..

.
INTERNSHIP AT MURREE BREWERY LTD. RAWALPINDI
AS A QUALITY CONTROL AND PRODUCTION MANAGEMENT

BY

NAME:

Muhammad Musaddaq Masood

Reg No:

!0-Arid-983

Email Adress:

[email protected]

7thth semester Bs.c (Hons) Food Science And Technology

DEPARMENT OF FOOD SCIENCE AND TECHNOLOGY

PMAS-university of arid agriculture Rawalpindi
Faculty of crop and food sciences

..

CONTENTS

Sr. No

Title

Page number

History of Murree Brewery,s Ltd

Murree Brewery,s Structure

Murree Brewery,s Goals and Objectives

10

Quality Assurance Department

12

Quality Testing Of Products

14

Products and Services

18

Tops Division

35

SWOT Analysis

43

Conclusion

45

References

46

ABSTRACT
The Murree Brewery Company Ltd was established in 1860.It is a Pakistan-based company .Its
products are only legally available in Pakistan owing to a prohibition on the exportation of
alcohol from Pakistan.
The Company is principally engaged in the manufacturing of Pakistan made foreign liquor
(PMFL) including alcoholic beer, non-alcoholic beer (NAB), non-alcoholic products (NAP),
which includes juices in tetra packs in Rawalpindi and food products, juices, glass bottles and
jars in Hattar. Murree Brewery Company Limited operates in three divisions: liquor division,
which includes PMFL, alcoholic beer, NAB, Big Apple, Lemonade, Cindy and Malt -79; tops
division, which includes food products and juices, and glass division, which includes glass
bottles and jars.
The Murree Brewery is one of the oldest public companies of the sub-continent. Its shares were
traded on the Calcutta Stock Exchange as early as 1902, and are now the oldest firm continuing
industrial enterprise of Pakistan.
Is aimed to have a good quality of products and it is providing different types of liquids to upper
class, middle class and low class people. The company believes that whatever we provide to the
customers should be the best for them. They should get the maximum satisfaction in this product.
This internship program helped me in the polishing of communication skills, a must-have to
survive and make it big in the present world. It even gave a good understanding of behavior of
customers when placed in different situations. It was a good opportunity to work on the skill of
patience, as a large number of customers were to be dealt with. It helped in developing the kind
of relations one needs to uphold in the corporate world and it helped in building up the right

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attitude.

HISTORY OF MURREE BREWERY,S LTD:

Consequent to the British annexation of the Punjab in 1849 from Sikh rule, and
more so after 1857 when the British Crown formally extended its sovereignty
over India, a structured administration commenced in the Punjab.

To meet the beer requirements of British personnel (mainly army), the Murree
Brewery was established in 1860 and incorporated a year later at Ghora Galli,
located in Pir Punjal range of the Western Himalayas at an elevation of 6000
above sea level, near the resort town of Murree.

Between 1885 & 1890 the company established Breweries in Rawalpindi &
Quetta & acquired an interest in the Oticumand (South India) & Norailiya
(Ceylon) breweries. A distillery was also established in the above period in
Rawalpindi next to the Brewery.

The Murree Brewery .at Ghora Galli was therefore among the first modern beer
breweries established in Asia .Murree Beer proved to be very popular among the
British troopers who were largely barracked in the Galis of these hills.

The virtues of the beer brewed form barley malt & hops as a light alcoholic
beverage were not lost on the local population who rapidly became avid
consumers. By the turn of the 20 century, the name Murree was famous for its
beer in Keg and bottle in the bars, beer halls and army messes of British India.
Murree Beer was first awarded a medal for product excellence at the Philadelphia
Exhibition in 1876, followed by numerous awards over the past 140 years.

In 1935, a massive earthquake totally demolished the Quetta brewery as well as

substantial part of Quetta town, killing thousands of persons, including a number
of our employees. At Ghora Galli (Murree), the scarcity of water became an
emerging problem.

By the 1920s, brewing was mostly transferred to the Rawalpindi brewery but
malting continued at Ghora Galli till the 1940s, when this property was sold. The
riots of 1947/48.

Park Lodge a handsome residential property was purchased by the company from

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historic brewery built in Gothic style architecture was burnt during the partition

Mrs. H. Whimper in 1888. It was the principal residence and head office of the
company till 1959, when it was taken by the Government of Pakistan to house the
office of the President of Pakistan. It remains an office of the Head of State of
Pakistan from 1960 till the present day. The original brewery was founded by two
closely connected English families. Edward Dyer was the first General Manager
of the Company. He was also the founder of the Dyer Menken breweries, Shimla
hills. Edward Whimper, a member of this family was the first person to climb
Matterhorn Mountain in 1865.

The Rawalpindi brewery is blessed with deep aquifers of good water. A railway
siding was extended to the premises in the 19th century, which is now derelict.

Under the present prohibition law, only non-Muslims and foreigners are permitted
to consume alcohol. Not withstanding the consequent reduction in demand, the
Company decided as policy to concentrate on product excellence. It was decided
to modernize the plants.

A Ziemann (German) brew house was installed in 1967, 'Saladin' Box Meltings
in 1971. Also in the late sixties, it was decided to embark on an ambitious longterm program to mature Malt Whiskies. Over the past four decades white oak
casks and vats have been procured from North America, Australia and Spain

Our two underground cellars now hold over half a million liters of Malt Whisky
for varying periods of maturation up to 12 years under controlled temperature
conditions.

