Report On Carew and Company PDF

Department of Biotechnology & Genetic Engineering
Islamic University, Kushtia-7003, Bangladesh
A Report On
Fermentation Technology & Distilled Beverages: Ethyl Alcohol from Molasses and Its Distillation
[Upon Visiting Carew & Company Bangladesh Limited, Darshana, Chuadanga]
Course No.: BT-312

Course Name: Field Work/Industrial Tour
SUBMITTED TO
Third Year Examination Committee
SUBMITTED BY
Zulkar Nain
Academic Info: 1017008/1275/2010-2011
May 2, 2015
INDUSTRIAL TOUR
TO
DARSHANA DISTILLERIES, CAREW & COMPANY (BANGLADESH) LIMITED
DARSHANA, CHUADANGA-7220, BANGLADESH
PRESENTED
BY
DEPARTMENT OF BIOTECHNOLOGY & GENETIC ENGINEERING
ISLAMIC UNIVERSITY, KUSHTIA-7003, BANGLADESH
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The main entrance of the Darshana distillery
All of us in front of distillery laboratory of Darshana distillery
Fermentation house of Carew & Company Limited

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CONTENTS
Abstract.......(iV)
Acknowledgement.....(v)
Part 1: Preliminary Concept 1-3
The Fusion of Biotechnology and Fermentation Technology......1

Why Fermentation Biotechnology is Important.......1
Fermentation and Production of Alcohol......2
Ethanol production by Yeasts....2
Distillation of Alcohol........3
Part 2: Carew & Company (Bangladesh) Limited 4-7
Basic Information.......4
Historical Background...5
Different Unit of Carew and Company.7
Part 3: Visit to Carew & Company (Bangladesh) Limited 8-11
A Combo Tour At a Glance.................................................................................9
Objectives of Our Tour........10
Part 4: Distillation Process of Carew & Company Limited 11-18
Sterilization of Wort......................11
Yeast Culture within Yeast Plant....12
Filling of Pitching Vat 13
Fermentation Process..15
Grading of Spirit..17
Foreign Liquor Products.17
Uses of Alcoholic Beverages....18
Part 5: Future Plan of Carew & Company Limited 18-18
Fish and Poultry Feed Production...........18

Reducing Ageing Time.........18
Bottle Manufacturing18
Globalization and Product Improvement18
Part 6: Alcoholic Beverages in Bangladeshi Perspective 18-19
Part 7: Recommendation for Carew & Company Limited 20-21

Development of Superior Microbial Strains20
Optimization of Existing Plant....20
Waste Management..21
Part 8: Refreshment Program 21-22
Part 6: Conclusion 22-23

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ABSTRACT
Nature blessed us with so many things; one of those is fermentation process, a very primitive
but smart and fundamental process of biological system. Fermentation, to make sense, is a
metabolic process in which an organism (usually microbes) converts a carbohydrate, such as
starch or sugar, into an alcohol or an acid. Fermentation of ethyl alcohol (C 2H5OH) from
molasses is one of the oldest technologies of its kind, and it is now widely used to produce
alcoholic beverages all over the world. Billions of yeasts restlessly working for breaking
molasses into ethanol and carbon-di-oxide (CO2) through the process of fermentation. In
Bangladesh, Carew & Company Limited (at Darshana, Chuadanga) utilizes this process for
producing alcohol (precisely, ethyl alcohol); and further they used this alcohol for producing
various types of distilled alcoholic beverages by fractional distillation. Unlike fermentation,
distillation is an artificial process by which mixture of different liquids can be separated based
on boiling point. Fermentation process in Carew and Company is carried out by
Saccharomyces cerevisiae. At least, four types of spirit i.e., rectified spirit, denatured spirit,
extra-neutral alcohol and country spirit, are produced by this industry; they also produce nine
foreign liquors (Gold Riband Gene, Yellow Label Malted Whisky, Tsarina Vodka, Fine Brandy,
Imperial Whisky, Old Rum, Rosa Rum, Orange Crackao and Cherry Brandy). At present, they
are the only leading company of alcoholic beverages since the year of 1938 in Bangladesh.
Besides alcoholic beverages production, they are intended to open some other projects such
as sugar mill, biofertilizers, fish feed production, bottle manufacturing. Although, Carew &
Company is the leading company in Bangladesh, it has some limitations in case of waste
managements, safety management, manual handling etc., which is now very important in
consideration of environmental pollution. By overcoming this situation and turning their
industry to the automation, there would be no competitor in the production of alcoholic
beverages
Keywords: Fermentation, Molasses, Distilled Beverages, Fractional Distillation,

Biofertilizers, Ethanol, Saccharomyces cerevisiae.
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ACKNOWLEDGEMENT
Biotechnology refers to the scientific and engineering principle to the processing of goods and
services. In reality, to perform any kind jobs and research in biotechnological perspective,
there should be a practical experience of biological processes besides proper theoretical
knowledge. Keeping it mind, industrial tour or field work is included in the syllabus of our 3rd
academic year under the course, BT-312. Undoubtedly, it is a timely and prudential step of our
respectable teachers. I have taken efforts in this project. It would not have been possible
without the kind support and help of many individuals and organizations. I would like to
extend my gratefulness to all of them.
First of all, I am extremely grateful to the Department of Biotechnology and Genetic

Engineering for providing this opportunity to gather some practical experience. Thanks to all
of our honorable teachers, especially, Dr. Anwarul Haque, Dr. Rezuanul Islam, Dr. Md. Abul
Kalam Azad, Dr. Md. Mizanur Rahman, Dr. Minnatul Karim, Nilufa Akter Banu, Md. Azizul
Islam and Anzana Parvin for providing theoretical basics and supports regarding this project.
I am highly indebted to all members of 3rd Year Examination Committee for their constant
supervision as well as for providing necessary information about this visit. I am extremely
grateful to Dr. Md. Abul Kalam Azad, Dr. Minnatul Karim, Dr. Rezuanul Islam, Rezuanul
Karim, Md. Khasrul Alam and Md. Azizul Islam, for their guidance and co-operation during
industrial visit.
I also express my grateful to the authority of Carew & Company (Bangladesh) Limited for
giving us such opportunity to visit their facility and time. I would like to express my deepest
gratitude to the Md. Abdul Quddus, Distillery General Manager of Carew and Company Ltd.,
who is very interesting person and help us to understand various aspects concerning alcoholic
beverage production, especially, the ageing and flavoring of distilled beverages. Special thanks
to the chemist Razibul Islam, who explained us all the materials, equipment and overall
process associated with molasses fermentation.
Special thanks to Uncle Mr. Aftab Hossain, father of one of our friend, because without him
we might not get the permission for visiting. Nevertheless, I express our gratitude toward my
families and friends for their kind co-operation and encouragement which help me in
completion of this report.
Zulkar Nain
Saturday, May 2, 2015
Department of Biotechnology and Genetic Engineering
A REPORT ON VISITING CAREW & COMPANY (BANGLADESH) LIMITED
Preliminary Concept
Biotechnology is the use of living systems and organisms to develop or make products. Apart
from referring to a type of energy metabolism, fermentation in the industrial sense is regarded as
any process for the production of various chemical or pharmaceutical compounds by means of
the mass cultivation of microorganisms. Thus, fermentation biotechnology concerns the use of
micro-organisms such as bacteria or yeasts, or cellular components such as enzymes, to alter
living or non-living materials for the production of knowledge, goods and services.
In biotechnology, fermentation has been defined as an anaerobic cellular process in which organic
compounds are converted into simpler molecules and chemical energy (ATP) is obtained. In
colloquial language fermentation has a much broader meaning, which tends to encompass the
complex of enzymatic and microorganism stimulated breakdown of macromolecules within the
fermentation substrate. Whatever, fermentation, for the good of this text, will be broadly defined
as bioprocessing using microorganisms (particularly bacteria yeasts and molds) and the
chemicals they produce (particularly enzymes, acids, gasses and volatile compounds) to achieve
desirable characteristics.
The Fusion of Fermentation and Biotechnology

