n.d Wines Submit

8/4/2019 n.d Wines Submit

1/47

TO STUDY THE WINE PROCESSING TECHNOLOGY &

PLANT DESIGN OF WINERY

Project Report

Submitted to the

N.D. Wines Pvt. Ltd., Nashik

In partial fulfillment of the requirements for the degree of

Bachelor ofTechnology

(FOOD TECHNOLOGY)

ByVinay Kumar & Amit Kumar

JAIPUR NATIONAL UNIVERSITY

July 2011


2/47

ACKNOWLEDGEMENT

Completion of any task is not at all a single person effort. It demands hard work,motivation, experience of many people. This project is also a team work effort and

to be a part of this quality improvement team is a proud privilege. It gives me

immense pleasure to acknowledge and remember all those who set my way for

successful completion of this project.

I am grateful to Mr.Vijay Kulkarni(General manager, N.D Wines Pvt. Ltd.,

Nasik), for allowing me to do my industrial training/project.

I sincerely acknowledge Mr.Achyut Niphade (Production manager) for providing

their valuable time and helping me

I take this opportunity to express my deep sense of gratitude to Mr. Sandeep

Bakshi , CEO & Director of Jaipur National University, for pursuing such a great

course of Food Technology in the institute and providing us such a wonderful

environment for studies and supporting us to have a good career in Food

Technology.

I am also obliged to Lecturers Mr. Rahul Agarwal, Mr. Rahul Saxena, Ms.Monica Premi for their guidance and suggestions.

Place : Nasik Vinay Kumar

Dated : July 2011


3/47

TABLE OF CONTENT

S. No Content No. Topic

1 1.0 Introduction Company Profile

2 2.0 Wine Processing Technology

3 3.0 Quality Standards of wine

3 4.0 Plant layout & Design

4 5.0 Plant cost evaluation

5 6.0 Capital Investment

6 7.0 Total Production cost

7 4.0 Results and Discussion

8 5.0 Glossary and Acronyms

9 6.0 Literature Cited / References


4/47

1.INTRODUCTION

1.1 COMPANY PROFILE:

N.D. GRAPES

Mr. Ashok Gaikwad and his friends together established N. D. Grapes Pvt. Ltd. in the year 1993,

N. D. Grapes started exporting table grapes to various countries all over the world. After regular

and stringent checks the renowned supermarkets in the U. K. like Tesco and J. Sainsbury have

conferred the certificate of merit to N.D. Grapes for adopting world class standard for preserving

the fruit and maintaining and storage plants. N. D. Grapes is the regular and sole supplier to J.

Sainsbury, Tesco and Marks & Spencers. Within a short period N. D. Grapes became the most

favored brand in countries like Hong Kong, Singapore, Malaysia, Africa, Europe etc. N. D.

Grapes is the first company to get the distinction of single largest exporter of India.

N .D. WINES PVT. LTD.

After enjoying huge success N. D. Grapes have now ventured into ancient and exquisite art of

wine making under the banner of N.D. Wines Pvt. Ltd. The beautifully landscaped winery is

located on the lake side and surrounded by lush green vineyard. At the winery the time tested art

of wine making has gained greater height under the expert eye of the famous French wine master

Mr. Jean Manual Jacquinot. The state of the art winery is well equipped with all importedmachinery made by the renowned French companies. With growing demand from the customers,

we have enhanced our crushing capacity from 200 tonnes to 1400 tonnes. N. D. Wines is geared

up to fulfill the rising demand of todays international wine market.

INFRASTRUCTURE

At N.D. Wines we believe Good taste is an important ingredient so utmost care is taken to

produce the best quality wines. Our winery is made as per French standard with all imported

machinery. The winery has a tank capacity of 9,91,000 liters for storage of wines. N.D. Winesadopts world class manufacturing and storage techniques for making and preserving wines.


5/47

CORE COMPETENCY

N.D. Grapes is the single highest exporter of home grown grapes for past several years. The 700

acres highly cultivable and spread out across the foothills of the Sahyadri range has been the

mainstay of our vine yards. N. D. Wines is the first winery in India to grow the world famous

Cabernet Sauvignon-reserve and Sauvignon Blanc- reserve used in making reserve wines on the

virgin soil. We have also mastered the art of growing Shiraz, Cabernet Sauvignon, Chenin Blanc,

Sauvignon Blanc the are specially used in making different variety of wines.

Grapes in Nasik

In India, the land of Nasik is a heaven for growing internationally acclaimed table and wine

variety grapes. Nestling at the feet of the Sahyadri Hills, Nasik is endowed with suitable soil. Its

pleasant, dust free and non corrosive climate, matching the topography of the south of France,

making it conducive for the growth of the wine fruit.

ACHIVEMENT

In short span of time N. D. Wines is very well known brand in the market and widely accepted

by the customers as the premium wine maker. We have strong holds in major states across India

like Maharashtra, Goa, Diu, Daman, Silvassa, Rajasthan, U.P., Chandigarh, Karnataka, M.P.,

Delhi etc. We are very proud to announce that N.D. Wines is one of the wines served in

prestigious and luxurious trains like The Deccan Odyssey promoted by Maharashtra

Government and Palace on Wheels promoted by Rajasthan Government. N. D. has also won

the international level Excellence Award for Entrepreneurship from J.M.C.C.I. presented by

his Excellency S. M. Krishna Governor of Maharashtra in Jan. 2005.

MISSION

In continuation of our legacy to produce globally approved quality grapes, now our mission is to

offer world class Wines to all customers.


6/47

1.2 WORK / DEPARTMENT

1.2.1 HUMAN RESOURCE AND ADMINISTRATION

The main function of this department is to record all the activities of the plant and complete

administration of the plant is carried out under this department. It is the head office of the plant

and this department controls all the activities regarding human resource development. It also

maintains aspects like salary, training etc. This department keeps all the records and finance of

the unit. It also looks in giving pay to the employees.

1.2.2 PURCHASE SECTION

This is section where all types of needs which helps to the production or help in the normal

functioning of the company like raw materials, machines, packing material, etc. Besides this all

type of assets(e.g. Stationary, P.C etc) are also controlled by this departments.

1.2.3PRODUCTION DEPARTMENT

Here, there are two different production area Red Wine and White Wine production.

1.2.4 MAINTENANCE DEPARTMENT

During production different types of troubles are faced by the production department these

related to the machinery and process for these troubles a department called maintenance

department, which helps production department. This section looks after and repairs all of the

machineries time to time and when required. The objective of this department is to oversee

maintenance of different commodities (electricity, machinery, etc.).

1.2.5 STORE & LOGISTICS DEPARTMENT

These both are different but they work together, store department are related to the finished

goods as well as raw materials also. It maintains FIFO and appropriate condition for the storage

of materials, where logistics dispatch the finished goods to the distributor or according to the

procedure they also maintain FIFO for the dispatch.


7/47

1.2.6 EXCISE DEPARTMENT:

1.3 WINES VARITIES:

1.3.1 SYRAH

This wine is made from Syrah, grown on the virgin soil of the Sahyadri hills located in Nasik, the climate

here is very similar to that of the South of France. Before pressing the grapes are specifically selected and

picked at perfect maturity level. N. D. Syrah has the color of the royal insignia, deep purple. The

overpowering nose is a reminder of the warm climate of the area, the strong aroma of bell peppers blends

well with soft aroma of cherries and blackcurrants, N.D. Syrah feels velvety to taste with a distinct

peppery flavor that lingers in the mouth.

N.D. Syrah goes well with Indian cuisine and is ideal with food cooked in the Tandoor as well as with

spiced vegetables.

Best served at : 18C.


