1. Jenn Sather, Piper Powelson, Kate Horton
The Brewing Process
Jenn Sather, Piper Powelson, Kate Horton

3. The Brew Basics Quick Process Overview Objectives Potential Risks
Controls
The Bottom Line
Questions and Answers

4. Process Overview
MASH TUN

5. Objectives Eliminate Batch Waste Use Top Quality Ingredients
Sufficient Sanitation
Fine-Tuned Bottling Process
Eliminate Employee Error

6. Potential Risks Error in process causing batch waste
Moldy Hops
Potential Risks
Error in process causing batch waste
1.The ingredients are substandard
2. Improper sanitation or filtration
3. Bottling line machine error
4. Employee error
Murky Beer
Inspector doing too much “sampling”

7. Risk Occurrence Subpar inputs Employee Error Improper machine settings
Improper or insufficient Sanitation
Subpar inputs
Employee Error
Improper machine settings

8. Controls To Mitigate Risk RISK: Error in process causes batch waste
The ingredients are substandard
CONTROLS
Implement detective and preventive quality control measures
DETECTIVE: At receiving, inspect bags for punctures or tears and materials have not been otherwise damaged in transit
PREVENTIVE: Store all input ingredients accurately
Record all relevant information regarding the order (date, lot #, etc) and keep a small sample to help determine cause of problems, if they should arise
DETECTIVE: At processing point, visually inspect for substandard indications such as mold, and check lot number with date received to ensure use of fresh ingredients
Store malt in a dry, pest-free location
Store hops in an oxygen-free freezer
Store yeast in temperature-controlled kegs to ensure quality of second generation

9. Controls To Mitigate Risk RISK: Error in process causes batch waste
Improper cleaning, sanitation or filtration
CONTROLS
2. Implement STRONG preventive and detective controls
PREVENTIVE: Cleaning is most effective between 140 and 180 degrees F.
PREVENTIVE: Establish a minimum cleaning time for all procedures
PREVENTIVE : Measure cleaner and check concentration; more is NOT better
DETECTIVE: Visual observation of soiled tanks and equipment
DETECTIVE: Test pH of sanitizer solutions before each sanitation cycle, record
DETECTIVE: Microbiological product sampling to ensure correct bacterial levels, record
TEMPERATURE: Since temperature fluctuates, measure at beginning, middle, and end of process, and adjust starting temperature as necessary

10. Controls To Mitigate Risk RISK: Error in process causes batch waste
Bottling line machine error
CONTROLS
3. Implement preventive and corrective controls to ensure fine-tuned bottling process
PREVENTIVE: Check machine settings per batch type against master manual
CORRECTIVE: Keep a log of previous bottling line error and solution for future troubleshooting techniques
PREVENTIVE: More than one team of employees trained
PREVENTIVE: Regular planned maintenance
The benefits of canning

11. Controls To Mitigate Risk RISK: Error in process causes batch waste
Employee error
CONTROLS
4. Implement preventive controls to minimize employee error during brewing process
PREVENTIVE: Utilization of a CIP system
PREVENTIVE: Development of a cleaning & sanitation manual that is
Detailed, up-to-date and systematic
Checklist style sanitation recording, day-end review by management
PREVENTIVE: Limit employee access to “E” beer during working hours
Employee cleaning at Boulder Beer
CIP = clean in place to minimize cross-contamination between process steps
checklist records to tie employee ID to batch number. Holds employees accountable

12. Focus control expense and labor on the front-end of brewing process
The Bottom Line
Objective Type
Risk Type
Risk Level
Controls
Control Type
Eliminate Employee Error
Employees are insufficiently trained on sanitation, machinery care and use, safety
Low
●Comprehensive safety, policy and equipment use training for new-hires.
●Annual or as-needed safety and equipment training for current employees
Preventive
Cross contamination between process steps by using the same cleaning devices leads to insufficient sanitation levels
Moderate
●Development of a cleaning and sanitation manual that is detailed, up-to-date and systematic.
●Checklist-style steps for sanitation process. ●Day-end review for completeness of logs by management.
Lack of communication between employees leads to insufficient sanitation levels
High
●Checklist-style steps for sanitation process is initialed by performing employee
Lack of communication between employees leads to improper machine settings
Access to "E" beer (under filled cans) leads to intoxication on the job and increased propensity for error
●Restricted access to "E" beer until after work shifts end. ●Weekly allowance for "E" beer. ●Security of "E" beer in the cooler. ●Anonymous reporting system to management by fellow employees.
Preventive/ Corrective
Highest probability of risk occurrence

13. Questions and Answers