Description
united breweries, taloja
Operations Research
Assignment – 2 Industrial Visit Report
Submitted by, Srushti More (37) MMS – I (A)
1
UNITED BREWERIES LIMITED
INTRODUCTION The United Breweries group is fully automated manufacturing unit at Taloja in Navi-Mumbai. Maharashtra Industrial Development Corporation (MIDC) at Taloja in Navi Mumbai.This plant maintains a very high standard of hygiene. The division has comprehensive quality assurance system which ensures that products are backed by the best of quality processes and ingredients, and measure up to world - class hygiene standards. The unit is spread over area of 22 acres and was the first green field project of the United Breweries group. There are employeed working at unite breweries ltd. The industrial aspects guided by Mr.Ashok Katta ( Officer Human Resource Department). OBJECTIVE ? ? ? ? ? ? Obtaining the best possible raw material at the least possible price. Low inventory increases efficiency since less capital is blocked. This results high return on investment. Efficient handling and storing of materials reduces the cost of procurement. Continuous supply reduces cost that may arise due to disruptions. Consistent quality of raw material ensures high quality product. Maintaining cordial relations with suppliers benefits the buyer in more than one way.
PRODUCT Heineken is positioned as a super-premium lager beer that will target the discerning beer drinker in India. Heineken, the iconic global beer brand launched in India by United Breweries locally brewed and bottled Heineken beer from their brewery in Taloja, near Mumbai. The entire process of making Heineken has been the result of close co-ordination between the Heineken Global Supply Chain and the united breweries limited team. The first Heineken was manufactured at taloja. Heineken has been launched in bespoke world class packaging, with imported green embossed bottlesand clear plastic labels, a first for any beer brand in India. UNITS AT UNITED BREWERIES ? ? ? ? ? Water affluent treatment plant Effluent treatment plant Administration block Brew house Quality control
2
? ? ? ? ? ? ?
Canning hall Can dispatch Bottling Packing material store Engineering store Utility Canteen
BRAND PRODUCTS ? ? ? ? ? ? ? Kingfisher draught Kingfisher premier large beer Tajmahal premium large beer Maharaja premium large pilsner Kingfisher strong premium beer Kingfisher blue Zingaro-super strong premium beer ? ? ? ? Heineken London pilsner- premium beer London pilsner- strong beer Kalyani black label-strong premium beer
MAIN INGREDIENTS The main ingredients in process of making beer are as follows: Beer is made from the extract of barley, hops, riceflakes, sugar, water and other enzymes(yeast). All the ingrediants are been added in a specific process of making beer. Barley Barley is the seed of a grain that looks a lot like wheat. Before barley can be used to make beer, it must be malted, which involves a natural conversion process. The barley must be allowed to germinate. This is done by soaking the barley in water for several days, and then draining the barley. This allows the husk to open and barley to start to sprout at this point it is called green malt. At the end process is removing any small roots that formed during germination and the malted barley is ready to begin the brewing process. Barley is brought usually from Rajasthan , Haryana and Punjab as been grown there on a large scale. Barley malt is brought in gunny bags of 60 to 70 kg and is been used usuing first in first out method. Hops The hops used to make beer are the flower of the hop vine.Hops contain acids, which give beer its bitterness, as well as oils that give beer some of its hop flavor and aroma. Adding hops to beer also inhibits the formation of certain bacteria that can spoil the beer. Hops function as flavoring agents and stabilizers in the making of beer. It is a cheaper substitute for making beers.the main idea behind using hops is adding aroma and flavor produced from the oil while hop is been boiled in beer process.
