ES Fermentation

Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology

Chemical Engineering Department
Fermentation
Submitted by:
Baldo, Jerlyn Mae B.
De Guzman, Khaye Anne F.
Dizon, Glyzel G.
Macasil, Renzo C.
Percil, Queenie Rose I.
Submitted to:
Engr. Milagros C. Cabangon
July 4, 2014
Objectives
Fermentation

General Objective:
To identify and enumerate the raw materials, unit operations and equipment involved in
manufacturing of products of fermentation
Specific Objectives:
To discuss the chemical reaction that takes place in beer fermentation
To discuss the process of brewing
To identify the step by step process involved in the fermentation of wine
To differentiate white wine production from red wine production
To identify and enumerate the raw materials, equipment and unit operation involved in
manufacturing cheese
To identify and enumerate the raw materials needed in production of cheddar cheese
To identify and enumerate the unit operations and the corresponding equipment involved in the
manufacturing of cheddar cheese
To determine the different types of distilled spirits
To understand the process of manufacturing distilled spirits.

To identify the different raw materials in manufacturing distilled spirits
Fermentation

Fermentation of Wine
Manufacturing companies of Wine in the Philippines:
1. Destileria Limtuaco & Co., Inc
The Philippine market has always enjoyed the world-class quality that Destileria
Limtuaco products have been known for. The distillery is proud of its wide range of distilled
spirits andalcoholic beverages expertly blended and produced with the highest degree of
manufacturing excellence, being the finest liquormakers in the Philippines.
For over 160 years, Destileria Limtuaco's excellent brand portfolio consists of distilled
spirits, whiskies, brandies, gins, rums, vodkas, tequilas, cocktails, herbal and sweet wines, and
the original medicinal wines. These products are produced strictly following
special manufacturing processes and well-guarded formula developed by the master blenders,
creating exceptional products of superior taste and quality that satisfies the impeccable taste of
Filipinos and connoisseurs the world over. Destileria Limtuaco is known as "The Oldest Distillery
in the Philippines".
2. Barcino Corporation
Barcino Corporation is a company engaged in the importation and distribution of wines
and the best Spanish beer in the Philippines. We also seek to venture into importing other
Spanish products like olive oil, cold cuts, cheeses, and other canned and bottled food as a
response to the markets growing need. Barcino Corporation was established in 2006 with the
main purpose of distributing wines and food in a small deli shop.
The company offers a wide selection of wine which boasts of 250 labels from Spain,
South Africa, Chile, Argentina, and Italy. Some of its most notable brands are multi-awarded
wines from Beronia, Martin Codax, Vallformosa, Ponte da Boga, Emilio Moro, etc. And to make
our wine range even more expanse, Barcino Corporation will also start importing from France,
Australia, and New Zealand.
3. The Straits Wine Company
Started in 2006, The Straits Wine Company is now Southeast Asias leading wine
importer, retailer and distributor, with operations in Singapore, Malaysia and Philippines. It has a
comprehensive range of services that caters to any and all wine needs. From private wine
parties to cellar planning, a trusted bottle shop to private client concierge, the Straits team
of wine professionals is at your disposal.
Our 12 retail wine bars across Singapore showcase a wide range of wines from around
the world including Australia, New Zealand, France, Spain, Italy, Argentina, Portugal, India,
USA, Lebanon, Japan, Switzerland and many, many more.
Straits Wine is also proud to offer a bespoke events planning service. Specializing in
personal, boutique wine experiences, our events team plans every aspect to the last detail.
Fermentation

From customized tastings, to incredible cheese boards or full themed events and parties, your
guests walk away with a very special memory and experience of a truly one-of-a-kind event.
Whether its buying wine for your house party, a girls night in or ordering for your restaurant,
Straits Wine is a one stop solution to your wine needs. The Straits Wine Company is currently
the largest wine retailer in the Southeast Asia region.
Uses of Wine:
Can prevent diseases

Wine is used for preventing diseases of the heart and circulatory system, including
coronary heart disease, hardening of the arteries (atherosclerosis), heart failure, heart attack,
and stroke. Wine contains ethanol (alcohol), which blocks various nerve pathways in the brain. It
also contains chemicals that might have beneficial effects on the heart and blood circulation
such as antioxidant effects, and preventing blood platelets from forming clots.
Marinate the cancer away

Marinating steak in wine for six hours can cut the cancer causing compounds formed
during frying or grilling by up to 90 percent. It can also make your meat more flavorful and juicy.
Grease Remover
If you have grease stains on your driveway or the floor of your garage, try pouring a little
white wine on the stain. The acidity will help remove some of the stain. Mix in some baking soda
for an added.
Disinfectant
Leftover white wine makes a great disinfectant for your kitchen. The alcohol combined
with the acidity can remove stains and kill germs without all the harsh chemicals of standard
cleaners. Just be careful as the acidity can damage some countertops like granite.
Soften your skin

The antioxidants that give red wine its glory in health circles are equally as beneficial for
your skin. Use leftover wine as a toner or dump it into your bath water and soak the night away.
You may not get a buzz, but you'll be left with baby soft skin. If we find out it can get rid of
wrinkles, we may never actually drink wine again.
History and Background Information
Enology, a word that comes from the Greek words for wine and study, is the term that is used to
describe the science of winemaking. This science has its roots in prehistoric times, as the effects of
alcohol were probably discovered when rotten fruit was consumed and found to have an intoxicating
effect, which was viewed as pleasant. Fermented liquid could be stored for a long time without fear of
decomposition, and a reliable drinking source was obtained (Wade, 1999).
The process of fermentation is described by the reaction:
Fermentation

C6H12O6 + yeast -> 2C2H5OH + 2CO2
glucose (sugar) -> ethanol carbon dioxide
Yeast is added to a solution containing glucose, and the yeast cells convert the simple sugars to
ethanol and carbon dioxide. The alcoholic solution that results from fermentation contains about 1215% ethanol, as yeast cells cannot survive in higher concentrations of ethanol (Wade, 1999).
High sugar content is necessary for fermentation to proceed in a desirable manner. Because of
this, the sugar-rich species of grape Vitis vinifera is used for the majority of the wines produced around
the world. As many as 4000 varieties of Vitis Vinefera have been developed and are used in the
production of wines. Although the specifics of winemaking can vary from location to location and the
individual fermenting techniques, the basic steps involved in winemaking are similar for most wineries.
There are three main categories of wine: table wines, sparkling wines, and fortified wines. Table
wines can be red, white, or rose, are allowed to ferment naturally, and account for the bulk of the
worlds wine production. Sparkling and fortified wines are made by processes similar to the table
wines, but extra steps are added to give the carbonation or extra alcohol desired.
Well documented in numerous Biblical references, evidence of wine can be traced back to
Egypt as far as 5,000 B.C. Tomb wall paintings showing the use of wine as well as actual wine jars
found in Egyptian tombs provide evidence of this fact. Because more northern climates and soil
produce better wine, the growth of the wine industry can be traced from its emergence along the Nile
River in Egypt and Persia northward into Europe and, eventually, to North America.
The colonists brought wine production to the east coast of the New World by the mid-1600s.
The earliest account of wine used in the New World may be when the Pilgrims fermented grapes to
celebrate their first Thanksgiving in 1623. Settlers tried to grow imported grape cuttings they brought
from Europe, but unfortunately the European cuttings had not developed immunities to the North
American plant diseases that eventually killed them. By the middle of the nineteenth century wineries
were established in Pennsylvania, Virginia, Ohio, Indiana, Alabama, Mississippi, and North Carolina.
In 1697, European cuttings of Vitis vinifera grapes were successfully introduced to California by
Franciscan priests at the Mission San Francisco Xavier. They soon became the dominant grape
species in California wine making. A great boost to California wine making came from Colonel Agoston
Haraszthy, a Hungarian nobleman, who introduced more high-quality European cuttings during the
1850s. His knowledge made him the founder of California's modern wine industry.
Today, California and New York state are by far the largest American producers of wine, and
California is one of the largest wine producers in the world. Though many of its table wines are known
for their quality, the enormous wineries of central and southern California produce gigantic quantities of
neutral, bulk wines that they ship elsewhere to make specific wines, such as dessert wines, or to blend
with other wines. They also make grape concentrates to fortify weaker wines and brandies that use
large quantities of grapes.
Raw Materials in Wine Fermentation:
Fruit
The grape itself contains all the necessary ingredients for wine: pulp, juice, sugars,
acids, tannins, and minerals; and these ingredients contain vitamins, seed, etc that are basically
found in wines.
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Yeast
Yeast converts sugar into alcohol. Therefore, it is responsible for the alcoholic content of
wine.
Additives:
Cane or Beet Sugar
It is also responsible for the increase the wines alcoholic content.
Sulfur Dioxide
It is usually added during fermentation to control the growth of wild yeasts.
Manufacturing Process:
A. Red Wine Process
1. Harvesting
Wine makers inspect sample clusters of wine grapes with a refractometer to determine if
the grapes are ready to be picked. The refractometer is a small, hand-held device (the size of a
miniature telescope) that allows the wine makers to accurately check the amount of sugar in the
grapes.If the grapes are ready for picking, a mechanical harvester (usually a suction picker)
gathers and funnels the grapes into a field hopper, or mobile storage container.
2. Crushing
The old way was to tread the grapes: the modern way is to crush and then destem them
with mechanical crusher-destemmers. The aim of crushing is to split the skins and release the
juice, enabling yeast activity and fermentation to begin. Destemming is not always necessary
and bunches may be crushed whole, but stems and stalks are usually removed if the winemaker
wishes to avoid high tannin levels in the wine. The object of destemming and crushing is to
remove the stem and gently break the berry skin. Care is taken to avoid excessive skin
maceration and breaking of seeds. The crushed fruit consisting of pulp, skin, and seed, called
must, is transferred to a container and about 30 mg/L of free SO2 is added. The purpose of SO2
addition is to prevent the development of unwanted microbes such as indigenous yeast and
harmful bacteria.
3. Maceration or Cold Soak

