Quality assurance and control, product safety and testing

CHAPTER 5

Quality assurance and control, product safety and testing Nigel Sadler Learn2Brew Ltd., Glemsford, Suffolk, United Kingdom

Contents 5.1 Introduction 5.1.1 What is quality? 5.1.2. Quality Assurance (QA) vs Quality Control (QC) 5.1.3. Food Safety: An overview 5.1.4. Due diligence 5.2. Pre-requisite programs 5.3. Quality management systems (QMS) 5.4. Some of the major points of QMS, PRPs and GMP in more detail 5.4.1. Specifications 5.4.2. Standard operating procedures (SOPs) 5.4.3. Process control 5.4.4. Record keeping 5.4.5. Raw materials 5.4.6. Brewery design 5.4.7. Other main considerations 5.4.8. Brewery equipment 5.4.9. Plant CIP and hygiene 5.4.10. Removal of soil: cleaning 5.4.11. Soil 5.4.12. Detergents and sterilants 5.4.13. Choice of detergent and sterilant 5.4.14. Possible problems 5.4.15. Materials used for general cleaning 5.4.16. A word of caution: SAFETY 5.4.17. Bacteria and other microbial problems 5.4.18. Brewery maintenance 5.4.19. Hygiene: staff 5.4.20. Staff training 5.4.21 Auditing 5.5. Food safety program - HACCP 5.5.1. The seven principles of HACCP 5.5.2. Types of HACCP hazard 5.5.3. Determining CCPs

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5.6. The Codex alimentarius decision tree (modified) 5.6.1. Explanations 5.6.2. Beware, HACCP plans can fail 5.7. Testing 5.7.1. Range of tests and methods 5.7.2. What, when and how to test

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Abstract As I sit here drafting this chapter I look back on a week that has seen three UK supermarkets and one large US craft brewer recall products for various reasons; allergens, incorrect labeling and faulty packaging. Plus, one global brewer being fined a large sum of money for breach of environmental health laws because of effluent discharge. In the case of the recalls they were done quickly, effectively and with minimal damage to both consumers and to their company reputation. Lesson: Things can and will go wrong. Even to the biggest and the best.

5.1 Introduction As I sit here drafting this chapter I look back on a week that has seen three UK supermarkets and one large US craft brewer recall products for various reasons; allergens, incorrect labeling and faulty packaging. Plus, one global brewer being fined a large sum of money for breach of environmental health laws because of effluent discharge. In the case of the recalls they were done quickly, effectively and with minimal damage to both consumers and to their company reputation. Lesson: Things can and will go wrong. Even to the biggest and the best. One of our chief tasks and aims must always be to have zero defects. Period. We all want, I hope, to produce products that are consistent, reliable and safe. Products that our buyers will return to time and again. This is where not only having award winning beers will show out eventually. This chapter may not be the most exciting in this book, particularly the area of HACCP formulation, but it is certainly one of the most important and indeed, under current food legislation in many countries, much of it is a legal requirement. Having spent a number of years in the small-scale brewing sector I am only too aware of the constraints on time, resources and finance that dog the smaller brewery. There are always 101 other things that seem more urgent and pressing than completing paperwork and drawing up operating procedures. However, consumers and retailers are looking towards safe

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reliable products. And the marketplace is competitive, those which implement much of what follows will be on a better footing in the long term than those who don’t. I am also aware that testing equipment and facilities in craft breweries will range from a simple hydrometer and thermometer to an on-site mini-lab. Don’t panic! Look to improve what you have when possible and use your current equipment effectively. In the UK I conduct audits of craft breweries of all shapes and sizes for a UK trade organization. Their aim is to ensure that their members meet a list of requirements pertaining to product safety and in particular traceability. It is interesting to note that the consistent weakness in the majority relate to QA and HACCP. In this chapter, we will address these areas. We will look at the importance of Pre-Requisite Programs (PRPs) and Good Manufacturing Practice (GMP). We will assess Quality Assurance vs Quality Control, implementation of a Quality Management System (QMS) and food safety program in the form of HACCP. Finally, a run through testing from grain to glass, both methodology and equipment. I would say here and now that without full engagement of senior management and all staff almost all quality management systems will undoubtedly fail. As with health and safety everyone in the company is responsible for quality. It’s a team thing!

5.1.1 What is quality? There are many different views on beer quality. As Professor Charlie Bamforth of UC Davis (author of Chapter 2 in this book) once said at a talk he gave in London “we all have our own definition of quality”. He’s right. When I ask the students I teach and beer lovers in general to highlight what they think is a good quality beer their answers include: • Lots of hop character • Good foaming head • No taints, well brewed • Crystal clear • Perfect example of a particular style • Complex character, depth of flavor • Free from adjuncts • Traditional • Micro/craft brewed • Cask (real) ale

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For some, simply disliking a beer will be enough for them to declare it as poor quality. It was once said that a terrible beer that meets specification requirements consistently could be argued to be a good quality product. The Oxford Dictionary online gives the following definitions for quality: “The standard of something measured against other things of a similar kind” and “General excellence of standard or level”. So where does this leave us? In my opinion a quality beer is one that is free from faults, is enjoyable, consistent and keeps customers coming back for more. A definition that many might agree with, I hope.

5.1.2 quality assurance (QA) vs quality control (QC) In the past, it was the role of the QC department or team to ensure that the final product rolling off the line met the specification. Unfortunately, this often led to the situation whereby out of spec material required dealing with i.e. reworking or blending and, in a worst-case scenario, disposal. Today’s preferred method is to adopt a stage by stage assessment of product whilst in production. Thus, monitoring at pre-determined points to ensure that at each point it is doing what it should be doing before allowing to proceed further. A “QC” check at each stage. It could also be said that the QA approach is as much about the process and people involved as it is about the finished product; beer. The control of quality through a ‘Quality System’ gives the following advantages over a ‘Final Inspection’ approach: • The use of documented procedures and specifications ensures that everybody knows what they are supposed to be doing • The responsibility for quality sits with the people who are operating the plant and making the beer • Quality problems will be identified as soon as they occur rather than much later when the process is over (QA vs QC) (see Table 5.1). • Traceability: Maintenance of accurate records makes it easier to track back and investigate raw materials or processes so that ‘due diligence’ in manufacturing can be proven Therefore, adopting the QA approach means that we must have, as a baseline, the following 5 key areas covered: 1. Reliable, consistent raw materials in accordance with our specifications 2. Well trained and motivated staff

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Table 5.1 QA Vs QC.

Definition

Focus

Target

QA is a series of checks, tests and activities for ensuring quality in the processes by which products are made or developed QA aims to prevent defects with a focus on raw material and process. QA is a proactive process Target of QA is to improve development and test processes so that defects do not arise during production: Right first time

QC is a set of checks for ensuring quality in finished products. The activities focus on identifying defects in the finished product QC aims to identify (and correct where possible) defects in the finished product. QC is a reactive process The aim of QC is to identify defects after a product is developed and before it's released i.e. sent to market

Source: https://www.diffen.com/difference/Quality_Assurance_vs_Quality_Control.