Biotechnology is defined as the use of biological systems, living organisms or derivatives thereof,
to make or modify products or processes for specific use (United Nations Convention on Biological
Diversity). For thousands of years, humankind has used biotechnology in agriculture, food
production, and medicine. The term is largely believed to have been coined in 1919 by Hungarian
engineer Karl Ereky. At its simplest, biotechnology is technology based on biology - biotechnology
harnesses cellular and biomolecular processes to develop technologies and products that help
improve our lives and the health of our planet. We have used the biological processes of
microorganisms for more than 6,000 years to make useful food products, such as bread and
cheese, and to preserve dairy products. Fermentation, on the other hand, is a metabolic process
in which an organism converts a carbohydrate, such as starch or a sugar, into an alcohol or an
acid. For example, yeast perform fermentation to obtain energy by converting sugar into alcohol.
Bacteria perform fermentation, converting carbohydrates into lactic acid. Needless to say,
fermentation is not a recent innovation rather it is one of the primitive process which is
commonly used by our ancestors.
Fermentation is a natural process. People applied this process to make products such as wine,
mead, cheese and beer long before the biochemical process was understood. In the 1850s and
1860s Louis Pasteur became the first zymurgist or scientist to study fermentation when he
demonstrated fermentation was caused by living cells. As our understanding on cellular and
biological processes increased with time, we now know fermentation process is nothing different
from the perspective of biotechnology. Moreover, fermentation is a fundamental process in
biotechnology and involved with many biotechnological application, thereby creating a new
discipline named fermentation biotechnology.
Why Is Fermentation Biotechnology Important?

Fermentation biotechnology is a very important discipline in modern society and is used in many
industries for the production of various foodstuffs and alcoholic beverages, bakers yeast,
biofuels, organic acids, enzymes, vitamins, antibiotics, vaccines, monoclonal antibodies, steroids,
hormones and fine chemicals. With the emergence of a modern fermentation biotechnology
industry in South Africa, this field of research and training of students is especially relevant. In
our growing economy this advanced manufacturing approach will create many jobs, especially in
the light of the new green economy that is built on green chemistry and biofuels.
Zulkar Nain
Biotechnology & Genetic Engineering 1
Islamic University, Kushtia, BD
Fermentation Process and Production of Alcohol

Alcohol may be the world's oldest known drug. Fermented grain, fruit juice and honey have been
used to make alcohol (ethyl alcohol or ethanol) for thousands of years. The production of
products containing alcohol has become big business in today's society and the consumption and
abuse of alcohol has become a major public health problem. The effects of alcohol abuse range
from a mild hang over to mass destruction, disease and deaths on a huge scale. Alcohol use in
moderation has little or no ill effects either for the user or those around them. But the misuse of
what has become one of the world's most dangerous drugs takes a devastating toll on both the
drinker and on society as a whole.
Alcoholic fermentation, also referred to as ethanol fermentation, is a biological process in which

molecules such as glucose, fructose, and sucrose are converted into cellular energy and thereby
produce ethanol and carbon dioxide as metabolic waste products. Because yeasts perform this
conversion in the absence of oxygen, alcoholic fermentation is considered an anaerobic process.
Alcoholic fermentation occurs in the production of alcoholic beverages and ethanol fuel, and in
the rising of bread dough.
Ethanol is obtained by fermentation using glucose produced from sugar from the hydrolysis of
starch, in the presence of yeast and temperature of less than 37 C to produce ethanol. For
instance, such a process might proceed by the conversion of sucrose by the enzyme invertase into
glucose and fructose, then the conversion of glucose by the enzyme zymase into ethanol (and
carbon dioxide). Several of the benign bacteria in the intestine use fermentation as a form of
anaerobic metabolism. This metabolic reaction produces ethanol as a waste product, just like
aerobic respiration produces carbon dioxide and water. Ethanol can be produced by different way
like below:
Ethanol Production by Yeast