In the practice of cold soak or cold maceration, the must is cooled to about 15 to 20 C
(41 to 68 F) to slow down the onset of fermentation by indigenous yeast, and contact between
skins and juice is promoted. The purpose of cold soaking is to encourage extraction of pigments
and other phenolic compounds from skins in the absence of ethanol. The skins are soaked for
one to two days and the must is pumped over or mixed to facilitate the phenolic extraction. The
cold maceration is thought to improve color, body, and mouth feel of the resulting wine. The
effectiveness of this approach will depend on variety, fruit composition and the condition of the
fruit.
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4. Must Adjustment
Grapes are generally harvested at 22 to 24 Brix for red wine production. Some varieties
may not have sufficient amount of sugar at harvest. For these varieties (e.g., Concord), sugar
addition to the must would be necessary. Sugar addition can be done to the must at the
beginning of fermentation. However, one needs to make an allowance for the volume of seeds
and skins when calculating the amount of sugar needed. To circumvent this problem, some
winemakers prefer to add sugar to the fermenting must after pressing and removing seeds and
skins. In low sugar, high acid American grapes such as Concord, sugar syrup in place of dry
sugar can be used. This process is also called amelioration. The advantage of this process is
that while sugar content increases, the acid level decreases due to dilution. To ensure the
quality of the resulting wine, the extent of amelioration within legal limits should be carefully
evaluated.
5. Must Treatment
The issue of SO2 addition needs some consideration. Some winemakers do not add free
SO2 to red must prior to fermentation. The rationale is to minimize SO2 levels in wine, facilitate
malolactic fermentation, and maybe to achieve flavor complexity by allowing indigenous yeast to
participate in alcoholic fermentation. The problem with this approach is that no SO2 addition can
leave must unprotected from the activity of undesirable microorganisms such as wild yeast and
spoilage-causing bacteria. We recommend the addition of a small amount (20 to 30 mg/L free
SO2) of SO2 to the clean must; must with rot will need higher (75 to 100 ppm) doses. This level
(20 to 30 ppm) is sufficiently high to discourage spoilage organisms but not too high to suppress
malolactic fermentation, if it is so desired.
6. Fermentation
After making all the necessary adjustments (sugar, acid, etc.) and additions, the red
must, consisting of juice, skin, and seeds is ready for fermentation. The must can be fermented
in open top containers. This allows for ease in must handling, cap management, and
temperature control. However, some provision should be made to keep the fruit flies away from
the fermenting must. Some winemakers prefer to use fermenters with closed tops or some
cover to keep fruit flies away. Smaller lots can be fermented in tubs, tanks, bins, or other
containers made of plastic or stainless steel. For larger must volumes, specially designed
stainless steel fermenters should be used. The fermentation should be conducted in a wellventilated area, and provisions should be made to remove excess CO2 generated during
fermentation.
A wide selection of yeast strains is available for conducting red wine fermentation. The
winemaker should choose the strain that will ferment the must efficiently and completely with
very little (below sensory threshold) amounts of undesirable compounds such as acetic acid,
ethyl acetate, and hydrogen sulfide. To obtain a clean and rapid fermentation, commercially
produced strains of active wine yeast in dry form should be used. Dry yeast must be properly
rehydrated before inoculating the must. We suggest that winemakers experiment with various
Fermentation

strains to make proper selection. Some winemakers use indigenous yeast strains. This practice
can sometimes give good results; however, it is risky and requires a lot more skill and attention.
7. Cap Management
With the onset of active fermentation the skins rise to the top of the fermenting liquid and
form a cap. Thus the skins and juice in a fermenter are somewhat separated. In order to
maximize the extraction of color and flavor from skin it is important to keep skins in close
contact with the juice during fermentation. To achieve this, the cap is punched and skins and
juice are mixed.
8. Skin Extraction
The color and tannins are the two major components that are extracted from skins
during fermentation. The purplish-red color of red grapes is due to the pigments known as
anthocyanins. The pigments are located mostly in the outer layers of the skins. In grapes, many
kinds of anthocyanins are present. They occur in both color and colorless forms. The amount of
pigment in colored or colorless form is strongly influenced by the pH of the wine and also by the
presence of free sulfur dioxide. Lowering the pH shifts the equilibrium towards the colored form
and SO2 has a bleaching effect on the (monomeric) anthocyanins.
Tannins are complex polymeric phenols. They react with proteins, and it is this property
that is used in tanning hides to make leather. They are bitter and astringent compounds with a
wide range of molecular sizes. Condensation and polymerization of smaller tannin molecules
leads to the formation of bigger tannin molecules such as condensed and highly condensed
tannins. These large tannin polymers are less astringent and assume yellow-red to yellowbrown color. When the tannins become too large, they precipitate.
Tannins also play an important role by forming complexes with pigments, which
contributes to color stability. These polymeric pigments (pigment and tannin complexes) are less
sensitive to changes in pH and SO2 levels in wine. During alcoholic fermentation, both the
pigments and tannins are extracted from the skin, but their pattern of extraction is slightly
different.
The extraction of color is rapid at the beginning of fermentation. It reaches a peak in the
first two to three days; and, then slightly declines during the remainder of fermentation. This
means a short maceration time of about two to three days is sufficient to obtain good color.
Tannins and other phenolic substances are also extracted quickly at the beginning but their rate
of extraction slows down as the fermentation proceeds. However, the concentration of total
phenols (this includes tannins) continues to increase towards the end of fermentation.
9. Carbonic Maceration
Carbonic maceration is an alternative fermentation process in which the fruit is allowed
to ferment spontaneously under a protective layer of CO2. This weight of the grapes is sufficient
to crush the fruit and release the juice, known as free-run, without mechanical pressure. The
resulting wines tend to be softer and less astringent than those fermented in the traditional way,
so this method is well suited to grapes which normally give hard, acidic wines. Wines made by
Fermentation

carbonic maceration are usually for drinking young and do not respond well to aging.
10. Pressing
Pressing the grape mass, or pomace, occurs after the free-run wine has been removed from
the fermentation vat. This process is not for white, and in fact is not always carried out at all.
'Press wine' is high in tannin and colouring pigments. At the discretion of the winemaker a
percentage of it may be blended with the free-run wine to add tannins, character and longetivity.
11. Malolactic Fermentation
This process is almost always encouraged in red winemaking. It is a secondary
fermentation in which malic acid is converted into lactic acid and CO2. It softens the acidity of
the wine and, once completes, adds to its complexity and stability. In many European cellars the
wines will mature for six months before the malolactic fermentation commences.
12. Maturing
- Maturing in Oak
High quality red wines today are almost always matured in oak. Oak contributes vanilla
and wood tannin flavours. For how long the winemaker ages the wine in barrel is one of the
crucial
decisions,
arrived
at
by
regular
tasting.
- Racking
The wine is racked every few months by transferring it to a clean sterile barrel, gently
aerating it and leaving any sediment in the bottom of the old barrel.
- Fining
The object of fining is to clarify the wine. The fining agent (usually egg white or bentonite
clay) is poured onto the surface. As it sinks through the wine it carries any solids to the bottom
of
the
vat.
- Filtration
The final option before bottling is whether or not to filter. Passing the wine through a fine
filter guarantees (or should guarantee) its stability and 'brightness' even under fairly adverse
conditions. But some winemakers believe it strips the wine of its character.
13. Stabilization
The practice of stabilization refers to the treatment of wine to prevent cloudiness and
formation of sediment in the bottle. Red wines are rich in tannin contents, which carry a negative
charge. The tannins interact with positively charged proteins which lead to agglomeration and
settling of the tannin-protein complex. Due to the removal of proteins in this manner, the
problem of proteinaceous haze in red wines is not a serious one. Some winemakers use a small
Fermentation

