A TECHNICAL REPORT

ON

SIX MONTHS INDUSTRIAL WORK EXPERIENCE SCHEME

(SIWES)

AT

NIGERIA BREWERIES PLC

NO 1 FACTORY ROAD ABA
ABIA STATE

BY

BROWN EMMANUEL ONYINYEOMA

REG NO: 2011244067

DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY

FACULTY OF ENGINEERING
NNAMDI AZIKIWE UNIVERSITY, AWKA
IN PARTIAL FULFILLMENT FOR THE AWARD OF BACHELOR’S

DEGREE IN ENGINEERING (B.ENG)

ON

NOVERMBER, 2014
Industrial Training Report At Nigerian Breweries Plc Aba

A Technical Report Presented to the

Department of Mechanical Engineering

Nnamdi Azikiwe University, Awka

Anambra State

By

Brown Emmanuel Onyinyeoma

2011244067

2013/2014

Academic Session
 DEDICATION

I dedicate this report to almighty God in Heaven, for his guidance,

protection and immense support through-out my six-months

industrial training at Nigerian Breweries Plc Aba, Abia State. All

glory; honor and adoration be highly ascribed unto your holy name.

Amen.

Also for my ever supportive parents, whom through their efforts; I

was able to secure a placement with the company to under the six

months industrial training, I pray that God will continue to keep

them, protect, and grant them long life and prosperity and they will

reap the good fruits of their labour.

Also I dedicate this report to my industrial based supervisors Engr

Audu Edwin, Mr Francis Isenu. (FISM), Mr Elisha Abraham, Mr

Chinemerem the Automation Engineer, Mr Innocent Okpa, the Brew

Manager Mr Ukeje Udah, and to all the staff of Aba brewery-whom

in one way or the other impacted to my knowledge during this

training, thanks and may my God in heaven also fulfill your heart

desires in Jesus name. Amen.

 ACKNOWLEDGEMENT

My gratitude goes to the staff of Nigeria Breweries Plc Aba, my

reviewers, colleagues who have offered invaluable information to me

during my six-months industrial training at Nigerian Breweries. The

success of this training is due in large measure to their

contributions. Their moral, materials, informative and financial

supports are highly rewarding and immensely appreciated.

Firstly, I want to extend my heartfelt thanks to my parents for their

committed effort in laying the good foundation for me.

Also to my siblings friends, course mates and colleague for their

encouragement, overwhelming support and invaluable information’s

during this program. I mostly thank this great citadel of learning for

granting me the opportunity to undergo this training exercise.

Finally, I give God thanks for his guidance and provision for me

throughout this program.

 Table of Content

Preliminary pager

Title page

Decoration

Dedication

Acknowledgement

Table of Content

Abstract

Dedication
 ABSTRACT

Nigerian Breweries Plc is the largest beverage industry in Nigeria,

incorporated by Heineken in 1946. The first bottle of beer, star

larger rolled off the bottling lines of it’s Lagos brewery in 1949. It is

the first brewery industry in Nigeria and it’s first and oldest branch

is Lagos brewery. Since it’s inception, the industry has undergone

several optimization processes and today boast of the most modem

brew house in the country.

This brewery has six major branches across the country, starting

with the oldest; Lagos brewery which was commissioned in 1949,

Aba brewery commissioned in 1957. This was followed by Kaduna

Brewery in 1963 and Ibadan brewery in 1982. In 1993, the company

acquired it’s fifth brewery in Enugu and in 2003 it commissioned it’s

sixth brewery (Ama brewery) sited at Amaeke Ngwo in Enugu State.

The company has a portfolio of high quality brands including: Star

larger (launched in 1949), Guilder larger in 1970, Legend Extra

stout (1992), Heineken larger 1998, Gold berg 2011, life continental

larger 2014.
The alcohol-free drinks includes: Maltina (1976) in three varieties

(Maltina classic: maltina straw berry, and maltina Pine Apple.

Maltina sip-it (2005) in Tetrapak), Amstel Malta in (1994), fayrouz in

pear and pineapple flavours (2006), climax Energy drink, Malta Gold

(2011).

Most of the products are packed in returnable bottles and all

products are now available in cans.

The company’s hand offices are located in Lagos.

