Jimma University BGI Ethiopia

DECLARATION
My name is TseganeshTafese, Iam 4th year chemical engineering student. I hadmy internship
experience in BGI Ethiopia,Hawassa industry plant from March-june,2019 under the supervision
of Mr.Abowerk.W and Mr.GedefawMazengia from jimma institute of technology
university,BGI-Ethiopia respectively.

Approval Sheet

I certify that,TseganeshTafese’s internship report is original and compiled in accordance with

the internship report writing guideline given by the university-Industry linkage office of the
university.

Name of students signature Date

TseganeshTafese___________ ___________

Name of advisor ___________ ___________

Jimma University BGI Ethiopia

Acknowledgement

I would like to praise to my lord Jesus Christ for giving me the patience to start and finalize this
work.My special gratitude goes to my supervisors Mr.AbowerkandMr.Gedefaw from Jimma
institute of Technology University-chemicalengineering and BGI-Ethiopia,hawasa respectively
for their earnest and constructive advises throughout the internship period and valuable
comments.A word of thanks must also go to Mr.Ermias head of chemical engineering
departmentfor his encouragement,creative suggestions and my heartfelt thanks to all staff of BGI
Ethiopia brew industry for critical comments and constant support.I would like to thank my
whole families for encouraging me in every aspect during the internship period.Moreover,Iam
thankful to FitsumMohammed who isshift leader in BGI-Ethiopia.
Jimma University BGI Ethiopia

EXECUTIVE SUMMERY

An internship is work –related learning experience for individuals who wish to develop hands on
work experience in certain occupational field, I recently have done my internship in BGI
Hawassa through internship and practical work.

This report contains historical background about B.G.I Ethiopia and also about the raw materials
used for beer production that is barely, malt, hops, water and yeast. And also the various unit
operations and their operating mechanisms used in this brewery. This report also contains what I
have gained in terms of improving my practical skills, what have gained in terms of upgrading
my theoretical knowledge, what I have gained in terms of improving my inter personal
communication skills, and also improving my leader ship skills and so on. This paper also
contains project done in B.G.I Hawassa, plc. I have undertaken my project work encountered
regarding production of lactic acid from brew spent grain by using lacto baccilus bacteria. Since
lactic acid is imported from other countries, it has an extra expense due to transportation and the
material only is also expensive. To overcome this we need to have an alternative technology to
produce lactic acid with a more cost effective way. So in my project I tried to show the
possibility of lactic acid production by using local, available and cost effective material which in
my case is spent grain.

Finally, I have come up with some recommendations for the problems that has been identified
during my internship, to ensure cost effectiveness and sustainability of the company at the same
time meet the environmental regulation.

Contents
CHAPTER ONE...........................................................................................................................viii
Jimma University BGI Ethiopia

1.1 Background of BGI Ethiopia.....................................................................................................1

1.2. Vision....................................................................................................................................1
1.3. Mission.................................................................................................................................1
1.4 Objective of the company......................................................................................................2
1.5 Main products of theBGI ETHIOPIA company....................................................................2
1.5.1 MainProducts of BGI Hawassa plant.....................................................................................3
1.6 Company’s Customers...........................................................................................................3
1.7 It’s Over All Organization Structure.....................................................................................4
CHAPTER TWO.............................................................................................................................6
Overall about Internship..................................................................................................................6
2.1. Objective of the Internship...................................................................................................6
2.2 How I get into the company...................................................................................................6
2.3. The section of the company I have been working................................................................7
2.4 The work flow of the section.................................................................................................7
2.4.1 BREW HOUSE OPERATION.......................................................................................7
2.4.1.2 Chemical stores....................................................................................................................9
2.4.1.8 Wort kettle (wort boiling...................................................................................................15
Wort boiling objectives..........................................................................................................15
2.4.2 Wortcooling (WORT CHILLER).................................................................................18
2.4.3Wort Aeration................................................................................................................18
2.4.4 Addition of Yeast (Pitching).........................................................................................19
3.4.5 Fermentation house Operations....................................................................................20
COOLING.....................................................................................................................................22
LAGERING...................................................................................................................................22
Yeast Propagation......................................................................................................................22
2.4.6 Beer Filtration...............................................................................................................22
2.4.7 Beer Packaging.............................................................................................................27
2.4.8 Finished goods store (fgs):............................................................................................33
2.4.9 UTILITY SECTION.....................................................................................................33
Under this section Boiler plant, Air compressor, Ammonia compressor, CO2 compressor,
water......................................................................................................................................33
Jimma University BGI Ethiopia

2.4.9.7 WASTE WATER TREATMENT......................................................................................36

2.4.10 Quality Control...........................................................................................................37
2.5 work tasks that have been executing...................................................................................41
2.6 Procedures that havebeen used while performing work tasks.............................................45
2.6.1 Performance at the company............................................................................................46
2.7. Challenges faced when performing tasks...........................................................................46
2.7.1 From the company:.......................................................................................................46
2.7.2 From outside:................................................................................................................46
2.8. The taken measures (alternative solution)..........................................................................46
CHAPTER THREE.......................................................................................................................47
Over All Benefits Gained fromInternship.....................................................................................47
3.1. Introduction.........................................................................................................................47
3.2 In Terms of Improving Practical Skills...............................................................................48
3.3 In Terms of Upgrading Theoretical Knowledge..................................................................48
3.4 In Terms of Improving Interpersonal Communication Skills..............................................48
3.5 In Terms of Improving Team Playing Skills.......................................................................49
3.6 In Terms of Improving Leadership Skills............................................................................49
3.7 In Terms of Understanding About Work Ethic Related Issues...........................................49
3.8 In Terms of Entrepreneurship Skills....................................................................................50
PART- TWO..................................................................................................................................51
CHAPTER FOUR.........................................................................................................................51
PROJECT CARRIED OUT...........................................................................................................51
4.1 The main problem of the company......................................................................................51
4.2 PRODUCTION OF LACTIC ACID FROM BREW SPENT GRAIN...............................51
4.2.1 INTRODUTION...........................................................................................................51
4.2.2 Problem Statement........................................................................................................52
4.3 Objective of the project.......................................................................................................53
4.3.1General objective...........................................................................................................53
4.3.2 Specific objectives........................................................................................................53
4.4 Significance of the study.....................................................................................................54
4.5 LITERATURE REVIEW....................................................................................................54
Jimma University BGI Ethiopia

4.6 METHODOLOGY..............................................................................................................56
4.6.1 Materials and Chemicals...................................................................................................56
4.6.2Main unit operation used in production of lactic acid from spent grain............................57
4.6.2.1 Preparation of Spent Brewery Grains (BSG).............................................................57
4.6.2.2Acid Hydrolysis..........................................................................................................57
4.6.2.3 Culture media preparation.........................................................................................57
4.6.2.4 Fermentation..............................................................................................................59
4.7 Material and ENERGY Balance..........................................................................................61
4.7.1 Material Balance...........................................................................................................61
4.7.2 Energy Balance.............................................................................................................64
CHAPTER FIVE...........................................................................................................................65
CONCLUSION AND RECOMMENDATION............................................................................65
5.1 Conclusion...........................................................................................................................65
5.2 Recommendation.................................................................................................................65
References......................................................................................................................................67
Appendix........................................................................................................................................ix
Jimma University BGI Ethiopia

List of Table

1. Different temperature gelatinization process

2. Additive chemical on machine process
3. Difference between draft and bottle design

List of figures

1. General organizational flow chart

2. Local malt storage
3. Imported malt storage
4. Chemical store
5. Mash tun
6. Mash filter
7. Flow sheet mash filter to whirl pool
8. Beer house process
9. Fermentation and filtration process
10. Blending and carbonation
11. Pasteurization
12. Bottling and packaging process
13. Finished goods store
14. Diagram of lactic acid production
Jimma University BGI Ethiopia

Acronyms
• TOD = Tank out door

• BBT = Bright Beer Tank

• CIP = cleaner in place

• HGB = High gravity beer

• LGB = Low gravity beer

• VDK = Vicinal Diketones

• DMS = Dimethyl sulphur

• KMS = Potassium di methane sulphid

• Op =Degree Plato

• Kg = Kilogram

• CO2 = Carbon dioxide

• UBT =unfilter buffer tank
• FBT = filter buffer tank
Jimma University BGI Ethiopia
Jimma University BGI Ethiopia

CHAPTER ONE

1.1 Background of BGI Ethiopia

BGI is a large-scale brewery and beverage production wing of Groupé Castel, operating
internationally in more than 53 countries.BGI Ethiopia PLC has been operating in Ethiopia since
1998GC and engaged in the production and distribution of beer, wine and beverages. BGI owns
five breweries including the iconic St. George Brewery in Addis Ababa, the Kombolcha
Brewery, the Hawassa Brewery, Zebidar Brewery and Raya beerMachew Northern Brewery with
a combined production capacity of 3.6 million Hectoliters of beer (bottle and Draft) annually.

BGI Ethiopia PLC. also owns and manages the Castel Winery and vineyard located in the town
of Zeway. Established in 2012, the winery produces twelve thousand Hectoliters of different
wine varieties annually under the brand names Acacia and Rift Valley. BGI Ethiopia’s products
are distributed by partner agents in all corners of the country and exported internationally to
North America (USA and Canada), Europe (UK, Italy, France, Germany, Switzerland, Belgium,
Netherland etc.) Middle East (Israel and UAE), Australia, Africa (Kenya, Tanzania, South
Africa, South Sudan, Djibouti etc.), Asia (China, Japan etc.)

The Hawassa brewery established in 2011GC, this is the largest brewery built by BGI Ethiopia
so far. It is located in 275km from Addis Abeba,Hawassa,SNNPRregionalstate.Its production
capacity ,started with 750,000HL.per annum and managed to double production to 1.5 million
HL. Currently number of employees,498permanents and 13 seasonal employees.

1.2. Vision
Its vision is to increase its production capacity and play significant role in supporting and
Beverage industry and to satisfy the demand of quality beer in Ethiopia and foreign country. To
insure competitiveness of the company through sustained innovation of its infrastructure and work
toward it based on well-managed and led organization for achieving best quality and high volume
products and be recognized as profitable and growth oriented company

1.3. Mission

Promoting the products in a fair and ethical way, producing high quality beer with affordable.
Price, diversifying quality beer the in order to meet the requirement of Ethiopian Beer
Customers, developing the distribution network that makes the products available for Everyone,
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committing with socio-economic problems of the country and training the staff to Upgrade them
to a high level of competence.

Striving to reach, maintain and expand our national market leadership through optimal customer
service and exceed the expectation of our customers for our existing and new products in both quality
and quantity.

Treating and serving all customers with respect, sensitivity and fairness.

1.4 Objective of the company

The primary objective of the company is to produce and distribute quality bottled and
Draughtbeer to local and foreign markets. It produces quality products to satisfy the needs of
Customers by covering the whole country and make healthy beer available for all.

