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Brewing Microbiology Practical Knowledge & Application by TPM methodology (non-yeast) Le Quang Hai VBL Group - Technological Controller VBL Microbiology Workshop 2009 Feb

VBL Brewing Microbiology Workshop v2 2011

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  • Brewing MicrobiologyPractical Knowledge &

    Application by TPM methodology

    (non-yeast)

    Le Quang Hai

    VBL Group - Technological Controller

    VBL Microbiology Workshop

    2009 Feb

  • Feb 2009 Le Quang Hai - VBL Technological Controller 2

    Chapter 1

    Brewing microbiology

  • Feb 2009 Le Quang Hai - VBL Technological Controller 3

    Micro-organisms

    During production of beer, several micro-organisms are likely to grow because of nutrient-rich environment (sugar, amino acid, phosphate, sulphate, oxygen, vitamins, minerals) and suitable conditions (temperature, time, pH)

    However, characteristics of beer alcohol, CO2, SO2, pH reduce the range of organisms. Examples:

    Lactobacillus (L.brevis, L.lindneri, L.brevisimilis, L.frigidus, L.coryniformis, L.Casei)

    Pectinatus cerevisiiphilus

  • Feb 2009 Le Quang Hai - VBL Technological Controller 4

    Microbiological defect and off-flavor

    Sensation Bacterium O2 Process stage

    Phenolic, Smoke, DMS Enterobacter

    - Aerogenes

    - Klepsiella

    + Wort, Fermentation

    DMS, H2S Flavobacterium

    - (Obesum)

    _ Wort

    Celery Aerobacter

    Escherichia

    _ Fermentation

    Sweat, Cheese, Iso-valeric acid Megasphera _ Wort, Fermentation

    Milky, Vingar, Propionic acid Pectinatus

    Cerevisiiphilus

    _ Wort, Beer

    Rotten apple, H2S Zymomonas _ Beer

    Vinegar Acetobacter + Wort, Beer

    Diacetyl, Sour Pediococcus

    Lactobacillus

    _

    or trace of oxygen is

    required

    Wort, Fermentation, Beer

    Buttery, Cheese, Rancid Clostridium _ Adjuncts, Wort

    Apple, Vinegar Acetomonas /

    Gluconobacter

    + Beer

    Phenolic, Smoke wild yeast _ Wort, Fermentation

    Anise wild yeast _ Wort, Fermentation

  • Feb 2009 Le Quang Hai - VBL Technological Controller 5

    Micro-organisms (ex: flourescence method)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 6

    Reclamation of beer spoilage in Germany

  • Feb 2009 Le Quang Hai - VBL Technological Controller 7

    Micro-organism type

    With requirement of Oxygen

    Organism grows from 1 108 times in less than 9 hours when circumstances are ideal

    Group Aerobic Env Anaerobic Env O2 effect

    Obligate Aerobe Growth No growth Use O2 as a food electron acceptor in aerobic respiration

    Microaerophil Growth if O2level not to high

    No growth Required O2 < 0.2 atm

    Obligate anaerobe No growth Growth O2 is a toxic substance

    Facultative aerobe / anaerobe

    Growth Growth Not require O2 to growth but utilize it when available

    Aerotolerant anaerobe Growth Growth Exclusively anaerobic (fermentative) type of metabolism but not insensitive to the presence of O2. Not required O2 and not utilize it

  • Feb 2009 Le Quang Hai - VBL Technological Controller 8

    Micro-organism type (cont)

    With temperature

    Psychrophiles (cold) : 0 300C

    Mesophiles (medium) : 20 500C

    Thermophiles (hot) : 40 700C

    With acid degree or pH value

    If 6 < pH < 8: optimum for micro-organisms

    If pH < 4: growth of most bacteria limited (except for acid tolerant bacteria

    With water and other nutrient (sugar, minerals)

    Osmophilous: growth in medium wealthy on sugar

    Xerophilous: growth in medium poor in water

    Halophilous: growth in medium wealthy on salt

    Bacteria growth is limited with less water

  • Feb 2009 Le Quang Hai - VBL Technological Controller 9

    Prevention of infection

    Sanitary mindset of personel

    Good housekeeping

    Hygiene design of equipment

    Hygiene maintenance

    Efficiency CIP (cleaning and disinfection)

    Monitoring through reliable microbiological control procedures

  • Feb 2009 Le Quang Hai - VBL Technological Controller 10

    Chapter 2

    Biofouling and Biofilm

    Source:

    IWW Water Center, Mulheim an der Ruhr, Duisburg Essen University

    Markus Timke, Analysis of Biofilm communities in Breweries, Biologies/Chemie der Universitat Osnabruck

  • Feb 2009 Le Quang Hai - VBL Technological Controller 11

    What are bio-fouling and biofilm

    Fouling: undesired deposit of materials on surface

    Organic: deposit of fat, oil, protein

    Inorganic: precipitation of inorganic crystal or scaling

    Particle: silt, clay, humid particles

    Bio-fouling: undesired deposit and growth of microorganisms on surface particles (interface) which can multiply on the expense of nutrient

    Biofilm: is a matrix of extracellular polymeric substance (EPS), associated with working materials, corrosion products, debris, soil, particles, etc

    Biofilm includes films on surface, flocs, (floating biofilms), mat and sludge all kinds of cell in matrix

  • Feb 2009 Le Quang Hai - VBL Technological Controller 12

    Examples of biofouling, biofilm

  • Feb 2009 Le Quang Hai - VBL Technological Controller 13

    Examples of biofouling, biofilm (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 14