Another wave of modernization was undertaken in the 1990s. New beer canning
and modern bottle filling facility from Holstein and Kappert (Germany) was
installed. Two units of alcohol rectification columns for producing extra neutral
grade of potable alcohol from Molasses were procured from France and Italy,
respectively, to give our Vodkas and Gins a qualitative edge.
Also in this period, the beer fermentation capacities were renewed. It is pertinent
to point out that our basic beer fermentation system installed in the 1930s was
then at the cutting edge of this technology. Known at the time as the Nathan
system, it incorporates fermentation and the laagering of beer in a single double
jacketed vessel. A variation of this system is now in extensive use worldwide.

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Tops Food and Beverages a division of the Company was established in 1969. It
processes fruits and markets fruit juices and allied food products. Two
manufacturing units are located in Rawalpindi and Hattar (NWFP) respectively. A
Tetra Pak packaging facility was added in 2001. The Hattar plant was installed in
1992.

The plant is based on a Recuperative Melter and two Emhart I.S. container
manufacturing machines and has the latest quality control equipment for online
inspection of containers.

The Murree Brewery is one of the oldest public companies of the sub-continent.
Its shares were traded on the Calcutta Stock Exchange as early as 1902, and are
now the oldest continuing industrial enterprise of Pakistan.

In 1997-1998 and 1998-1999, we were judged among the top 25 performing

public companies by the Karachi Stock Exchange.

.
ISO-9001 And ISO 9001 Certification:
The Murree Brewery Company Ltd has been certified from ISO 9001(Quality Management
System).Now they are working on ISO 14001(Environmental Management System).
Pakistans only Beers and Whisky firm:
Understandably, making beer and whiskey in a Muslim country, where 97 per cent of the
population is officially banned from enjoying your products, has never been an easy business.
Non-Muslims are exempt from the ban, but even for them getting a drink can be complicated:
some five-star hotels require foreigners to affirm in writing that they are non-Muslims and will
be responsible for anything that happens when they are under the influence before they can order

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a drink.

Page44

COMPANY STRUCTURE

Page44

MURREE BREWERY,S GOALS AND OBJECTIVES:

Following are the goals and objectives of the Murree Brewerys Ltd. which it has to be fulfilled.
And these are:

To achieve the Product Quality

Management Development

Profitability & Growth

The Vision & Mission:

To fulfill customer requirements & expectations through CARE

Continuous improvement

Alignment of our missions and goals

Responsibility and respect of our jobs and each other

Educate one another

We the people of Murree Brewery Co. make personal commitment to first understand our
customers requirement then to meet & exceed their expectations, by performing the
correct tasks on time and every time through

They provided area to Govt. of Pakistan in Zia-Ul-Haq era.

Also provided place for Govt. Bhandara High School.

Place for Golf Club.

Dispensary for employees.

Provide renovation facilities.

Post office for the area people.

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Social Responsibility:

Benefit to their employees.

Provident funds.

Pension.

Medical facilities.

Insurance.
Motto:

We respect our past. We are the industry leader in present and accepts the challenges of the
future.
.
Company Quality Policy:

Updating of employee skills by training

Acquisition of new technology

Re-evaluation of its quality control and quality assurance system

Prepare the best quality products, believing that quality is first priority and will take all
steps to encourage quality consciousness.

Meet all applicable regulatory requirements and system standards

To recognize that our workforce is our strength.

To satisfy the customer.

Continuously improve the skills systems and business of the organization.

They are committed to consistently meet their customers needs and expectation on
product quality and performance of optimum cost through their competent human
resource and continual improvement of process and system.
DEPARTMENTS MURREE BREWERY,S LTD.

1.

Marketing Department

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Flowing are departments in Murree Brewerys Limited:

2.

Sales department

3.

Commercial Department

4.

Accounts & Finance

5.

Production department

6.

Planning and storage department

7.

Technical services department

8.

Quality Assurance department

9.

Human resource department

QUALITY ASSURANCE DEPARTMENT:

Priorities of Quality Assurance Department:

Q.A Department is the back bone of every food industry that ensures the quality products.
Follow are the main functions of the quality assurance.

Inspection of the incoming raw material by the use of physical, chemical, biological and
sensory characters tests procedures

Inspection of the production during manufacturing process from to tail

Research and Development.

I.S.O, HACCP, GMP, GHP, application

Sanitation department runs according to QA department. QA department also inspects

utensils cleaning, personal hygiene and CIP.

Laboratories in Quality Assurance Department:

There are 4 labs which are as follows
1. Main lab
3. Incubation lab
4. Microbiology lab

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2. Sensory evaluation lab

5. Line control lab

1) Main Lab:
All the incoming raw materials are tested for their predefined Murree Brewerys quality
standards. If the incoming raw material full fills the quality requirements then the product
is passed if not then the product is failed and returned to supplier as no compromise on
quality inputs. PH, TDS, Hardness, Chlorine of boiler water & Tap water are tested and a
daily report is sent to the Boiler Engineer. PH, ROH, Color, Haze, Co2, brix % are also
tested in the main lab.
2) Incubation Lab:
Samples are taken from the line from production section and these samples as one sample per
batch is tested and kept in the incubation lab chronically for two years and studied for their
behavior in storage. If any complain comes from market about product then the product that
comes from market is compared for its quality with the reference sample from the incubation lab
of the same batch code.

3) Line Control Lab:

This is very critical lab for checking the online production in the NABH and BBH hall for its
best defined quality. The instrument that is used in the lab is calibrated according to the ISO
standards. The titratable acidity, brix , CO2, Steam Pressure, PH and filling temperature of the
product is noted if it matches with the predefined standards then well and good if not then the
production supervisor is given the suitable suggestions to adjust these parameters.
4) Sensory Evaluation Lab:

panel in the sensory evaluation lab and a Performa is given to the panelists and a blind evaluation
is done and their observations are recorded in the sensory evaluation Performa and submitted to
QCM.

