Cleaning and Sanitizing Brewery Process Equipment

Cleaning and Sanitizing Brewery Process Cleaning and Sanitizing Brewery Process

Equipment Equipment

Dana Johnson, BIRKO Dana Johnson, BIRKO CorporationCorporation

Henderson, ColoradoHenderson, Colorado

MBAA - RMD

February 15th , 2007

Pumphouse Brewery, Longmont, Colorado

pH & Growth Relationship of pH & Growth Relationship of MicrobesMicrobes

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 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/Brewery Location/Soil Composition:Soil Composition:

Brewhouse :Brewhouse : Protein, starch, minerals, beerstone, hop oils, Protein, starch, minerals, beerstone, hop oils,

hop resins, fermentable sugarshop resins, fermentable sugars Heat Exchanger:Heat Exchanger: Protein, starch, minerals, Protein, starch, minerals,

beerstone, hop oils, hop resins, fermentable beerstone, hop oils, hop resins, fermentable sugarssugars

Fermentation Tanks: Fermentation Tanks: Protein, starch, Protein, starch, minerals, beerstone, yeastminerals, beerstone, yeast

Maturation Tanks:Maturation Tanks: Protein, starch, minerals, beerstone, yeastProtein, starch, minerals, beerstone, yeast Bright Beer Tanks: Bright Beer Tanks: Beerstone, scaleBeerstone, scale

Solubility of Amino AcidsSolubility of Amino Acids

Cleaning/Sanitizing Cleaning/Sanitizing ChemicalsChemicals

General Classifications:General Classifications: Acid Cleaners Acid Cleaners Alkaline CleanersAlkaline Cleaners Enzymatic CleanersEnzymatic Cleaners Foam GeneratorsFoam Generators SolventsSolvents Sanitizers/DisinfectantsSanitizers/Disinfectants

•The Acid TestThe Acid TestAcids used for beverage processing Acids used for beverage processing

equipment cleaning:equipment cleaning: Organic Acids (Citric, lactic, acetic)Organic Acids (Citric, lactic, acetic) Mineral Acids (Hydrochloric, Phosphoric, Mineral Acids (Hydrochloric, Phosphoric,

Sulfuric)Sulfuric) Oxidizing Acids (Nitric, Peracetic Acid- PAA)Oxidizing Acids (Nitric, Peracetic Acid- PAA)

•Alkaline CleanersAlkaline Cleaners

Sodium/Potassium Hydroxide (caustic Sodium/Potassium Hydroxide (caustic soda, (NaOH, lye) caustic potash (KOH).soda, (NaOH, lye) caustic potash (KOH).

Sodium Hypochlorite (NaOCl, “chlorine Sodium Hypochlorite (NaOCl, “chlorine bleach”)bleach”)

NoncausticNoncaustic alkaline cleaners (sodium alkaline cleaners (sodium percarbonate, phosphates, surfactants, percarbonate, phosphates, surfactants, silicates)silicates)

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

Conventional CIPConventional 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 A NewNew ApproachApproach 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 TunA. Test #1 – Mash Tun The test was performed in the following The test was performed in the following

manner:manner: Caustic wash: 3% w/v pre-blended Caustic wash: 3% w/v pre-blended

mixture of 25% w/w caustic and caustic mixture of 25% w/w caustic and caustic additive– 2400 secondsadditive– 2400 seconds

Caustic rinse cycleCaustic rinse cycle Acid wash: 3% v/v nitric/phosphoric– Acid wash: 3% v/v nitric/phosphoric–

1200 s1200 s Acid rinse cycleAcid rinse cycle

Mash Mixer BeforeMash Mixer Before

Mash Mixer After (Traditional) Mash Mixer After (Traditional) CIPCIP

Brewkettle CIPBrewkettle CIP

The test was performed in the following The test was performed in the following manner:manner:

