BEER (BREWERY) PLANT [3561]
Brewing is the production of beer by steeping a starch source (commonly cereal grains, the most popular of which is barley) in water and fermenting the resulting sweet liquid with yeast. It may be done in a brewery by a commercial brewer, at home by a homebrewer, or by a variety of traditional methods such as communally by the indigenous peoples in Brazil when making cauim. Brewing has taken place since around the 6th millennium BC, and archaeological evidence suggests that emerging civilizations including ancient Egypt and Mesopotamia brewed beer. Since the nineteenth century the brewing industry has been part of most western economies. The basic ingredients of beer are water and a fermentable starch source such as malted barley. Most beer is fermented with a brewer's yeast and flavoured with hops. Less widely used starch sources include millet, sorghum and cassava. Secondary sources (adjuncts), such as maize (corn), rice, or sugar, may also be used, sometimes to reduce cost, or to add a feature, such as adding wheat to aid in retaining the foamy head of the beer. The proportion of each starch source in a beer recipe is collectively called the grain bill. Steps in the brewing process include malting, milling, mashing, lautering, boiling, fermenting, conditioning, filtering, and packaging. There are three main fermentation methods, warm, cool and spontaneous. Fermentation may take place in an open or closed fermenting vessel; a secondary fermentation may also occur in the cask or bottle. There are several additional brewing methods, such as barrel aging, double dropping, and Yorkshire Square. In India, ‘drinking’ has remained a bad word, clubbed with the other vices. While the beer and liquor market continues to grow at an impressive rate even against an economic recession, the social stigma remains in place, which manifests itself in anti-growth state policies. However, the Rs. 60.0 Billion organized beer and liquor industry has been growing at an impressive rate. In sharp contrast to the trend the world over, beer is losing ground to hard liquor in India. Amidst beers, the current trend is that lager beer is giving way to strong beer. Even as the liquor manufacturers could hope to garner the people who are shifting from beer to liquor, there is a vast country liquor market and a sizable grey market to contend with. United Breweries (UB), Shaw Wallace and McDowell (part of the UB Group) presently dominate the liquor and beer market. The market on its part is set to undergo a sea change with the arrival of MNCs. The removal of quantitative restrictions (QRs) on the import of bottled alcoholic beverages only makes the competition tougher. Among the alcoholic drinks, Beer is quite common and popular in almost every Country of the World. People of different Countries take beer in varying much like a soft drink in European Countries it is just a substitute of water. The alcoholic contents and main source stuff also keep varying according to the tests of the major part of population of the particular country although it is a fashion to ask for beer of every origin in every country.
COST ESTIMATION
Plant Capacity 427333 Bottle/Day
Land & Building (80000 sq.mt) Rs. 53.30 Cr
Plant & Machinery Rs. 120 Cr
Working Capital for 1 Month Rs. 45.37 Cr
Total Capital Investment Rs. 224.77 Cr
Rate of Return 40%
Break Even Point 54%
INTRODUCTION
DOMESTIC INDUSTRY
FORMULA NO. 1
PREPARATION PROCESS
FORMULA NO. 2
FORMULA NO. 3
A) PALE BEER
B) DARK BEER
C) STRONG BEER
MARKET SURVEY
INDUSTRY TREND ANALYSIS - NASCENT INDIAN BEER MARKET
PICKS UP STEAM
INDIA'S BEER GROWTH WILL COME FROM LOW BASE
ONWARDS AND UPWARDS FOR INDIA'S BEER MARKET
THREE KEY FACTORS DRIVING GROWTH
HUGE GROWTH IN BEER IMPORTS
INDIA - TOTAL BEER IMPORTS BY VOLUME (TONS) AND VALUE (USD '000)
TOP 12 MOST POPULAR BEERS BRANDS OF INDIA
MANUFACTURERS OF BEER
INGREDIENTS OF BEER
MALTED BARLEY BEFORE KILNING OR ROASTING
WATER
STARCH SOURCE
HOPS
YEAST
CLARIFYING AGENT
DETAILS OF BREWING PROCESS
MASHING
LAUTERING
BOILING
BREW KETTLE OR COPPER
WHIRLPOOL
HOPBACK
WORT COOLING
FERMENTING
FERMENTATION METHODS
WARM FERMENTATION
COOL FERMENTATION
CONDITIONING
KRÄUSENING
LAGERING
SECONDARY FERMENTATION
BOTTLE FERMENTATION
CASK CONDITIONING
FILTERING
SHEET (PAD) FILTERS
KIESELGUHR FILTERS
PACKAGING
BY-PRODUCTS
STEPS IN BEER MANUFACTURE
2. MILLING
3. MASHING
4. LAUTERING
5. WORT BOILING
6. WORT CLARIFICATION
7. FERMENTATION
8. STORAGE
9. FILTRATION
10. FILLING
QUALITY IN FREE TRADE ZONES
THE INCENTIVES AVAILABLE IN THESE FREE TRADE ZONES
ARE ENUMERATED BELOW
SEQUENCES IN BEER MANUFACTURE
CLEANING AND MILLING
MASHING
LAUTERING /WORT EXTRACTION
WORT BOILING
WHIRLPOOL
WORT COOLING
FERMENTATION
FILTRATION
BOTTLING
PASTEURIZATION
BREWING PROCESS
MANUFACTURING PROCESS IN DETAILS
MALTING
PREPARING THE MASH
BREWING THE WORT
FERMENTING
PASTEURIZING
PACKAGING
A) MALT GRINDING
B) ADJUNCTS' TREATMENTS
C) MASHING
TABLE 4. CARBOHYDRATE COMPOSITION OF A NORMAL WORT
PHASES IN ENZYMATIC BREAKDOWN OF PROTEIN
SEPARATION OF MASH
WORT BOILING
TABLE 5. ANALYSIS OF WORTS
TREATMENT OF THE WORK
FERMENTAION
FERMENTATION PROCESS
SEPARATION OF GREEN BEER
LAGERING
FILTERING
PACKAGING
PROCESS FLOW SHEET FOR BEER
PLANT LAYOUT OF BEER
PLANT LAYOUT BARLEY MILLING SECTION YEAST TANK, WASH TANK
PLANT LAYOUT OF PROCESS SECTION FERMENTATION SECTION
LIST OF PLANT AND MACHINERY
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
