2. To not only understand what you need to do, but also why
you are doing it and how you can impact performance
To get to know your colleagues so you can go to the right
people when you want to discuss something or need help.
Target
4. Not all people have sent in the 2 pictures and many
people have failed to describe the function of the
component.
CIP
5. CIP basic components
• CIP units consist of several components assuring their full functionality.
• The key components are:
– CIP storage tanks
– Delivery and return pumps
– Dosing pumps
– Heat exchangers
6. CIP recovery tanks
• Used to store:
– Fresh water
– Recoverd water
– Chemicals (alkalies, acids, disinfectants)
• Made usually from AISI 304 or 316.
• Equipped mostly with static sprayballs.
7. Diversey „Static Leg“
• Used to:
– Store fresh water
– De-aerate cleaning solutions
– Ballance volumes of CIP liquids in the circuit
– Prevent cavitation of CIP delivery pump
• Usually made from AISI 304 or 316.
8. CIP delivery pumps
• Centrifugal pumps.
• Supply CIP sollutions to the cleaned object.
• Assure necessary flow (m3/h) and pressure (Pa) in the mains as well as on static
sprayballs and rotaiting spray devices installed in the tanks.
9. CIP return pumps
• Self-priming pumps.
• Return CIP sollutions to CIP station.
• Their parameters must be aligned with CIP delivery pumps.
10. CIP dosing pumps
• Usually membrane pumps.
• Dose chemical concentrates in CIP recovery tanks or
in line.
• Modern „intelligent “ pumps can adjust dosing to
water flow to assure immediate equal distribution /
concentration in the whole CIP circuit.
11. CIP heat exchangers
• Used to control temperature of water and cleaning solutions.
• Plate or shell and tube
• Sizing is done according to flow, temperature and heating time
demands.
12. CIP system components
• Other components are essential as well to enable smooth run and control of the
cleaning process:
– Delivery and return mains
– Spray balls and heads
– Diverse types of valves
13. Connecting pipes
• Used to deliver cleaning solutions from CIP station to
the cleaned objects and back.
• Made from AISI 104 or 316.
• Different DNs.
• Elbows, fittings, T-pieces etc are used in the
installations.
14. Sight glass
• For visual check of
– Flow
– Dirt load
– Aeration
– Phase changes
• Built in CIP delivery or return mains as well as in product lines.
15. Valves
• Mechanical or pneumatical valves with actuators
operated by pressure air.
• Used to open/close pipes, tank inlets and outlets etc.
Often installed in manifolds.
• Single or double seat valves.
• Equipped with a leakage to prevent product and
detergent mixing for example
• Enable parallel pumping of product in one branch of the
main and cleaning of a connected branch without risk of
product contamination.
https://youtu.be/kX4BQWFJgSM
16. Static sprayballs
• Used for cleaning of production tanks as well as CIP
tanks.
• Lower cost compare to rotaiting heads.
• Simple installation (fixed with a pin).
• Easy maintanance.
• Good coverage of the cleaned surface.
• Limited mechanical action.
17. Rotating sprayheads
• Used for cleaning of (heavily soiled) production tanks.
• Different types are used for different vessels, soil types
etc.
• Very good mechanical action.
• Minimum spay time needed to cover the complete
internal surface of the tank (pattern).
• Significantly higher cost.
• Regular maintanance by OEM is needed.
18. Sampling valves
• Used for:
– CIP product sampling - no need to be aseptic.
– Aseptic sampling of manufactured products
– Must be fully CIP-cleanable to avoid distortion of
the micro results and contamination of the final
product.
19. CIP piston/membrane pneumatic
valves
• Used for dosing of CIP concentrates in line or in CIP
tanks.
• Operated by pressure air and spring.
• Valve’s positions control by proximity switches is highly
recommended here.
20. CIP instrumentation
• CIP units are fitted with a variety of monitoring devices to measure critical CIP
parameters:
– flow rate.
– pressure.
– conductivity.
– temperature.
• The monitoring devices send signals to the CIP control system indicating the
current status allowing the system:
– to control particular CIP steps
– to correct unfavourable situations.
– to alarm sequences if they cannot be corrected.
21. CIP instrumentation - flow
• Flow meters can be fitted to CIP delivery and
return lines to:
– Monitor the flow rate against the parameters set
for a particular CIP circuit.
– Correct it by increasing or decreasing the pump
speed.
– Control the CIP steps by volume.
• CIP flow meters are usually:
– magnetic flow meters.
– vortex flow meters.
22. CIP instrumentation - pressure
• Pressure transmitters can be fitted to:
– Monitor the levels in CIP tanks.
– Monitor the pressure in CIP lines.
• CIP pressure transmitters are usually diaphragm
type.
23. CIP instrumentation - conductivity
• Conductivity probes measure the conductance of liquids.
• When strong alkalies and acids are added to water the
conductance changes roughly proportional to
concentration.
• Conductivity probes are placed in CIP lines and tanks to
measure detergent concentration.
• Conductivity probes are placed in lines to manage phase
separation of CIP solutions.
• CIP conductivity probes:
– Are always inductive torroid type.
– Are always temperature compensated.
– Should have an exposed temperature probe.
24. CIP instrumentation - temperature
• Temperature probes are used to measure the
temperature in CIP tanks and lines.
• They are used to control the heating process of CIP
fluids.
26. Mechanical action
• Of critical importance during CIP and BW
– No mechanical action, no cleaning
– The right spray balls, the right flow (in CIP)
– The right pressure (in BW)
27. Chemistry
• Select the right detergent for the soil
– Organic soil mostly caustic
– Inorganic soil mostly acids
• Both caustic and acid can be enhanced by other components
like sequestrants, surfactants, threshold agents and corrosion
inhibitors
29. Time
• Increasing cleaning time improves cleaning in a linear
relationship. Double the contact time gives twice the cleaning
performance.