dose of bentonite to clarify the wine, which also helps in protein stability. However, winemakers
generally do not treat wine for protein instability unless a test warrants it.
14. Aging
The process of maturation and aging involves a series of changes that lead to the
improvement in the appearance, color, taste, and flavor of a wine. Red wine color is due to the
presence of anthocyanin pigments, which occur in monomeric and polymeric forms. Young
wines have higher levels of monomeric anthocyanin pigments in various colored and colorless
forms. The proportion of colored and colorless types is pH dependent. In the range of wine pH,
the lower the pH, the greater the concentration of pigments in red form. Therefore, to produce
young red wines of attractive color, the winemaker should strive for a lower wine pH. The
monomeric pigments are also susceptible to sulfur dioxide, which causes bleaching. This
reaction, however, is reversible and loss of SO2 can restore original color. This point is
important to remember when sulfating young red wines. As the wine matures, the monomeric
pigments are polymerized and the color becomes more stable. It is then less responsive to
changes in pH and SO2 levels.
15. Finishing or Bottling
Before bottling the wine should be completely stable. It remains vulnerable to oxidation
and contamination until the cork goes in. Mechanical bottling lines account for 95 percent of
modern bottling. It is important to fill the bottles to exactly the right level to allow adequate room
for the cork.
B. White Wine Process
1. Crushing
The first stage of controlled vinification is to crush the grapes and release the pulp and
juice, making them easier to press. A Key decision at this stage is whether or not to remove the
stems. Left with the grape stems allow juice to drain more freely during pressing. For some
wines, where white wines are being made from red grapes, crushing of any kind is avoided
(because it would colour the wine): grapes go whole into the press.
2. Pressing
- Cooling
Delaying fermentation until after pressing is essential. Where the ambient must
temperatures are high the juice is cooled by pumping it through 'must chillers'.
- Pressing
White wine grapes are always pressed. Better quality juice results when pressing is
gentle. If too aggressive the pips and stems break and bitter astringent flavours, which
overpower those natural in the grapes, are released. Good results are achieved with pneumatic
presses, which are now replacing traditional vertical wooden ones. Both types yield juice of the
highest quality and also enable the separation of different quality pressings.
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- Settling
The juice is drained from the press into settling vats where the skin, pip and stem
fragments remaining in suspension after pressing will settle to the bottom of the vat. The clean
juice is then racked into separate vats ready for fermentation to begin. Centrifuging can also be
carried out at this stage to clarify the wine, but it is an aggressive process, removing all the
larger particles in the must, even yeast cells. It is often carried out when cultured yeasts are to
replace
natural
ones
for
fermentation.
3. Fermentation
Traditionally in oak casks (increasingly favoured for many high quality wines) white wine
is now more often fermented in stainless steel vats which enable easier regulation of yeast
activity through temperature control. Prolonged fermentation at cool temperatures protects
primary fruit characteristics and ensures the conversion of all the sugar to alcohol. After
fermentation some winemakers chose to leave their wine in contact with its lees (yeast
sediment) which adds both flavour and freshness to the wine, retained by bottling it without
delay.
4. Malolactic Fermentation
To soften astringent acidic flavours and to add complexity, a second or malolactic
fermentation can be encouraged (it may occur quite naturally or be brought about artificially).
This converts harsher malic acids to softer lactic ones. Where retaining acidic qualities in the
wine is important (e.g. in warmer climates where the grapes gain greater sugar and fruit flavours
at the expense of their natural acidity) this second fermentation is prevented by removing the
yeasts
and
proteins
needed
to
initiate
it.
5. Maturing
- Clarification
Filtration, centrifuging or fining with bentonite clay (which 'collects' remaining yeasts,
proteins, grape skin particles etc, and precipitates them to the bottom of the vat) are used to
prevent unwanted malolactic fermentation and any further yeast activity once all the sugar in the
wine has been converted to alcohol It also removes substances leading to 'off tastes'. With
clarification the wine gains stability: the processes used for this stabilization, however are quite
aggressive and many believe they lead to flavour loss. Clarification is completed by removing
tartrates from the wine. Modern wineries now use thickly insulated stainless steel vats for cold
stabilization. By cooling the wine to around - 4C, tartrate crystals, which may otherwise form in
the bottle, precipitate and fall to the bottom of the vat. In Germany this process traditionally
occurred in large oak Fuders situated in cellars cool enough for tartrates to precipitate out at
ambient temperatures. After stabilization the wine may be bottled immediately or matured first in
oak
barrels.
- Maturing in Oak
Maturing white wine in new oak imparts flavours which can overpower wines of more
subtle character, but add depth and complexity to others. Older barrels give more moderate
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flavours
and
are
an
option
often
favoured
in
Burgundy.
6. Finishing
- Bottling
During bottling cleanliness is essential: any bacterial activity, which may be encouraged
by warm temperatures- especially when the wine is later transported or shipped for sale- is
prevented by passing the wine through a fine filter. Some producers bottle the wine straight from
its lees after fermentation to retain yeast character and freshness (even a slight spritz). Others,
particularly in the New World, inject CO2 at the bottling stage for the same effect.
INDUSTRIAL PROCESS FLOWCHART
EQUIPMENT FLOWCHART
Fermentation

