1.

DESCRIPTION OF BEER
1.1. Definition of Beer
Beer is made by transforming barley to malt and fermentation of malt in some conditions,
then this fermentated juice aramatized with hop and leaved for fermantation. It contains
carbondioxide in form of solution, has a smell and taste of own and it is a soft drink (3-5 % in
volume). Gas bubbles in it is the result of naturally occuring carbondioxide. Alcohol in beer,
is made on its own during fermentation, it is impossible to add alcohol in beer in production
process.
Alcohol degree of beer, decreases or increases according to malt quantity in beer juice. Beer
,its production is goes to B.C. 6000 years is stillone of the most consumed drinks in world.
Raw materials, used in beer production and required amount for 1 litre of beer are showned
on the chart below.
Raw materials

Unit

Required amount for 1 kg

malt

Barley

Kg.

1,3
Required amount for
production of 1 litre beer

Malt

Gr.

175

Malt Additive

Gr.

30

Hop

Gr.

1,7

Beer Fermentation

Gr.

(Rice)*

Malt additive and amount varies according to beer type and production methods. In
our country, usually rice is used as malt additive.

Mainly known bottom fermentation beer types are; Pilsen, Mnih, Dortmunt, top fermentation
beer types are; Ale, Stant and Porter. In Turkey, bottom fermantation beer types are being
produced.

1.2. Classification of Beer and Beer Types

Beers, generally, differentiates as bottom and top fermentation beers and these beers
differentiates according to their own known types. Beer is classified according to its
production , extract amount of juice, variety and type.

Bottom and top fermentation beers according to production.

Its seperated and called as 2-5%,5,7-8%,11-14% and 16% according to its juices
extract amount. This classification is very important for tax in some countries.

As to its variety, generally beers that are used in trade are understood. ( Special beer,
export beer, diet beer etc.)

Its seperated as colour, bitterness of hop and malt taste. For instance; Pilsen beer, Dortmund
beer and Mnih beer etc.

1.3. Beer Types According to Production

1.3.a Bottom Fermentaton Beer Types
Mainly known beer types, generally are taking the names of their production cities. It was
thought that these beers were only produced in those cities.
Mainly known bottom fermentation types are Pilsen, Mnih and Dortmund.
Pilsen beer is light coloured (0,5 N/10 L) and hop amount is high (400gr/hl) and its foam
lasts for a long time. Its characteristic feature is its bitter taste.
Dortmunt beer is also light coloured but its taste is softer,stout and its alcohol is high.

Mnih beer is dark coloured, aromatic, stout and little bitter. Aromatic malt taste is its
characteristic feature.
Pilsen beer is made of 11-12 balling juice. Malt is well dried in the oven and leaved in 80C
for 4-5 hours. Malt is kight coloured and in mashing very soft water is used. Its boiled once
or twice ; fermentated in low tenperature and reposed for 3 months.
Dortmund beer barleys sprout time is longer but parching-drying is same with pilsen. In
other words, totally melt and malt, that has dried like Pilsen, is used. Water, used in mashing,
contains carbonate, sulfate, CaCl2 . balling of juice is 13-14. double boiling is made. Amount
of hop is between Pilsen and Mnih beers.
Mnih beer is made of 11-14 boiling juice. Barleys, that is high in protein, are used. To make
sprout is contunued until complete melt. Amount of carbonate is high in water which was
used for mashing, but other kind of salts are not present. Tripartite method is applied. A little
hop is added. Fermentation is made in low temperature and reposed for 3 months.

1.3.b Top Fermentation Beer Types

Most known beer types are English Ale, Staut and Porter. Actually, when its spoken about
top fermentation beer, firstly English beers come to mind. Top fermantation beer are
produced in litte amounts in Europe, Germany and Belgium. Top fermantation beer produced
in Germany is 7% amount of total beer production. Main top fermentation German beers are
Berliner Weissbier, Bayerischen Weissbier, Bitterbier and Malzbier. Belgiums Lambic beer
is in this group. Weissbier, is made by mixing wheat malt to barley malt.

Ale : Its light coloured and made of well melt malts.

Hop amount is high.

Beer factories in England use six ordinals California winter barley.

Added water is rough and jips are added. Enfusion method is used. Balling of juice is 1112. there are types as Pale ale, Bitter ale, Mild ale, Scotch ale. Generally hop amount
is high ( 350 900 gr / hl). Also, 100-120 gr hop is added to barrels

Staut : Its dark coloured and contains hop. %10 black malt or parched barley and
sometimes caramel is added to well melt malt. Hop amount is high. (600-700gr/hl)

Porter : Light Staut beers are called as Porter.

Berliner Weissbier : It is made of 1/3 or barley wheat malt mix. Juice is not melt for
this type of beer. Balling of juice is 7-8. fermentation is made in 14-20C. These beers
are sore because its leaved for fermentation by mixing lactic asid bacteria to top
fermantation leaven. To repose is done by leaving in bottle for 2-3 weeks in 12-16C.

Bayerischen Weissbier : Wheat malt is 60-70%. Mashing is same as in bottom

fermentation beers. Balling of juice is 11-13 and fermentation is done in 12-25 C.
Lactic acid bacteria are not used. After fermentation beer is bottled and for 3-4 days in
10-12C then 3-4 weeks in 4-5C reposed.

Bitterbier : It is produced with enfusion method and a lot of hop added. Fermentation
is made in 9-13C, reposing is made in 5-7C for 2-3 months. During reposing, again
30-50 gr hop is added for one hectolitre.

Malzbier : It is dark coloured, contains little hop and it is sweet. After fermantation
sugar is added, reposing is made in bottle or thank. When enough amount of
carbondioxide is present it should be pastorized of filter immediately.

Lambic : It is peculiar to Brussels. 60% malt and uncooked wheat are used. The most
important feature is not adding leaven and spontane fermentation. In spontane
fermentation, termobacteria, wild leavens, lactic acid bacteria and Brettanomyceses
are active.

1.4. Beer Types As to Varieties

They are produced in a different way and have some features. These are export, light and
alcohol free beers.
4

Export Beers : Because these beers are sent to far and different clima countries,
their stability has to e very good, in other words they have to stay clear for a long
time without sedimentation for production of this beer, barleys, that gives high
enzimatic malt. So, proteins are shattering good while making malt. Malt shoul be
completely melt. Because there are melanoidins that plays as productive colloid,
it is colour is dark. At the end of mashing, PH should be 5,2-5,4 and for this reason
appropriate water mixture is used. In juice, dextrin amount should be high, so
mashing should not be in 62-63C. Hop should be fresh and for good coagulation,
it should put to boiler when juice is just starting to bail. Juice should not e boiled
for a long time.
In export beer production, beer should be clear at the end of fermentation. It is
better not to make thrashing beers even malts, because it destroys colloidal
balance. For botting beer without contact with air and for keeping used capsules
cork for a long time, it should be covered with aluminium.

