all about brewing

1. CleaningandSanitizingBreweryProcessEquipmentDanaJohnson,BIRKOCorporationHenderson,
Colorado
MBAA - RMDFebruary15th , 2007 Pumphouse Brewery,Longmont,Colorado
pH & Growth Relationshipof MicrobespHScale:
0______2_________5______7_______9________12_____14.
AcidNeutral Alkaline
pH 0-2: Veryfeworganismscansurvive verylongatthispH.
pH 2-5: Some acidtolerantorganismscansurvive,especiallyfungi (yeastandmold).
pH 5-9: Most bacteriagrow very well inthispHrange.
pH 9-12: Growth of most organismsisverylimited.Some alkalinetolerantorganismscansurvive.
pH 12-14: Veryfeworganismscansurvive atthispH.
BreweryLocation/SoilComposition:Brewhouse:Protein,starch,minerals,beerstone,hopoils,hop
resins,fermentablesugarsHeatExchanger:Protein,starch,minerals,beerstone,hopoils,hopresins,
fermentablesugarsFermentationTanks:Protein,starch,minerals,beerstone,yeastMaturation
Tanks:Protein,starch,minerals,beerstone,yeastBrightBeerTanks:Beerstone,scale
Solubilityof AminoAcids
Cleaning/SanitizingChemicalsGeneral Classifications:AcidCleanersAlkaline CleanersEnzymatic
CleanersFoamGeneratorsSolventsSanitizers/Disinfectants

2. The Acid TestAcidsusedforbeverage processingequipmentcleaning:OrganicAcids(Citric,lactic,
acetic)Mineral Acids(Hydrochloric,Phosphoric,Sulfuric)OxidizingAcids(Nitric,PeraceticAcid- PAA)
Alkaline CleanersSodium/PotassiumHydroxide (causticsoda,(NaOH,lye) causticpotash(KOH).Sodium
Hypochlorite (NaOCl,chlorine bleach)Noncausticalkalinecleaners(sodiumpercarbonate,phosphates,
surfactants,silicates)
SanitizersChlorine Bleach(hypochlorite)ChlorineDioxide(Cl02)Iodine(Iodophor)Ozone (O3)Peracetic
Acid(PAA)Quaternary Ammonium(Quat)
ConventionalCIPTriedandtrue.Rinseproductoutusingambienttowarmwater.CIPwith1-2ouncesof
causticblendpergallonof water(180 degree F.maximumtemperature) for15-30 minutes(orlonger)
dependingonconditions..Rinse.CIPwith1-2ouncesof an acidcleanerpergallonpergallonof warm
(120-140 degree F.) for15-30 minutestoneutralize the causticandfinishcleaning.Rinse withambient
temperature wateruntil the pHof the rinse waterisneutral (same pH as the tap watercomingin).
A NewApproachWe have discoveredanew waytokeepbeverage packagingmachinescleanusingthe
followingprocedure:Rinse outbeerandyeastwithambienttemperature water.Use a1-2 ounce per
gallonphosphoric/nitricacidmixture (140degree F.maximumtemperature) for15-30 minutes.No
rinse!Use a noncausticalkaline cleanerat1-2 ouncespergallonof warm(120-140 degree F.) tostart.
CIPfor 15-30 minutesdependingonconditions.Rinse withambienttemperature wateruntilthe pHof
the rinse waterisneutral (same pH as the tap watercomingin).
Mash Tun CIP (Traditional)A.Test#1Mash TunThe test wasperformedinthe followingmanner:Caustic
wash:3% w/v pre-blendedmixture of 25% w/w caustic and causticadditive 2400 secondsCausticrinse
cycleAcidwash:3%v/v nitric/phosphoric1200 sAcidrinse cycle
Mash MixerBefore
Mash MixerAfter(Traditional) CIP
Brewkettle CIPThetestwasperformedinthe followingmanner:Acidwash:3% v/vnitric/phosphoric
blend1200 sAcidrinse cycleCausticwash 3% w/vpre-blendedmixture of 25% w/w causticand caustic
additive 2400 sCausticrinse cycle