1.5 Main products of the BGI EthiopiaCompany

 St. George bottled beer
St. George is a Lager type beer made from expertly selected malts, premium blends of
hops and purified highland water. Moderated bitterness level, slight essence of grain
and unique bouquet of aromas give St. George beer its distinct taste and Ethiopian
flavor; making it the perfect brew for every occasion. St. George Beer is available in
330 ml. Bottles and 30 lt. Draft Beer kegs

 Castle beer
A truly unique premium lager beer produced from 100% pure malt and aged to
perfection more than any other beer in the market. Deep golden in color, when
poured, tiny bubbles rush to the top forming its thick and creamy white head. The
well-balanced body and slightly pronounced grain flavor give Castel Beer a robust
Jimma University BGI Ethiopia

taste, making it ideal for the most discerning of consumers. Castel Beer is available in
330 ml. embossed Bottles and 30 lt. Draft Beer kegs
 Panach’ beer
Panach’ is a refreshing lemon-lime and beer flavored drink with a slight sweetness
that can be enjoyed with meals or by itself at any time of the day. With only 2% of
alcohol per volume, pleasant fruity aromas and flavors, Panach’ is a worthy
refreshment companion that complements every occasion and situation, whether
formal or casual. Panach’ is available in 330 ml. Bottles

 Zebidar beer

Named after the ‘Zebidar Massif’ in the Gurage Region, Zebidar Beer is a full-bodied
Lager type beer, made from premium malt and hops. The low bitterness level gives
the beer it’s unique and crisp taste. Zebidar Beer is available in 330 ml. Bottles and 20
lt. Draft Beer kegs

 Raya beer

Raya is a full-bodied Lager type beer produced from high quality malt & hops, and
water from the natural mineral springs of Mount Mychew. The unique aromas from
the hops, the mineral water, slight tang of grain and moderate bitterness makes Raya
Beer enjoyable and one of a kind. Raya Beer is available in 330 ml. Bottles and 30 lt.
Draft Beer kegs
Jimma University BGI Ethiopia

1.5.1MainProducts of BGI Hawassa plant

BGI Hawassa brewery is huge company that produces both bottle beer and draught beer.From
its main raw materials, such as malt, water, hop and yeast. Most of barley malt are supplied from
local (Assela and Gondar) and foreign (Holland and France).The company has three main
products; these are St. George, Castle and Draught beer. These beers are in different alcoholic
content of 4.75 %, 5.5 %and 4.75% respectively.

1.6 Company’s Customers

The company aimed to produce quality products to satisfy the needs of customers. Their
products are bottled beer and flash pasteurized draft. From store, the beer is sold to wholesalers
and Consumers. Trucks transport the distribution of the product to different regions of the
country. The distributions are managed and controlled by the sales department of the company.
Apart from local, the company is also exporting beers to Djibouti, Israel, sometimes to USA and
Europe. The sales representative of the company distributes the product fairly to meet the need of
its customers. Otherwise, the opponent company gets advantages to take its client. Currently BGI
has so many costumers; its product is not keep in store since the products are familiar.

Generally main consumer or end users are: wholesalers and consumers in over all the country
and foreign countries such as Djibouti, Israel, USA, United Kingdom, Italy, and Australia.

1.7 It’s Over All Organization Structure

There is one head office in Addis Ababa, which controls the whole other branches. In each
Factory general manager is playing a gear role to coordinate the work. There are also different
Jimma University BGI Ethiopia

Departments that make the work flow easy and fast. In Hawassa brewery, there are five
Departments: Technical departments, Administration department, Sales and Marketing
Responsibilities to coordinate high level process issues of customer complaint and management,

Ensure the provision of necessary resource to establish and improve the management system,
establish effective internal communication, and ensure the presence of suitable organization

Structure and clear authority responsible.

General Manager: lead all over the company, apply yearly plan and occupational program,
check if the plan is applied or not and follow up all over working process of the company.

Legal Affairs: Give advice and suggestion on legal issue and question; give description and
explanation bout legal proclamation.

Quality control and food safety: Coordinates, follow up, and controls the quality of product,
checks if the raw material full fills the acceptable quality or not, controls the level of the quality
of chemical and inventory goods.

Finance Manager: Follow up and realize financial planning, perform beget preparation, indicate
the direction of financial sources of the company, and controls the collected finance

Technical Manager: Follows up the activities of processing machines, solves the problems which
are occurred in the work machines, maintains damaged machines controls firing, gives technical
training to workers etc.

Sales Manager: Gathers marketing information, searches market places, purchases raw
materials and imputes, applies customer attracting activities.

Procurement and purchase Manager:Control all types of properties from wasting and damaging,
sells used materials etc.

Production Department: Controls all production processes, supplies raw materials, identifies
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product types, formulate plans to increase products etc.

Figure 1 General organizational flow chart

CHAPTER TWO

Overall about Internship

2.1. Objective of the Internship
Internship is very important for knowing of the application of what is learnt theoretically,
improving interpersonal communication skills, upgrading theoretical knowledge, understanding
about work ethics related issues, improving team playing skills etc.
Internship is one method of making for university students potentially valuable and explore general
career avenues as well as specific companies. A part to securing good work experience, such
Jimma University BGI Ethiopia

arrangement can provide us with valuable work experience both practical and for resume
enhancement and an opportunity line up a job before graduation.
 To upgrade the theoretical knowledge to practical knowledge and real world.
 To expansion of knowledge and acquaintance with company in the field of chemical
engineering and hands-on training in practical skills typical for the company.
 To know myself and hopefully spending time with senior graduates, people with many years
of working experience in the company will be the future guidance for me.

2.2 How I get into the company

When I arrived at Hawassa BGI PLC Company on march/2019, I told for the guards as I am
student and applying for internship in the company. They allow me to enter inside and to meet
with the secretary of manager and I meet with the manager and I reported the letter that was
given from university linkage (UIL) office to the company head manager. He was accepting the
letter and encourages me to involve in all tasks to make the internship program more practical
and fruit full. Next to this, a company manager sent me to production manager, Gedefa, after
these the production manager send message to the shift leader and the shift leader assign a person
to help me to visit the overall flow of the company.

For one week I were visit the whole company and I saw general work shop, utility section, brew
house department, filtration department and bottling department. They encourage I to do

More, and create good relationship to factory workers. Supervisor and other colleagues

Within the BGI Hawassa Brewery support us to able to quickly understand what my work

Involved and to what extend to do it.

2.3. The section of the company I have been working.

As I have explained above in organizational structure there are five main departments and

Different sections are included under them. Among these sections I have been working in

Fabrication department. In this section there are five main house which are brew house,
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Fermentation house, filtration house,utilizationand packaging house.Thesefabrication department

is responsible forproduction of beer and its quality.

1. Brew house

2. Fermentation house

3. Filtration house

4. Utilization

5. Botteling

2.4 The work flow of the section

In fabrication section the production of beer and its packing is done.

2.4.1 BREW HOUSE OPERATION

Brew house is the major process center of the brewery, which is equipped with intricate network
of pipelines, tankers, pumps and corresponding control & regulation systems. Most of the time it
is called "The heart of the brewery", this is because all the raw materials needed for production
are mixed to form a wort (high extract) through different sequences of process.

Brew house operations are consisting of storage, malt milling, mashing, and lautering (wort

Separation), wort boiling, wort clarification, wort cooling, trub collector and wort aeration.

2.4.1.1 Malt Store:

The malt is supplied from local (Assela and Gondar) stored in the local malt storage room and
themalt from foreign (Holland and France) stored in a huge cylindrical container called Silo. On
each batch of malt, the names of supplier, dates of receive, order Number and quantities are fixed
for identification. We are using first in first out stock System. The malt is poured in the hopper
and transferred to milling machines. On the lines of transfer there is called destoner which
removes the stone by vibrating and also a magnet which traps some pieces of metals found in the
malt to protect milling rollers from damage. The dusts and husks of malt will be collected in
sacks.
Jimma University BGI Ethiopia

Figure 2 Local malt storage room

Figure 3Imported malt storage

2.4.1.2 Chemical stores:

The chemicals and other materials used in brewery are arranged accordingto their similarity
(group). Sand, carbon, risen, Caustic soda and ATR acid etc.
Jimma University BGI Ethiopia

Figure 4 Chemical store

2.4.1.3 Pretreatment of malt

Before malt milling the malt is free from impurities and the amount required for the brew is
weighed out. The malt is treated by the following equipment’s

1. Pressurized air used for avoid dusty particle

2. DE stoner used to remove high density materials and stones.

3. Screen used to remove oversized malt.

4. Magnets separation used to remove metals which could cause sparks

2.4.1.4 Malt Milling

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 lautertun 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.It is
storage for milled malt (grist). Since it is equipped with a mass measurement system at its
Jimma University BGI Ethiopia

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 tons.

2.4.1.5 Mashing process

Mashing is the process which a mixture of milled grain (typically grist) and hot water, and
heating this mixture in a vessel called a "mashtun”. Starches are break down to fermentable
sugar and extracted in to water from malt grain or grist by the process called mash. The mash use
heat at specific temperature to activate certain enzyme that breaks starch chain down to sugar
that can easily consumed by yeast.

Fig 5Mashtun

Objectives of Mashing

1. To form an extract with a desired profile of sugars and a desired level of proteins and other
minor chemical constituents.

2. Most of the extract is produced during mashing by the action of enzymes, which are allowedto
act at their optimum temperatures.

There are two main methods of mashing;

1. Infusion mashing- in which the grains are heated in one vessel; and
Jimma University BGI Ethiopia

2. Decoction mashing- in which a proportion of the grains are boiled and then returned to
themash, raising the temperature. Mashing involves pauses at certain temperatures (notably 55-
72and 74oc), and takes place in a " mashtun" an insulated brewing vessel with a false bottom.
Theend product of mashing is called a "mash".Mashing usually takes 1 to 2 hours, and during
this time the various temperature rests activatedifferent enzymes depending upon the type of
malt being used, its modification level, and theintention of the brewer. The activity of these
enzymes convert the starches of the grains todextrin’s and then to fermentable sugars such as
maltose. A mash rest from 55 °C activatesvarious proteases, which break down proteins,
otherwise cause the beer to be hazy. And a mashrest at 55 °C activates β-glucanase, which
breaks down gummy β-glucans in the mash, makingthe sugars flow out more freely later in the
process. In kombolcha the modern mashing process,commercial fungal based β-glucanase added
as a supplement. A mash also rests at temperature of72 °C is used to convert the starches in the
malt to sugar, which is then usable by the yeast later in the brewing process. Doing the latter rest
at the lower end of the range favors β-amylaseEnzymes, producing more low-order sugars like
maltotriose, maltose, and glucose which are more fermentable by the yeast. This in turn creates a
beer lower in body and higher in alcohol. Arest closer to the higher end of the range flavor α-
amylase enzymes, creating higherorderSugars and dextrin’s which are less fermentable by the
yeast, so a fuller-bodied beer with lessAlcohol is the result. Duration and pH variances also
affect the sugar composition of the resultingwort.

Steps of Starch Degradation:

1. Gelatinization: is the swelling and bursting of starch granules in hot aqueous solution. As a

result of water uptake the granules swell. Starch molecules released making a viscous solution

are more easily degraded by amylase enzymes. The degree of viscosity depends on the extent of

water uptake and is different for different types of cereals.

