Efficiency Parameter of Malt Distillery

                                               Jaipal Singh Datta  likes Beer
Efficiency Parameters of any unit are very important to convert that unit in to profit or loss.
One of the leading distillery in India near Goa is producing malt spirit with these parameters.

Consumption per Proof Liter
Yield per Metric Tonne of Malt   560 to 570 PL
1.0   Malt         1.8 Kg / PL
2.0   Coal         2.2 Kg / PL
3.0   Electricity    0.46 KWh / PL
4.0  Water          13 Liter / PL
5.0  Man Days       35.5 Days /1000 PL
Operation of Pot Still and Patent Still after fermentation of distillery wort and removal of alcohol by distillation from wash etc are the main job of distiller. His job depends on improvement of efficiency parameter of distillery small or big.

To improve efficiency of distillery one checks quality of yeast, temperatures, boiler efficiency, condensate collection, pressure reducing station for steam, crushing of Malt by milling machine,

Spirit is stored in barrels of virgin oak wood from Europe, America and even from India which are more porous. Distiller selects each barrel very carefully and blends his spirit from each barrel to produce Whiskey of uniform quality.

Costing of Packing Material in Rs
Brand 1 to 5                         Quart               Pints                   Nips
Empty Bottle                     125 to 160       153  to 171         128 to 153
PP Seal                               12 to 16           14 to 30              18  to  50
Labels                                  3   to  15         4  to 18                 10 to 50
Outer Carton                      17  to 27           25 to 30                 25 to 30
Mono Carton                       70 to 102  
Cost varies due to quality of bottle, size, weight in grams, PP Seal size, Guala Cap, Labels thickness, printing on labels and number of colours, size etc.
Cost of Spirit varies from 43 Rs to 50 considering quality and purity of Alcohol. It includes export fee of one state, import fee of other state, freight etc.
Flavouring material is added as per blender formula. It may cost from 20 Rs to 100 Rs / case
Cost of over head varies as per production / sales of individual units.  It may vary from Rs 40 per case to Rs 100 per case depending on the efficiency of Management.
Cost of conversion is charged by individual bottlers from 25 Rs to 40 Rs / case.
In IMFL Bottling units, there are many variations due to different sizes of bottles and size of neck for PP Seals. Inventory management is not very easy in comparison to other production units.
In many cases whiskey is filled in semi automatic plants, where quarts can be filled 1000 cases per line of Quarts. In case of Pints it may be 600 cases and in case of Nips it may be 350 cases per line.
                                                   Quart           Pints        Nips
Bottle capacity in ml                       750            375          180
Number of bottles per case              12             24             48
Bulk Liter                                         9               9             8.64 
If Alcohol is 42.8% V/V = 25 Degree Under Proof = 75 Degree Proof
than each outer carton contains
             Alcohol / case                  3.852      3.852        3.69792
               PL / Case                        6.75        6.75
Calculation in distillery is done on the basis of Alcohol Liter or AL. Earlier these calculations are done on the basis of Proof Liter ( PL ) or Over Proof (OP) or Under Proof (UP)
Some states add Bottling Fee, Excise Duty, Sales Tax etc