    Examples of biofouling, biofilm (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 15

    Affection of biofoul & biofilm

    Water quality: contamination by releasing micro-organisms

    Health: release of pathogens in water

    Hydrodynamic parameters: clogging, friction & hydraulic resistance

    Material: covering surface, changing surface properties, enhancing microbial influenced-corrosion

  • Feb 2009 Le Quang Hai - VBL Technological Controller 16

    EPS: house of the cells

    Has a composition of extracellular polymeric substance: polysaccharides, proteins, nucleic acids, forming hydrogels (> 95% water) of microbial origin

    Is an attachment of cells and of entire biofilm to surface

    Is the cohesion in microbial aggregation

    Is filling and forming the space between the cells, shape the three-dimensional biofilm structure

    Helps immobizing cells, allowing long-term syngenesis interactions

  • Feb 2009 Le Quang Hai - VBL Technological Controller 17

    Step formation of biofilm

  • Feb 2009 Le Quang Hai - VBL Technological Controller 18

    EPS and micro-organisms infection

  • Feb 2009 Le Quang Hai - VBL Technological Controller 19

    Examples of biofouling, biofilm

  • Feb 2009 Le Quang Hai - VBL Technological Controller 20

    Examples of biofouling, biofilm

  • Feb 2009 Le Quang Hai - VBL Technological Controller 21

    Where are biofilms in water system

  • Feb 2009 Le Quang Hai - VBL Technological Controller 22

    Mushroom model of biofilm

  • Feb 2009 Le Quang Hai - VBL Technological Controller 23

    Mushroom model of biofilm (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 24

    Principles to reduce biofoul & biofilm

    Nature of live: brewery has to learn to live with biofoul / bioflim and keep them under control elimination of their affection

    Detection: the growth of biofoul / biofilm and their affection

    Defining detection parameters (cell/cm2, CFU/cm2, biofilm thickness), points, sampling points to monitor their growth, affection

    Setting up a monitoring system: crucial for timely detection of biofilms and countermeasure optimization

    Tolerance of biofoul/biofilm growth: applying risk management in terms of Haccp and product quality to set up max tolerance. Either:

    Thickness of biofoul / biofilm

    Micro-organism plate count on suitable media

    Cleaning: is more important than killing biofilm organisms. Setting up a suitable cleaning regime with consideration of affection and cost

    Prevention: where possible, biofilm management is done by nutrient limitation (nutrients are potential biomass)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 25

    Biofilm growth and threshold

    Monitoring biofilm growth on time via quick testing method (ATP swab) or Onvida sensor

    Pain Threshold is defined by user where the affection of biofoul, biofilm pathogenic and product quality - is measurable

  • Feb 2009 Le Quang Hai - VBL Technological Controller 26

    Method to detect & monitor biofilm

  • Feb 2009 Le Quang Hai - VBL Technological Controller 27

    Killing vs Removal biofilm

    Killing does not necessary to remove biomass, so dead biomass can still cause problems for process, product and health (head exchanger, membranes, process water)

    Disinfection means inactivation of micro-organisms and this frequent job creates additional cost but not to sustainable solution

  • Feb 2009 Le Quang Hai - VBL Technological Controller 28

    Chapter 3

    Cleaning & Disinfection principles

    Source:

    HeiQ

    Paul Wood APB Microbiology Workshop

    Stijn Van Liefferinge, C&D Sopura SA

    DiverseyLever, Basic principle of CIP& Application

    John David Cluett, Cleanability of Stainless steel surface, Rank Afrikaans University, USA

  • Feb 2009 Le Quang Hai - VBL Technological Controller 29

    Cleaning principles

  • Feb 2009 Le Quang Hai - VBL Technological Controller 30

    What to clean: soil

    To eliminate impurity of solution called soil

    To disinfect a surface effectively, elimination of soil must be completed first

    Soil is any undesired matter on surface including product whether containing micro-organism or not

    Sources of soil:

    Residues of products (beer extracts, fats, lipids, proteins )

    Residues of water-soluble (salt, sugars) and acid-soluble products (calcium precipitates, dissolved inorganic)

    Residues of water/acid-non-soluble (yeast)

    Bio-film (bacteria, mould)

    Residues / carry-over matters from cleaning and disinfection products

    Contaminated by external environment (dust)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 31

    Cleaning of soil - Function

    Function of cleaning soil: is to remove/eliminate soil without leaving residues by either one or combination of actions:

    Dissolving / emulsifying

    Chemical reaction

    Physical: mechanical, thermal

    An effective cleaning of soil depends on soil characteristics, nature of surface and selection of

    Right physical actions

    Right cleaning product

    Sufficient activity of cleaning product (concentration, activity level)

    Right cleaning procedure (regime)

    Right cleaning tools/equipment

    Right process control conditions

  • Feb 2009 Le Quang Hai - VBL Technological Controller 32

    Cleaning soil

    Function: cleaning of soil is achieved by one / combination of energies:

    Mechanical

    Liquid rinsing flow (hl/h respective with designed flow Re)

    Pressure flow impact (bar)

    Brushing (kg/cm2, frequency time/s), stirring (rpm)

    Thermal: only effective when it goes with time and limited by machine component and economy reasons (0C)

    Chemical

    Removal of soil without leaving residues

    Concentration, frequency and contact time (economy use)