8/47

1.3.2 Cabernet Syrah

This wine is made from Cabernet Syrah, grown on the virgin soil of the Sahyadri hills located in Nasik.

Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine has got

a rich deep red color and is perfectly balanced. All the characteristics of the nice fruity aromas from the

N.D. Syrah are present and are reinforced by the full bodied structure of the N. D. Cabernet. The Length

of this wine is perfect.

This wine is perfect with all the Indian Foods.

Best served at : 18C

1.3.3Cabernet Sauvignon

This wine is made from Cabernet Sauvignon, grown on the virgin soil of the Sahyadri hills located in

Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine

comes in a striking deep red color. The nose develops a lilting aroma of bell pepper, cherries and


9/47

blackcurrants. Cabernet Sauvignon tastes like the warm climate of India, melting with the tannin coming

from the mature seeds and the after taste lingers in the mouth.

This wine is ideally served at dinner with any Indian dish.

Best served at : 18C to 20C.

1.3.4Cabernet Sauvignon Reserve




blackcurrants. Cabernet Sauvignon tastes like the warm Indian climate with a touch of silk.

This exotic wine can be served during and after dinner & goes well with all Indian cuisine.



10/47

1.3.5GalaxyRed




blackcurrants. Cabernet Sauvignon tastes like the warm climate of India, melting with the tannin coming

from the mature seeds and the after taste lingers in the mouth.

This wine is ideally served at dinner with any Indian dish.


1.3.6 Sauvignon Blanc Reserve

This wine comes from Sauvignon Blanc grown on the virgin soil of the Sahyadri hills located in Nasik.

Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine comes


11/47

in a striking green gold color. The nose develops a pleasant aroma of pineapple, banana, guava and the

typical aroma of grapefruit. Sauvignon Blanc is tangy, with a rich freshness that leaves behind a lingering

citrus and lemon flavor in the mouth.

This richly flavored wine is the perfect appetizer that goes well with any variety of fish, as well as

steamed lobster.


1.3.7 Chenin Blanc

This wine is made from Chenin Blanc, grown on the virgin soil of the Sahyadri hills located in Nasik.

Before pressing the grapes are specifically selected and picked at perfect maturity level. The color of this

wine is pale yellow with touches of green. The intense nose develops the pleasant aroma of pineapples,

grape fruits and native guavas, besides the flowery aroma of rose. The tangy taste of the N.D. Chenin

Blanc tickles the palate and leaves a lasting flavor and aroma of fruit in the mouth.

This wine is a perfect appetizer and goes well with food cooked in light spices followed by fish.



12/47

1.3.8 Sauvignon Blanc

This wine comes from Sauvignon Blanc grown on the virgin soil of the Sahyadri hills located in Nasik.

Before pressing the grapes are specifically selected and picked at perfect maturity level. N.D. Sauvignon

Blanc comes in enchanting pale gold green color. The nose develops exotic aromas of blackcurrant leaves

touched with a sweet whiff of pineapples, grapefruits, bananas and guavas with a noticeable aroma of

grapefruit. N.D. Sauvignon Blanc carries a lemony flavor which leaves a tingling freshness in the mouth.

This wine is an ideal appetizer that can be served with cashew nuts and almonds. It is suitable for all

types of fish and steamed jumbo prawns and goes well with delicately spiced Indian cuisines.



13/47

2.0 Wine Processing Technology:

2.0.1 Introduction:

Wine is an alcoholic beverage, made offermented fruit juice, usually from grapes. The natural chemical

balance of grapes lets them ferment without the addition ofsugars, acids, enzymes, or

other nutrients. Grape wine is produced by fermenting crushed grapes using various types ofyeast. Yeast

consumes the sugars in the grapes and converts them into alcohol. Different varieties of grapes and strains

of yeasts produce different types of wine.

Wines made from other fruits, such as apples and berries, are normally named after the fruit from which

they are produced (for example,apple wine or elderberry wine) and are generically called fruit wine or

country wine

2.0.2 HistoryArchaeological evidence suggests that the earliest known production of wine, made by fermenting grapes,

took place as early as 8,000 years ago in Georgia and 6,100 years ago inArmenia. These locations are all

within the natural area of the European grapevine Vitis vinifera.

Pressing wine after the harvest;Tacuinum Sanitatis, 14th century

Through an extensive gene-mapping project in 2006, Dr. McGovern and his colleagues analyzed the

heritage of more than 110 modern grape cultivars, and narrowed their origin to a region in Georgia, where

also wine residues were discovered on the inner surfaces of 8,000-year-old ceramic storage jars in

Shulavari, Georgia. Other notable areas of wine production have been discovered in Greece and date back

to 4500 BC. The same sites also contain the world's earliest evidence of crushed grapes. On January 11,
http://en.wikipedia.org/wiki/Alcoholic_beveragehttp://en.wikipedia.org/wiki/Fermentation_(wine)http://en.wikipedia.org/wiki/Grapehttp://en.wikipedia.org/wiki/Sugarhttp://en.wikipedia.org/wiki/Acidhttp://en.wikipedia.org/wiki/Enzymehttp://en.wikipedia.org/wiki/Nutrienthttp://en.wikipedia.org/wiki/Yeasthttp://en.wikipedia.org/wiki/Ethanolhttp://en.wikipedia.org/wiki/Apfelweinhttp://en.wikipedia.org/wiki/Elderberry_winehttp://en.wikipedia.org/wiki/Fruit_winehttp://en.wikipedia.org/wiki/Georgia_(country)http://en.wikipedia.org/wiki/Armeniahttp://en.wikipedia.org/wiki/Europehttp://en.wikipedia.org/wiki/Vitis_viniferahttp://en.wikipedia.org/wiki/McGovernhttp://en.wikipedia.org/wiki/File:29-autunno,Taccuino_Sanitatis,_Casanatense_4182..jpghttp://en.wikipedia.org/wiki/File:29-autunno,Taccuino_Sanitatis,_Casanatense_4182..jpghttp://en.wikipedia.org/wiki/File:29-autunno,Taccuino_Sanitatis,_Casanatense_4182..jpghttp://en.wikipedia.org/wiki/File:29-autunno,Taccuino_Sanitatis,_Casanatense_4182..jpghttp://en.wikipedia.org/wiki/McGovernhttp://en.wikipedia.org/wiki/Vitis_viniferahttp://en.wikipedia.org/wiki/Europehttp://en.wikipedia.org/wiki/Armeniahttp://en.wikipedia.org/wiki/Georgia_(country)http://en.wikipedia.org/wiki/Fruit_winehttp://en.wikipedia.org/wiki/Elderberry_winehttp://en.wikipedia.org/wiki/Apfelweinhttp://en.wikipedia.org/wiki/Ethanolhttp://en.wikipedia.org/wiki/Yeasthttp://en.wikipedia.org/wiki/Nutrienthttp://en.wikipedia.org/wiki/Enzymehttp://en.wikipedia.org/wiki/Acidhttp://en.wikipedia.org/wiki/Sugarhttp://en.wikipedia.org/wiki/Grapehttp://en.wikipedia.org/wiki/Fermentation_(wine)http://en.wikipedia.org/wiki/Alcoholic_beverage


14/47

2011 in one of Armenia'sVayots Dzor province cave was found a wine making press dating to

approximately 6,000 years ago.Literary references to wine are abundant in Homer (9th century BC, but

possibly composed even earlier), Alkman (7th century BC), and others. In Ancient Egypt, six of 36

wineamphoras were found in the tomb of King Tutankhamun bearing the name "Kha'y", a royal

chiefvintner. Five of these amphoras were designated as from the King's personal estate with the sixth

listed as from the estate of the royal house ofAten. Traces of wine have also been found incentral

Asian Xinjiang, dating from the second and first millennia BC.