2. Liquefaction: Liquefaction is the reduction of viscosity of the gelatinized starch by α-

Amylase. The long chains composed of glucose in starch (amylose and amylopectin) are very

Rapidly broken open to form smaller chains by α- amylase. This causes a very rapid reduction
ofthe viscosity of the gelatinized mash. β-amylase can only slowly degrade the long chains
fromthe non-reducing end, and so degradation by this enzyme alone would take days.
Jimma University BGI Ethiopia

3. Scarifications; is the complete degradation (hydrolysis) of starch to glucose,

Maltose, malt triose and dextrin’s by α- and β -amylase.

Table 1 different temperature with gelatinization process

Specific Significance
temperature

55℃ Entrance temperature ,prevntation protein

degradation

62 to 65℃ Optimum temperature for beta –amylase

74℃ To remove amylase enzyme

72to 75℃ Optimum temperature for alpha amylase

77℃ Mashing

PH monitoring during mashing process

During these time 4kg hydro chloric acid will be added for the purpose of PH adjustment, it has
been shown that PH value of the mash is an essential parameter for enzymatic reaction.

 thus lowering of PH results

 A higher attenuation limit
 More extensive protein broke down resulting in the production of more high and
low molecular weight protein degradation
 Reduction of viscosity
Jimma University BGI Ethiopia

 More rapid lautering

 Restriction of increasing coloring of wort boiling

Table 2 additive chemical on the mashing process

additive Use

H2SO4/HCL For adjustment PH since malt

enzymes are affected by PH

Hitampase for increasing enzyme activity

Bio glucanase HAB For aiding degradation beta

glucane

2.4.1.6 Lautering (Mash Filter)

Lautering is the separation of the wort (the liquid containing the sugar extracted during

Mashing) from the grains through the machine called mash filter. Most separation processes have
two stages: first wort run-off,during which the extract is separated in an undiluted state from the
spent grains, andSparging, in which extract which remains with the grains is rinsed off with hot
water. TheLauertun is a copper tank with holes in the bottom small enough to hold back the large
bitsOf grist and hulls. The bed of grist that settles on it is the actual filter. Some lauter tunes
haveProvision for rotating rakes or knives to cut into the bed of grist to maintain good flow. The

Knives can be turned so they push the grain, a feature used to drive the spent grain out of the

Vessel. Generally, lautertun is separation extracted wort from the spent grain.
Jimma University BGI Ethiopia

Lautering Process Objectives:

1. Achieve the specified wort clarity

2. Efficient recovery of extract at the required clarity and with minimum dilution.

3. Efficient removal of spent grains

4. Efficiency of the process, minimum down time

Figure 6 Mash Filter

2.4.1.7 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. Per heater decrease the residence times in the wort kettle by preheated the
wort to the specified boiling temperature. This makes boiling in the wort kettle less time taking
and decrease energy cost.

2.4.1.8Wort kettle (wort boiling)

The wort obtained is boiled for one and half hour, during this time hops are added in the dosing
tank. The main purpose of wort boiling is to extract flavor and aroma compounds from hop.

Wort boiling objectives:

 sterilization of wort, extraction and isomerization of hop components

 unstable colloidal protein coagulates and precipitates, known as "Hot Trub"
 Enzymes are inactivated to prevent the continued break down of proteins & starch dur-
ing fermentation
 increase in wort color and acidification of the wort
 concentrates the wort (i.e. evaporation will concentrate the wort)
Jimma University BGI Ethiopia

During boiling two group of hops are added in to the wort on the hop dosage tank.CO2 extract
and IKE is added when boiling is started because it isomerizes only upon boiling while IKE is
added around the end of boiling because it is already an isomerizes hop. In the wort kettle, boil-
ing may take up to 2hrs because, the bitter substance goes into a solution to a great extent, the
coagulable protein is precipitated better, and more DMS (dimethyl sulphur) compound is driven
out. But the energy cost increase with each minute of boiling and consequently only the absolute-
ly necessary boiling time must be used. It is however important the wort at the end of the boiling
process has reached the desired extract content. Since only in this way can the desired original
wort gravity be achieved.

2.4.1.8 WORT SETTLING (Whirlpool)

It is a separation equipment to maintain purity of the wort, which is an empty tank where the
wort enters tangentially with high speed and the coarse thrub collected at the bottom. Once boil-
ing is done, the wort is pumped into the clarisaver tangentially at about 30o tangents to the vessel
wall. Pumps are used to transport the hot wort from the wort kettle to clarisaver. The tangential
injection causes the hot wort in the vessel to rotate. At this time the denser solids which are
coagulated protein and vegetable matter from hops are forced out wards by the centrifugal force
produced and the coarse trub collect on the outside wall. The vessel is usually filled in 10-15 min
and after resting time which is up to 15-20min the wort has cleared and coarse trub is deposited
in center bottom of the clarisaver tank.
Jimma University BGI Ethiopia

Figure 7 flow sheet from mash filter to whirlpool

2.4.1.9 TRUB TANK

Trub is a material along with hop debris; left in the wort kettle or hop back after the wort has
been transferred and cooled. Brewery generally prefer that the bulk of trub to be left in the kettle
farther than stay in contact with fermenting wort, although it contains yeast nutrients, its
presence can impart off-flavor in finished beer.Trub is used for lees, or layer of sediment,left at
bottom of ferment or after yeast has completed the fermentation process. It is completed of the
heavy fats, protein and inactive yeast. Generally, trub tank can be used for collected
trubandremoved and into the lower tun

Premasher

Mash tun
Cooker

Spent grain
Lautertun
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Sugar, hop,

Wort kettle Caramel,

ZnSo4,

CaSo4

Sedimentation
tank
Oxygen

Wort cooler Wort

aeratio
n

Figure 2.7 Beer house process

2.4.2 Wortcooling (WORT CHILLER)

The wort leaving the Claris aver is at very high temperature (80-90oC) due to boiling in kettle.
Hence the wort must be cooled so that the yeast can undergo fermentation on the wort within 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. In B.G.I this stage is
achieved through a plate heat exchanger. A good heat exchanger can drop wort at 80oC to 8oC

2.4.3Wort Aeration

Yeast requires oxygen for the synthesis of fatty acids which form the main component of cell

membranes. It is the only time on the entire beer production process that oxygen is

deliberately added. The oxygen is taken up by the yeast within a few hours here air must be

injected as very small bubbles and turbulently mixed with the cold wort. In Hawassa

brewery aeration must have done up 200 hl of fourth brews if brewed for bigger TOD. For small
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TOD up to five brew must done. Wort aeration at high temperatures results in extensive

oxidation. As a result, the wort becomes darker and bitterer, that’s why aeration takes place

after cooling of wort and is injected at the outlet point of the chiller during which the wort is

flowing towards the fermentation and does not damage the wort quality, intensive aeration of

the yeast on pitching is important. But in addition the yeast should quite deliberately aerate

in the first few hours to increase its activity. If the aeration is not properly done it affects the

beer quality. Too low oxygen results in longer process time and low beer quality by happing

the following.

1. Insufficient yeast growth and dead cells - insufficient yeast harvest

2. Hanging or sluggish fermentations

3. Incomplete fermentations

4. Poor flavor and foam - prolonged diacetyl reduction

5. Reduced assimilation of amino acids

And also too high oxygen results in:

1. Vigorous fermentations with over-foaming or reduced utilization of fermenting vessel

Volume

2. Excessive yeast growth – loss of extract

3. Lower yeast glycogen depots

4. Poor flavor – increased level of higher alcohols and acetaldehyde

5. Reduced levels of DMS and H2S

2.4.4 Addition of Yeast (Pitching)

Pitching is the addition of yeast to the worth and thus the starting of primary fermentation.

The wort that is pitched at a temperature of 10oc and an extract of 11.5 to 12. 5op.At the start

of fermentation rapid yeast growth must be encouraged and this requires both the
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introduction of oxygen to the wort and very efficient mixing of the yeast with the wort. This

intimate mixing is achieved by dosing yeast into a flowing stream of wort. At BGI, the pipe

where yeast is dosed with as the wort passes to the fermentation tank is in a spiraling form so

as to cause turbulent mixing. In addition, Yeast for pitching is normally derived from

previous fermentations and maintained in yeast storage tanks as a slurry at <50C.

Stages of Yeast Growth: When yeast is added to wort, it goes through 5 basic stages of

growth. These are

I. Lag phase - period of adaptation

II. Accelerating growth phase- initiation of yeast growth

III. Exponential growth phase - rapid yeast growth, doubling every 2-3 hours

IV. Decelerating growth phase - nutrient supply depleted

V. Stationary phase - no yeast growth, cell viability begins to decline

3.4.5 Fermentation house Operations

Fermentation is the conversion of sugars to alcohol and carbon dioxide by using a live yeast

Under an aerobic condition.

Yeast
 C6H12O6 2C2H5OH +2CO2 + ENERGY

Fermentation is an exothermic process in other wards a process in which, as a chemical energy

can be obtained, stored and used by yeast. Fermentation is stage where simple sugar inside the
wort are converted into alcohol or simply fermentation is process wort became beer. To begin
fermentation process cooled wort is transfer in to fermentation vessel with capacity holding up to
2000 hecto litter of wort. In BGI Hawassa it has 18 fermentation vessel or TOD among these 12
are small TOD its capacity is 1000 hecto litter and 6 are big TOD its capacity is1250 hecto litter.
Inside the fermentation vessel, specific gravity of the pitched wort is measured before
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fermentation start so that it can compared with to another specific gravity these helps to
determine how much alcohol is in beer and when stop fermentation process.

2.4.5.1 FERMENTATION STAGES

Primary Fermentation

The primary stage of fermentation begins when yeast is introduced into cooled and aerated wort.
During this yeast growth occurs, production of flavor compounds like VDK, consumption of
most wort sugars, ethanol and CO2 production, and reduction in PH from 5.3 to 5.6 in the
pitching wort to 4.3 to 4.4 in the beer. During the reduction of PH organic acids are produced by
uptake of potassium ions by the yeast and release of hydrogen and the primary use of phosphate
ions by the yeast. The beer PH of between 4.2 and 4.4 is recommended because it accelerates
precipitation of colloidal unstable proteinand polyphenol complexes; it is an essential
requirement for good biological stability of the beer. But lower PH values less than 4.1 causes
acidic beer taste and must be avoided. The temperature of primary fermentation is from 12 oC to
150C for four days. After primary Fermentation the amount of VDK and the temperature are
checked by laboratory. The pressure is 0 bar for the freely movement of yeasts. At the end of
primary, the yeasts are harvested during these yeasts are transferred to yeast storage tank and
recycled up to ten generations by checking their consistency, viability and thickness.