    Environmental impact

    Affection on material being cleaned (machine component, pipe)

    Time is combined with energy to have necessary cleaning but sometimes a waste and limited by product process flow

  • Feb 2009 Le Quang Hai - VBL Technological Controller 33

    Cleaning product - Function

    Function of soil cleaning is achieved by the help of a cleaning product or also called carrying-product

    Without cleaning product, soil cannot be removed from surface/system

    Function of cleaning product: is to

    Set a complete and full contact between soil, surface and product by wetting, lowering surface tension

    Eliminate adhesion of soil on surface by rinsing

    Reduce soils gravity by dispersing soil in small particles

    Carry soil particles in product till it is discharged to sewer by dissolving or emulsifying and suspending them - keep floating detached particles to prevent precipitation

    Sequestering: eliminate / prevent the fall out water hardness salts

  • Feb 2009 Le Quang Hai - VBL Technological Controller 34

    Cleaning products

    Surfactants: makes a link between organic matter and water

    Anionic

    Cationic

    Non-ionic

    Amphoteric

    Wetting / Rinsing agent: reduces surface tension of water only

    Dispersing agent: keeps removed soil in suspension avoids the formation of soil floc

    Sequestering agent: binds itself to something else

    Alkaline:

    EDTA (Ethylene Diamine Tetra Acetic Acid) can dissolve scale binding with calcium and break it up when rinsing

    Phosphonates

    Na5P3O10 Gluconates

  • Feb 2009 Le Quang Hai - VBL Technological Controller 35

    Cleaning products

    Dissolving / Reaction agent

    Acids:

    H2SO4

    H3PO4

    HNO3

    Sulphamic acid

    Organic acid like acetic acid

    Alkaline:

    Strong alkaline: caustic soda

    Alkaline salts:

    Metalisicates,

    Na3PO4

    Na2CO3

    Oxidization agent

  • Feb 2009 Le Quang Hai - VBL Technological Controller 36

    Wetting & surface tension

    Surface tension is the result of intermolecular attractive force which assures the cohesion of molecules

    Both cleaning product and soil have surface tension

    Water has high surface tension > bad wetting action

    Wetting

    and low

    surface

    tension

    No wetting

    and high

    surface

    tension

    No wetting

    and high

    surface

    tension

    Wetting

    and low

    surface

    tension

  • Feb 2009 Le Quang Hai - VBL Technological Controller 37

    Surfactants

  • Feb 2009 Le Quang Hai - VBL Technological Controller 38

    Sequestrant

  • Feb 2009 Le Quang Hai - VBL Technological Controller 39

    Physical form of soil

    Physical form of soil on surface and its adhesion on surface

    Loose, dry soil on surface:

    Priority: mechanical (liquid flow)

    Addition: mechanical (pressure impact), thermal, chemical (dissolving / emulsifying)

    Sticky soil in liquid or solid form (yeast stone, protein):

    Priority: mechanical (pressure impact, liquid flow) + chemical (reaction, dissolving/emulsifying)

    Addition: thermal

    Solidified soil (dried yeast stone, beer/extract stone, scale)

    Priority: chemical (reaction, dissolving/emulsifying) + mechanical (liquid flow, pressure impact)

    Addition: thermal

  • Feb 2009 Le Quang Hai - VBL Technological Controller 40

    Composition of soil

    Composition of soil and removal method

    Organic: containing carbon element in molecule

    Alkali dissolvable organic matters like caustic soda in environment of non-CO2 gas

    Acid dissolvable organic matter like phosphoric acid

    Inorganic: not containing carbon element (Ca++, Mg++)

    Acid dissolvable inorganic matter

    Combination of organic and inorganic

  • Feb 2009 Le Quang Hai - VBL Technological Controller 41

    Practical soil in brewery

  • Feb 2009 Le Quang Hai - VBL Technological Controller 42

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 43

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 44

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 45

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 46

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 47

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 48

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 49

    Practical soil in brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 50

    Nature of surface

    Surface roughness is evaluated via parameter Ra (m) peak-to-valley height. The less the better. Stainless steel fermentation tank: Ra 0.8 m

    Other parameters: max Ra, waviness Wt, total depth Pt, spacing Nr

  • Feb 2009 Le Quang Hai - VBL Technological Controller 51

    Mechanical rinsing flow - pipeline

    Fluid movement: Reynolds index

    Reynolds index for pipeline: Re = *r*v/n

    : density of chemical product (g/cm3)

    v: average flow velocity (cm/s)

    r: pipe radius (cm)

    n: dynamic viscosity of liquid (g/cm*s)

    Flow during cleaning of pipe line at internal surface

    Re < 2,000 : laminar flow

    2,000 < Re < 3,000 : transition flow

    Re > 3,000 : turbulent flow

    Real turbulent flow starts only at Re > 10,000

    Internal pipe surface and welding line are failure of Re

  • Feb 2009 Le Quang Hai - VBL Technological Controller 52

    Mechanical rinsing flow pipeline (cont)

    Rule of thumb for liquid flow respectively with Re > 3,000

    Cold cleaning (ambient temperature): velocity >< pipe diameter

    For pipe diameter 50 mm, a flow > 3.5 m/s must be reached

    For pipe diameter > 50 100 mm, a flow > 2 m/s must be reached

    For pipe diameter > 100 mm, a flow > 1 m/s must be reached

    Hot cleaning (80 850C): velocity 1 1.5 m/s is sufficient

    Flow rate is calculated from pipe diameter and velocity

    If velocity is lower than above, cleaning is not effective, i.e. presence of soil residues after cleaning