Viticulture in India has a long history dating back to the time of the Indus Valley

civilization when grapevines were believed to have been introduced from Persia sometime in the

5000 BC The first known mentioning ofgrape-based wines was in the late 4th century BC writings

ofChanakya who was the chief minister of Emperor Chandragupta Maurya. In his writings, Chanakya

condemns the use of alcohol while chronicling the emperor and his court's frequent indulgence of a style

of grape wine known as Madhu

A 2003 report by archaeologists indicates a possibility that grapes were mixed with rice to produce mixed

fermented beverages in China in the early years of the seventh millennium BC. Pottery jars from

the Neolithic site ofJiahu, Henan contained traces oftartaric acid and other organic compounds

commonly found in wine. However, other fruits indigenous to the region, such as hawthorn, cannot be

ruled out.If these beverages, which seem to be the precursors ofrice wine, included grapes rather than

other fruits, these grapes were of any of the several dozen indigenous wild species of grape in China,

rather than from Vitis vinifera, which were introduced into China some 6000 years later.

One of the lasting legacies of the ancient Roman Empire was the viticulture foundation the Romans laid

in the lands that today are world renowned wine regions. Areas with Roman garrison towns,

like Bordeaux, Trier, and Colchester, the Romans planted vineyards to supply local needs and limit the

cost of long distance trading. In medieval Europe, the Roman Catholic Church staunchly supported wine,

since they required it for the Mass. Monks in France made wine for years, aging it in caves. An old

English recipe that survived in various forms until the 19th century calls for refining white wine from

bastardbad or tainted bastardo wine.

2.0.3 Grapes Varities

N.D wines has produced red and white type of wines from SYRAH, CABERNET SAUVIGNON,

CHENNIC BLANC, SAVIGNON BLANC. These Varieties of grapes are especially selected and picked

when at perfect maturity level in own grown vineyards.

2.0.4 Processing Method
http://en.wikipedia.org/wiki/Vayots_Dzorhttp://en.wikipedia.org/wiki/Homerhttp://en.wikipedia.org/wiki/Alkmanhttp://en.wikipedia.org/wiki/Ancient_Egypthttp://en.wikipedia.org/wiki/Amphorahttp://en.wikipedia.org/wiki/Tutankhamunhttp://en.wikipedia.org/wiki/Vintnerhttp://en.wikipedia.org/wiki/Atenhttp://en.wikipedia.org/wiki/Central_Asiahttp://en.wikipedia.org/wiki/Central_Asiahttp://en.wikipedia.org/wiki/Xinjianghttp://en.wikipedia.org/wiki/Viticulturehttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Indus_Valley_civilizationhttp://en.wikipedia.org/wiki/Indus_Valley_civilizationhttp://en.wikipedia.org/wiki/Grapevineshttp://en.wikipedia.org/wiki/Persiahttp://en.wikipedia.org/wiki/Grapehttp://en.wikipedia.org/wiki/Chanakyahttp://en.wikipedia.org/wiki/Chandragupta_Mauryahttp://en.wikipedia.org/wiki/Archaeologisthttp://en.wikipedia.org/wiki/Ricehttp://en.wikipedia.org/wiki/Chinahttp://en.wikipedia.org/wiki/Neolithichttp://en.wikipedia.org/wiki/Jiahuhttp://en.wikipedia.org/wiki/Henanhttp://en.wikipedia.org/wiki/Tartaric_acidhttp://en.wikipedia.org/wiki/Common_hawthornhttp://en.wikipedia.org/wiki/Rice_winehttp://en.wikipedia.org/wiki/Ancient_Rome_and_winehttp://en.wikipedia.org/wiki/List_of_wine_producing_regionshttp://en.wikipedia.org/wiki/Bordeaux_winehttp://en.wikipedia.org/wiki/Trierhttp://en.wikipedia.org/wiki/Colchesterhttp://en.wikipedia.org/wiki/Middle_Ageshttp://en.wikipedia.org/wiki/Roman_Catholic_Churchhttp://en.wikipedia.org/wiki/Eucharist_(Catholic_Church)http://en.wikipedia.org/wiki/Monkhttp://en.wikipedia.org/wiki/Francehttp://en.wikipedia.org/wiki/Bastardo_(grape)http://en.wikipedia.org/wiki/Bastardo_(grape)http://en.wikipedia.org/wiki/Francehttp://en.wikipedia.org/wiki/Monkhttp://en.wikipedia.org/wiki/Eucharist_(Catholic_Church)http://en.wikipedia.org/wiki/Roman_Catholic_Churchhttp://en.wikipedia.org/wiki/Middle_Ageshttp://en.wikipedia.org/wiki/Colchesterhttp://en.wikipedia.org/wiki/Trierhttp://en.wikipedia.org/wiki/Bordeaux_winehttp://en.wikipedia.org/wiki/List_of_wine_producing_regionshttp://en.wikipedia.org/wiki/Ancient_Rome_and_winehttp://en.wikipedia.org/wiki/Rice_winehttp://en.wikipedia.org/wiki/Common_hawthornhttp://en.wikipedia.org/wiki/Tartaric_acidhttp://en.wikipedia.org/wiki/Henanhttp://en.wikipedia.org/wiki/Jiahuhttp://en.wikipedia.org/wiki/Neolithichttp://en.wikipedia.org/wiki/Chinahttp://en.wikipedia.org/wiki/Ricehttp://en.wikipedia.org/wiki/Archaeologisthttp://en.wikipedia.org/wiki/Chandragupta_Mauryahttp://en.wikipedia.org/wiki/Chanakyahttp://en.wikipedia.org/wiki/Grapehttp://en.wikipedia.org/wiki/Persiahttp://en.wikipedia.org/wiki/Grapevineshttp://en.wikipedia.org/wiki/Indus_Valley_civilizationhttp://en.wikipedia.org/wiki/Indus_Valley_civilizationhttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Viticulturehttp://en.wikipedia.org/wiki/Xinjianghttp://en.wikipedia.org/wiki/Central_Asiahttp://en.wikipedia.org/wiki/Central_Asiahttp://en.wikipedia.org/wiki/Atenhttp://en.wikipedia.org/wiki/Vintnerhttp://en.wikipedia.org/wiki/Tutankhamunhttp://en.wikipedia.org/wiki/Amphorahttp://en.wikipedia.org/wiki/Ancient_Egypthttp://en.wikipedia.org/wiki/Alkmanhttp://en.wikipedia.org/wiki/Homerhttp://en.wikipedia.org/wiki/Vayots_Dzor


15/47

Flow Chart: For White wine making

Harvesting of grapes

Pressing

Chilling & Settling

Racking

Fermentation

Racking

Clarification &

Stablization

Storage

Blending(optional)

Filteration

BottlingCorking,Labelling &

Packaging


16/47

Flow Chart: For Red wine making

Harvesting of grapes

Destemming & Crushing

Chilling

Fermentation with skin

Pressing

Malo-Lactic

fermentation

Racking

Clarification &

Stablization

Storage

Blending (optional)

Filteration & BottlingCorking,Labelling &

Packaging


17/47

2.0.5 Process of Wine making:

The process of wine making involves following steps:

1) Crushing/pressing

After Harvesting the grapes are bought to the winery where special machines are used to destem the

grapes and crush it to remove the stems which contain astringent tannins and to break the skins of the

grapes without crushing the seeds. Like the stems, the seeds contain harsh, unwanted tannins.

