1. Protect Your Brand with
a Properly Managed
Sanitation Program
Brought to you by:
Indiana Brewer’s Guild
FlexPAC Inc.
Spartan Chemical
2.
3. Protecting Your Brand & Managed
Sanitation…
What does it mean?
Why is it important?
How does it reduce your risks?
How can it make you more profitable?
4. What is Sanitation?
Proper sanitation contributes to the control of bacteria. It is important
to follow proper procedures which means making the right choice. There
are no shortcuts in sanitation.
Consumer protection and product safety must be priorities
Sanitation is the law
Written procedures
Effectiveness
Safety oriented
Practical
Training
Understand the “why’s”
Continuous improvement
Updated regularly
5. Why Do We Clean?
Sanitation is the law
The Center for Disease Control estimates that between ten and twenty billion
dollars per year are spent on foodborne illness. 9,000 ultimately die
Government Regulation
Part 110.35c of the Good Manufacturing Practice Regulations states “ all utensils
and product contact surfaces of equipment shall be cleaned as frequently as
necessary to prevent contamination of food and food products.
Reduce Microbiological Contamination
Maintain product quality
Reduce spoilage
Sanitation is focused on destroying
6. Chemistry of Cleaning
The Principles of the Cleaning Process
Preparation
Washing
Rinsing
Sanitizing
Another key to your success will be the controllable factors in cleaning or
TACT
Temperature
Agitation
Concentration/Dilution Ratio
Time
7. Chemistry of Cleaning
Detergent Properties
Wetting - Breaks down surface tension
Penetration – Gets down into the dirt film
Emulsification
Soil Suspension
Sanitation Chemical Properties
pH
Detergents
Surfactants
Emulsifiers or Suspension Agents
8. Soil Types & Identification Simplified
Alkaline Soils
Mineral Deposits, Hard-Water, Iron/Rust, & any caustic cleaning
residues
Acidic Soils
Carbohydrates, carbonized soils, & other soils with food based
origins
Alkaline Cleaners Acidic soils
Acidic Cleaners Alkaline soils
11. MOST COMMON PAA UNITS
Flow: 0.03-12 GPM
Operating Pressure : 6-140
PSI
Injection Range 1:4000-
1:250
0.025%-0.4%
Max Temp: 100F
Inlet/Outlet: ¾” NPT
Flow: 0.15-30 GPM
Operating Pressure: 5-100
PSI
Injection Range: 1:4000-
1:333
0.025%-0.3%
Max Temp: 100F
Inlet/Outlet: 1 NPT
MiniDos 12 0.4% HAC
Part# 112608HAC
SuperDos 30 0.3% HAC
Part# 113228HAC
Flow: 0.25-45 GPM
Operating Pressure: 5-100 PSI
Injection Range: 1:4000-1:333
0.025%-0.3
Max Temp: 100F
Inlet/Outlet: 1-1/4 NPT
SuperDos 45 0.3% HAC
Part# 113230HAC
12. Why is Managed Sanitation Important?
It’s the first step in a great Brew!
Helps maintain & improve the integrity of your brew
Minimizes risk of spoilage in the brew process
Increase the lifespan of your equipment and assets
Maximize the perception of your operation by public & customers
A properly managed sanitation program can be one of your most
valuable assets
13. Symptoms of Poor Sanitation….
Produce off-flavors
Hazy or turbidity in beer
Too much acidity in the beer
Poor foam or “head” on the beer
Non-desirable aromas
Films on equipment and surfaces
14. Critical Control Points
Drains
Hoses & Fittings
Tools
External surfaces of equipment
Cracks & Crevices in flooring
Cracked welds, equipment crevices that are hard to scrub, & other recessed
surfaces on equipment
Seals and lids on equipment
Touch points on equipment and throughout brewery area
FLOORS
15. Drains…..Where the Wild Things Are
In 2004, a study by the USDA produced positive findings of Listeria in 27.8% of
food plant drains in an undisclosed Midwestern State
Drains harbor bacteria, active yeast, bio-films, and many other “bugs”
2 types of Micro’s – Free Form & BioFilm
Typical Micro-organisms found in drains
Listeria monocytogenes
Molds
Un-friendly Yeasts
Salmonella
E.coli
Other “spoilage” and/or “pathogenic” micro-organisms
16. Drains…..Where the Wild Things Are
Do’s of Drains
Develop a periodic SSOP for
cleaning the drains
Train your staff on proper drain
maintenance
Use foaming tools to prevent
overspray
Be tenacious about cleaning drains
Scrub drain in a circular or side-to-
side motion to break up bio-film
Properly care for tools that are
used for cleaning drains
Don’ts of Drains
Spray directly into a drain
Lay unclean drain grates/covers on
surfaces other than the floor
Touch drains and then touch other
surfaces w/o washing hands
Neglect Drains
Scrub drain in a vigorous up &
down motion
19. Documentation, Documentation,
Documentation
Master Sanitation Plan
Proper HAZCOM/GHS Program
SSOPs – Standard Sanitation Operating Procedure
Safety cards and proper labeling
Sanitation Manual
Titration or Concentration Log – Sanitizer & Cleaners
20. Verify & Validate
Use Titration Kits to maintain effective & consistent chemical
solutions
Verify PPM for your PAA Sanitizing solution to ensure adequate
concentration to achieve Sanitizing efficacy
Control costs and ensure sanitation requirements are met
Your chemical partner can provide you with an index for
concentration analysis
21. ATP Testing – Hygiena Ensure V2
Ability to measure and use for cleaning trends with sanitation
“Sleep Better at Night”