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The products that are prepared by the R & D section are evaluated by the sensory evaluation

5) Microbiology Lab:

Microorganisms plays very important role not only deteriorates the products but also
create health hazardous. Microbial testing is carried out to determine safety of workers,
products and process and working environment. Moreover water and Air microbial load
is also checked on monthly basis. All microbiology tests are carried out in micro lab.

Yeast is growing in this lab. The temperature and air and light is under control.
QUALITY TESTING OF PRODUCTS:
1) DETERMINATION OF BRIX:

Object:

To determine the amount of total soluble solids in products.

Scope:

Juices, Fizzy Drinks, Malts.

Apparatus:

Digital Refractometer, Hand Refractometer, Light source (Lamp), and Distilled

water (for calibration)

Procedure:

Calibrate the Refractometer it should show Zero reading of distilled water at 20 C.

Apply the thin layer of product on Refractometer slide.

Observe reading through lens by adjusting the shade with help of knob.

Note reading %. Clean the Refractometer slide with water.

2) DETERMINATION OF TITRABLE ACIDITY:

Objective: To determine the Acidity of Products either as citric acid, acetic acid or lactic acid.
Scope: Almost all juice products
Reagents: 1 % Phenolphthalein, 0 .1 N NaOH

Take sample in conical flask

Add some water for uniform stirring

Add 3-4 drops of phenolphthalein

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Procedure:

Titillate against 0.1 N NaOH

Light pink color is end point

Stop titration & note the reading

Calculation:
For Citric Acid =

ml of (0.1 N) NaOH used X 0.64

Weight of sample
For Acetic Acid =

ml of (0.1N) NaOH used X 0.60

Weight of sample
For Lactic Acid =

ml of (0.1N) NaOH used X 0.009

Weight of sample

3) VACUUM DETERMINATION IN CANNED PRODUCTS:

Objective:

To ensure the vacuum in sealed cans to avoid contamination.

Scope:

All canned products.

Procedure:

Keep the vacuum gauge on can.

Now press it & take vacuum should be 5 inches.

4) DETERMINATION OF HARDNESS
Objective: To determine the impurities in the water.
Scope: Tap Water, Boilers Water, R.O Water

Apparatus: Burette, conical flask.

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Reagents: Distilled Water, EDTA, Ammonia Buffer, Erich rum Black Tea.

Procedure:

Take 100 ml Distilled Water in a conical flask.

Add 3 to 4 Drops of Erich rum Black Tea as a Indicator.

Add 4 Drops of Ammonia Buffer.

Shake the Sample Well.

Titrate with EDTA until light blue end point achieved.

Note the Reading.

6) DETERMINATION OF ROH
Objective: Determination of Alcohol %age on the bases of boiling point
Scope: Alcoholic Beers
Reagents: antifoam solution and distilled water
Equipment:
Ebulliometer
Slide rule/conversion table
Alcohol/micro Bunsen burner
200 mL volumetric flask with stopper
50 mL pipette
100 mL graduated cylinder
Narrow range ebulliometer thermometer

Using a graduated cylinder, transfer the required amount of distilled water to the boiler.
Insert the thermometer. No water is added to the condenser for the determination of the
boiling point of water.

Protect the ebulliometer from drafts.

Ignite micro-burner/alcohol lamp. Adjust flame (which may require trial runs) to start the
temperature rise within 8-9 minutes.

Observe temperature rise, noting (writing) temperatures every 15 seconds; continue

reading temperature until 3 successive readings are the same. (Note that the smallest
graduation is 0.05C; estimate readings to 0.01.)

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Procedure:
Bring the sample and a supply of distilled dilution water to a temperature of 20C (68F).

Remove flame. Remove thermometer. Drain the hot water carefully.

Transfer 50 ml of the sample to a 200 ml volumetric flask (by pipette) and make up to
volume with distilled water, stopper and mix.

Rinse boiler 3 times with approximately 25 ml of diluted sample. Transfer by graduated

cylinder the required amount of diluted sample to boiler. Attach condenser firmly. Insert
thermometer. Add cold (ice) water to condenser jacket. Put finger over condenser vent
tube to prevent water from entering the boiler.

Light flame; adjust flame to attain temperature rise within 8-10 minutes. Observe and
record every 15 seconds until temperature stabilizes (three consecutive readings are the
same). Repeat the determination if condenser gets warm.

Remove flame; remove thermometer, drain sample; drain condenser.

Calculate the alcohol from the slide rule/conversion table that comes with the instrument;
multiply the alcohol found by the dilution factor.

7) DETERMINATION OF PH:
Objective: Determination of PH
Scope: Malts, Fizzy Drinks, Beers, Boilers Water, Tap Water, R.O Water
Procedure: Take Sample in beaker.

Turn PH meter on

Dip the electrode in the Beaker

Note the Constant Reading

8) DETERMINATION OF HAZE:
Objective: Determination the Turbidity
Scope: Malts, Fizzy Drinks, Beers, Boilers Water, Tap Water, R.O Water

Take the sample in the cuvette

Place the cuvette in the haze meter

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Procedure:

Press the start button and note the reading.

9) DETERMINATION OF COLOUR:
Objective: To Determine the color
Scope: Beers, Carbonated Drinks, Malts
Procedure:

Take the sample in the CUVETTE

Match the color with the standard disc.