Press machine

The grapes which are used for white wine are dumped to pneumatic press for juice extraction. After

removal of juice the left over materials such as stem, skin and seeds are removed. During the press cycle

every attempt is made to prevent unnecessary bruising to the stem , skin and seeds. This is done to avoid

tanninor any undesirable extract getting into the juice.

The grapes are used for making red wine are first destemmed and then crushed. Destemming is the

process of separating stems from the grapes. Depending on the wine making procedure, this process may

be undertaken before crushing with the purpose of lowering the development of tannin and vegetal flavors

in the resulting wine. After destemming the grape berries are immediately crushed by passing it through

the two rubber rollers rotating in opposite direction. Crushing is the process that breaks apart the grape


18/47

berries and allows the juice to pass through the fermentation tank along with the skin and seeds. Crushing

usually starts immediately after destemming using an equipment called crusher-destemmer.

Destemmer

Now along with the juice there is addition of SO2 . The main purpose of addition of SO2 is to suppress the

growth of bacteria, most of which are sensitive to it. It acts like a preservative and antioxidant. This SO 2

combines with the anthocyanin pigment and make them more soluble and added in the form of

KMS(potassium metabisulphite).

As soon as the juice sugar level, ph and titrable acidity is checked.

2) Chilling:

The juice which is extracted is now allowed to get chilled. Thus due to chilling effect the lees particles

such as dust, fibres, cellulose and any unwanted particles to get settle down. The chilling continues for 24

hours in case of white wine and 48-72 hours in case of red wine.

3) Fermentation:

Wine fermentation takes place when yeast ( s.cerevisiae) consumes the natural sugar present in grape

juice and converts it into alcohol and carbon dioxide under anaerobic condition. The process of

fermentation requires careful control for the production of high quality wines. Requirements include


19/47

suppression of growth of undesirable microorganisms, presence of adequate numbers of desirable yeast,

proper nutrition for yeast growth, temperature control for excessive heat, prevention of oxidation and

proper management of the cap of skins floating in the red must.

Although species ofSaccharomyces are generally considered more desirable for efficient fermentation.

Saccharomyces is preferred because of its efficiency in converting sugar to alcohol and because it is less

sensitive to the inhibiting effect of alcohol. Under favorable conditions, strain of Saccharomyces

cerevisae have produced up to 18%v/v of alcohol, although 15 to 16% is usual limit. Optimum

temperature for growth of common wine yeast is 25oC. Temperature control during alcoholic

fermentation is necessary to :

Facilitate yeast growth

Extract flavors and colors from the skins

Permit accumulation of desirable by products

Prevent under rise in temperature which kills the yeast cells.

In case of white wine the juice usually is fermented at about 11-18 oC, while in case of red wine it is

fermented at about 18-22oC. Temperature in the lower end of fermentation gives the wine having straight

forward fruit flavours and prevents undue loss of alcohol, But higher temperature leads to fast and

vigorous fermentation leading to complex characterized wine.


20/47

Fermentors

4) Racking:

This is one of the essential step in wine making i.e. to siphon the wine off the sediment (lees) into another

clean secondary, reattach the fermentation trap, and repeat after another one or two months and again

before bottling. This procedure is called racking. It is done when necessary, not just two or three times as

stated above. The rule is, as long as there are fresh deposits on the bottom after a regular interval ( 30 to

60 days), even if they are just a light dusting, the wine should be racked. Only when that interval passes

and there are no fresh lees and the specific gravity is 1000 or lower is the wine ready to be prepared

before bottling. It is not necessary that the interval between racking be 30 days, 45 days , 60 days, but it

should not be less than 3 weeks. It is perfectly okay that to leave the wine on the lees for 3 months ,

Beyond that and the wine enters a danger zone caused by dead yeast cells breaking down rotting, while

this can cause off-flavors and odours if allowed to go on too long, the bigger danger is the formation of

hydrogen-sulphide gas, which smells like rotten eggs and can be the death of wine. But if lees are stirred

every week or so, neither the off flavors nor hydrogen-sulphide gas formed. Indeed the wine is actually

improved by extended contact with the lees as they are stirred frequently.


21/47

During this entire period, the sulphur dioxide gas released into the wine from crushed Campden tablets or

KMS is slowly dissipated through the air lock and its protective qualities are l ost. It is therefore

necessary to replenish this protection, and this is done at every other racking, the new sulphites are added

to the receiving secondary and the wine racked into it.

Racking pump

5) Clarification and Stabilization:

The clarification and stabilization of winemaking involves removing insoluble and suspended materials

that may cause a wine to become cloudy, gassy, form unwanted sediment deposit or tartaric crystals,

deteriorate quicker or developed the assorted wine faults due to physical, chemical and microbiological

instablility. These process may include fining, filteration, centrifugation, floatation, refrigeration, barrel

maturation and racking. Most of these process will occur after the primary fermentation and before the

wine is bottled. The exception is for white wine production which will usually have the must separated

from some of grapes skin and particles prior to fermentation so as to avoid any unwanted maceration. The

timing and exact methods used will vary by producer, depending upon desired finish product such as a

completely bright and clear wine or a wine that still remains some of the flavors and color phenols. The

material are removed from the must during this stage winemaking dead yeast cells, bacteria , tartartes,

proteins, pectins various tannins and other phenolic compounds and pieces of grape skins, pulp, stems and

gums.

The process of clarification is also called as fining process. Fining agents may includes casein, gelatin,

bentonite, Spanish clay etc..The stabilization process involves chilling the clarified wine in order to cause

the precipitation of potassium bitartarate in the form of crystals. The process of stabilization increase the

clarity and brightness of a wine.


22/47

6) Storage:

The storage of wine is important step in winemaking. The storage of wine basically means aging of wine.

The main purpose of aging is to develop the aroma. This is carried in two ways:

Oak barrels

Stainless steel tanks containing Oak chip

N.D Wines has using the process of stainless steel tanks in addition of oak chips a/c to requirement and

have a advantage of this method no penetration of oxygen is possible.

7) Filteration:

Filteration is a technique used for clarification and microbiological stabilization was introduced to wine

making only 30-40 years ago. The advantage of filteration over fining is that it can clarify a young,

cloudy wine faster and more efficient than fining . It clarifies by removing particles in suspension that

cause cloudiness.

8) Bottling:

The first step in bottling of wine is depalletising, where the empty bottles are removed from the original

pallet packaging delivered from the manufacturer, so that individual bottles may be handled. The bottles

may then be rinsed with filtered water or air, and may have carbon dioxide injected into them in attempt

to reduce the level of oxygen with in the bottles. Then bottle enters in filling machine which fills the wine

(750 ml, 375 ml SWMA) in bottles and may also inject a small amount of CO2 inert gas on top of head

space of bottle.

Then bottle going to corking machine(corker) where a cork is compressed and pushed into the neck of

bottle. Whilst this is happening the corker vacuum the air out from bottle to form a negative pressure head

space. This removes any oxygen from the head space, which is useful as O2 can run the quality of product

by oxidation. A negative pressure headspace will also counteract pressure caused by the thermal oxidation

of wine, preventing the cork from being forced from the bottle. Some bottling lines incorporate a fill

height detector which reject under or over-filled bottles and also a metal detector.

9) Packaging:

When packaging is ideal for presentation, which helps add value and boost sales of wines and spirits.

These packages can also be customized with personal messages. Weddings, birthdays, anniversaries,

luxury cruises, promotional events are some of the occasions when a memorable gift of excellent wine


23/47

can be given with eloquent wine packaging. Generally, CFB box, wooden pallets and butter paper for

wrapping the wine bottles are used as packaging material.

