WASTEWATER TREATMENT OF

BREWERIES AND WINERIES

BREWERIES
 RAW MATERIALS USED
▪ Properly prepared cereal grain (usually barley and corn or rice): Grains
are carefully stored and handled to promote highest quality.
▪ Hops (scientific name Humulus lupulus): Hops are a form of cultivated
perennial hemp, and the useful portions of the vine, the sticky cones, are
developed from the bloom.
▪ Pure water: Large quantities of pure water are extremely important not
only as an ingredient, but for maintaining the cleanliness of the brewing
equipment. In beer, water with high concentration of lime or iron can
interfere with the fermentation process and discolor the final product.
▪ Brewer's yeast: Yeasts are fungi, which are microorganisms that reduce
sugar to alcohol by fermentation.
▪ Each ingredient can affect flavor, color, carbonation, alcohol content, and
other subtle changes in the beer.
 MANUFACTURING PROCESS

STEPS INVOLVED IN
MANUFACTURING:
➢ Malting

➢ Mashing

➢ Brewing the wort

➢ Fermenting

➢ Pasteurizing

➢ Packaging
 MALTING

• Fully ripened barley grains are soaked in cold water until they are fully
saturated. The water is changed once a day, and after 45-72 hours the
grains are placed in shallow tanks.
• The grain is aerated and stirred, which causes it to germinate,
releasing enzymes such as Malt Diastase.
• Malt diastase converts the starches contained in the grain to sugar for
fermentation. As soon as the germination is adequately complete, usually
six days, the grain is roasted to stop the germination process.
• The exact point at which the roasting starts and ends affects the flavor and
color of the beer. The product at this point is referred to as malt.
 PREPARING THE MASH

• The malt is crushed using iron rollers and transferred to the mash tank.
This tank is a large copper or stainless steel vessel that mixes the malt with
warm water until it is of porridge-like consistency. This mixture is called
mash.
• After mixing with similarly prepared cereal grains, the temperature of the
mash is raised incrementally from 38 -77°C so that the enzymes react.
• The enzymes break down the starch in the grain and convert it to simple
sugars. Later, the yeast will convert the sugars into alcohol. Once
complete, the mash is allowed to sit undisturbed so the solids can
descend to the bottom of the tank.
 BREWING THE WORT
• The liquid contained in the mash is transferred into another tank called as
lauter tun. This is accomplished by drawing the liquid out through the
bottom layer of mash solids, which acts as a filter.
• Hot water is added to the top of the mash tank to rinse the remaining
liquid, now called wort, from the mash. The solid remains of the grain are
dried and sold by the brewery as animal feed.
• The wort travels on to the brew kettles, where it is boiled to sterilize it,
and where the carefully prepared hops are added. The addition of the
hops is important because they contribute to the bitterness of the beer.
• The brew kettles are the most impressive equipment in the process.
Gleaming copper, they can be 2.0 - 3.6 m in diameter and two stories high.
• Steam usually provides the heating energy to the brew kettles. After
brewing is complete, the finished wort is filtered again and pumped to the
fermentation tanks.
FERMENTATION
 FERMENTING

❖ In the fermentation tanks, the atmosphere must be

carefully controlled to prevent any bacteria from interfering
with the yeast.
❖ Carefully maintained yeast (approximately one pound per
barrel of wort) is added to the wort, and the temperature
of the mixture is slowly reduced over a period between 10 -
15°C. In this temperature range, the yeast grows,
consuming the sugar in the wort, and bubbles of carbon
dioxide form.
❖ The wort has now become beer. The new beer is filtered
and transferred once more into the aging barrels, where
the temperature is controlled at 0.5°C for 2-24 weeks.
 PASTEURIZING
❖After aging, the beer can be pasteurized to kill
the remaining yeast and prevent further
alcohol production. This is accomplished by
heating the beer above 57°C. This process,
named after Louis Pasteur, is widely known for
preserving milk. Interestingly, Pasteur
originally developed this process to preserve
beer in 1860s.
 PACKAGING
❖ Whether packaged into cans, bottles, or barrels,
the beer is always moved gently through the
maze of piping in the bottling area. This is to
preserve the natural carbonation.
❖During bottling, additional carbon dioxide gas
from the fermentation kettles is used to improve
the aroma of the beer. High-speed packaging
lines can process thousands of cases of beer per
day, and with modern computerized control, the
inventory can be tracked throughout the
distribution network.
TECHNOLOGICAL PROCESS USED IN
BREWERIES
 BY-PRODUCTS
❖ Beer brewing produces several byproducts that can be
used by other industries.
❖ During the malting of the barley, rootlets form on the
grain and drip off. These can be collected and used for
animal feed.
❖ The hops that is filtered out from the finished wort can
also be collected and used again as fertilizer.
❖ The residual yeast from the brewing process is a rich
source of B Vitamins. It can be put to use by
pharmaceutical companies to make Vitamins or drugs,
or used as a food additives.
❖ Used beer cans and beer bottles are routinely recycled.
CHARACTERISTICS OF WASTEWATER
WINERIES
 RAW MATERIALS
▪ Pulp
▪ Juice
▪ Sugars
▪ Acids
▪ Tannins and Minerals.
▪ However, some manufacturers add yeast to increase
strength and Cane or Beet sugar to increase alcoholic
content.
▪ During fermentation, winemakers also usually add
sulfur dioxide to control the growth of wild yeasts.
 HARVESTING AND CRUSHING GRAPES

