Manufacturing of Pilsner beer

Pilsner is a colorless lager beer originally brewed in the city of Pilsen. Pilsner is brewed with pilsner malt and lager yeast, which is bottom-fermenting and distinguishes lagers from ales. Lightly kilned malted barley, spicy hops that so define the aroma and flavor of this style, lager yeast, and soft water are all that's needed for the skilled brewer to produce a fine pilsner.

Water used for this style of beer tend to be harder, with a higher calcium and magnesium content than water used for lager. The color of pilsner is also lighter than that of lager beer.

The production involves malting, milling, mashing, extract separation, hop addition and boiling, removal of hops and precipitates, cooling and aeration, fermentation, separation of yeast from young beer, aging, maturing, and packaging.

Barley grains are made to germinate by soaking in water. The germination process is interrupted in a special moment and the grain is then dried and heated. By this way is barley transformed to the malt.

Hot water is mixed with cracked grain in a large vessel commonly known as a “Mash Tun.” Due to the enzymes present in the malt, starches from the malt are converted into sugars. What brewers are creating in the mash tun is called wort: a sugar-rich liquid made from malt and other grains.

The malt is cooked with water in large cupreous tanks above an open flame during mashing. This process is repeated three times.

During lautering (separation of the liquid) process is the liquid extract (known as wort) separated from the grain scrap. Lautering refers to the process of separating the wort, or mash, from the residual grain as efficiently as possible. However, to obtain the highest level of efficiency during this step, lautering is generally broken into three phases: mashout, recirculation, and sparging.

Then hops finally step in at this stage. The hops release bitter essences that give Pilsner beer its typical aroma. Hot wort is again "cleaned" from hops and other settlements.

The wort is then cooled to the fermentation temperature 6-7 °C (44 °F). Subsequent fermentation takes place in stainless steel cylindroconical tanks in two phases: fermentation and maturation. Pilsners are bottom-fermenting types of beer made with a carbonation and brewing process characterized by cooler temperatures. Bottom fermentation beers need a longer rest period after the main fermentation that occurs in cold conditions (around 0 degrees) compared to top fermenting beers.

When the fermentation is over, the yeast is removed. During maturation phase is the beer allowed to lie and to mature for 3-4 weeks.
Manufacturing of Pilsner beer

Wine processing: Fermentation

Fermentation is a viable technique in the development of new products with modified physicochemical and sensory qualities, especially flavor and nutritional components

Alcoholic fermentation is widely employed for the preparation of beverages in which alcohol is major constituent. The conversion of grape juice to wine is a biotechnological tradition dating back to the dawn of civilization. Throughout the ages numerous winemaking strategies were developed resulting in the range of wine products, from champagne to port, available today.

Wine is an alcoholic beverage produced by the fermentation of sugars in fruit juices, primarily grape juice. In general, wines are classified into two types based on alcohol content: table wines(7 percent to 14 percent, by volume) and dessert wines (14 percent to 24 percent, by volume).

Fermentation is a relatively efficient, low energy preservation process which increases the shelf life, and decreases the need for refrigeration or other forms of food preservation technology. It is, therefore, a highly appropriate technique for use in developing countries and remote areas where access to sophisticated equipment is limited.

Fermented fruit wines are popular throughout the world, and in some regions, it makes a significant contribution to the diet of millions of individuals.

White wine fermentations are typically carried out for roughly one to two weeks at temperatures around 10 to 18 °C. Upon consumption of available glucose and fructose, the main sugars in grape juice, the wine is considered “dry” and separated from the yeast and grape lees (sediment).

Red wines are produced slightly differently than white wines. Like white wines, the alcoholic fermentation commences either through the action of indigenous yeasts or via direct inoculation of a starter culture. During the fermentation the grape material tends to float to the top of the vat forming a “cap.” To better enable extrac-tion of red pigments and to influence wine flavor, winemakers typically punch down the cap or pump juice from the bottom over the cap.

Although residual sugars are of obvious importance to the sweetness of wine, fermentable sugars in grapes are absolutely essential for fermentation. The single most signifi cant by-product of fermentation is ethanol. In addition, sugars may be metabolized to higher alco-hols, fatty acid esters, and aldehydes.

Fermentation occurs in vats of stainless steel, lined concrete or wood. Fermenting at too low a temperature inhibits extracting the best material from the grapes; too high and aromatic and flavor complexity are lost.

