cRADICO - PROCESS OUT FLOW

A UNIT OF BEVERAGE INDUSTRY OF

INDIA´

SUBMITTED TO : SUBMITTED BY:

Dr. S. K. Dubey Puneet Sharma(BM-08134)
Faculty, IMS. Ritesh Baliyan(BM-08150)
Rohit Yadav(BM-08156)
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History of distillation begins in the ancient Egypt. This technique was used
mainly for the production of perfumes.
First traces of distilled barley go back to the XIIth century.
Origin of the name "Whisky"
 The name of the "water of life" produced in Scotland and Ireland comes
from the Celtic, which have been official languages for ages.

 Before bearing the name of " 
" (or whiskey if it is produced in

Ireland or in the United States), the drink was called "



"(pronounced oos-kee-BAW or whis-kee-BAW) , which means
"Water of Life" in Celtic.

 The name evolved to become  

 , then 
 and finally 
.
 Radico Khaitan Ltd Plant(Rampur) :

Business Operation : Liquor

Background:
 adico Khaitan Ltd (adico Khaitan) was established in 1943 as ampur
Distillery.
 It entered the branded liquor segment in 1998; and subsequently, in 1999,
the company launched its flagship brand 8PM.
Business Profile:
 adico Khaitan¶s product range comprises
 Whiskey,
 um,
 Vodka,
 Gin, and Brandy.
 Brands include:

 8PM Whiskey,

 Contessa um,

 Old Admiral Brandy, and

 Magic Moments Vodka.

 It Has A Distillery At ampur, UP And Operates Bottling Plants Spread Across

ajasthan, Uttarakhand, And AP.

 Installed Capacity Of 60,000 KL Of ectified Spirit And 460 KL Of Malt Spirit.

 adico Khaitan Exports Products To Foreign Markets Like Africa, The Middle East,
Eastern Europe Etc.
Y


 Molasses Distillery 60 million litres per annum.

 Grain Distillery 30 million litres per annum,

 Malt Distillery 460 thousands liters per annum.

 The overall licensed capacity has been increased to 125 million liters per
annum.
  
 

 Barley

 Water: Water is another of the most important ingredients in the making

process of whisky.

 The quality of the whisky depends on the quality and purity of the water

 Yeast: `east (brewer's yeast, often mixed with culture yeast) will start the
fermentation process
 ÷
    

 The making process of whisky takes at least 3 years.

 If a grain (malted or not) spirit did not stay for at least 3 years in an oak
cask, it does not deserve the name of whisky.

Steps For Production Of Whiskey

1. Preparing the grain:
       

   

2. All grains except barley are first ground into meal in a gristmill. The meal
is then mixed with water and cooked to break down the cellulose walls that
contain starch granules. This can be done in a closed pressure cooker at
temperatures of up to 311iF (155iC) or more slowly in an open cooker at
212iF (100iC).
 Instead of being cooked, barley is malted.

 The first step in malting barley consists of soaking it in water until it is thoroughly
saturated.

 It is then spread out and sprinkled with water for about three weeks, at which time it
begins to sprout. During this germination the enzyme amylase is produced, which
converts the starch in the barley into sugars.

 Drying the barley and heating it with hot air from a kiln halt the sprouting. For
whiskey, the fuel used in the kiln includes peat, a soft, carbon-rich substance formed
when plant matter decomposes in water.

 The peat gives whiskey a characteristic smoky taste. The malted barley is then
ground like other grains.
   

 Mashing consists of mixing cooked grain with malted barley and warm
water.

 The amylase in the malted barley converts the starch in the other grains into
sugars.

 After several hours the mixture is converted into a turbid, sugar-rich liquid
known as mash. (In making malt whiskey the mixture consists only of
malted barley and water.

 After mashing the mixture is filtered to produce a sugar-rich liquid known

as wort.
 Fermenting
 The mash or wort is transferred to a fermentation vessel,

 These vessels may be made of wood or stainless steel.

 `east is added to begin fermentation, in which the single-celled yeast

organisms convert the sugars in the mash or wort to alcohol. The yeast may
be added in the form of new, never-used yeast cells (the sweet mash
process) or in the form of a portion of a previous batch of fermentation (the
sour mash process.)

