| Making The Most Of Brewery Engineering
Beer. A drink
soaked in tradition of malted barley, hops and water. A tradition,
which has been integrated with science to deliver varied flavors
and drinking pleasure. And, providing seam-less integration is what
the Brewery Technology Initiative has set as its mission. Whether
it is a first time customer or an existing brewery, BTI provides
total brewery engineering/technology services.... from feasibility
studies, technical support to complete turnkey installation. The
key lies in integration for optimum performance.
Our world-wide services include:
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Turnkey plants right from malt reception
to packaging |
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Critical Equipment and Integrated
Systems |
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Modernization, Refurbishment and
Expansion of existing plants |
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Life extension services for brewing
equipment |
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Process Automation & Control
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Project Management and Procurement
of critical equipment and off-sites |
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Engineering
Services Technical Audits |
PLANT ENGINEERING: Our core strength
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Engineering
forms the backbone of our delivery program. We follow stringent
international standards like DIN 8777 for brewhouse performance,
ASME, AD-Merkblatter for pressure vessels, ISA and CE standards.
The design team works with customers to identify the need for
design enhancement in various systems with a view to reduce
energy and other operating costs. This provides a competitive
advantage to our customers. The unique design of Wort Boiling
Kettle was conceived by this team. |
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The manufacturing facility has been accredited
with ASME H & U stamp for heating boilers and pressure
vessels and the entire manufacturing process has been certified
with ISO 9002. The 40,000 sq. ft. workshop has the capability
to deliver finish suitable for food grade vessels and systems.
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PROJECT
MANAGEMENT & CONSTRUCTION : A strong foundation
Praj team is geared up to support
customers anywhere in Asia, Africa, Russia & CIS and the
Indian sub-continent. With over 150 installations worldwide,
the expertise includes procurement of off-sites, auxiliaries
and other bought-out equipment, project planning, supervision
of erection and commissioning.
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MASH KETTLE
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The mash kettle is specially designed
to handle varying composition of malt and different mashing
programs. Distinguishing features of our mash vessels are:
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Agitator profile ensures gentle mash
handling with low peripheral velocity of 2.8 m/s. resulting
into low shear and turbulence.
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Heating areas are sized for 1 °C
/min with temperature rise in the range of 75 - 76 °C.
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Heating jacket positioning specific
to process requirements.
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Uniform mash mixing resulting into
high heat & mass transfer.
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LAUTERTUN
The lautertun is designed to attain the desired
wort clarity in a short span. Mash enters at the bottom through
specially designed bottom seat valves which ensure uniform
distribution of mash and bare minimum oxygen pick-up.
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Highlights:
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Absolutely plain true bottom. |
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False bottom flushing nozzles with
built-in check valves & special pop-up nozzles for thorough
cleaning of the underside. |
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Raking arm mechanism |
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- Adjustable location of knives in
horizontal plane. |
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- Three speed mechanism: during Mash
intake, Bed cutting and Spent grain discharge |
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Air free lautering consisting of
Closed loop ring pipe wort collection system. |
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Simple trouble-free mechanism for
spent grain removal |
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Mechanically operated Latching /
Delatching of the spent grain - sweeping blade. |
Major concern in a wort boiler is establishing sufficient
circulation rate, which in turn depends on control of maximum temperature
of wort. The design incorporates adequate measures to control the
steam flow rate.
Highlights:
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Wort guiding plate at the top ensures stripping
and uniform wort distribution.
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Facility to adjust the guiding plate position
in the vertical plane. An option of internal and external
wort boiler is available.
e-COMBOILER: Internal Boiler
e-COMBOILER is an innovation , which combines the best features
of the conventional internal and external boiler.
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Lower operating cost
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Easy access for tube cleaning.
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Preheating at lower copper volume.
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Less water/caustic requirement during CIP
resulting into lower ETP load.
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Preheating of wort within the boiler itself.
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The system comprises a cylindrical shell and
tube heat exchanger with vertical tubes, which are heated from the
outside by saturated steam. As a result the wort rises above the
surface. It gets deflected off a distributor cap from where it falls
back to the wort boiler surface.
WHIRLPOOL
The design and performance of the
whirlpool depends on an understanding of the relationship between
particle size, wort gravity, centrifugal separation and sedimentation.
