Std. Oper. Proc.

PBBR/UBL/OPM: B-11005
Operating & Maintenance Manual

Project Code: B-11005
STANDARD OPERATING PROCEDURE
United Breweries Limited, Nanjangud.
Page 1 of 11
STEP NAME: CIP YEAST TANKS
STEP DESCRIPTION: CIP OF YEAST TANKS
CIP OF YEAST PROPAGATOR

1. Connect CIP supply swing bend on flow plate to Yeast tank top line (Refer CIP flow sheet of Yeast
tank).
2. Connect hose pipe from yeast tank bottom outlet to suction of CIIP return pump.
3. Isolate bunging device on CIP line.
4. Connect hosepipe from the CIP return pump discharge to CIP return header.
5. Open the valves on the CIP supply line.
6. Start CIP supply pump.
7. Open all the valves on CIP return pump suction.
8. Open valves on CIP return pump discharge side.
9. Start CIP return pump.
10. A flow rate of 9 m3/h and a pressure of 2 bar (g) at the spray ball inlet to be maintained during CIP.
This means a pressure of @ 2.5 bar (g) to be maintained on the pressure gauge provided on the
tank top line.
Page 2 of 11
STEP NAME: YEAST PROPAGATOR WORT FILLING

STEP DESCRIPTION: YEAST PROPAGATOR WORT FILLING
YEAST PROPAGATORS WORT FILLING :

1.
Connect Swing bend from Yeast propagator bottom nozzle to wort supply on flow plate and open
manual valves.
2.
Open valve below yeast propagator on tee connection.
3.
Start hot water pump.
4.
Drain hot water and sterilize the line with hot water.
5.
Stop hot water pump.
6.
Start De-aerated water / chilled water transfer pump.
7.
Fill the complete wort line with De-aerated water / chilled water.
8.
Stop the De-aerated water / chilled water transfer pump.
9.
Keep open the Bunging device outlet.
10.
Start wort cooling pump (From Whirlpool to Unitank).Drain the water in the pipeline through the Tee
connection (drain valve) provided below the Yeast Propagator.
11.
Drain the water.
12.
Take the wort into Yeast propagator as per requirement.
13.
Stop wort transfer pump.
14.
Close valve below yeast propagator bottom wort inlet and open drain valve on tee connection.
15.
Start De-aerated water / chilled water transfer pump.
16.
Fill the complete wort line with De-aerated water / chilled water.
17.
Stop the De-aerated water / chilled water transfer pump.
18.
Start hot water pump.
19.
Sterilize the line with hot water.
20.
Stop hot water pump.
Page 3 of 11
STEP NAME: WORT STERILIZATION
STEP DESCRIPTION: WORT STERILIZATION
WORT STERILIZATION
1.
After filling of wort in yeast propagator I, apply heating to boil the wort for sterilization. (From
80C to 980C).For sterilization open valve on yeast propagator tank top line on flow plate.
2.
Open valve on steam inlet & condensate outlet on cone jacket of yeast propagator.
3.
Open valve on steam supply header of yeast section.
4.
Drain the condensate before control valve through drain point.
5.
Set temperature in temperature control loop of yeast propagator to 98 0C.
6.
Activate temperature control loop.
7.
Check physically for condensate removal.
8.
When temp reaches 980C deactivate temperature control loop.
9.
Close valve on steam supply on cone jacket & header to yeast section.
10.
Drain all condensate through trap by pass line.
11.
Start cooling with propylene glycol (33 % w/w) from 980C to 80C.
12.
Open valve on glycol supply header to yeast section.
13.
Open glycol inlet & outlet valve on shell jacket of yeast propagator.
14.
Set temperature in temperature control loop of yeast propagator to 8 0C.
15.
Activate temperature control loop.
16.
When temp reaches 80C deactivate temperature control loop.
17.
Close valve on glycol inlet & outlet on shell jacket.
18.
Pass the yeast from Carlsberg flask to yeast propagator with sterile air.
19.
Set pressure on bunging device 0.5 kg/cm2 (g) and open bunging device outlet valves.
20.
Connect swing bend on sterile air supply to yeast propagator tank top line and open manual
valve.
21.
Start aeration through wort aerator provided on cone of yeast propagator.
Page 4 of 11
22.
Set the sterile air flow rate as per requirement.
23.
Set temp as per brewers requirement in temperature control loop. Open manual valve on
glycol inlet & outlet on shell jacket.
24.
Check the yeast cell count every day.
25.
Once the yeast propagation is complete in yeast propagator I, take required quantity of wort in
yeast propagator II.
26.
Sterilize the wort & cool it.
27.
When required temperature is attained in yeast propagator II, transfer yeast from propagator I
to II.
28.
Continue propagation in propagator II.
29.
Once the propagation is complete in yeast propagator II, take required quantity of wort in
yeast propagator III.
30.
Sterilize the wort & cool it.
31.
When required temperature is attained in yeast propagator III transfer yeast from propagator II
to III.
32.
Continue propagation in propagator III.
33.
Once the propagation is complete, Yeast is ready for transfer
Page 5 of 11
STEP NAME: YEAST TRANSFER