3.0 Quality Standards of Wine:

These standards are

Parameter White wine standard Red wine standard Role of component

0Brix 20-23% 24-26% Maturity level

pH 3.20-3.35 3.65-3.75 Related to activity of

enzymes & taste

Titrable acidity 7-9 gm/ltr 5.0-6.5 gm/ltr Taste, sweet balance,

storage life

Volatile acidity 0.05-0.06% 0.06-0.08% Leads to off flavor,

spoilage

So2 25-28 ppm 28-32 ppm To prevent oxidation,

preservation

Co2 1000-1400 ppm 400-600 ppm It escape O2, carry

aroma

N2 Juice content 175 ppm 175 ppm Required for proper

growth of yeast while

fermentation

N2 gas content in wine 0.5-0.6 ppm 0.7-0.8 ppm Helps to remove

dissolved oxygen of

wine


24/47

PLANT LAYOUT

&

DESIGN OF WINERY


25/47

4.0) Plant layout:

The plant layout of N.D wines is as given below in drawing form

Tank Hall no.1

Specifications:Tank capacity 2000 ltr. 5000 ltr. 7000 ltr. 10,000 ltr. 14,000 ltr. 15,000 ltr. 20,000 ltr

Height(cm) 177.4 277 227.5 249.7 293 300.5 329.4

Inside

Dia.(cm)

119.5 149.8 200.1 225.6 249.3 250.2 250.8

Drip volume 76.3 ltr. 82.5 ltr. 84.8 ltr. 71.3 ltr. 73 ltr. 74.2 ltr. 85.4 ltr.

Shell

thickness(mm)

2.7 2.7 2.9 3.0 3.2 3.4 3.4

Height from

Datum (cm)

6.9 7.0 7.0 7.4 7.4 7.5 8.0

Total capacity: 474 KL

Total no. of Tanks: 46 Tanks

Area: 70*70 sq.ft

Height of floor to roof:

Tank Hall no.2

Specifications:Total No. of Tanks: 21Capacity: 17,000 ltr.Total Capacity of Tanks: 357 KL

Area of Hall: 25*108 sq.ft

Internal Dia. Of Tanks(cm): 329.3Shell thickness: 3 mm

Height of Tanks (cm): 320.7

Height floor to roof (cm):


26/47

4.1 Introduction to Plant design:

4.1.1General principles

The design of a process plant is a complex activity that will usually involve many different disciplines

over a considerable period of time. The design may also go through many stages from the original

research and development phases, through conceptual design, detailed process design and onto detailed

engineering design and equipment selection. Many varied and complex factors including safety, health,

the environment, economic and technical issues may have to be considered before the design is finalised .

At each stage it is important that the personnel involved have the correct combination of technical

competencies and experience in order to ensure that all aspects of the design process are being adequately

addressed. Evidence of the qualifications, experience and training of people involved in design activities

should be presented in the Safety Report to demonstrate that the complex issues associated with design

have been considered and a rigorous approach has been adopted.

The process design will often be an iterative process with many different options being investigated and

tested before a process is selected. In many occasions a number of different options may be available and

final selection may depend upon a range of factors.

The process design should identify the various operational deviations that may occur and any impurities

that may be present. In the mechanical design, the materials of construction chosen need to be compatible

with the process materials at the standard operating conditions and under excursion conditions. The

materials of construction also need to be compatible with each other in terms of corrosion properties.Impurities which may cause corrosion, and the possibility of erosion also need to be considered so that the

detailed mechanical design can ensure that sufficient strength is available and suitable materials of

construction are selected for fabrication.

4.1.2 Codes and Standards

Modern engineering codes and standards cover a wide range of areas including:

Materials, properties and compositions;

Testing procedures; for example for performance, compositions and quality;

Preferred sizes; for example for tubes, plates and standard sections;

Design methods and inspection and fabrication;

Codes of practice for plant operation and safety.


27/47

4.2 Production facilities

This section summarises the facilities needed in a wine making processing unit (winery).

4.2.1 Plant location

Because fresh grapes are bulky and spoil rapidly, it is better to locate a processing unit in the

area where they are grown. This reduces transport costs and also reduces the amount of handling,

which means that crops are more likely to be in good condition when they arrive at the

processing unit. If they are in good condition, they can be stored for a few days before they have

to be processed. Too much handling bruises them and they will spoil quickly. This increases the

cost to the processor, because the spoiled food has already been paid for. Pro cessed wines

products are likely to be sold in different markets and there is less reason to locate the unit near

to customers. An ideal site is close to a grapes growing area( near Nasik) and near to a main road

leading to an urban centre.

The location of the processing unit in a rural area means that there may be problems with:

Reliable electricity

Adequate supplies of potable water.

Contamination of supplies

Access for workers and staff (public transport, distance down an access road)

Quality of the road (dry season only, potholes that may cause damage to glass containers)

Absence of other facilities (e.g. schools, medical facilities, shops and entertainment) that make

working there less attractive than an urban location Each of these should be assessed before

choosing a site. In rural locations there is usually more land available for waste disposal

compared to urban sites, but there may be problems caused by insects and birds or straying

animals getting into the building. It is therefore important to have a site with cleared and fenced

land, preferably having short grass, which helps to trap airborne dust.

4.2.2 The building

All wineries businesses should have a hygienically designed and easily cleaned building to

prevent contamination of products. Buildings in rural areas may cost more to construct because


28/47

of higher transport costs for building materials, but rents in rural areas are usually lower than

urban centres. The investment in construction or the amount of rent paid should be appropriate to

the size and expected profitability of the business. Within the building, food should move

between different stages in a process without the paths crossing (Fig). This reduces the risk of

contaminating finished products by incoming, often dirty, crops, as well as reducing the

likelihood of accidents or of operators getting in each others way. There should be enough space

for separate storage of raw materials, away from ingredients, packaging materials and finished

products.

4.2.3 Roofs and ceilings

Overhanging roofs keep a building cooler, this is especially important when processing involves

heat. Fibre-cement tiles provide greater insulation than galvanised iron sheets against heat from

the sun. Roof vents allow heat and steam to escape and create a flow of fresh air through the

processing room. The vents must be screened with mesh to keep insects and birds out of the

room. If heat is a serious problem (e.g. fermentation), electric fans or extractors can be used if

they are affordable.

A panelled ceiling should be fitted in processing and storage rooms, rather than exposed roof

beams, which allow dust to accumulate and fall off in lumps and contaminate products. Beams

are also paths for rodents and birds, creating contamination risks from hairs, feathers or excreta.

It is important to ensure that there are no holes in the panelling or in the roof and no gaps where

the roof joins the walls, which would allow birds, rodents and insects to enter.

4.2.4 Walls, windows and doors

All internal walls should be plastered or rendered with concrete. The surface finish should have

no cracks or ledges, which could harbour dirt or insects. The lower parts of the walls are most

likely to get dirty from washing equipment, product splashing etc. They should either be tiled, orpainted with waterproof white gloss paint to at least one and a half metres above the floor.

Higher parts of walls and the ceiling can be painted with good quality white emulsion paint.

Natural daylight is preferable to and cheaper than, electric lighting in processing rooms. The

number and size of windows depends on the amount of money that a processor wishes to invest

and the security risk in a particular area (windows are more expensive than walls, especially


29/47

when security bars or grilles are needed). Storerooms do not need to have windows. Open

windows let in fresh air, but this also provide easy access for flying insects. All windows should

therefore be screened with mosquito mesh. Windowsills should be made to slope to prevent dust

accumulating and to prevent operators leaving cleaning cloths or other items lying there, which

can attract insects.

Storeroom doors should not have gaps beneath them and should be kept closed to prevent insects

and rodents from getting in and destroying stocks of product, ingredients or packaging materials.