FERMENTATION OF BEER
DEFINITION OF BEER
A fermented beverage made by the extraction and partial conversion, through malting, mashing
of cereal starch, most often Barley into fermentable sugars. Hops are usually added fermentation, is
performed primarily with yeast, primarily with part of the resulting carbon dioxide retained in the
beverage.
BRIEF HISTORY OF BEER
Ale is one of the oldest beverages humans have produced, dating back to at least the 5th
millennium BC and recorded in the written history of Ancient Egypt and Mesopotamia. As almost any
cereal containing certain sugars can undergo spontaneous fermentation due to wild yeasts in the air, it
is possible that beer-like beverages were independently developed throughout the world soon after a
tribe or culture had domesticated cereal. Chemical tests of ancient pottery jars reveal that beer was
produced about 7,000 years ago in what is today Iran, and is one of the first-known biological
engineering tasks to utilize the process of fermentation. In Mesopotamia, the oldest evidence of beer is
believed to be a 6,000-year-old Sumerian tablet depicting people drinking a beverage through reed
straws from a communal bowl. A 3900-year-old Sumerian poem honouring Ninkasi, the patron goddess
of brewing, contains the oldest surviving beer recipe, describing the production of beer from barley via
bread.The invention of bread and/or beer has been argued to be responsible for humanity's ability to
develop technology and build civilization. The earliest chemically confirmed barley beer to date was
discovered at Godin Tepe in the central Zagros Mountains of Iran, where fragments of a jug, at least
5000 years old was found to be coated with beerstone, a by-product of the brewing process. Beer may
have been known in Neolithic Europe as far back as 5000 years ago, and was mainly brewed on a
domestic scale. Ale produced before the Industrial Revolution continued to be made and sold on a
domestic scale, although by the 7th century AD beer was also being produced and sold by
European monasteries. During the Industrial Revolution, the production of beer moved
from artisanal manufacture to industrial manufacture, and domestic manufacture ceased to be
significant by the end of the 19th century. The development of hydrometers and thermometers changed
brewing by allowing the brewer more control of the process, and greater knowledge of the
results.Today, the brewing industry is a global business, consisting of several dominant multinational
companies and many thousands of smaller producers ranging frombrewpubs to regional breweries.
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[9]
More than 133 billion liters (35 billion gallons) are sold per yearproducing total global revenues of
$294.5 billion (147.7 billion) in 2006.
RAW MATERIALS FOR BREWING
MALT
Malt is a grain product that contributes flavor and color to the beer. Barley is the most commonly used
grain for malting and beer making, but some malts are also made from wheat, rye, and dinkel (spelt
wheat). Malted barley gives beer its color, malty sweet flavor, dextrins to give the beer body, protein to
form a good head, and perhaps most important, the natural sugars needed for fermentation. Malt also
contains small amounts of other sugars, such as sucrose and fructose, which are not products of starch
modification but were already in the grain.
A. BARLEY
Barley a member of the grass family, it is a major cereal grain. It was one of the first
cultivated grains and is now grown widely. It is also the worlds most nutritional crop and is
recommended for beer brewing. This is because barley contains many elements that are rich
sources of health and energy for brewing yeast. The composition of barley, including the
percentage of minerals, gives a general idea about its uses in brewing industry. Barley contains
about
STARCH
SUGARS
B-GLUCANS
PENTOSANS
LIPIDS
PROTEIN
Amino acids and peptides
Nucleic acids
Minerals
62-66%
`1-2%
3-5%
4-7%
2-3%
8-13%
0.5 %
0.2 0.3
2%
HOPS
Hops are the female flowers of the hop plant, Humulus lupulus. It Contains 0.31% volatile oil;
312% resinous bitter principles composed of -bitter acids other resins, some of which are oxidation
products of the - and -acids.They are used primarily as a flavoring and stability agent in beer, to
which they impart a bitter, tangy flavor, though hops are also used for various purposes in other
beverages.
YEAST
Yeast, a single-cell organism, is the sole agent of beer fermentation. During fermentation, yeast
converts sugars in the unfermented beer into alcohol and carbon dioxide.
A. Ale Yeast
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This is a top-fermenting yeast strain that is used to makeales. This yeast rises to the top of the
fermentation tank during fermentation, thus the name "top-fermenting." These work best at relatively
warm temperatures - between 59 and 77F (15 and 25C).
B. Lager Yeast
This is a bottom-fermenting yeast strain that is used to makelagers. This yeast sinks to
the bottom of the fermentation tank during fermentation, thus the name "bottom-fermenting." These
work best at relatively cold temperatures - between 41 and 50F (5 and 10C).
WATER
Finished beer is more than 90% water. The quality and characteristics of the water used for
brewing greatly affects the taste of the finished beer. The amount and composition of dissolved
minerals, such as calcium and magnesium, play a large part the taste of the beer. Brewing water must,
therefore, be clean, healthy, and of the right composition. Of the ions required for brewing, calcium is by
far the most important. This is because of the acidifying effect that calcium has on the wort.
MANUFACTURING OF BEER
RAW MATERIALS CONDITIONING
MALTING
Malting is the process where barley grain is made ready for brewing Malting is broken down into
three steps in order to help to release the starches in the barley. First, during steeping, the grain is
added to a vat with water and allowed to soak for approximately 40 hours, this is done because your
target is to awaken the embryo of the barley, The objective of steeping is to achieve a moisture content
of 46% with a strong uniform growth so when water is added with barley it breaks the wall of the
embryo then as the barley absorbs water it begins to respire, taking in oxygen and exhausting carbon
dioxide (CO2). In order to maintain optimum malting conditions for the barley kernels, the CO2 is drawn
off and replaced with fresh oxygen.. During germination, the grain is spread out on the floor of the
germination room for around 5 days, during this days germination converts the grains starch into sugar
and certain enzymes are formed. It is vital to preserve the enzymes, released through germination,
which enable the final conversion of starch to soluble, fermentable sugar, to be completed during
mashing.
The final part of malting is kilning when the malt goes through a very high temperature drying in a kiln;
The kiln operates much like a conventional oven. Hot air is forced through the green malt, drying and
roasting it so that all biochemical activity stops, and flavor develops, .The drying rate is dependent on
the air-on temperature and air flow, which varies between 45 75 deg. When kilning is complete, the
grains are now termed malt, the temperature the grain is exposed to determines the color and flavor of
the sugar found within the grain. final flavour and colour of the malt is established and the final moisture
content will be below 4.5%.Finally, malted barley contains more endosperm degrading enzymes than
barley, more soluble proteins, amino acids and more colour compounds. This enables greater hot water
extraction of malt sugars and amino acids during mashing, thus producing a greater yield of ethanol
during fermentation
ENZYMES THAT ARE FORMED DURING MALTING
Fermentation

Alpha Amylase
Alpha amylase is an endo acting enzyme that catalyses the hydrolysis of alpha-glucido-(1,4)glucose linkage at random within starch chains. Its not present in the barley but the amount of enzyme
will be produced mainly during second and fourth days of germination and increases throughout the
germination period.
Beta Amylase
Beta amylase is concentrated in the sub-aleurone layer of the barley grain and decline in amount
towards the central endosperm. Its present already in the barley in a bound form. The amount will be
increases considerably on the second and third days of germination and in the later phase will be
slowly decreases. The enzyme formation directly related to the respiration (requires proteolysis). So,
adequate aeration in the first germination phase is very important for malting production.
Limit dextrinase
Because of the alpha-(1,6) bound in amylopectin are not hydrolysed by alpha and beta amylase,
another enzyme is required to hydrolyse these bonds and allow complete conversion of starch to low
molecular weight is limit dextrinase enzyme. For the applications of this enzyme is to increase degree
of fermentability.
MASHING
In brewing mashing is the process of combining a mix of milled grain and water, known as
"liquor", and heating this mixture. Mashing allows the enzymes in the malt to break down the starch in
the grain into sugars, typically maltose to create a malty liquid called wort. There are two main methods
infusion mashing, in which the grains are heated in one vessel; and decoction mashing, in which a
proportion of the grains are boiled and then returned to the mash, raising the temperature. Mashing
involves pauses at certain temperatures (notably 45 C, 62 C and 73 C) [113F, 144F, and 163F],
and takes place in a "mash tun"an insulated brewing vessel with a false bottom. The end product of
mashing is called a wort", In large breweries, in which optimal utilization of the brewery equipment is
economically necessary, there is at least one dedicated vessel for mashing. In decoction processes,
there must be at least two. They practice decoction because of the unique malty flavor it lends to the
beer; boiling part of the grain results in Maillard reactions, The Maillard reaction is a chemical
reaction between amino acids and reducing sugars that gives browned foods their desirable flavor
which create melanoidins that lead to rich, malty flavors.
Fermentation

Temp C
Temp F
Enzyme
Breaks down
40-45 C
104.0-113.0 F
-Glucanase
-Glucan
50-54 C
122.0-129.2 F
Protease
Protein
62-67 C
143.6-152.6 F
-Amylase
Starch
71-72 C
159.8-161.6 F
-Amylase
Starch
FUNCTIONS OF ENZYMES
B-Glucanase is Beta Glucanase enzyme, which can catalyze Beta Glucan in barley plant or
grain sample efficiently into glucose and other low molecular material to reduce the viscosity of the
malt.
Diastatic enzymes
The diastatic brewing enzymes break down and convert starch (the endosperm of the grain)
into fermentable sugars and unfermentable dextrins. We are interested in the two diastatic enzymes
that become active during the mash. These are alpha-amylase and beta-amylase. They work together
to break down long complex chains of soluble (or gelatinized) starch molecules into sugars or
dextrins. Starch molecules are basically just long chains of glucose molecules. But due to the bonds
between them, they are not fermentable. Maltose has two glucose molecules bonded together and is
fermentable. Dextrins have long chains with four or more glucose molecules and are by products of
starch conversion. Dextrins are not fermentable and have no taste. They do however add body and
mouthfeel to beer.Alpha-amylase chops up starch molecules randomly into chunks that beta-amylase
can then work on. Until these molecules are chopped up, they are unfermentable and called dextrins.
What alpha-amylase does is called liquefication. It physically liquefies the starches, making them ready
for further enzymatic activity. Mash schedules that target the alpha-amylase enzymatic action (optimum
at 158F/50C) yield a wort with a high percentage of unfermentable sugars, or dextrins. The beer
produced is very rich, with a thicker body and mouthfeel.Beta-amylase breaks down starch and dextrins
into glucose (one molecule), maltose (two molecules) and maltotriose (three molecules). After betaamylase is through working, the starch has been broken down into fermentable sugar. Mash schedules
that target the beta-amylase enzymatic action (optimum at 140-149F/60-65C) yield a wort that is
highly fermentable. The beer produced will be drier tasting and contain more alcohol.It is important to
understand that although mash enzymes have an optimum temperature, they will work over a wide
range, and most of the time, the activity of enzymes overlap within that range. Both alpha-amylase and
Fermentation