Secondary Fermentation

It refers to the stage of fermentation after the majority of the wort sugars have been consumed
and there is a sharp decrease in the rate of fermentation. Generally, directly is converted or
consumed by yeasts, decrease the rate of ethanol and CO2 production, Yeast flocculation and
settling begins because yeasts feed on calcium ion they become massive and they flocculate
easily. Reduction of some flavor compounds by yeast metabolism or CO2 scrubbing as the result
of decrease in PH during fermentation a number of colloid dissolved substances and polyphenol
are precipitated as surface active compounds on CO2 bubbles and carried up wards with them as
a result of the adsorption on yeast cells. Part of isohumulene also precipitates on the top covering
Surface of scrubber because isohumulene are very surface active and they are captured by
theCO2 bubbles and carried upward. The foam trap is separated from CO2 by absorption with
water in the CO2 foam trap tank counter currently. The CO2 is transferred to the utility. The
temperature for secondary fermentation is 16 and the pressure is 0.6 for three days.
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COOLING

Now decrease the temperature from 12.5-16OC to 1.5OC in order to cool the fermentation
process which is used to deactivate the yeast and enzymes, because we do not need further
fermentation. The temperature is decreased by using glycol.

LAGERING

In these step there is further decreasing of the temperature up to ( -2.00-( -2.5)) o which is
used for coagulation of protein and in order to settle the dyed cell of yeast. Yeast, polyphenol-
protein settle down to the conical area of the TODs, as this stages the fermentor is pressurized
with CO2 .The main reason for laagering (cold storage) are containing fermentation scavenger
air.

Yeast Propagation
Yeast propagation is a process in which buying small amount of yeast and multiplies them to
alarge amount in a long period of application. Hawassa brewery buys a small amount of yeastand
use by multiply them for eleven generations. Yeast propagation and storage plant consists of
closed vessels of different sizes, made of chrome nickel steel in which the yeast is multiplieduntil
there is sufficient to pitch the vessel or tank. Multiplication of yeasts occurs in multiplyingtanks
(propagator) of increasing sizes up to the size which makes it possible to pitch a cylindroconical
fermenter. Yeast storage tanks are used to store yeasts when they are harvested from
thefermenter. They stored by considering their viability, consistency and thickness. Yeasts
arestored at a pressure of 0.5 bars to avoid the eating of them because at this pressure they
cannotmove freely. The yeasts taken in the logarithmic phase offers many advantages for
fermentation.These advantages are rapid initial fermentation, shorter fermentation time, rapid
drop in PH,more rapid and more extensive diacetyl removal and a clear and more rounded beer.

2.4.6 Beer Filtration

Filtration is a separation process in which the yeast cells and other turbidity causing materials
still present in the beer are removed from the beer.

The purposes of filtration are:

 To remove all suspended non biological materials

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 To stabilize the beer further by preventing non biological haze

Filtered beer is qualified to be stable. That means there is no active process going on since all
conditioning has stopped when the yeast and other enzymes are removed in the process. In BGI,
Filtration is achieved by the use of a centrifuge(separator) and candle filter. The candle filter
contains 168 candles and its maximum working pressure is 6bar. Before the filtration process is
started The filter aids are prepared in a Kieselguhr tank and to precoat is done in candle filter. It
is prepared by using three types of filter aid; speed plus, Speed flow and super aid.
Preparation of Precoat

1st Precoat

25kg of speed plus is added with dearated water inside the dosing tank with a suspension volume
of 6L/kg (150 litre of water) and mixing uniformily with high speed agitator precoat is done.

2nd Precoat

40kg of super aid and 20kg of super aid is added each with the same suspension factor inside
kieselguhr dosing tank and then by mixing with slow speed agitator precoat is done. Here only
25 kg of kieselguhr is consumed and the rest will be used as abody feed.

Body feed

When 50 litre remains in the kieselguhr dosing tank body is prepared with super aid and speed
flow each 20kg with the same suspension factor. Beer at lantern Afterprecoat is done,thelagered
high gravity beer from TOD enters mechanical separation equipment called the centrifuge or
separator by passing through lantern(site glass). In separator, the yeast separates from the beer by
a high speed rotational movement(7300rpm) up to 10-15% yeast remained in the beer. The yeast
cells settle down as aresult of density difference and ejected at the bottom. This unit operation
eases the load of clarifying for the proceeding filtration process.Then the high gravity beer that
contains 10-15% of yeast is pumped to unfiltered buffer tank to optimize the process by dosing
silica gel solution in the line.

The purpose of dosing silica gel is:

Jimma University BGI Ethiopia

 To reduce haziness(turbidity) by binding haze formation proteins pholyphenol

 To prevent the reaction between proteins and pholyphenol

When the level of un filter buffer tank reaches 60-65% candle filter starts filtration. During
filtration the beer passes through thecake(precoat) on the candle due to pressure difference and
then leave at top of the filter by passing through the candle. The driving force for filtration is
always the pressure difference between the filter inlet and out let. The maximum working
pressure of candle filter is 6bar. After filtration, High gravity beer with 180p OG is blended with
dearated water to lower the original gravity 11.05 0p.

Figure 8 Fermentation and filtration process

2.4.6.1 Beer Blending

B.G.I Ethiopia follows high gravity brewing. High gravity beers are beers brewed at higher than
sales gravity. The beer produced is called high gravity beer (17oP). They do this because it is
bet-ter to make a high gravity beer and later on blend it with dearated water to produce low
gravity beer than producing low gravity beer by itself interm of capacity of brewing and supply
of beer. The high gravity beer is blended with dearated water to prevent the pickup of oxygen by
Jimma University BGI Ethiopia

the beer. The blending water is dearated because dissolved oxygen in process water causes the
beer to have an off flavor, converts the alcohol to aldehydes and creates instability all because
oxygen causes oxidation.

2.4.6.2 Beer Carbonation

Carbon dioxide is a very important constituent of beer. It imparts sparkle and `mouth feel' and

sharpness associated with its properties as an acid gas. The concentration of carbon dioxide in

beer for sale is carefully controlled to ensure that consumers of the beer can drink a consistent

product. Beers that lack carbon dioxide, particularly lager beers, are dull and lifeless and

to lack condition and be flat. The carbon dioxide is the gas produced naturally in primary and

secondary fermentation and that added to the beer by `carbonation'. The blended beer must be

dosed with carbon dioxide before entering the bright beer tanks. The amount of carbon dioxide

added artificially here differs based on whether the beer is going to be in a draft form or bottle

form. The only difference between a draft and a bottled beer is the carbon dioxide content in it.

In the case of a bottled beer the content of carbon dioxide is 6.2g/L and for the cases draft it is

5.4g/L. the mixture goes through the homogenization tubes to get thoroughly mixed. Also

additives like tetra hop, KMS and vitamin C are dosed to the beer before it enters the bright beer

tanks
Jimma University BGI Ethiopia

Figure 9 Blending and carbonation

2.4.6.3 Bright Beer Storage

The filtered beer is pumped to the pressure storage tank (bright beer tank) and stored for two or

three days in it. Bright beer tanks are buffer vessels between the filter and filler. They are

constructedas verticalstainless-steel tanks without internal fittings and the entire cellar is

cooled to 0 to 2oc in a jacketed system. The bright beer tanks are the last stations before filling.
There are no safety devices after them. All safety measures must therefore be built in to them.

These include:

1. The tanks must be thoroughly cleaned by a CIP system

2. The cleaning must be carefully controlled

3. The tanks must have a smooth internal surface (like surface roughness)

4. The tanks must be previously counter-pressured with CO2 ; there must not be the slightest

oxygen picks up.

Jimma University BGI Ethiopia

2.4.7 Beer Packaging

It is one of the important sections (part) in brewing process (beer production process) which uses
complex machine and plant to maintain high quality of beer and to increase the demand of cus-
tomer by excellent presentation of the product. In this section two types of packaging are takes
place;

 Bottled Beer

 Kegging (Drought Beer)

2.4.7.1 Bottling Section

There are series steps in the beer filling by bottle;

A. De Palletizing: -This is done by man power in which the palletized crate with empty bottle
that collected from customer is put on the roller conveyor for the next process.

B. Decammatic:-This is the machine used to separate empty bottles from the crate, empty bot-
tles are lifted from the crate by gripper head & set down at predetermine place. The grippers
head has packaging bells which are operate pneumatically (use air). In B.G.I Brewery factory,
this uncaser machine has six grippe head each of heads have 24 packing bells which can hold up
to 24 empty bottle at the same time. After separationempty bottles are transferred to bottle
washer through belt conveyor and crates to crate washer by roller conveyor.

C. Bottle Washer: - The aim of bottle washer is to remove all visible dirt from the inside &
outside of the bottle and to ensure that the bottle has beensterilized (i.e. all beer spoilage micro-
organisms must be removed & killed).

There are different steps occur in this process

Step 1.pre-washer use water just moisture the bottles.

Step 2. Soak Use 3000m3 hot water 75oC and 2.25M NaOH are used.

Step 3. Soak the same with process in step 2 but with different amount of NaOH (1.85M)

Step 4. Soak ad reins used small amount of water (1300m3) to reins and goes to dry section

D. Empty bottle inspection (EBI): -This machine is modern machine which separated or re-
moved the bottle before filling includes;
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 Bottles containing foreign bodies

 Bottles with pigment or adhesive residues or other contaminations
 Bottles with defects in the mouth region, such as notches, cracks
 Bottles containing residual caustic from the waste washer, etc.

E. Beer Filling: -From the BBT, the beer is transferred to the filling machines by a pump or by
the CO2 pressure in the tank. During filling process three stages are performed: -

 First evacuation by vacuum used to remove air

 Second evacuation by vacuum used to purging or flesh the bottle with CO2 (which is used to
prevent any contact between the beer and O2)

 Third filling the beer and remove CO2 by vent tube

F. Pasteurization: -For beer to have a long shelf life, it must be microbiologically stabilized. It
stays for 30-45 min at 63-65oC temperature. The main reason for pasteurization is sterilization
purpose.the beer that comes in BBT for kegging is first pasteurized, pasteurization is carried out
in a plate HX in which there are four sections.

1. Regeneration section
2. Heating section
3. Holding section
4. Cooling section

Beer is pumped to the regeneration section where it flows counter-current to hot water and is
therefore pre-heated.in the heating section it is brought up to pasteurization temperature(72 oc) by
passing counter –current to hot steam.it is then held for a pre-determined period(3sec) in the
holding tube. The beer then passes back to the regeneration section where it loses heat to the
incoming beer.it subsequently runs counter-current to cold glycol in the cooling section and
cooled to(-1-(-2.5)) o c. The temperature achieved for pasteurization is 72oc for 3 seconds. The
pasteurized beer is the beer for kegging is stored
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Figure 10Pasteurization

G. Labeling: -First the sealed (crowned) bottles are conveyed from the crown machine on a con-
veyor belt to the labeling machine. The labels are automatically coated with glue, applied to the
bottles of their body & neck and brushed on the bottles by brushes. In Hawassa brewery the label
paper contains volume of the beer, food grade of the beer, name of factory but it is not including
expiration and production date.

H. Full Bottle Inspector (FBI): -is a machine that contains a sensor (light dependent) which is
used to reject (select):-Under fill & Over fill bottles, Miss label bottles (either neck or body label
bottles) and Uncrown bottle.

I. Incammatic: -is pneumatically operated machine w/c is used for packing of full bottles in to
crate. This machine can hold up 144 bottles at the same time which put in to six crates.