• Keep in mind that only time when all the other criteria have
been met, counts.
– Example when the CIP runs in bursts only the time the supply pumps
runs with the required flow counts. All the stops are not cleaning
time.
30. Temperature
• Cleaning temperature is very important
– For some soils (like fats) a minimum temperature is required.
– Increasing the temperature by 10° C improves cleaning by 2-3 fold
– Temperature kills microbes
• Equipment may limit the temperature
31. Temperature and time
Chemical reactions speed increase by 2 fold with every 10° increase in
temperature
Soils may denaturate or chemicals may become aggressive to the plant
construction materials at too high temperature.
Chemical reactions and sanitising processes are not instantaneous, they
are time dependent. Selection of the correct time for cleaning and
sanitising is very important.
32. Time
• Time is determined by:
• Type of soil on the surface being cleaned
• The size of the CIP circuit, time to condition, time at condition
• Cleaning program validation
Examples
Object being cleaned Time at condition, minutes
Vessels with light soil 10
Vessels with medium soil 10
Vessels with heavy soil 20
High temperature process equipment 40+
Soil is removed layer by layer; consecutive layers may differ in their nature and tenacity.
33. Chemicals
Chemical action is influenced by:
• Concentration of detergent or disinfectant
• Properties of the detergent or disinfectant used
• pH (acidic. alkaline or neutral)
• surfactant for wetting soil suspension
• facilitate swelling and rupture of soil and microorganisms
• sequesterants and chelants to match water conditions and break calcium bonds
• foam free
• compatible with process material gaskets. metals and resin coatings
• minimal impact on effluent
• the substrate compatibility – will the chemistry corrode the equipment?
35. Contents – sequences for
effective CIP
• Caustic shots: First step of vessel CIP.
Caustic level is pre-set at the CIP program and caustic solution is prepared at CIP
unit, at caustic tank or it is dosed inline before the CIP supply pump.
37. Contents – sequences for
effective CIP
• Rinse: it can be also called “intermediate” rinse if the following step is next step is
another detergent or disinfectant.
• This part is intended to remove from the circuit all detergent. Once the
conductivity meter of return circuits reaches a certain level, water is returned to
recovery tank. When it reaches 0 mS, then the phase is finished or next phase can
start.
• It can be called “final” rinse if there are no more phases after this.
38. Contents – sequences for
effective CIP
• Acid phase: depending on the type of product and water hardness of the site, an
acid step might be also required.
Once it’s finished, then another rinse will be required.
39. Contents – sequences for
effective CIP
• Disinfectant phase: in order to ensure food safety, a disinfectant step will be
necessary and make sure no microorganisms might damage and contaminate the
product and circuits.
• Tracking disinfectants can be also done by conductivity (ex: PAA mixed with acid,
so that the acid is an indirect measure for PAA)
Sometimes the disinfectants might not be tracked by conductivity, so they are
dosed proportionally with water entering to the circuit and the dosage is time-
controlled.
It will also require a rinse step afterwards.
40. Contents – sequences for
effective CIP
Different combinations:
Phases
Caustic
detergent
Intermediate
rinse
Acid
detergent
Intermediate
rinse
Disinfectant Final rinse
Caustic
detergent
Final rinse
Caustic
detergent
Intermediate
rinse
Acid
detergent
Final rinse
Caustic
detergent
Intermediate
rinse
Disinfectant Final rinse
42. Factors affecting cleaning of bottles
• Bottle-washers rely on various energy sources to clean bottles:
– Time
– Mechanical Action
– Chemical Concentration
– Temperature
• In the next section we will examine how these elements are implemented
in a bottle washer
43. Mechanical action in a bottle-washer
• Mechanical action in a bottle-washer is achieved by:
– repeated filling and emptying of the bottles which causes the solution
interface to sweep over the surface dislodging any softened soil.
– pulsed jets of detergent provide mechanical energy to remove soil.
44. Temperature
• Temperature increase generally hastens all reactions by:
• softening the soils by wetting with water.
• increasing the speed the detergent gets to the soil.
• speeding up reaction of the soil with the detergent (e.g. caustic with soil).
45. Temperature effect on diffusion
• temperature increases the rate of diffusion of chemical species through the
boundary layer to reach soil.
• it also increases the reaction rate (or rate constant) of cleaning chemical with
soil.
• Generally, the reaction rate doubles for every 10ºC rise in temperature
Glass
soil
Boundary layer
Transition layer
Solution bulk
OH-
OH-
OH-
OH-
OH-
OH-
OH-
OH-
46. Temperature and calcium carbonate
• Increase in temperature has an inverse solubility effect on some calcium salts.
• The higher the temperature the less soluble a calcium salt is.
• This has a great influence on the performance of bottle washers as typically water brings
in calcium ions and together with the carbonates formed with caustic, so deposits are
formed on heated surfaces e.g. heat exchangers
• Ca2+(aq) + CO3
2-(aq) CaCO3
• Carbonates are formed by the following reactions:
• Reaction of caustic with carbon dioxide: CO2 + 2OH- CO3
2- + H2O
• Breakdown of bicarbonates by increase in temperature:
2HCO3
- CO2 + CO3
2- + H2O
• Reaction of bicarbonates with caustic:
HCO3
- + OH- H2O + CO3
2-
47.
48. Time
• Time is critical for the detergent to reach and react with
soils.
• In bottle-washers the time for the detergent to clean the
bottle is referred to as the soak time. This is the time the
bottle is immersed in caustic solution in baths.
