Production Technology II

A Teaching Material Prepared For 3rd Year Industrial

Chemistry Students
By:
Moges Admasie ([Link].)
(Lecturer In Industrial Chemistry)
2014 E.C
 1

6/24/2022 Production Tech. II, By Moges A. 2

 Fermentation Technology
Outline
Introduction to fermentation Technology
1.1. Alcohol and Beverage Industries
1.2. Production of industrial alcohol
1.4. The raw materials for beer production
1.5. The process Technology of Beverage Industries
1.6. Process description and major unit operation of beer
production

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 Introduction to fermentation
 Chemical food stuff processing is a processing that involves the
manufacturing of chemical food stuff such as alcoholic
beverage, soft drinks, & etc.
 For the processing of any chemical food stuff fermentation is
important.
 What is fermentation, & its uses in food
processing?
 Fermentation in food processing typically is the conversion of
carbohydrates to alcohols & CO2 or organic acids using yeasts, bacteria,
or a combination there, under anaerobic conditions.

 It is the chemical breakdown of a substance by bacteria, yeasts, or other

microorganisms, typically involving effervescence/foaminess and the giving

off of heat.
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 Introduction to fermentation

 A more restricted definition of fermentation is the chemical

conversion of sugars into ethanol/Alcohol.
 The science of fermentation is known as zymurgy.
 Fermentation implies that the action of microorganisms is
desirable, & the process is used to produce alcoholic
beverages such as beer, wine & local alcohols.
 Fermentation is also employed in the leavening of bread, &
for preservation techniques to create lactic acid in sour foods
such as yogurt, or vinegar (acetic acid) for use in pickling
foods.

Production Tech. II, By Moges A.

6/24/2022 5
 Introduction to fermentation

 Generally, fermentation results in the breakdown of complex

organic substances into simpler ones through the action of
catalysis.

 For example, by the action of diastase, zymase, &

invertase, starch is broken down (hydrolyzed) into complex
sugars, then simple sugars, & finally alcohol.

 Fermentation occurs in large fermenting vessels and

typically lasts for one to three days.

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 Introduction to fermentation

Fermentation medium consists of:

a) Macronutrients (C, H, N, S, P, Mg sources  water,
sugars, lipid, amino acids, salt minerals)
b) Micronutrients (trace elements/ metals, vitamins)
c) Additional factors: growth factors, attachment proteins,
transport proteins, etc)
 For aerobic culture, oxygen is sparged (the process of
moisten by sprinkling with water, especially in brewing.)

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 Introduction to fermentation

 According to Silox and Lee, the five basic prerequisites of a

good fermentation process are:

1. A microorganism that forms a desired end product.

2. Economic raw materials for the substrate, e.g., starch or one of

several sugars.

3. Acceptable yields

4. Rapid fermentation

5. A product that is readily recovered and purified

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 Introduction to fermentation
 According to Lee, certain factors should be stressed in relation to the
fermentation chemical-conversion or unit-process concept, such as
microorganisms, equipment, and the fermentation it self.

 Certain critical factors of the fermentation are:

1. The pH
2. Temperature
3. Aeration, agitation
4. Pure-culture fermentation and,
5. Uniformity of yields.
 The microorganisms should be those w/c flourish under comparatively
simple & workable modifications of environmental conditions.

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 Uses of fermentation
 The primary benefit of fermentation is the conversion of sugars &
other carbohydrates. e.g. converting grape juice into wine, grains into beer,
carbohydrates into carbon dioxide to leaven bread, and sugars in
vegetables into preservative organic acids (lactic acid, acetic acid, formic
acid, citric acid, oxalic acid, uric acid, malic acid, tartaric acid etc.).
 Food fermentation has been said to serve for 5 main purposes:
1. Enrichment of the diet through development of a diversity of
flavors, aromas, & textures in food substrates.
2. Preservation of substantial amounts of food through lactic acid, alcohol,
acetic acid & alkaline fermentations
3. Biological enrichment of food substrates with protein, essential
amino acids, essential fatty acids, and vitamins
4. Elimination of anti-nutrients
5. A decrease in cooking times and fuel requirements

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 Fermentation Technology
 Fermentation is the process involving the biochemical activity of
organisms, during their growth, development, reproduction, even
senescence and death.
 Fermentation technology is the use of organisms to produce food,
pharmaceuticals and alcoholic beverages on a large scale
industrial basis.
 The basic principle involved in the industrial fermentation
technology is that organisms are grown under suitable conditions,
by providing raw materials meeting all the necessary requirements
such as carbon, nitrogen, salts, trace elements and vitamins.