J. Pallet (Palletization): -process is done manually by man power in which one pallet contains
50 crates and finally carried out by forklift car in to the storage house.
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Figure 11Bottling and Packaging Process

2.4.7.2 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 to 12.5 Kg/ 30 L or 10 to 15 Kg/50 L with a wall thickness of 1 to 2 mm.

At BGI, 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 72 0c 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
00c 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 four in number each having six heads. The heads are fitted on
the machines and the keg is fitted to the heads upside down. The keg used in BGI-brewery can
contain 30 litter having shelf life of one month but there are kegs that can contain up to 50 litter.
All kegs have a neck containing a threaded bush (Barnes neck) into which fits a keg valve fitting.
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This fitting is called the spear or extractor tube and through it the filling, emptying, cleaning and
automatic closing of the keg is achieved. Kegs have advantages over bottles. They allow the
partial dispense of the product and they operate as closed vessels with in-built leakage detection.
Kegs are returned containing excess gas pressure, which prevents contamination entering.

In BGI-Brewery cleaning, sterilizing and filling are carried out on one machine called a keg
racker. Empty kegs are delivered by truck and lifted by hand and put on to roller conveyer in
which the roller conveyer delivers to keg racker. There are 4 keg rackers in which cleaning,
sterilizing and filling are carried in 6 steps:

1. firsthead; - for rinsing the keg with hot water which comes from market

2. secondhead: -for hot water wash with ATR acid

3. Third head: -for rinsing the keg with hot water.

4. Fourth head: -Resting time, no cleaning

5. Fifth head: -for drying with steam and counter pressure with CO2

6. Sixth head: -for filling beer in to the keg from the buffer tank.

Table3 difference between draft and bottled beer

Draft Bottled beer

Pasteurized temperature 72℃ for 30 seconds 45-65℃ for one hour

Number of machinery and Small Large

space requirement

Time of expiration About one month About one year

End product in container short cylinder Bottle

CO2 %available 4.85-5.2 5.8-6.0

Additive Use vitamin c Use KMS

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2.4.7.3 CIP (CLEANING IN PLACE)

Cleaning and disinfecting of the brewery equipment at each stage of production is one of the
conditions necessary to obtain a beer with good biological stability and high quality. Chemicals
that used to clean equipments;

1- Caustic Soda (NaOH): -are cleaning agent which can removed organic compounds and to
de-stroy or kill all types of micro organisms

2- Acid (H3PO4): -used to remove inorganic matters or for neutralization. The main
objective of acid cleaning is to clean dirty materials which left from caustic cleaning in
tanks.

3- Disinfectant (Super Oxide): -are cleaning agents to clean the equipment beer line and
production machine, necessary disinfectants must be added such as peroxide chemical
filtered.

There are two types of CIP system.

Hot CIP: - In this CIP system hot water is used within the essential detergent chemicals
Equipments which need hot system are: -Yeast line - Yeast storage

- Treatment line

- Filter line

-Filling line -Beer line

-Bottling line

-Keg filter line

Cold CIP: - In this CIP system, cold water together with caustic and other related chemicals
are used Equipments which need cold CIP system

 Fermented tank

 Bright beer tank (BBT)

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2.4.8 Finished goods store (fgs):

After bottling the and kegging the store keepers take the product by listing their amount, the
loading and un loading is done by using fork lift cars. Then they distrubet to the market section.

Figure 12 Fished goods store

2.4.9 UTILITY SECTION

Under this section Boiler plant, Air compressor, Ammonia compressor, CO2 compressor, water

treatment plant and Refrigeration plant are present.

2.4.9.1 Raw water treatment plant

The source of water is from the well and municipal water. The water from the well is pumped

and stored in raw water tank. The capacity of this tanker is 170m3.The municipal water also

stored in row water tank. The operation of the motor in the ground is controlled by ultrasonic

sensors (mounted in raw water tanker) and water level sensor (under the ground). These the two

control circuits are connected in series and control the motor i.e. the motor stop its operation if

enough water is not available and the tanker is full.

From raw water tanker the water is pumped to sand filter tank so that the water passes through
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the layer of four sand filters and store in to filtered water tanker. The amount of water that has
going to be filtered in sand tanker is about 25m3/hr.

Filtered water is pumped to chlorinated water tank, for microbiological treatment and

Chlorinated water passes through the three carbon filter tank to remove the chlorine and then the
dechlorinated water passes through in gaff filter and then the process water is produced. The
process water is modified depending of the process.

2.4.9.2 Steam Boiler Plant

Steam boiler or simply a boiler is basically a closed vessel into which water is heated until the

water is converted into steam at required pressure. In Hawassa the core heat energy source of

The whole idea of heating system is to produce steam byevaporation of water under higher
pressure to increase the temperature content of the steam (160– 180) at 10 bars. The steam is
used for utilization of cleaning bottles, sterilization of beer,

cleaning beer line, for boiling or heating of malt in brew house. In this company, there are three

boilers in different capacity of steam production rate. They use fuel as raw material to produce

steam. The steam is condensed to 85oC after using in different sections and feed to the boiler.

This mechanism enables the company to reduce fuel consumption. If the level of recycled stem

is low fresh water is added by making it soft with chemical called resins.

2.4.9.3CO2 Compressor Plant

Carbon dioxide is collected through a permanently installed piping and valves system which

connects the top of each TOD with the CO2 collection main. We get CO2 and other gas in

Fermentation process. The amount of CO2 in this processes up to 99.9%.

First of all, the CO2 gas comes from fermentation inters in to foam trap. The CO2 get shower or
it showered by water to eliminate foam and other solid unwanted elements. WhenCO2, the
water moves down ward and gasCO2 moves to washer because gas have low density it go up and
gets in to washer. After it gets in washer CO2 gas washed by water again. The only difference
from foam trap and washer, the washer has different types of ceramic here. Ceramics helps to
avoid solid things that come from foam trap and also the water moves downward due to high
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density and the CO2 gas moves up and gets in to dryer. The CO2 gas has moisture when it outs
from washer, due to that reason it must be dried in the dryer because the moisture is not
necessary and affect our machineries. After CO2 out from dryer it is filtered. The filter is found
beyond the dryer. And CO2 sacked by compressor when it enters to the compressor its
temperature is 24degree centigrade. But after it outs from the compressor it gets 140℃. Then
itgets cooled by glycol. Then after it moves to molecular sieve and dry again. After that the CO2
gas moves in to "carbon active”. Generally, hear in carbon actives CO2 loses its odor. After this,
it Moves to" liquefier” and gas tanker CO2 moves by pipe and cold ammonia moves by shell.
This Process helps to solid CO2 gas. But other impurity gases cannot make powder and they
move out from atmosphere by valves. The ammonia have −30℃and above temperature after the
Conduction process it gets −21oc. This ammonia enters in to the 6 piston type compressor and
out by getting 72℃, and transfer to the condenser then it moves to floater (expansion valve) and
gets cools around -30℃ by evaporator liquefier and it recycle its process. Finally, the powder
CO2 used for different purposes by bottling in to cylinders. For the use in brewing and
packaging of beer, the liquid CO2 from the storage tanks must first to gaseous state heating the
liquid CO2 by heat exchangers.

2.4.9.4 Air Compressor Plant

Compressed air is used in the factory for cleaning in workshop, blowing of car tire, cleaning dust
of the machine, cleaning of floor and use for pneumatic system of Decrater and crater machine.
The machine which is use to compress air is called compressor. Air is compressed in two stages
first and second stages. Air is from atmosphere and filtered using air filter. This cleaned air
delivers to first stage and second stage. After each stage, compressed air cooled by fan. The body
of compressor is cooled by oil. There is also integrated dryer, moisture trap after each stay.

2.4.9.5 Ammonia Compressor Plant

Ammonia is compressed by six-stage compressor. Arrangement of the compressor is v type and

in each stage, there is reciprocated piston. The lubrication system is oil and this compressed
ammonia is cooled by glycol. Since oil and ammonia are mixed during lubrication so oil
separator is use to separate them. Finally, this compressed ammonia is use to cool glycol in
refrigeration
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2.4.9.6 Refrigeration Plant

In this plant there are three refrigerators. One cools pure water to 2 oc and the remaining two
cools glycol with some amount of water to -5 oc. Glycol is firstly cool by compressed ammonia
and these glycol cools the water. The reason of mixing water with glycol is to keep the water in
liquid state below 0oc. This glycol is circulated in the jackets of TODs to cool down beer to the
required temperature. The return glycol is again returned to the warm glycol tank and from this
again cools down to be reused again. This cold glycol also uses in changing gas state of CO2 in
to liquid state for storage. Also it used for cooling of water that used in wort cooling process.

2.4.9.7 WASTE WATER TREATMENT

After the brewery waste water has under gone physical and chemical treatment, it can be
biologically treated. Biological treatment of waste water can be either aerobic (with air/oxygen
supply) or anaerobic without oxygen. Aerobic systems have become a more attractive option
since biogas can be generated for energy use. Anaerobic treatment is characterized by biological
conversion of organic compounds by anaerobic microorganism in to biogas.

When we come to our (B.G.I) waste water treatment it is an aerobic system. And the process
starts by collecting waste waters that are removed from brew house and bottling house as a
whole.

 First the waste water from brew house is goes to brew house pump it whereas the waste
water from bottling house inserted to filling line pump pits. Both pump pits have a level
sensor which regulates the water percentage. The brew pump pit sensor automatically
starts when the level of water riches at 80% while the filling line pump pit starts at a
level of 60%.
 Then the waste that come from two pump pits gets a primary screen which screen out
large materials like plastics. After this the water entered in to influent pit which has three
pumps and six level sensors and within those an equipment called Deflator which
removes oil that is separated from water by decantation (density difference) system.

The water which is free from oil is pass in to static screen; this is screen which can trap materials
which has a size up to 0.5 mm and has a container which is a garbed out the trapped materials
then passed to equalization tank in this tank there are two additives thus are sodium hydroxide
Jimma University BGI Ethiopia

(NaOH) and CO2 in order to kill different germs and to regulate the pH of the water. This water
pH if not regulate it will pass to pH correction tank.; If the pH>6 we add HCL instead of CO2 to
lower the pH value then the water pass to Anaerobic Reactor, in which microorganism interact
and feed the unwanted substance. After a biomass interaction the water entered in to Re-aeration
tank which does mixing water well and works air sacking or spray beer odor to environment.
This tank is the last tank in which water is fully treated then mixed with the river. But the out
ward air collected from equalization tank, an aerobic reactor and pH correction tank is collected
and filtered in bio gas filter tank after filtration the clean biogas will burn by bio gas Torch.