Acid wash: 3% v/v nitric/phosphoric Acid wash: 3% v/v nitric/phosphoric blend– 1200 sblend– 1200 s

Acid rinse cycleAcid rinse cycle Caustic wash – 3% w/v pre-blended Caustic wash – 3% w/v pre-blended

mixture of 25% w/w caustic and caustic mixture of 25% w/w caustic and caustic additive – 2400 sadditive – 2400 s

Caustic rinse cycleCaustic rinse cycle

Kettle-Before CIPKettle-Before CIP

Kettle-After CIP (Acid First)Kettle-After CIP (Acid First)

Brewkettle After CIP (Acid Brewkettle After CIP (Acid First)First)

Fermentation Vessel CIPFermentation Vessel CIP(Acid Only)(Acid Only)

Test #1 – FV-42Test #1 – FV-42 The test was performed in the The test was performed in the

following manner:following manner: Acid Wash: 3% v/v Acid Wash: 3% v/v

nitric/phosphoric blend & 32 oz. nitric/phosphoric blend & 32 oz. detergent additive – 1200 sdetergent additive – 1200 s

Acid Rinse CycleAcid Rinse Cycle PAA SanitationPAA Sanitation

FV Before CIPFV Before CIP

FV After CIPFV After CIP

Cleaner vs. Sanitizer -Cleaner vs. Sanitizer -What’s the difference?What’s the difference?

Cleaners remove soil, scale, protein, etc.. Cleaners remove soil, scale, protein, etc.. Little government involvement regarding Little government involvement regarding claims unless bactericidal claims are claims unless bactericidal claims are made.made.

Registration for sanitizers are governed Registration for sanitizers are governed by the EPA, (sometimes FDA) and the by the EPA, (sometimes FDA) and the product must go through rigorous testing product must go through rigorous testing to be classified as a sanitizer. $$$$$.to be classified as a sanitizer. $$$$$.

Often used synonymously- technically Often used synonymously- technically speaking, there is a difference between speaking, there is a difference between sanitizing and disinfecting.sanitizing and disinfecting.

BIOFILMBIOFILM

Biofilm Definition: The attachment of Biofilm Definition: The attachment of organisms to a solid surface and organisms to a solid surface and subsequent entombment in a subsequent entombment in a protective polysaccharide coating.protective polysaccharide coating.

Marked increase in antibiotic and Marked increase in antibiotic and chemical resistance.chemical resistance.

Many different types of organisms Many different types of organisms can exist within the film, making can exist within the film, making detection and removal difficult.detection and removal difficult.

Biofilm RemovalBiofilm Removal

Mechanical action (i.e., hand-Mechanical action (i.e., hand-scrubbing) is the most effective scrubbing) is the most effective way to remove bioflims.way to remove bioflims.

For CIP, extreme pH, (<2, >12) For CIP, extreme pH, (<2, >12) along with oxidation, (HN03, along with oxidation, (HN03, NaOCl, PAA, Cl02) NaOCl, PAA, Cl02) OROR enzymes, enzymes, work best to rid surfaces of biofilm work best to rid surfaces of biofilm and prevent it from returning. and prevent it from returning.

Selective Micro Selective Micro TechnologiesTechnologies

Pure Chlorine dioxide generatorsPure Chlorine dioxide generators No flavor profile (no residuals!)No flavor profile (no residuals!) low ppm requirementlow ppm requirement non-corrosivenon-corrosive safesafe easy to useeasy to use easy to measureeasy to measure

ConclusionConclusion

Cleaning is the least glamorous part of Cleaning is the least glamorous part of daily packaging routine but likely the daily packaging routine but likely the most important for overall product most important for overall product quality.quality.

Depending upon the product you make, Depending upon the product you make, an unsanitary machine can have public an unsanitary machine can have public health consequences.health consequences.

Use the proper type and amount of Use the proper type and amount of chemicals- don’t scrimp, but overuse, chemicals- don’t scrimp, but overuse, either.either.