1. ICC Brewing School
December 2016

2. Module 4 – Quality and Resources
Cleaning
Water
Energy
Waste
CO₂ Recovery
December 2016
ICC Brewing School

3. Key Quality Parameters
CONSISTENCY
Flavor
Color
Bitterness
Carbonation
Clarity
Foam
Alcohol
‘Sterility’
Temperature
Carbonation
Flavor
Clarity
Foam
December 2016
ICC Brewing School

4. 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
December 2016
ICC Brewing School

5. Quality Analysis Parameter Relevance to Quality Alcohol content
Consumer ‘value’
Tax
Original and final gravity
Reflects alcohol content
Flavor pH
Affects microbial growth
Variance indicates contamination
Color
Customer perception
Bitterness
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
Possible contamination or infection
Foam (“cling”)
Sterility
Affects flavor, aroma, appearance
December 2016
ICC Brewing School

6. Cleaning Wild yeast Why clean? Bacteria Saccharomyces spp.
S. diastaticus ferments sugars that brewing yeast can’t –> over-attenuation
Bugs like wort, and beer
Wild yeast compete with brewing yeast, leading to different / off- flavors
Brettanomyces bruxellensis –> sour beers
Bacteria
Bacteria can flourish – live on carbohydrates that yeast can’t ferment
Lactics
Can grow in low pH
Produce dicetyl (and other off-flavors)
Bacteria give off-flavors and produce haze
Pectinatus cerevisiiphilus
Anaerobe
Produces haze, acetic acid and H₂S
December 2016
ICC Brewing School

7. 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
December 2016
ICC Brewing School

8. CIP System Design 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
December 2016
ICC Brewing School

9. 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
December 2016
ICC Brewing School

10. CIP Equipment
December 2016
ICC Brewing School

11. Tank Cleaning
December 2016
ICC Brewing School

12. 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
December 2016
ICC Brewing School

13. Design for Cleaning No ‘shadow’ areas Sanitary valves Avoid dead legs
Smooth welds
December 2016
ICC Brewing School

14. Water Brewing water (liquor) General-purpose water Boiler water
Sand filtered
Softened
May have mild sterilant (e.g. ClO₂) added
Boiler water
Must be softened
December 2016
ICC Brewing School

15. Process Gases Gas / Use Quality Requirement Reason
Air or oxygen / wort aeration
Sterile
Free from contamination by oil or grease
To avoid product infection
To avoid product contamination
Compressed air / driving valves, etc.
Dry
To avoid equipment damage
Nitrogen / elimination of oxygen
Purity – O₂ <0.005%
To avoid product oxidation
Carbon dioxide / elimination of oxygen or carbonation
December 2016
ICC Brewing School

16. Resource Use KPIs Energy: Water: 3.5 hl / hl of beer
Heating – 80 MJ/hl (0.085 MMBtu/bbl)
Electricity – 28 MJ/hl (9 kWh/bbl)
Water: 3.5 hl / hl of beer
People: > hl/person/y
December 2016
ICC Brewing School

17. Sources of Waste Spent grain Trub Waste yeast CIP liquids
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
Hot water
Packaging materials
Cardboard
Aluminum
Glass
December 2016
ICC Brewing School

18. Waste Reduction Spent grain Trub Water CIP liquids Packaging materials
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
December 2016
ICC Brewing School

19. Carbon Dioxide Recovery
Fermentation produces 4lb/bbl
Recovery process
Collect gas
Scrub / deodorize
Dry
Compress to liquid
Store
Purity
Target > %
December 2016
ICC Brewing School