3. Process control, whether manual or automated, and documented operating procedures 4. Hygiene via effective CIP regimes and staff personal hygiene 5. Defined maintenance routines As we will see further on in this chapter these points will form a part of an effective Quality Management System (QMS) and Food Safety program (HACCP).

5.1.3 Food safety: an overview There is now a global approach to food safety headed up by the Codex Alimentarius. This is now implemented now by the relevant national and local area authorities. For more information on the Codex visit: http://www.fao.org/faowho-codexalimentarius/standards/en/. The Food & Drug Administration (FDA) in the USA, the Food Standards Agency (FSA) in the UK and their various counterparts in other countries have regulations in place to protect the consumer whilst trying at the same time not to be a burden on businesses with unnecessary demands or requirements. In many cases the legislation is flexible and usually in proportion to the size and nature of the business. In general, the requirements usually include:

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Food business owners and operators should have, at the very least, a HACCP, or similar food safety system in place, which must be implemented and followed • All food businesses should be registered with the correct competent authority There’s also legislation that covers any equipment used in the production and packaging of food and drink. With regard to brewing we need to consider, amongst other things: • Fermenters, maturation tanks • Kegs, casks, cans, growlers, bottles plus caps/crowns • Hoses, pipes and fittings plus seals or gaskets In principle, any materials, equipment or articles that come into contact with food and drink shouldn’t pass on anything from their makeup which might endanger human health, bring about any changes in the composition of foods or affect the flavor and taste. Compliance with all these requirements, and evidence of such, is crucial in the event of any potential liability claim. It could be the only form of defence you can call upon in court.

5.1.4 Due diligence As mentioned above it is important that food and drink producers show that they have taken all reasonable steps to ensure product safety and meet consumer expectations in terms of nature and quality of the product. This forms the basis of what is known as a “due diligence defence”. How do we prove this? By having procedures and a management system in place to assess and reduce any food safety issues. Examples include having the following in place: • HACCP (Hazard Analysis Critical Control Point) or similar food safety program which is monitored and updated • Purchase specifications for all raw materials • Quality Assurance certification from all suppliers • Training of staff in food hygiene etc. • Full production records including reviews and audits of control systems • Finished product sampling and testing on-site or by an approved/ appropriate company or public health laboratory We will look at establishing such evidence in the coming sections.

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5.2 Pre-requisite programs Pre-requisite programs (PRPs) and Good Manufacturing Practice (GMP), the two often overlap, provide a sound footing on which to build other Quality Management Systems (QMS) especially an effective food safety program such as HACCP. A PRP outlines and defines practices and conditions which should be in place before and during the implementation of a HACCP system. It is a pathfinder program. There is now an internationally recognized prerequisite program defined in standard ISO 22002-1:2009. Things that can and perhaps should be covered by a PRP include: • Construction and layout of buildings including workspace and employee facilities • Utilities - the supply of water, electricity, gas etc. • Effluent - waste and sewage disposal • Equipment - suitability, accessibility for cleaning and maintenance • Control of raw materials • CIP - cleaning and sanitizing • Hygiene and Pest control • Personnel - training and hygiene • Foreign bodies and cross-contamination including allergens • Chemical contamination • Microbiological contamination • Damage during internal handling and transport • Glass and brittle plastic control • Visitor and contractor control • Maintenance • Compliance with legislation These can be written up as “policy” documents, standard operating procedures (SOPs) or more effectively in a company manual. As with all documentation they must be reviewed regularly and particularly when any changes have been made in ingredients, procedures, plant, fabric and other equipment. It is beyond the scope of this chapter to go into detail on all the above areas but those shown in bold will be discussed further in the coming pages. An effective PRP in place: • Forms a solid foundation for the implementation of a HACCP system or similar

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Enables the HACCP system to be simple and focused Identifies general and lower risk hazards allowing HACCP to focus on specific and significant hazards Decreases repetition within HACCP procedures Can be operated and documented separately Removes quality issues from the HACCP system

5.3 Quality management systems (QMS) Quality management is a complete system that ensures products, services and companies are consistent. It looks at how to achieve this via a number of steps and components. Another common term is Total Quality Management (TQM). As with both the Food Safety and QA there are key features of a quality management system, some of which we have already encountered: • Product specifications - enable people to know what has to be achieved • Procedures - there to explain in detail how tasks are to be done • Documentation - enables people to record and check what has been done rather than relying on memory • Monitoring - compares what is actually happening to what should be happening • Auditing - regular audits check that the QMS or its various aspects are being followed and highlights non-compliance which may result in corrective action • Corrective action - taken to put things right. Usually covered by a procedure which establishes what has to be done, by when and by whom. Should be reviewed • Review - looks at the whole system at regular intervals and checks it is still working • Improvement - it may be that following the review an improvement is needed and this would be specified. As already pointed out at the start, the long-term target should be zero defects Setting up a QMS can be daunting but it is once again a team game and should involve competent representatives from all areas of the brewery, from cask and keg cleaning through to sales and marketing. Setting up steps will most likely include: • Planning and detailing control of processes critical to achieving company objective(s)

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• • • •

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Ensuring staff understanding and a positive attitude early on to gain their commitment to quality and continual improvement. It is important keep staff informed and involved where possible. There may be different ideas or opinions on how the system should be set up, discussion and participation will help. Listen to suggestions Measurement of process and business performance. Decide on Key Performance Indicators (KPIs) Demonstrating leadership from the top. This really is crucial to the success of the whole program Focus on customer satisfaction Continuous improvement in all operations within the company

5.4 Some of the major points of QMS, PRPs and GMP in more detail 5.4.1 Specifications Specifications are designed to ensure product consistency. From raw materials to finished product there are certain parameters which need to be measured or checked. Many of us will rely on our supplier’s analysis and QA. This is perfectly acceptable, however, we should also ensure that upon arrival the raw material matches what we ordered, the paperwork is correct and the packaging is intact. However, be wary of drafting specifications which are too tight, allow some leeway through sensible tolerances which should be monitored. Specifications should ideally contain 3 elements namely, a target level, an upper limit, and a lower limit. The tolerance is the range between the upper and lower limits and must be decided based on the impact on parameters such as cost implications, brewery capabilities, accuracy of testing method and product quality. Warning levels can also be inserted prior to reaching the upper and lower limits. Data should be recorded and can be shown using charts. I have found that the use of charts gives a clear visual snapshot of where and when changes have occurred. They can be easier for many to read as opposed to scanning over a table of data. Fig. 5.1 is a typical chart showing measured International Bitterness Units (IBUs) over a 5 batch brew period. Our target is 23 IBUs and we have a 1 / 2 tolerance of 2. It can be seen, quickly, that batch 4 breached the upper limit. This event should trigger an investigation.

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IBUs 26 25 24 23 22 21 20 Gyle 1

Gyle 2 Top limit

Gyle 3 Actual

Gyle 4

Gyle 5

Lower limit

Figure 5.1 IBUs of final beer in sequential brews.

5.4.2 Standard operating procedures (SOPs) A standard operating procedure, or SOP, is a set of step-by-step instructions compiled by an organization to help workers carry out routine operations. SOPs aim to achieve efficiency, quality output and uniformity of performance, while reducing miscommunication and failure to comply with industry regulations. Wikipedia 2017.