The products of fermentation are as follows: Alcohol, glycerol, and carbon dioxide are obtained from yeast fermentation of various sugars; Butyl alcohol, acetone, lactic acid, monosodium glutamate, and acetic acid are products of bacteria action; and citric acid, gluconic acid, antibiotics,

After fermentation, all wines undergo a period of adjustment (maturation) and clarification prior to bottling. The process of maturation involves the precipitation of particulate and colloidal material from the wine as well as a complex range of physical, chemical, and biological changes that tend to maintain and/or improve the sensory characteristics of the wine.
Wine processing: Fermentation

Brewing process of Saké

Saké, a Japanese traditional alcohol beverage is produced by saccharification of rice starch by koji and alcoholic fermentation. Sake making has developed into a modern fermentation industry, producing clear, pale-colored rice wine with alcoholic content of 1% - 16% or higher. It has characteristics flavor and aroma, small amount of acid and slight sweetness.

Raw materials for saké: water used for saké should be colorless, tasteless and odorless, neutral or weakly alkaline, and substantially free of iron, nitrate, ammonia, organic substance and harmful organisms.

Rice of the short-grained varieties is considered best for saké manufacture and large grains are considered desirable.

The characteristics features in saké brewing are the use of ‘koji’ a culture of Aspergillus oryzae grown on and within steamed rice grains and parallel fermentation by saké yeast.

The first step is the preparation of milled rice and its steaming. This followed by the preparation of koji and the preparation of moto mash, starter for saké yeast prepared by mashing steamed rice, koji and water. The moto bubbles for a few days in a warm environment.

Koji and water are added in the evening, then the next morning more rice is added. Once all the rice has been incorporated, the rice mash is known as moromi.

The main fermentation takes 20-25 day. When fermentation has ceased the moromi mash is filtered to remove the solids; the filtrate thus obtained is fresh saké. After about a month, the fresh saké is pasteurized and stored.

Brewing process of Saké

Manufacturing of instant tea

The process of the production of instant tea consists of the following operations: selection of raw materials; extraction; aroma stripping; cream processing; concentration and drying.

Extraction is in most cases performed using water and countercurrent procedures.  Concentration of the extract is effected by evaporation of the water under reduced pressure at a moderately elevated temperature and during this process various methods for trapping the escaping volatile compounds have been devised. These trapped volatiles are concentrated and retained for incorporation into the final dried product.

Tea extract requires concentration before drying; a solids concentration of 40-45% is most common, although concentrations as low as ca. 20% and as high as 51% have been used.

High solids concentrations in the dryer feed are desirable to improve reconstitution properties of the instant tea powder. Thermal evaporation under reduced pressure is most commonly used, evaporators usually being of the falling film or plate types. The concentrated extract is turbid due to the formation of cream and solubilization of this cream is a fundamental problem in the production of instant teas soluble in cold water.

Cream processing can be accomplished by maintaining the temperature above 65 °C or by removal of the cream, for example by cooling and centrifugation. Cream treatment is especially necessary for cold water-soluble instants, which are commonly used for beverages like ice tea.

The finals step of drying the concentrated tea extract is commonly achieved by spray drying, but other methods, such as freeze drying or drum drying are the subject of published patents.
Manufacturing of instant tea

Decaffeination of tea by carbon dioxide supercritical process

Caffeine is an alkaloid which stimulates the central nervous, muscular and circulatory systems. Too much caffeine in tea are not good for elderly people and caffeine sensitive patients.

Tea is decaffeinated by various methods. Briefly the tea is prewetted and extracted by some organic solvent such as dichloromethane or ethyl acetate. Alternatively, an extraction using supercritical carbon dioxide can be used. Supercritical carbon dioxide is the most widely used solvent for decaffeination of food products. The gas is odorless, tasteless and inert.

When highly pressurized, carbon dioxide assumes a supercritical state and has properties of both a solid and a fluid. At this point, it becomes an efficient solvent for caffeine.

The compressed carbon dioxide is pumped into a chamber with tea. It extracts the caffeine, and the carbon dioxide is separated from the tea and carbon filtered to remove the caffeine.

Carbon dioxide processing leaves no toxic residues. In addition, extraction of the caffeine takes place at room temperature which protects product quality by preventing the breakdown of temperature-sensitive components.

After extraction occurs, the supercritical fluid turns back into a gas, so no solvent residue remains. CO2 decaffeinated teas best retain the original flavors of the teas.

Other advantages of supercritical CO2 as a decaffeination solvent:
*CO2 has suitable critical constant for this application
*CO2 in small amounts is physiological harmless an cause no environmental pollution
*CO2 is cheap, easily available and non flammable
Decaffeination of tea by carbon dioxide supercritical process

Processing of cherry wine

Cherry wines are usually best made from sour cherries since sweet ones contain too little acid. As with grape wines the best cherry wines are made from top quality fruit, ideally a bit overripened to maximize color and sugar. Brown rot, a common problem in overripened cherries will ruin cherry wine and must be avoided.