2.4.10 Quality Control

2.4.10.1Quality Control Procedures Done in The Laboratory

In Hawassa B.G.I., two type’s laboratory procedures are employed, and these are:

1. Physio-chemical laboratory procedures, and

2. Microbiological laboratory procedures.

Physical-Chemical Laboratory Procedures:

To produce a good beer with a consistently high quality a number of parameters must be
continually monitored like;

1. Analysis of beer to determine extract and alcohol content, the final attenuation, PH….

2. Determination of diacetyl content.

3. Measurement of bitterness.

4. Measurements of dissolved oxygen content in the beer.

5. Determination of the colloidal stability of beer by a forcing test.

Some of the procedures done on mash, wort and finished beer are as follows;

A. Iodine Reaction of Mash:

1. Objective-the quantitative determination of starch in mash/wort using iodine solution.

2. Field of application-The method can be applied to all pale worts.

Jimma University BGI Ethiopia

3. Principle-To all products to be examined, a dilute iodine solution is added. A blue 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:

1. Objective -pH determination.

2. Field of application-the method is applicable for wort and beer.

3. 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.

C. Vicinal Di ketones (VDK):

1. Objective -determination of vicinal diketone content in beer.

2. Field of application-The method can be applied to all filtered beers. In un matured beers, the
precursors of vicinal dike tones are also measured.

3. Principle-The vicinal dike tones, diacetyl and pentane Dione are distilled from beer and then
combined with a-phenylenediamine to form derivatives of quinoxaline. The amount of these
compounds are measured by the absorbance at 335nm by a spectrophotometer against a blank
ofdistilled water.

D. Color:

1. Objective-Determination of the color of wort and beers using spectrophotometers.

2. Field of application-The method can be applied to all types of wort and beers.

3. 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.

Bitterness:

1. Objective -Determination of bitterness.

2. Field of application-wort and beer with bitterness content up to 70 BU (bitterness unit). The
method shows a blank value of 8 BU for wort and 2-3 BU for beer.
Jimma University BGI Ethiopia

3.Principle-The results are only valid if the beer doesn’t contain the following compounds;
nheptyl-4-hydroxy benzoate, saccharin, salicylic acid, ascorbic 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:

1. Objective -Determination of oxygen content.

2. Field of Application-Applied to all filtered beers, bright beers and beer in packaging.

3. Principle-getting the oxygen content from a properly working oximeter.

G.CO2:

1. Objective -Determination of CO2 content.

2. Field of Application-Applied to all fermented beers, filtered beers, bright beers and beer in
packaging.

3. Principle-getting theCO2 content from a properly working altimeter

Haze (Turbidity):

1. Objective -Determination of haze stability of beer.

2. Field of application- Applied to all filtered beers, bright beers and beer in packaging.

3. Principle- sample of degassed beer is inserted in turbidity meter equipment and the
corresponding value is read from it at two different angles.

I. Foam Stability:

1. Objective -Determination of the foam stability of beer.

2. Field of application- Applied to bright beers and beer in packaging.

3. 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 I recorded.

J. Polyphenol Content:

1. Objective-The determination of total polyphenols in beer by spectrophotometer.

2. Field of application-The method can be applied to all beers.

Jimma University BGI Ethiopia

3. 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.

K. Foreign Gases:

1. Objective - the determination of foreign gases in bottled beer.

2. Field of application-The method can be applied to all beers.

3. Principle-Transferring all the dissolved gas in beer in to the Zham absorption burette and
reading the volume of the gas.

L. Total Hardness of Water:

1. Objective – determination of total hardness.

2.Field of application- treated and untreated

3. 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.

M. Calcium and Magnesium Content:

1. Objective - the determination of Calcium and magnesium.

2. Field of application-The method can be applied to water, wort and beer.

3. Principle- Calcium and magnesium are titrated by EDTA using 2 indicators, hence them

Concentration identified analytically. Other very important parameters in wort and beer quality

Such as:

1. Original Gravity

2. Specific Gravity
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3. Real Extract

4. Apparent Extract

5. Apparent degree of fermentation

6. Alcoholic Content V /V and W/W

Are all done by an equipment called Alcohlizer plus. This high-tech equipment first takes
asample 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.

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.

Some of the procedures done in the microbiological laboratory are:

1.Wort Bacteria:

1. Objective- estimating the number of wort bacteria.

Jimma University BGI Ethiopia

2. Field of Application-the method is applicable to pitching yeast and fermenting beer.

3. Principle-plating with an inhibitor for yeast.

2.Lactic Acid Bacteria:

1. Objective -specific detection of lactobacillus, pediococus and brettanomyces.

2. Field of Application-the method is applicable to filtered beer, packaged beer, and rinse water.

3. Principle-membrane filtration followed by anaerobic incubation on a selective medium

Containing actidione.

C. Yeast Count and Stains:

1. Objective: Determination of yeast cell concentration (population).

2. Field of application-The method is applicable to pitching yeast and fermenting beer.

3.Principle-microscopic count by a simple light microscope using a slide called haemo

cytometer.
Jimma University BGI Ethiopia

2.5 work tasks that have been executing

I am trying to work with operators in order to understand all beer production process and in order
to avoid errors. I was performing all process in fabrication department like milling of malt,
mashing, cooking, boiling and cooling of wort in brew house and fermentation and filtration in
fermentor houses and also packaging process in packaging house.

material and energy balance

material balance on the brew house

1.Maltintake

Air

INTAKE BIN

Malt in Malt out

Impurities

Given: Required: Solution:

Malt= 6100 kg
Malt out=? Input = output
Impurities= 0.4-1.4 kg (it is theoretically) Malt + air = impurities + malt out
Air= 29 kg (m=n*M,1mol*29 kg/mol) Malt out= 6100 kg + 29 kg – 0.5 kg
Malt out=6128.5 kg

2. Milling
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CLASSIC
Malt HAMMER MILL Grist

Impurities

Given Required Solution

Malt in=6128.5 Mass of grist=? Input= output
Impurities=2-7 kg (set from long time of working of the operators) Malt = grist + Impurities
Grist =6128.5kg-7 kg

3.Premasher

Hot water

PREMASHER
Grist Mash

Given Required
Grist = 6121.5 kg Mass of mash =?
Water = 150 hl (m= V * ₰)
Mass of water = density*volume =15000L *1000kg/m 3 *1m3/1000L
MH2O = 15000 Kg

Solution
From General Material Balance:
Input = output
Grist + Water = Mash
Mash = 6121.5 kg + 15000kg Mash =21121.5 kg

4. Mash tun
Jimma University BGI Ethiopia

Additives

MASH TUN
Mash in Mash out

Given: Required:
Mash = 21121.5 kg mash out =?
HCl = 0.5L (0.5 kg)
CaCl2 = 14 Kg

Hitampase = 0.5 Kg
Biogulucanase = 1 Kg
Solution

Mash out = Mash + HCl +CaCl 2 + Hitampase + Bioglucanse

= (21121.5 + 0.5 +14 + 0.5 + 1) Kg
Mash out = 21137.5 kg of wort

5. Mash filter
Jimma University BGI Ethiopia

Given: Required:
Mash = 21137.5 kg (from mash tun) Mass of spent grain =?
V Sparging Water = 150 hl

Vwort= 280hl (from mash filter, theoretical)

Solution:
Input = output
Mass of Mash + Mass of sparging water = Mass of extracted wort + Mass of spent grain
Mass of sparging water = V Sparging Water * ₰water
=15000 L * 1000 kg/m3 * 1 m3/1000 L = 15000 kg
Mass of extracted wort = Vwort * ₰wort
Specific gravity = ₰wort ₰water
₰wort = Specific gravity * ₰water
Specific Gravity = (Mass percent * 0.004) + 1
= (18.02 * 0.004) + 1= 1.07208
₰wort = 1.07208 * 1000 kg/m3
₰wort = 1072.08 kg/ m3
Mass of extracted wort = 28000 L * 1072.08 kg/ m3 * 1 m3/ 1000 L
Mass of extracted wort = 30018.24 kg
 Now to find the pure extracted wort we have to consider the 1st and 2nd wort.

N.B: Wort is the expected wort volume from mash filter Vwort (Real wort/theoretical wort)
Therefore:
Extract wort = Volume of 1ST Wort + Volume of SpargingWort
but: Volume of SpargingWort= Volume of sparging water +Volume of 2nd wort

Extracted wort = Volume of 1ST Wort + Volume of sparging water + Volume of 2nd wort
V 1st wort + V 2nd wort = Extracted wort – sparging water
V 1st wort + V 2nd wort =30018.24Kg - 15000 Kg
Pure wort extracted = 15018.24 kg
Now we can to find mass of spent grain:
Input = Output
Jimma University BGI Ethiopia

Mash + sparging water = Extracted wort + spent grain

Spent Grain = Mash out + sparging water – Extracted Wort
Spent Grain = 21137.5Kg + 15000Kg – 30018.24 kg = 6119.26 kg

2.6 Procedures that havebeen used while performing work tasks

To accomplish the tasks and others, I used methods and procedures I already had. Firstly, I
applied the courses that I earned theoretically at a campus it was a little bit confusing at first.
But, soon enough I managed to settle those ambiguities as practiced more and more. And
secondly, politely by asking any vaguely things may company advisers and technicians they
were answerable and gladly describe the ambiguities briefly.

2.6.1 Performance at the company

As I considered before, I see some things with in these four months. Based on this becoming
practically rich is not negotiable.

2.7. Challenges faced when performing tasks

There were some challenges I have been facing in the internship period. Most of these challenges
were from the company itself and some of them are from outside. I try to illustrate these
challenges in the following way.

2.7.1 From the company:

Lack of employed chemical engineers and library to get familiar with particular work, Shortage
of safety wears like eye glass and hand glove to protect ourselves from dust and chemical, The
company employers do not like sharing of the company service like paper, printer, copy machine
and transport service. There are no enough computer accesses to acquire data about the company.

2.7.2 From outside:

Due to lack of intercommunication between the factory and university industry linkage (UIL).
Jimma University BGI Ethiopia

2.8. The taken measures (alternative solution)

I try to consider myself as one of the responsible workers in the company and accept all work
ethics and rule of the factory.

1. Always try to get solution for each problem

2. At work try to approach each worker positively to make them open to share their
knowledge and skills.
3. try to read manuals and ask the section head in each department.

4. Act on solving problems and work flow practically

5. Practice how drawing in takes place and draw in on different unit operations by hand.

6. Practice how to measure quality of the products.

Jimma University BGI Ethiopia

CHAPTER THREE

Over All Benefits Gained from Internship

3.1. Introduction
Life is a result of experience and practices though a communication. There is a saying that says
practice makes perfect and this perhaps can be applied to internship session. For it is flashing
light to understandings, concerning to chemical engineering aspects that I should know the
theoretical education should be supported by practice. Practice makes the student confidential
with his/her knowledge enabling him/her compare what he/she learnt and real work in the real
world. In practice the gap between the theoretical part of (thing) and the practical one will be
minimized. I can say I have gained a lot of knowledge about work because of practice in BGI
Ethiopia.

3.2 In Terms of Improving Practical Skills

From this internship program, I have got a good chance to improve practical skill highly. I
developed skill by participating myself into different part as Ihad learned theoretically in
department course.

3.3 In Terms of Upgrading Theoretical Knowledge

In terms of upgrading my theoretical knowledge I gained detail and clear way of the application
of equipment’s, machines, chemicals and instruments for the production of beer. I can also
Jimma University BGI Ethiopia

identify the type of processes they used and the type of chemicals added in each type of
processes. Also gained a permanent knowledge for the next courses to apply the application of
the previous courses to do projects and other needed works. And also how can order spare part
list using their item code by referring manual and using inventory list on the computer for each
part according to maintenance plan.

