AS IS Document PP ()

(SAP ECC6.0 Implementation)

PROJECT

(( Project Name ))

Presented by

Process definition: ajor Proce!! Name inor Proce!! Name Su" Proce!! Name Proce!! ID) Inputs:

Proce!!

Alcohol Production
illin#$ %i&ue'action$ (ermentation$ Di!tillation

PP *+,

Input Grain(Rice, Bajara, Jawar)

-en.or External

T/pe o' Input (Data0 Acti1it/ 0 Proce!!)

Cate#or/ o' Input (-ital 0 E!!ential 0 De!ira"le) Essential

o.e o' In'ormation Hard Copy(raw dept)

INDE2
Sr. No. *. 4. 5. 6. 7. 6. 8. ,. Pro. ID Process Owner Process Objective Speci'ication o' Ra3 illin# Section %i&ue'action Section (ermentation Section Di!tillation Section Recei1er Section Stora#e Section Decanter Section aterial!

TA9%E O( CONTENTS)

*. SPECI(ICATION O( RA:

ATERIA%

A. Raw Material unloading on

rain !ard.

". #aste $%pt& "ags ' "& Product(

4.

I%%IN; SECTION

A. Dust ' "& Product( ". rain )eed to Milling Section.

*. Storage +an, 'Silo(

5. %I<=E(ACTION SECTION

A. -tilities.Au/iliaries ". $%pt& $n0&%e *ans ' "& Product( *. 1i2uefaction.

6. (ER ENTATION SECTION

A. !east Activation 3essel . Pre )er%entor ". )er%ent or I to 3I *. "eer well D. C>emical Con!umption $. $%pt& $n0&%e *ans ' "& Product(

7. Di!tillation !ection
A. Raw %aterial

". DIS+I11A+ION PRO*$SS D$S*RIP+ION

6. RECI-ER SECTION 8. STORA;E SECTION ,. DECANTER SECTION A. *attle )eed 'PROD-*+(

9. +4in Slop

PROCESS FLOW FOR DISTILLERY MANUFACTURING

1. SPECIFICATION OF RAW MATERIAL

A. Raw Material unloa in! on Grain Yar .

Rice, Wheat, Jowar, Bajra and Maize: Raw material should be free from fermentation inhibiting substances and micro organisms producing side products, Sand and other foreign particles like metals, threads etc !he raw material will ha"e an a"erage starch content of #$% w&w with moisture content of ma'imum ()% w&w and particle size distribution *ma' + as below, -esign Basis: Starch *."erage+ , #$%

Moisture *Ma'imum+ / (0,()% -r1 Matter substance *-S+ / 22, 30% 4article size distribution *Ma'+ as below, 0 ( mm / 0 5 mm 0 5 mm / 0 2 mm 0 2 mm / ( 0 mm : : : )0% *6ines+ $0% *Medium+ (0% *7oarse+

8Mention the record here as Opening Balance, Receive, Consumption and Balanced.9

C. Wa"te E#$t% &a!" ' &% Pro u(t)

6eed :rain to milling section we get empt1 bags ; this empt1 bags used as b1product

8Mention the record here as Opening Balance, Receive, Consumption and Balanced.9

*. MILLING SECTION

A. Du"t '&% Pro u(t) 6irst we are Separate -ust, Stone ; <ther waste in the :rain

&.Grain Fee to Millin! Se(tion .fter dust separate, 6ine :rain 6eed to Milling and :rind it 6lour 4article Size -istribution *Ma'+ as below, )0 BSS / ()%

=0 BSS , 5>% #0 BSS , =0% 20 SS / (5%

&. Stora!e Tan+ 'Silo) .fter :rind 7alicut the :rain 6lour and Store in the Silo ( ; ) Silo capacit1 >0 !on each 8Grain Flour Start to Li,ui-i(ation Se(tion9
8Mention the record here as Opening Balance, Receive, Consumption and Balanced.9