3. Kettle-Before CIP
Kettle-AfterCIP(AcidFirst)
Brewkettle AfterCIP(AcidFirst)
FermentationVessel CIP(AcidOnly)Test#1FV-42The testwas performedinthe followingmanner:Acid
Wash: 3% v/vnitric/phosphoricblend&32 oz. detergentadditive 1200 sAcidRinse CyclePAA Sanitation
FV Before CIP
FV AfterCIP
Cleanervs.Sanitizer-Whatsthe difference?Cleanersremove soil,scale,protein,etc..Littlegovernment
involvementregardingclaimsunlessbactericidalclaimsare made.Registrationforsanitizersare
governedbythe EPA,(sometimesFDA) andthe productmustgo throughrigoroustestingtobe classified
as a sanitizer.$$$$$.Oftenusedsynonymously- technicallyspeaking,there isadifference between
sanitizinganddisinfecting.
BIOFILMBiofilmDefinition:The attachmentof organismstoa solidsurface andsubsequententombment
ina protective polysaccharidecoating.Markedincrease inantibioticand chemical resistance.Many
differenttypesof organismscanexistwithinthe film, makingdetectionandremoval difficult.
BiofilmRemovalMechanical action(i.e.,hand-scrubbing) isthe mosteffective waytoremove
bioflims.ForCIP,extreme pH,(12) alongwithoxidation,(HN03,NaOCl,PAA,Cl02) ORenzymes,work
bestto ridsurfacesof biofilmandpreventitfromreturning.
SelectiveMicroTechnologiesPure ChlorinedioxidegeneratorsNoflavorprofile (noresiduals!)low ppm
requirementnon-corrosivesafeeasytouseeasytomeasure
ConclusionCleaningisthe leastglamorouspartof dailypackagingroutine butlikelythe mostimportant
for overall productquality.Dependinguponthe productyoumake,anunsanitarymachine canhave

4. publichealthconsequences.Use the propertype andamountof chemicals- dontscrimp,butoveruse,
either.
BrewingScience
Cleaning
2 BreweryCleaningandSanitation
Cleaningandsanitationare integral partsof successful brewing
Cleaning:removal of organicandinorganicresiduesand microorganisms
Sanitation:reduce the populationof viablemicroorganismsandpreventmicrobialgrowth
3 Cleaning
Cleaningagentsbroadlyfall intoalkaline oracidicdetergents;oftenwithaddedsurfactants,chelating
agents,andemulsifiers
Must (1) wetsurfaces,(2) penetrate residue deposits,(3) holdparticlesinsuspension,and(4) keep
inorganicionsinsolution
4 AlkalineDetergents
Effectivelyremoveorganics:oils,fats,proteins,starches
Hydrolyze peptide bonds,breakingdownproteins
Ineffective againstinorganicssuchascalciumoxalate andcan leave “beerstone”
PBW isa goodexample
5 AlkalineDetergents
SodiumHydroxide:“Itseffectivenessindissolvingproteinaceoussoilsandfattyoilsbysaphonificationis
virtuallyunsurpassed.This makesitanatural choice forcleaningsludge off the bottomsof boilersand
for cleaningbeerkegs.Sodiumhydroxideisanacutelyexcellentemulsifiertoo.Itisunrivaledinits

5. abilitytodissolve proteinandorganicmatterif usedinconjunctionwith chlorine,surfactants,and
chelatingagents.”
SodiumHydroxide /Hypochlorite Solutions:“Caustic/hypochlorite mixturesare particularlyeffectivein
removingtannindeposits,butare usedfora great varietyof cleaningtasks.These mixturescanbe used
inCIP systemsforoccasional purge treatmentsortobrightenstainlesssteel.”
6 AcidDetergentsOftenusedintwostepprocesswithalkaine detergents
Lesseffective againstsoil,tannins,oils,resins,andglucans
Remove beerstone/calciumoxalate, waterscale (CaandMg carbonates),andaluminumoxides
More effectiveagainstbacteria
7 AcidDetergents
PhosphoricAcid:widelyusedtoremove deposits,enhancedbyacid-stable surfactants.Generallyless
effectivebelow16centigrade.
NitricAcid:removesdepositsandhasbiocidial properties,particularlyinmixture withphosphoricacid.
Alsobreaksdownprotein.AcidCleaner#5is an example.
8 AdditivesSurfactants/WettingAgents
ChelatingAgents(EDTA,sodiumgluconate,sodiumtripolyphosphate)
Emulsifiers(orthophosphatesandcomplex phosphates)
9 Sanitation
Sanitizingordisinfectingagentsusedtoreduce the levelof microorganisms
Simple physical methodsincludehotwaterorhot steam
Chemical sanitizersrange ineffectiveness,temperature,andcontacttime requirements
10 Alkaline Sanitizers
Chlorine:Broadspectrumgermicidesthatdisruptmembranes,inhibitglucose metabolism, andoxidize
protein.Active atlowtemperatures,inexpensive,leaveslow residue
QuaternaryAmmonium:stable andnon-corrosive,rapidbactericidal actionatlow concentrations.
Efficientagainstgram-positive bacteria,yeast,andmold.Ineffective againstgram-negative bacteria.
(Quantum)

