1

Total Brewery
Expertise
Right from conceptualization,
technology, design, plant
engineering upto project
installations - Praj offers
every solution backed up
by expertise and experience.

Brewery
Plants

Hot Processing Brewhouse

Mash Kettle
The aim of mashing is to ensure high extraction rate while
maintaining quality of the extract. Apart from the ingredients
used, parameters like temperature, optimum level of chemical &
bio-chemical conversion, effective mixing with proper agitator design,
vessel wall temperature, appropriate process control and many other
factors have equal impact on quality of wort produced and therefore
on the quality of final product. The mash kettle is specially designed
to handle varying composition of malt and different mashing profiles.

Integrated solutions for brewery plants

Highlights
Kettle equipped with unique Dimple type heating jackets
The uniquely designed agitator profile ensures low shear stress
on Mash
Variable frequency drive for varying agitator speeds

BEER. A drink soaked in tradition of

Exclusive collaboration with Meura (global leader in Mash filtration

malted barley, hops and water.

technology in India) for supply of Mash filters. Today, Praj-Meura

A tradition that has been integrated

has the largest installed reference base in India for Mash filters

with science to deliver varied flavors

and drinking pleasure. And, providing

Beer Filtration and Beer Recovery Systems in association with

seamless integration is what the

Bucher-Filtrox (global leaders in beer filtration technology in India).

PRAJ Brewery Technology Solutions

Around 80% of the beer produced in India is filtered through Praj-

offers. Whether it is a new brewery or

Filtrox filteration plants

an existing one, Praj offers an entire

range of Brewing Equipment, Project

Complete Yeast Management Solutions, Fermenting Tank Farms,

Management Services & Solutions -

Bright Beer Tanks and CIP Systems designed and sized to meet

right from conceptual study to plant

varied process requirements of different brands and brewers.

installation to commissioning along

with many value added services

Brewery Solutions and plant performance guarantees compliance

with the international standards such as DIN 8777, EBC and MEBAK

Highlights:
Energy savings systems such as
Heat Recovery system and Wort
Flash System in the Brewhouse
Mash filter based brewhouse for
higher productivity, larger volumes
and increased brewhouse yield

Linear mash temperature increase with uniform heat distribution

The final beer quality and the overall plant output depends upon the
Lauter Tun performance and that is why it is called the heart
of brewhouse.
Highlights:

Advantages
Intimate mixing of water and grist
to ensure homogenous mash from
the start
Uniform Heating & temperature
distribution with specially
designed heating jackets
Innovative agitator design ensures
homogenous mash mixing and
proper sacchrification throughout
operation
Flexibility to process different
varieties of Malts
Low shear mash produces clear
and improved quality wort and
eases lautering operation

Lauter Tun

Higher filtration area as compared to conventional lauter tuns

Simple trouble-free mechanism for

spent grain removal

Innovative design of Raking Arm with Variable Frequency Drive for

adjusting speeds during Mash intake, Bed cutting and Spent grain
discharge

Mechanically operated Latching/

Delatching for spent grain
removal.

Adjustable location of knives in horizontal plane with zigzag and

straight knives
Specially designed Cup type arrangement which ensures uniform
Wort run off across the lautering bed.
False bottom flushing nozzles with built-in check valves and special
pop-up nozzles for thorough cleaning of the underside
Placement of Wort Collection and flushing nozzles backed up by
process calculations.
Special sparging system ensures gentle and even distribution with
effective leaching of wort
Air free lautering consisting of closed loop ring pipe wort
collection system.

Advantages:
High extract efficiency
Higher filtration area ensures
lower cycle times
Low oxygen pickup
Flexibility to take various
raw material with different
configurations
Clear and improved quality wort
production Improved Beer

Whirlpool

Mash Filter
Praj, in association with Meura,
Belgium (world leaders in Mash
Filtration technology) offer high
efficiency Mash Filters in India
and subcontinent. The Mash Filter
option is most suitable for large
capacity breweries and for different
types of raw material configuration.

Highlights of Mash Filter :

High productivity (upto 14 brews/day)
High extract yields (practical yield at least equal or greater than the
lab yield)
Very Bright Worts with low solids content < 5ml/l
Acceptance of high proportion of Adjuncts (upto 100 % with the use
of exogenous enzymes)

The hot break formed during the wort boiling process has to be
separated from the wort. Efficient trub separation is the prime
function of any whirlpool. Apart from trub separation removal of the
unwanted volatiles like DMS also takes place in the whirlpool.

Highlights
Sloping bottom and inverted cone design ensures efficient
trub separation
Tangential entry of wort at optimum velocity helps keep the trub
particles intact
2/3 wort outlets maintains the trub cone till the end of wort cooling
High flowrates decreasing at the end of the wort cooling to ensure
less disturbance to trub cone

Wort Kettle

Wort Boiling is regarded as the turning point in the brewing of Beer.

