Industrial technology for beer production. Industrial technology for beer production in factories

Over the weekend, I made a long-planned trip to an interesting production facility: I visited a brewery, saw how and what they use to brew beer, walked around the workshops and, of course, tasted the products.

I suggest we walk together.

2. A theater begins with a hanger, and a brewery begins with a store. Of course this is not true. The visit to the factory ends with the store. So for now we just take pictures and pass by.

3. Checkpoint of the brewery in Mytishchi. This is one of the most modern breweries in Europe. Here we go.

4. Cute door sticker. I support a policy of openness, thanks to which you can read this report.

5. There is a small queue at the entrance. Several excursions came to the plant. We'll go in the first batch.

6. In the corridor on the walls hang paintings by Valery Barykin, which formed the basis for the collection series of Zhiguli beer.

7. I really like these works, socialist realist pin-ups.

8. One of the first pictures, as far as I remember.

9. Each picture has many details that you can look at for a long time.

10. This is based on “Three Plus Two”, there is also one with “Hipsters”.

11. Hipsters.

12. Roofers?


I apologize for the abundance of pictures, but they are really cool.

13. And these are the limited edition cans themselves.

14. The main brands of the Moscow Brewing Company: Zhiguli, Khamovniki, Trekhgornoye. In addition, there are licensed ones.

15. Our guide Elena Prekrasnaya, works at a factory in logistics. Excursions are conducted by company employees.

16. The main components of beer: hops, malt and water.


The hops we use are imported; unfortunately, we do not yet have enterprises that can provide the required and stable quality of raw materials. So, beer may also become more expensive.

17. Depending on the varieties and heat treatment, there are various types malt. There are three main types.

18. Accordingly, everything affects the taste and quality of beer.

19. In a dark way?

20. General scheme brewing beer.

21. It all starts with grout. The malt is crushed and mixed with water in these containers. These are just the covers.

23. Filters are visible in the background.

24. One of the most important components is water. Here it is extracted from artesian wells, after which it undergoes additional filtration and processing.

25. These are water filters.

26. The process is fully automated and controlled from this Brewery Control Center.

27. We go downstairs and find ourselves in a huge refrigerator. This is where the wort is cooled.

28. What happens in the fermentation department is what makes beer beer - yeast converts sugar into alcohol during the fermentation process and carbon dioxide.


One of the jokes is to move the sign on the door, hiding the letter "b".

29. The containers are amazing in their size. There are thousands of hectoliters, i.e. thousand hundreds liters. About a dozen railway tanks of beer are fermenting in such “barrels” at the same time.


After fermentation, the beer must mature; the process is not quick.

30. The equipment is all the most modern.

31. At all stages of production, products are subjected to hundreds of analyzes.

32. This gray device on the right is a beer analyzer; it produces many parameters in a few minutes. Costs the same as an apartment in Mytishchi.

33. After the beer has been prepared, it needs to be filtered. The plant has several different filtration units.

34. Here the beer is filtered through a kieselguhr filter. Diatomaceous earth - sedimentary rock, ground to flour.

35. Main Pipeline.

36. Finished and filtered beer goes to the bottling shop, where it is packaged in glass bottles, cans, polyethylene containers (correctly PET) and kegs. There's a break here now.

37. There is a photograph hanging near the bottling workshop showing that everything is fine at the plant.

38. Another photo - at the plant control panel.

39. Model of a factory, assembled from almost 30 thousand Lego parts.

40. My son envied grown men who had so many details.

41. Soon the model will have to be completed: in reality, the plant is expanding.

42. Visiting a brewery and not trying the beer is wrong. Therefore, after visiting the workshops, we go to try the beer. Everything is the freshest and most delicious. “Zhiguli” is a well-known brand, a joint project with a restaurant on Arbat.

43. I remember Khamovniki when they were still near Frunzenskaya. Now the IPC continues the tradition. New products include non-alcoholic beer Trekhgornoye and a sponsorship contract with Spartak.

44. — Demand that the beer be topped up after the foam settles!


In fact, this is one of the varieties - “Khamovniki keg” - it is specially poured this way, then the foam falls off, turning into beer. This is called the “avalanche effect”.

45. Elena treats everyone present.


After the tasting, we say thank you and go to the exit.

46. ​​Taking this opportunity, we take a photo of the empty stand at the entrance and the bottle tree. It's time for us to go to the store and then home - let's continue in a family atmosphere.

