Cleaning and Sanitizing Brewery Process Equipment

1. MBAA - RMD February 15th , 2007 Cleaning and Sanitizing Brewery Process Equipment Pumphouse Brewery, Longmont, Colorado Dana Johnson, BIRKO Corporation Henderson, Colorado

2. 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.

3. 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

4. Solubility of Amino Acids

5. Cleaning/Sanitizing Chemicals General Classifications: • Acid Cleaners • Alkaline Cleaners • Enzymatic Cleaners • Foam Generators • Solvents • Sanitizers/Disinfectants

6. 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)

7. 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)

8. Sanitizers • Chlorine Bleach (hypochlorite) • Chlorine Dioxide (Cl02) • Iodine (Iodophor) • Ozone (O3) • Peracetic Acid (PAA) • Quaternary Ammonium (Quat)

9. 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).

10. 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).

11. 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

12. Mash Mixer Before

13. Mash Mixer After (Traditional) CIP

14. 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

15. Kettle-Before CIP

16. Kettle-After CIP (Acid First)

17. Brewkettle After CIP (Acid First)

18. 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

19. FV Before CIP

20. FV After CIP

21. 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.

22. 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.

23. 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.

24. Selective Micro Technologies • Pure Chlorine dioxide generators • No flavor profile (no residuals!) • low ppm requirement • non-corrosive • safe • easy to use • easy to measure

25. 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.