1	Cleaning and Sanitizing for Brewpubs & MicroBrewery Operations MBAA Technical Meeting Bo’s Brewery Bistro 9/11/03 Presented by Steve Gray Enerco Corp.
2	Discussion Agenda Why Clean? - Microbes that affect Beer Basic Cleaning and Sanitizing Concepts Sanitizers - Options - What’s Best for Me? Cleaning and Sanitizing Recommendations for Brewpubs & Microbreweries Q&A - Discussion Forum
3	MICROBES IN BEER Both yeast and mold strains can cause spoilage Saccharomyces yeasts - off odors and turbidity (low pH level - 4-5) Lactobacillus, Acetobacter, Glucoobacter - cause ropiness (oily viscous texture)
4	MICROBES IN BEER Pediococcus cerevisae - causes a sweet odor called “sarcinae sickness” Zymomonas case turbidity, and off odors Acetobacter spp. Sour beers by converting ethanol to acetic acid
5	Factors Affecting Microbial Growth pH Moisture content Oxidation-reduction potential (Eh) Nutrient content Anitmicrobial constituents Biological structures
6	Factors Affecting Microbial Growth Temperature of storage Relative humidity of the environment Presence and concentration of gases in the environment
7	Selecting Cleaning Compounds Type of surface to be cleaned - material construction Type of soil to be removed - organic, inorganic or mixture Method of application - manual, spray, CIP, high pressure, soak, foam
8	Selecting Cleaning Compounds Temperature of cleaning Hardness of Water Economics of Cleaning process
9	Types of Surfaces Stainless Soft metals - Brass, zinc, aluminum, copper Plastics
10	Soil Types Organic - proteins, carbohydrates, fats, oils, etc. Inorganic - hard water scale, corrosion products, milkstone, beerstone, etc.
11	“Rule of Thumb” Organic Soils - Alkaline or neutral cleaners Inorganic Soils - Acidic Cleaners
12	Method of Application Manual Cleaners Circulation Cleaners(CIP, Spray cleaners) Soak Cleaning High/Medium Pressure Spray Cleaning Foam Cleaning COP Cleaning
13	Temperature Caustics - 150ºF - 180ºF (65-82º C) Chlorinated Alkaline CIP - 140-150ºF (60-66ºC) - Can clean at lower temperatures in certain applications (125ºF) Acidic CIP Cleaners - 150-160ºF (65-71ºC) Manual Cleaners - No higher than 120ºF Foam Cleaning - Ambient to 120ºF
14	Water Hardness Soft Hard
15	Economics Consider “Total Cost of Clean” Break costs into - Labor, Energy and Materials
16	Mode of Action - Cleaning Compounds Detergent dissolves in water - prevents precipitation of hard water salts Apply to surface - dissolves water soluble soils Penetration of the soil layer Dispersion of the soil - hold soils in suspension
17	Mode of Action - Cleaning Compounds Emulsifications - Suspension of oil and fat droplets Saponification - Reaction between strong alkalies and fats - form soluble soaps Solubilization of proteins Free Rinsing of soils from surface
18	Components of Cleaning Compounds Surface Active Agents - Surfactants (foam suppresants and foam production) - New synthetics - biodegradable Sequestrants - Lock up water hardness. Complex phosphates - or sodium gluconate and EDTA
19	Components of Cleaning Compounds Detergent Alkalies - Sodium carbonate, sodium silicates, borates & caustic alkalies - sodium and potassium hydroxides
20	Keys to Sanitizer Selection Non-toxic Wide spectrum of anti-microbial activity Biocidal vs. biostatic (control only) Compatible with traces of cleaner solution
21	Keys to Sanitizer Selection Non-corrosive to surfaces Easily measured for biocidal activity Free rinsing Rapid biocidal action
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23	Recommended Usage Levels for Hypochlorites: Process Water - 0.5-10 ppm Stainless Steel - 100-200 ppm CIP Sanitizing - 100-200 ppm Porous Surfaces - 200-2,000 ppm Walls - 200-400 ppm No Rinse Needed - < 200 ppm