• Typically soak time in bottle-washers runs from 5 to 30
minutes, depending on soil levels and whether the bottles
have paper labels or not.
• Soak times are determined by the design and the intended
speed of the machine.
• If for any reason the time have to be changed this will
influence the whole line efficiency.
49. Chemical concentration
• The concentration of the detergent in the bottle washer has an effect on
how quickly the bottles are cleaned.
• An increase in temperature speeds up the reaction between the detergent
and the soil.
• It also increases the diffusion rate of the detergent from the bulk of the
solution across the boundary layer.
• The effect of increasing the concentration is not as pronounced as an
increase in temperature.
50. Chemical components in bottle washers
• In this section we will review some of the major chemical
components used in bottle washing compounds and describe
their function.
• These include:
– Caustic based detergents
– Chelants or sequestrants
– Surfactants
52. Sequestrants - chelants
• Most problems in bottle washers involve calcium and magnesium hardness
ions.
• Controlling the behavior of these ions can prevent these problems
• Sequestrants or chelants can assist in cleaning by dissolving calcium bound
soils on the surface of the bottle.
• Some sequestrants or chelants, typically polyphosphates, assist in anti-
redeposition.
• The chief role of the sequestrants is to solubilize calcium and magnesium ions
brought in by water to prevent scaling and precipitation of undesirable salts
onto the bottles.
• Sequestrants solubilize the ions by surrounding them and effectively alter
their properties.
53. Dosing and Control
• Bottle-washers are in a constant state of product dilution, either by incoming water
into the rinse zones or by carry-over of pre rinse water into the wash zones.
• Various chemical materials must be added regularly to maintain various chemical
concentrations and hence the effectiveness of the bottle-washer:
– caustic in the form of raw caustic or blended detergent into the wash zones.
– additives to enhance detergency in the wash zones.
– de-foamers to provide foam control in the wash zones.
– rinse additives to prevent scaling and enhance rinsing in the rinse zones.
– sanitisers to provide microbiological control in cold rinse section.
– sanitisers to provide microbiological control in final rinse section (subject to potable
water regulations).
54. Dosing and Control
• There are various options for managing the various concentrations:
– regular titration and manually initiated dosing.
– automatic dosing initiated by a timer.
– automated dosing linked to the machine bottle output.
– automated dosing linked to the incoming rinse water flow rate.
– automated dosing linked to various concentration measuring probes.
– automated dosing linked to a primary chemical flow rate.
• In the following slides we will explore some of the configurations
employed.
55. Wash zones – caustic control and dosing
• Wash zones require the addition of caustic in the form of either raw caustic
or blended caustic product.
• They also often require the addition of additives and defoamers.
• Caustic:
– the free caustic concentration can be titrated every hour and dosing of caustic
manually initiated.
– the caustic concentration can be monitored by conductivity and dosing
initiated automatically or manually, when concentration falls below a set
point.
• care must be taken with conductivity control, as it will measure all conducting
species and over time these may make a significant contribution to the overall
conductivity, leading to inaccurate concentration control.
• conductivity control must always be supplemented with regular titration checks.
56. Wash zones – additive control and
dosing
• Additives dosing:
– Matched pump dosing:
• dosing a fixed ratio to NaOH (1:10) when the NaOH pump is running, a properly choosen
additive pump is running too, dosing the required amount of additive.
• +Easy to set up, simple
• -If caustic dosing have a problem due to carbonate, or other conductive material, additive
dosing suffering too. Can lead to very rapid degradation of cleaning performance.
– Time based dosing:
• adding a fixed amount of additive on a timed basis
• delivering a fixed additive dose every so many machine running hours
– Bottle counter dosing
• linking the additive dosing to the bottle-washer drive mechanism
• Can be dosed on a gram per bottle base
57. Wash zones – caustic and additive
dosing
Multiple zones:
In case of more than one caustic zone, the question is often asked what should
be the caustic and additive concentration in the individual zones?
• Three different practice:
1. Zone 1=Zone 2 Zone 1 diluted from pre-rinse, Zone 2 loosing by reactions
active dosing required to both zones
2. Zone 1<Zone 2 Zone 1 diluted from pre-rinse, Zone 2 diluted from Zone 1
active dosing for both zone is required
3. Zone 1>Zone 2 Zone 1 has the highest concentration, Zone 2 just filled up
with the same concentration but not dosed, carry over
makes stable, somewhat lower cconcentration.
4. Dosing in Zone 1 gives the best use of chemicals as you have the longest contact
time.
58. Dosing overview
Pre
rinse
Caustic 1 Caustic 2 Caustic
recovery
Hot rinse Warm rinse Cold rinse Fresh
water
Bath? yes yes yes yes yes yes yes No
NaOH Conductivity Carry over Carry
over
Primary
Additive
Bottle
counter
Carry over
Secondary
additive
Bottle
counter
Carry over
Deafoamer Timer Timer
Scale control Proportional
to water
pH control Proportional to
water
Sanitizer Proportional
to water
61. Wet Lubrication Restrictions
• Wet lubes use relatively high volumes of water
• Solution cascades into drip trays (if present) and often onto the floor
• Spent solution on the floor represents a safety risk from slippage
• Excess foam and bio-film gives aesthetically undesirable environment
and they represent micro risk to the food product (cross contamination).
62. Conventional wet lubrication
1 litre
Lube
solution Less than 100 ml
on track
More than 900 ml
on floor
0.1 ml
active ingredient
65. Dry Lubrication Restrictions
• Separation of Conveyor Lubrication from Conveyor Hygiene:
• dry lubricants provide excellent slip but have practically no detergency.
• track cleaning programs are required to maintain cleanliness.
