Week 1 Flashcards
Pasteurization effect occurs in temps at or above what?
120F / 49C
Complete and adequate pasteurization requires what?
Minimum of 5min at 140F / 60C
Define a pasteurization unit
Pasteurization Unit = 1 min @ 60C
PUs increase linearly by time and logarithmically by temp
Name the basic stages of a beer packaging line.
- Depalletizing
- Rinser (or bottle washer if returnable bottle line)
- Filler
- Tunnel pasteurizer (unless sterile fill)
- Labeler (if bottle line)
- Packer
- Palletizer
What are the three basic challenges in beer packaging?
Quality
Package appeal and appearance
Cost Effectiveness
What possible quality problems can be associated with the container?
- Dimensional consistency - cartons must feed into and through machine, at design speed, without disruption
- Material consistency - material gauge and flexibility held to close tolerances to allow for high speed feeding
- Surface characteristics - including “slip angle” - angle at which carton will slide off of others
- Carton scoring - must flex or bend, must be consistent and adequate
Why is sanitation a concern in packaging?
Requires the same level of commitment as brewery area
**sanitation is both a quality issue and a performance issue in packaging
Necessary to maintain quality of product on product contact surfaces
What is the main cost center of a packaging brewery?
-Typically requires 60% initial capital
- Commands 70% of “follow-on” capital
- commands 80% maintenance budget
Packaging materials alone usually cost more than total brewing operations
What is the impact of material consistency on packaging line performance?
Automated controls cannot generally accommodate material variability. Variability often needs manual intervention and thus limits high-speed capability of the line
Reason for glass end bottle treatment?
Improve hardness (reduce breakage)
“Scuffing” protection
Name 3 advantages of glass bottles
- Flavor inert
- gas impermeable
- consistent shape (not with old molds) = well known handling characteristics,
- recyclable
Three advantages of PET?
Light
Unbreakable
Simple alteration of bottle designs
Is PET a hydrophobic material?
No, it is hydroscopic and will suck up water and impact ability to form
AA in PET bottles
AA can be formed during heating (260-280C) - during the injection moulding process.
Higher moisture content also creates higher AA
Higher temps and longer time of PET in hot fluid condition
Formed in pre-form manufacturing process
Permeability of PET?
Gases, water vapor and flavors
Permeability of CO2 = 5 times more than that for O2
Minimum CO2 reduction and O2 intake for PET bottles for beer during shelf-life?
Max reduction of CO2 = <15%
Max intake of O2 = 1mg/l
What are a type I and type II statistical error?
Type I: concluding that samples are different when they are not (producer risk?)
Type II: missing a difference that is there (consumer risk)
How much of a normal population falls within +- 3õ of the mean?
Virtually all of it
What is a good measure of a ”typical” value from a sample of well-behaved data?
X-bar or u
What does it mean if one of your QC samples falls outside of the upper control limit on your X-bar Chart?
Means that there is an assignable cause and you should go and find and fix it
The speed rating of the filling process usually determines what?
The output rating of the entire packaging line - need to run 90-95%
Torque rating for a twist top crown?
8-12
Name 3 critical control factors for effective beer delivery into the bottle/can
?????
Fill volume
In-package oxygen
Carbonation level
Appearance
The two primary sources of in-package oxygen within the filling process are…
Absorption - dissolved O2 into the liquid
Entrainment - air which is drawn into the package. This is the most common cause of elevated in-package O2
Highest TPO (total package oxygen) is what?
No more than 20ppb DO
Foam rate stability in bottle & can filling is achieved by controlling what three factors?
Delivery temp - cold and consistent
Delivery pressure - maintain above beers CO2 saturation pressure throughout delivery system
Controlling turbulence within the delivery line - turbulence from bends, changes in pipe diameter. Higher velocities exaggerate these effects
Ideal delivery pressure of beer into bowl filler is…
Around 2 bar (30psi) above the bowl operating pressure
How to control oxygen in headspace of filler bowl?
Purge system with cold, deaerated water initially and then, during filling, purged gas from the containers are vented into headspace of bowl and should be continually infused with fresh CO2 and vented from another point
The two primary purposes of the bowl level and pressure controls are:
Ensure a smooth, adequate supply of beer to filling valve stations
Maintain the desired CO2 counter pressure on the beer throughout the filling process
Requirements for effective beer level control in the bowl…
Incoming beer pressure sufficient to over come pressure during operation - rec at least 1 bar above bowl pressure
Smooth, well tuned operation - no surging or valve hunting
Adequate response time of control components to avoid low liquid level at start-up or overflow during shut down
What is a jetter?