Processing room doors should be kept closed unless they are fitted with thin metal chains, or

strips of plastic or cloth hung from door lintels. These keep out insects and birds, but allow easy

access for staff. Alternatively, mesh door screens can be fitted.

4.2.5 Floors

Floors in processing rooms and storerooms should be made of good quality concrete, smooth

finished and without holes or cracks. Over time, spillages of acidic fruit products react with

concrete and erode it. Paints can protect floors, but vinyl-based floor paints are expensive. Red

wax household floor polishes should not be used because they wear away easily and could

contaminate products or spoil the appearance of packages. The best way to protect floors is to

clean up spillages as they occur and make sure that the floor is thoroughly washed after each

days production. Dirt can collect in corners where the floor and the walls join. To prevent this,the floor should be curved up to meet the wall. The floor should also slope to a drainage channel.

Proper drainage prevents pools of stagnant water forming, which would allow insects to breed.

The drainage channel should be fitted with metal gratings that are easily removed so that the

drain can be cleaned. Rodents and crawling insects can also get into the building through the

drain and a wire mesh cover should be fitted over the drain opening. This too should be easily

removed for cleaning.

4.3 Services

4.3.1 Lighting and power

Where lighting is needed, florescent tubes use less electricity than light bulbs. Electric power

points should be located at least one metre above the floor so that there is no risk of them getting

wet when the floor and equipment is washed down. Ideally, waterproof sockets should be used.


30/47

Each power point should only be used for one machine. Multiple sockets should not be used

because they risk overloading a circuit and causing a fire. All plugs should have fuses that are

appropriate for the power rating of the equipment and the mains supply should have an earth

leakage trip-switch. Cables should be properly fixed to walls or run vertically from the ceiling to

machines. There should be no exposed wires at any connection. Electric motors should be fitted

with separate starters and isolators.

4.3.2 Water supply and sanitation

Potable water is essential in all winery , as an ingredient in some products and for washing down

equipment. An adequate supply of potable water should be available from taps in the processing

room. If there is no mains supply, or if the mains supply

is unreliable or contaminated, water from boreholes is likely to be relatively free from

microorganisms, but it may be contaminated with sand. River water is likely to be contaminated

and should only be used if no other source is available. Samples of water should be periodically

checked (e.g. once per year) for contamination by micro-organisms at the Bureau of Standards.

To remove sediment, two high level covered storage tanks should be installed, either in the roof-

space or on pillars outside the building. They are filled when mains water is available or with

water pumped from boreholes. While one tank is being used any sediment in water in the other

tank settles out. The capacity of each tank should be enough for one days production. The tanksshould have sloping bases and be fitted with drain valves at the lowest point to flrs. Out any

sediment that has accumulated. If necessary, water should be treated to remove micro-organisms.

There are four ways of treating water at a small scale: by filtration; by heating; by ultra-violet

light and by chemical sterilants, such as hypochlorite (also known as chlorine solution or

bleach). Domestic water filters are too slow for the large amounts of w ater required and other

water treatment methods are likely to be too expensive for small-scale producers.

Micro-organisms can also be destroyed by boiling water for 10-15 minutes, but this is not

realistic for large volumes because of the high fuel costs and the time required to do this each

day. Also, boiling does not remove sediment and boiled water may also need to be filtered.

Ultra-violet light destroys micro-organisms in water and commercial treatment units are suitable

for processors that use a lot of water. Again, this method does not remove sediment.


31/47

Dosing water with bleach is fast, cheap and effective against a wide range of microorganisms.

Water for cleaning should contain about 200 ppm of chlorine (by mixing 1 litre of bleach into

250 litres of water). Water that is used as an ingredient should not contain more than 0.5 ppm

chlorine (by adding 2.5 ml of bleach to 250 litres of water), to avoid contaminating products with

a chlorine smell. Care is needed when using bleach because it damages the skin and particularly

the eyes and can cause breathing difficulties if inhaled. It also corrodes aluminium equipment.

Equipment should be thoroughly cleaned after each days production, using a cleaning routine

that is clearly understood and followed by production workers (see Section 6, Quality

Assurance). Solid wastes should be placed in bins and removed from the building at intervals,

rather than letting them accumulate during the day. Wastes should never be left in a processing

room overnight. Wastes should be taken far away from the processing site and

either buried or turned into compost.

Large volumes of liquid wastes are created in wine processing and these should be carefully

disposed of to prevent local pollution of streams or lakes. If mains drainage is not available, a

soak-away should be constructed in a place that cannot contaminate drinking water supplies.

Water should not be allowed to simply soak into the ground, because this will create swampy

conditions, which attract insects that contaminate products, as well as introducing a health

hazard.

Toilets should be separated from the processing area by two doors or be located in a separate

building. Workers should have hand-washing facilities with soap and clean towels. A summary

of the basic rules on hygiene and sanitation.

4.4 Basic rules for hygiene and sanitation in wine making:

4.4.1 Facilities required in the processing room

A changing room where clothing and shoes that are not worn for work can be stored.

Separate hand-washing facilities for staff, with soap, clean water, nail brrs.es and

Clean towels.

Toilets, which should be separated from the processing room by two doors or located

In a nearby building.

First aid materials.


32/47

Protective aprons or coats washed regularly, hats/hairnets and if necessary, gloves

and shoes.

Cleaning chemicals, stored away from the processing room.

4.4.2 Ways of working

Clean the processing room, toilets, washing facilities and storerooms every day

Use the correct chemicals to clean equipment, make sure there are no food residues

and rinse the equipment with clean water.

Make sure all cleaning cloths are washed and boiled each day. Do not hang them on

equipment, or put them on products or window ledges to dry.

Do not leave dirty equipment until the end of the day before cleaning it.

Keep the area around the processing room clean and tidy. Keep grass cut short.

Put all wastes into bins that are not used for anything else. Empty the bins periodically

during the day away from the processing site. Clean up any spillages as they occur.

Prevent all animals from entering the processing area or storerooms.

Visitors should only enter the processing room wearing protective clothing and under

supervision.

Do not wear clothing or jewellery that can get caught in machinery.

Wear a hat that completely covers the hair. Do not comb your hair in a processing room

or storeroom.

Cover all cuts, burns and sores with a clean, waterproof dressing. Do not handle any food

if you have sores, boils, septic spots, a bad cold, sore throat or a stomach upset. Report

any of these to the manager and do alternative work

Do not smoke or eat in any room where there is open food because bacteria can be

transferred from the mouth to the food.

Do not spit in a processing room or storeroom.

Wash hands and wrists thoroughly with soap after using the toilet, eating, smoking,

coughing, blowing your nose, combing your hair, handling waste food, rubbish or

Cleaning chemicals. Dry them on a clean towel before handling food again.

Keep fingernails cut short.


33/47

Do not wear perfume or nail varnish as these can contaminate products.

Do not cough or sneeze over food.

Keep food covered wherever possible.

Keep all food, tools and equipment off the floor.

Keep ingredients in sealed containers.

Do not use broken or dirty equipment.

Report any signs of insects, rodents or birds to the manager

4.4.3 Production planning

Production planning involves thinking ahead to make sure that everything is in place to produce

the required amount of wines. Inadequate planning causes stoppages in production because for

example, not enough fruit is bought, an ingredient is used up, or there are not enough staff toproduce the required amount of product in the time available. The short harvest season for many

raw materials means that everything must be in place and working properly at the start of the

harvest so that enough crop can be processed to produce sufficient product for the following

year.

The amount of less perishable ingredients, such as Active dry yeast, KMS, bentonite, CO2 and

packaging materials that are stored as stock depends on a number of factors:

A large amount of stock ties up cash while it is waiting to be used.