Light Beers : Light beers are high attennuationy and must not include
carbonhydrate that harmful for diabetics more than 0,75 gr/100 ml. The protein
amount is maximum 0,5gr/100ml and alcohol amount 4,3% and also these beers
calory amount is low. To create this, by the beer producing,it must be waited a
long time between 62-64C that maltot oceurs mashing. Apart from that, in
fermantation drastase enzyme preparate or malt extraer or for one hectolitre 500800 gr malt flour is added. Than the remained dextrin shattered and it is prowded
to have fermentation by leavens for this reason, light beers, contains more alcohol
also amount of hop is high.

Alcohol free beers : the beers that contains 0,5-1,5% alcohol are called as less
alcohol beer, the beer that has less alcohol than 0,5% are called as alcohol free
beer.

These beers are being produced in different ways for example. It is marketed by mixing beer
and juice or fermentation of juice is stopped by pastorization or filteration. Also, to have less
alcohol in beer, a mashing process may applied that has little fermentable sugars (malt)in

juice. In some countries, alcohol free beer is being produced by taking alcohol in beer with
vacuum distillation. But the beers that has less alcohol than 1,5% are not prefered much.

1.5. The Materials Used In Beer Production

1 BARLEY : It is a one of year plant of Mordeum gramine family.
In Turkey, two ordinals barleys are used (Mordeum disdichum). Although, in Europe, the two
ordinals barleys that harvested in summer are efficient, in Turkey, the barleys that harvested
in winter are efficient.
The chemical composition of ordinal barley which is an important factor in beer production
is;
Protein

11,1%

Starch

63,2%

Oil

2,94%

Cellulose

5,83%

Other materials with azote 14,0%

Ash

2,93%

The most important material of marley is starch. Because the alcohol in beer occurs by
shattering of starch. While the amount of protein in the barley increases, the sprout of barley
becomes forceful. So, it makes harder to control beer production. The amount of protein in the
particle, starch and extract are converse commensurate.
2 HOP : Hop that being used in beer production is a more years plant from canabinaceae
family. Although, being more wild species of hop in Turkey, the culture races are more
efficient.
The main factors of hop that makes producing beer more valuable are alpha acid, essential oil
and wetness.

The most important section of hop is yellow lupuline. This section includes preservative and
taste giving materials. The composition of yellow lupuline has two sections. These are
essential oils that give to the beer its flavoring and rosins that gives to the beer its bitterness
and preservative. Also, the reason of using hop in beer production is lupuline dust.
The chemical composition of hop is;
Water

12,5%

Ash

7,5 %

Cellulose

13,3%

Materials with azote 17,5%

Ether oils

0,4%

Ether extracts

18,3%

Tanine

3,0%

Azote free extract

27,5%

The most important materials in beer production between these are ether oils and rosins.
Especially lupuline dusts include ether oils and rosins.
3 WATER : Water is important in beer production as much as barley and hop. Water is
being used for making barley sprout, preparing mash, feeding to vapor boiler and cleaning.
The water, being used in beer production, is much more than the beer producted. Due to the
fact that 80% percent of beer is water, it is important and it must be qualified as clear drinking
water.

2. Beer Production in Turkey and In World

2.1. Beer Production In The World
Beer is a drink made from grains (especially from barley) and it gets its special smell and
taste from hop.
The history of beer is as old as beginning of grain farming. 8000 years earlier, the people who
has lived in Maditerranean producted beer first. Old Egyptians thought that Farming God
Ostristaught people to make beer. In addition to be understood from the written sources,
before making beer,viniculture and wine pressing in Babil, making beer is also known in
Mediterranean.
Today, thousands barrels of beer is being prduced in beer companies. But modern production
techniques are not much different from the old Egyptian kitchens and the middle ages
monasteries. It is being supposed, the beer and bread founded with a coincidence. For both of
them leaven is needed and cause of these living beings are small that can not be seen with
necked eyes, nobody could know to make a frothy drink with adding leaven to grassy barley
and first made beers did not include hop. Since many centuries, people looked for different
tastes by adding to beer many different horbs. The beer with hop is needed first at 14. century.
Especially, beer that went into wines place at North countries where the climate was not
convenient to product beer, is the traditional drink of Germans, Englishs and
Scandinavians. Today, there are so many beer species being produced with special names in
Germany and England. German and English beers are seperated from each other with leaven
techniques and hop amount. English beers are being produced with top beer techniques and its
alcohol amount is 4% - 6,5%. The beers named Lagerin german includes hop and its
alcohol amount is low. German beers that produced with bottom fermenting includes 3% - 5%
alcohol.

Worlds Biggest Beer Producers and Markets

According to 1998 (million hectoliters)
Beer Producers

Production Amounts

Anheuse-Busch

Beer Market

Market Size

130

USA

226

Heineken NV

79

China

199

Miller Brewing Co.

56

Germany

105

Interbrew

48.3

Brasil

82

South African Breweries

47.7

Japan

72

Source: Impact Databank

2.2. Beer Production In Turkey

In Turkey, the first beer company was found by private sector in stanbul in 19. century , but
before this, it was known in Turkey. For example, according to some formal documents dated
1842, the beer was being produced with a name Barley Water. After the first beer company
that was found by Swiss Bomonti brothers, an another company was found in 1909 in
stanbul, called as Nektar. In 1912, these two company united with a name Bomonti Nektar
In zmir. The company in stanbul was producing beer and malt, the company in zmir was
producing just beer with the malt produced in stanbul.
In 1926, at the time of republic, the beer production entered to government monopoly. But a
special permission was given to Bomonti- Nektar company for producing beer by government
till 1938.
In 1934, the first beer company of government was found in Atatrk Orman iftlii in
Ankara. In 1955, the beer was started to produce by private sector with getting out the beer
from monopoly products. Today 85% of the total beer production of turkey is belong to
private sector.
Tables about beer and malt are in appendix.

3. Description of Process
Beer is a beverage made of malt including alcohol and CO2. As another saying; germinated
grain aromatized with hopfen. This means malt must enters alcohol fermentation. There are
5 sections in beer production:
1. Grinding the malt
2. Mashing and Boiling
3. Fermentation and Maturing
4. Filtration
5. Bottling, barrelling and Pastorisation
3.1 Grinding The Malt
Malt is need to be grinded and mixed with water for mashing for beer production. After
grinding of malt, endosperms must be like flour. On the other hand the shells of malt must
remain in big particles. This can happens if the malt is easily melting and fully dry.
Uncracked shells prevents the materials causes unwanted smells and also they are required in
the straining of mash. In straining process, they are used as filters.
The mill used in grinding of malt is located above the mashing-boiling section. The malt
coming from the silos passes from magnets to be seperated from iron particles within. Then
grinded malt is weighted in automatic scales. Dusts in malt are absorbed while entering the
mill from malt silos.
3.2 Mashing and Boiling
MASHING
The seperation of starch into yeastible sugar particles called as mashing. Grinded malt mixes
with water in mash boiling tank and warmed up to various temperatures.