beta-amylase will work well together within the range of 145 to 158F (63-70C). So in general, if you
want a thinner, drier, more alcoholic beer you can rest your mash in the lower portion of this range, and
if you want a richer more dextrinous beer with more mouthfeel and body, you should rest your mash in
the upper portion of this range. A good compromise is made by mashing in the middle, around 152F
(67C).
Mashing involves protein rest
The process of activating the proteolytic enzymes is called the protein rest.
Proteolytic Enzymes
Two groups of proteolytic enzymes are important in the brewing process,
protease and peptidase. Protease breaks down the very large protein molecules into smaller amino
acid chains, which enhances the head retention of beer and reduces haze. The other enzyme is
peptidase. It breaks down the smaller amino acid chains released by protease, but only works from the
ends, releasing nutrients used by the yeast. Most proteins in the wort are not soluble until the wort
reaches the 113-131 range of the protein rest. The two enzyme's temperature ranges overlap, but the
ideal temperature for a protein rest is 122F (50C). The enzymes are denatured by temperatures
greater than 150 F (65C). Its ideal pH range is a little below the normal mash pH of 5.2-5.8, but it
works well enough at this range that you shouldn't worry about lowering the mash pH to accommodate
them.
LAUTERING
Lautering is a process in brewing beer in which the mash is separated into the clear
liquid wort and the residual grain. Lautering usually consists of 3 steps: mashout, recirculation, and
sparging.Mashout is the term for raising the temperature of the mash to 77 C (170 F). This both stops
the enzymatic conversion of starches to fermentable sugars, and makes the mash and wort more fluid.
Mashout is considered especially necessary if there is less than 3 liters of water per kilogram of grain or
if the grain is more than 25% wheat or oats. The mashout step can be done by using external heat, or
simply by adding hot water.Recirculation consists of drawing off wort from the bottom of the mash, and
adding it to the top. Lauter tuns typically have slotted bottoms to assist in the filtration process.
Sparging is trickling water through sugars.
BOILING
After mashing, the beer wort is boiled with hops (and other flavourings if used) in a large tank known as
brew kettle though historically the mash vessel was used and is still in some small breweries The
boiling process is where chemical and technical reactions take place, including sterilization of the wort
to remove unwanted bacteria, releasing of hop flavours, bitterness and aroma compounds
through isomerization, stopping of enzymatic processes, precipitation of proteins, and concentration of
the wort. . Hops lupulin glands produced alpha acids in which the bitter taste of the beer comes from,
the longer the boiling the bitter the beer.
WHIRPOOLING
At the End of the Boil, the wort is set into a whirlpool. The so called teacup effect forces the
more dense solids into a cone in the whirpool tank, simply in this process the hops are separated from
the wort.
Fermentation

WORT COOLING
After the whirlpool, the wort must be brought down to fermentation temperatures (20
26Celsius) before yeast is added. After cooling, oxygen is often dissolved into the wort to revitalize the
yeast and aid its reproduction.
FERMENTATION
After the wort is cooled and aerated usually with sterile air yeast is added to it, and it begins
to ferment. It is during this stage that sugars won from the malt are metabolized into alcohol and carbon
dioxide, and the product can be called beer for the first time. Fermentation happens in tanks which
come in all sorts of forms, from enormous cylindro-conical vessels, through open stone vessels, to
wooden vats.
AGING
After an initial or primary fermentation, beer is conditioned, matured or aged, in one of several
ways, which can take from 2 to 4 weeks, several months, or several years, depending on the brewer's
intention for the beer. The beer is usually transferred into a second container, so that it is no longer
exposed to the dead yeast and other debris (also known as "trub") that have settled to the bottom of the
primary fermenter. This prevents the formation of unwanted flavours and harmful compounds such
as acetylaldehydes.
Krausening
Krusening is a conditioning method in which fermenting wort is added to the finished beer. The
active yeast will restart fermentation in the finished beer, and so introduce fresh carbon dioxide; the
conditioning tank will be then sealed so that the carbon dioxide is dissolved into the beer producing a
lively "condition" or level of carbonation. The krusening method may also be used to condition bottled
beer.
Lagering
Lagers are stored at near freezing temperatures for 16 months while still on the yeast. The
process of storing, or conditioning, or maturing, or aging a beer at a low temperate for a long period is
called "lagering", and while it is associated with lagers, the process may also be done with ales, with
the same results that of cleaning up various chemicals, acids and compounds.
Secondary fermentation
During secondary fermentation, most of the remaining yeast will settle to the bottom of the
second fermenter, yielding a less hazy product.
Bottle fermentation
Fermentation

Some beers undergo a fermentation in the bottle, giving natural carbonation. This may be a second or
third fermentation. They are bottled with a viable yeast population in suspension. If there is no residual
fermentable sugar left, sugar and/or wort may be added in a process known as priming. The resulting
fermentation generates CO2 that is trapped in the bottle, remaining in solution and providing natural
carbonation. Bottle-conditioned beers may be either filled unfiltered direct from the fermentation or
conditioning tank, or filtered and then reseeded with yeast.
FILTERING
Filtering the beer stabilizes the flavour, and gives beer its polished shine and brilliance. Not all
beer is filtered. Filters come in many types. Many are in the form of sheets or "candles". Others use a
fine powder such as diatomaceous earth, also called kieselguhr. The powder is added to the beer and
recirculated past screens to form a filtration bed.Filters range from rough filters that remove much of the
yeast and any solids (e.g., hops, grain particles) left in the beer, to filters tight enough to strain colour
and body from the beer. Filtration ratings are divided into rough, fine, and sterile. Rough filtration leaves
some cloudiness in the beer, but it is noticeably clearer than unfiltered beer. Fine filtration removes
almost all cloudiness. Sterile filtration removes almost all microorganismPACKAGING
PACKAGING
Packaging is putting the beer into the containers in which it will leave the brewery. Typically, this means
putting the beer into bottles, aluminium cans and kegs/casks, but it may include putting the beer into
bulk tanks for high-volume customers.
I. History of Distilled Spirits

The first clear evidence of distilled alcoholic beverages are found in Asia dating to around 800 BC. The
Japanese distilled Shochu from sake (rice wine), Arrack was made in India from a mix of rice and
molasses, and in the Caucasus mountains (modern day Georgia) Skhou was distilled from mares milk.
There are some records pointing to a type of distillation used by the Egyptians to create perfumes, but
the evidence is not conclusive.
Greek alchemists in Alexandria in the first century AD began to improve on just basic steam collecting
devices and developed the first stills. As Europe descended into the Dark Ages it was ironically (Islam
forbids alcohol consumption) the medieval Arabs who continued the distillation research. It would
appear that their research was directed towards perfumes and purifying water rather than creating
alcoholic beverages.In the Middle Ages of Europe the earliest evidence of alcoholic distillation comes
from Salerno in southern Italy in the 12th century. It was not until 1437 however that the production of
brandy (using wine as a base for distillation) is first noted. In the 14th Century the popularity of distilled
Fermentation

spirits rose and were commonly used as medicinal remedies for the Black Death. The basic process of
distillation today has not changed very much since the 9th Century. Many distillers actually prefer
traditional methods to the modern techniques that can also be used. The traditional French alembic
copper pot stills are widespread across Europe and America, the personal touch each of these stills
provides is highly touted and coveted.
II. Companies
Emperador Distillers, Inc.
IBM Plaza
8 Eastwood Ave
Quezon City 1110
Tanduay Distillers
J Nepomuceno
Maynila
San Miguel Brewery Inc.
United Mandaluyong Fire Emergency and Rescue Volunteer Inc.
Pinatubo
Mandaluyong 1550
Ginebra San Miguel Inc.
433 St. Francis Street St. Francis Avenue Ortigas, Metro Manila
III Types of Distilled Spirits

Types of Distilled Spirit
Fermentation
Raw Material
Picture

Brandy
Grapes
Tequila
Blue Agave
Rum
Sugar Cane
Vodka
Fermentation
Potatoes

Gin
Whiskey
Juniper Berries
Grains
IV. Raw Materials

Sugar
In making distilled spirits choosing the appropriate sugar source is first thing to do because your sugar
source will clearly tell what type of distilled spirits you will have when you have done all process needed
to have a certain spirits. Whiskeys, for example, start with a sugar sourced from the starch in cereal
grains (refer to step 3 to learn how starch becomes sugar). The style of whiskey is also largely
dependent on which grains, or combination of grains, are chosen; for instance, Bourbon is a mixedgrain whiskey dominated by corn, while malt whiskeys are produced exclusively from malted barley.
Other spirits such as Brandies are produced from grapes and fruit, Rum is made from sugar cane or
sorghum molasses, and Tequila is made from the sweet nectar of the agave cactus.
Water
Fermentation