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 Fermentation Technology
 The end products formed as a result of their metabolism during their life span are
released into the media, which are extracted for use by human being and that have a
high commercial value.
 The major products of fermentation technology produced economically on a large
scale industrial basis are wine, beer, cider ( an alcoholic beverage made from the
fermented juice of apples), vinegar, ethanol, cheese, hormones, antibiotics, complete
proteins, enzymes and other useful products.
 Fermentation process is carried out in a container called the fermenter or bioreactor.
 The design and nature of the fermenter varies depending upon the type of
fermentation carried out.
 Invariably all the fermenters have facilities to measure some of the fermentation
parameters like temperature, pressure, pH, elapsed fermentation time, liquid level,
mass etc.

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 Fermentation Technology
The different types of fermenters are:
1) External recycle airlift fermenter: For producing bacterial
biomass, with methanol as substrate.
2) Internal recycle airlift fermenter: For producing yeast with oil as
substrate.
3) Tubular tower fermenter: Used for making beer, wine, vinegar
etc.
4) Nathan fermenter: Used in brewing industry.
5) Stirred fermenter: Used for making antibiotics.

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 Fermentation Technology
Types of Fermentation Processes/ operation mode of bioreactors:
 There are three different process/ operation mode of fermentation:
(1) Batch fermentation: This term is attributed to that type of fermentation wherein
there is change in culture medium, number of microorganisms and the amount of
the product produced (i.e. the metabolite or target protein).
 All nutrients are provided at the beginning of the cultivation and products are removed at
the end
 In batch fermentation six phases of the microbial growth are seen.
(a) Lag phase:
 Immediately after inoculation, there is no increase in the numbers of the microbial
cells for some time and this period is called lag phase.
 This is in order that the organisms adjust to the new environment they are inoculated
into.
(b) Acceleration phase: The period when the cells just start increasing in numbers
is known as acceleration phase.

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 Fermentation Technology
Types of Fermentation Processes/ operation mode of bioreactors:
 There are three different process/ operation mode of fermentation:
(1) Batch fermentation:
 In batch fermentation six phases of the microbial growth are seen.

(c) Log phase: This is the time period when the cell numbers steadily increase.
(d) Deceleration phase: The duration when the steady growth declines.
(e) Stationary phase: The period where there is no change in the microbial cell number is
the stationary phase. This phase is attained due to depletion of carbon source or accumulation
of the end products.
(f) Death phase: The period in which the cell numbers decrease steadily is the death phase.
 This is due to death of the cells because of cessation/ termination of metabolic activity and
depletion of energy resources.
 Depending upon the product required the different phases of the cell growth are
maintained. For example:-
 For microbial mass the log phase is preferred.
 For production of secondary metabolites i.e. antibiotics, the stationary phase is preferred.
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 Fermentation Technology
Types of Fermentation Processes:
 There are three different process of fermentation:
2) Fed-batch fermentation: In this type of fermentation, freshly prepared culture
media is added at regular intervals/ sequentially without removing the culture fluid.
 This increases the volume of the fermentation culture.
 This type of fermentation is used for production of proteins from recombinant
microorganisms.
3) Continuous fermentation: In this type of fermentation the products are removed
continuously along with the cells and the same is replenished with the cell girth and
addition of fresh culture media.
 This results in a steady or constant volume of the contents of the fermenter.
 This type of fermentation is used for the production of single cell protein ( refers
to the crude, a refined or edible protein extracted from pure microbial
cultures, dead, or dried cell biomass.), antibiotics and organic solvents.