10

Purpose of Mashing
To make the enzymes influence the extract materials in malt and splitted them into low
molecules to pass into must, so that the best extract from malt can be gained.
Mashing Methods
The mixture formed of malt and water is called the mash. There are two types of mashing;
1. Decoction
2. Infusion
Infusion Method
The main principle of this method is rising the temperature of mash slowly to 75-78C. No
boiling happens in this method. So the enzymes do not get damages. In brewering mashing is
made with good soluble malt. Besides this another method called Double Mashing can be
used. A lot of diastase is required to sugarize the additive starch. For this reason infusion
method is important.

11

100C
90
80
70
60
50
40
30
1

(hour)

Infusion Diagram
Double Mashing Method
Malt starch is an expensive ingredient. To reduce the cost of beer, the starches of rice and
corn are used. But the starch must be pasted, else amilase cant influence the starch. To
prevent this, the additives must be boiled before addition. During the boiling, both rice and
corn particles must be in small pieces. During this operation starch becomes sticky and then
can be added to grinded malt.
This method is prefered in bright colored beer production. In fact double mashing is a type of
infusion method.
Straining of the Mash
The seperation of extract gained in mashing and strainig of must have to be complete and
done in a short time. This operation is done in two stages;
1. First must is strained
12

2. Remaining crashed seeds are washed in hot water at 80C, then sent to straining tank
to be strained.
3.3 Straining Tank
This tank is used for straining of mash. It looks like mashing tank. The shells in mash settle
on the perforated base and form a filtering layer. After the main must flows, the remained
extracts on the filter are gained with hot water. Straining tanks are cylindrical in shape and
have perforated bases. The holes are like long cracks. The equipment is made of stainless
steel. There is a plate layer 1 cm below the base. Strained must passes from the perforated
base and accumulate here. Then must is sent to boiling tank. To prevent themust to become
cooler straining tank is built double sided.
Crashed Seeds
After the straining lots of crashed seeds remain. 110 kg grained malt leaves 110-120 kg
crashed seeds including %80 water. Wet crashed seeds can be fermentated to sugar up to
%0.5. Crashed seeds are transfered to their tanks via air flow.
3.4 Boiling
The must gained from straining tank is sent to must boiling tank. The boiling of must is the
turning point in the production. Practically, all the malt must and hopfen are boiled 1-2hours
together. Nothing can be added meanwhile.
Some or all of the hopfen can be exchanged with hopfen extract. If the hopfen is seperated
from the extract and independently isomerizeda it can be more efficient. Previously
isomerized hopfen will be added to beer after fermentation.
Many complex reactions occurs during te boiling process. By the heating of the must all
enzymes like amilase, whick stabilized the carbohydrate composition, become ineffective. At
boiling temperature the must is purified from germs. During the boiling, proteins collapse and
some of them react each other with the help of some simple nitrogen mixtures and
13

polyphenoles. Remaining unsoluble precipitate is called sediment. Some of the sediment is

seperated in the boiling of must and called hot sediment. But the remaining spare part collapse
during the cooling of must. This is called cold sediment. After 1 hour boiling %10 of volume
is vaporized. By the vaporizing volatile aromatic compounds are removed.
Purpose of Boiling
1. Evaporating the water to set the extract concentration in required levels.
2. Demolishing the ferments and sterilize the must.
3. Collapsing the proteins.
4. Transfering the characteristics of beer, the flavour materials in hopfen, into must.
Boiling of Hopfen
Hopfens can be added to the boiling tank after the hot sediment collapses. To prevent foaming
a little amount of hopfen(less tan %10 of whole hopfen) can be added in the beginning of
boiling.
Hopfens must be added in three stages;
First addition, %25 of whole hopfen, to help the sediment to collapse 15-25 minutes after the
most efficient part of boiling.
Second and major addition, %50 of whole hopfen, 30 minutes after the beer gets bitter.
Last addition, before discharging the boiling tank or 15 minutes before the boiling ends.
Cooling of Must
After boiling must is sent to cooler. There are two types of coolers;

14

a) Open Coolers: In this type of coolers must is in contact with air

b) Close Coolers: During the cooling the contact with atmosphere is cut.
Well-known close coolers :
1) Double piped Coolers
2) Plate Coolers
3) Shell and Tube Coolers
4) Must Ventilating Coolers.
3.5 Fermentation and Maturing
Introduction to Fermentation
Fermentation is the cracking of big molecules of carbonhydrates by the help of
microorganisms. Fermentation can be divided into two parts, according to the existence of
oxygen in the cracking reaciton;
1. Oxidative Fermentation: Oxygen is used in oxidative fermentation. In formula;
C6H12O6 + 6O2 6CO2 + 6H2O + 72 cal.
Eg.: Acetic acid, citric acid, oxalic acid and formic acid fenmentation
2. Inoxidative Fermentation: Oxygen is not used. Examples of Inoxidative Fermentation
are, Ethyl alcohol(as in beer production), lactic acid, propionic acid and butic acid
fermentations.
C6H12O6 2C2H5OH + 2CO2 + 28 cal.

15

When the must is cooled to required temperature, it is mixed with yeast and sent to floatation
pools. Thereare two types of fermentation;
1. Top Fermentation
2. Bottom Fermentation

Bottom Fermentation
There are three stages in this fermentation;
1. Floatation
2. Major Fermentation
3. Maturing of second Fermentation
3.6 Floatation
The must coming from cooling, is fermented before transfering to floatation pools. How must
is fermented is explained below;
Before dosing the yeast an air flow is given from the bottom to obtain homogenization. At the
moment of must entering the tank dosing starts and finishes just before the flowing stops.
Entering the floatation pool fermented, the must is matured there for 6 days. At this time
period must is warmed up to 8-9C, so the yeasts increase. After the finish of floatation,
fermented must is pumped to fermentation tanks.
Purpose of Floatation
1. To sediment the dead yeasts
2. To float the unwanted materials gained from hopfens
16

3. To sediment the cold sediments.

3.7 Beer Yeasts

Beer yeasts are members of the Saccharomyces genus and in bottom fermentation the name of
the culture yeasts used is Saccharomyces Carlsbergensis. There is an important role of the
yeasts in beer quality. The must does not include any microorganisms because of the mashing
and boiling processes. Fermentation is totally done by the beer yeasts. In brewery the pure
yeasts are called culture yeast and the rest is called untamed yeasts. The yeasts we are using
can not include dead ones over %5 also cany include foreign microorganisms especially
bacteries.
In brewery bottom fermentation yeasts are divided into two groups; Lump
Yeasty(Bruchhefen) and Powder Yeast(Staubhefen). Lump yeasts sediments the bottom near
the end of fermentation but their fermentation degree(atteniation) is lower than Powder
Yeasts.
Floatation Pools
Floatation cellar is located below the must coolers. The cellar have to be easily cleaned, have
the required equipment to release the CO2, have adjustable temperature control and beer must
be in full control.
The optimum capacity of floatation pools are arranged as the %25 volume of must gained
once from mashing. Because the foam needs %25 volume not be overflowed. The depth of
the pools are 1-2 m. They are made of stainless steel. There are cooling pipes located at the
basements.
Major Fermentation
The fermented must at 9C is sent to fermentation tanks. In there it is warmed up to 12C and
stays at 12C for 6 days to be fermented. At the end of major fermentation the yeast collapses
17

to base and the young beer gets brighter. The bitter and dark layer in the surface of the beer is
cleaned and then beer is pumped to maturing tanks. The main event in the major fermentation
is the ethyl alcohol fermentation.
3.8 Chemical Mechanism of Ethyl Alcohol Fermentation
Lavosier found that the products of fermentation are CO2 and alcohol in 1789. In 1815 GayLussac formulized this;
C6H12O6 2C2H5OH + 2CO2
Glucose