 CHAPTER ONE

COMPANY OVERVIEW

Background

Nigerian Breweries (NB Plc) is a subsidiary of the Dutch brewer,

Heincken. It is Nigeria’s pioneer and largest brewer with current

annual production capacity estimated at 10mn hectoliters. Founded

in 1946, NB operates 6 breweries in Nigeria. The first was

commissioned in Lagos in 1949 and five others have subsequently

been established in Aba (1957), Kaduna (1963), Ibadan (1982) and

Ama (2003).

Over the years, NB launched a series of alcoholic and non-alcoholic

brands carefully crafted for the Nigerian consumer these includes:

star larger bear, the company’s first product, guilder larger beer,

Heineken (larger), Maltina (Malt drinks in four varieties; Maltina

classic, maltina straw berry, maltina exotic and Maltina with (pine

apple flavour) and legend Extra stout.

In 1990, Nigeria stock Exchange (NSE) listed NB as one of the most

capitalized and actively traded companies outside the banking and

insurance sector. As at December 2007, NB had 131,026 share

holders. Haneken N.V of Hrolland has a majority shareholding of

54.1%.

In 2014, NB commenced the production of Heineken lager beer

locally, which was an internationally high quality premium beer.

Presently – NB produces Heineken beer in it’s new state of the art

brewery in Ama (Enugu state, south East Nigeria).

In addition, NB recently attached maltina sip-nit in 2005 a variant of

maltina in a “Handy pack”. One of the latest products of NB is

Gulder Max a stronger, darker and higher gravity brewed variant of

the regular gulder with a 65% alcoholic content. This was done to

strengthen the existing brands and also increase the beer options

obtained elsewhere in the world.

Product brands

Star beer has assumed the image and stature of a national icon. A

beer associated with brightness, social fun, high quality taste and

style a world class brand, brewed by NB Plc.

 Star was introduced into the

Nigerian market in 1949 as the first indigenous beer brand. It

overcame quickly the problem of market acceptance and it’s

popularity gave other prospective investors courage to consider the

establishment of a brewery.

Gulder larger beer was introduced in 1970, relaunched in 1972 it

comes packed in a unique brown 60cl bottle. The beer is made from

malted barley, hops and water with a distinctively bitter taste.

 The gulder bottle was changed to a

brand new fashionable packaging with an attractive golden stenoil

and Gulder embossed on both sides of the bottle on 6 th Sept 2014.

Gulder is also exported to the United Kingdom.

Maltina is Nigeria’s premier malt drink and it is available in four

varieties, (Maltina classic, Maltina straw berry,

Maltina exotic and Maltina with pineapple.

Amstel Malta is a non-alcoholic malt beverage meaning it is brewed

from barley, hops, yeast, and water

much like beer corn and caramel color may also be added.

Legend Extra stout brand now relaunched in a brand new and

fashionable packaging.
 The new legend extra start now

comes with a new attractive body and neck label. A unique, bottom-

fermenting alcoholic beverage produced from sorghum malt,

sorghum and Maize and flavoured with a natural stout aroma

compound with 7.4% alcoholic content.

The Distribution Chain

NB delivers it’s products to the customers through 147 key

distributors and wholesalers. The company does not own and is not

liable for the logistics related to the distribution of it’s products it’s

key distributors are carefully selected to ensure that the company’s

products are available across Nigeria.

Management

Nigeria Breweries has eleven member board comprises the

chairman, Chief K:B Jamodu, the managing Director/Chief

Executive Officer, M.J. Herkemij (Dutch) and nine others O.S

 Adebanji, Dr O.O. Ajayi, Prof. (Mrs) J.O Akande, W. Fignant (Dutch),

E.E Imoagene, L he comedic (French), Th. A. deMan (Dutch) E.J.

Van Willeyen (Dutch) I.E Yamson (Ghanaion).

CHAPTER TWO

My six months industrial training program at NB Plc Aba, began

on the 24th day of May 2014. After the screening process and

interview, I resumed work under the mechanical maintenance

department headed by Mr Innocent Okpa. I was invited for safety

induction as a new trainee staff to bring to my knowledge the safety

precautions governing the company’s operations, they include.

 Use of safety boots

 Use of reflective jacket

 Use of ear plugs around a noisy area

 Always having your identification card for easy identification.

 Uses of the caution tape

 Observing all the safety rules, signs and symbols around the

premises.

 Use of the muster point in case of fire alarm

 Use of the conveniences

 Use of plain goggles around the packaging line etc.