• Sensitivity to change:
• some line conditions such as the intermittent use of water showers, product spills, or
lines which fill more than one type of packaging can be difficult.
• The presence of lubricant is not obviously visible to operators:
• dry lubes leave just a film on the surface of the slat chain, operators may require
educating about this.
66. Application Notes
• Dry lubricants are much more slippery than conventional ‘wet’ products.
• Coefficients of friction (µ) for conventional products range from 0.11 to 0.16, for Dry
Tech Lubricants µ can be as low as 0.06.
• Low friction due to over-lubrication can cause problems.
• Dry lubricants generally only work where they are dosed.
• Symptoms of insufficient lubrication are the same as for wet track treatment.
• Over lubrication causes problems.
• Lubricant on the floor is very dangerous.
67. Semi dry lubricants
• A technology fusion of the advantages from wet lubrication like
– Single Product for Lubrication & Cleaning
– Use Existing Dosing & Control
– Ease of Implementation
– Minimal Equipment Investment Requirements
• And dry lubrication with
– Significant water savings
– Reduced operational costs
– Improved plant aesthetics
– Reduced micro and operator’s risk due to less water on the floors.
68. Application Principles
• Wet track treatment application principles apply:
• volume at a rate between 50 and 110 mls/min per track.
• constant pressure – design target 2.0 bar.
• consistent dilution rate and perhaps multiple concentrations to cover different
situations.
• timed zoning to optimise lubricant volume vs friction.
69. Zoning - Timers
• Adjustment of the spray on/off time is essential.
• The achievable on/off times are a function of many things but significantly
the durability of the lubricant – its ability to maintain a low friction interface
without constant replenishment.
• On /off times are typically of the range 40% on to 15% on, with on times
less than 1 minute duration.
• Zone timing control is achieved by solenoid valves in the track treatment
supply line to each zone, the solenoid valves are either fitted with a local or
remote cyclic timer.
• Zone solenoid valves can also be used to shut down lubrication when a
conveyor is not running, by linking the solenoid to the conveyor drive motor.
70. System Performance
Implementing in different zones (up to 80% water reduction)
Typically greater than 65% water reduction when steady state.
Dependant on dosing & control system and initial baseline.
72. Nozzles and nozzle bars
• Nozzles are placed at the start of each conveyor, they are arranged on bars for
ease of installation, using one spray point per conveyor track.
• Nozzle bars can consist of 1 to 20 jets per bar, and are normally located above the
conveyor but occasionally under the conveyor as shown.
73. Nozzles and nozzle bars
Each nozzle comprises a series of parts as shown
tube nut
ferrule
filter
jet retaining cap
jet
blanking cap
tube nut
retaining nut
back nut
ferrule
jet retaining cap
filter
bracket
welded stud
jet
jet body
spraybar
74. Distribution system
The distribution system connects the dilutor to the nozzles. A good distribution
system does not have big pressure differences in the system.
Options:
Steel or plastic piping
Tree system or ring main with drop down.
75. Diluters and constant water pressure sets
• Based on the required flow and concentration we can select a diluter.
• There are 2 diluter options – Dosatron and the standard Flow meter / Diaphragm pump systems.
Flow meter / diaphragm pump systems: these are the most common
type. The water flow through the flow meter triggers the electrical
dosing pump to inject track treatment product proportional to flow.
Dosatron: this is a hydraulically driven system used
for low cost applications. The water flow through
the unit drives the small hydraulic pump to inject
concentrate track treatment product proportional to
flow.
76. Zoning
• In many packaging operations zoning of the distributions will provide
operational benefits:
– High soil load areas (RGB before the washer) need more flow to wash the lines
– Low soil areas (eg between the labeler and the end of the line) need less flow
– Flow (and concentration) can be optimized.
77. Useful options
Here are some simple solutions
water supply
pressure relief valve
by pass valve
constant pressure water
to track treatment diluter
multi stage centrifugal pump
20l balance tank
Consistent water pressure is critical to effective track treatment.
L
1000 l
tote tank
raised stand
25 lit sealed
balance tank
level probe
lube conc.
to diluter
sight glass and vent
Running out of lube concentrate can be a problem
79. When is performance effective?
• Packages are conveyed without problems
• Lines are clean and free of micro
• Nozzles are spraying (not blocked)
• There is little or no foam on the floor and
on the bottles (to avoid issues with EBI)
• There is minimal wear to the conveyors
80. How to measure performance?
• Co-efficient of friction
• The co-efficient of friction between two surfaces (μ) is a useful way to quantify
the relative effect of different lubricants.
• The co-efficient of friction (μ) =
Friction force (in grams)
Bottle weight (in grams)
81. How to measure performance?
• The friction force is measured using a spring
balance, dynamometer, or Correx meter.
83. Optimum concentration
• Wet lubricants have characteristic curves of concentration vs friction reduction.
• High concentration does not necessarily mean low friction, but usually more foam.
Friction
Concentration
zone of minimal
friction
point of least friction
Friction
Concentration
foam foam
20,000 bph
8,000 bph
C1 C2
84. What is required from a track treatment
product apart from lubrication?
A 1019 - B
86. 86
Definition of Beer
• Slightly alcoholic beverage originally made from malt, water and hops,
but today ingredients may include rice, maize, sugar and others.
• German Duke Wilhelm IV proclaimed on April 23rd 1516 in Ingolstadt
the so called “Reinheitsgebot” (purity law) saying that beer can be only
made from the above listed raw materials.
87. 87
Brewing in Europe
• Development of European brewing:
– Change to brewing industry started in in Central European Christian monasteries
where beer was produced both for their own consumptions and for sale.
