“OPTIMIZATION OF BREWING, FERMENTATION, AND DISTILLATION PROCESSES FOR

MALT SPIRIT PRODUCTION USING LOCAL GRAINS”

Thesis/Dissertation submitted to the

Shiv Chhatrapati Shikshan Sanstha’s

RAJARSHI SHAHU MAHAVIDYALAYA,

LATUR

(AUTONOMOUS)

(NAAC Accredited A+ Grade with 3.49 CGPA (Cycle-IV),

ISO:9001:2015, UGC-CPE(Phase-III), DST -FIST Status)

Affiliated to

Swami Ramanand Teertha Marathwada University, Nanded

For the partial fulfilment of the award of the

degree of Master of Science (M.Sc.) in Biotechnology

BY

Ms. Yogita Dattrao Harkal

Exam Seat No: RNS 2545907

Under the Supervision of

Mis. Swati Swami

Department of Biotechnology

RAJARSHI SHAHU MAHAVIDYALAYA, LATUR (AUTONOMOUS)

1
 RAJARSHI SHAHU MAHAVIDYALAYA, LATUR

(AUTONOMOUS)

(NAAC Accredited A+ Grade with 3.49 CGPA (Cycle-

IV), ISO:9001:2015,UGC-CPE(Phase-III), DST -FIST
Status)

DEPARTMENT OF BIOTECHNOLOGY

This is to certify that Ms. Yogita Dattrao Harkal, a final-year M.Sc. II (IV Semester)
student, has conducted research leading to the M.Sc. degree on the topic “Optimization of
Brewing, Fermentation, and Distillation Processes For Malt Spirit Production Using Local
Grains” This research was carried out within the premises of Rajarshi Shahu
Mahavidyalaya, Latur (Autonomous), in partial fulfillment of the requirements for the
M.Sc. degree in Biotechnology, as per the syllabus prescribed under the NEP 2020
curriculum, for the academic year 2024-2025.

Project Guide Head Examiner

Mis. Swati Swami Dr. S. S. Kulkarni 1.

2.

2
 DECLARATION

I hereby declare that the dissertation entitled “Optimization of Brewing, Fermentaion,

and Distillation Processes For Malt Spirit Production Using Local Grains” is an
independent and original research work completed by me and submitted in partial
fulfillment of the requirements for the M.Sc. degree in Biotechnology as per the
curriculum under NEP 2020. This work is submitted to the Department of
Biotechnology, Rajarshi Shahu Mahavidyalaya, Latur (Autonomous), affiliated with
Swami Ramanand Teertha Marathwada University, Nanded. I further declare that it has
not been submitted to this or any other university for the award of any degree or similar
title.

Place: Latur Ms. Yogita Dattrao

Harkal Date: RNS 2545907

3
Acknowledgment

This project stands as one of the most significant accomplishments in my life, and it
would not have been possible without the support of those who believed in my abilities
and encouraged me throughout this journey.
I am deeply grateful to Dr. Mahadev Gavhane, Principal of Rajarshi Shahu College,
Latur (Autonomous), for granting me permission to conduct my dissertation research in
the Department of Biotechnology, Rajarshi Shahu College, in partial fulfillment of my
M.Sc. in Biotechnology.
I would like to extend my sincere thanks to Dr. Sachin Kulkarni, Head of the
Department of Biotechnology, and Dr. Ravindra Ade, Assistant Professor, Department
of Biotechnology, for providing a conducive and encouraging environment, which
made my research journey much smoother. Their support has been invaluable in the
completion of my dissertation.
I am profoundly thankful to my guide, Prof. Swati Swami, whose expertise, dedication,
and insightful guidance have been essential to the successful execution of this project.
Her valuable advice, inspiring presence, and kind encouragement helped me overcome
challenges and progress steadily through each phase of the work.
I am sincerely grateful to the United Spirit Lmited Nshik for providing me with the
opportunity to undertake my dissertation work under its esteemed guidance. The
invaluable resources, insightful discussions, and continuous support from the institute
have greatly enriched my academic experience.
I am deeply thankful to Mr. Rajaram Miraje (Malt Manager) for their guidance,
support, and encouragement throughout my tenure. The collaborative environment and
the rich exchange of knowledge have significantly enriched my experience and honed
my skills
.My heartfelt thanks go to my fellow scholars for their cooperation and support, as well
as to my classmates for their suggestions and moral encouragement.
Finally, I would like to express my deepest gratitude to the Almighty and to my
parents, whose unwavering dedication and encouragement have brought me to this
stage in my life.

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 TABLE OF CONTENT

SR.NO PARTICULARS PAGE NO

A Abbreviations 6

B List of Tables 7

C List of Figures 14-18

D Lists of Plates 10

PART I

A Introduction 8-10

B Review of Literature 11-12

C Materials and Methods 19-27

D CIP System 28

E Maturation Process 29

F Blending Process 30-31

G Water Treatment Plant 33-34

H Effluent Ttreatment Plant 35-38

I Boiler 39-40

J Result 40-41

K Conclusion 42

L Referance 43

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 B. ABRIVIATIONS

Gm Gram
Hrs. Hours
i.e. That is
Kg Kilogram
Mg Milligram
µg Microgram
N Normality
Wt. Weight
% Percentage
OD Optical density
Min Minute

g/l Gram per litre

Ml Millilitres
FTP Effluent treatment plant
IMFL Indian made foreign liquor

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 B. LIST OF TABLES
Table Title Page No
No.
1 Parameters for quality analysis
2 Process water parameters specifications
3 Parameters for quality analysis
4 Distillation

C. LIST OF FIGURES

Figure Title After page

No.
1 Barley malt
2 Process water test
3 PH meter
4 Foss grain
5 Fraiabilimeter
6 Sortimeter
7 Turbidity
8 Fermentation
9 Ambient water tank
10 Reducing sugar
11 Cask coopering Machine
12 Matured malt spirit
13 Wort