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 Fermentation Technology
Procedure of Fermentation:
(a) Depending upon the type of product required, a particular bioreactor is selected.
(b) A suitable substrate in liquid media is added at a specific temperature, pH and then
diluted.
(c) The organism (microbe like algae, fungi, yeast, bacteria and enzyme) is added to it.
(d) Then it is incubated at a specific temperature for the specified time.
(e) The incubation may either be aerobic or anaerobic.
i. Aerobic conditions are created by bubbling oxygen through the medium.
ii. Anaerobic conditions are created by using closed vessels, wherein oxygen cannot diffuse
into the media and the oxygen present just above is replaced by carbon dioxide released.
(f) After the specified time interval, the products are removed, as some of the products are
toxic to the growing cell or at least inhibitory to their growth.
 The organisms are re-circulated.
 The process of removal of the products is called downstream processing or the method by
which the products of fermentation are recovered and separated is known as downstream
processing.
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 Production of industrial alcohol

Industrial Alcohol
 The production of industrial alcohol, ethanol become
commercially feasible on a large scale after 1906 when the
Industrial Alcohol Act was passed.

 This act allowed the sale of tax-exempt alcohol, if it has first

denatured to prevent its use in various Alcohol beverages.

 Industrial Alcohol is commonly employed as a solvent and to

a lesser extent as a raw material for chemical synthesis.

 Smaller amounts are also used as a motor fuel like gasoline

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 Production of industrial alcohol
Microorganism:
 Choice of fermentation microorganism for the alcohol production
depends upon the type of carbohydrate employed in the medium.
 For example if starch and sugar are raw materials in the medium then
specially selected strains of Saccharomyces crevisiae are utilized.
 Production from Lactose of whey is accomplished with Candida
pseudotropicalis.
 If it is sulfur waste liquor fermentation the Candida utilize is the best
organism, because of its ability to ferment pentose.
 So particular strains of these various organisms actually employed for the
fermentation are selected for several properties.

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 Production of industrial alcohol
Microorganism:
 They must grow rapidly, have higher tolerance to the high concentrations of sugar
but at the same time they must be able to produce much larger amounts of alcohol and
be resistant to the produced alcohol.

Media
 The media for the commercial production includes:
 Blackstrap Molasses / Corn (Blackstrap molasses has greater use)
 Grains
 Sulfite waste liquor
 Whey
 Potatoes
 Wood Wastes

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 Production of industrial alcohol
Media
 For Molasses fermentation , molasses must be diluted with water to a sugar conc. between
10 -18%.
 Concentrations greater than 20% are not employed as they could be detrimental to yeast.
 The pH of the medium is set between 4-5 by adding sulfuric acids or lactic acids, or by
employing Lactic acid bacteria to bring initial lactic acid fermentation.
 Microbial contaminants are usually inhibited by the low pH, high sugar conc. and
anaerobic conditions of the fermentation and by the high alcohol production by the yeast.
 Starchy media such as corn, rye and barley must undergo initial starch hydrolysis.
 This can be accomplished by mashing with barley malt, by addition of dilute acids or by
utilizing fungal amylolytic enzymes (Aspergillus and Rhizopus).
 In most of the cases, malt is used to accomplish hydrolysis of starch by mixing 30% barley
and 70% corn with water and carry on the mashing procedures similar to the wine or beer
making procedures.