PRODUCTS AND SERVICES:

Beers

Non Alcoholic Beers

Carbonated Soft Drinks

Energy Drinks

Malt Whiskies

Matured Malt Whiskies

Rum

Brandy

Malts

1) Murree Beer
An all time favorite since 1860. Alc. Contents 4.5% v/v. Brewed from local

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BEERS

six row barley, malts and Bavarian hop products. Has a distinctive
taste and flavor.
2) Murrees Classic Larger
Premium beer, inputs identical to the millennium Beer. Alco. 5.5% v/v.
A real classic. Smooth on the plate. Taste and flavor close to classic
European lagers.

3) Murrees Millennium
Our flagship beer 8% Alc. v/v. Brewed from highest grade Australian malt and
hallertau a German Hop products. The millennium is celebration brew for
special occasion.

4) Lite Export Pils

Is brewed from continental Malts and Hops.
A light beer Alc. 3.5% v/v. Correspond in
flavor and quality to the famous beer brewed
in Pilsen, Czech Republic,. An ideal summer
drink.

1) Malting
After screening Fully ripened barley grains are "steeped," or soaked in cold water until
they are fully saturated. The water is changed once a day, and after 45-72 hours the grains
are placed in shallow tanks.
To increase moisture level up to 40% in the barley. This process completed in 5 hours.
Water is used for steeping the barley. Air should be also provide from bottom through the
small holes.

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BREW HOUSE

In germination there is a germinating box which have name as Saladin malt box. Wet
Barley goes through pipes to the germination box. Barley spread in the box the
germination process is of one week and temperature of box is 18 to 20 c. temperature
should be under controlled. Temperature is a main factor to achieve best results. The
grain is aerated and stirred, which causes it to germinate, releasing enzymes such as malt
diastase. Malt diastase converts the starches contained in the grain to sugar for
fermentation.
In germination box we measure the size of seed root this length tell us that how much
enzymes are generated in the barley seed. The germination is a key process and back
bone of the brew plant.
After germination the barley come to kill in the killing box. the barley is roasted with the
help of hot air with temperature 40 to 72c. moisture content reduce to 5% and barley
again come to his hard form. The germ portion is removed in this process. , the grain is
roasted to stop the germination process. The exact point at which the roasting starts and
ends affects the flavor and color of the beer. The product at this point is referred to as
malt.
Barley is stored in silos for future processing.

2) Mashing

The malt is crushed using iron rollers and transferred to the mash tank (or "tun"). This
tank is a large copper or stainless steel vessel that mixes the malt with warm water until it
is of porridge-like consistency. This mixture is called mash. After mixing with similarly
prepared cereal grains, the temperature of the mash is raised incrementally from 100170F (38-77C) so that the enzymes react. The enzymes break down the starch in the
grain and convert it to simple sugars. Later, the yeast will convert the sugars into alcohol.
Once complete, the mash is allow to sit undisturbed so the solids can descend to the
bottom of the tank.

3) Brewing

Beer requires these ingredients for proper brewing: prepared cereal grain (usually barley
and corn or rice), hops, pure water, and brewer's yeast. Each ingredient can affect flavor,

The liquid contained in the mash is transferred into another tank called a lauter tun. This
is accomplished by drawing the liquid out through the bottom layer of mash solids, which
acts as a filter. Hot water is added to the top of the mash tank to rinse the remaining

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color, carbonation, alcohol content, and other subtle changes in the beer.

liquid, now called wort, from the mash. The solid remains of the grain are dried and sold
by the brewery as animal feed.

The wort travels on to the brew kettles, where it is boiled to sterilize it, and where the
carefully prepared hops are added. The addition of the hops is important because they
contribute to the bitterness of the beer. The brew kettles are the most impressive
equipment in the process. Gleaming copper, they can be 7-12 feet (2-3.6 m) in diameter
and two stories high. Steam usually provides the heating energy to the brew kettles.
Boiling take placed in 1 hour and temperature is 100c.

After brewing is complete, the finished wort is filtered again and pumped to the
fermentation tanks.

After filtration the wort is cool on 8c in D.V room which have a series of heat
exchangers.

Rest the wort for 30 minutes

Before fermentation done the CIP of the fermentation tank through hot water and caustic
soda.

4) Fermentation:

In the fermentation tanks, the atmosphere must be carefully controlled to prevent any
"rouge" bacteria from interfering with the yeast. Carefully maintained yeast
(approximately one pound per barrel of wort) is added to the wort, and the temperature of
the mixture is slowly reduced over a period of days to between 50F and 60F (10-15C).
In this temperature range, the yeast grows, consuming the sugar in the wort, and bubbles
of carbon dioxide form. The wort has now become beer.

After fermentation beer double filtered. 1st filtered by the addition of chemicals.

2nd filtered through a filter unit which has a series of 12 filtered sheets.

After fermentation the beer transfer to the Beer Bottling Room(BBT) where condition
done by adding flavors, and badge prepared according to product requirement.
After this final beer transfer to the BBH where filling, pasteurization, packaging done.

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Flow Diagram Of Brew House:

Beer Bottling Hall (BBH)

Flow Diagram

TIN PACK HALL

Murree Brewery have a varieties of tin pack products according to different volumes like as
250ml and 450ml.

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Tin Pack:

Tin Pack Hall Flow Diagram

Empty Tin

Packaging

Depalletized

Coding

Washing&

Storing

Labeling

Filling

Cooling& Drying

Capping

Pasteurization

Murrees Matured Malt Whiskies:

Murrees premium Malt whiskies are brewed from a Barley Malt mash, distilled on traditional
pot stills and matured in imported oak wood casks & vats for
guaranteed periods specified on respective packaging. Jim Murray
one of Englands best known writers on Scotch Whiskies comments
on Murres 8 years old classic Malt whisky at page 202 in his Complete

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Screening

book of Whisky (1997) as follows:

Not only does Murrees 8 years old single matured malts compare
favorably, it is much better than a lesser Scotch malt, which comes
now here near matching this whiskys crisp and delicate maltiness.
in maltiness, character &crispness to any reputed Scottish Malt whisky of equal age.