Ethanol

2 mols of ethyl alcohol and 2 mols of CO2 are produced from 1 mol glucose. Also many by
products are produced too.
The enyzm, generating alcohol from sugar is zymase. It is a copmplex one originated from a
mixture of enzymes. They generate the alcohol in continious reacitons following each other.
According to the theory of Meyerhor et al., alcohol fermentation occurs in 12 stages; 6
carboned hexoz is divided into 3 carboned trioses, glycerin aldehyte and dioxiacheten. These
trioses tranformed into pyruvic acid. 2carboned acet aldehyte and 1 carbone CO2 is generated
from pyruvis acid. Acet aldehyte produce alcohol by gaining H.
Enzymes used in ethyl alcohol fermentation;
1. Hexocinase
2. Oxoisomerase
3. Phosphohexocinase
4. Aldolase

18

5. Phosphotrioisomerase
6. Phosphatedehidrase
7. Phosphoglicerineacidcinase
8. Phosphogliceremutase
9. Enolase
10. Pyruvatecinase
11. Carboxilase
Maturing
After the major fermentation young beer still contains fermetable extracts. This is %1-2 in
volume. To ferment the remained sugar young beer is sent to maturing tanks. Bottom
fermentation beers stays in maturing 3 weeks at 0-2C. this time can be changed according to
season and sales.
At the end maturing, tanks can be mixed with each other to obtain the wanted gas, color and
extract values, then sent to filtering. Before the filtering the beer cooled to -1C with the
gluchol at -2C.
Introduction to Filtration
To obtain the required brightness, beer must be filtered at least one time. Various types of
straining methods can be applicated. These are; Kieselguhr filters, Sheet filters and Pulp
filters.
Filtration Theory

19

At the end of maturing some amount of sediment collapses to bottom. This causes turbidity in
beer. To prevent this event beer must be filtered. After the filtration;
1. Beer must be sterile and clean as availible.
2. Losses of CO2 must be prevented.
3. The contact of beer with air must be prevented.
4. No infections can be occured.
To get the best result from filtration beer must be cooled as much as possible. The more the
beer cold the more the cold sediment arise. Good filtration means, preventing the warming up
of beer itself and seperating the sediments.
3.9 Introduction to Bottling
The bottles come to Bottle Washing Machine by conveyors.
Washing
The bottles are located the hives in the machine. The washing operation takes 20-30 minutes.
In this operation bottles are washed internally and externally. The washing operation stages;
a) Upside and down the bottles to discharge the remainings
b) Approximately 20 minutes, washing with %1 caustic solution at 90C.
c) Spraying caustic solution into bottles
d) Spraying hot water to external sides to remove the stickers
e) Spraying cold water to inside of bottles and then bottles leave the machine clean, dry
and empty.

20

Washed bottles are controlled by Empty Bottle Control equipment. If the bottle is not clean
as wanted it is sent to washing again.
Filling
The bottles are filled with the ventilles of the filling machine. In this operation;
a) The air inside is sucked with vacuum
b) CO2 at 1.5 bar pressure is given to the bottle
c) While CO2 is releasing beer is filled to the bottles
d) A tiny layer of water is charged to the bottle to make the beer foamed.
e) Taps are pressed to bottles by capsulling pistons and bottles leave the bottle filling
machine
Pasteurising
After the filling the bottles are sent to tunnel pasteur. In here the temperature of beer is risen.
Holding the beer at this temeperature for while then temperature is decreased. This cycle sets
beers biological stability.
Passing of bottles from hot to cold areas is the principle of Pasteur. Water is sprayed to
passing bottles. The temperature of sprayed water can be adjusted to wanted beer temperature
in bottles. The wanted temperature is obtained at preheat andsuper heating areas.
Tunnel Pasteurising
After the bottles are filled and tapped, they enter the tunnel pasteur. The bottles are transfered
in conveyors during this operation. During the operation water is sprayed over the bottles. The
pasteur temperature of beer is gained by adjusting the tenperature of spraying water. The

21

pasteur temperature is usually 63C. Beer stays 20 minutes at this temperature. Then cold
water is sprayed over and leave the system.
The water used in pasteur is very important. It must be clean and have a pH degree of 8. Else
pasteur doesnt works.

3.10 Introduction to Barreling

The main subject is to fill the pasteurised beer into barrels made of aliminium and stainless
steel. Aliminium barrels are preferred to be light and cheaper.
Preperation of Barrels for Filling
Empty barrels come to barrel reverser. Filling is done from bottom to barrels. So the tap of
barrel must be downwards. Then the barrels come to pressure kontrol section. Here the
pressure is controlled to be 1.5 atu. Passing the pressure control, the barrels come to external
washer. Here, the barrels are washed with hot water and brushes, then pass to intermal
washing.
Internal Washing
1st Head: Churn beer is discharged with air. Cold water is given and discharged with air
2nd Head: Hot water is given and discharged with air.
3th Head: Caustic is given and discharged with air
4th Head: Caustic is given. Some of it remains inside the barrels. Barrell with caustic comes
to filling machine.

22

Pasteurising for Barreling

The beer coming from filtering at 2-3C is pasteurised before filling. Dry-Pasteur is used in
barrelling. It has 4 stages;
1) Regeneration
2) Heating
3) Holder Tube
4) Cooling
Beer is pumped to first stage. There, it is heated by counter-flowing hot beer. It is warmed up
to Pasteur temperature. It done by counter-flowing by hot water. After than stays in tube for a
calculated time. This beer is then comes to first stage. When the filling starts, pasteurised beer
is pumped to buffer tank and then to filling machine.
Filling
1st Head: Caustic is discharged with air. Hot water is given and discharged with air.
2nd Head: Hot water is given and discharged wtih air. Acid is given and discharged with air.
3rd Head: Cold water is given and discharged with air. Saturated steam at 130C is given.
4th Head: Steam is discharged by giving CO2
5th Head: CO2 is given. Filling starts slow and then speed up. While beer entering the barrell
CO2 is discharged.
After the filling, the barrells are again turned upwards.