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 Production of industrial alcohol
Fermentation:
 Fermentation is carried out in large reactors at a temperature between 21 -
27oC, but heat evolution might raise the temperature to 30oC, so cooling
coils are used to bring the temperature down.
 Fermentation lasts for about 2-3 days, but actual time period depends
upon the substrate utilized and temperature.
 The fermentation broth at completion of fermentation ranges from 6-9
percent alcohol by volume and this alcohol reflects the yield 0f 90 -98%
theoretical conversion of substrate sugar to alcohol.
 So yields should not be confused with "proof" as proofing means alcohol
concentration designation and it will be twice the percentage in vol of
ethanol as dissolved in water e.g. 70% ethanol is 140 proof.
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 1.1. Alcohol and Beverage Industries
What is the beverage industry?
 The beverage industry (also known as the drink industry)
manufactures drinks and ready-to-drink products.
 Examples are bottled water, soft drinks, energy drinks, milk products,
coffee and tea-based products, nutritional beverages, and alcohol.
 The beverage industry is traditionally a market with specific high
demands regarding hygiene and its related technologies.
 Exquisite hygiene is needed to maintain the end product's high-
quality standards and shelf life, whether it is mineral/drinking water,
lemonade, fruit juice, beer, wine, or (sparkling) wine.
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 1.1. Alcohol and Beverage Industries
Classification of Beverages
 Beverages may be classified on various ways in which the classification criteria may
depends on various factors as mentioned below:
Natural and Synthetic (Ingredients used in manufacture)
 Natural beverage: are fruit based beverages, malt beverages and dairy beverages
 Synthetic beverage: Contain ingredients which are prepared synthetically like
flavouring and colouring materials.e.g. Soft drinks which contain flavoured sugar
syrup
Carbonated and Non-carbonated (Degree of mechanical carbonation)
 Carbonated Beverage: Carbon dioxide is dissolved in syrup or water, which
creates bubbles upon release of pressure and fizzing in the beverage.
 The carbonated beverages are commonly referred as Soft Drink. Cola or lemonade
beverages are typical examples of carbonated beverages.
 Non-Carbonated Beverage: includes majority of fruit and dairy based beverages.
 Also includes hot beverages and alcoholic beverages that do not contain carbon
dioxide.
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 1.1. Alcohol and Beverage Industries
Classification of Beverages
Alcoholic and Non-alcoholic (presence or absence of alcohol)
 Alcoholic beverages: Contain ethyl alcohol which can be consumed for its intoxicating
and mind-altering effects. E.g. beer, wine and Spirit
 Non-Alcoholic beverages: Includes beverages which do not contain alcohols
Hot and Cold (Temperature of serving)
 Hot beverage: Those served at temperature of above 65-70℃. The examples of hot
beverages are tea, coffee, chocolate and milk.
 Cold beverages: Those served at chilled temperature. iced tea and cold coffee are
served chilled. Most of the fruit beverages, dairy drinks, alcoholic drinks and soft
drinks are example of cold drinks.
Stimulating and Non-stimulating (Based on physiological effect)
 Stimulating beverage: stimulates the body systems mainly to nervous system and
circulatory system.
 It is mainly due to the presence of certain chemical compounds like caffeine in
coffee and tea, many phenolic compounds in herbal drinks and ethyl alcohol in
alcoholic beverages.
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 1.1. Alcohol and Beverage Industries
What is the beverage industry?
 Beverage production varies mainly depending on the product being
made.
 The beverage industry consists of two major categories:
 Alcoholic beverage industry: The alcoholic beverage industry
includes distilled spirits, (sparkling) wine, cider, and brewing.
 Non-alcoholic beverage industry: The non-alcoholic beverage
industry is comprised of soft drink (or soft beverage industry) or
syrup manufacture; soft drink and water bottling and canning),
fruit juices bottling, canning, and boxing, the coffee industry, and
the tea industry.

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 Alcoholic Beverages
Alcoholic beverages contain ethyl alcohol which can be consumed for its
intoxicating and mind-altering effects.
Alcoholic beverages are produced by the process of natural or controlled
fermentation.
Ethanol is a psychoactive drug, a depressant, & many societies
regulate or restrict its sale & consumption.
Countries place various legal restrictions on the sale of alcoholic
drinks to young people.

On the basis of raw material used and process technology used in their
manufacture alcoholic beverages may be classified into three major

groups: Beer; Wine and Spirit

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 Alcoholic Beverages
a) Beer
 It is the worlds third most consumed beverage overall after water &
tea.
 Beer is prepared by fermenting the wort (soluble liquid of barley malt
digest) with appropriate yeast to attain an alcohol level in the range of 4-8
percent.
 Apart from alcohol, beer is also characterized by the effervescence i.e.
foam which is produced by carbon dioxide and bitterness.
 The bitterness and aroma in beer is contributed by the hops
(Humulus lupulus) solids as α-iso-acids and other polyphenols.
 There are many variants of beer but two are more popular.
 These are called as Lager beer which is fermented by bottom yeast
i.e. Saccharomyces uvarum at lower temperature (7-12℃) for longer
period,
 while the Ale is manufactured by using top fermenting yeast
i.e. Saccharomyces cerevisiae at relatively higher temperature (18-25℃).
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 Alcoholic Beverages
b) Wine
 Wines are made from variety of fruits. Such as grapes, peach, plum or
apricots.
 However, the most commonly used one is grapes, both green as well as red
grapes.
 The grapes are macerated to release juice which is fermented naturally by wide
range of yeasts including Saccharomyces spp., Pichia spp., Stellata spp. and certain
lactic acid bacteria.
 The duration of fermentation is also longer as compared to beer and
mostly fermented wine is aged (months to year) to develop desirable
sensory characteristics.
 There are two major type of wines i.e. white wine (made from green
grapes) and red wine (from red or blue grapes).
 The red wine contain anthocyanin (as colouring pigment) and subjected
to secondary fermentation termed as Malolactic fermentation to mellow
the flavour of wine.
 The alcohol content in wine ranges from 9-16% (v/v).
 Sparkling wines are characterized by effervescence produced by carbon
dioxide, example: Champagne.