24. SSOP – Standard Sanitation Operating
Procedures
Components to build an SSOP
Information Section
SSOP Title/Application
Frequency of SSOP
PPE Required
Chemicals Required
Equipment Required
Cleaning/Sanitation Procedure
Notes Section
25. Why is Training Important??
Efficacy through standardization
Optimize your processes
Consistency of results reduces RISK
Maintain quality of brew and integrity of equipment –
extend your assets
MOST IMPORTANT – FREES UP YOUR TIME TO DO WHAT YOU
LOVE… BREW BEER!!!!
26. Safety – Respect Your Chemis
The Do’s and Don'ts of Food Sanitation
Doers
Become familiar with chemicals and their applications
Read the labels and SDS on all products
Know your products
Use proper dilution
PPE fanatics
Wear recommended protective clothing when dispensing or using chemicals
Wear proper footwear in the appropriate environment
Lead by example, always teaching safety via PPE, etc.
Know the proper methods of dealing with an injury related to chemical exposure
27. Safety – Respect Your Chemis
The Do’s and Don'ts of Food Sanitation
Don'ts
Mix acid in chlorinated products
Add water to concentrated chemical (add the chemical to the water)
Mix chemicals without following directions
Dispense chemicals in unlabeled containers
Transport liquid products in open containers
Add chemicals to hot water unless following a written procedure that
includes the precautions
Substitute chemicals
Manually clean equipment when it is running
29. Hand Hygiene and PPE
Establish a policy on hand-washing and PPE
Gloves should be worn, disposed, and changed frequently
Per OSHA HAZCOM – proper PPE MUST be made available for
employees where needed
Hands are the #1 transmission mode for micro-organisms
31. Looking Forward
What rules & regulations could breweries become susceptible to?
FSMA, GFSI, 3rd Party Audits, HACCP
Would you be ready?
32. Get More Out of Your Supplier Partner
Direct Sellers generally are more of a 1-trick pony, have expertise, but it’s
limited to their individual product/program
Brokers or Buying Groups can provide more than 1 program or service, but
aren’t generally cost-competitive and don’t bring the most value &
comprehensive programs to market
An Integrated Supply Chain Partner has access to multiple key channels along
with designed programs to meet the diverse needs from both a product and
program perspective
33. Takeaways………
Having a Managed Sanitation Program is an important factor in the
consistent quality of your product
There are several tools available to help you be more efficient and
effective
Implement documentation as needed to standardize your program and
make it easier to cross-train
Validate results and processes whenever possible
Be mindful of the “future of the Brewing Industry” and the potential
changes in regulations in regards to Food/Beverage Safety
DO NOT neglect Safety – PPE, GHS/HAZCOM, BBP, etc.
Utilize an Integrated Supply Chain Partner whenever possible
34. When You Brew That Perfect Beer
“It’s Beautiful……”
I want to get a feel for who all we have in the room.. By a show of hands, who in here is a head brewer, brewmaster, or personally responsible for day-to-day brewing? How about anyone that has other responsibilities within your respective organizations, whether it’s ownership, sales, logistics, etc.?
Now who’s involved in sanitation?
Let’s take a look through several different lenses as to what people see when they hear “Brewer”
Brewers wear so many “Hats” that it’s important that something as critical as Sanitation is not overlooked
PAA dilution should be 1 oz. – 1.5 oz. per 5 gallons of water to give you a sanitizing solution of 88 – 130 ppm
It’s important to have a sanitizer that has been tested effective under hard water conditions.. Most breweries use water with a high grain count, which can affect the concentration of the PPM in the sanitizing solution… That is why its also critical to titrate or test your Sanitizing Solutions to establish standards and ensure you are hitting the proper PPMs
Quat sanitizers are hardly ever used as they tend to leave a residue that can negatively affect the brew cultures and lead to bitter beer tastes
Iodine, is used because its effective and doesn’t have a negative effect on the brewer’s yeast. It’s drawback is that it can be expensive, it can be a little harsh to handle and can stain stuff.
They may compete with the production strain for essential nutrients; they can also induce stuck fermentation or over-attenuated beers. There are two major groups of microorganisms responsible for contaminating wort and beer – Wild Yeast & Bacteria
Not all of these would necessarily be present in a brewery environment, but these are common micros found in drains
Free Form are micros that float in water and generally evacuate a system
BioFilm is much harder to control – forms a polysaccharide matrix resistant to chemicals
Make sure that you have a bucket of strong Sanitizer – 800 ppm – 1500 ppm to place the drain brush and grates in
Color code according to your training and SSOPs
Generally black is for drains
Be sure to change-out mops to avoid build-up of bacteria or opportunity for bacteria to grow
CLARKE MACHINE IS VERY IMPORTANT TO DISCUSS – agitates and picks up solution, preventing re-contamination, etc.
IMPORTANT FOR THE TRANSFER UNIT