I was also introduced to some of the maintenance staff and issued

with my personal protective equipment.

The mechanical maintenance department has the responsibility of

making available and in good operating conditions the machines

needed for brewing processes. They also supervise contractors

carrying out mechanical projects within the company.

NB Plc Comprises of two major sectors; the administrative and

production sectors.

The Administrative Sector

 The administrative sector does the paper related works of the

company. They bring out the ideas with which the company can be

run best. They include

 The human resources’ department (HR)

 The total productive management (TPM)

 The logistics department

 The finance department

 The planning department etc.

They ensure and see to the general welfare of the company’s staff.

The Production Sectors

The sector is made of 4 departments and they are directly

concerned with the production activities of the company. They carry

out the decisions reached by the administrative sector and also

report back to them. they include;

 The Brewing department

 The utilities department

 The packaging department

 The finished product store (FPS)

 The Brewing Department

The brewing department is concerned with the brewing processes,

production starts with the brewing department. But before I

continue I would like to explain the term brewing.

Brewing

Brewing is the process of producing beer by steeping cereal grains in

water and fermenting the resulting sweet liquid with yeast.

Brewing started far back in the 6 th millennium BC, and

archaeologist found evidence that emerging civilization including the

ancient Egyptians and the Mesopotamians carried out brewing

processes.

Basically, the ingredients of beer are water and a fermented starch

source such as malted barley, millet sorghum, cassava roots, potato,

agave.

This process (Brewing) involves basically 9 steps namely

 Malting
 Milling

 Mashing

 Lautering

 Boiling

Other ingredients of beer are, brewer’s yeast, to produce the

fermentation and hop as flavouring to offset the sweetness of the

malt.

Malting

The malting process of NB Plc Aba takes place at the malting plant

away from the brewery premise.

Malting is germinated cereal grains. Malting is the process of drying

germinated cereal grains. It develops the enzymes required to modify

the grains starches into sugar. It also develops enzymes such as

proteases, which breaks down the proteins in the grain into forms

that can be used by yeast.

Malted grain is used to make beer, whisky, malted shakers, malted

vinegar. The term ‘malt’ refers to several products of the process: the

grains to which this process had been applied, for example; malted

barley.

Figure 1 Malted Barley

Malting is the process of converting barley

or other cereal grains into malt, for use in brewing, distilling, or in

foods and take place in a malting (malting plant). The malting

process starts with drying the grains moisture content below 14%

and storing for around six weeks to overcome seed dormancy. The

grains are immersed in water two or three times over two or three

days. When the grains has absorbed a moisture content of around

46%. It is transferred to the malting or germination floor, where it is

constantly stirred to be air dried for five days. The grain at this point

is called green malt. The green malt is then kiln dried to the desired
colour and specification. After these processes the malt is

transported to the brewery where it is stored temporary at the silo.

The Silo

This is a structure for bulk storage of grains materials like malted

barley, sorghum which are used for brewing beer.

Figure 2. Discharging Of Malted Barley At The Silo Figure 3. The Silo

At the silo there are bucket elevators that transfer the grains to the
storage units and a digital scaling device that weights the grain
before it goes into the silo tanks.

The Milling Process

This is the stage in brewing where the malted barley or

sorghum is grinded to grist form, by a hammer mill, sieved by a

rotary sieve and stored temporary at the grist bin. The equipment
 found at the milling section are the; classic Hammer mill, the Rotary

sieve, the grist bin, the blowers, gear motors etc. These machines

are automatically controlled and inspected on weekly and monthly

bases. I participated in the maintenance activities on some of the

machines. Mostly, they were to check oil level of the gear motor,

noise level of rotating parts in case wear and lubrication of bearings,

leaks etc. for instance, once maintenance activities are to carried out

on the mill, the machine is turned to maintenance mode. Some of

the maintenance done on the different parts of the mill are.

Product Inlet (flexible tube)

Feed Lock

Milling Chamber
Mill Motor

Product Outlet (flexible tube)

Figure 4. The hammer Mill

 Drive Motor

Figure 5 The feeding Unit of the hammer mill

Milling chamber

Figure 6 The milling chamber of the Hammer mill

The Feed Lock

 Once a week:- Metal pieces should be removed

 Every six month:- the oil level in the gear motor should be checked,

and the bearings greased,

 Every 24 months:- the operation of pneumatic cylinders should be

checked, and the gear motor oil change.