23

4. Capacity Choose
The annual beer production of Turkey is 8 millions hl. EFES PLSEN provides the %75 or 6
millions of this production.
We are willing to establish a factory to be able to produce annually 1200000 hl of malt beer
according to the marketing location and natural underground waters capacity. According to
this quantity our montly production is 100000 hl.
However we have to rearrange our production according to some conditions. For example we
take a break to production in Ramazan Fests. In these times our factory stops for planned
yearly upkeeping. In statistics of beer sales it seems that the major proportion of the sales are
made in May-December 6 months period. This is approximately 800.000 hl of our production.
So we have to produce 800.000 hl of beer in 6 months in a year. The beer production
capacities during the most of the sales are made;

800.000 hl
hl
= 130.000
6 months
month
130.000 hl
hl
= 5000
26 days
day

According to these values we need 3 pieces of 1500hl and 1 piece of 500 hl capacity pulling
tanks for daily 5000 hl production.
Filters loose 8 hours of time during the fill-up and excretion, so they are working;
5000 hl
hl
= 350
flux.
16 hours
h
The mass balance calculation is built up in the basis of boiling tank capacity. If we go rewind
the process from the end, the producti losses are; %0.2 in fermentation and %0.4 in filtration.
So for monthly 130.000 hl/month production;

24

130.000

hl
1
1
hl

= 138.000
month 0.96 0.98
month

The fermentation tank is designed to be filled with %75 liquid and %25 foam. This process is
done twice in month so;

138.000

hl
30days 69.000hl

=
month 15days 15 days

For the 3000 hl liquid portion;

69.000 hl product
= 23 pieces of tank.
3000 hl volume
The %25 of the tanks are departured for foam so:
3000
= 4000 hl is the capacity, one of 23 tanks.
0.75
Amount of malt required monthly;

138.000

hl
kg-malt
tons
15
= 2.070.000 kg-malt = 2.070
month
hl
month

Amount of malt required daily;

2070

tons
month
malt
1
= 80 tons
month
26 days
day

One month is taken as 26 days because of the weekends. So if we want to use 80 tonsmalt/day we need to choose the capacity of boling tank 10.000lt to make 8 times boiling a
day.

25

5. Flow Diagrams
5.1. Block Flow Diagram

Malt

Malt Mill

Bottling

Malt
Boiler

Straining
Tank

Water

Water

Filtering

Fermentati
on Tank

Boiling
Tank

Water

Plate
Cooler

Beer

5.2. Process Flow Diagram

Process Flow Diagram is in appendix.

6. Mass and Energy Balances

6.1 Mass Balances
Basis: One Boiling Tank
System: Mill + Malt-10.000 kg + Malt Mashing Tank

Malt-10.000 kg Mill Grinded Malt +380 hl water Malt Mashing Tank Main Mash
In mashing tank 3.8 hl water is added per 100 kg malt. So;

26

10.000 kg malt

3.8 hl
= 380 hl water.
100 kg

Input :

Malt = 10.000 kg
Water = 380 hl = 38.000 hl = 38.000 kg
Input = Output 10.000 + 38.000 = 48.000 kg = Main Mash
Basis: A Boiling Process
System: Straining Tank

Water used in straininng tank can be assumed to be 1/1 proportion to water used in mashing
tank. Mash required for one boiling can be strained in 3 hours.
Input:

Main Mash = 48.000 kg

Washing Water = 37.000 lt = 37.000 kg
Output:

Must = 750 hl = 75.000 lt = 75.000 kg

Input = Output 48.000 + 37.000 = 75.000 + Crushed seeds.
Crushed Seeds = 10.000 kg.
Crushed seeds are %80 water and %20 dry portion.

27

Water in crushed seeds;

10.000

80
= 8000 kg = 80 hl
100

Dry portion in crushed seeds = 10.000 8000 = 2000 kg.

Basis: A Boiling Process
System: Boiling Tank
Input:

Must = 750 hl =75.000 kg

Hopfen used in boiling = 750 hl

100g
= 75000 g = 75 kg
1hl

Output:

Hot Must = 675 hl = 67500 kg

Input = Output 75.000 + 75 = 67.500 + Steam Losses
Steam Losses = 7575 kg
This means, %10 of the Must is evaporated during the boiling process.
Basis : A Boiling Process
System : Cooling
Input:

28

Hot Must = 675 hl = 67500 lt = 67500 kg

Output :

Cold Must = 650 hl = 65000 lt = 65000 kg

Input = Output 67500 = 65000 + Cooling Losses
Cooling Losses = 2500 kg.
This means, %4 of the Must is lost during the cooling process.

6.2 Energy Balances

1.Boiling:
1.1 Malt Mashing Boiler:

In this tank the mixture is warmed up to 80C from 35C. So the mashing occurs in 2 hours
50 minutes. The required heat and steam:
Q = m.c.T

m = Total Mash

m = Malt + Water for Malt

m = 10.000 kg + 38.000 kg = 48.000kg
Basis : 1 hour of Mashing

Cp of Malt = 1

kcal
kg.C

Q = 48.000 1 (80-35) = 2.160.000

kcal
h

29

Malt Mashing Process = (2 hours

Q = 2.160.000

60 min
) + 50 min = 170 minutes.
1 hour

kcal
60 min 1 mashing
kcal

762.350
heat is required.
mashing 1 hour 170 min
h

Looking up the saturated steam heat tables:

P = 3 At

y = 1 H = 2676.1

kJ
kg

x = 1 h = 419.04

kJ
kg

H = H-h = 2676.1 419.04 = 2257.06

kJ 1 kcal
kcal

.
540
kg
kg 4.18 kj

Basis : Amount of steam for 1 hour of mashing

m = amount of steam
kcal
)
kg-steam
h
1411
kcal
h
540
kg

(762.350

Q = m.H

m=

1.2 Boiling Tank

Must is boiled from 65C to 100C. This process occurs in 2.5 hours. Boiling occurs in two
parts:
a) Heating
b) Vaporizing

30

a)Heating:
Takes 1 hour to complete:
t2 = 100C

t1=65C t = 35C

Amount of Must from mass balance m = 75.000 kg-must

QI = m.Cp.t = 75.000 1

kcal
kcal
35C = 2.625.000
kg.C
h

Q
=
Used Steam; mI =
H

kcal
)
h 4860 kg-steam
kcal
h
540
kg

(2.625.000

b)Vaporizing:
Takes 1.5 hours to complete. The amount of steam given to the system is equal to the amount
of steam lost in boiling of the must. Because the energy of steam given to system is equal to
the loss of vapor during the boiling. So steam loss calculated previous mass balance;
Basis : A Boiling Process

msteam = 7575

kg
vaporizing

QB = m B H B = 7575 kg 540

kcal
kcal
= 4.090.500
.
kg
vaporizing

Vaporizing takes 1.5 hour;