6. 11 AcidicSanitizers
HydrogenPeroxide:broadspectrum,betteragainstgram-negative.
PeroxyaceticAcid:germicidal,novaporissuesorfoam.Requiresrelativelyhighconcentrations.
AnionicAcids(StarSan)
Iodophores:wide biocidalspectrum,equallyeffective toall microorganisms,butmayhave staining
problems.(IOStar)
12 Methodsin BreweryCleaning
Manual: “Many craft brewersdonot have the luxuryof cleaning-in-place systemsandhave tomanually
cleanand sanitize theirequipment.Theyoftenhave touse soft-bristledbrushes,non-abrasive pads,
cloths,andhandheldspray hosesforcleaning.Whencleaningmanually,greatcare mustbe takento
assure that brushesandequipmentare cleanedtoavoidcross-contamination.”
CleaninPlace
13 In DepthCIPPrinciplesandPractice of CleaninginPlace
The followingslidesare from:
PrinciplesandPractice of CleaninginPlace
Graham Broadhurst
Great LakesWater ConservationConference,October2010
14 CIP / SIP - DefinitionCIP=CleaninginPlace
To cleanthe product contact surfacesof vessels,equipmentandpipeworkinplace.i.e.without
dismantling.
SIP= SteriliseinPlace
To ensure productcontact surfacesare sufficientlysteriletominimise productinfection.
15 How CIPWorks Mechanical Chemical Sterilant/Sanitiser
Removes‘loose’soil byImpact/Turbulence
Chemical

7. Breaksup and removesremainingsoil byChemical action
Sterilant/Sanitiser
‘Kills’remainingmicro-organisms(toanacceptable level)
16 Factors affectingCIP
Mechanical
Chemical
Temperature
Time
17 CIP OperationPRE-RINSE- Mechanical Removal of Soil
DETERGENT - Cleaningof RemainingSoil - Caustic,AcidorBoth
FINALRINSE- Wash Residual Detergent/Soil
STERILANT/SANITISER- ColdorHot
18 Typical CIPTimesVessel CIPMainsCIPPre-Rinse 10to 20 mins
Vessel CIP
Mains CIP
Pre-Rinse
10 to 20 mins
5 to 10 mins
CausticDetergent
30 to 45 mins
20 to 30 mins
Rinse
10 to 15 mins
AcidDetergent
15 to 20 mins
Sterilant

8. 19 Typical CIPTemperature
Brewhouse VesselsHot85°C
Brewhouse MainsHot85°C
ProcessVesselsCold<40°C
ProcessMainsHot 75°C
YeastVesselsHot75°C
YeastMains Hot 75°C
20 CIP Detergent- Requirements
Effective ontargetsoil
Nonfoamingor include anti-foam
Free rinsing/Nontainting
Noncorrosive – Vessels/pipes,joints
Controllable - Conductivity
Environmental
21 CausticDetergents AdvantagesDisadvantages
Excellentdetergencypropertieswhen“formulated”
Disinfectionproperties,especiallywhenusedhot.
Effective atremoval of proteinsoil.
Autostrengthcontrol by conductivitymeter
More effectivethanacidinhighsoil environment
Cost effective
Disadvantages
DegradedbyCO2 formingcarbonate.
Ineffective atremovinginorganicscale.
Poorrinsability.
Notcompatible withAluminium