    If velocity is higher than above, there is no improvement of cleaning but a risk of water hammer, damage to pipe work and fittings

    If velocity is as above but soil residues are found at final rinse, look at effectiveness of other cleaning actions and energies

  • Feb 2009 Le Quang Hai - VBL Technological Controller 53

    Mechanical rinsing flow pipeline (cont)

    Flow rate in liter per minute

  • Feb 2009 Le Quang Hai - VBL Technological Controller 54

    Mechanical rinsing flow - tank

    Reynolds index for tank: Re = mF/n

    mF: mass flow of medium film a meter tank width (circumference)

    n: dynamic viscosity of liquid (g/cm*s)

    Flow during cleaning internal surface of tank

    Lamination film 200 < Re < 500 : 0.5 1.5 L/min/m2

    Turbulent film Re > 3,000 : 1.4 3.3 L/min/m2

    As experiment, at Re > 3000 and Ra = 0.8 stainless steel tank, the flow speed on internal tank surface is about 0.022 0.025 m/s

    Extra mechanical effect: pulse dwell with fixed spay ball

  • Feb 2009 Le Quang Hai - VBL Technological Controller 55

    Mechanical rinsing flow Plate Heat Exchanger

    Rule of thumb, cleaning of heat exchanger requires a detergent flow rate which is 20 30% higher than the product flow rate

    For high soil content product like wort, cleaning rinsing flow of PHE is in reverse direction of product flow, i.e. cleaning product going from outlet of PHE to discharge at inlet of PHE

  • Feb 2009 Le Quang Hai - VBL Technological Controller 56

    Mechanical flow pressure impact

    Flow pressure impact is critical in cleaning of soil in tank. All tank cleanings are done by spray device system

    Spray ball inlet flow pressure is very critical

    Static spray head : 1 2.5 bars

    Rotary spray ball / disk : 5 8 bars

    Too little pressure: tank wall is not reached, less flow pressure impact to remove sticky/solidified soil, not enough rinsing flow for tank

    Too high pressure: reduces effectiveness of rinsing flow

  • Feb 2009 Le Quang Hai - VBL Technological Controller 57

    Thermal of cleaning flow

    Temperature is defined according to

    Cleaning product used (supplier spec)

    Customer specification (machine, system, fittings, sealant)

    Soils characteristics

    Material surface to be cleaned

    Not always higher temperature of cleaning fluid, lower cleaning time!!

  • Feb 2009 Le Quang Hai - VBL Technological Controller 58

    Disinfection principles

  • Feb 2009 Le Quang Hai - VBL Technological Controller 59

    What to disinfect: micro-organisms

    Function of disinfection: destroying of beer spoiling and not-beer spoiling micro-organisms to an acceptable level

    Micro-organisms can be :

    Pathogenic

    Harmful

    Troublesome

    to health or to the quality of products

    Bacterial spores are usually not killed and difficult to be killed

    Micro-organisms are destroyed by one or combination of methods

    Chemical disinfectants

    Physical: UV, heat

    Sterilization destroys all forms of live

  • Feb 2009 Le Quang Hai - VBL Technological Controller 60

    Source of micro-infection

    Source of contamination:

    Production process

    Apparatus having dead ends

    Chinks, fittings, couplings

    Surface, material, system cavities

    Open vessels (air suction)

    Residues from previous process

    Pre-run / Post run

    CIP process

    Contaminated final rinse water

    Bio-film

    Others

    Man: flora from hand, breath, skin, clothes, production tools

    Insects, dust

  • Feb 2009 Le Quang Hai - VBL Technological Controller 61

    Disinfection

    An effectiveness of disinfection depends on:

    Type of micro-infection, i.e. micro-organism species

    Level of micro-infection, i.e. number of micro-organisms

    Type of disinfection method, e.g. disinfectants

    Concentration of disinfection dose

    Type and conditions of surface

    Temperature

    Movement of liquid

    Type and amount of soil residues, dirts

  • Feb 2009 Le Quang Hai - VBL Technological Controller 62

    Disinfectants

    Selection of disinfectant is a consideration of:

    Broad spectrum and biodegradability, especially spore forming

    Minimum influence of at application conditions: pH, low temperature, presence of protein

    Neutralization by CO2

    Composition should not changed or reduced by carrier (ex water hardness)

    Food and health safety: no smell, taste / colour or harmful to man

    No influence on material / surface (ex: corrosion)

    Easily rinse-able by water (ex residue after cleaning)

    Environment friendly and local legal compliance

    Technological useful (contact/exposure time, installation)

    Recoverable

    Cost (i.e. consumption, price)

    Disinfectants can be not stable at storage (both concentrated solution and working solution)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 63

    Disinfectants (cont)

    Common disinfectants:

    Chlorine (NaOCl and ClO2)

    Iodophores

    Halogenated acetic acid ester

    Halogen carbon acid

    Peroxydes

    Gluteralhehyde

    Quaternary ammonium compounds (QAC)

    Amphoterics

    Salicylates

  • Feb 2009 Le Quang Hai - VBL Technological Controller 64

    Chapter 4

    Cleaning & Disinfection System & Procedure (Regime)

    Source:

    HeiQ

    Stijn Van Liefferinge Sopura SA

  • Feb 2009 Le Quang Hai - VBL Technological Controller 65

    Control and reduction of soil load

    CIP is a cleaning system integrated into production process can be manually controlled or completely automated