QB = 4.090.500

kcal 1 vap 60min

kcal
= 2.727.000

(Energy in 1 hour)
vap 90min 1hour
h

Basis : Steam used in 1 hour vaporizing

31

mB =

Q
=
H

kcal
)
h = 5050 kg-steam
kcal
h
540
kg

(2.727.000

Amonunt of steam required for total Boiling;

mT = mB + mI = 5050 + 4860 = 9910

kg-steam
.
h

Basis : 1 hour of boiling and mashing

Total heat for boiling; QT = QI + QB = 2.727.000 + 2.625.000 = 5.352.000

kcal
h

Total heat for mashing and boiling; QT = QBoiling + QMashing

= 762.350 + 5.352.000 = 6.114.350

kcal
h

Total steam for mashing and boiling; ST = SB + SMash

= 9910 + 1411 = 11.320

kg-steam
h

Efficiency of the tanks assumed = 0.90;

Total heat for the system; Maximum Heat = 6.114.350

(mmax)steam =

100
kcal
6.793.720
90
h

Qmax
6.793.720
kg-steam
= 12.580
=
540
h
H

PLATE COOLERS

Must enters the cooler at 100C and leaves at 9C. Cooling water enters at 2C and leaves at
85C. Basically cooling time is assumed to be 1 hour.

32

must = 105

kg
lt

mmust = 675 hl must = 67500 lt 1.05 = 70.875 kg-must

%88 of must is water and rest of it is extract.

Cpwater = 1

kcal
kg.K

Cpextract = 0.38

kcal
kg.K

Cpmixture = 0.88 Cpwater + 0.12 Cpextract = (0.88 1) + (0.38 0.12) = 0.925

Qmust = mmust Cpmust T = 70.875 0.925 (100-9) = 5.965.903

kcal
kg.K

kcal
h

According to these data and %2 leakage in the system;

Heat gained = Heat given. From this we can calculate the amount of the cold water.
Qmust x 0.96 = mwater x Cpwater x T

mwater = Q must

0.96
0.96
= 5.965.903
= 69.000 kg water is required.
Cp water T
1 (85-2)

2. FERMENTATION

Two types of reaction occur in the fermentation tank.

a) Oxidative reaction : C6H12O6 + 6O2 6CO2 + 6H2O
b) Unoxidative reaction : C6H12O6 + O2 2C2H5OH + 2CO2
Every fermentation tank can cover the boiling capacity.

33

Fermentation process takes 6 days and 2 days for cooling also 7 days for maturing, totally
takes 15 days to complete.
Sugar percentages in the tank:
0th day %12.5

4th day %2.60

1st day %10.90

5th day %2.20

2nd day %6.15

6th day %2.10

3rd day %3.70

Cooling starts

According to this heat transfer during the fermentation;

1st day: Neither fill-up nor pour-out happen. Temperature rises from 9C to 12C
2nd day : Sugar fermentation from %10.9 to %6.15 (12C)
3th day : Sugar fermentation from %6.15 to %3.70 (12C)
4th day : Sugar fermentation from %3.70 to %2.60 (12C)
5th day : Sugar fermentation from %2.60 to %2.20 (12C)
6th day : Sugar fermentation from %2.20 to %2.10 (12C)
135 kcal heat is gained from 1 kg of sugar and %75 (3000hl) of a fermentation tank is liquid;
1st day : No cooling

2nd day : 1 tank (3000

hl
(10.9 - 6.15)
kcal
135kcal/1kg-sugar = 1.923.750
)
1tank
100
day

heat exit.

34

3th day : 1 tank (3000

hl
(6.15 - 3.70)
kcal
135kcal/1kg-sugar = 992.250
)
day
1tank
100

heat exit.

4th day : 1 tank (3000

hl
(3.70 - 2.60)
kcal
135kcal/1kg-sugar = 445.500
)
heat
day
1tank
100

exit.

5th day : 1 tank (3000

hl
(2.60 - 2.20)
kcal
135kcal/1kg-sugar = 162.000
)
heat
day
1tank
100

exit.

6th day : 1 tank (3000

hl
(2.20 - 2.10)
kcal
135kcal/1kg-sugar = 40.500
)
1tank
100
day

heat exit.

QTotal = 3.564.000

kcal
day

Energy Exchange during Maturing

Q = m.C.T Q = 1 tank 300

T1 = 12C

Cp = 1

hl
lt
kcal
100
1 (12-(-1)) = 3.900.000
1tank
1hl
day

T2 = -1C In two days time

kcal
kg.C

Q = 3.900.000

kcal
kcal
= 1.950.000
2days
day

35

3. BOTTLING AND BARRELING

According to our factorys capacity our daily production is 5000

will be saled in bottles and te rest in barrels.
According to our standarts;

Bottle washing 9500

kcal
hl

Barrel washing 5600

kcal
hl

Bottle Pastorization 9000

kcal
hl

a) Bottle Beer Production

5000

hl
hl
0.60 = 3000
day
day

For bottle washing;

Qw = 9500

kcal
hl
1day
kcal
3000

= 1.187.500
hl
day 24 hours
h

For bottle pastorization;

Qp = 9000

kcal
hl
1day
kcal
3000

= 1.125.000
hl
day 24 hours
h

For bottling;

QTotal = Qw + Qp = 2.312.000

kcal
h
36

hl
. %60 of this production
day

Amount of steam used for bottling;

m=

QTotal
2.312.500
kg-steam
= 4282
=
540
h
H

b) Production rate for barrels;

5000

hl
hl
0.40 = 2000
day
day

Energy consumption for barreling; Q = 5600

kcal
hl

For barrel washing;

Qw = 5600

kcal
hl
1day
kcal
2000

= 466.600
hl
day 24 hours
h

Amount of steam required;

m=

Qw
kg-steam
= 466.600/540 = 864
H
h

7. Design of Process Units

Malt Boiler:

The boiler has two inlets. These are water and malt. Approximately every 100kg-malt
requires 3.8hl water add-on. Also 100kg malt has a 0.7hl volume. For these reasons we
assume the boiling process in a basis of 10.000kg malt;

10.000 kg-malt

0.7hl
= 70 hl volume
100 kg-malt

37

10.000 kg-malt

3.8 hl-water
= 380 hl waters volume
100 kg-malt

According to this maximum volume of our boiler;

Vmax = (70 + 380) 1.6 = 720 hl
However we are designing 550hl Mashing Boiler via engineering approach.
These boiler are have to be made of stainless steel and in cylindrical shape. Mashing boiler is
designed to be 5m in diameter and 3m height. This boiler has heating sites both in bottom and
lateral surface. Our boiler has 100m2 heating area and a mixer to obtain homogeneous mixing.
For the calculation of heating area required for the mashing process, we need to look up for
the amount of heat given in 1 hour time:

QM = 762.350

kcal
h

U = 1950

kJ
h.C

Q = U.A.T (Process is thought like an evaporator)

762.350

kcal 4.18 kJ

= 1950 A (80-35) A=36 m2

h
1 kcal

Fermentation Tank:

Fermentation occurs in the boiler in a 15 days period. This means two fermentation can be
made in a month time. According to our monthly production capacity;

