Hygiene for Fresh Beer Production

Dr Colin CourtMarch-April 2016

First – Some Definitions

• Pasteurisation Unit (PU): Lethal rate on beer spoilage organisms over 1 minute @ 600 C (1400 F)1

• Tunnel Pasteurisation: Typically carried out at between 15-20 PUs2

- High exposure time required to achieve this result

• Low or Zero Lethal Pasteurisation: Typically carried out at <10 PUs (10 PU ~ 105 Reduction3)- Can be achieved by reducing Pasteurisation time or temperature

• Flash Pasteurisation: No need for pasteuriser tunnel750 C for 1 minute gives 20 PU equivalent kill

1 Benjamin 2 Del Vecchio 3 Dallyn

Hygiene Requirements

The type of Pasteurisation has a large impact on the hygiene level desiredand/or required in the pre-Pasteurisation process areas

Critical Points

Tunnel Pasteurisation

Critical Points

Low or Zero Lethal Pasteurisation

Critical Points

Flash (or No) Pasteurisation

Approach to ImprovingHygiene Outcomes

Methodical approach built on 6 steps:

Detection of CRITICAL AREAS which might have an impact on quality and process safety

GAP ANALYSIS to identify the GAP between the current critical point specification and the required one for the desired hygiene requirement

Discussion on the INTERVENTION needed to close the GAP

Design and Agreement on the ACTION around each intervention

Recommendation of a PROGRAMS to support the intervention

Continuous MONITORING of the programs to protect the integrity of the system hygiene.

Critical Area

1

Gap Analysis

2

Intervention3

Actions4

Program5

Monitor6

Step 1: Critical Areas

Why Do It:

Facilitate the process shift from tunnel to Flash Past

Create a road map for hygiene improvement

Improved control points and specify values

More accurate GAP analysis when we identify areas for intervention

Better hygiene integrity of the overall process

What is Needed:

Evaluation of current tunnel CCP’s

Identifying new CCP’s and values for new standard

Detail:

System check with customer and C&S brewery specialists

Look at current CCP’s versus required CCP’s – includes;

Environment such walls, floors, drains, air systems, building layout, etc.

Personal Hygiene, hands, hair, eyes, clothes

Process incl. materials flow and equipment

Compile a risk assessment

Identify what validation protocols will be needed for each new CCP

Produce and implement a corrective action plan based on the system check

What is Needed:

• Hygiene GAP Analysis (Audixx)

Detail:

• C&S specialists conduct a full Hygiene GAP Analysis at the plant

• 2 week process, supported by Technical Support Specialists and service associates

• The analysis covers the complete process from Brewing to Packaging and identifies the hygiene GAPS in the facility

• This becomes our working document

• Create a GAP list from the analysis

Why Do It:

• Identify the GAPS between the New CCP’s and the current CCP’s at the plant.

• More accurate assessment of the hygiene interventions

• Can be a scheduled audit for benchmarking purposes

Step 2: Gap Analysis

Why Do It:

• To identify the type of intervention necessary to deliver the required result

• To capture the procedural aspects of Good Hygiene Practices and develop appropriate C&S regimes

• To be able to better asses the programs that can be employed

What is Needed:

• Identify the interventions required to deliver the agreed results and attain specified CCP values

Detail:

• C&S Expert together with brewer explore the options of what intervention could be helpful

• Determine the best interventions against each gap identified

• Each hygiene GAP will trigger an intervention

Step 3: Interventions

Why Do It:

• Equipment selection

• Prioritize the program actions according to the area

• Cost scenarios

• Establish time-line and responsibilities

• Validate the interventions

What is Needed:

• To agree on an action plan

• Provide for the implementation of the required interventions and establish theprocedural andstructural pre-requisites to complete the project

Detail:

• Complete site inspection with local engineering and OEM’s where necessary

• Prioritization of procedural and structural changes including timing, responsibilities, etc.

• Support OEM’s with appropriate projects

• Oversee all engineering projects and confirm effectiveness of intervention

Step 4: Actions

What is Needed:

• Based on the identified interventions and agreed actions, select the most appropriate program to deliver the required results

• Implement and control parameters

Detail:

• Establish overall C&S Budget and Equipment Capex

• Propose the most appropriate programme

• Identify procedural changes required to implement the programme

• Deliver, install, commission and train

• Oversee initial results and adjust for conformance

Why do it:

• To select the most appropriate method of achieving the desired results

• Cost planning

• Final agreement on programmes

Step 5: Program Selection

Investment Considerations

Equipment Considerations:

Chemical Distribution Station Conveyor Lubrication Foam Stations Filler Hygiene System CIP update

C&S Budget:

Increase in daily filler External cleaning Increase in daily Filler CIP Increase in daily Flash Pasteuriser and BBT cleaning Increase in Personnel and Environment Hygiene

Sustainability, OH&S, Quality, Shelf Life, Range Extension & Brand Protection Opportunities

What is Needed:

• Implement, Monitor and Control hygiene programs

Detail:

• Provide a C&S service team

• Work on a project basis to get the best value

• Comprehensive Global Service and Technical support encompassing:

– R&D

– Engineering

– Technical Support

Why do it:

• Protect the integrity of the hygiene system

• Set “Action Priorities” to support hygiene programs

Step 6: Monitor

Practical Example: Micro Load

Microbiological test points for breweries using flash pasteurization

“Internal” Filler Surfaces:

1. Bottle Inspector

2. Inlet Carousel Filler

3. Outlet Carousel Filler

4. Centering Tube Filler

5. Crosshead

6. Steering Elements

7. Corker Elements 2

34

5

67

7

Microbiological test points for breweries using flash pasteurization

“External” Filler Surfaces:

1. Floor Below Filler

2. Conveyor Belt Filler-Inlet

3. Conveyor Belt Filler-Outlet

4. Filling Table

5. Bottle Shower Post Capper

2 3

4

5

Practical Example: Micro Load

“Internal” Surfaces

• Bottle inspector 7 (<0,5%)

• Inlet carousel filler 1 (<30%)

• Outlet carousel filler 3 (25-30%)

• Centering tube filler 6 (5-10%)

• Crosshead 5 (5-10%)

• Steering elements 4 (5-10%)

• Corker elements 2 (25-30%)

“External” Surfaces

• Floor below filler 1 (>50%)

• Conveyor belt filler-inlet 4 (25-30%)

• Conveyor belt filler-outlet 2 (40-50%)

• Filling table 3 (40-50%)

• Bottle shower after capper 5 (10-15%)

Micro Load Analysis

The ranking is an indication on how often beer spoiling microbes are found in practice. It is not a direct indication on the “most critical areas”.

The percentage indicates how often the samples show these contaminations typically in practice.

Contamination ranking from breweries running flash Pasteurisation based on field data

Questions?

Thank You