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We offer simple & effective Brewery Plants that show a right mix of milling, controlled fermentation and automation. They help produce the highest quality beers with little investment. Our Breweries have excellent brewing capacity and innovative brewing technology which is safer for environment. They cover process like Milling, Mashing, Wort Boiling, Fermentation, etc. We undertake engineering, manufacturing, fabrication & supply of Brewery process plant.
Different kinds of malt are passed through mill, where they are ground into grist. Then, the grist is carried by a conveyor into the grist-case, set for mashing the next day.
Mixed with hot water or liquor, the grist form a mash in the Mash Tun. Natural enzymes of the malt break down its starch into sugars, which dissolve in surrounding liquor so as to make sweet wort. And this extract run off from the Mash Tun into boiling kettles.
WORT BOILING :
Boiled vigorously, the wort in the kettles is heated up to the boiling point. Hops are added to provide bitterness to the final beer.
During the process of boiling, a large amount of tannin and protein is precipitated, this along with the spent hops has to be separated from the now bitter wort bulk. This task is performed in a whirlpool separator in which a vortex of wort is developed, enabling solids to settle out. At this stage, aroma hops are added.
FERMENTATION :Cooled wort is move into the Fermenting Vessel (FV) at a temperature between 18 to 20°C, depending upon the time of the year. Yeast is included at this point and the fermentation begins. The yeast breaks down the sugars, which was extracted from the malt so as to form CO2 and alcohol. The yeast obtains energy during fermentation, and this allows it to multiply itself some four, or more times.
After a 7 days period the beer is ready in FV to rack into cask, or transferred to tanker then sent to our bottlers, Frederic Robinson of Stockport.
CASK RACKING :
The casks and racking plant are thoroughly sterilized. Additional finings are added to the casks, and racking machine is used to fill the beer directly from the FV. The casks are sealed with a shive into the bung hole, and stored at 10 to 15°C for a 5 days minimum period, so as to allow the secondary fermentation, which is performed by a small amount of yeast still in suspension.
The beer is ready to be sent to supermarket, which leaves the brewery in tanker directly from the vessels of fermentation, ending up in a shrink wrapped tray of labeled bottles.
COLD CONDITIONING :
Pumped from the tanker via a chiller, which brings the beer temperature down to 0°, before the beer goes into cold conditioning tank. The beer is kept at this temperature for minimum 10 days, and during this time more of the tannin and protein, referred to the stage of Wort Boiling, precipitates out of the solution. This is a main part of the process, as the shelf-life of the final beer bottle depends on the success of the process of cold conditioning.
The beer is go through a filter that eliminates all the chill haze formed during cold conditioning, as well as any other yeast particles, which may be present. The bright, clear and stable beer is then passed into the Bright Beer Tank (BBT).
BRIGHT BEER TANK :
Different physical parameters of the beer are tested and adjustments are made prior to bottling, in the BBT.
Pumped from the BBT to the filling machine, the beer is filled into bottles that have been sterile-water rinsed and electronically examined for any damage sign or foreign material. As the bottle is filled it is sealed with crown-cork and move to the pasteurizer.
On the go to the pasteurizer, the bottles are checked electronically in order to ensure that each bottle is filled to the correct height and has a crown. Through water jets the bottles are carried along a moving bed, in the pasteurizer. Here the temperature slowly raise to 60°C, and maintained for 20 minutes. Then the temperature slowly cool down again. This task effectively sterilizes everything in the bottle.
The bottles are labeled after pasteurization, and packed into trays, then shrink wrapped and palletized, ready to be sent to Broughton.