fermenter.
9.3.5.13. After all the yeast has been transferred, the yeast discharge
valve is closed and the yeast transfer pump stopped. The
vessel is then ready for cleaning.
9.3.5.14. Repeat steps 1-13.

9.3.6. Final Fermenter (9 units)

9.3.6.1. The Fermentation Aide (FA) opens the front and manhole and
sludge discharge valve of an empty fermenter. The other
closes the CO2 gas vent valve.
9.3.6.2. The fermenter is sprayed with high pressure water jet to
remove sludge and slime inside the vessel. If the fermenter
has stubborn slime which could not be removed, the inside
part of the vessel is scrubbed by the FA using nylon/steel
 brush. The top manhole should be opened and the vessel
should be free of any trace of carbon dioxide gas before the
FAPF enters the vessel.
9.3.6.3. After cleaning, the sludge discharge valve and the front-end
manhole are closed. The CO2 gas vent valve is opened to
low quality CO2 gas foam trap which is vented to the
atmosphere.
9.3.6.4. The Fermenter aide signal the Fermentation man that the vat
is ready for loading.
9.3.6.5. On the scheduled time of loading , depending on the
distillation and fermentation times required in process, the
Fermentation man signals the Fermentation aide to start
transferring the yeast culture from the pre-fermenter (PF)to
Final fermenter (vat) and open the cooling water to flow on
the external surface of the vessel.
9.3.6.6. Five to ten minutes after the yeast transfer pump has been
started, the Fermentation man signals the Mixing operator to
start transfer wort from the mixing tank to the Final
fermenter.
9.3.6.7. When the fermenter is filled up to desire volume required,
the wort transfer pump and the yeast transfer pump, if not
stopped earlier, are stopped.
9.3.6.8. The Fermenter Tender closes the yeast transfer valve and the
wort transfer valve. Fermentation then proceeds.
9.3.6.9. Immediately after the fermentation had been fully loaded,
the Fermentation man instructs and supervises the
Fermentation tenders in opening the suction valve and
discharge valve of the external shell and tube heat exchanger
attached to the fermenter. The FM starts the pump to re
circulate the fermenting beer through the beer cooler.
9.3.6.10. Thirty to sixty minutes after the fermenter had been fully
loaded, the Fermentation man instructs the Fermenter tender
to open the CO2 gas vent valve to the high quality of CO2
 foam gas trap to put the vessel “on line” to the CO2 recovery
Plant.
9.3.6.11. For the duration of fermentation, the FA gets the brix of the
beer every even hour. The FM man jots down the fermenting
medium every hour as indicated by the temperature
indicator. All these data are recorded and graphed on the
blackboards provided for the purpose. On the other hand, the
Fermenter tenders keep the surface of the vessels and beer
cooler tubes free of slime.
9.3.6.12. After the twelve hours of fermentation, the Fermentation
man instructs the Fermenter tender to shift the the 2-way CO
gas vent valve to the low quality CO2 gas foam trap. The FT
will stops the beer cooler pump and close the suction to
discharge valves of the external shell and tube heat
exxhangers attached to the fermenter and open those for the
adjacent fermenter also attached to the same beer cooler.
The beer cooler pump is again started.
9.3.6.13. Afetr 18-22 hours of fermentation, the Laboratory analyst will
obtain a 500ml sample of fermented beer to determine the
alcohol percent and expected alcohol production of the
contents of the fermenter and post the results on record
sheet and black boards provided for the purpose.
9.3.6.14. After 20-24 hours fermentation, the Fermenter tender opens
the beer discharge valve in front of the fermenter to transfer
the beer the beer supply tank using the liquid-level controlled
beer pump and informs the Fermentation man who in turn
signals the distillation personnel of the action. The Fermenter
tender closes the cooling water valve of the fermenter.
Depending on the rate of beer feeding to the beer stills, the
distillation time for the fermenter lasts depends on the
number of Columns operating.
9.3.6.15. Five to ten minutes before the fermenter is scheduled to be
emptied, the Fermenter Tender opens slowly the front end
 manhole of the fermenter to check the level of the liquid in
the vessel.
9.3.6.16. After all the beer had been pumped out of the fermenter, the
Fermenter tender closes the beer discharge valve of the
vessel and opens that of the next vessel scheduled for
distillation.