Yeasts, especially strain of Saccharomyces cerevisiae are the main producer of ethanol. They have
been used as a major biological tool for the production of ethanol since the discovery of
fermentation process by the time of L. Pasteur. But in 1815, Gay-Lussac formulated the
conversion of glucose to ethanol and carbon-monoxide (CO2). The formula is given below:
C6H12O6 2C2H5OH + CO2
Yeast converts di- and oligo-saccharides through EMP pathway into pyruvic acid. Specially,
Saccharomyces cerevisiae do this process. Ethanol fermentation is used the production of beer,
wine and bread. It's worth noting that fermentation in the presence of high levels of pectin result
in the production of small amounts of methanol, which is toxic when consumed.
Fermentation of ethanol is carried out in a large fermenter (size 1000 to 1.5 million dm 2). The
inoculum of microorganism is maintained in fermenter at the optimum growth conditions such
as temperature, pH, oxygen and concentration of carbohydrate, the substrates. Before starting
the fermentation pure inoculum (starter inoculum) of species of Saccharomyces is prepared by
inoculating the well-defined and sterilized medium. At the same time fermentation medium is
formulated, sterilized and transferred to the sterilized fermenter. Liquid medium in fermenter is
inoculated with a small inoculum of yeast. Growth conditions of liquid broth is maintained to
provide optimum conditions at temperature, pH, oxygen etc. for the production of ethanol.
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Figure-1: Ethanol production by Saccharomyces cerevisiae
After inoculation at the optimum growth conditions for different periods the culture fluid is
filtered when growth of the microorganism is over. Consequently, the yeast cells (biomass) are
separated from the supernatant. From the supernatant, products are recovered and purified. The
yeast mass is used for the effluent treatment or as the source of single cell protein.
Distillation of Alcohol
Fermentation alone does not produce beverages with an alcohol content greater than 12 to 15%
because the fermenting yeast is destroyed at high alcohol concentrations. To produce beverages
of higher alcohol content the aqueous solution must be distilled. Distillation was one of the
earliest separation techniques used by alchemists and pharmacists. And, generally, distillation,
along with chromatography and filtration, is still considered to be a key method of separating and
purifying substances.
Distillation is a separation process for a mixture of liquids or oils. It relies on differences in the
boiling points of the component liquids to be separated. The mixture to be separated is added to
a Distilling Pot where it is heated to the boiling point. Lower boiling components will
preferentially vaporize first. This vapor passes into a Distilling Head and then into a Condenser.
Within the Condenser the vapor is cooled and it liquefies. The resulting liquid is then collected in
a Receiving Flask. Initially, low boiling components are collected in the Receiving Flask. As the
distillation proceeds, these components are depleted from the Distilling Pot and higher boiling
components begin to distil over. Switching out the Receiving Flask at the appropriate point allows
for the separation of the component liquids of the mixture.
Mixtures of a large number of similarly boiling liquids can be separated by a technique called
Fractional Distillation. In fractional distillation, a distilling column allows the vapor arising from
the distillation pot to be repeatedly recondensed and revaporized. After a number of these
recondensation/revaporization steps, the lower boiling component will be relatively free of any
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higher boiling components. This allows for a more thorough separation of the liquids. This
method of distillation is employed during the Oil Refining process.
Most manufacturers of liquor report the Alcohol content by its Proof. In the US system, the Proof
is double the Vol. Percentage Alcohol:
Proof = 2 x Volume Percentage
Historically, the term Pro of derives from a method of measuring the Alcohol content of liquors
so as to prove they were not diluted. If gunpowder mixed with liquor would still ignite after the
Alcohol burnt off, then the Alcohol was not considered to be diluted. The minimum Vol.
Percentage Alcohol required for ignition is 57%; which, historically, was assigned a value of 100
Degrees Proof. Levels of Alcohol in liquor are still measured by Proof, for tax purposes, but the
scale is different in different countries.
Carew & Company (Bangladesh) Limited
Figure-2: Main gate of Darshana distilleries, Carew & Company Bangladesh Ltd.
Basic Information
Carew & Company (Bangladesh) Limited (1935), which is situated at Darshana of Damurhuda
Upazilla of Chuadanga district is the largest sugar mill of Bangladesh. Carew & Company has a
distillery also which is the lone wine producing plant of Bangladesh. It was established by private
industrialists in 1935 and has a sugar mill, one Distillery and one Pharmaceutical unit under its
ownership. Machinery & apparatus of the sugar mill were supplied by M/S Blairs Ltd. of Glasgow,
U.K. It ongoing trial production in 1938-39 and commercial production from 1939 to till now.
Carew & Company (Bangladesh) Limited is an enterprise of Bangladesh Sugar & Food Industries
Corporation (BSFIC). BSFIC is an autonomous body of Ministry Of Industries (Government of
Bangladesh).
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FACTORY INFO TIME AND CAPACITY

Establishment of Industry 1935
Experimental Production 1938
Commercial Production 1938
Nationalization 1972
Sugarcane Crushing Capacity 1,150 Metric Ton
Amount of Sugarcane Production 11,500 Metric Ton
Storage Capacity of Sugarcane 7,200 Metric Ton
Capacity of Steel Tank (Molasses) 6,500 Metric Ton
BMRI Certification 1982 83
The original cane crushing capacity of Carew & Co. Sugar Mills was 1016 Metric Tons per day.
After nationalization in 1973, the sugar mill was partially restructured during 1978-85 under
Australian assistance at a cost of Tk. 208.84 million. As a result, the economic operating life of the
sugar mill amplified for a few years and its daily cane crushing capacity also amplified to 1150
Metric Tons with conforming increase in sugar production capacity to 11,500 Metric Tons per
annum. Since 1972-73, the sugar mill has produced 12,566 Metric Tons of Sugar per annum on
average at an average sugar recovery rate of 8.14% from sugarcane. Highest sugar production
was 19,840 Metric Tons in 1990-91.
UNIT UNDER YEAR OF EQUIPMENT ANNUAL

CAREW & COMPANY ESTABLISHMENT SUPPLIER COMPANY PRODUCTION RATE
Messers Blares Ltd.,
Sugarcane Mill 1938 11500 metric ton
Glasgo, England
Messers Pingris Ltd.,
Distillery Mill 1938 45, 00000 metric ton
Etmolate, France
Pharmaceuticals 1951 Local collection 90, 000 liter
Biofertilizer 2012 Local collection
Total cane-cultivable land in the mill zone of Carew & Co. Sugar Mill is about 45,600 acres of which
15,600 acres per annum on average is brought under sugarcane cultivation. The sugar mill has
contributed Tk. 1073.00 million to the National Ex-cheered as dividend taxes and duties since
1972-73. Total land under Carew & Company (Bangladesh) Ltd. is 3559.89 acres including
9(nine) profitable farms as detailed below:
LAND AREA AMOUNT IN ACRE

