brewery brochure 140114

8/10/2019 Brewery Brochure 140114

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Total BreweryExpertise

Right from conceptualization,technology, design, plantengineering upto projectinstallations - Praj offersevery solution backed up

by expertise and experience. BreweryPlants


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Integrated solutions for brewery plants

BEER. A drink soaked in tradition of

malted barley, hops and water.

A tradition that has been integrated

with science to deliver varied flavors

and drinking pleasure. And, providing

seamless integration is what the

PRAJ Brewery Technology Solutions

offers. Whether it is a new brewery or

an existing one, Praj offers an entire

range of Brewing Equipment, Project

Management Services & Solutions -

right from conceptual study to plant

installation to commissioning along

with many value added services

Exclusive collaboration with Meura (global leader in Mash ltration

technology in India) for supply of Mash lters. Today, Praj-Meura

has the largest installed reference base in India for Mash lters

Beer Filtration and Beer Recovery Systems in association with

Bucher-Filtrox (global leaders in beer ltration technology in India).

Around 80% of the beer produced in India is ltered through Praj-

Filtrox lteration plants

Complete Yeast Management Solutions, Fermenting Tank Farms,

Bright Beer Tanks and CIP Systems designed and sized to meet

varied process requirements of different brands and brewers.

Brewery Solutions and plant performance guarantees compliancewith the international standards such as DIN 8777, EBC and MEBAK

Mash Kettle

The aim of mashing is to ensure high extraction rate while

maintaining quality of the extract. Apart from the ingredients

used, parameters like temperature, optimum level of chemical &

bio-chemical conversion, effective mixing with proper agitator design,

vessel wall temperature, appropriate process control and many other

factors have equal impact on quality of wort produced and therefore

on the quality of nal product. The mash kettle is specially designed

to handle varying composition of malt and different mashing proles.

Highlights

Kettle equipped with unique Dimple type heating jackets

The uniquely designed agitator prole ensures low shear stress

on Mash

Variable frequency drive for varying agitator speeds

Linear mash temperature increase with uniform heat distribution

Advantages

Intimate mixing of water and grist

to ensure homogenous mash from

the start

Uniform Heating & temperature

distribution with specially

designed heating jackets

Innovative agitator design ensures

homogenous mash mixing and

proper sacchrication throughout

operation

Flexibility to process different

varieties of Malts

Low shear mash produces clear

and improved quality wort and

eases lautering operation

Lauter Tun

Highlights:

Higher ltration area as compared to conventional lauter tuns

Innovative design of Raking Arm with Variable Frequency Drive for

adjusting speeds during Mash intake, Bed cutting and Spent grain

discharge

Adjustable location of knives in horizontal plane with zigzag andstraight knives

Specially designed Cup type arrangement which ensures uniform

Wort run off across the lautering bed.

False bottom flushing nozzles with built-in check valves and special

pop-up nozzles for thorough cleaning of the underside

Placement of Wort Collection and flushing nozzles backed up by

process calculations.

Special sparging system ensures gentle and even distribution with

effective leaching of wort

Air free lautering consisting of closed loop ring pipe wort

collection system.

Simple trouble-free mechanism for

spent grain removal

Mechanically operated Latching/

Delatching for spent grain

removal.

Advantages:

High extract efciency

Higher ltration area ensures

lower cycle times

Low oxygen pickup

Flexibility to take various

raw material with different

congurations

Clear and improved quality wort

production Improved Beer

The nal beer quality and the overall plant output depends upon the

Lauter Tun performance and that is why it is called the heart

of brewhouse.

Hot Processing Brewhouse

Highlights:

Energy savings systems such as

Heat Recovery system and Wort

Flash System in the Brewhouse

Mash lter based brewhouse for

higher productivity, larger volumes

and increased brewhouse yield

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Praj, in association with Meura,

Belgium (world leaders in Mash

Filtration technology) offer high

efciency Mash Filters in India

and subcontinent. The Mash Filter

option is most suitable for large

capacity breweries and for different

types of raw material conguration.