Thanks to the IPC for the tour. You can sign up for a tour on the company’s website, I highly recommend it.

Some of my other reports:

Characteristics of raw materials

Basic technological operations

Assortment and physical and chemical parameters types of beer

Fundamental technological scheme production

Hardware and technological diagram of beer production

Part 2 Biochemical transformations at various stages of beer production

Transformations during mashing and filtering the mash

Factors influencing:

a) the process of boiling wort with hops

b) processes during cooling and oxidation

Transformations during fermentation of beer wort and post-fermentation of beer

Part 1 Beer production technology

CHARACTERISTICS OF RAW MATERIALS FOR BEER PRODUCTION

Malt and unmalted raw materials. The main raw material for beer production is barley malt (light, dark and special varieties), the characteristics of which are given in Table. 21.2. The main varietal characteristics of beer (color, taste, smell, aroma) largely depend on the quality of the malt and the ratio of its types in the recipe. The standard for beer allows the use of unmalted barley, rice milled wheat, and low-fat corn flour. The main requirements for the quality of malt substitutes are purity and compliance with the requirements for food raw materials. The use of unmalted raw materials is economically profitable and technologically justified. Therefore, when preparing 10...11% light beer, it is imperative to use at least 20% unmalted raw materials without the use of enzyme preparations. When using more than 20% unmalted barley, the use of enzyme preparations is mandatory.

In the production of Zhigulevskoe beer, it is allowed to use raw sugar in an amount of up to 6% of the mass of mashed grain products.

Water. The quality of water and its ionic composition have a great influence on the formation of organoleptic characteristics of beer. Process water must meet all requirements for drinking water. It should be transparent, colorless, palatable, odorless, with a total hardness of 2...4 mEq/l and pH 6.8...7.3.

Water is considered optimal for beer production if the ratio of the concentration of calcium ions to the total alkalinity of the water (alkalinity index) is at least 1, and the ratio of calcium and magnesium ions is 1:1...3:1.

Water hardness and its salt composition are regulated using various water treatment methods: reagent, ion exchange, electrodialysis and membrane, based on the principle of reverse osmosis.

To remove unpleasant odors, water is deodorized by passing it through a column filled with activated carbon.

Hops and hop products. Hops are the traditional and most expensive raw material for brewing production. It gives beer a specific bitter taste and aroma, helps remove certain proteins from the wort, serves as an antiseptic, suppressing the activity of contaminating microflora, and increases the foam stability of beer. There are two main types of hops: bittering and aromatic. In brewing, predominantly female inflorescences of aromatic hops are used - hop cones containing lupulin. The latter contains aromatic and bitter substances.

Bittering hop substances include α- and β-acids, soft α-, β-, and hard resins. The content of α-acids, depending on the hop variety, can reach 16%. The most valuable derivatives of α-acids for brewing - isocompounds - provide about 90% of the bitterness of beer.

Aromatic substances are represented mainly by essential oil, the content of which ranges from 0.3 to 2%. Important component hops - tannins, the amount of which reaches 3%.

“According to their intended purpose, hops are divided into two groups: fine varieties with a bitter substance content of about 15% and α-acids from 3 to 5%, used for the production of beer using classical technology, and coarse varieties with a bitter substance content of more than 20%, intended for the production of powders, granules and extracts. Dried hop cones, ground, granulated or briquetted hops, as well as various hop extracts are used in brewing.

Hops and hop products should be stored in a dry, dark and cooled room with a temperature of 0 to 2 °C and a relative humidity of no higher than 70%.

Enzyme preparations. Used when using more than 20% of unmalted raw materials in an amount from 0.001 to 0.075% by weight of processed raw materials.

Amylolytic (Amylosubtilin G10x, Amylo-rizin Px, etc.), proteolytic (Protosubtilin G10x), cytolytic (Cytorosemin P10x, Celloconingin P10x, etc.) enzyme preparations, as well as their mixtures in the form of multienzyme compositions, are used.

Amylolytic preparations are used for mashing with an increased amount of unmalted raw material and low quality of the original wort. They significantly increase the extract yield and improve the quality of the wort.