2) BOLSKAYA VODKA & SILVER TOP GIN

Produce under arrangement with Bols international B.V. Netherlands
Distilled from extra neutral grade alcohol under arrangement with
Bols international BV, Netherlands world famous distillers of fine
liquors.
3) MURREE GINS
Tower of London Gin is rich in juniper flavour extracted from the juniper berries of the world
famous Ziarat juniper forest near Quetta.London Dry Gin is a typical English
s\dry gin with a delicate flavor, balanced aromatics and botanicals. Lemo
lime & citrus Gins Convey the flavor of citrus fruits.

The barley is first soaked in water, then spread inside the germination box allowing it to
germinate. The germination produces sugar and thus converts the barley into malt. As the
germination releases heat, the barley has to be turned regularly, and the temperature need to be
controlled. The malt is then transferred to the kiln, spread over a mesh and dried over a fire.
The malt is coarsely ground by roller. In the mash tun it is mixed with hot water at specified
temperatures, in which the malt sugars are dissolved. The resulting sweet solution is called wort.
Wort is cooled, and yeast is added, while the solid residue of the malt is sold as cattle feed. The
temperature is done in vats till a beer, with around 7-8% alcohol, is formed.
Distillation takes place in onion-shaped pot still made from copper. In the first distillation, which
takes place in the wash stills, the alcohol fraction is raised to somewhat over 20%. The product,
called low wines, the is distilled a second time in spirit stills, which results in a spirit with over
60% alcohol. In distillation process, the first and the last fractions are recycled back for Redistillation process, while only the middle cut via the spirit safe goes to the spirit store to be
filled into barrels. The spirit safe is locked by the Excise men.
By law, the spirit can only be called whisky after at least three years of maturation. Usually no
new casks are used, but rather the casks are charred before use, which helps to release vanilla
from the wood.

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DISTILLERY HOUSE:

Once matured, the whisky is bottled. To achieve a more uniform taste, usually many casks are
blended. Whisky may also be filtered a t low temperature (about +5 to -5 Celsius) to remove fat
particles. And finally it is colored with caramel to achieve a Uniform Color.
Flow Diagram of Distillation Unit:

Distillation

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In distillation Unit we prepare Alcohol through fermentation of Molasses

Distillation is a method of separating mixtures based on differences in their volatilities in a

boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a
chemical reaction.
Distillation of fermented solutions has been used since ancient times to produce distilled
beverages with higher alcohol content. The premises where distillation is carried out, especially
distillation of alcohol are known as a distillery.
Fractional Distillation
Fractional distillation is the separation of a mixture into its component parts, or fractions, such as
in separating chemical compounds by their boiling point by heating them to a temperature at
which several fractions of the compound will evaporate. It is a special type of distillation.
Generally the component parts boil at less than 25 C from each other under a pressure of one
atmosphere (atm). If the difference in boiling points is greater than 25 C, a simple distillation is
used.
Fermentation
Fermentation is a metabolic process whereby electrons released from nutrients are ultimately
transferred to molecules obtained from the breakdown of those same nutrients.
Yeast carries out fermentation in the production of ethanol in beers, wines and other alcoholic
drinks, along with the production of large quantities of carbon dioxide.
Molasses
Molasses is a viscous byproduct of the processing of sugar cane or sugar beets into sugar.
The quality of molasses depends on the maturity of the sugar cane or sugar beet, the amount of
sugar extracted, and the method of extraction.
Fermenter
Yeast added to fermentation occurs.
8% alcohol is pure here.
Condenser
A device or unit used to condense vapor into liquid.
E10, E11, E50, E51, E43 are condensers.

C50
It is Impurity Column.
Alcohol is passed to C40 and Vapours are condensed in E50 & E51.

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C10
It is Feed Column and boiling done here

C40
It is Rectifying Column.
We get 96% alcohol here and remaining fusel oil (have 30 40 % alcohols) is passed to C10
with wash.

SSR
It is Spirit Receiver and water are added here to reduce the percentage of alcohol upto 43 or 37
% (depend on requirement).Essence and Colour are also added here.

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Bottling Hall Flow Diagram:

Non Alcoholic Beers

Malt 79 & Cindy:

Malt 79 & Cindy malt drinks are brewed from golden barley malt and hops.
Ideal thirst quenching summer drinks. Once you get the taste of real grain
beverages rich in natural sugars, you will never look back to synthetic colas.
Non alcoholic malt drinks are recommended by doctors for a variety of elements. Our non
alcoholic malt drinks our genuine earth drinks.
MALTS:

APPLE MALT

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Types Of Malts:

PEACH MALT

LEMON MALT

ELICHE MALT

STRAWBERRY MALT

MALTS PROCESSING FLOW DIAGRAM:

Matured Barley

Filtration

Conditioning

NAB HALL

Steeping

Filtration

Germination

Cooling

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Killing

Grinding

Wort Boiling

Mashing
NAB HALL:

Lautering

Rinser
Here empty bottles are washed.

Screening 2
Screening of filled bottle (check the particles).
Screening 3

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Screening 1
Screening of empty bottles.

Screening of final product in bottle (again check the particles).

