INSTITUTE OF TECHNOLOGY

DEPARTMENT OF FOOD PROCESS

ENGINEERING AND POST HARVEST
TECHNOLOGY
INTERNSHIP FINAL REPORT
HOSTING COMPANY : ASELLA MALT
FACTORY
CONTENT
 Background
 Vision of the factory
 Mission of the Factory
 The work task we have been execute
 Raw Material
 Malt
 Water treatment
 Quality Control
 Overall Internship Experience and Benefit
 Conclusion and Recommendation
Background of Asella Malt Factory
•Asella Malt Factory established on the road of Addis Ababa to
Assela near Kulumsa Agricultural Research center in September
3,1984G.C.
•This malt factory far away167km from Addis Ababa & 8km
from Asella town .
•The aim of the factory is producing and providing malt for the
existing brewery factories.
•The initial capacity of the factory was100,000 quintals of barley
per year
•Now a day the factory produce 360,000 quintals of malt in a
year, the factory require 600,000 quintals of raw malt barley per
year.
 Vision of the Factory
 The factory envisioned to be known malt producer in 2019 G.C by producing and
delivering quality malt to domestic and foreign market which meets international
standards.

Mission of the Factory

 Satisfying customers needs and to be a competitive organization by producing
high quality of malt.
 Assisting researchers and producers of malt barley to increase malt production in
quality and quantity
 Reducing country’s foreign malt product import to save foreign currency and
contributing to national economic development.
 To improve production capacity and reduce the cost of production.
The work task we have been execute

 raw material quality control

 steeping barley quality control
 germination barley quality control
 green barley quality control
 finished malt quality control
Raw Material
Barley
 Barley is useful cereal rich with starch, enzymes, husks and also
less protein
 Barley is rich in nutritional content like starch, carbohydrate,
mineral, vitamin and less protein content.
 The germination capacity of malting barley is above 96%.
 Malt barley=starch + protein (nitrogen)
Cont.…
The reason why barley preferable than other grain is
depends on the following criteria:-
 Barley contain Husk used as filter media or filter bed during wort
extraction
 Barley naturally contains alpha amylase and beta amylase enzymes
which used for converting starch into glucose
 Naturally barley contain low protein content than other cereal grain
Types of barley and Variety
Two row barley has
 Lower enzyme content
 Less protein
 More starch and Thinner husk than six-row barley.
Six row barley has a
 Higher enzyme content for converting starch into
fermentable sugars
 More protein
 Less starch
 A thicker husk than two-row barley
Malt
 Malt is the heart for beer production.
 Malt is a friable package of husk, starch, less protein, flavor
precursor, Aroma, nutrient along with a balanced supply of enzymes.
 Malting is to convert barley into a product (malt) that has
appropriate color, aroma and physical characteristics and that will
yield a high level of extractable and fermentable material during
brewing with minimal processing problems.
 Malting is the process of modifying barley uniformity under
precisely controllable condition of Temperature ,Moisture and Time.
 Malt= starch+nitrogen+enzyme+aroma+flavor+colour.
Objective of malting
 To activate the enzymes and modify the structure of enzymes for
readily solubilizing and to produce a desirable flavor.
 To convert complex compounds (starch) and protein into simple
compounds.
 To break down starch endosperm, cell wall and protein matrix.
 To ensure the balanced amount of enzymes for mashing.
 To prevent over modification ,starch loss, rootlet formation.
 Flow of malt process or production process of malt

Dust CO2

Barley Barley Cleaning & Steeping

Delivery Storage Grading

Air
Water
Polishing &
Weighing Kilning Germination

Hot air
Weighing & Turning
Bagging Dispatching to Customer Cold Air Water
Steeping
 Steeping is the initial stage of malting process which barley is
immersed in water for wet and dry steeping in 32 hours for
initiates’ germination process .
During steeping process the moisture content rise from 12% to
45% and following process is done
 Aeration
 CO2 extraction
 Floating barley rejected for animal feed
 The 90% of water is used in the steeping process.
Objective of steeping

 To evenly Hydrate the endosperm barley to target moisture.