    03 type of CIP programs:

    Regular Cleaning and Disinfection (C&D)

    Disinfection only

    Occasional Cleaning & Disinfection

    TPM 1st priority: Regular CIP program is set up and controlled for a standard soil load and micro-infection level and routes. It is effective when

    Soil type and load level (thickness) is controlled (what and how much)

    Soil deposited location is controlled (where)

    CIP program conditions are controlled

    TPM 2nd priority: Less soil load is on surface and system, less cleaning activities (procedure) is required, i.e. lower cost, higher productivity

  • Feb 2009 Le Quang Hai - VBL Technological Controller 66

    Control and reduction of soil (cont)

    Control of soil load - examples

    Scheduled inspection of tank before / after CIP

    No violent fermentation, no overfoam at FST

    Cleaning within time tolerance after emptying

    Contamination of recovery cleaning chemical products

    Reduction of soil load - examples

    Settlement and draining caustic in washer

    Mess-filtration of caustic at washer

    Pre-rinsing yeast harvest on pipe before CIP

    Keeping system cleaned and dry for a period of stop time

    Soil development conditions are present and monitored so that occasional CIP is applied

  • Feb 2009 Le Quang Hai - VBL Technological Controller 67

    Standard CIP recovery & circulation

  • Feb 2009 Le Quang Hai - VBL Technological Controller 68

    Standard CIP program Functions of step

    Pre-rinse: reducing of soil to a level where the designed CIP regime (procedure) is applied, normally by water rinse or recuperation caustic

    Medium change: obtaining right conc of cleaning chemical, normally in CIP supply pipe

    Rinse: eliminating soil by hot/cold caustic, acid agent is used in some conditions (under CO2 pressure)

    Intermediate rinse: recuperating and reducing conc of cleaning chemical to an acceptable level

    Medium change: obtaining right conc of disinfection chemical, normally in CIP supply pipe

    Disinfection: destroying micro-organisms

    Medium change: recuperating and reducing conc of disinfectant to an acceptable level

    Final rinse: eliminating disinfectant residues before re-using by disinfected water

  • Feb 2009 Le Quang Hai - VBL Technological Controller 69

    Example of a CIP program

    Object InFlow Steps OutFlow/Recup. Parameters

    Group 2 T Strength Duration Rest Pulses

    Fermenter (Vertical) 1 Fresh Caustic pulses to drain Ambient 1% w/v 1 min 10 min 4

    Fermenting and/or Storage Tank 2 Recup Water rinse to drain Ambient 1 min 2 min 3

    Rest Beer Tank 3 Recup Acid circulation to Group 1 and 2 Ambient by supplier 3 min 1 min 8

    Unfiltered Beer Buffer Tank 4 Recup Water rinse to drain Ambient 1 min 2 min 2

    (Waste Yeast Tank, see remarks) 5 Recup Disinfectant circulation to Group 1 and 2 Ambient by supplier 3 min 1 min 8

    Foam catcher 6 Fresh Water rinse to Group 1 and 2 Ambient 1 min 2 min 4

    Ste

    ps

  • Feb 2009 Le Quang Hai - VBL Technological Controller 70

    Conditions of CIP: run & change steps

    Pre-rinse: one / combination of either some or all

    Soil load (thickness): visual assessment before and after pre-rinsing majority of sticky soil

    Circle count: pre-rinsing volume and total volume of all circles; Or: pre-rinsing time / circle and total time of all circles

    Circle ends: Empty signal if applicable (LAL)

    Number of circles

    Pressure of flow on CIP supply pipe (after pump) or pipe head to spray ball

    Flow rate of CIP supply pipe (after pump)

    Medium change to rinse: one / combination of either some or all

    Concentration / conductivity at pipe head to spray ball or sometimes at return pipe to drain

    Medium volume at desired point

    Time to reach the concentration / conductivity

    Opening time of draining valve

  • Feb 2009 Le Quang Hai - VBL Technological Controller 71

    Conditions of CIP: run & change steps (cont)

    Rinse: one / combination of either some or all

    Soil load at final rinse: visual assessment (color), chamber count of soil (soil density), identification of soil

    Circle starts: temperature, conc/conductivity = designed value

    Hot cleaning: temperature after PHE, temperature at return pipe (recovery)

    Conc/cond at pipe head to spray ball (rinse to drain) or at return pipe to drain (recovery)

    Circle count: pre-rinsing volume and total volume of all circles; Or: pre-rinsing time / circle and total time of all circles

    Circle ends: Empty signal if applicable (LAL)

    Number of circles

    Spray ball: pulse and pause duration

    CIP return pump: run / stop duration

    Pressure of flow on CIP supply pipe (after pump) or pipe head to spray ball

    Flow rate of CIP supply pipe (after pump)

    Chemical contamination load after rinse (COD, turbidity, EBC, UVA rate): recovery system

  • Feb 2009 Le Quang Hai - VBL Technological Controller 72

    Conditions of CIP: run & change steps (cont)

    Final rinse: one / combination of either some or all

    Micro-infection: ATP swab, micro analysis of final rinsing sample

    Disinfectants/cleaning product infection: smell, concentration, indicator (phenolphthalein)

    Circle count: pre-rinsing volume and total volume of all circles; Or: pre-rinsing time / circle and total time of all circles

    Circle ends: Empty signal if applicable (LAL)