Some stock deteriorates over time and money is lost due to spoilage

If processors buy smaller quantities more often, this is more expensive than buying in bulk.

Decisions on stock levels therefore depend on the cost and reliability of supplies, their shelf life

and the amounts that are used each day. If production stoppages happen too frequently, the

amount of product available for sale falls to a level where the business cannot afford to pay the

bills and it fails. Successful business people manage their cash flow, so that enough money is

available to buy the inputs needed for production, before income is received from the sale of

products. To do this they plan their production carefully. Careful production planning is used to

find the:


34/47

1. Number of workers required and their different jobs

2. Equipment needed to achieve the planned production level

3. Weights of raw materials and ingredients to be bought

4. Number of packages required

5. It can also identify any bottle-necks in the process.

Production can be planned using the calculations. The information required to do this includes:

How much product (kg or litres) is sold (not made) each month?

How many hours are worked per day?

How many days are worked per month?

This information is first used to calculate the daily production rate, so that ingredients and

packaging can be ordered. Then the average amount of production per hour (termed productthroughput) can be calculated to find the size of equipment and numbers of workers required.

4.4.5 Daily production rate

The daily production rate is calculated as follows:

This figure is used to decide how much raw material, ingredients and packaging to buy. One of

the main causes of error is to over-estimate the number of working days, particularly if there are

regular power failures or if staff is often absent.

4.4.6 Packaging

When selecting packaging materials, the processor should consider:

Technical requirements of the product (for protection against light, crushing, air, moisture etc.)

The design (for promotional and marketing requirements)

The relative cost and availability of different types of packaging.

Packaging is often the biggest problem for small-scale processors in India and advice should be

sought from food technologists or agents of packaging manufacturers. New glass jars and bottles

are available in market. Because of their heavy weight, high bulk and fragility, they are


35/47

expensive to transport and breakages can be high if they are not properly packed. There are also

minimum order sizes, which may be too high for individual small-scale processors. Re-used

bottles for local market are collected and sold in India , but great care is needed to ensure that

they are properly cleaned, because they may have been used to store chemicals, such as

pesticides or kerosene. This is time-consuming, but bottle cleaners and rinsers can be constructed

to save time and labour costs.

4.4.7 Equipment and Machineries

The throughput figure allows the processor to decide the size and/or number of pieces of

equipment that are required. In doing this, decisions need to be taken on the benefits of

employing a larger number of workers or buying a machine to do a particular job.

Equipment used in wineries are Press machine, Destemmer, Fermentation tanks and storage

tanks, racking pumps, pumpover, autoclave, bottling and corking machine etc.

The size of equipment and machineries are depends upon production planning, capacity of wine

making.

4.4.8 Staff

The numbers and types of workers needed to operate a wine processing business depend on the

amount of production and also on the degree of mechanisation of the process. This type of

processing is more seasonal than many other types and temporary staff is commonly employed

during harvest times. Machinery such as a pulper finisher for juice preparation, fermentation,

racking or machines for filling and corking wine bottles, can significantly reduce the numbers of

workers needed. However, a processor needs to carefully compare the cost of labour with the

cost of maintenance, spare parts and possibly loan repayments from buying the equipment to see

which is most cost-effective.

When deciding the number of people needed to produce a particular amount of product, the

process charts in Section 4 can be used to break down a process into different stages. A decision

can then be taken on whether a particular stage can be done manually and the number of people

who will be needed, or whether a machine will do the work. It is important also to include work

such as store management, quality assurance and bookkeeping when planning the number of

staff members that are needed.


36/47

It is possible to have all workers doing the same type of work throughout the day (e.g. everyone

prepares stemmed grapes together then moves on to load a dpress machine and then all packing

of aged wines bottles the previous days production). However, it is often more efficient to

allocate different jobs to each worker as the day progresses. A convenient way of planning this is

to draw an Activity Chart . This shows the type of work that is to be done each hour during the

day, the number of people involved and the sequence of work that individuals do during the day.

This type of chart can also be used to train workers in each of the different jobs in a process.

4.5 Health and safety

All processors have a responsibility to provide safe and healthy working conditions for their

staff. In wine processing the main dangers are as follows:

4.5.1 Damage to skin

When workers handle raw grapes and handling of packaging material,during cleaning of tank

halls, machineries they should wash their hands regularly or be provided with thin gloves to

prevent skin damage from cleaning agents. In particular, care is needed with grapes, which

contain an enzyme that attacks the skin. Care is also needed when handling bleach to avoid

damage to the skin.

4.5.2 Burns and cuts

Aprons or coats and heat resistant gloves should be provided and staff should be trained to

handle such foods safely . There are also dangers of cuts from sharp blades on motorised cutters

or liquidisers. Staff should be properly trained to use machines safely, particularly when cleaning

them and workers should not wear cloths or jewellery that could become tangled in moving

equipment.

4.6 Record Keeping

There are four sets of records that should be kept by the owner of a small fruit and vegetable

processing unit:


37/47

1. Financial records

2. Production records

3. Quality assurance records

4. Sales records.

5. Excise Records

As with other inputs to a business, keeping records is an investment of time and money and this

must be related to the scale and profitability of the business (the benefits must outweigh the

costs).

Records must be used for them to have any value.

This means that the processor must understand why the information is collected and what it can

be used for. Processors should also put in place a system of checks to ensure that one person

does not have responsibility for a whole area of record keeping. For example the person who

keeps records of purchases should be different to the person who records levels of stocks and

manages the storeroom.

Table 4 .1 Types of records for wine processing business

Type of record Information to be recorded

Production records Methods for red and white wine making

Raw materials and ingredients received and suppliers

Wastage % at different stages of the process

Stock levels for each ingredient

Production volumes and measurements

Maintenance programs and schedules

Quality assurance Records Target amounts of ingredients and any changes made to recipe

Measurements made at process control points

Batch numbers and product code numbers

Cleaning procedures and schedulesSales records Names of customers and amounts sold to each

Weekly and monthly sales volumes

Financial records Income from sales

Costs of all process inputs

Staff records

Cash flow

Profit/loss


38/47

Tax records

Bank statements

Evaluation card no. 1

Question Yes or

No

Notes if required

1. Do you know how to calculate your

production rate?

2. Do you know how to calculate the

amounts and true costs of ingredients

required for a given production rate?

3. Do you know how to plan labour

requirements and how to allocate jobs todifferent workers to maximise efficiency?

4. Do you have correct maintenance

procedures for your equipment?

5. Do you keep adequate records?

5.0 Equipment Cost estimation of Winery

Table: 4.2

Sr.no Equipment/machinery Quantity Estimated cost

1. Wine fermentor and

storage tanks

75 Tanks 2.4 Cr.

2. Destemmer 1 7 Lakh

3. Press machine 2 45 lakh

4. Racking pumps 5 20,000

5. Micofilter 2 set 9,000

6. Bottling machine 1 6.5 Lakh

7. Temp. sensor 70 3750

8. Temp. control panel 1 set 5000

9. Chilling plant 1 35 lakh

10. Gaskets 200 5000


39/47

11. Water treatment 1 60,000

12. Weigh lifter 1 20,000

13. K-type wine filter 1 2.5 lakh

14. Racking pipes 10 1 lakh

15. Plant piping 10 lakh

5.1 Laboratory material cost:

Table:4.3

Sr.no Material Quantity Estimated cost Use

1. Hand

refractometer

2 1000 0brix

2. Hydrometer 1 5000 Density check

3. pH meter 1 4500 pH

4. Torque meter 1 150

5. So2 assembly 1 2000 analysis

6. Volatile acidity

assembly

1 1500 analysis

7. Ebulliometer 1 20,000 Alcohol estimation

8. Thermometer 2 500 Temp.

9. Distillation waterunit

1 1500 Distilled water

10. Analytical weigh

balance

1 55,000 Micro weighing

11. Pipette 10 250 Measurement of

sample

12. Burette & stand 4 350 titration

13. Weigh balance 1 2000 For weighing

14. Test tubes 10 150 analysis15. Microfilter 1 300 Filteration of wine

sample16. Injection 2 100

17. Heating coil 1 5000 To heat the sample

18. Conical flask 5 150 For taking sample

19. Beaker 4 150 For sample


40/47

20. Test tube stand 3 100

21. Chemicals for

analysis

15 8000 For laboratory

analysis

22. Computer 1 25000 For record keeping

23. Record files 5 200 For record keeping

5.2 Land & Infrastructure cost:

Land Purchased cost: 1.2 crore

Land area: 9900 sq. ft

Infrastructure build up cost: ( constru material + labor cost)= (70 lakhs + 25 lakhs) = 95 lakhs