There should be detailed SOPs in place for each critical production process covering everything from container/vessel cleaning through to dry hopping and bottling to ensure consistency of process. SOPs should be well written and clear. They need to be available both at point of operation and copies in the main brewery manual. Some years ago, I trained and qualified as a Driving Instructor. It was during and just after this time that a phenomenon, which might be called “Operating Procedure Degradation”, became very apparent to me. When we learn to drive, we do everything by the book and as the instructor tells us. This ensures we pass our test. However, within a short time we tend to take short cuts and stop doing certain things through over familiarity. My own youngest daughter, within 3 months of passing her test, wasn’t using rear view mirrors or signaling properly. Others are tempted to use their phone. These changes can and often do lead to accidents. The same occurs in the workplace if we’re not careful. It is important that operating procedures are monitored and checked regularly to ensure compliance.

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5.4.3 Process control A ‘process’ can be defined as a “system of activities that uses resources to transform inputs into outputs”. The elements of process control are shown below. CONTROL Training Instructions

INPUT Raw materials Information

PROCESS

OUTPUT Product Service Information

RESOURCES Equipment Personnel Finance

If each of these elements is correct and fit for purpose, then the process can be said to be under control. Note that Process Control is not part of a product specification. Most processes in small breweries are controlled manually, automation occurs as we grow. Automated processes are not infallible and require monitoring too (Table 5.2).

5.4.4 Record keeping Traceability from grain to glass has already been pointed out as an essential requirement. We must know all the details of the beer we produced and where it went to when sold in terms of “first customer”. Brew sheets and process records, packing lists and delivery details must all be maintained and checked for any possible gaps which, if found, should be filled promptly whilst the information is still to hand. Remember our traceability requirement. However, record keeping is not just about production. Effective record keeping will enable you to track other areas of the business such as sales, duty/tax, container location, raw material costs, energy costs and staff training. There are a number of brewery specific software programs out there that will make many of these tasks easier and less time consuming.

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Table 5.2 Typical processes controlled in brewing operations (O’Rourke, 2012). Process stage

Measurement that is controlled

Effects on final quality

Mashing

Time/temperature/pH/ density Liquor treatment/ composition Temperature/pressure/ duration Temp of fermentation Duration, temperature Temperature of filtration Yeast count; finings additions Primings; dose

Extract yield, wort fermentability Extract yield, flavor

Wort boiling Fermentation Maturation Filtration Cask beer

Kegging

Bottling/ Canning

Pasteurization Carbonation level Pasteurization

Bitterness, beer stability ABV and flavor profile Flavor development & stability Colloidal stability Beer clarity Carbonation level; secondary fermentation Risk of microbial contamination Dispense/flavor etc. Risk of microbial contamination

5.4.5 Raw materials Raw materials are our key ‘input’ in the process control diagram above. It is crucial to ensure that our hops, malts, and water, amongst other things, are not only what we ordered but also comply fully with food safety requirements. Remember, traceability from grain to glass and the “due diligence defence”. All raw materials should arrive undamaged in a clean vehicle, be accompanied by an analysis sheet which shows a batch number or code. Ideally, all deliveries will be checked at time of arrival. Never sign for anything unseen or at least make a note to that effect on the delivery ticket for the driver to take back. Compliance to food safety requirements can be part of the supplier’s general QA statement, a copy of which you should have on file. Most of our raw materials will come in ‘ready to use’ format and but one or two others may require additional processing e.g. grinding of malt to produce grist. This is an added area of responsibility and will need to be done in a manner such that it doesn’t present a threat to our product safety and suitability.

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In addition to the above, other areas you might wish to consider include: • Raw materials must be stored in an appropriate manner and area to avoid contamination, pest infestation, loss of quality etc. Space can be tight in a small brewery, I am only too aware, but we must keep all our ingredients safe and secure • For any raw materials which require additional processing, e.g. malt milling, the processing operation should be located in a suitable area. Think about adequate ventilation, fire safety, pest infestation etc. and other possible hazards which need to be considered and assessed

5.4.6 Brewery design In an ideal world, we would all have purpose planned, well designed and constructed breweries which allow smooth flow of product from start to finish without hindrance. This not only reduces risk of crosscontamination but optimizes process efficiency. It’s also pretty expensive. Whatever we choose it is important that both the brewery design and that of other facilities allow not only efficient production but also proper cleaning/sanitation and maintenance. Plus of course it must be fabricated and fitted out with suitable materials for food production. So, what should we be looking for in terms of brewery design and a clean working environment? The building itself needs to be located in an area suitable for access of large delivery vehicles or outgoing goods. Access is also important if you want to have visitors for brewery tours or events. Whilst it might be romantic to brew in the “old dairy” or similar ancient buildings they are not always the best or easiest sites. Modern purpose-built units are far more suitable with good lighting, usable space and high ceilings. Also check out what the neighbors are doing. Avoid sites next to businesses that might be a possible source of contamination. Obviously, you also need to ensure the building has: • A clean and consistent water supply not only for brewing but cleaning down. Needs to be at the pressure and flow rates you need • Efficient effluent removal • A consistent and sufficiently specified power and gas supply. Usually single phase up to 4BBL and 3-phase above that but make sure you

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have, for example, the electrical power to supply all the kit you will be using plus a bit extra Starting with the flooring. Ideally, it should be constructed from concrete to at least 15 cm depth with a suitable protective coating on top. Any unprotected concrete will suffer greatly due to the various acids and alkalis used across production and packaging and of course the very nature of beer itself. • The flooring has to withstand repeated and thorough cleaning and sanitising, which is usually of a chemical nature, constant wetting and steam • The flooring may also be subject to physical abuse e.g. movement of casks, kegs, and pallet trucks so must have properties to withstand such loads and abrasion • Slips and trips are one of the main sources of industrial injury so all flooring must provide a safe working surface, in both wet and dry conditions, for personnel and handling equipment e.g. sack barrows and forklifts • Ideally, wall to floor skirting should be a continuation of the floor coating up to a height of 15 cm or so. This provides a smooth seal for cleaning and maintaining floor integrity by minimizing seepage • Floors should slope down to drainage points. This will prevent puddles of water developing after cleaning. The drains themselves should be of the correct size for the requirement in the area and fitted with traps. These ensure any solids, e.g. spent grain and broken glass, are held and can be removed for disposal Which now leads us to the walls and the ceiling. Most of us will choose to use anti-fungal/anti-mold paints or coatings which must be capable of being washed. Part of your maintenance program may well include a specified interval for repainting key areas. Natural ventilation or air-conditioning should supply sufficient air movement to help prevent mold growth. Pest proofing is essential and so all process areas should be protected against entry of rodents, birds and where possible insects. Pest control will be part of your PRP program. Staff facilities such as kitchen, toilets and shower/changing rooms must be positioned away from the process area, fitted with appropriate sinks, lockers etc. Toilets should have a double door entry. Ventilation whether by window or extractor fan should ensure sufficient air movement to eliminate odors.

