Transcript Module 4 – QA and Utilities

ICC Brewing School
December 2016
Module 4 – Quality and Resources
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Quality
Cleaning
Water
Energy
Waste
CO₂ Recovery
December 2016
ICC Brewing School
Key Quality Parameters
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Flavor
Color
Bitterness
Carbonation
Clarity
Foam
Alcohol
‘Sterility’
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Temperature
Carbonation
Flavor
Clarity
Foam
Quality Control
• Controlling natural variability
– Raw materials vary
– Yeast is a living thing
• Set parameters/specifications for key attributes
• Must include target and (realistic) ranges
– Bitterness: 12 ±1 IBU
– DO: <50ppb
– Color: 20 ± 1 °L
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Quality Analysis
Parameter
Relevance to Quality
Alcohol content
Consumer ‘value’
Tax
Original and final gravity
Reflects alcohol content
Flavor
pH
Affects microbial growth
Flavor
Variance indicates contamination
Color
Customer perception
Bitterness
Flavor
Aroma
Customer perception – subjective only
Flavor compounds e.g. diacetyl, esters
Give characteristic aroma and flavor
Dissolved oxygen
Flavor (stale, “wet cardboard”)
Haze
Flavor (trueness-to-type)
Customer expectations
Clarity
Customer perception
Possible contamination or infection
Foam (“cling”)
Customer perception
Sterility
Affects flavor, aroma, appearance
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Cleaning
• Wild yeast
• Why clean?
– Bugs like wort, and beer
– Wild yeast compete with brewing
yeast, leading to different / offflavors
– Bacteria can flourish – live on
carbohydrates that yeast can’t
ferment
– Bacteria give off-flavors and
produce haze
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– Saccharomyces spp.
• S. diastaticus ferments
sugars that brewing yeast
can’t –> over-attenuation
– Brettanomyces bruxellensis –>
sour beers
• Bacteria
– Lactics
• Can grow in low pH
• Produce dicetyl (and other
off-flavors)
– Pectinatus cerevisiiphilus
• Anaerobe
• Produces haze, acetic acid
and H₂S
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Cleaning
• Clean-in-place (CIP)
– Most common form of cleaning
especially in large breweries
– Avoids need to open vessels and
lines
– Safer than manual cleaning
– Tanks must be fitted with spray
balls and/or rotating nozzles
– Can be fully automated
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CIP System Design
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Recovery or single-use?
Cleaning program?
Type of spray head?
Flowrates and delivery pressures?
Chemical ‘cocktail’
– Acid or caustic?
– Surfactants and wetting agents
– Oxidizers and sanitizers
• Level of automation and monitoring
• Running costs
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CIP Program
• Initial rinse to remove loose soil – flush to drain
• Detergent (caustic or acid) recirculation to clean – recover and
control strength
• Clean water rinse to remove detergent – recover for next initial
rinse
• Sterilant rinse – hot water (185°F / 85°C) or peracetic acid
(CH₃CO₃H) or chlorine dioxide (ClO₂)
Recovery System
Single Use System
High capital cost – requires dedicated tanks
Low capital cost – requires in-line injection
system only
Low running costs – chemicals and water
recovered
Higher running costs
Different equipment requires different CIP
plants
Can clean any plant
Simple to operate
Complex system of dosing pumps and
sensors required
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CIP Equipment
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Tank Cleaning
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CIP Equipment
Spray Ball
Rotating Jet
Large volume / low pressure
Lower volume / high pressure
Relies on liquid penetrating dirt
Dirt removed mechanically
Can use burst rinsing
Must maintain continuous flow
Need to ensure flooded tank bottom
Tank bottom cleaned by jet
impingement
Feed needs filtration to avoid blocking
Less prone to blockage
Cheap / no maintenance
Expensive – moving parts require
maintenance – may include rotation
sensor
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Design for Cleaning
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No ‘shadow’ areas
Sanitary valves
Avoid dead legs
Smooth welds
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Water
• Brewing water (liquor)
• General-purpose water
– Sand filtered
– Softened
– May have mild sterilant (e.g. ClO₂) added
• Boiler water
– Must be softened
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Process Gases
Gas / Use
Air or oxygen / wort
aeration
Quality Requirement
Sterile
Free from contamination by oil
or grease
Reason
To avoid product infection
To avoid product
contamination
Compressed air / driving Free from contamination by oil
valves, etc.
or grease
Dry
To avoid product
contamination
To avoid equipment damage
Nitrogen / elimination of
oxygen
Free from contamination by oil
or grease
Sterile
Purity – O₂ <0.005%
To avoid product
contamination
To avoid product infection
To avoid product oxidation
Carbon dioxide /
elimination of oxygen or
carbonation
Free from contamination by oil
or grease
Sterile
Purity – O₂ <0.005%
To avoid product
contamination
To avoid product infection
To avoid product oxidation
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Resource Use KPIs
• Energy:
– Heating – 80 MJ/hl (0.085 MMBtu/bbl)
– Electricity – 28 MJ/hl (9 kWh/bbl)
• Water: 3.5 hl / hl of beer
• People: > 10 000 hl/person/y
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Sources of Waste
• Spent grain
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Husk left after wort production
High liquid content (80 %)
Has value as cattle feed or fuel
Drainings high in suspended solids and BOD
• Trub
– High suspended solids
– Very high BOD
• Waste yeast
– Value as pig food
– Can be processsed e.g. Marmite
• CIP liquids
– High pH
– High suspended solids
– Hot water
• Packaging materials
– Cardboard
– Aluminum
– Glass
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Waste Reduction
• Spent grain
– Burn in biomass boiler
– Recover / re-use last runnings
• Trub
– Centrifuge to recover wort
• Water
– Balance supply and use
• CIP liquids
– High pressure / low volume rinses
– Recovery systems instead of single-use
• Packaging materials
– Long runs
– Machine operation/maintenance
– Recycling programs
• On-site wastewater treatment
– Anaerobic digestion
– Gas engines
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Carbon Dioxide Recovery
• Fermentation produces 4lb/bbl
• Recovery process
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Collect gas
Scrub / deodorize
Dry
Compress to liquid
Store
• Purity
– Target > 99.995%
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