Industry Overview
Beer is an alcoholic beverage with a relatively low alcoholic content, generally ranging from 2 to 7% by volume, produced through the saccharification of starch followed by fermentation. The principal raw materials include malted cereal grains, most commonly barley, along with adjuncts such as rice, sugar, cassava, and corn. Hops contribute bitterness, flavour, and preservative properties, while water constitutes approximately 90–95% of the product and yeast facilitates fermentation to produce ethanol and carbon dioxide.
Beer production follows a sequence of key operations including grinding, mashing, lautering, wort boiling, cooling, fermentation, storage, filtration, and filling. Traditionally, beer is broadly classified into two styles, ale and lager, with barley, wheat, and rye among the commonly used grains.
Beer has a long history dating back to ancient civilizations. One of the oldest known brewing recipes was recorded on stone tablets in Sumer, in southern Mesopotamia. Historical evidence indicates that beer was brewed thousands of years ago, including in ancient Babylon and Egypt. Over time, brewing practices evolved, while the fundamental principles of converting grain-derived starches into fermentable sugars and subsequently fermenting them have remained central to beer production.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1500 Bottles/Day |
| Land & Building (3000 sq.mt.) | Rs. 2.04 Cr |
| Plant & Machinery | Rs. 67 Lac |
| Working Capital for 1 Month | Rs. 25 Lac |
| Total Capital Investment | Rs. 3.12 Cr |
| Rate of Return | 18% |
| Break Even Point | 68% |
Content Index
- INTRODUCTION
- CLASSIFICATION OF BEER
- ALES
- LAGERS
- EXAMPLES OF ALES:
- EXAMPLES OF LAGERS:
- BEER STRENGTH
- BREWING-RAW MATERIALS
- BREWING - THE RAW MATERIALS
- MALT
- GRAIN
- BARLEY- PATIALA (OWN FIELDS)
- MALT:
- HOPS
- HOPES IN THE FORM OF FLAKES
- YEAST
- YEAST UNDER A MICROSCOPE.
- WILD YEAST
- ALE YEAST
- LARGER YEAST
- WATER
- ADDITIVES & PROCESSING AIDS
- ADDITIVES
- ASCORBIC ACID (VITAMIN C)
- SULPHUR DIOXIDE
- CARAMEL
- PROPYLENE GLYCOL ALGINATE
- PROCESSING AIDS
- LIST OF MACHINERY
- MACHINERY TECHNICAL DETAILS
- MILL SYSTEM
- MASH TUN & LAUTER TANK
- BREW KETTLE & WHIRLPOOL
- HOT WATER TANK
- REFRIGERATING SYSTEM - GLYCOL WATER TANK
- BEER MANUFACTURE PROCESS
- PROCESS OF BEER MANUFACTURING
- MALT MILL
- MASH KETTLE
- LAUTER TUN
- WHIRLPOOL
- FERMENTATION
- LAGGERING
- PACKAGING
- THERE ARE 3 TYPES OF PACKING MEDIA
- CAN OF BEER OF 330 ML.
- BOTTLE OF BEER 650 ML.