The special features include:
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Optimally selected L/D ratio and
wort entry location result in excellent hot break |
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Minimum Shear |
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Tangential wort entry at a low velocity
of 5 m/s. |
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Inverted cone/sloping bottom with
robust supports to avoid deflection due to temperature fluctuations.
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Fluid driven trub removal device. |
Praj's Fermentation system is characterized
by specially designed fast chilling jackets for varying duties.
The unitanks are designed as per ASME/ AD Merkblatter standards.
Highlights:
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Cooling duty of 14°C to 0°C in just
24 hours
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Embossed type cooling jackets of the unitanks
ensures :
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- high heat transfer coefficients
- parallel brine flow and lower pressure drops
- low glycol holdup
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Pulse TIG welding technique for less heat
input and hence less distortion
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Spot radiography of all weld joints
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Full radiography of weld joints covered by
the jacket and dished end.
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Effective yeast separation
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Effective cleaning system
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FILTRATION
While beers differ primarily
in clarity and in original gravity, color and taste, it
is the filtration technique that sets your beer apart. PRAJ,
in association with FILTROX-WERK AG of Switzerland, offers
comprehensive range of filtration products for sterile,
hygienic filtration to ensure clear and bright beer. The
range includes:
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Candle filter for Kieselgur
filtration |
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Horizontal leaf filter for
PVPP stabilization |
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Module/sheet filter for polishing
of beer |
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CLEANING IN PLACE (CIP) SYSTEMS
4 Loop System
Automated cleaning and disinfections, with either
recovery or disposal of the cleaning liquid is another crucial step
in beer production. An integrated four loop CIP system, incorporating
water, caustic and acid is provided for the following :
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Brewhouse vessels, piping and valves
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Wort cooling and treatment equipment,
piping, valves and pumps |
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Yeast vessel, fermentation/lagering
tanks, piping, valves and pumps |
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Filtration equipment, bright beer
tanks, bottle filling machine, piping, valves and pumps |
The CIP system can be an automated,
sequenced system with the option of manual intervention or a semi-automatic
system. All process equipment are provided with in-built cleaning
systems to facilitate thorough cleaning. Options like stationery/rotating
spray balls, spray nozzles, tank cleaning machines, cleaning turbines
are carefully selected to suit specific requirements.
PROCESS CONTROL & AUTOMATION
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Brewing is a critical
bioprocess and hence it is essential to monitor each and every
step in brewing. To simplify all steps of monitoring, we offer
process control and automation right from malt reception to
the tank farm/cellar upto bottling.
Level 1:
To control critical process parameters and maintain consistency
in product quality.
Level 2: PLC based Control System with Data Acquisition
facility to control critical process parameters and log
data.
Level 3: PLC based control system with
auto sequencing and data acquisition system. This system
facilitates control of critical process parameters and automation
of Standard Brew Logging, Fault Logging, with a provision
of generating reports with an option of internet based remote
access.
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UTILITIES
We provide engineering and integration of utilities
with the process plant. We also provide complete project management
package including procurement assistance, expediting, inspection,
supervision of installation and commissioning. The utilities
include:
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Steam generation and distribution
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Refrigeration plant |
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Water storage, treatment plant and
distribution |
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Compressed Air plant |
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CO2 Recovery, purification, liquefaction,
storage and distribution plant |
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Wastewater (effluent) treatment plant
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Packaging-hall equipment |
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Plant Electricals |
SPECIAL SYSTEMS
Yeast Drying System
The process involves autolysis of yeast that ensures complete inactivation
of yeast cells before drying. A double drum dryer ensures no spillage
of liquid yeast and hence does not require any yeast recycling system.
Yeast consists of high nutrient value in terms of
protein. Breweries sell the dried yeast as value-added product to
the food, pharma industry as a filler supplement, as well as, to
the animal feed industry, depending upon the quality of the product.
Heat Recovery System for Brew House
The heat generated by the vapors from the wort kettle is collected
in the form of hot water reservoir. This hot water is re-utilized
for Wort preheating, CIP, Boiler feed water. Thus, utilizing the
waste energy from the brewhouse.
WASTEWATER TREATMENT PLANT
We offer anaerobic UASB process for primary
treatment of wastewater followed by extended aeration and sludge
recycle process. Depending upon the location of the plant and treated
effluent requirement, the tertiary treatment plant is added.
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