The Grinding Chamber

 Once a week:- The condition of the sieve should be checked for

tear and the condition of the sieve synthetic seal.

 Once a month:- The conditions of the hammers and suspension

rods should be check for wear. Also observe the changes in capacity.

 Every four months:- Replace the lubricant in the main bearings,

check the condition of the impact plates and the sieve adjusters
 Every 25 months:- Check the condition of the stop profile of the

sieves stop profile, also observe the coupling for defects.

 Every 60 months:- Replace the rotor bearing and inspect the rotor

shaft

The Air Filter and Fan

 Once a week:- Check the compressed air pressure if it is below 150

pa and loss of charge of the bags if <> 20 bags

 Every for months:- Check the elastic connection at fan outlet.

 Every six months:- Grease the bearings, check the correct operation

of the dust removal

The Deduster
 On regular basis check for pressure difference modifications

 If the pressure difference lows, the air flow will not be activated

 If the pressure difference is to high, the bag fitters are clogged.

Flexible Tubes

There are two flexible tubes on the classic mill at the product intake

and between the outlet pope and the mill. The flexible tubes are

used in order to avoid the propagation of vibrations’ to adjacent

equipment.

The Mashing in Process

 The mashing – in process is the mixing of the malt grist with water

at a pre-specified mashing in temperature. The mashing in process

takes place in a mashing in tank, which allows a quick and

homogeneous mashing-in. the mashing-in tank has four main

components: the hydrator; the mixing chamber, the sealing water

and a transfer pum

Grist Inlet
The slide valve

Water
inlet

Hydrator

Mash outlet
Mash pump

The hydrator
The hydrator is the first step in Mash preparation. It reduces the

emission of dust and the hydrator is maintenance free.

The mixing chamber

This is where the mixing of the grist with water takes place.

Sealing water
The sealing water is pumped into the mixing chamber by a media

mechamasher pump, it has a good water tightness and the sealing

water lubricates the braids. The mechamasher pump is

automatically controlled by solenoid valves and flow switches.

Outle
Pump inlet
Geared motor

Stator
Sealing

Figure 7 The Mechamasher pump.

Maintenance of the Mashing-in Tank

At the end of every mashing-in operation, CIP operation are always

carried out CIP (cleaning in progress). This cleaning operation is

 automatically carried out, and done regularly to avoid contamination

of the mashing-in tank.

Each month:- The water tightness of the braid should be checked.

Each 6 month:- The geared motor oil level, tightness of the bolts,

and the pressure regulator on control value should be checked.

Each 24 months:- The oil in the geared motor should be replaced.

Lautering

Lautering is the separation process, where the extract is won during

the mashing from the spent grain. This takes place in a Mash-tun

and mash-copper. These are vessels with false bottom designed for

this kind of separation.

Lautering has two stages namely;

 Wort run-off-during which the extract is separated in an undiluted

state from the spent grain and

 Sparging in which the extract which remains with the grain is

rinsed off with hot water.

The mash-tun and mash-copper has rotating rake arms at their

bottom with a central geared drive unit.

Mash-filter

The mash filter is a frame with membrane clement one side of the

frame and filter cloth element on the other surface. The mash-filter

has about 20 mash-filter frames arranged side by side on the mash

filter unit. It separates the wort from the spent-grain by compression

action. The mash filter frame is made up of several components like:

Mash de-aeration, (cloth elements, the head piping, membrane

elements, leak detection, work de-aeration, polypropylene-element),

the fixed shield mobile shield, Back casing, Rails, spent grains

hopper, spent grain expeller, cylinder and hydraulic unit, shifting

equipment, Air Panel.

 Movable Plate

Back casing
Head Piping
Shifting motor
intermediate tank
hydraulic unit

Rail
Incoming compressed
air for the membrane
Fixed Shield

Figure 8 The mash filter

 Incoming Compresseed Air for the membranes

Movable plate

Rail

Back casing

Shifting motor
Hydraulic Unit
Head piping
Intermediate tank

Fixed Shield

Figure 9 General view of the mash filter

Regularly, the mash filter is maintained to eliminate unforeseen

break-down. And the maintenance works are carried out based on

the different parts of the mash-filter.

