Detailed Project Report (DPR) on beer (brewery) plant

BEER (BREWERY) PLANT [3561]

Brewing is the production of beer by steeping a starch source (commonly cereal grains, the most popular of which is barley) in water and fermenting the resulting sweet liquid with yeast. It may be done in a brewery by a commercial brewer, at home by a homebrewer, or by a variety of traditional methods such as communally by the indigenous peoples in Brazil when making cauim. Brewing has taken place since around the 6th millennium BC, and archaeological evidence suggests that emerging civilizations including ancient Egypt and Mesopotamia brewed beer. Since the nineteenth century the brewing industry has been part of most western economies. The basic ingredients of beer are water and a fermentable starch source such as malted barley. Most beer is fermented with a brewer's yeast and flavoured with hops. Less widely used starch sources include millet, sorghum and cassava. Secondary sources (adjuncts), such as maize (corn), rice, or sugar, may also be used, sometimes to reduce cost, or to add a feature, such as adding wheat to aid in retaining the foamy head of the beer. The proportion of each starch source in a beer recipe is collectively called the grain bill. Steps in the brewing process include malting, milling, mashing, lautering, boiling, fermenting, conditioning, filtering, and packaging. There are three main fermentation methods, warm, cool and spontaneous. Fermentation may take place in an open or closed fermenting vessel; a secondary fermentation may also occur in the cask or bottle. There are several additional brewing methods, such as barrel aging, double dropping, and Yorkshire Square. In India, ‘drinking’ has remained a bad word, clubbed with the other vices. While the beer and liquor market continues to grow at an impressive rate even against an economic recession, the social stigma remains in place, which manifests itself in anti-growth state policies. However, the Rs. 60.0 Billion organized beer and liquor industry has been growing at an impressive rate. In sharp contrast to the trend the world over, beer is losing ground to hard liquor in India. Amidst beers, the current trend is that lager beer is giving way to strong beer. Even as the liquor manufacturers could hope to garner the people who are shifting from beer to liquor, there is a vast country liquor market and a sizable grey market to contend with. United Breweries (UB), Shaw Wallace and McDowell (part of the UB Group) presently dominate the liquor and beer market. The market on its part is set to undergo a sea change with the arrival of MNCs. The removal of quantitative restrictions (QRs) on the import of bottled alcoholic beverages only makes the competition tougher. Among the alcoholic drinks, Beer is quite common and popular in almost every Country of the World. People of different Countries take beer in varying much like a soft drink in European Countries it is just a substitute of water. The alcoholic contents and main source stuff also keep varying according to the tests  of the major part of population of the particular country although it is a fashion to ask for beer of every origin in every country.

COST ESTIMATION

Plant Capacity                                             427333 Bottle/Day  
Land & Building (80000 sq.mt)               Rs. 53.30 Cr
Plant & Machinery                                      Rs. 120 Cr
Working Capital for 1 Month                    Rs. 45.37 Cr
Total Capital Investment                          Rs. 224.77 Cr
Rate of Return                                           40%
Break Even Point                                      54%



INTRODUCTION    
DOMESTIC INDUSTRY    
FORMULA NO. 1    
PREPARATION PROCESS    
FORMULA NO. 2    
FORMULA NO. 3    
A) PALE BEER    
B) DARK BEER    
C) STRONG BEER    
MARKET SURVEY    
INDUSTRY TREND ANALYSIS - NASCENT INDIAN BEER MARKET
   PICKS UP STEAM    
INDIA'S BEER GROWTH WILL COME FROM LOW BASE    
ONWARDS AND UPWARDS FOR INDIA'S BEER MARKET    
THREE KEY FACTORS DRIVING GROWTH    
HUGE GROWTH IN BEER IMPORTS    
INDIA - TOTAL BEER IMPORTS BY VOLUME (TONS) AND VALUE (USD '000)    
TOP 12 MOST POPULAR BEERS BRANDS OF INDIA    
MANUFACTURERS OF BEER    
INGREDIENTS OF BEER    
MALTED BARLEY BEFORE KILNING OR ROASTING    
WATER    
STARCH SOURCE    
HOPS    
YEAST    
CLARIFYING AGENT    
DETAILS OF BREWING PROCESS    
MASHING    
LAUTERING    
BOILING    
BREW KETTLE OR COPPER    
WHIRLPOOL    
HOPBACK    
WORT COOLING    
FERMENTING    
FERMENTATION METHODS    
WARM FERMENTATION    
COOL FERMENTATION    
CONDITIONING    
KRÄUSENING    
LAGERING    
SECONDARY FERMENTATION    
BOTTLE FERMENTATION    
CASK CONDITIONING    
FILTERING    
SHEET (PAD) FILTERS    
KIESELGUHR FILTERS    
PACKAGING    
BY-PRODUCTS    
STEPS IN BEER MANUFACTURE    
2. MILLING    
3. MASHING    
4. LAUTERING    
5. WORT BOILING    
6. WORT CLARIFICATION    
7. FERMENTATION    
8. STORAGE    
9. FILTRATION    
10. FILLING    
QUALITY IN FREE TRADE ZONES    
THE INCENTIVES AVAILABLE IN THESE FREE TRADE ZONES
    ARE ENUMERATED BELOW    
SEQUENCES IN BEER MANUFACTURE    
CLEANING AND MILLING    
MASHING    
LAUTERING /WORT EXTRACTION    
WORT BOILING    
WHIRLPOOL    
WORT COOLING    
FERMENTATION    
FILTRATION    
BOTTLING    
PASTEURIZATION    
BREWING PROCESS    
MANUFACTURING PROCESS IN DETAILS    
MALTING  
PREPARING THE MASH    
BREWING THE WORT    
FERMENTING    
PASTEURIZING    
PACKAGING    
A) MALT GRINDING    
B) ADJUNCTS' TREATMENTS    
C) MASHING    
TABLE 4. CARBOHYDRATE COMPOSITION OF A NORMAL WORT    
PHASES IN ENZYMATIC BREAKDOWN OF PROTEIN    
SEPARATION OF MASH    
WORT BOILING    
TABLE 5. ANALYSIS OF WORTS    
TREATMENT OF THE WORK    
FERMENTAION    
FERMENTATION PROCESS    
SEPARATION OF GREEN BEER    
LAGERING    
FILTERING    
PACKAGING    
PROCESS FLOW SHEET FOR BEER    
PLANT LAYOUT OF BEER    
PLANT LAYOUT BARLEY MILLING SECTION YEAST TANK, WASH TANK    
PLANT LAYOUT OF PROCESS SECTION FERMENTATION SECTION    
LIST OF PLANT AND MACHINERY    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    


APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS    
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)