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26	Recommended Usage Levels for Quats: Walls & Ceilings for Mold - 2,000 - 5,000 ppm (Spray on down day) Equipment Sanitizing - 200 ppm Floors & Drains - 800 ppm Floor Mats - 1,800 ppm Foot Baths - 2,400 ppm No Rinse - <200 ppm
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31	Other Modes of Sanitizing Hot Water Air Steam UV Light
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34	MicroBrewery/BrewPub Cleaning & Sanitizing Typical soils - Sugars, starches, proteins, beerstone, some fats/oils
35	Challenges faced by Micros/BrewPubs Time to clean Economics Making hot water No sprayballs for tank cleaning Constraints of system and production facility - design/space Environmental concerns
36	Brewing Equipment - Sequence of Cleaning Tanks: Cereal cooker, mash tun, lauter tun, brew kettle, whirlpool and hot wort tanks Pre-Rinse - drain. Burst rinse if possible Detergent wash: Caustics - 1-3%, 140-180ºF - 30-45 minutes Chlorinated Alkalies - 1/2 -1 ounce per gallon - 125-150ºF - 30-45 minutes
37	Brewing Equipment - Sequence of Cleaning Tanks: Cereal cooker, mash tun, lauter tun, brew kettle, whirlpool and hot wort tanks Post Caustic Rinse - drain. Burst rinse if possible - Check pH to neutral Acidic wash if necessary - 1/2 -1 ounce per gallon - 150-165ºF (or lower - 125-140ºF) - 30-45 minutes Drain/Rinse Sanitize
38	Brewing Equipment - Sequence of Cleaning Lines and Heat Exchangers: Clean in place with solution used to clean tanks/kettles Post Caustic Rinse - drain. Check pH to neutral Acidic wash if necessary - 1/2 -1 ounce per gallon - 150-165ºF (or lower - 125-140ºF) - 30-45 minutes Drain/Rinse Sanitize
39	Brewing Equipment - Sequence of Cleaning Fitting, Pipes and Valves Clean all fittings, reducers, parts, adapters, valves, etc. - manually or in COP tank. Immerse in appropriate sanitizing solution Rinse with potable water before reuse
40	Brewing Equipment - Sequence of Cleaning Storage Tanks Remove all CO2, open vent lines and manholes Clean tanks with caustic or chlorinated alkaline cleaner as noted previously Acid rinse/wash as required Drain and sanitize Foam or manually clean tank exteriors
41	Brewing Equipment - Sequence of Cleaning Floor and Wall Surfaces Use high/medium pressure, foam or manual cleaning applications with mild alkaline or acidic cleaners Apply quat sanitizer periodically
42	Brewing Equipment - Sequence of Cleaning Filter Cleaning Diatomaceous silica filters - flush with water between filter cycles - clean weekly with chemicals (caustic - 1.6% - 140ºF - 30-60 minutes) Flush rinse with fresh water
43	Brewing Equipment - Sequence of Cleaning Keg Cleaning Prepare a keg washing solution of between 2-3% caustic at 165-180ºF wash temperature. If purge w/CO2 - use Acidic CIP cleaner at 1-2 ounces per gallon - 150ºF Flush rinse with fresh water
44	Special Cleaning Needs Beer Lines - Important to clean regularly Use Caustic (1%) or 1/2 ounce per gallon chlorinated alkaline CIP cleaner May also use “line pigs” to facilitate mechanical action Glycol systems Clean periodically Ensure adequate concentration (max 50%) Test regularly
45	Special Cleaning Needs Passivation of Stainless Process Equipment Maintain chromium oxide film to minimize corrosion & pitting Clean surfaces first - chlorinated alkaline CIP cleaner at 2-4 ounces per gallon - 140ºF for 30 minutes Passivate with a phos/nitric acid - 25% (1 gallon per 3 gallons of water) - 130-140ºF - 60 minutes Rinse until pH has reached a level of between 6-8
46	Related Issues Chemical storage Pails, drums, totes, bulk Handling Buckets, drum pumps, scrub pad, brushes Foamers, sprayers, CIP systems Dosing/Control Manual/Automatic
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