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 Alcoholic Beverages
c) Spirit
 Spirit is a class of alcoholic beverages which are unsweetened and
produced by distillation of fermented base.
 The fermented base may be molasses (by-product of sugar industry), fruit
juices, cereal extract or sometime a combination of many fermentable
substrates.
 Spirits are characterized by relatively higher alcohol content which may
be as high as 20 percent.
 The process of distillation increases the concentration of alcohol but
reduced the level of congeners (chemicals that are responsible for flavor
of alcohols).

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 Alcoholic Beverages
Alcoholic beverages belonging to the category of spirit

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 Classification of Alcohols
What are the possible criteria for classification of alcohol
based on production technology?
Distilled drinks,
Fermented drinks.
 Alcoholic beverages that have lower alcohol content (beer &
wine) are produced by fermentation of sugar or starch-
containing plant material are fermented drinks. Eg. Beer, wine,
sake….
 Beverages of higher alcohol content are produced by
fermentation followed by distillation are distilled drinks. Eg.
Vodka, gin, whisky
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 The raw materials, Process Technology, Process
description and major unit operation of beer production
The Raw Materials
The main raw materials for beer production are:
Water

Cereals Malt ,mainly barley

Hops Yeast

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The raw materials, Process Technology Process description and
major unit operation of beer production

The raw materials

Grains & fruits supplying carbohydrates are the basic raw
materials.
The variety of grains & fruits employed are wide, changing
from country to country or from beverage to beverage.
e.g. Russia ferments potatoes by distillation obtains vodka;
but the world‘s chief raw materials for fermentations are the
cereals like corn, barley, & rice, together with the grape.

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 Cont.…

 Grain contains the natural sugars required for

fermentation.
 It also provides beer with flavor, color, body, %
texture.
Hops are small, green, cone-shaped flowers from the
hop plant.
 Hops provide beer with a spicy, bitter flavor and
contribute natural substances that prevent bacteria from
spoiling beer.

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 Cont.…
Two species of yeast used to make beer, called brewer’s
yeast:- are Saccharomyces cerevisiae & Saccharomyces
uvarum.
Each yeast species is used in a slightly d/t method of
fermentation & produces a distinct type of beer.
 Water constitutes as much as 95% of the ingredients
used in the brewing process.

 The mineral content in water particular, the levels of

salts such as calcium, sulfate, & chloride dissolved in the
water influence the quality & flavor of the beer it is used to
produce.

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 Cont.…
 Modern brewers add minerals & other natural elements
to water or eliminate them by boiling or filtration so that
the water used in the brewing process always produces
beer with the same flavors.

 This enables brewers to produce identical-tasting beer at

different brewing locations throughout the world.

The cereals employed are barley, malted to develop the

necessary enzymes & the desired flavor, as well as malt
adjuncts.

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 Cont.…
Brewing sugars & syrups (corn sugar, or glucose) &
yeast complete the raw materials.

For beer most important cereal is barley, which is

converted into malt by partial germination.

Beer is made by the process of fermentation.

A liquid mix, called wort, is prepared by combining

yeast & malted cereal, such as corn, rye, wheat or
barely.

Fermentation of this liquid mix produces alcohol &

CO2. Production Tech. II, By Moges A. 38
6/24/2022
 Cont.…

 Brewing is the production method of beer by

steeping a starch source in water gives wort and
fermenting the resulting sweet liquid (wort) with
yeast.

 The art & science of brewing lies in converting

natural food materials into a pure, pleasing
beverage.

