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8/10/2019 Brewery Brochure 140114
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Total BreweryExpertise
Right from conceptualization,technology, design, plantengineering upto projectinstallations - Praj offersevery solution backed up
by expertise and experience. BreweryPlants
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Integrated solutions for brewery plants
BEER. A drink soaked in tradition of
malted barley, hops and water.
A tradition that has been integrated
with science to deliver varied flavors
and drinking pleasure. And, providing
seamless integration is what the
PRAJ Brewery Technology Solutions
offers. Whether it is a new brewery or
an existing one, Praj offers an entire
range of Brewing Equipment, Project
Management Services & Solutions -
right from conceptual study to plant
installation to commissioning along
with many value added services
Exclusive collaboration with Meura (global leader in Mash ltration
technology in India) for supply of Mash lters. Today, Praj-Meura
has the largest installed reference base in India for Mash lters
Beer Filtration and Beer Recovery Systems in association with
Bucher-Filtrox (global leaders in beer ltration technology in India).
Around 80% of the beer produced in India is ltered through Praj-
Filtrox lteration plants
Complete Yeast Management Solutions, Fermenting Tank Farms,
Bright Beer Tanks and CIP Systems designed and sized to meet
varied process requirements of different brands and brewers.
Brewery Solutions and plant performance guarantees compliancewith the international standards such as DIN 8777, EBC and MEBAK
Mash Kettle
The aim of mashing is to ensure high extraction rate while
maintaining quality of the extract. Apart from the ingredients
used, parameters like temperature, optimum level of chemical &
bio-chemical conversion, effective mixing with proper agitator design,
vessel wall temperature, appropriate process control and many other
factors have equal impact on quality of wort produced and therefore
on the quality of nal product. The mash kettle is specially designed
to handle varying composition of malt and different mashing proles.
Highlights
Kettle equipped with unique Dimple type heating jackets
The uniquely designed agitator prole ensures low shear stress
on Mash
Variable frequency drive for varying agitator speeds
Linear mash temperature increase with uniform heat distribution
Advantages
Intimate mixing of water and grist
to ensure homogenous mash from
the start
Uniform Heating & temperature
distribution with specially
designed heating jackets
Innovative agitator design ensures
homogenous mash mixing and
proper sacchrication throughout
operation
Flexibility to process different
varieties of Malts
Low shear mash produces clear
and improved quality wort and
eases lautering operation
Lauter Tun
Highlights:
Higher ltration area as compared to conventional lauter tuns
Innovative design of Raking Arm with Variable Frequency Drive for
adjusting speeds during Mash intake, Bed cutting and Spent grain
discharge
Adjustable location of knives in horizontal plane with zigzag andstraight knives
Specially designed Cup type arrangement which ensures uniform
Wort run off across the lautering bed.
False bottom flushing nozzles with built-in check valves and special
pop-up nozzles for thorough cleaning of the underside
Placement of Wort Collection and flushing nozzles backed up by
process calculations.
Special sparging system ensures gentle and even distribution with
effective leaching of wort
Air free lautering consisting of closed loop ring pipe wort
collection system.
Simple trouble-free mechanism for
spent grain removal
Mechanically operated Latching/
Delatching for spent grain
removal.
Advantages:
High extract efciency
Higher ltration area ensures
lower cycle times
Low oxygen pickup
Flexibility to take various
raw material with different
congurations
Clear and improved quality wort
production Improved Beer
The nal beer quality and the overall plant output depends upon the
Lauter Tun performance and that is why it is called the heart
of brewhouse.
Hot Processing Brewhouse
Highlights:
Energy savings systems such as
Heat Recovery system and Wort
Flash System in the Brewhouse
Mash lter based brewhouse for
higher productivity, larger volumes
and increased brewhouse yield
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Praj, in association with Meura,
Belgium (world leaders in Mash
Filtration technology) offer high
efciency Mash Filters in India
and subcontinent. The Mash Filter
option is most suitable for large
capacity breweries and for different
types of raw material conguration.