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5.4.7 Other main considerations • • • • • • •

Suitable ventilation must be in place throughout especially in high risk areas e.g. fermentation where CO2 is a hazard or milling with risk of dust inhalation or explosion Lighting has to be adequate in all areas, no dark corners Light tubes or bulbs are covered to eliminate physical hazards from breakage Well designed and constructed storage facilities for raw materials, process aids, and CIP materials. Chemicals should be stored in secure and preferably bunded facilities It is essential that all storage areas are fully accessible and cleanable Storage areas should not permit pest access Storage areas need to allow control of temperature and also possibly humidity, particularly important for finished product

5.4.8 Brewery equipment Most main brewing equipment is either fabricated from new or bought in second hand. However, there can be quite a few ancillary bits and pieces ranging from plastic measuring jugs to mash paddles that might need to be checked out. The main points to consider are: • Vessel design and material of construction will impact on process as well as possible CIP regime. Consider: Temperature probes, spray balls, cooling, valves (vacuum and pressure relief), access • All equipment coming into contact with food should be of food grade material which can be cleaned and disinfected easily • Equipment which measures process parameters, particularly those identified as critical under a HACCP plan should be tested and calibrated regularly. The test results should be recorded. Examples are thermometers and pH meters • Any containers of non-food or dangerous substances, e.g. CIP materials, are identifiable and ideally color coded. Some chemical containers may have to be locked away to prevent food contamination • Pipework, pumps and valves should be appropriate for the allocated task. Not all can be cleaned and sanitised easily. Centrifugal pumps and butterfly valves are simplest and often cheapest to install, fortunately they are easy to clean and sanitize. Problems can occur with ball valves and positive displacement pumps

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5.4.9 Plant CIP and hygiene It is of utmost importance that effective systems are in place and documented regimes are implemented to ensure that adequate cleaning, sanitising and pest control are in place. These systems should be monitored to ascertain their effectiveness and records kept. It is of particular importance to product integrity and stability that cleaning and disinfection is effective once beyond the boil stage, if in doubt do it again! When it comes to plant cleaning the system chosen will very much depend on the size of brewery and the finances available. Fully automated recovery systems won’t be the first option for most. Many get by on a mix of power washers, spray balls and portable pumps with reservoirs. As pointed out above whichever method you use it is important to test for its effectiveness. A particularly swift method for this is ATP bioluminescence (see the “Testing” section). Remember also that pump, valve and pipework design will also impact on CIP efficiency. Some pumps and valves are not possible to clean and sanitize completely and therefore should not be used in wort or beer main circuits (Table 5.3).

5.4.10 Removal of soil: cleaning The majority of small scale breweries will rely on manual or pressure washing to remove and loosen the bulk of soil. Manual cleaning can involve brushing and/or scrubbing to remove loose soil. It is important to make sure that any abrasive or scrubbing material does not damage or scratch the surface being cleaned, particularly in fermenting vessels. Heavy scour marks can harbor bacteria; avoid wire wool and hard scourers. After scrubbing the surface, the dirt must be rinsed off with clean water. Pressure washers that produce a high pressure hot jet of water or even steam are in common use. They enable hard to reach areas to be cleaned and also reduce the level of detergent required. Beware that steam can bake on residues so wash equipment first on the cold-water setting. It is not advisable to use high pressure jets on open vessels as there is a risk of spreading contamination. Full CIP systems are designed to allow vessels, pipework, pumps and other items to be cleaned in situ i.e. without removal or dismantling.

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Table 5.3 Cleaning regimes and definitions. Term

Definition

Physical cleanliness Chemically clean

Visually clean

Microbiologically clean Cleaning-in-place (CIP) Soil Detergent Disinfection

Production sterility Chemical sterilant Sanitization

Cleaned surface imparts no contamination to product. Cleaned surface wets completely with clean water and forms a continuous film Absence of microbiological contamination Automatic cleaning of plant without the need to dismantle Any substance in the wrong place but typically residues from process liquids and solids A chemical cleaning agent, often with surfactant properties for removing soil from surfaces Treatments that kill micro-organisms and reduce loadings to a desired concentration. It does not imply total killing (sterilization) Term used in industrial microbiology to describe a state in which plant or processes are disinfected to produce conditions which do not result in spoilage A chemical disinfectant Process which is a combination of cleaning and disinfection

Adapted from Singh and Fisher (1999).

5.4.11 Soil It is important to understand the nature of the soil to be removed, it will either be organic or inorganic: • Organic soil will be essentially proteins, fats, carbohydrates and yeast • Inorganic soil will include scale from water and calcium oxalate There is a generally accepted sequence for cleaning and sterilization, it is as follows: • Prewash/soak • Detergent • Rinse • Sterilant • Rinse Rinse water should be checked with litmus paper or a pH meter to ensure rinse water is neutral.

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The final rinse depends on the sterilant as some e.g. peracetic acid are regarded as a “no rinse” sterilant.

5.4.12 Detergents and sterilants Detergents are either a single chemical or more likely to be a blend which is designed to break down and remove soil from the surface. Their effect aids the cleaning process by: • Increasing the wetting power of water and helping to penetrate the soil • Dissolving the soil and subsequently maintaining it in suspension • Removing soil in the rinse process with the cleaning water In general, organic soil is best tackled by an alkali detergent such as caustic soda and inorganic soil will favor acidic treatment such as phosphoric acid. Sterilants are designed to kill microorganisms and reduce their number to a manageable level.

5.4.13 Choice of detergent and sterilant When selecting a detergent we should always choose the detergent which: • Is appropriate for the type of soil to be removed • Is suitable for the area of the brewery or kit being cleaned • Takes into account safety considerations • Is compatible with materials of construction and process It is normal for detergents to contain: • An acid or alkali base • Wetting agents that help increase the effectiveness of the water by reducing surface tension and increasing penetration • Sequestrants or chelating compounds that soften water by removing calcium and magnesium ions • Dispersing or emulsifying agents which keep insoluble soil particles in solution In general, most alkali detergents are based on caustic soda (sodium hydroxide). This can also be chlorinated to increase effectiveness in heavily soiled areas such as plate heat exchangers. A hot caustic clean with sodium hydroxide at 80 85 °C through the mash tun/lauter tun, copper and plate heat exchanger should be undertaken once a week or every 8 10 brews. This not only maintains

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efficiency but will prevent the possible build-up of compounds known as “nitrosamines” which are carcinogenic. Acid detergents can be nitric, sulfuric or phosphoric acid or blends. Acids help to break down scale built up of phosphates, carbonates, silicates and oxalates. Again, wetting agents can be added. Common craft brewing sterilants include: • Steam or hot water ( . 90 °C for 15 minutes) • Chlorine containing compounds such as sodium hypochlorite and chlorine dioxide • Oxidants (non-rinse type) e.g. peracetic acid and hydrogen peroxide There are a number of conditions which affect detergent and sterilant efficiency: • Concentration too little is ineffective and too much may leave residue, is costly and possibly hazardous • Temperature some are designed for optimum effectiveness whilst cold and others work more effectively when heated e.g. caustic soda is at its most effective at 85 °C • pH level check against product recommendation • Water hardness check against product recommendation • Contact time too little will be ineffective

5.4.14 Possible problems It is essential that the right product is chosen for the task, not all detergents are safe on all surfaces or may have other detrimental effects. Some sterilants are corrosive and could possibly leave taints in finished beer. Key points to look out for: • Caustic soda must not be introduced into an enclosed CO2 rich environment to avoid possible vessel collapse/implosion. CO2 also reduces caustic soda’s effectiveness. Caustic will dissolve aluminum. Use at approx. 1.5 3% concentration and it is most effective, as a bacteriocide, when hot • Hypochlorite attacks steel and can be corrosive. Do not mix with acid under any circumstances as this will produce chlorine gas • Nitric acid and phosphoric acid are very corrosive when concentrated There are a great many proprietary products available and their manufacturers will happily provide advice on their use.