3
There are many different kinds of hops, each of which gives a different taste, aroma and amount of bitterness to the beer it is used. The best quality hops grow at germany and so are imported from there. Hops are available in 3 forms: ? ? ? Liquid Oil Pellets Liquid and Pellet form of hops are used for brewing. Rice flakes Rice flakes, in local terms is known as poha is produced on large scale in Maharashtra and thus easily available and they are sometimes also brought / purchased from states of Hyderabad and Andhra Pradesh. Sometimes even broken rice is also used instead of flakes Sugar Sugar is purchased from Maharashta itself. M 30 is used the quality sugar being made into use in the process of making alcohol. There are 2 types of beer: mild and strong where in process of strong beer more sugar is been added while making. Water MIDC has provided with reliable water supply system. The system caters to the water needs of the industries within MIDC industrial areas and also those outside, in the adjoining areas. Not only that, the system caters to the needs of many large and small local bodies all over the State which in turn serve their domestic and commercial consumers. MIDC supplies treated, potable water to all industrial units. Yeast Yeast is the single-celled micro-organism that is responsible for creating the alcohol and carbon dioxide found in beer. Yeast is basically a bacteria that lies between 5 degree to 14 degree celcius, which can be preserved and used upto 6 generations.There are many different kinds of yeasts used to make beer that helps to give beer its various tastes. PROCESS OF BEER MANUFACTURING Following is the process in beer manufacturing unit: Malt mill Initial Process: ? ? ? Separate dust from barley malt Separation of foreign particles. Sizing of barley malt
4
? ?
Crushing barley between two rollers (such that white skin and dust particles are separated) Grind it to form a powder form of malt.
Raw material malt is stored in silo .There are 4 silo’s available at the factory which has a capacity of 200 M tones each, the speciality is that upto 6 months no germs are generated also the quality remains good. Every 10 days the new stock is added to the silo. United breweries have their own farm fields at Patiala and also available from Rajasthan, Haryana, Punjab. They import 30% of barley malt. Consumption per day is 20 metric tons. Brew House (kitchen of beer) After the barley is separated and cleaned it is then sent to the brew house department. In the brew house the following processes take place: ? ? ? ? ? ? ? ? ? Mash Kettle Lauter Tun Wort Kettle Whirlpool & PHE (Plate Heat Exchanger) Yeast Room Fermentation Tank Lagering Process Filtration Process
Mash Kettle The mash is the process that converts the starches in the malted barley into fermentable sugars. Here the barley malt is mixed with rice flakes and water and boiled for one hour. The temperature is maintained at 102 deg C. The proportion of the components is 25000 litres of water, 1700 barley malt, 550 broken rice or rice flakes,There are two separate Mash Kettle each of capacity of 25000 litres. Here 16 brews are manufactured per day, where 1 brew = 25000 litres. Lauter tun After the mashing, the mash is pumped to a lauter tun where the resulting liquid is strained from the grains in a process known as lautering. Lauter is a separation of husk and liquid from grain is taken place.Wort is pumped into lauter tun and water is added to form a proper mixture. It is then mixed for one hour using blades at 1000 C. And it is allowed to settle and form a filter bed made of husk and undissolved flakes the process time is 2 days. Then the filterate is pumped to wort kettle. The left out is husk (dried) which is ben sold at price of Rs.2 per kg. This is fed to cattle so that they give good quality milk.
5
Wort Kettle The next step in the beer brewing process is called the boil. At the end of the boil we will have a finished wort.The liquid part from lauter is known as wort. 500 kg Sugar and 5 kg Hops are added manually at this stage. Then the wort is mixed to dissolve sugar and hops for one hour and at the end of process the temperature comes to 90 degree Celsius. The required process time is one hour. The boiling hops are added to add bitterness to the beer and give hop flavor and aroma to the beer. Whirlpool At the end of the boil, the wort is set into a whirlpool. there is a separate tank for whirlpooling. In whirlpool process the impurities settles at center that is it enables the undissolved particles to settle at the bottom. Hot steam evaporates and then cooling process continues till almost 1 hour. The temperature reduces to 65-70 degree C. The bottom of the whirlpool is often slightly sloped toward the outlet. Plate Heat Exchanger Since yeast cannot be added at 70 deg C the wort is reduced to 6-7 deg C and pumped to fermentors. The wort is circulated through one set of tubes while chilled water is circulated through another set. The tubes with hot wort running through them transfer heat to the tubes holding the chilled water. Fermentation The final mixture is moved to fermentor where it is mixed with Yeast which will convert the mixture of malt and hops into Beer. The Yeast converts Sugar and Proteins into Alcohol. The temperature maintain at 4 to 6 deg. C. till the fermentation the desired concentration of alcohol is reached approximately for 7 days and next 7 days when the temperature reaches 6 to 14 deg. C. Laggering After fermentation the temperature of beer is lowered to 0 deg. C and let it matured for a period of one week (7 days) and then transferred to packaging unit. The alcohol is fermented itself.this process is known as laggering. Fermentation process and laggering process is carried out in the same fermentor. Filteration There are various kinds of filters namely: ? ? ? Candle Filter( Thick Cloth) Sand Filter Hi Flow Filter .