 The sour mash method is more often used because it is effective at room
temperature and its low pH (high acidity) promotes yeast growth and
inhibits the growth of bacteria. The sweet mash method is more difficult to
control, and it must be used at temperatures above 80iF (27iC) to speed up
the fermentation and to avoid bacterial contamination. After 3 or 4 days, the
end product of fermentation is a liquid containing about 10% alcohol .
 Distilling
 The wash is heated so that most of the alcohol (which boils at 172iF
[78iC]) is transformed into vapor but most of the water (which boils at
212iF [100iC]) is not

 This vapor is transferred back into liquid alcohol in a water-cooled

condenser and collected.

 This consists of a tall cylindrical column filled with a series of perforated

plates. Steam enters the still from the bottom, and distiller's beer enters
from the top

 The product of the initial distillation²known as low wine²is distilled a

second time to produce a product known as high wine or new whiskey,
which contains about 70% alcohol.
 Distillers remove bad-tasting congeners (usually aldehydes, acids, esters,
and higher alcohols) in various ways.

 Some congeners boil at a lower temperature than alcohol and can be boiled
off

 Some are lighter than alcohol and will float on top, where they can be
poured off.
 Ê

 Whiskey is aged in wooden barrels, usually made from charred white oak.
White oak is used because it is one of the few woods that can hold a liquid
without leaking but which also allows the water in the whiskey to move

back and forth within the pores of the wood, which helps to add flavor

 The aging process is a complex one, still not fully understood, but at least
three factors are involved

1. First, the original mixture of water, alcohol, and congeners react with each
other over time.

2. Second, these ingredients react with oxygen in the outside air in oxidation
reactions.

3. Third, the water absorbs substances from the wood as it moves within it.
(Charring the wood makes these substances more soluble in water.)
 BLENDING
 They are produced from single batches and are ready to be bottled straight from the

barrel. All other whiskeys are blended

 Often neutral grain spirit is added to lighten the flavor, caramel is added to
standardize the color, and a small amount of sherry or port wine is added to help the

flavors blend

 Blending is often considered the most difficult and critical process in producing
premium Scotch whiskeys. A premium blended Scotch whiskey may contain more
than 60 individual malt whiskeys, which must be blended in the proper proportions
 BOTTLING
 Glass is always used to store mature whiskey because it does not react with
it to change the flavor

 Modern distilleries use automated machinery to produce as many as 400

bottles of whiskey per minute

 The glass bottles move down a conveyor belt as they are cleaned, filled,
capped, sealed, labeled, and placed in cardboard boxes

 The whiskey is ready to be shipped to liquor stores, bars, and restaurants.

 Èuality Control
 There are certain basic precautions that all whiskey makers take to ensure
quality.

 The water used must be taken from an appropriate natural source. It must
be filtered so that it is free from organic matter.

 The grain used must be very clean. It is also passed through screens to
eliminate grains that are too small.

 The yeast is carefully grown to avoid contamination by other

microorganisms.

 The temperature of distillation is monitored with thermometers in the

boiling liquid, which are visible through glass windows in the still.

 During aging, samples of whiskey are evaluated by experienced tasters to

determine if it is mature.
 ›

  Ê

      
 Effluent Treatment Plant
 The Distillery complies with Zero Discharge concept set up by CPCB.

 Primary Treatment of the Effluent yields Bio Gas, which is used as fuel in
Cogen Boiler to generate steam and then Power through a backpressure
Turbine.

 Environmentally Friendly
 Meeting out 100% Pollution Control norms, the Treated Effluent is not
discharged outside and in turn is mixed and cured with organic mass like
Press Mud of Sugar Mills and suitable organic manures to manufacture Bio
Manure or Bio Compost, a bio fertilizer used successfully in growing the

crop of sugar canes etc.

 Cogeneration Plant

 The cogeneration plant of ampur Distillery consist of 26 MT capacity

India's first stand alone Bio Gas fired steam boiler and 2 MW Turbine
Generator in tandem to make adico Khaitan self reliant on its requirement
for power for its normal operation.

 Backward Integration


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