138.000

hl
30 days 69.000hl

=
is the total capacity of a fermentation process. For the
month 15 days 15 days

3000hl liquid phase of the fermentation process;

38

69.000
= 23 tanks are required.
3000
The %25 part of the tank is seperated for foams;
3000
= 4000 hl one of 25 tanks.
0.75
4000hl volumed tank is made of stainless steel. We are designing a tank with a diameter of
6m and 18m height.
Calculation of the heat transfer area for fermentation process in the fermentation tank:
The energy exchange in the fermentation process is:
QTotal = 3.564.000 kcal/day
In fermentation process, in the cooling we are always using the same heating pocket so we are
taking the daily maximum heat transfer value. This amount of heat is for 2 days time:

2 days Q = 1.923.750

kcal 4.18 kJ 1 day

kJ

335.053
day 1 kcal 1 kcal
h

Q = U.A.Tlog U = 460

T1 = T2 = 12C

Tlog =

kJ
h

t1 = -4C

t2 = 0C

T1 T2 (12 0) (12 (4))

=
14
12
T1
ln(
)
ln
16
T2

335.053

kJ
kg
= 460
A 14 A=50 m2
h
h

39

Calculation of the heat transfer area in the fermentation tank for the maturing process:
Before we calculated the amount of energy exchange in maturing process;

Q = 1950000

kcal
kcal
kj
1day
kJ
= 1950000
4.18

= 339625
day
day
1 kcal
24 hours
h

U = 460 kj/h T1 = 12C

Tlog =

T2 = -1C

t1 = -4C

t2 = 0C

T1 T2 (12 (+3))
=
6.5
T1
12
ln(
)
ln
4
T2

Q = U.A.Tlog 339625 = 460 A 6.50 A = 114 m2

In conclusion the heat transfer areas for fermentation and maturing processes happening in
different times in the fermentation tank are different either. And the area for maturing is
bigger.
Boiling Tank:

As told above we are designing a set of tanks willing to make 8 times boiling a day in which
each of them has the capacity of 10.000hl and the total for 80tons of malt. These tanksa are
again made of stainless steel. Our tanksa are 6m in diameter and 3.6 m in height. Boiling
process happens in outer boilers so we are using pipe type heat exchangers.
We took the basis 1 hout for boiling;
Looking to the amount of the energy in the heating section of the boiling process:

QI = 2625000

kcal
h

40

Q = U.A.T 2625000 4.18 = 1950 A (100-65) A=160 m2

Straining Tank:

In this tank water is sprayed from perforated trays. To obtain this 200kg-malt is strained in a
standart 1m2 staining area. For our capacity of 10.000kg-malt;

10.000kg-malt

1m 2
= 50m 2 area is needed.
200kg-malt

This 50m2 area is designed to be 8m in diameter and 25m in circumference. Again this tank is
made of stainless steel.
According to literature for the straining flippers, 6 armed 8.1 rpm system is enough for our
process. Straining tank is shaped cyclindrical like mashing tank is. This tank is 8m in
diameter, 1.8 m in height and has a capacity of 900hl. Orifices in the tank are thin and
splitted.
These straining tanks must have the capacity to strain the required malt in 3 hours period.
Plate Cooler:

We are planning to cool the must in 100C to 2C in plate coolers. The heat transfer area of
our cooler according to previous mass and energy balances is calculated as;

Tlog =

(100 85) (9 2)
10.50
15
ln
7

Qgained = Qgiven = U.A.TU = 1972

kcal
m 2 .hC

Q = mwater x Cpwater x T = U.A.Tlog

69.000 1 (85 2) = 1972 A 10.50 A = 276m2.

41

We assumed the cooling liquid is cold water in 2C.

Filters:

Beer is being filtered to obtain the required clearness. There are many types of filtering;
Kieselguhr Filter, Horizontal Filter, Vertical Fitler and Plate Surrounding Filter. We prefer to
use Kieselguhr Filter and PVPP(PoliVinilPoliPolidan). PVPP is made of plastic and polimer
inert material.
Pumps:

We are using 4 HP powered 4 pumps to meet the water need in our plant. These pumps have
total 40 tons water/h pumping capacity. Our plant needs 350 hl water/ hour.
Bottling Machine:

Our beer production capacity is 5000 hl/day. %60 of this amount is for bottling and the rest is
for barreling.

8. Location and Layout

The most important raw material of beer is water. Approximately %90-92 of beer consists of
water. For this reason the land of the factory must be rich in ground water.
Also product wastes need to be removed by the water arcs from the factory.
The other important ingredient of beer is malt. So it must be easy to supply the required malt
for production. The factory can be nearby the malt factories. We also need hopfen for
production. This ingredient can be imported.
Another important factor in the choice of the location is marketing strategies. For example
factories can be established in cities , in which the beer consumption is too much. If we want

42

to export our production our factory must be nearby the export centers such as airports and
seaports. By the way we must pay attention to the land prices, construction expenses.
In conclusion we decided to establish our factory in Lleburgaz according to all factors told
above.
Another factor is the structure of the soil in factory land. The land structure have to be enable
to allow locating pipes underground to pump the products to the tanks.
The lay out of the plant can be arranged according to process flow. We are establishing the
equipments according to their location in the process. So we dont have to pay extra money
for pumping anf piping.
The main production plan of beer;
Malt Boiling Fermentation Maturing Filtration Bottling.
Our plant lay-out is in appendix.

9. Economical Analysis
Total Instrument Costs
Instruments

Quantity

Price

Total

Mashing Tank

120.000$

120.000$

Straining Tank

30.650$

30.650$

Boiling Tank

147.750$

295.500$

Plate Cooler

150.110$

150.110$

Fermentation Tank

23

192.690$

4.431.870$

Filter

304.000$

304.000$

Pumps

350$

1400$

43

Bottling Machine

900.000$

TOTAL

900.000$
6.233.530$

Capital Estimation Based on Instrument Price

Proportion of

Cost

Instrument Cost
Instruments

100

6.233.530$

Building Instruments

47

2.929.759$

Instruments and

18

1.122.035$

Piping

66

4.114.129$

Electric System

11

685.688$

Buildings

18

1.122.035$

Enlarging

10

623.353$

Service Processes

70

4.363.471$

Land

374.011$

Direct Expenses

346

21.568.013$

Engineering and

33

2.057.064$

Construction Expenses

41

2.555.747$

Indirect Expenses

74

4.612.812$

Total Expenses

420

26.180.826$

Contractor Expenses

21

1.309.041$

Unexpected

42

2.618.082$

Fixed Capital

483

30.107.949$

Managing Capital

86

5.360.835$

Control

Control

44

TOTAL CAPITAL

569

35.468.735$

Total Product Cost Estimation

As the capacity is assumed 1.200.000 hl/year
Unit

Cost(kg/$)

Proportion of

Net Mass(kg)

Cost($)

mass(%)
Malt

0.25

20,5

24.600.000

6.150.000

Hopfen

1.5

0,17

204.000

204.000

So 1 lt of beer costs 6.354.000 $ / 120.000.000 lt = 0,053 $ as raw material.