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5.4.15 Materials used for general cleaning •

Suitable bins to hold all waste material should be positioned around the plant and emptied regularly. Think about recycling. Color coding can be useful • Brooms and brushes to sweep and clean the floor • Squeegees to push excess water from the floors to drains • Sufficient hoses and hose points to clean all surfaces (walls, floors and equipment). Retractable hoses on reels with guns are the best to reduce trip hazards and ensure water is not left running • Special pads/brushes for cleaning surfaces of the plant. Care must be taken not to scratch inside and outside surfaces of stainless steel plant Any personnel performing cleaning duties should be suitably clothed and protected using Personal Protective Equipment (PPE).

5.4.16 A word of caution: SAFETY Almost all chemicals whether for cleaning or sterilizing are harmful to health and fall under the Control of Substances Hazardous to Health (COSHH) legislation in the UK but there are similar regulations in most countries. It is essential that appropriate measures are taken when preparing or using them. Every chemical should be supplied with a Material Safety Data Sheet (MSDS) or similar from the manufacturer. Ensure you have these filed and that they are accessible. They should be read prior to using a product. The MSDS will detail safety measures, first aid and handling procedures. A COSHH register of hazardous substances on site should ideally form part of your brewery records. It can be particularly useful in the event that the emergency services are called. Those using the chemicals and those nearby should be provided, by the brewery management, with appropriate PPE such as goggles, gauntlets, boots and overalls. First Aid trained staff and access to suitable equipment for emergency treatment should be considered and installed .e.g. safety showers, eyewash stations etc. Staff using the products should be trained and sent on a suitable awareness course first. Do not use a hazardous product if a safer alternative is available. Ensure chemicals e.g. detergents and sterilants are kept in a secure, preferably bunded, area away from others that may cause an adverse

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reaction or those intended for “food” use. Don’t store acids with alkalis or hypochlorite. It is recommended that you obtain and display a copy of the Hazard Symbols for chemicals and ensure they are understood by all staff.

5.4.17 Bacteria and other microbial problems Although beer is not the most welcoming medium for many types of bacteria there are a few that can cause us problems. An ineffective cleaning and sanitising regime will obviously increase the risk of bacterial infection in the product. The three main types that we should be aware of are similar in their action in that they all “sour” beer and cause hazes, these are Lactobacillus, Pediococcus and Acetobacter. • Malt dust is liable to contain molds such as Fusarium and Aspergillus. These can lead to the formation of mycotoxins i.e. Deoxynivalenol (DON). Fusarium can also be a source of possible “gushing” when a beer container is opened. • Water is a potential source of coliform bacteria which lead to an unstable wort. • During mashing and wort separation there is the risk of Lactobacillus contamination at temperatures ,60 °C leading to souring occurring. • Yeast cake and slurry can become contaminated during handling with both wild yeast (S. Diastaticus) and bacteria i.e. Lactobacillus and Pediococcus. These can lead to a range of off flavors and over attenuation during fermentation and maturation. • Racking and packing are both areas where the finished products are exposed to further possible bacterial infection such as Zymomonas and Pectinatus. • Point of dispense can see Lactobacillus, Acetobacter and wild yeast causing flavor and clarity issues. Usually poor cellar practice is the major source of such contamination.

5.4.18 Brewery maintenance This is an area that is often overlooked for various reasons and only rears its head when something breaks down. Unfortunately, most small breweries are run on very tight budgets and one of the last things available in many cases is off the shelf spares for pumps and other equipment.

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There are various approaches to maintenance and these should be considered on their merits, some are more workable and suitable than others. Financial reserves are the usual constraint for many particularly when first starting up. There are four key maintenance regimes, in general the first three apply to the majority of microbreweries and they’re as follows: No maintenance: This basically means the plant is used and left to run without any form of checking or servicing. When something fails it is replaced with a spare. The faulty item is sent off for repair, if possible, or thrown away. • Advantages - easy to set up and works in some cases • Disadvantages - risk of equipment failure at essential process points and high cost of replacements parts/spare equipment Breakdown maintenance: Again no checking or servicing but when equipment fails it is repaired on site there and then. • Advantages - no unnecessary maintenance work done on the brewery • Disadvantages - risk of equipment failure at essential process points and high cost of spares/stock Planned maintenance: All equipment is checked and serviced routinely whether required or not. Usually done on a weekly basis. The idea being that breakdowns will be kept to a minimum and disruption avoided. • Advantages - the work can be carried out at a set time e.g. every Friday afternoon and minimizes risk of breakdown at key times • Disadvantages - costly in terms of time, personnel and money. Equipment may be serviced unnecessarily Preventive maintenance: All equipment is monitored closely, usually by an engineering team and therefore more “big brewery” practice. Assessments and predictions are made as to when something is likely to fail. A subsequent planned maintenance program is then put in place. Accurate record keeping is essential. A planned maintenance program develops and changes as new information is taken into account. • Advantages - makes the most efficient use of resources i.e. time and personnel. Maintenance work can be undertaken at times to suit production. Less chance of breakdown/failure • Disadvantages - requires accurate record keeping and qualified personnel in most cases. Cost of spares

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It is important that any work is carried out by trained personnel in accordance with Health & Safety legislation. Appropriate PPE should be provided and worn when some operations are carried out. Incorrect maintenance by inexperienced or unqualified personnel can be both dangerous and detrimental to the business. Failure to maintain equipment can have a serious effect on the brewery’s business performance in one way or another from being unable to supply product on time to actual contamination of beer resulting in possible destruction of it or, in a worst-case scenario, prosecution. It is therefore recommended that some form of program is implemented early on to increase reliability and remove or reduce the possible risk of equipment failure and therefore improve business performance. In summary: • Keep the plant and all equipment in a good state of repair • Ensure all equipment functions as intended, particularly that used for the monitoring of CCPs in a HACCP plan. Any faults or failures need to be reported and dealt with • Have effective building and fabric maintenance to prevent contamination of product by flaking paint, debris and other foreign matter • Effective cleaning of plant and equipment during maintenance will remove dirt and product residue helping to minimize the risk of contamination

5.4.19 Hygiene: staff In general, it is a requirement that those producing or handling food are trained in food hygiene to a level commensurate with their role. This can be conducted in-house by a competent member of staff or obtained externally. Certificates are always a bonus for staff and prove training has been undertaken. It is critical to ensure that all those coming into contact with beer during its production are not likely to contaminate the product by maintaining an appropriate degree of personal cleanliness and behave and operate in an appropriate manner. The following are important and should be taken into account: • Any member of staff with a condition that’s detrimental to food safety should report it immediately to management. Illnesses such as jaundice, diarrhea, vomiting, fever, and infected skin lesions are of concern