STEP DESCRIPTION: YEAST TRANSFER
YEAST TRANSFER FROM YEAST PROPAGATOR TO YEAST
STORAGE TANK / PITCHING TANK :1.
Connect swing bend for yeast transfer from yeast propagator outlet to yeast supply header to
yeast storage tank / pitching tank & open manual valve.
2.
Connect swing bend for yeast inlet on yeast storage / pitching tank on flow plate from yeast
supply header from yeast propagator & open manual valves.
3.
Connect hose pipe from hot water header to yeast propagator bottom nozzle on tee
connection below sight glass.
4.
Open drain valve on yeast storage / pitching tank on tee connection before sight glass.
5.
Sterilize the line by passing hot water followed by chilled water.
6.
Set pressure on bunging device & keep bunging device outlet valve open.
7.
Connect swing bend on the Flow Plate from sterile air supply to Yeast propagator tank top &
open manual valves.
8.
Increase pressure in yeast propagator up to 1.5 kg/cm 2.
9.
Open valve on yeast transfer line from yeast propagator to yeast storage / pitching tank.
10.
Open valve below yeast propagator & transfer yeast from yeast propagator to yeast storage /
pitching tank.
11.
Drain water hold up from line through valve below yeast storage / pitching tank when yeast is
seen in sight glass open yeast inlet valve below yeast storage / pitching tank and close drain
valve on tee connection
12.
At the end of transfer, chase the transfer line with chilled water followed by hot water to
sterilize line.
13.
Depressurize the yeast propagator slowly.
STEP NAME: YEAST PITCHING.

Page 6 of 11
STEP DESCRIPTION: YEAST PITCHING

YEAST PITCHING FROM YEAST STORAGE TANK / PITCHING TANK:1.
Ensure sufficient yeast is ready in Yeast Storage / pitching tank for transferring yeast to Wort line.
2.
Set pressure on bunging device.
3.
Connect swing bend on the Flow Plate from sterile air supply to yeast storage / pitching tank top
& open manual valves.
4.
Connect swing bend on flow plate to connect tank bottom outlet for yeast supply and open
manual valves on flow plate.
5.
Open valves on yeast pitching pump suction line.
6.
Open valves on the discharge of the yeast pitching pump.
7.
Sterilize the yeast pitching line.
8.
Start yeast pitching pump.
9.
Yeast pitching rate is 15 to 20 hl/hr.
10.
When the required quantity of yeast is pitched into Wort, stop yeast pitching pump.
11.
Close yeast pitching pump discharge valve immediately.
12.
Close valves on pump suction line.
13.
Depressurize the Yeast Storage Tank (Release the pressure slowly through Bunging device).
14.
Flush the yeast holdup in the line to gutter.
STEP NAME: YEAST COLLECTION
Page 7 of 11
STEP DESCRIPTION: YEAST COLLECTION
YEAST COLLECTION FROM UNITANK :1.
Set pressure on bunging device
2.
Connect swing bend from CO2 supply to Unitank Top and bunging device outlet to CO 2 collection
header on the Unitank flow plate & open manual valves.
3.
Connect hosepipe from Unitank bottom outlet to Yeast cropping Pump suction.
4.
Connect hosepipe from yeast cropping pump discharge to yeast transfer line in the Unitank
section.
5.
Increase pressure in Unitank up to 0.5 kg/cm 2 (g).
6.
Connect the Swing bend from Unitank Yeast supply header to yeast storage tank bottom yeast
inlet on flow plate, Open manual valves on flow plate & open drain valve on tee connection below
yeast storage tank.
7.
Connect the swing bend to the valves on the Hot CIP supply header & tee connection on Unitank.
8.
Connect a hosepipe from tee connection on yeast storage tank bottom & gutter in the yeast
section.
9.
Do hot CIP of yeast transfer line & sterilize the line.
10.
Open valve on Unitank bottom outlet nozzle.
11.
Start Yeast Cropping pump.
12.
Drain chilled water through drain valve till the yeast is seen in the flow glass below the yeast
storage tank.
13.
Close drain valve on the tee connection below yeast storage tank (drain).
14.
Open valve on the yeast storage tank bottom yeast inlet.
15.
After completion of yeast collection (decided by the brewer by observing the sight glass of the
Unitank bottom),
16.
Close valve on Unitank outlet.
17.
Chase the line with chilled water.
18.
When water is seen in the sight glass below the yeast storage tank, open drain valve on the tee
connection below yeast storage tank (drain) and close valve on the yeast storage tank bottom
yeast inlet.
Page 8 of 11
19.
Stop yeast cropping pump.
20.
Close the valves on transfer line.
21.
Close the valves on the flow plate.
Maintaining Yeast Temperature :1.
Set the required temperature in TIC of yeast storage tank.
2.
Ensure that the manual inlet & outlet valves on the Glycol header are open.
3.
Open valve on the glycol supply line to yeast storage tank.
4.
Ensure that air is vented out of the jacket and glycol line by opening the vent valve before glycol
circulation.
5.
Activate temperature controller to open control valve.
6.
To vent air, close valve on glycol return line.
7.
Open the Vent valve.
8.
Start glycol supply. When the glycol comes out of the air vent, close vent valve on glycol return
line.
9.
Open valve on the glycol return line.
10.
Timer to be set for approx. 5 minutes for yeast agitator.
STEP NAME: GLYCOL CIRCULATION (VENTING OF JACKETS)
Page 9 of 11
STEP DESCRIPTION: GLYCOL CIRCULATION IN YEAST TANK
GLYCOL CIRCULATION (VENTING OF THE JACKETS):1.
Set the temperature of Wort / Yeast to be maintained in Yeast Tank.
2.
Activate the temperature control loop after wort filling.
3.
During start up the air inside the jacket and pipelines to be vented out. Following steps to be
followed for venting the air.
4.
Keep the jacket vent valve crack open.
5.
Keep the valve on the glycol return line closed.
6.
Open the glycol supply valve to the jackets and start glycol circulation.
7.
Vent air completely from the jacket vent.
8.
When glycol starts coming out of vent valve, close vent valve and open glycol return valve.
9.
Vent valve should always remain closed once the air is vented out.
Page 10 of 11
Page 11 of 11