Protosubtilin G10x is used with increased quantities of unmalted raw materials and to improve the quality of wort from low-quality malts, as well as to eliminate colloidal haze in beer. Cytolytic drugs increase the yield of the extract due to the hydrolysis of non-starch polysaccharides, mainly hemicellulose. At the same time, the quality of the wort and the stability of the beer increase.

The most promising means is the use of multienzyme compositions (MEC), which make it possible to maintain the high quality of Zhigulevsky beer when using up to 60% unmalted raw materials.

The products of breweries - beer - are weak alcoholic drink. Beer is made mainly from barley malt and hops. At different stages of the technological process, barley wort undergoes biochemical transformations under the action of enzymes from both malt and brewing yeast. The nutrients necessary for yeast - carbohydrates, amino acids and mineral salts - are contained in beer wort.

The technological process of brewing includes the following stages: malt production, wort boiling, beer wort fermentation (main fermentation), beer aging and maturation (fermentation), filtration and bottling. To produce malt, barley is soaked, germinated and dried.

During the malting process, enzymes accumulate in the grain, which then convert grain starch into fermentable sugars and grain proteins into amino acids. When malt is dried under the influence of high temperature, aromatic substances are formed, giving beer its characteristic smell and taste.

A complex technological stage is the boiling of the wort. The crushed malt is treated with warm water, and under the action of enzymes, 75% of the malt dry matter goes into solution. Cooking is carried out in several stages. The temperature is adjusted to create the best conditions for the action of amylolytic (starch-breaking) and proteolytic (protein-breaking) enzymes. When the wort is boiled, the proteins coagulate, and the hop substances dissolve and give the wort its characteristic bitterness and aroma.

The fermentation process of beer wort is divided, as stated above, into two periods - main fermentation and post-fermentation. The main fermentation takes place in fermentation tanks (open containers) or tanks (closed containers).

Depending on the properties of the yeast used, fermentation can be bottom (cold - at a temperature of 6-10°C) and top (warm - at a temperature of 14-25°C). As a result of fermentation, 3-8% alcohol, up to 0.4% carbon dioxide and by-products accumulate in beer.

The main fermentation is carried out until a certain amount of alcohol corresponding to a given variety is obtained.

The bulk of the yeast settles to the bottom of the vessel, and only part remains in the young beer at the post-fermentation stage. This stage takes place in hermetically sealed containers, under pressure at a temperature of about 0 ° C and consists of slow fermentation of the remaining sugars, saturation of the beer with CO 2 and sedimentation of the yeast.

During maturation, complex biochemical transformations of substances occur in beer and organoleptic characteristics change. After the main fermentation, the product acquires the taste and aroma (bouquet) of the finished drink.

The most important processes during the fermentation of beer wort with yeast are shown in Diagram 4. Beer is clarified due to the settling of yeast and various suspensions - protein particles, hop resins, etc. For complete clarification, the beer is filtered and bottled and bottled under pressure.

Scheme 4. The most important processes during the fermentation of beer wort.

This is how beer is produced using classical technology. However, in recent decades, new progressive methods have been developed and applied to reduce the duration of technological stages. There are two such methods: beer production in a continuous flow and in large vertical containers - cylindrical-conical tanks (CCT).

The beer production technology at CCT is as follows. The tank is filled 80-85% with chilled wort at a temperature of 8-10°C during the day, for which 4 boils are used: the first portion of the wort is aerated and yeast is added to it. Fermentation takes place at a temperature of 12-13 ° C; after reaching the final degree of fermentation, the beer is cooled to 0.5-1.5 ° C and kept for another 6-7 days.

Currently, using this progressive technology, not only Zhiguli beer is produced, but also varietal beer: 12% beer in 18-20 days instead of 38 and 13% beer in 22 days instead of 50. At the same time, a significant economic effect and the product is obtained high quality. The technology of beer production in CCT is widely used in our country.

Brewing beer is one of the most complex technological processes in food industry. To obtain a high-quality drink, brewers need to take into account many nuances and carefully select ingredients. Next we will look at important stages classical brewing technology, which is used by most modern factories.

First, let's find out what beer is made from. In the traditional recipe, only four ingredients are allowed:

Malt– a product obtained by sprouting cereals. To make beer, barley that has been malted is used, a process that promotes germination of the grain. After soaking, barley swells and chemical reactions begin inside the grains, breaking down starch into malt sugar needed for fermentation.