Late-picked Montmorency cherries that are immediately crushed give a good wine. Cherrie should be crushed in a grape crusher destemmer- must pump machine with the crusher rollers separate so as to minimize cracking of the pits.

Up to 10% of the pits may be broken to enhance flavor. The fruit juice is called ‘must’. The must should be treated with SO2, inoculated with wine yeast and fermented like red grape wine.

Initially aerate the must to promote vigorous yeast growth. Later on, maintain anaerobic condition for rapid production of ethanol.

The pulp must be pressed and left to drain. Pressing is done after 2 or 3 days of skin contact, sugar is added and the wine fermented dry. The skin color is readily extracted during fermentation. Pressing as soon as possible will help to reduce the bitter herbaceous skin character and almond flavor from the pits.

Generally, fermentation requires 25-30 ° C temperature and around 10-15 days. The ethanol produced varies from 7 to 15%. After fermentation allow to settle yeast and other debris, filter it, and pasteurize it.

A good cherry wine is smooth and medium sweet, light but with full cherry flavors. The color depends of the types of cherries used.

Cherry wines do not keep well and develop an off flavor after about 18 months.
Processing of cherry wine

Tea withering process

Physically withering is partially reduces moisture content and conditions the leaf physically and biochemically for the subsequent stages of manufacture.

The withering of tea leaves is the first step in processing black tea. The loss of water in fresh leaves makes it easier for the subsequent rolling and fermenting.

During this stage, the cell sap become more concentrated and cell membrane permeability increases.

In tea withering, green tea leaves are spread over a wire-netted platform and trough. A fan driven by induction motor pushes air from below the platform to dry the tea leaves. During this withering process water vaporizes and the rate of water evaporation is related to the humidity and temperature.

Withering optimization can take anywhere from 6 hours under artificial air and temperature conditions up to 18 hours under natural conditions.

Withering will increases the amino acids for aroma formation, caffeine for cup character, and organic acids for flavor.

Chemical withering is the key process for formation of white tea color, essential to activate the enzyme polyphenol oxidase and peroxidase for color development of white tea.
Tea withering process

Tea processing

A cup of infusion of made tea is completely different from infusion of fresh tea flushes in color, taste and favor. These characteristics are developed during the manufacturing process after the harvesting of tea flushes.

Black tea is the major kind of tea consumed in the world. The traditional process for the manufacture of black tea may be broken down into stages called:
*Plucking or harvesting

*Withering – this process results in disrupting the cell structure of the leaves and initiation of the fermentation process.

*Leaf maceration or rolling. Rolling of tea leaves originally done manually, whereas nowadays is performed by machines.

*Fermentation

*Firing or drying. This process is to stop the fermentation and to reach the favorable moisture content to suppress microorganism growth.

*Sorting and packaging

The entire tea manufacturing process, from plucking through drying, is usually completed in 6 to 24 hours, depending on climatic conditions and the type of manufacturing equipment employed.

Green tea is made by a process similar to that used for black tea manufacturer except that the fermentation stage is drastically altered by steaming at high temperature the a flush prior to the maceration stage, causing the enzymes in the flush to be inactivated (de-enzyming or fixation).

The basic manufacturing processes of oolong tea include sunlight withering, light rolling, de-enzyming, rolling and drying. The plucking standard for Oolong tea is different from other kinds of tea. It is recommended that shoots with one bud and three to four leaves be plucked.
Tea processing 

Process of beer brewing

Beer is a staple beverage of many consumers. Brewing is the production of beer through steeping a starch source in water and then fermenting with yeast.

The brewer begins with malted barley or another grain cereal. Malted barley is dried, sprouted or germinated barley which the brewer grinds and then heats with warm water, which converts the starches to sugars.

The actual brewing process takes place in two distinct phases, going first from warm to hot and then from cool to cold. Besides sanitation, heating and boiling also helps to prepare all the sugars and proteins for proper fermentation, creating a number of the good flavors in beer.

The brew-house operations yield a fermentable liquid called wort after adding hops.  This takes most of a working day.

After being boiled and cooled, the wort is fermented into beer, which takes approximately a week.  Hops give beer its distinctive bitter flavor. It also helps remove some solids, which are precipitated out.

The younger beer is chilled, aged, filtered and carbonated. It is then ready to be packaged into kegs, bottles or cans.

It is done in a brewery by a brewer, and the brewing industry is part of most western economies.
Process of beer brewing