Factory and Residence 167.45
Cane Purchase Center 5.30
Transportation Road 48.35
Commercial Farms (10) 3335.56
Total 3556.66
The distillery of Carew & Co.(BD)ltd. has an yearly production capacity of 2.80-3.00 million proof
liter of spirit from molasses which is used for making rectified spirit, denatured spirit, country
liquor and 35,000/36,000 cases of foreign liquor.
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Historical Background
The origin of the concern which was then only a distillery date back to the year 1850 when Mr.
Joni Maxwell created a distillery as Jaujmow Cawnpore. Later in 1810 or 1811, he move this
distillery to a place called Collaghat situated near the ram Gonga River in the Jalalabad Tehsail
of the Shahjahanpur district. The object of the distillery was to manufacture Ram for the
commissariat department of the army and the Ram produces at Collaghat was sent in boats to
Canpure from where it was invoiced to the commissariat at Alahabad.
In the year 1832 the agent for the concerned messes. Fairly Ferguson and co. Calcutta for some
reason suspended payment and assigned being appointed Mr. Barron become the agent and
ultimately brought the concern in the name of John OBarrien Saunders who was interned
financed by messes. Lyall Matheson and co.
Distillation at Rosa state in about the year 1837 and at some time during the year 1839and 1840
the first attempt at refining sugar was made. For a time the farm carried on in Barrons name,
then in the name of Saunders, Barron. In 1840 after Saunder had left and a Capt. Backeet had
joined it was called Barron and Backett. Backett did not stay long; he left in 1845 and form 1846
the concern was known as Barron and co. Mr. Robert Russel Carew form that the company now
takes its name first came to Rosa on the 11th march with a view to joining Barron in his business.
Prior to this he was connected with the Dhobah sugar co. and was the associated with Mr. Jone
Lyll and Mr. Jone Ronnic who were later to become the agent from Rosa.
At the time of the Mutiny Carew was in England and Rosa was being managed by a Mr. Brand and
Carews younger brother. The Mutiny broke out in Shahjahanpur on the 31st of May and the
factory at Rosa was plundered. Mr. Brand and the young Carew were however, able to get out of
the factory are before the trouble started and were given protection by Thakurs of a neighboring
village. It is known that they were created hospitably but both of them lost their lives during the
Mutiny. Mr. Brand died of sickness while he and Carew and Co. with their protector were on their
way to luck-now. It is said that the young Carew died of exhaustion after reaching the residency
at Luckhnow.
When Mr. Robbert Russle Carew heard in England of the Mutiny the destruction of the factory
and the death of his brother he immediately set out for India and on his arrival here made planes
for the re-building of the distillery and sugar works. He had a great deal of difficulty in this
connection and met with the considerable to obtain timber required urgently in connection with
the re- building and he was not allowed to employ and workers. However, on his making several
applications to the authorities, including the Governor General it was eventually decided that in
so far it was possible assistance should be given to him and the local authorities were instructed
accordingly.
In 1857 Carew felt that he and his partner were getting too old to manage the business at Rosa,
and he decided that Joint Stock Company should be formed. This was formed in that year and was
named as Carew & Company Limited and the work was entrusted to a manager at Rosa and
Managing agent in Calcutta. The first Managing agents weer Messsrs. Layll Dennie & Co. but they
as also their successors, Messrs. Gray & Co. and Messrs. Gray Lyall & Co. had a very short time,
and the managing agency issued to Messrs. Lyall Marshall& Company, who continue as managing
agent till 1947 when Messrs. Gladstone lyall & company, took over.
As the year passed the business at Rosa increased and branched were established at Asansol amd
Kaoni. The latter, however was closed down many years ago, but another unite was established
in 1938 (at Bangladesh). Messrs Gladstone Lyall & Co. Ltd Culcutta. Become the secretaries &
treasure of Carew &Co. Ltd. Darsana and continue up to September 1962, a public company was
constituted to Karachi in the name & style of Carew & Company Ltd. With the idea for taking over
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this asset and liability of the Carew & Co Ltd. Mr. J.M. Bannerman, the director of Carew & Co. Ltd
and 3 others become the chairman and director of the Pakistani company. The registered office
of the company was subsequently transferred from Karachi to Dacca (now Dhaka).
A vending agreement was then reached between the Carew & Co (Pak) Ltd. and M/S. Carew & Co.
Ltd on September 21, 1964, in terms of which all the assets & liability as on September 30, 1964,
relating to Darsana factory were transferred to Pakistani company at a consideration value of
Rs.1,33,444. As a result such vending agreement the properties were transferred to Pakistani
company managing the distillery at the Darsana factory but Pakistani company could not float
shears for subscription, though it received permission from the controller of capital issues in July,
1965, and pay the consideration value to Carew & Co., Calcutta.
With the outbreak of Indo-Pak war in Sept. 65, the Government declared the property as enemy
property. Carew & Company (Pakistan) Ltd. challenged the government order including
ownership of the property and filed write petition in favors of declaring the company as enemy
property by Government. The board of directors of Carew & Company (Pakistan) Ltd. Then
preferred an appeal against this order of the high court before the supreme court-Pakistan and
obtained an interim order preserving status ago, by virtue of which the company continued to be
in possession and management of the property and business. The hearing of the said appears was
awaited until the liberation of Bangladesh.
After liberation in 1972 the Government of Bangladesh directed that wherever the word
Pakistan exists should be replaced with Bangladesh. From this sensitive corner, the name of the
company was changed and renamed as Carew& Company (Bangladesh) Ltd.
The Government of Bangladesh in pursuance of Presidents order no. 51 of 1971, published in the
Extraordinary Bangladesh Gazette on 23rd may, 1972, nationalized the Carew & Company
(Bangladesh) Ltd and put it under the management of Bangladesh Sugar & Food Industries
Corporation and is continuity as such till to date.
Different Unit of Carew & Company Ltd.

There are three major units in Carew & Company (Bangladesh) Ltd., these units are related to
each other, as follows:
Unit I - Sugar Mill: Sugarcane is used as raw material to produce sugar and by the time molasses
is produced as a byproduct, in this unit. This sugar is qualitatively and quantitatively perfect in
our country and foreign country. Large scale of sugar demand is now full filled by this great sugar
mill. This sugar mill plays a vital role in our economy.
Unit II - Distillery: Byproduct of sugar mill, molasses is used to produce alcohol in this unit,
which is then used to produce distilled alcoholic beverages. Molasses contains 48-52% of total
sugar and it was then used by the yeast to produce ethyl alcohol.
Unit III Biofertilizer: Biofertilizer means the fertilizers derived from biological waste such as
house hold waste & drug. Organic biofertilizer are thoroughly produced from the third unit of
Carew & Company, where press mud waste are used as raw materials. Press mud are waste
produced as the byproduct of alcohol production.
However, our tour is totally intended for the study of the fermentation process and distillery unit,
therefore we will stick to Unit I and Unit II, and discuss further in details.
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Visit to Carew & Company (Bangladesh) Ltd.

On the 27th April, 2015, we left our university campus at 7.30 am for industrial tour and destined
for Darshana distilleries by the Kushtia Jhenida Road, Jhenida Chuadanga Road and finally by
Darshana distilleries routes. We arrived in front of Carew & Company (Bangladesh) Ltd., at 9.45
am and after a short brief by our respectable teachers, we entered into the industrial area at 10.16
am with our coordinators and the authority of Carew and Company.
Shortly after the entrance, the chairman of our examination committee, Dr. Md. Abul Kalam Azad,
split us into two groups so that we can visit and explore more comfortably. Luckily, I got Dr. Md.
Abul Kalam Azad in our group. At first he took us to the distillery laboratory for showing us the
basic protocol, stock culture of molasses and yeast strains along with other teachers, Md.
Rezuanul Karim and Md. Azizul Islam.
Figure-3: Microphotograph of Saccharomyces Figure-4: Stock solution of molasses and mother