Water. In brewing, water is distinguished by its composition and salt concentration. For some types of beer, “hard water” (high salt content) is better, for example, for Munich. There are varieties made exclusively with low-salt water, such as Pilsner beer. Modern technologies allow you to regulate the concentration of salts in water with a very high degree of accuracy, which simplifies production.

Hop. Gives beer a characteristic bitter taste, fragrant aroma and is responsible for foaming. It is impossible to replace hops in beer production without loss of quality. This is a unique plant, which contains more than 200 substances responsible for taste. Interestingly, only the cones of female hop plants are suitable for beer.

Yeast. Modern breweries use special brewer's yeast of the Saccharomycetes family, which is not found in nature, but is artificially bred specifically for brewing. Depending on the fermentation technology, two types of yeast are involved in beer production:

• top fermentation (Saccharomycetaceae cerevisiae) – suitable for such types of beer as porter, ale and stout;
• bottom fermentation (Saccharomycetaceae carlsbergensis) – used in the production of lager and Central European beer.

The difference between these types of brewer's yeast is that at the final stage, top-fermenting yeast collects on the surface (float), and bottom-fermenting yeast - at the bottom of the wort. This significantly affects the taste.

Stages of beer production

1. Preparation of wort. First, the barley malt is crushed, but the grains should not turn into a homogeneous mass. The composition of the wort requires large and small grains. This is called malt milling. The ratio of large and small particles differs in different types of beer.

The malt grind is then mixed with water. This process is called "mashing" and the resulting mixture is called mash. When water is added, barley enzymes begin to break down the starch into malt sugar. To speed up fermentation, brewers heat the mash to 76°C.

Next, the finished wort is filtered. The boiled mash is poured from the boiler into a special sieve, closed at the bottom. The mashed malt remains in this state for some time until solid particles called grains settle at the bottom. When the sieve is opened, clean liquid wort begins to seep through it and the layer of spent grain, which is collected in a special kettle for subsequent brewing.

2. Boiling the wort. The wort obtained at the previous stage is heated, brought to a boil and hops are added. The number of cones depends on the type of beer and the preferences of the master. Each recipe uses a different amount of hops.

Cooking the wort takes 2-3 hours. During this process, all microorganisms die and enzymes are destroyed, so further chemical reactions are impossible. Brewers achieve a predetermined density of the initial wort, which is designated as beer gravity on the label of the finished product.

Next, the brewed wort is filtered to remove any remaining hops and allowed to settle. The smallest particles that could not be filtered out at the previous stage fall out at the bottom. Some plants also speed up the removal of unwanted residues by centrifuge.

3. Fermentation. Clean wort flows through pipes to the bottom of fermentation tanks, called cylindrical tanks. After the liquid has cooled to the desired temperature, yeast is added to the vat. For top-fermented beer, before adding yeast, the wort is cooled to 18-22°C, for bottom-fermented beer - to 5-10°C.

A day after the yeast is added, a thick layer of foam appears on the surface of the fermentation tank. This means that the yeast has successfully begun to convert sugar into carbon dioxide and alcohol. During fermentation, a lot of heat is generated, so the wort needs constant cooling, the temperature must be stable.

During the fermentation stage, brewers monitor the concentration of carbon dioxide in the vats. When the maximum permissible level is reached, the gas is discharged through special pipes. Fermentation stops after the yeast has converted all the sugar into alcohol.

4. Maturation. The previous stages resulted in young, unfiltered beer that requires further maturation (does not apply to wheat varieties). For ripening, large containers made of stainless steel, and the process itself lasts from several weeks to four months.

During ripening, it is necessary to maintain a stable temperature and pressure in the containers; fluctuations are unacceptable. On modern enterprises The technological process is controlled by special equipment that can automatically change temperature and pressure.

5. Filtration. After maturation, the beer undergoes another filtration with two different filters designed to remove large and small particles. After this, the foamy drink becomes absolutely transparent and ready for bottling.

6. Bottling. At the final stage of production, beer is poured into containers different types. Before filling bottles, kegs or kegs, all containers are washed, then the air trapped inside is removed. Beer is a perishable alcoholic beverage that requires sterile conditions. Without sterility, the shelf life of the finished product is only a couple of days. When bottling into glass containers, bottles are pre-pasteurized - slowly heated to a temperature of 65°C, which significantly extends the shelf life of beer.

To systematize all the information, I suggest looking at the following diagram illustrating the sequence of stages.