3.4 In Terms of Improving Interpersonal Communication Skills

 Problem solving
 Motivation
 Negotiation and conflict control-to reach an agreement
 Politeness
 Being openness
 Self – confidence
 Honesty and
 Personal right and obligation.

3.5 In Terms of Improving Team Playing Skills

I developed very interesting behavior that is never happened before. Improved: -

 How can be patient?

 Giving respect for others
 How can make Close relation with the community of our environment
 Develop listening skill
 Problem solving

3.6 In Terms of Improving Leadership Skills

 How Can Establishing Direction as a Leader of a Team
 Aligning People
 Motivating and Inspiring
 Focus On Team and Overall Goals
 Communication with Each People Under My Control
Jimma University BGI Ethiopia

3.7 In Terms of Understanding about Work Ethic Related Issues

Work Ethics Is a Set of Values Based On Hard Work and Diligence. It Is Also a Belief in The
Moral Benefit of Work and Its Ability to Enhance Character. From This Program I
developedHow to Improve Work Related Issues Before I Meet Such an Organization or When I
Contact MYSelf in Such Social Network Environment, Some of Them Includes Punctuality,
Attendance, Conducting Quality Work, Respect for Fellow Workers, Honesty, And Showing
Initiative. A Work Ethic Includes Being Reliable, Having Initiative, Or Pursuing New Skills.
And Also, I Gained a Good Work Ethics for Better Positions, More Responsibility and
Ultimately Promotion (Placed in Positions of a Greater Responsibility). These All Are Teaching
me a Lot for The Future Work Life of my Self. Characteristics That I Gained Generally Includes
Being:

1. Strong Work Ethics-Learning, The Most Efficient Way to Complete Tasks and Finding Ways
to Save Time While Completing Daily Assignments.

2. Dependable and Responsible, Come On Time, Responsible for The Actions.

3. Adaptability-Adapting to The Personality, Work Habits of Co- Workers and Supervisors’.

Being Open to Change and Improvements to Complete Work in More Efficient

4. Possessing A Positive Attitude- To Get the Job Done in A Reasonable Period of Time
Motivates Others to Do the Same Within Challenges.

5. Honesty and Integrity- Is The Responsibility of Each Person to Use Their Own Individual
Sense of Moral and Ethical Behavior When Working Within the Scope of Their Job

3.8 In Terms of Entrepreneurship Skills

As Entrepreneurship Is the Process of Creating Something New with Value by Devoting the
Necessary Time and Effort, Assuming The Necessary Risks, And Expecting Rewards for
Undertaking, From This Internship Program I Gained Different Ideas to:

Make myself-free from the limit of standardized pay for standardized work (profit), freedom
from supervision and rules of bureaucratic organizations (independence), freedom from routine,
boring and unchallenging jobs (satisfying way) and it makes me interested in:

 High need for achievement

Jimma University BGI Ethiopia

 Willingness to take risks

 A need to exercise leadership
 Self-confidence and
 Creativity

PART- TWO

CHAPTER FOUR

PROJECTCARRIED OUT

4.1 The main problem of the company

The main technical problem that faced during internship period was created by worker and
machines itself. Some problem of company is listed below.
Jimma University BGI Ethiopia

 Local malt storage in the company does not follow the controlling parameters such as:
temperature and humidity.
 By product usage problem such as: spent grain and biogas.
 The company imports different materials from Western Europe and it costs a lot for long
journey transportation.
 Under fill problem in bottling section and breaking of glass bottle due to beer filler
machine and sensor problem respectively.
 Transportation of imported malt from silo to milling section makes use of bucket
conveyer with high expenditure of energy.

4.2 PRODUCTION OF LACTIC ACID FROM BREW SPENT GRAIN

4.2.1 INTRODUTION
Brewer's spent grains (BSG) is the solid residue remaining after mashing and lautering,
consisting primarily of grain husks and other residual compounds not converted to fermentable
sugars by the mashing process. Brewer's spent grain(BSG) is the most abundant brewing by-
product, corresponding to about 85% of total by-products generated. Traditionally this material
has been landfilled or sold as animal feed (mostly for ruminants that can cope with the high fibre
content). However, BSG is difficult to store because of the rapid deterioration owing to
microbial activity and, therefore, it is not always suitable for food applications. In addition, the
environmental implications of increased methane emission owing to this hard to digest material
are gaining attention.

Lactic acid, commonly used in food, chemical and pharmaceutical industries, has recently
received much attention for the production of biodegradable plastics. Poly lactic acid (PLA) is
biodegradable aliphatic polyester produced from renewable sources, which, due to its excellent
physical and chemical properties and environment compatibility, considered the best candidate
to replace on the market petroleum-based plastics. It has a wide range of applications ranging
from medical devices, such as suture treads and scaffolds, to commodity products like bottles
and films for food packaging.

An optically pure L(+)- or D(-)-lactic acid can be obtained by microbial fermentation when the
appropriate microorganism is selected. Biotechnological processes for the production of lactic
Jimma University BGI Ethiopia

acid usually include lactic acid fermentation and product recovery and/or purification. There
have been numerous investigations on the development of biotechnological processes for lactic
acid production, with the ultimate objectives to enable the process to be more efficient and
economical. Biological production of lactic acid has attracted a great deal of interest due to its
potential uses in many industries, and the production of polylactide polymer. Although the
biological production of lactic acid has some advantages over chemical synthesis, it still requires
the cheaper substrates for industrial feasibility.

Thus lactic acid production become critical to our country since Ethiopia is following and will
follow green economy strategies.

4.2.2Problem Statement

Now a day’s, the numbers of brewery industries are increasing in Ethiopia and they generate a
high amount of barley spent grain. This by-product is mainly used as a low value cattle feed or
simply deposited as a waste into land fill. Beside this, Barley spent grain remains from animal
feed also creates bad odor on the environment which in turn affects health of people who live
around the area, so that Conversion of such waste into lactic acid helps to reduce environmental
pollution and energy problem of developing countries, like Ethiopia.

It is also used as a starting material for manufacture of biodegradable poly-lactate polymers. Due
to its numerous applications, lactic acid production has a global market in excess of 100,000 to
150,000 tons per year, and an annual 15% growth rate of this market is predicted due to the
possibility of making biodegradable plastics. With this increased demand comes a greater
interest in finding alternative methods to produce lactic acid at the lowest cost possible.

4.3 Objective of the project

4.3.1General objective

The general objective of this project is lactic acid production from brewery spent grain.

4.3.2 Specific objectives

 synthesis of Lactic acid from brewer's spent grain via fermentation using micro
organisms
Jimma University BGI Ethiopia

 To show possibility of lactic acid production from brew spent grain by cheap local
available material
 To describe material and energy balance on unit operation.

4.4 Significance of the study

The purpose of this project is to make sustainability in case of supply and cost, and to
establish a method to quantify voluntary reduction in environment pollution resulting from
spent grain. In addition the project achieves

 Inorder to conduct a research and make it useful.

 Continuing of healthful living without injury

 Safety also deals with the improvements in working condition for better health

 Getting production with the cheapest cost.

4.5 LiteratureReview
Lactic acid was the first organic acid to be commercially produced by fermentation, with
production beginning in 1881. It is present in many foods both naturally or as a product of
microbial fermentation. It is also a principal metabolic intermediate in most living organisms
from anaerobic prokaryotes to humans. In 1839, Fremy performed lactic acid fermentation of
several carbohydrates, such as sugar, milk sugar, mannite, starch and dextrin. A discovery that
was then confirmed by Gay- Lussac, in 1840, Louradour prepared lactic acid by fermentation of
whey and converted it into iron lactate by dissolution of metallic iron in it. Other fermentation
experiments were performed by many different scientists to produce lactic acid from cane sugar
beyond 1847(Pagana, et al, 2014). Blondeau discovered lactic acid as a fermentation product in
1847. Originally, the lactic acid of fermentation and that found in muscle tissue were regarded as
identical. Liebig, who in 1947 re-examined meat extract, suspected that the two acids might not
be identical. He asked Engelhardt to carry out an examination of the salts of the two acids.
Engelhardt confirmed Liebig’s thought that the contents of water of crystallization and the
solubility of the salts of the two lactic acids differed and thus the acids were
different(Kotzamanidis, et al, 2002). Welceneus, in 1873, proved they have the same structure,
Jimma University BGI Ethiopia

but different physical properties. It was also investigated by Pasteur as one of this first
microbiological yeast cultures of distilleries, it was not until the year 1877 that lactic acid
bacteria were isolated in pure cultures when Lister isolated Streptococcus lactis. During this
same period, Delbruck was endeavoring to find out the most favorable temperature for lactic acid
fermentation in distilleries. He concluded that relatively high temperature favored high yields of
lactic acid(Santos et al, 2013).

The biotechnological production of lactic acid from cheap raw materials is necessary. This is
because polymer producers and other industrial users usually require large quantities of lactic
acid at a relatively low cost. Raw materials for lactic acid production should have the following
characteristics: cheap, low levels of contaminants, rapid production rate, high yield, little amount
of by-product formation, ability to be fermented with some pre-treatment, and year-round
availability(Laopaiboon et al., 2009). However, this is still economically unfavorable because the
refined carbohydrates are too expensive that they eventually result in higher production costs.
Therefore, there are attempts to select cheap raw materials for the economical lactic acid
production. Cheap raw materials, such as wheat starch, cellulosic materials, whey, and molasses,
have been used for lactic acid production. Among these, starch and cellulosic materials are
currently receiving a great deal of attention, because they are cheap, abundant, and renewable.
Consequently, inexpensive starch, starch derivatives or starch containing waste materials as
substrate would offer great advantages when combine with minimal preprocessing and
supplementation( Wee et al., 2006).
Jimma University BGI Ethiopia

Spent grains are resulted from mashing process and obtained after rendering the malt and cereal
grain content soluble in water. After extraction, the spent grains and wort (water with extracted
matter) are called mash and need to be separated. The separated, brewers’ spent grain (BSG)
amount consists about 85% of the total byproducts(Oladeji, 2016). Brewers’ spent grain (BSG) is
a readily available, high volume low cost byproduct of brewing and is a potentially valuable
resource for industrial exploitation. Although BSG is the main byproduct of the brewing process,
it has received little attention as a marketable commodity, and its disposal is often an
environmental problem(Anamaria et al., 2017).

Therefore intention behind my project to produce lactic acid from spent grain and to reduce
environmentalpollutionbecause there is a rapid growth of brewery industries in Ethiopia. There
are about eleven breweries in full function and production. There are also some breweries being
expanded and expected to be completed for the next few years. In Ethiopia around 263,736 kg
barley spent grain is generated daily. The spent grain from Ethiopian breweries, now a days is
only used for animal feed.