cerevisiae strain of yeasts.
In the laboratory, chemist Mr. Razibul Islam gave a wonderful speech about the basic process of
molasses fermentation and the production of distilled alcoholic beverages. He also showed us
stock solution and yeast mother strain on semi solid media. In the meantime, Dr. Abul Kalam Azad
showed us a microbial strain through the microscope, and we see a bunch of Saccharomyces
cerevisiae strain which was yeast (commonly called fungi). I took a macro-shot of yeast strains
which is provided above, not so clear though!
After exploring the distillery lab, we moved to the fermentation house. Chemist Razibul Islam led
us to the fermentation house to show us what and how fermentation occurs in the fermenter and
how the distillation of alcohol works. There we saw some big size fermenter in which yeast are
continuously cultured within diluted molasses and urea is provided as the source of nitrogen. We
were amazed when urea is given to yeasts as feed, they start bubbling, which was really incredible
thing to see because yeasts are too minute to create such bubbling, and its more like fish bubbling
in the water at the time of feeding. But they were able to do it by their billions of collective efforts.
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Figure-5: Extra Neutral Alcohol (ENA) plant house
Then we went to the Yeast plant, ENA plant and Distillation plant; and observed the mechanism
of distillation and production of safe spirit through the distillation process. After this, we exit the
fermentation house and moved to the Rectified Spirit Vat House followed by the Foreign
Liquor Production Division. In the former, there are many rectified spirit containing vat of
varying size.
In the foreign liquor production division, bottling and packaging are done manually by hand.
There, Distillery General Manager Md. Abdul Kuddus, showed us seven foreign liquor brand and
gave a brief and intellectual speech. Those foreign liquor were: Yellow Label Malted Whisky,
Tsarina Vodka, Fine Brandy, Imperial Whisky, Gold Riband Gin, Old Rum and Rosa Rum.
Figure-6: Packaging and bottling of foreign liquor brands
After visiting the foreign liquor production house, we took some photographs with Dr. Md. Abul
Kalam Azad and Distillery General Manager (GM) Md. Abdul Kuddus. Then we met the other
group and rest teachers in front of DS Godown. Then GM Md. Abdul Kuddus told us about the
future plans and their systems advancement and its negative side, but he assured that he will
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change the plot as a whole if he capable. He also invite us to do research or job in their industry
and appreciate us for visiting their company. Meanwhile, the father of one of our friend Setu, Md.
Aftab Hossain is came to meet us with his family, and we cordially welcomed him and took some
photographs with all.
Figure-7: Our group photo in front of foreign liquor brand division with our coordinator, Dr. Md. Abul
Kalam Azad, Distillery GM Md. Abdul Kuddus and chemist Razibul Islam
Finally, we left Darshana Distilleries at 11. 51 am and go to the historical place, Mujibnagar
Amrokanon, then to Aath Shaheed Smriti Complex (recreation program discussed later in
details). Lastly, we go to Sundian Chinese Restaurant for having launch. After having launch, we
got into the bus and came back to our lovely campus.
A Combo Tour at a Glance

Our industrial tour plan was visiting Carew & Company (Bangladesh) Ltd. but we also visited
Mujibnagar Amrokanon and Aath Shaheed Smriti Complex. Then we got some fun and launch at
Sundian Chinese Restaurant. Finally, then we got back to our campus and our industrial tour is
end by then. Various places we visited with time we arrived there are listed in the following table.
EVENTS PLACES TIME

Departure Islamic University Campus 7.30 AM
Arrival Carew & Company (BD) Ltd. 9.45 AM
Leave Carew & Company (BD) Ltd. 11.51 AM
Arrival Mujibnagar Amrokanon 12.42 PM
Visit Aath Shaheed Sriti Complex 2.10 PM
Lunch Sundian Chinese Restaurant 3.00 PM
Leave Islamic University Campus 4.00 PM
Arrival Islamic University Campus 6.15 PM
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In a nutshell, we passed a wonderful day with both academic purposes and refreshment with full
of joy. We really enjoyed the day and it was a big day for us all.
Objectives of Our Tour

In course of our academic study, fermentation is very popular process, we often heard of.
Fermentation is very important for all kind of biological system, and obviously our study tour to
Carew & Company (Bangladesh) Ltd. at Darshana, Chuadanga was involved with this primitive
process. The main objectives of our industrial tour are given below:
To gain or achieve the practical experience of fermentation system;

To know the present advancement of fermentation technology;
To know how alcohol is produced by fermentation process;
To know the difference between recombinant strain and mother strain in fermentation;
To know the major types of product by molasses fermentation; and
To know how to face major problems related to fermentation technology.
Whatever, our main purposes of this industrial tour was to understand the fermentation process
in a close view and to estimate the importance of fermentation technology in our daily life.
Distillation Process of Carew & Company

Carew & Company (Bangladesh) Ltd., produces alcoholic beverage only from the distilled liquors
(spirit) based on the yeast fermentation process of molasses. Molasses is received from the sugar
factory, which contain 48% to 52% of total sugar. The starting material normally comprises either
sugary materials (fruit, juices, plant sap, sugarcane, honey) or starchy materials (grains or roots),
which need to be hydrolyzed to simple sugars before the fermentation. When these substrates
are incubated with suitable microorganisms and allowed to ferment, the end-product is a liquid
containing anything from a few percent up to 16% or more of alcohol, with an acid pH and
depleted in nutrients for most contaminating microorganisms. Further distillation will increase
the alcohol strength and produce spirits of many types, e.g., whisky, brandy, vodka, gin, rum, etc.,
which can contain between 40 and 50% ethanol. The alcoholic beverages can be drunk fresh but
normal practice for many requires a period of storage or ageing, leading in many cases to
improved organoleptic properties.
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Figure-8: Distillery laboratory at Carew & Company (Bangladesh) Ltd.
However, the yeast species used in this context is Saccharomyces cerevisiae. The detailed
procedure from molasses to spirit is very long and step by step process and all the steps are
briefly described below.
Sterilization of Wort
For sterilization, 14-14.5 brix of wort poured into the plant till the one third portion of plant
(approximately, 500 liters). Then 500 gram of T.S.P and 1 liter of H2SO4 are added to the wort and
heated it until it reaches at the temperature of 110-115C. This way sterilization of wort was
completed. Finally, sterilized wort allowed to cool down so that it can be used in Yeast Plant. It is
to be mentioned that H2SO4 is used for the hydration of ethylene thereby help producing ethyl
alcohol.
Yeast Culture within Yeast Plant

Yeast grown in laboratory condition cannot be used instantly. Before using, yeast must be
cultured in yeast plant through the series of plants, Yeast Plant I, Yeast Plant II and Yeast Plant III.
Detailed process of serial culture is given below:
Yeast Plant I: Firstly, 10 liters of cultured yeasts from laboratory is mixed with 100 liters of
sterilized diluted molasses media. At this stage, there are 160-220 million yeasts per milliliter of
culture. Then 500 gram urea and 1-2 penicillin is added to the media and allowed for the
propagation of yeasts for 12 hours.
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Figure-9: Three yeast plant
Yeast Plant II: After 12 hours, yeast from 1st Plant are transferred into Yeast Plant II. The amount
of media in plant II is 500 liter. Like Plant I, 500 gram of urea and 2 penicillin are added to the
media and allowed propagation for 8-10 hours.
Yeast Plant III: In the very same manner, after 8-10 hours, yeasts from plant II are transferred
to the Yeast Plant III and 1 kg of urea and 3 penicillin is added to the media. The amount of media
in plant III is about 2500 liters.
Figure-10: Distillery part of fermentation house with Yeast and ENA plant
Filling the Pitching Vat

