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

2. pH & Growth Relationship of Microbes pH Scale: 0______2_________5______7_______9________12_____14. Acid  Neutral  Alkaline n n pH 0-2: Very few organisms can survive very long at this pH. n pH 2-5: Some acid tolerant organisms can survive, especially n pH 2-5: Some acid tolerant organisms can survive, especially fungi (yeast and mold). n n pH 5-9: Most bacteria grow very well in this pH range. n n pH 9-12: Growth of most organisms is very limited. Some alkaline tolerant organisms can survive. n n pH 12-14: Very few organisms can survive at this pH.

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

4. Solubility of Amino Acids

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

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

7. Alkaline CleanersAlkaline Cleaners n Sodium/Potassium Hydroxide (caustic soda, (NaOH, lye) caustic potash (KOH). n Sodium Hypochlorite (NaOCl, “chlorine bleach”) n Noncaustic alkaline cleaners (sodium percarbonate, phosphates, surfactants, silicates)

8. Sanitizers Sanitizers n Chlorine Bleach (hypochlorite) n Chlorine Dioxide (Cl02) n Iodine (Iodophor) n Ozone (O3) n Peracetic Acid (PAA) n Quaternary Ammonium (Quat)

9. 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 15- 30 minutes (or longer) depending on conditions..   Rinse.   CIP with 1-2 ounces of an acid cleaner per gallon 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 pH of the rinse water is neutral (same pH as the tap water coming in).

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

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

12. Mash Mixer Before

13. Mash Mixer After (Traditional) CIP

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

15. Kettle-Before CIP

16. Kettle-After CIP (Acid First)

17. Brewkettle After CIP (Acid First)

18. Fermentation Vessel CIP (Acid Only) n 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

19. FV Before CIP

20. FV After CIP

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

22. BIOFILM n 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.

23. Biofilm Removal n Mechanical action (i.e., hand-scrubbing) is the most effective way to remove bioflims. n For CIP, extreme pH, ( 12) along with oxidation, (HN03, NaOCl, PAA, Cl02) OR enzymes, work best to rid surfaces of biofilm and prevent it from returning.

24. Selective Micro Technologies n 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

25. Conclusion n 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.