What is a bubble breaker?
Between the filling station and the crowning station, the bottle will pass beneath a “jetter” which is a high velocity (45-150psi)- low volume stream of potable water (some use steam).
This agitates the surface of the beer and causes a quick foam rise
The rising foam displaces the air in the bottle as the crown is placed onto the bottle. Cap on foam.
For cans, a station - bubble breaker - will blow low pressure, high volume of CO2 across the liquid as the lid is placed on and goes to the seamer
A properly operating can/bottle filling process is defined by the following 5 things:
Consistent fill levels
Consistently low (“acceptable”) levels (what’s the average?) of in-package air content (TPO less than 20ppb)
Consistent CO2 vol per container
Low (“acceptable”) beer losses (0.1%-0.2% acceptable)
A consistent and efficient process which operates at rated speed
Name the advantages of the short tube filling process
Often incorporates a pre-evacuation stage prior to fill
Simple procedure to alter fill levels (adjust to switch out tubes with different lengths
Faster filler speeds
Describe characteristics of long tube filler
Utilizes a SS tube to deliver liquid into the container
Excellent fill level consistency
Smooth and controlled liquid fill with min agitation or contact with air in the container
Less critical of beer condition at entry to the filler
What are the three advantages of packaging beer in cans?
Totally prevents contact with light
Allows no measurable ingress of oxygen
Allows no measurable egress of CO2
What is the purpose of the first seaming operation in canning
The first operation roll forms the “loose” seam by compressing the cover curl on the lid and forming it around the flange at the top of the can to create the loose seam.
It is critical that this operation forms the proper countersink depth and seam thickness
What is meant by the term “seam overlap?”
Seam overlap is the overlap between the cover hook and body hook in the final seam
Why is maintenance critical to seaming performance?
It is a precision process that requires precise and repeatable machinery
Very little wear on components can be tolerated
Machine setup and adjustment is critical as well as scheduled maintenance
What are the “5-S’s”?
I Japanese method to control cleaning and organization of your working area. Everything has a place and that is where it is kept.
Improves efficiency, standardizes everything, minimizes variability, can eliminate problems and also allows for accountability
What are the characteristics of effective problem solving?
- An agenda - the “Problem Statement”
- Definition and specification of the problem
- Effective generation and use of information - the “is - is not” table
- Care in application of change
-Teamwork as a means, not an end - multidisciplinary group
Define packaging efficiency
Actual output over a period of time
Should include ALL machines on the line as every machines efficiency will impact overall efficiency.
May or may not include “normal” disruptions to operations, but their calculation should remain consistent
What machine is seen as the “critical machine” in most beer packaging operations
Often the filler
Stopping the filler stops everything and will result in low fills, oxygen pickup, etc
Not necessarily the filler in all situations. The critical machine is the slowest of the process stages which make up the line and the entire line’s output rate is limited to that of the slowest component
Define the term accumulation as it applies in packaging
Building accumulation capacity in a packaging line allows for the critical machine to always be supplied with a constant input material (rinsed bottles) and to be freed from an accumulation of product at its exit, thus allowing it always to run. Accumulation built into a packaging line allows for a buffer in case one machine goes down or needs attention, this accumulation will keep the line running while the down machine is attended to, hopefully being fixed before the accumulation runs out and affects the operation of machines either upstream or downstream.
Why is an understanding of accumulation important for efficiency?
If you don’t have appropriate accumulation, you have stops in your line and decreased efficiency
Name 5 areas in the packaging line where inspection might take place
- Empty bottle grading
- Empty bottle inspection
- Residual liquid/caustic control
- Filler/closure management (glass fragment detection/metal detector)
- Label control
- Filled bottle control
Name 4 common returned bottle faults
- Polluted (dirty) bottles
- Bottles with foreign substances and residual liquid
- Bottles with throat (neck finish) damage
- Scratched bottles (scuffed)
- Damaged bottles (blisters, etc)
Name 4 basic types of empty bottle inspections
- Mouth inspection (sealing surface, thread inspection)
- Side wall inspection (abrasion, failures on internal wall)
- Bottom inspection (half and non- transparent failures, foils)
- Residual liquid detection (caustic, residual water, oil)
Name 3 techniques for fill height measurement
Completeness control
Fill level monitoring w/ Roentgen bridge measurement
Detection of untight containers by measuring the product loss
Why is label inspection done?