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Staff known or suspected to be suffering from or to be carrier of a disease or illness transmitted through food should be barred from entering food handling areas. This should be established at the time of employment or after any prolonged bout of illness All production staff should maintain a high degree of personal cleanliness and wear protective clothing where appropriate. Overalls, aprons etc. should be laundered regularly. Ideally fresh work apparel every day. Staff must always wash their hands before handling and particularly after using the toilet, having a smoking or lunch break and after handling raw materials which might contaminate production Production staff must not engage in behavior that will affect food safety e.g. smoking, spitting, chewing or eating, sneezing or coughing Personal effects like watches and jewelry should not be worn or brought to food handling areas Visitors and contractors coming into processing areas should wear appropriate protective clothing and adhere to stipulated personal hygiene provision

5.4.20 Staff training •

As mentioned above all staff involved in beer production should be trained in food hygiene/safety up to a level appropriate for operation. This should include HACCP and allergens. All personnel should be aware of their roles and responsibilities in protecting beer from contamination or deterioration and beer handlers should have the knowledge and skills to handle food hygienically. Training requirements should be determined at regular intervals and refresher courses should be considered. Ideally the effectiveness of training programs should be assessed by a test or exam, and a qualification gained as evidence, and training programs need to be reviewed for continuous improvement.

5.4.21 Auditing What is an audit? It’s a systematic examination, conducted both internally and externally and very often by an independent person or authority, to determine whether: • Quality activities comply with plans • Systems are implemented effectively

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Systems are suitable to achieve objectives There are 3 types of audit: First Party Internal audit by the company on itself to ensure compliance and to maintain or improve processes, systems and quality Second Party Supplier audit. Undertaken by a company on its suppliers the purpose of which is to ensure raw material quality and services as an aid to “due diligence” Third Party An outside audit performed by: 1. Customers 2. Accreditation bodies 3. National or Local environmental health authority If you are selected for an audit make sure you are ready. For many of us audits can be somewhat daunting but preparation is key to success as in all things. Make sure you can locate everything you will require during the audit e.g. records and other paperwork. It is extremely inefficient for the audit process when a company cannot find information within its own system. The auditor is trying to ensure that there is an effective system in place. If the person/people responsible for the system are unable to locate relevant data and information then how can the auditor have confidence in the system? Audits can be time consuming allow plenty of time. Audits are about checking systems not people Not a witch-hunt! Failing an audit is a chance to re-assess and learn Look to improve! What to expect on the day of the audit? Generally, the procedure will involve an “Opening meeting” the purpose of which is to allow introductions on both sides. The auditor will then outline the purpose and scope of the audit and clarify any questions you may have. He or she will also give a proposed schedule for the day. It is important that a senior member of staff should be available to attend both this and the closing meeting. After the Opening meeting the auditor will then conduct the audit, this may well involve an initial walk through the whole plant or the area selected for audit. The auditor may well ask staff questions. It is important they answer honestly. After the audit has been undertaken there will be a “Closing meeting”. Here the auditor will discuss their findings and make comments. A formal audit report will be issued, usually within 14 days of the audit having taken place. In this report the auditor will:

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1. Categorize their findings in various levels of severity: a. Major non-conformance b. Minor non-conformance c. Observation d. Recommendation for improvement 2. A non-conformance report will be issued if necessary and will give details of the failure and possible cause(s) 3. The required corrective action to be undertaken 4. Audit follow-up to ensure that the action has been taken to correct the non-conformance and the cause of the problem has been dealt with It must be remembered that: a. Auditing is about improvement b. Auditing is not a fault-finding exercise c. Auditing encourages a continual improvement loop: PLAN DO CHECK ACT d. Auditing gives verification of food safety and quality systems which are essential for your customers and for legal compliance

5.5 Food safety program - HACCP The HACCP food safety management program started life in the late 1950 s in the USA ostensibly to provide NASA astronauts with risk-free food on their journeys into space. HACCP stands for Hazard Analysis Critical Control Point. It is generally now a requirement in most countries that all food producing premises have a HACCP or similar plan in place. This plan may well be inspected by local Environmental Health Officers and buyers alike. Food business operators are responsible for providing supervision and instruction and/or hygiene training commensurate with work activities. All brewery personnel responsible for the development and maintenance of the HACCP plan, or other relevant systems, should be trained adequately in the application of HACCP principles. At least one member of the HACCP team should be trained to Level 3 or 4. HACCP plans are designed to highlight essential control points, critical to food safety, within a production system to ensure that resources are concentrated in the right areas to minimize risk. Food safety programs are not about quality or health and safety. A well-designed HACCP plan should never be: • A millstone round the neck of the company

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A solely academic exercise Overly burdensome and a complicated system of control Left in the cupboard in the office, forgotten Written by a third party without significant input by the brewery HACCP team At its simplest HACCP involves: • Identifying hazards what can affect the product and where in the process • Accessing how likely they are to occur • Control measures how to control or remove the critical hazards identified • Monitoring the controls • Corrective action when there is deviation • Documentation There are distinct benefits in implementing a HACCP system other than legal compliance. These range from preventing costly food safety incidents to defending legal action against the business for food safety failures. Other key points are: • Protecting the reputation of the business • Minimizing costly product recalls • Developing a “right first time” approach within the business • Preventing the need to reprocess or destroy product • Increasing confidence with customers and consumers • Reducing complaints and increasing customer confidence • Being used for accreditation and certification to win new contracts The consequences of not having a HACCP plan, or similar, could mean contravention of food safety legislation, difficulty in demonstrating due diligence in the event of a prosecution, loss of business, increased risk of wastage and increased costs. There are five steps which form the basis of the HACCP preparation and set up process. 1. Assemble the HACCP team. This can be one person or several. In a small brewery it’s likely to be a small number. The team must be trained so they understand the principles and workings of HACCP. Outside consultants are also available. National or local authorities can also provide limited guidance. If you choose to call in a consultant it goes without saying it would be preferential to find one with working knowledge of craft brewing

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2. Describe the products and processes involved at each stage: • product name • description of the technology processes • product characteristics • primary packing, transport packing • storage conditions, transportation conditions • product labeling • shelf life for each pack format 3. Intended use and likely customers? In our case, we’re lucky that beer is not a favorable environment for pathogens and the majority of people will consume the product without risk but you must consider those with certain allergies, pregnant women and people on medication as these may well be more at risk, even if they have been warned not to drink alcohol 4. Construct the process flow diagram consider who draws it up and what areas should it cover 5. Confirmation of process flow diagram on site

5.5.1 The seven principles of HACCP After completing the five steps above the seven HACCP principles, on which the system is based, need to be worked through in sequence. 1. Conduct a hazard analysis. Identify the hazards and specify the control measures. 2. Determine the critical control points (CCPs). These are steps in the process where control measures must be implemented to prevent, eliminate or reduce a hazard to an acceptable level. This is best done by using a decision tree (see below) 3. Establish critical limits. These are the limits which need to be monitored e.g. pH, temperature, cleaning/sterilization regime to define when something moves from being at an acceptable level to unacceptable. Critical limits must be defined and measurable 4. Establish a system to monitor the control of each CCP. For most craft breweries, this will be done by observation, visual inspection, and basic testing which should be supported by external professional lab checks. Consider the frequency of monitoring, continuous or at set intervals, and who monitors 5. Establish the appropriate corrective action(s) when the monitoring shows a CCP is not under control. This is also done when a critical