❑ Vine yardists inspect sample clusters of wine grapes with a refractometer

to determine if the grapes are ready to be picked.
❑ If the grapes are ready for picking, a mechanical harvester gathers and
funnels the grapes into a field hopper, or mobile storage container. Some
mechanical harvesters have grape crushers mounted on the machinery,
allowing vineyard workers to gather grapes and press them at the same
time. The result is that vineyards can deliver newly crushed grapes,
called must, to wineries, eliminating the need for crushing at the winery.
This also prevents oxidization of the juice through tears or splits in the
grapes' skins.
❑ The field hoppers are transported to the winery where they are unloaded
into a crusher-stemmer machine. The grapes are crushed and the stems
are removed, leaving liquid ‘must’ that flows either into a stainless steel
fermentation tank.
MANUFACTURING PROCESS
 FERMENTING THE MUST
❑ During the fermentation process, wild yeast are fed
into the tank to turn the sugar in the ‘must’ into
alcohol. To add strength, varying degrees of yeast may
be added. In addition, cane or beet sugar may be
added to increase the alcoholic content. Adding sugar
is call chaptalization.
❑ Usually chaptalization is done because the grapes have
not received enough sun prior to harvesting. The
winemaker will use a handheld hydrometer to measure
the sugar content in the tank or vat. The ‘wine must’
ferments in the tank for approximately 7 to 14 days,
depending on the type of wine being produced.
 AGEING AND PACKAGING
❖ After crushing and fermentation, wine needs to be stored, filtered, and
properly aged. After fermentation, certain wines will be crushed again and
pumped into another fermentation tank where the wine will ferment
again for approximately 3 to 7 days. This is done not only to extend the
wine's shelf life but also to ensure clarity and color stability.
❖ The wine is then pumped into settling tanks. The wine will remain in the
tank for 1 to 2 months. Typically, racking is done at 10 to 16 °C for red
wine, and 0 °C for white wine.
❖ After the initial settling (racking) process, certain wines are pumped into
another settling tank where the wine remains for another 2 to 3 months.
During settling the weighty unwanted debris settle to the bottom of the
tank and are eliminated when the wine is pumped into another tank. The
settling process creates smoother wine.
❑ After the settling process, the wine passes through a number of
filters or centrifuges where the wine is stored at low temperatures
or where clarifying substances trickle through the wine.
❑ After various filtering processes, the wine is aged in stainless steel
tanks or wooden vats. Most large wineries age their wine in large
temperature-controlled stainless steel tanks that are above ground,
while smaller wineries may still store their wine in wooden barrels
in damp wine cellars.
❑ The wine is then filtered again to remove unwanted sediment. The
wine is now ready to be bottled, corked, sealed, crated, labeled,
and shipped to distributors.
❑ Most medium- to large-sized wineries now use automated bottling
machines, and most moderately priced and expensive wine bottles
have corks made of a special oak. The corks are covered with a
peel-off aluminium foil or plastic seal.
TECHNOLOGICAL PROCESS USED IN WINERIES
CHARACTERISTICS OF WASTEWATER
 WASTEWATER TREATMENT PROCESS
• There are three primary pre-treatment
processes utilized at breweries:
1. pH neutralization
2. Solid removal
3. Biological treatment
 pH Neutralization
❑Adjusting the pH in a waste stream can be one
of the most difficult processes in wastewater
treatment.
Two key components of these systems include the following:
❑Flow equalization is a technique used to consolidate
wastewater effluent in holding tanks for “equalizing”
temperature or pH before introducing wastewater
into downstream treatment processes.
❑Chemical adjustment of brewery pH and flocculation
of solids are the most common pretreatment
techniques used at breweries. The acidity or
alkalinity of wastewater affects both wastewater
treatment and the environment. Brewery
wastewater tends to gravitate towards a higher pH
due to the amount of caustic used for cleaning.
 Solid Removal Brewers
❑ Physical treatment is used for removing coarse solids and other large materials,
rather than dissolved pollutants.
❑ This may be a passive process, such as sedimentation to allow suspended
pollutants to settle out or float to the top naturally.
❑ Screening is typically a first step to remove glass, labels, and bottle caps, floating
plastic items and spent grains.
❑ After the wastewater has been screened, it may flow into a grit chamber where
sand, grit, and small stones settle to the bottom.
❑ With the screening completed and the grit removed, wastewater still contains
dissolved organic and inorganic constituents along with suspended solids.
❑ The suspended solids consist of minute particles of matter that can be removed
from the wastewater with further treatment, such as sedimentation or chemical
flocculation.
❑ Flocculation is the stirring or agitation of chemically-treated water to induce
coagulation. Flocculation enhances sedimentation performance by increasing
particle size, resulting in increased settling rates.
 BIOLOGICAL TREATMENT
❑ Anaerobic wastewater treatment is the biological treatment of
wastewater without the use of air or elemental oxygen. Anaerobic
treatment is characterized by biological conversion of organic
compounds by anaerobic microorganisms into biogas. Biogas is
mainly methane (55-75 vol%) and carbon dioxide (25-40 vol%) with
traces of hydrogen sulfide.
❑ Aerobic biological treatment is performed in the presence of
oxygen by aerobic microorganisms that metabolize the organic
matter in the wastewater, thereby producing more microorganisms
and inorganic end products. Aerobic treatment utilizes biological
treatment processes, in which microorganisms convert non-settle
able solids to settle able solids. Sedimentation typically follows,
allowing the settleable solids to settle out.
WASTEWATER TREATMENT PROCESS
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