Bottled water filtration selection guide for products and applications rev 1 d
21 Cost efficient QM in microbreweries agk
1. Cost efficient Quality Management
in Microbreweries
Axel G. Kristiansen
Deputy Director DTU Diplom
Danish Technical University
Nordic Meet on Brewing Technology 18th – 20th MAY 2016
2. Many microbrewer’s Quality Challenges
• Lack of time
• Lack of money
• The microbrewer does every job in the brewery
• Sometimes limited technical and QA knowledge
• Too late, if the customer has to tell, my quality is poor
• Quality is inexpensive, missing quality is costly...
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3. Definition of Quality
Most people agree, Quality is important, but what is good Quality ?
One definition of quality is:
“Quality is meeting the needs and expectations of
customers”
Customers want quality, that corresponds to the price, that they are
prepared to pay and the level of competition in the market.
Another definition offered:
‘’Quality is, when the customer returns – not the Beer’’.
Quality may also relate to the consistency in manufacturing
meaning, that the brewery is able to produce the same quality brew
after brew.
5. Useful Terminology for any
(micro)brewer
Sample Plan List os samples taken during process: The
sampling plan is maybe the most important
element of the Quality System !
Recipe List of all ingredients incl. amounts. Does not
explain the manufacturing process.
Process
Description
Manufacturing guide to produce a defined
amount of product on a defined plant.
Analysis A laboratory’s measurements of contents of
certain contents in the product or in raw
materials. Does not explain the used recipe or
process.
Specification The brewery’s limits for which analytical
values, we will accept for selected parameters.
Production log The brewery’s registrering of the used process
for each batch, i.e. temperatures, times and
volumes.
Declaration The Brewery’s garanti to the consumers and the
authorities about certain contents in the final
product. Does not explain the used recipe nor
process. 519-05-2016
6. Example of a production log
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Fermentation control: Temperature and % Plato during fermentation:
Allows the Brewer to spot slow fermentations and when fermentation
has ended. Cost and effort: Almost nothing.
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Days
% P
7. Before venturing into expensive equipment
1. Am I selling and distributing beer nationwide and
with a long shelf life – or selling locally only ?
2. What do I need to measure in the microbrewery ?
3. And which accuracy of measurement do I need ?
4. Basic instruments: Cheap
5. Basic instruments: Costs < 2000 €
6. Portable instruments: Costs > 2000 €
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8. What makes sense to measure ?
• Chemical parameters (Alcohol, Colour, Bitterness)
• Microbiology (level of infection, pitching yeast standard)
• Raw material checks (malt, hops, glass bottles)
• Flavour (positive flavors and off – flavors)
• Packaging quality (fill level, labelling standards)
• Customer satisfaction (product shelf life)
• Manufacturing logs:
• Raw materials used
• Mashing diagrams
• Fermentation logs
• Samples taken / analysed
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Sara Poyri examining fermentation charts
in a Danish medium size brewery 2012
9. Example of a Beer chemical Analysis (large brewery)
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10. Only 7 chemical parameters define the
Beer Style and - Quality
1) Original Extract OG [% P] g/100 g
2) Specific Gravity SG [g/ml] 1.00XX
3) Real Extract ER [% P] g/100 g
4) Real Degree of Fermentation RDF [%] g/100 g
5) pH [number]
6) Alcohol by Volume ABV [%] ml/100 ml
7) CO2 [%] g/100 ml
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11. These 7 chemical parameters can all
be measured in the microbrewery by
the microbrewer him/her self
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12. The microbrewer’s choices
1. What do I need to measure in the
microbrewery ?
2. Basic instruments: Cheap
3. Basic instruments: Costs < 2000 €
4. Portable instruments: Costs > 2000 €
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13. Malt after the mill – often forgotten
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Visual examination of crushed malt enables checks for:
• whole kernels (should not be there !)
•That all kernels are squeezed
• Some flour – not too much
15. Extract analysis in spent grains:
Shows whether we make efficient use of the malt
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Example of home made press Saccharometer
16. Refractometer:
Shows OG of wort
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Refractometer,
hand held
Microbrewer using refractometer
Accuracy: +/- 0.2 % P
Obs.: Other limitations;
but convenient
Refractometer,
Lab. Bench type
17. The good old Saccharometer
Shows OG of wort
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Saccharometer Selection of Saccharometers
Reading af
Saccharometer
Accuracy: +/- 0.1 % P
18. Use of Saccharometer in practice
as seen in many breweries
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Time consuming – very manual
19. Pycnometer
Methods with highest accuracy:
Densitometry using Pycnometry
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Accuracy: +/- 0.03 % P
Shows OG of wort
20. pH – meter
Shows mash – and wort condition
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Hand held pH - meter Brewers measuring wort pH
Accuracy: +/- 0.1 pH
21. More Brewhouse tests
Break formation measured
by an Imhoff cone
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For check of efficiency of wort boil: For check of fermentation start:
Wort aeration checked by
a simple flow meter
22. ...and some simple packaging tests
most of these are rarely seen used…
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Humidity test - labels Glue testAir in headspace test
23. CO2–measurement of bottled beer
to ensure same pressure in each bottle
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23
Quick – not so accurate
24. Taste testing:
A Powerfull Quality – and Diagnostic Tool
Can reveal process defects
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Some times under estimated
for its process diagnostic power
25. The microbrewers choices
1. What do I need to measure in the
microbrewery ?