The second fundamental raw material, is water. Spirits are commonly 60% by volume, water, as such a
good spirit cannot be made from bad water. At CAS the water used in making our spirits is ultra-purified
using a sophisticated 7 stage treatment process. This level of treatment creates nearly pure H2O, to
which natural minerals are added, carefully adjusting the amount of each mineral to suit the spirit being
distilled.
Yeast
The third fundamental raw material, is the yeast. Yeast, not only creates the alcohol in spirits, but also
contribute in large part to the flavors associated with each spirit. Proprietary yeast strains are carefully
selected, to create unique flavor profiles for each spirit.
V. Unit Processing
A. Preparation of Raw Materials
HARVESTING
Harvesting is the most critical stage in producing distilled spirits because here in harvesting we need to
choose the raw material that will let us have our desired product also in harvesting we need to test the
sugar content of each source of sugar because we dont want a fruit to have small amount of sugar
because that will not make the taste of the spirit good.
B. Conditioning of Raw Materials
COOKING
There are types of distilled spirits that uses cooking to condition the raw material like in tequila and rum.
In tequila the blue agave was burned for 40-72 hours so that the starch content of the blue agave
become a simple sugar, In Rum making they commonly cook the juice they get from the sugar cane to
convert this to molasses
MILLING
Raw materials are typically milled or crushed to make the starches in the grains, or the sugars in the
fruit,readily available for the mashing process and/or fermentation.
Juicing
They commonly do this conditioning with the distilled spirits that uses fruit as the sugar source. Like in
Tequila after they turn the cooked blue agave to fibers they juice it with the use of tahona. In some type
of brandy they also juice the product before they star the fermentation
Fermentation

MASHING
The Mashing Process has two primary functions: first it breaks up and dissolves starches and sugars
into water, secondly it converts any available starch into sugars. Starches are, simply put, long chains
of sugar molecules linked together, like a string of pearls. The Mashing Process breaks the starch into
individual sugars, similar to cutting up a string of pearls. The Mashing Process starts by heating water
to a specified temperature, and then adding milled grains. The mixture continues to heat until, small
crystals of starch in the grains begin to swell, burst and eventually dissolve into the water. Once all of
the starch has been dissolved, it is converted to sugar using natural enzymes (chemicals that act like
scissors) found in malted grains. The final product of mashing is a sweet liquid called called wort.
C. Heart Of The Process
FERMENTATION
The fermentation process varies by distillery, and there's a great deal of variation involved. At one
extreme is "natural fermentation," where yeasts inherent in the environment are relied upon to ferment
the sugars in open vats. At the other extreme, fermentation is tightly controlled under laboratory-like
conditions. For efficiency and predictability, most commercial rum fermentation processes fall between
these two extremes; distilleries purchase and add the specific yeast cultures they want and take basic
precautions appropriate to their environment. Time is also factor for fermentation; some ferments last
only several hours while others can take up to two weeks.
DISTILLATION
Distillation is the name of the process that allows us to separate the alcohol weve made through
fermentation from the rest of the non-alcoholic liquid. This increases the ABV (from say 15% alcohol to
something like 45% alcohol), while also changing the taste, flavour and removing the colour. Continuing
with the wine example if we distil fermented grape juice (wine around 10-15% abv) then we end up
Fermentation

with Brandy (at around 40% abv). The more we distil, or the closer we get to pure ethanol, or 100%
alcohol, the less of the original flavours from the fermentation remain we end up with what we
call neutral spirit, as it is relatively odourless and flavourless.
.
D. Refining Process
MATURING
During maturation, spirits like Whiskey, Brandy, and others, undergo a transformation from a clear spirit,
heavy in grain flavor, to a golden brown spirit complex in flavor. A majority of the flavor, and all of the
color found in aged spirits comes from chemical compounds found in the wooden barrels used to store
the spirits. The most important flavor compounds are created when the barrel is charred. These flavors
include vanilla, caramel, smoke, and spices like cinnamon and cloves. Spirits are sampled regularly to
monitor the maturation process. Once a spirit has been deemed to have reached its peak maturation it
is removed from the barrel and diluted to the appropriate alcohol content for bottling.
BLENDING
The spirits produced by the distillation process are typically too high in alcohol to bottle directly, so the
spirit is transferred to mixing tanks where it is combined with carefully crafted, ultra-pure water. The
mixture is proofed or checked for alcohol content, and adjusted until the alcohol content is suitable for
bottling, or transferring into barrels for maturation. Every batch undergoes a final quality check, based
on it's organoleptic profile (fancy term for taste and smell), before it is approved for bottling.
E. Packaging
BOTTLING
Once the spirits have been blended and proofed to the final alcohol content. They are ready for bottling.
Each bottle is filled and labeled by hand, before being boxed, and sold to one of several retail
establishments ready to be enjoyed in your favorite cocktail.
VII. Process Flow Chart
Fermentation

VIII Flowchart
A. Tequila Process Flowchart
Fermentation

Rum Making
Fermentation

Brandy Making
IX.Equipments:
Coa
Fermentation

A sharp edged blade that is commonly used by farmers to remove the nectar from the leaf so that the
nectar can be processed
Tahona
A Big Rotating wheel that is used to juice the fibers of
agave that will be fermented and turned the juice into
alocoholic beverages after the fermentation.
Juicer
A machine that extracts the juice from the fiber by adding
water while pressing down the fibers.
Distillery
Fermentation
blue
an

Used to increase the alcoholic content of the fermented juice by boiling the mash then when the alcohol
become a vapor the vapor will turn into a liquid because of a condenser.
Fermentation Tank
Fermentation tanks, also called bioreactors, used for
industrial fermentation processes are glass, metal or
plastic tanks, equipped with gages and settings to control
aeration, stir rate, temperature, pH and other parameters
of interest. Units can be small enough for bench-top
applications (5-10 L) or up to 10,000 L in capacity for
large-scale industrial applications. Fermentation units
such as these are used in the pharmaceutical industry for
the growth of specialized pure cultures of bacteria, fungi
and yeast, and the production of enzymes and drugs.
FERMENTATION OF CHEESE
Introduction
A dairy product is food produced from the milk of mammals. Dairy products are usually high
energy-yielding food products. Dairy product, milk and any of the foods made from milk, including
butter, cheese, ice cream, yogurt, and condensed and dried milk. A production plant for the processing
of milk is called a dairy or a dairy factory. Apart from breastfed infants, the human consumption of dairy
products is sourced primarily from the milk of cows, yet goats, sheep, yaks, camels, and other
mammals are other sources of dairy products consumed by humans. Dairy products are commonly
found in European, Middle Eastern, and Indian cuisine, whereas aside from Mongolian cuisine they are
little-known in traditional East Asian cuisine.
Fermentation

Milk has been a part of our nutrition since time immemorial. Around 10 000 BC, the agricultural
revolution occurred changing societies from nomadic tribes to those who settled in communities. With
this came domesticated animals and the ingenuity for people to use by-products such as milk. In
ancient Egypt, milk and other dairy products were reserved for royalty, priests and the very wealthy. By
the 5th century AD, cows and sheep in Europe were prized for their milk.
By the 14th century, cows milk became more popular than sheeps milk. European dairy cows
were brought to North America in the early 1600s. Louis Pasteur, a French microbiologist, conducted
the first pasteurization tests in 1862. Pasteur is credited with revolutionizing the safety of milk and, in
turn, the ability to store and distribute milk well beyond the farm. Commercial pasteurization machines
were introduced in 1895.
In 1884, the first milk bottle was invented in New York state. In the 1930s, milk cans were
replaced with large on-farm storage tanks, and plastic coated paper milk cartons were invented, which
allowed for wider distribution of fresh milk.
Definition of Terms
Fermentation is the decomposition of carbohydrates by bacteria and microorganisms to produce new
products.
Pasteurization is the process of heating a food, which is usually a liquid, to a specific temperature for a
predefined length of time and then immediately cooling it after it is removed from the heat. This process
slows spoilage caused by microbial growth in the food.
Rennet is an enzyme that was traditionally collected from the stomach of a milk-fed calf (natural
rennet). This enzyme is responsible for the coagulation of the milk proteins to produce curds.
Brief History
CHEESE MANUFACTURING
Cheese is an ancient food whose origins predate recorded history. There is no conclusive
evidence indicating where cheese making was originated, either in Europe, Central Asia or the Middle
East, but the practice had spread within Europe prior to Roman times and, according to Pliny the Elder,
had become a sophisticated enterprise by the time the Roman Empire came into being.
The earliest evidence of cheese-making in the archaeological record dates back to 5,500 BCE,
in what is now Kujawy, Poland, where strainers with milk fats molecules have been found. Earliest
proposed dates for the origin of cheesemaking range from around 8000 BCE, when sheep were first
domesticated. Since animal skins and inflated internal organs have, since ancient times, provided
storage vessels for a range of foodstuffs, it is probable that the process of cheese making was
discovered accidentally by storing milk in a container made from the stomach of an animal, resulting in
Fermentation