At united breweries hi flow filters are used these works on hi flow chemical that is alike to sand filters. They are imported from germany and featured such that they never dilutes in with beer. All the impurities get chocked on the upper side leaving pure content on the lower side. A filter is changed onces in a day, it chocks after 2.5 lakh liters of beer been filtered at a time.
6
Before the process of filteration the beer is known as green beer and after the process of filteration it is known bright beer, it is then sent to bright beer tank (BBT). Once the process is done the produced beer is to be sent to the packing of beers in various available form which are then sold in the market as per the demand of the consumers and upto certain capacity decided by the company. PACKING Packaging is putting the beer into the containers in which it will leave the brewery. Typically this means in bottles and kegs, but it might include cans or bulk tanks for high-volume customers. The most important thing about the bottling and kegging process is to keep the beer from being contaminated by stray yeasts, and to keep oxygen away from the beer. These are the main things that can reduce the shelf-life of beer. There are 3 types of packing: ? ? ? Keg Cans Bottles
Detailed information about the same is as follows: Keg Keg is a barrel like container which is used to store unpasturized beer. It is available in varying capacities of 10, 20, 30 and 50 litres. Unpasturized beer has a very short shelf life of approximately 5-6 days and so cant be stored for longer span of time. The beer is produced in the morning and dispatched in the evening. It has only produced in the required quantities and not in excess as per the demand in market. This beer is mainly supplied to pubs, bars and five star hotels as per their demand for the day. Cans The cans are imported from Thailand, UAE and Singapore, Canada, France. United Breweries now procures its cans from a local unit Raxem Industries which is located in Taloja itself. This helps UB to reduce its overhead costs involved in the manufacturing of beer. Each can has a capacity of 330ml. The cans can be preserved and stored upto 6 months from date of packing. In the machines at canning department, 72 cans are been filled at 1 time. 25000 cans are filled up in 1 hour. Almost about 70000 to 80000 cases are been exported, Where, 1 case = 330ml x 24 cans. The overall sales per day inclusive of all packing media is about 50000 cases, so break even quantity is 6 lakhs.
7
Bottles The bottling plant was inaugurated by Dr.Viajy Mallya on 12th April 1995. The new bottles and reuse bottles are in a ratio of 20:80 respectively.United breweries group doesn’t produce bottles but they obtain second hand bottles from local scrap dealers.They then recycle these bottles,for reuse of bottles, the bottles are washed and thoroughly cleaned also the labels are removed before washing and then they are sent to bottling process. There are 2 sizes of bottles 350 ml and 650 ml. Process at bottling unit Once the final quality of the beer has been achieved, it is ready for bottling. The bottling of beer is one of the most complex aspects of brewery operations and the most labor intensive of the entire production process. The layout of the bottling line will depend on a number of factors but typically consists of a series of processes as shown below taken placed at the bottling unit. ? ? ? ? ? ? ? ? ? ? ? Bottle washer Empty bottle inspection Bottle filler Crown fixing Pasteurization Labeling Coding(batching) Box making Box filling Box packing Palletizing
Bottle washer The bottles that are to be reused are been washed properly in bottle washer machine, the are throughly rinsed in machine, To start the process, the empty bottles are loaded onto the bottling line, where they are first rinsed with a chlorine solution, and then blasted with CO2 to remove the solution. All the labels are rinsed befor e cleaning the bottles. At an considerable extent 36000 bottles are washed per hour. Total breakage in this bottle washing process is about 1.5% . Empty bottle inspection Once the bottles are been rinsed properly,the empty bottles are been inspected such that if there is any damaged bottle,the bottle is taken off. The empty bottles are been inspected by the machine that also require few labourers at work.also here if there is any breakage the bottle is taken off with the help of steel rod. Then the checked undamaged bottles are been sent for filling the beer in bottles.