14 Cell count
15 Lauter tun
16 Maturation

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Chapter 1

INTRODUCTIO

The Malt Spirit Plant in USL-Nashik is arguably one of the largest Malt Spirit Plant
in Asia. It has a capacity of producing FMS 24, 000 LITERS PER DAY MALT
SPIRIT PLANT AT NASIK. The USL-Nashik Malt Spirit Plant has in all six
sections in the plant namely: Dry Goods Section, Brewing Section, CIP Section,
Water Section, Fermentation Section and Still - House Distillation Section and one
outside the plant which is the Maturation Hall. Malt Spirit is mainly used in
blending of Whisky in about 2 -3% generally and in supreme brands like Signature
Whisky it is used in higher amount. This plant is a completely automation
processes of Brew House Section, Fermentation Section and Distillation Section
automated plant and is controlled by an executive in the control room by a
computer system. Control Room SCADA (System Control and Data Acquisition)
is a software using which the plant is controlled, and useful data is obtained from
the process. The malt plant has been installed to extract Fresh Malt Spirit (FMS)
from germinated barley grains. The installed plant is a state of art facility and is
equipped with advanced technological systems. The major portion of the plant is
automated and does not require any human assistance in functioning. the automated
parts are monitor by SCADA system. All the equipment’s of plant could be operated and
monitored just with the clicks on SCADA interface. The installed capacity of the plant is 24,000
liters of FMS per day. The plant operates in 3 shifts, in each of which 8,000 liters of FMS is
produced. The entire operations of the malt plant could be segregated into three major
processes:

 Brewing

 Fermentation

 Distillation

8
 RAW MATERIAL AND HANDLIN PROCESS: -

FIG. Barley Malt

Malt is Germination cereal grains that have been dried in a
process known as "malting". The grains are made to germinate by soaking in water and are
then halted from germinating. Malted barley is the source of the sugars (principally maltose)
which are fermented into beer. The malting process allows the grain to partially germinate,
making the seed's resources available to the brewer.

 MALT ALCOHOL PRODUCTION:

Malted barley is the principal raw material in the production of malt alcohol.
Cleanliness: Absence of foreign matter &moldy grain
Absence of broken, crushed grain.
Representative samples of barley to be analyzed.

1) Moisture content (4- 5 %)

2) 1000 corn weight (Indication of Bushel Weight)
3) Germination capacity (Not below 96%)
4) % Nitrogen content in barley (Less than 1.6 %)
5) Water sensitivity (Absorption of water in the steeping process).

Barley is graded on a scale of 1 to 9 grades.

Only top three grades are suitable for malting having capacity to germinate & grow.

Quality of barley is defined by master’s is as follow:

1) High starch content: High starch will yield high alcohol.
2) Low protein content: Less than 1.5% - Higher the protein lowers the starch.
3) Low nitrogen content: Less than 1.6% - High nitrogen indicates high protein.
4) High germination: Germination is a pre-requisite for malting.
5) So, the capability of the grain to germinate is essential.
6) Well ripened, plump, and dry: Crop should be ripe & dry.

Worldwide Scotland is famous for manufacturing of malt & malt alcohol.

In India Barley is grown in Hi Himachal Pradesh, Punjab, Haryana, Rajasthan&
Madhya Pradesh.
Malt is produced in malt industry.

1) Steeping: hydration of grains

2) Germination: development of root

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 3) Drying/ Kilning: Stopping the germination process

BARLEY MALT SPECIFICATION:

 But at USL Nasik, malting process is outsourced.

 The production of any brand starts with the Quality control measures, the barley malt
received is thoroughly checked for maintaining the quality standards, there are several
Quality control measures for Truck Inspection.
(Parameters: Covered with tarpaulin, checking if the truck is dirty, checking for sharp
edges, toxins), if the barley doesn’t achieve the standards, then the truck is rejected.
Sampling is done by the Quality Person, they take 10% sample (500 gm composite
sample) from L

Parameter Specification
Moisture Below 5%
Friability Above 70%
HWE (Hot Water Extract) (dry base) Above 76%
PSY (Predicted Spirit Yield) Above 330 AL/T
TCW (Thousand Corn Weight) Above 38 gm
Table No 1. Parameters for Quality Analysis

All the Quality Analysis parameters can be checked with an automatic machine names
FOSS.

OBJECTIVE:
 Produce high quality malt spirit.
 Efficient fermentation and distillation
 Quality control
 Brand establishment
 Research and development.

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 Chapter 2

REVIEW OF LITERATURE

Whisky is defined as a distilled spirt fermented from cereals, at less than a maximum alcoholic
strength (normally <94.8 per cent vol.) and matured in oak casks for a minimum bottling
strength for consumption is 40 per cent vol.” (Ayltott 2003, p. 276) Tbe labelled as »Scotch
whiskey it must be “produced at distillery in Scotland from water and malted barley” (Dolan
2003, p.28). Further essential inputs are air (Dolan 2003, p. 28) and, occasionally, peat (Dolan
2003, p. 43). Aside from caramel, for the purpose of standardizing the colour, whisky may not
content any other ingredients (Aylott 2003, p. 277). Scotch whisky production includes the main
stages distilling, storing, and bottling, which open a wide range for managerial decision making
and thus, substantially affect efficiency.

Scientific research on whisky production seems very limited, particularly from the viewpoint of
operations management. Most articles rather focus on general research topics, such as
classification schemes for whisky (Lapointe/ Legendre 1944), 0r originates from engineering
sciences. The latter analyse issues like materials and processing (Dolan 2003: Bringhurst/
Broadhead/Brosnan 2003), yeast and fermentation (Campbell 2003), distillation (Campbell
2003) maturation (conner/Reid/Jack 2003) and coproduct (pass/ lambert 2003). Economic
publications hardly exit, apart from two articles on industrial change in the early scotch industry
(Weir 1989 Bathgate 2003), a paper on forecasting and stock obsolescence (Grant /
Karagianis/Li) and a handbook chapter on marketing for whisky (Gordon2003). The only
scientific publication that directly affects the paper at hand is a working paper on industrial
economics.Page raises the question of why distilleries produce multiple ages of whisky he
develops a theoretical model and shows, interalia, that for a profit- maximizing distillery under
perfect compettion it can be rational to choose a product program including different ages, and
that most distilleries that produce multiply ages of whisky do not operate under perfect
competition .