the milk being turned to curd and whey by the rennet from the stomach. There is a legend with
variations about the discovery of cheese by an Arab trader who used this method of storing milk.
Cheesemaking may have begun independently of this by the pressing and salting of curdled
milk to preserve it. Observation that the effect of making milk in an animal stomach gave more solid and
better-textured curds may have led to the deliberate addition of rennet.
Early archeological evidence of Egyptian cheese has been found in Egyptian tomb murals,
dating to about 2000 BCE. The earliest cheeses were likely to have been quite sour and salty, similar in
texture to rustic cottage cheese or feta, a crumbly, flavorful Greek cheese.
Cheese produced in Europe, where climates are cooler than the Middle East, required less salt
for preservation. With less salt and acidity, the cheese became a suitable environment for useful
microbes and molds, giving aged cheeses their respective flavors.
Cheese Producing Companies

Companies
Brief Information
Eden Cheese is a product of Mondelz
International, a new Company comprised of
the global snacking and food brands of the
former Kraft Foods
Magnolia has been making every meal a

delight for 30 years since it started in 1981 as
a business unit of San Miguel Corporation's
Magnolia Ice Cream Division.
Magnolia entered into a joint venture with New
Zealand Dairy Board (NZDB) in 1987; named
as Philippine Dairy Products Corporation
(PDPC); SMC owning 70% until in July 2002
buying out NZDB share and became Magnolia
Incorporated, a subsidiary of San Miguel Pure
Foods Company.
Alaminos Goat Farm is known in the industry
as the home of the most pampered boer goats
in the Philippines, Managed by Art Almeda, he
imported his first batch of 30 heads of fullblood boer does and two award-winning full-
Fermentation

blood Boer bucks from Southern Australis in
year 2005.
CHEESE MANUFACTURING
Introduction
DIFFERENT KINDS OF CHEESE

Cheese is a
food derived from milk,
produced in a wide range of flavors, textures, and forms. It comprises proteins and fat from milk, usually
the milk of cows, buffalo, goats, or sheep. It is produced by coagulation of the milk protein casein.
Typically, the milk is acidified and addition of the enzyme rennet causes coagulation. The solids are
separated and pressed into final form. Some cheeses have molds on the rind or throughout. Most
cheeses melt at cooking temperature.
Etymology
The word cheese comes from Latin caseus, from which the modern word casein is closely
derived. The earliest source is from the proto-Indo-European root kwat-, which means "to ferment,
become sour.
Classification of Cheese according to Moisture
1. Soft Cheese - examples are Brie, Comembre, Cottage and Cream
Fermentation

2. Semisoft Cheese examples are Limburger, Munster, Port du Salut and Roquefort
3. Hard Cheese examples are Cheddar, Edem, Gruyere and Swiss
Fermentation

4. Very Hard Cheese examples are Asiago, Parmesan, Romano and Sapsago
Cheddar Cheese
Cheddar cheese is a relatively hard, pale yellow to off-white (unless artificially coloured), and
sometimes sharp-tasting, cheese. Originating in the English village of Cheddar in Somerset, cheeses of
this style are produced beyond this region and in several countries around the world.
Raw Materials
Fermentation

1. Milk
The quality of cheese is influenced by the composition and quality of the raw milk. On
the average, , cow milk consists of 3.7% fat, 3.4% protein, 4.8% lactose and 0.7% ash and
has a pH of (6.6). Milk is raw milk (whole or 3.3%). The milk must be "ripened" before adding
in the rennet. The term ripening means allowing the Lactic acid bacteria (LAB) to turn
lactose into lactic acid which lowers the pH of the solution, greatly aiding in the coagulation
of the milk. This is vital for the production of cheese curds that are later formed into
Cheddar. The milk of the cow is used in the production of cheddar cheese.
2. Rennet/chymosin/pepsin
Rennet is an enzyme that was traditionally collected from the stomach of a milk-fed calf
(natural rennet). Animal based rennet typically contains 90% chymosin and 10% pepsin in
purified form and is considered by many cheese makers to be the preferred rennet. Different
ratios are available such as 92-85% chymosin and 8-15% pepsin. This enzyme is
responsible for the coagulation of the milk proteins to produce curds. Cheese produced this
way is neither vegetarian nor Kosher. Coagulation can also be achieved using acids, but
yields lower-quality Cheddar. The two key components of natural rennet are chymosin and
bovine pepsin. Extracts from plants such as nettles were found to produce similar effects,
and have been used in some types of cheese-making (vegetable rennet).
When calf-rennet grew scarce in the 1960s, scientists developed a synthesized type of
Chymosin by fermenting certain bacteria or fungi (microbial rennet), but this also wasn't
useful for all types of cheese-making.[clarification needed] A solution using recombinantgene (GMO microbial rennet) technology was developed and approved by the U.S. Food
and Drug Administration in 1990. This splices the calf-gene for producing chymosin into the
genes of certain bacteria, yeasts or fungi, producing pure chymosin. Rennet is used in the
manufacture of most ripened cheeses to hydrolyze the peptide bond and cause aggregation
of casein micelles.
Cheese Making Reaction
Fermentation

Lactose is the major sugar in human and cows milk (4-8%). Lactose is a disaccharide of two
monosaccharides: galactose and glucose. The term saccharide comes from the Latin (saccharum,
sugar) and refers to the sweet taste of some simple carbohydrates. Monosaccharides (or simple
sugars, as they are sometimes called) are carbohydrates that cannot be hydrolysed to simpler
compounds. Monosaccharides are classified according to the number of carbon atoms present.
Galactose and glucose are both examples of a hexose as they both contain six carbon atoms. Glucose
is the most abundant natural monosaccharide. In lactose, C1 of the galactose unit is linked to the
hydroxyl group at C4 of the glucose unit. During the ripening process (four weeks for Modern
Camembert) a series of chemical and biological changes take place, including: proteolysis, lipolysis and
glycolysis. One of the major products from the glycolytic biochemical pathway is lactic acid. The IUPAC
name of lactic acid is 2-hydroxypropanoic acid. Unlike lactose and its monosaccharide constituents,
lactic acid has a chain structure. The structures of the four organic compounds discussed above are
displayed in the figure below.
Key Idea: In compounds containing

carbon-hydrogen bonds (known as
organic compounds), the carbon
atoms bind to one another through
single, double or triple covalent
bonds to form chains or rings.
Process Flowchart
Fermentation

Unit Operation
Pasteurization
The raw milk is heated from about 10C to at least 72C is held for 15 s, and then is
usually cooled to the separation temperature of about 55C. Pasteurization is carried out to kill
bacteria in the milk. The mass of bacteria in milk is so small that it will be considered
insignificant in this analysis.
Equipment
Pasteurizer
Separation
Fermentation
Mechanism
The
pasteurizer
heats the raw milk
from about 10C to
at least 72C is
held
for
15
seconds, and then
cooled
to
the
separation
temperature
of
about 55C.
Reagent
Used
and Feed
-there
is
no
reagent used in
pasteurization
Product
/
Outcome
-Pasteurized milk
is the product of
this process

Centrifugal separators are used to remove fat from whole milk. Practically all the fat in
milk is contained within fat globules which are surrounded by a protein-based fat globule
membrane. It is more accurate to consider that separators remove fat globules, rather than fat,
from whole milk. The entire fat globule is less dense than the remainder of the milk. Within the
separation process skim milk can be considered as the heavy component and fat globules as
the light component. The heavy stream contains only about 0.06% of the light component while
the light stream (cream) contains a mixture of light and heavy components.
Equipment
Mechanism
Reagent Used and