8
Bottle filler Refilling of 650 ml or 350 ml bottles is done at 26000 bottles in 1 hour. The machine is automated that speeds up and slows down as and when required. Once the beer bottles are filled up the checking of level of beer is done manually with help of tubelight.every bottle is checked manually before crowning. In case if the bottle breaks while refilling,there is systematic cleaning done with water and sweep machine. Crown fixing After the bottle has been cleared of air, the next step is to cap the bottles as soon as possible with the crowner.Crown caps are made up of chromium coated sheets, mainly used for sealing bottles, used in beverages & various brands of beers. Crown caps are used for closing off drink bottles and gives an excellent seal. These crown fixing is done after bottle refill. Pasteurization Pasteurization is done after bottles have been filled and crowned. The bottles are loaded at one end of the pasteurizer and passed under sprays of water as they move along the conveyor. The sprays are so arranged that the bottles are subjected to increasingly hot water until the pasteurization temperature is reached by the beer in the bottles .The bottles are then gradually cooled with water until they are discharged from the end of the pasteurizer. Temperature changes have to be made in stages to prevent the bottles from breaking. Labeling Before labeling, it is absolutely essential that the bottles are dry and free of condensation. This is especially important with pressure-sensitive labels that use non-water-soluble glues. Wet glue, which is typically used as an adhesive in glue applications, is much less sensitive to residual water on the bottle. An air knife can eliminate virtually all of the surface moisture on the bottles after the post rinse. Coding(batching) Once the labeling is done the next important step is to do coding or batching to the stock of the beer being produced. This is the most significant step.here the beer bottles are been coded in machines. Box making The box making process is started so that the cases can be used for keeping beer bottles. For the purpose of keeping cans one particular box can hold a capacity of 24 cans and in case of bottles of 350ml and 650 ml 12 bottles can be stored in one box Box filling The beer bottles are filled in box, under manual observation with the use of bottle filling machine in box. The machine lifts the bottles and fills in the box, this process is done carefully so that the breakages can be avoided.
9
Box packing The boxes are packed properly so as to avoid damages to the bottle, One particular box of beer consists of 12 bottles. These boxes are sealed and then sent to market. Palletizing If the palletized load of beer is to be warehoused, the temperature of the beer should not exceed 3°C. Care should be taken to avoid damage from fork trucks, and excessive heights should be avoided in stacking of pallets. There is a huge ware house at united breweries at the rear end of the bottling unit. Hence this was the entire process conducted at the bottling unit at united breweries ltd. To take an overview of the entire process from the initial stage at the brewery, The following diagram will show the entire brewering process, from the brew house to the bottling unit in a systematic represented way.
10
COSTING The actual cost of making one filled beer bottle is Rs.20, which after implementing the major exise duty and value added tax the cost is raised to Rs.95.(where for Mild beer excise duty is 150% of manufacturing cost and in case of strong beer is 175% of manufacturing cost.Also 25% value added tax is applicable for all cases) The market price of one single beer bottle is Rs.150 inclusive of all taxes. Almost about 4 lakh litres is per day production where united breweries have to pay 1.5 crores to Maharashtra government as part of excise duty and value added tax. PRODUCTION CAPACITY Capacity of productionat united breweries is as follows: ?
? ?
Kegs Cans
- Produced as per market requirements ( as the life in kegs is very short and hence to be consumed within the day). - 18000 cans per hour
Bottles - 30000 bottles per hour and which can be increased to 36000 Currently the plant is operating at 80% capacity
QUALITY MANAGEMENT ? ? ? ? ? ? Quality and hygiene are the key elements of the United Breweries groups manufacturing units. Quality Management Systems laid out along the lines of ISO 9000 are strictly adhered to, controlling quality at every stage of production. Quality of the beer is checked electronically at the end of each process and the quality of the final packaged product is manually checked. Timely cleaning process is done at regular intervals in short span of time during the entire time. Kingfisher contributes to the environment by making use of used bottles by recycling them. A management focused on building brand equity on one hand and exploiting it to the hilt on the other with concerted emphasis on quality.
????????????????????????????????????????