– Later on brewing became an important civic right and in 14th century home
produced beer became a subject of trade as well.
– Until 1850 mainly top - fermented beers were produced from wheat and barley
malts.
– In 1842- Pilsner Urquell was founded in the city of Plzeň (Pilsen).
• It's first brewmaster, Josef Groll developed a new type of bottom fermented "Pilsner Beer“.
• This type of beer was copied by many other breweries and became the most popular beer
type around the world.
88. 88
Brewing in Europe
• Foundation of other important breweries:
• 1847 Carlsberg, Copenhagen, Denmark.
• 1851 Anheuser-Busch, St.Louis, Missouri, USA.
• 1862 Cooper’s brewery Adelaide, Australia.
• 1864 Heineken, Amsterdam, Holland.
• 1870 Binding-Brauerei, Frankfurt/Main, Germany.
• 1872 Löwenbrau AG, Munich, Germany.
• 1873 The Adolphus Coors Brewing comp., Golden, Colorado, USA.
• 1876 Hokkaido Kaitakushi Brewery
89. 89
Education, Science & Technology
• 1707 – the first Eurpopean Technical University was founded in Prague.
• 1816 - malting and brewing lectures started on request of the Czech
brewmasters.
• 1833 – Profesor C.J.N. Balling described the process of fermentation
and developed a formula for original gravity calculation.
• 1865 - Weihenstephan Brauereihochschule (near Munich), Germany.
• 1883 - VLB Berlin.
90. 90
Brewing raw materials
• Water - makes up 85-95% of the beer mass.
• Malt - produced by “germinating” barley and then stopping the
process by “kilning”. The total process is called “malting”.
• Other starch / sugar donors like rice, maize or sugar.
• Hops - the flowers of a climbing plant “Humulus lupus”. Can be
supplied as natural hops, pellets or liquid extract. Hops provide
the bitter flavor in beer.
• Yeast - very special strains of yeast are used for brewing and
maintaining the purity of the yeast culture is of paramount
importance to the brewer as it plays a big part in defining the
fermentation and flavor.
91. 91
Water
• Water - water quality is very important to brewing. Brewers are concerned about:
– microbiological quality.
– oxygen content.
– chemical composition - the salts dissolved in water used for brewing have a marked
effect on the final taste of the beer. Sometimes all the salts are stripped from the water
using “de ionizing” systems, and the desired balance of salts are then added.
– pH - the enzymes used in brewing are pH sensitive.
• Technological water used for:
• steep (malt production).
• cleaning procedures.
• cooling and heating systems.
• To produce 100 Kg of malt you need 3.5 - 15 Hl water.
• To produce 1 Hl of beer you need 2.7 - 15 Hl water.
94. 9 SP 1033 - D
Malt
•Usually made from barley (Pilsner type of beer).
•Malt for White beer/ Weißbier/ Weizenbier made from wheat.
•(Whisky malt is made from barley smoked with peat during kiln
drying).
95. 9 SP 1033 - D
Malt supplements / substitutes
•Cereals other than barley are sometimes used in brewing, sometimes to
produce a different beer, other times to reduce production costs.
•Typical cereals are wheat, rice, corn and sorghum.
Rice Corn
97. 97
Yeast
• The key role of yeast:
– to convert fermentable sugars into alcohol, CO2 and heat:
Fermentable sugars Alcohol + CO2 + Heat
Brewers' yeast: Saccharomyces cerevisiae
• In Greek:
saccharus = sugar
myces = fungi
In Latin:
cerevisia = beer
Yeast
99. 99
Yeast processing
• Objective - to produce and maintain a pure yeast culture for
fermentation.
• Comprises “yeast propagation tanks”, “yeast storage tanks” or “brinks”,
“yeast pitching tanks”, “yeast pitching lines” and “yeast harvest” or
“collect lines”.
• Yeast processing consists of:
– Yeast propagation – preparation of fresh yeast culture.
– Yeast handling – includes pitching in wort, collecting from fermentation
vessels, washing, storing in yeast storage tanks and dicharging.
101. 101
Yeast propagation
• Fresh yeast is cultured and propagated from single cells.
• The volume of fresh yeast culture is increased gradually to avoid
inhibition by substrate.
• Yeast propagation is a critical hygiene area.
102. 1 SP 1033 - D
Yeast handling
•Used yeast is stored at 2 – 5o
C (35 - 40o
F) for reuse:
– up to 10 generations in open fermentation vats.
– 3-8 generations in CCTs.
•Yeast is sometimes washed with phosphoric acid to kill beer
spoilage bacteria.
•New trend: ClO2 is used for the same purpose.
•Excess yeast is sold for food or pharmaceutical production.
•Yeast handling is also a critical hygiene area.
104. 104
Brewing process
• Brewing is typically a batch process, brewing different brands one
by one - very occasionally a continuous process.
• The brewing process has its own volumetric measurement system:
– “Hectoliters” Hl, equivalent to 100 liters.
– “Barrels” equivalent to 31 US gallons.
– 1 barrel = 1.17Hl
• The brewhouse vessel capacities define the size of each batch,
called a “brew”. Typical brew size would be 500 - 1000 hectoliters
for a larger brewery.
• Brewery size is defined by the designed brewhouse output,
typically 0.5 to 10 million hectoliters per year with some very
large plants up to 20 MM hectoliters.
105. 105
Milling
• Objective - to mill the “malt” to release the starch, protein and enzymes.
– can be done wet or dry - “wet milling” and “dry milling”
– the “husk” is retained as well as the ‘flour” in the milled malt, which is called
“crushed /milled malt or grist”
– the grist is sent to the “mash tun”
– sometimes other cereals are used in combination with malt - most commonly rice
and maize, also need milling. These are called “adjuncts”. Adjuncts also refers to
other materials added during the process.