Maintenance of the Mash-filter different Part

The Clothes

It is scheduled that once every year the o-rings and the poly

propylene elements should be checked for wear and leaks. And at

every CIP the condition of the clothes should be check and the cloth

elements has a life span of 2500 brews.

 Mash filter cloth

Clothe Element

Mash Filter frame

The Membrane Element

The membrane element has a life span of 5000 brews and should

be check after each CIP, and once every year the poly propylene be

checked.

Membrane element

The Back casing-Hydraulic Unit

 The oil filter the hydraulic unit is changed once every year. The at

level is checked once every month, and the conditions of the flexible

tubes are checked for any leaks.

Transverse shaft

Coupling Chain
Shifting Hydraulic
motor

Solenoids for shifting change

of direction

Figure 10 The back casing Hydraulic unit

Air Panel
Every six months the air and oil filter should be replaced. And the

safety valve should be inspected once every year.

Air Panel
[

Spent Grains Hopper

 Every month tightness of the air tight compression gland of the

shaft should be checked and replaced if necessary.

End Bearings Security barrier

Sprayer Ramp Gear motor of

the transporter
screw
Intermediate
bearings

Transporter screw

Figure 11 Spent grain Hopper

The gear motor housing temperature and oil level should be checked

for leaks. Check oil quality every 12 months lubricate the rolling

bearings in gear unit; check and possibly replace the bronze wearing

rings.
Spent Grains Expeller

The spent grain expeller is a convey or unit that moves the spent

grain from the spent grain to the spent grain storage tank. This is

maintained on every month to ensure the tightness of the airtight

compression gland of the shaft, the year motor oil.

 CHAPTER THREE

Filtering the Malt Mash

This is the stage where the wort is separated completely from the

insoluble solid components of the grain, called draff. A sprinkling

system washes out the last remaining extract from the daff and

peels. And the wort is pumped off into the whirl pool (boiling kettle

for boiling).

The wort is boiled in order to:

 Sterilize the wort

 To destroy the enzymes still surviving in the wort

 To dissolve the useful components of the hop.

 To reduce the water content of the wort

Some additives like the dissolved sugar are added at this stage and

the mixture is passed through plate heat exchanger to cool down the

temperature of the wort.

After the filtering, boiling and cooling processes, the cooled wort is

pumped to the fermentation tank there yeast is added, which

converts the sugar to alcohol and carbon dioxide.

The Laboratory and Technological Departments

These departments are also under the brewing processes and they

do the quality and process control analysis.

Throughout the brewing process, they carry out the product

measurement and controls with regards to the quality and taste of

the final taste of the final product, such as Sugar content, PH,

attenuation, micro-biological checks. After fermentation process the

product is further filtered using the filtrux and high precision beer

filters to obtain a Bright Beer before it is stored at the B.B.T (Bright

Beer tank) ready to be bottled (Package).

Figure 12 Bright beer filters

Packaging

Packaging is simply done in order to break bulk and ease

distribution. The packaging department of NB Plc is purely

 responsible for packaging of filtered beer/malt drinks brewed by the

brew house.

Packaging has 12 stages, and they are all aimed at filling of liquid

product into washed/sterile bottles, pasteurizing filled bottles as

well as labeling, coding and crating of these bottles.

The purposes of Packaging are:

 To break bulk

 To decorate

 To inform

 To further treat (pasteurization) and

 Protect:

Capacity of the packaging department

The packaging department has two bottling lines and one canning

line.

The bottling and canning lines are fully automated and the bottling

line runs at 30,000 big bottles per hour and 37,000 small bottles per

hour. The canning line runs at 57,000 cans per hour.

Basic Packaging Equipments For Bottles

There are 13 basic packaging equipment namely:

1. De-palletizer

2. Unpacker

3. Crate washer

4. Bottle washer

5. Empty Bottles inspector (EBI)

6. Empty crate inspector

7. Filler/crowner

8. Filled bottle inspector (FBI)

9. Pasteurizer

10. Labeller

11. Video jet/laser jet

12. Packer

13. Palletizer

De-palletizer

This is a robot with one carriage head, designed to hold 14 creates

at a time.
The DE-palletizer is responsible for discharging creates of empty

bottles arranged on pallets onto the create conveyor to the

unpacked.

Figure 13 De-palletizer

Un-Packer

This machine un-cases bottles onto a bottle conveyor for on-ward

transport to bottle washer. It has a grab assembly consisting of 5 to

8 grab heads. It’s function is to unpack bottles onto the bottle

conveyor to bottle washer.

