Cleaning and Sanitizing Brewery Process Equipment MBAA RMD

Cleaning and Sanitizing Brewery Process Equipment MBAA - RMD February 15 th , 2007 Pumphouse Brewery, Longmont, Colorado Dana Johnson, BIRKO Corporation Henderson, Colorado

p. H & Growth Relationship of Microbes p. H Scale: 0______2_____5______7_______9____12_____14. Acid Neutral Alkaline n n p. H 0 -2: Very few organisms can survive very long at this p. H 2 -5: Some acid tolerant organisms can survive, especially fungi (yeast and mold). n n p. H 5 -9: Most bacteria grow very well in this p. H range. p. H 9 -12: Growth of most organisms is very limited. Some alkaline tolerant organisms can survive. n p. H 12 -14: Very few organisms can survive at this p. H.

Brewery Location/ Soil Composition: n n n n Brewhouse : Protein, starch, minerals, beerstone, hop oils, hop resins, fermentable sugars Heat Exchanger: Protein, starch, minerals, beerstone, hop oils, hop resins, fermentable sugars Fermentation Tanks: Protein, starch, minerals, beerstone, yeast Maturation Tanks: Protein, starch, minerals, beerstone, yeast Bright Beer Tanks: Beerstone, scale

Solubility of Amino Acids

Cleaning/Sanitizing Chemicals General Classifications: n Acid Cleaners n Alkaline Cleaners n Enzymatic Cleaners n Foam Generators n Solvents n Sanitizers/Disinfectants

• The Acid Test Acids used for beverage processing equipment cleaning: n Organic Acids (Citric, lactic, acetic) n Mineral Acids (Hydrochloric, Phosphoric, Sulfuric) n Oxidizing Acids (Nitric, Peracetic Acid- PAA)

• Alkaline Cleaners n n n Sodium/Potassium Hydroxide (caustic soda, (Na. OH, lye) caustic potash (KOH). Sodium Hypochlorite (Na. OCl, “chlorine bleach”) Noncaustic alkaline cleaners (sodium percarbonate, phosphates, surfactants, silicates)

• Sanitizers Chlorine Bleach (hypochlorite) n Chlorine Dioxide (Cl 02) n Iodine (Iodophor) n Ozone (O 3) n Peracetic Acid (PAA) n Quaternary Ammonium (Quat) n

Conventional 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 1530 minutes (or longer) depending on conditions. . · Rinse. · CIP with 1 -2 ounces of an acid cleaner 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 p. H of the rinse water is neutral (same p. H as the tap water coming in).

A New Approach n 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 p. H of the rinse water is neutral (same p. H as the tap water coming in).

Mash Tun CIP (Traditional) n n n A. Test #1 – Mash Tun The test was performed in the following manner: Caustic wash: 3% w/v pre-blended mixture of 25% w/w caustic and caustic additive– 2400 seconds Caustic rinse cycle Acid wash: 3% v/v nitric/phosphoric– 1200 s Acid rinse cycle

Mash Mixer Before

Mash Mixer After (Traditional) CIP

Brewkettle CIP n n n The test was performed in the following manner: Acid wash: 3% v/v nitric/phosphoric blend– 1200 s Acid rinse cycle Caustic wash – 3% w/v pre-blended mixture of 25% w/w caustic and caustic additive – 2400 s Caustic rinse cycle

Kettle-Before CIP

Kettle-After CIP (Acid First)

Brewkettle After CIP (Acid First)

Fermentation Vessel CIP (Acid Only) Test #1 – FV-42 n The test was performed in the following manner: n Acid Wash: 3% v/v nitric/phosphoric blend & 32 oz. detergent additive – 1200 s n Acid Rinse Cycle n PAA Sanitation n

FV Before CIP

FV After CIP

Cleaner vs. Sanitizer -What’s the difference? n n n Cleaners remove soil, scale, protein, etc. . Little government involvement regarding claims unless bactericidal claims are made. Registration for sanitizers are governed by the EPA, (sometimes FDA) and the product must go through rigorous testing to be classified as a sanitizer. $$$$$. Often used synonymously- technically speaking, there is a difference between sanitizing and disinfecting.

BIOFILM Biofilm Definition: The attachment of organisms to a solid surface and subsequent entombment in a protective polysaccharide coating. n Marked increase in antibiotic and chemical resistance. n Many different types of organisms can exist within the film, making detection and removal difficult. n

Biofilm Removal Mechanical action (i. e. , hand-scrubbing) is the most effective way to remove bioflims. n For CIP, extreme p. H, (<2, >12) along with oxidation, (HN 03, Na. OCl, PAA, Cl 02) OR enzymes, work best to rid surfaces of biofilm and prevent it from returning. n

Selective Micro Technologies Pure Chlorine dioxide generators n No flavor profile (no residuals!) n low ppm requirement n non-corrosive n safe n easy to use n easy to measure n

Conclusion Cleaning is the least glamorous part of daily packaging routine but likely the most important for overall product quality. n Depending upon the product you make, an unsanitary machine can have public health consequences. n Use the proper type and amount of chemicals- don’t scrimp, but overuse, either. n