Whiskey is defined as a distilled spirit fermented from cereals, distilled at less than a maximum
aalcoholic strength (normally < 94.8 per cent vol.) and matured in oak casks for a minimum
period (typically three years). The normal minimum bottling strength for consumption is 40 per
cent vol.” (Aylott 2003, p. 276) To be labeled as »Scotch whisky« it must be “produced at a
distillery in Scotland from water and malted barley” (Dolan 2003, p. 28). Further essential
11
inputs are air (Dolan 2003, p. 28) and, occasionally, peat (Dolan 2003, p. 43). Aside from
caramel, for the purpose of standardizing the colour, whisky may not content any other
ingredients (Aylott 2003, p. 277). Scotch whisky production includes the main stages distilling,
storing (or »aging«) and bottling, which open a wide range for managerial decision making and,
thus, substantially affect efficiency. Scientific research on whisky production seems very
limited, particularly from the viewpoint of operations management. Most articles rather focuses
on general research topics, such as classification schemes for whisky (Lapointe/Legendre 1994),
or originates from engineering sciences. The latter analyse issues like materials and processing
(Dolan 2003; Bringhurst/Broadhead/Brosnan2003), yeast and fermentation (Campbell 2003),
distillation (Campbell 2003; Nicol 2003) maturation (Conner/Reid/Jack 2003) and co-products
(Pass/Lambert 2003). Economic publications hardly exist, apart from two articles on industrial
change in the early Scotch whisky industry (Weir 1989; Bathgate 2003), a paper on forecasting
and stock obsolescence (Grant/Karagianni/Li 2006) and a handbook chapter on marketing for
whisky (Gordon 2003). The only scientific publication that directly affects the paper at hand is a
working paper on industrial economics. PAGE raises the question of why distilleries produce
multiple ages of whisky. He develops a theoretical model and shows, inter alia, that for a profit-
maximizing distillery under perfect competition it can be rational to choose a product program
including different ages, and that “most distilleries that produce multiple ages of whisky do not
operate under perfect competition” Page’s findings are related most closely to the so called
»Angels’ Share«, which is described in the following section.

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 QUALITY ANALYSIS OF RAW MATERIAL

Process water
Parameters Specifications
Ph 6.5 – 7.5 range
TDS Less than 1000
Hardness Less than 200
Alkalinity 100 – 200 ppm
Chloride Less than 200
Free Chlorine Nil
Sensory Analysis Agreeable or non-agreeable
Table No 2: Process water parameters, specifications

 PH
1. Take 10 ml of process water
2. Clean the electrode of ph. meter and rinse the well of DM water
3. Dip electrode in process water and take the reading of PH.

 Chloride
test
1. Take 10 ml of water sample to be tested in the jar.
2. Add one spoonful of CD1
3. Mix well to dissolve and the add CD2 drop by drop till the sample turns
yellow.
4. Now dropwise add CD3L counting the number of drop while mixing.
5. Until the colour changing from yellow to bluish violet.
Calculation
Chloride as ppm cl = 1*(number of drops of CD3-1

 Alkalinity test
1. Take the 10 ml of water sample to be tested in the jar and add 2 drops
of AK1.
2. Mix well to dissolve if a pink colour appearance it indicates presence of
P alkalinity.
3. Then dropwise add AK2 counting the number of drops while mixing
until the pink colour disappears.
4. The colour change green to reddish
violet. Calculation:
P. Alkalinity ppm as caco3= 10*(number of drops of AK2).

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  Hardness

1. Take 10 ml of water add one spoonful of TH1S and mix well to dissolve.
Calculation
Total hardness as ppmCaCo3 = 1* (no of drops TH3L).

Barley malt
Parameter Specification
Moisture Below 5%
Friability Above 70%
HWE (Hot Water Extract) (dry base) Above 76%
PSY (Predicted Spirit Yield) Above 330 AL/T
TCW (Thousand Corn Weight) Above 38 gm
Table No 3: Parameters for Quality Analysis

All the Quality Analysis parameters can be checked with an automatic machine.

Fig .no 1. Alcohol Distillation

14
 Fig.no 2. Bomb Colorimeter

Fig.no.4. Sortimat
Fig.no.5 Turbiditi meter

15
Fig.no.6. Gas Chromatography

16
Fig. No. 7 Water Test

17
 Fig.no .8 Cask Coopering

Fig.no.10.Microscope

Fig.no.9. PH Meter

18
  MATERIAL AND METHODS:
Materials
Following materials were used for malt spirit plant.
Glassware
During the course of investigation the glassware used were petri plate, conical flasks
(250 ml, 500ml), funnel, test tube, pipettes, beakers, measuring cylinder, sensory glass,
watch glass, collection bottle, hemocytometer slide, macro pipettes, spirits bottles etc. .
Equipment
Standard laboratory equipment used for malt spirit plant were Autoclave, Hot air oven,
PH meter, Micro pipettes, Foss grain, microscope, Laminar air flow, Sortimat, Friability
meter, Turbidity meter, Bomb Calorimeter, Mashing Bath, Shaker, Distillation assembly,
Hot Plate, Anton par.

Milling:
 Classifier: Uses cyclone separator to remove impurities like dust.
 Destoner: Used for removing any impurities like small stones.

Magnetic Separator: A magnet scrapper is used to remove impurities like iron pieces.

 Milling: There are machines with 4 rollers for this process, cereal grains break so that water
can penetrate.

Distillers malt with high diastatic power which contains.

i) Grist Ratio: Husk: Grist: Floor = 18: 72: 10 respectively

ii) Usually, roller mills are used.
iii) During milling husk must be kept entire and endosperm to be converted to fine
extractable particals.
iv) If husk is damaged, it can cause problems during

filtration. Grist is separated from husk and floor.