.. LI/UIFICATION SECTION

A. Utilitie"0Au1iliarie"

A.1. Pro(e"" Water2 4rocess water should be filtered and shall not contain an1 ?,7<@A or 7<@A6<RM bacteria with total germs count being limited to (00 nos&ml 7hloride ions concentration should be less than )> ppm A.*. So-t water Soft, 6iltered water, free from algae and suspended solids, commercial zero hardness 7hlorine ion content should be less than )> ppm !emp of cooling water: 5( to 5) A... In"tru#ent Air2 7ompressed, dried, oil free air at $ 0 Bg&cm) *g+ pressure and 5)7 temperature with dew point / =07 A.3. Stea#2

-r1, Saturate and regulated at a constant pressure of 5 > Bg&cm) *g+ at the inlet of jet 7ooker or at constant pressure of 5 > kg&cm) *g+ when handling Rice or Wheat based slurr1 A.4. En5%#e"2 .lpha / .m1lase / 7ompletel1 soluble in water confirming to specs of food grade enz1mes

B. Empty Enzyme Cans ( By Product) We get enz1me empt1 cans as wastage *6% Pro u(t+

.. LI/UIFICATION SECTION2

C.1. Pre7Ma"8er 4re,Masher is a mi'er with combine effect of Screw ; Ribbon used for making thick paste of slurr1 using :rain 6lour and hot 4rocess Water 4re,Mashed slurr1 enters into Slurr1tank b1 gra"it1 C.*. Slurr% Tan+ Mi'ing of slurr1 in the slurr1 tank b1 an agitator and adding enz1me to reduce the "iscosit1 of slurr1 !otal residence time in this tank is C half hour ; tank 7apacit1 is 5= m5 C.. Initial Li,ui-i(ation Tan+ An !his !ank We are holding the Slurr1 and increased the temp *#0 to 30 -eg 7+ b1 Steam !otal residence time in this tank is C one hour ; tank 7apacit1 is $$ m5 C.3. 9et Coo+er !his is used to cook the 4re, @iDuified Slurr1 7ooking slurr1 is heated from 30 to ()0 7 b1 using steam of 5 > kg&cm) *g+ !he cooked slurr1 is then passed to Retention Eessel

C.4. Retention :e""el An retention "essel the cooked slurr1 is hold at a pressure of ( > kg&cm) !otal residence time in this Eessel is C $,2 minutes ; 7apacit1 is (> m5 C.;. Fla"8 Tan+ !his is the instantaneous flashing tanks place An this flashing, some part of water is e"aporated called flashed steam and temp of the Slurr1 is reduced to 22,30 from ()0 7

C.<. Li,ui-i(ation Tan+ An this tank we hold flashed slurr1 and add enz1me here which is diluted with water .n agitator is pro"ided in this tank to keep whole mass in suspension !otal residence time in this tank is C one hour ; tank 7apacit1 is $$ m5 C.=. Partial Pre7Sa((8ari-i(ation Tan+ An 4artial 4re,Saccharification tank is a .dditional @iDuified slurr1 tank .n agitator is pro"ided in this tank to keep whole mass in suspension 8A-ter t8at Sa((8ari-ie Slurr%> W8i(8 i" (oole 'P?E) to .37.4 De!. C> i" t8en entere in to Fer#entation Se(tion.9
8Mention the record here as Opening Balance, Receive, Consumption and Balanced.9

3. FERMENTATION SECTION

A. Yea"t A(ti@ation :e""el 0 Pre Fer#entor An Feast .cti"ation Eessel & 4re,6ermentor, @iDuified Slurr1 is mi'ed with reDuired Duantit1 of process water and acti"e -r1 Feast .cti"ation or growth of culture 1east is done b1 sparging the air through .ir SpurgerGs