Highlights of Mash Filter :
High productivity (upto 14 brews/day)
High extract yields (practical yield at least equal or greater than the
lab yield)
Very Bright Worts with low solids content < 5ml/l
Acceptance of high proportion of Adjuncts (upto 100 % with the use
of exogenous enzymes)
Unique Features of
PRAJ WORT KETTLE
Options of External as well as
Internal wort boiling system (Praj
e-COMBOILER)
Variable speed control of wort
circulation pump provides gentle
handling of wort & helps in
maintaining hot break together
The special design fountain entry
of wort provides the large surface
for the volatiles removal
Low pressure steam and hence
lower temperature difference
reduces the thermal stress
exerted on wort
Lower heat flux and Optimum heat transfer area ensures more
number of brews between cleaning
Less energy consumption and Heat recovery system as an
add on module
Advantages:
Low energy consumption compared to conventional
boiling systems
Excellent volatiles stripping capability
Improved hops Utilization
Effective hot break formation Low shear - vigorous boiling
Lower TBU increase means Lower thermal degradation of wort
Lower DMS values
Mash Filter
Highlights
Sloping bottom and inverted cone design ensures efcient
trub separation
Tangential entry of wort at optimum velocity helps keep the trub
particles intact
2/3 wort outlets maintains the trub cone till the end of wort cooling
High flowrates decreasing at the end of the wort cooling to ensure
less disturbance to trub cone
Automatic trub cleaning device ensures full cleaning with less
water consumption
Large surface area due to tangential entry allows for escape of the
unwanted volatiles
Advantages
Effective trub separation
Compact Trub Cone formation
Lower levels of suspended solids in nal worts
Unwanted Volatiles stripping
WORT COOLER - Single stage Heat Exchanger
Single-stage wort cooling with precooled brewing water ensures that
the wort is cooled to the pitching temperature in one pass. So the total
heat used is returned to the brewing process again. Wort to chilled
water ratio is optimized to reduce chilled water consumption and
reduce the refrigeration load.
Yeast Management
Praj offerings include :
Yeast Propagation systems with 2 stage and 3 stage
propagation facility
Yeast storage section with hygienic design agitator
Beer Filtration
While beers differ primarily in clarity and in original gravity, color and
taste, it is the ltration technique that sets your beer apart.
PRAJ, in association with Bucher-
Filtorx of Switzerland, offerscomprehensive range of ltrationproducts for sterile, hygienic ltrationto ensure clear and bright beer.
WhirlpoolThe hot break formed during the wort boiling process has to be
separated from the wort. Efcient trub separation is the prime
function of any whirlpool. Apart from trub separation removal of the
unwanted volatiles like DMS also takes place in the whirlpool.
Wort Aeration System
The specially designed, ventury
type aeration nozzle, creates a slight
vacuum which draws the oxygen into
the unit. This action causes a very
ne spreading of oxygen bubblesover a very large contact area, which
can then react with the wort.
Option of complete, automatic
standalone Wort Aeration skid
Easy installation and
interconnection in the existing
brewhouse
Control based on the Wort
DO level
Cold Process Area
Wort Boiling is regarded as the turning point in the brewing of Beer.
Any change in boiling practice is to be monitored carefully and
thoroughly to ensure they do not affect the quality and flavour of
the nal beer. Generally boiling wort at, or near, normal atmospheric
pressure gives the most acceptable results.
Wort Kettle
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The range :
Candle lter for Kieselgur ltration
Pre coat candle lter for
stabilization of beer with PVPP
Module/sheet lter for polishing
of beer
Salient Features of Filtrox Filters:
New SYNOX 2.0 PF /PS lter
series which supersedes
FILTROjet, (was a best-selling
candle lter worldwide) Industrial
machines between 30 and 1,200
hl/hr in operation Patented STABOX 25 mm
candle to maximize available
sludge volume and minimizing
turnaround timings
New and Patented JETCONTROL
2.0 inlet distributor
Automated cleaning and
disinfections, with either
recovery or disposal of the
cleaning liquid is another
crucial step in beer production.
An integrated four loop CIP
system, incorporating water,
caustic and acid is provided
for the following:
Brewhouse vessels, piping
and valves
Wort cooling and treatment equipment, piping, valves and pumps
Yeast vessel, fermentation/lagering tanks, piping, valves and
pumps
Filtration equipment, bright beer tanks, bottle lling machine,
piping, valves and pumps
The CIP system is fully automated, sequenced system with the optionof manual intervention or a semi-automatic system. All processequipment are provided with in-built cleaning systems to facilitatethorough cleaning. Options like stationery/rotating spray balls, spraynozzles, tank cleaning machines, cleaning turbines are carefullyselected to suit specic requirements.
Value Added Offerings Systems
Brewhouse Heat recovery System
Waste energy recovery from brewhouse thereby driving down energy
use by 25%.
Multiple references of different Brewlengths
Complete automatic standalone Wort Aerationskid which can be
easily integrated with existing brewery with Control based on the
Wort DO level
Complete automatic standalone Beer Carbonationskid with control
system based on beer carbonation level.
Beer Recovery Systemfrom surplus in collaboration with
Bucher-Filtrox
Yeast Drying System:Double
Drum Dryer which ensures no
spillage of liquid yeast and
hence does not require any yeast
recycling system
Wort Flash Evaporation System
in the Brewhouse: With just
4% evaporation in Wort Kettle
followed by 2% evaporation in
flash vessel under vacuum with
quality conformance to the desired
analytical results.
New total drain system TDS with scavenge pipe inserts.
SYNOX 2.0 PS Candle Filter for PVPP stabilization ensures fast
turnaround time and low PVPP losses.