Std. Oper. Proc.

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PBBR/UBL/OPM: B-11005

Operating & Maintenance Manual

STANDARD OPERATING PROCEDURE

United Breweries Limited, Nanjangud.

STEP NAME: CIP YEAST TANKS

STEP DESCRIPTION: CIP OF YEAST TANKS

CIP OF YEAST PROPAGATOR

United Breweries Limited, Nanjangud.

STEP NAME: YEAST PROPAGATOR WORT FILLING

YEAST PROPAGATORS WORT FILLING :

Open valve below yeast propagator on tee connection.

Start hot water pump.

Stop hot water pump.

Start De-aerated water / chilled water transfer pump.

Stop the De-aerated water / chilled water transfer pump.

Keep open the Bunging device outlet.

Drain the water.

Take the wort into Yeast propagator as per requirement.

Stop wort transfer pump.

Start De-aerated water / chilled water transfer pump.

Stop the De-aerated water / chilled water transfer pump.

Start hot water pump.

Sterilize the line with hot water.

Stop hot water pump.

United Breweries Limited, Nanjangud.

Open valve on steam supply header of yeast section.

Drain the condensate before control valve through drain point.

Set temperature in temperature control loop of yeast propagator to 98 0C.

Activate temperature control loop.

Check physically for condensate removal.

When temp reaches 980C deactivate temperature control loop.

Drain all condensate through trap by pass line.

Open valve on glycol supply header to yeast section.

Set temperature in temperature control loop of yeast propagator to 8 0C.

Activate temperature control loop.

When temp reaches 80C deactivate temperature control loop.

Close valve on glycol inlet & outlet on shell jacket.

Start aeration through wort aerator provided on cone of yeast propagator.

United Breweries Limited, Nanjangud.

Set the sterile air flow rate as per requirement.

Check the yeast cell count every day.

Sterilize the wort & cool it.

Continue propagation in propagator II.

Sterilize the wort & cool it.

Continue propagation in propagator III.

Once the propagation is complete, Yeast is ready for transfer

United Breweries Limited, Nanjangud.

STEP NAME: YEAST TRANSFER

Sterilize the line by passing hot water followed by chilled water.

Increase pressure in yeast propagator up to 1.5 kg/cm 2.

Depressurize the yeast propagator slowly.

STEP NAME: YEAST PITCHING.

STEP DESCRIPTION: YEAST PITCHING

Set pressure on bunging device.

Open valves on yeast pitching pump suction line.

Open valves on the discharge of the yeast pitching pump.

Sterilize the yeast pitching line.

Start yeast pitching pump.

Yeast pitching rate is 15 to 20 hl/hr.

Close yeast pitching pump discharge valve immediately.

Close valves on pump suction line.

Flush the yeast holdup in the line to gutter.

STEP NAME: YEAST COLLECTION

United Breweries Limited, Nanjangud.