Feed
Centrifugal Separator
-The fat globules -there

is
no
are separated from reagent used in
the whole milk milk separation.
using
centrifugal
forces. The heavy
milk is tossed to
the side of the
separator and the
cream is siphoned
to be subjected to
different processes
to produce cheese.
Product
Outcome
-Fat globules and

skim milk is the
product of this
process.
Coagulation
Generally 3 to 4 oz. (85 to 110 g) of rennet are added per 1,000 lb. (450 kg) of mix. The
rennet will serve to coagulate the milk protein and form curds. The vat must be mixed
thoroughly after the addition of the rennet to ensure equal mixing, and it also helps to dilute the
rennet to make it easier to spread around.
Pure water is used when diluting the rennet as any pH that is not near 7 will rapidly
decrease the effectiveness of the rennet, as will chlorine. Thus, water with impurities will result
in a vastly decreased yield of cheese.
Fermentation

Equipment
Mechanism
Reagent Used and

Feed
Product / Outcome
Cheese Vat
The rennet will

serve to coagulate
the milk protein and
form curds. The vat
must be mixed
thoroughly after the
addition
of
the
rennet to ensure
equal mixing, and it
also helps to dilute
the rennet to make
it easier to spread
around.
3 to 4 oz. (85 to
110 g) of rennet is
added per 1,000
lb. (450 kg) of mix.
Coagulated milk is
the product.
Pure water is used

when diluting the
rennet as any pH
that is not near 7
will
rapidly
decrease
the
effectiveness
of
the rennet, as will
chlorine.
Setting the curd
Once the rennet is added, the mixture must be allowed to set and form curds. The
mixture is kept at around 29 to 31 C (84 to 88 F). Generally temperature is controlled by
flowing warm water through the jacket of the vat. Setting time varies, and allowing a proper
amount of time is vital. It commonly takes anywhere from 30 to 40 minutes to set the curd.
The most common way to determine when the curd is set is by inserting a flat blade at a
45 degree angle into the curd and raising it slowly. If the curd breaks cleanly leaving a glassy
fracture, it is ready for cutting. In a large Cheddar manufacturing facility, this may also be tested
using a viscometer.
Equipment
Mechanism
Reagent
and Feed
Cheese Vat
The
-there
Fermentation
temperature
Used
is
no
Product / Outcome
The curd texture is the

is controlled by reagent used in
flowing
warm setting of curd.
water through the
jacket of the vat. It
commonly takes
anywhere from 30
to 40 minutes to
set the curd.
product
Cutting the curd
The curd is cut into 0.63-to-1.59-centimetre (0.25 to 0.63 in) cubes using stainless steel
wire knives. A smaller cube size means the cheese will be lower moisture whereas a larger cube
size will result in a high moisture cheese.
It is important that cutting time is minimized and that the cuts be clean. The best way to
determine how efficient the cutting job was is to determine the fat content of the whey. The
optimal level of fat content of whey is 0.3% fat or less.
The curds are handled gently after cutting to prevent fat and protein loss to the whey.
The curd is prevented from sticking to the sides of the vat, but minimal agitation is desired. The
curds are allowed to set again for 10 to 15 minutes. Fat and protein loss may affect the ability of
the cheese to be considered Cheddar cheese, depending on the region where it is created.
Equipment
Mechanism
Stainless Steel Knives
Stainless
steel -there is no reagent
knives are used to used in cutting of
uniformly cut the curds.
curds at various
points during the
process. The device
is
basically
a
Fermentation
Reagent Used and

Feed
Product / Outcome
0.63
to
1.59
centimeter cubes of
curd is the product.

stainless steel frame
with stainless steel
wires, which cuts
the curd cleanly
Cooking the curd
The curd is cooked by adding hot water to the jacket of the vat (up to 39 C (102 F)).
The curd is stirred constantly during this step to avoid uneven cooking or overcooking, and the
cooking will only take 2060 minutes. The whey's pH will be around 6.1 to 6.4 by the end of the
cooking.
Equipment
Mechanism
Reagent Used and

Feed
Product / Outcome
Industrial Mixer
The industrial mixer

constantly
stirred
the curd to have
uniformly
cooked
curds.
-there is no reagent
used
in
milk
separation
Evenly
cooked
curds
are
the
product.
Draining the curd
Fermentation

Whey is removed from the curds by allowing it to drain out of the vat. A gate is generally
present to prevent curds from escaping. When most of the whey is gone, the curds are raked to
either side of the vat, allowing whey to drain down the middle of the two piles.
Equipment
Mechanism
Reagent Used and

Feed
Product / Outcome
Cheese Vat
Cheese
vat
contains two piles
that is used to drain
the whey from the
curd
-there
is
no
reagent used in
milk separation
Dried curd is the

product.
Cheddaring
Cheddaring is the unique step in making Cheddar cheese. It is a multi-step process that
gives Cheddar its unique flavor.
Equipment
Cheddaring Machine
Fermentation
Mechanism
the curd is cut into slabs ab

out 8 inches
wide. These slabs are piled
on one another, usually 4 sl
abs high, and the piles turn
ed
Reagent
Used and
Feed
Product /
Outcome
-there is
no
reagent
used in
cheddari
8 inches
slabs is
the
product

every 10to15 minutes. This
piling increases the weight
on the lower slabs, which
forces more whey from the
product
ng
Setting
The curds are allowed to set until they reach a pH of about 6.4.
Equipment
Mechanism
Reagent Used and

Feed
Product / Outcome
Cheese Vat
The curds are set in

the cheese vat until
they reach a pH of
about 6.4.
-there
reagent
setting.
Curd with a 6.4 pH

is the product.
Milling the curd
Fermentation
is
no
used in

When the turning process is complete, the loaves must be cut down into a size that fits
in the mill. The mill will cut the matted curd into about 1.3 centimetres (0.51 in) pieces. During
this process, the milled curds are constantly stirred to avoid re-matting.
Equipment
Milling
Machine
Mechanism
Reagent
and Feed
Used
The
milling
machine cuts the
matted curd into
about
1.3
centimetres (0.51
in) pieces.
-there
is
no
reagent used in
milling the curd.
Product / Outcome
1.3 centimetre curd

is the product.
Salting
When all of the curd is milled, salt must be added. The amount of salt varies, but it will
be between 1% and 3% by weight. The salt must be mixed thoroughly. Salt helps remove some
of the whey from the cheese which lowers moisture content, adds to the flavour of the cheese
and will also stop the cheese from becoming too acidic, which imparts a bitter taste.
Equipment
Mechanism
Salting Machine
-This
equipment
sprays a specified
amount of salt into
the butter to help
preserve it.
Fermentation
Reagent
Used
and Feed
-there
is
no
reagent used in
salting
Product
/
Outcome
-Cheddar cheese
is the product of
this process

Packaging and Pressing
The curds are placed into moulds that will be used to press the curds and form the
blocks of Cheddar. After this, the cheddar cheese will be aged.
Equipment
Mechanism
Presser
The
curds
are
placed into moulds
that will be used to
press the curds and
form the blocks of
Cheddar.
Fermentation
Reagent Used and

Feed
-there is no reagent
used
in
the
packaging
and
pressing.
Product / Outcome
-Cheddar cheese is
the product of this
process

Aging
Mild Cheddar is generally only aged for one to two months, but mature Cheddar can age
for a year or more, even past twelve years. Aging time depends on the type of Cheddar being
made.
Equipment
Storage
Process Layout
Fermentation
Mechanism
room
-Is basically a
room
of
controlled
temperature
mostly used for
storage of foods.
Reagent Used
and Feed
-there is no
reagent used
in aging.
Product
Outcome
-Cheddar
cheese is the
product of this
process

Fermentation

References:
Fermentation

Bayquen, C. Dairy Products. In C. Bayquen, Industrial Chemical Processes (Food Industries).
"Dairy
Product
Meaning".
Retrieved
on
July
http://www.britannica.com/EBchecked/topic/149947/dairy-product.
Jones, Faro. (1999) Lactobacillus acidophilus.University of Wisconsin-Madison Department of

Bacteriology.
Organic
Chemistry.
"Fermentation".
Retrieved
on
July
1,
2014
http://mv.picse.net/fermentation/cheese-making/assessment-activities/assessment-one/.
The 2004 Old Farmer's Almanac. (2004).
Fermentation
2,
2014
from
from

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