    Number of circles

    Spray ball: pulse and pause duration

    CIP return pump: run / stop duration

    Pressure of flow on CIP supply pipe (after pump) or pipe head to spray ball

    Flow rate of CIP supply pipe (after pump)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 73

    Volume for a CIP circle

    Sufficient fill volume for a C&D circle is important for an effective CIP: cleaning flow and sometimes soaking

    Cleaning product and water consumption is made up on a given CIP route

    A fill volume is about 1.3 calculated volume of pipe route + volume of chemical thickness on vessel surface (1.5 3.5 L/m2)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 74

    Chapter 5

    Cleaning & Disinfection Agents

    Source:

    HeiQ

    Stijn Van Liefferinge Sopura SA

    Paul Wood APB Microbiology workshop

    DiverseyLever, Basic principle of CIP& Application

  • Feb 2009 Le Quang Hai - VBL Technological Controller 75

    Selection of cleaning products

    Factors affecting selection of cleaning products

    Nature of soil

    Nature of material of unit / system (surface, type of steel, heat stability)

    Hardness of material

    Temperature

    Cleaning method, procedure

    CIP equipment / system

    Possible danger of product man safety

    Influence on product food safety

    Biological degradability environment

    Cost

  • Feb 2009 Le Quang Hai - VBL Technological Controller 76

    Application properties of cleaning product

  • Feb 2009 Le Quang Hai - VBL Technological Controller 77

    Some chemical products ex Sopura

    ATR B

    Based on phosphoric acid combined with non-foaming non-ionic biodegradable surfactants

    Removal yeast deposit and beer stone on vessel surface under CO2pressure condition

    Caustic Purexol:

    Based on sequestrants + KOH + 3g chlorine / 100 g product

    Alkaline chlorinated detergent for the simultaneous deep cleaning and sanitation removal sticky and organic scale (solidified) on surface

    Normal application frequency: once 12 18 months

    Septacid S

    Based on sulphuric acid, bromacetic acid and corrosion inhibitors

    Simultaneous cleaning and sanitation with strong bacteriocidal actions on yeast, both gram positive and negative bacteria

  • Feb 2009 Le Quang Hai - VBL Technological Controller 78

    Chapter 6

    Spray heads

    Source:

    DiverseyLever, Basic principle of CIP& Application

    Sani-matic spray ball

    Toftejorg high pressure impact Rotary Jet Head

  • Feb 2009 Le Quang Hai - VBL Technological Controller 79

    Static spray head

    Static / fixed spray head:

    2 types: spray ball and spray disk

    Operation pressure: normally low pressure: 1 2 bar

    Key parameters of spray ball should obtain to get effective cleaning:

    Specific flow rate

    Pressure and pressure curves

    Connection inner and outer diameter

    Spray ball types: 3600, 1800 upward, 1800 downward, 1800 directional bias shot, 2700 upward, 1200 upward

    Choice of spray ball types depends on:

    Distance of device from walls of tank

    Depth of installation

    Tank dimension

    Type of cleaning product used

    Tank use

    pump specification

  • Feb 2009 Le Quang Hai - VBL Technological Controller 80

    Guide line for spray ball

    3600: applied for heavily soil or tank with internal devices

    1800 upward spray: cleaning top of tank, lower half of tank will be cleaned from the fluid running down side

    1800 down spray: cleaning specific internal instrument or other items that interfere with cleaning used downstream spraying ball

    2700 upward spray: covering more surface and allow direct cleaning (pressure impact of cleaning product) of more heavily soiled areas, specially top tank dome, yeast ring.

    Bottom center of tank may have outlet valves or other fixtures that do not require direct exposure to cleaning unit

  • Feb 2009 Le Quang Hai - VBL Technological Controller 81

    Static spray head pattern

  • Feb 2009 Le Quang Hai - VBL Technological Controller 82

    Static spray head pattern (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 83

    Static spray head parameters

  • Feb 2009 Le Quang Hai - VBL Technological Controller 84

    Static spay ball Installation depth

  • Feb 2009 Le Quang Hai - VBL Technological Controller 85

    High pressure rotary spray head

    High pressure rotary spray head

    High pressure: 5 8 bar

    Impact throw length is 5 15 meter

    Rotary Jet head provides 3600 indexed impact cleaning over a defined period

    Working principle: flow of fluid makes nozzles performs a gear rotation around vertical and horizontal axes. Normally, 1st cycle nozzle lay out a coarse pattern on tank surface. A full pattern is reached after 8 cycles

    Choice depends on desired jet impact length and flow rate at desired pressure

  • Feb 2009 Le Quang Hai - VBL Technological Controller 86

    Rotary spray head pressure curve

  • Feb 2009 Le Quang Hai - VBL Technological Controller 87

    Pressure loss at spray head

    To obtain sufficient pressure at spray ball, pressure at cleaning pump must be compensated for hydraulic pressure loss (mainly) and other losses (friction, fittings, bend)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 88

    Chapter 7

    Hygiene Requirements and Standards

    Source: Heineken Hygienic Design Manual (HeiQ)

    DiverseyLever, Basic principle of CIP& Application

    Martin Hees, Industry Marketing Food

  • Feb 2009 Le Quang Hai - VBL Technological Controller 89

    What is hygiene?