Pasteurization:
Pasteurization is a process of heating a food, usually liquid, to a specific temperature for a
definite length of time, and then cooling it immediately. This process slows microbial growth in
food. Pasteurization is not intended to destroy all pathogenic micro-organisms in the food or
liquid. In that unit, temperature gradually increase and decrease from 25 to 60 C

RESERVE OSMOSIS PLANT

Reverse Osmosis:
Reverse Osmosis (RO) is a filtration method that removes many types of large molecules and
ions from solutions by applying pressure to the solution when it is on one side of a selective
membrane. The result is that the solute is retained on the pressurized side of the membrane and
the pure solvent is allowed to pass to the other side. To be "selective," this membrane should not
allow large molecules or ions through the pores (holes), but should allow smaller components of
the solution (such as the solvent) to pass freely.
Reverse osmosis is most commonly known for its use in drinking water purification from
seawater, removing the salt and other substances from the water molecules.
RO Plant:
A reverse osmosis plant is a manufacturing plant where the process of reverse osmosis takes
place. An average modern reverse osmosis plant needs six kilowatt-hours of electricity to
desalinate one cubic metre of water.
In RO plant, we remove the hardness of water.
RO can give you all of these benefits:
Delicious, pure, salt-free drinking water

Crystal-clear, pure ice cubes

Peace of mind, knowing your water is highly pure

Compact, simple equipment

Cheaptooperate - only requires water pressur

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Flow Diagram of RO Plant:

Sand Filter
Sand filters are used for water purification.

Particles are removed in sand filter.

Carbon Filter
Carbon filtering is a method of filtering that uses a piece of activated carbon to remove
contaminants and impurities, utilizing chemical adsorption.

Big Lemon

Big Peach

Big Orange

Big Apple

Murree Brewery have a varities of Carbonated soft drinks. These drinks are processed under
pressure of Co2. These drinks are free from alcohol. These drinks have a great public demand
and also have a energy source.
Processing:

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CARBONATED SOFT DRINKS:

The syrup is prepared by the mixture of water and sugar in the mixture tank.
Add colors and flavors in the syrup.
Add the chemicals and preservatives in the syrup.
Homogenize the syrup.
Pasteurized the syrup.
Filtration of the syrup.
Then transfer the syrup to the pet plant for furture processing like filling, packing,
storing.

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Pet Plant Flow Diagram:

(For 500 and 1500 ml bottles)

Drying
Wet bottles are dried here.

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Rinsing
Empty bottles are passed to rinser through air conveyer and are washed.

Screening
Screening of final product in bottle (check the particles).
Pasteurization
Pasteurization is a process of heating a food, usually liquid, to a specific temperature for a
definite length of time, and then cooling it immediately. This process slows microbial growth in
food.
Pasteurization is not intended to destroy all pathogenic micro-organisms in the food or liquid.
Instead, pasteurization aims to reduce the number of viable pathogens so they are unlikely to
cause disease (assuming pasteurization product is stored as indicated and Consumed before its
expiry date).Temperature is kept from 0 to C.

TOPS DIVISION
(1) Procurement of Raw Materials:
The first step involved in the production of a product is the procurement of goods and
raw materials that combine and give the desired end product. For that purpose suppliers that have
good track record are contacted, and once the supplier evaluation is done, the raw material before
delivery comes in the form of a sample. The quality team checks that sample for its suitability in
accordance with the need of the product. This may involve performing some particular quality
tests on the sample and ensuring that it fulfills the set parameters. Once the sample is approved
the raw material is ordered in bulk.
(2) Reception of Raw Material:
Once the raw material arrives at the factory, initially two departments are brought into
action, the security team and the purchase office. They arrange for the transit of the goods and
before unloading the quality of the raw material is checked by the quality control personnel. This
checking first involves the physical inspection of the raw material. Then a random sample is
taken from the lot and checked for quality parameters, it dictates that whether the goods are to be
quarantined or sent back (if the quality tests are not cleared) or unloaded.
(3) Storage of Raw Material:
in bulk and they may be used for longer periods so their safety and proper storage is very much
required. Store conditions are set at optimum for long storage of the raw material. Raw materials

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This is an important step in the production of the product as the raw materials are ordered

that are stored include Sugar, other artificial sweeteners, stabilizers, emulsifiers, fruit pulp,
flavors, colors, concentrated acids and chemicals for use in the factory. Concentrated acids and
chemicals are stored separately than the chemicals and ingredients intended for use in food.
Proper conditions of ventilation, temperature, humidity etc are maintained. Pest control practices
are also employed. The raw material stock should be placed on specific racks and not on to the
floor; similarly recommended spacing from the wall is also maintained (about 6 inches).
(4) Raw Materials Brought for Production:
Now from the chemical and goods store all the required chemicals per requirement of the
batch are brought to the production area. An indent is issued which specifies the name and
quantity of the raw material that is to be brought to the production area. These materials are
temporarily stored in the dispensing room for immediate use as required. Weighing of
ingredients is done in the dispensing room and large and extra storage in the dispensing room is
avoided.
(5) Sugar Syrup Preparation:
Sugar is an important ingredient in the tetra pack juice which gives sweetness to the juice.
It is added in the juice mixture in the form of syrup. Syrup is prepared in the syrup tank having
capacity of thousands of liters. Water is added in the common sugar and then steam is introduced
which melts the sugar and prepares a hot mixture of sugar and water. A common batch of syrup
usually contains 500 Kg of Sugar which is added with 200 L of water. Continuous agitation is
ensured by the means of an electric motor installed at the top of the tank that rotates a rod having
iron arms. Temperature in the syrup tank is maintained at about 200 to 250 oC. Some other
ingredients of the juice also have to be added in the syrup. These include Sodium Benzoate and
Carboxy Methyl Cellulose (CMC).
(6) Addition of other ingredients:
In the factory there are blending tanks of two different capacities, large ones with a capacity
of 9000 L and the smaller ones with 3000 L capacity. Water is major ingredient in the juice
production, water used in the production is chlorinated water and have good quality. All other
water used in the machines is softened water. Water softening plant is installed in the production
includes using an ion exchange resin, the resin exchanges the hard ions of water with itself and
gives Na ions to the water that does not make the water hard). Tank is filled with water at the