Any change in boiling practice is to be monitored carefully and
thoroughly to ensure they do not affect the quality and flavour of
the final beer. Generally boiling wort at, or near, normal atmospheric
pressure gives the most acceptable results.

Wort Aeration System

The specially designed, ventury
type aeration nozzle, creates a slight
vacuum which draws the oxygen into
the unit. This action causes a very
fine spreading of oxygen bubbles
over a very large contact area, which
can then react with the wort.

Automatic trub cleaning device ensures full cleaning with less

water consumption

Option of complete, automatic

standalone Wort Aeration skid

Large surface area due to tangential entry allows for escape of the
unwanted volatiles

Easy installation and

interconnection in the existing
brewhouse

Advantages
Effective trub separation
Compact Trub Cone formation

Control based on the Wort

DO level

Lower levels of suspended solids in final worts

Unwanted Volatiles stripping

Unique Features of
PRAJ WORT KETTLE
Options of External as well as
Internal wort boiling system (Praj
e-COMBOILER)
Variable speed control of wort
circulation pump provides gentle
handling of wort & helps in
maintaining hot break together
The special design fountain entry
of wort provides the large surface
for the volatiles removal
Low pressure steam and hence
lower temperature difference
reduces the thermal stress
exerted on wort

Lower heat flux and Optimum heat transfer area ensures more
number of brews between cleaning
Less energy consumption and Heat recovery system as an
add on module
Advantages:
Low energy consumption compared to conventional
boiling systems
Excellent volatiles stripping capability
Improved hops Utilization

WORT COOLER - Single stage Heat Exchanger

Single-stage wort cooling with precooled brewing water ensures that
the wort is cooled to the pitching temperature in one pass. So the total
heat used is returned to the brewing process again. Wort to chilled
water ratio is optimized to reduce chilled water consumption and
reduce the refrigeration load.

Cold Process Area

Effective hot break formation Low shear - vigorous boiling

Lower TBU increase means Lower thermal degradation of wort
Lower DMS values

Yeast Management
Praj offerings include :
Yeast Propagation systems with 2 stage and 3 stage
propagation facility
Yeast storage section with hygienic design agitator
Beer Filtration
While beers differ primarily in clarity and in original gravity, color and
taste, it is the filtration technique that sets your beer apart.

PRAJ, in association with BucherFiltorx of Switzerland, offers

comprehensive range of filtration
products for sterile, hygienic filtration
to ensure clear and bright beer.

The range :
Candle filter for Kieselgur filtration
Pre coat candle filter for
stabilization of beer with PVPP
Module/sheet filter for polishing
of beer
Salient Features of Filtrox Filters:
New SYNOX 2.0 PF /PS filter
series which supersedes
FILTROjet, (was a best-selling
candle filter worldwide) Industrial
machines between 30 and 1,200
hl/hr in operation
Patented STABOX 25 mm
candle to maximize available
sludge volume and minimizing
turnaround timings
New and Patented JETCONTROL
2.0 inlet distributor

New total drain system TDS with scavenge pipe inserts.

Value Added Offerings Systems

SYNOX 2.0 PS Candle Filter for PVPP stabilization ensures fast

turnaround time and low PVPP losses.

Brewhouse Heat recovery System

Fermentation & Lagering

Prajs Fermentation system is characterized by specially designed
fast chilling jackets for varying duties. The unitanks are designed as
per ASME/ AD Merkblatter standards. Most optimum and consistent
cooling duties are achieved with both Glycol and Ammonia
cooled Unitanks.
Embossed type cooling jackets of the Unitanks ensures :
High heat transfer coefficients
Parallel Coolant flow and lower pressure drops

Waste energy recovery from brewhouse thereby driving down energy

use by 25%.
Multiple references of different Brewlengths
Complete automatic standalone Wort Aeration skid which can be
easily integrated with existing brewery with Control based on the
Wort DO level
Complete automatic standalone Beer Carbonation skid with control
system based on beer carbonation level.
Beer Recovery System from surplus in collaboration with
Bucher-Filtrox

Pulse TIG welding technique for less heat input and hence less
distortion.
Spot radiography of all weld joints full radiography of weld joints
covered by the jacket and dished end.

Manufacturing

Tank design facilitates proper Yeast settlement and Yeast cropping

Total covered area of 2, 00,000 sq. ft. and open area of

3,40,000 sq. ft.
Accredited with ASME U & H stamp, ISO 9001- 2000 certification
& CE marking.
Codes and standards followed include ASME Section VIII,Div.1,
BS 5500, ASNI (SNT-TC-IA 1984 & 1988), TEMA, DIN, IS 2825 and
AD Merkblatter.

