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MBAA - RMD. February 15 th , 2007. Cleaning and Sanitizing Brewery Process Equipment. Pumphouse Brewery, Longmont, Colorado. Dana Johnson, BIRKO Corporation Henderson, Colorado. pH & Growth Relationship of Microbes. pH Scale: 0______2_________5______7_______9________12_____14.

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cleaning and sanitizing brewery process equipment

MBAA - RMD

February 15th , 2007

Cleaning and Sanitizing Brewery Process Equipment

Pumphouse Brewery, Longmont, Colorado

Dana Johnson, BIRKO Corporation

Henderson, Colorado

ph growth relationship of microbes
pH & Growth Relationship of Microbes

pH Scale:

0______2_________5______7_______9________12_____14.

Acid Neutral Alkaline

  • pH 0-2: Very few organisms can survive very long at this pH.
  • pH 2-5: Some acid tolerant organisms can survive, especially fungi (yeast and mold).
  • pH 5-9: Most bacteria grow very well in this pH range.
  • pH 9-12: Growth of most organisms is very limited. Some alkaline tolerant organisms can survive.
  • pH 12-14: Very few organisms can survive at this pH.
brewery location soil composition
Brewery Location/Soil Composition:
  • Brewhouse :
  • Protein, starch, minerals, beerstone, hop oils, hop resins, fermentable sugars
  • Heat Exchanger: Protein, starch, minerals, beerstone, hop oils, hop resins, fermentable sugars
  • Fermentation Tanks: Protein, starch, minerals, beerstone, yeast
  • Maturation Tanks:
  • Protein, starch, minerals, beerstone, yeast
  • Bright Beer Tanks: Beerstone, scale
cleaning sanitizing chemicals
Cleaning/Sanitizing Chemicals

General Classifications:

  • Acid Cleaners
  • Alkaline Cleaners
  • Enzymatic Cleaners
  • Foam Generators
  • Solvents
  • Sanitizers/Disinfectants
the acid test
The Acid Test

Acids used for beverage processing equipment cleaning:

  • Organic Acids (Citric, lactic, acetic)
  • Mineral Acids (Hydrochloric, Phosphoric, Sulfuric)
  • Oxidizing Acids (Nitric, Peracetic Acid- PAA)
alkaline cleaners
Alkaline Cleaners
  • Sodium/Potassium Hydroxide (caustic soda, (NaOH, lye) caustic potash (KOH).
  • Sodium Hypochlorite (NaOCl, “chlorine bleach”)
  • Noncaustic alkaline cleaners (sodium percarbonate, phosphates, surfactants, silicates)
sanitizers
Sanitizers
  • Chlorine Bleach (hypochlorite)
  • Chlorine Dioxide (Cl02)
  • Iodine (Iodophor)
  • Ozone (O3)
  • Peracetic Acid (PAA)
  • Quaternary Ammonium (Quat)
conventional cip
Conventional CIP

“Tried and true”.

  • Rinse product out using ambient to warm water.
  • CIP with 1-2 ounces of caustic blend per gallon of water (180 degree F. maximum temperature) for 15-30 minutes (or longer) depending on conditions..
  • Rinse.
  • CIP with 1-2 ounces of an acid cleaner per gallon per gallon of warm (120-140 degree F.) for 15-30 minutes to neutralize the caustic and finish cleaning.
  • Rinse with ambient temperature water until the pH of the rinse water is neutral (same pH as the tap water coming in).
a new approach
A NewApproach
  • We have discovered a new way to keep beverage packaging machines clean using the following procedure:
        • Rinse out beer and yeast with ambient temperature water.
        • Use a 1-2 ounce per gallon phosphoric/nitric acid mixture (140 degree F. maximum temperature) for 15-30 minutes.
        • No rinse!
        • Use a noncaustic alkaline cleaner at 1-2 ounces per gallon of warm (120-140 degree F.) to start. CIP for 15-30 minutes depending on conditions.
        • Rinse with ambient temperature water until the pH of the rinse water is neutral (same pH as the tap water coming in).
mash tun cip traditional
Mash Tun CIP (Traditional)
  • A. Test #1 – Mash Tun
  • The test was performed in the following manner:
  • Caustic wash: 3% w/v pre-blended mixture of 25% w/w caustic and caustic additive– 2400 seconds
  • Caustic rinse cycle
  • Acid wash: 3% v/v nitric/phosphoric– 1200 s
  • Acid rinse cycle
brewkettle cip
Brewkettle CIP
  • The test was performed in the following manner:
  • Acid wash: 3% v/v nitric/phosphoric blend– 1200 s
  • Acid rinse cycle
  • Caustic wash – 3% w/v pre-blended mixture of 25% w/w caustic and caustic additive – 2400 s
  • Caustic rinse cycle
fermentation vessel cip acid only
Fermentation Vessel CIP(Acid Only)
  • Test #1 – FV-42
  • The test was performed in the following manner:
  • Acid Wash: 3% v/v nitric/phosphoric blend & 32 oz. detergent additive – 1200 s
  • Acid Rinse Cycle
  • PAA Sanitation
cleaner vs sanitizer what s the difference
Cleaner vs. Sanitizer -What’s the difference?
  • Cleaners remove soil, scale, protein, etc.. Little government involvement regarding claims unless bactericidal claims are made.
  • Registration for sanitizers are governed by the EPA, (sometimes FDA) and the product must go through rigorous testing to be classified as a sanitizer. $$$$$.
  • Often used synonymously- technically speaking, there is a difference between sanitizing and disinfecting.
biofilm
BIOFILM
  • Biofilm Definition: The attachment of organisms to a solid surface and subsequent entombment in a protective polysaccharide coating.
  • Marked increase in antibiotic and chemical resistance.
  • Many different types of organisms can exist within the film, making detection and removal difficult.
biofilm removal
Biofilm Removal
  • Mechanical action (i.e., hand-scrubbing) is the most effective way to remove bioflims.
  • For CIP, extreme pH, (<2, >12) along with oxidation, (HN03, NaOCl, PAA, Cl02) OR enzymes, work best to rid surfaces of biofilm and prevent it from returning.
selective micro technologies
Selective Micro Technologies
  • Pure Chlorine dioxide generators
  • No flavor profile (no residuals!)
  • low ppm requirement
  • non-corrosive
  • safe
  • easy to use
  • easy to measure
conclusion
Conclusion
  • Cleaning is the least glamorous part of daily packaging routine but likely the most important for overall product quality.
  • Depending upon the product you make, an unsanitary machine can have public health consequences.
  • Use the proper type and amount of chemicals- don’t scrimp, but overuse, either.