    Hygiene is

    Compliance with all conditions

    During design & use of process equipment

    To achieve the greatest possible suitability of process

    For the purpose to guarantee the highest possible safety for customer of the product

    Functions of hygiene are

    Clean-ability of equipment: easily to clean, disinfect protect product from contamination

    Avoidance of penetration of micro-organism from external to system

    Inhibition of micro-organism growth in equipment: like dead-ends, gaps, cracks, bio-film

    Suitability of process in compromising hygiene compliance and other equipment functional requirements (ex OPI)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 90

    Hygiene zone

    Zone B: basic level of hygienic design and maintenance for open areas like outside buildings, walking way, canteen

    Zone M: medium level of hygienic design and maintenance to protect the interior of food processing equipment during closed processes like fermentation, filtration

    Zone H: high level of hygienic design and maintenance to protect product contamination during open processing like culturing / propagation, filling from environment and exterior of equipment

  • Feb 2009 Le Quang Hai - VBL Technological Controller 91

    What hygiene practices

    Hygienic standards should be set for

    Suitable selection of equipment and design

    Materials and accessories for C&D (ex smooth, no crevices, pits, edges, blind ends)

    Correct construction

    Process layout (ex cross contamination)

    Process automation of the installation

    Effective cleaning is difficult to check but a few below method is used:

    Visual inspection before and after cleaning

    Water break test (no drops on clean surface)

    ATP-free swap test

  • Feb 2009 Le Quang Hai - VBL Technological Controller 92

    ATP bio-luminescence

    ATP is a molecule found in living organisms a main immediate source of usable energy for all activities of cell

    Enzymes called Luciferases that emit light and when ATP is brought into contact with a combination Luciferin Luciferase, a reaction is taken place, resulting in production of light from release of Luciferase

    The higher contamination, the more ATP present and more light is produced

  • Feb 2009 Le Quang Hai - VBL Technological Controller 93

    ATP-free swab

    ATP is practically used to evaluate the effective cleaning level instead of waiting for 3 5 days period where incubation of samples required

    How ATP-free swab test works:

    ATP swabs are pre-moistened with agents that help to lift soil off surface

    After taking sample with the swab, it pushes into tube, is shaken and finally into illuminometer

    Clean sample gives low light level

    Dirty level gives high light level. The measure is made in RLU (Relative Light Unit)

    Normally RLU > 100, the surface is not hygiene

  • Feb 2009 Le Quang Hai - VBL Technological Controller 94

    Application areas of ATP in a brewery

  • Feb 2009 Le Quang Hai - VBL Technological Controller 95

    Application areas of ATP in a brewery (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 96

    ATP test example in a brewery

  • Feb 2009 Le Quang Hai - VBL Technological Controller 97

    Hygiene in piping, fittings, connections

  • Feb 2009 Le Quang Hai - VBL Technological Controller 98

    Hygiene in piping, fittings, connections (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 99

    Hygiene in piping, fittings, connections (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 100

    Hygiene in piping, fittings, connections (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 101

    Hygiene in piping, fittings, connections (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 102

    Hygiene in piping, fittings, connections (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 103

    Hygiene in piping, fittings, connections (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 104

    Hygiene in piping, fittings, connections (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 105

    Hygiene in product contact surface

  • Feb 2009 Le Quang Hai - VBL Technological Controller 106

    Hygiene in product contact surface (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 107

    Hygiene in product contact surface (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 108

    Hygiene in accessories (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 109

    Hygiene in accessories (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 110

    Hygiene in accessories (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 111

    Hygiene in accessories (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 112

    Hygiene in process equipment (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 113

    Hygiene in process equipment (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 114

    Hygiene in process equipment (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 115

    Hygiene in process equipment (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 116

    Hygiene in process equipment (cont)

  • Feb 2009 Le Quang Hai - VBL Technological Controller 117

    Hygiene in fittings, connections

  • Feb 2009 Le Quang Hai - VBL Technological Controller 118

    Hygienic standards - others

    Other hygienic standards are reference in Heineken Hygienic Design Manual for:

    Materials: plastic, elastics, adhesives, stainless steel

    Piping system, tees, flanges, gasket, coupling, hosing,

    Valves

    Other accessories

    Heat exchanger

    Pump

    Process equipment: spray ball, drive shaft and bearing,

    Hygiene standards for high risk local machine cleaning is set up by brewery

    Haccp (Iso 22000) requires food safety risk analysis, pre-requisitition program and verification of risks and control plan

  • Feb 2009 Le Quang Hai - VBL Technological Controller 119

    Hygiene audit

    After standards available, Hygiene is maintained by schedule Hygiene Audit by qualified staff

    Hygiene Audit is a mandatory requirement of brewery operation

  • Feb 2009 Le Quang Hai - VBL Technological Controller 120

    Chapter 8

    Disinfection by UV Light

    Source: UV Wikipedia encyclopedia

    American Water Works Association

  • Feb 2009 Le Quang Hai - VBL Technological Controller 121

    UV Light Application

    UV-C 265 nm is germicidal, (1) di-merizes on ADN and inhibits bacteria to replicate molecule ADN, (2) produces a condense ozone environment (air)

    Germicidal effectiveness is depended type of bacteria and UV dosage (Ws/m2) at the application point

    Each bacterium has different UV resistance: protozoan cyst > bacteria spore > viruses > vegetative bacteria

    UV dosage = UV intensity W/cm2 * Exposure time t (seconds)

    UV intensity = UV intensity of Lamps * number of Lamps * Intensity Factor / Transmission Loss