 Cleaning the barley from microbial, tannins, acids which cause
spoil taste of beer and cause haze.
 Remove the growth of inhibitor.
 To allow uniformly growth of the barley kernel during germination.
 To increase the moisture content of the barley from12% to 45%
within 32 hours.
 To provide fresh air and suck carbon dioxide and exhausting
outside.
Germination
 Germination is the development of enzymes by hydrolyzing the
cell walls and softening endosperm to remove the cell wall and
protein matrix.
 The process takes 3 -5 days depending on kernel size of the
barley.
 Small size germinate faster than large size.
 Moisture content 44%-45%.
Objective of germination process
 To produce maximum balanced enzymes.
 To hydrolyze cell wall and protein matrix.
 kilning

 Kilning is a gentle drying to stop germination, preserve

enzymes, develop flavor and color, and produce storable
product.
Objective of kilning
 To arrest biochemical reaction and stabilize enzymes activity.
 To produce stable product and removing moisture.
 To permit removal of rootlets.
 To develop color ,aroma and flavor compounds.
Quality Control
Quality Analysis for raw barley
•Sieve Analysis
•Mixation of food barley
•Germination capacity
Quality Analysis for green malt
•Moisture Content
•Acrospires Length
Quality Analysis for finish malt
•Friability
• Protein content Analysis
•Wort extraction
Saccharification is the complete degradation of starch to maltose by
alpha amylase and beta amylase enzymes
Maltose=glucose + glucose
. Water Treatment Plant
 raw water is received through pumps from local river called Kulumsa.
 then the water is directly entered in to tanks also it is mixed with
chemicals by dosing pumps. then, in the factory using some chemical
such as: aluminum sulfate (500L water for 50kg aluminum sulfate) used
for dust, dirt and unnecessary materials form flock then when this
flocculation dense and settled down to the bottom, sodium carbonate
(500L water for 50kg of sodium carbonate) used for adjust PH of water
and chlorine (160L water for 50kg of chlorine liquid) used for kill any
pathogens.
 Then the factory used treated water for the purpose of steeping,
germination and for other purpose.
Water hardness (Determining of hardness)

 Water hardness is formed when water percolates through deposit of Calcium and
Magnesium containing minerals such as lime stone, chalk etc. The total hardness is
an expression of the sum of calcium and magnesium contents.
 There are two types of hardness:
 Temporary hardness: is the water hardness caused by combination of calcium ions
and bicarbonate ions in the water. Temporary hardness is removed by boiling .
 Permanent hardness: is a hardness in which the mineral content can’t be removed
with boiling. it is usually caused by the presence of calcium and magnesium sulphate
in the water which becomes more soluble as the water temperature rises, so the
hardness of the water can be easily removed by using a water softener.
 Overall Internship Experience and Benefit
How good we have been in Performing our Work
We have been performing our task by discussing with production planners and
technicians to develop our practical skill.
Over All Benefit
Internship program is very essential in terms of improving our practical skill,
because most of us were simply familiarize with theoretical knowledge. Therefore,
internship program is enables us the following ;
 Inter personal communication
 The ability to work as a team
 It increases our confidence
Improving Theoretical Knowledge
 Some of the points that we improved our theoretical knowledge’s are: -
 To know about different chemicals and machines used during malting.
 To relate the theoretical knowledge with the real work.
 To gain the knowledge of method/procedure of malting process.
Improving Interpersonal Communication
to analyze and perfect performance of targeted evaluating and inspection, to exchange
information with the different section in the factory, and to improve relationship with others
The challenges we have been facing during performing our work task
 In the morning and night air condition is difficult.
 If the service is left us it is difficult to rich the company on foot,due to the distance
between the company and the Asella town.
Conclusion
Generally in our stay we have develop the following point:-
 We upgrade and improve our theoretical and practical knowledge.
 The internship provides an opportunity for us to apply and reflect
our knowledge and concepts acquired in the classroom.
 It creates confidence in doing and managing of work.
 It enables us to be creative, knowledgeable and to be a risk taker
for one company.
Recommendation
 Create cover grain on steep tank: the company must be construct
cover grain on the top of the steep tank in order to reduce loss and
the cross contamination of steeping barley that occurred during the
aeration process.
 In germination process: In this room the company should have to be
carefully controlling the Temperature, Moisture and Time in order
to prevent the over shooting of the green malt.
 The factory should be change the grading machines in the case it
cannot be grade appropriately, that means after it grade the raw
barley there is high percentage of third grade barley in the first and
second barley.
THANK YOU
FOR
ATTENTION