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limit has been breached. In brewing this can result in reworking, recall and even destruction of product 6. Establish procedures for verification to confirm the system is working effectively. Usually done in the form of an internal audit checking that the flow diagram, process and hazards are unchanged and remain effective. HACCP plans need to be updated if anything changes e.g. process, equipment, increase in customer complaints, new scientific information 7. Establish documentation and records covering the program. These should cover: • Details of the HACCP and its pre-requisites • CCPs and their determination • CCP monitoring and methods • Reviews and HACCP meetings • HACCP staff training • Breaches of CCPs • Corrective actions • Customer complaints

5.5.2 Types of HACCP hazard What sort of hazards are we likely to encounter? Even though brewing and beer are relatively “safe” compared to say preparing cooked chicken ready meals the hazards are actually similar. Potential hazards are either microbiological, physical or chemical. • Microbiological hazards include bacteria, molds, viruses and even parasites • Physical hazards cover everything from stones, metal, glass fragments (bottled beers, light bulbs) to pests and pieces of brewing equipment (plastic/wood) • Chemical hazards include allergens, glycol from cooling systems and cleaning/sterilization liquids. In the case of beer, allergens are mainly from gluten or sulfites (SO2). These must be identified clearly on product labeling depending on quantities and local legislation

5.5.3 Determining ccps Use the Codex decision tree below to help identify Critical Control Points.

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5.6 The Codex alimentarius decision tree (modified)

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5.6.1 Explanations Monitoring Required to identify deviations, prompt corrective actions and identify trends towards loss of control. The monitoring method must provide a ‘real time’ result. Automatic, on-line monitoring is preferable. The frequency of monitoring must be appropriate to the process. Monitoring procedures and activity must be documented in detail. Corrective action A corrective action procedure should state what immediate action is required to recover control of the process. There are three levels of corrective action that need to be put in place; immediate action, short term action and long-term action. A corrective action procedure should state what immediate action is required such as should production or sales should be stopped, product recalled, who to inform and what to do with the affected product. Then how and where to record the actions taken. Product recall is a request to customers and consumers to return products and is normally due to safety issues. All companies should have a product recall procedure in place taking into account distribution of product and the method of announcement e.g. press and social media. Validation Validation is the process of collecting scientific evidence to show that the HACCP plan is effective, particularly with regard to the critical control points and the critical limits. The HACCP plan must be accurate and validated before being implemented and there are various ways of achieving validation depending on the complexity and scale of the HACCP plan. It is essential that the validation process is carried out by people who fully understand HACCP and the capabilities of the specific operation to which the plan will be applied i.e. brewing. Evidence of validation should be recorded. Verification Verification is “the application of methods, procedures, tests and other evaluations, in addition to monitoring, to determine compliance with the HACCP plan”. (Codex, 2003) There are various methods of verification which include auditing, data analysis, sampling and testing. Using data analysis is important because it

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confirms not only the effectiveness of the HACCP plan but can act also as a catalyst for process improvements. Samples and tests can be useful to identify general trends and prompt further investigation. Results may require expert interpretation as it can sometimes be difficult to link a particular result to a specific cause. Review and maintenance Once the HACCP plan has been implemented, review and maintenance becomes essential. Effective HACCP reviews are a reassessment of the HACCP plan to ensure it continues to be valid over time. They must be a scheduled activity e.g. every year. HACCP maintenance involves supporting the elements and resources which enable the system to remain valid over time. Continual development of the HACCP team is essential to ensure that the skills and knowledge of the team are current. Documentation Is the basis of evidence that proves that the HACCP system is working and record keeping needs to provide a daily account of actual events. All changes must be documented.

5.6.2 Beware, HACCP plans can fail Success of a HACCP plan is not always guaranteed. Numerous reasons can cause HACCP to fail. Here are some of the most common and possible solutions to help overcome them. 1. Problem: Lack of management engagement; left to workforce to implement. Solution: Senior staff should lead by example and commit to the HACCP plan from the word go. 2. Problem: Poorly set-up pre-requisite plan. Solution: Prior to going ahead with establishing the HACCP plan it is essential to ensure the supporting PRP covers all requirements adequately. 3. Problem: Lack of training and resources Solution: Key staff must be trained in HACCP to varying levels with those charged with drawing up the plan being at least Level 3 or 4. Management needs to ensure funds and personnel are available. Working on a QMS/PRP or HACCP will usually be in addition to the day job. This can place a strain on staff.

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4. Problem: Misunderstanding the aim of a food safety plan vs quality. Solution: A food safety program is there to protect and its successful implementation is paramount. 5. Problem: The HACCP is too complex, too many CCPs and rather cumbersome. Solution: Good staff training. Ensure it’s written in everyday language; not overly technical and full of acronyms and jargon. Keep it simple. Re-visit the CCPs, are they correct? Are they covered in the pre-requisites? They should be achievable. Monitoring needs to be focused and any corrective action taken promptly. 6. Problem: HACCP drawn up and then put in the bottom drawer. Forgotten. Solution: HACCP is an everyday living document that should be in constant use. It should be checked and reviewed. Operations and staff need to be supervised to confirm its use and effectiveness.

5.7 Testing When considering using raw materials most of us can perform basic sight, smell and taste tests where appropriate. Unusual looks, smells or tastes are an indication that it might not be best to brew with it until further more detailed testing can be undertaken. In this section, we will look at the various tests available to us from the very simple, such as iodine for starch conversion, up to mini lab systems. A modest budget will actually get you quite a bit of kit if you shop around. At the very least I would recommend the following equipment: • Hydrometers at least 3, high quality and covering OG in a range from 1.005 to 1.080 • Refractometer quick on-the-go wort gravity checks • Test sieves check your grist particle distribution if you mill your own grist • Accurate scales 2 sets, one for measures up to 1 kg for liquor salts, finings powders and accurate to 0.1 g and the second for larger amounts of hops, malts etc. up to 50 kg and accurate to 10 g minimum • Digital temperature probe safer than glass and high degree of accuracy. Temperature control across the brewing process is crucial. • pH meter good for water, wort and beer • Iodine test kit starch conversion for mash efficiency

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Alkalinity testing tablets or meter for liquor control, flavor and extract efficiency • Microscope/haemocytometer/methylene blue stain yeast counts and viability for accurate and consistent pitching rates as well as yeast health • Basic sensory analysis tests can be made from every day foodstuffs • Selection of calibrated laboratory flasks, beakers, funnels and test cylinders A dedicated member of staff to undertake lab work with a more formal approach to testing will become essential as you expand as will increased space and additional, usually more expensive, equipment. Detailed test methodologies are beyond the scope of this chapter but are available from the American Society of Brewing Chemists (ASBC), the European Brewery Convention (EBC), the Institute of Brewing and Distilling and The Mitteleuropäische Brautechnische Analysenkommision e.V. (MEBAK).