Fermentation & Lagering
Prajs Fermentation system is characterized by specially designed
fast chilling jackets for varying duties. The unitanks are designed as
per ASME/ AD Merkblatter standards. Most optimum and consistent
cooling duties are achieved with both Glycol and Ammonia
cooled Unitanks.
Embossed type cooling jackets of the Unitanks ensures :
High heat transfer coefcients
Parallel Coolant flow and lower pressure drops
Low Coolant hold up
Pulse TIG welding technique for less heat input and hence less
distortion.
Spot radiography of all weld joints full radiography of weld joints
covered by the jacket and dished end.
Tank design facilitates proper Yeast settlement and Yeast cropping
Well equipped manufacturing facilities with automatic welding and
polishing machines.
Total covered area of 2, 00,000 sq. ft. and open area of
3,40,000 sq. ft.
Accredited with ASME U & H stamp, ISO 9001- 2000 certication
& CE marking.
Codes and standards followed include ASME Section VIII,Div.1,
BS 5500, ASNI (SNT-TC-IA 1984 & 1988), TEMA, DIN, IS 2825 and
AD Merkblatter.
Working in various grades of Stainless Steel, Copper, Carbon steels,
Nickel, Titanium, Hastalloy and other exotic materials
Large pool of approved vendors
Stringent raw material testing methods
Effective supply chain management.
Well laid out Quality System
HSE practices in line with international standards
Plant Engineering :
Our core strength
Engineering forms the backbone of our delivery program. We follow
stringent international standards like DIN 8777 for brewhouse
performance, ASME, ADMerkblatter for pressure vessels, ISA an d
CE standards. The design team works with customers to identify
the need for design enhancement in various systems with a view to
reduce energy and other operating costs. This provides a competitive
advantage to our customers.
Project Management
Project management is the key
strength of PRAJ handling projects.
Timely and smooth completion of
the projects are an essence of
PRAJ Project Management.
PRAJ has a strong pool of project
managers with experience of
working on a global scale. The
Project managers are well trained
with many of them certied
Project Management Associate
(CPMA), who have passed
International Project Management
Association - Level D Examination,
Switzerland. The site team
has signicant experience andknowledge on the local conditions.
Cleaning InPlace (CIP)Systems
Manufacturing
8/10/2019 Brewery Brochure 140114
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BreweryPlants
Argentina I India I South Africa
The Netherlands I Thailand I UAE I USAPraj Worldwide
Praj Industries Limited
Praj Tower, 274 & 275,
Bhumkar Chowk - Hinjewadi Road,
Hinjewadi, Pune 411 057. Indiainfo@praj.net | www.praj.net
Utilities
We provide engineering and
integration package for utilitiesalong with the process plant. We
also provide complete project
management package including
procurement assistance, expediting,
inspection, supervision of installation
and commissioning.
The utilities include:
Steam generation and distribution
Refrigerationplant
Water storage, treatment plant
and distribution
Compressed Air plant CO2
Rcovery, purication, liquefaction,storage and distribution plant
Wastewater (effluent)
treatment plant
Packaging-hall equipment
Plant Electricals
Process Control & Automation
Brewing is a critical bioprocess
and hence it is essential to monitoreach and every step in brewing. To
simplify all steps of monitoring, we
offer process control and automation
right from malt reception to the
tank farm/cellar upto bottling. Plant
can be offered with different levels
of automation to suit the needs
of the brewer and operating personnel. The automation system
can be customized to the highest level based on specic process
requirement such as recipe management, safety interlocks, real time
data management, security management etc. The automation system
can also be offered with an open technology platform, which permits
connectivity to third party applications and ERP systems.
Praj Matrix- Innovation Center
Brewery Laboratory following EBC standards
State of the Art own R&D facility for Brewery Analysis in India.
11 laboratories - 2 labs as per 10,000 clean area classication
Staff Includes - 80% PhD holders and 20% Graduates
Analysis facility from Raw material to nal product
Standards Followed include EBC, ASBC and MEBAK
Global Alliances
Meura
Mash Filters. Keeping in mind the need for rapid expansion of
capacity, as well as higher capacities being planned by new breweries,
Praj provides Mash Filters in alliance with Meura, Belgium for
India and Subcontinent. The Meura range of lters can replace the
traditional Lauter TunsThe Meura range can be most appropriately
designed for brewery capacities higher than 0.5 million HLPA.
Bucher Filtrox
Beer Filtration systems:. Bucher -Filtrox lters are the most preferred
lters in Breweries. Having completed over 18 years of co-operation in
the India, Praj and Filtrox have commissioned more than 40 Filtration
plants in India. Over 80 % of Beer produced in India is ltered through
the Praj Filtrox candle lters.Praj along with Bucher Filtrox also
offers Beer recovery systems from surplus yeast, using cross flow
membrane ltration (CMF) technology.
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