  • Feb 2009 Le Quang Hai - VBL Technological Controller 122

    UV Intensity

    In air, UV transmission = 100% at a distance of 1 meter to application point. The closer the stronger and vice versa (table)

    In distilled purifying water, UV transmission = 100% at a distance of 10 mm to application point

    UV intensity sensor provides only means of ensuring that adequate disinfection

    Ex: 04 lamps of 66 W/m2 each, reactor: 70 L, water flow: 320 L/min, T10 = 0.95

  • Feb 2009 Le Quang Hai - VBL Technological Controller 123

    Conditions of UV transmission

    Water quality factors

    Shielding caused by suspension solids

    UV light scattering by colloidal solids

    UV absorbance by dissolved organics (w

    Quartz sleeve foul by inorganic constituents (Ca, Mg, Al, Fe, Mn,

    Quartz sleeve transmission ability (colorization of quartz over time)

    Water quality (color, air bubble, other factors affecting transmission)

    UV lamp low-pressure (LP)

    Giving optimum germicidal wave length 260 nm monochromatic

    Optimum lamp operating temperature

    Lamp age and spectral shift

  • Feb 2009 Le Quang Hai - VBL Technological Controller 124

    Conditions of UV transmission

    Reactor

    Internal chamber surface reflecting capability

    UV dose delivered is path-dependent

    UV sensor

    Number of sensors and placing them at optimum positions

    Routine check with reference sensor

    Factory check to control linearity and drifting

    Sensor window cleaning

  • Feb 2009 Le Quang Hai - VBL Technological Controller 125

    UV Reactor monitoring

    As the minimum

    UV intensity by sensor

    Water flow rate

    Lamp outage

    In addition

    Water turbidity

    Quartz foul

    Start-up / out-specification operation / shut-down

  • Feb 2009 Le Quang Hai - VBL Technological Controller 126

    Chapter 9

    QNet in micro-infection investigation & problem solving

  • Feb 2009 Le Quang Hai - VBL Technological Controller 127

    Setting up a QNet

    Only setting up a QNet when reoccurrence of micro-infection is high and daily solution does not give sustainable improvement

    Steps to build up QNet and investigation of micro-infection

    Identifying process flow and machine boundary (the closed product source of supply) related to the detection point of product micro-infection normally P&I is used

    Identifying all product inflows, outflows to external extents of the machine boundary P&I and/or site check

    Identifying all product internal flows in machine boundary P&I and site check

    Identifying, marking all machine components in the boundary and defining their functions

    Defining possible soil sources of soil and soil characteristics on each machine component

    Defining possible sources of micro-infection, if necessary extra detection point is installed, at each machine component

    Hygiene and CILT audit on site to check for compliance at least 3 times at different moment. The more auditing times, the more problem is found because of more

    opportunities to catch abnormally

    Restoring basic conditions according to Hygiene requirements

  • Feb 2009 Le Quang Hai - VBL Technological Controller 128

    Setting up a QNet (cont)

    Steps to build up QNet and investigation of micro-infection (cont)

    Defining reverse clockwise activities of a full cycle (repeat activity) and flow routes of each product flow machine component.

    Check generation points (of soil, infection according to above identification), detection point and control points of all cycles. Make correction or improvement

    Check if the micro-infection is eliminated

    If not, repeat the same steps to the upstream (inflow) process flow/machine boundary and downstream (outflow) process flow / machine boundary

    Defining also the reverse clockwise activities of new process flows/machines, sources of soil/contamination, generation point, detection point and control point. Make correction or

    improvement

    Update new control point and condition in QM for training, monitoring

  • Feb 2009 Le Quang Hai - VBL Technological Controller 129

    Setting up a QNet (cont)

    Detection pointProduct inflow

    Function: Product supply

    Product outflow

    Function: overflow from filling

    Product outflow

    Function:product discharge

    Internal flow

    Function:CIP to spray ball

    Product inflow

    Function: CIP supply

    Product buffer tank system

  • Feb 2009 Le Quang Hai - VBL Technological Controller 130

    Setting up a QNet (cont)

    New

    detection point

    Product inflow

    Function: Water supply

    Product outflow

    Function: overflow from filling

    Product outflow

    Function: CIP supply to Buffer tank

    Water

    Product inflow

    Function: CIP supply

    Caustic

    CIP system

  • Feb 2009 Le Quang Hai - VBL Technological Controller 131

  • Feb 2009 Le Quang Hai - VBL Technological Controller 132

    Setting up a QNet (cont)

    Weekly cleaning

    Product buffering

    Sterilization

    Waiting (time)

    Product buffering

    Weekly cleaning

    Pre-rinsing

    Caustic medium change

    Caustic rinsing

    Post rinsing water

    Flushing in tank, pipe

    Filling and supplying

    Emptying

    Pre-rinsing

    Sterilizing

    Cooling (fresh water)

    Flushing in tank

    Filling and supplying

    Emptying

    Buffer

    tank

    -pro

    cess f

    low

    cycle

    Level making-up

    Supplying fresh water at

    30% tank level to 80%

    Waiting

    Supplying water till

    level drops to 30%

    Level making-up

    Fre

    sh w

    ate

    r ta

    nk

    -

    pro

    cess flo

    w c

    ycle

    Detection point

    New

    detection point

    New

    generation point

  • Feb 2009 Le Quang Hai - VBL Technological Controller 133

  • Feb 2009 Le Quang Hai - VBL Technological Controller 134

  • Feb 2009 Le Quang Hai - VBL Technological Controller 135

    END