5.7.1 Range of tests and methods 1. Temperature A good quality digital probe is invaluable for checking everything from hot liquor through to chilled beer. No glass thermometers should be used in the production area but are acceptable in the lab (assuming your lab isn’t in the production area). Make sure you check the readings regularly using boiling and ice water to maintain accuracy. 2. Test sieves and magnifying glass Check milled grist, whether brought in pre-crushed or you do it yourself. It should be consistent and clean with long sections of grain husk present to enhance mash bed stability and run-off. Sizes and generally recommended levels for the three main mash systems are as follows, shown below in Table 5.4 as % retained on each sieve post milling: 3. pH A good pH meter will not be cheap and they might need replacement of the bulb sensors every 6-9 months. As with the thermometer calibration is essential and appropriate pH buffer solutions are required for this, usually pH4 and pH7. pH is a good measure of liquor

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Table 5.4 Sources: various. Mesh mm

Mash tun

Lauter tun

Mash filter

.1.25 .0.50 .0.15 ,0.15

20 35 35 10

15 40 35 10

5 10 40 45

treatment i.e. mash pH through to fermentation progress from start to finish. Acidity below pH3.8 is likely to indicate bacterial infection. It is a useful tool to indicate rinse water is running neutral after cleaning and sanitation. Good old-fashioned litmus paper is good for this too. However, it must be born in mind that there is a chemical shift in pH measurements as temperature rises. Ideally all pH readings should be taken at 20 °C to ensure consistency. 4. Alkalinity/hardness test kits The simplest consist of tablets which are dissolved in a fixed volume, 50 100 mL, of brewing liquor until a color change is recorded. More advanced digital versions are also available. Monitoring of alkalinity and hardness content prior to each brew is recommended to ensure correct treatment for establishing mash pH. 5. Hydrometer The more accurate the better. These are fragile! Used in conjunction with a test cylinder and thermometer to monitor wort to finished beer gravity. Check the manufacturer’s guidance on temperature and possible compensation requirement. Most are calibrated to either 15 °C or 20 °C. 6. Refractometer Handy little things for on-the-go ballpark wort readings. No need to chill down a whole test cylinder of liquid as is necessary when using a manual hydrometer. Again, might be calibrated in Brix or Plato so conversion chart may be necessary. Good for monitoring wort run off strength from the mash. Not used with finished beer due to its alcohol content. More expensive digital versions exist but are calibrated, in most cases, in Brix or Plato so the reading might need to be adjusted depending on what approach you use.

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7. Iodine test for starch Invaluable for assessing starch breakdown in the mash. Inexpensive and is a simple process. 5 mL of wort is placed on a white ceramic tile or dish, a couple of drops of iodine solution are dripped in and stirred. The resulting color shows whether starch is present (black, blue, dark brown) or starch free (yellowish). Recommended when brewing recipes for the first time, when changing malt suppliers or when new season’s malt comes in. 8. Microscope and hemocytometer Cell counting and viability testing are crucial to establish correct pitching rates when re-using cropped yeast. A microscope with a magnification of 400 3 is recommended. Beware cheap hemocytometers as they are neither accurate nor well made. In principle, the process involves counting the number of yeast cells in a defined volume of slurry, wort or beer. Additional equipment will include a clicker counter, cover slips and a cell stain which is usually methylene blue. A number of sources will give the procedure and calculations e.g. ASBC, EBC. 9. Sensory kit Can be made up using a range of domestic items so needn’t cost a fortune. Most of us have access to vinegar (acetic), butterscotch food flavoring (diacetyl), water based emulsion paint/cooking apples (acetaldehyde) and canned corn (DMS). Taking it to the next level there are capsule and pre-mixed liquid solutions on the market. These are dosed into 1 L or so of relatively low character beer then used for aroma and taste testing. The capsules are not cheap and are one use only so bear in mind the costs. Some of the test liquids, if stored properly, can be used up to 1 month from opening. It’s important that all staff have knowledge of ingredients and final beer quality. Regular testing sessions should be conducted. This helps with flavor and aroma identification right through to finished beer consistency. Other worthwhile tests include: • Triangle Test - pick the odd one out of 3 glasses of beer • Trueness to type Test - in which a whole range of attributes are assessed and recorded. Particularly useful when monitoring product flavor attributes, comparison of beers brewed at different times or monitoring new materials or process changes

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Flavor Profiling - beers are assessed for important attributes in the aroma, taste and aftertaste of the beer e.g. malty, hoppy, fruity, roast, DMS, sweet, sour, bitter, diacetyl, and cardboard. Useful for describing your products, comparison to others on the market, NPD (new product development) and monitoring consistency. 10. Microbiological There are one or two rapid tests open to craft brewers that are relatively simple to perform and useful for various applications. The first is rapid ATP Bioluminescence which gives a reading for the presence of bugs due to a particular reaction which detects ATP (adenosine tri-phosphate). This compound is the source energy in all living things. A swab is taken from, say, a recently cleaned and sanitised fermenting vessel. The swab stick is inserted into a tube with the relevant solution, left for a minute or so and then placed in a handheld detector unit which then gives a bug count. The second method uses “dip slides” and is particularly useful for liquids testing e.g. in heating and cooling systems such as pasteurizers and air conditioning units. The dip slide test consists of a sterile culture medium on a plastic carrier that is dipped into the liquid to be sampled. The culture is then incubated, allowing for microbial growth. A bacterial reference chart is used to determine the number of bacteria in the sample. Unfortunately, neither of these rapid tests can determine the nature of the microbes present, that’s when other methods are required and an external lab is best for these unless you have a microbiologist in the team and have money to invest in the equipment. 11. Color There are basically two methods used by craft brewers for wort and beer color checks. The Lovibond comparator type which uses various shades of colored glass placed next to the sample being tested and the digital version directing a beam of light through a cuvette. Checking wort pre-boil and post-boil and finished beer is a useful guide to consistency.

5.7.2 What, when and how to test A rudimentary raw materials and process testing regime might look something like this:

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Material

Frequency

Method

Reason

Malt

Every brew

Free from mold etc. Correct mill settings

Hops

Every brew

Taste, odor, appearance, crush (test sieves) Odor, appearance

Water

Every brew

Mash

Every brew

Wort Sweet

Every brew

pH, SG, clarity

Wort Bitter

Every brew

pH, SG, sediment, color, taste, clarity

Yeast

Every brew

Wort in FV

Every day

Finished beer at racking

Every brew

Odor, appearance, viability (microscope and methylene blue stain) Taste and odor, SG, pH, temperature, copper finings Taste and odor, FG, pH, yeast count (microscope)

Adapted from Bamforth (2002).

Taste, odor, clarity, alkalinity level, pH pH, temperature, iodine test

Free from mold and damage Well cleaned, free from leaf, strig and foreign matter Good aroma Free from taints Correct liquor treatment Successful liquor treatment Optimisation of extract recovery Starch conversion Extract recovery Fix cut off point for last runnings Evaporation rate Success of boil: color, bitterness, gravity obtained Trub carryover Copper finings efficiency Free from contamination Establish pitching rate

Fermentation progress Flavor profile: VDK (Diacetyl) Correct flavor profile Yeast count cask ale priming and fining