– Where wort straining is to be carried out in a lauter tun, great care is taken to
ensure that the husk (outer shell) remains intact as it will form a filter bed.
– If wort straining is to be carried out in a mash filter, then milling is done in a
hammer mill and everything is crushed.
106. 106
Mashing chemistry
• Malt contains primarily husk, grist, fine grist and flour containing starch,
proteins, and enzymes as well as many other compounds like non-starch
polysaccharides, polyphenols, nitrogen-containing compounds etc.
– husk - the outer shell which will form the filter medium.
– enzymes which can break down starch to fermentable sugars - and amylase.
– enzymes which can break down proteins to polypeptides and amino acids -
protease.
– enzymes which can break down glucans and pentosans - Glucanase.
• The sugar is needed for fermentation into alcohol.
• The polypeptides for beer “head retention”.
• The amino acids as yeast nutrients.
• Glucans cause filtration difficulties and harsh flavours.
107. 107
Mashing chemistry
• Different enzymes have different optimum operating
temperatures:
– amylase - 72 to 75o
C. (162 - 167o
F)
– amylase - 60 to 65o
C. (162 - 167o
F)
– Protease - 45 to 55o
C. (110 - 140o
F)
– glucanase - 42 to 44o
C. (108 - 111o
F)
• Enzyme action is affected by pH, and the mash will be
maintained at a pH of around 5.4 to 5.8
110. 110
Mashing
• Objective - to convert starch to sugars, and protein to polypeptides
and amino acids.
• Grist and water are mixed “mashed in” for example in a ratio 100 kg.
of grist to 400 liters of water in the “Mash Tun”.
• The “mash” is heated, and held at different temperatures, “rests”, for
differing times, to optimize particular enzyme reactions.
– 42 - 50o
C “protein & Glucan rest” protease & Glucanase
– 60 - 75o
C “sugar rests” alpha and beta amylase
• The sugar rests are also called “conversion rests” and must convert all
the starch to fermentable and unfermentable sugars - saccharification
.
• The mash is then heated to 78o
C, to stop most enzyme action, or to
100o
C, to stop all enzyme action; this is the “mashing out”
temperature.
111. 111
Mashing continued
• Heating the mash during mashing can be done in two ways:
– the “infusion method” where heating is done in the mash tun up-to
78oC (no boiling!). Therefore, some enzyme action is still
maintained.
– the “decoction method” where part of the mash is pumped to a
“mash cooker” where it is heated up-to the boiling point, boiled for
ca. 10-20 min and then sent back to the mash tun to increase the
overall mash temperature. Using this approach all enzyme action is
stopped.
• When mashing is complete the mash is sent to the “lauter tun” or
a “mash filter” for straining.
• Mashing takes 2 - 3 hrs.
112. 112
Adjuncts
• When other cereal “adjuncts” are added to the brewing process they
have to be dealt with a little differently because they may not contain
adequate conversion enzymes as malt does.
• They are mixed in “cereal cooker” with water and some “malt mash”
• The mixture is heated for at 80o
C for 10 - 15 mins. Breaking open or
the “gelatinizing the starch grains.”.
• The alpha amylase enzyme from the malt mash acts on the starch in
the adjunct to “liquefy” it. Sometimes alternate enzyme sources are
used.
• The mixture is transferred to the malt mash in the mash tun, where
the complete conversion “saccharification” of cereal starch to sugars
takes place.
113. 113
Wort straining – lauter tun
• Objective - to separate the “wort” from the “spent grains”.
• The entire mash is transferred to the “lauter tun”
• The lauter tun has a false bottom with fine slots cut in it.
• The mash settles on the false bottom and the husks form a filter bed.
• The wort filters through the “husk” filter bed, is recirculated until clear,
and the “first wort” is sent to the “wort kettle”.
• The lauter tun is fitted with “rakes” which stop the filter bed from
compacting during filtration.
• The mash is “sparged” with hot water to rinse through the remaining or
“second wort”.
115. 115
Wort Straining - Mash Filter
• Mash Filters are a plate and
frame device.
• Fitted with Polypropylene
filter cloths.
• Fitted with elastic plastic
membranes for mash
compression with air.
• Allow for faster filtration and
better yields.
• Latest models made by Meura
116. 116
Fill filter with mash Filter 1st wort 1st compression
Sparge with water 2nd compression
Mash filter operation
118. 118
Wort boiling
• Objectives:
– to obtain flavors from the hops by “isomerising” insoluble hop alpha acids,
forming soluble and bitter iso-alpha compounds.
– to remove more volatile undesired flavors by aggressive boiling.
– to develop the protein precipitates, “hot break” and “cold break” also known as
“trub”.
– to sterilize the wort and stop enzymatic activity.
– to concentrate the sugars and the wort itself.
• Hops may be added as flowers, pellets or liquid extract.
• Fermentable and unfermentable sugars may be added to increase alcohol
yield and provide specific end product characteristics .
• The hot break, a reaction product of hops, proteins and polyphenols
agglomerates.
• The process takes 1 to 2 hrs. at 100o
C and heat exchange surfaces
become fouled.
120. 120
Wort treatment
• Objective - to prepare the “sweet wort” for fermentation.
• This is a multi stage process
– “hot break” separation
– wort stripping
– wort cooling
– “cold break” separation (partly removed in the whirlpool and in the wort
cooler, partly stay in the beer)
– wort aeration
– yeast pitching
121. 121
Hot break separation
• Objective - removal of the hot break from the “hopped wort”
• The hot break is removed from the hopped wort by either
precipitation and sedimentation or centrifugation.