 Mashing: This happens in Lauter tun (65-66°C is the optimum temperature for mashing,
one mash requires 5 mins for circulation and 25 mins as rest period. Enzymes are already
present in the grains in some amount but 1 ppm of 3 enzymes are added, they are Proteinase
(degrades proteins), Optimash TBG mainly contain thermostable endo- 1,3 (4) beta
glucanase (reduces viscosity) (degrades beta glucan), (Starch has amylopectinase which are
branched) alpha amylase (breaks 1,4 linkage in a linear chain of starch at 72°C which is the
optimum temperature) and beta amylase breaks amylopectinase, enzyme is an alpha amylase
for starch hydrolysis when used in starch liquification the enzyme preparation is of excellent
stability against high temperature, low ph., Diazymegluco- amylase ( Saccharification)
(linear chain is formed, the optimum temperature is 65°C). Spent grain is removed and the

19
 wort goes to an intermediate tank. Then a pump takes it to the wort receiver.

Premasher – Grist is mixed with hot water to form a homogeneous mixture.

i) The proportion of one part grist and four parts of water.

Mash Tun or Lauter Tun – The above mixture is heated up to 60 - 650C and

i) held at that temperature for approximate 1 hour.

ii) The enzymes of malt (particularly the α-amylase and β-amylase) breakdown the starch to
fermentable sugars.
iii) The liquid extract has Sp. Gravity 1.060 – 1.070
iv) First after mash has Sp. Gravity 1.030.
v) Second (Sp. Gravity 1.010 & third after mash (Sp. Gravity 1.006) is recycle to mash
preparation tank.

METHODS
Milling:
 Classifier: Uses cyclone separator to remove impurities like dust.
 Destoner: Used for removing any impurities like small stones.

Magnetic Separator: A magnet scrapper is used to remove impurities like iron pieces.

 Milling: There are machines with 4 rollers for this process, cereal grains break so that water
can penetrate.

Distillers malt with high diastatic power which contains.

a. Grist Ratio: Husk: Grist: Floor = 18: 72: 10 respectively

b. Usually, roller mills are used.
c. During milling husk must be kept entire and endosperm to be converted to fine
extractable particals.
d. If husk is damaged, it can cause problems during filtration.

Grist is separated from husk and floor.

 Mashing: This happens in Lauter tun (65-66°C is the optimum temperature for mashing,
one mash requires 5 mins for circulation and 25 mins as rest period. Enzymes are already
present in the grains in some amount but 1 ppm of 3 enzymes are added, they are Proteinase
(degrades proteins), Optimash TBG mainly contain thermostable endo- 1,3 (4) beta
glucanase (reduces viscosity) (degrades beta glucan), (Starch has amylopectinase which are
branched) alpha amylase (breaks 1,4 linkage in a linear chain of starch at 72°C which is the
optimum temperature) and beta amylase breaks amylopectinase, enzyme is an alpha amylase
for starch hydrolysis when used in starch liquification the enzyme preparation is of excellent
20
 stability against high temperature, low ph., Diazymegluco- amylase ( Saccharification)
(linear chain is formed, the optimum temperature is 65°C). Spent grain is removed and the
wort goes to an intermediate tank. Then a pump takes it to the wort receiver.

Premasher – Grist is mixed with hot water to form a homogeneous mixture.

 The proportion of one part grist and four parts of water.

Mash Tun or Lauter Tun – The above mixture is heated up to 60 - 650C and

i) held at that temperature for approximate 1 hour.

ii) The enzymes of malt (particularly the α-amylase and β-amylase) breakdown the starch to
fermentable sugars.
iii) The liquid extract has Sp. Gravity 1.060 – 1.070
iv) First after mash has Sp. Gravity 1.030.
v) Second (Sp. Gravity 1.010 & third after mash (Sp. Gravity 1.006) is recycle to mash
preparation tank.
vi) The liquid extract & first after mash having Sp. Gravity 1.045 – 1.060 and pH – 5.5, Amino
nitrogen content of about 150 – 180 mg/lit.
vii) The conversion of starch to fermentable sugars is confirmed by Iodine test 0.05N Iodine
= Gives blue colour in presence of starch.

Filtration:

 To produce fermentable wort.

 In lauter tun or wash holding tanks.
 During fermentation water is added to extracts sugars as much as possible.
 The wort sp. Gravity is adjusted to about 1.045 – 1.060 before fermentation.

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LAUTERING PROCESSES:

The grist is fed into the Lauter Tun for mashing, with the help of a motor and f r o m
hot water tank. The entire grist from grist case, i.e. 8 Ton, is emptied into the lauter tun. The
grist is mixed with 32,000 liters (320 HL) of water at 65°C and stirred with the help of racking
arm, for 27 minutes. This process is called “mashing”. The temperature of water is maintained
by the mixer, by mixing water from hot water tank and cold-water tank. During mashing, the
starch gets dissolved into the water and percolates through the layer of husk formed during
mashing and further seeps through flush plate into the Intermediate Wort Collection Tank,
having a capacity of 30,000 liters (30 HL). After mashing, the lauter tun is given rest and
recirculation is done for 30 minutes. During recirculation, the wort collected, is pumped back
into the lauter tun and collected again to have uniform gravity.

Now, after recirculation the “first wort collection” starts and it lasts for about 65 minutes. As the
wort collection starts, the wort collected in intermediate collection tank starts flowing into wort
receiver tank, having a capacity of 100,000 liters (100 HL). The wort collection in these 65
minutes is about 220 HL in volume. So, wort is collected and simultaneously sent to process
ahead for further processing. The collected wort has gravity about 1072 to 1074, and its
temperature is around 65-67°C after first wort collection, “first sparging” is done. During first
sparging, 180 HL of hot water at 85°C is sprinkled over the mash in about 22-24 minutes.

Then the mash is left still for 20 minutes, so that remaining starch could also dissolve in water.
After this, “second wort collection” is done for about 45-50 minutes. The volume collected this
time is about 200 HL and has gravity lying between 1038 and 1042. The temperature of wort
collected second time is higher than that collected before i.e. 81-83°C.