The cost of beer is %20 of Total Production Expenses
So total production cost is 31.770.000 $
Total cost of 1 lt beer is 31.770.000 $ / 120.000.000 lt = 0,265 $ /lt
Marketing Price will be 0.413$ / lt
TOTAL COST PRODUCT = PRODUCTION COSTS + GENERAL EXPENSES
PRODUCTION EXPENSES = DIRECT PRODUCTION EXPENSES + FIXED
EXPENSES + COMPANY EXPENSES
GENERAL EXPENSES = MANAGEMENT EXPENSES + TRANSPORTATION +
R&D

45

Production Costs
Proportion of Total

Cost ($)

Cost(%)
Raw Materials

20

6.354.000$

Labor

20

6.354.000$

Control Labor

1.588.500$

Maintenance and Repair

1.588.500$

Laboratory

10

3.177.000$

TOTAL

60

19.062.000$

Proportion of Total

Cost ($)

Fixed Expenses

Cost(%)
Corrosion

953.100$

Tax

953.100$

Insurance

1.270.800$

TOTAL

10

3.177.000$

Proportion of Total

Cost ($)

Company Expenses

Cost(%)
Company Expenses

1.588.500$

46

General Expenses
Proportion of Total

Cost ($)

Cost(%)
Management Expenses

1.588.500$

Transportation

15

4.765.500$

R&D

1.588.500$

TOTAL

25

7.942.500$

GENERAL TOTAL

100

31.770.000$

Salary Distrubition
Total Labor Cost is 6.354.000 $
Position

Person

Salary ($/month)

Cost ($/month)

General Director

7000

7000 $

Chemical

4200

37800 $

4900

24500 $

4200

21000 $

Chemist

2100

16800 $

Workers

200

1400

280.000 $

Security

20

1400

28.000 $

Drivers

20

1400

28.000 $

Managing Officials

30

2800

84.000 $

Engineering
Mechanical
Engineering
Electrical
Engineering

TOTAL(Monthly)

527.100 $/month

TOTAL(Annual)

6.354.000 $/year

47

Recovery
In one year period company will gain 120.000.000 x 0.413 = 49.560.000 $
Net Profit = 49.560.000 (120.000.000 x 0.265) = 17.760.000 $
As the capital estimation is calculated = 35.468.735 / 17.760.000 2 years

Cash Flow Diagram

Total Investment = 35.468.735 $
Fixed Capital Investment = 30.107.949 $
Working Capital = 5.360.835 $
Working life = 10 years
Cost of Land = 374.011 $
Money Invested at the end of first year = 14.866.969 $
Money Invested at the end of second year = 14.866.969 $
Depreciation = Double Declining Balance Depreciation Method
dk = 2/n(FCI - dk)
dk3 = 2/10 x (30.107.949 0) = 6.021.589,8 $
dk4 = 2/10 x (30.107.949 6.021.589,8) = 4.817.271,85 $
dk5 = 2/10 x (30.107.949 (dk3 + dk4) = 3.853.817,5 $
dk6 = 3.083.054 $
dk7 = 2.466.443 $
dk8 = 1.973.154,5 $
dk9 = 1.578.523,7 $
dk10 = 1.262.819 $
dk11 = 1.010.255,1 $
dk12 = 808.204,1 $
R COMd = 49.560.000 31.770.000 = 17.790.000 $
From the equation; (R - COMd dk) x (1-t) + dk
3rd year = 14.847.897,5 $
4rd year = 14.546.818 $

48

5th year = 14.305.954 $

6th year = 14.113.263 $
7th year = 13.959.110 $
8th year = 13.835.788 $
9th year = 13.737.131 $
10th year = 13.658.205 $
11th year = 13.595.064 $
12th year = 13.544.551 $
The sum of these values = 140.143.781,5 $
Profit = 140.143.781,5 35.468.735 = 104.675.046,5 $
Annual Profit = 104.675.046,5/12 = 8722920,5 $
Cash Flow Diagram
80.000.000
60.000.000
Money

40.000.000
20.000.000
0
-20.000.000

10

-40.000.000
Year

49

15

10. Conclusion
Beer production of Turkey is sufficient for its own needs. %75 of beer sales are made by
EFES PLSEN. Our project is planned to produce %15 need of countrys beer poverty. In
consideration with the potential working power and qualified persons, there will be any
problems on operating this plant. However, most of the equipments, have to be used in beer
production, must be imported from foreign countries, especially from Germany. This causes
the establishing expenses to be increased. With hardworking and enough R&D studies on this
subject can solve the expensive imported instruments costs problem. Beside this the whole
raw materials used in beer production can be gained from our countrys own agriculturel
production. So there is no shortage of raw materials indeed. According to economical
analyses, our factorys payback time is approximately 2 years. This result is satisfactory and
the investment seems feasible.

50

11.Appendix
Tables of Beer Productions and Consumptions
Tables of Malt Production
Factory Lay-out Plan
Fermentation of Etyhl Alcohol
Process Flow Diagram
Change of Parameters During Fermentation
Pictures of Equipments

51

Mashing
+
Malt
Boilers

Fermentation
Tanks

Maturing
Tanks

Bottling
+
Bottle Washibg

Filtering

Security

Warehouse

Firehouse
Manageme
nt Building

Work
shop

Dining
Hall
+
Lockers

Lab

Waste Water Treatment

+
Steam Production
52

Change of Parameters During Fermentation

Day

P(BAR)

0,4

0,4

0,4

0,4

0,4

0,4

0,4

0,4

0,4

10

0,4

11

0,4

12

0,4

13

0,4

14

0,4

15

0,4

Day

Ph

4,58

4,33

4,23

4,19

4,22

4,22

4,22

4,22

4,22

10

4,22

11

4,22

12

4,22

13

4,22

14

4,22

15

4,22

53

Day

T(C)

12

12

12

12

12

-1

-1

-1

10

-1

11

-1

12

-1

13

-1

14

-1

15

-1

Day

Extract(%)

12,5

10,9

6,15

3,7

2,6

2,2

2,1

2,1

2,1

2,1

10

2,1

11

2,1

12

2,1

13

2,1

14

2,1

15

2,1

54

Some Pictures of Equipments Used in Breweries

Fermentation Tanks

55

56

12. Preferences
ZEN, Il, (1988), ODT Intership Report

PALACIOLU, Sibel, (1999) Gazi niversitesi Project

KUNZE, International Edition, (1995) Technology Brewing

and Malting
BNGLL, Feyza, (1999), Bira retim Teknolojisi
YAVUZLUHANOLU, Bur, Private Meeting, stanbul
Internet Resources
www.efespilsen.com.tr
www.steinecker.com
www.tuborg.com.tr
www.kimyamuhendisi.com
www.odevsitesi.com
www.kimyaevi.org

57