Figure 14 The un-packer

Bottle washer

This machine is designed to wash dirty returned bottles. It is

the largest machine on the line. Basically, it washes by agitating hot

caustic soda/water mix with the aid of pump.

Figure 15 The Bottle washer

Crate Washer
The crate washer has the responsibility of washing the empty crates

off of dirt’s it washes by spraying hot caustic soda/water mix on the

crates.

Figure 16 The crate washer

Empty Creates inspector (E.C.I)

The E.C.I is another important machine on the line with regards to

transportation safety. It identifies and rejects crates with defects.

Empty Bottle Inspector (EBI)

The EBI is probably the most important machine on the line with

regards to consumer safety.

It identifier and rejects’ bottles with defects such as

 Foreign objects

 Dirty

 Too tall, too short, too fat, too slim

 Bottles with residual fluids. Like paint, kerosene etc.

Figure 17 Empty Bottle Inspector EBI

Filler crowner

This is perhaps the critical machine on the line it has a ring tank,

lift cylinders, vent tubes or filling tubes for filling.

The filler has 96 vent tubes. Fundamentally this machine fills and

crowns’ the bottles. It is the point of contact between the bottle and
the beer. The filler speed normally determines the line speed. The

filler/crowner is pneumatically operated.

Figure 18 The Filler/crowner

[

Pasteurizer

The pasteurizer is the only public health measure which, if properly

applied will adequately protect against all infectious beer-borne

disease organism which may have entered the beer prior to

pasteurization. The drinks are introduced into the pasteurizer in an

increasing temperature order the temperature of the pasteurizer is

highest at the middle and lowest at the entry and exit of the

pasteurizer.
Labeller

This machine consists basically the carrousel, the labeling station

and the glue pump.

This is used for neatly pasting both neck and body labels on bottles

of drinks.

The machine uses uses glue for this purpose

Figure 19 The Labeller

Full bottle inspector FBS

The FBS is a very important machine on the line with regards to

consumer safety. It identifies and removes bottles with defect such

as

 Low fills

 Leakages

 No labels

 Uncorked bottles

Packer

This machine is similar to the unpacked. It has grab assembly

which consists of grab heads. Functionally, it does the exact

opposite of the un-packer i.e. casing of bottles.

Figure 20 The packer

Full crate inspector (FCI)

The FCI’s Job is to ensure that each create is fully filled, and that no

partially filled create go to the trade.

Palletizer

The palletizer is used to arrange crates of finished products on

pallets. This is done for convenience of distribution. The palletizer is

programmed to arrange crates of the product in pallets of 70 crates.

This makes loading and off loading from trucks easy and fast. This

is an interesting machine with lots of mechanism and automation

controls.

Figure 21 The Palletizer

Basic canning equipment

 The canning line at NB Plc consist of 9 basic equipment namely;

1. The empty can elevator

2. Empty can inspector

3. Filler/crowner

4. Can coding machine

5. Can code scanner

6. Shrink wrapper

7. Coded pack scanner

8. Palletizer

9. Pallet shrink wrapper

Empty can elevator

This elevator is responsible for the supply of empty cans to the

canning line. It has a capacity of 2500 cans per pallet. The elevator

is pneumatically operated and picks the cans layer by layer from the

pallet.
 Figure 22 The Empty Cans Elevator

The Empty Can Inspector (ECE)

This machine is a photographical type that checks the body

condition of each can for defects such as:-

1. Flange of can

2. High wall of can 1

3. The mid wall of the can

 Dome Reg

 Lower mid wall

 Low wall 2

 Chime
 Mouth

 Outer dome

 Mid dome

Figure 23 The video jet/laser jet

The Filler

This machine fills the empty cans’ with drink and caps it, has 96

vent tubes. It is the point of contact between the drink and the can.
It also determines the speed of the line and this machine is

pneumatically operated.

The Can Coder

This machine is responsible for the printing of codes like the.

Production date, expiry date, batch code on the bottom of each can.

After the coding process, the code scanner scan’s to ensure that

each can has it’s codes printed correctly at their bottom, code

scanner also inverts the can to the upright position and sends it to

the shrink wrapper through conveyors belts.