Highlights of Mash Filter :

High productivity (upto 14 brews/day)

High extract yields (practical yield at least equal or greater than the

lab yield)

Very Bright Worts with low solids content < 5ml/l

Acceptance of high proportion of Adjuncts (upto 100 % with the use

of exogenous enzymes)

Unique Features of

PRAJ WORT KETTLE

Options of External as well as

Internal wort boiling system (Praj

e-COMBOILER)

Variable speed control of wort

circulation pump provides gentle

handling of wort & helps in

maintaining hot break together

The special design fountain entry

of wort provides the large surface

for the volatiles removal

Low pressure steam and hence

lower temperature difference

reduces the thermal stress

exerted on wort

Lower heat flux and Optimum heat transfer area ensures more

number of brews between cleaning

Less energy consumption and Heat recovery system as an

add on module

Advantages:

Low energy consumption compared to conventional

boiling systems

Excellent volatiles stripping capability

Improved hops Utilization

Effective hot break formation Low shear - vigorous boiling

Lower TBU increase means Lower thermal degradation of wort

Lower DMS values

Mash Filter

Highlights

Sloping bottom and inverted cone design ensures efcient

trub separation

Tangential entry of wort at optimum velocity helps keep the trub

particles intact

2/3 wort outlets maintains the trub cone till the end of wort cooling

High flowrates decreasing at the end of the wort cooling to ensure

less disturbance to trub cone

Automatic trub cleaning device ensures full cleaning with less

water consumption

Large surface area due to tangential entry allows for escape of the

unwanted volatiles

Advantages

Effective trub separation

Compact Trub Cone formation

Lower levels of suspended solids in nal worts

Unwanted Volatiles stripping

WORT COOLER - Single stage Heat Exchanger

Single-stage wort cooling with precooled brewing water ensures that

the wort is cooled to the pitching temperature in one pass. So the total

heat used is returned to the brewing process again. Wort to chilled

water ratio is optimized to reduce chilled water consumption and

reduce the refrigeration load.

Yeast Management

Praj offerings include :

Yeast Propagation systems with 2 stage and 3 stage

propagation facility

Yeast storage section with hygienic design agitator

Beer Filtration

While beers differ primarily in clarity and in original gravity, color and

taste, it is the ltration technique that sets your beer apart.

PRAJ, in association with Bucher-

Filtorx of Switzerland, offerscomprehensive range of ltrationproducts for sterile, hygienic ltrationto ensure clear and bright beer.

WhirlpoolThe hot break formed during the wort boiling process has to be

separated from the wort. Efcient trub separation is the prime

function of any whirlpool. Apart from trub separation removal of the

unwanted volatiles like DMS also takes place in the whirlpool.

Wort Aeration System

The specially designed, ventury

type aeration nozzle, creates a slight

vacuum which draws the oxygen into

the unit. This action causes a very

ne spreading of oxygen bubblesover a very large contact area, which

can then react with the wort.

Option of complete, automatic

standalone Wort Aeration skid

Easy installation and

interconnection in the existing

brewhouse

Control based on the Wort

DO level

Cold Process Area

Wort Boiling is regarded as the turning point in the brewing of Beer.

Any change in boiling practice is to be monitored carefully and

thoroughly to ensure they do not affect the quality and flavour of

the nal beer. Generally boiling wort at, or near, normal atmospheric

pressure gives the most acceptable results.

Wort Kettle

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The range :

Candle lter for Kieselgur ltration

Pre coat candle lter for

stabilization of beer with PVPP

Module/sheet lter for polishing

of beer

Salient Features of Filtrox Filters:

New SYNOX 2.0 PF /PS lter

series which supersedes

FILTROjet, (was a best-selling

candle lter worldwide) Industrial

machines between 30 and 1,200

hl/hr in operation Patented STABOX 25 mm

candle to maximize available

sludge volume and minimizing

turnaround timings

New and Patented JETCONTROL

2.0 inlet distributor

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:

Brewhouse vessels, piping

and valves

Wort cooling and treatment equipment, piping, valves and pumps

Yeast vessel, fermentation/lagering tanks, piping, valves and

pumps

Filtration equipment, bright beer tanks, bottle lling machine,

piping, valves and pumps

The CIP system is fully automated, sequenced system with the optionof manual intervention or a semi-automatic system. All processequipment are provided with in-built cleaning systems to facilitatethorough cleaning. Options like stationery/rotating spray balls, spraynozzles, tank cleaning machines, cleaning turbines are carefullyselected to suit specic requirements.

Value Added Offerings Systems

Brewhouse Heat recovery System

Waste energy recovery from brewhouse thereby driving down energy

use by 25%.

Multiple references of different Brewlengths

Complete automatic standalone Wort Aerationskid which can be

easily integrated with existing brewery with Control based on the

Wort DO level

Complete automatic standalone Beer Carbonationskid with control

system based on beer carbonation level.

Beer Recovery Systemfrom surplus in collaboration with

Bucher-Filtrox

Yeast Drying System:Double

Drum Dryer which ensures no

spillage of liquid yeast and

hence does not require any yeast

recycling system

Wort Flash Evaporation System

in the Brewhouse: With just

4% evaporation in Wort Kettle

followed by 2% evaporation in

flash vessel under vacuum with

quality conformance to the desired

analytical results.