To insure that labels are present and oriented correctly. This is important for branding, but also for legal purposes.
List 4 goals of modern labeling
- Easy handling and operation
- Consistent positioning on the bottle
- Reduction of adhesive consumption
- Flexibility in equipment change-over
- Short times for change-over and prep during brand changeovers
- Easy to maintain and repair
- Must match speed of filler and keep buffer by them at minimum
List 5 techniques/technologies for labels
- Cold glue technology
- Hot glue technology
- Without glue - plastic sleeves
- Stickers
- Printing directly onto bottle
List 5 types of label glues
- Hot melt
- casein glue
- Casein-free glue
- Starch glue
- Dextrin glue
- Synthetic resin dispersion for PET
- Water based synthetic resin dispersion
Describe the steps in the application of a paper bottle label
1 - glue is applied to SS roller
2 - pallet takes glue from glue roller
3 - pallet removes label from label box
4 - label is dated
5 - Gripper cylinder removes label from pallet
6 - Gripper sponge presses label to bottle
7 - bottle is turned 90 degrees
8 - Label is brushed on bottle
List an advantage of sleeve labeling
No glue consumption
What is the average oxygen uptake during keg filling?
0.023 mg/l = 23 ppb
What specifications must be met by a 30L keg?
- Keg body coated w/ polyurethane totally or just base and handle ring
- material thickness
- no deformation at an internal overpressure of 5 bar
- material surfaces smooth, resistant to hot water, alkaline and acid detergents
- internal surfaces must be flavor and taste neutral, scratch resistant, corrosion resistant and welded joints free of holes and roughness
What is the residual amount of beer in a 50 L keg?
What remains in the keg’s pipe (spear)
Approx 97ml
Why is exterior keg cleaning important?
Because you don’t want any pollution on the outside of the keg to contaminate parts of the filler or harbor molds/contaminates that may impact the quality of the beer when tapped
How does surface finish affect keg spear cleaning?
The surface of the spear needs to be ultra smooth to assist with cleaning as it does not benefit from any mechanical action during the keg cleaning process - it’s only cleaned via caustic via gravity, not high pressure.
Is beer filled into a keg at a constant rate?
No
List the operating cycles of a linear keg washer-filler
In a linear keg washer-filler, kegs are moved in groups at a time via a “transport beam”
Invert keg, remove cap, tighten fitting and then
Station 1 -
- Test of rest pressure, draining of residual beer, driving out/expelling of CO2 - drained of effluent
- Water pre-rinsing and then expelling of water residuals w/ sterile air
- Hot caustic interval flushing for walls and standpipe (60-80C @ 1.5-2%)
- Charging of caustic, compressing of the gas head space - spring cage is submerged in caustic
Station 2 - Holding station where the caustic casts out of the spear to the problem zones and internal walls.
Station 3
- Caustic and caustic residuals are expelled with sterile air
- Mixed water intermediate rinsing
- Expelling of water residual with sterile air
- Acid interval rinsing (spear and walls)
- Expelling of acid with compressed air
Station 4
- Hot water interval rinsing (spear and walls - preheats keg and rinsing any remaining acid)
- Expelling of water residuals with steam
- Steam pressure build up pressure control
Station 5 (first sterilization station)
- waiting station to give steam time to sterilize all surfaces (127C @ 3 bar)
Station 6 (second sterilization station)
- active steaming with fresh steam, check for pressure
- expansion of expelling of steam residuals with CO2 part pressurizing
Station 7 (filling station):
- pressurizing to end-pressure with CO2 (keg pressure is higher than saturation pressure to avoid foaming and keep carbonation)
- filling with slow start (until spring cage is covered to prevent turbulence) and end phase (to ensure correct fill), fast main filling phase. 50l keg = 35-50 secs fill time
Rinse fitting and fitting plate to prevent mold, etc.
Re-invert
Put cap on
Palletize
List basic operating steps in a rotary keg washer-filler
In a rotary keg filler, there are two separate units: one for cleaning and one for filling
Once keg is attached to a head at the start, it is always attached through the entire revolution. Then removed at end and then goes to the next rotary station.