11
doc_824183286.docx
united breweries, taloja
Operations Research
Assignment – 2 Industrial Visit Report
Submitted by, Srushti More (37) MMS – I (A)
1
UNITED BREWERIES LIMITED
INTRODUCTION The United Breweries group is fully automated manufacturing unit at Taloja in Navi-Mumbai. Maharashtra Industrial Development Corporation (MIDC) at Taloja in Navi Mumbai.This plant maintains a very high standard of hygiene. The division has comprehensive quality assurance system which ensures that products are backed by the best of quality processes and ingredients, and measure up to world - class hygiene standards. The unit is spread over area of 22 acres and was the first green field project of the United Breweries group. There are employeed working at unite breweries ltd. The industrial aspects guided by Mr.Ashok Katta ( Officer Human Resource Department). OBJECTIVE ? ? ? ? ? ? Obtaining the best possible raw material at the least possible price. Low inventory increases efficiency since less capital is blocked. This results high return on investment. Efficient handling and storing of materials reduces the cost of procurement. Continuous supply reduces cost that may arise due to disruptions. Consistent quality of raw material ensures high quality product. Maintaining cordial relations with suppliers benefits the buyer in more than one way.
PRODUCT Heineken is positioned as a super-premium lager beer that will target the discerning beer drinker in India. Heineken, the iconic global beer brand launched in India by United Breweries locally brewed and bottled Heineken beer from their brewery in Taloja, near Mumbai. The entire process of making Heineken has been the result of close co-ordination between the Heineken Global Supply Chain and the united breweries limited team. The first Heineken was manufactured at taloja. Heineken has been launched in bespoke world class packaging, with imported green embossed bottlesand clear plastic labels, a first for any beer brand in India. UNITS AT UNITED BREWERIES ? ? ? ? ? Water affluent treatment plant Effluent treatment plant Administration block Brew house Quality control
2
? ? ? ? ? ? ?
Canning hall Can dispatch Bottling Packing material store Engineering store Utility Canteen
BRAND PRODUCTS ? ? ? ? ? ? ? Kingfisher draught Kingfisher premier large beer Tajmahal premium large beer Maharaja premium large pilsner Kingfisher strong premium beer Kingfisher blue Zingaro-super strong premium beer ? ? ? ? Heineken London pilsner- premium beer London pilsner- strong beer Kalyani black label-strong premium beer
MAIN INGREDIENTS The main ingredients in process of making beer are as follows: Beer is made from the extract of barley, hops, riceflakes, sugar, water and other enzymes(yeast). All the ingrediants are been added in a specific process of making beer. Barley Barley is the seed of a grain that looks a lot like wheat. Before barley can be used to make beer, it must be malted, which involves a natural conversion process. The barley must be allowed to germinate. This is done by soaking the barley in water for several days, and then draining the barley. This allows the husk to open and barley to start to sprout at this point it is called green malt. At the end process is removing any small roots that formed during germination and the malted barley is ready to begin the brewing process. Barley is brought usually from Rajasthan , Haryana and Punjab as been grown there on a large scale. Barley malt is brought in gunny bags of 60 to 70 kg and is been used usuing first in first out method. Hops The hops used to make beer are the flower of the hop vine.Hops contain acids, which give beer its bitterness, as well as oils that give beer some of its hop flavor and aroma. Adding hops to beer also inhibits the formation of certain bacteria that can spoil the beer. Hops function as flavoring agents and stabilizers in the making of beer. It is a cheaper substitute for making beers.the main idea behind using hops is adding aroma and flavor produced from the oil while hop is been boiled in beer process.