New total drain system TDS with scavenge pipe inserts.

SYNOX 2.0 PS Candle Filter for PVPP stabilization ensures fast

turnaround time and low PVPP losses.

Fermentation & Lagering

Prajs Fermentation system is characterized by specially designed

fast chilling jackets for varying duties. The unitanks are designed as

per ASME/ AD Merkblatter standards. Most optimum and consistent

cooling duties are achieved with both Glycol and Ammonia

cooled Unitanks.

Embossed type cooling jackets of the Unitanks ensures :

High heat transfer coefcients

Parallel Coolant flow and lower pressure drops

Low Coolant hold up

Pulse TIG welding technique for less heat input and hence less

distortion.

Spot radiography of all weld joints full radiography of weld joints

covered by the jacket and dished end.

Tank design facilitates proper Yeast settlement and Yeast cropping

Well equipped manufacturing facilities with automatic welding and

polishing machines.

Total covered area of 2, 00,000 sq. ft. and open area of

3,40,000 sq. ft.

Accredited with ASME U & H stamp, ISO 9001- 2000 certication

& CE marking.

Codes and standards followed include ASME Section VIII,Div.1,

BS 5500, ASNI (SNT-TC-IA 1984 & 1988), TEMA, DIN, IS 2825 and

AD Merkblatter.

Working in various grades of Stainless Steel, Copper, Carbon steels,

Nickel, Titanium, Hastalloy and other exotic materials

Large pool of approved vendors

Stringent raw material testing methods

Effective supply chain management.

Well laid out Quality System

HSE practices in line with international standards

Plant Engineering :

Our core strength

Engineering forms the backbone of our delivery program. We follow

stringent international standards like DIN 8777 for brewhouse

performance, ASME, ADMerkblatter for pressure vessels, ISA an d

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.

Project Management

Project management is the key

strength of PRAJ handling projects.

Timely and smooth completion of

the projects are an essence of

PRAJ Project Management.

PRAJ has a strong pool of project

managers with experience of

working on a global scale. The

Project managers are well trained

with many of them certied

Project Management Associate

(CPMA), who have passed

International Project Management

Association - Level D Examination,

Switzerland. The site team

has signicant experience andknowledge on the local conditions.

Cleaning InPlace (CIP)Systems

Manufacturing


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BreweryPlants

Argentina I India I South Africa

The Netherlands I Thailand I UAE I USAPraj Worldwide

Praj Industries Limited

Praj Tower, 274 & 275,

Bhumkar Chowk - Hinjewadi Road,

Hinjewadi, Pune 411 057. [email protected] | www.praj.net

Utilities

We provide engineering and

integration package for utilitiesalong with the process plant. We

also provide complete project

management package including

procurement assistance, expediting,

inspection, supervision of installation

and commissioning.

The utilities include:

Steam generation and distribution

Refrigerationplant

Water storage, treatment plant

and distribution

Compressed Air plant CO2

Rcovery, purication, liquefaction,storage and distribution plant

Wastewater (effluent)

treatment plant

Packaging-hall equipment

Plant Electricals

Process Control & Automation

Brewing is a critical bioprocess

and hence it is essential to monitoreach 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. Plant

can be offered with different levels

of automation to suit the needs

of the brewer and operating personnel. The automation system

can be customized to the highest level based on specic process

requirement such as recipe management, safety interlocks, real time

data management, security management etc. The automation system

can also be offered with an open technology platform, which permits

connectivity to third party applications and ERP systems.

Praj Matrix- Innovation Center

Brewery Laboratory following EBC standards

State of the Art own R&D facility for Brewery Analysis in India.

11 laboratories - 2 labs as per 10,000 clean area classication

Staff Includes - 80% PhD holders and 20% Graduates

Analysis facility from Raw material to nal product

Standards Followed include EBC, ASBC and MEBAK

Global Alliances

Meura

Mash Filters. Keeping in mind the need for rapid expansion of

capacity, as well as higher capacities being planned by new breweries,

Praj provides Mash Filters in alliance with Meura, Belgium for

India and Subcontinent. The Meura range of lters can replace the

traditional Lauter TunsThe Meura range can be most appropriately

designed for brewery capacities higher than 0.5 million HLPA.

Bucher Filtrox

Beer Filtration systems:. Bucher -Filtrox lters are the most preferred

lters in Breweries. Having completed over 18 years of co-operation in

the India, Praj and Filtrox have commissioned more than 40 Filtration

plants in India. Over 80 % of Beer produced in India is ltered through

the Praj Filtrox candle lters.Praj along with Bucher Filtrox also

offers Beer recovery systems from surplus yeast, using cross flow

membrane ltration (CMF) technology.

brewery brochure 140114

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