The next task after yeast culture is to fill the pitching vat. There are three successive steps through
which pitch vat is filling up. They are provided below:
Step I: If the media brix is 6-6.5 from plant III, then it is ready to pour into pitch vat.
Meanwhile, it was upgraded to the 9.0 brix by the addition of appropriate amount of wort.
Now, 2 liters of H2SO4, 2 kg of urea and 1 kg of T.S.P is added to the pitch vat.
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Step II: Again, if the brix of the media is down to 6-6.5, it is to be upgraded to 9.0 brix with
appropriate amount of wort. At this stage, 2 liters of H2SO4, 2 kg of urea and 1 kg of T.S.P
is added again.
Step III: In this step, when the media brix is get lower to 6-6.5, then pitch vat is make full
with appropriate amount of wort. Then, 4 kg of H2SO4, 4 kg of urea, and 2 kg of T.S.P is
added to the wort.
When the media brix is again 6-6.5, half of the total amount of yeast is transferred to another
pitching vat. In the same way, another more pitching vat is filled.
Figure-11: Pitching vat besides the distillation room
Fermentation Process
To carry out the fermentation process, 3500 gallons of yeast media from pitching vat is taken into
one fermentation vat. Meanwhile, fermentation vat of 16,000-17,000 gallons capacity is filled up
stepwise with wort. For one single fermentation vat, total 10-12 kg of urea is added by three times
and total 8-10 liters of H2SO4 added by two times. Time needed for fermentation is about to 24-
30 hours. Alcohol or spirit is produced by the fermentation process by the following way:

12 22 11 6 12 6 + 6 12 6

6 12 6 22 5 + 22
As soon as the fermentation in a fermentation vat is completed, it is subjected to fractional

distillation by which spirit is isolated. The whole process is very long and it takes about 110-120
hours.
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Figure-12: Fermentation in a large fermentation vat
Figure-13: Yeasts bubbling during the urea feeding
Grading of Spirit
There are four types of spirit produced by the distillation at Darshana distilleries. They are:
Rectified Spirit (RS), Denatured Spirit (DS), Country Spirit (CS), and Extra Neutral Alcohol (ENA).
Rectified Spirit
Rectified spirit, also known as neutral spirits, rectified alcohol, or ethyl alcohol of agricultural
origin is highly concentrated ethanol which has been purified by means of repeated distillation, a
process that is called rectification.
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It typically contains 95% alcohol by volume (ABV) (190 US proof). The purity of rectified spirit
has a practical limit of 95.6% ABV when produced using conventional distillation processes,
because a mixture of ethanol and water becomes an azeotrope at this concentration. Neutral
spirits are used in the production of blended whiskey.
Denatured Spirit
Denatured alcohol, also called methylated spirits or spiritus, is ethanol that has additives to make
it poisonous, extremely bad tasting, foul smelling or nauseating, to discourage recreational
consumption. In some cases, it is also dyed. Denatured alcohol is used as a solvent and as fuel for
alcohol burners and camping stoves. Because of the diversity of industrial uses for denatured
alcohol, hundreds of additives and denaturing methods have been used.
The main additive has traditionally been 10% methanol, giving rise to the term "methylated
spirits". Other typical additives include isopropyl alcohol, acetone, methyl ethyl ketone, methyl
isobutyl ketone, and denatonium. Denaturing alcohol does not chemically alter the ethanol
molecule. Rather, the ethanol is mixed with other chemicals to form an undrinkable solution.
Extra Neutral Alcohol

Extra neutral alcohol is colorless and has a neutral smell and taste. It is generally distilled from
sugarcane molasses. It is used as a base for manufacturing Indian made foreign liquor. It has a
strength of 75 proof when bottled. The Potable alcohol is a triple distillated alcohol with negligible
impurities to be used in the high cosmetic industry, perfumeries as well as for the production of
white alcohol brands such as vodkas, liquors and aperitifs. The distillation method used can also
be patent still or continuous distillation method.
Figure-14: Outline of overall process of fermentation and distillation
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Foreign Liquor Products

At present, Carew and Company produces nine brand of foreign liquor products which are all
distilled alcoholic beverages with 42.76% alcohol contents or 75 proof. Following seven brands
are well-known and rest two, Orange Crackao and Cherry Brandy, are just recent upcomings,
hence they are not provided in the following list.
BRAND NAME COMPOSITION ALCOHOL CONTENT

Gold Riband Gene ENA + Distilled Water + Gin Flavour (from IFF) 42.76%
Yellow Label ENA + Distilled Water + Malt + Yellow Label
42.76%
Malted Whisky Malted Whisky Flavor + Caramel
Tsarina Vodka RS + Distilled Water 42.76%
Fine Brandy RS + Distilled Water + Brandy Flavor + Caramel 42.76%
Imperial Whisky RS + Distilled Water + Whisky Flavor + Caramel 42.76%
CS + Distilled Water + Matured in Wooden Vat +
Old Rum 42.76%
Caramel
CS + Distilled Water + Matured in Wooden Vat +
Rosa Rum 42.76%
Caramel
Figure-15: All nine foreign liquor brand in one shot
Uses of Alcoholic Beverages

Alcoholic beverages are very important in our daily life. These are used in various purposes, some
are given below:
In many countries, alcoholic beverages are commonly consumed at the major daily meals
(lunch and dinner);
In places and eras with poor public sanitation, such as Medieval Europe, consumption of
alcoholic beverages (particularly weak or "small" beer) was one method of avoiding water-
borne diseases such as the cholera;
Ethanol of alcoholic beverages allows them to be stored for months or years in simple wood
or clay containers without spoiling, which was certainly a major factor in their popularity;
In colder climates, strong alcoholic beverages are popularly seen as a way to "warm up" the
body, possibly because ethanol is a quickly absorbed source of food energy and dilates
peripheral blood vessels; and
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In many cultures, both contemporary and historical, alcoholic beverages mostly because
their neurological effects have also played an important role in various kinds of social
interaction.
Instead of these above mentioned uses, there are many more useful aspects of alcoholic beverages
that make it so popular in the present world.
Future Plan of Carew & Company Limited

Besides production of distilled alcoholic beverages, sugar and biofertilizers, Carew & Company
has some other interests in different direction, i.e., fish feed production, large scale production
of existing products and their globalization.
Fish and Poultry Feed Production

Poultry feed is produced from microbial biomass from tannery industry, therefore, it has
antibiotic resistance effects which is transferred into our body due to long time consumption of
poultry meat thereby increase antibiotic resistance in our body. So, we try to focus on poultry and
fish feed production from our yeast biomass which is a pure old strain, and thus it would not
create antibiotic resistance in human said Md. Abdul Quddus, Distillery General Manager at
Carew & Company (Bangladesh) Ltd.
Reducing Ageing Time

Carew & Company (Bangladesh) Ltd. has done some breakthrough work on ageing time. The
more ageing time, the more taste will be but long ageing time is very difficult to maintain and a
restriction for production increment. In this case, Carew & Co. reduce ageing time of some of their
brand without harming taste and flavor. We are successfully able to reduce 6 years and 3 years
of ageing into 6 month and 3 month, respectively said Distillery General Manager Md. Abdul
Quddus.
Bottle Manufacturing
At present, bottle are purchased from other industry which is less productive and loss of huge
money. Keeping it mind, Carew & Company have made a decision to manufacture bottle by own
for their product and obviously it will upgrade the company and its quality by many times.
Globalizing and Product Improvement