Typically there are three rotary stations:
Rotary one: pre-cleaning
Rotary two: main cleaning (with a caustic “soak” in the time between station 1 & 2)
Rotary three: filling (with steam sterilization on transport bt station 2 & 3)
List the advantages of a rotary keg washer-filler
- Faster
- There is no break of treatment by change os stations
- Continuous product flow
- Product sparing filling
- Continuous material flow
- Simple and clear piping system
- Advantageous dimensioning of piping
- Better pursuit of material flow w/ possibility of rejection
No pump stopping and starting (like with linear) - better wear on machine
Flow rates are more exact bc of no down time
List advantages and disadvantages of a flat keg fitting
Advantages;
- Easy handling at publican
- No twisting of hoses
- No tightening by force
- Fewer parts
Disadvantages:
- Short spraying - sprays out instead of being contained in basket
- Fitting less protected
Name some inspection technologies
- Camera technology
- Infrared light detection
- Light barriers
- CCD cameras paired with computer editing matched with acceptable or non-acceptable tolerances and for specific areas, w/ polarization filters, w/ mirrors
- Roto-scan technology
- HF (high frequency) Technology - to check residual liquids and caustic (no oil!)
- X-ray
- Metal detectors
What are the pros and cons vs returnable and non-returnable bottles
Returnables:
Pros
- not having to buy new bottles every time, which is expensive.
- less environmental impact with reusing bottles - can be reused 30 cycles, even 50-60 cycles are possible
Cons
- having to ensure that returned bottles get back to your brewery and that the bottles are able to be handled by your brewery, are in sound shape, cleaned and sanitized properly and ready for product.
- checking for defects in bottles and insuring customer safety and product quality then rests even more on brewery
- process for this is quite involved and expensive
- need the space and resources to have a designated machine for cleaning/sanitizing
Non-returnables:
Pros:
- less involved process for ensuring a consistent, clean and ready to fill bottle.
- doesn’t require a bottle cleaner & sanitizer
- not reliant on customers returning bottles to have a ready available supply
Cons:
- bottles are expensive to continuously buy (not sure how in comparison to bottle washer/sanitizer and operation of such machine)
- one use is less environmentally friendly (still a recyclable product)
How do you verify steps when cleaning kegs?
You can run a “monitor keg” through your keg cleaning system which will allow you to see if pressures and settings are correct to ensure every part of the keg internals are being cleaned.
You will also record each kegs service history and physically take apart the fittings and remove spear to visual inspect them and keg internal surface and periodically perform additional cleaning or adjustment to your SOPs if necessary
If there is a problem with keg cleaning, what is the most common problem?
Ensuring that the outside surface of the spear is cleaned
What quality concerns must be considered when operating a manual or semi-automatic bottling/canning system?
What are the two prominent economic factors of a small packaging operation?
- Packaging labor costs
- Bottle line material costs
??
What are the advantages of rotary filling machines?
Faster
More efficient
Can lower O2 pickup
Name the key elements of an effective filler maintenance program
- frequent cleaning and sanitation - on a schedule!
- replacement of wear parts as needed
- skill and knowledge levels appropriate to the needs
- an assertive maintenance approach based on:
- scheduled intervals
- acceptable operating standards for quality and efficiency
What are pump curves?
A pump curve is an illustration of a pump’s nominal operation when in new condition. The curve will show:
- Pressure/flow characteristics throughout the pumps operating range
- Operating efficiency at various points (given by manufacturer)
- Suction head requirements (ie, pressure at the pump inlet)
- Many curves also indicate the drive horsepower required at various flow rates
What are some special requirements when pumping finished beer?
- laminar flow so as to not create turbulence 1.5m/sec
- the appropriate velocities to insure a linear flow and to not exasterbate any shear stresses on the product
- need to maintain dynamic pressure to keep CO2 in solution as we pump.
What is the principle of operation of a centrifugal pump?
Works by “slinging” fluid outward from the center of an impeller. This outward force creates pressure at the pump discharge, this results in a void at the eye of the impeller that requires external liquid pressure to refill it - “suction head”
What is the principle of operation of positive displacement pumps?
Positive displacement pumps operate through physical displacement of fluid by a moving component of the pump - either a rotary or reciprocal movement.
This creates equal flow rates at a give drive rate, regardless of viscosity - but viscosity does impact hp requirements and friction losses within the piping system.
If pump is dead headed - the discharge flow path is blocked, the pressure will cause the driver to stall and/or the internal components of the pump will fail.
These pumps provide gentle, low sheer forces and also pumping heavy solids.