Water supply boring cost: 3.5 lakhs

Digital Generator cost: 20.5 lakhs

Land & Infrastructure total cost: 23,900,000 INR

Excise License fees: 31000 INR.

6.0 Capital Investment of Winery plant: Installed Capacity 10 Lakh Ltr.

A.Land & Infrastructure cost: 23,900,000B. Excise License Fees: 31,000 INR

C.Plant Equipment & machinery cost: 3,48,22,750 INR

D.Laboratory cost : 1,32,900 INR

Total Capital Investment: ( A+B+C+D)= (23,900,000 + 31,000 + 3,48,22,750 + 1,32,900)

= 58,886,650 INR ( ESTIMATED)

measurement


41/47

7.0 Total Production Cost:

Material Balance of Process flow sheet

Pomance 320 kg.

Residue 20 kg

650 kg juice

CO2

Residue 10 kg.

Destemming/Crushing

Chilling & Settling

Racking

Fermentation

Racking

Clarification &Stablization

Storage

Receiving of Harvested

Grapes( 1000 kg)


42/47

Basis: 1 litre of 13.5% w/w ethanol in wine

Input of grapes = Output + Accumulation

1000 kg = output ( wine) + (320+20+10) kg.

Output of wine = 650 kg or 650 litre wine

Table: 4.3

Manpower Quantity Duration Payskill/ personProduction 30 5 months 3500 INR

Wine aging 10 7 months 4000 INR

Operator 3 12 months 6000 INR

Maintenance 1 12 months 6000 INR

Table: 4.4

Administration Quantity Duration Payskill/person

Manager 1 12 months 25,000 INR

Production manager 1 25000

Accounts 2 9000

Winemaster 1 6 Lakhs

Electricity charges per annum: 10 lakhs

Raw material cost:

Wine Grapes :

Amount: 900 ton

Cost: 2.25 crore

Blending(optional)

Filteration

BottlingCorking,Labelling &

Packaging


43/47

Yeast: S.cerevisiae

Amount: 100 kg.

Cost: 3000/kg

Oak chips & Chemicals:

Cost: 4.5 Lakhs

Raw material total cost: 2.33 cr.

Manpower cost per annum: 10.93 LakhsAdministration cost: 79.92 Lakhs

Total Production Cost: (Electricity Charges + Raw material cost + Manpower cost +Administration cost)

= ( 10 lakhs + 2.33 cr. + 10.93 lakhs + 79.92 lakhs)

= 3,42,22000 INR

Production cost/ litre ( bulk wine): Total Production cost/ annual production

= 3,42,22000/ 6,00000 ltr.= 57.036 INR/ltr of Bulk wine


44/47

4.0 RESULT AND DISCUSSION

I worked at the N.D Wines Pvt. Ltd, India as the PRODUCTIONTRAINING

and learnt the process of Wine making Process Technology and Plant design of

winery. Their implementation on the site as well as the preparation of the

supporting documents of Capital Investment. Plant Design is made up of three

components:-

1. Documentation - Tells us what to do and how to do it.

2. Plant LayoutIt includes the representation of each section of plant and it;s

Design

3. Cost Evaluation Estimating the capital investment, Production cost and

where improvements will be made.

The design of a process plant is a complex activity that will usually involve many

different disciplines over a considerable period of time. The design may also go

through many stages from the original research and development phases, through

conceptual design, detailed process design and onto detailed engineering design

and equipment selection. Many varied and complex factors including safety,

health, the environment, economic and technical issues may have to be considered

before the design is finalised .

I have completed all the documents (Plant layout, SOPS. Hygiene & Sanitation,

CIP sheet, cost analysis etc), Designing of Training module, conducting training,

physical inspection plan, compliance monitoring, etc


45/47

Glossary and Acronyms

Acid preserves Foods that have a high acid content that inhibits spoilage.

Adulteration Deliberate contamination of foods with materials of low quality.

Brix Units of measurement of sugar concentration

Case hardening The formation of a dry skin on a wet food due to over-rapid drying. It slowsthe rate of drying and can lead to spoilage during storage.

Chlorination The addition of chlorine to water to destroy micro-organisms.Contamination Materials that are accidentally included with a food (e.g. dirt, leaves, stalks

etc.).

Critical control Stages in a process where quality control can have a major effect Pointson food quality or safety.

Cross

contamination The transfer of soils or micro-organisms from raw food to processed food

Enzymes Natural proteins in foods that can cause changes to colour, flavour or textureof the food.

FIFO First in, first out inventory scheme for raw materials and finished products.Fill-weight The amount of food placed into a container or package and written on the

label (also net weight).Humidity The amount of water vapour in air.

Hydrometer An instrument that measures specific gravity of liquids, used to measure

salt,sugar or alcohol concentration.Low-acid Foods foods that have little acid and therefore can contain food poisoning

bacteria if poorly processed.

Minimum weight All packages have a fill-weight equal to or greater than that shown on the

label.Net weight The amount of food filled into a container.

Pectin A natural gelling agent found in some fruitspH A scale used to express acidity or alkalinity, from 1 (strong acid) through 7(neutral) to 14 (strong alkali).

Potable water Clean and wholesome water that will not cause illness.

Preservation Index a figure that is calculated to show that the amounts of acid,sugar and salt are enough to prevent spoilage of foods.

Quality assurance A management system which controls each stage of food production from

raw material harvest to final consumption.Refractometer An instrument that measures the refractive index of a liquid, which is used to

measure soluble solids in syrups or salt in brines.

Shelf life The time that a processed food can be stored before changes in colour,

flavour, texture or the number of micro-organisms makes it unacceptable.Sodium benzoate A chemical preservative that is particularly effective against yeasts.

Sodium

metabisulphite A chemical preservative that is effective against moulds and yeasts.


46/47

Acronyms

CCP Critical Control Point

FIFO First in, First out inventory control system

GHP Good Hygienic Practices

GMP Good Manufacturing PracticesHACCP Hazard Analysis Critical Control Point system

ROPP Roll on Pilfer Proof (caps for bottles)TOTO Twist on Twist off (lids for jars)

UHT Ultra-High Temperature (sterilisation of foods)


47/47

5.0 References/Literature Cited:

1. Plant Design & Economics edited by Max S.Peter, Klaus D.

Timmerhaus

2. Food Plant Economics Zacharias B.Maroulis , George D.Saravacos

3. Wine tech engineers Pvt.Ltd.

4. Seepra refrigeration Pvt. Ltd.

5.www.winemaking.co.nz
http://www.winemaking.co.nz/http://www.winemaking.co.nz/http://www.winemaking.co.nz/http://www.winemaking.co.nz/

n.d Wines Submit

Documents

Transcript of n.d Wines Submit