Cleaning In
Place (CIP)
Systems

Brewhouse vessels, piping

and valves

Wort Flash Evaporation System

in the Brewhouse: With just
4% evaporation in Wort Kettle
followed by 2% evaporation in
flash vessel under vacuum with
quality conformance to the desired
analytical results.

Low Coolant hold up

Well equipped manufacturing facilities with automatic welding and

polishing machines.

Automated cleaning and

disinfections, with either
recovery or disposal of the
cleaning liquid is another
crucial step in beer production.
An integrated four loop CIP
system, incorporating water,
caustic and acid is provided
for the following:

Yeast Drying System: Double

Drum Dryer which ensures no
spillage of liquid yeast and
hence does not require any yeast
recycling system

Working in various grades of Stainless Steel, Copper, Carbon steels,

Nickel, Titanium, Hastalloy and other exotic materials
Large pool of approved vendors
Stringent raw material testing methods
Effective supply chain management.
Wort cooling and treatment equipment, piping, valves and pumps
Yeast vessel, fermentation/lagering tanks, piping, valves and
pumps
Filtration equipment, bright beer tanks, bottle filling machine,
piping, valves and pumps
The CIP system is fully automated, sequenced system with the option
of manual intervention or a semi-automatic system. All process
equipment are provided with in-built cleaning systems to facilitate
thorough cleaning. Options like stationery/rotating spray balls, spray
nozzles, tank cleaning machines, cleaning turbines are carefully
selected to suit specific requirements.

Well laid out Quality System

HSE practices in line with international standards
Plant Engineering :
Our core strength
Engineering forms the backbone of our delivery program. We follow
stringent international standards like DIN 8777 for brewhouse
performance, ASME, ADMerkblatter for pressure vessels, ISA and
CE standards. The design team works with customers to identify
the need for design enhancement in various systems with a view to
reduce energy and other operating costs. This provides a competitive
advantage to our customers.

Project Management
Project management is the key
strength of PRAJ handling projects.
Timely and smooth completion of
the projects are an essence of
PRAJ Project Management.
PRAJ has a strong pool of project
managers with experience of
working on a global scale. The
Project managers are well trained
with many of them certified
Project Management Associate
(CPMA), who have passed
International Project Management
Association - Level D Examination,
Switzerland. The site team
has significant experience and
knowledge on the local conditions.

Utilities
We provide engineering and
integration package for utilities
along with the process plant. We
also provide complete project
management package including
procurement assistance, expediting,
inspection, supervision of installation
and commissioning.
The utilities include:

of the brewer and operating personnel. The automation system

can be customized to the highest level based on specific process
requirement such as recipe management, safety interlocks, real time
data management, security management etc. The automation system
can also be offered with an open technology platform, which permits
connectivity to third party applications and ERP systems.
Praj Matrix - Innovation Center
Brewery Laboratory following EBC standards
State of the Art own R&D facility for Brewery Analysis in India.

Steam generation and distribution

11 laboratories - 2 labs as per 10,000 clean area classification

Refrigerationplant

Staff Includes - 80% PhD holders and 20% Graduates

Water storage, treatment plant

and distribution

Analysis facility from Raw material to final product

Compressed Air plant CO2

Rcovery, purification, liquefaction,
storage and distribution plant
Wastewater (effluent)
treatment plant
Packaging-hall equipment
Plant Electricals
Process Control & Automation
Brewing is a critical bioprocess
and hence it is essential to monitor
each and every step in brewing. To
simplify all steps of monitoring, we
offer process control and automation
right from malt reception to the
tank farm/cellar upto bottling. Plant
can be offered with different levels
of automation to suit the needs

Praj Worldwide

Brewery
Plants

Standards Followed include EBC, ASBC and MEBAK

Global Alliances
Meura
Mash Filters. Keeping in mind the need for rapid expansion of
capacity, as well as higher capacities being planned by new breweries,
Praj provides Mash Filters in alliance with Meura, Belgium for
India and Subcontinent. The Meura range of filters can replace the
traditional Lauter TunsThe Meura range can be most appropriately
designed for brewery capacities higher than 0.5 million HLPA.
Bucher Filtrox
Beer Filtration systems:. Bucher -Filtrox filters are the most preferred
filters in Breweries. Having completed over 18 years of co-operation in
the India, Praj and Filtrox have commissioned more than 40 Filtration
plants in India. Over 80 % of Beer produced in India is filtered through
the Praj Filtrox candle filters.Praj along with Bucher Filtrox also
offers Beer recovery systems from surplus yeast, using cross flow
membrane filtration (CMF) technology.

Argentina I India I South Africa

The Netherlands I Thailand I UAE I USA

Praj Industries Limited

Praj Tower, 274 & 275,
Bhumkar Chowk - Hinjewadi Road,
Hinjewadi, Pune 411 057. India
info@praj.net | www.praj.net