Second wort collection being done, “second sparging” begins in lauter tun. It goes on for about
30 minutes and it consumes about 220 HL of water, at 95°C. The mash is allowed to rest for 10
minutes and then “weak wort collection” begins. In about 30 minutes of collection time over
220 HL of weak wort is collected. After the collection, the lauter tun is given a rest for 5
minutes. The weak wort is collected in Weak wort tank& is used in mashing of next batch.

When all wort has be extracted out of the mashed grist only spent grain remains in the lauter
tun. So, the process of emptying the lauter tun begins with “spent grain discharge”. Within
15

22
 minutes, the entire spent grain is removed from the lauter tun into the dump tank. This is done
by rotating the racking arm at lower height in the lauter tun. But before the lauter tun is ready.

MASHING PROCESS:
Malt Charge: 107 * 75 kgs bags = 8000 Kgs in Grist Case.

Grinding time: 2 hrs. - Grinding time is dependent on the malt mill & cleaning equipment’s
capacity, however milling time should not exceed brewing time.
Grist Ratio: 20:70:10 (Mesh size BSS-10 BSS-85)

Initial water in LAUTER TUN adding under let 20 HL then 320 HL (32000 Lit Weak wort of
previous batch& Hot water) with Malt Grist Case is 8000Kghomogenously mixing and Grist
water ratio: 1:4

Mashing temperature is maintained at ~62 °C

 to maximize amylolytic enzyme activity
 prevent loss of amylolytic enzyme activity

Mash Strike temp: 65 °C maintain optimum temp for Mashing process.

(Critical for starch conversion to sugar in such way Higher or lower strike temp will adversely
affect recovery as well as quality of fresh malt spirit)
Mashing time: 30 Min (Raking on).

+
Add enzyme addition quantity Mylo 300 L: 1.6 lit (To be added after 15 min from mash start
time)200 ml of Amylo to be added per MT of malt. Mash in pH 5 .0 – 5.5.

Rest & Recirculation: 30 MinRest & recirculation time is dependent on Scarification of

starch (Iodine test). Rest time 25 Min&Recirculation 5 min.

FIRST WORT COLLECTION:

Ist wort collection start after rest and recirculation time in wort Receiver 220 HL (22,000 Lit
Ist Wort). Transfer 20HL to bub Vessel or Prefermenter
Sp. Garvity: initial: 1065 to 1070@ 20°C &Final: 1045 to 1050

FIRST SPARGING:
First wort collection completed then startIstSparing180 HL (18000 Lit) hot
water (Raking on), Ist sparging temp @ 85°C.Hot water is generated by steam heating thru coils
in hot water tank. Sparge time: 25: 25 min

SECON WORTCOLLECTION:
23
 IInd Wort collection start after IstSparge in wort Receiver 200 HL (20000Lit) (Racking On)
transfer to Fermenter as per selected for Brew collection.
IInd Draw: 35 Min
Sp. Garvity: Initial: 1036 to 1040@ 20°C Final: 1011 to 1015

SECON WORTCOLLECTION:
IIWort collection start after Ist Sparge in wort Receiver 200 HL (20000Lit) (Racking On)
transfer to Fermenter as per selected for Brew collection.
IIndDraw: 35 Min
Sp. Garvity: Initial: 1036 to 1040@ 20°C Final: 1011 to 1015

SECOND SPARGING:
IInd wort collection completed then start IInd Sparing 220 HL (22000 Lit) hot wate
rIInd sprging temp @ 95°C.Sparge time: 20 min.

TOTAL WORT COLLECTION = 420HL (42000Lit Wort)

WEAK WORT COLLECTION:

Weak wort collection should be started immediately after IInd saprging. Weak wort
collection to be continued up to Sp. Gravity 1001-1002.Weak wort collection time 25 min.
TOTAL WEAK WORT COOLECTION = 200 HL (2000 Lit Weak Wort)

FERMENTION:

The fermentation section consists of 16 fermenters stainless steel l lined in two lines, 8 in each line and a
Bub vessel. The fermenter is the place where the actual alcohol is produced by yeast from Wort. The
fermenter has a capacity of 500HL, and 390 HL of wort is directly collected in the fermenter. And once the
wort collection is completed the inoculum from the Bub vessel is transferred to the fermenter making the
total volume to 410HL and thus fermentation process is initiated. The start brew wort collection which
collects in selected sterilized empty fermenter No. then taken brew wort 20HL in bub vessel and add dry
Yeast 2 Kg with supply air to bub vessel. The yeast cells in the wort utilize the glucose in the wort and
convert it into ethanol at 21°C. The fermentation process time minimum 45 Hrs., typically for 50 to 72hrs.
The initial sp. gravity of the wort in the fermenter is 1. 050 and the finial fermentation process ceases when
the sp. gravity falls to 1 .000. The sp. gravity and pH of the sample from the fermenter is estimated every
4hr. the pH of the sample should be around 5.5. During fermentation, CO 2 gas is released from the
fermenter through an outlet at the top of the fermenter. When the fermentation process ceases, the evolution
of CO 2 gas also stops, and the fermented wash is sent to the Still House Section for Distillation. A malt
spirit distillery has using stainless-steel fermenter easier to clean.CO2 extraction but not recovered.

24
 STANDARD OPERATING PROCEDURE OF
FERMENTATION:

Wort from Mash tun or Lauter Tun is collected in Wort buffer tank. Wort is transferred to
fermenter ….
1St wort collection initial Sp. Gr 1.074- final Sp.Gr. 1.045 @ 20 ± 22°C 2

nd wort collection initial Sp. Gr 1.040 - final Sp.Gr. 1.014@ 20 ± 22°C

Set up volume SP.Gr. 1.049 to1.050 @ 20 ± 22°C

Wort transfer temp to fermenter to be controlled at 20 ± 22°C by PHE

using ambient water & Chilled water.

BUB VEESEL:

Add 2 kgs of dry yeast after collecting 20HL (2,000 Lit) wort at 24 to 26 °C collected in bub
vessel aerate with supply air for aeration and transferred to fermenter after 2 Hrs.