Carew & Company is one of the industry of its kind, and they constantly focusing on their
production increment. They mainly focus on how to increase the distilled alcoholic beverages
production by many fold as of today. Another bigger steps they are trying to achieve that is to
globalize their products and make some of the novel category of alcoholic beverages. We
successfully produced a lemon flavored (which is imported from France) liquor named as Orange
Crackao, said Md. Abdul Quddus, Distillery General Manager of Carew & Company (Bangladesh)
Ltd. He further added that they are working on it.
Alcoholic Beverages in Bangladeshi Perspective

In Bangladesh, the consumption of alcohol is strictly prohibited both as a social function and as a
religious rite by most of the religions. Yet, the problem of alcoholism is becoming a threat to the
nations welfare. Information obtained from law enforcement authorities, treatment providers
and other sources indicate that problems of alcohol abuse have become quite common in
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Bangladesh. Although the problem is more serious in urban areas of the country (probably due
to easy accessibility of alcoholic beverages), there are indications that it is emerging at an
increasing rate in rural areas. Alcohol is being produced by some pharmaceutical industries in
Bangladesh. In addition, local alcoholic beverages called cholai and tari are consumed by the
lower socioeconomic classes, while workers drink another distilled beverage called Bangla Mad.
Moreover, some crude forms are produced and used by the poor, usually by fermentation of
boiled rice, sugar-cane, and molasses.
According to the 2003 World Health Survey (total sample size n = 282; males n = 275 and females
n = 7), the mean value (in grams) of pure alcohol consumed per day among drinkers was 4.9
(total), 4.9 (males) and 4.1 (females). In Bangladesh, statistically recorded adult per capita alcohol
consumption (age 15+) is provided below:
# Sources: FAO (Food and Agriculture Organization of the United Nations), World Drink Trends 2003
Figure-16: Statistical record of adult per capita alcohol consumption (age 15+)
Although no systematic assessment has been undertaken so far to establish the prevalence and
patterns of substance abuse in Bangladesh, reports from different governmental and non-
governmental drug addiction and treatment centers and from various journals and studies report
increasing drug-related crimes in the country. It is noted that the younger generation, especially
students, are most vulnerable to this problem.
At least 90 Bangladeshis died in 1998, including 70 in Gaibandha, after consuming illegal

homemade alcohol. In the following year, there was an incident of alcohol poisoning in the north-
eastern town of Narsingdi, about 50 miles from the capital Dhaka, where 96 people reportedly
died and more than 100 hospitalized as a result of drinking illegal homemade liquor.
However, without knowing the strength, people are using different types of homemade alcoholic
beverages as such in a risk of health hazards as well as death. A national survey need to be
conducted to obtain how many types of alcoholic beverages being manufactured, their strength
and true picture of alcohol use so that strategy plan can be developed of its healthy use if needed
at all. In addition, Carew & Company should aware of these issues.
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Recommendation for Carew & Company (Bangladesh) Ltd.

Following recommendations are intended for the improvement or the better output of the
Industry we visited last week, Carew & Company (Bangladesh) Ltd. I think some aspects of the
distilleries should be analyzed and should have taken some measures.
Superior Microbial Strain

Microbes (specifically, yeasts) are responsible for the conversion of sugar into ethanol. Different
types of strain are used different types alcoholic beverages or one type of beverages. Sometimes,
quality of beverage vary according to the strain used in fermentation. Different types of microbes
vary in their metabolism and therefore in alcohol. Development of improved and superior
microbial strain is very important in case of large scale production of alcohol because old or
natural strain might not work as efficiently as of todays.
In Carew & Company, they use an old yeast strain, Saccharomyces cerevisiae (named turbo) from
the beginning, which is not so efficient. To increase the production rate in short time with
constant quality, recombinant superior yeasts should be developed through mutation and
selection.
Existing Plant Optimization

Sometimes new setup is problematic and costly too. In such case, some measures can be taken in
account for the increment of production and quality of alcoholic beverages through optimizing
the existing plant in many other ways. Some ideas are as follows:
Reduction of Ageing Time

Ageing time is very important for taste and flavor in case of alcoholic beverages but its difficult
to maintain for long time. It is said that the more ageing time the greater taste and quality of the
beverages but it is now possible to reduce ageing time without harming the taste and quality.
Carew and Company already done some work on it, and walk on it with continuity.
Maintaining of Aseptic Condition

One of the major problem, we found at Carew & Company in the maintenance of sterile condition.
Sterile condition is not maintained in this industry and therefore the beverages produced by this
industry should be subjected for the contamination test prior to marketing. This contamination
issue should be fixed as soon as possible because this industry is going to flood the whole country
in near future.
Clean and Safety Protocol

It is very important that the beverages we drink is to be clean and safe. So it is essential to prepare
beverages in a safe, hygienic way. If germs (such as harmful micro-organisms and parasites) get
into our foods and drinks, they may give us food poisoning (resulting, for example, in diarrhoea
or vomiting). It is a great lament for me to say that clean and safety protocol is not maintained at
Carew and Company (Bangladesh) Ltd. They still work manually which is not safe rather very
risky and unproductive. It should be automatic in which clean and safety protocol will be
exclusively maintained.
Increased Taste and Flavor

Beer and wine may be flavored before fermentation. Spirits may be flavored before, during, or
after distillation. Sometimes flavor is obtained by allowing the beverage to stand for months or
years in oak barrels, usually American or French oak. A few brands of spirits have fruit or herbs
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inserted into the bottle at the time of bottling. This industry is concerned at this matter but it
should be more.
Waste Management
Waste disposal and proper effluent treatment is another big issue, we found at Darshana
distilleries. It should not be like this because alcohol is highly inflammable and other wastes as
by product could be the reasons of environmental hazard. In addition, contamination risk could
be high from this undisposed wastes. Therefore, the authority of the Carew & Company should
take an action immediate in this matter.
Refreshment Program
After finishing our visit to Darshana Distillery, we had a detour to the historical place Mujibnagar
Amrokanon. Mujibnagar, formerly known as Baidyanathtala is a town in the Meherpur District of
Bangladesh. It is a common reference for the government in exile formed by the leaders of the
Awami League, who were leading the guerrilla war for the independence of Bangladesh (then
East Pakistan) from Pakistan (then West Pakistan) in 1971. Throughout the war with the Pakistan
Army, the Mujibnagar government was served as the nominal head of the pro-independence
guerrilla militias, mainly the Mukti Bahini. Although the state gained independence only in
December 1971, the Mujibnagar government is recognized as the first official government of
Bangladesh.
Figure-17: Recreation at Meherpur Amrokanon
Whatever, we explored the area (but not fully because of time). It was really a touchy place and it
remind us about our liberation war. We enjoyed the place very much and took part in some
snapshot, did some fun with my friends. After finishing there, we went to another historical place
Aath Shaheed Smriti Complex, where eight martyrs are murdered during the liberation war.
Then we went to the Sundian Chinese Restaurant for having lunch. There we had our lunch with
all of our friends and respectable teachers. I enjoyed that very much because it was the first
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industrial tour in my life. After having meal, we set out for our campus finally, and reached at
evening.
Conclusion
Fermentation technology is a very vibrant and fast growing area of biotechnology, absorbing an
ever increasing process and products. With a longer history than any area of biological sciences,
fermentation technology has a longer and brighter future, in the service of mankind, covering
such important areas as food and medicine. Although, industrial tour is part of our 3rd year
academic course, it is very important for a person who is destined to be biotechnologist or
researcher of biological science. This types of tour increases our practical knowledge. The reason
behind this is, we have to live in a practical life where something occurs in real, so if we dont have
enough knowledge to deal with the real life circumstances then we have nothing.
However, fermentation is very important as I said earlier. By visiting Darshana distilleries, we