List some factors that affect the output pressure and flow of a centrifugal pump
Output pressure and flow are dependent upon:
- the pump design
- it’s rotation rate
- the resistance of the discharge piping and components (valves, etc)
- inlet pressure
- the liquid’s viscosity
Higher flow rate = pressure will drop @ same RPM
What is cavitation?
The net suction head must be kept higher than the “vapor pressure” (the pressure at which a liquid at a given temp will vaporize, or boil) for the liquid being moved. If not, the liquid will vaporize within the pump, creating cavitation.
The gas vapor creates tiny bubbles, “cavities” of vapor in the liquid stream that then collapse violently once they reach the higher pressure side of the impeller
List 4 demands on modem brewery cleaning systems
- Removal of production residues, technical residues, organic/inorganic sediments, bulk of microorganisms on surfaces which have direct/indirect contact with product
- No cross contamination with product residues and other soils
- maintain product quality
- maintain plant efficiency
- no nutrients or shelter for microorganism
- easy disinfection
- minimized cleaning/disinfection expenses
List 3 factors that affect cleaning time
- Dirt type
- Kind, quality and efficiency of the cleaning detergent
- concentration of active components
- cleaning temp
- mechanical action
What parameters have an effect on cleaning mechanical action?
- Pressure
- Flow rate
- Fluid mechanics
- Flow velocity - turbulent flows
- Measured value for turbulent/laminar
- Influence of diameter
3.5 meter/sec - creates turbulent flow
1.5 meter/sec - creates laminar flow
List 3 factors that may help a dirt particle stay on a surface
- Colloid film
- Fat layers
- Adhesive force
- Surface roughness/geometry
- Electrostatic forces
- Van der Waalsche forces (??)
- Absorption
List the basic phases in a CIP cleaning cycle
- Pre-rinse with hot (~60C) water
- Addition of tensides (wetting agents)
- Alkaline cleaning solutions (caustic)
- Acid cleaning (neutralize caustic and dissolve mineral soils)
- Water rinse (clean water)
List 5 errors which can lead to poor cleaning performance
- Cleaning parameters not adjusted
- Flow rate too low
- Air accumulation
- No defined flow paths, parallel flows
- Poor welding joints
- Incorrect installation of components
- Usage of improper components
- Unsuitable piping geometry
- Usage of unsuitable cleaning detergents
- Use of unsuitable pipe and gasket materials
Which type of spray apparatus delivers the most surface impingement?
All are generally equal with the correct flow rate (??) Not static spray balls
Can use rotary spray heads and rotary jet heads for larger tanks
Define the “cold spot” in pasteurization
The “cold spot” is in the center of the container, 1/3 height of the container. This point will determine the pasteurization reference to determine time and temp
Name 5 factors that must be considered in the biological preservation of beer
- Increasing % consumption of bottled beer
- Expansion from regional to national markets
- Expansion from national to international markets
- Changing distribution patterns by shipper/distributors
- Longer shelf-life requirements
- Specialized staff reductions
List some advantages of flash pasteurization
- Heating up and cooling down in line: lower thermal load (O2)
- Minimum hot holding times 35 sec @ 70C
- Small space required
- Slight energy consumption
- Cheaper and more gentle on product
“Unsafe method” as beer has to be filled AFTER pasteurization and can possibly become contaminated
List some advantages of tunnel pasteurization
- 20 min on 62C - keeping time 20 min - 20 min cooling (lower temps @ longer times)
*safe method - beer is sealed and contained and then pasteurized. No possibility for recontamination
List the important characteristics of draught beer
- usually unpasteurized
- shorter shelf life than bottled/canned beer (why? Exposure to draft line systems)
- usually less carbonated than bottle/cans
- stored in and served from bulk containers
- able to represent freshest version of any beer compared to small pack beers
What is the most common draft keg?
Half barrel
What are the two main types of pumps?
Centrifugal
Positive Displacement
What is one of the most important things to keep maintained on a centrifugal pump?
Mechanical seal
Define “feet of head”
Unit of measurement for pressures at the pump inlet and outlet - denotes pressure created by the weight of a column of liquid.
**Based on “specific gravity” of the liquid and the height of the column
Column of water 2.31 feet exerts 1 psi
10 meters of water height = 1 bar
Feet of Head/2.31 = psi
Define “suction head pressure”
The sum of liquid column pressure PLUS any externally applied system pressure
What is the minimum length of holding line (line before the pump)?
L = 5 times the diameter of the pipe
