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A Report on

Mohan Rocky Springwater Breweries Ltd.,

Khopoli, Maharastra

(Industrial Visit on 6th April 2010)

Brewer/Director(Mohan Rocky Breweries Ltd.): Guided by:

Mr. Chauhan Prof. Shaji Joseph

Instructor: Submitted By:

Mr. Devesh Manish Gupta, Roll: 9126 PGPBM 2009-2011 Section: Y1

Report by MANISH GUPTA

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Mohan Rocky Springwater Breweries Ltd., Khopoli

On 6th April 2010, students of Y1 had a visit to Mohan Rocky Breweries Ltd. Khopoli, which is a beer manufacturing company.

LOCATION:

Mohan Rocky Springwater Breweries Ltd.

Khopoli 401 203,

Raigarh dist., Maharashtra

Telephone: +91 2192 262403

INTRODUCTION :

Mohan Rocky Breweries Ltd. produces both Mild and Strong beers, and the products are Golden Eagle, Super Stud, Loin 5000 ,Meakin’s 10000. It undertakes all the process, starting from the production of beer to bottling to packaging and packing. The customers of Mohan Rocky Breweries are Wholesalers and Defense, they distribute their products in Maharashtra and do not have retailers as their direct customers.

We all had a very great time to experience each and ever process in brewing of beer. Term Brewing is used for the process of production of beer, and the Brewer is the person who produces the beer, with all the quality checks.

Leading Brand of Mohan Rocky Springwater Breweries Ltd :---

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PROCESS OF BREWING AND MANUACTURING OF BEER:

Raw Materials:

Alcohol can be prepared from starchy material. Hence in the initial process is to get the raw material, which can be any starchy material, such as Rice Flakes, Barley, Malt, Sugar etc. Mohan Breweries uses Rice Flakes and Barley or a mixture of both according to the concentration, as the raw materials. They get Rice Flakes from the Northern India (Haryana).

Process:

Malt is prepared from the barley, by crushing and separating the husk from it. The process is all about breaking the complex sugar in to simpler forms.

Mixture of water, Rice Flakes, Malt is mixed in the mashing tank which generate Sweet Barley water, which is nothing but the mixture of Glucose, Fructose and Maltose.

Water+Rice Flakes+Malt Put into Mashing Tank Output Sweet Barley Water

(Glucose+Fructose+Maltose)

Temperature of 77-80 degree Celsius is maintained inside the mashing tank and the continuous stirring process is done, which takes 4 hours to produce the sweet barley water, and the by product is the cattle feed.Barley water thus produced is tested with iodine to find the proper concentration and the quality. All the process of brewing in Mohan Rocky Breweries Ltd. Undertake In-process Quality Control, such as Chemical Process - Iodine test, Physical Process - Turbidity test, Gravity Test etc.

Barley Water is then put into the Whirlpool tank and the temperature of 10-20 degree Celsius is maintained. Tank is made up of copper, where HOPS LEAFS (Imported from Germany) are added to add the bitterness and the aroma in the beer. The output of the whirlpool tank is called WORT.

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Mashing Tanks

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Fermentation :

It is called as the heart of any brewing process, because it is the cardinal process in the manufacturing of beer.WORT produced in the earlier process is put into the tank and the Peach & yeast are added and the Bottom Fermentation is done, and the Aerobic and Anaerobic reaction is carried out. It takes duration of 8-10 days to produce C2H5OH(Ethanol) or Alcohol.This process is called bottom fermentation because, the yeast after fermentation gets settled down and removed.

Again second fermentation process is carried out and the settled down yeast are taken away. The temperature in this process is maintained at 0 degree Celsius for 22 days.DELLA TOFFOLA is a machinery container where the concentrated material prepared in the earlier process are put in and the yeast is removed, in addition to this, filtration and the polishing of the beer is done, hence this make the beer more clear and shiny.

Carbonization:

Carbonization is the process by which CO2 is added to the beer produced from the above process. Again the second carbonization process is carried our, where temperature is maintained at zero degree and more Carbon Dioxide is added to the liquid manually.

Bottling:

All the empty bottles are brought in the bottling plant where the bottles are washed, sterilized and made germ free and clean. These bottles are then used for filling up the beer.

Tunnel Pasteurization:

Beers once filled in bottles and capped, then it goes along Pasteurization process which increases its shelf life from 24 hour to 6 months. In this process, the rain of warm water (60 degree Celsius) are poured over the filled and capped bottles, hence increases the shelf life. This process is called Tunnel Pasteurization.

Labeling and Packaging:

It is among the final process, in which the labels are sticked over the bottles and the final product are packed in the group of 6 bottles per carton using the hydraulic machine.

Report by MANISH GUPTA

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Report by MANISH GUPTA

Hot Water Tank

Malt

Hops

Copper Tank

Hopback

PROCESS Tank

Bottling

Cash or Keg

Add Yeast to Fermenter

Chiller

Mashing Tank

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INPROCESS QUALITY CONTROL:

3 tests are performed by Mohan industry in manufacturing of beer:

1. Turbidity Test.2. Gravity Test.3. Iodine Test for Sugar.

FACTS:----

0.31% of Glycerine is added to Beer. Production capacity is 1 Lakh bottles per day. Cases is 1.54 Lakh bottles per month. By-product that come out of Mashing Tank is used for cattle feed. Government Charges upto 200% excise duty over the products. Mohan Breweries challenge, that they have the world’s best water source. Mohan Breweries sister concern are in Ghaziabad, Punjab, Lucknow, Kolkata and

Chennai.

Channels of distribution: ( 2 Level Channel )Manufacturer Wholesaler Retailer Consumer

CONCLUSION:

It was a nice experience because we have seen that how to apply theoretical knowledge in

practical life which is basically more important while studying Management course. We have

discussed many concepts with the guide related to operation management, Inventory Control,

maintaining labors, security at working place etc and from the discussion we come to know that

how to apply theoretical knowledge and also modifications in it according to situation.

THANK YOU.

Report by MANISH GUPTA