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Process Technology, Process description and major
unit operation of beer production

General Major Steps in the brewing process include:

Malting
Milling
Mashing
Lautering
Boiling
Fermenting
Conditioning
Filtering and
Packing

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Process Technology, Process description and major unit operation
of beer production
General Steps in the brewing process include:
Malting
The first step in brewing, called malting, involves steeping the grain
in water for several days until it begins to germinate,
During germination, enzymes within the grain convert the hard,
starchy interior of the grain to a type of sugar called maltose.
 At this point, the grain is called malt.
After several days, when the majority of the starch has been
converted to sugar, the malt is heated & dried. This process, called
kilning, stops the malt from germinating.

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 The Brewing Process

Malting Process

steeping germination

 Malting develops the diastatic enzymes that accomplish the conversion of

starch to sugar during brewing & begins a limited process of conversion that
makes the starches more accessible to the brewer.
 Malting also gives brewing grains their distinctive colors and flavors.

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 The Brewing Process
A portion of the malt may be further roasted to varying depths of color
and flavor to create different styles of beer.

 Milling:
 After kilning, the dried malt is processed in a mill, which cracks the
husks (the outer coating of the grain).
The cracked malt is transferred to a container called a mash tun, & hot
water is added.

 Mashing
The malt steeps in the liquid, usually for one to two hours and this
process, called mashing, breaks down the complex sugars in the grain
& releases them in the water, producing a sweet liquid called wort.

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 The Brewing Process
The temp. & amount of time used to mash the malt affects the body & flavor of the
finished beer.
 Lautering: is the separation of the clear liquid wort (the liquid containing the sugar
extracted during mashing) from the grains.
 Lautering usually consists of three steps: mashout, recirculation, and sparging.
 Mashout: is the term for raising the temperature of the mash to 77 °C (170 °F),
which stops the enzymatic conversion of starches to fermentable sugars, and makes
the mash and wort more fluid or to free up more starch and reduce mash viscosity.
 Recirculation: consists of drawing off wort from the bottom of the mash, and adding
it to the top. Lauter tuns typically have slotted bottoms to assist in the filtration
process. The mash itself functions much as a sand filter to capture mash debris and
proteins. This step is monitored by use of a turbidimeter to measure solids in the wort
liquid by their opacity.
 Sparging is trickling water through the grain to extract additonal sugars. This is a
delicate step, as the wrong temperature or pH will extract tannins from the chaff (grain
husks) as well, resulting in a bitter brew. Sparging is typically conducted in a lauter
tun ( the traditional vessel used for separation of the extracted wort)

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 The Brewing Process

Dry Malt Mashing Lautering

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 The Brewing Process
Boiling
 In the next step, called brewing, the wort is transferred to a large brew kettle and
boiled for up to two hours.
 Boiling effectively sterilizes the wort to kill any bacteria that may spoil the wort
during fermentation.
 During this stage of the brewing process, hops are added to the wort to provide a
spicy flavor & bitterness that balances the sweetness of the wort.
 The types of hops used & the length of time they are boiled are
determined by the style of beer being made.
 To produce a beer with a stronger, more bitter flavor, hops are boiled for
at least 30 minutes and often longer. This enables the bitter oils in the hops
to fully infuse into the wort.

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 The Brewing Process

Fermentation
After brewing, the wort is cooled & then strained to remove
the hop leaves and other residue.
The brewer transfers the wort to a vessel/fermentation tank
in which the fermentation process takes place.

This vessel may be a deep, flat container with an open top

or a tall cylindrical vat with a conical base.

Yeast is then added or pitched into the wort to begin

fermentation and it begins to ferment.

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 The Brewing Process
 It is during this stage that sugars won from the malt are converted
into alcohol and carbon dioxide, and the product can be called beer
for the first time.
Saccharomyces cerevisiae floats on top of the liquid as it
ferments the grain sugars & prefers warm temp. ranging from
16°C to 22°C.
Saccharomyces uvarum sinks to the bottom of the liquid &
ferments best at cool temp. ranging from 3°C to 10°C.

The first fermentation lasts from a few days to two weeks.