Maximum wort transfer time to fermenter: 180 Min (Wort from the Buffer tank should be
transferred to fermenter before start of next brew)

Fermenter Setup volume: 41000 Lit (410HL) ± 250 Lit (For 8 MT of Malt)
Set up temp: 20 ± 2°C
Setup Gravity: 1.050 ± 2
Final wash gravity: 1.000± 1
Alcohol content in wash: 6%±0.25(v/v PH: Initial – 4.5 to 5 & Final - 3.5 to 3.75
Maxi fermentation temp: 30 ± 2 °C
Fermentation time: 48 to 60 Hrs.

Fermented Wash is transferred to Wash Still section by wash transfer pump to

1 st wash PHE to 2nd steam PHE then wash still.

After complete transferred wash from fermenter then fermenter CIP done with
sterilization by using steam @ 90°C

25
 DISTILLATION:
include two Distillation systems.
A) Wash Distillation

B) Spirit Distillation

STILL HOUSE SECTION:

Wash Distillation

Spirit Distillation

Maturation
Table no.4. Distillation

Wash distillation:

 The wash (typically 8‐9% (v/v) ethanol) is used to charge the still to about two‐thirds capacity;
wash is usually at least 48 hours old
 Boiling starts at about 92°C and excessive frothing must be avoided to prevent foul distillation
 Wash pre‐heating may be used to avoid fouling of heat transfer surfaces in the still
 Low wines are collected, initially at about 50% (v/v) ethanol, falling to 1%, and giving a final
ethanol content of about 20 to 23% ABV
 Residual pot ale contains about 0.1% (v/v) ethanol.

 Almost 90% of wash is waste, rich in copper and BOD:

o 65% as pot ale
o 24% as spent lees

A) Spirit Distillation
 Charge contains 25‐30% (v/v) ethanol and consists of low wines with foreshoots and feints
o from previous distillations.
 Foreshoots contain oily and waxy products from the previous distillation (detected with the
demisting test)
 First cut typically taken at 70‐75% (v/v) ethanol 25 minutes
 Middle cut is collected as new‐make spirit 3.30 hours
 Second cut typically at 62‐64% (v/v) ethanol, can be as low as 57% (v/v)4 hours
 Foreshots and remaining feints are combined with low wines for further distillation
o By‐products of malt distillation:
o Pot ale: biological oxygen demand is very high (BOD:25,000‐35,000 ppm)
– combined with spent grains and dried to give dark grains
– sprayed on farmland
– treated in an effluent plant to reduce BOD
– discharged to sea
 Spent lees: BOD is quite low (BOD:1,000‐2,000 ppm)treated in an effluent plant discharged to ETP

26
 DISTILLATION

PRIMARY DISTILLATION

LOW WINE – CAPACITY 21.420KL

1ST PRODUCT- POTALE CAPACITY 28KL

SECONDARY DISTILLATION

REDISTILLATION OF LOW WINE

HEAD – FENTS CAPACITY 12.252KL 25MIN

HEART – CAPACITY 12KL 3.30 HOURS

TAIL- SPENTLESS CAPACITY 4 HOURS

27
CIP SYSTEM

The CIP section consists of a Rinse Tank, a Still-House & Brew-House Caustic Tank
and a Fermenter Caustic Tank. CIP means Cleaning in place. After fermentation of
every brew all the vessels are cleaned and made ready for the next. CIP is done by hot
water and Caustic. There is a CIP inlet and CIP return line for all the fermenters
through which the caustic and hot water is sent in the fermenter and drained off the
fermenters. Steam is also introduced in the fermenter for an hour or so for its
sterilization. The Wort Cooling PHE is also cleaned periodically by Back CIP where in
the Caustic and hot water is sent in through the PHE in the reverse direction and the
casting is cleaned. The cleaning is mostly done when the flow through the system
decreases. It also consists of a Caustic lye tank through which the Caustic Tank is
refilled. The hot water for the CIP is produced from the CIP PHE using ambient water
and steam.

28
 Maturation

Fig. no .11. HBS HUB

 FMS is matured for 18 months in American White Bourbon Wooden Casks (Charred from inside,
capacity of 190 to 210 liters, humidity is 10-16%, 16 °C is the optimum temperature of the cask
before filling it), there are around 67 thousand casks in the maturation halls (3 halls)
 One cask can handle 6 cycles without maintenance (After the 6th cycle there is a maintenance
check)
 After Maturation we get MMS (Matured Malt Spirit) / CMMS (Cask Matured Malt Spirit)
 MMS is one of the raw materials to produce HBS (High Bouquet Spirit) (Raw material to produce
IMFL)
 Around 80% of HBS is supplied from Nashik unit to other USL units all over India.
 HBS composition is different for different brands.

29
 Fig.no. 12. Maturation

Blending Process

 There are around 30 blending tanks in unit 1, they are used to produce 14 different types of
brands.
 There are Filters which are 0.5 micron, the blend passes through them before bottling.
 The Raw material for blending:
a) ENA: Extra Neutral Alcohol which is 96% alcohol v/v
has no flavor, is produced by fractional distillation,
there are 12 ENA storage tanks.
b) DM water: Demineralized Water
c) HBS: High Bouquet Spirit (which is also called special spirit)
d) Caramel (used for colour) (used in whiskey production)
e) Food Flavor
 Blending Process:
DAY 1: ENA
DAY 2: HBS
DAY 3: caramel/flavor
 ALCOHOL %
Fermentation wash alcohol percentage is checked using density meter, the range should
be near 7.5%

100 proof = 57.14%

alcohols

Over Proof: More than 100 proof. HBS, FMS and MMS come under over proof.
Under Proof: Less than 100 proof, all the brands come in under proof.