4.6 Methodology
4.6.1 Materials and Chemicals
 Materials

 Fermenter
 shaker
 Oven
 flask
 Distillation column
 Treated spent grain
 Brew spent grain
 millers
 thermometer
 PH. meter

 Chemicals
Jimma University BGI Ethiopia

 Sodium Hydroxide (NaOH)

 Sulfuric acid (H2SO4)
 penophatalin
 Yeast extract

4.6.2Main unit operation used in production of lactic acid from spent grain

4.6.2.1 Preparation of Spent Brewery Grains (BSG)

The main aim of the project was lactic acid production from brewery spent grain
usingmicroorganisms. First the raw material was obtained from BGI brewery Ethiopia located in
HAWASSA. It was successively wash with distilled water to remove impurities, and then dried
at drier. Afterward it was treated with sodium hydroxide solution at room temperature to
enhance its metal sorption capacity. The excess of alkaline solution was removed by washing
spent grains with distilled water until it was completely free from the base in successive
washings. This material was designated as TSG (Treated Spent Grains). Then TSG was dry in an
oven. The dried biomass was grind and sieve and the particles having sizes of 250-500 p.m. was
used in the tests and stored at less than 4°C refrigerator.

4.6.2.2Acid Hydrolysis

Diluted acids transform starch into glucose. Sulfuric acid is prepared and added to the non-
soluble component (BSG). The BSG was then hydrolyzed in the autoclave.After hydrolysis,
the solid part was separated from the liquid by vacuum filtration unit toremove the non-
fermentable component. The filtered hydrolyzate was neutralized withNaOH until the pH
became in a range of 5-5.5.

4.6.2.3 Culture media preparation

The lactic acid bacteria belong to two main groups, the homofermentors and the
heterofermentorsHomofermentative produces mainly lactic acid whilst heterofermentative
produces lactic acid plus appreciable amount of ethanol, acetate, and carbon dioxide,
respectively.The lactic acid bacteria are also divided into three groups based on fermentation
patterns: Homofermentative produces more than 85% lactic acid from glucose .One mole of
glucose can be converted to two moles of lactic acid, generating a net of 2 ATPs per mole of
glucose metabolized.
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Glycolysis
Glucose ------------------------------► Pyruvate

NADH NAD+

2 Pyruvate * 2 Lactic acid

Lactate dehydrogenase

Heterofermentative produces only 50% lactic acid and considerable amounts of ethanol, acetic
acid and carbon dioxide, one mole of glucose converted to one mole of lactic acid, one mole of
ethanol, and one mole of CO2. One mole of ATP is generated per mole of glucose, resulting in
less growth per mole of glucose metabolized. Because of the low energy yields, lactic acid
bacteria often grow more slowly than microbes capable of respiration, and produce smaller
colonies of 2-3 mm.

Acetaldehyde + NADH + H+________________^ Ethanol + NAD+

C 6HI206 _________________^ CH3CHOHCOOH + C2H5OH + C0 2

Glucose Lactic Acid Ethanol Carbon dioxide

Less known heterofermentative species which produce DL-lactic acid, acetic acid and carbon
dioxide. The ability of lactobacilli to convert lactose to lactic acid is employed in the successful
treatment of lactose intolerance. People suffering from this condition cannot metabolize lactose
due to lack or dysfunction of the essential enzyme systems. Lactic acid, by lowering the pH of
the intestinal environment to 4 to 5, inhibits the growth of putrefactive organisms and E. coli,
which require a higher optimum pH of 6 to 7. They are differentiated from other organisms by
their ability to ferment hexoses to lactic acid.The lactic acid bacteria have limited biosynthetic
ability, requiring preformed amino acids, B vitamins, purines, pyrimidines, and typically a sugar
as energy source. A rich medium is usually employed when cultivating LAB. These multiple
requirements restrict their habitats to areas where the required compounds are abundant (animals,
plants, and other multicellular organisms). LAB can grow at temperatures from 5-45 °C, and not
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surprisingly are tolerant to acidic conditions. Most strains are able to grow at pH 6.The aim of
this step is to culture the microorganism that is used for fermentation. Before conducting the
fermentation, the media for the preparation ofmicroorganism must prepare. toremove the
microorganisms which could share the glucose concentration prepared for lactic acid production,
sterilization carried out in the autoclave.

4.6.2.4 Fermentation

Fermentation is defined as an energy yielding process whereby organic molecules serve as both
electron donors and electron acceptors. The molecule being metabolized does not have all its
potential energy extracted from it. Hence, lactic acid bacteria are widely used as a low cost
method for food preservation by fermentation and generally no or little heat is required during
the fermentation. In fermentation, pyruvic acid molecules are turned into waste product and a
little bit of energy (only two ATP molecules per molecule of glucose is produced by the homo
fermentative pathway through the Embden-Meyerhof pathway. Yeast extract clearly exhibits the
most significant effect on lactic acid production, especially at the beginning of growth, with the
lactic acid concentration increasing nearly linearly with an increase in yeast extract level. The
importance of yeast extract at the early stages of fermentation was probably caused by the amino
acids and vitamins that are crucial for growth. However, if the medium contained a sufficient
quantity of yeast extract from brewing as a source of nitrogen and growth factors, the amount of
commercial yeast extract could be reduced or even replaced without a decrease in lactic acid
production.Prior to performing the fermentation, the samples were conditioned to a temperature
of 37°C. All the fermentation experiments were carried out at this temperature. The pH was
checked before adding the culture media and it was maintained by usingNaOH. The pH (5.0-
5.5) was optimum for themicroorganismculture.

4.6.2.5 Lactic acid recovery

The fermented liquor obtained after the above fermentation contains lactic acid
together with various impurities such as the un-reacted raw materials, cells and
culture media-derived saccharides. The samples were centrifuged and filtered
through paper filter. Then fermented broth was added to the conical flask and drops
of Phenolphthalein indicator is added. Sodium hydroxide is filled the burette.
Start the titration until the solution retains a very slight pink tinge and record the
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volume of sodium hydroxide used. The percentage of lactic acid in the sample is:

% lactic acid = (ml of NaOH used) (concNaOH) ( equivalent weight of lactic acid)

Weight of Sample

Figure lactic acid isomers

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Flow Diagram of Lactic acid production

4.7 Material and ENERGY Balance

4.7.1 Material Balance

1 Balance on dryer
Mass of spent grain(Msg) in wet form is 200gm and mass of dry spent grain(Mdsg) is
75gm then

Msg Dryer Mdsg

Then to calculate moisture contents (MC)

MC=200gm-75gm=125gm of water contents

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2 Balance on miller

Given Mdsg Miller Mp

Mass of powder (Mp) from the measurement is 73gm

Where Ml=mass lost Ml

Ml=Mdsg-Mp=75-73=2g of lost through the process

3 Balance on hydrolyser

Assume water needs to hydrolysis the spent grain is 650ml or 650g Mw

where

Mw=mass of water, Ms=mass of solution Mp Hydrolyser Ms

MS=Mp+Mw=650+73=723 gm of solution needed

4 Balance filter

Ms=Mpd+Mh then Mh=Ms-Mpd Mpd (580gm)

Mh=723-580=143gm of husk release Ms Filter Mh

Where
Mpd=mass of product

Mh=mass of husk

Ms of solution

5 Balance on heaters

During this process to heat the solution to get 375gm or 375ml of a concentrated solution and
take mass of H2SO4 is 0.7gm

Mv=Mpd+MH2SO4-Mc Mc

Mv=580+0.7-375=205gm of water vapor Mpd Heaters Mv

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Where

Mv=mass of water vapor

Mc=mass of concentrated solution MH2SO4

6 Balance on fermenter

On fermentation process 5gm of yeast and 0.05gm of NaoH became added

Mfd= Mc+My+MNaoH=375+0.05+5=380.05gm

Where My

Mfd=mass of fermented product

Mc=mass of concentrated product Mc Fermente Mfd

r
My=mass of yeast

MNa7
Balance on filtration

During filtration process pure liquid or cellulose in quantity is 280gm

Mdcell=Mfd-Mpl=380.05-280Mdcell

=100.05gm of dead cell removeMfd Mpl

Filtration
Where

Mdcell=mass of dead cell

Mpl=mass of pure liquid

8 Balance on distillation process

In distillation process mass of pure ethanol is 70l or 70gm then

Mpw=Mpl-Em

280-70=210 litter of ethanol can be obtained through separation process

Distillation
Mpl Em
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Water

4.7.2 Energy Balance

1 Energy balance on dryer

Heat supply to the dryer (Q)=Mdsg*Cp(Tout-Tin)

Dryer

T=378Specific heat capacity of spent grain is 2.25kj/kgk T=298℃

Q=Mdsg*Cp(Tout-Tin) Msg=200g
Mdsg=75gsss

Q=0.075*2.25*(378-298)

Q=13.5KJ is release during process

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CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 Conclusion

Beer is an alcoholic beverage obtained from the fermentation of extracted wort that is obtained
from starchy raw materials which is barley in the form of malt. Four raw materials namely
barley, hops, water and yeast are required for the production of beer. The quality of the raw
materials has a decisive influence on the quality of the final product. The soluble compound such
as amino acids, fermentable sugar and small peptides are dissolved in water resulting in liquid
known as wort. By the fermentation process the wort is then transformed into beer with the
addition of yeast. In BGI yeast is originally propagated and recovered after fermentation. Bottom
fermented yeast is used in this brewery; the fermentation is slow at low temperature and settles to
bottom of the tank at the end of fermentation. At the end, filtration is commenced. This process
is a separation process in which the yeast cell and other turbidity causing materials still present in
the beer are removed from the beer. Substance which would cause turbidity in the next course of
weeks or months are also removed. Once the desired quality of the beer is attained in the bright
beer tank, the beer will finally be filled in the bottle and keg. As easy as it may sound the actual
production is much more time consuming and need to be done with care.
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5.2 Recommendation

Recovery spent grain to use it as a raw material for other production

Malt transportation

Transportation from silo to milling section makes use of bucket conveyer with high expenditure
of energy as it moves the malt a long distance. I recommend that the silo must not be too far from
the milling section. Also the way of local grain storage in the company doesn’t follow controlling
parameters such as temperature, humidity so as a food engineer I recommend the company to use
appropriate post-harvest handling techniques.

Bottling section

At B.G.I in bottling section due to the beer filler machine and the breaking of glass bottle by the
EBI and FBI sensor the Company lose greater than 25 million birr per year. So my
recommendation is for the beer filler machine the operator should focus and controlling the
optimum amount of CO2 which added to the empty bottles must be adjusted. Again for both two
sensors, in order to protect the breaking of glass bottle we can add some smoother or softener
materials in to the conveyer.
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References
[1]Boiler, Compressor, Cooling System and Other different manuals of BGI Hawassa, Brewing
and Malting Technology 4th edition byW. Kun

[2]. Brewing Science and practice by Dennis E. Briggs, Chris A. Boulton, Peter A. Brookes.4.
Food Chemistry4th revised and extended ed. By H.-D. Belitz · W. Grosch · P. Schieberle.

[3].Hand book of Factory visit BGI Hawassa

[4]. Handbook of Hawassa brewery the 29th February 2003G.C.

[5]. Hand out of Maintenance management by Freselam and Thomas BDU IOT, 2004 E.C.
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