- PROCESS FLOW DIAGRAM
- LICENSES REQUIRED
- EXCISE, LICENSE, TAX, DUTY & OTHER LEGAL REQUIREMENTS:
- OTHER LICENSES REQUIRED FOR THE SETUP:
- MAHARASHTRA
- PERMISSION TO USE OF SPIRIT UNDER MAHARASHTRA STATE EXCISE DEPARTMENT
- ANNEXURES:
- HOW TO STORE BEER
- SOME TIPS TO STORE BEER ARE:
- TOP INTERNATIONAL BRANDS LIST
- SOME INDIAN BRANDS ARE :-
- MARKET POSITION
- MARKET SEGMENTATION
- COMPETITIVE LANDSCAPE IN INDIA BEER MARKET
- BEER MEASURES
- SERVICE OF BEER
- FAULTS IN BEER
- BOTTLED/CANNED BEER STORAGE
- GLOSSARY OF TERMS
- PRINCIPLES OF PLANT LAYOUT
- SOME OF THE FACTORS IN RAIL-TRACK PLANNING ARE:
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE :
- PLANT LOCATION FACTORS
- RAW MATERIAL SUPPLIERS
- MALTS
- HOPS
- YEAST
- MACHINERY SUPPLIERS
- COMPLETE MACHINERY
- DESTONER
- MALT MILL
- BEER FILTER
- FERMENTER
- PASTEURIZER
- FILLED BOTTLE INSPECTOR
- PRODUCT PHOTOGRAPHS
- MACHINERY PHOTOGRTAPHS
- MILL SYSTEM
- MASH SYSTEM (MASH TUN&LAUTER TANK)
- HOT WATER TANK
- MASH PUMP
- PLATE HEAT EXCHANGER HOPS FILTER
- WORKING PLATFORM
- WORT INSPECTION PLATFORM WORT BALANCE TANK
- COMBINATION OF MASH PIPELINE
- VENTURIFOUR-WAY（THERMOMETRIC
- OXYGENATION COMBINATION）
- MEASURING TUBE
- BRIX MEASURING UNIT
- SPENT GRAINS DISCHARGE RAKE
- ELECTRIC STEAM HEATER
- FERMENTATION TANK
- REFRIGERATING SYSTEM - GLYCOL WATER TANK
- STERILIZATION TANK
- CONTROL CABINET
- RAW MATERIAL PHOTOGRAPHS
- MALTS
- HOPS
- YEAST
Appendix
- 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)
Frequently Asked Questions
The main raw materials used in beer manufacturing are water, malted grains, hops, yeast, and selected adjuncts or processing aids. Malted barley is a common starch source, while rice, sugar, cassava, corn, wheat, or other grains may also be used depending on the beer style and formulation. Hops contribute bitterness, flavour, and preservative properties. Yeast converts fermentable sugars into alcohol and carbon dioxide during fermentation, while water forms the largest proportion of the finished beverage.
The main steps in beer manufacturing are grinding, mashing, lautering, wort boiling, cooling, fermentation, storage, filtration, and filling. During mashing, starches from the malt are converted into fermentable sugars. Lautering separates the liquid wort from spent grain, after which the wort is boiled and commonly treated with hops. The cooled wort is fermented with yeast, followed by conditioning or storage, filtration where required, and final packaging into bottles, cans, or other suitable containers.
Ale and lager are the two traditional broad categories of beer, distinguished primarily by their yeast and fermentation characteristics. Ales are generally associated with top-fermenting yeast and warmer fermentation conditions, while lagers typically use bottom-fermenting yeast and cooler fermentation conditions followed by extended conditioning. These differences influence flavour, aroma, clarity, and maturation characteristics. Individual beer styles can vary considerably, so the distinction provides a broad classification rather than describing every characteristic of a particular beer.
A beer manufacturing plant requires equipment covering grain preparation, brewing, fermentation, cooling, filtration, storage, and packaging. The report identifies equipment such as a mill system, mash tun and lauter tank, brew kettle and whirlpool, hot water tank, glycol-water refrigeration system, fermentation tanks, filtration equipment, pasteurizer, and filled bottle inspector. Supporting equipment can include pumps, heat exchangers, measuring units, working platforms, control cabinets, sterilization tanks, and material-handling systems. The exact equipment configuration depends on the process design and intended production requirements.
Beer can be packaged in containers such as cans and glass bottles, with the report specifically referring to 330 ml cans and 650 ml bottles. Packaging selection depends on product positioning, distribution requirements, filling-line capabilities, storage conditions, and market preferences. A suitable packaging system must protect the beer from contamination and excessive exposure to oxygen and light while maintaining product quality during handling and distribution. Packaging operations generally follow the brewing, fermentation, maturation, and filtration stages.
Hops are used in beer production primarily to provide bitterness, flavour, aroma, and preservative properties. They help balance the sweetness contributed by malt-derived sugars and are an important component in defining the sensory character of many beer styles. Hops may be processed and added at appropriate stages of wort production, and the report also refers to hops in flake form. The quantity, type, and timing of hop addition can influence the final beer's bitterness, aroma, and overall flavour profile.
Beer plant planning should consider process flow, plant location, raw material availability, utilities, equipment arrangement, storage, packaging, material movement, and regulatory requirements. A well-designed layout should support efficient movement of raw materials, work-in-process materials, finished products, personnel, and waste while maintaining appropriate hygiene and operational safety. The report also covers plant location factors, plant layout principles, rail-track planning, road planning, machinery suppliers, raw material suppliers, licensing requirements, and provisions related to storage and handling.
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