3
There are many different kinds of hops, each of which gives a different taste, aroma and amount of bitterness to the beer it is used. The best quality hops grow at germany and so are imported from there. Hops are available in 3 forms: ? ? ? Liquid Oil Pellets Liquid and Pellet form of hops are used for brewing. Rice flakes Rice flakes, in local terms is known as poha is produced on large scale in Maharashtra and thus easily available and they are sometimes also brought / purchased from states of Hyderabad and Andhra Pradesh. Sometimes even broken rice is also used instead of flakes Sugar Sugar is purchased from Maharashta itself. M 30 is used the quality sugar being made into use in the process of making alcohol. There are 2 types of beer: mild and strong where in process of strong beer more sugar is been added while making. Water MIDC has provided with reliable water supply system. The system caters to the water needs of the industries within MIDC industrial areas and also those outside, in the adjoining areas. Not only that, the system caters to the needs of many large and small local bodies all over the State which in turn serve their domestic and commercial consumers. MIDC supplies treated, potable water to all industrial units. Yeast Yeast is the single-celled micro-organism that is responsible for creating the alcohol and carbon dioxide found in beer. Yeast is basically a bacteria that lies between 5 degree to 14 degree celcius, which can be preserved and used upto 6 generations.There are many different kinds of yeasts used to make beer that helps to give beer its various tastes. PROCESS OF BEER MANUFACTURING Following is the process in beer manufacturing unit: Malt mill Initial Process: ? ? ? Separate dust from barley malt Separation of foreign particles. Sizing of barley malt
4
? ?
Crushing barley between two rollers (such that white skin and dust particles are separated) Grind it to form a powder form of malt.
Raw material malt is stored in silo .There are 4 silo’s available at the factory which has a capacity of 200 M tones each, the speciality is that upto 6 months no germs are generated also the quality remains good. Every 10 days the new stock is added to the silo. United breweries have their own farm fields at Patiala and also available from Rajasthan, Haryana, Punjab. They import 30% of barley malt. Consumption per day is 20 metric tons. Brew House (kitchen of beer) After the barley is separated and cleaned it is then sent to the brew house department. In the brew house the following processes take place: ? ? ? ? ? ? ? ? ? Mash Kettle Lauter Tun Wort Kettle Whirlpool & PHE (Plate Heat Exchanger) Yeast Room Fermentation Tank Lagering Process Filtration Process
Mash Kettle The mash is the process that converts the starches in the malted barley into fermentable sugars. Here the barley malt is mixed with rice flakes and water and boiled for one hour. The temperature is maintained at 102 deg C. The proportion of the components is 25000 litres of water, 1700 barley malt, 550 broken rice or rice flakes,There are two separate Mash Kettle each of capacity of 25000 litres. Here 16 brews are manufactured per day, where 1 brew = 25000 litres. Lauter tun After the mashing, the mash is pumped to a lauter tun where the resulting liquid is strained from the grains in a process known as lautering. Lauter is a separation of husk and liquid from grain is taken place.Wort is pumped into lauter tun and water is added to form a proper mixture. It is then mixed for one hour using blades at 1000 C. And it is allowed to settle and form a filter bed made of husk and undissolved flakes the process time is 2 days. Then the filterate is pumped to wort kettle. The left out is husk (dried) which is ben sold at price of Rs.2 per kg. This is fed to cattle so that they give good quality milk.
5
Wort Kettle The next step in the beer brewing process is called the boil. At the end of the boil we will have a finished wort.The liquid part from lauter is known as wort. 500 kg Sugar and 5 kg Hops are added manually at this stage. Then the wort is mixed to dissolve sugar and hops for one hour and at the end of process the temperature comes to 90 degree Celsius. The required process time is one hour. The boiling hops are added to add bitterness to the beer and give hop flavor and aroma to the beer. Whirlpool At the end of the boil, the wort is set into a whirlpool. there is a separate tank for whirlpooling. In whirlpool process the impurities settles at center that is it enables the undissolved particles to settle at the bottom. Hot steam evaporates and then cooling process continues till almost 1 hour. The temperature reduces to 65-70 degree C. The bottom of the whirlpool is often slightly sloped toward the outlet. Plate Heat Exchanger Since yeast cannot be added at 70 deg C the wort is reduced to 6-7 deg C and pumped to fermentors. The wort is circulated through one set of tubes while chilled water is circulated through another set. The tubes with hot wort running through them transfer heat to the tubes holding the chilled water. Fermentation The final mixture is moved to fermentor where it is mixed with Yeast which will convert the mixture of malt and hops into Beer. The Yeast converts Sugar and Proteins into Alcohol. The temperature maintain at 4 to 6 deg. C. till the fermentation the desired concentration of alcohol is reached approximately for 7 days and next 7 days when the temperature reaches 6 to 14 deg. C. Laggering After fermentation the temperature of beer is lowered to 0 deg. C and let it matured for a period of one week (7 days) and then transferred to packaging unit. The alcohol is fermented itself.this process is known as laggering. Fermentation process and laggering process is carried out in the same fermentor. Filteration There are various kinds of filters namely: ? ? ? Candle Filter( Thick Cloth) Sand Filter Hi Flow Filter .