The Can Coder

Figure 24 The Can Coder

Shrink Wrapper
The shrink wrapper is a robotic machine that selects and arranges

the filled cans in 24(s) and put them in cartons, while the shrinking

film (polytene) falls on the carton before it goes into the heating

chamber for shrinking.

Figure 25 The Shrink wrapper

Palletizer

This machine receives the drinks in cartons and arranges them in

120(s) on every pallet.

Figure 26 The Palletizer

The MSK Pallet Shrinker

This machine is a robotic machine that shrikes the whole load of

drinks on a pallet using a polytene material. This is done to reduce

damage to products during transportation and also ease the process

of loading and off-loading from trucks.

 Figure 27 The MSK pallet shrinker

Safety Precautions Observed At The Packaging Department

These safety precautions are observed at the packaging department

to ensure the safety of workers and food.

For the food

1. Ensure that inspection machines (EBJ and FBI) are functional at all

times.
2. Always observe, implement and sustain effective hygienic

conditions

3. Always identify evaluate and eliminate potential food hazards. Etc.

For the workers

1. Always use a reflective jacket

2. Always use an ear plug

3. Always use a safety goggle

4. Always use a safety boat

5. Do not operate a machine you do not have prior training on.

6. If you see any hazardous condition report to the closest safety

officer

7. If any operation is unsafe to carry out do not it and prevent others

from doing it too.

Other Functions Of The Packaging Department

1. They are responsible for material Accounting

2. They also prepare the budget for every packaging operations

3. They also maintain proper house keeping

4. They carry out maintenance activities on their equipment

5. They implement the TPM methodology TPM= total productivity

management.

CHAPTER FOUR

THE UTILITY DEPARTMENT

FUNTIONS OF UTILITIES IN THE BREWERIES

They ensure and provide efficient and uninterrupted services for the brewery at
different locations. The services they provide include the following:

 Compressed air,

 Cooling or refrigeration,

 Treated water,

 CO2 production,

 Steam generation, and

 Electrical power generation.

These services they provide are used for the following purposes.

(1). COMPRESSED AIR

 To operate pneumatic control valves and instruments. E.g. actuators, slide

valves, recorders and controllers.

 As an aid for packing and unpacking bottles at Packer and un-packer.

 To transfer product from one vessel to the other. Transportation of grains.

 As a source of Oxygen to aerate the cold wort.

  To maintain counter pressure in the annular tank of the filling machines.

 To pressurize the product in the Bright Beer Tank (BBT).

 To transfer spent grain from the mash filter hopper to the spent grain
hopper.

(2). COOLING OR REFRIGERATION

 To lower the temperature of wort to the yeast pitching temperature.

 To chilled carbonated water.

 To maintain the temperature of beer in the BBT at about -1oC.

 To control the temperature of wort during fermentation.

 To maintain a constant temperature of about 2oC in the yeast tank.

 To maintain a constant temperature of 7oC in the hop store.

 To liquefy Carbon Dioxide at the temperature of -23oC.

 To maintain alcohol water temperature of -5oC.

(3). CARBON DIOXIDE.

 It is used to carbonate alcoholic and non-alcoholic drinks in order to

preserve their quality.

 It is used for beer washing in order to expel foreign gases resulting from

Air-pick up.

 To preserve the BBT during beer filtration in order to prevent air pick up.

 To carbonate chilled water.

(4). TREATED WATER,

 To prepare mash during brewing.

 To cool hot wort in the first stage of the wort cooler Plate Heat Exchanger.

 To dilute products in the form of chilled water.

 To dissolve cleaning detergents.

 As heat transfer medium in the pasteurizer. (To heat up or cool down the
products)

 As heat transfer medium in the compressors and heat exchangers.

 For the preparation of alcohol water.

 For cooking, drinking, washing, and flushing of toilets and fire fighting.

(5). STEAM.

Steam is used as heat transfer medium in the following:

o Mash Tun – To boil the mash in the tun.

o Mash Copper – To also boil the mash.

o Wort Copper – The steam is still used for boiling here.

o Degasifier – To raise the boiler feed water temperature to 105oC.

o Pasteurizer – Steam is used here for heating and super heating.

o Bottle Washer – To heat up the Soda compartment of the washer.

o Mash filter – To transfer spent grain from the mash filter hopper to the
spent grain hopper.

(6). ELECTRICITY
 To provide light in the brewery.

 To provide heat through heating elements.

 To provide electrical energy to drive electric motors.