2. Basic instruments: Cheap
3. Basic instruments: Costs < 2000 €
4. Portable instruments: Costs > 2000 €
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26. The microscope – cheap, yet powerfull
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Microscope in daily use in one leading
Danish microbrewery’s basic lab.
Acetic Acic bacteria found
In the draft beer from a
Microbrewery
28. FermentoFlash – example of automatic
beer analysis
• Alcohol (% v/v & w/w)
• Extract – real & apparent
• Original gravity
• Density
• Osmotic pressure
• Degassing of sample
• 10 ml sample
• Analysed in 1 minute
• Printer or PC
• Calibration with reference
beer (up to 18 different)
• Prize: ~ 2000 € + VAT
www.funke-gerber.de
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Accuracy: +/- 0.02 % ABV
29. The microbrewer’s choices
1. What do I need to measure in the
microbrewery ?
2. Basic instruments: Cheap
3. Basic instruments: Costs < 2000 €
4. Portable instruments: Costs > 2000 €
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30. Portable Density Meter
to achieve fast and accurate chemical parameters
• Density
• Specific gravity
• Extract
• Alcohol
• Viscosity 0 – 1000
mPa*s
• Temperature
compensated 0 – 40°C
Sample: 2 ml
Time: Few seconds
Price: Approx. 2000 €
www.anton-paar.com
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31. Portable CO2 / DO Measurement
to measure Oxygen take – up during production
Anton Paar – CarboQC
www.anton-paar.com
Dr. Thiedig – Digox
www.thiedig.com
Pentair’s CO2 Gehaltemeter
www.Pentair.com
3119-05-2016
Several suppliers
32. Lab. bench Methods – accurate, not cheap
Highest accuracy (do You need it ?)
Densitometry using automatic apparatuses
(most common is PAAR densitometer based on ultrasonic
vibrations. The PAAR unit may be a stand-alone or may be built
into an automatic complete wort analyzer called a SCAWA)
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33. Automised micro methods
Aber instruments: Lab Yeast
Analyzer:
Viability by. capasitans
metering
Chemometec: NucleoCounter
viabilitet by Iodine staining
Beckman Coulter: Vi-Cell
viabilitet by Trypan Blue
staining in flow cell
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34. Customers satisfaction – some times forgotten
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• Do You know, what your customers think
of your beers in trade ?
• Winning beer competitions is nice, but your
everyday customer pays your profit
• Do You systematically collect complaints
statistics and use complaints for process
Improvements ?
35. Axel G. Kristiansen
Thank you for your attention !
Conclusion:
Quality can be managed and product consistency achieved even in the
smallest Brewery for little effort and limited costs !
37. Type of Chambers for Yeast Cell Count
Haemocytometer with counting chamber type:
• Thomas
• Neubauer or Neubauer improved
• Bürker-Türk
• Malassez
Data for Bürker-Türk:
• Depth: 0.1 mm
• Number of large squares: 9
• Large square area: 1 mm2
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38. Prepare the Counting Chamber
Representative sample: mix thoroughly
Dilute if necessary
Take up sample with pipette
Cover with cover slip both of the 2 sections
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39. Count the Cells in the Counting Chamber
Count all 16 small squares in the large square
Count the 2 sections:
• All cells inside the squares
• Include cells touching the left and top boundaries
• Exclude cells touching the right and bottom boundaries
• Budding cells: daughter cells larger than ½ mother cell
• Use the counter – do NOT rely on your memory
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42. Real/Apparent Extract
• Real extract is the amount of carbohydrate
measured in weight % Plato.
It is measured by measuring the density of the
wort/beer (without alcohol) and transformed
into %Plato
• Apparent extract is the amount of
carbohydrate measured in weight % (% Plato).
It is measured by measuring the density of the
beer and transformed into %Plato
42
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43. Apparent and Real Extract
Real extract
Apparent Extract
Alcohol
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44. Real Degree of Fermentation
The real degree of fermentation – RDF – is a
calculated, not measured, figure expressing the
percentage of the extract which has been fermented
by the yeast.
• RDF = 100*(OE - ER) / OE
OE and ER in % Plato, RDF in %
• Pilsner type beers: RDF is normally 66-72 %
• Low energy/lite beers: RDF can be as high as 85-90 %
• The higher the RDF the more alcohol is formed with the
same amount of extract
• A stronger beer can be produced by increasing the
Plato and/or increasing RDF
• The RDF is depended on the mashing profile, the type
of raw materials, the fermentation method and the use
of external enzymes
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45. Other type O2 Measurement
Dr. Thiedig – Digox
www.thiedig.com
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