When the yeast has consumed most of the fermentable

sugar, the wort becomes beer.
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 The Brewing Process
 Conditioning
The beer is transferred to an airtight container, called a
conditioning tank, for a second fermentation or aging period,
where the beer becomes naturally carbonated.
Some brewers inject CO2 gas into the beer when aging is
complete to give it a bubbly, effervescent quality.
Carbonation gives beer a light and refreshing feel in the mouth when
consumed and also enhances flavors and aromas.
To naturally carbonate beer, a small amount of sugar (called priming
sugar) is added to the beer after fermentation has completed.
Aging lasts for a few weeks to several months, depending on the
type of beer being produced.
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 The Brewing Process
 Filtration
After aging, the beer may appear cloudy from yeast cells & other
particles that remain suspended in the liquid.
The most common method of removing these impurities is
filtration, a process in which the finished beer is pumped, under
pressure, through a sterile filtering system that traps nearly from
the liquid, resulting in a clear liquid beer.
Filtering the beer stabilizes the flavour, and gives beer its
polished shiny and brilliance.
Even after filtration, some yeast may remain in the beer.
To kill the remaining yeast, the beer is pasteurized/heated to
82°C after it has been sealed in cans or bottles.
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 The Brewing Process

 Draught (drawn from the tap) beer, which is stored in metal

kegs, usually is not pasteurized and must be kept

refrigerated to prevent it from spoiling.

 Some brewers & beer drinkers believe that filtering &

pasteurizing beer robs it of much of its original flavor &

character.

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 The Beer production Process block flow diagram

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 The Brewing Process

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The process of brewing beer 53
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The process of brewing beer 54
 Beer Characteristic
The two major categories of beer are ales & lagers,
and the yeast used in fermentation determines the
differences between the two.
Ales are fermented with Saccharomyces cerevisiae at
warm temp. for short periods of time, typically a week.

This yeast ferments in warmer temp. to produce a fruity

flavor that characterizes ale.

Ales are aged, or conditioned, for one to three weeks.

Ales should be served at room or cellar temp. about 13°C.

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 Beer Characteristic
Lagers are usually drier, crisper, and less fruity in taste
than ales.
Lagers are fermented with Saccharomyces uvarum at
cooler temp. for longer periods up to two weeks,
which encourages the flavor components in lagers to
mellow/mature.
Lagers are aged for up to 12 weeks.
Lagers are best served chilled.
 All beer can be further described by 3 additional variables:
color, bitterness, and gravity.
Color is determined by the type & amount of malt used to
make the beer.

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 Beer Characteristic
e.g lightly roasted malt produces a light-colored beer,
while beer made only with barley that has been dark
roasted is nearly black in color.

Bitterness depends on the type and amount of grain and

hops used in the beer's production.

The mineral content of the brewing water can also

emphasize hop bitterness.
Beer made with H2O that has a high level of dissolved
minerals is bitterer than beer made with water low in
minerals.

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 Types Of Beer
 Porter and stout are dark ales that are nearly black in color &
have a hearty flavor and dense body. Its London brewer.
 The barley used to produce these beers is roasted to a dark, rich
color.
 Both beers range in taste from sweet to dry (lacking any
sweetness).
 Porter is lighter in body and higher in alcohol than stout, but
stout tends to be bitterer.
 Mild ale (England beer) has a gentle, sweet taste that is meant to
satisfy the thirst. It is usually tawny to dark in color.

 fewer calories & less alcohol 2 % than regular beer.

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 Types Of Beer
 Pilsner beer (Bohemian) the most popular of all the lagers
 It is a clear, golden lager with a dry but soft malty taste
and flowery hop aroma.
 Bock beer is a full-bodied, smooth lager with a somewhat
sweet taste.
 It is dark in color & may have an alcohol content as high
as 8%.
 Light beer and ice beer (Steam Beer) (California beer) are
typically lagers.
 Light beer contains fewer calories (as a result, usually lower in
alcohol).

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 Types Of Beer

 Wheat beer is brewed by mixing wheat with barley usually

in equal parts.

 The result is a light-colored and somewhat cloudy beer

with a refreshing, tart flavor.

 Wheat beer typically contains less alcohol than other

types of beer.

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 Wine and its Processing
.

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 Wine

 Wine making/vinification, is the production of wine,

starting with selection of the grapes or other and ending with
bottling the finished wine.
 Although most wine is made from grapes, it may also be
made from other fruit or non-toxic plant material like
peaches, or plums.
 Mead is a wine that is made with honey being the primary
ingredient after water.
 Wine Making can be divided into two general categories:
still wine production (without carbonation) &
 sparkling wine production (with carbonation).