-iluted Saccharif1ing ?nz1me is added while diluted 4rotease is added to Feast .cti"ation Eessel during Slurr1 filling !otal residence time in each 1east acti"ation "essel is about (),(2 hours When acti"ation of 1east is completed, it is transferred to fermantor with the help of pre, ferment or 1east acti"ation "essel recirculation pump Both the acti"ation "essel is used in batch wise manner &. Fer#entor or I to :I .ll the fementers are designed for batch process with total c1cle time of #0 hours 6ermenters are filled with proper proportion of @iDuified slurr1 and process Water to achie"e the reDuired alcohol concentration of 3% "&" *a"erage+ -uring residence time sugar *in form of glucose+ released b1 saccharif1ing enz1me is con"erted to alcohol ; carbon -i,o'ide b1 1east When the reaction is complete i e desired alcohol concentration is reached with no loss of residual sugar, the ferment or mash is transferred to beer well with the help of fermented mash recirculation pump Side entr1 agitator will help to keep the whole mass *1east Hsuspended solids from grains+ in suspension Spra1 balls are pro"ided for 7A4 cleaning of fermenters caustic solution of ) >,5 0% w&w is used as 7A4 solution Breather "al"es are working as safet1 s1stem for ferment or in both the casesI pressure well as "acuum C. &eer well .fter completion of reaction ferment or mash is transferred to beer well erment or mash is ed to distillation section to strip out alcohol !ith the help o "eer !eel trans er pump Side entr1 agitator will help to keep the whole mass in suspension D. C8e#i(al Con"u#$tion

#.$. Enzyme%.m1loglcosidase / 7ompletel1 soluble in water confirming to specs of food grade enz1mes

#.&. 'rea #.(. )in* +ulphat #.,. Magnesium +ulphat #.-. .nti oam #./. 0ormalin #.1. Caustic 2ye #.3. Pro Penicillin #.4. 2actrol #.$5. +tar 6ydro #.$$. #ry 7east

E. Empty Enzyme Cans ( By Product) enz1me empt1 cans as wastage *6% Pro u(t+

8.nd !e are mention the record hears as Opening Balance, Receive, Consumption and Balanced.9

4. DISTILLATION SECTION

A. Raw #aterial
A.1. Fer#ente wa"8

6ermented wash with alcohol concentration of 3% "&" *min+ *in case it contains substances that cause choking & scaling the column ma1 ha"e to clean periodicall1 !he1 freDuenc1 of cleaning will ha"e to be decided based on the contents of the wash+

A.*. Utilitie"

4rocess water &soft water&dm water 6iltered water, free from algae and suspended solids Jon, corrosi"e and commercial zero Kardness for soft water

A... Coolin! water

7ooling water at ) > kg&cm *g+ pressure at the inlet flange of header at operating floor A.3. Air Moisture free, oil free and dust free compressed air at $ kg&cm *g+ pressure at 50deg temperature with dew point / =0deg -r1 saturated and regulated steam at pressure of 5 > kg&cm *g+ H 0 ( kg &cm

&. DISTILLATION PROCESS DESCRIPTION

&.1. ANALYSER COLUMN 0DEGASIFYING COLUMN -egasif1ing column mounted abo"e anal1zer column, both operated under "acuum !he preheated fermented wash is fed to degasif1ing column through flow control "al"e "aporsG from degasif1ing are fed to aldeh1de column -egasif1ing column bottom liDuid is fed to the top of the anal1zer column through gas separator Rectifier "apor is used to heat the anal1zer column through thermos1phon reboiler 6lash steam from the flash tank is used to heat the anal1zer column !he top "apors from anal1zer column are fed to pre /rectifier column while bottom liDuid Spent wash free of alcohol is discharged to DECANTER SECTION. '&% Pro u(t) &.*. ALDE?YDE COLUMN !his column further concentration alcohol from degasif1ing column to 3>% "&" and also separates low boiling impurities liker aldeh1de from column top &... PRE RECTIFIER COLUMN 0STRIPPER COLUMN 4re rectifier column is operated under "acuum !he purpose of this column is to concentrate low boiling impurities and also to concentrate alcohol @6< .J- K6< are drawn from the pre rectifier column at the reDuired rate to 6< draw tank !hese draws are cooled in the pre rectifier @6<&K6< cooler &.3. EATRACTI:E DISTILLATIONM COLUMN ?'tracti"e distillation column is operated under atmospheric pressure this column is principall1 used for remo"al of close boiling impurities and high boiling impurities !he RS from the pre rectifier column is fed to the column and dilution water *m waterHspent lees from the rectifier column bottom+is fed on the top tra1 of e'tracti"e distillation column Steam is pro"ided to heat the column EaporsG of ?- column are used to heat simmering column .lcohol water mi'ture from ?- column bottom is fed to the rectifier column b1 using ?- bottom transfer pump