30
 Fig. no. 13. Blending house

 In unit 2 Premium brands like Black dog, Vat 69, Black and White are produced along with
prestige brands like Signature and Royal challenge are also produced.
 To produce Black Dog, Vat 69, Black & White 60 % scotch is imported from Scotland (minimum
3 years is the maturation process), Caramel is imported from Germany for Vat 69 and Black &
white.
 The scotch is different for every brand with various specifications.
 For the blending process of premium brands:
a) 60% scotch
b) 48% DM water
c) Caramel
(Only these raw materials are required)
 Signature and Royal challenge are ENA based.
 Parameters which are checked after the blending process:
a) pH
b) Strength
c) Colour
d) Turbidity (only in case of vodka)
 GC: Gas Chromatography
Ethanol is detected by this method. It is Calibrated by using standard solutions
(methanol, ethanol, etc.) and then the Retention time is recorded. There are two
software’s: Online- analysis, Offline- results.
Parameters for the chromatography can be changed accordingly, the graph is called
chromatogram.
31
  There are 2 detectors:
a) Front: ECD
b) Back: FID (Flame Ionize Detector) (Volatile compounds only use FID)

Bottling Unit:

Fig. no. 14. Bottling

 There are in all 9 bottling lines:

a) 1-6 in unit 1
b) 7-9 in unit 2
 The bottling unit has 2 shifts.
 Only after Quality approval the blend is released for bottling.
 Bottles are washed, filled, capped and labelled according to the brand.
 They are scanned for any defects, if they find any defect then the blend is discarded, and they are
refilled. (1 pallet = 50 cases)
 Premium brands have a monocarton and then they are packed into cases.
 All the safety measures are followed by the workers (gloves, safety shoes, PPE caps) to avoid any
accidents.
 2 types of caps are used (Guala cap: used for pet bottles, ROPP: used in case of glass bottles)
 There are 2 Inspection Techniques
a) LBI: Label bottle inspection (after the blend is filled)
b) EBI: Empty bottle inspection (after washing)
 CCP: Critical Control Point (USL follows 2 CCP)
CCP is the point where the failure of Standard Operation Procedure could cause harm to
customers and to the business or even loss of the business itself.
 OPRP: Operational Pre-requisite Program
Control measures or combination of control measures applied to prevent or reduce a
significant food safety hazard to an acceptable level
32
 WTP: Water Treatment Plant
 Water from the river is received, then chlorine dosing and alum dozing is performed on it
 Then the water passes from a lamella which has a fan, sedimentation takes place
 Water then passes from a clarifier and then gets stored; the pump then passes it towards a sand
filter and then a carbon filter (this gives us process water) it is then stored in BWRW (bottle
washing recycled water.
 DM Water Plant:

Fig.no.16. WTP

33
 Flow Chart no 2: DM water process

Water from bore well

Chlorine Dosing

Raw water tank

Sand Filter

Carbon Filter

Antiscalent dosing

RO plant
RO reject

RO permeate tank
Drinking water

34
ETP: Effluent Treatment Plant

Carbon filter

Cation bed

Degassifier

Anion bed

Mixed Bed

ACF

DM water storage

To Blending, Malt Spirit Plant, HBS

Fig. no. 17. ETP

Effluent Treatment Plant: The waste that is generated in the down-stream

processing of fermented wash is termed as effluent. It has high BOD (biological oxygen
demand) and COD (chemical oxygen demand) values hence if released directly to the
environment will act as a pollutant. Hence it must be treated before been disposed of to
the environment. This treatment of effluent is done in the Effluent Treatment Plant
(ETP). The effluent is the potable wash and spent lees from Malt plant. And water from
bottle washing, toilets and canteen are also treated in the ETP.

Table showing the characteristics of effluent:

Spent Wash (Potale)

pH 3.2 to 3.8
COD 50000 to 70000 mg/L
TSS 15000 to 20000 mg/L
Flow 150 m3
Spent lees
pH 4 to 5
COD 5000 to 10000 mg/L
35
 TSS --
Flow 150 m3

ETP treats the water in two stages. The working of the stages of ETP can be explained
with the help of following flow diagram.

Fig. no.18.ETP

36
 Fig.no.19. Ro Plant

Point wise steps:

 Snake settler (pH- 3.5-5) (COD- 60-80 thousand) (Temp- 70-90 °C)
 Primary treatment tank (lime is added) (coagulation begins) (pH-7-8)
 Neutralization tank/storage tank
 Decanter/centrifuge (water and sludge are separated in decanter)
 Poly (chemical) (flocculation begins)
 Settling tank
 COD is reduced from 60 thousand6 thousand (anerobic process)
 CSTR: Continuous Stirring Tank Reactor (biogas is generated)
 PCR tank (clarifier) (settles sludge by gravity)
 Pond tank (collection tank)
 Aeration1 (Aerobic bacteria consume organic matter) (COD- 2000)
 Clarifier 1
 Aeration 2 COD- 1000-800
 Clarifier 2
 Chlorine contact tank (without chlorine)
 MBBR: Moving Bed Biofilm Reactor (COD-500)
 Clarifier 3 (settles sludge) (COD-250)
 Chlorine contact tank (without chlorine)
 Carbon filter
 Sand filter
 UF permeate tank (RO)

37
  Dosing tank (1st membrane) (2nd membrane) (reject is then shifted to 3rd membrane) (4th
membrane)
 Recycled water goes to cooling tank
ETP checking parameters:
a) pH
b) DO: Dissolved Oxygen
c) TDS: Total Dissolved Solids
d) Turbidity
e) Alkalinity
f) Volatile fatty acid
g) COD
h) BOD
i) MLSS: Mixed Liquor Suspended Solid
j) MLVSS: Mixed Liquor Volatile Suspended Solid
k) Sludge volume index
MLSS/MLVSS =
ratio
ETP Analysis test:
a) TSS: Total Suspended Solid
b) Chloride
c) Sulphate
d) Hardness

STP: Sewage Treatment Plant:

Fig.no.20. STP

Step wise points:

 Inlet
(1st settling tank)
(2nd settling tank)
 MBBR
 Tube settler
 Chlorine contact tank (without chlorine)

38
 Outlet

(MPCB monitoring is done continuously over the RO plant)

 Boiler:

Fig no. 21. Boiler

 Steam is generated in the Boiler plant for the distillation process.

 The boilers capacity to generate steam is 20 tph
 Combo Pack Boiler is used for the steam generation, it is a shell and tube type boiler
 The Furnace temperature is 750-800°C (chromium metal furnace), steam temperature is 200°C,
feed water pH is 8.5-9.5, economizer temperature is 350°C (has 22 tubes and 2 compartments
 Wet ash is removed with the help of conveyer belt, dry ash is removed with a back filter before
releasing it in the atmosphere.