At united breweries hi flow filters are used these works on hi flow chemical that is alike to sand filters. They are imported from germany and featured such that they never dilutes in with beer. All the impurities get chocked on the upper side leaving pure content on the lower side. A filter is changed onces in a day, it chocks after 2.5 lakh liters of beer been filtered at a time.
6
Before the process of filteration the beer is known as green beer and after the process of filteration it is known bright beer, it is then sent to bright beer tank (BBT). Once the process is done the produced beer is to be sent to the packing of beers in various available form which are then sold in the market as per the demand of the consumers and upto certain capacity decided by the company. PACKING Packaging is putting the beer into the containers in which it will leave the brewery. Typically this means in bottles and kegs, but it might include cans or bulk tanks for high-volume customers. The most important thing about the bottling and kegging process is to keep the beer from being contaminated by stray yeasts, and to keep oxygen away from the beer. These are the main things that can reduce the shelf-life of beer. There are 3 types of packing: ? ? ? Keg Cans Bottles
Detailed information about the same is as follows: Keg Keg is a barrel like container which is used to store unpasturized beer. It is available in varying capacities of 10, 20, 30 and 50 litres. Unpasturized beer has a very short shelf life of approximately 5-6 days and so cant be stored for longer span of time. The beer is produced in the morning and dispatched in the evening. It has only produced in the required quantities and not in excess as per the demand in market. This beer is mainly supplied to pubs, bars and five star hotels as per their demand for the day. Cans The cans are imported from Thailand, UAE and Singapore, Canada, France. United Breweries now procures its cans from a local unit Raxem Industries which is located in Taloja itself. This helps UB to reduce its overhead costs involved in the manufacturing of beer. Each can has a capacity of 330ml. The cans can be preserved and stored upto 6 months from date of packing. In the machines at canning department, 72 cans are been filled at 1 time. 25000 cans are filled up in 1 hour. Almost about 70000 to 80000 cases are been exported, Where, 1 case = 330ml x 24 cans. The overall sales per day inclusive of all packing media is about 50000 cases, so break even quantity is 6 lakhs.
7
Bottles The bottling plant was inaugurated by Dr.Viajy Mallya on 12th April 1995. The new bottles and reuse bottles are in a ratio of 20:80 respectively.United breweries group doesn’t produce bottles but they obtain second hand bottles from local scrap dealers.They then recycle these bottles,for reuse of bottles, the bottles are washed and thoroughly cleaned also the labels are removed before washing and then they are sent to bottling process. There are 2 sizes of bottles 350 ml and 650 ml. Process at bottling unit Once the final quality of the beer has been achieved, it is ready for bottling. The bottling of beer is one of the most complex aspects of brewery operations and the most labor intensive of the entire production process. The layout of the bottling line will depend on a number of factors but typically consists of a series of processes as shown below taken placed at the bottling unit. ? ? ? ? ? ? ? ? ? ? ? Bottle washer Empty bottle inspection Bottle filler Crown fixing Pasteurization Labeling Coding(batching) Box making Box filling Box packing Palletizing
Bottle washer The bottles that are to be reused are been washed properly in bottle washer machine, the are throughly rinsed in machine, To start the process, the empty bottles are loaded onto the bottling line, where they are first rinsed with a chlorine solution, and then blasted with CO2 to remove the solution. All the labels are rinsed befor e cleaning the bottles. At an considerable extent 36000 bottles are washed per hour. Total breakage in this bottle washing process is about 1.5% . Empty bottle inspection Once the bottles are been rinsed properly,the empty bottles are been inspected such that if there is any damaged bottle,the bottle is taken off. The empty bottles are been inspected by the machine that also require few labourers at work.also here if there is any breakage the bottle is taken off with the help of steel rod. Then the checked undamaged bottles are been sent for filling the beer in bottles.