– if precipitation and sedimentation are used the hopped wort is
pumped to a large vessel and allowed to stand whilst the hot break
settles in 15- 30 mins, after which the hopped wort is drawn off.
– there are two centrifugation methods:
• use of a desludging centrifugal separator.
• use of a “whirlpool”. The whirlpool is a large cylindrical vessel. The
tangential entry of the hopped wort causes a whirlpool effect depositing
the hot break in the center of the vessel
124. 124
Wort cooling
• Objective - to cool the wort to a temperature at which yeast can
metabolize.
• The wort is passed through a plate heat exchanger called a “wort
cooler”.
• The wort temperature is reduced from 90 - 95o
C to 6 -15o
C.
• When the temperature becomes less than 60o
C the cold break
starts to precipitate.
• Hygiene becomes critical from this point onwards as the
temperature is now suitable for bacteria and yeast to grow in this
nutrient rich environment.
126. 126
Wort aeration & yeast pitching
• Objective - to aerate the wort to allow the yeast to multiply during
the aerobic stage of fermentation, and to add the yeast.
• Wort is aerated with sterile air and/or pure oxygen at a rate of 5 - 8
mg/liter.
• Yeast slurry is added at at 0.6 – 0.7 liters/Hl of wort.
• The aeration process is “in line”.
• The yeast pitching can be in line, or directly into the fermenter, most
often it is in line.
• The yeast population in wort will climb from 20 x 106 cells per ml at
pitching to
70 - 100 x 106 cells per ml at the end of fermentation.
127. 127
Fermentation
• Objective -to use yeast to ferment the sugars in the wort into
alcohol.
• Two processes:
– top fermentation to produce ales.
– bottom fermentation to produce lagers.
• With top fermentation the yeast rises to the top of the fermenter
when fermentation is complete, with bottom fermentation, the yeast
falls to the bottom.
• The fermented wort is now called “green beer” and must be
protected from “oxidation” from the air using carbon dioxide.
130. 130
• CIP
• CO2 collection
• Pressure relief
• Vacuum relief
Fermenter top set
131. 131
Bottom fermentation
• Aerated wort with yeast is transferred to the fermenter at
about 6°C – 8°C.
• Cold break, hot break particles, and insoluble hop resins
may be settled and removed from the vessel bottom.
• The yeast adapts to its environment and consumes the
available oxygen while multiplying.
• The yeast respiration becomes anaerobic producing alcohol
and C02.
• A thick white foam head develops and C02 is collected.
• Maximum temperature of 9°C - 12°C is reached and
maintained.
132. 132
Bottom fermentation
• As fermentation progresses the foam head develops brown
patches of resins.
• Foam head collapses leaving a “trub line” at the top of the
fermenter.
• Resins, proteins, polyphenols, cold break and “beerstone”
are deposited on the fermenter walls.
• Temperature is reduced to 1°C – 6°C, yeast growth stops and
the yeast sinks to the bottom of the fermenter in three
layers.
• The middle yeast layer, containing vigorous yeast cells, is
harvested from the bottom of the fermenter and sent to
yeast processing.
135. 135
Aging
• Objectives:
– remove haze materials
– mature the beer taste by modifying off flavor substances
– carbonate the beer
• Aging typically comprises one of 4 processes:
– simple aging
– ruh aging
– krausening
– ale conditioning
• Generally associated with bottom fermented beers.
• Also called “maturation”, “storage”, “conditioning” or “lagering”.
136. 136
Simple aging
• This is the simplest process
– yeast is harvested from fermented beer leaving a yeast cell count of > 3MM cells /
ml.
– beer is chilled to 0°C to -2°C, transferred to aging tanks which are under CO2 top
pressure.
– chill haze, the reaction product of flavenoids and protein at low temperature and
remaining cold break (protein/polyphenol complexes) and beerstone precipitated by
cooling.
– CO2 is generated or bubbled through it to:
• Purge any undesirable yeast metabolic by products, acetaldehyde, diacetyl, sulfidic, selected
hop volatiles.
– process takes 10 – 12 days in CCTs or up-to several months in classical aging
(lager) tanks
– low soil - typically low yeast, protein, polyphenols and beerstone
137. 137
Ruh aging
• Beer with some remaining sugar, “fermentable extract” and yeast
transferred to Ruh tanks at 12°C – 15°C.
• Secondary fermentation takes place:
– Consumes available fermentable extract
– Purges any undesirable yeast metabolic by products, acetaldehyde,
diacetyl, sulfidic, hop volatiles.
• Tank is sealed and natural carbonation and pressurization takes
place, yeast precipitates.
• Takes 12 - 24 hours.
• Beer then cooled to -2o
C and ready for filtration.
– Chill haze and remaining cold break (protein/polyphenol complexes)
and beerstone precipitated by cooling.
138. 138
Ale conditioning
• Prior to end of fermentation most yeast is removed by skimming or
centrifugation, leaving 0.25 - 2 MM cells/ml.
• Priming syrup (fructose) added.
• Further hops may be added to maintain bitterness.
• Secondary fermentation occurs for 3 - 5 days at 12 - 15o
C.
• Beer is chilled to 0o
C and stored for 5 - 14 days
– chill haze (protein/polyphenol complexes) and beerstone precipitated by
cooling.
140. 140
Aging
• Sometimes the aging process is carried out in the same tank as
fermentation, then known as a “fermenter storage” tank, a “combi”
tank or a “uni-tank”.
• Protecting the beer from “oxidation” by air contact is critical.
• Aging tanks become soiled with “beerstone”, protein polyphenol
complexes, yeast, and hop resins if secondary hopping occurs .