9. Activityaffectedbywaterhardness.
22 AcidDetergentsAdvantagesDisadvantages
Effective atremoval of inorganicscale
NotdegradedbyCO2
Notaffectedbywaterhardness
Lendsitself toautomaticcontrol byconductivitymeter.
Effective inlowsoil environment
Readilyrinsed
Disadvantages
Lesseffective atremovingorganicsoil.New formulationsmore effective.
Limitedbiocidal properties - Newproductsbeingformulatedwhichdohave biocidal activity
Limitedeffectivenessinhighsoil environments
Highcorrosionrisk - NitricAcid
Environment–Phosphate/Nitrate discharge
23 DetergentAdditives Sequestrants(ChelatingAgents)
Materialswhichcan complex metal ionsinsolution,preventingprecipitationof the insoluble saltsof the
metal ions(e.g.scale).
e.g.EDTA, NTA,GluconatesandPhosphonates.
Surfactants(WettingAgents)
Reduce surface tension–allowingdetergenttoreachmetal surface.
24 Sterilant/SanitiserRequirements
Effective againsttargetorganisms
Fast Acting
Low Hazard
Low Corrosion
NonTainting

10. No EffectOnHead Retention
Acceptable FoamCharacteristics
25 Sterilants/Sanitisers
Chlorine Dioxide
Hypochlorite
Iodophor
AcidAnionic
QuaternaryAmmonium
HydrogenPeroxide
PAA (PeroxyaceticAcid) –ppm
26 CIP SystemsSingleUse RecoveryTankAllocationNumberof Circuits
Water/Effluent/Energycosts
Recovery
DetergentRecovery
Rinse/Interface Recovery
Tank Allocation
Numberof Circuits
27 Single Use CIPSystemsSterilantCausticAcidWaterCIPReturn
CIPBufferTank
Water
Conductivity
Flow
CIPReturn
Caustic
Acid
Sterilant

11. CIPSupply
CIPSupplyPump
Temperature
CIPHeater
Steam
28 RecoveryCIPSystems1 x Supply – 3 Tank System
Final Rinse Tank
Water
Conductivity
Flow
CIPReturn
Caustic
Acid
Sterilant
CIPSupply
CIPSupply/ RecircPump
Temperature
CIPHeater
Steam
Pre-Rinse Tank
CausticTank
CIPReturn/ Recirc
CIPSupply/ Recirc
LSH
LSL
Temp
29 RecoveryCIPSystems2 x Supply – 4 Tank System– Separate Recirc

12. CIPSupplyA
LSH
Final Rinse Tank
Water
Cond
Flow
CIPReturnA
Caustic
Sterilant
CIPSupplyA Pump
Pre-Rinse Tank
CausticTank
LT
Temp
CausticRecirc Pump
Acid
AcidTank
AcidRecirc Pump
CIPReturnB
CIPSupplyB
CIPSupplyB Pump
30 RecoveryCIPSystem
31 Single Use vsRecoverySingle Use CIPRecoveryCIPLow Capital Cost
Small Space Req.
Low ContaminationRisk
Total Loss
HighWater Use
HighEnergy Use

13. HighEffluentVols.
LongerTime/Delay
Use forYeast
RecoveryCIP
HighCapital Cost
Large Space Req.
HigherContaminationRisk
Low Loss
Low WaterUse
Low EnergyUse
Low EffluentVols.
ShorterTime/Delay
Use forBrewhouse &Fermenting
32 CIP SystemsCIPTankSizing
Pre-Rinse
CIPFlowx Time
Detergent
Vol of CIP inProcessMains & Tank + Losses
Final Rinse
Flowx Time – Water Fill
33 CIP SystemsPractical Points
CIPSupplyPump
Recirculation
Shared/CommonwithCIPSupply,or
DedicatedtoTank
CIPSupplyStrainer
CIP ReturnStrainer