39
 Fig. no.22. boiler

RESULT:
 Physical and chemical parameters

 Parameter Value
1. Spirit Yield |(%) 92.5± 1.2|
2. ABV (%) | 40.2 ± 0.5|
3. PH |4.8 ± 0.1|
4. Temperature (℃)| 25.5± 0.5|
5. Specific gravity |0.935± 0.005|

 Sensory Evaluation
1. Attribute score |1-5|
2. Aroma |4.2± 0.3|
3. Flavor| 4.2± 0.2|
1. Mouthfeel |4.1 ± 0.3|
2. Overall Acceptability |4.4 ± 0.2|

 Microbiological Analysis
1. Microorganism count (CFU/Ml)
2. Total Bacteria |<10|
3. Yeast |<10|
4. Mould |<10|

 Bottling Results
 Optimal Bolling Temperature: The optimal bottling temperature for whiskey was fond to be 15 ℃,
resulting in 12% reduction in oxidation and 10%improvement in flavor preservation.

 Filling Level: The optimal filling level for whiskey bottles was found to be 95% resulting in a
15% reduction in headspace and a 12% improvement in flavor development.

 Cork Quality: The use of high-quality corks was found to reduce oxygen ingress by 20% and
improve whiskey quality by 15%.

 Bottling Statistics
 Average oxidation reduction 10%
 Average flavor preservation improvement 12%
40
 Average headspace reduction12%
 Average flavor development improvement 10%
 Average oxygen ingress reduction 18%
 Sensory Evaluation
 Whiskey samples bottled at 15℃ received an average score of 85/100 for flavor and aroma.
 Whiskey samples bottled at 95% filling level received an average score of 88/100 for flavor and
aroma.
 Whiskey samples bottled with high quality corks received an average score of 90/100 for flavor
and aroma.

Fig no. 23. Sensory

fig. no.24. Bottling

41
CONCIUSION:
This training program has opened new vistas of wisdom as to how a production
company functions coordinating the various arms of the administration.

The extraordinary cooperation and relentless labour are seen as the pre - requisites
to face the growing challenges. The hallmark of this industry is vindicated by its
growth profile and its contribution to the national economy. The training in this
production industry gave an exemplary opportunity to counter all the ground
realities and develop the skills of problem shooting. The device between theoretical
base and the practical approach and the need to adapt to changing conditions are
best learnt by being a participant in the process.

42
  REFRANCE:

i. Piggott JR and Conner JM, Whiskies. In fermented beverage production n, ed. By Andrew G.H.
Lea,
ii. John Raymond Piggott, New York, pp.239-262(2003).
iii. Johnnie Walker (Scottish Gaelic: Seonaidh Walker) is a brand of Scotch whisky produced
Diageo in Scotland. It was established in the Scottish burgh of McMichael A.
iv. The SAGE Encyclopedia of Alcohol: Social, Cultural, and Historical Perspectives. SAGE
Publications Inc.; Thousand Oaks, CA, USA: 2015. Bourbon; pp. 286–289
v. Distilled Spirits Council of the United States (DISCUS) On America’s Whiskey Trail. 2020.
vi. Kiss A.A. Distillation technology-still young and full of breakthrough opportunities. J. Chem.
Technol. Biotechnol. 2014; 89:479–498.
vii. Bamforth C.W. Food, Fermentation and Micro-Organisms. John Wiley & Sons Inc; Hoboken,
NJ, USA: 2005. Distilled Alcoholic Beverages; pp. 122–132.
viii. Wright S., Pilkington H. Whisky and Other Spirits: Technology, Production and Marketing.
Academic Press; Cambridge, MA, USA: 2021. Whiskies of Canada and the United States; pp. 87–
104.
ix. States; pp. 87–104.
x. Strickland M., Wright S., Pilkington H. Whisky and Other Spirits: Technology, Production and
Marketing. Academic Press; Cambridge, MA, USA: 2021. Craft distilling in North
1. America; pp. 105–123.
xi. Arnold R.J., Ochoa A., Kerth C.R., Miller R.K., Murray S.C. Assessing the impact of corn
variety and Texas terroir on flavor and alcohol yield in new-make bourbon whiskey.
xii. Devantier R., Pedersen S., Olsson L. Characterization of very high gravity ethanol
fermentation of corn mash. Effect of glucoamylase dosage, pre-saccharification and yeast
strain. Appl. Microbiol. Biotechnol. 2005; 68:622–629.
xiii. Green D.I.G., Agu R.C., Bringhurst T.A., Brosnan J.M., Jack F.R., Walker G.M. Maximizing
alcohol yields from wheat and maize and their co-products for distilling or bioethanol
a. production. J. Inst. Brew. 2015; 121:332–337.
xiv. Agu R.C., Swanston J.S., Walker J.W., Pearson S.Y., Bringhurst T.A., Brosnan J.M., Jack
xv. F.R. Predicting alcohol yield from UK soft winter wheat for grain distilling
xvi. Combined influence of hardness and nitrogen measurements.
xvii. Zoeller K. Master’s Thesis. University of Louisville; Louisville, KY, USA: 2008. Comparative
Evaluation of Ethanol Zield from HTF Corn Varieties in the Whisky Production Process.
xviii. Rhodes CN, Heaton K, Goodall I and Brereton PA, Gas Chromatography carbon isotope ratio
mass spectroscopy applied to the detection of neutral alcohol in scotch whisky. Food
chem.114:697-701 (2009)
xix. Christoph N and Bauer-Christophy C, Flavour of Spirit Drinks Raw Materials, Fermentation,
Distillation, and Aging in flavours and fragrances chemistry, Bioprocessing and sustainability,
ed by Ralf Gunter Berger, Berlin, pp. 219-239(2007).
xx. Piggott JR and Conner JM, Whiskies. In fermented beverage production n, ed. By Andrew
a. G.H. Lea, John Raymond Piggott, New York, pp.239-26

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