• Combi tanks are heavily soiled with both fermentation and aging
soils.
• The level and complexity of soiling varies widely.
142. 142
Filtration
• Objective: To removing any remaining yeast debris and polyphenol/
protein “chill haze”.
• Chill haze and “permanent chill haze” are the result of reactions
between “flavenoids”, “oxidized flavenoids” called “tannoids”
(polyphenols) and protein.
• Chill haze resolubilizes when the beer temperature is raised,
permanent chill haze does not.
• Permanent chill haze is a direct result of oxidation of flavenoids and
creation of chemical bonds between Nitrogen-containing compounds
and polyphenols.
• Filtration uses two processes which are sometimes combined:
– kieselguhr / DE (de-atomized earth) filtration.
– “PVPP” (polyvinylpolypyrrolidone) or “silica gel” adsorption , which is
added prior to filtration and removed in the kieselguhr filter.
143. 143
Filtration continued
• DE filtration removes the suspended matter - yeast and
haze.
• PVPP absorbs polyphenols, preventing them from reacting
with proteins.
• Silica gel absorbs proteins, preventing them from reacting
with polyphenols.
• Polyphenols and proteins react at low temperatures to
produce “chill hazes” Adding PVPP or Silica Gel to prevent
this is sometimes called “chill proofing”.
144. 144
DE filtration
• The filter is pre coated with coarse kieselguhr and then a layer
of fine kieselguhr.
• Any air residues, that could cause beer oxidation, are removed
from the filter with CO2, beer or DAW, “De-aerated water” also
known as “DAW” or “DA water”.
• “Body feed” kieselguhr is added to the beer flow into the filter,
at 50 - 100 g/hl.
• Over time the filter bed becomes clogged, measured by the
“P” (differential pressure) and the filtration is stopped, the
filter bed discarded and the filter flushed, hot water sterilized
and recoated.
• There are two common types of kieselguhr filters:
– “pressure leaf” or “screen disc” filters
– “candle” or “meta” filters
145. 145
• Filters can be vertical or
horizontal.
• Comprise a series of circular
filter elements with perforated
surfaces.
• A kieselguhr filter bed is coated
onto the filter elements.
• Beer is fed into the filter shell
and filtered through the
kieselguhr.
Vertical pressure leaf filters
DE - pressure leaf filter
148. 148
Filtration continued
• PVPP adsorption
– PVPP adsorption is either carried out as a separate process after
DE filtration or by addition of PVPP before DE filtration.
– when the PVPP process is carried out separately it can be reused
after regenerating with pure caustic soda.
• Silica Gel treatment is usually carried out by adding silica gel to
the beer prior to DE filtration.
• Other methods of removing chill hazes include the use of
papain and tannic acid.
149. 149
Final filtration
• To trap any kieselguhr that may break through the DE Filter
• To remove micro organisms
• This is done using sheet, or cartridge filters with small pore
sizes.
• Generally the filter material is backflushed with water when it
becomes clogged , sterilized with hot water and discarded when
it is no longer usable
150. 150
Filtration continued
• The lay out of filtration areas vary, but inevitably there will be heat
exchangers used for cooling beer and “buffer” and “surge” tanks
used for beer storage during filtration.
• When beer is “high gravity brewed”, that is brewed more
concentrated than the plant intend to package it, carbonated de-
aerated water “gravity liquor” is added at the filtration stage to
correct the concentration.
• When “blending” of beer is required it takes place at filtration.
Sometimes more hops and other flavor enhancers are added at the
filtration stage also.
• CO2 is added during filtration to ensure the correct carbonation level.
• After filtration the “bright beer” is sent to “bright beer tanks” , also
called “BBT’s”, “government tanks” or “package release tanks”.
155. 155
Bright beer storage
• Beer is stored at < 4o
C
• It is stored under CO2 top pressure of around 0.9 bar . To
prevent oxidation from air pick up and to maintain the CO2
level in the beer.
• Beer is sent to the various packaging configurations
• Bright beer tanks carry low soil loads, primarily beerstone and
polyphenol deposits.
156. 156
High gravity brewing (HGB)
• Used to:
• increase output of the brewery.
• lower cost.
• Principle:
• Brew and ferment strong wort.
• Adjust the original gravity of beer with specially treated de-aerated water
before filling.
157. 157
Sensorial analysis
• Essential part of the QA Process - checking beer quality by sensorial analysis (color, smell,
taste).
• Taste Panel:
• typically brewmaster, QA manager, MD, sales manager….
• important presence of women (more sensitive smell and taste compare to men).
• Tasting:
• takes place in the morning (9,00-11,00).
• tasting room:
• usually part of QA department - quiet, clean, neutral environment.
• triangle test.
• individual approach (no “teamwork”).
• limited amounts of samples.
• starting with low alcohol beers, continue with stronger ones.
• special glasses with a bow.
158. 1 SP 1033 - D
Sensorial analysis - tasting
•Pour small amount of beer into the glass and evaluate:
• Beer head (using stop watch).
• Clearness - brilliant…opalescent…turbid.
• Aroma - low…average…strong.
• Off-Aroma - Intensity (no…low…strong).
• Description (yeasty, malty, oxidized..).
• Bitterness:
• Evaluate after few seconds after the first taste!
• Intensity (low, average…strong).
• Character (gentle, …harsh…).
• Taste:
• Body/Palatefulness (low..average..strong).
• Zip /Sharpness (low…average…strong).
• Dark beers:
• Caramel (low..average..strong).
• Sweetness (low…average..strong).
• Off-Taste:
• Intensity (no…low…strong).
• Description (yeasty, malty, oxidized..).
Human tongue
sensorial zones
