Transcript pH Scale - Knudsen Beverage Consulting

Cleaning and Sanitizing Brewery Process Equipment
MBAA - RMD
February 15th , 2007
Pumphouse Brewery, Longmont, Colorado
Dana Johnson, BIRKO Corporation
Henderson, Colorado
pH & Growth Relationship of
Microbes
pH Scale:
0______2_________5______7_______9________12_____14.
Acid  Neutral Alkaline


pH 0-2: Very few organisms can survive very long at this pH.
pH 2-5: Some acid tolerant organisms can survive, especially fungi (yeast
and mold).


pH 5-9: Most bacteria grow very well in this pH range.
pH 9-12: Growth of most organisms is very limited. Some alkaline tolerant
organisms can survive.

pH 12-14: Very few organisms can survive at this pH.
Brewery Location/
Soil Composition:







Brewhouse :
Protein, starch, minerals, beerstone, hop oils, hop
resins, fermentable sugars
Heat Exchanger: Protein, starch, minerals,
beerstone, hop oils, hop resins, fermentable sugars
Fermentation Tanks: Protein, starch, minerals,
beerstone, yeast
Maturation Tanks:
Protein, starch, minerals, beerstone, yeast
Bright Beer Tanks: Beerstone, scale
Solubility of Amino Acids
Cleaning/Sanitizing Chemicals
General Classifications:
 Acid Cleaners
 Alkaline Cleaners
 Enzymatic Cleaners
 Foam Generators
 Solvents
 Sanitizers/Disinfectants
•The Acid Test
Acids used for beverage processing equipment
cleaning:
 Organic Acids (Citric, lactic, acetic)
 Mineral Acids (Hydrochloric, Phosphoric, Sulfuric)
 Oxidizing Acids (Nitric, Peracetic Acid- PAA)
•Alkaline Cleaners



Sodium/Potassium Hydroxide (caustic soda,
(NaOH, lye) caustic potash (KOH).
Sodium Hypochlorite (NaOCl, “chlorine
bleach”)
Noncaustic alkaline cleaners (sodium
percarbonate, phosphates, surfactants,
silicates)
• Sanitizers
Chlorine Bleach (hypochlorite)
 Chlorine Dioxide (Cl02)
 Iodine (Iodophor)
 Ozone (O3)
 Peracetic Acid (PAA)
 Quaternary Ammonium (Quat)

Conventional CIP
“Tried and true”.
 Rinse product out using ambient to warm water.
 CIP with 1-2 ounces of caustic blend per gallon of
water (180 degree F. maximum temperature) for 1530 minutes (or longer) depending on conditions..
 Rinse.
 CIP with 1-2 ounces of an acid cleaner per gallon per
gallon of warm (120-140 degree F.) for 15-30
minutes to neutralize the caustic and finish cleaning.
 Rinse with ambient temperature water until the pH
of the rinse water is neutral (same pH as the tap
water coming in).
A New Approach

We have discovered a new way to keep beverage packaging machines
clean using the following procedure:
 Rinse out beer and yeast with ambient temperature water.
 Use a 1-2 ounce per gallon phosphoric/nitric acid mixture
(140 degree F. maximum temperature) for 15-30 minutes.
 No rinse!
 Use a noncaustic alkaline cleaner at 1-2 ounces per gallon
of warm (120-140 degree F.) to start. CIP for 15-30
minutes depending on conditions.
 Rinse with ambient temperature water until the pH of the
rinse water is neutral (same pH as the tap water coming
in).
Mash Tun CIP (Traditional)






A. Test #1 – Mash Tun
The test was performed in the following
manner:
Caustic wash: 3% w/v pre-blended mixture of
25% w/w caustic and caustic additive– 2400
seconds
Caustic rinse cycle
Acid wash: 3% v/v nitric/phosphoric– 1200 s
Acid rinse cycle
Mash Mixer Before
Mash Mixer After (Traditional)
CIP
Brewkettle CIP





The test was performed in the following
manner:
Acid wash: 3% v/v nitric/phosphoric blend–
1200 s
Acid rinse cycle
Caustic wash – 3% w/v pre-blended mixture
of 25% w/w caustic and caustic additive –
2400 s
Caustic rinse cycle
Kettle-Before CIP
Kettle-After CIP (Acid First)
Brewkettle After CIP (Acid First)
Fermentation Vessel CIP
(Acid Only)
Test #1 – FV-42
 The test was performed in the following
manner:
 Acid Wash: 3% v/v nitric/phosphoric
blend & 32 oz. detergent additive –
1200 s
 Acid Rinse Cycle
 PAA Sanitation

FV Before CIP
FV After CIP
Cleaner vs. Sanitizer -What’s
the difference?



Cleaners remove soil, scale, protein, etc..
Little government involvement regarding
claims unless bactericidal claims are made.
Registration for sanitizers are governed by
the EPA, (sometimes FDA) and the product
must go through rigorous testing to be
classified as a sanitizer. $$$$$.
Often used synonymously- technically
speaking, there is a difference between
sanitizing and disinfecting.
BIOFILM



Biofilm Definition: The attachment of
organisms to a solid surface and
subsequent entombment in a protective
polysaccharide coating.
Marked increase in antibiotic and chemical
resistance.
Many different types of organisms can
exist within the film, making detection and
removal difficult.
Biofilm Removal
Mechanical action (i.e., hand-scrubbing)
is the most effective way to remove
bioflims.
 For CIP, extreme pH, (<2, >12) along
with oxidation, (HN03, NaOCl, PAA,
Cl02) OR enzymes, work best to rid
surfaces of biofilm and prevent it from
returning.

Selective Micro Technologies
Pure Chlorine dioxide generators
 No flavor profile (no residuals!)
 low ppm requirement
 non-corrosive
 safe
 easy to use
 easy to measure

Conclusion



Cleaning is the least glamorous part of
daily packaging routine but likely the most
important for overall product quality.
Depending upon the product you make, an
unsanitary machine can have public health
consequences.
Use the proper type and amount of
chemicals- don’t scrimp, but overuse,
either.