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area where water is softened by the ion exchange method (method of water softening that

level of about 8000 liters and chemical ingredients are added as per the set formulation for
different products. Ingredients include potassium metabisulphite (KMS), sucralose, fruit pulp,
sodium cyclamate, citric acid, artificial flavors and colors. Continuous agitation is also ensured
here by means of the similar electric motor as installed on the syrup tank. After addition of all the
ingredients, sugar syrup is added in the juice mixture present in the blending tank. Sugar syrup is
added up to the required o Brix for different products. The blender continuously checks for the

Brix of the juice with the help of a refractometer and stops the addition of sugar syrup once the
required o Brix is obtained. Then the juice sample is sent to the laboratory for quality checking.
Different tests are performed on the juice sample to ensure that all the ingredients are added in
set proportion and the product will perform well and stay safe during its expected shelf life
period. Normally tests that are performed in the laboratory include:

pH
% Acidity (total percentage of dominant acids in juice)
Preservative concentration (concentration of free SO2 in ppm)
o
Brix (concentration of sugars in Juice)
Color
Taste
Smell

If all quality parameters are within the standard range then the product is moved on to the
next step. Otherwise any corrections that can be made to the juice are done and discarded if
nothing can be performed to bring the product under optimum range.
(7) Batch product Blending:
The juice mixture is allowed to blend in the blending tank, a complete batch is blended at
the room temperature to ensure the mixing of all the ingredients. Normally a blending of 2 hours
is performed.
(8) Homogenization:
The juices in which fruit pulp is added have to be homogenized in order to ensure the
even distribution of fruit particles. Usually the mango juice and others in which pulp is added are
homogenized. Juices without the pulp addition need not to be homogenized. Tetra Pak
with the help of motors. These pumps are three in number and completely mix the juice and the
pulp. Pressure of about 100 to 150 psi is maintained in the homogenizer.

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homogenizer is installed within the pasteurizing plant. It contains a tank and pumps operating

(9) Pasteurization of Juice:

Tetra Therm Aseptic pasteurizer is employed for the pasteurization of the juice. It is also
a complex machine having different gauges and valves for temperature and pressure control.
Continuous monitoring is made necessary here with the help of an operator that checks for the
temperature and pressure conditions at regular intervals. Juice is heated in the plate heat
exchanger with the help of steam to a temperature of about 98-102 oC for about 30 seconds and
then cooled to about 28 oC. Holding time of 30 seconds in very much important for proper
pasteurization which is attained by the flow of juice in the holding tubes for a certain period of
time.

Cooling is performed with the incoming cold juice and also with the chilled water. There is juice
holding tank in the pasteurizing pant where juice is temporarily stored in case if the next unit
operation is not ready.
(10) Filling:
employed. There are three filling machines in the factory, one is A3 FLEX which provides the
flexibility to change the Pack size and it is used for the filling of 200 ml and 1 liter packs. Other

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Tetra Pak Juice is always filled aseptically. For this purpose aseptic filling machines are

two machines are Tetra Brik Aseptic (TBA) and these are used for packing and filling of 250 ml
pack. These packing machines are very sophisticated and complex. These are prepared before the
operation is initiated; it includes placing the packaging material, setting the MPM strip, checking
for the oil and water levels of machine etc. Filling is fully automatic and a computer based
logical control system operates the machines on the set instructions. Quality is also assured at
this step by checking the Hydrogen Peroxide (H2O2) concentration of the water mixture used to
sterilize the packaging material in the aseptic filling machine. If the concentration of this
hydrogen peroxide in the solution is below the recommended level, it would not be able to
properly sterilize the packaging material which may affect the shelf life of the packaged juice. A
normal range of 30 40 % is maintained. Densiometer is instrument used for this purpose. Then
to ensure that the pack is printed with the date and batch code (an automatic printer does this
operation, it has a sensor that senses the pack passing under it and accurately prints the date on
the prescribed space on the pack, air pressure is also made to fall on the pack before it passes
under the sensor to remove any water droplets and moisture).

seal are there on the pack: Longitudinal Seal (LS) and Transversal Seal (TS).
Process of aseptic filling: A motor in the filling machine looses the packaging material and it

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Another quality parameter that is periodically checked is the seal on the tetra pak. Two types of