8
Bottle filler Refilling of 650 ml or 350 ml bottles is done at 26000 bottles in 1 hour. The machine is automated that speeds up and slows down as and when required. Once the beer bottles are filled up the checking of level of beer is done manually with help of tubelight.every bottle is checked manually before crowning. In case if the bottle breaks while refilling,there is systematic cleaning done with water and sweep machine. Crown fixing After the bottle has been cleared of air, the next step is to cap the bottles as soon as possible with the crowner.Crown caps are made up of chromium coated sheets, mainly used for sealing bottles, used in beverages & various brands of beers. Crown caps are used for closing off drink bottles and gives an excellent seal. These crown fixing is done after bottle refill. Pasteurization Pasteurization is done after bottles have been filled and crowned. The bottles are loaded at one end of the pasteurizer and passed under sprays of water as they move along the conveyor. The sprays are so arranged that the bottles are subjected to increasingly hot water until the pasteurization temperature is reached by the beer in the bottles .The bottles are then gradually cooled with water until they are discharged from the end of the pasteurizer. Temperature changes have to be made in stages to prevent the bottles from breaking. Labeling Before labeling, it is absolutely essential that the bottles are dry and free of condensation. This is especially important with pressure-sensitive labels that use non-water-soluble glues. Wet glue, which is typically used as an adhesive in glue applications, is much less sensitive to residual water on the bottle. An air knife can eliminate virtually all of the surface moisture on the bottles after the post rinse. Coding(batching) Once the labeling is done the next important step is to do coding or batching to the stock of the beer being produced. This is the most significant step.here the beer bottles are been coded in machines. Box making The box making process is started so that the cases can be used for keeping beer bottles. For the purpose of keeping cans one particular box can hold a capacity of 24 cans and in case of bottles of 350ml and 650 ml 12 bottles can be stored in one box Box filling The beer bottles are filled in box, under manual observation with the use of bottle filling machine in box. The machine lifts the bottles and fills in the box, this process is done carefully so that the breakages can be avoided.
9
Box packing The boxes are packed properly so as to avoid damages to the bottle, One particular box of beer consists of 12 bottles. These boxes are sealed and then sent to market. Palletizing If the palletized load of beer is to be warehoused, the temperature of the beer should not exceed 3°C. Care should be taken to avoid damage from fork trucks, and excessive heights should be avoided in stacking of pallets. There is a huge ware house at united breweries at the rear end of the bottling unit. Hence this was the entire process conducted at the bottling unit at united breweries ltd. To take an overview of the entire process from the initial stage at the brewery, The following diagram will show the entire brewering process, from the brew house to the bottling unit in a systematic represented way.
10
COSTING The actual cost of making one filled beer bottle is Rs.20, which after implementing the major exise duty and value added tax the cost is raised to Rs.95.(where for Mild beer excise duty is 150% of manufacturing cost and in case of strong beer is 175% of manufacturing cost.Also 25% value added tax is applicable for all cases) The market price of one single beer bottle is Rs.150 inclusive of all taxes. Almost about 4 lakh litres is per day production where united breweries have to pay 1.5 crores to Maharashtra government as part of excise duty and value added tax. PRODUCTION CAPACITY Capacity of productionat united breweries is as follows: ?
? ?
Kegs Cans
- Produced as per market requirements ( as the life in kegs is very short and hence to be consumed within the day). - 18000 cans per hour
Bottles - 30000 bottles per hour and which can be increased to 36000 Currently the plant is operating at 80% capacity
QUALITY MANAGEMENT ? ? ? ? ? ? Quality and hygiene are the key elements of the United Breweries groups manufacturing units. Quality Management Systems laid out along the lines of ISO 9000 are strictly adhered to, controlling quality at every stage of production. Quality of the beer is checked electronically at the end of each process and the quality of the final packaged product is manually checked. Timely cleaning process is done at regular intervals in short span of time during the entire time. Kingfisher contributes to the environment by making use of used bottles by recycling them. A management focused on building brand equity on one hand and exploiting it to the hilt on the other with concerted emphasis on quality.
????????????????????????????????????????
11
doc_824183286.docx