14. CIPTank Connections
34 Typesof CIPVESSEL CIP - SprayheadSelection - Scavenge Control
MAINSCIP - Adequate Velocity - Total Route Coverage
BATCH/COMBINEDCIP - Complex Control - Time Consuming
35 Vessel CIPFlowof CIPfluidfromCIPsupplytovessel sprayhead
Internal surfacescleanedbysprayimpact/deluge
Returnfromvessel byCIPscavenge (return) pump
CIPReturn
CIPSupply
CIPScavenge Pump
ProcessVessel
CIPGas pipe
Isolate fromProcess
36 Vessel CIP - Sprayheads
StaticSprayballs
HighFlow/ Low Pressure
RotatingSprayheads
Low Flow/MediumPressure
CleaningMachines
Low Flow/High Pressure
HighImpact
37 Vessel CIP –Sprayballs
Advantages
No movingparts
Low Capital Cost

15. Low pressure CIPsupply
VerificationbyFlow
Disadvantages
HighWater & EnergyUse
HighEffluentvolumes
Limitedthrow – Small vessels
Spray Atomisesif Pressure High
No impact- longCIPtime and/orhighdetergentstrength
Higherabsorptionof CO2 bycaustic
38 Vessel CIP –Rotary Sprayheads
Advantages
Nottoo Expensive
Some Mechanical Soil Removal
LowerFlow
Reasonable Water/EnergyUsage
Reasonable Effluent
Disadvantages
Movingparts
Limitedthrow – Small vessels
Possible blockage
Rotationverification
Supplystrainer
39 Vessel CIP –CleaningMachines
Advantages
Highimpact,aggressive cleaning
Good forheavydutycleaning
Low water/energyuse

16. Low effluent
Effective inlarge vessels
Lowerabsorptionof CO2 by caustic
LowerFlowmeanssmallerPipework
40 Vessel CIP –CleaningMachines
Disadvantages
Expensive
Movingparts
Highpressure CIPsupplypump
Possible blockage
Rotationverification
Supplystrainer
41 Mains CIP
Flowof CIP fluidfromCIPsupply,throughprocesspipeworkandbacktoCIP set
The entire processroute mustsee turbulent CIPFlow
No/Minimal Tees/deadlegs
Isolate fromotherprocesslines
CIPReturn
CIPSupply
Isolate fromProcess
Isolate fromotherProcessroutes
ProcessRoute beingCIP’d
42 Mains CIPTurbulent& LaminarFlow
43 Mains CIPTurbulent& LaminarFlow
TurbulentFlow
Flatvelocityprofile

17. ThinBoundarylayer
Effective CIP
LaminarFlow
Streamline flow
Velocityprofile,fasteratcentre
Ineffective CIP
ThinBoundaryLayer at pipe wall
44 Mains CIPTurbulentFlow – Minimise Boundarylayer–
Re > 3000
Minimise Boundarylayer–
Laminarlayeron internal pipe wall
Excessive velocity
HighPressure drop/ Energyinput
45 Mains CIP – CIPFlow
46 ProcessPipeworkDesignforCIP
Ensure Total Route coverage
AvoidSplitroutes
AvoidDeadends
AvoidTees
Most Critical on Yeast& nearerpackaging
47 ProcessPipeworkDesignforCIP
Isolate CIPfromProcess
Mixproof Valves
Flowplates
CIPReturn

18. ProcessLine – Not beingCIP’d
ProcessLine –beingCIP’d
FLOWPLATE
Physical Break betweenroutes
48 Batch/CombinedCIPCombinesCIPof Why? Vessel/sand
Pipeworkinone clean
Why ?
Pipeworktoolarge for‘mains’CIPe.g.Brewhouse 200to 600 mm.
PipeworklinkedtoVessel e.g.RecirculationLooporEWH.
49 Batch/CombinedCIPSupply of abatchvolume of CIPto processvessel
Internal recirculationof CIPwithin/throughprocessvessel
Transferof CIP to nextvessel
Pumpedreturnof CIPbatch volume toCIPset.
50 CIP Monitoring&Control On-Line
DetergentTemperature
DetergentStrength- Conductivity
ReturnConductivity
DetergentStartInterface
DetergentEndInterface
Rinse Conductivity
ReturnFlow
Recirc/ReturnTime
SupplyPressure
51 CIP Monitoring&Control Off-Line
Visual Inspection

19. Final Rinse returnsampling
pH
Micro
ATP
Vessel/Pipeworkswabs