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 Wine
 Wines are classified as natural (alcohol 10 to 22%), fortified
(alcohol 14 to 30%), sweet or dry/ sparkling.
 The most common wines are produced from grapes.
 when grapes are ripe, the grapes are crushed & fermented in
large vats to produce wine.
 By quick-aging methods it is possible to put out a good sweet
wine in 4 months.
 The wine may be held at about freezing for 3 weeks to
month, & a small amount of oxygen gas bubbled in.
 Then the wine is racked, clarified, and further filtered in the
usual manner.

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 Wine making/Processing

 Cultivation and harvesting of grapes for wine is known as

viticulture or winegrowing.

 The production of wine (starting from grape selection, its

fermentation, to the bottling of wine) is known as
vinification.

 Winery is the place where wine is produced.

 Oenology is the branch of science deals with wine and

winemaking process.

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 Wine making/Processing

 In common, there are five steps in the winemaking process.

 These are:

 Harvesting and Crushing

 Pressing/maceration

 Fermentation

 Clarification

 Aging/maturation and bottling

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 Wine making/Processing

 In common, there are five steps in the winemaking process.

 Harvesting and Crushing

 During the harvesting process, grapes are picked the

vineyard by hand or machines

 After harvesting the grapes are crushed into small pieces,

which is must.

 Must is the fresh juice of grapes containing seeds, solids

and skins of the grapes.


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 Wine making/Processing
 Up until crushing, the steps for white and red wines are the same.
 Red wine is made from the must (pulp) of red or black grapes that undergo
fermentation together with the grape skins.
 The must allowed to sit to get tannins, flavours and color.
 The time period for which must is allowed to sit is called maceration.
 After maceration, juice portion is separated from must and the process that
separates the grape juice from the fiber and other solids (must) is called pressing.
 The juice portion separated from the must is called free run and the rest of the
remaining of must is called pomace
 White wine is made by fermenting juice which is made by pressing crushed grapes
to extract a juice; the skins are removed and play no further role.
 The grape juice portion is quickly separated from the must without giving any
maceration time to prevent the tannin and color from leaching in the wine.

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 Wine making/Processing

 Rarely white wine is made from red grapes, this is done by

extracting their juice with minimal contact with the grapes'
skins.

 Rose wines are either made from red grapes where the
juice is allowed to stay in contact with the dark skins long
enough to pick up a pinkish color/by blending red wine
and white wine.

 White & rose wines extract little of the tannins contained in

the skins.

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 Wine making/Processing

 Fermentation
 In fermentation the action of yeast upon sugar solution breaks
down the sugar into alcohol and carbon dioxide
 To start primary fermentation yeast is added to the must (pulp)
for red wine or juice for white wine.
 During this fermentation, which often takes b/n one & two
weeks, the yeast converts most of the sugars in the grape juice
into ethanol (alcohol) & CO2.
 Then the free run wine is pumped off into tanks & the skins are
pressed to extract the remaining juice & wine, the press wine
blended with the free run wine at the wine maker's discretion.

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 Wine making/Processing

 The most commonly yeast used in winemaking is

Saccharomyces cerevisiae.

 The process of fermentation is continued until all the sugar is

converted into alcohol, which results in a dry wine

 If sweet wine is to be prepared, winemakers stop the

fermenting process in between before all the sugar has
been converted into alcohol.

 The complete fermentation process may take about a week

to a month or even more to convert the sugar into alcohol.

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 Wine making/Processing
Clarification
 In this process we remove any tannins, proteins, and dead yeast from the
wine.
 For clarification, we can either go for filtration or fining treatment.
 In filtration, we pass the wine through coffee filter like material, which
consists of series very small holes or pores , which allows liquid and
particles small enough to fit through.

 Large particles are held back and removed from the liquid.
 Fining is done by introducing an agent to wine that physically
binds with unwanted molecules usually called colloids.
 common fining agents include: gelatin, egg whites, bentonite and
carbon

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 Wine making/Processing
Aging/maturation and bottling

 Aging refers to group of reactions that tend to

improve the flavor and test of wine.

 Aging can be done in the bottle, stainless steel or

ceramic tanks or oak barrels

 Once aging finished, the wine is bottled with a

screw cap or cork and distribute to the consimer.

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 Wine making/Processing
Process block flow diagram for wine making

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6/24/2022
THANK YOU!
Production Tech. II, By Moges A. 74