THE COMPLETE PROCESS OF MALTINA PRODUCTION

Grains Intake /Pre –Treatment
There are two separate intake pits; one for the intakes of malt while the other is for adjunct (raw/malted sorghum and maize grist). The grains are discharged into the intake pit, which has a chain and a screw conveyor connected to its base, these conveyors transport the grains horizontally through a magnet (removes metallic objects from the grains). It is then conveyed to a drum sieve for bigger object to be removed. From the drum sieve, the grains move downward to the screen sieve shaker for object smaller than the size of the grains to be removed. These grains are then discharged into the bucket elevator which transport the grains vertically and empties into a chain conveyor at the top, which then transfers   the grains to designated silo.


Storage
The per-treated grains are then sent to their different silos for storage until the need arises for its usage. During storage, the grains in the silos are checked for infestation with insect and rise in temperature which is not expected to exceed 35°C otherwise the moisture content of the grains will rise beyond normal due to rise in temperature and condensation  

Treatment
When the grains are needed for production, it will be discharged from the bottom of the silo to the bucket elevator which conveys it upward to combi cleaner (destoner). This machine removes stones of different sizes from the grains.

Milling
From the destoner, it goes directly into the hammer mill where the beaters in the mill crush the grains to smaller sizes. The discharge opening of the mill is covered with a perforated metal screen of  2.5 mm  which retains  coarse materials for  further  grinding  while allowing the properly sized  materials to pass through 

Weighing
From the hammer mill, the resulting  grist will be conveyed via a screw conveyor  to the weighing bin, which weighs the  quantity of the raw materials needed
The quantity of the raw material required for one brew of maltina includes;  

malt
Sorghum malt
Raw sorghum
maize grist
6 tons 
2.4tons
6 tons
2 tons

Mashing
The weighed grist  is transported  via a pneumatic conveyor (air blower ) into a  mashing  Vessel where it is mixed  with water the malt is mashed into the mash tun while the adjunct is mashed into the mash copper and is allowed  to under go protein  rest, gelatinization rest, and liquefaction rest before  it is transferred into the mash  tun to mix with  the malt and under go saccharification rest together.

Mashing Processes
The adjunct is mixed with ambient water at about  32°c  and hot water of about 85oc  into the mash copper to achieve a pre mash water of 50oc. After mashing-in into the mash copper, the temperature is maintained at 50oc and left for 50mins protein rest {breaking down of protein to amino-acids} at this point, Amylex is added. Here the PH is checked and the norm should be b/w 5.2-5.6. Correction is made by adding either lactic acid or calcium chloride. The mash is then heated up to 75oc at 1oc rise per min. At about 73oc, mashing-in of malt into the mash tun{MT} is done. Before the malt grist start droping into the mash tun, lactic acid is added also PH is checked and correction {5.2-5.6} is done where necessary. Protein rest is imposed into the mash tun at this point too. At 75oc in the mash copper {MC}, the mash is allowed to rest {gelatinization} for 40 Mins so as to expose the starch by liberating them from the confines of the protein already broken down, After which it is heated to 93oc. At 93oc, a rest (Liquefaction) for 10 mins is imposed; this makes the starch soft and more exposed and ready for sugar conversion. The mash then is transferred into the mash tun. Initially, the transfer is done directly and when the temperature in the mash tun is 60oc. the transfer is done via a cooler so as to bring the mash temperature to 66oc. Before entering the mash tun, PH test is carried out to confirm it is between 5.5-5.7 otherwise, correction too is made. At the end of transfer, the mash is allowed to rest {saccharification} for about 15 mins. At this point, starch is being converted into sugar and a mash sample is taken for sacharification test.

Mash Filtration
After mashing, the mash is pumped to a mash filter where the resulting liquid is strained from the grains. sparge water is used to rinse the mash filter. The filtrate {wort} is sent to the wort copper for boiling while the spent grains are sent to the spent grain silo.

Wort Boiling
At this point, the liquid {filtrate} is called wort. The wort is transferred into the wort copper for boiling. During boiling, hops, sugar, caramelized dextrose maltase {CDM}, calcium chloride {CalCl}, maltina complex is added. Wort boiling processes serves as to;
i.   Sterilize the wort {some bacteria and moulds that could have                                survived the brewing process so far are killed}
ii.   Terminate enzymatic processes
iii.    Coagulate proteins
iv. Volatilize off flavours
v.   Isomerize hop resins {extract the bittering substance from hops} hops gives the bettering taste to the beverages.

Wirlpool Rest
After wort boiling, the wort will be send to a whirlpool vessel for the coagulated proteins (trub) and other heavy materials to be separated from the wort. The hot Wort is pumped in at an angle tangential to the whirlpool vessel. This produces a force of in-flow that causes the trub particles to accelerate towards the centre of the vessel. They form large flocs, which then settle down at the center bottom line of the vessel to form a trub cone. The clarified wort is run off from above the trub cone through senses of run off points on the whirlpool vessel.

Wort Cooling
The clarified wort which leaves the whirlpool around 85oC has to be cooled down to 0°C before carbonation. This is achieved by passing counter flows of cold water against wort on either sides of the plate heat exchanger. The process of heat transfer i.e heat loss by the wort and the heat gained by the water   tends to bring the temperature down.  

Filtration
The unclearified malted drink is transferred to the KG filter for it to be filtered. As it is moving to the KG filter, it will pass through a cooler which tends to maintain the temperature at 00C from the cooler to a stabilizer (BK 75). Here, the protein component of the beverages is coagulated to form bigger particles. It is at this  stage that certain corrections  like colour dosing, hops dosing  are made. It  moves to the KG filter,  this  KG filter contains different candle size that are coated with filter powders (Keiselgur) to entrap the  coagulated protein particles while  it moves  through a pipe to the  carbon blender for carbonation. 

Carbonation
It moves from the KG filter to carbon blender for addition of carbon (iv) oxide. O2 gives the  soft  drink an appetizing taste (mouth feel)  and also increases the shelf life of the beverage. At this stage, dilution of the original gravity (OG)  is carried out and  it is done with deaerated  water (DAW)

BBT Storage
The carbonated drink is send to the  BBT for storage until when  the need arises it will be send to packaging department for it to be bottled.

Packaging
 When the drinks are needed for bottling, it  will be sent from the bright beverage tank (BBT) to the bottling hall. Here the  bottles are washed and inspected before they are conveyed to the filler/crowner to be filled with the beverage. From the filler/crowner, the bottle is conveyed to the full bottle inspector (FBI) that inspects and removes under filled bottles, improper corked bottles from the line. The bottles move on the conveyor to the pasteurizer where the microorganisms are rendered inactive. From the pasteurizer, it goes to the labeling machine where the maltina bottle is labelled then to the coding machine that prints the production date, expiring date and batch no on the labeled product. The labeled bottles moves on the conveyor to the packer where they are packed into crates. From there to the full crate inspector (FCI) which inspects and removes any crate that contains improper crating. From the (FCI), the crate is conveyed to the palletizer where it is palletized after which it is transported to the full bottle store where it is stored before its distribution.
Share on Google Plus

Declaimer - MARTINS LIBRARY

The publications and/or documents on this website are provided for general information purposes only. Your use of any of these sample documents is subjected to your own decision NB: Join our Social Media Network on Google Plus | Facebook | Twitter | Linkedin

READ RECENT UPDATES HERE