learn something in real life which boost up ourselves to work on biological science. It encourages
us to learn something new and motivated to do something better, because biological science is
not a steady and constant science rather its an ever growing and never ending science which is
still at its childhood. We should do more practical works like this because it help us to be creative,
or conceive the fuel from which innovative something could be done (who knows!). We always
confined to our theoretical stage but its obviously needed to do something in practical rather
than reading. I really enjoyed this industrial tour, and learnt many things which was slipped
through from our course curriculum, or maybe I didnt get it. I never forget this lovely memory of
my industrial tour. It still rejoices mine.
Lastly, from my point of view, industrial tour is very much important along with theoretical
knowledge so that we could see how theory works in real life and what it could be and I think
these small practical knowledge would be the greatest asset to our higher education, research or
in our professional life.
Reference
Dubey, R. C. (1993) A Text Book of Biotechnology. 4th Edition. Chapter 17: pp. 387-401. Ram
Nagar, New Delhi: S. Chand & Company. ISBN: 81-219-2608-4
Pelczar, M. J., Krieg, N. R. (1986) Microbiology. 5th Edition. New Delhi: Tata McGraw Hill
Publishing Company Ltd. ISBN: 0-07-049234-4
Tortora, Gerard J., Funke, B. (2010) Microbiology: An Introduction. 10th Edition. U.S.: Pearson
Education Inc. ISBN-13: 978-0-321-55007-1
Stunbury, P. F., Hall J. S. (1984) Principle of Fermentation Technology. 2nd Edition. Chapter 1-2.
Burlington: Butterworth-Heinemann: ISBN 0-7506-4501-6
Barrios, J., Tomashini A, (2002) Microbial Secondary Metabolites Production and Strain
Improvement. Industrial Journal of Biotechnology.
Nordic Food Club (2012) Fermentation: Traditional biotechnology. Web:

http://nordicfoodlab.org/blog/2012/03/fermentation-traditional-biotechnology.
Biotech (2013) fermentation. Web: http://biotech.about.com/od/glossary/g/Fermentation.htm.
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Wikipedia Free Online [n.d] Denatured Alcohol. Web:

http://en.wikipedia.org/wiki/Denatured_alcohol
World Health Organization (2003) WHO Global Status Report on Alcohol: Bangladesh. Web:
http://www.who.int/substance_abuse/publications/en/bangladesh.pdf.
General Chemistry [n.d.] Distillation of alcohol. Web:

http://infohost.nmt.edu/~jaltig/Distillation.pdf.
Chemumass [n.d.] Distillation. Web: http://www.chem.umass.edu/people/samal/269/distill.pdf
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Department of Biotechnology & Genetic Engineering

Islamic University, Kushtia-7003, Bangladesh

Course No.: BT-312

The main entrance of the Darshana distillery

All of us in front of distillery laboratory of Darshana distillery

Fermentation house of Carew & Company Limited

The Fusion of Biotechnology and Fermentation Technology......1

Fish and Poultry Feed Production...........18

Part 7: Recommendation for Carew & Company Limited 20-21

Part 6: Conclusion 22-23

Keywords: Fermentation, Molasses, Distilled Beverages, Fractional Distillation,

First of all, I am extremely grateful to the Department of Biotechnology and Genetic

The Fusion of Fermentation and Biotechnology

Why Is Fermentation Biotechnology Important?

Fermentation Process and Production of Alcohol

Alcoholic fermentation, also referred to as ethanol fermentation, is a biological process in which

Ethanol Production by Yeast

C6H12O6 2C2H5OH + CO2

Figure-1: Ethanol production by Saccharomyces cerevisiae

Proof = 2 x Volume Percentage

Carew & Company (Bangladesh) Limited

FACTORY INFO TIME AND CAPACITY

UNIT UNDER YEAR OF EQUIPMENT ANNUAL

LAND AREA AMOUNT IN ACRE

Different Unit of Carew & Company Ltd.

Visit to Carew & Company (Bangladesh) Ltd.

Figure-3: Microphotograph of Saccharomyces Figure-4: Stock solution of molasses and mother

Figure-5: Extra Neutral Alcohol (ENA) plant house

Figure-6: Packaging and bottling of foreign liquor brands

A Combo Tour at a Glance

EVENTS PLACES TIME

Objectives of Our Tour

To gain or achieve the practical experience of fermentation system;

Distillation Process of Carew & Company

Figure-8: Distillery laboratory at Carew & Company (Bangladesh) Ltd.

Yeast Culture within Yeast Plant

Figure-9: Three yeast plant

Filling the Pitching Vat

Figure-11: Pitching vat besides the distillation room

As soon as the fermentation in a fermentation vat is completed, it is subjected to fractional

Figure-12: Fermentation in a large fermentation vat

Figure-13: Yeasts bubbling during the urea feeding

Extra Neutral Alcohol

Figure-14: Outline of overall process of fermentation and distillation

Foreign Liquor Products

BRAND NAME COMPOSITION ALCOHOL CONTENT

Figure-15: All nine foreign liquor brand in one shot

Uses of Alcoholic Beverages

Future Plan of Carew & Company Limited

Fish and Poultry Feed Production

Reducing Ageing Time

Globalizing and Product Improvement

Alcoholic Beverages in Bangladeshi Perspective

At least 90 Bangladeshis died in 1998, including 70 in Gaibandha, after consuming illegal

Recommendation for Carew & Company (Bangladesh) Ltd.

Superior Microbial Strain

Existing Plant Optimization

Reduction of Ageing Time

Maintaining of Aseptic Condition

Clean and Safety Protocol

Increased Taste and Flavor

Figure-17: Recreation at Meherpur Amrokanon

However, fermentation is very important as I said earlier. By visiting Darshana distilleries, we