&.4. RECTIFIER CUM EA?AUST COLUMN !his column is operated under pressure !his column is principall1 used to concentration the alcohol and to draw ?J. !he pre,heated feed from ?- column is fed to rectifier cum e'haust column !he feed is heated with the spent lees coming out from the rectifier cum e'haust column bottoms in the rectifier feed pre,heater !he "apors from column top are used to heat anal1zer coloum these "apors are fed to reboiler for anal1zer column 7ooling water is used for condensing the "apors in the "ent condenser !he condensate is collected in the rectifier reflu' tank @e"el of rectifier reflu' tank is maintained with le"el control "al"e ?J. is draw from the rectifier cum e'haust column from the upper tra1s, which is cooled in the rectifier ?J. cooler and sent to the simmering column !. draw is collected in the !. mi'ing bottle Kigh boiling impurit1 light fusiol oil hea"1 fusiol oil are drawn from the rectifier cum e'haust column at the reDuired flow rate, which is controlled b1 obser"ing flow rates in rot meters respecti"el1 @6< and K6< are fed to the fusiol oil column feed tank Spent lees from column bottom rec1cled back to ?- column as dilution water (0,)0% spent less Duantit1 is purged from the rectifier column !he percentage of spent lees purge Duantit1 will depend upon the !-S&impurit1 le"el in the spent less 4ressure in the column is maintained b1 pressure control "al"e When pressure increases abo"e set point, 47E will open to maintain the pressure An this case alcohol "apors coming out of 47E are condensed and collected in !. mi'ing bottle as a !. FOSSIL OIL CONCENTRATION COLOUM 6<7 column is operated under atmospheric pressure !his column principall1 used for concentration of fusil oil, low boiling impurities and rec1cle of balance alcohol in the s1stem .lcohol water mi'ture from ?- column is directl1 fed to 6<7 column !echnical alcohol draw is taken to !. mi'ing bottle @6<&K6< draws are taken from 6<7 column !he separated fusil oil from the decanter is taken to storage and fusil washing is fed back to reco"er1 column @ees from reco"er1 column bottom is drained to gutter through reco"er1 column siphon &.;. SIMMERING COLOUM

Simmering column is operated under atmospheric pressure !his column is principall1 used for remo"al of Methanol and -iacet1le from ?J. !he column is operated at "er1 high reflu' rate at around (00,(>0 since the concentration of the low boiling impurities is "er1 low as compared to the main product ?J. is drawn from simmering column bottom and after cooling in ?J. cooler "ent to ail% re(ei@er".

C.Pro u(t 7 ( ?J. 7 ) RS 7 5 Ampure 7 = 6usel <il *B1 4roduct+

8.nd !e are mention the record hears as Opening Balance, Receive, Consumption and Balanced.9

;. RECI:ER SECTION

An this section we are collect the product as ?J., RS, Ampure and 6usel oil Keir fusel oil is a b1 product ?"er1 )= hours *morning 3 am+ we will check total production, Dualit1 Recei"er product later sent to storage
8Mention the record here as Opening Balance, Receive, Consumption and Balanced.9

<. STORAGE SECTION

!his is the storage tank for the product . Sale

B !ransferring to bottling
8Mention the record here as Opening Balance, Receive, Consumption and Balanced.9

=. DECANTER SECTION

-ecanter separate the solids and liDuid from the distillation wastes*cattle feed+ Solids name cattle feeds and liDuid name thin sloop Kear cattle feed is a product

A. Cattle Fee 'PRODUCT) 7attle feed is produced where moisture is checked and solids in cattle feed and thin slop sent to ?!4
8Mention the record here as Opening Balance, Receive, Consumption and Balanced.9

T8in Slo$ !hin sloop sent to Bio :as