A TECHNICAL REPORT ON

STUDENT INDUSTRIAL WORK EXPERIENCE

UNDERTAKEN AT

NIGERIA BREWERIES PLC.

BY

OJIELO FECHUKWU PERPETUA

DEPARTMENT OF FOOD SCIENCE AND TECHNOLOGY,

INDUSTRY- BASED SUPERVISOR: MR. OBENTA YUSUF

AN INSDUSTRIAL TRAINING REPORT WRITTEN IN PARTIAL FULFILMENT OF

FROM: SEPTEMBER 2024 TO DECEMBER 2024

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 DEDICATION

I dedicate this report formally to God almighty for taking me through this period of SIWES,
whose favor has been the source of my strength and health throughout this programme. I
would also like to dedicate this to my aunt Nkiruka Nwokeabia, Uncle Chukwuemeka Abako
and my siblings- Jennifer, Kenneth, Cynthia and Blessing- who have been my backbone both
financially and spiritually during the course of my Industrial Training.

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 ACKNOWLEDGEMENT

I want to thank God Almighty in a special way for giving me life, strength of mind and body
to carry out the scheme successfully. For all those who have inspired me in one way or
another in the course of this programme,

I send my best regards to the ITF body and all those in charge of this work experience
scheme for the opportunity to learn outside the lecture hall and have insights on what
working entails, coupled with acquisition of certain industrial skills.

I appreciate the Technological Department of Ama brewery Plc, the Technological Controller
Mr. Gideon Eke, my able Supervisor, Mr. Obenta Yusuf and the entire team for all the love
and care. It was a magnificent experience with the team.

I also wish to utilize this medium to acknowledge the very hardworking and wonderful Head
of the Department of Food Science and Technology, University of Nigeria Nsukka Dr.
Uzodinma Eunice and my ardent supervisor, Dr. A.N Nwosu for her invaluable and periodic
advice during the training experience.

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 TABLE OF CONTENTS

Cover Page

Dedication i

Acknowledgement ii

Table of Contents iii

Abstract iv

List of Figures v

CHAPTER ONE

INTRODUCTION

1.0 Introduction to the Industrial Work Experience Scheme 1

1.1 Brief history of Nigerian breweries plc. Ama 1

1.2 Plant Structure 2

1.3 Organizational Chart 3

1.4The organization mission and vision statement 4

CHAPTER TWO

2.0 Overview of Beer 5

2.1 Raw Materials in Brewing 7

2.1.1 Storage of Raw materials 11

2.2 Grains/Silo handling, intake, storage and treatment 12

2.2.1 Malt/Grain intake procedure 12

2.2.2 Intake in Silo 13

2.2.3 Treatment/milling process 14

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2.2.4 Dust management during intake and treatment 15

2.2.5 Cleaning and fumigation of the silo 15

2.3 Brewing operational process in Ama 16

2.3.1 Milling 18

2.3.2 Mashing 18

2.3.3 Wort Boiling 19

2.3.4 Wort Clarification/Whirlpool 22

2.3.5 Wort Cooling, Aeration and Yeast Pitching 23

2.4 Yeast Management 25

2.4.1 Yeast Propagation 26

2.4.2 Pitching Rates 26

2.4.3 Microbiological Contamination during propagation 26

2.4.4 Attenuation 27

2.4.5 Yeast Flocculation 27

2.4.6 Beer Flavor vs yeast 27

2.5 Fermentation, RUH and Maturation 27

2.5.1 Fermentation 27

2.5.2 RUH (warm Maturation) 29

2.5.3 Deep cooling/Cold storage 30

2.5.3 Bright Beer Filtration 30

CHAPTER THREE

3.0 Quality Control/Laboratory Analysis 31

3.1 Safety Rules in the laboratory 31

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3.2 Quality Control 31

3.3 Quality checks in Brewing 32

3.3.1 Process Analysis and Quality checks in the laboratory 32

3.4 Microbiology Laboratory 38

3.4.1 Microbiological Laboratory equipment and uses 38

3.5 Water Analysis 40

CHAPTER FOUR

4.0 CONCLUSION AND RECOMMENDATION

4.1 Conclusion 42

4.2 Recommendations 42

Reference 43

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 LIST OF FIGURES

FIG 1 The Ama brewery layout 3

FIG 2 Ama Brewery Organogram 3

FIG 3 Silo 10

FIG 4 Grain intake in progress 14

FIG 5 Intake system showing the Silos 14

Fig 6 Milling system 15

FIG 7 Brewing Operation Flow Diagram 17

FIG 8 Hammer mill inlet feed mechanism 18

FIG 9 Internal structure 18

FIG 10 An example of a decoction mashing diagram/profile 20

FIG 11 Wort kettle/wort copper 21

FIG12: External design of whirlpool 22

FIG 13 Internal of whirlpool 22

FIG 14 Plate heat exchange 24

FIG 15 Wort cooling system 25

FIG 16 OHAUS moisture analyzer 33

FIG 17 Consort pH meter 34

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FIG 18 Anton Pear tester 35

FIG 19 Spectrophotometer 35

FIG 20 Turbidity meter 36

FIG 21 Nibem foam tester 37

FIG 22 CTPO: CO2 and total package oxygen analyzer 38

FIG 23 RPU monitor 38

FIG 24 GAS chromatography 39

FIG 25 MRC autoclave 39

FIG 26 Incubator 40

FIG 27 Refrigerator 40

FIG 28 fluorescence microscope 40

FIG 29 Cover slip 41

FIG 30 Slide 41

FIG 31 Colony Counter 41

FIG 32 Laminar flow hood/cabinet 42

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 ABSTRACT

This report contains information pertaining to the Students Industrial Work Experience
Scheme (SIWES)/industrial training programme undertaken in a brewing company (Nigerian
breweries) that lasted for a duration of three-four months. It is the accepted skill training
programme which forms part of the approval of minimum academic standard in the various
degree programmes for all Nigerian universities. The training was centered on beer
production processes and quality control for different brands, done majorly in the
technological and partially in brewing department of the company. The technological
department (quality control) plays a crucial role in ensuring that the final product meets both
internal and external standards for safety, taste and consistency. The department is
responsible for monitoring and testing raw materials, production processes and finished
products through rigorous sensory, microbiological and entrance control analysis. Quality
control ensures that every batch of raw material and beer adheres to the required
specification, mitigating potential defects and ensuring product quality throughout the
brewing process. The quality control team contributes significantly to maintaining the
brewery’s reputation and consumer satisfaction. While Brewing is the production of beer by
steeping a starch source (commonly cereal grains, the most popular of which is barley) in
water and fermenting the resulting sweet liquid with yeast. For the Brewing of Beer, four (4)
essential raw materials are needed they are. Malt and Adjuncts, Hops and Hop Products,
Water and Yeast. Steeped grains such as malted barley are milled to grist, then the grist is
soaked with water and heated at a specific temperature known as Mashing, the mash is then
filtered to get spent grain and wort, the wort is boiled furthermore and during this process,
hops and adjuncts are added to the wort. The wort is allowed to cool through the action of a
plate heat exchanger and then allowed to clarify. Yeast introduction known as yeast pitching
commences on the clarified wort and fermentation process begins. After fermentation must
have lasted for about 2-5 days, the young beer is then filtered with the aid of the Kiehsigur
powder after which it is referred to as matured beer. The matured beer is stored in a Bright
beer tank (BBT) which is then sent to bottling hall for packaging. The packaged beer is then
sent to the logistics department for sales and distribution to vendors.