goes inside the machine for further operation. Sensors are installed at this point that check for the
availability of packaging material and thereby controlling the working of machine. MPM strip is
stitched with the packaging material at one end by the help of strip applicator that operate at the
temperature of 655oC. Pressure rollers are employed at that point. 60 % width of the strip is
attached with the packaging material whereas 40 % remains suspended as such. Then the
packaging material travels to the vertical chamber at the bottom of which it bathes in the H 2O2
solution at 72oC. Drops of H2O2 are removed by special rollers while any moisture that may
remain on packaging material is removed by air knife at 125 oC. Then two forming rings bend the
packaging material and its LS is formed by high temperature. Juice is filled in the packaging
material and it moves to the 4 jaws section, 2 of them are cutting jaws while other 2 are pressure
jaws (100 bar pressure). TS is formed here and temperature reaches to about 340 oC so chilled
water is dropped on the pack. Juice packs after filling, and printing with date, batch number etc
runs on the conveyer and moves to the next unit operation.
(11) Straw Application:
Tetra Straw Applicator 21 is used to place the straw on the juice pack. This is an
automatic machine and receives the juice packs that come to it on the conveyer belts. Glue is
used to attach the straw on the pack. Glue in the form of pellets is put in the machine where it is
melted to a temperature of around 170 oC. The melted glue is allowed to pass through a jet nozzle
which precisely injects the glue on the pack. There are two nozzles for glue injection but setting
can be done to make only one nozzle functional. The straw also run in the machine, they are
simultaneously cut and fixed on to the glue point. Water from a small pipe is allowed to fall on
the straw immediately after it is fixed to the pack in order to let the glue cool down. Juice pack

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then moves on the conveyer belt to the next unit operation.

(12) Packing:
Separate packs are placed in trays of fixed capacity. The trays are made up of soft card
board and are light in weight. 250 ml packs are placed in somewhat large trays having capacity
of 27 packs and 200 ml packs are placed in slightly smaller trays having capacity of 24 packs.
Packing is manual and workers are employed in the hand packing of the juice packs. The
packaging in this fashion is still loose and not safe for transportation and storage so a
polyethylene sheet is used to wrap the trays tightly. For this purpose a machine called shrink

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wrap is utilized.

Shrink wrap consists of conveyer belt that passes through a chamber of high temperature
which is usually 180oC. The tray with the juice packs is loosely wrapped with a polyethylene
sheet of fixed sized and then allowed to move on the conveyer belt slowly. When the trays reach
the hot chamber, the high temperature serves to shrink the polyethylene sheet that ultimately
tightly wraps the tray. So, it becomes easy to handle such trays during storage and transportation.
Several quality parameters are considered at this step as well. One of them is the thickness of the
polyethylene sheet / film. Thickness should be between 45 to 55 microns. Then the film should
also be transparent so that the contents inside it are visible. Finally it should be of suitable length
so as to fit the tray tightly, 19 inches is recommended in this respect.
(13) Finished Goods Store:
The finished and packaged product is now ready for storage. Large storage space is
available in the factory area. The company has its other storage outlets in Rawalpindi / Islamabad
area and also in other parts of the country. From there the product is purchased by the sellers. All
the process in then controlled by the sales department. After the delivery of the product for sale
there are always chances of some of the product not performing well during its storage, so the
product is exchanged with other batches by the company and in serious cases whole batch has to

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be brought back and discarded.

SWOT ANALYSIS:
Swot analysis of Murree Brewery Company
Strengths:

Company has a lot of products (Malt whisky, non alcoholic and alcoholic beers and
juices)

Company has set up a good monopoly in the market

Company has very large area for further development

Company have very good relationship with the government

Smooth relation with employee.

Good working environment.

Rich experience of the management.

Good brand equity

Giving the very good return from inception Well combination of new energetic and
experienced employees.

Have very large area for the production

Production capacity

Premium Quality Product

There is lack of proper control in the organization

Using too old machines for production

Not all employees have his/her cabin

Not very popular in rural area

Low Advertising & Promotion Spends

Less Manpower

Low Market Share

Inefficient Distributors

Lack Of Personal Hygienic Conditions

Lack Of Experienced Employers

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Weakness:

Poor Research and Development

Opportunities:

Company exist in very financial products (liquor division, glass division) it provide a
better opportunity to the company.

Company has power to lead their competitor

Company has options for the choice customer

Stability through increased brand awareness, market penetration and Service offerings

Regional Expansions

Production Volumes
Higher Profits
Increased Market share

Threats:

Competition from local and multinational players.

Company has lack of proper control in the organization.

A lot of company has enter in this field

Rising inflation could reduce savings and investments

Competitors High Spends
Government Laws

Focus managers and staff on areas that need development.

Monitor and improve team and individual performance over time.

Develop individual or team-based training needs analysis program.

Safety and Training workshops should be held for employs.

Arrange different products in different sections.

Arrange a workshop on saftey of workers

Focus on research and development

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Suggestions:

Focus on the daily cleaning of instruments and production halls.

Arrange learning and teaching program of workers.

Improve the Personal Hygienic Condition

Conclusion:
The production & quality control Department of Murree Brewery,s Ltd. seems to be catering to
the needs and wants of the customer & employees very effectively and efficiently. But issues like
decentralized- decision making is still lacking. The control is mostly in the upper levels. But the
good aspect is that they treat their lower levels in a nice manner. Also the production and quality
control Department is still going under its initial changes and need time to get settled in the
organization. As the technological advancement, is getting more intense with the passage of time,
the production department & quality control of Murree Brewery,s Ltd. is trying its best to settle
the employees within the organization according to this advancement. The practices they are
performing in the organization and its rapid growth shows its effectiveness and the accepting
behavior of their employees shows they want this new change in the environment and want to
grow with the organization. Overall production & quality control department of Murree Brewrys
is performing well; it is also providing its employees opportunities for their career development

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and for their better future.

REFERENCES:
Resource persons:

Mr. Khurram Manzoor, QCM

Mr. Sohail Ahmad, Assistant Manager Production.

Muhammad Shurjeel QAO.

Mr. M. Ali Abbas QA. Lab Supervisor.

Mr. Umair, Senior QCO.

Mr. Arslan Ali QCO.

Mr. Shamas QCO.

Mr. Umer Afzal QCA.

Mr. M. Aqeel QCA.

Website:

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www.murreebrewery.com.pk